2004 DAEWOO LACETTI Iat

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 237
DAEWOO V–121 BL4
Shift Solenoid Valve: Solenoid 1,2
The shift solenoids are two identical, normally open elec-
tronic exhaust work that control upshifts and downshifts in
all forward gear ranges. These shift solenoids valves to-
gether in a combination of ON and OFF sequences to con-
trol the line pressure and shift mechanisms (clutches,
brakes).
Solenoid 1 controls the high or low of the line pressure
(flow to each clutch valve) by the operation type (ON/
OFF), i.e. solenoid 1is ON, line pressure will be low
(87~116 psi (6~8bar)), solenoid 1 is OFF, line pressure will
be high (232~261 psi (16~18bar)).
Solenoid 2 controls the oil flow to clutch valve E or lockup
clutch valve by the ON/OFF signal.
The TCM monitors numerous inputs to determine the ap-
propriate solenoid state combination and transaxle gear
for the vehicle operating conditions.
Gear
Solenoid 1Solenoid 2
Park, NeutralONON
FirstON/OFFON
SecondON/OFFOFF
ThirdON/OFFOFF
FourthON/OFFOFF
ReverseON/OFFON
Line PressureResistance
Solenoid
valve 1/Sole-
noid valve 2ON(low)
89.9~98.6 psi
(6.2~6.8 bar)
OFF(high)
S 221.9~253.24
psi
S (15.3~17.46
bar)26.5 ± 0.5ohm
Pressure Control Solenoid Valve (EDS
VALVE 3,4,5,6)
The pressure control valve (EDS valve 3,4,5,6) is a preci-
sion electronic pressure regulator that controls the opera-
tion of the clutches, brakes and the lock–up clutch.
The valve reduces the system pressure with which the
downstream solenoid valves and electrical pressure regu-
lating valves are supplied. It is possible to use smaller so-
lenoid valves as a result. The EDS require a constant input
pressure.

AISIN AUTOMATIC TRANSAXLE 5A2 – 109
DAEWOO V–121 BL4
Installation Procedure
1. Connect the negative battery cable.
2. Install the TCM and retaining bolts.
Tighten
Tighten the TCM retaining bolts to 5 NSm (44 Ib–in).
3. Connect the TCM electrical connector.
4. Connect the negative battery cable.
FLUID COOLER INLET PIPES AND
HOSES
Removal Procedure
1. Raise and support the vehicle.
2. Drain the transaxle fluid.
3. Remove the clip from the hose, then disconnect the
hose from the fluid cooler inlet pipe.
4. Remove the inlet pipe union bolt from the radiator.
5. Remove the fluid cooler inlet pipe bolt from the
transaxle.
6. Remove the inlet pipe fitting nut from the transaxle.
7. Remove the fluid cooler inlet pipe and hoses.

5A2 – 110IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Installation Procedure
1. Install the fluid cooler inlet pipe fitting nut into the
transaxle.
Tighten
Tighten the fluid cooler inlet pipe fitting nut to 35 NSm
(26 Ib–ft).
2. Install the fluid cooler inlet pipe bolt into the trans-
axle.
Tighten
Tighten the fluid cooler inlet pipe bolt to 9 NSm (80 Ib–
in).
3. Install the inlet pipe union bolt into the radiator.
Tighten
Tighten the inlet pipe union bolt to 35 NSm (26 Ib–ft).
4. Connect the hose to inlet pipe and install the clip
into the hose.
5. Lower the vehicle.
6. Fill the transaxle with the fluid.
FLUID COOLER OUTLET PIPE AND
HOSES
Removal Procedure
1. Drain the transaxle fluid.
2. Remove the front outlet pipe union bolt from the
radiator.
3. Remove the clip from the hose.
4. Remove the rear outlet pipe clip bolt from the trans-
axle.
5. Remove the rear outlet pipe fitting nut from the
transaxle.
6. Remove the fluid cooler outlet pipe and hoses.

AISIN AUTOMATIC TRANSAXLE 5A2 – 183
DAEWOO V–121 BL4
FORWARD AND REVERSE CLUTCH
1. Seal Ring
2. Flange
3. Disc
4. Plate
5. Flange
6. Snap Ring
7. Flange
8. Disc
9. Plate10. Snap Ring
11. Clutch Balancer
12. Forward Clutch Retrun Spring
13. Forward Clutch Piston
14. O–Ring
15. Forward Clutch Drum
16. O–Ring
17. Intermediate Shaft Sub–assembly

AISIN AUTOMATIC TRANSAXLE 5A2 – 187
DAEWOO V–121 BL4
15. Using a small screwdriver, remove the O–ring from
the forward clutch drum.
16. Using a small screwdriver, remove the O–ring from
the intermediate shaft sub–assembly.
Inspection Procedure
1. Check to see if the sliding surface of the disc, plate
flange are worn or burnt. If necessary, replace
them.
S If the lining of the disc is peeling off or discol-
ored, or even if a part of the printed number is
defaced, replace all discs.
S Before assembling new discs, soak them in ATF
for at least 15 minutes.
2. Using vernier calipers, measure the free length of
the spring together with the spring seat.
S Standard free length: 24.04 mm (0.9465 in.)

5A2 – 188IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Assembly Procedure
1. Coat a new O–ring with ATF, and install it to the
intermediate shaft sub–assembly.
2. Coat a new O–ring with ATF, and install it to the
forward clutch drum.
3. Coat the forward clutch drum with ATF, install the
forward clutch drum.
Notice : Be careful not to damage the O–ring and lip seal
of forward clutch drum.
4. Coat the forward clutch piston with ATF, install the
forward clutch piston.
Notice : Be careful not to damage the lip seal of forward
clutch piston.

AISIN AUTOMATIC TRANSAXLE 5A2 – 223
DAEWOO V–121 BL4
Operations of Clutches and Brakes
Clutch & BrakeOperation
C1Forward ClutchConnects intermediate shaft and front sun gear.
C2Direct ClutchConnects input shaft and Planetary carrier.
C3Reverse ClutchConnects intermediate shaft and rear sun gear.
B1O/D & 2nd BrakeLock rear sun gear
B22nd BrakeLock rear sun gear
B31st & Reverse BrakeLock Planetary carrier
F11way Clutch No.1Lock counterclockwise rotation of rear sun gear, when B2 op-
erations
F21way Clutch No.2Lock counterclockwise rotation of planetary carrier

5B – 10IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
1. Roller Bearing
2. Transaxle Main Shaft
3. Washer
4. Washer Retaining Ring
5. 4th Speed Gear
6. Needle Cage
7. Synchronizer Ring
8. Shift Sleeve
9. Synchronizer Key
10. 3rd & 4th Synchronizer Spring
11. Washer
12. Circlip
13. 3rd Speed Gear
14. Washer
15. Washer Retaining Ring
16. 2nd Speed Gear
17. Needle Cage
18. Inside Synchronizer Ring
19. Intermediate Ring
20. Outside Synchronizer Ring
21. Sliding Gear
22. 1st & 2nd Synchronizer Key
23. 1st & 2nd Synchronizer Spring
24. Washer
25. Circlip
26. 1st Speed Gear
27. Needle Cage28. Needle Cage
29. Main Shaft Disc
30. Retaining Ring
31. Groove Ball Bearing
32. Washer
33. Retaining Ring
34. 5th Speed Gear
35. Needle Cage
36. Synchronizer Ring
37. 5th Shift Sleeve
38. 5th Synchronizer Spring
39. 5th Synchronizer Key
40. Retaining Ring
41. Needle Sleeve
42. Input Drive Shift
43. Input Shaft Cluster Gear
44. Bolt
45. Retaining Ring
46. Cluster Bearing Ring
47. Groove Ball Bearing
48. Cluster 5th Speed Gear
49. Retaining Ring
50. Washer
51. Reverse Idler Gear
52. Reverse Idler Gear Shaft
53. Ball