automatic transaxle DAEWOO NUBIRA 2004 Service Workshop Manual

5A1 – 16IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Hold Mode (1.8 DOHC)

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 17
DAEWOO V–121 BL4
POWER FLOW DIAGRAM
Park/Neutral

5A1 – 18IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Park/Neutral
In Park or Neutral with the engine running there is no drive
to the planetary gear set. Line pressure (from the oil pump)
is supplied to the valve body. Only clutch B is supplied and
the torque converter is released.
Control
Line Pressure Control Valve
The line pressure control valve sets the general pressure
level in the valve body. When gearshifts are not taking
place, the line pressure varies between two levels, de-
pending on the turbine torque. Line pressure increase lin-
early by time. But it has a limit point. When pressure reach-
es that point, excess oil pressure drains back into the oil
sump.
Reduction Valve
The reduction valve reduces the line pressure with which
the downstream solenoid valves and pressure control so-
lenoid valves (EDS) are supplied. This makes it possible
to use smaller solenoid valves.
The line pressure comes from the oil pump and flows to the
reduction valve. The inlet port to the reduction valve will be
blocked and line pressure will be maintained at the ap-
propriate level.
Solenoid Valve 1, 2
Solenoid Valve 1 controls the line pressure (high and low)
to the clutch valves. Solenoid Valve 1 is either ON or OFF.
When the solenoid is turned ON the line pressure will be
low [87~116psi (6~8bar)].When the solenoid is turned
OFF the line pressure will be high [232~261psi
(16~18bar)].
Solenoid 2 controls the fluid flow to clutch valve E or the
TCC clutch valve. When solenoid 2 is ON fluid is directed
to the TCC pressure valve and if the solenoid is switched
OFF fluid will flow to the inlet at clutch valve E.The TCM monitors numerous inputs to determine the ap-
propriate solenoid state combination and transaxle gear
for the vehicle operating conditions.
In Park and Neutral solenoid valve 1 is ON. So line pres-
sure flows to the safety valve and the line pressure control
valve via the solenoid valve.
Clutch B Engaged
In Park and Neutral solenoid valves 1 and 2 are both ON.
Pressure control solenoids (EDS) 4 and 6 are also turned
ON.
When EDS 6 is ON, the fluid supplied from the reduction
valve flows to the safety valve, clutch valve B and holding
valve B. The oil that is supplied to the inlet port of the clutch
valve presses on the valve spool. Line pressure then flows
to the holding valve and check ball, engaging clutch B.
Lock–up Clutch (TCC)
Solenoid 2 is turned ON and the line pressure control
valves spool will be depressed. Fluid will now flow through
the torque converter pressure valve.
As a result, the oil pressure behind the converter lock–up
clutch piston and in the turbine zone is equal. The direction
of flow is through the turbine shaft and through the space
behind the piston, to the turbine chamber.
Lubrication/Cooling.
The lubricating valve ensures that the converter is sup-
plied with cooling oil first if the pump rate is low. The lubri-
cating pressure valve in addition guarantees that the nec-
essary amount of cooling and lubricating oil is available via
the bypass duct.
The fluid, which is supplied from the torque converter,
flows to the cooler via the lubrication valve.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 19
DAEWOO V–121 BL4
Reverse

5A1 – 20IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Reverse
In Reverse, transaxle drive is via the input shaft and clutch
B. The elements of this transaxle function are as follows:
S Clutch B is engaged and drives the reverse sun
gear in a clock––wise direction.
S The D band is engaged and holds the planetary
gear carrier (front & rear) stationary causing the
differential pinion to rotate clockwise.
S The differential rotates in a counterclockwise direc-
tion.
S The output shaft is driven in a counterclockwise or
reverse direction.
Control
Clutch B Engaged
The line pressure, which is supplied by the oil pump, is di-
rected to clutch B via the manual valve. The position of the
check ball will change allowing direct pressure to clutch B.
Brake D Engaged
The line pressure, which engaged clutch B, is also sup-
plied to clutch valve D.In Reverse, solenoid 1 is switched ON and EDS 4 is
switched OFF. This will cause the fluid supplied to the re-
duction valve to flow to clutch valve D via the EDS 4.
The spool of clutch valve D will be depressed allowing fluid
to pass to holding valve D.
Lock–up Clutch (TCC)
Solenoid 2 is turned ON and the line pressure control valve
spool will be depressed. Fluid will now flow through the
torque converter pressure valve.
As a result, the oil pressure behind the converter lock–up
clutch piston and in the turbine zone is equal. The direction
of flow is through the turbine shaft and through the space
behind the piston, to the turbine chamber.
Lubrication/Cooling
The lubricating valve ensures that the converter is sup-
plied with cooling oil first if the pump rate is low. The lubri-
cating pressure valve in addition guarantees that the nec-
essary amount of cooling and lubricating oil is available via
the bypass duct.
The fluid, which is supplied from the torque converter,
flows to the cooler via the lubrication valve.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 21
DAEWOO V–121 BL4
Drive Range – First Gear

5A1 – 22IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Drive Range – First Gear
In Drive 1, transaxle drive is via the input shaft to clutch B.
The elements of this transaxle function are as follows:
S Clutch B is engaged to drive the rear sun gear.
S The rear sun gear drives the front planetary gear
carrier clockwise.
S The rear planetary gear carrier drives the front ring
gear and front planetary gear carrier clockwise.
Control
Clutch B Engaged
In Park and Neutral solenoid valves 1 and 2 are both ON.
Pressure control solenoids (EDS) 4 and 6 are also turned
ON.
When EDS 6 is ON, the fluid supplied from the reduction
valve flows to the safety valve, clutch valve B and holding
valve B. The oil that is supplied to the inlet port of the clutch
valve presses on the valve spool. Line pressure then flows
to the holding valve and check ball, engaging clutch B.Clutch F Engaged
EDS 5 will be switched ON. The line pressure, which
passed through the reduction valve, will flow to the holding
valve and the clutch valve inlet. As a result the valve spool
is depressed.
Lock–up Clutch (TCC)
Solenoid 2 is turned ON and the line pressure control valve
spool will be depressed. Fluid will now flow through the
torque converter pressure valve.
As a result, the oil pressure behind the converter lock–up
clutch piston and in the turbine zone is equal. The direction
of flow is through the turbine shaft and through the space
behind the piston, to the turbine chamber.
Lubrication/Cooling
The lubricating valve ensures that the converter is sup–
plied with cooling oil first if the pump rate is low. The lubri-
cating pressure valve in addition guarantees that the nec-
essary amount of cooling and lubricating oil is available via
the bypass duct.
The fluid, which is supplied from the torque converter,
flows to the cooler via the lubrication valve.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 23
DAEWOO V–121 BL4
Drive Range – Second Gear

5A1 – 24IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Drive Range – Second Gear
In Drive 2, the transaxle drive is via the input shaft and
clutch E. The elements of this transaxle function are as fol-
lows:
S Clutch E is applied to drive the front ring gear.
S The front ring gear drives the front planetary gear
carrier.
S The front planetary gear carrier drives the differen-
tial pinion gear clockwise.
S Brake F is applied holding the front sun gear sta-
tionary.
Control
Clutch E Engaged
Solenoid 2 will be switched OFF. Line pressure, which is
supplied by the reduction valve, flows to the inlet port of
clutch valve E. Fluid will then pass through the clutch valve
and clutch E will engage.Clutch F Engaged
EDS 5 will be switched ON. The line pressure, which
passed through the reduction valve, will flow to the holding
valve and the clutch valve inlet. As a result the valve spool
is depressed.
Lock–up Clutch
Solenoid valve 2 is turned ON and the line pressure control
valve spool will be depressed. Fluid will now flow through
the torque converter pressure valve.
As a result, the oil pressure behind the converter lock–up
clutch piston and in the turbine zone is equal. The direction
of flow is through the turbine shaft and through the space
behind the piston, to the turbine chamber.
Lubrication/Cooling
The lubricating valve ensures that the converter is sup-
plied with cooling oil first if the pump rate is low. The lubri-
cating pressure valve in addition guarantees that the nec-
essary amount of cooling and lubricating oil is available via
the bypass duct.
The fluid, which is supplied from the torque converter,
flows to the cooler via the lubrication valve.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 25
DAEWOO V–121 BL4
Drive Range – Third Gear