Automatic Transaxle System

General Information

Automatic Transaxle System

 2009 > G 1.6 DOHC >

Specifications
Transaxle model A4CF1
Engine model Gasoline 1.6L
T/con 3 elements 2 phases 1 stage
T/con size (!) 236
O/PUMP type Parachoid
T/M CASE type Separated
Clutch: 3EA
Friction elements Brake: 2EA
OWC : 1EA
Planetary gear 2EA
1st 2.919
2nd 1.551
Gear ratio 3rd 1.000
4th 0.713
Reverse 2.480
Final gear ratio 4.619
Fluid pressure balance piston 2EA
Stall speed 2,000~2,700 rpm
Accumulator 4EA
Solenoid valve 6EA (PWM:5EA, VFS:1EA)
Shift lever position 6 range (P,R,N,D,2,L)
Oil filter 1EA

PWM : Pulse Width Modulation

VFS : Variable Force Solenoid

Tightening Torques
Item Nm kgf.m lb-ft
Shift cable bracket 15~22 1.5~2.2 10.8~15.9
Input shaft speed sensor 10~12 1.0~1.2 7.2~8.6
Output shaft speed sensor 10~12 1.0~1.2 7.2~8.6
Manual control lever 17~21 1.7~2.1 12.3~15.2
Inhibitor switch 10~12 1.0~1.2 7.2~8.6
Oil pan 10~12 1.0~1.2 7.2~8.6
Oil drain plug 40~50 4.0~5.0 28.9~36.1
Pressure check plug 8~10 0.8~1.0 5.8~7.2
Front roll support bracket bolt 50~65 5.0~6.5 36.2~47.0
Rear roll support bracket bolt 50~65 5.0~6.5 36.2~47.0
Transaxle support bracket bolt 60~80 6.0~8.0 43.4~57.8
 Lubricants
Item Specified lubricant Quantity
Transaxle fluid liter (US qt, lmp.qt) GENUINE DIAMOND ATF SP-III or SK ATF SP -III 6.8 (7.2, 5.98)

Sealant
Item Specified sealant
Rear cover
Torque converter housing LOCTITE FMD-546
Oil pan
 2009 > G 1.6 DOHC >

Special Service Tools

Tool
Illustration Use
(Number and name)
09200-38001 Removal and installation of the transaxle.
Engine support fixture

09624-38000 Supporting of the crossmember.

Crossmember supporter
 Automatic Transaxle System

Automatic Transaxle System

Automatic Transaxle System

 2009 > G 1.6 DOHC >

Description
The new small sized automatic transaxle (A4CF1) is for gasoline 1.6 engine.
The transaxle (A4CF1) has improved on the durability, fuel consumption and efficiency by the new main features as
follows:

The new main features

1. The hydraulic centrifugal oil pressure balance piston.
2. The full line pressure variable control system.
3. The long travel damper clutch.
4. The disc type return spring.
5. The ultra flat torque converter.

Functions
Item Contents
Components The full line pressure variable control operates in the valve body to improve the fuel consumption.
The long travel damper clutch is applied to the torque converter to improve the engine revolution
change reduction capability and the fuel consumption. (17~20)
The oil pump of the trochocentric type is changed to parachoid type to improve the processing and
the capacity efficiency at the low RPM range.
The disc type return spring is applied to the low&reverse brake to improve the durability and reduce
the length.
The hydraulic centrifugal oil pressure balance piston is applied to the inside of clutch to improve the
durability and the shift control capability.
The low noise gear and the gear teeth face grinding are applied to the transfer driven gear to
improve the noise and the durability.
Electronic The oil pressure value set by TCM is coupled with the engine torque so that the stable shift feeling
control system can be improved.
The engine torque reduction control operates effectively to improve the shift feeling and the
durability.
When shifting, the shift can skip from 1!3 and 2!4.
The reverse clutch, not L/R brake is controlled when controlling the N"R shift so that the N"R
shift feeling can be improved.
The range of the damper clutch direct control expands to improve the fuel consumption.
The current control chip is installed into the TCM to regulate the solenoid control current and
control the oil pressure securely according to the change of the temperature and voltage.
The FPC (Flexible Printed Circuit) harness is composed of thin and flat copper in insulating film,
like electric wire.
The tachometer is operated by the change of the frequency forwarded from the TCM to the
instrument cluster, not vehicle speed sensor.

Mechanical system
Function
Torque Converter
The torque converter is the power plant which delivers the power of engine to the automatic transaxle. It consists of
3 elements: 2 phases and 1 stage type.
3 elements: 2 phases and 1 stage type.
- The flowing section portion of the torque converter changes the round type to the flat type to reduce the length of
the torque converter.
- The maximum operating degree of the damper clutch installed inside the transaxle increases from 11 to 18 to
improve the engine revolution change reduction capability and the fuel consumption.

Oil Pump
The oil pump is made of aluminum (the reaction shaft support) to reduce weight and selects the parachoid type to
improve the processing and the capacity efficiency at the low RPM range.

Brakes
The automatic transaxle (A4CF1) uses the low and reverse brake and the second brake. The low and reverse brake
is fixed by the low and reverse annulus gear and overdrive planetary carrier.
- The disc type return spring is applied to the low and reverse brake. It minimizes the slip of the friction material
from the uniform spring operation power to improve the durability and reduce the length.
The overdrive sun gear is held on the transaxle case by the second brake.
Clutch
The multiple clutches and the one way clutch are used as the transaxle device.
The retainer of each clutch is composed of precision sheet metal parts for productivity and the light weight.
The hydraulic centrifugal oil pressure balance device resides inside the clutch assembly.
Generally, the oil remaining in the piston oil pressure chamber pushes the piston by the centrifugal force. The is oil
filled in between the piston and the return spring retainer to prevent the piston from being pushed. This occurs by
centrifugal force and both of the power is offset so that the piston doesn't move. As a result, this improves the
durability and the shift control ability.

1. Underdrive Clutch
The driving force of input shaft is delivered to the underdrive sun gear.
The operating oil pressure in the underdrive clutch components operates between the piston and the retainer and
pushes the piston to the clutch discs to deliver the driving force from the retainer to the hub.
pushes the piston to the clutch discs to deliver the driving force from the retainer to the hub.

2. Reverse clutch and overdrive clutch

The reverse clutch delivers the driving force of input shaft to the reverse sun gear.
The overdrive clutch delivers the driving force of input shaft to the overdrive planetary carrier and the low and reverse
annulus gear.
The operating oil pressure of the reverse clutch operates between the reverse clutch retainer and reverse clutch
piston and it has the whole overdrive clutch moved to deliver through the hub splines.

Structure Of The Reverse And The Overdrive Clutch

1. Snap ring 8. Clutch plate 15. Reverse clutch piston
2. Clutch reaction plate 9. Snap ring 16. D-ring
3. Clutch disc 10. Spring retainer 17. D-ring
4. Clutch plate 11. Return spring 18. D-ring
5. Snap ring 12. D-ring 19. Reverse clutch retainer
6. Clutch reaction plate 13. Overdrive clutch piston
7. Clutch disc 14. D-ring

Parking System
The parking system for A4CF1 model is the cam type.
The roller type installed to the existing new generation AT needs support to move the roller when operating the
parking system. The cam type for A4CF1 model doesn't need the support and the structure is simpler. It only needs
the guide to prevent from moving the cam idly.
 Operation
Hydraulic Control System
Main Features
The VFS (Variable Force Solenoid) installed in the valve body is applied to transaxle. VFS varies the line pressure
from 4.5bar to 10.5bar according to throttle open angle and shift range to improve the fuel consumption and shift
ability.
The reducing valve installed in the valve body makes the solenoid control pressure using the reducing pressure
instead of the line pressure like the HIVEC transaxle.
The material of spool valve in the valve body is changed from the steel to aluminum to reduce the oil leakage by the
thermal expansion between the valve body and spool valve at the high temperature.
The switch valve, the solenoid valve and the fail safe valve are operated to drive the vehicle at 3rd speed and reverse
even if an electronic control parts malfunction occurs.

Electronic Control System

Sensor And Actuator Function

Item Function
Input speed sensor Detect the input shaft rpm(TURBINE RPM) at the OD/RVS retainer
Output speed sensor Detect the output shaft rpm(T/F DRIVEN GEAR RPM) at the T/F driven gear
Engine rpm signal Receive the engine rpm via CAN communication with ECM
Fluid temperature sensor Detect the temperature of ATF through the thermistor
Brake switch Detect the brake operation at the contact switch of the brake pedal
ON/OFF solenoid valve
Control the hydraulic passage for the shift control
(SCSV-A)
Change the line pressure from 4.5 bar to 10.5 bar according to throttle open angle and
VFS solenoid valve
shift ranges
PCSV-A(SCSV-B) Control the OD or L/R hydraulic pressure to the pressure control valve for shift control
PCSV-B(SCSV-C) Control the 2/4 or REV hydraulic pressure to the pressure control valve for shift control
PCSV-C(SCSV-D) Control the UD hydraulic pressure to the pressure control valve for shift control
PCSV-D(DCCV) Control the hydraulic pressure for the damper clutch control
Cluster Send the signal of the current position of shift lever and vehicle speed

CAN Communication
Layout
ECM- TCM CAN Communication error management
No. Item Error management
1 Engine rpm 3,000 RPM
2 Engine torque 80%
3 Vehicle speed 0 km/h
4 A/C Switch OFF
5 Engine coolant temperature 70C
6 TPS 50%
7 Shift range hold signal OFF
 2009 > G 1.6 DOHC >

Basic Inspection Adjustment

Transaxle Fluid Level
Inspection
1. Drive the vehicle until the fluid reaches normal operating temperature [70~80C(158~176F)].
2. Place the vehicle on a level surface.
3. Move the gear selector lever through all gear positions. This will fill the torque converter with trans fluid. Set the
selector lever to the "N" (Neutral) position.
4. Before removing the oil level gauge, wipe all contaminants from around the oil level gauge. Then take out the oil
level gauge and check the condition of the fluid.

If the fluid smells as if it is burning, it means that the fluid has been contaminated by fine particles from the
brushes and friction materials, a transmission overhaul may be necessary.

5. Check that the fluid level is in the "HOT" mark on the oil level gauge. If fluid level is low, add automatic transaxle
fluid until the level reaches the "HOT" mark.

Automatic transaxle fluid :

DIAMOND ATF SP-III, SK ATF SP-III
Automatic transaxle fluid capacity:
6.8liter(7.2 US qt, 5.98lmp.qt)

Low fluid level can cause a variety of abnormal conditions because it allows the pump to take in air along with
fluid. Air trapped in the hydraulic system forms bubbles, which are compressible. Therefore, pressures will be
erratic, causing delayed shifting, slipping clutches and brakes, etc. Improper filling can also raise fluid level too
high. When the transaxle has too much fluid, gears churn up foam and cause the same conditions which occur
with low fluid level, resulting in accelerated deterioration of automatic transaxle fluid. In either case, air bubbles
can cause overheating, and fluid oxidation, which can interfere with normal valve, clutch, and brake operation.
Foaming can also result in fluid escaping from the transaxle vent where it may be mistaken for a leak.

6. Insert the oil level gauge securely.

When new, automatic transmission fluid should be red, The red dye is added so the assembly plant can
identify it as transmission fluid and distinguish it from engine oil or antifreeze. The red dye, which is not an
indicator of fluid quality, is not permanent. As the vehicle is driven the transmission fluid will begin to look
darker. The color may eventually appear light brown.

Replacement
If you do not have a fluid changer replace the fluid by the following procedure.
1. Disconnect the hose, which connects the transmission and the oil cooler (inside the radiator).
2. Start the engine and let the fluid drain out.

Running conditions : "N" range with engine idling

The engine should be stopped within one minute after it is started. If the fluid has all drained out before then,
the engine should be stopped at that point.
 the engine should be stopped at that point.

3. Remove the drain plug(A) from the bottom of the transmission case to drain the fluid.

4. Install the drain plug via the gasket, and tighten it the specified torque.

Tightening torque :
40~50 Nm (4.0~5.0kgf.m, 28.9~36.2lb-ft)

5. Pour the new fluid in through the oil filler tube.

Stop pouring if the full volume of fluid cannot be poured in.

6. Repeat the procedure in step (2).

Check the old fluid for contamination. If it has been contaminated, repeat the steps (5) and (6).

7. Pour the new fluid in through the oil filler tube.

8. Reconnect the hose (step 1) and firmly replace the oil level gauge.
Wipe off any dirt around the oil level gauge and insert it into the filler tube.
9. Start the engine and run it at idle for 1~2 minutes.
10. Move the select lever through all positions, and then move it to the "N" or "P" position.
11. Drive the vehicle until the fluid temperature rises to the normal temperature (70~80C(158~176F)), and then
check the fluid level again. The fluid level must be at the HOT mark.
12. Firmly insert the oil level gauge into the oil filler tube.

Torque Converter Stall Test

This test measures the maximum engine speed when theselect lever is at the "D" or "R" position and the torque
converter stalls. This tests the operation of the torque converter, starter motor and one-way clutch operation and the
holding performance of the clutches and brakes in the transmission.

Do not let anybody stand in front of or behind the vehicle while this test is being carried out.

1. Check the automatic transmission fluid level and temperature and the engine coolant temperature.
A. Fluid level : At the HOT mark on the oil level gauge
B. Fluid temperature : 80~100C (176~212F)
C. Engine coolant temperature : 80~100C (176~212F)
2. Check both rear wheels (left and right).
3. Pull the parking brake lever on, with the brake pedal fully depressed.
4. Start the engine.
5. Move the select lever to the "D" position, fully depress the accelerator pedal and take a reading of the maximum
engine speed at this time.

The throttle should not be left fully open for any more than 5 seconds.
If carrying out the stall test two or more times, move the select lever to the "N" position and run the engine
at 1,000 r/min to let the automatic transaxle fluid cool down before carrying out subsequent tests.
Move the select lever to the "R" position and carry out the same test again.

Stall rpm : 2,000~2,700 RPM

Range Condition Passable cause

R range slip Reverse REV in D range normal
L/R in D range abnormal
D1 rang slip D range 1st/ Sports mode 1st L/R in reverse range abnormal
UD in reverse range normal
D3 range slip 3rd gear hold OD in 3rd gear slip
(1st and 2nd gear normal)
Forwarding, reverse slip D range, R range Torque converter
Oil pump, Manual valve in the valve
Driving device abnormal

Hydraulic Pressure Test

1. Warm up the engine until the automatic transaxle fluid temperature is 80~100C(176~212F).
2. Jack up the vehicle so that the wheels are free to turn.
3. Connect the special tools(09452-21500, 09452-21000) oil pressure gauge to each pressure discharge port.
4. Measure the hydraulic pressure at each port under the conditions given in the standard hydraulic pressure table,
and check that the measured values are within the standard value ranges.
5. If a value is outside the standard range, correct the problem while referring to the hydraulic pressure test diagnosis
table.
A. Bottom side
1. RED pressure port 5. DA pressure port
2. OD pressure port 6. UD pressure port
3. 2/4 pressure port 7. LR pressure port
4. REV pressure port 8. DR pressure port

Standard Hydraulic Pressure Table

 Automatic Transaxle System

Automatic Transaxle System - Automatic

Transaxle

Automatic Transaxle System

 2009 > G 1.6 DOHC >

Components (1)

1. Torque converter 13. Parking sprag 25. Accumulator piston

2. Differential oil seal 14. Detent spring 26. Coil spring
3. Converter housing 15. Manual control shaft 27. O-ring
4. Oil pump 16. Spacer 28. Oil filter
5. Thrust washer 17. Differential 29. Valve body
6. Underdrive(U/D) clutch 18. Oil separate 30. Oil pan
7. Thrust bearing 19. Oil separate mounting bolt 31. Drain plug
8. Underdrive(U/D) clutch hub 20. Transfer driven gear 32. Valve body cover bolt
9. Transfer drive gear mounting bolt 21. Output speed sensor 33. Valve body connector
10. Transfer drive gear 22. Shift cable bracket 34. Valve body connector mounting clip
11. Parking sprag shaft 23. Plug 35. Oil level gauge
12. Sprag spring 24. Input speed sensor 36. Oil level gauge bracket bolt

Components (2)
38. Low & reverse brake piston 49. 2ND brake plate 59. Reverse sun gear
39. 2ND brake return spring 50. 2ND brake disc 60. Thrust bearing
40. Low & reverse brake spring 51. 2ND brake pressure plate 61. Overdrive(O/D) hub
retainer 52. Snap ring 62. Thrust bearing
41. Low & reverse brake return spring 53. 2ND brake piston 63. Reverse & Overdrive(O/D) clutch
42. Snap ring 54. D-ring 64. Thrust bearing
43. Wave spring 55. 2ND brake retainer 65. Rear cover
44. Low & reverse pressure plate 56. D-ring 66. Rear cover bolt
44-1. Low & reverse brake plate 57. Low & reverse planetary gear 67. One way clutch inner race
45. Low & reverse brake disc set 68. Transmission case
46. Snap ring 58. Snap ring
47. Reaction plate
48. Snap ring
 2009 > G 1.6 DOHC >

Removal
Use fender covers to avoid damaging painted surfaces.
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
Mark all wiring and hoses to avoid misconnection.
1. Disconnect the air duct (A).

2. Disconnect the PCM connectors, remove the PCM (A), and remove the battery (B).

3. Remove the battery tray (A).

4. Disconnect the inhibiter switch connector (A), solenoid valve connector (B) and the input speed sensor connector
(C).
5. Remove the shift cable assembly (A).

6. Remove the ground cable (A) by removing a bolt.

7. Disconnect the output speed sensor connector (A).

8. Remove the oil cooler hoses by moving clamps (A).

9. Install the special tools (09200-38001), the engine support fixture and the adapter on the engine assembly.

10. Remove the transaxle support bracket bolts(3ea).

11. Remove the transaxle upper mounting bolts (A-2ea) and the starter motor mounting bolts (B-2ea).

12. Remove the under shield covers(A).

13. Remove the side mud cover (A).

14. Drain the transalxe fluid by removing the drain plug (A).

15. Remove the bracket (A).

16. Disconnect the drive shafts from the transaxle. (refer to Front Driveshaft in DS group)
17. Remove the plastic dust cover (A).
18. Remove the torque converter mounting bolts(A-3ea) by rotating the crankshaft.

19. Remove the roll stopper bracket by removing bolts(A).

20. Supporting the transaxle with a jack, remove the transaxle lower mounting bolts (A-3ea, B-2ea).

21. Lowering the jack slowly, remove the transaxle.

When removing the transaxle assembly, be careful not to damage any surrounding parts or body
 components.

Installation
1. Raise the vehicle and use a transmission jack to install the transmission assembly from underneath.

Be careful not to damage any surrounding parts or body components.

2. Install the transaxle lower mounting bolts (A-3ea, B-2ea) after fitting the transaxle assembly into the engine
assembly.

Tightening torque :
[A] : 43~49Nm (4.3~4.9kgf.m, 31.1~35.4lb-ft)
[B] : 43~55Nm (4.3~5.5kgf.m, 31.1~39.8lb-ft)

3. Install the roll stopper bracket(A).

4. Install the torque converter assembly mounting bolts (A-3ea).

Tightening torque :
46~53 Nm (4.6~5.3 kgf.m, 33.3~38.3 lb-ft)
5. Install the plastic dust cover (A).

6. Connect the drive shafts to the transaxle. (refer to Front Driveshaft in DS group)
7. Install the bracket (A).

8. Install the side mud cover (A).

9. Install the under shield covers(A).

10. Install the transaxle upper mounting bolts (A-2ea) the starter motor mounting bolts (B-2ea).

Tightening torque :
[A] 60~80 Nm (6.0~8.0 kgf.m, 43.4~57.9 lb-ft)
[B] 43~55 Nm (4.3~5.5 kgf.m, 31.1~39.8 lb-ft)

11. Install the transaxle insulator mounting bracket bolts(3ea).

Tightening torque :
90~110 Nm (9~11 kgf.m, 65~79 lb-ft)

12. Remove the special tool (09200-38001).

13. Connect the transaxle oil cooler hoses (A) to the tubes by fastening the clamps.

14. Install the output speed sensor connector (A).

15. Install the ground cable (A) to transaxle.

16. Install the shift cable assembly (A).

Tightening torque :
10~14Nm (1.0~1.4kgf.m, 7.2~10.1lb-ft)
17. Connect the inhibiter switch connector (A), solenoid valve connector (B) and the input speed sensor connector(C).

18. Install the battery tray (A).

19. After installiing the battery (B), install the PCM (A).

20. Connect the air duct (A).

21. After completing the installation perform the following procedure;
A. Adjust the shift cable.
B. Refill the transaxle fluid.
C. Clean the battery posts and cable terminals with sandpaper and grease them to prevent corrosion before
installing.

When replacing the automatic transaxle, reset the automatic transaxle's values by using the High- Scan Pro.
1. Connect the Hi-Scan Pro or GDS connector to the data link connector under the dash pad and power cable
to the cigar jack under the center facia.
2. Turn the ignition switch on and power on the Hi-Scan Pro.
3. Select the vehicle's name.
4. Select 'AUTOMATIC TRANSAXLE'.
 Automatic Transaxle System

Valve Body System - Solenoid Valve

Automatic Transaxle System

 2009 > G 1.6 DOHC >

Description
TCM calculates the best condition using the information from all kinds of sensors. If the solenoid valve receives the
information on the oil pressure, the solenoid valve actuates according to the driving signal. All kinds of regulators in
the valve body are controlled to change the oil passage and also the line pressure is controlled by TCM.

! PWM (Pulse Width Modulation) Solenoid Valve

Structure and functions
PWM solenoid valve is composed of five solenoid valves and the oil capacity in the solenoid valve is changed by the
electric duty value of TCM. The oil pressure of the valve body and the torque converter engages or disengages the
damper clutch. The solenoid valves send the operating oil pressure to the clutches and brakes at each range and also
control the strength and weakness of oil pressure to reduce shock when shifting.

PWM (Pulse Width Modulation) solenoid

PWM solenoid valve

Range PCSV-A PCSV-B PCSV-C PCSV-D ON, OFF
(SCSV-B) (SCSV-C) (SCSV-D) (DCCV) (SCSV-A)
N, P OFF ON ON OFF ON
1st ON ON OFF OFF ON
2nd ON OFF OFF ON OFF
3rd OFF ON OFF ON OFF
4th OFF OFF ON ON OFF
Reverse OFF OFF ON OFF ON
 LOW OFF ON OFF OFF ON

PWM (Pulse Width Modulation) Solenoid Valve Control Feature

PWM solenoid valve is controlled linearly according to the duty ratio.

Oil pressure range:

0~4.3 kgf/cm! (0~422kpa, 0~61.2psi)

Type 3way & Normal High

Input voltage 12V
Coil resistance 3.20.2" (at 25C, 77F)
Cycle 50Hz
 2009 > G 1.6 DOHC >

Removal
1. Remove the battery terminal.
2. Lift the vehicle.
3. Remove the under cover.
4. Loosen the drain plug and drain the transaxle oil.
5. Remove the oil pan. (Refer to Automatic transaxle's disassembly in overhaul manual)
6. Remove the oil filter.
7. Remove the valve body. (Refer to Valve body's disassembly in overhaul manual)
8. Disconnect the main harness(A) from valve body.

9. Remove the solenoid valve assembly(A).

Installation
1. Install the solenoid valve.

Apply the ATF oil or White Vaseline to the O-ring to prevent damage.

2. Connect the solenoid valve connector to the valve body.

When connecting the solenoid valve connector, check the connector for rust, dirt, or oil, then clean and
reconnect it.

3. Install the valve body. (Refer to Valve body's reassembly in overhaul manual)

Tightening torque :
 10~12Nm(1.0~1.2kgf.m, 7~8lb-ft)

4. Install the oil filter.

Tightening torque :
10~12Nm(1.0~1.2kgf.m, 7~8lb-ft)

5. Continue to apply liquid gasket at application points at the oil pan with 2.5mm (0.098in) thickness.

Liquid gasket Part name : Threebond 1281B

6. Tighten the mounting bolt with the specified torque after installing the oil pan.

Tightening torque :
10~12Nm(1.0~1.2kgf.m, 7~8lb-ft)

7. Install the drain plug.

Tightening torque :
40~50Nm(4.0~5.0kgf.m, 28.9~36.2lb-ft)

8. Installation is the reverse of the removal.

 Automatic Transaxle System

Valve Body System - VFS (Variable Force

Solenoid) Valve

Automatic Transaxle System

 2009 > G 1.6 DOHC >

Description
VFS valve controls the regulator valve and varies the line pressure from 4.5bar to 10.5bar according to the throttle
open angle and the shift range. The holder is installed on the upper side of the case and the filter is installed to the
two places on the holder outside to prevent in the strange material from flowing in the VFS.

VFS (Variable Force Solenoid) Valve Control Feature

PWM solenoid valve is linear controlled according to the current value.

type 3way & Normal High
Input voltage 12V
Coil resistance 3.50.2!(at 25C, 77F)
Operating current 0 ~ 1200 mA
 2009 > G 1.6 DOHC >

Removal
1. Remove the battery terminal.
2. Lift the vehicle.
3. Remove the under cover.
4. Loosen the drain plug and drain the transaxle oil.
5. Remove the oil pan. (Refer to Automatic transaxle's disassembly in overhaul manual)
6. Remove the oil filter.
7. Remove the valve body. (Refer to Valve body's disassembly in overhaul manual)
8. Disconnect the VFS solenoid valve connector (A).

9. Remove the solenoid valve assembly (B).

Installation
1. Install the solenoid valve (B).

Apply the ATF oil or White Vaseline to the O-ring not to be damaged.

2. Connect the solenoid valve connector (A).

When connecting the solenoid valve connector, check the connector for rust, dirt, or oil, then reconnect it.

3. Install the valve body. (Refer to Valve body's reassembly in overhaul manual)

Tightening torque :
10~12Nm(1.0~1.2kgf.m, 7~8lb-ft)
4. Install the oil filter.

Tightening torque :
5~7Nm(0.5~0.7kgf.m, 4~5lb-ft)

5. Continue to apply liquid gasket at application points at the oil pan with 2.5mm (0.098in) thickness.

Liquid gasket Part name : Threebond 1281B

6. Tighten the mounting bolt with the specified torque after installing the oil pan.

Tightening torque :
10~12Nm(1.0~1.2kgf.m, 7~8lb-ft)

7. Install the drain plug.

Tightening torque :
40~50Nm(4.0~5.0kgf.m, 28.9~36.2lb-ft)

8. Installation is the reverse of the removal.

 Automatic Transaxle System

Automatic Transaxle Control System - Shift

Lever

Automatic Transaxle System

 2009 > G 1.6 DOHC >

Components

1. Shift lever knob 4. Shift lock cably assembly

2. Shift lever assembly 5. Retainer
3. Control cable assembly 6. Brake pedal assembly
 2009 > G 1.6 DOHC >

Removal
1. Remove the center console cover (A).

2. Remove the center console. (refer to Console in BD group)

3. Disconnect the connector (A).

4. Remove the cotter pin (A) from the shift cable.

5. Remove the shift cable holder.

6. Remove the shift lock cable (A).
7. Remove the shift lock cable mounting nut (B).
8. Remove the shift lever assembly by removing the bolts(4ea).

9. Remove the retainer (A) and nuts (B).

10. Remove the shift cable assembly from the transaxle. (refer to Automatic transaxles removal)
11. Remove the shift cable assembly.

Inspection
1. Check the shift cable for proper operation and for damage.
2. Check the boots for damage if boots are applied.
3. Check the boots for wear, abrasion, sticking, restricted movement or damage if boots are applied.
4. Check for the weak or damaged spring.

Adjustment
Adjusting the shift cable
1. Set the room side lever and the manual lever (A) to N position.
2. Push the shift cable (B) lightly to "F" direction shown to eliminate the free play.

3. Tighten the adjusting nut (C).

Tightening torque :
10~14Nm (1.0~1.4kgf.m, 7.2~10.1lb-ft)

4. Check that this part operates at each range of the manual lever corresponding to each position of the room lever.

Installation
1. Install the shift cable assembly while the manual lever on the transaxle is placed in the neutral position.
(refer to Automaic Transaxle Installation)
2. Install the retainer (A) and nuts (B).

Tightening torque :
10~14Nm (1.0~1.4kgf.m, 7.2~10.1lb-ft)

3. Install the shift lever assembly (A).

Tightening torque :
10~14Nm (1.0~1.4kgf.m, 7.2~10.1lb-ft)
4. Install the shift lock cable mounting nut (B).

5. Install the shift lock cable (A).

6. Install the shift cabble holder.
7. Insert the cotter pin (A) from the shift cable.

8. Connect the connector (A).

9. Install the center console. (refer to Console in BD group)

10. Install the center console cover (A).
 Automatic Transaxle System

Automatic Transaxle Control System - Input

Speed Sensor

Automatic Transaxle System

2009 > G 1.6 DOHC >

Description
1. Type : HALL SENSOR
Sensor type 2. Operating voltage : DC 12V
3. Current consumption : 22mA (Max)

1. Input speed sensor: Detect the input shaft rotation at the OD & REV retainer side to control oil
pressure when shifting.
Function
2. Feedback control, clutch-clutch control, damper clutch control, shift range control, incorrect ratio
control and sensor trouble detection signal.

Connector

Item Inspection item Standard value

Air gap Input speed sensor 0.035in(0.9mm)
Sensor resistance Input speed sensor Over 1 M!
HIGH Over 4.8V
Output voltage
LOW Below 0.8V
 2009 > G 1.6 DOHC >

Removal
1. Remove the battery terminal.
2. Remove the battery and battery tray.
3. Remove the air duct.
4. Remove the air cleaner assembly. (Refer to Automatic transaxle's Removal)
5. Remove the input speed sensor connector (A).

6. Remove the input speed sensor(A).

Installation
1. Install the new O-ring to the input speed sensor.
2. Install the input speed sensor (A).

Tightening torque :
10~12Nm(1.0~1.2kgf.m, 7~8lb-ft)

While installing the input shaft speed sensor, do not allow dust or other foreign particles to enter the transaxle.
3. Check the connector for dust, dirt, or oil, and then connect the input speed sensor connector (A) securely.

4. Installation is the reverse of removal.

 Automatic Transaxle System

Automatic Transaxle Control System -

Output Speed Sensor

Automatic Transaxle System

2009 > G 1.6 DOHC >

Description
1. Type : HALL SENSOR
Sensor type 2. Output voltage : DC 12V
3. Current consumption : 22mA (Max)

1. Output speed sensor : Detect the output shaft rpm(T/F DRIVEN GEAR RPM) at the T/F driven
gear
Function
2. Feedback control, clutch-clutch control, damper clutch control, shift range control, incorrect ratio
control and sensor trouble detection signal.

Connector

Item Inspection item Standard value

Air gap Output speed sensor 0.025in(0.65mm)
Sensor resistance Output speed sensor Over 1 M!
HIGH Over 4.8V
Output voltage
LOW Below 0.8V
 2009 > G 1.6 DOHC >

Removal
1. Remove the battery terminal.
2. Remove the battery and battery tray.
3. Remove the air duct.
4. Remove the air cleaner assembly. (Refer to Automatic transaxle's Removal)
5. Remove the output speed sensor connector(A).

6. Remove the output speed sensor(A).

Installation
1. Install the new O-ring to the output shaft speed sensor.
2. Remove the output speed sensor (A).

Tightening torque :
10~12Nm(1.0~1.2kgf.m, 7~8lb-ft)

While installing the output speed sensor, do not allow dust or other foreign particles to enter the transaxle.
3. Check the connector for dust, dirt, or oil, then connect the output speed sensor connector (A) securely.

4. Installation is the reverse of removal.

 Automatic Transaxle System

Automatic Transaxle Control System -

Transaxle Oil Temperature Sensor

Automatic Transaxle System

2009 > G 1.6 DOHC >

Description
1. Type : Thermister
Sensor type
2. Use available temperature :-40~160C(-40~320F)
1. Detect the temperature of ATF through the thermistor which is exposed outside.
Function and feature
2. When shifting the range, it is used as the oil pressure control information.

Connector

Temp.[C(F)] Resistance (K!) Temp.[C(F)] Resistance (K!)

-40(-40) 139.5 80(176) 1.08
-20(-4) 47.4 100(212) 0.63
0(32) 18.6 120(248) 0.38
20(68) 8.1 140(284) 0.25
40(104) 3.8 160(320) 0.16
60(140) 1.98

Installation Location
 2009 > G 1.6 DOHC >

Removal
1. Remove the battery terminal.
2. Lift the vehicle.
3. Remove the under cover.
4. Loosen the drain plug and drain the transaxle oil.
5. Remove the oil pan. (Refer to Automatic transaxle's disassembly in overhaul manual)
6. Remove the oil filter.
7. Remove the valve body. (Refer to Valve body's disassembly in overhaul manual)
8. Disconnect the main harness connector (A) from the valve body and remove oil temperature sensor.

Installation
1. Install oil temperature sensor and connect the main harness connector (A) to the valve body.

When connecting the oil temperature connector, check the connector for rust, dirt, or oil, then reconnect it.

2. Install the valve body. (Refer to Valve body's reassembly in overhaul manual)

Tightening torque :
10~12Nm(1.0~1.2kgf.m, 7~8lb-ft)

3. Install the oil filter.

Tightening torque :
5~7Nm(0.5~0.7kgf.m, 4~5lb-ft)

4. Continue to apply liquid gasket at application points at the oil pan with 0.098in(2.5mm) thickness.
 Liquid gasket Part name : Threebond 1281B

5. Tighten the mounting bolt with the specified torque after installing the oil pan.

Tightening torque :
10~12Nm(1.0~1.2kgf.m, 7~8lb-ft)

6. Install the drain plug.

Tightening torque :
40~50Nm(4.0~5.0kgf.m, 28.9~36.2lb-ft)

7. Installation is the reverse of the removal.