U-100 & New Nubira

SERVICE TRAINING MANUAL

AUTOMATIC
TRANSMISSION
(4HP16)

DAEWOO

DAEWOO MOTOR CO., LTD

CONTENTS

1. General Information 3
2. Operation .. 16
3. Power Flow . 18
4. Electrical Component . 24
5. Hydraulic Component ..... 36
6. Hydraulic Power Flow . 40
7. Diagnosis . 48
8. Mechanical Components . 74
9. Special Tool

. 81

GENERAL
INFORMATION

INTRODUCTION

4HP-16

Description of Automatic Transmission

The 4HP-16 is a Automatic transmission with 4 forward gears,one reverse gear and electronichydraulic control.
It is designed for use in vehicle with front-wheel drive and a transverse engine. The transmission is
operated via the selector lever and possibly also a switch.
The 4HP-16 transmission has a hydrodynamic Torque Converter with a controlled slip lock-up
clutch. A planetary gear train establishes the mechanical gear ratios. The integral constant ratio can
be adapted to the engines power output and the vehicles weight.
The electronic-hydraulic control makes controlled power shifts and various shift programs possible.
In selector lever position P, the output is locked mechanically.
The special feature of this transmission is that it operates without freewheels.Shifting between
individual gears takes place by means of overlapping clutch engagement and release.
The advantages of overlap shifting are as follows:
- The transmission can be of more compact design and is lighter on account of absence
of freewheels and the lower number of shift elements.
- Lower drag losses,higher efficiency.
- Lower peak torque acting on the components and drive line.
However,overlap shifting necessitates high-performance hardware and software,and precision
engine signals.

Structure of Automatic Transmission

2

10
11

1. Input Shaft
2. Torque Converter
3. Oil Pump
4. Brake F
5. Hydraulic Control Unit

6. Output Speed Sensor

7. Brake D
8. Brake C
9. Clutch B
10. Input Speed Sensor
11. Clutch E
14

13

12

12. Planetary Gear Set (Rear)

13. Planetary Gear Set (Front)
14. Central Spur Gear
15. Parking Lock Gear

15

16. Lateral Shaft

16
17

17. Differential

GENERAL
INFORMATION

SPECIFICATIONS

4HP-16

Specifications
NO

Items

Model : 4HP-16

Specifications
4: Four Speed
H: Hydraulic
P: Planetary Gear
16 : Torque Capacity(240Nm)

Dimension of Torque
Converter

273mm

Weight of Transmission

76 Kg(Wet), 70.9 Kg(Dry)

Gear Ratio

Remarks

240 Nm/at 4500 RPM

1st : 2.719
2nd : 1.487
3rd : 1.000
4th : 0.717

Reverse : 2.529
5

Final Gear Ratio

3.945 (2.0L DOHC)

Oil Type

ESSO-LT(71141)

Change Period of Oil

Not Required

Oil Capacities

4L
4L
2L
6.9L
6.9L

NO

Items

Output Speed Sensor

10

11

12

4.111 (1.8L SOHC / 1.6 DOHC)

When drain plug opening or

Bottom pan removal
Exchange torque converter
Overhaul
Total

Specification

Input Speed Sensor

Solenoid "1,2"

Remarks

Resistance

(Hall sensor)

Resistance to Ground

Clearance

0.1~1.3mm

Resistance

788~872

Resistance to Ground

Clearance

0.1~2.0mm

Resistance

26.50.5

Resistance to Ground

At 20

1 :Connect (12V), 0 : Disconnect (0V)

P/N Switch

L1

L2

L3

L4

GENERAL
INFORMATION

4HP-16

SPECIFICATIONS

Specifications
NO

Items

13

Oil Temperature Sensor

(PTC thermistor)

Specifications

PTC: Positive Temperature

Cofficient) thermistor.

14

Pressure Control Solenoid

(EDS)

15

Resistance
to Ground

Resistance

5.70.45

Resistance
to Ground

Resistance

5.70.45

Resistance
to Ground

Resistance

5.70.45

Resistance
to Ground

Low : 6.2 ~8.6

Time lag Test

Stall Test (U-100 / Nubira)

754
820
889
962
1,039
1,118
1,202
1,288
1,379
1,472
1,569
1,670
1,774
1,882
5.70.45

High : 15.3 ~17.4

Line Pressure(Bar)
(Solenoid No.1)

16

17

-10
0
10
20
30
40
50
60
70
80
90
100
110
120
Resistance

At 20

At 20

P,R,N,D

Less than 1.2sec

ND

Less than 1.5sec

NR

D: 2400 ~2800 / 2500~2800 RPM

R: 1300 ~2200 / 1600~2000 RPM

Remarks

GENERAL
INFORMATION

GENERAL DESCRIPTION

4HP-16

Shift Lever Position

The driver engage the travel position via the selector lever :
P - Park position.
R - Reverse
N - Neutral
D - Forward speeds : For travel in 1st ~ 4th gear
3 - For travel in 1st to 3rd gear
2 - For travel in 1st to 2nd gear
1 - For travel in 1st gear
Driving Mode
1) Economy/Power Mode
This mode is selected by power switch On or Off which is located on shift lever
when the ignition switch is On.
When the power mode is selected,the shift-up will be delayed to increase torque.
2) Hold Mode
- When the driver push the hold button, the driver can hold the demanded gear
intentionally.
- At the winter season ,this mode will be possible as winter mode function.
D range -2,3,4
3 range - 2,3
2 range - 2
1 range - 1
3) Emergency Mode
- When driving in D,3,2,1 : 4th gear holding
- After ignition switch Off and On : 3rd gear holding

GENERAL
INFORMATION

SHIFT POINT CHART( U-100 1.8 SOHC)

Shift Point Chart- Economy Mode

4HP-16

GENERAL
INFORMATION

SHIFT POINT CHART( U-100 1.8 SOHC)

Shift Point Chart- Power Mode

4HP-16

GENERAL
INFORMATION

SHIFT POINT CHART( U-100 2.0 DOHC)

Shift Point Chart- Economy Mode

10

4HP-16

GENERAL
INFORMATION

SHIFT POINT CHART( U-100 2.0 DOHC)

Shift Point Chart- Power Mode

11

4HP-16

GENERAL
INFORMATION

SHIFT POINT CHART( U-100 2.0 DOHC)

4HP-16

T P S [% ]

Shift Point Chart- Hold Mode(2.0L DOHC)

23 43

11 5 .7
32

1 0 6 .0

34

9 6 .4
8 6 .8
7 7 .1
6 7 .5
5 7 .8
4 8 .2
3 8 .6
2 8 .9
1 9 .3
9 .6
0 .0
0

700

1400

2100

2800

3500

4200

4900

5600

6300

7000
[rp m ]

Shift Point - VSS / TPS (Based on 2.0L DOHC,Economy mode)

Application

12 Shift

TPS

10%

VSS(Km/h)

18

23 Shift

34 Shift

25% 50% 100% 10% 25% 50% 100% 10% 25% 50% 100%
20

27

57

37

38

Down Shift

Application

49 108

50

53

74

168

TCC
Engage(4th)

TCC
Release(4th)

Shift gear

43

32

21

10%(TPS)

10%(TPS)

VSS(Km/h)

43

22

12

70

65

12

GENERAL
INFORMATION

SHIFT POINT CHART( NUBIRA 2.0 DOHC)

4HP-16

T P S [% ]

Shift Point Chart- Economy Mode

21 12

11 5 .7

32

23

43 34

1 0 6 .0
9 6 .4
8 6 .8
7 7 .1
6 7 .5
5 7 .8
4 8 .2
3 8 .6
2 8 .9
1 9 .3
9 .6
0 .0
0

700

1400

2100

2800

3500

4200

4900

5600

6300

7000
[rp m ]

T P S [% ]

Shift Point Chart- Power Mode

21 12

11 5 .7

32

23

43 34

1 0 6 .0
9 6 .4
8 6 .8
7 7 .1
6 7 .5
5 7 .8
4 8 .2
3 8 .6
2 8 .9
1 9 .3
9 .6
0 .0
0

700

1400

2100

13

2800

3500

4200

4900

5600

6300

7000
[rp m ]

GENERAL
INFORMATION

SHIFT POINT CHART( NUBIRA 2.0 DOHC)

4HP-16

T P S [% ]

Shift Point Chart- Hold Mode

23 43

11 5 .7
32

1 0 6 .0

34

9 6 .4
8 6 .8
7 7 .1
6 7 .5
5 7 .8
4 8 .2
3 8 .6
2 8 .9
1 9 .3
9 .6
0 .0
0

700

1400

2100

2800

3500

4200

4900

5600

6300

7000
[rp m ]

Shift Point - VSS / TPS (Based on Economy mode)

Application

12 Shift

TPS

10%

VSS(Km/h)

18

23 Shift

34 Shift

25% 50% 100% 10% 25% 50% 100% 10% 25% 50% 100%
19

27

53

32

36

Down Shift

Application

52

103

45

49

79

156

TCC
Engage(4th)

TCC
Release(4th)

Shift gear

43

32

21

10%(TPS)

10%(TPS)

VSS(Km/h)

35

24

14

68

65

14

GENERAL
INFORMATION

4HP-16

OVERLAP SHIFTING

Overlap Shifting
The 4HP-16 automatic transmission hasnt one way clutch and very simple structure of power train,
but the TCM controls pressure to apply, release clutch and brake during shifting to adjust engine
torque,therefore shifting feel will be optimized

Pressure

Engine RPM

Disengage Clutch

Overlap

Engage Clutch

Time

15

GENERAL
INFORMATION

TIGHTENING TORQUE

4HP-16

Tightening Torque
Item

Specification(Kg.cm)

N.m

217 ~ 253

21.7 ~25.3

1980 ~ 2420

198 ~ 242

Rear cover attachment bolts(13mm-5EA)

217 ~ 253

21.7 ~ 25.3

P/N Position switch(10mm-2EA)

90 ~ 110

9 ~ 11

Baffle plate attachment(T27-3EA)

90 ~ 110

9 ~ 11

Oil pump housing(T27-9EA)

90 ~ 110

9 ~ 11

Oil filter(10mm-1EA)

90 ~ 110

9 ~ 11

Input speed sensor attachment bolt

72 ~ 88

7.2 ~ 8.8

Output speed sensor attachment bolt

72 ~ 88

7.2 ~ 8.8

Valve upper and lower body attachment bolt

(T27-17EA)

52 ~ 66

5.2 ~ 6.6

Valve body attachment bolt(T27-7EA)

72 ~ 88

7.2 ~ 8.8

Oil pan

54 ~ 66

5.4 ~ 6.6

Oil drain plug

405 ~ 495

40.5 ~ 49.5

Oil level checking plug

405 ~ 495

40.5 ~ 49.5

Pressure check plug

180 ~ 220

18 ~ 22

Valve cover attachment bolt

540 ~ 660

540 ~ 66

Solenoid attachment bolt

540 ~ 660

540 ~ 66

Pressure regulator(EDS) attachment bolt

540 ~ 660

540 ~ 66

Oil cooler pipe union bolt

300 ~ 350

30 ~ 35

Shift control cable guide bolt

50 ~ 100

5 ~ 10

Shift control cable nut

50 ~ 100

5 ~ 10

Transmission upper side fixing bolt

600 ~ 850

60 ~ 85

Transmission lower side fixing bolt(long length)

270 ~ 350

27 ~ 35

Transmission lower side fixing bolt(short length)

170 ~ 250

17 ~ 25

Mounting bracket fixing bolt

1,000

100

Torque converter fixing bolt

400 ~ 500

40 ~ 50

Bearing plate bolts(T25-15EA)

Slotted nut

16

FUNCTION OF COMPONTS

OPERATION

4HP-16

Structure of Automatic Transmission

Valve Body
Torque
Converter

Brake
"F"

ClutchB
BrakeD

VSS

Brake
C

ISS
ClutchE

Oil Pump

Input shaft

Helical
Gear
Parking
Lock Gear

Rear Planetary Gear Set

Front Planetary Gear

Side Shaft
Differential Gear

Function of Components
Function

Components
Clutch "B"
Clutch "E"

Connects Input shaft & Rear Planetary Sun Gear

Connects Input shaft & Rear Planetary Carrier,Front Planetary
Ring Gear

Brake "C"

Locks rotation of Rear Planetary Sun Gear both direction

Brake "D"

Locks rotation of Rear Planetary Carrier&Front Planetary Ring

Gear both direction

Brake "F"

Locks rotation of Front Planetary Sun Gear both direction

17

Remarks

4HP-16

RANGE REFERENCE CHART

OPERATION

Range Reference Chart

Component
Range

Solenoid

Pressure Control Solenoid

3

Clutch

P (Park)

ON

ON

R (Reverse)

ON,OFF

ON

N (Neutral)

ON

ON

4 th

ON,OFF

OFF

OFF,ON

3 rd

ON,OFF

OFF

OFF,ON

ON

2 nd

ON,OFF

OFF

ON

ON

ON

1 st

ON,OFF

ON

ON

ON

ON

ON

ON

Brake
C

ON

ON

ON

Emergency 3rd

OFF

OFF

OFF

OFF

OFF

OFF

Emergency 4 th

OFF

OFF

OFF

OFF

OFF

OFF

Operation of Powertrain

Clutch B
(Helical Gear I)

Engine

Brake C

(Helical Gear II)

Brake F
Clutch E

Brake D

(Front Planetary Gear)

18

(Rear Planetary Gear)

(Differential Gear)

POWER FLOW

POWER FLOW (PARK/NEUTRAL)

4HP-16

Powertrain (P/N)
Clutch

Shift Lever

P (Park)

N (Neutral)

Brake
E

Gear Ratio

Clutch B
(Helical Gear I)

Engine

Brake C
Brake F

(Helical Gear II)

Brake D

(Front Planetary Gear)

Clutch E
(Rear Planetary Gear)

Differential Gear)

Engine Torque converter pump Turbine Input shaft ClutchB The rear planetary
sun gear is applied only, but there is not held component,and so this range doesnt matter of
power flow.

19

POWER FLOW (REVERSE)

POWER FLOW

4HP-16

Powertrain (Reverse)
Clutch

Selector Lever

R (Reverse)

Brake
E

Gear Ratio
2.529

Clutch B

(Helical Gear I)

Engine

Brake C
(Helical Gear II)

Brake F

Brake D

(Front Planetary Gear)

Clutch E
(Rear Planetary Gear)

(Differential Gear)

Engine Torque converter pump Turbine Input shaft ClutchB Rear planetary
carrier gear Rear planetary ring gear Front planetary carrier Helical gear I Helical
gear II Differential gear

20

POWER FLOW

POWER FLOW ( 1ST GEAR)

4HP-16

Powertrain (1st gear)

Clutch

Selector Lever

Brake
E

1 st

1 st

1 st

1 st

Gear Ratio

2.719

Clutch B

(Helical Gear I)

Engine

Brake C
(Helical Gear II)

Brake F

Brake D

(Front Planetary Gear)

Clutch E
(Rear Planetary Gear)

(Differential Gear)

Engine Torque converter pump Turbine Input shaft ClutchB Rear planetary sun
gear Rear planetary carrier Front planetary ring gear Front planetary carrier Helical
gear I Helical gear II Differential gear

21

POWER FLOW (2ND GEAR)

POWER FLOW

4HP-16

Powertrain (2nd gear)

Clutch

Selector Lever

Brake
E

2 nd

2 nd

2 nd

Gear Ratio

1.487

Clutch B

(Helical Gear I)

Engine

Brake C
(Helical Gear II)

Brake F

Brake D

(Front Planetary Gear)

Clutch E

(Rear Planetary Gear)

(Differential Gear)

Engine Torque converter pump Turbine Input shaft ClutchE Front planetary ring
gear Front planetary carrier Helical gear I Helical gear II Differential gear

22

POWER FLOW (3RD GEAR)

POWER FLOW

4HP-16

Powertrain (3rd gear)

Clutch

Selector Lever

Brake

3 rd

3 rd

Gear Ratio
1.000

Clutch B

(Helical Gear I)

Engine

Brake C
(Helical Gear II)

Brake F

Brake D

(Front Planetary Gear)

Clutch E

(Rear Planetary Gear)

(Differential Gear)

Engine Torque converter pump Turbine Input shaft ClutchB,E Rear planetary
sun gear,carrier Rear planetary ring gear Front planetary carrier Helical gear I Helical
gear II Differential gear

23

POWER FLOW (4TH GEAR)

POWER FLOW

4HP-16

Powertrain (4th gear)

Clutch

Selector Lever
D

4 th

Brake
E

Gear Ratio
0.717

Clutch B

(Helical Gear I)

Engine

Brake C
(Helical Gear II)

Brake F

Brake D

(Front Planetary Gear)

Clutch E

(Rear Planetary Gear)

(Differential Gear)

Engine Torque converter pump Turbine Input shaft ClutchE Rear planetary
carrier Rear planetary ring gear Front planetary carrier Helical gear I Helical gear II
Differential gear

24

ELECTRICAL
COMPONENT

OUTPUT SPEED SENSOR

4HP-16

Output Speed Sensor

The output(vehicle) speed sensor(OSS) is a hall effect sensor that generates information in relation
to transmission output speed of helical gear I to the TCM. The VSS information is used by the TCM
to control shift timing,line pressure and TCC apply or release.
The OSS mounts in the case at the speed sensor rotor which is helical gear 1 and it is designed to
detect frequency(20 ~ 8,000 Hz) to send the TCM.

OSS Rotor(Helical gear I)

Output speed sensor

An air gap of 0.1mm~1.3mm is

maintained between the sensor
and the teeth on the speed sensor
rotor.
Resistance : Infinite

B10

OSS

Hall I.C

TCM

B5
2

25

8V Ref

ELECTRICAL
COMPONENT

INPUT SPEED SENSOR

4HP-16

Input Speed Sensor

The input speed sensor is a magnetic inductive pickup that generates information in relation
to transmission input speed signal to the TCM. The TCM uses transmission input speed sensor
information to control line pressure, TCC apply or release and shift patterns.
This information is also used to calculate the appropriate operating gear ratios and slippage.

The input speed sensor mounts on the valve body

and an air gap of 0.1mm~2.0mm is maintained between
the clutch Bpiston and sensor.
The sensor consist of a permanent magnetic surrounded
by a coil wire.
Higher transmission input speed induce higher frequency
(100 ~ 8,000Hz)and higher voltage measurement at the
sensor.
Resistance : 788 ~ 872 ohm
(Input speed sensor)

B2
16

L B7

(Input speed
sensor)

15

B4

(Shield earth)

26

TCM

ELECTRICAL
COMPONENT

TRANSMISSION FLUID
TEMPERATURE SENSOR

4HP-16

Fluid Temperature Sensor

The temperature sensor is PTC(Positive Temperature Coefficient) thermistor that provides
information to the TCM regarding transmission fluid temperature.
The internal electrical resistance of the sensor varies in relation to the operating temperature of
the transmission fluid.The TCM sends a 5 volt reference signal to the temperature sensor and
measures the signal voltage in the electrical circuit.
The TCM measures this voltage as another input to help control line pressure,shift schedules and
TCC apply or release.
When transmission fluid temperature reaches 120(248 ),the TCM enters Protection mode.
Above this temperature,the TCM modifies transmission shift schedules and TCC apply in an
attempt to reduce fluid temperature by reducing transmission heat generation. During Protection
mode, the TCM applies the TCC more progressively than Economy mode.
Also,the TCM performs the 2-3 and 3-4 shifts delay to help reduce fluid heat generation.

TFT Sensor

2000
1800

Sensor Resistance()

TFT Sensor
1600

A4
5V Ref

1400

TCM

1200
4

1000

B1

800
600
-1 0

10

20

30

40

50

60

70

80

90

90

110

Temperature ()

27

120

Resistance : 1472 ohm at 20 deC

ELECTRICAL
COMPONENTS

4HP-16

POSITION OF SOLENOIDS

Valve body & Solenoid position

Pressure Control
Solenoid(EDS) 5

Pressure Control
Solenoid(EDS) 3
Pressure Control
Solenoid(EDS) 6

1
3
6

2
4

5
8

Solenoid 1
Solenoid 2

(Connector)

The connector is based on

engine wiring harness

Pressure Control
Solenoid(EDS) 4

E103A314

Specification of Solenoids (Wiring color based on the Transmission side)

Components
Input speed sensor
Vehicle speed sensor
Oil temperature
sensor
Solenoid No. 1

Connector Pin
No.

Wiring Harness
Color

16

Gr

15

V(1 wire)

12

Gr

V(2 wires)

13

Lg

Pressure control
solenoid No.3

V(2 wires)

Pressure control
solenoid No.4

V(1 wire)

Pressure control
solenoid No.5

V(2 wires)

10

V(2 wires)

11

Solenoid No. 2

Pressure control
solenoid No.6

28

Resistance
788 ~ 872
(Hall sensor)
1472
26.5 0.5
26.5 0.5
5.7 0.45
5.7 0.45
5.7 0.45
5.7 0.45

ELECTRICAL
COMPONENT

4HP-16

SOLENOID 1,2

Solenoid 1,2
The 4HP16 transmission uses two normally
close type On/Off solenoids.
The No.1 solenoid particularly controls line
pressure(High/Low) and clutch,brake control
valves.
Another No.2 solenoid controls the oil flowing to
clutchE or TCC valve through the reduction
valve.

(Solenoid No.1,2)

Operating Condition of Solenoids

Gear

Solenoid 1

P/N

Solenoid 2

ON

ON

ON / OFF

ON

1 st

ON / OFF

ON

2 nd

ON / OFF

OFF

3 rd

ON / OFF

OFF

4 th

ON / OFF

OFF

Solenoid 1

C 8

12V

Solenoid 2

13

A1

12

A9

TC M

29

ELECTRICAL
COMPONENT

PRESSURE CONTROL SOLENOID

4HP-16

Pressure Control Solenoid (EDS)

The 4HP16 transmission uses three normally
open type pressure control solenoids(NO
3,5,6)
and a normally close type pressure control
solenoid(NO 4) for controlling clutch,brake,
TCC.
The TCM controls these solenoids with various
information to shift up and down of gears.
The TCM controls the EDS on a positive duty
cycle which is defined as the percent of time
current is flowing through the solenoid coil
during each cycle.

(Pressure Control Solenoid)

Operating Condition of Pressure Control Solenoids

Application

Pressure
Control
Solenoid

Condition(Current : 0 Amp)
3

Open

Close

Open

Open

Resistance

Remarks

5.7 0.45

At 20

C 6
C 7

EDS3 EDS4

EDS5

EDS6 1 1

A12

10

A10

A3

A 11

12V

TC M

30

ELECTRICAL
COMPONENT

PRESSURE CONTROL SOLENOID

4HP-16

Pressure Control Graphic (Solenoid No. 3,5,6)

6

Pressure(bar)

5
4
3
2
1

100

200

300

400

500

600

700

800

Current ( )

Pressure Control Graphic (Solenoid No. 4)

6

Pressure(bar)

5
4
3
2
1

100

200

300

400

500

600

700

Current ( )

31

800