Automatic Transaxle System

Automatic Transaxle System

General Information
 2009 > D 1.6 TCI-U >

Special tool

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
 2009 > D 1.6 TCI-U >

SPECIFICATION

Transaxle model A4CF2

Engine model Gasoline 2.0L/ Diesel 1.6L
Torque converter 3 elements 2 phases 1 stage
Torque converter size Ø236
Oil pump type Parachoid
Transaxle 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 3.849(Gasoline)/ 3.532(Diesel)
Fluid pressure balance piston 3EA
Stall speed 2,000~2,700 rpm
Accumulator 4EA
Solenoid valve 6EA (PWM:5EA, VFS:1EA)
Gear shift position 4 range (P,R,N,D)
Oil filter 1EA

Tightening torque
Item Nm kgf.m lb-ft
Control cable bracket 19~23 1.9~2.3 14~17
Eye bolt 28~34 2.8~3.4 19~24
Oil cooler feed tube 19~23 1.9~2.3 14~17
Oil filter 10~12 1.0~1.2 7~8
Input shaft speed sensor 10~12 1.00~1.2 7~8
Output shaft speed sensor 10~12 1.00~1.2 7~8
Manual control lever 17~21 1.70~2.1 13~15
Inhibitor switch 10~12 1.00~1.2 7~8
Valve body cover 10~12 1.00~1.2 7~8
Valve body mounting bolt 10~12 1.0~1.2 7~8
Manual control shaft detent 8~10 0.8~1.0 6~7
Manual valve lever 9~12 0.9~1.2 6.5~8
Parking rod guide 8~10 0.8~1.0 6~7
Rear cover 20~27 2.0~2.7 14~19
Torque converter housing 43~55 4.3~5.5 32~41
Oil pump 20~27 2.0~2.7 14~19
Transfer drive gear 8~12 0.8~1.2 6~8
Transfer drive gear lock nut 18~21 1.8~ 2.1 13~16
Oil drain plug 35~45 3.5~4.5 25~32
Differential drive gear 130~140 13~14 94~101
Pressure check plug 8~10 0.8~1.0 6~7
Front roll stopper bracket subframe bolt 50~65 5.0~6.5 36~47
Front roll stopper insulator bolt and nut 90~110 9~11 65~80
Front roll stopper bracket bolt 60~80 6.0~8.0 43~58
Rear roll stopper bracket subframe bolt 50~65 5.0~6.5 36~47
Rear roll stopper insulator bolt and nut 65~80 6.5~8.0 47~58
Rear roll stopper bracket bolt 60~80 6.0~8.0 43~58
Transaxle mounting sub bracket bolt 60~80 6.0~8.0 43~58
Transaxle mounting bracket bolt 50~65 5.0~6.5 36~47
Transaxle mounting insulator bolt 90~110 9.0~11 65~80

Lubricant

Item Specified lubricant Quantity

Transaxle fluid liter (US qt, lmp.qt) GENUINE DIAMOND ATF SP-III or SK ATF SP -III 6.6 (6.9, 5.81)

Sealant
Item Specified sealant
Rear cover
Torque converter housing LOCTITE FMD-546
Oil pan
 Automatic Transaxle System

Automatic Transaxle System

Automatic Transaxle System
2009 > D 1.6 TCI-U >

Hydraulic Circuit

N range, P range

D range(1st)
D range(2nd)
D range(3rd)
D range(4th)
R range
L range
 2009 > D 1.6 TCI-U >

Description

The new small sized automatic transaxle (A4CF2) is for gasoline 2.0&Diesel 1.6 engine.
The transaxle (A4CF2) is improved on the durability, fuel consumption and efficiency by the new main features as
followed.

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
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.
Components 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.
The oil pressure value set by TCM is coupled with the engine torque so that the stable shift feeling
can be improved.
The engine torque reduction control operates effectively to improve the shift feeling and the durability.
It can be the skip shift of 13 and 24 when shifting.
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.
Electronic
control system 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 the thin and flat copper in the 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.

Transaxle structure
Mechanical system
Function
Torque Converter
The torque converter, as the power plant which delivers the power of engine to the automatic transaxle, consists of 3
elements, 2 phases and 1 stage type.
- The flowing section form 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 18.5° to
improve the engine revolution change reduction capability and the fuel consumption
Oil pump
The oil pump is made of the aluminum (the reaction shaft support) to loose the weight and selects the parachoid type to
improve the processing and the capacity efficiency at the low RPM range.

Brakes
The automatic transaxle (A4CF2) 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 at the 1st speed.
- The disc type return spring is applied to the low and reverse brake and 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 at the 2nd speed.
Clutch
The multiple clutches and the one way clutch are used as the transaxle device.
The retainer of each clutch is composed of the precision sheet metal parts to realize the productivity and the light
weight.
The hydraulic centrifugal oil pressure balance device places inside the clutch assembly.
Generally the oil remained in the piston oil pressure chamber pushes the piston by the centrifugal force. But to prevent
the piston from being pushed, the oil filled in between the piston and the return spring retainer occurs the centrifugal
force and both of the power is offset so that the piston don't move. In result, it improves the durability and the shift
control ability.

1. Underdrive Clutch
The underdrive clutch is engaged at 1st, 2nd and 3rd speed.
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.
2. Reverse clutch and overdrive clutch
The reverse clutch is engaged at the reverse and delivers the driving force of input shaft to the reverse sun gear.
The overdrive clutch is engaged at the 3rd and 4th speed and 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 overdrive clutch
retainer and it has the whole overdrive clutch moved to deliver into the hub via retainer.

Structure of the reverse and the overdrive clutch

Parking system
The parking system for A4CF2 model is the cam type.
The roller type installed to the existing new generation AT needs the support to move the roller when operating the
parking system and is so complicated. But the cam type for A4CF2 model doesn't need the support and the structure is
simply. It only needs the guide to prevent from moving the cam idly.

POWER TRAIN
UD/C OD/C REV/C 2-4/B LR/B OWC
P

 R


N

D1



D2


D3


D4


L

OPERATION

Hydraulic control system

MAIN FEATURES
The VFS (Variable Force Solenoid) installed in the valve body is applied to transaxle(A4CF2). 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.
And the reducing valve which is 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 the 3rd speed and reverse
even thought the malfunction of the electronic control parts occur.

Structure of hydraulic circuit

ELECTRONIC CONTROL SYSTEM
SENSOR AND ACTUATOR FUNCTION
ITEM FUNCTION
Input shaft speed sensor Detect the input shaft rpm(TURBINE RPM) at the OD/RVS retainer
Output shaft speed sensor Detect the output shaft rpm(T/F DRIVE GEAR RPM) at the T/F drive 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
Inhibitor switch Detect the position of select lever through the contact switch
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(TCC) Control the hydraulic pressure for the damper clutch control
Torque reduction operation Receive the signal of engine reduction pressure operation from ECM via CAN
signal communication
Send the signal of the current position of shift lever and vehicle speed and operate the
Cluster
lamp, distance meter and speed meter

TCM
The TCM which is adapted to the new small sized automatic transaxle (A4CF2) is integrated into the PCM and deliver
information via CAN communication.
 ITEM BOSCH TCM
Hardware Integrated type
Duty driving Chopping method
Main oil pressure control components Turbin torque, Vehicle speed
ATF Temp. compensation control Independently
Direct control range Wide

TLE6288 current control chip

The TLE6288 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. In this case, the control signal of solenoid
valve is divided into the Peak signal and the Hold signal.
1. Peak : The 12 voltage signal applied to move the solenoid plunger quickly.
2. Hold : The signal applied to keep holding the pulled solenoid valve.

FPC (Flexible Printed Circuit) HARNESS

The FPC (Flexible Printed Circuit) harness is composed of the thin and flat copper in the insulating film like electric wire.

Item Round Wire Type FPC Type

Weight (g) 96.6 72
Practical use of space Low High
TM installation capability Bad Good
Softness High Low
Drawing modification Normal Low
Quality occurring High Low
Tighten in solenoid valve Bad Good
Measurement Unstable Stable

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 70°C
6 TPS 50%
7 Shift range hold signal OFF
 2009 > D 1.6 TCI-U >

BASIC INSPECTION ADJUSTMENT

TRANSAXLE FLUID LEVEL

INSPECTION
1. Drive the vehicle until the fluid reaches normal operating temperature [70~80°C(158~176°F)].
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) or "P" (Park) 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
bushes 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:
6.6liter(6.9 US qt, 5.81lmp.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 dve is added so the assembly plant can identify it
as transmission fluid and distinguish it from engine oil or antifreeze. The red dve, 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 have a fluid changer, use this changer to replace the fluid. If you do not have a fluid changer 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.

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.

TORQUE:
35~45 Nm (3.5~4.5kgf.m, 25~32lb-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, which was disconnected in step (1) above, and firmly replace the oil level gauge.
(In case of this "replace", this means after wiping off any dirt around the oil level gauge, 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"(Neutral) or "P" (Park) position.
11. Drive the vehicle until the fluid temperature rises to the normal temperature (70~80°C(158~176°F)), 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 the select lever is at the "D" or "R" position and the torque
converter stalls to test 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 : 80~100°C (176~212°F)
C. Engine coolant temperature : 80~100°C (176~212°F)
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 eight 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

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

ELEMENTS IN USE IN EACH GEAR

UD/C OD/C REV/C 2-4/B LR/B OWC
P

R


N

D1



D2


D3


D4


L

HYDRAULIC PRESSURE TEST

1. Warm up the engine until the automatic transaxle fluid temperature is 80~100°C(176~212°F).
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
STANDARD HYDRAULIC PRESSURE TABLE
 Automatic Transaxle System

Automatic Transaxle System

Automatic Transaxle System - Automatic Transaxle
2009 > D 1.6 TCI-U >

COMPONENTS(1)

COMPONENTS(2)
 2009 > D 1.6 TCI-U >

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. Remove the engine cover.

2. Remove the battery heat shield (A).

3. Remove the battery (A) and the battery tray (B).

4. Remove the upper cover (C) of the air cleaner assembly after disconnecting the AFS(Air Flow Sensor)
connector (A), the clamp (B).
5. Remove the lower cover (A) of the air cleaner assembly.

6. Remove the ground cable (A) from transaxle.

7. Disconnect the inhibiter switch connector (A), the solenoid valve connector (B) and the input shaft speed
sensor connector (C).
8. Disconnect the output shaft speed sensor connector (A).

9. Remove the shift cable assembly (A).

10. Remove the oil cooler hoses (A).

11. Install the special tools (09200-38001), the engine support fixture and the adapter on the engine assembly.
12. Remove the transaxle upper mounting bolts (A-2ea) and the starter motor mounting bolts (B-2ea).

13. After removing the mounting bolts, take the transaxle insulator mounting bracket off.
14. Remove the steering joint assembly bolt. (refer to Steering column/shaft in ST group)
15. Remove the front wheels and tires. (refer to removal in SS group)
16. Remove the side mud cover (A).

17. Remove the under shield cover (A).

18. Drain the transaxle fluid by removing the oil drain plug (A).
19. Remove the lower arm ball joint mounting nut, the stabilizer link mounting nut, and the tie rod end mounting
nut from the front knuckles. (refer to Front suspension system in SS group)
20. Remove the roll stopper mounting bolts (A, B).

21. Supporting the sub frame (A) with a jack and the Special tool (09624-38000), remove the mounting bolts.
(refer to Stabilizer's removal in SS group)
22. Disconnect the drive shafts (A,B) from the transaxle.

23. Remove the drive plate mounting bolts (A-4ea).

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

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

TORQUE : 43-55Nm (4.3-5.5kgf.m, 31.1-39.8lb-ft)

2. Install the drive plate mounting bolts (A-4ea).

TORQUE : 46-53Nm (4.6-5.3kgf.m, 33.3-38.3lb-ft)

3. Connect the drive shafts (A, B) to the transaxle.

4. Supporting the sub frame (A) with a jack and the Special tool(09624-38000), install the mounting bolts.
(refer to Stabilizer's installation in SS group).

TORQUE : 140-160Nm (14-16kgf.m, 101-118lb-ft)

5. Install the roll stopper mounting bolts (A, B).

TORQUE : 50-65Nm (5-6.5kgf.m, 36.2-47.0lb-ft)

6. Install the lower arm ball joint mounting nut, the stabilizer link mounting nut, and the tie rod end mounting
nut to the front knuckles. (refer to Front suspension system in SS group)
7. Install the under shield cover (A).

8. Install the side mud cover (A).

9. Install the front wheels and tires. (refer to installation in SS group)

10. Install the steering joint assembly bolt. (refer to Steering column/shaft in ST group)
11. Install the transaxle insulator mounting bracket.

TORQUE : 60-80Nm (6.0-8.0kgf.m, 43.4-57.9lb-ft)

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

TORQUE :
[A] 43-55Nm (4.3-5.5kgf.m, 31.1-39.8lb-ft)
[B] 39-60Nm (3.9-6.0kgf.m, 28.2-43.4lb-ft)
13. Remove the special tool (09200-38001).

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

15. Install the control cable assembly (A).

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

17. Connect the inhibiter switch connector (A), solenoid valve connector (B) and the input shaft speed sensor
connector (C).

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

19. Install the lower cover (A) of the air cleaner assembly.
20. Install the upper cover (C) of the air cleaner assembly and connect the AFS(Air Flow Sensor) connector
(A), the clamp (B).

21. Install the battery (A) and the battery tray (B).

22. Install the battery heat shield (A).

23. Install the engine cover.
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 connector to the data link connector under the crash 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'.
5) Select 'RESETTING AUTO T/A VALUES' and perform the procedure
 6) Perform the procedure by pressing F1 (REST).

ADJUSTMENT
1. Install the transaxle control cable and adjust as follows.
2. Move the shift lever and the transaxle range switch to the "N" Position, and install the control cable.
3. When connecting the control cable to the transaxle mounting bracket, install the clip until it contacts the
control cable.
4. Remove any free-play in the control cable by adjusting nut and then check to see that the select lever
moves smoothly.
5. Check to see that the control cable (A) has been adjusted correctly.
 Automatic Transaxle System

Automatic Transaxle System

Automatic Transaxle Control System - 0UW\[:WLLK
:LUZVY
2009 > D 1.6 TCI-U >

Description

1. Type : HALL SENSOR

Sensor type 2. Operating voltage : DC 12V
3. Current consumption : 22mA (Max)

1. Input shaft 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 shaft speed sensor 0.05in(1.3mm)
Sensor resistance Input shaft speed sensor Over 1 M

HIGH Over 4.8V
Output voltage
LOW Below 0.8V
 2009 > D 1.6 TCI-U >

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 shaft speed sensor connector (A).

6. Remove the input shaft speed sensor(A).

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

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 shaft speed sensor connector (A)
securely.

4. Installation is the reverse of removal.

 Automatic Transaxle System

Automatic Transaxle System

Automatic Transaxle Control System - 6\[W\[:WLLK
:LUZVY
2009 > D 1.6 TCI-U >

Description

1. Type : HALL SENSOR

Sensor type 2. Output voltage : DC 12V
3. Current consumption : 22mA (Max)

1. Output shaft speed sensor : Detect the output shaft rpm(T/F DRIVE GEAR RPM) at the
T/F drive 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 shaft speed sensor 0.033in(0.85mm)
Sensor resistance Output shaft speed sensor Over 1 M

HIGH Over 4.8V
Output voltage
LOW Below 0.8V
 2009 > D 1.6 TCI-U >

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 shaft speed sensor connector(A).

6. Remove the output shaft speed sensor(A).

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

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

While installing the output shaft 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 shaft speed sensor connector (A) securely.

4. Installation is the reverse of removal.

 Automatic Transaxle System

Automatic Transaxle System

Automatic Transaxle Control System - :VSLUVPK=HS]L
 2009 > D 1.6 TCI-U >

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 the each range and
also control the strength and weakness of oil pressure to reduce the shock when shifting the range.

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) (TCC SV) (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/cm² (0~422kpa, 0~61.2psi)

Type 3way & Normal High

Input voltage 12V
Coil resistance 3.2±0.2 (at 25°C, 77°F)
Cycle 50Hz
 2009 > D 1.6 TCI-U >

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 'A4CF2' overhaul manual)
6. Remove the oil filter.
7. Remove the valve body. (Refer to Valve body's disassembly in 'A4CF2' 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 not to be damaged.

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 reconnect
it.

3. Install the valve body. (Refer to Valve body's reassembly in 'A4CF2' overhaul manual)
 TORQUE :
10~12Nm(1.0~1.2kgf.m, 7~8lb-ft)

4. Install the oil filter.

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 Ø2.5mm (0.098in) thickness.

Liquid gasket Part name : Threebond 1281B

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

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

7. Install the drain plug.

TORQUE :
35~45Nm(3.5~4.5kgf.m, 25~32lb-ft)

8. Installation is the reverse of the removal.

 Automatic Transaxle System

Automatic Transaxle System

Automatic Transaxle Control System - =-:=HYPHISL
-VYJL:VSLUVPK=HS]L
 2009 > D 1.6 TCI-U >

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 controlled linearly according to the current value.

type 3way & Normal High

Input voltage 12V
Coil resistance 3.5±0.2
(at 25°C, 77°F)
Operating current 0 ~ 1200 mA
 2009 > D 1.6 TCI-U >

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 'A4CF2' overhaul manual)
6. Remove the oil filter.
7. Remove the valve body. (Refer to Valve body's disassembly in 'A4CF2' 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 'A4CF2' overhaul manual)
 TORQUE :
10~12Nm(1.0~1.2kgf.m, 7~8lb-ft)

4. Install the oil filter.

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 Ø2.5mm (0.098in) thickness.

Liquid gasket Part name : Threebond 1281B

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

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

7. Install the drain plug.

TORQUE :
35~45Nm(3.5~4.5kgf.m, 25~32lb-ft)

8. Installation is the reverse of the removal.

 Automatic Transaxle System

Automatic Transaxle System

Automatic Transaxle Control System - Shift Lever
2009 > D 1.6 TCI-U >

COMPONENTS
 2009 > D 1.6 TCI-U >

REMOVAL
1. Remove the shift lever knob (A).

2. Remove the multi switch assembly (A).

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

4. Remove the air duct (A).

5. Remove the shift locking cable (A) from the shift lever assembly.
6. Remove the mounting nuts (A-2ea).

7. Remove the shift cable assembly (C) by removing the clip (A) and the clamp (B).

8. Disconnect the connector (A).

9. Remove the shift lever assembly (A).

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

In case, remove the crush pad and cowl cross bar. (refer to Crush pad in BD group and Heater unit in
HA group)

11. Remove the control cable assembly from the transaxle (refer to Automatic transaxle's removal).
12. Remove the control cable assembly.

INSTALLATION
1. Install the control cable assembly to transaxle. (refer to Automatic transaxle's installation)
2. Install the retainer (A) and nuts (B).

TORQUE : 12-15Nm (1.2-1.5kgf.m, 8.7-10.8Ib-ft)

In case, install the crush pad and cowl cross bar. (refer to Crush pad in BD group and Heater unit in HA
group)
3. Install the shift lever assembly (A).

TORQUE : 9-14Nm (0.9-1.4kgf.m, 8.7-10.8lb-ft)

4. Connect the interlock switch connector (A).

5. Install the shift cable assembly (C) by installing the clip (A) and the clamp (B).
6. Install the mounting nuts (A-2ea).

7. Install the shift locking cable (A).

8. Install the air duct (A).

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

10. Install the multi switch assembly (A).

11. Install the shift lever knob (A).

ADJUSTMENT
Adjusting method for the control cable
1. Set room side lever and T/M side lever (A) to "N" position.
2. Connect the room side lever and shift cable. (refer to Shift lever's 'Installation')
3. Connect the T/M side lever (A) to cable (B) in this following order;
A. Push the cable (B) lightly to "F" direction shown to eliminate FREE PLAY of the cable (B).
B. Tighten the adjusting nut(C).

4. After adjusting the cable (B) according to procedure no. 2-3, check to be sure that this part operates surely
at each range of T/M side corresponding to each position of room lever.
 Automatic Transaxle System

Automatic Transaxle System

Automatic Transaxle Control System -;YHUZH_SL6PS
;LTWLYH[\YL:LUZVY
2009 > D 1.6 TCI-U >

DESCRIPTION

1. Type : Thermister
Sensor type
2. Use available temperature :-40~160°C(-40~320°F)

1. Detect the temperature of ATF through the thermistor which is exposed

Function and feature outside.
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 > D 1.6 TCI-U >

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 'A4CF2' overhaul manual)
6. Remove the oil filter.
7. Remove the valve body. (Refer to Valve body's disassembly in 'A4CF2' overhaul manual)
8. Disconnect the main harness connector (A) from the valve body.

Installation
1. 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 'A4CF2' overhaul manual)

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

3. Install the oil filter.

 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 Ø0.098in(2.5mm) thickness.

Liquid gasket Part name : Threebond 1281B

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

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

6. Install the drain plug.

TORQUE :
35~45Nm(3.5~4.5kgf.m, 25~32lb-ft)

7. Installation is the reverse of the removal.

 Automatic Transaxle System

Automatic Transaxle System

Automatic Transaxle Control System -0UOPIP[LY:^P[JO
2009 > D 1.6 TCI-U >

Description

1. Type : ROTARY
Sensor tyep 2. Available temperature range : -40~150°C(-40~320°F)
3. TORQUE : 10~12Nm(1.0~1.2kgf.m, 7~8lb-ft )
Detect the position of select lever through the contact switch. It makes starting possible in "P" and
Function
"N".
 2009 > D 1.6 TCI-U >

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. Disconnect the inhibitor switch connector (A).

6. Remove the control cable(A) from the manual control lever.

7. Remove the inhibitor switch and manual control lever.

Installation
1. Set the inhibitor switch to the "N" position.
2. Set the inhibitor switch control shaft to the "N" position.
3. Install the inhibitor switch and manual control lever.

TORQUE
Shaft nut: 17~21Nm(1.7~2.1kgf.m, 12~15lb-ft)
Bolt(2EA): 10~12Nm(1.0~1.2kgf.m, 7~8lb-ft )

4. Install the control cable (A) to the manual control lever.

5. Connect the inhibitor switch connector (A).

6. Installation is the reverse of the removal.

7. Turn the ignition switch ON after installation.
Move the shift lever from "P" range to "L" range, and verify that the A/T gear position indicator follows the
transaxle range switch.