TCM

Manual
Valve

Solenoid
Valve 1

Line
Pressure
Control
Valve

31
PCS Valve 6

Damper

Damper

Damper

Damper

Clutch
Valve D

Holding
Valve D

Selector
Valve

Converter
Shift Valve

Safety
Valve

Converter
Input Valve

Torque
Converter

Clutch
Valve C

Holding
Valve C

Clutch
Valve E

Holding
Valve E

TCC Clutch
Valve

Cooler

Lubrication
Valve

Clutch
Valve F

Holding
Valve F

PARK/NEUTRAL

PCS Valve 5

Clutch
Valve B

Holding
Valve B

PCS Valve 4

PCS Valve 3

Solenoid
Valve 2

Reduction
Valve

Oil Pump

HYDRAULIC
CIRCUIT

V-220(N/A)

TCM

Manual
Valve

Solenoid
Valve 1

Line
Pressure
Control
Valve

32
PCS Valve 6

Damper

Damper

Damper

Damper

Clutch
Valve D

Holding
Valve D

Selector
Valve

Converter
Shift Valve

Safety
Valve

Converter
Input Valve

Torque
Converter

Clutch
Valve C

Holding
Valve C

Clutch
Valve E

Holding
Valve E

TCC Clutch
Valve

Cooler

Lubrication
Valve

Clutch
Valve F

Holding
Valve F

REVERSE

PCS Valve 5

Clutch
Valve B

Holding
Valve B

PCS Valve 4

PCS Valve 3

Solenoid
Valve 2

Reduction
Valve

Oil Pump

HYDRAULIC
CIRCUIT

V-220(N/A)

TCM

Manual
Valve

Solenoid
Valve 1

Line
Pressure
Control
Valve

33
PCS Valve 6

Damper

Damper

Damper

Damper

Clutch
Valve D

Holding
Valve D

Selector
Valve

Converter
Shift Valve

Safety
Valve

Converter
Input Valve

Torque
Converter

Clutch
Valve C

Holding
Valve C

Clutch
Valve E

Holding
Valve E

TCC Clutch
Valve

Cooler

Lubrication
Valve

Clutch
Valve F

Holding
Valve F

DRIVE - 1ST GEAR

PCS Valve 5

Clutch
Valve B

Holding
Valve B

PCS Valve 4

PCS Valve 3

Solenoid
Valve 2

Reduction
Valve

Oil Pump

HYDRAULIC
CIRCUIT

V-220(N/A)

TCM

Manual
Valve

Solenoid
Valve 1

Line
Pressure
Control
Valve

34
PCS Valve 6

Damper

Damper

Damper

Damper

Clutch
Valve D

Holding
Valve D

Selector
Valve

Converter
Shift Valve

Safety
Valve

Converter
Input Valve

Torque
Converter

Clutch
Valve C

Holding
Valve C

Clutch
Valve E

Holding
Valve E

TCC Clutch
Valve

Cooler

Lubrication
Valve

Clutch
Valve F

Holding
Valve F

DRIVE - 2ND GEAR

PCS Valve 5

Clutch
Valve B

Holding
Valve B

PCS Valve 4

PCS Valve 3

Solenoid
Valve 2

Reduction
Valve

Oil Pump

HYDRAULIC
CIRCUIT

V-220(N/A)

TCM

Manual
Valve

Solenoid
Valve 1

Line
Pressure
Control
Valve

35
PCS Valve 6

Damper

Damper

Damper

Damper

Clutch
Valve D

Holding
Valve D

Selector
Valve

Converter
Shift Valve

Safety
Valve

Converter
Input Valve

Torque
Converter

Clutch
Valve C

Holding
Valve C

Clutch
Valve E

Holding
Valve E

TCC Clutch
Valve

Cooler

Lubrication
Valve

Clutch
Valve F

Holding
Valve F

DRIVE - 3RD GEAR

PCS Valve 5

Clutch
Valve B

Holding
Valve B

PCS Valve 4

PCS Valve 3

Solenoid
Valve 2

Reduction
Valve

Oil Pump

HYDRAULIC
CIRCUIT

V-220(N/A)

TCM

Manual
Valve

Solenoid
Valve 1

Line
Pressure
Control
Valve

36
PCS Valve 6

Damper

Damper

Damper

Damper

Clutch
Valve D

Holding
Valve D

Selector
Valve

Converter
Shift Valve

Safety
Valve

Converter
Input Valve

Torque
Converter

Clutch
Valve C

Holding
Valve C

Clutch
Valve E

Holding
Valve E

TCC Clutch
Valve

Cooler

Lubrication
Valve

Clutch
Valve F

Holding
Valve F

DRIVE - 4TH GEAR

PCS Valve 5

Clutch
Valve B

Holding
Valve B

PCS Valve 4

PCS Valve 3

Solenoid
Valve 2

Reduction
Valve

Oil Pump

HYDRAULIC
CIRCUIT

V-220(N/A)

TCM

Manual
Valve

Solenoid
Valve 1

Line
Pressure
Control
Valve

37
PCS Valve 6

Damper

Damper

Damper

Damper

Clutch
Valve D

Holding
Valve D

Selector
Valve

Converter
Shift Valve

Safety
Valve

Converter
Input Valve

Torque
Converter

Clutch
Valve C

Holding
Valve C

Clutch
Valve E

Holding
Valve E

TCC Clutch
Valve

Cooler

Lubrication
Valve

Clutch
Valve F

Holding
Valve F

EMERGENCY 3RD GEAR

PCS Valve 5

Clutch
Valve B

Holding
Valve B

PCS Valve 4

PCS Valve 3

Solenoid
Valve 2

Reduction
Valve

Oil Pump

HYDRAULIC
CIRCUIT

V-220(N/A)

TCM

Manual
Valve

Solenoid
Valve 1

Line
Pressure
Control
Valve

38
PCS Valve 6

Damper

Damper

Damper

Damper

Clutch
Valve D

Holding
Valve D

Selector
Valve

Converter
Shift Valve

Safety
Valve

Converter
Input Valve

Torque
Converter

Clutch
Valve C

Holding
Valve C

Clutch
Valve E

Holding
Valve E

TCC Clutch
Valve

Cooler

Lubrication
Valve

Clutch
Valve F

Holding
Valve F

EMERGENCY 4TH GEAR

PCS Valve 5

Clutch
Valve B

Holding
Valve B

PCS Valve 4

PCS Valve 3

Solenoid
Valve 2

Reduction
Valve

Oil Pump

HYDRAULIC
CIRCUIT

V-220(N/A)

HYDRAULIC
DIAGNOSIS

CHECK OIL LEVEL/CONDITION

V-220(N/A)

Oil Level Inspection

The fluid level plug is intended to be
used for diagnosis a transmission fluid
leak or resetting the transmission fluid
level after service that involves a loss
of fluid.
The fluid level diagnosis procedure is
follows :
1) Park the vehicle on a hoist,inspection
pit or level to obtain a correct fluid
level measurement.
2) Place a fluid container below the fluid
level plug.
3) Start the engine and allow the engine
to idle for approximately 5 minutes or,
if possible,drive the vehicle until warmup (405) the transmission fluid.

Oil Level Check Plug

Oil Drain Plug

4) With the brake pedal depressed, move

the shift lever through the gear ranges,
pausing a few seconds in each range.
Return the shift lever to the P(Park)
position.
5) Remove the fluid level plug.Because
the transmission operates correctly
over a range of fluid level,fluid may
or may not drain out of the plug hole
when the plug is removed.
6) If fluid drains through the plug hole the transmission may have been overfilled.When the fluid
stops draining the fluid level is correct.
7) Install the fluid level plug and torque the proper specification.
Oil Type

ESSO - LT(71141) / ISU H50235

Oil Capacity

7.4 L

Maintenance Period

Not required

Oil Filter

Not required

39

HYDRAULIC
DIAGNOSIS

TIME LAG TEST

V-220(N/A)

Time Lag Test

The time lag test is a performance test which components is carrying out good or not good.
* Caution
- Test at normal operating temperature.
- Have 1 min interval between tests.
- Make average out of 3-times tests.
1) Fully apply the parking brake.
2) Start the engine and check the idle speed
3) Shift the selector lever from N to D range.
Measure the time it takes from shifting the selector until the shock is felt.
Time lag : Less than 1.2 seconds.
4) In same way ,measure the time from N to Rrange.
Time lag : Less than 1.5 seconds.

If actual data is longer than specified from N to D range

- Line pressure is too low.
- Clutch B is slipping.
- Brake F is slipping.
If actual data is longer than specified from N to R range
- Line pressure is too low.
- Clutch B is slipping.
- Brake D is slipping.

40

HYDRAULIC
DIAGNOSIS

STALL TEST

V-220(N/A)

Stall Test
* Caution
- Test at normal operating temperature.
- Never perform this test several times nor for more than 5 sec
1) Fully apply the parking brake.
2) Step down strongly on the brake pedal with your left foot.
3) Start the engine.
4) Shift the selector lever from N to D range.
Depressing accelerator pedal with your right foot and read quickly the highest engine RPM
at this time. (Stall RPM : 2,000 ~ 2,400)
5) In reverse position, the stall test is not possible, because of stall protection mode.

If actual data is lower than specified value at D.range

- Engine power may be insufficient.
- Stator one way clutch is not operating properly.
If actual data is higher than specified value at Drange
- Line pressure is too low.
- Clutch B is slipping
- Brake F is slipping.

41

HYDRAULIC
DIAGNOSIS

HYDRAULIC TEST

V-220(N/A)

Hydraulic Test
Measure Line Pressure.
1) Remove the transmission case pressure test plug and mount the oil pressure gauge
and scanner-100.
2) Fully apply the parking brake.
3) Step down strongly on the brake pedal with your left foot.
4) Start the engine and warm-up engine.
5) Select the required gear range and set the engine RPM at 2500.
6) Read the oil pressure value and compare the specification value.

Oil Pressure Gauge

E
B

Range

Solenoid "1"

RPM

Specification

Off

2500

15.3 ~ 17.4 (Bar)

On

2500

6.2 ~ 8.6 (Bar)

P,R,N,D

42

ELECTRICAL
COMPONENT

INPUT/OUTPUT OF TCM

V-220(N/A)

Input/output Of TCM

Input Factor
- Power Supply(B+)
- Ignition (B+)
- Ground(B -)
- Engine RPM(Sirius D6)
- TPS (Sirius D6)
- Engine Torque(Sirius D6)
- Input Speed Sensor
- Output Speed Sensor
- Transmission Fluid
Temperature Sensor
- PNP Switch
- Hold Mode Switch
- Brake Switch

Output factor

TCM
CAN Hi CAN Lo

CAN Hi CAN Lo

ECM
ECMTCM
RPM, TPS, Engine Torque,
ECT
TCM ECM
VSS, Engine Torque Control
Request

( Location of TCM)
43

- Solenoid 1,2
- Pressure Control
Solenoid 3,4,5,6
- Hold Mode Lamp/
Warning Lamp
- Engine Torque Control
(Sirius D6)
- Vehicle Speed
(ECM/Cluster)
- Serial Data for Scan-tool

ELECTRICAL
COMPONENT

OUTPUT SPEED SENSOR

V-220(N/A)

Output Speed Sensor

The output(vehicle) speed sensor(OSS) is a hall effect sensor that relays information relative
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)

An air gap of 0.1mm~1.3mm is

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

Output speed sensor

B10

OSS

Hall I.C

8V Ref

TCM

B5
2

44

ELECTRICAL
COMPONENT

INPUT SPEED SENSOR

V-220(N/A)

Input Speed Sensor

The input speed sensor is a magnetic inductive pickup that relays information relative
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

15

B4

(Input speed sensor)

(Shield earth)

45

TCM

TRANSMISSION FLUID
TEMPERATURE SENSOR

ELECTRICAL
COMPONENT

V-220(N/A)

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 123(253), 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

Sensor Resistance()

2000

A4

1800

5V Ref

9
1600
1400

TFT Sensor

TCM

1200

1000

B1

800
600
-10

10

20

30

40

50

60

70

80

90

90

110 120

Temperature ()

46

Resistance : 1472 ohm @ 20 dec

ELECTRICAL
COMPONENT

POSITION OF SOLENOIDS

V-220(N/A)

Valve body & Solenoid position

Pressure Control
Solenoid(EDS) 5

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

1 2
3 4 5
6 7 8 9

Solenoid 1
Solenoid 2

(Connector)

The connector is based on

engine wiring harness
Pressure Control
Solenoid(EDS) 4

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

Components

Connector Pin
No.

TCM Connector
Pin No.

16

B2

15

B4

B10

B5

A4

B1

C8

12

A9

C8

13

A1

Pressure control
solenoid No.3

C7

A11

Pressure control
solenoid No.4

C7

A3

Pressure control
solenoid No.5

C7

10

A10

C7

11

A12

Input speed sensor

Vehicle speed sensor
Oil temperature
sensor
Solenoid No. 1
Solenoid No. 2

Pressure control
solenoid No.6

47

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

E103A314

ELECTRICAL
COMPONENT

SOLENOID 1,2

V-220(N/A)

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

C8

12V

Solenoid 2

13

A1

12

A9

TCM

48

ELECTRICAL
COMPONENT

PRESSURE CONTROL SOLENOID

V-220(N/A)

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

C6
C7 12V

EDS3 EDS4

EDS5

EDS6 11

A12

10

A10

A3

A11

TCM

49

ELECTRICAL
COMPONENT

PRESSURE CONTROL SOLENOID

V-220(N/A)

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 ()

50

800

ELECTRICAL
COMPONENT

PNP POSITION SWITCH

V-220(N/A)

PNP Position Switch

The Park Neutral Position(PNP) switch is located on the selector shaft and informs
the TCM of the current selector lever position P-R-N-D-3-2-1.
The selector lever position is transmitted to the TCM in encoded form along 4 lines.
The encoding is such that malfunctions in the connecting lead are identified.
In addition, the position switch controls the starter interlock,the reversing light and the
selector lever position indicator on the instrument panel.

1(B +)

7(B+)
(Rev Lamp)

2(L2)

8(GND)
Rev Lamp

3(L1)
4(L3)

9(PNP Relay)
5(L4)
6(Not used)

10(Ground)

Selector Range Encoding

Selector Range

L1

L2

L3

L4

Selector Range

Starting Circuit

Reverse Lamp

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

51

ELECTRICAL
COMPONENT

PNP SWITCH

V-220(N/A)

PNP Switch Circuit

Power Supply(15)

10A

L1

C1

L2

B15

TCM
L3

B6

L4

B11

PNP Switch

52

ELECTRICAL
COMPONENT

CAN COMMUNICATION

V-220(N/A)

CAN (Controller Area Network) Communicating (SIRIUS-D6 type ECM)

The TCM receives and transmits some messages between the ECM and TCM for
optimum control through the CAN lines as follows :
- Engine RPM
- Engine Torque Control
- Throttle Position Sensor Signal
- Engine Coolant Temperature Sensor Signal
- Engine Torque Reduction Control Request
- Output(Vehicle) Speed Sensor Signal
- P/N Position signal
- Gear state

CAN Hi

ECM
CAN Lo

41

A8

22

A16

B1

C1

EBCM

53

CAN Hi

TCM
CAN Lo