V220

SERVICE TRAINING MANUAL

AUTOMATIC
TRANSMISSION
(4HP-16, N/A)

CONTENTS
1. General Information 3
2. Power Flow . 9
3. Hydraulic Component ..... 17
4. Mechanical Components . 22
5. Special Tool 28
6. Hydraulic Circuit . 31
7. Hydraulic Diagnosis. 39
8. Electrical Component . 43
9. Shift Pattern .. 54
10. Diagnosis ...... 58

GENERAL
INFORMATION

INTRODUCTION

V-220(N/A)

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.

Figure of Automatic Transmission

GENERAL
INFORMATION

SPECIFICATION

V-220(N/A)

Specification
No

Items

Specifications

Remarks

4 : four Speed
H : Hydraulic
P : Planetary gear
16 : Torque capacity

Model : 4HP-16

Torque converter

273 mm

Weight of transmission

76 kg(Wet), 70.9kg(Dry)

Torque converter capacity

9.27 kg

1st : 2.719
2nd : 1.487
3rd : 1.000
4th : 0.717
Reverse : 2.529

Gear ratio

Final gear ratio

3.945 (2.5L DOHC)

Oil type

ESSO-LT71141
ISU H50235

Change period of oil

Not required

Oil capacities

4L
4L
2L
7.4L
7.4L

No

Items

Inter-changeable

When drain plug opening

Bottom pan removal
Excahnge torque converter
Overhaul
Total

Specifications

Remarks

Output speed sensor

Resistance
Resistance to ground
Clearance

10

Input speed sensor

Resistance
Resistance to ground
Clearance

788 ~ 872

0.1 ~2.0 mm

11

Solenoid '1', '2'

Resistance
Resistance to ground

26.5 0.5

P/N Switch

12

L1
L2
L3
L4

(Hall sensor)

0.1 ~ 1.3 mm

At 20 C

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

P
0
0
1
0

R
0
0
0
1

N
0
1
0
0

D
1
1
1
0

3
1
1
0
1

2
1
0
1
1

1
0
1
1
1

GENERAL
INFORMATION

SPECIFICATION

V-220(N/A)

Specification
No

Specifications

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

Oil tmperature sensor

(PTC thermistor)
13
PTC :Positive
temperature coefficient

14

Pressure control
solenoid (EDS)

15

Line pressure (Bar)

(Solenoid No.1)

16

Time lag test

17

Stall test

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

Resistance
Resistance to ground

5.7 0.45 ohm

ohm

Resistance
Resistance to ground

5.7 0.45 ohm

ohm

Resistance
Resistance to ground

5.7 0.45 ohm

ohm

Resistance
Resistance to ground

5.7 0.45 ohm

ohm

High : 15.3 ~ 17.4

At 20 C

P,R,N,D

Low : 6.2 ~ 8.6

Less than 1.2 sec

N -> D

Less than 1.5 sec

N -> D

V-220 2.5L DOHC

At 20oC

D:
R:

~
~

rpm
rpm

GENERAL
INFORMATION

GENERAL DESCRIPTION

V-220(N/A)

Shift Lever Position

P - Park position.
R - Reverse
N - Neutral
D - Forward 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 Modes
1. Driving mode
The TCM recognize drivers actions to ensure adapted and efficient shifting
performance.(Low fuel consumption High driving performance)
These below modes are selected according to drivers intention and road gradient
automatically by the Fuzzy control logic to improve fuel economy and better driveability
as well as better safety.
1) Economy mode / Medium mode /Sporty mode (By drivers intention)
2) By road gradient :
- Load 1 : Moderate road gradients
- Load 2 : Active while going steeply upwards
- Load 3 : Down-hill driving(Increased engine braking)
2. Hold Mode
- When the driver push the hold button, the driver can hold the demanded gear
intentionally.
- Winter function : When vehicle is on slippery road such as snow or mud etc., vehicle
can be easily escaped from slippery road by hold button on at D,3 or 2 range.
- Fuzzy is applied to avoid busy shifting in most of hill driving condition.Hold button &
3 range is an additional function to avoid busy shifting in case that fuzzy is not sufficient.
- In condition of hold mode, driver can use automatic transmission as 4 speeds manual
transmission.
(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

OVERLAP SHIFTING

V-220(N/A)

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

GENERAL
INFORMATION

TIGHTENING TORQUE

V-220(N/A)

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

POWER FLOW

FUNCTION OF COMPONENTS

V-220(N/A)

Structure of Automatic Transmission

Component

Function

Clutch "B" Connects Input shaft & Rear Planetary Sun Gear
Clutch "E" 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

10

RANGE REFERENCE CHART

POWER FLOW

V-220(N/A)

Range Reference Chart

Component
Range

Solenoid

Pressure Control Solenoid

3

Clutch

P (Park)

ON

ON

R (Reverse)

ON,OFF

ON

N (Neutral)

ON

ON

4th

ON,OFF

OFF

ON,OFF

3rd

ON,OFF

OFF

ON,OFF

ON

2nd

ON,OFF

OFF

ON

ON

ON

1st

ON,OFF

ON

ON

ON

ON

Emergency 3rd

OFF

OFF

OFF

OFF

OFF

OFF

Emergency 4th

OFF

OFF

OFF

OFF

OFF

OFF

ON

ON

Brake
C

O
ON

ON

O
O

ON

O
O

O
O

O
O

Operation of Powertrain

Clutch B
(Helical Gear I)

Engine

Brake C
Brake F
Clutch E

Brake D

(Front Planetary Gear)

11

(Helical Gear II)

(Rear Planetary Gear)

(Differential Gear)

POWER FLOW (PARK/NEUTRAL)

POWER FLOW

V-220(N/A)

Powertrain (P/N)
Clutch

Shift Lever

P (Park)

N (Neutral)

Brake
E

Gear
Ratio

Clutch B
(Helical Gear I)

Engine

Brake C
(Helical Gear II)

Brake F
Clutch E

Brake D

(Front Planetary Gear)

(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.

12

POWER FLOW (REVERSE)

POWER FLOW

V-220(N/A)

Powertrain (Reverse)
Clutch

Shift Lever

R (Reverse)

Brake
E

D
O

Gear
Ratio
2.529

Clutch B
(Helical Gear I)

Engine

Brake C
(Helical Gear II)

Brake F
Clutch E

Brake D

(Front Planetary Gear)

(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

13

POWER FLOW ( 1ST GEAR)

POWER FLOW

V-220(N/A)

Powertrain (1st gear)

Clutch

Shift Lever

Brake
E

Gear
Ratio

1st

1st

1st

1st

2.719

Clutch B
(Helical Gear I)

Engine

Brake C
(Helical Gear II)

Brake F
Clutch E

Brake D

(Front Planetary Gear)

(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

14

POWER FLOW (2ND GEAR)

POWER FLOW

V-220(N/A)

Powertrain (2nd gear)

Clutch

Shift Lever

Brake
E

Gear
Ratio

2nd

2nd

2nd

1.487

Clutch B
(Helical Gear I)

Engine

Brake C
(Helical Gear II)

Brake F
Clutch E

Brake D

(Front Planetary Gear)

(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

15

POWER FLOW (3RD GEAR)

POWER FLOW

V-220(N/A)

Powertrain (3rd gear)

Clutch

Shift Lever

Brake

3rd

3rd

Gear
Ratio

1.000

Clutch B
(Helical Gear I)

Engine

Brake C
(Helical Gear II)

Brake F
Clutch E

Brake D

(Front Planetary Gear)

(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

16

POWER FLOW (4TH GEAR)

POWER FLOW

V-220(N/A)

Powertrain (4th gear)

Clutch

Shift Lever
D

4th

Brake
E

Gear
Ratio

0.717

Clutch B
(Helical Gear I)

Engine

Brake C
(Helical Gear II)

Brake F
Clutch E

Brake D

(Front Planetary Gear)

(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

17

HYDRAULIC
COMPONENT

OIL PUMP

V-220(N/A)

Oil Pump
The oil pump is located in zone between the
torque converter and the transmission
housing.
And the pump is driven directly from the
engine via the converter shell(neck),and
supplies the transmission and selector unit
with oil.
The pump draws in the oil through a filter
and
pumps the pressurized oil through the
system pressure valve in the hydraulic
control unit.
Therefore, the oil pressure is defined and the
surplus oil returned to the pump intake end.
The pump supplies not only the hydraulic
selector unit with pressurized oil,but also the
shift elements and the converter. In addition,
the oil performs an internal lubrication
function and cools the transmission.

18

1: Intake
2: Exhaust

HYDRAULIC
COMPONENT

HYDRAULIC VALVES

V-220(N/A)

Function of Valves
1) Manual Valve(Shift Valve)
The driver selects the direction of travel ,park position and neutral position via the shift
valve which directs line pressure into the various circuits by opening and closing feed
passages.The circuits that are fed by the manual valve are P(Park), R(Reverse),
N(neutral) D,3,2,1.
2) Line Pressure Control Valve
The system pressure valve determines the general pressure level in the control system.
The system pressure is established between high and low levels in accordance with the
solenoid 1 is ON or OFF. The line pressure control valve primarily serves the clutch.
Cooling and lubricating oil then reaches the converter.
- Low Pressure(solenoid1ON) : 6.2~8.6 Bar
- High Pressure (solenoid1OFF) : 15.3~17.4 Bar
3) Pressure-Reduction Valve
The pressure-reduction valve reduces the system pressure with which the downstream
solenoid valves and electrical pressure regulating valves are charged. It is possible to
reduce line pressure to lower pressure than the main line pressure.
4) Selector Valve
The selector valve is controlled by solenoid valve2 and pressure control solenoid3 for
applying clutch E and lock-up clutch.
5) Safety Valve
In the event of a power failure while the vehicle is moving,the safety valve applies
brakeCand clutchE to get 4th gear.
When the vehicle is restarted and the TCM in the emergency -run mode, the clutchBand
clutchEare applied to get 3rd gear.
6) Converter Pressure Valve
The converter pressure valve controls to supply the converter with cooling oil in the
lock-up clutch open position. When the lock-up clutch is closed,the supply line to the the
converter is interrupted and the space between the lock-up clutch and converter cover is
bled.
7) Lock-up Clutch Valve
The lock-up clutch controls pressure control solenoid3 when the solenoid2 is OFF and
transfers line pressure to clutch.
8) Lubricating Valve
The lubricating valve ensures that the converter is supplied with cooling oil first if the
pump
rate is low.The lubricating pressure valve in addition guarantees that the necessary
amount of cooling and lubricating oil is available via the bypass duct.

19

HYDRAULIC
COMPONENT

VALVE BODY ASSEMBLY

V-220(N/A)

VALVE Body Assembly

: Valve housing No.1

: Valve housing No.2
: Valve housing No.3

Pressure Control Solenoid(EDS) 5

Pressure Control Solenoid(EDS) 3

Pressure Control Solenoid(EDS) 6

Solenoid 1
Solenoid 2

Pressure Control Solenoid(EDS) 4

20

HYDRAULIC
COMPONENT

VALVE BODY COMPONENT

V-220(N/A)

Valve Body Component

1. Lubricating valve
2. Lock-up clutch valve
3. Converter pressure valve
4. Clutch valve F
5. Holding valve E
6. Clutch valve E
7. Holding valve B
8. Clutch valve B
9. Manual valve
10. Line pressure control valve
11. Reduction valve
12. Clutch valve D
13. Holding valve D

1. Converter shift valve

1. Clutch valve C

2. Selector valve

2. Holding valve C
3. Pressure control solenoid valve
4. Safety valve

3. Solenoid valve
4. Pressure control solenoid valve
5. Holding valve F

21

HYDRAULIC
COMPONENT

VALVE BODY CHANNEL PLATE

V-220(N/A)

Valve Body Channel Plate Oil Supply Circuit

Brake F

Brake C

Brake D

Clutch E

Clutch B

22

MECHANICAL
COMPONENTS

TORQUE CONVERTER HOUSING

Torque converter housing

1. Torque converter housing

2. Torque converter
3. Gasket
4. Metal gasket
5. Oil baffle plate
6. Bolt
7. Magnet
8. Oil filter
9. O-ring

23

10. Pressure plug

11. Oil drain plug
12. Oil level plug
13. Screw
14. Bolt
15. Oil pump assembly
16. Oil pump seal
17. Washer
18. O-ring

V-220(N/A)

MECHANICAL
COMPONENTS

TRANSMISSION HOUSING AND

DIFFERENTIAL

Transmission housing & Differential

1. Torque converter housing

2. Bushing
3. Shift seal
4. Drive axle seal
5. Sealing sleeve
6. Breather
7. Cap
8. Sealing sleeve
9. Cable terminal
10. Speed output sensor
11. Washer
12. Bolt
13. Shim
14. Shim
15. P/N switch
16. Bolt

24

17. Pin
18. Support bolt
19. Parking pawl
20. Leg spring
21. Connecting bar
22. Clamping sleeve
23. Detent disc
24. Stop bush
25. Selector shaft
26. Differential gear
27. Roller bearing
28. Roller bearing
29. Drive axle seal
30. Side shaft
31. Roller bearing
32. Roller bearing

V-220(N/A)

MECHANICAL
COMPONENTS

VALVE BODY ASSEMBLY

V-220(N/A)

Valve body assembly

1. Valve body
2. Solenoid valve
3. Pressure control solenoid (EDS3)
4. Pressure control solenoid (EDS4)
5. Pressure control solenoid (EDS5)
6. Pressure control solenoid (EDS6)
7. Screw
8. Bracket
9. Bracket
10. O-ring
11. Input speed sensor

25

12. Screw
13. Oil pan
14. Gasket
15. Oil pan bracket
16. Bolt
18. Valve body wiring harness
19. O-ring
20. Plug
21. Clip
22. Clip

MECHANICAL
COMPONENTS

CASE AND ASSOCIATED PARTS

Case and association parts

26

V-220(N/A)

MECHANICAL
COMPONENTS

CASE AND ASSOCIATED PARTS

Case and association parts

1. Inner disc carrier F

39. Needle bearing

2. Clutch plate F

40. Rear planetary gear set

3. Clutch disc F

41. Snap ring

4. Clutch outer disc F

42. Rear sun gear

5. Spring disc

43. Needle bearing

6. Snap ring

44. Snap ring

7. Cup spring

45. Piston B

8. O-ring

46. Clutch plate B

9. O-ring

47. Clutch outer disc B

10. Piston F

48. Clutch disc B

11. Slot nut

49. Spring disc

12. Roller bearing

50. Piston ring

13. Adjusting ring

51. Inner disc carrier E

14. Bearing plate

52. Needle bearing

15. Roller bearing

53. Snap ring

16. Spur gear

54. Clutch plate E

17. Piston D

55. Clutch disc E

18. Spring disc

56. Clutch outer disc E

19. Snap ring

57. Spring disc

20. Clutch plate

58. Retaining ring

21. Cup spring

59. O-ring

22. Clutch disc D

60. Oil dam

23. Spring disc

61. Cup spring

24. Disc carrier

62. O-ring

25. Fitting key

63. Piston E

26. Clutch disc C

64. O-ring

27. Clutch outer disc C

65. Input shaft

28. Cup spring

66. O-ring

29. Clutch disc C

67. O-ring

30. Snap ring

68. Piston

31. Piston C

69. Oil dam

32. Cylinder C

70. O-ring

33. Snap ring

71. Cup spring

34. Front ring gear

72. Stop ring

35. Oil tray

73. Shim

36. Front planetary gear set

74. Needle bearing

37. Front sun gear

75. O-ring

38. Snap ring

76. Piston ring

77. Rear cover

27

V-220(N/A)

MECHANICAL
COMPONENTS

HOUSING TIGHTENING TORQUE

V-220(N/A)

Tightening Sequence of Housing

23

22

21

20

9
10

19

11

18

12
17
16

15

14

13

Tightening Sequence and Torque

No

Bolts Number

Tightening Torque

No

Bolts Number

Tightening Torque

15

16

22

23

20

15

17

11

23

12

15

18

21

23

23

15

19

10

23

16

15

20

20

23

15

21

23

15

23

22

19

23

23

23

23

16

23

24

18

23

10

23

25

23

11

14

23

26

17

23

12

23

27

23

13

13

23

28

23

14

23

23

29

23

15

12

23

28

SPECIAL TOOL

SPECIAL TOOL

Special tool

29

V-220(N/A)

SPECIAL TOOL

SPECIAL TOOL

Special tool

30

V-220(N/A)

SPECIAL TOOL

SPECIAL TOOL

Special tool

31

V-220(N/A)