KIA Sportazh - Kia Sportage
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Automatic transmission
   The general information
   Search of malfunctions - the general information
   Reading of codes DTC, clearing of memory of the processor
   Checks and adjustments of components of control system АТ
   Checks and adjustments of a mehaniko-hydraulic part
   Check and adjustment приводного cable АТ
   Removal and installation of the lever of selector AT
   Removal and installation АТ
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Control кузовные the sizes
Schemes of electric connections



Kia Sportage>> Automatic transmission>> The general information

The general information

More detailed information on a design, principles of functioning and service of design AW can be found in the Management 179 (Automatic transmissions of modern cars) publishing houses ARUS.

Design typical АТ (1 from 2)

1 — the Hydrotransformer
2 — Entrance shaft O/D
3 — the Oil pump
4 — Disk brake O/D
5 — Friction clutch O/D
6 — the Entrance shaft of a friction clutch of forward transfers
7 — the Friction clutch of forward transfers
8 — the Friction clutch of direct perception
9 — Obgonnaja муфта O/D

10 — the Disk brake of a mode 2
11 — the Disk brake of transfers from 2nd and above
12 — the Disk brake of modes L and R
13 — a Forward number of back planetary assemblage
14 — the Back row of back planetary assemblage
15 — Forward planetary assemblage (O/D)
16 — Obgonnaja муфта №1
17 — Obgonnaja муфта №2

Design typical АТ (2 from 2)

1 — Obgonnaja муфта O/D
2 — Friction clutch O/D
3 — the Satellite of forward planetary assemblage
4 — Disk brake O/D
5 — the Friction clutch of forward transfers
6 — the Friction clutch of direct perception
7 — the Disk brake of a mode 2
8 — Obgonnaja муфта №1
9 — the Disk brake of transfers from 2nd and above
10 — the Disk brake of modes L and R
11 — Obgonnaja муфта №2
12 — the Orbital gear wheel of a forward number of back planetary assemblage

13 — the Orbital gear wheel of a back row of back planetary assemblage
14 — the Target shaft
15 — the Satellite of a back row of back planetary assemblage
16 — the Solar gear wheel of back planetary assemblage
17 — the Satellite of a forward number of back planetary assemblage
18 — the Intermediate shaft
19 — the Entrance shaft of a friction clutch of forward transfers
20 — Solar gear wheel O/D
21 — Entrance (primary) shaft O/D

For a complete set of cars considered in the present Management can be used 4-step (including raising transfer) automatic transmissions (АТ) series 03-72LE company Aisin Warner manufactures (AW372LE).

Playing a role of ordinary coupling during the moment трогания the car from a place, during movement АТ performs work on a gear change.

The basic components АТ are the blocked hydrotransformer (the rotation converter), a three-row step planetary reducer and an elektronno-hydraulic control system. To a gear change without rupture of a stream of capacity in a planetary reducer are applied гидроприводные multidisk brakes (4 pieces), обгонные муфты (3 pieces) and multidisk friction clutches (3 pieces).

Management of switching of all transfers, and also hydrotransformer blocking carries out the special electronic module (TCM), working in a close connection with the engine management module (ECM) and continuously communicating with the last.

Possibility of blocking of the hydrotransformer at movement in a cruiser mode about the speed, exceeding some threshold value allows to raise essentially profitability of the expense of fuel at the expense of decrease in working turns of the engine.

Liquid cooler ATF is built in a radiator of system of cooling of the engine, one more, an external air cooler is established directly ahead of a radiator of system of cooling.

TCM supervises functioning of all executive mechanisms AT (клапанная assemblage, couplings, brake assemblages) taking into account a choice of one of three set modes of transmission: ECONO (the normal mode), POWER or HOLD, - see the Head Controls and operation receptions). On the basis of the analysis of the data arriving from various information gauges (not necessarily directly related to functioning actually transmissions), TCM chooses optimum from the point of view of profitability, smoothness of switchings and so forth a mode of functioning АТ. The Component of control system АТ is the self-diagnostics subsystem, - at revealing of serious malfunction the management module switches transmission in a special emergency (safe) mode with the limited range of switchings. Switching in emergency operation allows to drive away the car under the own steam on a car repair shop for performance of detailed diagnostics and necessary regenerative repair. On the basis of the data arriving from gas traditionally established under a pedal of the gauge-switch of activation of a mode kickdown, TCM carries out transmission switching on adjacent used in a present situation transfer at full squeezing of a pedal that allows to raise essentially car dynamic characteristics, for example during overtaking fulfilment. Thanks to application of special gauge-switch N/R engine start can be carried out only when selector AT lever is in position Р or N that allows to prevent casual трогание the car at start attempt.

Unique procedure of service АТ which performance should be made on a regular basis, check of level of a working liquid (ATF) which order of performance is stated in the Head Current leaving and service is. Necessity for regular replacement ATF is absent.

In the present chapter the general procedures of service АТ lying within qualification of the average mechanic-fan are considered only most. The information on a design and principles of functioning of separate executive elements АТ is more low resulted.

Klapannaja assemblage

Klapannaja assemblage is located in the pallet картера transmissions and under control TCM exercises administration of streams ATF in a box. A part assemblages liquids supervising pressure valves are connected among themselves by internal channels. Clearing taken away of the pallet картера трансмиссионной liquids (ATF) is provided with the mesh filter which has been built in in маслозаборник of pump assemblage.

Design клапанной assemblages АТ

1 — the Valve of activation of a mode kickdown
2 — the Valve of switching 3-4
3 — the Secondary valve-regulator
4 — Dempfernyj the valve of transfer of a backing
5 — the Valve of switching 2-3
6 — the Valve of switching 1-2
7 — Reduktsionnyj the valve
8 — the Throttle valve
9 — Zapornyj the valve of restriction of throttle pressure

10 — the Valve of manual switching
11 — the Electromagnetic valve-switch And
12 — the Electromagnetic valve blocking муфты the hydrotransformer
13 — the mode Valve-modulator L
14 — the Electromagnetic valve-switch In
15 — the Primary valve-regulator
16 — the Operating valve of the hydrotransformer
17 — the Intermediate valve-modulator

Hydroaccumulators

The main function of the accumulator is maintenance of absence of stress of switchings of transmission towards increase of transfer at the expense of smoothing of operation of friction clutches. In considered transmission three relatives on an accumulator design are used: friction clutches of forward transfers and direct perception and a disk brake of transfers from 2nd and above.

The accumulator consists of the valve and a spring. To подпружиненной to the valve party плюсуется the main pressure, whose action is constantly enclosed to effort developed by a spring and presses the valve when assemblage is in an inactive condition.

Accumulator design

1 — the Working party
2 — To the internal piston of an under control component

3 — the Main pressure (from the valve of manual switching)
4 — the Party противодавления
5 — the Main pressure

At giving of operating pressure upon the corresponding executive mechanism (a friction clutch or a multidisk brake) the same pressure (from the valve of manual switching) is put to the working party of the valve of the corresponding accumulator. Under the influence of the given pressure the valve starts to be wrung out downwards, overcoming противодавление and the effort developed by a spring. On filling of working volume some time by the time of which end the executive mechanism appears completely included is required to the accumulator, - the given delay and provides smoothness of operation of an under control friction clutch/brake and, accordingly, absence of stress of switching АТ.

Hydrotransformer blocking

Blocking муфта provides possibility of transfer of a twisting moment from a cranked shaft of the engine to directly entrance shaft O/D of transmission.

Blocking operation occurs only in a cruiser mode at movement with a speed over 69 km/h (43 miles/ch) and at temperature of a cooling liquid not less 50С. At delay of speed of movement below a threshold of inclusion raising (O/D) transfers (69 km/h), no less than at decrease in temperature of a cooling liquid more low 50С, blocking муфта automatically it is disconnected.

Blocking inclusion

At delivery by the management module (TCM) a corresponding command during car movement on 2nd, 3rd or 4th (O/D) to transfer operation of the electromagnetic valve blocking муфты leads to opening of drainage channels and, as consequence, dump of the main pressure from the spring party operating золотникового the hydrotransformer valve. Under the influence of the main pressure (from the valve of switching 1-2), a zolotnik brought from an opposite side, there is its switching to giving being under the pressure of the hydrotransformer трансмиссионной liquids through the turbine on the back party blocking муфты, - superseded from an opposite side муфты ATF through the operating valve is deduced in the pallet картера (the stream трансмиссионной a liquid banished through cooler ATF, at the included blocking of the hydrotransformer is reduced). As a result blocking муфта nestles on a forward cover, mechanically with it being blocked. As муфта the forward cover has шлицевую landing to the turbine, from this point on, муфта and the turbine start to rotate as a unit, providing transfer of a twisting moment from a cranked shaft of the engine directly on entrance shaft O/D of transmission.

Equipment муфты демпферными springs allows to lower level of noise and the vibrations made трансмиссионной by a line.

Principle of inclusion of blocking of the hydrotransformer

And — Dump
In — The Main pressure
With — Pressure of the hydrotransformer
D — Dump
Е — The Main pressure (from the valve of switching 1-2)
F — The Operating valve of the hydrotransformer
G — To cooler ATF

НЭ/м the valve blocking муфты (Вкл)
1 — the Forward cover
2 — the Turbine
3 — the Pump
4 — Blocking муфта
5 — Springs
6 — the Cover
7 — the Working element of a zolotnik № 3
8 — the Working element of a zolotnik № 2

Blocking switching-off

At delivery by the management module (TCM) commands on blocking switching-off there is a closing of the electromagnetic valve under the influence of effort developed by its spring. As a result перекрывания drainage channels and alignment of pressure from both parties of the operating valve of the hydrotransformer, last under the influence of effort developed by a spring is switched, providing giving being under the pressure of hydrotransformer ATF on the forward party blocking муфты. As a result blocking муфта it is wrung out from a forward cover, deducing last from gearing with the block the mufta-turbine, - surplus of volume of the liquid which are under the pressure of the hydrotransformer, it is deduced through the operating valve in cooler ATF and further in the pallet картера.

Principle of switching-off of blocking of the hydrotransformer

And — Dump
In — The Main pressure
With — Pressure of the hydrotransformer
D — Dump
Е — The Main pressure (from the valve of switching 1-2)
F — The Operating valve of the hydrotransformer

G — To cooler ATF
НЭ/м the valve blocking муфты (Вкл)
1 — the Forward cover
2 — the Turbine
3 — the Pump
4 — Blocking муфта
5 — Springs
6 — the Cover

Cooler ATF

At the switched off blocking of the hydrotransformer transmission generates heat considerable quantity which basic part accumulates трансмиссионной a liquid.

For selection of heat from ATF it is organised special two-level охладительный a path. The first step of cooling is organised by means of a lining of tubes трансмиссионного a contour in the bottom tank of a radiator of system of cooling. After return of a part of heat of a cooling liquid of the engine in a radiator of system of cooling, ATF goes in маслоохладитель. The heat exchanger of cooler ATF is established ahead of a radiator of system of cooling and blown by a running stream of air which selects at ATF remained superfluous heat. Pressure ATF is supported at constant level in 1.9 атм at the expense of inclusion in охладительный a path of transmission special перепускного the valve.

The main source of a thermal emission in АТ is the hydrotransformer. As at inclusion of blocking of the hydrotransformer turbulence of stream ATF in it decreases, capacity of a thermal emission of transmission is appreciably reduced also. Taking into account the given factor, in design АТ function of reduction of a stream трансмиссионной liquids through cooler ATF for the period of inclusion blocking муфты is put. If there is an overheat, TCM develops a special command on switching-off of blocking of the hydrotransformer for the purpose of restoration of intensity of circulation ATF through the cooler heat exchanger.

Appointment of separate executive elements АТ

Card of operation of actuation mechanisms АТ

The card is presented in the table.

The device
Mode

Э/м кл. And

Э/м кл. In

Friction clutch O/D

Friction clutch of forward transfers

Р

R

N

D

1st transfer

2nd transfer

3rd transfer

O/D
2 1st transfer
2nd transfer
L 1st transfer

The device
Mode

Friction clutch of direct perception

Brake O/D

Brake of a mode "2"

Brake of transfers from 2nd and above

Р

R

N

D

1st transfer

2nd transfer

3rd transfer

O/D
2 1st transfer
2nd transfer
L 1st transfer

The device
Mode

Brake of modes "L" and "R"

Обг. муфта O/D

Обг. муфта №1

Обг. муфта №2
Внутр. The piston Plank beds. The piston

Р

R

N

D

1st transfer

2nd transfer

3rd transfer

O/D
2 1st transfer
2nd transfer
L 1st transfer

Friction clutches

The general information

Friction clutches consist of the set of ring plates placed in the case and frictional disks and the executive piston (it).

Plates are made of a steel, have smooth surfaces and are equipped in regular intervals placed on external edge шлицами; frictional disks represent thin metal rings with the frictional overlays pasted from both parties and non-uniformly ошлицованным internal edge. Plates and disks take places in the friction clutch case through one.

At the released piston frictional disks rotate in the assemblage case freely, and backlashes between them and ring plates are filled трансмиссионной by a liquid. At giving on the piston of pressure of a plate densely nestle on disks, forming the monolithic block. ATF it is superseded from backlashes and under the influence of centrifugal force through specially provided in the case of a friction clutch channels it is taken away in the pallet картера АТ. Отпускание the piston at pressure removal occurs under the influence of returnable springs.

1 — the Ring plate
2 — the Frictional disk
3 — the Returnable spring
4 — the Piston
5 — the Case

Friction clutch of raising transfer (O/D)

Provides blocking of a solar gear wheel with the holder of satellites (водилом) forward planetary assemblage.

The friction clutch is involved in all modes АТ on all transfers, except raising and, at the expense of blocking of planetary assemblage, provides transfer of a twisting moment from entrance shaft O/D inside трансмиссионной assemblages. Special, built in in the executive piston of a friction clutch, a control ball provides pressure deduction in the included condition and its dump at switching-off. The thin lock ring is used for fixing of all except one disks of the friction clutch, the second lock ring fixes a nave of disk brake O/D.

Friction clutch of forward transfers

Provides a joint of the entrance shaft with intermediate shaft of transmission.

The friction clutch is involved in all modes АТ on all transfers of a forward course and, through the nave, provides twisting moment transfer to the intermediate shaft jointed with водилом of back planetary assemblage. Special, built in in the executive piston of a friction clutch, a control ball provides pressure deduction in the included condition and its dump at switching-off. The thin lock ring is used for fixing of all except one disks of the friction clutch, the second lock ring fixes a nave of a friction clutch of the direct perception, rotating thus together with the case of a friction clutch of forward transfers.

Friction clutch of direct perception

Provides a joint of an entrance shaft of a friction clutch of forward transfers with a solar gear wheel.

The friction clutch is involved on a reverse gear, and also on 3rd and 4th transfers to modes R and D accordingly and provides transfer of a twisting moment from the nave to a solar gear wheel of back planetary assemblage. The nave of a friction clutch of direct perception rotates together with the case of a friction clutch of forward transfers, thus, at simultaneous activation of both friction clutches direct (direct) transfer of a twisting moment is provided. When the friction clutch of direct perception is involved only, the case of a friction clutch of forward transfers continues to rotate, without transferring thus a twisting moment to an intermediate shaft. Special, built in in the executive piston of a friction clutch, a control ball provides pressure deduction in the included condition and its dump at switching-off.

Disk brake assemblages

The design of multidisk brake assemblages is similar to a design of friction clutches.

Disk brake of raising transfer (O/D)

Blocks rotation of a solar gear wheel of forward planetary assemblage.

Brake disks (have internal gearing) are planted on шлицы naves, plates (have external gearing) are jointed шлицами with приболченным to картеру АТ the case of brake assemblage. The brake nave is connected directly to a solar gear wheel of forward planetary assemblage and at inclusion of 4th transfer in a mode D transmissions is blocked with the case of brake assemblage. The special, brake assemblage built in in the executive piston, a control ball provides pressure deduction in the included condition and its dump at switching-off. One lock ring is used for fixing of the spring holder, the second lock ring fixes working disks and plates.

Disk brake of a mode 2

Blocks rotation of a solar gear wheel of back planetary assemblage.

The brake is used for maintenance of braking with the engine while translating transmissions in a mode 2. Brake disks are planted on шлицы cases of a friction clutch of direct perception, plates are jointed шлицами with the case of the central support, in turn приболченным to картеру transmissions. At brake activation the nave of a friction clutch of the direct perception, having шлицевую landing to a solar gear wheel of back planetary assemblage is blocked. The special, brake assemblage built in in the executive piston, a control ball provides pressure deduction in the included condition and its dump at switching-off.

Disk brake of transfers from 2nd and above

Blocks an external holder обгонной муфты № 1, preventing thereby rotation of a solar gear wheel counter-clockwise.

Brake disks are planted on шлицы naves, plates are jointed шлицами with the case of the central support, in turn приболченным to картеру transmissions. The brake is involved in modes D and 2 transmissions at movement on 2nd, 3rd both 4th (O/D) transfers and its nave simultaneously is an external holder for обгонной муфты № 1. The special, brake assemblage built in in the executive piston, a control ball provides pressure deduction in the included condition and its dump at switching-off.

Disk brake of modes L and R

The holder of satellites blocks (drove) a forward number of back planetary assemblage.

Brake assemblage has a two-piston design and is located in a back part картера АТ. Brake disks are planted on шлицы cases of the holder of satellites (drove) a forward planetary number, plates are jointed шлицами with картером transmissions. In modes L and R АТ the brake provides blocking drove a forward planetary number, and in both cases both pistons are used. Special, built in in executive pistons of brake assemblage, control balls provide pressure deduction in the included condition and its dump at switching-off.

Обгонные муфты

Обгонная муфта O/D

Serves for a joint of a solar gear wheel with водилом in a lobby (O/D) to planetary assemblage and prevention of their rotation counter-clockwise.

The external holder муфты is a part drove, internal - a part of a solar gear wheel of forward planetary assemblage.

When the solar gear wheel perceives a twisting moment from involved friction clutch O/D, муфта provides gearing of components with transfer of rotation from the hydrotransformer turbine directly to an entrance shaft of a friction clutch of forward transfers.

At inclusion of 4th transfer friction clutch O/D is switched off and activated a disk brake of raising transfer. Thus the case of a friction clutch and a solar gear wheel forward (O/D) planetary assemblage are blocked, and the engine twisting moment starts to be transferred rotating round a solar gear wheel clockwise водилу, thus locks обгонной муфты are uncoupled, providing course freedom drove.

Обгонная муфта № 1

Serves for prevention of rotation of a solar gear wheel of a planetary number counter-clockwise during operation of a disk brake by 2nd and above transfers at movement in a mode D АТ.

The external holder муфты is a part of a nave of brake assemblage of 2nd and above transfers, internal - a part of a solar gear wheel of a planetary number.

At the disconnected brake the solar gear wheel rotates counter-clockwise as on 1st and back transfers and locks муфты are uncoupled.

Activation of a disk brake by 2nd and above transfers leads to deduction of an external holder муфты (brake naves), rotation of a solar gear wheel counter-clockwise stops in view of its blocking with a brake nave at the expense of operation of locks обгонной муфты.

Обгонная муфта № 2

Blocks rotation counter-clockwise the holder of satellites (drove) a forward number of back planetary assemblage.

Муфта it will be involved only on the first transfer in modes D and 2 АТ, mainly in need of fast acceleration.

The external holder муфты is a part drove a forward number of back planetary assemblage, internal - a part of a basic (jet) plate of a disk brake of modes L and R.

At a start of motion the friction clutch of forward transfers provides a drive of an orbital gear wheel of a back row of planetary assemblage that forces a solar gear wheel to rotate counter-clockwise. The perception of the given rotation водилом a forward planetary number is blocked by locks обгонной муфты. As a result, the twisting moment is transferred to a target shaft of transmission only by means of an orbital gear wheel of a forward number.

At movement on any other transfer of a forward course the solar gear wheel rotates counter-clockwise and locks обгонной муфты remain uncoupled. At sharp acceleration drove a forward number rotates clockwise, perceiving a twisting moment from a target shaft, also providing unhooking of locks муфты. The factor of braking is thus eliminated by the engine.

At movement in a mode L the brake of modes L and R blocks rotation drove a forward planetary number, and even gearing обгонной муфты № 2 does not lead to inclusion of braking by the engine.

Planetary reducer

In case of need address to materials stated in the previous subsections.

Forward planetary assemblage (O/D)

Single-row planetary assemblage O/D consists of a solar gear wheel, the complete set fixed in the holder (drove) satellites and an orbital gear wheel.

Entrance shaft O/D constantly rotates clockwise, perceiving a twisting moment from the turbine of the hydrotransformer jointed with водилом of planetary assemblage. The drive of a solar gear wheel is carried out by friction clutch O/D involved in all modes and on all transfers, except the raising.

From an entrance shaft rotation is transferred to satellites of planetary assemblage, forcing them to rotate counter-clockwise. Friction clutches O/D and forward transfers are connected to car driving wheels. The external holder обгонной муфты O/D rotates clockwise, perceiving a twisting moment from drove planetary assemblage of raising transfer. Resistance of a solar gear wheel and the effort developed водилом, leads to blocking of locks обгонной муфты and, as consequence, to a joint of the given components with each other, the monolithic block a solar gear wheel is as a result formed - drove - an entrance shaft. At rotation of a solar gear wheel with entrance shaft satellites are blocked in an orbital gear wheel that leads to transfer of a twisting moment to an entrance gear wheel of a friction clutch of forward transfers.

In need of inclusion of raising transfer friction clutch O/D is released and will be involved the disk brake of raising transfer blocking a solar gear wheel round which starts to rotate drove, untwisted by entrance shaft O/D. Satellites are compelled to run all over a solar gear wheel, forcing an orbital gear wheel to rotate with большей, than own (satellites) in the angular speed. As a result of operation of the described scheme the transfer relation of raising transfer (0.730: 1) is formed.

Back planetary assemblage

In considered АТ (AW372LE) the back planetary assemblage of design Simpson consisting of two planetary numbers (satellites in водиле and an orbital gear wheel), planted on the general solar gear wheel is used.

The solar gear wheel is planted on шлицы naves of a friction clutch of direct perception. Drove a forward planetary number by means of шлицов it is jointed with brake assemblage of modes L and R and обгонной муфтой № 1. The orbital gear wheel of a back planetary number is resulted in rotation by a friction clutch of forward transfers. Back drove also an orbital gear wheel of a forward number, have шлицевую landing to the day off to a shaft.

The demanded transfer relation is reached at the expense of a combination of blocking of components of a reducer.

The mechanism of parking blocking

The external surface of an orbital gear wheel of a forward planetary number has gear structure, - while translating the selector lever in position Р the special rod equipped with a cam provides deployment of the blocking lever with input of its working ledge in gearing with teeths on an external surface of a gear wheel that leads to blocking of a target shaft of transmission. In any other position of the lever of the selector the target shaft remains free.

1 — the Orbital gear wheel of a forward number of back planetary assemblage
2 — the Cam
3 — the Blocking lever

Pump station

The hydraulic pressure used at management by functioning АТ is forced in system by special pump station. Though the rotor of the converter of rotation also can be considered as some kind of the pump, generated by it the stream of a hydraulic liquid is consumed exclusively actually by the hydrotransformer, without taking part in any way in functioning of other components of transmission. The liquid arrives on an input of the converter and is issued from it not at the expense of functioning of own pump (rotor), and being forced by the special oil pump.

From an exit of oil pump ATF arrives in the special regulator which is responsible for maintenance of working pressure in a path at constant level. The control of functioning of transmission is carried out by means of various hydraulic lines. On картере АТ some gates are provided, allowing to make pressure gaugings in lines for the purpose of check of serviceability of functioning of transmission in various conditions. Thus it is not necessary to forget that pressure in all these control lines is forced by exclusively pump station AT.

On considered models the volume oil pump шестеренчатого the type which drive is carried out directly from a nave of the converter of rotation is used, on шлицы which the leading gear wheel of pump assemblage is planted.

1 — the Epiploon
2 — the Case
3 — the Sealing ring
4 — the Conducted gear wheel
5 — the Leading gear wheel
6 — the Support статора
7 — the Holder № 1 persistent bearing
8 — Rings
9 — the Holder № 2 persistent bearings
10 — the Holder № 3 persistent bearings

The functioning principle трансмиссионный pump stations is in detail considered in the Management 179 (Automatic transmissions of modern cars) publishing houses ARUS.