Repair Hyundai Getz
Hyundai Getz. The maintenance+ 1. Operation and maintenance service
+ 2. The engine
- 3. Transmission
Coupling
Possible malfunctions of coupling, their reason and ways of elimination
Transmission
Possible malfunctions of a transmission, their reason and ways of elimination
Drive of forward wheels
Possible malfunctions of a drive of forward wheels, their reasons and ways of elimination
+ 4. A running gear
+ 5. A steering
+ 6. Brake system
+ 7. An electric equipment
+ 8. A body
9. Electric equipment schemes
Hyundai Getz>> Transmission>> Transmission
Mechanical transmission
Mechanical five-speed transmission М5AF3 is shown on fig. 3.22 and 3.23.
Transfer numbers of the transmission aggregated with various engines, are resulted in tab. 3.1.
Table 3.1
Transfer numbers of a mechanical transmission
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Transmission transfer
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Working volume of the engine, l
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1,1
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1,3
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1,5
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1,6
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I
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3,615
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3,615
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3,615
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3,615
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II
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1,950
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1,950
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1,950
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1,950
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III
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1,286
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1,286
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1,286
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1,286
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IV
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0,971
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1,030
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0, 971
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1,031
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V
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0,780
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0,825
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0,825
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0,825
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Backing
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3,250
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3,250
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3,250
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3,250
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The main transfer
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4,294
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3,842
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3,650
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3,650
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Following special tools and adaptations are necessary for repair and transmission service:
– A traverse for engine posting at removal and transmission installation (number under the catalogue of spare parts and adaptations 09200-38001);
– The complete set of support traverses for engine posting at removal and transmission installation (number under the catalogue of spare parts and adaptations 09200-1С000).
Data for checks and adjustments, mm
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Axial backlash of the back bearing
Primary shaft
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0,01-0,09
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Axial backlash of the bearing secondary
Shaft
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0,05-0,10
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Preliminary tightness of bearings
Differential
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0,15-0,20
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Axial backlash of a leading gear wheel
The main transfer
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0,025-0,15
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Axial backlash of the forward bearing
Primary shaft
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0,01-0,12
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Check of level and oil replacement in a mechanical transmission
Check of level of oil
Be convinced of absence подтекания oils from a transmission. Turn away a stopper маслозаливного apertures and check up oil level. At oil pollution fill in fresh oil.
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THE NOTE
Oil level should be at the bottom edge of an aperture. At level decrease add oil while it will not start to follow, and wrap a stopper.
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Turn away a stopper маслозаливного apertures and a finger check up oil level.
Replace oil in картере transmissions if it is considerably polluted or not that viscosity.
Oil replacement
Establish the car on an equal horizontal platform, turn away a stopper маслосливного apertures and merge oil.
Wrap a stopper маслосливного apertures with a new lining the moment 30–35 Н·м.
Fill in fresh oil through a bulk aperture (fig. 3.24) to level of its bottom edge.
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THE NOTE
Capacity картера transmissions – 2,15 l.
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Recommended oil – SAE 75W-90 (API-GL-4).
Removal and installation of a mechanical transmission
Disconnect wires from the storage battery and remove the battery.
Remove a shelf of the storage battery, having turned away five bolts of its fastening.
Remove an arm of a shelf of the storage battery (fig. 3.25).
Remove the case of the air filter. At first remove the top part of the filter, then the bottom part (fig. 3.26).
One of three bolts is in the bottom part of the top cover of a casing.
Remove an arm of the air filter (fig. 3.27).
Remove the switch of light of a backing.
Turn away bolts of fastening of the working cylinder of a drive of coupling.
Remove lock шплинт a tip of a cable of a gear change (fig. 3.28).
Remove lock шплинт a tip of a cable of a choice of transfers (fig. 3.29).
Remove lock washers of covers of cables of a gear change and a choice of transfers (fig. 3.31).
Disconnect a flexible shaft of a drive of a speedometer.
Remove a forward wheel.
Remove a starter (fig. 3.31).
Turn away the top bolt of fastening of a transmission to the engine (fig. 3.32).
Lift the car and remove a support of the brake mechanism.
Disconnect steering draught from a suspension bracket rack.
Merge oil from картера transmissions, having turned away a stopper of a drain aperture.
Remove the gauge of speed of rotation of a wheel and turn away a bolt of fastening of a rotary fist.
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THE PREVENTION
At adaptation installation watch to damaging a hook of the holder the top cover of a casing.
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Remove a shaft of a drive of a wheel (fig. 3.33) and turn away a nut of a nave of a wheel.
Establish to a traverse (number under the catalogue of spare parts and adaptations 09200-38001) for engine posting at removal and installation of a transmission from support.
Turn away bolts of fastening of support of a suspension bracket of a transmission:
To a body (left-hand side) (fig. 3.34);
Bolt of an elastic support (fig. 3.35).
Remove a back arm of a suspension bracket of a transmission, having lifted the car (fig. 3.36).
Uncover картера couplings.
Establish трансмиссионную a rack under a transmission.
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THE NOTE
Needlessly not выпрессовывайте epiploons as their damages are thus possible.
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Turn away the bottom bolts of fastening of a transmission to the engine.
Remove a transmission.
Transmission installation is spent in an order, the return to removal.
Be convinced of absence подтекания oils from a transmission.
Replacement of an epiploon of differential
Disconnect a shaft of a drive of a wheel from a transmission as it is specified in subsection «Drive of forward wheels».
Take an epiploon (fig. 3.37) a screw-driver with a flat edge.
Оправкой 09431-21200 запрессуйте a new epiploon in a nest картера transmissions.
Put on an equal edge of an epiploon трансмиссионное oil HYUNDAI GENUINE PARTS MTF 75W-90 class API GL-4.
Gear change drive
The trosovyj drive of a gear change is shown on fig. 3.38.
Removal
Remove the handle of the lever of a gear change (fig. 3.39).
Remove the central console (fig. 3.40).
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Fig. 3.41. Bolts of fastening of cables of switching and a choice of transfers to the bottom part of the instrument panel
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Turn away bolts of fastening of cables to the bottom part of the panel of devices (fig. 3.41).
Take out lock шплинт a tip of a cable of a gear change (the subsection «Removal and transmission installation» see).
Take out lock шплинт a tip of a cable of a choice of transfers (the subsection «Removal and transmission installation» see).
Remove stoppers of a cover of cables of switching and a choice of transfers (the subsection «Removal and transmission installation» see).
Remove the case of the lever of a gear change in gathering.
Check of a technical condition
Check up the following:
— Correctness of action of a cable of a choice of transfers and absence of its damages;
— Correctness of action of a cable of a gear change and absence of its damages;
— Protective covers of tips of cables on absence of damages;
— Plugs on absence of deterioration, истирания, jammings, decrease in mobility and other damages;
— Springs on absence of easing or damages.
Installation of cables of a drive of a gear change is spent in an order, the return to removal.
The gear change lever
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Fig. 3.42. The gear change lever: 1 – the handle of the lever of a gear change; 2 – a core of the lever of a gear change; 3 – a finger; 4 – a cover; 5 – a pillow; 6 – the case; 7 – a gear change cable; 8 – a cable of a choice of transfers; 9 – the lever of a choice of transfers
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The gear change lever is shown on fig. 3.42.
Automatic transmission
Technical characteristics
Model..... A4AF3
Type..... Four-stage, with one transfer of a backing
Hydrotransformer type..... With the three-wheeled directing device, one-stage with two jet wheels
Transfer numbers of the transmissions aggregated with various engines, are resulted in tab. 3.2.
Table 3.2
Transfer numbers of a transmission
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Transmission transfer
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Working volume of the engine, l
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1,3
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1,5
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1,6
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|
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I
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2,846
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2,846
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2,846
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II
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1,581
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1,581
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1,581
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III
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1,000
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1,000
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1,000
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IV
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0,685
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0,685
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0,685
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Backing
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2,176
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2,176
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2,176
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The main transfer
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3,656
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3,443
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3,656
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Applied special tools and adaptations:
– A traverse for engine posting at removal and transmission installation (number under the catalogue of spare parts and adaptations 09200-38001);
– The complete set of support traverses for engine posting at removal and transmission installation (number under the catalogue of spare parts and adaptations 09200-1С000);
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THE NOTE
The adapter is used together with adaptations 09452-21002 and 09452-21500.
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THE NOTE
The control manometre is used together with adaptations 09452-21001 and 09452-21002.
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– An adapter for joining of a control manometre for pressure check
Oils (number under the catalogue of spare parts and adaptations 09200-21002);
– An adapter for joining of a control manometre for check of pressure of oil (number under the catalogue of spare parts and adaptations 09452-21002);
– A control manometre for check of pressure of oil (number under the catalogue of spare parts and adaptations 09452-21500).
Applied working liquids and lubricants
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Application place
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The name
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Volume
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Carter of an automatic transmission
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Working liquid GENUINE HYUNDAI
ATF SP-III
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6,7 l
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Condensing edges of epiploons of target shaft of differential
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Working liquid
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As required
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Surface of sliding of the plug
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Greasing for chassis SAE J310, NLGI No. 0
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The same
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Surface of a friction of the lever of the selector
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Universal greasing SAE J310, NLGI
No.2
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>
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Check of level of oil in an automatic transmission
Execute a trip on the car for warming up of oil of an automatic transmission to normal working temperature (80–90 °С).
Establish the car on an equal horizontal platform.
Serially establish the selector lever in position of inclusion of all transfers for filling with hydrotransformer and hydrosystem oil then establish the selector lever in position «N» (neutral).
Before to take out маслоизмерительный щуп, remove a dirt round its aperture. After that take out щуп and check up an oil condition. The transmission is subject to repair at presence at least one of following signs of decrease in quality of oil:
– A smell of "burnt" oil;
– Considerable dimness of colour of oil;
– Appreciable presence of a considerable quantity of metal particles in oil.
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THE NOTE
Insufficient level of oil can cause variety of infringements of work of a transmission as in the pump together with oil air will arrive. At air hit in oil air vials are formed. Thereof there are fluctuations of pressure of oil that becomes the reason of a delay of a gear change, proslipping of friction clutches and brakes.
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Oil level should be at a label of "NOTES" (hot) щупа. At level decrease to add oil to a label of "NOTES".
It is used трансмиссионное oil GENUINE DIAMOND ATF SP-III.
Excess of normal level of oil is inadmissible. At pouring in картер transmissions of excessive quantity of oil it foams tooth gearings that leads to the same infringements of work, as well as at insufficient level of oil, and also to fast deterioration of properties of oil. In both cases formation of air vials causes an overheat and premature oxidation of oil therefore normal work of valves, friction clutches and servo-drivers is broken. Besides, foaming causes oil emission through a ventilating aperture of a transmission that at box survey can be perceived as oil leak.
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THE PREVENTION
During the given check ahead and behind the car there should not be people.
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Check of blocking of the hydrotransformer
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THE NOTE
Oil should be heated-up to normal working temperature (80–90 °С). The temperature of a cooling liquid also should be the normal worker (nearby 80–90 °С).
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At check of blocking of the hydrotransformer the maximum turns of the engine are defined at full loading and positions «D» and «R» the selector lever. Working capacity муфты a free wheeling статора the hydrotransformer and keeping ability of friction clutches of a transmission and a brake of lowering transfer and a backing is thus checked.
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THE PREVENTION
Press a pedal against the stop only during such time which is necessary for reception of the maximum indications of a tachometre, and at all do not keep a pedal in the pressed position more than 5 with. In need of repetition of check of blocking of the hydrotransformer preliminary allow to the engine to work 2 mines at frequency of rotation of a cranked shaft about 1000 mines-1; the selector lever should be in neutral position to lower oil temperature.
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Check up oil level in картере transmissions.
Enclose колодки under back wheels.
Connect a control tachometre.
Completely tighten the lever of a drive of a lay brake and against the stop press a brake pedal.
Start up the engine.
At a finding of the lever of the selector in position «D» against the stop press a pedal of an accelerator before reception of the maximum indication of a tachometre.
Frequency of rotation of a cranked shaft at the moment of hydrotransformer blocking – 2200–2800 mines-1.
Establish the selector lever in position «R» and repeat check of blocking of the hydrotransformer as it is specified above.
Possible results of check.
1. Frequency of rotation of a cranked shaft at blocking of the hydrotransformer above norm at a finding of the lever of the selector in position «D».
If frequency of rotation of the engine at which there is a hydrotransformer blocking, above norm the reason of it is proslipping of a back friction clutch or муфты a transmission free wheeling. In this case check up hydraulic system to establish the proslipping reason.
2. Frequency of rotation of a cranked shaft at blocking of the hydrotransformer above norm at a finding of the lever of the selector in position «R».
If frequency of rotation of the engine at which there is a hydrotransformer blocking, above norm the reason of it is proslipping of a forward friction clutch or a brake of raising transfer and a transmission backing. In this case check up hydraulic system to establish the proslipping reason.
3. Frequency of rotation of a cranked shaft at blocking of the hydrotransformer below norm at a finding of the lever of the selector in position «D» or «R».
If frequency of rotation of the engine at which there is a hydrotransformer blocking, below norm the reason of it is the lack of the capacity developed by the engine, or malfunction of the hydrotransformer. Check up the engine on presence of admissions of ignition of a mix, infringement of installation of an advancing of ignition, correctness of adjustment of backlashes in the mechanism of a drive of valves. If the engine is serviceable, the hydrotransformer is faulty.
Check of work of a drive of switching
Check of action of the lever of the selector
Translating the selector lever in all positions, check up smoothness of its course and clearness of switching. Check up correctness of work of the index of position of the lever of the selector.
Be convinced that the selector lever is established in all positions.
Start up the engine and be convinced that the car begins movement by a forward course while translating the lever of the selector from position «N» in position «D» and movement by a backing at lever installation in position «R».
At infringement of work of the lever of the selector adjust тросовый a drive of management and the plug of the lever of the selector.
Check up mobile parts of the lever of the selector on deterioration presence.
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THE NOTE
At adjustment of position of the case of the switch track that the sealing ring has not dropped out of the case. A fastening bolt tighten, without making excessive effort.
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Adjustment of the switch of the selector
Establish the selector lever in position «N» (neutral).
Disconnect a cable from the lever of a drive of an accelerator (fig. 3.45), having weakened an inhaling of a lock nut.
Establish the lever of a drive of the selector in position «N» (neutral).
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Fig. 3.46. Adjustment of the switch of the selector: 1, 3 – the lever of a drive of the selector; 2 – the selector switch; 4 – bolts of fastening of the switch of the selector
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Turn of the case of the switch of the selector combine the end of the lever of a drive of the selector in width of 12 mm with a part of a flange of the case of the switch in width of 12 mm (fig. 3.46).
Tighten fastening bolts (two bolts) the moment 10–12 Н·м.
Be convinced that the selector lever is in position «N» (neutral).
Rotation of a nut with a fillet choose a weak point of a cable of management and be convinced of smoothness of moving of the lever of the selector.
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THE NOTE
Before assemblage put hermetic DC780 or similar on an average part of a carving of the adjusting screw.
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During a trial trip be convinced of correctness and clearness of a gear change.
Adjustment of the switch of mode Kick-down
Carefully remove a dirt round the adjusting screw of the switch of mode Kick-down.
Ослабьте a screw counternut.
Twice turn on and tighten the adjusting screw the moment 5 Н·м.
Tighten the adjusting screw the moment 5 Н·м, then turn away it approximately on 1/3 turns.
Tighten a counternut of the screw the moment 15–22 Н·м.
Pressure adjustment in a highway
Merge oil from картера transmissions. The stopper маслосливного apertures картера transmissions is shown on fig. 3.47.
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THE NOTE
Change of pressure upon one turn of the adjusting screw makes 0,39 kgs/sm 2.
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Remove the oil pallet (fig. 3.48).
Remove the oil filter (fig. 3.49).
Remove the gauge of temperature of oil (fig. 3.50).
Press a pad of a sealant of a contact socket (fig. 3.51) the electromagnetic valve and wring out it inside.
Remove the hydraulic block, watching that the valve of manual switching thus has not dropped out.
Rotation of the adjusting screw (fig. 3.52) the regulator valve establish demanded pressure in a highway (pressure in a brake of mode Kick-down). At screw rotation clockwise pressure decreases, at rotation counter-clockwise – raises.
Pressure should be 8,77–9,18 kg/sm 2.
Be convinced available and correctness of installation of a sealing ring of the hydraulic block.
Replace a sealing ring of a contact socket of the electromagnetic valve.
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Fig. 3.53. Installation in картере a socket of the electromagnetic valve (an arrow position of a groove of the case of a socket is shown)
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Establish the hydraulic block on картер transmissions, then insert in картер a socket of the electromagnetic valve (fig. 3.53) so that the groove of the case of a socket was in the position shown by an arrow.
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THE NOTE
Process of adjustment of lowering pressure in the absence of diagnostic device NI-SCAN is more low described.
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Track that wires have not been clamped.
Tighten bolts of fastening of the hydraulic block the moment 10–12 Н·м.
Establish the oil filter.
Establish the oil pallet with a new lining.
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THE NOTE
Nominal lowering pressure makes (4,2±0,22) kg/sm 2. At adjustment of lowering pressure establish average value of the specified limit.
Change of pressure of oil on each turn of the adjusting screw makes 0,22 kgs/sm 2.
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Fill in in картер transmissions demanded quantity of oil for automatic transmissions.
Check up pressure of oil and if necessary adjust it.
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THE PREVENTION
The given adjustment is spent at temperature of oil 80–90 °С. If adjustment is carried out at temperature above specified, pressure idling the engine will fall and correctly adjust pressure it can to appear impossible.
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Adjustment of lowering pressure
Remove details up to the oil filter, as well as at pressure adjustment in a highway.
To remove the hydraulic block it is not required.
Establish the adjusting screw in the bottom part of the hydraulic block demanded lowering pressure. At rotation of the adjusting screw clockwise lowering pressure decreases, at rotation counter-clockwise – increases.
Establish the oil filter and the oil pallet the same as and at pressure adjustment in a highway.
Check up pressure and if necessary adjust it.
Replacement of epiploons of target shaft of differential
Disconnect a shaft of a drive of a wheel from a transmission.
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Fig. 3.54. An arrangement of epiploons of target shaft of differential for the left and right parties
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Remove an epiploon of a target shaft (fig. 3.54) a screw-driver with flat шлицем.
Оправкой (09431-21200) запрессуйте a new epiploon of a target shaft of differential in a nest картера transmissions.
Put трансмиссионное oil on condensing edge of an epiploon.
Replacement of the electronic block of management (ЭБУ) the engine and transmission
ЭБУ (fig. 3.55) is located by the engine and transmission under the panel of devices from outside the driver (over a brake pedal).
Removal and installation of an automatic transmission
Removal
Disconnect wires from the storage battery and remove the battery.
Remove a shelf of the storage battery.
Remove an arm of a shelf of the storage battery.
Remove the case of the air filter.
One of three bolts is in the bottom part of the top cover of a casing.
Remove an arm of the air filter.
Separate a socket of the switch of the selector (fig. 3.56).
Separate sockets of the electromagnetic valve and the gauge of temperature of oil (fig. 3.57)
Remove lock шплинт a cable of management of the selector (fig. 3.58).
Remove маслоналивную a tube (fig. 3.59).
Remove a lock plate of a cable of management of the selector.
Disconnect hoses of a cooler of oil (fig. 3.60).
Disconnect a flexible shaft of a drive of a speedometer.
Remove a wheel.
Remove a starter.
Turn away the top bolt of fastening of a transmission to the engine (fig. 3.61).
Lift the car and remove a support of the brake mechanism.
Disconnect steering draught.
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THE NOTE
At adaptation installation track to damaging a hook of the holder the top cover of a casing.
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Remove a lateral cover of a transmission (fig. 3.63).
Remove the gauge of speed of rotation of a wheel and turn away a bolt of fastening of a rotary fist.
Remove a shaft of a drive of a wheel and turn away a nut of a nave of the left wheel.
Establish to a traverse for engine posting at removal and transmission installation (number under the catalogue of spare parts and adaptations 09200-38001). Fix the engine for a traverse.
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THE PREVENTION
If on the engine the hydrotransformer the epiploon from outside transmissions can be damaged at first is established. Therefore it is necessary to connect the hydrotransformer to a transmission at first. At arm installation балансирной a support do not suppose смятия an elastic pillow that can cause vibration at engine work idling.
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Turn away bolts of fastening of support of a suspension bracket of a transmission:
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Fig. 3.64. Bolts of fastening of support of a suspension bracket of a transmission to a body at the left
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To a body (left-hand side) (fig. 3.64);
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Fig. 3.65. Bolts of fastening of support of a suspension bracket of a transmission to a body from above
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To a body (the top party) (fig. 3.65);
Bolt of fastening of an elastic support (fig. 3.66).
Remove a back arm of a suspension bracket of a transmission, preliminary having lifted the car.
Uncover картера the hydrotransformer (fig. 3.67).
Turn away bolts of fastening of a cover of the hydrotransformer (fig. 3.68).
Turn away a bolt of fastening of a cover of the block of cylinders (fig. 3.69).
Establish a jack under a transmission.
Turn away the bottom bolts of fastening of a transmission to the engine (fig. 3.70).
Remove a transmission.
Installation
Пристыкуйте a transmission with the hydrotransformer to the engine, screw bolts of its fastening and tighten them.
Establish a cable of management of the selector and adjust it, as set forth below:
Establish the lever of the selector and the selector switch in position «N» and attach a cable of management of the selector;
Attach a cable to an arm of a suspension bracket of a transmission and establish a stopper so that it concerned a cable;
Choose a weak point of a cable nut rotation then check up smoothness of moving of the lever of a choice of transfers;
Check up correctness of adjustment of a cable.
Gear change drive
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Fig. 3.71. Cables of a drive of a gear change: 1 – a cable of management of the selector; 2 – a cable of blocking of the lever of the selector
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Cables of a drive of a gear change are shown on fig. 3.71.
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Fig. 3.72. A gear change drive: 1 – a cable of management of the selector; 2 – the bottom casing of the index; 3 – the top casing of the index; 4 – the handle of the lever of the selector; 5 – a core of the lever of the selector; 6 – an arm of the lever of the selector; 7 – the mechanism of blocking of the lever of the selector; 8 – the index; 9 – ползун; 10 – a cable of blocking of the lever of the selector
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The gear change drive is presented on fig. 3.72.
Removal
Turn away screws of fastening of the central console (fig. 3.73).
Remove lock шплинт a cable of management of the selector (fig. 3.74).
Disconnect a cable of management of the selector, having wrung out its screw-driver (fig. 3.75).
Disconnect a cable of blocking of the lever of the selector from a blocking cam (fig. 3.76).
Turn away a bolt of fastening of a cable of blocking of the lever of the selector (fig. 3.77).
Separate a contact socket of the index of a mode of movement (fig. 3.78).
Remove an arm of the lever of the selector (fig. 3.79).
Remove a cable, having turned away bolts of fastening of its cover to the bottom part of the panel of devices (fig. 3.80).
Remove the button of the handle of the lever of the selector for what turn away screws of its fastening, wring out the button upwards, and then press it.
Check of a technical condition
Check up the following:
– A clamp on deterioration presence;
– The plug on presence of deterioration or damages;
– A spring on presence of damages or easing;
– On presence of deterioration a pin on the end of a core of the lever of the selector.
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THE PREVENTION
After each removal самоконтрящиеся nuts are subject to obligatory replacement.
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Installation of a drive of a gear change is spent in an order, the return to removal.