2004 DAEWOO LACETTI torque converter

5A1 – 56IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
SYMPTOM DIAGNOSIS
Oil Leakage
Notice :
– Careful localization of leakage points may make it
possible to prevent incorrect or cost–intensive re-
pairs.
Test Steps :– Thoroughly clean the transaxle, engine, and sur-
rounding area(using a steam jet, for example).
– To locate leakage, use a suitable identifying spray
or similar product.
– Depending on the amount of leakage, take the
car for a short or a longer test drive – It may prove
sufficient to place the car on a hoist and run the
engine at idle speed to trace the leak.
– If possible, determine exactly which type of oil is
escaping.
Symptom
Possible CauseAction
Transaxle Oil Leak-
ageOil Pump(Torque Converter Sealing)S Visually check torque converter sealing.
S Replace the converter sealing as described in
the transaxle repair on the vehicle service.
Crankshaft Sealing RingS Check whether engine oil or TFT is leaking out.
S If leak is engine oil, replace the sealing ring as
described in the engine repair instruction.
Torque ConverterS Visual check.
S Fit an exchange converter as described in the
repair instruction.
Oil Content Too HighS Check oil level(TFT and axle oil) as described
in this chapter.
S Correct oil level, and recheck after a test drive.
Notice : Comply with the measuring procedure (fill-
ing procedure) in the repair instruction. Check the oil
level at the overflow plug adjust to proper level if nec-
essary.
O–ring at Bolt Head Damaged or Miss-
ingS Check O–ring.
S Replace O–ring as described in the repair in-
struction.
Shaft SealS Visually check the shaft seal.
S Replace the sealing ring as described in the
repair instruction.
Hose Clamp LooseS Check to ensure that the hose clamp fits tightly.
S If necessary, retighten clamp.
Oil Pan Gasket Not Installed ProperlyS Check to see if the gasket was positioned
properly.
S Install gasket properly as described in the re-
pair instruction.
Oil Pan Gasket DamagedS Check the gasket visually.
S Replace gasket as described in the repair in-
struction.
Bolt at Bracket LooseCheck the Tightening Torque
Retighten bolt
Sealing Ring at Oil DipstickS Check O–ring.
S If necessary, replace O–ring.
Sealing Ring Near End–Cover Connec-
tion DefectiveS Check sealing rings.
S Put in new sealing ring Check O–ring as de-
scribed in the repair instruction.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 57
DAEWOO V–121 BL4
Symptom ActionPossible Cause
Sealing Ring Selector ShaftS Check sealing ring.
S Replace sealing ring as described in the repair
instruction.
O–ring at Socket OutletS Check O–ring.
S Replace O–ring as described in the repair in-
struction.
O–ring and Speed Sensor ConnectionS Check O–ring.
S Replace O–ring as described in the repair in-
struction.
Oil Leak Incorrectly IdentifiedS No oil leak is possible at this point.
Speed Sensor Itself Is LeakingS Check speed sensor.
S Replace speed sensor as described in the re-
pair instruction.
Hair Line Crack at the Piping in the Con-
nection Area, Sealing Ring Fit in Trans-
axle HousingS Pressurize the line with compressed air and
check it.
S Replace lines as described in the repair in-
struction.
O–ring Defective, IncorrectCheck O–ring.
Replace O–rings as described in the repair instruc-
tion.
Plug LooseCheck the Tightening Torque for the screw plug.
Tighten to torque specified in the repair instruction.
Noise
SymptomPossible CauseAction
NoiseTFT Level Too LowS When the TFT level is too low, the gear wheels
from the transaxle oil pump might generate
noise.
S Check the TFT level as described in the repair
instruction and fill to the proper level.
Monolith in Catalytic Converter Has
BrokenS Check according to the exhaust gas diagnostic
procedure or by shaking the catalytic converter
casing.
S Replace catalytic converter if necessary.
Noise from Auxiliaries (e.g. exhaust
system, alternator, drive shafts.)S Check these components; if necessary, elimi-
nate the faults as described in the repair in-
struction
Noise from Tires or Wheel BearingsS Eliminate fault if necessary
Noise from Planetary GearsS Whistling noise on traction and overrun(in first
gear only)caused by high rotating speeds(func-
tionally unavoidable)
Cumulative Tooth Backlash in the Com-
plete Drive LineS Production status. Customer must be con-
vinced.
Jerky Noise of the Parking Lock (e.g.
when the car is standing on a gradient)S Load–reversal reaction
S Apply the handbrake before selection the park-
ing Lock (position P)

5A1 – 192IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
FLUID LEVEL SET AFTER SERVICE
1. Add transaxle fluid through the fill cap hole prior to
adjusting the fluid level. The amount of fluid to add
should be based on the type of service done.
Adjustment Notice
S Use ESSO LT 71141 transaxle fluid only.
S Oil pan removed : 4L (4.2 qt)
S Torque converter removed : 2L (2.1 qt)
S Complete overhaul : 6.7L (7.1qt)
S Drain plug removed : 4L (4.2 qt)
2. Check the transaxle fluid level. Refer to ”Transaxle
Fluid Level Checking Procedure” in this section.
3. Add additional fluid through the fill cap hole in 0.5
liter (0.5 quart) increments until the fluid comes out
through the plug hole.
4. Allow the fluid to finish draining out through the plug
hole, then install the fluid level plug.
5. When the fluid level setting procedure is completed,
wipe any fluid from the transaxle case with a rag or
shop towel. Also, check that the fluid fill cap and the
vent tube are properly installed.
REPAIRING FLUID LEAKS
Locating Leaks
General Method
1. Verify that the leak is transaxle fluid.
2. Thoroughly clean the suspected leak area.
3. Operate the vehicle for about 25 kilometers (15
miles) or until the transaxle reaches normal operat-
ing temperature, 88°C (190°F).
4. Park the vehicle over clean paper or cardboard.
5. Turn the engine off and look for fluid spots on the
paper.
6. Make the necessary repairs to correct the leak.
Powder Method
1. Thoroughly clean the suspected leak area.
2. Apply an aerosol–type powder (foot powder) to the
suspected leak area.
3. Operate the vehicle for about 25 kilometers (15
miles) or until the transaxle reaches normal operat-
ing temperature, 88°C (190°F).
4. Turn the engine off.
5. Inspect the suspected leak area and trace the leak
path through the powder to find the source of the
leak.
6. Make the necessary repairs.

5A1 – 208IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
10. Raise and suitably support the vehicle.
11. Drain the transaxle fluid.
12. Remove the oil cooler pipes from the transaxle. Re-
fer to ”Oil Cooler Pipes/Hoses” in this section.
13. Remove the drive axle. Refer to Section 3A, Auto-
matic Drive Axle.
14. Remove the starter motor. Refer to Section 1E, En-
gine Electrical.
15. Remove the torque converter bolts.
16. Support the transaxle.
17. Remove the rear transaxle mounting bracket bolts
(a) and damping block connection bolt and nut (b).
18. Support the transaxle assembly using the transaxle
support fixture DW260–010.

5A1 – 210IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
4. Install the rear transaxle mounting bracket bolts (a).
Tighten
Tighten the rear transaxle mounting bracket bolts (a)
to 62 NSm (45 lb–ft).
5. Install the damping block connection bolt and nut
(b).
Tighten
Tighten the damping block connection bolt and nut (b)
to 68 NSm (50 lb–ft).
6. Install the torque converter bolts.
7. Install the starter motor. Refer to Section 1E, En-
gine Electrical.
8. Install the drive axle. Refer to Section 3A, Automat-
ic Drive Axle.
9. Install the oil cooler pipes from the transaxle. Refer
to ”Oil Cooler Pipes/Hoses” in this section.
10. Lower the vehicle.
11. Install the left transaxle mounting bracket. Refer to
”Left Transaxle Mounting Bracket” in this section.

5A1 – 212IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
UNIT REPAIR
TORQUE CONVERTER
Disassembly and Assembly Procedure
1. Remove the transaxle assembly. Refer to ”Trans-
axle Assembly” in this section.
2. Remove the torque converter assembly.
3. Installation should follow the removal procedure in
the reverse order.
TRANSAXLE HOLDING FIXTURE
ASSEMBLY
Tools Required
DW260–020 Transaxle Support Fixture
CAUTION : To reduce the possibility of personal inju-
ry or transaxle damage, make sure, when doing the
next step, that all of the bolts for the support fixture
are installed as shown, and that the bolts are tight-
ened to 11 NSm (98 lb–in).
Disassembly and Assembly Procedure
1. Install the transaxle support fixture DW260–020
onto the transaxle.
2. Torque the support fixture bolts to 11 NSm (98 lb–
in).
3. Position the transaxle with the rear cover facing up.
VALVE BODY
Disassembly and Assembly Procedure
1. Remove the oil pan bolts and oil pan.
2. Remove the oil pan gasket.
Installation Notice
Tighten the oil pan bolts to 6 NSm (53 lb–in).

5A1 – 224IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
10. Turn the disc carrier C/D by 180°.
11. Using assembly bracket Press down cup spring and
take out the snap ring.
12. Remove the disc set D.
13. Installation should follow the removal procedure in
the reverse order.
DIFFERENTIAL
Disassembly and Assembly Procedure
1. Remove the torque converter housing. Refer to
”Torque Converter” in this section.
2. Lift out the differential.
3. Installation should follow the removal procedure in
the reverse order.
Removal Notice
S Don’t disassemble the differential to avoid incorrect
operation.
SIDE SHAFT
Disassembly and Assembly Procedure
1. Remove the differential. Refer to ”Differential” in
this section.
2. Tilt and remove the side shaft.
3. Installation should follow the removal procedure in
the reverse order.
Removal Notice
S Don’t disassemble the differential to avoid incorrect
operation.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 227
DAEWOO V–121 BL4
2. Find the disc set’s thickness. Refer to the below
table.
PF
Disc set’s Thickness
3.01~3.19mm1.8mm
3.20~3.48mm2.1mm
3.49~3.88mm2.5mm
3.89~4.08mm2.7mm
4.09~4.30mm3.0mm
PE is 4.20mm so, the disc set’s thickness is
3.0mm.
3. Replace clutch B’s setting disc. (3.0mm)
TORQUE CONVERTER HOUSING
Disassembly and Assembly Procedure
1. Remove the torque converter bolts.
2. Hit the torque converter housing lightly.
3. Remove the torque converter housing.
Installation Notice
S First pre–tighten the bolts in the following or-
der.(7,20)(12,23)(16,4)
Tighten
Tighten the bolts to 15 NSm (11 lb–ft).
S Then, tighten the bolts in the following order. (15,3)
(16,4) (14,5) (13,23) (12,22)(11,21)
(10,20) (9,19) (8,18) (7,17) (6) (1,2)
S Last, in numerical order, tighten the bolts all the
way.(123)
Tighten
Tighten the bolts to 23 NSm (17 lb–ft).
4. Take out the metal gasket.
5. Take out the paper gasket.
6. Remove the oil filter bolt and oil filter.
Installation Notice
Tighten
Tighten the oil filter bolt to 10 NSm (89 lb–in).