2004 DAEWOO LACETTI automatic transmission

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TABLE OF CONTENTS
Section 0B General Information
Section 1 Engine
Section 1A General Engine Information
Section 1C1 1.4L/1.6L DOHC Engine Mechanical
Section 1C2 1.8L DOHC Engine Mechanical
Section 1D Engine Cooling
Section 1E Engine Electrical
Section 1F Engine Controls
Section 1G Engine Exhaust
Section 2 Suspension
Section 2A Suspension Diagnosis
Section 2B Wheel Alignment
Section 2C Front Suspension
Section 2D Rear Suspension
Section 2E Tires and Wheels
Section 3 Driveline/Axle
Section 3A Automatic Transaxle Drive Axle
Section 3B Manual Transaxle Drive Axle
Section 4 Brakes
Section 4A Hydraulic Brakes
Section 4B Master Cylinder
Section 4C Power Booster
Section 4D Front Disc Brakes
Section 4E1 Rear Disc Brakes
Section 4E2 Rear Drum Brakes
Section 4F Antilock Brake System
Section 4G Parking Brake
Section 5 Transmission/Transaxle
Section 5A1 ZF 4HP16 Automatic Transaxle
Section 5A2 AISIN Automatic Transaxle
Section 5B Five-Speed Manual Transaxle
Section 5C Clutch
Section 6 Steering
Section 6A Power Steering System
Section 6B Power Steering PumpSection 6C Power Steering Gear
Section 6E Steering Wheel and Column
Section 7 Heating, Ventilation, and Air
Conditioning (HVAC)
Section 7A Heating and Ventilation System
Section 7B Manual Control Heating, Ventilation,
and Air Conditioning System
Section 7D Automatic Temperature Control HVAC
Section 8 Restraints
Section 8A Seat Belts
Section 8B Supplemental Inflatable Restraints
(SIR)
Section 9 Body and Accessories
Section 9A Body Wiring System
Section 9B Lighting Systems
Section 9C Horns
Section 9D Wipers/Washer Systems
Section 9E Instrumentation/Driver Information
Section 9F Audio Systems
Section 9G Interior Trim
Section 9H Seats
Section 9I Waterleaks
Section 9J Windnoise
Section 9K Squeaks and Rattles
Section 9L Glass and Mirrors
Section 9M Exterior Trim
Section 9N Frame and Underbody
Section 9O Bumpers and Fascias
Section 9P Doors
Section 9Q Roof
Section 9R Body Front End
Section 9S Body Rear End
Section 9T1 Remote Keyless Entry and Anti–Theft
System
Section 9T2 Immobilizer Anti–Theft System

GENERAL INFORMATION 0B – 19
DAEWOO V–121 BL4
Manual Transaxle Identification Number
Plate (D16)
1. Identification Code
2. Sequential Number
Identification
Code
EngineGear Ratio
SY1.4L DOHC3.722 CR
CR1.6L DOHC3.722 CR
CV1.8L DOHC3.722 CR
Manual Transaxle Identification Number
Plate Location (D16)
The manual transaxle identification number is attached to
the top of the transmission case near the engine.
Automatic Transaxle Identification Number
Plate (ZF 4HP16)
1. Part Number
2. Sirial Number
3. Model Code
4. Manufactured Nation and Company
Part Code
Engine
AW1.8L DOHC
Automatic Transaxle Identification Number
Plate Location (ZF 4HP16)
The automatic transaxle identification number plate is at-
tached on the rear bottom side of the transaxle case near
the bulk head.

GENERAL ENGINE INFORMATION 1A – 3
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
20Inspect the bearing clearances.
Are the bearing clearances more than the specified
values?Crankshaft
0.026 ~0.046
mm
(0.0010~0.001
8 in.)
Connecting
Rod 0.019 ~
0.070 mm
(0.0007 ~
0.0027 in.)Go to Step 21Go to Step 22
21Replace the bearing, if necessary.
Is the repair complete?–Go to Step 1–
22Inspect the oil galleries.
Are the oil galleries cracked, porous, or plugged?–Go to Step 23Go to Step 24
23Repair or replace the engine block.
Is the repair complete?–Go to Step 1–
24Inspect the gallery plugs.
Are any of the gallery plugs missing or installed im-
properly?–Go to Step 25Go to Step 26
25Install the plugs or repair, as necessary.
Is the repair complete?–Go to Step 1–
26Inspect the camshaft.
Is the camshaft worn or is there evidence of poor
machining?–Go to Step 27System OK
27Replace the camshaft.
Is the repair complete?–Go to Step 1–
OIL LEAK DIAGNOSIS
Most fluid oil leaks are easily located and repaired by visu-
ally finding the leak and replacing or repairing the neces-
sary parts. On some occasions, a fluid leak may be difficult
to locate or repair. The following procedures may help you
in locating and repairing most leaks.
Finding the Leak:
1. Identify the fluid. Determine whether it is engine oil,
automatic transmission fluid, power steering fluid,
etc.
2. Identify where the fluid is leaking from.
1) After running the vehicle at normal operating
temperature, park the vehicle over a large sheet
of paper.
2) Wait a few minutes.
3) Find the approximate location of the leak by the
drippings on the paper.
3. Visually check around the suspected component.
Check around all the gasket mating surfaces for
leaks. A mirror is useful for finding leaks in areas
that are hard to reach.
4. If the leak still cannot be found, it may be neces-
sary to clean the suspected area with a degreaser,
steam, or spray solvent.
1) Thoroughly clean the area.2) Dry the area.
3) Operate the vehicle for several miles at normal
operating temperature and varying speeds.
4) After operating the vehicle, visually check the
suspected component.
5) If you still cannot locate the leak, try using the
powder or black light and dye method.
Powder Method:
1. Clean the suspected area.
2. Apply an aerosol–type powder, (such as foot pow-
der), to the suspected area.
3. Operate the vehicle under normal operating condi-
tions.
4. Visually inspect the suspected component. Trace
the leak path over the white powder surface to the
source.
Black Light and Dye Method:
A dye and light kit is available for finding leaks. Refer to the
manufacturer ’s directions when using the kit.
1. Pour the specified amount of dye into the engine oil
fill tube.
2. Operate the vehicle under normal operating condi-
tions as directed in the kit.
3. Direct the light toward the suspected area. The
dyed fluid will appear as a yellow path leading to
the source.

1C2 – 72I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
62. Install a new crankshaft rear oil seal using installer
J–36792 or KM–635.
63. Install the flywheel or flexible plate.
64. Install the flywheel or the flexible plate bolts.
Tighten
Tighten the flywheel bolts to 65 NSm (48 lb–ft). Use
the angular torque gauge KM–470–B to tighten the
flywheel bolts another 30 degrees plus 15 degrees.
For the automatic transmission, tighten the flexible
plate bolts to 45 NSm (33 lb–ft).
65. Install the engine. Refer to ”Engine” in this section.
CRANKSHAFT BEARINGS AND
CONNECTING ROD BEARINGS –
GAUGING PLASTIC
Tools Required
KM–470–B Angular Torque Gauge
Inspection Procedure – Crankshaft
1. Coat the crankshaft bearings with engine oil.
2. Install the upper crankshaft bearings into the engine
block crankshaft journals.
3. Install the lower crankshaft bearings into the crank-
shaft bearing caps.
4. Install the crankshaft.
5. Inspect the crankshaft end play with the crankshaft
bearings installed.
6. Check for permissible crankshaft end play. Refer to
”Engine Specifications” in this section.

ENGINE COOLING 1D – 5
DAEWOO V–121 BL4
COMPONENT LOCATOR
RADIATOR/FAN
1. Holder Transmission Fluid Pipe (Automatic Trans-
mission Only)
2. Upper Radiator Bumper
3. Front Upper Center Panel
4. Radiator
5. Lower Radiator Bumper6. Spring Clamp
7. Upper Radiator Hose
8. Main Cooling Fan
9. Auxiliary Cooling Fan
10. Drain Cock

1F – 468IENGINE CONTROLS
DAEWOO V–121 BL4
DIAGNOSTIC TROUBLE CODE (DTC) P0401
EXHAUST GAS RECIRCULATION INSUFFICIENT FLOW
Circuit Description
An Exhaust Gas Recirculation (EGR) system is used to
lower Nitrogen Oxide (NOx) emission levels caused by
high combustion temperatures. It accomplishes this by
feeding small amounts of exhaust gases back into the
combustion chamber. When the air/fuel mixture is diluted
with the exhaust gases, combustion temperatures are re-
duced
A linear EGR valve is used on this system. The linear EGR
valve is designed to accurately supply exhaust gases to
the engine without the use of intake manifold vacuum. The
valve controls exhaust flow going into the intake manifold
from the exhaust manifold through an orifice with an En-
gine Control Module (ECM) controlled pintle. The ECM
controls the pintle position using inputs from the Throttle
Position (TP) and Manifold Absolute Pressure (MAP) sen-
sors. The ECM then commands the EGR valve to operate
when necessary by controlling an ignition signal through
the ECM. This can be monitored on a scan tool as the De-
sired EGR Position.
The ECM monitors the results of its command through a
feedback signal. By sending a 5 volt reference and a
ground to the EGR valve, a voltage signal representing the
EGR valve pintle position is sent to the ECM. This feed-
back signal can also be monitored on a scan tool and is the
actual position of the EGR pintle. The Actual EGR Position
should always be near the commanded or Desired EGR
Position.
This diagnostic will determine if there is a reduction in EGR
flow.
Conditions for Setting the DTC
S DTCs P0106, P0107, P0108, P0117, P0118,
P0122, P0123, P0201, P0202, P0203, P0204,
P0351, P0352, P0402, P0404, P1404, P0405,
P0406 and P0502 are not set.
S Test in Decel Fuel Cutoff (DFCO) mode.
S Barometric Pressure (BARO) is greater than 72
kPa (10.4 psi).
S Vehicle speed is greater than 18 km/h (11.2
mph).
S A/C clutch/transmission clutch are unchanged.
S Rpm is between 1400 and 3000 for manual
transaxle.
S Rpm is between 1300 and 2900 for automatic
transaxle.
S Compensated MAP is with 10.3 to 32 kpa (1.5 to
4.6 psi) range.
S Start test
S Throttle position (TP) sensor is less then 1%.
S EGR is less than 1%.
S Change in MAP is less than 1.0 kpa (0.15 psi)Note : Test will be aborted when:
S Change in vehicle speed is greater than 5km/h (3.1
mph).
S Rpm is increased more than 75.
S EGR opened less than 90% commanded position.
Action Taken When the DTC Sets
S The Malfunction Indicator Lamp (MIL) will not illumi-
nate.
S The ECM will store conditions which were present
when the DTC set as Failure Records data only.
This information will not be stored in the Freeze
Frame data.
S A history Diagnostic Trouble Code (DTC) is stored.
S EGR is disabled.
Conditions for Clearing the MIL/DTC
S A history DTC will clear after 40 consecutive warm–
up cycles without a fault.
S DTC(s) can be cleared by using the scan tool.
S Disconnecting the ECM battery feed for more than
10 seconds.
Diagnostic Aids
The EGR Decel Filter value can be a great aid in determin-
ing if a problem exists and to verify repairs. The EGR De-
cel Filter is an average of the difference in the expected
MAP change and the actual MAP change caused by open-
ing the EGR valve during a deceleration, and is used to de-
termine when the MIL is illuminated. By driving the vehicle
up to approximately 97 km/h (60 mph) and decelerating to
32 km/h (20 mph), it can be determined if the EGR system
is OK, partially restricted, or fully restricted.
A more negative number (less than –3) indicates that the
system is working normally, whereas a positive number in-
dicates that the system is being restricted and that the ex-
pected amount of EGR flow is was not seen. A number
that falls between negative 3 and positive 2 indicates that
the system is partially restricted but not restricted enough
to cause an emissions impact.
The EGR Decel Filter value should always be at –3 or low-
er. If the EGR Decel Filter number becomes more positive
(towards 0 or more), then the EGR system is becoming re-
stricted. Look for possible damage to the EGR pipe or for
a restriction caused by carbon deposits in the EGR pas-
sages or on the EGR valve.
Test Description
Number(s) below refer to the step number(s) on the Diag-
nostic Table.
1. The On–Board Diagnostic (EOBD) System Check
prompts the technician to complete some basic
checks and store the freeze frame and failure re-
cords data on the scan tool if applicable. This

SECTION : 5A1
ZF 4 HP 16 AUTOMATIC TRANSAXLE
CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool
or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help
prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
TABLE OF CONTENTS
INTRODUCTION5A1–3 . . . . . . . . . . . . . . . . . . . . . . . . . . .
ZF 4HP 16 Automatic Transaxle 5A1–3. . . . . . . . . . . .
Transaxle Components 5A1–4. . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS5A1–5 . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 5A1–5. . . . . . . . . . . . . . . . . . . .
Transaxle Gear Ratio 5A1–5. . . . . . . . . . . . . . . . . . . . . .
Fluid Capacity 5A1–5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 5A1–5. . . . . . . . . .
Shift Speed Chart 5A1–7. . . . . . . . . . . . . . . . . . . . . . . . .
Line Pressure 5A1–8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS5A1–9 . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 5A1–9. . . . . . . . . . . . . . . . . . . . . . .
SCHEMATIC AND ROUTING DIAGRAMS5A1–11 . . .
Transaxle Control Module (1 of 2) 5A1–11. . . . . . . . . .
Transaxle Control Module (2 of 2) 5A1–12. . . . . . . . . .
Shift Mode Diagram 5A1–13. . . . . . . . . . . . . . . . . . . . . .
Power Flow Diagram 5A1–17. . . . . . . . . . . . . . . . . . . . .
COMPONENT LOCATOR5A1–33 . . . . . . . . . . . . . . . . . .
Transaxle Identification Information 5A1–33. . . . . . . .
Torque Converter 5A1–34. . . . . . . . . . . . . . . . . . . . . . . .
Transaxle Housing 5A1–35. . . . . . . . . . . . . . . . . . . . . . .
Oil Pump 5A1–36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Cover & Oil Pan Cover 5A1–37. . . . . . . . . . . . . .
Parking Lever 5A1–38. . . . . . . . . . . . . . . . . . . . . . . . . . .
Input Shaft & Shift Gear 5A1–39. . . . . . . . . . . . . . . . . .
Valve Body 5A1–41. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Shift Control 5A1–42. . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTIC INFORMATION AND PROCEDURES
DIAGNOSIS5A1–43 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Basic Knowledge Required 5A1–43. . . . . . . . . . . . . . . .
Functional Check Procedure 5A1–43. . . . . . . . . . . . . .
Line Pressure Check Procedure 5A1–43. . . . . . . . . . .
Clutch Plate Diagnosis 5A1–45. . . . . . . . . . . . . . . . . . .
Cooler Flushing and Flow Test 5A1–45. . . . . . . . . . . . . Transaxle Fluid Level Service Procedure 5A1–45. . . .
Electrical/Garage Shift Test 5A1–47. . . . . . . . . . . . . . .
Road Test Procedure 5A1–47. . . . . . . . . . . . . . . . . . . . .
Torque Converter Lock–Up Clutch(TCC)
Diagnosis 5A1–48. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TCM Initialization Procedure 5A1–50. . . . . . . . . . . . . .
Shift Speed Chart 5A1–51. . . . . . . . . . . . . . . . . . . . . . . .
Internal Wiring Harness Check 5A1–51. . . . . . . . . . . .
Transaxle Wiring Harness Connector 5A1–54. . . . . . .
Symptom Diagnosis 5A1–56. . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTIC TROUBLE CODE DIAGNOSIS5A1–60
Diagnostic Trouble Code (DTC) Identification 5A1–60
DTC P0562 – System Voltage Low 5A1–68. . . . . . . . .
DTC P0563 – System Voltage High 5A1–71. . . . . . . .
DTC P0601 – Internal Control Module Memory
Checksum Error 5A1–74. . . . . . . . . . . . . . . . . . . . . . .
DTC P0603 – Internal Control Module Keep
Alive Memory(KAM) Error 5A1–76. . . . . . . . . . . . . . .
DTC P0604 – Internal Control Module Random
Access Memory(RAM) Error 5A1–78. . . . . . . . . . . . .
DTC P0606 – Transaxle Control Module
Processor Fault 5A1–80. . . . . . . . . . . . . . . . . . . . . . . .
DTC P0703 – Brake Switch Circuit
Malfunction 5A1–83. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0705 – Transmission Range Sensor
Circuit Malfunction(PRNDL Input) 5A1–86. . . . . . . .
DTC P0710 – Transmission Fluid Temperature
Sensor Circuit Malfunction 5A1–89. . . . . . . . . . . . . .
DTC P0715 – Input Speed Sensor(ISS) Circuit
Malfunction 5A1–92. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0716 – Input Speed Sensor(ISS) Circuit
Range/Performance 5A1–95. . . . . . . . . . . . . . . . . . . .
DTC P0717 – Input Speed Sensor(ISS) Circuit
No Signal 5A1–98. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0720 – Output Speed Sensor(OSS)
Circuit Malfunction 5A1–101. . . . . . . . . . . . . . . . . . . .
DTC P0721 – Output Speed Sensor(OSS)
Circuit Range/Performance 5A1–104. . . . . . . . . . . . .

5A1 – 54IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
TRANSAXLE WIRING HARNESS
CONNECTOR
Wiring Harness Connector
Pin numberDescription
1Output Speed Sensor (+)
2Output Speed Sensor (–)
3Solenoid Valve (+)
4Transmission Fluid Temperature Sensor (–)
5Pressure Control Solenoid Valve (+)
6Pressure Control Solenoid Valve (EDS3)
7Pressure Control Solenoid Valve (EDS4)
8Not Used
9Transmission Fluid Temperature Sensor (+)
10Pressure Control Valve Solenoid Valve (EDS5)
11Pressure Control Valve Solenoid Valve (EDS6)
12Solenoid Valve 1
13Solenoid Valve 2
14Not Used
15Input Speed Sensor (–)
16Input Speed Sensor (+)
Component Resistance Chart
ComponentPass
Through
PinsResistance
20°C (68°F)
OhmsResistance w140°C
(212°F) Ohms
Solenoid 13, 1226.5± 0.5Ω26–345 Ω (not relative to temperature)
Solenoid 23, 1326.5± 0.5Ω26–345 Ω (not relative to temperature)
Pressure Control
Solenoid Valve (EDS3)5, 65.7± 0.45Ω5.3–6.3 Ω (not relative to temperature)
Pressure Control
Solenoid Valve (EDS4)5, 75.7± 0.45Ω5.3–6.3 Ω (not relative to temperature)
Pressure Control
Solenoid Valve (EDS5)5, 105.7± 0.45Ω5.3–6.3 Ω (not relative to temperature)