2004 DAEWOO NUBIRA check oil

5A1 – 202IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
7. Remove the oil pan and oil pan gasket.
Installation Procedure
1. Install the oil pan, oil pan gasket and bolts.
Tighten
Tighten the oil pan bolts to 6 NSm (53 lb–in).
2. Install the oil cooler inlet and outlet pipes. Refer
to”Oil Cooler Pipe/Hose” in this section.
3. Install the transaxle fluid drain plug using the plug
remove/installer DW260–070.
4. Install the engine under cover. Refer to Section 9N,
Frame and Underbody.
5. Refill the transaxle fluid. Refer to ”Transaxle Fluid
Level Checking Procedure” in this section.
6. Connect the negative battery cable.

AISIN AUTOMATIC TRANSAXLE 5A2 – 3
DAEWOO V–121 BL4
SPECIFICATIONS
GENERAL SPECIFICATIONS
Definition
1.6 DOHC
Transaxle Fluid TypeISU DEXRON III or ESSO JWS 3309
Transaxle Fluid Capacity5.77L (6.1 qts)
TRANSAXLE GEAR RATIO
GearRatio
1.6 DOHC
First2.875
Second1.568
Third1.000
Fourth0.697
Reverse2.300
Counter1.020
Differential3.750
FLUID CAPACITY
Capacity
1.6 DOHC
Transaxle Fluid (dry fill)5.77L (6.1 qts)
Transaxle Fluid (drain and refill)2.1L (2.2 qts)
Notice : Fluid capacity (drain and refill) could be changed according to the some condition, therefore be sure to check
the fluid using the oil stick guage.
LINE PRESSURE SPECIFICATION
ApplicationIdlingStall
At ”D” range3.9–4.2 kg/cm2 (55–60 psi)11.3–12.5 kg/cm2 (161–178 psi)
At ”R” range6.0–6.9 kg/cm2 (85–98 psi)16.2–18.6 kg/cm2 (230–265 psi)

5A2 – 20IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
1. Transaxle Housing
2. Oil Seal
3. Oil Reservoir Plate
4. Transaxle Oil Apply Pipe
5. Differential Gear Oil Apply Pipe
6. Transaxle Oil Apply Pipe Clamp
7. Spring
8. Check Valve Pipe Clamp
9. Apply Gasket
10. Brake Drun Gasket
11. Transaxle Wire
12. O–ring
13. Valve Body
14. Parking Lock Pawl
15. Parking Lock Pawl Shaft
16. Torsion Spring
17. Manual Valve lever Shaft
18. Manual Valve Lever
19. Parking Lock Rod
20. Parking Lock Pawl Bracket
21. Manual Detent Spring
22. Pin
23. Spacer24. Oil Seal
25. Transmission Range (TR) Switch
26. Lock Washer
27. Control Lever
28. Washer
29. Gasket
30. Oil Strainer
31. Oil Pan
32. Gasket
33. Magnet
34. Direct Clutch Accumulator Piston
35. O–ring
36. Spring
37. O–ring
38. Forward Clutch Accumulator Piston
39. O–ring
40. Spring
41. O–ring
42. Overdrive Brake Accumulator Piston
43. O–ring
44. O–ring
45. Spring

AISIN AUTOMATIC TRANSAXLE 5A2 – 27
DAEWOO V–121 BL4
WIRING HARNESS AND
CONNECTOR INSPECTION
1. Reproducing test
Perform symptom simulation test on the basis of
user’s condition. Refer to the below factors.
S Occuring–road condition, speed, accelerate,
reduce speed, straight, curve, air temperature,
weather, etc.
2. Inspect the connection condition of between con-
nectors.
Inspect the failure between connectors by visual
check and contact pressure check.
S Connector disconnected
S Terminals rusted
S Terminals deformation or loose fit
3. Inspect the Continuity of the wiring harness.
Disconnect both ends connector of wiring har-
ness, measure resistance between one connec-
tor terminal and other.
S Normal : 1Ω or less (No open circuit)
S Abnormal :
Ω (Open circuit)
Notice : Measure the resistance while slightly shaking
wire harness vertically and horizontally.
It is rare case wiring harness is broken at the middle of it,
and most cases occur at the connector.
4. Inspect the short circuit of the wiring harness.
Disconnect the connectors of the wiring harness
at both ends, measure resistance between the
applicable terminals of the connector and body
earth.
S Normal : 1M Ω or higher (No short circuit)
S Abnormal : Low resistance (Short circuit)Measure the resistance between one terminal
an another terminal in the same connector.(Ex-
cept between power supply or between earth).
S Normal : 1M Ω or higher (No short circuit)
S Abnormal : Low resistance (Short circuit)
Notice : Measure the wiring harness while slightly shaking
vertically and horzontally.
It is usual case of the short circuit that wiring harness is
crowded body and clamping failure.
5. Temporary connection failure of the connector.
It is thought that temporally the connection fail-
ure of the connector is cause when you can not
decide cause of DTC detection.
Therfore make sure to inspect and clean the
connector and delete the memorized DTC.
ROAD TEST
Road test is to diagnosis failure symptom accurately and
check the failure symptom after procedure.
Confirm whether below condition before road test. Oil tem-
perature is hot condition (50°C (122°F) ~ 80°C (176°F)).
1. D range test
S Check for up–shift, down–shift, kick–down and
lock–up operation at the shift point shown in the
shift schedule.
S Check for engine brake operation.
S Check for Check abnormal shock, noise and
harshness.
2. ”P” range test
Park vehicle on a gradient (more than 5°), shift
into the ”P” range and release parking brake.
Then, check to see no moving vehicle by opera-
tion of parking lock pawl.

5A2 – 28IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
FUNCTION CHECK
Confirm whether below condition before function check.
S Oil temperature is hot condition (50°C (122°F) ~
80°C (176°F)).
S Switch of A/C and light etc are off.
Stall Test
Stall test’ purpose is to inspect overall performance of A/T
and engine by measuring the stall speed in ”D” and ”R”
range.1. Chock 4 Wheels and apply parking brake fully, lock
vehicle perfectly.
2. Fully pressed on foot brake pedal with left foot.
3. Shift into ”D” and ”R” range, fully press on accelera-
tor pedal with right foot.
Quickly read stall speed at this time.
Standards
2390 ± 150 rpm
Notice : Do not continuously run longer than 5 sec be-
cause of extreme increasing oil temp.
Make sure to keep interval for more than 1 min between
stall tests.
Result of Stall Test
Cause of Failure
Lower than standards
both ”D” and ”R”Less engine power
Torque converter one way clutch failure
Higher than standards
only ”D”Lower line pressure
S Pressure control solenoid (PCS) failure
S Primary regulator valve failure
Forward clutch (C1) failure (Slipping)
No.2 One–way clutch (F2) failure
Higher than standards
only ”R”Lower line pressure
S Pressure control solenoid (PCS) failure
S Primary regulator valve failure
Reverse clutch (C3) failure (Slipping)
1st & reverse brake (B3) failure (Slipping)
Higher than standards
both ”D” and ”R”Lower line pressure
S Pressure control solenoid (PCS) failure
S Primary regulator valve failure
Oil pump failure
Oil strainer failure (clogging)
Oil leak for each range circuit
Time Lag Test
Time lag is time till slightly shock can be felt when shift le-
ver is shifted ”N”  ”D” and ”N”  ”R” while engine idling.
Time lag test can inspect hydraulic condition and clutch/
brake condition.
1. Chock 4 Wheels and apply parking brake fully, lock
vehicle perfectly.
2. Measure time lag by using stop watch from moment
when shift lever is shifted in ”N”  ”D” and ”N” 
”R” until moment slightly shock can be felt.”N  D”less than 0.7 sec
”N”  ”R”less than 1.2 sec
Notice : Make sure to take 3 measurement and take the
average value.
Make sure to keep interval for more than 1 min between
time lag tests. (That purpose is to remove clutch/brake
pressure was left unfinished.)

AISIN AUTOMATIC TRANSAXLE 5A2 – 29
DAEWOO V–121 BL4
Result of Time Lag TestCause of Failure
Longer than standards ”N”  ”D”Lower line pressure
S Pressure control solenoid (PCS) failure
S Primary regulator valve failure
Forward Clutch (C1) failure (Slipping)
Timing solenoid failure
Oil leak for ”D” range circuit
Longer than standards ”N”  ”R”Lower line pressure
S Pressure control solenoid (PCS) failure
S Primary regulator valve failure
Reverse clutch (C3) failure (slipping)
1st & reverse brake (B3) failure (slipping)
Oil leak for ”R” range circuit
Hydraulic Test
Hydraulic test can inspect working condition inside A/T by
measuring line pressure in ”D” / ”R” range and ”idle” / ”stall”
condition.
1. Chock 4 Wheels and apply parking brake fully, lock
vehicle perfectly.2. Install oil pressure gage adapter DW240–010–02 to
test hole for line pressure.
3. Fully pressed on foot brake pedal with left foot, shift
into ”D” and ”R” range and measure line pressure
”idle” / ”stall” condition.
Line pressure
Mpa (kgf/cm
2)
DR
Engine idle0.37 (3.9)
–0.14 (4.2)0.59 (6.0)
–0.68 (6.9)
Engine stall1.10 (11.3)
–1.23 (12.5)1.58 (16.2)
–1.83 (18.6)
Notice : Do not continuously run longer than 5 sec be-
cause of extreme increasing oil temp.
Make sure to keep interval for more than 1 min between
stall tests.
Make sure to check no oil leak after installing oil pressure
gage adapter.
Result of Hydraulic Test
Cause of Failure
Higher than standards
both ”D and ”R”Pressure control solenoid (PCS) failure
Primary regulator valve failure
Lower than standards
both ”D and ”R”Pressure control solenoid (PCS) failure
Primary regulator valve failure
Oil pump failure
Oil strainer failure (clogging)
Oil leak for each range circuit
Lower than standards
only ”D”D” hydraulic circuit failure
Forward clutch (C1) failure
Lower than standards
only ”R””R” hydraulic circuit failure
Reverse clutch (C3) failure
1st and reverse brake (B3) failure

5A2 – 30IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Manual Shifting Test
Manual shifting test is to determine whether failure symp-
tom is within electrical failure or mechanical failure.
1. Disconnect wire harness of shift solenoid, check
the range and gear positions correspond with below
table when driving by manual shifting.
Range
Gear
D3rd gear
RReverse
Notice : Make sure to disconnect only wire harness of shift
solenoid.
UNIT INSPECTION
Drive Plate Deflection
S Inspect drive plate deflection if within standard
value.
Standard Value
within 0.2mm (0.008 in)
Action :
Standard value is not within the specified value, replace
drive plate.
When ”abnormal wear” or ”stick” on torque converter
sleeve or oil pump is found, replace torque converter and
A/T.
Notice :
S When assembling torque converter and drive plate.
Be sure to use correct bolt with correct length. The
bolt pushes up torque converter front cover, and it
damages lock–up clutch lining. As a result, it cause
major failure ”No move”.
S Do not tighten the bolts by using impact wrench.
Cooler Pipe Bending and Choke
S Inspect it whether there is abnormal pipe bending in
the cooler pipe, pipe deformation and small cross–
section area of pipe line.
Action : Replace failure parts.S Apply compressed air of 2kg/cm
2 from cooler pipe
inlet side, inspect whether there is not cooler pipe
choke by confirming air flow smooth.
Action : Remove foreign particles and clean inside of pipe
line.
Normal
Vehicle Speed Sensor
1. Remove the connector of vehicle speed sensor,
connect 12V power supply and voltmeter to the ter-
minal.(Do not mistake polarity)
2. Check voltage change from approx. 0V to 12V with
vehicle speed sensor driven gear rotated.
Notice : The voltage change should be 4 times for 1 revo-
lution of the vehicle speed sensor driven gear.
Action : If the result of inspection is bad, replace the ve-
hicle speed sensor.

AISIN AUTOMATIC TRANSAXLE 5A2 – 159
DAEWOO V–121 BL4
99. Install the thrust needle roller bearing to the trans-
axle case.
Notice : Check the direction of the bearing.
100. Place the oil pump through the input shaft, and
align the bolt holes of the oil pump with the trans-
axle case.
101. Install the 6 oil pump bolts.
Tighten
Tighten the bolts to 25 NSm (18 lb–ft).
102. Measure the end play in axial direction.
Notice : If the end play is not as specified, select and re-
place the thrust needle roller bearing.
S End play 0.3
0.9 mm (0.012
0.035 in.)
S Bearing: mm (in.)
Inner diameter
Outer
diameterThichness
32.5 (1.280)48.5 (1.909)4.21 (0.1657)
32.9 (1.295)48.5 (1.909)3.62 (0.1425)
103. Make sure that the input shaft rotates smooth-
ly.