2004 DAEWOO NUBIRA clutch

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.

5A2 – 36IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
DIAGNOSTIC TROUBLE CODE DIAGNOSIS
DIAGNOSTIC TROUBLE CODE CHART
DTCDESCRIPTIONTYPEIlluminate
MILBlink
Hold
Lamp
P0562System Voltage LowBYe sNo
P0563System Voltage HighBYe sNo
P0601Internal Control Module Memory Checksum ErrorAYe sNo
P0604Internal Transmission Control Module (TCM) Random Access
Memory (RAM) ErrorBYe sNo
P0705Transmission Range (TR) Switch Circuit MalfunctionBYe sNo
P0712Transmission Fluid Temperature Sensor Circuit Low InputAYe sNo
P0713Transmission Fluid Temperature Sensor Circuit High InputAYe sNo
P0717Input Shaft Speed (ISS) Sensor Circuit No SignalAYe sNo
P0722Output Shaft Speed (OSS) sensor Circuit No SignalAYe sNo
P0727Engine Speed Input Circuit No SignalAYe sNo
P0741Torque Converter Clutch (TCC) Circuit Stuck OffBYe sNo
P0742Torque Converter Clutch (TCC) Circuit Stuck OnBYe sNo
P0743Torque Converter Clutch (TCC) ElectricalBYe sNo
P0748Pressure Control Solenoid (PCS) ElectricalAYe sNo
P0751Shift Solenoid 1 (SS1) Stuck OffBYe sNo
P0753Shift Solenoid 1 (SS1) ElectricalAYe sNo
P0756Shift Solenoid 2 (SS2) Stuck OffBYe sNo
P0758Shift Solenoid 2 (SS2) ElectricalAYe sNo
P0785Timing Solenoid (ST) ElectricalAYe sNo
P1781Engine Torque Signal ErrorAYe sNo
P1791Throttle Position Signal ErrorAYe sNo
P1792Engine Coolant Temperature (ECT) Signal ErrorDNoNo
U2105CAN ErrorAYe sNo
* Description of Type
S Type A : TCM will request the illumination of MIL and store DTC when TCM detects a failure on the first ignition
cycle.
S Type B : TCM will request the illumination of MIL and store DTC when TCM detects failures on two consecutive
ignition cycle.
S Type D : TCM will not request the illumination of MIL or hold lamp, but will store DTC when TCM detects a failure
on the first ignition cycle.

AISIN AUTOMATIC TRANSAXLE 5A2 – 65
DAEWOO V–121 BL4
DIAGNOSTIC TROUBLE CODE (DTC) P0741
TORQUE CONVERTER CLUTCH (TCC) CIRCUIT STUCK
OFF
Conditions for Setting the DTC
S Lockup solenoid is stuck OFF.
S D range selected
S Engine water normal temperature
S 20 seconds have passed since the transaxle was
placed in D.
S Engine revolution is 600 rpm or greater.
S No failure of input speed sensor / engine revolution
/ water temperature signal / solenoid electrical /
ranger sensor / throttle signal
Action Taken When the DTC Sets
S TCM will request the illumination of MIL and store
DTC when TCM detects failures on two consecu-
tive ignition cycles.Conditions for Clearing the DTC
S The TCM turns off the MIL when no further failures
detected for three consecutive ignition cycles.
S The scan tool can clear the DTC from the TCM his-
tory.
S The TCM clears the DTC from the TCM history
memory after forty consecutive warm up cycles
without fault.
Cause of Failure
S Lockup solenoid
S Inside A/T
S Inside valve body
S TCM

5A2 – 66IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
DTC P0741 Torque Converter Clutch (TCC) Circuit Stuck Off
StepActionValue(s)YesNo
11. Turn the ignition OFF.
2. Install the Scan tool.
3. With the engine OFF, turn the ignition switch to
the ON position.
4. Select Store Freeze Frame/Failure Records
from the Diagnostic Trouble Codes Information
menu.
5. Store Freeze Frame/Failure Records.
6. Select Clear DTC Information from the Diag-
nostic Trouble Codes Information menu.
7. Clear DTC Information.
8. Perform two vehicle drive cycles.
Is the Maifunction Indicator Lamp (MIL) ON?–Go to Step 2Repair the tem-
porary connec-
tion failure of
connector (Re-
fer to ”Wiring
Harness and
Connector In-
spection” in this
section.)
21. Select Request DTC by Status from the Diag-
nostic Trouble Codes Information menu.
2. Request DTC by Status.
Is DTC P0741 displayed?–Go to Step 3Repair the tem-
porary connec-
tion failure of
connector (Re-
fer to ”Wiring
Harness and
Connector In-
spection” in this
section.)
31. Turn the ignition OFF.
2. Replace the master TCM and perform simula-
tion test again under user condition.
Is DTC P0741 reappeared?–Go to Step 4Replace the
TCM
41. Estimate the failure of lockup solenoid, lockup
clutch or internal valve body.
2. Inspect the lockup solenoid. Refer to ”Unit In-
spection” in this section.
Is the condition of lockup solenoid OK?–Go to Step 5Replace lockup
solenoid
51. Estimate the failure of lockup clutch or internal
valve body.
Is problem found?–Replace the
valve body as-
semblySystem OK

AISIN AUTOMATIC TRANSAXLE 5A2 – 67
DAEWOO V–121 BL4
DIAGNOSTIC TROUBLE CODE (DTC) P0742
TORQUE CONVERTER CLUTCH (TCC) CIRCUIT STUCK
ON
Conditions for Setting the DTC
S Lockup solenoid is stuck ON.
S D range selected
S Engine water normal temperature
S 20 seconds have passed since the transaxle was
placed in D.
S Engine revolution is 600 rpm or greater.
S No failure of input speed sensor / engine revolution
/ water temperature signal / solenoid electrical /
ranger sensor / throttle signal
Action Taken When the DTC Sets
S TCM will request the illumination of MIL and store
DTC when TCM detects failures on two consecu-
tive ignition cycles.Conditions for Clearing the DTC
S The TCM turns off the MIL when no further failures
detected for three consecutive ignition cycles.
S The scan tool can clear the DTC from the TCM his-
tory.
S The TCM clears the DTC from the TCM history
memory after forty consecutive warm up cycles
without fault.
Cause of Failure
S Lockup solenoid
S Inside A/T
S Inside valve body
S TCM

5A2 – 68IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
DTC P0742 Torque Converter Clutch (TCC) Circuit Stuck On
StepActionValue(s)YesNo
11. Turn the ignition OFF.
2. Install the Scan tool.
3. With the engine OFF, turn the ignition switch to
the ON position.
4. Select Store Freeze Frame/Failure Records
from the Diagnostic Trouble Codes Information
menu.
5. Store Freeze Frame/Failure Records.
6. Select Clear DTC Information from the Diag-
nostic Trouble Codes Information menu.
7. Clear DTC Information.
8. Perform two vehicle drive cycles.
Is the Malfunction Indicator Lamp (MIL) ON?–Go to Step 2Repair the tem-
porary connec-
tion failure of
connector (Re-
fer to ”Wiring
Harness and
Connector” in
this section.)
21. Select Request DTC by Status from the Diag-
nostic Trouble Codes Information menu.
2. Request DTC by Status.
Is DTC P0742 displayed?–Go to Step 3Repair the tem-
porary connec-
tion failure of
connector (Re-
fer to ”Wiring
Harness and
Connector” in
this section.)
31. Turn the ignition OFF.
2. Replace the master TCM and perform simula-
tion test again under user condition.
Is DTC P0742 reappeared?–Go to Step 4Replace the
TCM
41. Estimate the failure of lockup solenoid, lockup
clutch or internal valve body.
2. Inspect the lockup solenoid. Refer to ”Unit In-
spection” in this section.
Is the condition of lockup solenoid OK?–Go to Step 5Replace lockup
solenoid
51. Estimate the failure of lockup clutch or internal
valve body.
Is problem found?–Replace the
valve body as-
semblySystem OK

AISIN AUTOMATIC TRANSAXLE 5A2 – 69
DAEWOO V–121 BL4
DIAGNOSTIC TROUBLE CODE (DTC) P0743
TORQUE CONVERTER CLUTCH (TCC) ELECTRICAL
Conditions for Setting the DTC
S TCM detects that the ON signal of the lockup sole-
noid monitor during 0.5 seconds when lockup sole-
noid driver outputs the OFF signal.(When the TCC
circuit is open or short to battery).
S The above detection 2 times at shifting continuous-
ly.(When the Tcc circuit is open or short to battery).
S TCM detects that the OFF signal of the lockup sole-
noid monitor during 0.3 seconds when lockup sole-
noid driver outputs the ON signal.(When the TCC
circuit is short to ground).
S The above detection 1 time at shifting continuous-
ly.(When the TCC circuit is short to ground).
Action Taken When the DTC Sets
S TCM will request the illumination of MIL and store
DTC when TCM detects failures on two consecu-
tive ignition cycles.
S No TCC lockup solenoid
S 1st gear fixed under the 10km/hConditions for Clearing the DTC
S The TCM turns off the MIL when no further failures
detected for three consecutive ignition cycles.
S The scan tool can clear the DTC from the TCM his-
tory.
S The TCM clears the DTC from the TCM history
memory after forty consecutive warm up cycles
without fault.
S TCM detects the ON signal of the lockup solenoid
monitor during 160 ms when lockup solenoid driver
outputs the ON signal and TCM detects the OFF
signal of the lockup solenoid monitor during 160 ms
when lockup solenoid driver outputs the OFF sig-
nal.
Cause of Failure
S Wiring harness or connector between lockup sole-
noid and TCM
S Lockup solenoid
S TCM

5A2 – 70IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
DTC P0743 Torque Converter Clutch (TCC) Electrical
StepActionValue(s)YesNo
11. Turn the ignition OFF.
2. Install the Scan tool.
3. With the engine OFF, turn the ignition switch to
the ON position.
4. Select Store Freeze Frame/Failure Records
from the Diagnostic Trouble Codes Information
menu.
5. Store Freeze Frame/Failure Records.
6. Select Clear DTC Information from the Diag-
nostic Trouble Codes Information menu.
7. Clear DTC Information.
8. Perform two vehicle drive cycles.
Is the Malfunction Indicator Lamp (MIL) ON?–Go to Step 2Repair the tem-
porary connec-
tion failure of
connector (Re-
fer to ”Wiring
Harness and
Connector In-
spection” in this
section.)
21. Select Request DTC by Status from the Diag-
nostic Trouble Codes Information menu.
2. Request DTC by Status.
Is DTC P0743 displayed?–Go to Step 3Repair the tem-
porary connec-
tion failure of
connector (Re-
fer to ”Wiring
Harness and
Connector In-
spection” in this
section.)
31. Turn the ignition OFF.
2. Inspect the resistance between the vehicle har-
ness and lock–up solenoid. Refer to ”Unit In-
spection” in this section.
3. Disconnect the TCM connector (X–1) and in-
spect the resistance between the terminal A5
and A23.
Is the measurement within the specified value?20°C (68°F)
11–16 WGo to Step 4Go to Step 5
41. Estimate the failure of between the vehicle wir-
ing harness connector and TCM.
2. Inspect the connector. Refer to ”Wiring Har-
ness and Connector Inspection” in this section.
3. Inspect the connection condition between the
connectors (C–1).
Is the connection condition OK?–Go to Step 6Repair the wir-
ing harness
connectors.
51. Estimate the failure of between the vehicle har-
ness and lockup solenoid.
2. Disconnect the connector (X–3) of T/M wire
and inspect the resistance between lock–up
solenoid connector terminal 4 and ground.
Is the measurement within the specified value?20°C (68°F)
11–16 WGo to Step 7Go to Step 8
61. Replace the master TCM.
2. Perform the reproducing test under user condi-
tion after confirming no DTC.
Is DTC displayed?–Repair the tem-
porary connec-
tion failure of
connector (Re-
fer to ”Wiring
Harness and
Connector In-
spection” in this
section.)Replace the
TCM