2004 DAEWOO NUBIRA checking oil

5A1 – 46IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
sible, drive the vehicle for a few kilometers (N–D,
N–R, shift until two gear). This will allow the trans-
axle to be within the correct temperature range.
Transaxle fluid level should be checked at tempera-
ture 20 to 45°C (68 to 113°F).
CAUTION : Removal of the fluid filler plug when the
transaxle fluid is hot may cause injury if fluid drains
from the filler hole.
2. Switch off accessories, especially air conditioner,
heater.
3. With the brake pedal pressed, move the gear shift
control lever through the gear ranges, pausing a
few seconds in each range. Return the gearshift
lever to P(Park). Turn the engine OFF.
4. Park the vehicle on a hoist, inspection pit or similar
raised level surface. The vehicle must be level to
obtain a correct fluid level measurement.
5. Place a fluid container below the fluid filler plug.
6. Clean all dirt from around the fluid filler plug.
Remove the fluid filler plug. Clean the filler plug and
check that there is no damage to the ”O” ring.
S If fluid drains through the filler hole the transaxle
may have been overfilled. When the fluid stops
draining the fluid level is correct. Install the fluid
filler plug and tighten it to 45NSm(34 lb–ft).
S If fluid does not drain through the filler hole, the
transaxle fluid level may be low. Lower the ve-
hicle, and start the vehicle in P(Park) with the
parking brake and the brake applied. With the
engine idling, move the gear shift lever through
the gear ranges, pausing a few seconds in each
range and adding the fluid until gear application
is felt. Return the gear shift lever to P(Park).
Turn the engine OFF and raise the vehicle.
Check if the fluid level is aligned with the bottom
of the filler hole. If not, add a small quantity of
fluid to the correct level. Install the fluid filler
plug and tighten it to 45NSm(34 lb–ft).
7. When the fluid level checking procedure is com-
pleted, wipe any fluid around the filler plug with a
rag or shop towel.
Fluid Level Set After Service
1. Depending on the service procedure performed,
add the following amounts of fluid through the filler
plug hole prior to adjusting the fluid level:
Oil pan removal – 4 liters (4.23 quarts)
Converter removal – 2 liters ( 2.11 quarts)
Overhaul – 6.9liters (7.3 quarts)
Oil drain plug removal – 4 liters (4.23 quarts)
2. Follow steps 1 through 4 of the Fluid Level Diagno-
sis Procedure.
3. Clean all dirt from around the fluid filler plug.
Remove the fluid filler plug. Clean the filler plug and
check that there is no damage to the ”O” ring.
4. Lower the vehicle with the filler plug still removed
and start the vehicle in P(Park) with the parking
brake and the brake applied. With the engine idling,move the gear shift lever through the gear ranges,
pausing a few seconds in each range and adding
the fluid until gear application is felt. Then add an
additional 0.5 liters of fluid. Return the gear shift
lever to P(Park). Turn the engine OFF and raise the
vehicle. Install the fluid filler plug and tighten it to
45NSm (34 lb–ft).
5. Drive the vehicle at 2.2 miles(3.5km) to 2.8
miles(4.5 km) with light throttle so that the engine
does not exceed 2500 rpm. This should result in
the transaxle temperature being in the range 20 to
45°C (68 to 11°F). With the brake applied, move
the shift lever through the gear ranges, pausing a
few seconds in each range at the engine idling.
6. Return the gear shift lever to P(Park). Turn the en-
gine OFF and raise the vehicle on the hoist, if appli-
cable, ensuring the vehicle is level. When the three
minutes passed after the engine stopped, remove
the filler plug. Check if the fluid level is aligned with
the bottom of the filler hole. If not, add a small
quantity of fluid to the correct level. Install the fluid
filler plug and tighten it to 45NSm (34 lb–ft).
7. Wipe any fluid around the filler plug with a rag or
shop towel.
Fluid Leak Diagnosis and Repair
The cause of most external leaks can generally be Lo-
cated and repaired with the transaxle in the vehicle.
Methods for Locating Leaks
General Method
1. Verify that the leak is transaxle fluid.
2. Thoroughly clean the suspected leak area.
3. Drive the vehicle for approximately 25 km (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. Drive the vehicle for approximately 25 km (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.
Dye and Black Light Method
1. Add dye to the transaxle though the transaxle fluid
filler plug. Follow the manufacturer’s recommenda-
tion for the amount of dye to be used.
2. Use the black light to find the fluid leak.
3. Make the necessary repairs.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 49
DAEWOO V–121 BL4
Functional Check Procedure
Inspect
1. Install a tachometer or scan tool.
2. Operate the vehicle unit proper operating tempera-
ture is reached.
3. Drive the vehicle at 80 to 88km/h (50 to 55 mph)
with light throttle(road load).
4. Maintaining throttle position, lightly touch the brake
pedal and check for release of the TCC and a slight
increase in engine speed(rpm).
5. Release the brake slowly accelerate and check for
a reapply of the Lock up clutch and a slight de-
crease in engine speed(rpm).
Torque Converter Evaluation
Torque Converter Stator
The torque converter stator roller clutch can have one of
two different type malfunctions :
A. Stator assembly freewheels in both directions.
B. Stator assembly remains Locked up at all times.
Condition A – Poor Acceleration Low
Speed
The car tends to have poor acceleration from a stand still.
At speeds above 50 to 55km/h(30 to 35mph), the car may
act normal. If poor acceleration is noted, it should first be
determined that the exhaust system is not blocked, and
the transaxle is in 1st(First) gear when starting out.
If the engine freely accelerates to high rpm in N(Neutral),
it can be assumed that the engine and exhaust system are
normal. Checking for poor performance in ”Drive” and ”Re-
verse” will help determine if the stator is freewheeling at all
times.
Condition B – Poor Acceleration High
Speed
Engine rpm and car speed limited or restricted at high
speeds. Performance when accelerating from a standstill
is normal. Engine may overheat. Visual examination of the
converter may reveal a blue color from overheating.
If the converter has been removed, the stator roller clutch
can be checked by inserting two fingers into the splined in-
ner race of the roller clutch and trying to turn freely clock-
wise, but not turn or be very difficult to turn counter clock-
wise.
Noise
Torque converter whine is usually noticed when the ve-
hicle is stopped and the transaxle is in ”Drive” or ”Re-
verse”. The noise will increase when engine rpm is in-
creased. The noise will stop when the vehicle is moving or
when the torque converter clutch is applied because both
halves of the converter are turning at the same speed.
Perform a stall test to make sure the noise is actually com-
ing from the converter :1. Place foot on brake.
2. Put gear selector in ”Drive”.
3. Depress accelerator to approximately 1200rpm for
no more than six seconds.
Notice : If the accelerator is depressed for more than six
seconds, damage to the transaxle may occur.
A torque converter noise will increase under this load.
Important : This noise should not be confused with pump
whine noise which is usually noticeable in P (Park), N
(Neutral) and all other gear ranges. Pump whine will vary
with pressure ranges.
The torque converter should be replaced under any of the
following conditions:
S External leaks in the hub weld area.
S Converter hub is scored or damaged.
S Converter pilot is broken, damaged or fits poorly
into crankshaft.
S Steel particles are found after flushing the cooler
and cooler lines.
S Pump is damaged or steel particles are found in the
converter.
S Vehicle has TCC shudder and/or no TCC apply.
Replace only after all hydraulic and electrical diag-
noses have been made.(Lock up clutch material
may be glazed.)
S Converter has an imbalance which cannot be cor–
rected. (Refer To Converter Vibration Test Proce-
dure.)
S Converter is contaminated with engine coolant con-
taining antifreeze.
S Internal failure of stator roller clutch.
S Excess end play.
S Heavy clutch debris due to overheating (blue con-
verter).
S Steel particles or clutch lining material found in fluid
filter or on magnet when no internal parts in unit are
worn or damaged(indicates that lining material
came from converter).
The torque converter should not be replace if :
S The oil has an odor, is discolored, and there is no
evidence of metal or clutch facing particles.
S The threads in one or more of the converter bolt
holes are damaged.
–correct with thread insert.
S Transaxle failure did not display evidence of dam-
age or worn internal parts, steel particles or clutch
plate lining material in unit and inside the fluid filter.
S Vehicle has been exposed to high mileage(only).
The exception may be where the Lock up clutch
damper plate lining has seen excess wear by ve-
hicles operated in heavy and/or constant traffic,
such as taxi, delivery or police use.
Lock–Up Clutch Shudder Diagnosis
The key to diagnosing lock–up clutch(TCC) shudder is to
note when it happens and under what conditions.

5A1 – 58IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Symptom ActionPossible Cause
NoiseThe Engine’s Torsional Vibrations are
Being Transmitted to the Drive ShaftsS At low speeds in fourth gear, vibration can
arise (driving at too low an engine speed)
S Noise is functionally unavoidable; due to toler-
ances. Convince the customer.
NoiseTorque Reaction Strut LooseS Check mounting and repair if necessary.
Shift quality
Notice :
– The assessment of shaft quality is, to a large ex-
tent, an individual, subjective matter. Take careful
note of how the customer describes the complaint
and of the manner in which he or she handles the
vehicle and the controls.
– A sudden deterioration of shift quality may also
be caused by the transaxle selecting an emergency
or substitute program
Test Steps :– Carry out the general checks described in the
automatic transaxle diagnostic information.
– Perform a test drive to answer the following ques-
tions.
In which driving situations does the shift quality
complaint arise?
To which shifts does the complaint apply?
Is the complaint reproducible within a short period,
or has it only occurred sporadically or on a single
occasion?
– Check the oil level and oil quality
– Interrogate the fault memory and read out mea-
surement block data.
Symptom
Possible CauseAction
Shift QualityRapid Pressure Build–up in the ClutchS Operating error (position selected several times
in quick succession).
Jerk When Parking Lock Is ReleasedS Refer to ”Noise” in this section.
Incorrect Electronic Transaxle Control
moduleS Check the data status for transaxle control
module ; refer to ”TCM” in this section.
Emergency/Substitute Program Has
Been ActivatedS For checking and remedial action, refer to
”Emergency/Substitute program” in this sec-
tion.
Accelerator Pedal in Indefinite Position
Between Full Throttle and Kick DownS Persuade customer to choose clearly between
kick down and full throttle
S Check setting according go engine repair in-
struction ; adjust if necessary.
Control Overlap Between to Clutches
During ShiftS Production status
S Convince the customer
Temperature Sensor
(Not Fault Memory)S Check function according to ”Emergency/Sub-
stitute program” in this section.
Kick Down Setting IncorrectS Check
A) Floor mat is obstructing accelerator pedal
B) The kick down setting as described in the
Engine Section.
Malfunction
Notice :
The faults dealt with here concern transaxle functions
such as ”traction” (forwards and reverse) and all type of
shifts. Entries will not always be made in the fault memory.Test Steps :
Perform the general checks according to the automatic
transaxle diagnostic procedure.
– Test drive
– Check oil level and quality
– Interrogate fault memory

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 59
DAEWOO V–121 BL4
SymptomPossible CauseAction
MalfunctionDefective Clutch in Transaxle It There Is
Still No Drive With the TCM Discon-
nectedS This is usually due to too little oil being added
or to internal leakage.
S Repair is not possible ; if necessary, exchange
transaxle.
Kick Down Switch Not Functioning
ProperlyS For checking and remedial action, refer to
”Emergency/Substitute Program” in this sec-
tion.
Kick Down Switch Not Operating Prop-
erlyS For checking and remedial action, refer to En-
gine Instruction.
Vehicle Is in Emergency ModeS For checking and remedial action, refer to
”Emergency/Substitute Program” in this sec-
tion.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 191
DAEWOO V–121 BL4
6. Check the oil fluid level. If fluid does not drain
through the plug hole after adding a total of 4 liters,
then the transaxle was either underfilled or the
transaxle is leaking fluid. Inspect the transaxle for
fluid leaks. Fix any leaks before setting the trans-
axle fluid level.
7. Install the fluid level plug using the plug remover/in-
staller DW260–070.
Tighten
Tighten the Plug to 45 NSm (33 lb–ft).
8. When the fluid level checking procedure is com-
pleted, 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.
CHANGING THE FLUID
Tools Required
DW260–070 Plug Remover/Installer
Removal and Installation Procedure
1. Raise and suitably support the vehicle.
2. Place a fluid container below the fluid drain plug.
3. Remove the transaxle fluid drain plug using the
plug remover/installer DW260–070.
Tighten
Tighten the Plug to 45 NSm (33 lb–ft).
4. Adding transaxle fluid. Refer to ”Transaxle Fluid
Level Checking Procedure” in this section.
5. Connect the negative battery cable.

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 – 200IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
8. Remove the oil cooler inlet pipe bolt from the left
lower side of the radiator.
9. Remove the oil cooler inlet pipe bolt from the trans-
axle side.
10. Remove the oil cooler inlet pipe assembly.
Installation Procedure
1. Install the oil cooler inlet pipe assembly and the
bolts.
Tighten
Tighten the oil cooler inlet pipe bolts to 35 NSm (26 lb–
ft).
2. Install the oil cooler outlet pipe assembly and the
bolts.
Tighten
Tighten the oil cooler outlet pipe bolts to 35 NSm (26
lb–ft).
3. Refill the transaxle fluid. Refer to ”Transaxle Fluid
Checking Procedure” in this section.
4. Install the engine under cover. Refer to Section 9N,
Frame and Underbody.
5. Connect the negative battery cable.

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.