2004 DAEWOO NUBIRA Engine Electrical

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 43
DAEWOO V–121 BL4
DIAGNOSTIC INFORMATION AND
PROCEDURES DIAGNOSIS
BASIC KNOWLEDGE REQUIRED
You must be familiar with some basic electronics to use
this section of the Service Manual. They will help you to
follow diagnostic procedures.
Notice : Lack of the basic knowledge of this transaxle
when performing diagnostic procedures could result in in-
correct diagnostic performance or damage to transaxle
components.
Do not, under any circumstances, attempt to diagnose a
transaxle problem without this basic knowledge.
Notice : If a wire is probed with a sharp instrument and not
properly sealed afterward, the wire will corrode and an
open circuit will result.
Diagnostic test probes are now available that allow you to
probe individual wires without leaving the wire open to the
environment. These probe devices are inexpensive and
easy to install, and they permanently seal the wire from
corrosion.
Special Tools
You should be able to use a Digital Volt Meter (DVM), a cir-
cuit tester, jumper wires or leads and a line pressure gauge
set.
The functional check procedure is designed to verify the
correct operation of electronic components in the trans-
axle.
This will eliminate the unnecessary removal of transaxle
components.
FUNCTIONAL CHECK PROCEDURE
Begin with the Functional Check Procedure which pro-
vides a general outline of how to diagnose automatic
transaxle. The following functional check procedure will in-
dicate the proper path of diagnosing the transaxle by de-
scribing the basic checks and then referencing the loca-
tions of the specific checks.
S Check the fluid level according to the Fluid Level
Service Procedure.
S Check the transaxle for fluid leaks.
S Check if the transaxle fluid is not burnt by color and
smell.
S Ensure that the transaxle is not in Limp Home
Mode(LHM).
S Check the battery terminals and the ground con-
nections for corrosion or looseness.
S Check that the cooler flow is not restricted.S Check all electrical connections for tightness.
S Use on–board diagnostic tool or a scan tool to see
if any transaxle trouble codes have been set. Refer
to the appropriate ”Diagnostic Trouble Code (DTC)”
information and repair the vehicle as directed. After
repairing the vehicle, perform the road test and
verify that the code has not set again.
S Perform the Electrical/Garage Shift Tests.
S Perform the Road Test Procedure in this section.
S Inspect the oil and check for metal or other contam-
inants in the oil pan.
LINE PRESSURE CHECK
PROCEDURE
The 4HP 16 A/T uses a trochoid type oil pump to produce
hydraulic pressure, and a pressure control solenoid (sole-
noid 1) to control that pressure at the pressure regulator
valve, after it leaves the pump. The transaxle pressure
control solenoid is controlled by an electrical signal that
ranges from 0 to 12 volts corresponds to minimum line
pressure (approx. 89.9 to 124.7 psi (6.2 to 8.6 bar)) and
0 volt corresponds to a maximum line pressure (approx.
221.9 to 252.4 psi (15.3 to 17.4 bar)) in all range.
Line pressures are calculated for two sets of gear ranges
– Drive–Park–Neutral and Reverse. This allow the trans-
axle line pressure to be appropriate for different pressure
needs in different gear ranges:
Gear
Range
Solenoid
1RPMPressure
Drive,
ReverseOff2,500221.9~252.4psi
(15.3~17.4 bar)
On2,50017.4~269.8psi
(1.2~18.6 bar)
Neutral,
ParkOff2,500221.9~252.4psi
(15.3~17.4 bar)
On2,50089.9~269.8 psi
(6.2~18.6 bar)
Before performing a line pressure check, verify that the
pressure control solenoid is receiving the correct electrical
signal from the TCM:
1. Install a scan tool.
2. Start the engine and set parking brake.
3. Check for a stored pressure control solenoid diag-
nostic trouble code, and other diagnostic trouble
codes.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 47
DAEWOO V–121 BL4
Repairing the Fluid Leak
Once the leak point is found the source of the leak must
be determined. The following list describes the potential
causes for the leak:
S Fasteners are not torqued to specification.
S Fastener threads and fastener holes are dirty or
corroded.
S Gaskets, seals or sleeves are misarranged, dam-
aged or worn.
S Damaged, warped or scratched seal bore or gasket
surface.
S Loose or worn bearing causing excess seal or
sleeve wears.
S Case or component porosity.
S Fluid level is too high.
S Plugged vent or damaged vent tube.
S Water or coolant in fluid.
S Fluid drain back holes plugged.
ELECTRICAL/GARAGE SHIFT TEST
This preliminary test should be performed before a hoist
or road test to make sure electronic control inputs is con-
nected and operating. If the inputs are not checked before
operating the transaxle, a simple electrical condition could
be misdiagnosed as a major transaxle condition.
A scan tool provides valuable information and must be
used on the automatic transaxle for accurate diagnosis.
1. Move gear selector to P (Park) and set the parking
brake.
2. Connect scan tool to Data Link Connector (DLC)
terminal.
3. Start engine.
4. Turn the scan tool ON.
5. Verify that the appropriate signals are present.
These signals may include:
S ENGINE SPEED
S VEHICLE SPEED
S THROTTLE POSITION
S TRANSAXLE GEAR STATE
S GEAR SHIFT LEVER POSITION
S TRANSAXLE FLUID TEMPERATURE
S CLOSED THROTTLE POSITION LEARN
S OPEN THROTTLE POSITION LEARNT
S CLOSED ACCEL. PEDAL POSITION LEARNT
S OPEN ACCEL. PEDAL POSITION LEARNT
S A/C COMPRESSOR STATUS
S MODE SWITCH
S THROTTLE POSITION VOLTAGE
S GEAR SHIFT LEVER POSITION VOLTAGE
S TRANS. FLUID TEMPERATURE VOLTAGE
S A/C SWITCH
S MODE SWITCH VOLTAGE
S BATTERY VOLTAGE
6. Monitor the A/C COMPRESSOR STATUS signal
while pushing the A/C switch.S The A/C COMPRESSOR STATUS should come
ON when the A/C switch is pressed, and turns
OFF when the A/C switch is repushed.
7. Monitor the GEAR SHIFT LEVER POSITION signal
and move the gear shift control lever through all the
ranges.
S Verify that the GEAR SHIFT LEVER POSITION
value matches the gear range indicated on the
instrument panel or console.
S Gear selections should be immediate and not
harsh.
8. Move gear shift control lever to neutral and monitor
the THROTTLE POSITION signal while increasing
and decreasing engine speed with the accelerator
pedal.
S THROTTLE POSITION should increase with
engine speed.
ROAD TEST PROCEDURE
S Perform the road test using a scan tool.
S This test should be performed when traffic and road
conditions permit.
S Observe all traffic regulations.
The TCM calculates upshift points based primarily on two
inputs : throttle angle and vehicle speed. When the TCM
wants a shift to occur, an electrical signal is sent to the shift
solenoids which in turn moves the valves to perform the
upshift.
The shift speed charts reference throttle angle instead of
”min throttle” or ”wot” to make shift speed measurement
more uniform and accurate. A scan tool should be used to
monitor throttle angle. Some scan tools have been pro-
grammed to record shift point information. Check the
introduction manual to see if this test is available.
Upshift Procedure
With gear selector in drive(D)
1. Look at the shift speed chart contained in this sec-
tion and choose a percent throttle angle of 10 or
25%.
2. Set up the scan tool to monitor throttle angle and
vehicle speed.
3. Accelerate to the chosen throttle angle and hold the
throttle steady.
4. As the transaxle upshifts, note the shift speed and
commanded gear changes for :
S Second gear.
S Third gear.
S Fourth gear.
Important : Shift speeds may vary due to slight hydraulic
delays responding to electronic controls. A change from
the original equipment tire size affects shift speeds.
Note when TCC applies. This should occur in fourth gear.
If the apply is not noticed by an rpm drop, refer to the
”Lock–up Clutch Diagnosis” information contained in this
section.

5A1 – 48IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
The Lock up clutch should not apply unless the transaxle
has reached a minimum operating temperature of 8°C
(46°F) TRANS TEMP AND engine coolant temp of 50°C
(122°F).
5. Repeat steps 1–4 using several different throttle
angles.
Part Throttle Detent Downshift
At vehicle steeds of 55 to 65km/h (34 to 40mph) in Fourth
gear, quickly increase throttle angle to greater than 50%.
Verify that :
S TCC apply.
S Transaxle downshift to 3rd gear.
S Solenoid 1 turns ON to OFF.
S Solenoid 2 turns OFF.
Full Throttle Detent Downshift
At vehicle speeds of 55 to 65km/h (34 to 40mph)in Fourth
gear, quickly increase throttle angle to its maximum posi-
tion (100%)
Verify that :
S TCC release.
S Transaxle downshift to Second gear immediately.
S Solenoid 1 turns ON to OFF
S Solenoid 2 turns OFF.
Manual Downshifts
1. At vehicle speeds of 60km/h (40mph)in Fourth
gear, release accelerator pedal while moving gear
selector to Manual Third (3). Observe that :
S Transaxle downshift to Third gear immediately.
S Engine slows vehicle down.
2. Move gear selector back to overdrive(D) and accel-
erate to 31mph (50km/h). Release the accelerator
pedal and move the gear selector to Manual
First(1) and observe that :
S Transaxle downshift to second gear immediate-
ly.
S Engine slows vehicle down
Notice : A Manual First––Third Gear Ratio will occur at
high speeds as an upshift safety feature. Do not attempt
to perform this shift.
Coasting Downshifts
1. With the gear selector in Overdrive(D), accelerate
to Fourth gear with TCC applied.
2. Release the accelerator pedal and lightly apply the
brakes, and observe that :
S TCC release.
S Down shifts occur at speeds shown ON the shift
speed chart.
Manual Gear Range Selection
Upshifts in the manual gear ranges are controlled by the
shift solenoids. Perform the following tests by accelerating
at 25 percent TP sensor increments.
Manual Third (3)
S With vehicle stopped, move the gear selector to
Manual third(3) and accelerate to observe :
– 1–2 shift.
– 2–3 shift.
Manual Second (2)
S With vehicle stopped, move the gear selector to
Manual second(2) and accelerate to observe :
– 1–2 shift.
S Accelerate to 40km/h(25mph) and observe :
– 2–3 shift does not occur
– TCC does not apply
Manual First (1)
S With vehicle stopped, move gear selector to Manu-
al First(1). Accelerate to 30km/h(19mph) and ob-
serve :
– No upshifts occur
Reverse (R)
S With vehicle stopped, move gear selector to R(Re-
verse) and observe :
– Solenoid 1 is OFF
– Solenoid 2 is OFF
Use a scan tool to see if any transaxle trouble codes have
been set. Refer to ”Diagnostic Trouble Codes”in this sec-
tion and repair the vehicle as directed. After repairing the
vehicle, perform the hoist test and verify that the code has
not set again.
If the transaxle is not performing well and no trouble codes
have been set, there may be an intermittent condition.
Check all electrical connections for damage or a loose fit.
You also have to perform a snapshot test which can help
catch an intermittent condition that dose not occur long
enough to set a code.
You may want to read ”Electronic Component Diagnosis”
in this section to become familiar with transaxle conditions
caused by transaxle electrical malfunction.
If no trouble codes have been set and the condition is sus-
pected to be hydraulic, take the vehicle on a road test.
TORQUE CONVERTER LOCK–UP
CLUTCH(TCC) DIAGNOSIS
To properly diagnosis the lock–up clutch(TCC) system,
perform all electrical testing first and then the hydraulic
testing.
The TCC is applied by fluid pressure which is controlled by
a solenoid Located inside the valve body. The solenoid is
energized by completing an electrical circuit through a
combination of switches and sensors.

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.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 69
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DTC P0562 – System Voltage Low
StepActionValue(s)YesNo
1Perform an On–Board Diagnostic (EOBD) System
Check.
Is the check completed?–Go to Step 2Go to ”On–
Board Diagnos-
tic System
Check”
21. Install the scan tool.
2. Turn the ignition ON and record then clear
DTC(s), then turn ignition OFF.
3. Turn the ignition ON and start the engine.
4. Run the engine to 1,200 rpm.
5. Select system voltage on the scan tool.
6. Drive the vehicle and observe the scan tool for
system voltage.
Is the voltage within the values shown?9–16VGo to Step 4Go to Step 3
31. Disconnect the negative battery cable.
2. Measure the voltage of the battery at the bat-
tery.
Is the voltage within the values shown?9–16VGo to Step 4Go to ”Section
1E, Engine
Electrical”
41. Turn the headlamp ON.
2. Turn the air conditioner ON.
3. Run the engine to 1,200rpm.
4. Observe the scan tool for system voltage.
Is the voltage within the values shown?9–16VGo to Step 6Go to Step 5
51. Turn the ignition OFF.
2. After testing the charging system, repair the
alternator circuit if necessary.
Is the action completed?–System OK–
6The vehicle would not have started if F2 or EF1 were
blown.
Was a problem found?–Go to Step 7Go to Step 8
7Replace the fuse.
Is the replacement complete?–System OK–
81. Turn the ignition ON.
2. Measure the voltage of F2, EF1.
Is the voltage within the values shown?9–16VGo to Step 10Go to Step 9
9Repair the fuse voltage supply lines for an open.
Is the action completed?–System OK–
101. Turn the ignition OFF.
2. Disconnect the TCM wiring connector.
3. Measure the resistance between EF1 fuse and
terminal B3 of the TCM wiring connector.
Is the resistance within the values shown?0ΩGo to Step 12Go to Step 11
11Repair the circuit(between EF1 and terminal B3) for
short to ground and open.
Is the repair completed?–System OK–

5A1 – 72IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
DTC P0563 – System Voltage High
StepActionValue(s)YesNo
1Perform an On–Board Diagnostic (EOBD) System
Check.
Is the check completed?–Go to Step 2Go to ”On–
Board Diagnos-
tic System
Check”
21. Install the scan tool.
2. Turn the ignition ON and record then clear
DTC(s), then turn ignition OFF.
3. Turn the ignition ON and start the engine.
4. Run the engine to 1,200 rpm.
5. Select system voltage on the scan tool.
6. Drive the vehicle and observe the scan tool for
system voltage.
Is the voltage within the values shown?9–16VGo to Step 4Go to Step 3
31. Disconnect the negative battery cable.
2. Measure the voltage of the battery.
Is the voltage within the values shown?9–16VGo to Step 4Go to ”Section
1E, Engine
Electrical”
41. Turn the headlamp ON.
2. Turn the air conditioner ON.
3. Run the engine to 1,200rpm.
4. Observe the scan tool for system voltage.
Is the voltage within the values shown?9–16VGo to Step 6Go to Step 5
51. Turn the ignition OFF.
2. After testing the charging system, repair the
alternator circuit if necessary.
Is the action completed?–System OK–
6Inspect the F2, EF1 fuse for an open.
Was a problem found?–Go to Step 7Go to Step 8
7Replace the fuse if necessary.
Is the replacement complete?–System OK–
81. Turn the ignition ON.
2. Measure the voltage of F2, EF1.
Is the voltage within the values shown?9–16VGo to Step 10Go to Step 9
9Repair the fuse voltage supply lines for an open.
Is the repair completed?–System OK–
101. Turn the ignition OFF.
2. Disconnect the TCM wiring connector.
3. Measure the resistance between EF1 fuse and
terminal B3 of the TCM wiring connector.
Is the resistance within the values shown?0ΩGo to Step 12Go to Step 11
11Repair the circuit(between EF1 and terminal B3) for
a short to ground and open.
Is the repair completed?–System OK–
121. Disconnect the C105 connector and TCM con-
nector.
2. Turn the ignition ON.
3. Measure the voltage of the terminal B3(TCM
wiring connector).
Is the voltage within the values shown?9–16VGo to Step 13Go to Step 14

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 81
DAEWOO V–121 BL4
DTC P0606 – Transaxle Control Module Processor Fault
StepActionValue(s)YesNo
1Perform an On–Board Diagnostic (EOBD) System
Check.
Is the check completed?–Go to Step 2Go to ”On–
Board Diagnos-
tic System
Check”
21. Install the scan tool.
2. Turn the ignition ON and record then clear
DTC(s), then turn ignition OFF.
3. Turn the ignition ON and start the engine.
4. Run the engine to 1,200 rpm.
5. Select system voltage on the scan tool.
6. Drive the vehicle and observe the scan tool for
system voltage.
Is the voltage within the values shown?9–16VGo to Step 4Go to Step 3
31. Disconnect the negative battery cable.
2. Measure the voltage of the battery at the bat-
tery.
Is the voltage within the values shown?9–16VGo to Step 4Go to ”Section
1E, Engine
Electrical”
41. Turn the headlamp ON.
2. Turn the air conditioner ON.
3. Run the engine to 1,200rpm.
4. Observe the scan tool for system voltage.
Is the voltage within the values shown?9–16VGo to Step 6Go to Step 5
51. Turn the ignition OFF.
2. After testing the charging system, repair the
alternator circuit if necessary.
Is the action completed?–System OK–
6The vehicle would not have started if F2 or EF1 were
blown.
Was a problem found?–Go to Step 7Go to Step 8
7Replace the fuse if necessary.
Is the replacement complete?–System OK–
81. Turn the ignition ON.
2. Measure the voltage of F2, EF1.
Is the voltage within the values shown?9–16VGo to Step 10Go to Step 9
9Repair the fuse voltage supply lines for an open.
Is the action completed?–System OK–
101. Turn the ignition OFF.
2. Disconnect the TCM wiring connector.
3. Measure the resistance between EF1 fuse and
terminal B3 of the TCM wiring connector.
Is the resistance within the values shown?0ΩGo to Step 12Go to Step 11
11Repair the circuit(between EF1 and terminal B3) for
short to ground and open.
Is the repair completed?–System OK–

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Repairing the Fluid Leak
The following are potential causes for fluid leaks. Check
and repair, as necessary.
S Fasteners are not tightened to specifications.
S Fastener threads and tapped holes are dirty or cor-
roded.
S Gaskets, seals or sleeves are misaligned, dam-
aged, or warped, or scratched.
S The manual shaft is nicked or damaged.
S There is a loose or worn bearing causing excess
seal or sleeve wear.
S Case or component porosity.
S The fluid level is too high.
S There is a plugged vent or a damaged vent tube.
S There is water or coolant in the fluid.
S Fluid drain back holes are plugged.
CASE POROSITY REPAIR
CAUTION : Epoxy adhesive may cause skin irritations
and eye damage. Read and follow all information on
the container label as provided by the manufacturer.
1. Thoroughly clean the area to be repaired with a
cleaning solvent. Air dry the area.
2. Using instructions from the manufacturer, mix a
sufficient amount of epoxy to make the repair.
3. While the transaxle case is still hot, apply the
epoxy. You can use a clean, dry soldering acid
brush to clean the area and also apply the epoxy
cement. Make certain that the area to be repaired is
fully covered.
4. Allow the epoxy cement to dry for 3 hours before
starting the engine.
5. Repeat the fluid leak diagnosis procedures. Refer
to ”Fluid Leak Diagnosis and Repair” in this sec-
tion.
SHIFT CONTROL LEVER ASSEMBLY
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the floor console. Refer to Section 9G,
Interior Trim.
3. Disconnect the electrical switch connectors.