2004 DAEWOO NUBIRA Engine Electrical

5A1 – 196IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Installation Procedure
1. Install the shift control cable into the fire wall of the
vehicle.
2. Install the shift control cable onto the transaxle
mount.
3. Install the shift control cable onto the shift control
assembly.
4. Install the shift control cable adjuster pinch nut.
Tighten
Tighten the nut to 8 NSm (71 lb–in).
5. Install the clip to the shift control cable at the trans-
axle mount connection.
6. Install the clip to the select lever connection on the
transaxle case.
7. Adjust the shift control cable. Refer to ”Shift Control
Cable Adjustment” in this section.
8. Connect the negative battery cable.
SHIFT CONTROL CABLE
ADJUSTMENT
Adjustment Procedure
It is very important to match the shift control lever correctly
with the selector lever connection. Place the shift control
lever in the P position and check the selector lever connec-
tion to see if it is all the way forward. If it is not, proceed with
the following adjustment.
1. Remove the battery and battery tray. Refer to Sec-
tion 1E, Engine Electrical.
2. Remove the floor console. Refer to Section 9G,
interior Trim.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 197
DAEWOO V–121 BL4
3. Place the shift control lever in the P position.
4. Loosen the pinch bolt nut on the shift control lever.
5. Place the selector lever connection all the way for-
ward on the transaxle case.
6. Insert the shift control cable into the shift control
lever tightly.
7. Secure the shift control cable with the shift control
cable adjuster pinch bolt and nut.
Tighten
Tighten the nut to 8 NSm (71 lb–in).
8. Install the floor console.
9. Install the battery and the battery tray. Refer to
Section 1E, Engine Electrical.
TRANSAXLE CONTROL
MODULE(TCM)
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the wiring connectors.
3. Remove the transaxle control module(TCM) from
the bracket.
Installation Procedure
1. Install the TCM into the bracket.
2. Connect the wiring connectors.
3. Connect the negative battery cable.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 199
DAEWOO V–121 BL4
3. Install the shift lever and the shift lever nut.
Tighten
Tighten the shift lever nut to 10 NSm (89 lb–in).
4. Connect the shift control cable and the retaining
clip.
5. Connect the park/neutral position switch electrical
connector.
6. Connect the negative battery cable.
OIL COOLER PIPES/HOSES
Removal Procedure
Important : Place a drip pan under the hoses to catch the
fluid that will run out of the lines.
1. Disconnect the negative battery cable.
2. Raise and suitably support the vehicle.
3. Remove the engine under cover. Refer to Section
9N, Frame and Underbody.
4. Remove the oil cooler outlet pipe bolt from the right
lower side of the radiator.
5. Remove the oil cooler outlet pipe bracket bolt.
6. Remove the oil cooler outlet pipe bolt from the
transaxle side.
7. Remove the oil cooler outlet pipe assembly.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 203
DAEWOO V–121 BL4
CONTROL VALVE BODY ASSEMBLY
Tools Required
DW260–070 Plug Remover/Installer
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the transaxle wiring harness and the
park/neutral position switch electrical connector.
3. Raise and suitably support the vehicle.
4. Remove the engine under cover. Refer to Section
9N, Frame and Underbody.
5. Remove the transaxle fluid drain plug using the
plug remover/installer DW260–070 and drain the
transaxle fluid.
6. Remove the oil pan, oil pan gasket. Refer to ”Oil
Pan, Oil Pan Gasket” in this section.
7. Remove the valve body mounting bolts.
8. Remove the automatic transmission input speed
sensor mounting bolt.
9. Remove the automatic transmission output speed
sensor mounting bolt.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 205
DAEWOO V–121 BL4
7. Lower the vehicle.
8. Connect the transaxle wiring harness and the PNP
switch electrical connector.
9. Refill the transaxle fluid. Refer to ”Transaxle Fluid
Level Checking Procedure” in this section.
10. Connect the negative battery cable.
LEFT TRANSAXLE MOUNTING
BRACKET
Tools Required
DW110–060 Engine Support Fixture
Removal Procedure
1. Remove the battery. Refer to Section 1E, Engine
Electrical.
2. Install the engine support fixture DW110–060.
3. Remove the left transaxle mounting bolts.
4. Remove the left transaxle mount bracket cage bolts
and nut.
5. Remove the transaxle mounting bracket.

5A1 – 206IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Installation Procedure
1. Install the left transaxle mount bracket cage bolts
and nut.
Tighten
S Tighten the left transaxle mount bracket cage
bolt (a) to 110 NSm (81 lb–ft).
S Tighten the left transaxle mount bracket cage
bolt (b) to 65 NSm (48 lb–ft).
S Tighten the nut (c) to 65 NSm (48 lb–ft).
2. Install the left transaxle mounting bolts to 48 NSm
(35 lb–ft).
3. Remove the engine support fixture DW110–060.
4. Install the battery. Refer to Section 1E, Engine
Electrical.
TRANSAXLE ASSEMBLY
Tools Required
DW110–060 Engine Support Fixture
DW260–010 Transaxle Support Fixture
Removal Procedure
1. Disconnect the negative battery cable.
2. Position the select lever park position.
3. Remove the battery. Refer to Section 1E, Engine
Electrical.
4. Install the engine support fixture DW110–060.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 211
DAEWOO V–121 BL4
12. Install the upper transaxle–to–engine bolts.
Tighten
Tighten the upper transaxle–to–engine bolts to 75
NSm (55 lb–ft).
13. Install the clips to the shift control cable and con-
nect the shift cable.
14. Install the park/neutral position switch electrical
connector.
15. Connect the transaxle wiring harness to the trans-
axle.
16. Remove the engine support fixture DW110–060.
17. Install the battery. Refer to Section 1E, Engine
Electrical.
18. Add the transaxle fluid. Refer to ”Transaxle Fluid
Level Checking Procedure” in this section.
19. Connect the negative battery cable.

SECTION : 5A2
AISIN 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 erminals. 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
SPECIFICATIONS5A2–3 . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 5A2–3. . . . . . . . . . . . . . . . . . . .
Transaxle Gear Ratio 5A2–3. . . . . . . . . . . . . . . . . . . . . .
Fluid Capacity 5A2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line Pressure Specification 5A2–3. . . . . . . . . . . . . . . .
Fastener Tightening Specifications 5A2–4. . . . . . . . . .
SPECIAL TOOLS5A2–5 . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 5A2–5. . . . . . . . . . . . . . . . . . . . . . .
SCHEMATIC DIAGRAMS5A2–8 . . . . . . . . . . . . . . . . . . .
Transmission Control Module (1 of 4) 5A2–8. . . . . . . .
Transmission Control Module (2 of 4) 5A2–9. . . . . . . .
Transmission Control Module (3 of 4) 5A2–10. . . . . . .
Transmission Control Module (4 of 4) 5A2–11. . . . . . .
Shift Mode Diagram 5A2–12. . . . . . . . . . . . . . . . . . . . . .
COMPONENT LOCATOR5A2–17 . . . . . . . . . . . . . . . . . .
Shift Select Control 5A2–17. . . . . . . . . . . . . . . . . . . . . .
Automatic Transaxle Components 5A2–18. . . . . . . . .
Bearing and Races Installation Position
Direction 5A2–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS5A2–25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Connector View 5A2–25. . . . . . . . . . . . . . . . .
Wiring Harness and Connector Inspection 5A2–27. . .
Road Test 5A2–27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function Check 5A2–28. . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Inspection 5A2–30. . . . . . . . . . . . . . . . . . . . . . . . . .
On–Vehicle Repair (Matrix Chart) 5A2–34. . . . . . . . . .
DIAGNOSIS TROUBLE CODE DIAGNOSIS5A2–36 .
Diagnosis Trouble Code Chart 5A2–36. . . . . . . . . . . . .
DTC P0562 System Voltage Low 5A2–37. . . . . . . . . .
DTC P0563 System Voltage High 5A2–40. . . . . . . . . .
DTC P0601 Internal Control Module Memory
Checksum Error 5A2–43. . . . . . . . . . . . . . . . . . . . . . .
DTC P0604 Internal Transmission Control Module
(TCM) Random Access Memory (RAM)
Error 5A2–45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0705 Transmission Range (TR) Switch
Circuit Malfunction 5A2–47. . . . . . . . . . . . . . . . . . . . .
DTC P0712 Transmission Fluid Temperature
(TFT) Sensor Circuit Low Input 5A2–50. . . . . . . . . .
DTC P0713 Transmission Fluid Temperature
(TFT) Sensor Circuit High Input 5A2–53. . . . . . . . . .
DTC P0717 Input Shaft Speed (ISS) Sensor
Circuit No Signal 5A2–56. . . . . . . . . . . . . . . . . . . . . . .
DTC P0722 Ouput Shaft Speed (OSS) Sensor
Circuit No Signal 5A2–59. . . . . . . . . . . . . . . . . . . . . . .
DTC P0727 Engine Speed Input Circuit No
Signal 5A2–62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0741 Torque Converter Clutch (TCC)
Circuit Stuck Off 5A2–65. . . . . . . . . . . . . . . . . . . . . . .
DTC P0742 Torque Converter Clutch (TCC)
Circuit Stuck On 5A2–67. . . . . . . . . . . . . . . . . . . . . . .
DTC P0743 Torque Converter Clutch (TCC)
Electrical 5A2–69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0748 Pressure Control Solenoid (PCS)
Electrical 5A2–72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0751 Shift Solenoid 1 (SS1) Stuck Off 5A2–75
DTC P0753 Shift Solenoid 1 (SS1) Electrical 5A2–77
DTC P0756 Shift Solenoid 2 (SS2) Stuck Off 5A2–80
DTC P0758 Shift Solenoid 2 (SS2) Electrical 5A2–82
DTC P0785 Timing Solenoid (ST) Electrical 5A2–85.
DTC P1781 Engine Torque Signal Error 5A2–88. . . . .
DTC P1791 Throttle Position Signal Error 5A2–91. . .
DTC P1792 Engine Coolant Temperature (ECT)
Signal Error 5A2–93. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC U2105 Can Error 5A2–95. . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR5A2–97 . . . . . . . . . . . . .
ON–VEHICLE SERVICE 5A2–97. . . . . . . . . . . . . . . . . . .
Transaxle Fluid Level Checking Procedure 5A2–97. .
Fluid Drain Procedure 5A2–97. . . . . . . . . . . . . . . . . . . .
Locating Fluid Leaks 5A2–98. . . . . . . . . . . . . . . . . . . . .
Case Porosity Repair 5A2–98. . . . . . . . . . . . . . . . . . . . .
Fluid Cooler Flushing 5A2–99. . . . . . . . . . . . . . . . . . . . .
Control Cable Adjustment 5A2–99. . . . . . . . . . . . . . . . .