2004 DAEWOO NUBIRA ECO mode

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 13
DAEWOO V–121 BL4
SHIFT MODE DIAGRAM
Economic Mode (1.8 DOHC)

5A1 – 14IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Lock–up Clutch Applied (Economic Mode ; Fourth Gear)
(1.8 DOHC)

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.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 51
DAEWOO V–121 BL4
SHIFT SPEED CHART
Up Shift Speed
MODELFirst–Second gear
(±3.0 mph (4.8km/h))Second–Third gear
(±4.0 mph (6.4km/h))Third–Fourth gear
(±5.0 mph (8km/h))
10%
TPS25%
TPS50%
TPS100%
TPS10%
TPS25%
TPS50%
TPS100%
TPS10%
TPS25%
TPS50%
TPS100%
TPS
1.8 DOHC
mph (km/h)9 (15)11
(18)18
(29)32
(52)18
(29)23
(37)34
(55)62
(99)25
(45)34
(55)47
(76)98
(157)
Down Shift Speed
MODELDown Shift (±4.0 mph (6.4km/h))Lock Up Clutch
Applied
(Fourth)Lock Up Clutch
Released
(Fourth)
Fourth–
Third
(Coast)Third–
Second
(Coast)Second–
First
(Coast)10%25%10%25%
1.8 DOHC
mph (km/h)25 (41)13 (21)7 (11)48 (77)48 (77)42 (68)42 (68)
INTERNAL WIRING HARNESS CHECK
StepActionValue(s)YesNo
11. Disconnect the transaxle harness.
2. Measure the resistance between terminals 3
and 13 of the transaxle wiring connector.
Is the resistance within the values shown?Refer to Com-
ponent Resist-
ance ChartGo to Step 3Go to Step 2
21. Disconnect the internal transaxle harness from
the first solenoid valve.
2. Measure the resistance of the first solenoid
valve.
Is the resistance within the values shown?Refer to Com-
ponent Resist-
ance ChartGo to Step 20Go to Step 22
3Measure the resistance between terminals 3 and 13
the second solenoid valve.
Is the resistance within the values shown?Refer to Com-
ponent Resist-
ance ChartGo to Step 5Go to Step 4
41. Disconnect the internal transaxle harness from
the second solenoid valve.
2. Measure the resistance of the second solenoid
valve.
Is the resistance within the values shown?Refer to Com-
ponent Resist-
ance ChartGo to Step 20Go to Step 22
5Measure the resistance between terminals 5 and 6
the transaxle wiring connector(EDS 3).
Is the resistance within the values shown?Refer to Com-
ponent Resist-
ance ChartGo to Step 7Go to Step 6
61. Disconnect the internal transaxle harness from
the pressure control valve 3(EDS 3).
2. Measure the resistance of the EDS 3.
Is the resistance within the values shown?Refer to Com-
ponent Resist-
ance ChartGo to Step 20Go to Step 22
7Measure the resistance between terminals 5 and 7
the transaxle wiring connector(EDS 4).
Is the resistance within the values shown?Refer to Com-
ponent Resist-
ance ChartGo to Step 9Go to Step 8

5A1 – 60IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
DIAGNOSTIC TROUBLE CODE DIAGNOSIS
DIAGNOSTIC TROUBLE CODE (DTC) IDENTIFICATION
DTCDescriptionIndicationDefault Action
P0562System Voltage LowMIL ONS The TCM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Failure Records buffer.
S Adopt Emergency/Substitute mode and constant 4th
gear by hydraulic control.
S After ignition OFF/ON: 3rd gear by hydraulic control.
Possible P, R and N also possible.
S Power supply cut off to the EDS valve.
P0563System Voltage HighMIL ONS The TCM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Failure Records buffer.
S Adopt Emergency/Substitute mode and constant 4th
gear by hydraulic control.
S After ignition OFF/ON: 3rd gear by hydraulic control.
Possible P, R and N also possible.
S Power supply cut off to the EDS valve.
P0601Internal Control Module
Memory Checksum ErrorMIL ONS The TCM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Failure Records buffer.
S Adopt Emergency/Substitute mode and constant 4th
gear by hydraulic control.
S After ignition OFF/ON : 3rd gear by hydraulic control.
Possible P, R and N also possible.
S Power supply cut off to the EDS valve.
P0603S Internal Control Module
Keep Alive
Memory(KAM)ErrorMIL ONS The TCM will record operating conditions at he time
the diagnostic fails. This information will be stored in
the Failure Records buffer.
S Adopt Emergency/Substitute mode and constant 4th
gear by hydraulic control.
S After ignition OFF/ON: 3rd gear by hydraulic control.
Possible P, R and N also possible.
S Power supply cut off to the EDS valve.
P0604Internal Control Module
Random Access Memory
(RAM) ErrorMIL ONS The TCM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Failure Records buffer.
S Adopt Emergency/ Substitute mode and constant 4th
gear by hydraulic control.
S After ignition OFF/ON : 3rd gear by hydraulic control.
Possible P, R and N also possible.
S Power supply cut off to the EDS valve.
P0606S Transaxle Control Mod-
ule Processor FaultMIL ONS The TCM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Failure Records buffer.
S Adopt Emergency/Substitute mode and constant 4th
gear by hydraulic control.
S After ignition OFF/ON: 3rd gear by hydraulic control.
Possible P, R and N also possible.
S Power supply cut off to the EDS valve.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 61
DAEWOO V–121 BL4
DTCDefault Action Indication Description
P0703Brake Switch Circuit
MalfunctionNo ChangeS TCM assume that the brake light always active.
S Open lock up clutch.
P0705Transmission Range Sen-
sor Circuit Malfunction
(PRNDL Input)MIL ONS The TCM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Failure Records buffer.
S Adopt Emergency/ Substitute mode and constant 4th
gear by hydraulic control.
S After ignition OFF/ON : 3rd gear by hydraulic control,
position P, R and N also possible.
P0710S Transmission Fluid
Temperature Sensor
Circuit MalfunctionNo ChangeS TCM assume the transaxle fluid temperature is
140°F (60°C).
S No influence at vehicle running.
P0715S Input Speed Sensor
Circuit MalfunctionMIL ONS The TCM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Failure Records buffer.
S Adopt Emergency/Substitute mode and constant 4th
gear by hydraulic control.
S After ignition OFF/ON : 3rd gear by hydraulic control,
position P, R and N also possible.
S Open lock up clutch.
P0716S Input Speed Sensor
Circuit Range/Perfor-
manceMIL ONS The TCM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Failure Records buffer.
S Adopt Emergency/ Substitute mode and constant 4th
gear by hydraulic control.
S After ignition OFF/ON : 3rd gear by hydraulic control,
position P, R and N also possible.
S Open lock up clutch.
P0717S Input Speed Sensor
Circuit Range/Perfor-
manceMIL ONS The TCM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Failure Records buffer.
S Adopt Emergency/ Substitute mode and constant 4th
gear by hydraulic control.
S After ignition OFF/ON : 3rd gear by hydraulic control,
position P, R and N also possible.
S Open lock up clutch.
P0720Output Speed Sensor Cir-
cuit MalfunctionMIL ONS The TCM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Failure Records buffer.
S Adopt Emergency/ Substitute mode and constant 4th
gear.
S Open lock up clutch.
P0721Output Speed Sensor Cir-
cuit Range/PerformanceMIL ONS The TCM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Failure Records buffer.
S Adopt Emergency/ Substitute mode and constant 4th
gear.
S Open lock up clutch.

5A1 – 62IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
DTCDefault Action Indication Description
P0722S Output Speed Sensor
Circuit No SignalMIL ONS The TCM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Failure Records buffer.
S Vehicle running remains actual gear.
S Open lock up clutch.
P0725S Engine Speed Input
Circuit MalfunctionNo ChangeS Adopt Emergency/Substitute mode and constant 4th
gear.
S Open lock up clutch.
P0726S Engine Speed Input
Circuit Range/Perfor-
manceMIL ONS The TCM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Failure Records buffer.
S Adopt Emergency/ Substitute mode and constant 4th
gear.
S Open lock up clutch.
P0727S Engine Speed Input
Circuit No SignalMIL ONS The TCM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Failure Records buffer.
S Adopt Emergency/ Substitute mode and constant 4th
gear.
S Open lock up clutch.
P0731S Gear 1 Incorrect RatioMIL ONS The TCM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Failure Records buffer.
S Adopt Emergency/ Substitute mode and constant 4th
gear.
S High line pressure
P0732S Gear 2 Incorrect RatioMIL ONS The TCM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Failure Records buffer.
S Adopt Emergency/ Substitute mode and constant 3rd
gear.
S High line pressure.
P0733S Gear 3 Incorrect RatioMIL ONS The TCM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Failure Records buffer.
S Adopt Emergency/ Substitute mode and constant 4th
gear.
S High line pressure
P0734S Gear 4 Incorrect RatioMIL ONS The TCM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Failure Records buffer.
S Adopt Emergency/ Substitute mode and constant 4th
gear by hydraulic control.
S After ignition OFF/ON : 3rd gear by hydraulic control.
Possible P, R and N also possible.
S High line pressure.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 63
DAEWOO V–121 BL4
DTCDefault Action Indication Description
P0781S 1–2 Shift MalfunctionMIL ONS The TCM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Failure Records buffer.
S Adopt Emergency/ Substitute mode and constant 1st
gear.
S Open lock up clutch.
P0782S 2–3 Shift MalfunctionMIL ONS The TCM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Failure Records buffer.
S Adopt Emergency/ Substitute mode and constant
2nd gear.
S Open lock up clutch.
P0783S 3–4 Shift MalfunctionMIL ONS The TCM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Failure Records buffer.
S Adopt Emergency/ Substitute mode and constant 3rd
gear.
S Open lock up clutch.
P1604S Data Check of Internal
& Extended Ram FailedMIL ONS The TCM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Failure Records buffer.
S Adopt Emergency/ Substitute mode and constant 4th
gear by hydraulic control.
S After ignition OFF/ON : 3rd gear by hydraulic control.
Possible P, R and N also possible.
S Power supply cut off to the EDS valve.
P1606S Failure of External
WatchdogMIL ONS The TCM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Failure Records buffer.
S Adopt Emergency/Substitute mode and constant 4th
gear by hydraulic control.
S After ignition OFF/ON: 3rd gear by hydraulic control.
Possible P, R and N also possible.
S Power supply cut OFF to the EDS valve.
P1671CAN Transmit Message
FailureMIL ONS The TCM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Failure Records buffer.
S Adopt Emergency/ Substitute mode and constant 4th
gear by hydraulic control.
S After ignition OFF/ON : 3rd gear by hydraulic control.
Possible P, R and N also possible.
P1672CAN Bus OFF FailureMIL ONS The TCM will record operating conditions at the time
the diagnostic fails. This information will be stored in
the Failure Records buffer.
S Adopt Emergency/ Substitute mode and constant 4th
gear by hydraulic control.
S After ignition OFF/ON : 3rd gear by hydraulic control.
Possible P, R and N also possible.