2004 DAEWOO NUBIRA lock

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.

5A1 – 50IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
TCC shudder should only occur during the APPLY and/or
RELEASE of the Lock up clutch.
While TCC Is Applying Or Releasing
If the shudder occurs while TCC is applying, the problem
can be within the transaxle or torque converter.
Something is not allowing the clutch to become fully en-
gaged, not allowing clutch to release, or is trying to release
and apply the clutch at the same time. This could be
caused by leaking turbine shaft seals, a restricted release
orifice, a distorted clutch or housing surface due to long
converter bolts, or defective friction material on the TCC
plate.
Shudder Occurs After TCC Has Applied :
In this case, most of the time there is nothing wrong with
the transaxle! As mentioned above, once the TCC has
been applied, it is very unlikely that will slip. Engine prob-
lems may go unnoticed under light throttle and load, but
become noticeable after TCC apply when going up a hill
or accelerating, due to the mechanical coupling between
engine and transaxle.
Important : Once TCC is applied there is no torque con-
verter assistance. Engine or driveline vibrations could be
unnoticeable before TCC engagement.
Inspect the following components to avoid misdiagnosis of
TCC shudder and possibly disassembling a transaxle and/
or replacing a torque converter unnecessarily :
S Spark plugs – Inspect for cracks, high resistance or
broken insulator.
S Plug wires – Lock in each end, if there is red dust
(ozone) or black substance (carbon) present, then
the wires are bad. Also look for a white discolor-
ation of the wire indicating arcing during hard accel-
eration.
S Distributor cap and rotor – look for broken or un–
crimped parts.
S Coil – look for black on bottom indication arcing
while engine is misfiring.
S Fuel injector – filter may be plugged.
S Vacuum leak – engine won’t get correct amount of
fuel. May run rich or lean depending on where the
leak is.S EGR valve – valve may let it too much unburnable
exhaust gas and cause engine to run lean.
S MAP sensor – like vacuum leak, engine won’t get
correct amount of fuel for proper engine operation.
S Carbon on intake valves – restricts proper flow or
air/fuel mixture into cylinders.
S Flat cam – valves don’t open enough to let proper
fuel/air mixture into cylinders.
S Oxygen sensor – may command engine too rich or
too lean for too long.
S Fuel pressure – may be too low.
S Engine mounts – vibration of mounts can be multi-
plied by TCC engagement.
S Axle joints – checks for vibration.
S TPS – TCC apply and release depends on the TPS
in many engines. If TPS is out of specification, TCC
may remain applied during initial engine starting.
S Cylinder balance – bad piston rings or poorly seal-
ing valves can cause low power in a cylinder.
S Fuel contamination – causes poor engine perfor-
mance.
TCM INITIALIZATION PROCEDURE
When one or more operations such as shown below are
performed, all learned contents which are stored in TCM
memory should be erased after the operations.
S When A/T H/W is replaced in a vehicle,
S When a used TCU is installed in other vehicle,
S When a vehicle condition is unstable (engine RPM
flare, TPS toggling and so on; at this kind of unsta-
ble conditions, mis–adaptation might be done).
1. Connect the Scan 100 with a DLC connector in a
vehicle.
2. Turn ignition switch ON.
3. Turn the power on for the Scan 100.
4. Follow the ”TCM LEARNED INITIALIZE” procedure
on the Scan 100 menu.
Notice : Before pushing ”Yes” Button for TCM initialization
on the Scan 100 screen, make sure that the condition is
as follows:
Condition :
1. Engine idle.
2. Select lever set ”P” range.

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

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 57
DAEWOO V–121 BL4
Symptom ActionPossible Cause
Sealing Ring Selector ShaftS Check sealing ring.
S Replace sealing ring as described in the repair
instruction.
O–ring at Socket OutletS Check O–ring.
S Replace O–ring as described in the repair in-
struction.
O–ring and Speed Sensor ConnectionS Check O–ring.
S Replace O–ring as described in the repair in-
struction.
Oil Leak Incorrectly IdentifiedS No oil leak is possible at this point.
Speed Sensor Itself Is LeakingS Check speed sensor.
S Replace speed sensor as described in the re-
pair instruction.
Hair Line Crack at the Piping in the Con-
nection Area, Sealing Ring Fit in Trans-
axle HousingS Pressurize the line with compressed air and
check it.
S Replace lines as described in the repair in-
struction.
O–ring Defective, IncorrectCheck O–ring.
Replace O–rings as described in the repair instruc-
tion.
Plug LooseCheck the Tightening Torque for the screw plug.
Tighten to torque specified in the repair instruction.
Noise
SymptomPossible CauseAction
NoiseTFT Level Too LowS When the TFT level is too low, the gear wheels
from the transaxle oil pump might generate
noise.
S Check the TFT level as described in the repair
instruction and fill to the proper level.
Monolith in Catalytic Converter Has
BrokenS Check according to the exhaust gas diagnostic
procedure or by shaking the catalytic converter
casing.
S Replace catalytic converter if necessary.
Noise from Auxiliaries (e.g. exhaust
system, alternator, drive shafts.)S Check these components; if necessary, elimi-
nate the faults as described in the repair in-
struction
Noise from Tires or Wheel BearingsS Eliminate fault if necessary
Noise from Planetary GearsS Whistling noise on traction and overrun(in first
gear only)caused by high rotating speeds(func-
tionally unavoidable)
Cumulative Tooth Backlash in the Com-
plete Drive LineS Production status. Customer must be con-
vinced.
Jerky Noise of the Parking Lock (e.g.
when the car is standing on a gradient)S Load–reversal reaction
S Apply the handbrake before selection the park-
ing Lock (position P)

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 – 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.