2004 DAEWOO NUBIRA check engine

AISIN AUTOMATIC TRANSAXLE 5A2 – 99
DAEWOO V–121 BL4
FLUID COOLER FLUSHING
Flushing Procedure
1. Drain the fluid from the transaxle and refill the
transaxle with new transaxle fluid. Refer to ”Fluid
Drain Procedure” in this section.
2. Let the engine idle for 5 minutes.
3. Drain the fluid from the transaxle and refill the
transaxle with new transaxle fluid. Refer to ”Fluid
Drain Procedure” in this section.
CONTROL CABLE ADJUSTMENT
Adjustment Procedure
The various shift control cable positions must match at the
shift control lever in the vehicle and at the selector lever
on the transaxle to provide proper transaxle shifting.
Place the shift control lever in the PARK position and
check the selector lever connection to verify that it is in the
forward most position. If it is not, the following adjustment
must be performed:
1. Disconnect the negative battery cable.
2. Remove the floor console. Refer to Section 9G,
Interior Trim.
3. Place the shift control lever in the PARK position.
4. Loosen the control cable adjusting nut.
5. Move the Transmission Range (TR) switch lever
counterclockwise until stopping the lever.

5A2 – 116IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
15. Connect the fluid cooler inlet and outlet pipe and
hose into the transaxle. Refer to ”Fluid Cooler Inlet
or Outlet Pipe and Hoses” in this section.
16. Install the left and right drive axle assemblies. Refer
to Section 3A, Automatic Transaxle Drive Axle.
17. Install the battery and battery tray. Refer to Section
1E, Engine Electrical.
18. Fill the transaxle with fluid. Refer to ”Fluid Drain
Procedure” in this section.
19. Check the fluid level. Refer to ”Transaxle Fluid Lev-
el Checking Procedure” in this section.

FIVE–SPEED MANUAL TRANSAXLE 5B – 5
DAEWOO V–121 BL4
DIAGNOSIS
ISOLATE NOISE
Identify the cause of any noise before attempting to repair
the clutch, the transaxle, or their related link–ages.
Symptoms of trouble with the clutch or the manual trans-
axle include:
S A great effort required to shift gears.
S The sound of gears clashing and grinding.
S Gear blockout.
Any of these conditions requires a careful analysis. Make
the following checks before disassembling the clutch or
the transaxle for repairs.
Road Travel Noise
Many noises that appear to come from the transaxle may
actually originate with other sources such as the:
S Tires.
S Road surfaces.
S Wheel bearings.
S Engine.
S Exhaust system.
These noises may vary according to the:
S Size of the vehicle.
S Type of the vehicle.
S Amount of insulation used in the body of the ve-
hicle.
Transaxle Noise
Transaxle gears, like any mechanical device, are not ab-
solutely quiet and will make some noise during normal op-
eration.
To verify suspected transaxle noises:
1. Select a smooth, level asphalt road to reduce tire
and resonant body noise.
2. Drive the vehicle far enough to warm up all the lu-
bricants thoroughly.
3. Record the speed and the gear range of the trans-
axle when the noise occurs.
4. Check for noises with the vehicle stopped, but with
the engine running.
5. Determine if the noise occurs while the vehicle op-
erates in:
S Drive – under a light acceleration or a heavy
pull.
S Float – maintaining a constant speed with a light
throttle on a level road.
S Coast – with the transaxle in gear and the
throttle partly or fully closed.
S All of the above.
Bearing Noise
Differential Side Bearing Noise
Differential side bearing noise and wheel bearing noise
can be confused easily. Since side bearings are pre–
loaded, a differential side bearing noise should not dimin-
ish much when the differential/transaxle is run with the
wheels off the ground.
Wheel Bearing Noise
Wheel bearings produce a rough growl or grating sound
that will continue when the vehicle is coasting and the
transaxle is in NEUTRAL. Since wheel bearings are not
pre–loaded, a wheel bearing noise should diminish con-
siderably when the wheels are off the ground.
Other Noise
Brinelling
A brinelled bearing causes a ”knock” or ”click” approxi-
mately every second revolution of the wheel because the
bearing rollers do not travel at the same speed as the
wheel. In operation, the effect is characterized by a low–
pitched noise.
A brinelled bearing is caused by excessive thrust which
pushes the balls up on the pathway and creates a triangu-
lar–shaped spot in the bearing race. A brinelled bearing
can also be caused from pressing one race into position
by applying pressure on the other race.
A false indication of a brinelled bearing occurs as a result
of vibration near the area where the bearing is mounted.
Brinelling is identified by slight indentations, resulting in a
washboard effect in the bearing race.
Lapping
Lapped bearing noise occurs when fine particles of abra-
sive materials such as scale, sand, or emery circulate
through the oil in the vehicle, causing the surfaces of the
roller and the race to wear away. Bearings that wear loose
but remain smooth, without spalling or pitting, are the re-
sult of dirty oil.
Locking
Large particles of foreign material wedged between the
roller and the race usually causes one of the races to turn,
creating noise from a locked bearing. Pre–loading regular
taper roller bearings to a value higher than that specified
also can result in locked bearings
Pitting
Pitting on the rolling surface comes from normal wear and
the introduction of foreign materials.
Spalling
Spalled bearings have flaked or pitted rollers or races
caused by an overload or an incorrect assembly that re-
sults in a misalignment, a cocking of bearings, or adjust-
ments that are too tight.
After completing these checks, refer to the ”Diagnosis
Chart” in this section.

5B – 6IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
SYMPTOM DIAGNOSIS
ChecksAction
Check for a knock at low speeds.S Replace any worn drive axle CV joints.
S Replace any worn side gear hub.
Check for a noise most pronounced on turns.S Correct any abnormalities in the differential gear.
Check for a clunk upon acceleration or deceleration.S Tighten any loose engine mounts.
S Replace any worn drive axle inboard joints.
S Replace any worn differential pinion shaft in the
case.
S Replace any worn side gear hub in the case.
Check for a clunking noise in turns.S Replace any worn outboard CV joint.
Check for a vibration.S Replace any rough wheel bearing.
S Replace any bent drive axle shaft.
S Replace any out–of–round tires.
S Balance any unbalanced tire.
S Replace any worn CV joint in the drive axle shaft.
S Correct an excessive drive axle angle by adjusting
the trim height.
Check for a noise in the NEUTRAL gear with the engine
running.S Replace any worn cluster bearing shaft.
S Replace any worn clutch–release bearing.
S Replace any worn input shaft cluster gears.
S Replace any worn first–gear/bearing.
S Replace any worn second–gear/bearing.
S Replace any worn third–gear/bearing.
S Replace any worn fourth–gear/bearing.
S Replace any worn fifth–gear/bearing.
S Replace any worn mainshaft bearings.
Check for a noise in the first gear (1) only.S Replace any chipped, scored, or worn first–gear
constant mesh gears.
S Replace any worn first–second gear synchronizer.
S Replace any worn first–gear/bearing.
S Replace any worn differential–gear/bearing.
S Replace any worn–ring gear.
S Adjust, repair, or replace the shift lever and the rods.
Check for a noise in the second gear (2) only.S Replace any chipped, scored, or worn second–gear
constant mesh gears.
S Replace any worn first–second gear synchronizer.
S Replace any worn second–gear/bearing.
S Replace any worn differential–gear/bearing.
S Replace any worn–ring gear.
S Adjust, repair, or replace the shift lever and the rods.
Check for a noise in the third gear (3) only.S Replace any chipped, scored, or worn third–gear
constant mesh gears.
S Replace any worn third–fourth gear synchronizer.
S Replace any worn third–gear/bearing.
S Replace any worn differential–gear/bearing.
S Replace any worn–ring gear.
S Adjust, repair, or replace the shift lever and the rods.

FIVE–SPEED MANUAL TRANSAXLE 5B – 15
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
CHECKING FLUID LEVEL
1. With the vehicle on a level surface and the fluid in
the transaxle cold, remove the filler plug and check
the fluid level. The fluid should come to the bottom
edge of the plug hole.
2. If the level is low, add SAE 80 manual transaxle
fluid through the filler plug hole until the fluid begins
to run out.
3. Reinstall the filler plug and tighten it securely.
4. If the fluid is contaminated, drain the oil after re-
moving the differential gear cover.
SHIFT LINKAGE ADJUSTMENT
(LEFT–HAND DRIVE SHOWN,
RIGHT–HAND DRIVE SIMILAR)
1. Disconnect the negative battery cable.
2. Position the gearshift lever into NEUTRAL.
Important : All the gears must be easy to engage when
the vehicle is stationary, the engine is running, and the
clutch is disengaged.
3. Loosen the rod clamp bolt.

FIVE–SPEED MANUAL TRANSAXLE 5B – 25
DAEWOO V–121 BL4
11. Connect the clutch release cylinder pipe.
12. Connect the speedometer speed sensor electrical
connector.
13. Connect the backup lamp switch electrical connec-
tor.
14. Remove the engine support fixture J–28467–B.
15. Install the drive axle shaft. Refer to Section 3B,
Manual Transaxle Drive Axle.
16. Install the shift linkage assembly. Refer to ”Shift
Linkage Assembly” in this section.
17. Install the battery and battery tray. Refer to Section
1E, ENGINE ELETRICAL.
18. Inspect the fluid level. Refer to ”Checking Fluid Lev-
el” in this section.

5C – 8ICLUTCH
DAEWOO V–121 BL4
CLUTCH RELEASE POINT
ADJUSTMENT
Adjustment Procedure
1. Apply the parking brake.
2. Run the engine at idle speed.
3. While you move the shift lever into the reverse
position, depress the clutch pedal slowly and mea-
sure the distance between the point when gear
noise is not heard and the point the clutch pedal is
completely depressed. The distance should be 30
to 40 mm (1.2 to 1.6 inches).
4. If the distance is not within the specified value,
check the following:
S Clutch pedal height
S Clutch pedal play
S Air in the system
S Clutch cover and disc pressure plate
AIR BLEEDING
Bleed the hydraulic system to remove the air which en-
tered when the pipes were disconnected for repairs. The
clutch/brake fluid in the clutch/brake reservoir must be
maintained at the MIN level or higher during air bleeding.
1. Attach a vinyl hose to the bleeder plug. Place the
other end of the vinyl tube in a glass container half–
filled with brake fluid.
2. Slowly pump the clutch pedal several times.
3. While you press the clutch pedal, loosen the bleed-
er screw until the fluid starts to run out. Close the
bleeder screw.
4. Repeat Step 3 until there are no air bubbles in the
fluid.
5. Fill the reservoir with brake fluid up to the proper
level.
PRESSURE PLATE AND CLUTCH
DISC
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the transaxle from the vehicle. Refer to
Section 5B, Five–Speed Manual Transaxle.
3. Remove the pressure plate bolts and the pressure
plate.
Important : Support the pressure plate when you remove
the last bolt.

6A – 2IPOWER STEERING SYSTEM
DAEWOO V–121 BL4
DIAGNOSIS
POWER STEERING SYSTEM
PRESSURE TEST
Tools Required
KM–354–B Pressure Test Gauge Kit
Check the fluid pressure as follows to determine whether
the trouble is in the pump or the gear unit.
Test Procedure
1. Check the power steering fluid level and the power
steering pump belt tension. Refer to ”Checking and
Adding Fluid” in this section and Section 6B, Power
Steering Pump.
2. Disconnect the high pressure line at the pump. Use
a small container to catch any fluid.
3. Connect the hose of the pressure test gauge kit
KM–354–B to the power steering pressure hose
from the power steering pump.
4. Place the gear selector lever in PARK (automatic
transaxle–equipped vehicles) or NEUTRAL (manual
transaxle–equipped vehicles). Set the parking
brake.
5. Open the gauge valve fully.
6. Start the engine and let it idle.
7. Turn the steering wheel from lock to lock several
times to warm the fluid to operating temperature.
8. Increase the engine speed to 1,500 rpm.
Notice : The power steering pump could be damaged if
the valve is fully closed for more than 5 seconds.
9. Close the gauge valve fully, and read the pressure.
The pump pressure with the valve closed should be
between 8,330 kPa to 8,820 kPa (1,208 psi to
1,279 psi). With electronic variable orifice, the pres-
sure should be between 8,500 kPa to 8,960 kPa
(1,233 psi to 1,299 psi).
10. Immediately open the gauge valve fully.
11. Turn the steering wheel all the way to the left and
the right. If the pressure is within the specified lim-
its, the problem is not in the pump. Check the pow-
er steering gear for leaks.
POWER STEERING SYSTEM LEAK
TEST
General Procedure
Inspect the following:
S The fluid reservoir for overfill.
S Fluid for aeration and overflow.
S The hoses for loose connections.
S The torsion bar, stub shaft and adjuster seals for
leaks.
S The component sealing surfaces for damage.
Important : Verify the exact point of the leak. The point
from which the fluid is dripping is not necessarily the point
at which the system is leaking. When service is required,
clean the leak area upon disassembly, replace the leaking
seal, check the component sealing surfaces for damage
and reset the torque bolt to specifications, where required.
External Leak Check
The purpose of this procedure is to pinpoint the location of
the leak. In some cases, the leak can be easily located, but
seepage–type leaks may be harder to find. To locate seep-
age leaks, use the following method:
1. With the engine off, wipe dry the complete power
steering system.
2. Check the power steering fluid level in the pump’s
reservoir. Adjust the fluid level as necessary. Refer
to ”Checking and Adding Fluid” in this section.
Notice : Do not hold the steering wheel at a stop for any
length of time as this can damage the power steering
pump.
3. Start the engine. Turn the steering wheel counter-
clockwise and clockwise from stop to stop several
times.
4. Find the exact area of the leak and repair it.