DAEWOO NUBIRA 2004 Service Repair Manual

5A1 – 2IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
DTC P0722 – Output Speed Sensor(OSS)
Circuit No Signal 5A1–107. . . . . . . . . . . . . . . . . . . . . .
DTC P0725 – Engine Speed Input Circuit
Malfunction 5A1–110. . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0726 – Engine Speed Input Circuit
Range/Performance 5A1–112. . . . . . . . . . . . . . . . . . .
DTC P0727 – Engine Speed Input Circuit No
Signal 5A1–114. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0731 – Gear 1 Incorrect Ratio 5A1–116. . . . . .
DTC P0732 – Gear 2 Incorrect Ratio 5A1–118. . . . . .
DTC P0733 – Gear 3 Incorrect Ratio 5A1–120. . . . . .
DTC P0734 – Gear 4 Incorrect Ratio 5A1–122. . . . . .
DTC P0781 – 1–2 Shift Malfunction 5A1–124. . . . . . .
DTC P0782 – 2–3 Shift Malfunction 5A1–126. . . . . . .
DTC P0783 – 3–4 Shift Malfunction 5A1–128. . . . . . .
DTC P1604 – Data Check of Internal &
Extended Ram Failed 5A1–130. . . . . . . . . . . . . . . . . .
DTC P1606 – Failure Of External Watchdog 5A1–132
DTC P1671 – CAN Transmit Message
Failure 5A1–134. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1672 – CAN Bus Off Failure 5A1–136. . . . . . . .
DTC P1673 – CAN Receive ECM Message
Failure 5A1–138. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1839 – EDS 3 Output Shorted To
Ground 5A1–140. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1840 – EDS 3 Output Shorted To
Power 5A1–142. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1841 – EDS 3 Output Open 5A1–144. . . . . . . .
DTC P1850 – Solenoid 1 Output Shorted To
Ground 5A1–146. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1851 – Solenoid 1 Output Shorted To
Power 5A1–148. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1852 – Solenoid 1 Output Open 5A1–150. . . .
DTC P1853 – Solenoid 2 Output Shorted To
Ground 5A1–152. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1854 – Solenoid 2 Output Shorted To
Power 5A1–154. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1855 – Solenoid 2 Output Open 5A1–156. . . .
DTC P1861 – EDS 4 Output Shorted To
Ground 5A1–158. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1862 – EDS 4 Output Shorted To
Power 5A1–160. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1863 – EDS 4 Output Open 5A1–162. . . . . . . .
DTC P1864 – EDS 5 Output Shorted To
Ground 5A1–164. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1865 – EDS 5 Output Shorted To
Power 5A1–166. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1866 – EDS 5 Output Open 5A1–168. . . . . . . .
DTC P1867 – EDS 6 Output Shorted To
Ground 5A1–170. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1868 – EDS 6 Output Shorted To
Power 5A1–172. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1869 – EDS 6 Output Open 5A1–174. . . . . . . .
DTC P1871 – EDS Valve Power Supply
Circuit Shorted to Power 5A1–176. . . . . . . . . . . . . . .
DTC P1874 – Solenoid Valve Power Supply
Circuit Shorted to Power 5A1–178. . . . . . . . . . . . . . .
DTC P1881 – 2–1 Shift Malfunction 5A1–180. . . . . . .
DTC P1883 – 3–2 Shift Malfunction 5A1–182. . . . . . .
DTC P1884 – 4–3 Shift Malfunction 5A1–184. . . . . . .
DTC P1885 – 3–1 Shift Malfunction 5A1–186. . . . . . .
DTC P1886 – 4–2 Shift Malfunction 5A1–188. . . . . . .
MAINTENANCE AND REPAIR5A1–190 . . . . . . . . . . . .
ON–VEHICLE SERVICE 5A1–190. . . . . . . . . . . . . . . . . .
Transaxle Fluid Level Checking Procedure 5A1–190.
Changing the Fluid 5A1–191. . . . . . . . . . . . . . . . . . . . . .
Fluid Level Set After Service 5A1–192. . . . . . . . . . . . .
Repairing Fluid Leaks 5A1–192. . . . . . . . . . . . . . . . . . .
Case Porosity Repair 5A1–193. . . . . . . . . . . . . . . . . . . .
Shift Control Lever Assembly 5A1–193. . . . . . . . . . . . .
Shift Control Cable 5A1–195. . . . . . . . . . . . . . . . . . . . . .
Shift Control Cable Adjustment 5A1–196. . . . . . . . . . .
Transaxle Control Module(TCM) 5A1–197. . . . . . . . . .
Park/Neutral Start Switch 5A1–198. . . . . . . . . . . . . . . .
Oil Cooler Pipes/Hoses 5A1–199. . . . . . . . . . . . . . . . . .
Drive Axle Oil Seal 5A1–201. . . . . . . . . . . . . . . . . . . . . .
Oil Pan, Oil Pan Gasket 5A1–201. . . . . . . . . . . . . . . . .
Control Valve Body Assembly 5A1–203. . . . . . . . . . . .
Left Transaxle Mounting Bracket 5A1–205. . . . . . . . . .
Transaxle Assembly 5A1–206. . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR 5A1–212. . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Converter 5A1–212. . . . . . . . . . . . . . . . . . . . . . .
Transaxle Holding Fixture Assembly 5A1–212. . . . . . .
Valve Body 5A1–212. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Cover 5A1–213. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch B/E 5A1–214. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch B/E Measurement Procedure 5A1–217. . . . . .
Planetary Gear Set 5A1–220. . . . . . . . . . . . . . . . . . . . .
Brake C/D 5A1–221. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential 5A1–224. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Side Shaft 5A1–224. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake F, Slotted Nut 5A1–225. . . . . . . . . . . . . . . . . . . . .
Torque Converter Housing 5A1–227. . . . . . . . . . . . . . .
Shift Mechanism 5A1–228. . . . . . . . . . . . . . . . . . . . . . . .
Parking Lock System 5A1–229. . . . . . . . . . . . . . . . . . . .
Bearing Plate(With Spur Gear) Assembly 5A1–229. .
Oil Pump Assembly 5A1–229. . . . . . . . . . . . . . . . . . . . .
Differential/Side Shaft Outer Race, Bearing
Shim 5A1–230. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 3
DAEWOO V–121 BL4
Important Measurement/Adjustment 5A1–230. . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION5A1–232 . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical Components 5A1–232. . . . . . . . . . . . . . . . .
Electronical Components 5A1–236. . . . . . . . . . . . . . . .
TCM Inputs That Affect the 4HP 16
Transaxle 5A1–241. . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION
ZF 4HP 16 AUTOMATIC TRANSAXLE
The ZF 4 HP 16 is a four–speed automatic transaxle de-
signed for cars with front–wheel drive and a transversely
mounted engine.
The transaxle has a hydrodynamic torque converter with
a controlled slip lock–up clutch.
A planetary gear train establishes the mechanical gear ra-
tios. The integral constant ratio can be adapted to the en-
gine’s power output and the vehicle’s weight. The elec-
tronic–hydraulic control makes controlled power shifts and
various shift programs possible. In selector lever position
”P”, the output is locked mechanically.The special feature of this transaxle is that it operates with-
out freewheels. Shifting between individual gears takes
place by means of overlapping clutch engagement and re-
lease.
The advantage of overlap shifting is as follows:
– The transaxle can be of more compact design
and is lighter on account of the absence of free-
wheels and the lower number of shift elements
– Lower drag losses, i.e. higher efficiency
– Lower peak torques acting on the components
and driveline.
However, overlap shifting necessitates high–performance
hardware and software, and precision engine signals.

5A1 – 4IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
TRANSAXLE COMPONENTS

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 5
DAEWOO V–121 BL4
SPECIFICATIONS
GENERAL SPECIFICATIONS
Definition
Transaxle Type4–speed with four–wheel drive and transverse engine
Input Torque240 NSm (177 lb–ft)
Transaxle Weight76kg (168 lb)
Torque Converter Capacity9.72kg (21.4 lb)
Transaxle Fluid Type (manufacture company)ESSO LT 71141 or TOTAL ATF H50235
Transaxle Fluid Capacity7.3qt (6.9L)
TRANSAXLE GEAR RATIO
GearRatio
First2.719
Second1.487
Third1.000
Fourth0.717
Reverse 2.529
Final3.945:1
FLUID CAPACITY
LitresQuarts
Bottom Pan Removal44.2
Complete Overhaul6.97.3
Torque Converter Removal22.1
(Measurements are approximate)
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Bearing Plate Bolts23.517.5–
Slotted Nut220162–
Rear Cover Attachment Bolts23.517.5–
Baffle Plate Attachment Bolts10–89
Park/Neutral Position Switch10–89
Fluid Pump Connecting Bolts10–89
Fluid Filter Housing Cover Attachment Bolts10–89
Input Speed sensor Attachment Bolts8–71
Output Speed Sensor Attachment Bolts8–71
Valve Body Bolts8–71
Valve Body Upper & Lower Fixing Bolts6–53
Fluid Pan Connecting Bolts6–53
Fluid Pan Drain Plug4533–

5A1 – 6IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Application Lb–InLb–Ft NSm
Fluid Level Plug4533–
Line Pleasure Plugs2015–
Valve Housing 1 Cover Attachment Bolts6–53
Solenoid Valve Attachment Bolts6–53
Pressure Control Regulator(EDS) Attachment Bolts6–53
Oil Cooler Inlet Pipe Bolts3526–
Oil Cooler Outlet Pipe Bolts3526–
Shift Control Cable Adjuster Pinch Nut8–71
Shift Control Cable Attachment Nut8–71
Upper Transaxle–to–Engine Bolts7555–
Selector Lever(On Transaxle Case)1511–
Torque Converter Attachment Bolts4533–
Shift Control Assembly Mounting Bolt, Nut8–71
Lower Engine–to–Transaxle Bolts(a)7555–
Lower Engine–to–Transaxle Bolt(b)2115–
Lower Engine–to–Transaxle Bolts(c)3123–
Rear Transaxle Mounting Bracket Bolts6245–
Damping Block Connection Bolt and Nut6850–
Left Transaxle Mount Bracket Cage Bolt(a)11 081–
Left Transaxle Mount Bracket Cage Bolt(b)6548–
Left Transaxle Mount Bracket Cage Nut(c)6548–
Left Transaxle Mounting Bolts4835–

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 7
DAEWOO V–121 BL4
RangePark/
Neutr
alRever
seD321
GearNR1st2nd3rd4th1st2nd3rd1st2nd1st
Solenoid Valve
1ONON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFF
Solenoid Valve
2ONONONOFFOFFOFFONOFFOFFONOFFON
Line Pressure
Control Sole-
noid Valve 3
(EDS 3)OFFOFFOFFONON/
OFFON/
OFFOFFONON/
OFFOFFONOFF
Line Pressure
Control Sole-
noid Valve 4
(EDS 4)ONOFFONONONOFFONONONONONON
Line Pressure
Control Sole-
noid Valve 5
(EDS 5)OFFOFFONONOFFOFFONONOFFONONON
Line Pressure
Control Sole-
noid Valve 6
(EDS 6)ONOFFONONONOFFONONONONONON
Brake BAAAAAAAA
Brake CH
Brake DH
Clutch EAAAAAA
Brake FHHHHHHH
Lock–up
ClutchA
A = Applied
H = Holding
ON = The solenoid is energized.
OFF = The solenoid is de–energized.
** = Manual Second–Third gear is only available above approximately 100 km/h (62 mph).
*** = Manual First–Second gear is only available above approximately 60 km/h (37 mph).
Note : Manual First–Third gear is also possible at high vehicle speed as a safety feature.
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)

5A1 – 8IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Down Shift Speed
MODELDown Shift (±4.0 mph (6.4km/h))Lock Up Clutch Applied
(Fourth)Lock Up Clutch
Released
(Fourth)
Fourth–Th
ird
(Coast)Third–Sec
ond
(Coast)Second–Fi
rst
(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)
LINE PRESSURE
Gear RangeSolenoidLine PressureB PortE Port
Park / NeutralONLOW90~124.7 psi
(6.2~8.6 bar)
OFFHIGH221.9~252.3 psi
(15.3~17.4 bar)
ReverseONLOW89.9~124.7 psi
(6.2~8.6 bar)
OFFHIGH221.9~252.3 psi
(15.3~17.4 bar)
DriveONLOW90~124.7 psi
(6.2~8.6 bar)
OFFHIGH137.7~162.4 psi
(9.5~11.2 bar)
3ONLOW90~124.7 psi
(6.2~8.6 bar)90~124.7 psi
(6.2~8.6 bar)
OFFHIGH221.9~252.3 psi
(15.3~17.4 bar)137.7~162.4 psi
(9.5~11.2 bar)
2ONLOW90~124.7 psi
(6.2~8.6 bar)
OFFHIGH137.7~162.4 psi
(9.5~11.2 bar)
1ONLOW90~124.7 psi
(6.2~8.6 bar)
OFFHIGH221.9~252.3 psi
(15.3~17.4 bar)

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 9
DAEWOO V–121 BL4
SPECIAL TOOLS
SPECIAL TOOLS TABLE
Scan Tool
DW110–060
Engine Support Fixture
DW260–020
Transaxle Holding
Fixture
DW260–010
Transaxle Support
Fixture
DW260–030
Axle Seal Installer
DW260–050
Park/Neutral Position
Switch Installer
DW260–060
Brake F Split Stop Ring
Remover/Installer
DW260–070
Transaxle Fluid Plug
Remover/Installer

5A1 – 10IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
DW240–010
Universal Pressure
Gauge Set
DW260–150
Clutch E Stop Ring
Remove/Installer
DW260–140
Clutch B Stop Ring
Remover/Installer
DW260–160
Brake C/D Snap Ring
Remover/Installer
DW260–080
Clutch B/E Shim
Setting Gauge
DW260–120
Clutch B
Adjust Ring
DW260–130
Clutch E
Adjust Ring
DW260–100
Clutch B/E
Disc Thickness
Measuring Fixture
DW260–090
Clutch B/E (Snap Ring
Play, Installation
Space) Measuring
Fixture
DW260–110
Brake F Disc Clearance
Measuring Bar

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 11
DAEWOO V–121 BL4
SCHEMATIC AND ROUTING DIAGRAMS
TRANSAXLE CONTROL MODULE (1 OF 2)