DAEWOO NUBIRA 2004 Service Repair Manual

5A1 – 82IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
121. Disconnect the C105 connector and TCM con-
nector.
2. Turn the ignition ON.
3. Measure the voltage of the terminal B3(TCM
wiring connector).
Is the voltage within the values shown?9–16VGo to Step 13Go to Step 14
13Repair the circuit from EF1 to terminal B3 of the TCM
for a short to power.
Is the repair complete?–System OK–
141. Turn the ignition OFF.
2. Disconnect the C206 connector.
3. Measure the resistance between F2 fuse and
terminal C15 or C16 of the TCM wiring connec-
tor.
Is the resistance within the values shown?0ΩGo to Step 16Go to Step 15
15Repair the circuit(between F2 and terminal C15 or
C16) for a short to ground and open.
Is the repair completed?–System OK–
161. Turn the ignition ON.
2. Measure the voltage of the terminal C15 or
C16(TCM wiring connector).
Is the voltage within the values shown?9–16VGo to Step 17Go to Step 18
17Repair the circuit(between F2 and terminal C15 or
C16) for short to power.
Is the repair complete?–System OK–
181. Inspect the transaxle wiring for poor electrical
connections at the transaxle connector.
2. Look for possible bent, backed out, deformed,
or damaged terminals.
3. Check for weak terminal tension.
Was a condition found?–Verify repair
and Go to Step
1Go to Step 19
19Replace the TCM.
Is the replacement complete?–Go to Step 20–
201. After the repair, use a scan tool ”clear info”
function and road test the vehicle.
2. Review the ”DTC info”.
Has the last test failed or is the current DTC dis-
played?–Begin diagno-
sis againRepair verified
exit DTC chart

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 83
DAEWOO V–121 BL4
DIAGNOSTIC TROUBLE CODE(DTC) P0703
BRAKE SWITCH CIRCUIT MALFUNCTION
Circuit Description
The brake switch is used to indicate brake pedal status to
the transaxle control module(TCM). The brake switch is a
normally open switch. Applying the brake pedal closes the
switch, supplying voltage to the TCM. Releasing the brake
pedal interrupts voltage to the TCM.
This DTC is stored at start–up. If the TCM receives a brake
switch signal after start–up, the DTC will be stored in
memory.
Conditions for Setting The DTC
S Brake switch stuck to closed.
S Brake switch wiring harness shortage to ground.
S Brake switch wiring harness shortage to power.S Immediately after the above condition occurs.
Action Taken When The DTC Sets
S No lamp control required but diagnostic information
should be stored immediately when malfunction is
detected.
S TCM assume that the brake light always active.
Conditions For Clearing The MIL/DTC
S Using a scan tool can clear history DTCs.
Diagnostic Aids
S Inspect the poor wiring harness connection for TCM
connectors and transaxle wiring connectors.
S Inspect the improperly formed or damage terminals.

5A1 – 84IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
DTC P0703 – Brake Switch Circuit Malfunction
StepActionValue(s)YesNo
1Perform an On–Board Diagnostic (EOBD) System
Check.
Is the check completed?–Go to Step 2Go to ”On–
Board Diagnos-
tic System
Check”
21. Install the scan tool.
2. Turn the ignition ON. With the engine OFF.
3. Record then clear DTC(s)
4. Select scan tool stransmission data display.
5. Disconnect the brake switch connector.
6. Did the brake switch status change from” on” to
”off”?–Go to Step 3Go to Step 4
31. Replace the brake switch.
2. Refer to Brake Replacement.
3. After the ignition OFF, turn ignition ON.
Is the DTC reset?–Go to Step 4Go to Step 15
4Inspect the EF13.
Is the fuse blown?–Go to Step 5Go to Step 6
5Replace the fuse.
Is the action complete?–System OK–
61. Turn the ignition OFF.
2. Disconnect the C102 wiring connector and the
brake switch wiring connector.
3. Measure the resistance between the terminal
D5 of the C102 connector and the terminal 3 of
the brake switch wiring connector.
Is the resistance within the values shown?0ΩGo to Step 8Go to Step 7
7Repair the open circuit between the C102 connector
and the brake switch connector.
Is the action complete?–System OK–
81. Turn the ignition ON.
2. Measure the voltage of the C102 connector, 6
terminal.
Is the voltage within the values shown?11–14vGo to Step 9Go to Step 10
9Repair the short to power between the C102 con-
nector and the brake switch connector.
Is the action complete?–System OK–
101. Turn the ignition OFF.
2. Disconnect the brake switch wiring connector
and TCM wiring connector.
3. Measure between the brake switch connector,
terminal 4 and TCM connector, terminal A5.
Is the resistance within the values shown?0ΩSystem OKGo to Step 11
11Repair the open or short to ground between brake
switch connector and TCM.
Is the action complete?–System OK–
121. Turn the ignition ON.
2. Measure the voltage of the brake switch wiring
connector, terminal 4.
Is the voltage within the values shown?11–14vGo to Step 13Go to Step 14

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 85
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
13Repair the short to power between the brake switch
wiring connector and TCM.
Is the action complete?–System OK–
14Replace the TCM.
Is the action complete?–Go to Step 15–
151. After the repair, use a scan tool ”clear info”
function and road test the vehicle.
2. Review the ”DTC info”.
Has the last test failed or is the current DTC dis-
played?–Begin diagno-
sis againRepair verified
exit DTC chart

5A1 – 86IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
DIAGNOSTIC TROUBLE CODE(DTC) P0705
TRANSMISSION RANGE SENSOR CIRCUIT
MALFUNCTION (PRNDL INPUT)
Circuit Description
The Transmission range switch is located on the selector
shaft and informs the TCM of the current selector lever
position P–R–N–D–3–2–1.
The selector lever position is transmitted to the TCM in en-
coded form along 4 lines. The encoding is such that mal-
functions in the connecting lead are identified.
The TR switch is located on the selector shaft, which is
connected to the selector lever via a pull cable. In addition,
the TR switch controls the starter interlock, the reverse
lights and the selector lever position indicator on the in-
strument panel.
Conditions for Setting The DTC
S TR switch stuck to closed.
S TR switch wiring harness shortage to ground.
S TR switch wiring harness shortage to power.
S Immediately after the above condition occurs.Action Taken When The DTC Sets
S The Malfunction Indicator Lamp(MIL) will illuminate.
S 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.
Conditions for Clearing the MIL/DTC
S The MIL will turn OFF when the malfunction has
not occurred after three–ignition cycles.
S A history DTC will clear after 40 consecutive warm
up cycles without a fault.
S Using a scan tool can clear history DTCs.
Diagnostic Aids
S When DTC P0705 sets, the possible cause of TR
switch.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 87
DAEWOO V–121 BL4
Gear Position And Range Signal Chart.
L1L2L3L4
P00120
R00012
N01200
D1212120
31212012
21201212
10121212
DTC P0705 – Transmission Range Sensor Circuit Malfunction
(PRNDL Input)
StepActionValue(s)YesNo
1Perform an On–Board Diagnostic (EOBD) System
Check.
Is the check completed?–Go to Step 2Go to ”On–
Board Diagnos-
tic System
Check”
21. Install the scan tool.
2. Turn the ignition ON.
3. Record then clear DTC(s) and turn the ignition
OFF, then turn the ignition ON.
4. Applying the brakes and select each transaxle
range (P, R,N,D,3,2,1), while monitoring scan
tool.
Refer to Gear Position And Range Signal Chart.
Does each selected transaxle range match scan tool
and signal range chart?–Go to Step 3Go to ”Diag-
nostic Aids”
3Inspect the F2 for open?
Was a problem found?–Go to Step 4Go to Step 5
4Replace the fuse as necessary.
Is the action complete?–System OK–
5Inspect the TR switch. Refer to ”Diagnostic Aids”.
Was the problem found?–Go to Step 6Go to Step 7
6Replace the TR switch.
Is the action complete?–System OK–
71. Disconnect the TR switch connector and TCM
connector.
2. Measure the resistance between terminal 3 of
the TR switch and terminal C1 of the TCM con-
nector.
3. Measure the resistance between terminal 2 of
the TR switch and terminal B15 of the TCM
connector.
4. Measure the resistance between terminal 4 of
the TR switch and terminal B6 of the TCM con-
nector.
5. Measure the resistance between terminal 5 of
the TR switch and terminal B11 of the TCM
connector.
Is the resistance within the values shown?0ΩGo to Step 9Go to Step 8

5A1 – 88IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
8Repair the malfunctioning terminals as necessary.
Is the action complete?–System OK–
91. Turn the ignition ON.
2. Measure the voltage of terminal 3.
3. Measure the voltage of terminal 2.
4. Measure the voltage of terminal 4.
5. Measure the voltage of terminal 5.
Is the voltage within the values shown?11–14VGo to Step 10Go to Step 11
10Repair the malfunctioning terminals as necessary.
Is the action complete?–System OK–
11Replace the TCM.
Is The action complete?–Go to Step 12–
121. After the repair, use a scan tool ”clear info”
function and road test the vehicle.
2. Review the ”DTC info”.
Has the last test failed or is the current DTC dis-
played?–Begin diagno-
sis againRepair verified
exit DTC chart

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 89
DAEWOO V–121 BL4
DIAGNOSTIC TROUBLE CODE(DTC) P0710
TRANSMISSION FLUID TEMPERATURE SENSOR
CIRCUIT MALFUNCTION
Circuit Description
The TFT sensor is a positive temperature coefficient
thermistor (temperature sensitive resistor) that provides
information to the TCM regarding transaxle fluid tempera-
ture. The temperature sensor is located in valve body. Cal-
culated temperature is a factor used to determine the shift
time and shift delay time.
The internal electrical resistance of the sensor varies in
relation to the operating temperature of the transaxle fluid.
The TCM sends a 5 volt–reference signal to the tempera-
ture sensor and measures the voltage rise in the electrical
circuit. A higher fluid temperature creates a higher resist-
ance in the temperature sensor, thereby measuring a
higher voltage signal.
The TCM measures this voltage as another input to help
control line pressure, shift schedules and TCC apply.
When transaxle fluid temperature reaches 120°C (248°F)
the TCM enters ”hot mode.” Above this temperature the
TCM modifies transaxle shift schedules and TCC apply in
an attempt to reduce fluid temperature by reducing trans-
axle heat generation.Conditions for Setting The DTC
S The calculated temperature is compared with the
predetermined min. and max. value.
S If the temperature is less than min. value or greater
than max value then the current temperature is re-
garded as of range and the corresponding error but
will be set.
S Transmission fluid temperature is not between
–40°C (–40°F) and 150°C (302°F).
Action Taken When The DTC Sets
S No lamp control required but diagnostic information
should be stored immediately when malfunction is
defected.
S TCM assumes the transaxle fluid temperature is
60°C.
S No influence on drivability.
Conditions for Clearing the MIL/DTC
S Using a scan tool can clear history DTCs.
Diagnostic Aids
S When DTC P0710 sets, the possible cause of fault
could be Transmission Temperature Sensor.

5A1 – 90IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
DTC P0710 – Transmission Fluid Temperature Sensor Circuit
Malfunction
StepActionValue(s)YesNo
1Perform an On–Board Diagnostic (EOBD) System
Check.
Is the check completed?–Go to Step 2Go to ”On–
Board Diagnos-
tic System
Check”
21. Install the scan tool.
2. Turn the ignition ON, with the engine OFF.
3. Record then clear DTC(s) and turn the ignition
OFF, then turn the ignition ON.
4. Select TFT on the scan tool.
5. Drive the vehicle and observe the scan tool for
either of the flowing conditions:
6. The TFT does not change more than 1.5°C
(34.7°F) in 80 seconds since start–up.
7. The TFT changes more than 20°C (68°F) with-
in 7 seconds (unrealistic change).
Did either of the fail conditions occur?–Go to Step 3Go to ”Diag-
nostic Aids”
31. Turn the ignition OFF.
2. Disconnect the transaxle wiring connector.
3. Measure the resistance between terminals 9
and 4 of the transaxle wiring connector.
Is the resistance within the values shown?TFT 25°C
990 ΩGo to Step 7Go to Step 4
41. Remove the oil pan.
2. Disconnect the wiring connector of the trans-
axle fluid temperature sensor.
3. Inspect the automatic transaxle wiring harness
for an intermittent short or open.
Was a problem found?–Go to Step 5Go to Step 6
5Replace the automatic transaxle wiring harness.
Is the replacement complete?–System OK–
6Replace the TFT sensor.
Is the action complete?–System OK–
71. Disconnect the automatic transaxle wiring con-
nector and disconnect the wiring connector of
the TCM(transaxle control module).
2. Measure the resistance between terminal 4 of
the transaxle wiring connector and terminal B1
of the TCM wiring connector.
3. Measure the resistance between terminal 9 of
the transaxle wiring connector and terminal A4
of the TCM wiring connector.
Is the resistance within the values shown?0ΩGo to Step 9Go to Step 8
81. Inspect the automatic transaxle wiring harness
for an intermittent short to ground or open con-
dition.
2. Inspect the automatic TFT sensor wiring har-
ness for an intermittent short to ground or open
condition.
3. Repair the circuits if necessary.
Is the repair complete?–System OK–

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 91
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
91. Turn the ignition ON.
2. Measure the voltage of terminal A4 of the TCM
wiring connector.
3. Measure the voltage of terminal B1 of the TCM
wiring connector.
Is the voltage within the values shown?9–16VGo to Step 10Go to Step 11
101. Inspect the automatic transaxle wiring harness
for an intermittent short to power.
2. Inspect the automatic TFT sensor wiring har-
ness for an intermittent short to power.
3. Repair the circuits if necessary.
Is the repair complete?–System OK–
11Replace the TCM.
Is the replacement complete?–Go to Step 12–
121. After the repair, use a scan tool ”clear info”
function and road test the vehicle.
2. Review the ”DTC info”.
Has the last test failed or is the current DTC dis-
played?–Begin diagno-
sis againRepair verified
exit DTC chart