speed sensor DAEWOO LACETTI 2004 Service Repair Manual

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–

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 35
DAEWOO V–121 BL4
TRANSAXLE HOUSING
1. Transaxle Housing
2. Bushing
3. Shaft Seal
4. Axle Shaft Seal
5. Sealing Sleeve
6. Breather Pipe
7. Sleeve Protector
8. Type Plate
9. Cable Terminal10. Output Speed Sensor
11. Washer
12. Bolt
13. Shim
14. Shim
15. Park/Neutral Position Switch
16. Bolt
17. Sealing sleeve

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 41
DAEWOO V–121 BL4
VALVE BODY
1. Control Valve Body
2. Valve Body Wiring Harness
3. O–ring
4. Plug
5. Cable Terminal
6. Retaining Clip
7. Input Speed Sensor
8. Cap Screw9. Solenoid Valve
10. Cap Screw
11. Fixing Plate
12. Fixing Plate
13. Cap Screw
14. Solenoid Valve
15. Solenoid Valve

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.

5A1 – 52IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
81. Disconnect the internal transaxle harness from
the pressure control valve 4(EDS 4).
2. Measure the resistance of the EDS 4.
Is the resistance within the values shown?Refer to Com-
ponent Resist-
ance ChartGo to Step 20Go to Step 22
9Measure the resistance between terminals 5 and 10
the transaxle wiring connector(EDS 5).
Is the resistance within the values shown?Refer to Com-
ponent Resist-
ance ChartGo to Step 11Go to Step 10
101. Disconnect the internal transaxle harness from
the pressure control valve 5(EDS 5).
2. Measure the resistance of the EDS 5.
Is the resistance within the values shown?Refer to Com-
ponent Resist-
ance ChartGo to Step 20Go to Step 22
11Measure the resistance between terminals 5 and 11
the transaxle wiring connector(EDS 6).
Is the resistance within the values shown?Refer to Com-
ponent Resist-
ance ChartGo to Step 13Go to Step 12
121. Disconnect the internal transaxle harness from
the pressure control valve 6(EDS 6).
2. Measure the resistance of the EDS 6.
Is the resistance within the values shown?Refer to Com-
ponent Resist-
ance ChartGo to Step 20Go to Step 22
13Measure the resistance between terminals 4 and 9
the transaxle wiring connector(transaxle tempera-
ture sensor).
Is the resistance within the values shown?Refer to Com-
ponent Resist-
ance ChartGo to Step 15Go to Step 14
141. Disconnect the internal transaxle harness from
the transaxle temperature sensor.
2. Measure the resistance of the transaxle tem-
perature sensor.
Is the resistance within the values shown?Refer to Com-
ponent Resist-
ance ChartGo to Step 20Go to Step 22
15Measure the resistance between terminals 15 and
16 the transaxle wiring connector(transaxle input
speed sensor).
Is the resistance within the values shown?Refer to Com-
ponent Resist-
ance ChartGo to Step 17Go to Step 16
161. Disconnect the internal transaxle harness from
the transaxle input speed sensor.
2. Measure the resistance of the input speed sen-
sor.
Is the resistance within the values shown?Refer to Com-
ponent Resist-
ance ChartGo to Step 20Go to Step 22
17Measure the resistance between terminals 1 and 2
the transaxle wiring connector(transaxle output
speed sensor).
Is the resistance within the values shown?Refer to Com-
ponent Resist-
ance ChartGo to Step 19Go to Step 18
181. Disconnect the internal transaxle harness from
the transaxle output speed sensor.
2. Measure the resistance of the transaxle output
speed sensor.
Is the resistance within the values shown?Refer to Com-
ponent Resist-
ance ChartGo to Step 20Go to Step 22
19Measure the resistance between terminals of inter-
nal wiring harness.
Is the resistance within the values shown?Refer to Com-
ponent Resist-
ance ChartNo problem
found, exit
tableGo to Step 21

5A1 – 54IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
TRANSAXLE WIRING HARNESS
CONNECTOR
Wiring Harness Connector
Pin numberDescription
1Output Speed Sensor (+)
2Output Speed Sensor (–)
3Solenoid Valve (+)
4Transmission Fluid Temperature Sensor (–)
5Pressure Control Solenoid Valve (+)
6Pressure Control Solenoid Valve (EDS3)
7Pressure Control Solenoid Valve (EDS4)
8Not Used
9Transmission Fluid Temperature Sensor (+)
10Pressure Control Valve Solenoid Valve (EDS5)
11Pressure Control Valve Solenoid Valve (EDS6)
12Solenoid Valve 1
13Solenoid Valve 2
14Not Used
15Input Speed Sensor (–)
16Input Speed Sensor (+)
Component Resistance Chart
ComponentPass
Through
PinsResistance
20°C (68°F)
OhmsResistance w140°C
(212°F) Ohms
Solenoid 13, 1226.5± 0.5Ω26–345 Ω (not relative to temperature)
Solenoid 23, 1326.5± 0.5Ω26–345 Ω (not relative to temperature)
Pressure Control
Solenoid Valve (EDS3)5, 65.7± 0.45Ω5.3–6.3 Ω (not relative to temperature)
Pressure Control
Solenoid Valve (EDS4)5, 75.7± 0.45Ω5.3–6.3 Ω (not relative to temperature)
Pressure Control
Solenoid Valve (EDS5)5, 105.7± 0.45Ω5.3–6.3 Ω (not relative to temperature)

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 55
DAEWOO V–121 BL4
Component Resistance w140°C
(212°F) Ohms Resistance
20°C (68°F)
Ohms Pass
Through
Pins
Pressure Control
Solenoid Valve (EDS6)5, 115.7± 0.45Ω5.3–6.3 Ω (not relative to temperature)
Transaxle Temperature Sensor*4, 9980–1,000 Ω
Input Speed Sensor15, 16830 ± 5 Ω788–871 Ω (not relative to tempera-
ture)
Output Speed Sensor*1, 2


* The resistance of the transaxle is necessarily dependent on the temperature.

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.