engine electrical DAEWOO LACETTI 2004 Service Repair Manual

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 205
DAEWOO V–121 BL4
7. Lower the vehicle.
8. Connect the transaxle wiring harness and the PNP
switch electrical connector.
9. Refill the transaxle fluid. Refer to ”Transaxle Fluid
Level Checking Procedure” in this section.
10. Connect the negative battery cable.
LEFT TRANSAXLE MOUNTING
BRACKET
Tools Required
DW110–060 Engine Support Fixture
Removal Procedure
1. Remove the battery. Refer to Section 1E, Engine
Electrical.
2. Install the engine support fixture DW110–060.
3. Remove the left transaxle mounting bolts.
4. Remove the left transaxle mount bracket cage bolts
and nut.
5. Remove the transaxle mounting bracket.

5A1 – 206IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Installation Procedure
1. Install the left transaxle mount bracket cage bolts
and nut.
Tighten
S Tighten the left transaxle mount bracket cage
bolt (a) to 110 NSm (81 lb–ft).
S Tighten the left transaxle mount bracket cage
bolt (b) to 65 NSm (48 lb–ft).
S Tighten the nut (c) to 65 NSm (48 lb–ft).
2. Install the left transaxle mounting bolts to 48 NSm
(35 lb–ft).
3. Remove the engine support fixture DW110–060.
4. Install the battery. Refer to Section 1E, Engine
Electrical.
TRANSAXLE ASSEMBLY
Tools Required
DW110–060 Engine Support Fixture
DW260–010 Transaxle Support Fixture
Removal Procedure
1. Disconnect the negative battery cable.
2. Position the select lever park position.
3. Remove the battery. Refer to Section 1E, Engine
Electrical.
4. Install the engine support fixture DW110–060.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 211
DAEWOO V–121 BL4
12. Install the upper transaxle–to–engine bolts.
Tighten
Tighten the upper transaxle–to–engine bolts to 75
NSm (55 lb–ft).
13. Install the clips to the shift control cable and con-
nect the shift cable.
14. Install the park/neutral position switch electrical
connector.
15. Connect the transaxle wiring harness to the trans-
axle.
16. Remove the engine support fixture DW110–060.
17. Install the battery. Refer to Section 1E, Engine
Electrical.
18. Add the transaxle fluid. Refer to ”Transaxle Fluid
Level Checking Procedure” in this section.
19. Connect the negative battery cable.

SECTION : 5A2
AISIN AUTOMATIC TRANSAXLE
CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool
or equipment could easily come in contact with exposed electrical erminals. Disconnecting this cable will help
prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
TABLE OF CONTENTS
SPECIFICATIONS5A2–3 . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 5A2–3. . . . . . . . . . . . . . . . . . . .
Transaxle Gear Ratio 5A2–3. . . . . . . . . . . . . . . . . . . . . .
Fluid Capacity 5A2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line Pressure Specification 5A2–3. . . . . . . . . . . . . . . .
Fastener Tightening Specifications 5A2–4. . . . . . . . . .
SPECIAL TOOLS5A2–5 . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 5A2–5. . . . . . . . . . . . . . . . . . . . . . .
SCHEMATIC DIAGRAMS5A2–8 . . . . . . . . . . . . . . . . . . .
Transmission Control Module (1 of 4) 5A2–8. . . . . . . .
Transmission Control Module (2 of 4) 5A2–9. . . . . . . .
Transmission Control Module (3 of 4) 5A2–10. . . . . . .
Transmission Control Module (4 of 4) 5A2–11. . . . . . .
Shift Mode Diagram 5A2–12. . . . . . . . . . . . . . . . . . . . . .
COMPONENT LOCATOR5A2–17 . . . . . . . . . . . . . . . . . .
Shift Select Control 5A2–17. . . . . . . . . . . . . . . . . . . . . .
Automatic Transaxle Components 5A2–18. . . . . . . . .
Bearing and Races Installation Position
Direction 5A2–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS5A2–25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Connector View 5A2–25. . . . . . . . . . . . . . . . .
Wiring Harness and Connector Inspection 5A2–27. . .
Road Test 5A2–27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function Check 5A2–28. . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Inspection 5A2–30. . . . . . . . . . . . . . . . . . . . . . . . . .
On–Vehicle Repair (Matrix Chart) 5A2–34. . . . . . . . . .
DIAGNOSIS TROUBLE CODE DIAGNOSIS5A2–36 .
Diagnosis Trouble Code Chart 5A2–36. . . . . . . . . . . . .
DTC P0562 System Voltage Low 5A2–37. . . . . . . . . .
DTC P0563 System Voltage High 5A2–40. . . . . . . . . .
DTC P0601 Internal Control Module Memory
Checksum Error 5A2–43. . . . . . . . . . . . . . . . . . . . . . .
DTC P0604 Internal Transmission Control Module
(TCM) Random Access Memory (RAM)
Error 5A2–45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0705 Transmission Range (TR) Switch
Circuit Malfunction 5A2–47. . . . . . . . . . . . . . . . . . . . .
DTC P0712 Transmission Fluid Temperature
(TFT) Sensor Circuit Low Input 5A2–50. . . . . . . . . .
DTC P0713 Transmission Fluid Temperature
(TFT) Sensor Circuit High Input 5A2–53. . . . . . . . . .
DTC P0717 Input Shaft Speed (ISS) Sensor
Circuit No Signal 5A2–56. . . . . . . . . . . . . . . . . . . . . . .
DTC P0722 Ouput Shaft Speed (OSS) Sensor
Circuit No Signal 5A2–59. . . . . . . . . . . . . . . . . . . . . . .
DTC P0727 Engine Speed Input Circuit No
Signal 5A2–62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0741 Torque Converter Clutch (TCC)
Circuit Stuck Off 5A2–65. . . . . . . . . . . . . . . . . . . . . . .
DTC P0742 Torque Converter Clutch (TCC)
Circuit Stuck On 5A2–67. . . . . . . . . . . . . . . . . . . . . . .
DTC P0743 Torque Converter Clutch (TCC)
Electrical 5A2–69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0748 Pressure Control Solenoid (PCS)
Electrical 5A2–72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0751 Shift Solenoid 1 (SS1) Stuck Off 5A2–75
DTC P0753 Shift Solenoid 1 (SS1) Electrical 5A2–77
DTC P0756 Shift Solenoid 2 (SS2) Stuck Off 5A2–80
DTC P0758 Shift Solenoid 2 (SS2) Electrical 5A2–82
DTC P0785 Timing Solenoid (ST) Electrical 5A2–85.
DTC P1781 Engine Torque Signal Error 5A2–88. . . . .
DTC P1791 Throttle Position Signal Error 5A2–91. . .
DTC P1792 Engine Coolant Temperature (ECT)
Signal Error 5A2–93. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC U2105 Can Error 5A2–95. . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR5A2–97 . . . . . . . . . . . . .
ON–VEHICLE SERVICE 5A2–97. . . . . . . . . . . . . . . . . . .
Transaxle Fluid Level Checking Procedure 5A2–97. .
Fluid Drain Procedure 5A2–97. . . . . . . . . . . . . . . . . . . .
Locating Fluid Leaks 5A2–98. . . . . . . . . . . . . . . . . . . . .
Case Porosity Repair 5A2–98. . . . . . . . . . . . . . . . . . . . .
Fluid Cooler Flushing 5A2–99. . . . . . . . . . . . . . . . . . . . .
Control Cable Adjustment 5A2–99. . . . . . . . . . . . . . . . .

5A2 – 36IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
DIAGNOSTIC TROUBLE CODE DIAGNOSIS
DIAGNOSTIC TROUBLE CODE CHART
DTCDESCRIPTIONTYPEIlluminate
MILBlink
Hold
Lamp
P0562System Voltage LowBYe sNo
P0563System Voltage HighBYe sNo
P0601Internal Control Module Memory Checksum ErrorAYe sNo
P0604Internal Transmission Control Module (TCM) Random Access
Memory (RAM) ErrorBYe sNo
P0705Transmission Range (TR) Switch Circuit MalfunctionBYe sNo
P0712Transmission Fluid Temperature Sensor Circuit Low InputAYe sNo
P0713Transmission Fluid Temperature Sensor Circuit High InputAYe sNo
P0717Input Shaft Speed (ISS) Sensor Circuit No SignalAYe sNo
P0722Output Shaft Speed (OSS) sensor Circuit No SignalAYe sNo
P0727Engine Speed Input Circuit No SignalAYe sNo
P0741Torque Converter Clutch (TCC) Circuit Stuck OffBYe sNo
P0742Torque Converter Clutch (TCC) Circuit Stuck OnBYe sNo
P0743Torque Converter Clutch (TCC) ElectricalBYe sNo
P0748Pressure Control Solenoid (PCS) ElectricalAYe sNo
P0751Shift Solenoid 1 (SS1) Stuck OffBYe sNo
P0753Shift Solenoid 1 (SS1) ElectricalAYe sNo
P0756Shift Solenoid 2 (SS2) Stuck OffBYe sNo
P0758Shift Solenoid 2 (SS2) ElectricalAYe sNo
P0785Timing Solenoid (ST) ElectricalAYe sNo
P1781Engine Torque Signal ErrorAYe sNo
P1791Throttle Position Signal ErrorAYe sNo
P1792Engine Coolant Temperature (ECT) Signal ErrorDNoNo
U2105CAN ErrorAYe sNo
* Description of Type
S Type A : TCM will request the illumination of MIL and store DTC when TCM detects a failure on the first ignition
cycle.
S Type B : TCM will request the illumination of MIL and store DTC when TCM detects failures on two consecutive
ignition cycle.
S Type D : TCM will not request the illumination of MIL or hold lamp, but will store DTC when TCM detects a failure
on the first ignition cycle.

AISIN AUTOMATIC TRANSAXLE 5A2 – 65
DAEWOO V–121 BL4
DIAGNOSTIC TROUBLE CODE (DTC) P0741
TORQUE CONVERTER CLUTCH (TCC) CIRCUIT STUCK
OFF
Conditions for Setting the DTC
S Lockup solenoid is stuck OFF.
S D range selected
S Engine water normal temperature
S 20 seconds have passed since the transaxle was
placed in D.
S Engine revolution is 600 rpm or greater.
S No failure of input speed sensor / engine revolution
/ water temperature signal / solenoid electrical /
ranger sensor / throttle signal
Action Taken When the DTC Sets
S TCM will request the illumination of MIL and store
DTC when TCM detects failures on two consecu-
tive ignition cycles.Conditions for Clearing the DTC
S The TCM turns off the MIL when no further failures
detected for three consecutive ignition cycles.
S The scan tool can clear the DTC from the TCM his-
tory.
S The TCM clears the DTC from the TCM history
memory after forty consecutive warm up cycles
without fault.
Cause of Failure
S Lockup solenoid
S Inside A/T
S Inside valve body
S TCM

AISIN AUTOMATIC TRANSAXLE 5A2 – 67
DAEWOO V–121 BL4
DIAGNOSTIC TROUBLE CODE (DTC) P0742
TORQUE CONVERTER CLUTCH (TCC) CIRCUIT STUCK
ON
Conditions for Setting the DTC
S Lockup solenoid is stuck ON.
S D range selected
S Engine water normal temperature
S 20 seconds have passed since the transaxle was
placed in D.
S Engine revolution is 600 rpm or greater.
S No failure of input speed sensor / engine revolution
/ water temperature signal / solenoid electrical /
ranger sensor / throttle signal
Action Taken When the DTC Sets
S TCM will request the illumination of MIL and store
DTC when TCM detects failures on two consecu-
tive ignition cycles.Conditions for Clearing the DTC
S The TCM turns off the MIL when no further failures
detected for three consecutive ignition cycles.
S The scan tool can clear the DTC from the TCM his-
tory.
S The TCM clears the DTC from the TCM history
memory after forty consecutive warm up cycles
without fault.
Cause of Failure
S Lockup solenoid
S Inside A/T
S Inside valve body
S TCM

5A2 – 70IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
DTC P0743 Torque Converter Clutch (TCC) Electrical
StepActionValue(s)YesNo
11. Turn the ignition OFF.
2. Install the Scan tool.
3. With the engine OFF, turn the ignition switch to
the ON position.
4. Select Store Freeze Frame/Failure Records
from the Diagnostic Trouble Codes Information
menu.
5. Store Freeze Frame/Failure Records.
6. Select Clear DTC Information from the Diag-
nostic Trouble Codes Information menu.
7. Clear DTC Information.
8. Perform two vehicle drive cycles.
Is the Malfunction Indicator Lamp (MIL) ON?–Go to Step 2Repair the tem-
porary connec-
tion failure of
connector (Re-
fer to ”Wiring
Harness and
Connector In-
spection” in this
section.)
21. Select Request DTC by Status from the Diag-
nostic Trouble Codes Information menu.
2. Request DTC by Status.
Is DTC P0743 displayed?–Go to Step 3Repair the tem-
porary connec-
tion failure of
connector (Re-
fer to ”Wiring
Harness and
Connector In-
spection” in this
section.)
31. Turn the ignition OFF.
2. Inspect the resistance between the vehicle har-
ness and lock–up solenoid. Refer to ”Unit In-
spection” in this section.
3. Disconnect the TCM connector (X–1) and in-
spect the resistance between the terminal A5
and A23.
Is the measurement within the specified value?20°C (68°F)
11–16 WGo to Step 4Go to Step 5
41. Estimate the failure of between the vehicle wir-
ing harness connector and TCM.
2. Inspect the connector. Refer to ”Wiring Har-
ness and Connector Inspection” in this section.
3. Inspect the connection condition between the
connectors (C–1).
Is the connection condition OK?–Go to Step 6Repair the wir-
ing harness
connectors.
51. Estimate the failure of between the vehicle har-
ness and lockup solenoid.
2. Disconnect the connector (X–3) of T/M wire
and inspect the resistance between lock–up
solenoid connector terminal 4 and ground.
Is the measurement within the specified value?20°C (68°F)
11–16 WGo to Step 7Go to Step 8
61. Replace the master TCM.
2. Perform the reproducing test under user condi-
tion after confirming no DTC.
Is DTC displayed?–Repair the tem-
porary connec-
tion failure of
connector (Re-
fer to ”Wiring
Harness and
Connector In-
spection” in this
section.)Replace the
TCM

5A2 – 72IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
DIAGNOSTIC TROUBLE CODE (DTC) P0748
PRESSURE CONTROL SOLENOID (PCS) ELECTRICAL
Conditions for Setting the DTC
S TCM detects that the feed back voltage is greater
than 4.9 volts and detects the detection 500 milli-
seconds continuously.(When the PCS circuit is
short to battery).
S TCM detects that the feed back voltage is less than
70.mV for 70 milliseconds and detects the 12.5
seconds continuously.(When the PCS circuit is
short to ground or open).
Action Taken When the DTC Sets
S TCM will request the illumination of MIL and store
DTC when TCM detects a failure on the first ignition
cycle.
S No lockup control
S No engine torque reduction control
S No engagement pressure control
S No 4th gearS No self–learning control
S After failure decision : emergency mode
Conditions for Clearing the DTC
S The TCM turns off the MIL when no further failures
detected for three consecutive ignition cycles.
S The scan tool can clear the DTC from the TCM his-
tory.
S The TCM clears the DTC from the TCM history
memory after forty consecutive warm up cycles
without fault.
S TCM detects the feed back voltage is between
70mV and 4.9 v for 12.5 seconds continuously.
Cause of Failure
S Wiring harness or connector between Pressure
Control Solenoid (PCS) and TCM
S PCS
S TCM

AISIN AUTOMATIC TRANSAXLE 5A2 – 73
DAEWOO V–121 BL4
DTC P0748 Pressure Control Solenoid (PCS) Electrical
StepActionValue(s)YesNo
11. Turn the ignition OFF.
2. Install the Scan tool.
3. With the engine OFF, turn the ignition switch to
the ON position.
4. Select Store Freeze Frame/Failure Records
from the Diagnostic Trouble Codes Information
menu.
5. Store Freeze Frame/Failure Records.
6. Select Clear DTC Information from the Diag-
nostic Trouble Codes Information menu.
7. Clear DTC Information.
8. Perform one vehicle drive cycle.
Is the Malfunction Indicator Lamp (MIL) ON?–Go to Step 2Repair the tem-
porary connec-
tion failure of
connector (Re-
fer to ”Wiring
Harness and
Connector” in
this section.)
21. Select Request DTC by Status from the Diag-
nostic Trouble Codes Information menu.
2. Request DTC by Status.
Is DTC P0748 displayed?–Go to Step 3Repair the tem-
porary connec-
tion failure of
connector (Re-
fer to ”Wiring
Harness and
Connector” in
this section.)
31. Turn the ignition OFF.
2. Inspect the resistance between the vehicle har-
ness and Pressure Control Solenoid (PCS).
Refer to ”Unit Inspection” in this section.
3. Disconnect the TCM connector (X–1) and in-
spect the resistance between the terminal A4
and A2.
Is the measurement within the specified value?20°C (68°F)
5.0–5.6 WGo to Step 4Go to Step 5
41. Estimate the failure of between the vehicle wir-
ing harness connector and TCM.
2. Inspect the connector. Refer to ”Wiring Har-
ness and Connector” in this section.
3. Inspect the connection condition between the
connectors (C–1).
Is the connection condition OK?–Go to Step 6Repair the wir-
ing harness
connectors.
51. Estimate the failure of between the vehicle har-
ness and PCS.
2. Disconnect the connector (X–3) of T/M wire
and inspect the resistance between PCS con-
nector terminal 3 and 8.
Is the measurement within the specified value?20°C (68°F)
5.0–5.6 WGo to Step 7Go to Step 8
61. Replace the master TCM.
2. Perform the reproducing test under user condi-
tion after confirming no DTC.
Is DTC displayed?–Repair the tem-
porary connec-
tion failure of
connector (Re-
fer to ”Wiring
Harness and
Connector” in
this section.)Replace the
TCM