aisin automatic transaxle DAEWOO LACETTI 2004 Service Owner's Guide

AISIN AUTOMATIC TRANSAXLE 5A2 – 27
DAEWOO V–121 BL4
WIRING HARNESS AND
CONNECTOR INSPECTION
1. Reproducing test
Perform symptom simulation test on the basis of
user’s condition. Refer to the below factors.
S Occuring–road condition, speed, accelerate,
reduce speed, straight, curve, air temperature,
weather, etc.
2. Inspect the connection condition of between con-
nectors.
Inspect the failure between connectors by visual
check and contact pressure check.
S Connector disconnected
S Terminals rusted
S Terminals deformation or loose fit
3. Inspect the Continuity of the wiring harness.
Disconnect both ends connector of wiring har-
ness, measure resistance between one connec-
tor terminal and other.
S Normal : 1Ω or less (No open circuit)
S Abnormal :
Ω (Open circuit)
Notice : Measure the resistance while slightly shaking
wire harness vertically and horizontally.
It is rare case wiring harness is broken at the middle of it,
and most cases occur at the connector.
4. Inspect the short circuit of the wiring harness.
Disconnect the connectors of the wiring harness
at both ends, measure resistance between the
applicable terminals of the connector and body
earth.
S Normal : 1M Ω or higher (No short circuit)
S Abnormal : Low resistance (Short circuit)Measure the resistance between one terminal
an another terminal in the same connector.(Ex-
cept between power supply or between earth).
S Normal : 1M Ω or higher (No short circuit)
S Abnormal : Low resistance (Short circuit)
Notice : Measure the wiring harness while slightly shaking
vertically and horzontally.
It is usual case of the short circuit that wiring harness is
crowded body and clamping failure.
5. Temporary connection failure of the connector.
It is thought that temporally the connection fail-
ure of the connector is cause when you can not
decide cause of DTC detection.
Therfore make sure to inspect and clean the
connector and delete the memorized DTC.
ROAD TEST
Road test is to diagnosis failure symptom accurately and
check the failure symptom after procedure.
Confirm whether below condition before road test. Oil tem-
perature is hot condition (50°C (122°F) ~ 80°C (176°F)).
1. D range test
S Check for up–shift, down–shift, kick–down and
lock–up operation at the shift point shown in the
shift schedule.
S Check for engine brake operation.
S Check for Check abnormal shock, noise and
harshness.
2. ”P” range test
Park vehicle on a gradient (more than 5°), shift
into the ”P” range and release parking brake.
Then, check to see no moving vehicle by opera-
tion of parking lock pawl.

5A2 – 28IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
FUNCTION CHECK
Confirm whether below condition before function check.
S Oil temperature is hot condition (50°C (122°F) ~
80°C (176°F)).
S Switch of A/C and light etc are off.
Stall Test
Stall test’ purpose is to inspect overall performance of A/T
and engine by measuring the stall speed in ”D” and ”R”
range.1. Chock 4 Wheels and apply parking brake fully, lock
vehicle perfectly.
2. Fully pressed on foot brake pedal with left foot.
3. Shift into ”D” and ”R” range, fully press on accelera-
tor pedal with right foot.
Quickly read stall speed at this time.
Standards
2390 ± 150 rpm
Notice : Do not continuously run longer than 5 sec be-
cause of extreme increasing oil temp.
Make sure to keep interval for more than 1 min between
stall tests.
Result of Stall Test
Cause of Failure
Lower than standards
both ”D” and ”R”Less engine power
Torque converter one way clutch failure
Higher than standards
only ”D”Lower line pressure
S Pressure control solenoid (PCS) failure
S Primary regulator valve failure
Forward clutch (C1) failure (Slipping)
No.2 One–way clutch (F2) failure
Higher than standards
only ”R”Lower line pressure
S Pressure control solenoid (PCS) failure
S Primary regulator valve failure
Reverse clutch (C3) failure (Slipping)
1st & reverse brake (B3) failure (Slipping)
Higher than standards
both ”D” and ”R”Lower line pressure
S Pressure control solenoid (PCS) failure
S Primary regulator valve failure
Oil pump failure
Oil strainer failure (clogging)
Oil leak for each range circuit
Time Lag Test
Time lag is time till slightly shock can be felt when shift le-
ver is shifted ”N”  ”D” and ”N”  ”R” while engine idling.
Time lag test can inspect hydraulic condition and clutch/
brake condition.
1. Chock 4 Wheels and apply parking brake fully, lock
vehicle perfectly.
2. Measure time lag by using stop watch from moment
when shift lever is shifted in ”N”  ”D” and ”N” 
”R” until moment slightly shock can be felt.”N  D”less than 0.7 sec
”N”  ”R”less than 1.2 sec
Notice : Make sure to take 3 measurement and take the
average value.
Make sure to keep interval for more than 1 min between
time lag tests. (That purpose is to remove clutch/brake
pressure was left unfinished.)

AISIN AUTOMATIC TRANSAXLE 5A2 – 29
DAEWOO V–121 BL4
Result of Time Lag TestCause of Failure
Longer than standards ”N”  ”D”Lower line pressure
S Pressure control solenoid (PCS) failure
S Primary regulator valve failure
Forward Clutch (C1) failure (Slipping)
Timing solenoid failure
Oil leak for ”D” range circuit
Longer than standards ”N”  ”R”Lower line pressure
S Pressure control solenoid (PCS) failure
S Primary regulator valve failure
Reverse clutch (C3) failure (slipping)
1st & reverse brake (B3) failure (slipping)
Oil leak for ”R” range circuit
Hydraulic Test
Hydraulic test can inspect working condition inside A/T by
measuring line pressure in ”D” / ”R” range and ”idle” / ”stall”
condition.
1. Chock 4 Wheels and apply parking brake fully, lock
vehicle perfectly.2. Install oil pressure gage adapter DW240–010–02 to
test hole for line pressure.
3. Fully pressed on foot brake pedal with left foot, shift
into ”D” and ”R” range and measure line pressure
”idle” / ”stall” condition.
Line pressure
Mpa (kgf/cm
2)
DR
Engine idle0.37 (3.9)
–0.14 (4.2)0.59 (6.0)
–0.68 (6.9)
Engine stall1.10 (11.3)
–1.23 (12.5)1.58 (16.2)
–1.83 (18.6)
Notice : Do not continuously run longer than 5 sec be-
cause of extreme increasing oil temp.
Make sure to keep interval for more than 1 min between
stall tests.
Make sure to check no oil leak after installing oil pressure
gage adapter.
Result of Hydraulic Test
Cause of Failure
Higher than standards
both ”D and ”R”Pressure control solenoid (PCS) failure
Primary regulator valve failure
Lower than standards
both ”D and ”R”Pressure control solenoid (PCS) failure
Primary regulator valve failure
Oil pump failure
Oil strainer failure (clogging)
Oil leak for each range circuit
Lower than standards
only ”D”D” hydraulic circuit failure
Forward clutch (C1) failure
Lower than standards
only ”R””R” hydraulic circuit failure
Reverse clutch (C3) failure
1st and reverse brake (B3) failure

5A2 – 30IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Manual Shifting Test
Manual shifting test is to determine whether failure symp-
tom is within electrical failure or mechanical failure.
1. Disconnect wire harness of shift solenoid, check
the range and gear positions correspond with below
table when driving by manual shifting.
Range
Gear
D3rd gear
RReverse
Notice : Make sure to disconnect only wire harness of shift
solenoid.
UNIT INSPECTION
Drive Plate Deflection
S Inspect drive plate deflection if within standard
value.
Standard Value
within 0.2mm (0.008 in)
Action :
Standard value is not within the specified value, replace
drive plate.
When ”abnormal wear” or ”stick” on torque converter
sleeve or oil pump is found, replace torque converter and
A/T.
Notice :
S When assembling torque converter and drive plate.
Be sure to use correct bolt with correct length. The
bolt pushes up torque converter front cover, and it
damages lock–up clutch lining. As a result, it cause
major failure ”No move”.
S Do not tighten the bolts by using impact wrench.
Cooler Pipe Bending and Choke
S Inspect it whether there is abnormal pipe bending in
the cooler pipe, pipe deformation and small cross–
section area of pipe line.
Action : Replace failure parts.S Apply compressed air of 2kg/cm
2 from cooler pipe
inlet side, inspect whether there is not cooler pipe
choke by confirming air flow smooth.
Action : Remove foreign particles and clean inside of pipe
line.
Normal
Vehicle Speed Sensor
1. Remove the connector of vehicle speed sensor,
connect 12V power supply and voltmeter to the ter-
minal.(Do not mistake polarity)
2. Check voltage change from approx. 0V to 12V with
vehicle speed sensor driven gear rotated.
Notice : The voltage change should be 4 times for 1 revo-
lution of the vehicle speed sensor driven gear.
Action : If the result of inspection is bad, replace the ve-
hicle speed sensor.

AISIN AUTOMATIC TRANSAXLE 5A2 – 31
DAEWOO V–121 BL4
Input Speed Sensor
S Inspect resistance of each input speed senor be-
tween terminals.
Notice :
S Make sure to inspect resistance again at 20°C
(68°F) when resistance differ from standards ex-
cept 20°C (68°F).
S It might become infinity ohm when inspect resist-
ance at higher temperature.
Action : If the result of inspection is bad, replace ISS.
Transmission Range (TR) Switch
S Remove TR switch connector and inspect continuty
each range according to the conection chart.
Action : If the result of inspection is bad, replace the TR
switch.
Transmission Fluid Temperature Sensor
S Inspect the resistance between the terminals of
TFT sensor at 10°C (50°F) and 110°C (230°F).
Standard Value
10°C (50°F)11 0°C (230°F)
5.80~7.09 kΩ0.23~0.263 kΩ
Action : If the result of inspection is bad, replace the TFT
sensor.

5A2 – 32IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Shift Solenoid (NO.1,2), Timing Solenoid,
Lock–Up Solenoid
1. Inspect the resistance of each shift solenoid be-
tween the terminal and the body earth.
Action : If the result of inspection is bad, replace each so-
lenoid.
Notice :
S Make sure to inspect resistance again at 20°C
(68°F) when resistance differ from standards ex-
cept 20°C (68°F).
S It might become infinity ohm when inspecting resist-
ance at higher temperature.
2. Inspect the operation of each shift solenoid.
S Solenoid (No.1,2), Lock–up solenoid (Normal
open type)
No battery connection
Leak air
Battery connectionNo leak air
S Timing solenoid (Normal close type)
No battery connection
No leak air
Battery connectionLeak air
Action : If the result of inspection is bad, replace the each
solenoid.
Notice : Do not damage the strainer on the tip of solenoid
while inspecting operation.
Pressure Control Solenoid
S Inspect the resistance of each pressure control so-
lenoid between terminals.
Action : Repalce the valve body assembly. (No replace-
ment of solenoid by itself)
Notice :
S Make sure to inspect resistance again at 20°C
(68°F) when resistance differ from standards ex-
cept 20°C (68°F).
S It might become infinity ohm when inspecting resist-
ance at higher temperature.

AISIN AUTOMATIC TRANSAXLE 5A2 – 33
DAEWOO V–121 BL4

5A2 – 34IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
ON–VEHICLE REPAIR (MATRIX CHART)

AISIN AUTOMATIC TRANSAXLE 5A2 – 35
DAEWOO V–121 BL4

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.