engine DAEWOO NUBIRA 2004 Service Repair Manual

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 193
DAEWOO V–121 BL4
Repairing the Fluid Leak
The following are potential causes for fluid leaks. Check
and repair, as necessary.
S Fasteners are not tightened to specifications.
S Fastener threads and tapped holes are dirty or cor-
roded.
S Gaskets, seals or sleeves are misaligned, dam-
aged, or warped, or scratched.
S The manual shaft is nicked or damaged.
S There is a loose or worn bearing causing excess
seal or sleeve wear.
S Case or component porosity.
S The fluid level is too high.
S There is a plugged vent or a damaged vent tube.
S There is water or coolant in the fluid.
S Fluid drain back holes are plugged.
CASE POROSITY REPAIR
CAUTION : Epoxy adhesive may cause skin irritations
and eye damage. Read and follow all information on
the container label as provided by the manufacturer.
1. Thoroughly clean the area to be repaired with a
cleaning solvent. Air dry the area.
2. Using instructions from the manufacturer, mix a
sufficient amount of epoxy to make the repair.
3. While the transaxle case is still hot, apply the
epoxy. You can use a clean, dry soldering acid
brush to clean the area and also apply the epoxy
cement. Make certain that the area to be repaired is
fully covered.
4. Allow the epoxy cement to dry for 3 hours before
starting the engine.
5. Repeat the fluid leak diagnosis procedures. Refer
to ”Fluid Leak Diagnosis and Repair” in this sec-
tion.
SHIFT CONTROL LEVER ASSEMBLY
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the floor console. Refer to Section 9G,
Interior Trim.
3. Disconnect the electrical switch connectors.

5A1 – 196IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Installation Procedure
1. Install the shift control cable into the fire wall of the
vehicle.
2. Install the shift control cable onto the transaxle
mount.
3. Install the shift control cable onto the shift control
assembly.
4. Install the shift control cable adjuster pinch nut.
Tighten
Tighten the nut to 8 NSm (71 lb–in).
5. Install the clip to the shift control cable at the trans-
axle mount connection.
6. Install the clip to the select lever connection on the
transaxle case.
7. Adjust the shift control cable. Refer to ”Shift Control
Cable Adjustment” in this section.
8. Connect the negative battery cable.
SHIFT CONTROL CABLE
ADJUSTMENT
Adjustment Procedure
It is very important to match the shift control lever correctly
with the selector lever connection. Place the shift control
lever in the P position and check the selector lever connec-
tion to see if it is all the way forward. If it is not, proceed with
the following adjustment.
1. Remove the battery and battery tray. Refer to Sec-
tion 1E, Engine Electrical.
2. Remove the floor console. Refer to Section 9G,
interior Trim.

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3. Place the shift control lever in the P position.
4. Loosen the pinch bolt nut on the shift control lever.
5. Place the selector lever connection all the way for-
ward on the transaxle case.
6. Insert the shift control cable into the shift control
lever tightly.
7. Secure the shift control cable with the shift control
cable adjuster pinch bolt and nut.
Tighten
Tighten the nut to 8 NSm (71 lb–in).
8. Install the floor console.
9. Install the battery and the battery tray. Refer to
Section 1E, Engine Electrical.
TRANSAXLE CONTROL
MODULE(TCM)
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the wiring connectors.
3. Remove the transaxle control module(TCM) from
the bracket.
Installation Procedure
1. Install the TCM into the bracket.
2. Connect the wiring connectors.
3. Connect the negative battery cable.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 199
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3. Install the shift lever and the shift lever nut.
Tighten
Tighten the shift lever nut to 10 NSm (89 lb–in).
4. Connect the shift control cable and the retaining
clip.
5. Connect the park/neutral position switch electrical
connector.
6. Connect the negative battery cable.
OIL COOLER PIPES/HOSES
Removal Procedure
Important : Place a drip pan under the hoses to catch the
fluid that will run out of the lines.
1. Disconnect the negative battery cable.
2. Raise and suitably support the vehicle.
3. Remove the engine under cover. Refer to Section
9N, Frame and Underbody.
4. Remove the oil cooler outlet pipe bolt from the right
lower side of the radiator.
5. Remove the oil cooler outlet pipe bracket bolt.
6. Remove the oil cooler outlet pipe bolt from the
transaxle side.
7. Remove the oil cooler outlet pipe assembly.

5A1 – 200IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
8. Remove the oil cooler inlet pipe bolt from the left
lower side of the radiator.
9. Remove the oil cooler inlet pipe bolt from the trans-
axle side.
10. Remove the oil cooler inlet pipe assembly.
Installation Procedure
1. Install the oil cooler inlet pipe assembly and the
bolts.
Tighten
Tighten the oil cooler inlet pipe bolts to 35 NSm (26 lb–
ft).
2. Install the oil cooler outlet pipe assembly and the
bolts.
Tighten
Tighten the oil cooler outlet pipe bolts to 35 NSm (26
lb–ft).
3. Refill the transaxle fluid. Refer to ”Transaxle Fluid
Checking Procedure” in this section.
4. Install the engine under cover. Refer to Section 9N,
Frame and Underbody.
5. Connect the negative battery cable.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 201
DAEWOO V–121 BL4
DRIVE AXLE OIL SEAL
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the drive axles. Refer to Section 3A, Auto-
matic Transaxle Drive Axle.
Notice : Be careful not to damage the bore of the transaxle
case.
3. Remove the transaxle drive seal using a screwdriv-
er. If necessary, crush the seal first with the screw-
driver in order to loosen the seal from the case.
Tools Required
DW260–030 Axle Seal Installer
Installation Procedure
1. Install the transaxle drive seal using the axle seal
installer DW260–030.
2. Install the drive axles. Refer to Section 3A, Auto-
matic Transaxle Drive Axle.
3. Connect the negative battery cable.
OIL PAN, OIL PAN GASKET
Tools Required
DW260–070 Plug Remover/Installer
Removal Procedure
1. Disconnect the negative battery cable.
2. Raise and suitably support the vehicle.
3. Remove the engine under cover. Refer to Section
9N, Frame and Underbody.
4. Place a fluid container below the fluid drain plug.
5. Remove the transaxle fluid drain plug using the
plug remover/installer DW260–070 and drain the
transaxle fluid.
6. Remove the oil cooler inlet and outlet pipes. Refer
to ”Oil Cooler Pipe/Hose” in this section.

5A1 – 202IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
7. Remove the oil pan and oil pan gasket.
Installation Procedure
1. Install the oil pan, oil pan gasket and bolts.
Tighten
Tighten the oil pan bolts to 6 NSm (53 lb–in).
2. Install the oil cooler inlet and outlet pipes. Refer
to”Oil Cooler Pipe/Hose” in this section.
3. Install the transaxle fluid drain plug using the plug
remove/installer DW260–070.
4. Install the engine under cover. Refer to Section 9N,
Frame and Underbody.
5. Refill the transaxle fluid. Refer to ”Transaxle Fluid
Level Checking Procedure” in this section.
6. Connect the negative battery cable.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 203
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CONTROL VALVE BODY ASSEMBLY
Tools Required
DW260–070 Plug Remover/Installer
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the transaxle wiring harness and the
park/neutral position switch electrical connector.
3. Raise and suitably support the vehicle.
4. Remove the engine under cover. Refer to Section
9N, Frame and Underbody.
5. Remove the transaxle fluid drain plug using the
plug remover/installer DW260–070 and drain the
transaxle fluid.
6. Remove the oil pan, oil pan gasket. Refer to ”Oil
Pan, Oil Pan Gasket” in this section.
7. Remove the valve body mounting bolts.
8. Remove the automatic transmission input speed
sensor mounting bolt.
9. Remove the automatic transmission output speed
sensor mounting bolt.

5A1 – 204IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
10. Remove the control valve body.
Installation Procedure
1. Install the control valve body and the bolts.
Tighten
Tighten the valve body mounting bolts to 8 NSm (71
lb–in).
2. Install the input speed sensor mounting bolt.
Tighten
Tighten the input speed sensor mounting bolt to 8
NSm (71 lb–in).
3. Install the output speed sensor mounting bolt.
Tighten
Tighten the output speed sensor mounting bolt to 6
NSm (53 lb–in).
4. Install the oil pan and oil pan gasket. Refer to ”Oil
Pan Gasket” in this section.
5. Install the transaxle fluid drain plug using the plug
remove/installer DW260–070.
6. Install the engine under cover. Refer to Section 9N,
Frame and Underbody.

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.