manual transmission DAEWOO NUBIRA 2004 Service User Guide

5A1 – 180IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
RangePark/
Neutr
alRever
seD321
GearNR1st2nd3rd4th1st2nd3rd1st2nd1st
Solenoid Valve
1ONON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFF
Solenoid Valve
2ONONONOFFOFFOFFONOFFOFFONOFFON
Line Pressure
Control Sole-
noid Valve 3
(EDS 3)OFFOFFOFFONON/
OFFON/
OFFOFFONON/
OFFOFFONOFF
Line Pressure
Control Sole-
noid Valve 4
(EDS 4)ONOFFONONONOFFONONONONONON
Line Pressure
Control Sole-
noid Valve 5
(EDS 5)OFFOFFONONOFFOFFONONOFFONONON
Line Pressure
Control Sole-
noid Valve 6
(EDS 6)ONOFFONONONOFFONONONONONON
Brake BAAAAAAAA
Brake CH
Brake DH
Clutch EAAAAAA
Brake FHHHHHHH
Lock–up
ClutchA
A = Applied
H = Holding
ON = The solenoid is energized.
OFF = The solenoid is de–energized.
** = Manual Second–Third gear is only available above approximately 100 km/h (62 mph).
*** = Manual First–Second gear is only available above approximately 60 km/h (37 mph).
Note : Manual First–Third gear is also possible at high vehicle speed as a safety feature.
DIAGNOSTIC TROUBLE CODE(DTC) P1881
2–1 SHIFT MALFUNCTION
Circuit Description
The special feature of 4HP 16 Auto Transaxle is that it op-
erates without freewheels. Shifting between individual
gears takes place by means of overlapping clutch engage-
ment and release.
The advantage of overlap shifting are as follows:
– The transaxle can be of more compact design
and is lighter on account of the absence of free-
wheels and the lower number of shift elements.– Lower drag losses, i.e. higher efficiency.
– Lower peak torque acting on the components and
driveline.
However, overlap shifting necessitates high–performance
hardware and software, and precision engine signals.
Conditions for Setting the DTC
S Transmission oil temperature is greater than –10°C
(14°F).
S Selector lever is not in N(Neutral), P(Park) position.
S System voltage is greater than 9 volts.

5A1 – 182IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
RangePark/
Neutr
alRever
seD321
GearNR1st2nd3rd4th1st2nd3rd1st2nd1st
Solenoid Valve
1ONON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFF
Solenoid Valve
2ONONONOFFOFFOFFONOFFOFFONOFFON
Line Pressure
Control Sole-
noid Valve 3
(EDS 3)OFFOFFOFFONON/
OFFON/
OFFOFFONON/
OFFOFFONOFF
Line Pressure
Control Sole-
noid Valve 4
(EDS 4)ONOFFONONONOFFONONONONONON
Line Pressure
Control Sole-
noid Valve 5
(EDS 5)OFFOFFONONOFFOFFONONOFFONONON
Line Pressure
Control Sole-
noid Valve 6
(EDS 6)ONOFFONONONOFFONONONONONON
Brake BAAAAAAAA
Brake CH
Brake DH
Clutch EAAAAAA
Brake FHHHHHHH
Lock–up
ClutchA
A = Applied
H = Holding
ON = The solenoid is energized.
OFF = The solenoid is de–energized.
** = Manual Second–Third gear is only available above approximately 100 km/h (62 mph).
*** = Manual First–Second gear is only available above approximately 60 km/h (37 mph).
Note : Manual First–Third gear is also possible at high vehicle speed as a safety feature.
DIAGNOSTIC TROUBLE CODE(DTC) P1883
3–2 SHIFT MALFUNCTION
Circuit Description
The special feature of 4HP 16 Auto Transaxle is that it op-
erates without freewheels. Shifting between individual
gears takes place by means of overlapping clutch engage-
ment and release.
The advantage of overlap shifting are as follows:
– The transaxle can be of more compact design
and is lighter on account of the absence of free-
wheels and the lower number of shift elements.– Lower drag losses, i.e. higher efficiency.
– Lower peak torque acting on the components and
driveline.
However, overlap shifting necessitates high–performance
hardware and software, and precision engine signals.
Conditions for Setting the DTC
S Transmission oil temperature is greater than –10°C
(14°F).
S Selector lever is not in N(Neutral), P(Park) position.
S System voltage is greater than 9 volts.

5A1 – 184IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
RangePark/
Neutr
alRever
seD321
GearNR1st2nd3rd4th1st2nd3rd1st2nd1st
Solenoid Valve
1ONON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFF
Solenoid Valve
2ONONONOFFOFFOFFONOFFOFFONOFFON
Line Pressure
Control Sole-
noid Valve 3
(EDS 3)OFFOFFOFFONON/
OFFON/
OFFOFFONON/
OFFOFFONOFF
Line Pressure
Control Sole-
noid Valve 4
(EDS 4)ONOFFONONONOFFONONONONONON
Line Pressure
Control Sole-
noid Valve 5
(EDS 5)OFFOFFONONOFFOFFONONOFFONONON
Line Pressure
Control Sole-
noid Valve 6
(EDS 6)ONOFFONONONOFFONONONONONON
Brake BAAAAAAAA
Brake CH
Brake DH
Clutch EAAAAAA
Brake FHHHHHHH
Lock–up
ClutchA
A = Applied
H = Holding
ON = The solenoid is energized.
OFF = The solenoid is de–energized.
** = Manual Second–Third gear is only available above approximately 100 km/h (62 mph).
*** = Manual First–Second gear is only available above approximately 60 km/h (37 mph).
Note : Manual First–Third gear is also possible at high vehicle speed as a safety feature.
DIAGNOSTIC TROUBLE CODE(DTC) P1884
4–3 SHIFT MALFUNCTION
Circuit Description
The special feature of 4HP 16 Auto Transaxle is that it op-
erates without freewheels. Shifting between individual
gears takes place by means of overlapping clutch engage-
ment and release.
The advantage of overlap shifting are as follows:
– The transaxle can be of more compact design
and is lighter on account of the absence of free-
wheels and the lower number of shift elements.– Lower drag losses, i.e. higher efficiency.
– Lower peak torque acting on the components and
driveline.
However, overlap shifting necessitates high–performance
hardware and software, and precision engine signals.
Conditions for Setting the DTC
S Transmission oil temperature is greater than –10°C
(14°F).
S Selector lever is not in N(Neutral), P(Park) position.
S System voltage is greater than 9 volts.

5A1 – 186IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
RangePark/
Neutr
alRever
seD321
GearNR1st2nd3rd4th1st2nd3rd1st2nd1st
Solenoid Valve
1ONON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFF
Solenoid Valve
2ONONONOFFOFFOFFONOFFOFFONOFFON
Line Pressure
Control Sole-
noid Valve 3
(EDS 3)OFFOFFOFFONON/
OFFON/
OFFOFFONON/
OFFOFFONOFF
Line Pressure
Control Sole-
noid Valve 4
(EDS 4)ONOFFONONONOFFONONONONONON
Line Pressure
Control Sole-
noid Valve 5
(EDS 5)OFFOFFONONOFFOFFONONOFFONONON
Line Pressure
Control Sole-
noid Valve 6
(EDS 6)ONOFFONONONOFFONONONONONON
Brake BAAAAAAAA
Brake CH
Brake DH
Clutch EAAAAAA
Brake FHHHHHHH
Lock–up
ClutchA
A = Applied
H = Holding
ON = The solenoid is energized.
OFF = The solenoid is de–energized.
** = Manual Second–Third gear is only available above approximately 100 km/h (62 mph).
*** = Manual First–Second gear is only available above approximately 60 km/h (37 mph).
Note : Manual First–Third gear is also possible at high vehicle speed as a safety feature.
DIAGNOSTIC TROUBLE CODE(DTC) P1885
3–1 SHIFT MALFUNCTION
Circuit Description
The special feature of 4HP 16 Auto Transaxle is that it op-
erates without freewheels. Shifting between individual
gears takes place by means of overlapping clutch engage-
ment and release.
The advantage of overlap shifting are as follows:
– The transaxle can be of more compact design
and is lighter on account of the absence of free-
wheels and the lower number of shift elements.– Lower drag losses, i.e. higher efficiency.
– Lower peak torque acting on the components and
driveline.
However, overlap shifting necessitates high–performance
hardware and software, and precision engine signals.
Conditions for Setting the DTC
S Transmission oil temperature is greater than –10°C
(14°F).
S Selector lever is not in N(Neutral), P(Park) position.
S System voltage is greater than 9 volts.

5A1 – 188IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
RangePark/
Neutr
alRever
seD321
GearNR1st2nd3rd4th1st2nd3rd1st2nd1st
Solenoid Valve
1ONON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFFON/
OFF
Solenoid Valve
2ONONONOFFOFFOFFONOFFOFFONOFFON
Line Pressure
Control Sole-
noid Valve 3
(EDS 3)OFFOFFOFFONON/
OFFON/
OFFOFFONON/
OFFOFFONOFF
Line Pressure
Control Sole-
noid Valve 4
(EDS 4)ONOFFONONONOFFONONONONONON
Line Pressure
Control Sole-
noid Valve 5
(EDS 5)OFFOFFONONOFFOFFONONOFFONONON
Line Pressure
Control Sole-
noid Valve 6
(EDS 6)ONOFFONONONOFFONONONONONON
Brake BAAAAAAAA
Brake CH
Brake DH
Clutch EAAAAAA
Brake FHHHHHHH
Lock–up
ClutchA
A = Applied
H = Holding
ON = The solenoid is energized.
OFF = The solenoid is de–energized.
** = Manual Second–Third gear is only available above approximately 100 km/h (62 mph).
*** = Manual First–Second gear is only available above approximately 60 km/h (37 mph).
Note : Manual First–Third gear is also possible at high vehicle speed as a safety feature.
DIAGNOSTIC TROUBLE CODE(DTC) P1886
4–2 SHIFT MALFUNCTION
Circuit Description
The special feature of 4HP 16 Auto Transaxle is that it op-
erates without freewheels. Shifting between individual
gears takes place by means of overlapping clutch engage-
ment and release.
The advantage of overlap shifting are as follows:
– The transaxle can be of more compact design
and is lighter on account of the absence of free-
wheels and the lower number of shift elements.– Lower drag losses, i.e. higher efficiency.
– Lower peak torque acting on the components and
driveline.
However, overlap shifting necessitates high–performance
hardware and software, and precision engine signals.
Conditions for Setting the DTC
S Transmission oil temperature is greater than –10°C
(14°F).
S Selector lever is not in N(Neutral), P(Park) position.
S System voltage is greater than 9 volts.

5A2 – 4IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Drain Plug1713–
Control Cable Adjusting Nut8–71
Shift Control Lever Assembly Mounting Bolts8–71
Manual Valve Lever Shaft Nut12–106
Transmission Range (TR) Switch Bolts5.4–48
Input Speed Sensor Retaining Bolt5.4–48
Output Speed Sensor Retaining Bolt7.4–65
TCM Retaining Bolts5–44
Fluid Cooler Inlet Pipe Fitting Nut3526–
Fluid Cooler Inlet Pipe Bolt9–80
Inlet Pipe Union Bolt3526–
Fluid Cooler Rear Outlet Pipe Fitting Nut3526–
Fluid Cooler Rear Outlet Pipe Clip Bolt9–80
Front Outlet Pipe Union Bolt3526–
Lower Transaxle–to–Engine Retaining Bolts (a)7354–
Lower Transaxle–to–Engine Retaining Bolts (b)3123–
Lower Transaxle–to–Engine Retaining Bolts (c)2115–
Upper Transaxle–to–Engine Mounting Bolts7354–
Upper Transaxle Mounting Bracket Bolts6044–
Rear Mounting Bracket Bolts6044–
Damping Block Connection Nut and Bolt8059–
Torque Converter Bolts4543–
Screw Plugs7.4–65
Transaxle Apply Clamp Bolt5.4–48
Oil Reservoir Lock Plate Bolts5.4–48
Transaxle Case Plate Bolt9.8–87
Transaxle Housing Bolts2922–
Manual Detent Spring Bolt9.8–87
Parking Lock Pawl Bracket Bolts7.4–65
Planetary Ring Gear Nut (Standard)9.8–87
Planetary Ring Gear Nut (Maximum)2922–
Transaxle Rear Cover Bolts2518–
Oil Pump Bolts2518–
Valve Body Bolts11–97
Oil Strainer Bolts9.8–87
Oil Pan Bolts7–62
Unions2518–
Stator Shaft Bolts2518–
Shift Solenoid Valve Bolts11–97
Differential Case–to–Differential Ring Gear Bolt10275–

5A2 – 20IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
1. Transaxle Housing
2. Oil Seal
3. Oil Reservoir Plate
4. Transaxle Oil Apply Pipe
5. Differential Gear Oil Apply Pipe
6. Transaxle Oil Apply Pipe Clamp
7. Spring
8. Check Valve Pipe Clamp
9. Apply Gasket
10. Brake Drun Gasket
11. Transaxle Wire
12. O–ring
13. Valve Body
14. Parking Lock Pawl
15. Parking Lock Pawl Shaft
16. Torsion Spring
17. Manual Valve lever Shaft
18. Manual Valve Lever
19. Parking Lock Rod
20. Parking Lock Pawl Bracket
21. Manual Detent Spring
22. Pin
23. Spacer24. Oil Seal
25. Transmission Range (TR) Switch
26. Lock Washer
27. Control Lever
28. Washer
29. Gasket
30. Oil Strainer
31. Oil Pan
32. Gasket
33. Magnet
34. Direct Clutch Accumulator Piston
35. O–ring
36. Spring
37. O–ring
38. Forward Clutch Accumulator Piston
39. O–ring
40. Spring
41. O–ring
42. Overdrive Brake Accumulator Piston
43. O–ring
44. O–ring
45. Spring

5A2 – 102IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
3. Remove the E–ring.
4. Disconnect the shift control cable from the TR
switch lever.
5. Remove the retaining nut and then remove the
washer and the control lever.
6. Using a driver, unstake the lock washer and re-
move the nut.
Installation Procedure
1. Install the Transmission Range (TR) switch onto the
manual valve lever shaft and temporarily install the
2 adjusting bolts.
2. Install the new lock washer and nuts.
Tighten
Tighten the nuts to 12 NSm (106 Ib–in).
3. Temporarily install the control lever.
4. Turn the lever counterclockwise until it stops, then
turn it clockwise 2 notches.
5. Remove the control lever.

FIVE–SPEED MANUAL TRANSAXLE 5B – 63
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
FIVE–SPEED MANUAL TRANSAXLE
This five–speed transaxle assembly is a transmission of
constant–mesh design.
Combined in the assembly are:
S All forward gears.
S The reverse gear.
S The differential output.
The basic components of the five–speed transaxle as-
sembly units are the:
S Transaxle case.
S Input shaft.
S Input shaft gears.S Output shaft.
S Output shaft gears.
S Ring gear and differential assembly.
Forward Gear
Shifting to a forward gear is accomplished through a com-
bination of synchronizers with blocker rings controlled by
sliding shift forks.
Reverse Gear
Reverse gear is not synchronized and uses a sliding idler
gear arrangement.
Differential Assembly
The differential is a conventional arrangement of gears
that is supported by tapered roller bearings. The final out-
put gear turns the ring gear and differential assembly
which turns the drive axle shafts.