parking brake DAEWOO NUBIRA 2004 Service Manual PDF

SECTION : 5A1
ZF 4 HP 16 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 terminals. 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
INTRODUCTION5A1–3 . . . . . . . . . . . . . . . . . . . . . . . . . . .
ZF 4HP 16 Automatic Transaxle 5A1–3. . . . . . . . . . . .
Transaxle Components 5A1–4. . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS5A1–5 . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 5A1–5. . . . . . . . . . . . . . . . . . . .
Transaxle Gear Ratio 5A1–5. . . . . . . . . . . . . . . . . . . . . .
Fluid Capacity 5A1–5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 5A1–5. . . . . . . . . .
Shift Speed Chart 5A1–7. . . . . . . . . . . . . . . . . . . . . . . . .
Line Pressure 5A1–8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS5A1–9 . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 5A1–9. . . . . . . . . . . . . . . . . . . . . . .
SCHEMATIC AND ROUTING DIAGRAMS5A1–11 . . .
Transaxle Control Module (1 of 2) 5A1–11. . . . . . . . . .
Transaxle Control Module (2 of 2) 5A1–12. . . . . . . . . .
Shift Mode Diagram 5A1–13. . . . . . . . . . . . . . . . . . . . . .
Power Flow Diagram 5A1–17. . . . . . . . . . . . . . . . . . . . .
COMPONENT LOCATOR5A1–33 . . . . . . . . . . . . . . . . . .
Transaxle Identification Information 5A1–33. . . . . . . .
Torque Converter 5A1–34. . . . . . . . . . . . . . . . . . . . . . . .
Transaxle Housing 5A1–35. . . . . . . . . . . . . . . . . . . . . . .
Oil Pump 5A1–36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Cover & Oil Pan Cover 5A1–37. . . . . . . . . . . . . .
Parking Lever 5A1–38. . . . . . . . . . . . . . . . . . . . . . . . . . .
Input Shaft & Shift Gear 5A1–39. . . . . . . . . . . . . . . . . .
Valve Body 5A1–41. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Shift Control 5A1–42. . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTIC INFORMATION AND PROCEDURES
DIAGNOSIS5A1–43 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Basic Knowledge Required 5A1–43. . . . . . . . . . . . . . . .
Functional Check Procedure 5A1–43. . . . . . . . . . . . . .
Line Pressure Check Procedure 5A1–43. . . . . . . . . . .
Clutch Plate Diagnosis 5A1–45. . . . . . . . . . . . . . . . . . .
Cooler Flushing and Flow Test 5A1–45. . . . . . . . . . . . . Transaxle Fluid Level Service Procedure 5A1–45. . . .
Electrical/Garage Shift Test 5A1–47. . . . . . . . . . . . . . .
Road Test Procedure 5A1–47. . . . . . . . . . . . . . . . . . . . .
Torque Converter Lock–Up Clutch(TCC)
Diagnosis 5A1–48. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TCM Initialization Procedure 5A1–50. . . . . . . . . . . . . .
Shift Speed Chart 5A1–51. . . . . . . . . . . . . . . . . . . . . . . .
Internal Wiring Harness Check 5A1–51. . . . . . . . . . . .
Transaxle Wiring Harness Connector 5A1–54. . . . . . .
Symptom Diagnosis 5A1–56. . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTIC TROUBLE CODE DIAGNOSIS5A1–60
Diagnostic Trouble Code (DTC) Identification 5A1–60
DTC P0562 – System Voltage Low 5A1–68. . . . . . . . .
DTC P0563 – System Voltage High 5A1–71. . . . . . . .
DTC P0601 – Internal Control Module Memory
Checksum Error 5A1–74. . . . . . . . . . . . . . . . . . . . . . .
DTC P0603 – Internal Control Module Keep
Alive Memory(KAM) Error 5A1–76. . . . . . . . . . . . . . .
DTC P0604 – Internal Control Module Random
Access Memory(RAM) Error 5A1–78. . . . . . . . . . . . .
DTC P0606 – Transaxle Control Module
Processor Fault 5A1–80. . . . . . . . . . . . . . . . . . . . . . . .
DTC P0703 – Brake Switch Circuit
Malfunction 5A1–83. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0705 – Transmission Range Sensor
Circuit Malfunction(PRNDL Input) 5A1–86. . . . . . . .
DTC P0710 – Transmission Fluid Temperature
Sensor Circuit Malfunction 5A1–89. . . . . . . . . . . . . .
DTC P0715 – Input Speed Sensor(ISS) Circuit
Malfunction 5A1–92. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0716 – Input Speed Sensor(ISS) Circuit
Range/Performance 5A1–95. . . . . . . . . . . . . . . . . . . .
DTC P0717 – Input Speed Sensor(ISS) Circuit
No Signal 5A1–98. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0720 – Output Speed Sensor(OSS)
Circuit Malfunction 5A1–101. . . . . . . . . . . . . . . . . . . .
DTC P0721 – Output Speed Sensor(OSS)
Circuit Range/Performance 5A1–104. . . . . . . . . . . . .

5A1 – 2IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
DTC P0722 – Output Speed Sensor(OSS)
Circuit No Signal 5A1–107. . . . . . . . . . . . . . . . . . . . . .
DTC P0725 – Engine Speed Input Circuit
Malfunction 5A1–110. . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0726 – Engine Speed Input Circuit
Range/Performance 5A1–112. . . . . . . . . . . . . . . . . . .
DTC P0727 – Engine Speed Input Circuit No
Signal 5A1–114. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0731 – Gear 1 Incorrect Ratio 5A1–116. . . . . .
DTC P0732 – Gear 2 Incorrect Ratio 5A1–118. . . . . .
DTC P0733 – Gear 3 Incorrect Ratio 5A1–120. . . . . .
DTC P0734 – Gear 4 Incorrect Ratio 5A1–122. . . . . .
DTC P0781 – 1–2 Shift Malfunction 5A1–124. . . . . . .
DTC P0782 – 2–3 Shift Malfunction 5A1–126. . . . . . .
DTC P0783 – 3–4 Shift Malfunction 5A1–128. . . . . . .
DTC P1604 – Data Check of Internal &
Extended Ram Failed 5A1–130. . . . . . . . . . . . . . . . . .
DTC P1606 – Failure Of External Watchdog 5A1–132
DTC P1671 – CAN Transmit Message
Failure 5A1–134. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1672 – CAN Bus Off Failure 5A1–136. . . . . . . .
DTC P1673 – CAN Receive ECM Message
Failure 5A1–138. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1839 – EDS 3 Output Shorted To
Ground 5A1–140. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1840 – EDS 3 Output Shorted To
Power 5A1–142. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1841 – EDS 3 Output Open 5A1–144. . . . . . . .
DTC P1850 – Solenoid 1 Output Shorted To
Ground 5A1–146. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1851 – Solenoid 1 Output Shorted To
Power 5A1–148. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1852 – Solenoid 1 Output Open 5A1–150. . . .
DTC P1853 – Solenoid 2 Output Shorted To
Ground 5A1–152. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1854 – Solenoid 2 Output Shorted To
Power 5A1–154. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1855 – Solenoid 2 Output Open 5A1–156. . . .
DTC P1861 – EDS 4 Output Shorted To
Ground 5A1–158. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1862 – EDS 4 Output Shorted To
Power 5A1–160. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1863 – EDS 4 Output Open 5A1–162. . . . . . . .
DTC P1864 – EDS 5 Output Shorted To
Ground 5A1–164. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1865 – EDS 5 Output Shorted To
Power 5A1–166. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1866 – EDS 5 Output Open 5A1–168. . . . . . . .
DTC P1867 – EDS 6 Output Shorted To
Ground 5A1–170. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1868 – EDS 6 Output Shorted To
Power 5A1–172. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1869 – EDS 6 Output Open 5A1–174. . . . . . . .
DTC P1871 – EDS Valve Power Supply
Circuit Shorted to Power 5A1–176. . . . . . . . . . . . . . .
DTC P1874 – Solenoid Valve Power Supply
Circuit Shorted to Power 5A1–178. . . . . . . . . . . . . . .
DTC P1881 – 2–1 Shift Malfunction 5A1–180. . . . . . .
DTC P1883 – 3–2 Shift Malfunction 5A1–182. . . . . . .
DTC P1884 – 4–3 Shift Malfunction 5A1–184. . . . . . .
DTC P1885 – 3–1 Shift Malfunction 5A1–186. . . . . . .
DTC P1886 – 4–2 Shift Malfunction 5A1–188. . . . . . .
MAINTENANCE AND REPAIR5A1–190 . . . . . . . . . . . .
ON–VEHICLE SERVICE 5A1–190. . . . . . . . . . . . . . . . . .
Transaxle Fluid Level Checking Procedure 5A1–190.
Changing the Fluid 5A1–191. . . . . . . . . . . . . . . . . . . . . .
Fluid Level Set After Service 5A1–192. . . . . . . . . . . . .
Repairing Fluid Leaks 5A1–192. . . . . . . . . . . . . . . . . . .
Case Porosity Repair 5A1–193. . . . . . . . . . . . . . . . . . . .
Shift Control Lever Assembly 5A1–193. . . . . . . . . . . . .
Shift Control Cable 5A1–195. . . . . . . . . . . . . . . . . . . . . .
Shift Control Cable Adjustment 5A1–196. . . . . . . . . . .
Transaxle Control Module(TCM) 5A1–197. . . . . . . . . .
Park/Neutral Start Switch 5A1–198. . . . . . . . . . . . . . . .
Oil Cooler Pipes/Hoses 5A1–199. . . . . . . . . . . . . . . . . .
Drive Axle Oil Seal 5A1–201. . . . . . . . . . . . . . . . . . . . . .
Oil Pan, Oil Pan Gasket 5A1–201. . . . . . . . . . . . . . . . .
Control Valve Body Assembly 5A1–203. . . . . . . . . . . .
Left Transaxle Mounting Bracket 5A1–205. . . . . . . . . .
Transaxle Assembly 5A1–206. . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR 5A1–212. . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Converter 5A1–212. . . . . . . . . . . . . . . . . . . . . . .
Transaxle Holding Fixture Assembly 5A1–212. . . . . . .
Valve Body 5A1–212. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Cover 5A1–213. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch B/E 5A1–214. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch B/E Measurement Procedure 5A1–217. . . . . .
Planetary Gear Set 5A1–220. . . . . . . . . . . . . . . . . . . . .
Brake C/D 5A1–221. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential 5A1–224. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Side Shaft 5A1–224. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake F, Slotted Nut 5A1–225. . . . . . . . . . . . . . . . . . . . .
Torque Converter Housing 5A1–227. . . . . . . . . . . . . . .
Shift Mechanism 5A1–228. . . . . . . . . . . . . . . . . . . . . . . .
Parking Lock System 5A1–229. . . . . . . . . . . . . . . . . . . .
Bearing Plate(With Spur Gear) Assembly 5A1–229. .
Oil Pump Assembly 5A1–229. . . . . . . . . . . . . . . . . . . . .
Differential/Side Shaft Outer Race, Bearing
Shim 5A1–230. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 43
DAEWOO V–121 BL4
DIAGNOSTIC INFORMATION AND
PROCEDURES DIAGNOSIS
BASIC KNOWLEDGE REQUIRED
You must be familiar with some basic electronics to use
this section of the Service Manual. They will help you to
follow diagnostic procedures.
Notice : Lack of the basic knowledge of this transaxle
when performing diagnostic procedures could result in in-
correct diagnostic performance or damage to transaxle
components.
Do not, under any circumstances, attempt to diagnose a
transaxle problem without this basic knowledge.
Notice : If a wire is probed with a sharp instrument and not
properly sealed afterward, the wire will corrode and an
open circuit will result.
Diagnostic test probes are now available that allow you to
probe individual wires without leaving the wire open to the
environment. These probe devices are inexpensive and
easy to install, and they permanently seal the wire from
corrosion.
Special Tools
You should be able to use a Digital Volt Meter (DVM), a cir-
cuit tester, jumper wires or leads and a line pressure gauge
set.
The functional check procedure is designed to verify the
correct operation of electronic components in the trans-
axle.
This will eliminate the unnecessary removal of transaxle
components.
FUNCTIONAL CHECK PROCEDURE
Begin with the Functional Check Procedure which pro-
vides a general outline of how to diagnose automatic
transaxle. The following functional check procedure will in-
dicate the proper path of diagnosing the transaxle by de-
scribing the basic checks and then referencing the loca-
tions of the specific checks.
S Check the fluid level according to the Fluid Level
Service Procedure.
S Check the transaxle for fluid leaks.
S Check if the transaxle fluid is not burnt by color and
smell.
S Ensure that the transaxle is not in Limp Home
Mode(LHM).
S Check the battery terminals and the ground con-
nections for corrosion or looseness.
S Check that the cooler flow is not restricted.S Check all electrical connections for tightness.
S Use on–board diagnostic tool or a scan tool to see
if any transaxle trouble codes have been set. Refer
to the appropriate ”Diagnostic Trouble Code (DTC)”
information and repair the vehicle as directed. After
repairing the vehicle, perform the road test and
verify that the code has not set again.
S Perform the Electrical/Garage Shift Tests.
S Perform the Road Test Procedure in this section.
S Inspect the oil and check for metal or other contam-
inants in the oil pan.
LINE PRESSURE CHECK
PROCEDURE
The 4HP 16 A/T uses a trochoid type oil pump to produce
hydraulic pressure, and a pressure control solenoid (sole-
noid 1) to control that pressure at the pressure regulator
valve, after it leaves the pump. The transaxle pressure
control solenoid is controlled by an electrical signal that
ranges from 0 to 12 volts corresponds to minimum line
pressure (approx. 89.9 to 124.7 psi (6.2 to 8.6 bar)) and
0 volt corresponds to a maximum line pressure (approx.
221.9 to 252.4 psi (15.3 to 17.4 bar)) in all range.
Line pressures are calculated for two sets of gear ranges
– Drive–Park–Neutral and Reverse. This allow the trans-
axle line pressure to be appropriate for different pressure
needs in different gear ranges:
Gear
Range
Solenoid
1RPMPressure
Drive,
ReverseOff2,500221.9~252.4psi
(15.3~17.4 bar)
On2,50017.4~269.8psi
(1.2~18.6 bar)
Neutral,
ParkOff2,500221.9~252.4psi
(15.3~17.4 bar)
On2,50089.9~269.8 psi
(6.2~18.6 bar)
Before performing a line pressure check, verify that the
pressure control solenoid is receiving the correct electrical
signal from the TCM:
1. Install a scan tool.
2. Start the engine and set parking brake.
3. Check for a stored pressure control solenoid diag-
nostic trouble code, and other diagnostic trouble
codes.

5A1 – 44IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
4. Repair vehicle, if necessary.
Inspect:
S Fluid level.
S Manual linkage.
Install or Connect:
S Scan tool (scanner)
S Oil pressure gauge at line pressure port (clutch B or
E ports on transaxle case)
5. Put gear selector in Park and set the parking brake.6. Start engine and allow it to warm up at idle.
7. Access the ”Solenoid 1 Control Mode” on the scan-
ner.
8. Switching solenoid 1 ON/OFF, accelerating the en-
gine to 2,500rpm, and then read the line pressure
at the each gear.
9. Compare data to the Drive–Park–Neutral line pres-
sure chart below.
Notice : Total test running time should not exceed 2 min-
utes, or transaxle damage could occur.
CAUTION : Brake must be applied at all times to pre-
vent unexpected vehicle motion.
If pressure readings differ greatly from the line pressure
chart, refer to the Diagnosis Charts contained in this sec-
tion.
Notice : Clutch damage may occur.
The scanner is only able to control the pressure control so-
lenoid in Park and Neutral with the vehicle stopped.
This protects the clutches from extremely high or low pres-
sures in Drive or Reverse rang.
Gear Range
SolenoidLine
Pressure B PortE Port
Park / NeutralONLOW90~124.7 psi (6.2~8.6 bar)
OFFHIGH221.9~252.3 ps
i (15.3~17.4 bar)
ReverseONLOW90~124.7 psi (6.2~8.6 bar)
OFFHIGH221.9~252.3 psi
(15.3~17.4 bar)
DriveONLOW90~124.7 psi (6.2~8.6 bar)
OFFHIGH137.7~162.4 psi
(9.5~11.2 bar)
3ONLOW90~124.7 psi (6.2~8.6 bar)90~124.7 psi (6.2~8.6 bar)
OFFHIGH221.9~252.3 psi
(15.3~17.4 bar)137.7~162.4 psi
(9.5~11.2 bar)
2ONLOW90~124.7 psi (6.2~8.6 bar)
OFFHIGH137.7~162.4 psi
(9.5~11.2 bar)
1ONLOW90~124.7 psi (6.2~8.6 bar)
OFFHIGH221.9~252.3 psi
(15.3~17.4 bar)

5A1 – 46IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
sible, drive the vehicle for a few kilometers (N–D,
N–R, shift until two gear). This will allow the trans-
axle to be within the correct temperature range.
Transaxle fluid level should be checked at tempera-
ture 20 to 45°C (68 to 113°F).
CAUTION : Removal of the fluid filler plug when the
transaxle fluid is hot may cause injury if fluid drains
from the filler hole.
2. Switch off accessories, especially air conditioner,
heater.
3. With the brake pedal pressed, move the gear shift
control lever through the gear ranges, pausing a
few seconds in each range. Return the gearshift
lever to P(Park). Turn the engine OFF.
4. Park the vehicle on a hoist, inspection pit or similar
raised level surface. The vehicle must be level to
obtain a correct fluid level measurement.
5. Place a fluid container below the fluid filler plug.
6. Clean all dirt from around the fluid filler plug.
Remove the fluid filler plug. Clean the filler plug and
check that there is no damage to the ”O” ring.
S If fluid drains through the filler hole the transaxle
may have been overfilled. When the fluid stops
draining the fluid level is correct. Install the fluid
filler plug and tighten it to 45NSm(34 lb–ft).
S If fluid does not drain through the filler hole, the
transaxle fluid level may be low. Lower the ve-
hicle, and start the vehicle in P(Park) with the
parking brake and the brake applied. With the
engine idling, move the gear shift lever through
the gear ranges, pausing a few seconds in each
range and adding the fluid until gear application
is felt. Return the gear shift lever to P(Park).
Turn the engine OFF and raise the vehicle.
Check if the fluid level is aligned with the bottom
of the filler hole. If not, add a small quantity of
fluid to the correct level. Install the fluid filler
plug and tighten it to 45NSm(34 lb–ft).
7. When the fluid level checking procedure is com-
pleted, wipe any fluid around the filler plug with a
rag or shop towel.
Fluid Level Set After Service
1. Depending on the service procedure performed,
add the following amounts of fluid through the filler
plug hole prior to adjusting the fluid level:
Oil pan removal – 4 liters (4.23 quarts)
Converter removal – 2 liters ( 2.11 quarts)
Overhaul – 6.9liters (7.3 quarts)
Oil drain plug removal – 4 liters (4.23 quarts)
2. Follow steps 1 through 4 of the Fluid Level Diagno-
sis Procedure.
3. Clean all dirt from around the fluid filler plug.
Remove the fluid filler plug. Clean the filler plug and
check that there is no damage to the ”O” ring.
4. Lower the vehicle with the filler plug still removed
and start the vehicle in P(Park) with the parking
brake and the brake applied. With the engine idling,move the gear shift lever through the gear ranges,
pausing a few seconds in each range and adding
the fluid until gear application is felt. Then add an
additional 0.5 liters of fluid. Return the gear shift
lever to P(Park). Turn the engine OFF and raise the
vehicle. Install the fluid filler plug and tighten it to
45NSm (34 lb–ft).
5. Drive the vehicle at 2.2 miles(3.5km) to 2.8
miles(4.5 km) with light throttle so that the engine
does not exceed 2500 rpm. This should result in
the transaxle temperature being in the range 20 to
45°C (68 to 11°F). With the brake applied, move
the shift lever through the gear ranges, pausing a
few seconds in each range at the engine idling.
6. Return the gear shift lever to P(Park). Turn the en-
gine OFF and raise the vehicle on the hoist, if appli-
cable, ensuring the vehicle is level. When the three
minutes passed after the engine stopped, remove
the filler plug. Check if the fluid level is aligned with
the bottom of the filler hole. If not, add a small
quantity of fluid to the correct level. Install the fluid
filler plug and tighten it to 45NSm (34 lb–ft).
7. Wipe any fluid around the filler plug with a rag or
shop towel.
Fluid Leak Diagnosis and Repair
The cause of most external leaks can generally be Lo-
cated and repaired with the transaxle in the vehicle.
Methods for Locating Leaks
General Method
1. Verify that the leak is transaxle fluid.
2. Thoroughly clean the suspected leak area.
3. Drive the vehicle for approximately 25 km (15
miles) or until the transaxle reaches normal operat-
ing temperature (88°C, 190°F).
4. Park the vehicle over clean paper or cardboard.
5. Turn the engine OFF and look for fluid spots on the
paper.
6. Make the necessary repairs to correct the leak.
Powder Method
1. Thoroughly clean the suspected leak area.
2. Apply an aerosol type powder (foot powder) to the
suspected leak area.
3. Drive the vehicle for approximately 25 km (15
miles) or until the transaxle reaches normal operat-
ing temperature (88°C, 190°F).
4. Turn the engine OFF.
5. Inspect the suspected leak area and trace the leak
path through the powder to find the source of the
leak.
6. Make the necessary repairs.
Dye and Black Light Method
1. Add dye to the transaxle though the transaxle fluid
filler plug. Follow the manufacturer’s recommenda-
tion for the amount of dye to be used.
2. Use the black light to find the fluid leak.
3. Make the necessary repairs.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 47
DAEWOO V–121 BL4
Repairing the Fluid Leak
Once the leak point is found the source of the leak must
be determined. The following list describes the potential
causes for the leak:
S Fasteners are not torqued to specification.
S Fastener threads and fastener holes are dirty or
corroded.
S Gaskets, seals or sleeves are misarranged, dam-
aged or worn.
S Damaged, warped or scratched seal bore or gasket
surface.
S Loose or worn bearing causing excess seal or
sleeve wears.
S Case or component porosity.
S Fluid level is too high.
S Plugged vent or damaged vent tube.
S Water or coolant in fluid.
S Fluid drain back holes plugged.
ELECTRICAL/GARAGE SHIFT TEST
This preliminary test should be performed before a hoist
or road test to make sure electronic control inputs is con-
nected and operating. If the inputs are not checked before
operating the transaxle, a simple electrical condition could
be misdiagnosed as a major transaxle condition.
A scan tool provides valuable information and must be
used on the automatic transaxle for accurate diagnosis.
1. Move gear selector to P (Park) and set the parking
brake.
2. Connect scan tool to Data Link Connector (DLC)
terminal.
3. Start engine.
4. Turn the scan tool ON.
5. Verify that the appropriate signals are present.
These signals may include:
S ENGINE SPEED
S VEHICLE SPEED
S THROTTLE POSITION
S TRANSAXLE GEAR STATE
S GEAR SHIFT LEVER POSITION
S TRANSAXLE FLUID TEMPERATURE
S CLOSED THROTTLE POSITION LEARN
S OPEN THROTTLE POSITION LEARNT
S CLOSED ACCEL. PEDAL POSITION LEARNT
S OPEN ACCEL. PEDAL POSITION LEARNT
S A/C COMPRESSOR STATUS
S MODE SWITCH
S THROTTLE POSITION VOLTAGE
S GEAR SHIFT LEVER POSITION VOLTAGE
S TRANS. FLUID TEMPERATURE VOLTAGE
S A/C SWITCH
S MODE SWITCH VOLTAGE
S BATTERY VOLTAGE
6. Monitor the A/C COMPRESSOR STATUS signal
while pushing the A/C switch.S The A/C COMPRESSOR STATUS should come
ON when the A/C switch is pressed, and turns
OFF when the A/C switch is repushed.
7. Monitor the GEAR SHIFT LEVER POSITION signal
and move the gear shift control lever through all the
ranges.
S Verify that the GEAR SHIFT LEVER POSITION
value matches the gear range indicated on the
instrument panel or console.
S Gear selections should be immediate and not
harsh.
8. Move gear shift control lever to neutral and monitor
the THROTTLE POSITION signal while increasing
and decreasing engine speed with the accelerator
pedal.
S THROTTLE POSITION should increase with
engine speed.
ROAD TEST PROCEDURE
S Perform the road test using a scan tool.
S This test should be performed when traffic and road
conditions permit.
S Observe all traffic regulations.
The TCM calculates upshift points based primarily on two
inputs : throttle angle and vehicle speed. When the TCM
wants a shift to occur, an electrical signal is sent to the shift
solenoids which in turn moves the valves to perform the
upshift.
The shift speed charts reference throttle angle instead of
”min throttle” or ”wot” to make shift speed measurement
more uniform and accurate. A scan tool should be used to
monitor throttle angle. Some scan tools have been pro-
grammed to record shift point information. Check the
introduction manual to see if this test is available.
Upshift Procedure
With gear selector in drive(D)
1. Look at the shift speed chart contained in this sec-
tion and choose a percent throttle angle of 10 or
25%.
2. Set up the scan tool to monitor throttle angle and
vehicle speed.
3. Accelerate to the chosen throttle angle and hold the
throttle steady.
4. As the transaxle upshifts, note the shift speed and
commanded gear changes for :
S Second gear.
S Third gear.
S Fourth gear.
Important : Shift speeds may vary due to slight hydraulic
delays responding to electronic controls. A change from
the original equipment tire size affects shift speeds.
Note when TCC applies. This should occur in fourth gear.
If the apply is not noticed by an rpm drop, refer to the
”Lock–up Clutch Diagnosis” information contained in this
section.

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)

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 177
DAEWOO V–121 BL4
DTC P1871 – EDS Valve Power Supply Circuit Shorted to Power
StepActionValue(s)YesNo
1Perform an On–Board Diagnostic (EOBD) System
Check.
Is the check completed?–Go to Step 2Go to ”On–
Board Diagnos-
tic System
Check”
21. Install the scan tool.
2. Turn the ignition ON, with the engine OFF.
3. Start engine and allow it to warm up at idle.
4. Put gear selector in Part and set the parking
brake.
5. Observe ”EDS 3,4,5,6’s input ampere and out-
put ampere” on the scan tool.
Is the amperes within the values shown?EDS ampere
(0–2 Amp)Go to
Diag-
nostic Aids"Go to Step 3
31. Turn the ignition OFF.
2. Disconnect the transaxle wiring connector and
TCM connector.
3. Measure the voltage of the transaxle wiring
terminal 5.
Is the voltage within the values shown?11–14VGo to Step 4Go to Step 5
4Repair the circuit for a short to power.
Is the action complete?–System OK–
51. Remove the oil pan.
2. Disconnect the EDS valve wiring connector.
3. Turn the ignition ON.
4. Measure the voltage of the EDS 3 terminal 2.
5. Measure the voltage of the EDS 4 terminal 2.
6. Measure the voltage of the EDS 5 terminal 2.
7. Measure the voltage of the EDS 6 terminal 2.
Is the voltage within the values shown?11–14VGo to Step 6Go to Step 7
6Repair the circuits(power supply lines) for a short to
power.
Is the action complete?–System OK–
7Replace the TCM.
Is the action complete?–Go to Step 8–
81. After the repair, use a scan tool ”clear info”
function and road test the vehicle.
2. Review the ”DTC info”.
Has the last test failed or is the current DTC dis-
played?–Begin diagno-
sis againRepair verified
exit DTC chart

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 179
DAEWOO V–121 BL4
DTC P1874 – Solenoid Valve Power Supply Circuit Shorted to
Power
StepActionValue(s)YesNo
1Perform an On–Board Diagnostic (EOBD) System
Check.
Is the check completed?–Go to Step 2Go to ”On–
Board Diagnos-
tic System
Check”
21. Install the scan tool.
2. Turn the ignition ON, with the engine OFF.
Then, start engine and allow it to warm up at
idle.
3. Put gear selector in Park and set the parking
brake.
4. Observe ”solenoid 1,2” on the scan tool.
Is the solenoid ON ?–Go to ”Diag-
nostic Aids”Go to Step 3
31. Turn the ignition OFF.
2. Disconnect the transaxle wiring connector and
TCM connector.
3. Measure the voltage of the transaxle wiring
terminal 3.
Is the voltage within the values shown?11–14VGo to Step 4Go to Step 5
4Repair the circuit for a short to power.
Is the action complete?–System OK–
51. Remove the oil pan.
2. Disconnect the solenoid 1,2 wiring connector.
3. Turn the ignition ON.
4. Measure the voltage of the solenoid 1 terminal
2.
5. Measure the voltage of the solenoid 2 terminal
2.
Is the voltage within the values shown?11–14VGo to Step 6Go to Step 7
6Repair the circuits(power supply lines) for a short to
power.
Is the action complete?–System OK–
7Replace the TCM.
Is the action complete?–Go to Step 8–
81. After the repair, use a scan tool ”clear info”
function and road test the vehicle.
2. Review the ”DTC info”.
Has the last test failed or is the current DTC dis-
played?–Begin diagno-
sis againRepair verified
exit DTC chart

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 229
DAEWOO V–121 BL4
PARKING LOCK SYSTEM
Disassembly and Assembly Procedure
1. Remove the parking lock assembly.
S Parking lock system is consist of parking pawl,
leg spring, support bolt.
2. Installation should follow the removal procedure in
the reverse order.
BEARING PLATE(WITH SPUR GEAR)
ASSEMBLY
Disassembly and Assembly Procedure
1. Remove the piston F. Refer to ”Brake F” in this
section.
2. Remove the bearing plate bolts and bearing plate.
3. Installation should follow the removal procedure in
the reverse order.
Installation Notice
Tighten
Tighten the bearing plate bolts to 27 NSm (17 lb–ft).
OIL PUMP ASSEMBLY
Disassembly and Assembly Procedure
1. Remove the oil pump housing bolts.
2. Using the plastic hammer. Take out the oil pump
housing.
Installation Notice
Tighten
Tighten the oil pump housing bolts 10 NSm (89 lb–in).
3. Remove the stator shaft bolts.