Text preview for : en_4j2_5a2.pdf part of Daewoo Nubira/Lacetti Also known as: Chevrolet Nubira / Lacetti, Chevrolet Optra Optra5, Suzuki Forenza Reno
Covers the 1.4L, 1.6L and 1.8L engine.
Year 2004
Back to : Service Manual - Daewoo L | Home
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
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 5A23 General Specifications . . . . . . . . . . . . . . . . . . . . 5A23 Transaxle Gear Ratio . . . . . . . . . . . . . . . . . . . . . . 5A23 Fluid Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A23 Line Pressure Specification . . . . . . . . . . . . . . . . 5A23 Fastener Tightening Specifications . . . . . . . . . . 5A24 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 5A25 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . 5A25 SCHEMATIC DIAGRAMS . . . . . . . . . . . . . . . . . . . 5A28 Transmission Control Module (1 of 4) . . . . . . . . 5A28 Transmission Control Module (2 of 4) . . . . . . . . 5A29 Transmission Control Module (3 of 4) . . . . . . . 5A210 Transmission Control Module (4 of 4) . . . . . . . 5A211 Shift Mode Diagram . . . . . . . . . . . . . . . . . . . . . . 5A212 COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . 5A217 Shift Select Control . . . . . . . . . . . . . . . . . . . . . . 5A217 Automatic Transaxle Components . . . . . . . . . 5A218 Bearing and Races Installation Position Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A224 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A225 Electrical Connector View . . . . . . . . . . . . . . . . . 5A225 Wiring Harness and Connector Inspection . . . 5A227 Road Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A227 Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . 5A228 Unit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 5A230 OnVehicle Repair (Matrix Chart) . . . . . . . . . . 5A234 DIAGNOSIS TROUBLE CODE DIAGNOSIS . 5A236 Diagnosis Trouble Code Chart . . . . . . . . . . . . . 5A236 DTC P0562 System Voltage Low . . . . . . . . . . 5A237 DTC P0563 System Voltage High . . . . . . . . . . 5A240 DTC P0601 Internal Control Module Memory Checksum Error . . . . . . . . . . . . . . . . . . . . . . . 5A243 DTC P0604 Internal Transmission Control Module (TCM) Random Access Memory (RAM) Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A245 DTC P0705 Transmission Range (TR) Switch Circuit Malfunction . . . . . . . . . . . . . . . . . . . . . 5A247 DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input . . . . . . . . . . 5A250 DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input . . . . . . . . . . 5A253 DTC P0717 Input Shaft Speed (ISS) Sensor Circuit No Signal . . . . . . . . . . . . . . . . . . . . . . . 5A256 DTC P0722 Ouput Shaft Speed (OSS) Sensor Circuit No Signal . . . . . . . . . . . . . . . . . . . . . . . 5A259 DTC P0727 Engine Speed Input Circuit No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A262 DTC P0741 Torque Converter Clutch (TCC) Circuit Stuck Off . . . . . . . . . . . . . . . . . . . . . . . 5A265 DTC P0742 Torque Converter Clutch (TCC) Circuit Stuck On . . . . . . . . . . . . . . . . . . . . . . . 5A267 DTC P0743 Torque Converter Clutch (TCC) Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A269 DTC P0748 Pressure Control Solenoid (PCS) Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A272 DTC P0751 Shift Solenoid 1 (SS1) Stuck Off DTC P0753 Shift Solenoid 1 (SS1) Electrical DTC P0756 Shift Solenoid 2 (SS2) Stuck Off DTC P0758 Shift Solenoid 2 (SS2) Electrical 5A275 5A277 5A280 5A282
DTC P0785 Timing Solenoid (ST) Electrical . 5A285 DTC P1781 Engine Torque Signal Error . . . . . 5A288 DTC P1791 Throttle Position Signal Error . . . 5A291 DTC P1792 Engine Coolant Temperature (ECT) Signal Error . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A293 DTC U2105 Can Error . . . . . . . . . . . . . . . . . . . . 5A295 MAINTENANCE AND REPAIR . . . . . . . . . . . . . 5A297 ONVEHICLE SERVICE . . . . . . . . . . . . . . . . . . . 5A297 Transaxle Fluid Level Checking Procedure . . 5A297 Fluid Drain Procedure . . . . . . . . . . . . . . . . . . . . 5A297 Locating Fluid Leaks . . . . . . . . . . . . . . . . . . . . . Case Porosity Repair . . . . . . . . . . . . . . . . . . . . . Fluid Cooler Flushing . . . . . . . . . . . . . . . . . . . . . Control Cable Adjustment . . . . . . . . . . . . . . . . . 5A298 5A298 5A299 5A299
5A2 2IAISIN AUTOMATIC TRANSAXLE
Shift Control Lever Assembly . . . . . . . . . . . . . Transmission Range (TR) Switch . . . . . . . . . Shift Control Cable . . . . . . . . . . . . . . . . . . . . . . Shift Select Cover . . . . . . . . . . . . . . . . . . . . . . Input Shaft Speed (ISS) Sensor . . . . . . . . . . Output Shaft Speed (OSS) Sensor . . . . . . . . Transmission Control Module (TCM) . . . . . . Fluid Cooler Inlet Pipes and Hoses . . . . . . . . 5A2100 5A2101 5A2104 5A2105 5A2106 5A2107 5A2108 5A2109 Direct Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A2171 Planetary Ring Gear . . . . . . . . . . . . . . . . . . . . 5A2178 OneWay Clutch . . . . . . . . . . . . . . . . . . . . . . . 5A2180 Forward and Reverse Clutch . . . . . . . . . . . . . 5A2183 Counter Driven Gear . . . . . . . . . . . . . . . . . . . . 5A2192 Valve Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A2195 Differential Case . . . . . . . . . . . . . . . . . . . . . . . . 5A2208 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A2218 Transaxle Description . . . . . . . . . . . . . . . . . . . 5A2218 Electronical Components . . . . . . . . . . . . . . . . 5A2218 Hydraulic Control System . . . . . . . . . . . . . . . . 5A2221 Automatic Transaxle System . . . . . . . . . . . . . 5A2222
Fluid Cooler Outlet Pipes and Hoses . . . . . . 5A2110 Transaxle Assembly . . . . . . . . . . . . . . . . . . . . . 5A2111 UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A2117 Major Component Disassembly . . . . . . . . . . . 5A2117 Major Component Assembly . . . . . . . . . . . . . 5A2137 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A2167
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AISIN AUTOMATIC TRANSAXLE 5A2 3
SPECIFICATIONS
GENERAL SPECIFICATIONS
Definition 1.6 DOHC Transaxle Fluid Type Transaxle Fluid Capacity ISU DEXRON III or ESSO JWS 3309 5.77L (6.1 qts)
TRANSAXLE GEAR RATIO
Gear First Second Third Fourth Reverse Counter Differential Ratio 1.6 DOHC 2.875 1.568 1.000 0.697 2.300 1.020 3.750
FLUID CAPACITY
Capacity 1.6 DOHC Transaxle Fluid (dry fill) Transaxle Fluid (drain and refill) 5.77L (6.1 qts) 2.1L (2.2 qts)
Notice : Fluid capacity (drain and refill) could be changed according to the some condition, therefore be sure to check the fluid using the oil stick guage.
LINE PRESSURE SPECIFICATION
Application At "D" range At "R" range 3.94.2 Idling kg/cm2 (5560 psi) 6.06.9 kg/cm2 (8598 psi) Stall 11.312.5 kg/cm2 (161178 psi) 16.218.6 kg/cm2 (230265 psi)
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5A2 4IAISIN AUTOMATIC TRANSAXLE
FASTENER TIGHTENING SPECIFICATIONS
Application Drain Plug Control Cable Adjusting Nut Shift Control Lever Assembly Mounting Bolts Manual Valve Lever Shaft Nut Transmission Range (TR) Switch Bolts Input Speed Sensor Retaining Bolt Output Speed Sensor Retaining Bolt TCM Retaining Bolts Fluid Cooler Inlet Pipe Fitting Nut Fluid Cooler Inlet Pipe Bolt Inlet Pipe Union Bolt Fluid Cooler Rear Outlet Pipe Fitting Nut Fluid Cooler Rear Outlet Pipe Clip Bolt Front Outlet Pipe Union Bolt Lower TransaxletoEngine Retaining Bolts (a) Lower TransaxletoEngine Retaining Bolts (b) Lower TransaxletoEngine Retaining Bolts (c) Upper TransaxletoEngine Mounting Bolts Upper Transaxle Mounting Bracket Bolts Rear Mounting Bracket Bolts Damping Block Connection Nut and Bolt Torque Converter Bolts Screw Plugs Transaxle Apply Clamp Bolt Oil Reservoir Lock Plate Bolts Transaxle Case Plate Bolt Transaxle Housing Bolts Manual Detent Spring Bolt Parking Lock Pawl Bracket Bolts Planetary Ring Gear Nut (Standard) Planetary Ring Gear Nut (Maximum) Transaxle Rear Cover Bolts Oil Pump Bolts Valve Body Bolts Oil Strainer Bolts Oil Pan Bolts Unions Stator Shaft Bolts Shift Solenoid Valve Bolts Differential CasetoDifferential Ring Gear Bolt NSm 17 8 8 12 5.4 5.4 7.4 5 35 9 35 35 9 35 73 31 21 73 60 60 80 45 7.4 5.4 5.4 9.8 29 9.8 7.4 9.8 29 25 25 11 9.8 7 25 25 11 102 LbFt 13 26 26 26 26 54 23 15 54 44 44 59 43 22 22 18 18 18 18 75 LbIn 71 71 106 48 48 65 44 80 80 65 48 48 87 87 65 87 97 87 62 97
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AISIN AUTOMATIC TRANSAXLE 5A2 5
SPECIAL TOOLS
SPECIAL TOOLS TABLE
DW26002102 Automatic Transaxle Overhaul Fixture
DW240050 Overdrive Brake Adapter
DW240020 Brake/Clutch Spring Compressor
DW24006001 Brake Spring Compressor Bolt/Nut
DW240030 Forward Clutch Adapter
DW24006002 Brake Spring Compressor Plate
DW240040 Direct Clutch Adapter
DW240070 1st/Reverse Brake Adapter
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5A2 6IAISIN AUTOMATIC TRANSAXLE
DW240080 2nd Brake Adapter
DW26003102 Tranaxle Case Oil Seal Installer
DW240090 Planetary Ring Gear Remover
DW240120 Measuring Terminal
DW240100 Counter Drive Gear Installation Adapter
DW240130 Differential Preload Adapter
DW260041 Planetary Ring Gear Nut Removal/Installation Socket (52mm)
DW260013 Transaxle Support Fixture
DW26003101 Tranaxle Housing Oil Seal Installer
DW240140 Transaxle Housing Side Bearing Outer Race Adapter
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AISIN AUTOMATIC TRANSAXLE 5A2 7
DW240150 Transaxle Case Side Bearing Outer Race Adapter
DW240170 Adapter Handle
DW240160 Transaxle Case Outer Tapered Roller Bearing Race Adapter
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5A2 8IAISIN AUTOMATIC TRANSAXLE
SCHEMATIC DIAGRAMS
TRANSMISSION CONTROL MODULE (1 OF 4)
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AISIN AUTOMATIC TRANSAXLE 5A2 9
TRANSMISSION CONTROL MODULE (2 OF 4)
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5A2 10IAISIN AUTOMATIC TRANSAXLE
TRANSMISSION CONTROL MODULE (3 OF 4)
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AISIN AUTOMATIC TRANSAXLE 5A2 11
TRANSMISSION CONTROL MODULE (4 OF 4)
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5A2 12IAISIN AUTOMATIC TRANSAXLE
SHIFT MODE DIAGRAM
Economic Mode (1.6 DOHC)
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AISIN AUTOMATIC TRANSAXLE 5A2 13 Power Mode (1.6 DOHC)
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5A2 14IAISIN AUTOMATIC TRANSAXLE UpSlope 1 Mode (1.6 DOHC)
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AISIN AUTOMATIC TRANSAXLE 5A2 15 UpSlope 2 Mode (1.6 DOHC)
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5A2 16IAISIN AUTOMATIC TRANSAXLE DownSlope Mode (1.6 DOHC)
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AISIN AUTOMATIC TRANSAXLE 5A2 17
COMPONENT LOCATOR
SHIFT SELECT CONTROL
1. 2. 3. 4.
Select Control Lever Assembly Bolt Nut Select Control Cable
5. 6. 7. 8.
Clamp Ering Cable Fastener Bolt
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5A2 18IAISIN AUTOMATIC TRANSAXLE
AUTOMATIC TRANSAXLE COMPONENTS
1. 2. 3. 4. 5. 6. 7.
Breather Hose Clip Breather Plug Oring Input Speed Sensor Oil Cooler Outlet Union Oring
8. 9. 10. 11. 12. 13.
Oil Cooler Inlet Union Oring Screw Plug Oring Washer Drain Plug
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AISIN AUTOMATIC TRANSAXLE 5A2 19
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5A2 20IAISIN AUTOMATIC TRANSAXLE
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. Transaxle Housing Oil Seal Oil Reservoir Plate Transaxle Oil Apply Pipe Differential Gear Oil Apply Pipe Transaxle Oil Apply Pipe Clamp Spring Check Valve Pipe Clamp Apply Gasket Brake Drun Gasket Transaxle Wire Oring Valve Body Parking Lock Pawl Parking Lock Pawl Shaft Torsion Spring Manual Valve lever Shaft Manual Valve Lever Parking Lock Rod Parking Lock Pawl Bracket Manual Detent Spring Pin Spacer 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. Oil Seal Transmission Range (TR) Switch Lock Washer Control Lever Washer Gasket Oil Strainer Oil Pan Gasket Magnet Direct Clutch Accumulator Piston Oring Spring Oring Forward Clutch Accumulator Piston Oring Spring Oring Overdrive Brake Accumulator Piston Oring Oring Spring
DAEWOO V121 BL4
AISIN AUTOMATIC TRANSAXLE 5A2 21
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5A2 22IAISIN AUTOMATIC TRANSAXLE
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. Planetary Ring Gear Oring 1st and Reverse Brake Piston Oring 1st and Reverse Brake Piston Return Spring Plate Disc Flange Snap Ring Planetary Gear Thrust Washer No. 2 OneWay Clutch AntiRattle Clip Flange Disc Plate 2nd Brake Piston Return Spring Oring 2nd Brake Piston Oring 2nd Brake Clutch Cylinder Snap Ring Thrust Bearing Race Front Planetary Sun Gear Thrust Bearing Race 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. OneWay Clutch Assembly Thrust Washer Rear Planetary Sun Gear Snap Ring Flange Disc Plate Thrust Bearing Race Thrust Needle Roller Bearing Forward Clutch Hub Thrust Bearing Race Thrust Needle Roller Bearing Thrust Bearing Race Forward and Reverse Clutch Assembly Thrust Needle Roller Bearing Snap Ring O/D Brake Return Spring O/D Brake Piston Oring Seal Ring Transaxle Rear Cover Apply Gasket Oring Screw Plug
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AISIN AUTOMATIC TRANSAXLE 5A2 23
1. 2. 3. 4. 5. 6. 7.
Side Bearing Outer Race Differential Case Shim Outer Tapered Roller Bearing Race Counter Driven Gear Oil Seal Oil Pump
8. 9. 10. 11. 12. 13. 14.
Thrust Needle Roller Bearing Direct Clutch Assembly Thrust Bearing Race Direct Clutch Hub Counter Driven Gear Transaxle Case Plate Apply Gasket
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5A2 24IAISIN AUTOMATIC TRANSAXLE
BEARING AND RACES INSTALLATION POSITION AND DIRECTION
Mark
Front Race Diameter : mm(in) Inside Outside 29.0 (1.142) 45.50 (1.7913) 30.6 (1.205)
Thrust Bearing Diameter : mm(in) Inside 32.5 (1.280) 17.8 (0.701) 42.5 (1.673) 33.3 (1.311) 18.1 (0.713) 43.2 (1.701) Outside 48.5 (1.909) 30.2 (1.189) 57.5 (2.264) 46.5 (1.831) 29.6 (1.165) 62.0 (2.441)
Rear Race Diameter : mm(in) Inside 20.5 (0.807) 18.1 (0.713) Outside 32.6 (1.283) 28.2 (1.110)
A B C D E F G
19.3 (0.760) 34.95 (1.3670) 19.3 (0.760)
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AISIN AUTOMATIC TRANSAXLE 5A2 25
DIAGNOSIS
ELECTRIC CONNECTOR VIEW
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5A2 26IAISIN AUTOMATIC TRANSAXLE
X1 : TCM Vehicle Side Wiring Connector A1 A2 A4 A5 A6 A7 A11 A12 A14 A15 A16 A17 A23 A24 Ground Pressure Control Solenoid Ground Pressure Control Solenoid LockUp Solenoid Ignition (+) CAN (Low) Transmission Fluid Temperature Sensor Transmission Fluid Temperature Sensor Ground Timing Solenoid Shift Solenoid No.2 Shift Solenoid No.1 CAN (High) Ground B+ B1 B3 B4 B6 B7 B8 B16 B18 B19 B20 B22 B23 B25 R Clock Hold Input Speed Sensor D N Input Speed Sensor Ground L 2 P Stop Lamp Switch DLC Output Speed Sensor
X2 : Transmission Range (TR) Switch Connector 1 2 3 4 5 6 7 8 9 P R Ground 2 N ST() D 1 ST(+) X4 : Output Speed Sensor Connector 1 2 3 Ignition Ground Output Speed Sensor 1 2 8 10 1 2 3 4 5 6
X3 : Transaxle Wiring Connector Transmission Fluid Temperature Sensor Timing Solenoid Pressure Control Solenoid LockUp Solenoid Shift Solenoid No.1 Transmission Fluid Temperature Sensor Ground Pressure Control Solenoid Ground Shift Solenoid No.2
X5 : Input Speed Sensor Input Speed Sensor Ground Input Speed Sensor
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AISIN AUTOMATIC TRANSAXLE 5A2 27
WIRING HARNESS AND CONNECTOR INSPECTION
1. Reproducing test Perform symptom simulation test on the basis of user's condition. Refer to the below factors. Occuringroad condition, speed, accelerate, reduce speed, straight, curve, air temperature, weather, etc. Inspect the connection condition of between connectors. Inspect the failure between connectors by visual check and contact pressure check. S S S S 3. Connector disconnected Terminals rusted Terminals deformation or loose fit S S
Measure the resistance between one terminal an another terminal in the same connector.(Except between power supply or between earth). Normal : 1M or higher (No short circuit) 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 failure 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.
2.
Inspect the Continuity of the wiring harness. Disconnect both ends connector of wiring harness, measure resistance between one connector terminal and other. S S Normal : 1 or less (No open circuit) Abnormal : R (Open circuit)
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 temperature is hot condition (50°C (122°F) ~ 80°C (176°F)). 1. D range test S Check for upshift, downshift, kickdown and lockup operation at the shift point shown in the shift schedule. Check for engine brake operation. Check for Check abnormal shock, noise and harshness.
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 S Normal : 1M or higher (No short circuit) Abnormal : Low resistance (Short circuit) 2.
S S
"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 operation of parking lock pawl.
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5A2 28IAISIN AUTOMATIC TRANSAXLE
1.
FUNCTION CHECK
Confirm whether below condition before function check. S S Oil temperature is hot condition (50°C (122°F) ~ 80°C (176°F)). Switch of A/C and light etc are off. 2. 3.
Chock 4 Wheels and apply parking brake fully, lock vehicle perfectly. Fully pressed on foot brake pedal with left foot. Shift into "D" and "R" range, fully press on accelerator pedal with right foot. Quickly read stall speed at this time. Standards 2390 ± 150 rpm
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. Result of Stall Test Lower than standards both "D" and "R" Higher than standards only "D"
Notice : Do not continuously run longer than 5 sec because of extreme increasing oil temp. Make sure to keep interval for more than 1 min between stall tests. Cause of Failure
Less engine power Torque converter one way clutch failure Lower line pressure S Pressure control solenoid (PCS) failure S Primary regulator valve failure Forward clutch (C1) failure (Slipping) No.2 Oneway clutch (F2) failure 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) 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 "N ³ D" "N" ³ "R"
Higher than standards only "R"
Higher than standards both "D" and "R"
Time Lag Test
Time lag is time till slightly shock can be felt when shift lever is shifted "N" ³ "D" and "N" ³ "R" while engine idling. Time lag test can inspect hydraulic condition and clutch/ brake condition. 1. 2. Chock 4 Wheels and apply parking brake fully, lock vehicle perfectly. Measure time lag by using stop watch from moment when shift lever is shifted in "N" ³ "D" and "N" ³ "R" until moment slightly shock can be felt.
less than 0.7 sec 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.)
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AISIN AUTOMATIC TRANSAXLE 5A2 29
Result of Time Lag Test Longer than standards "N" ³ "D" Cause of Failure 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 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 2. 3. Install oil pressure gage adapter DW24001002 to test hole for line pressure. 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/cm2) Engine idle Engine stall D 0.37 (3.9) 0.14 (4.2) 1.10 (11.3) 1.23 (12.5) R 0.59 (6.0) 0.68 (6.9) 1.58 (16.2) 1.83 (18.6)
Longer than standards "N" ³ "R"
Hydraulic Test
Hydraulic test can inspect working condition inside A/T by measuring line pressure in "D" / "R" range and "idle" / "stall" condition.
Notice : Do not continuously run longer than 5 sec because of extreme increasing oil temp. Make sure to keep interval for more than 1 min between stall tests. 1. Chock 4 Wheels and apply parking brake fully, lock vehicle perfectly. Result of Hydraulic Test Higher than standards both "D and "R" Lower than standards both "D and "R" Make sure to check no oil leak after installing oil pressure gage adapter. Cause of Failure Pressure control solenoid (PCS) failure Primary regulator valve failure Pressure control solenoid (PCS) failure Primary regulator valve failure Oil pump failure Oil strainer failure (clogging) Oil leak for each range circuit "D" hydraulic circuit failure Forward clutch (C1) failure "R" hydraulic circuit failure Reverse clutch (C3) failure 1st and reverse brake (B3) failure
Lower than standards only "D Lower than standards only "R"
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5A2 30IAISIN AUTOMATIC TRANSAXLE Manual Shifting Test
Manual shifting test is to determine whether failure symptom 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 D R Gear 3rd gear Reverse
Normal
S
Apply compressed air of 2kg/cm2 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.
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)
Vehicle Speed Sensor
1. Remove the connector of vehicle speed sensor, connect 12V power supply and voltmeter to the terminal.(Do not mistake polarity) Check voltage change from approx. 0V to 12V with vehicle speed sensor driven gear rotated.
2.
Notice : The voltage change should be 4 times for 1 revolution of the vehicle speed sensor driven gear.
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 lockup clutch lining. As a result, it cause major failure "No move". Do not tighten the bolts by using impact wrench.
S
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 : If the result of inspection is bad, replace the vehicle speed sensor.
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Action : Replace failure parts.
AISIN AUTOMATIC TRANSAXLE 5A2 31
Input Speed Sensor
S Inspect resistance of each input speed senor between terminals.
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) 5.80~7.09 k 110°C (230°F) 0.23~0.263 k
Action : If the result of inspection is bad, replace the TFT sensor. Notice : S Make sure to inspect resistance again at 20°C (68°F) when resistance differ from standards except 20°C (68°F). It might become infinity ohm when inspect resistance at higher temperature.
S
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.
DAEWOO V121 BL4
5A2 32IAISIN AUTOMATIC TRANSAXLE Shift Solenoid (NO.1,2), Timing Solenoid, LockUp Solenoid
1. Inspect the resistance of each shift solenoid between the terminal and the body earth.
S
Timing solenoid (Normal close type) No leak air Leak air
No battery connection Battery connection
Action : If the result of inspection is bad, replace each solenoid. Notice : S Make sure to inspect resistance again at 20°C (68°F) when resistance differ from standards except 20°C (68°F). It might become infinity ohm when inspecting resistance at higher temperature. Inspect the operation of each shift solenoid. S Solenoid (No.1,2), Lockup solenoid (Normal open type) Leak air No leak 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 solenoid between terminals.
S 2.
Action : Repalce the valve body assembly. (No replacement of solenoid by itself) Notice : S Make sure to inspect resistance again at 20°C (68°F) when resistance differ from standards except 20°C (68°F). It might become infinity ohm when inspecting resistance at higher temperature.
No battery connection Battery connection
S
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AISIN AUTOMATIC TRANSAXLE 5A2 33
DAEWOO V121 BL4
5A2 34IAISIN AUTOMATIC TRANSAXLE
ONVEHICLE REPAIR (MATRIX CHART)
DAEWOO V121 BL4
AISIN AUTOMATIC TRANSAXLE 5A2 35
DAEWOO V121 BL4
5A2 36IAISIN AUTOMATIC TRANSAXLE
DIAGNOSTIC TROUBLE CODE DIAGNOSIS
DIAGNOSTIC TROUBLE CODE CHART
DTC DESCRIPTION TYPE Illuminate MIL Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes No Yes Blink Hold Lamp No No No No No No No No No No No No No No No No No No No No No No No
P0562 P0563 P0601 P0604 P0705 P0712 P0713 P0717 P0722 P0727 P0741 P0742 P0743 P0748 P0751 P0753 P0756 P0758 P0785 P1781 P1791 P1792 U2105
System Voltage Low System Voltage High Internal Control Module Memory Checksum Error Internal Transmission Control Module (TCM) Random Access Memory (RAM) Error Transmission Range (TR) Switch Circuit Malfunction Transmission Fluid Temperature Sensor Circuit Low Input Transmission Fluid Temperature Sensor Circuit High Input Input Shaft Speed (ISS) Sensor Circuit No Signal Output Shaft Speed (OSS) sensor Circuit No Signal Engine Speed Input Circuit No Signal Torque Converter Clutch (TCC) Circuit Stuck Off Torque Converter Clutch (TCC) Circuit Stuck On Torque Converter Clutch (TCC) Electrical Pressure Control Solenoid (PCS) Electrical Shift Solenoid 1 (SS1) Stuck Off Shift Solenoid 1 (SS1) Electrical Shift Solenoid 2 (SS2) Stuck Off Shift Solenoid 2 (SS2) Electrical Timing Solenoid (ST) Electrical Engine Torque Signal Error Throttle Position Signal Error Engine Coolant Temperature (ECT) Signal Error CAN Error
B B A B B A A A A A B B B A B A B A A A A D A
* 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.
DAEWOO V121 BL4
AISIN AUTOMATIC TRANSAXLE 5A2 37
DIAGNOSTIC TROUBLE CODE (DTC) P0562 SYSTEM VOLTAGE LOW
Conditions for Setting the DTC S System voltage is too low. S TCM detects that voltage is less than 9 volts for 0.5 seconds continuously. S Engine revolution is 600 rpm or greater. Action Taken When the DTC Sets S TCM will request the illumination of MIL and store DTC when TCM detects failures on two consecutive ignition cycle. Conditions for Clearing the DTC S S S The TCM turns off the MIL when no further failures detected for three consecutive ignition cycles. The scan tool can clear the DTC from the TCM history. The TCM clears the DTC from the TCM history memory after forty consecutive warm up cycles without fault.
Cause of Failure S S S TCM wiring harness and connectors Battery TCM
DAEWOO V121 BL4
5A2 38IAISIN AUTOMATIC TRANSAXLE DTC P0562 System Voltage Low
Step 1 1. 2. 3. 4. 5. 6. 7. Action Turn the ignition OFF. Install the Scan tool. Turn the ignition ON, with the engine OFF. Run the engine to 600 rpm or greater. Record then clear DTC(s). Select system voltage on the scan tool. Drive the vehicle and observe the scan tool for either of the flowing conditions: Is the voltage within the values shown? 1. Disconnect the battery cable. 2. Measure the battery voltage. Is the voltage within the values shown? 1. Replace the battery. Is the replacement completed? 1. Turn the headlamp ON. 2. Turn the air conditioner ON. 3. Run the engine to 600 rpm or greater. 4. Observe the scan tool for system voltage. Is the voltage within the values shown? 1. Turn the ignition LOCK. 2. Repair the alternator circuit if necessary. Is the action completed? Inspect the EF1,F2 fuse for an open. Was a problem found? Inspect the EF1,F2 fuse for short. Replace the fuse if necessary. Is the replacement complete? 1. Turn the ignition ON. 2. Measure the voltage of EF1, F2. Is the voltage within the values shown? Repair the fuse voltage supply lines for open. Is the action completed? 1. Turn the ignition LOCK. 2. Disconnect the TCM wiring connector. 3. Measure the resistance between EF1 fuse and terminal A24 of the TCM wiring connector. Is the resistance within the values shown? Repair the circuit (between EF1 and terminal A24) for short to ground and open. Is the repair completed? 1. Disconnect the C105 connector and TCM connector. 2. Turn the ignition ON. 3. Measure the voltage of the terminal A24. Is the voltage within the values shown? Repair the circuit from EF1 to terminal A24 of the TCM for short to battery. Is the repair completed? Value(s) 916v Yes Go to Step 4 No Go to Step 2
2
916v
Go to Step 4
Go to Step 3
3 4
916v
System OK Go to Step 6
Go to Step 5
5
System OK
6 7
Go to Step 7 System OK
Go to Step 8
8
916v
Go to Step 10
Go to Step 9
9 10
0
System OK Go to Step 12
Go to Step 11
11
System OK
12
916v
Go to Step 13
Go to Step 14
13
System OK
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AISIN AUTOMATIC TRANSAXLE 5A2 39
Step 14 Action 1. Turn the ignition LOCK. 2. Disconnect the C201 connector. 3. Measure the resistance between F2 fuse and terminal A6 of the TCM wiring connector. Is the resistance within the values shown? Repair the circuit (between F2 and terminal A6) for short to ground and open. Is the repair completed? 1. Turn the ignition ON. 2. Measure the voltage of the terminal A6. Is the voltage within the values shown? Repair the circuit (between F2 and terminal A6) for short to battery. Is the repair completed? 1. Inspect the transaxle wiring for poor electrical connectors at the transaxle connector. 2. Look for possible bent, backed out, deformed, or damaged terminals. 3. Check for week terminal tension. Was a condition found? Replace the TCM. Is the replacement complete? 1. 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 displayed? Value(s) 0 Yes Go to Step 17 No Go to Step 15
15
System OK
16
916v
Go to Step 17
Go to Step 18
17
System OK
18
Verify repair and Go to Step 20
19 20
Go to Step 20 Begin diagnosis again
Repair verified Exit DTC chart
DAEWOO V121 BL4
5A2 40IAISIN AUTOMATIC TRANSAXLE
DIAGNOSTIC TROUBLE CODE (DTC) P0563 SYSTEM VOLTAGE HIGH
Conditions for Setting the DTC S System voltage is too high. S TCM detects that voltage is greater than 18 volts for 0.5 seconds continuously. S Engine revolution is 600 rpm or greater. Action Taken When the DTC Sets S TCM will request the illumination of MIL and store DTC when TCM detects failures on two consecutive ignition cycle. Conditions for Clearing the DTC S S S The TCM turns off the MIL when no further failures detected for three consecutive ignition cycles. The scan tool can clear the DTC from the TCM history. The TCM clears the DTC from the TCM history memory after forty consecutive warm up cycles without fault.
Cause of Failure S S S TCM wiring harness and connectors Battery TCM
DAEWOO V121 BL4
AISIN AUTOMATIC TRANSAXLE 5A2 41 DTC P0563 System Voltage High
Step 1 1. 2. 3. 4. 5. 6. 7. Action Turn the ignition OFF. Install the Scan tool. Turn the ignition ON, with the engine OFF. Run the engine to 600 rpm or greater. Record then clear DTC(s). Select system voltage on the scan tool. Drive the vehicle and observe the scan tool for either of the flowing conditions: Is the voltage within the values shown? 1. Disconnect the battery cable. 2. Measure the battery voltage. Is the voltage within the values shown? 1. Replace the battery. Is the replacement completed? 1. Turn the headlamp ON. 2. Turn the air conditioner ON. 3. Run the engine to 600 rpm or greater. 4. Observe the scan tool for system voltage. Is the voltage within the values shown? 1. Turn the ignition LOCK. 2. Repair the alternator circuit if necessary. Is the action completed? Inspect the EF1,F2 fuse for an open. Was a problem found? Inspect the EF1,F2 fuse for short. Replace the fuse if necessary. Is the replacement complete? 1. Turn the ignition ON. 2. Measure the voltage of EF1,F2. Is the voltage within the values shown? Repair the fuse voltage supply lines for open. Is the action completed? 1. Turn the ignition LOCK. 2. Disconnect the TCM wiring connector. 3. Measure the resistance between EF1 fuse and terminal A24 of the TCM wiring connector. Is the resistance within the values shown? Repair the circuit (between EF1 and terminal A24) for short to ground and open. Is the repair completed? 1. Disconnect the C105 connector and TCM connector. 2. Turn the ignition ON. 3. Measure the voltage of the terminal A24. Is the voltage within the values shown? Repair the circuit from EF1 to terminal A24 of the TCM for short to battery. Is the repair completed? Value(s) 916v Yes Go to Step 4 No Go to Step 2
2
916v
Go to Step 4
Go to Step 3
3 4
916v
System OK Go to Step 6
Go to Step 5
5
System OK
6 7
Go to Step 7 System OK
Go to Step 8
8
916v
Go to Step 10
Go to Step 9
9 10
0
System OK Go to Step 12
Go to Step 11
11
System OK
12
916v
Go to Step 13
Go to Step 14
13
System OK
DAEWOO V121 BL4
5A2 42IAISIN AUTOMATIC TRANSAXLE
Step 14 Action 1. Turn the ignition LOCK. 2. Disconnect the C201 connector. 3. Measure the resistance between F2 fuse and terminal A6 of the TCM wiring connector. Is the resistance within the values shown? Repair the circuit (between F2 and terminal A6) for short to ground and open. Is the repair completed? 1. Turn the ignition ON. 2. Measure the voltage of the terminal A6. Is the voltage within the values shown? Repair the circuit (between F2 and terminal A6) for short to battery. Is the repair completed? 1. Inspect the transaxle wiring for poor electrical connectors at the transaxle connector. 2. Look for possible bent, backed out, deformed, or damaged terminals. 3. Check for week terminal tension. Was a condition found? Replace the TCM. Is the replacement completed? 1. 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 displayed? Value(s) 0 Yes Go to Step 17 No Go to Step 15
15
System OK
16
916v
Go to Step 17
Go to Step 18
17
System OK
18
Verify repair and Go to Step 20
19 20
Go to Step 20 Begin diagnosis again
Repair verified Exit DTC chart
DAEWOO V121 BL4
AISIN AUTOMATIC TRANSAXLE 5A2 43
DIAGNOSTIC TROUBLE CODE (DTC) P0601 INTERNAL CONTROL MODULE MEMORY CHECKSUM ERROR
Conditions for Setting the DTC S The Transmission Control Module (TCM) detects a difference between the calculated checksum data and rear checksum data. 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 consecutive ignition cycle. 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 history. S The TCM clears the DTC from the TCM history memory after forty consecutive warm up cycles without fault. Cause of Failure S Harness or connector between TCM and ECM S ECM S TCM
DAEWOO V121 BL4
5A2 44IAISIN AUTOMATIC TRANSAXLE DTC P0601 Internal Control Module Memory Checksum Error
Step 1 Action 1. 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 Diagnostic Trouble Codes Information menu. 7. Clear DTC Information. 8. Perform one vehicle drive cycle. Is the Malfunction Indicator Lamp (MIL) ON? 1. Select Request DTC by Status from the Diagnostic Trouble Codes Information menu. 2. Request DTC by Status. Is DTC P0601 displayed? Value(s) Yes Go to Step 2 No Inspect Transmission Control Module (TCM) wiring harness and connector for signs of an intermittent condition. Repair as necessary.
2
Replace the Transmission Control Module (TCM)
Inspect Transmission Control Module (TCM) wiring harness and connector for signs of an intermittent condition. Repair as necessary.
DAEWOO V121 BL4
AISIN AUTOMATIC TRANSAXLE 5A2 45
DIAGNOSTIC TROUBLE CODE (DTC) P0604 INTERNAL TRANSMISSION CONTROL MODULE (TCM) RANDOM ACCESS MEMORY (RAM) ERROR
Conditions for Setting the DTC S The Transmission Control Module (TCM) cannot carry out the four RAM initialization routines. S TCM detects that the RAM cannot be written and read correctly. Action Taken When the DTC Sets S TCM will request the illumination of MIL and store DTC when TCM detects failures on two consecutive ignition cycle. Conditions for Clearing the DTC S S S The TCM turns off the MIL when no further failures detected for three consecutive ignition cycles. The scan tool can clear the DTC from the TCM history. The TCM clears the DTC from the TCM history memory after forty consecutive warm up cycles without fault.
Cause of Failure S S S Harness or connector between TCM and ECM ECM TCM
DAEWOO V121 BL4
5A2 46IAISIN AUTOMATIC TRANSAXLE DTC P0604 Internal Transmission Control Module (TCM) Random Access Memory (RAM) Error
Step 1 Action 1. 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 Diagnostic Trouble Codes Information menu. 7. Clear DTC Information. 8. Perform two vehicle drive cycles. Is the Malfunction Indicator Lamp (MIL) ON? 1. Select Request DTC by Status from the Diagnostic Trouble Codes Information menu. 2. Request DTC by Status. Is DTC P0604 displayed? Value(s) Yes Go to Step 2 No Inspect Transmission Control Module (TCM) wiring harness and connector for signs of an intermittent condition. Repair as necessary.
2
Replace the Transmission Control module (TCM)
Inspect Transmission Control Module (TCM) wiring harness and connector for signs of an intermittent condition. Repair as necessary.
DAEWOO V121 BL4
AISIN AUTOMATIC TRANSAXLE 5A2 47
DIAGNOSTIC TROUBLE CODE (DTC) P0705 TRANSMISSION RANGE (TR) SWITCH CIRCUIT MALFUNCTION
Conditions for Setting the DTC S TCM detects more than two equal signals from the Park/Neutral Position switch circuit for 10 seconds continuously. S TCM detects the no signal of TR switch circuit for 2 seconds continuously. S Vehicle speed is 30 km/h (19 mph) or greater. S Engine revolution is 1500 rpm or greater. Action Taken When the DTC Sets S TCM will request the illumination of MIL and store DTC when TCM detects failures on two consecutive ignition cycle. S TCM judges with the priority. (D>2>1>R>N>P) S No timing solenoid control for ND S No selflearning control S No lockup S No prevent reverse gear control 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 history. S The TCM clears the DTC from the TCM history memory after forty consecutive warm up cycles without fault. S TCM detects single "D range" signal of the TR switch. Cause of Failure S Wiring harness or connector between TR switch and TCM S TR switch S TCM
DAEWOO V121 BL4
5A2 48IAISIN AUTOMATIC TRANSAXLE DTC P0705 Transmission Range (TR) Switch Circuit Malfunction
Step 1 Action 1. 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 Diagnostic Trouble Codes Information menu. 7. Clear DTC Information. 8. Perform two vehicle drive cycles. Is the Malfunction Indicator Lamp (MIL) ON? 1. Select Request DTC by Status from the Diagnostic Trouble Codes Information menu. 2. Request DTC by Status. Is DTC P0705 displayed? Value(s) Yes Go to Step 2 No Repair the temporary connection failure of connector (Refer to "Wiring Harness and Connector Inspection" in this section.)
2
Go to Step 3
Repair the temporary connection failure of connector (Refer to "Wiring Harness and Connector Inspection" in this section.) Go to Step 5
3
1. Turn the ignition OFF. 2. Inspect the continuity between the vehicle harness and the Transmission Range (TR) Switch. 3. Disconnect the TCM connector (X1) of the vehicle harness and inspect the continuity for the each terminal according to the position of the select lever. P : B20 R : B1 N : B8 D : B7 2 : B19 1 : B18 Does the inspection OK?
Go to Step 4
4
1. Estimate the failure of between the vehicle wiring harness connector and TCM. 2. Inspect the connector. Refer to "Wiring Harness and Connector Inspection" in this section. 3. Inspect the connection condition between the TCM connectors (C1). Is the connection condition OK? 1. Estimate the failure of between the vehicle harness and TR switch. 2. Disconnect the connector (X2) of the vehicle harness and inspect the continuity between the terminals. Refer to "Wiring Harness and Connector Inspection" in this section. Is the condition of TR switch OK?
Go to Step 6
Repair the wiring harness connectors.
5
Go to Step 7
Replace the TR switch.
DAEWOO V121 BL4
AISIN AUTOMATIC TRANSAXLE 5A2 49
Step 6 Action 1. Replace the master TCM. 2. Perform the reproducing test under user condition after confirming no DTC. Is DTC displayed? Value(s) Yes Repair the temporary connection failure of connector (Refer to "Wiring Harness and Connector Inspection" in this section). No Replace the TCM.
7
1. Estimate the failure of the vehicle harness. 2. Inspect continuity and short circuit for the vehicle harness and inspect the connection condition between connectors (C2). Refer to "Wiring Harness and Connector Inspection" in this section. Is the condition OK?
Repair the tem- Replace the veporary connechicle harness tion failure of or adjustment connector between connectors.
DAEWOO V121 BL4
5A2 50IAISIN AUTOMATIC TRANSAXLE
DIAGNOSTIC TROUBLE CODE (DTC) P0712 TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR CIRCUIT LOW INPUT
Conditions for Setting the DTC S TCM detects that A/D value of Transmission Fluid Temperature sensor (TFT) signal is less than 10 for 5 minutes continuously after 1 time of this detection. (A/D VALUE 10: 24mV) 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 history. S The TCM clears the DTC from the TCM history memory after forty consecutive warm up cycles without fault. S TCM detects the temperature of the transmission fluid is between 0°C (32°) and 150°C (302°F) for 10 seconds continuously. Cause of Failure S Wiring harness or connector between Transmission Fluid Temperature (TFT) sensor and TCM S TFT sensor S TCM
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. TCM judges the temperature of the transmission fluid is 200°C (392°F). No lockup control No 4th gear No selflearning control No timing solenoid control ND
S S S S S
DAEWOO V121 BL4
AISIN AUTOMATIC TRANSAXLE 5A2 51 DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input
Step 1 Action 1. 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 Diagnostic Trouble Codes Information menu. 7. Clear DTC Information. 8. Perform one vehicle drive cycle. Is the Malfunction Indicator Lamp (MIL) ON? 1. Select Request DTC by Status from the Diagnostic Trouble Codes Information menu. 2. Request DTC by Status. Is DTC P0712 displayed? Value(s) Yes Go to Step 2 No Repair the temporary connection failure of connector (Refer to "Wiring Harness and Connector Inspection" in this section.)
2
Go to Step 3
Repair the temporary connection failure of connector (Refer to "Wiring Harness and Connector Inspection" in this section.) Go to Step 5
3
1. Turn the ignition OFF. 2. Inspect the resistance between the vehicle harness and Transmission Fluid Temperature (TFT) sensor. Refer to "Unit Inspection" in this section. 3. Disconnect the TCM connector (X1) and inspect the resistance between the terminal A11 and A12. Is the measurement within the specified value? 1. Estimate the failure of between the vehicle wiring harness connector and TCM. 2. Inspect the connector. Refer to "Wiring Harness and Connector Inspection" in this section. 3. Inspect the connection condition between the connectors (C1). Is the connection condition OK? 1. Estimate the failure of between the vehicle harness and TFT sensor. 2. Disconnect the connector (X3) of T/M wire and inspect the resistance between TFT sensor connector terminal 1 and 6. Is the measurement within the specified value?
10°C (50°F): 5.807.09 kW 110°C (230°F): 0.2310.263 kW
Go to Step 4
4
Go to Step 6
Repair the wiring harness connectors.
5
10°C (50°F): 5.807.09 kW 110°C (230°F): 0.2310.263 kW
Go to Step 7
Go to Step 8
DAEWOO V121 BL4
5A2 52IAISIN AUTOMATIC TRANSAXLE
Step 6 Action 1. Replace the master TCM. 2. Perform the reproducing test under user condition after confirming no DTC. Is DTC displayed? Value(s) Yes Repair the temporary connection failure of connector (Refer to "Wiring Harness and Connector Inspection" in this section). No Replace the TCM.
7
1. Estimate the failure of the vehicle wiring harness or between connectors. 2. Inspect continuity and short circuit for the vehicle wiring harness and inspect the connection condition between connectors (C3). Refer to "Wiring Harness and Connector Inspection" in this section. Is the condition OK? 1. Estimate the failure of T/M wire or between connectors of TFT sensor. 2. Inspect fluid temperature. Refer to "Unit Inspection" in this section. Is the problem found? 1. Estimate the failure of T/M wire. Inspect continuity and short circuit for the T/M wire and inspect the connection condition between connectors (C3). Refer to "Wiring Harness and Connector Inspection" in this section. Is the condition OK?
Repair the tem- Replace the veporary connechicle harness tion failure of or adjustment connector between connectors
8
Replace TFT sensor
Go to Step 9
9
Repair the temporary connection failure of connector
Replace the T/M wire or adjustment between connectors
DAEWOO V121 BL4
AISIN AUTOMATIC TRANSAXLE 5A2 53
DIAGNOSTIC TROUBLE CODE (DTC) P0713 TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR CIRCUIT HIGH INPUT
Conditions for Setting the DTC S TCM detects that A/D value of Transmission Fluid Temperature sensor (TFT) signal is less than 15 and the minimum A/D value is more than 943, when it is past 15 minutes after ignition ON.(A/D value 943 : 4.7 v) S After 1 time of above detection. S Gear selector position is except P and N. S Engine revolution is 400 rpm or greater. 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 TCM judges the temperature of the transmission fluid is 200°C (392°F). S No lockup control S No 4th gear S No selflearning control S No timing solenoid control ND Conditions for Clearing the DTC S S S The TCM turns off the MIL when no further failures detected for three consecutive ignition cycles. The scan tool can clear the DTC from the TCM history. The TCM clears the DTC from the TCM history memory after forty consecutive warm up cycles without fault. TCM detects the temperature of the transmission fluid is between 0°C (32°F) and 150°C (302°F) for 10 seconds continuously.
S
Cause of Failure S S S Wiring harness or connector between Transmission Fluid Temperature (TFT) sensor and TCM TFT sensor TCM
DAEWOO V121 BL4
5A2 54IAISIN AUTOMATIC TRANSAXLE DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input
Step 1 Action 1. 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 Diagnostic Trouble Codes Information menu. 7. Clear DTC Information. 8. Perform one vehicle drive cycle. Is the Malfunction Indicator Lamp (MIL) ON? 1. Select Request DTC by Status from the Diagnostic Trouble Codes Information menu. 2. Request DTC by Status. Is DTC P0713 displayed? Value(s) Yes Go to Step 2 No Repair the temporary connection failure of connector (Refer to "Wiring Harness and Connector Inspection" in this section.)
2
Go to Step 3
Repair the temporary connection failure of connector (Refer to "Wiring Harness and Connector Inspection" in this section.) Go to Step 5
3
1. Turn the ignition OFF. 2. Inspect the resistance between the vehicle harness and Transmission Fluid Temperature (TFT) sensor. Refer to "Unit Inspection" in this section. 3. Disconnect the TCM connector (X1) and inspect the resistance between the terminal A11 and A12. Is the measurement within the specified value? 1. Estimate the failure of between the vehicle wiring harness connector and TCM. 2. Inspect the connector. Refer to "Wiring Harness and Connector Inspection" in this section. 3. Inspect the connection condition between the connectors (C1). Is the connection condition OK? 1. Estimate the failure of between the vehicle harness and TFT sensor. 2. Disconnect the connector (X3) of T/M wire and inspect the resistance between TFT sensor connector terminal 1 and 6. Is the measurement within the specified value?
10°C (50°F): 5.807.09 kW 110°C (230°F): 0.2310.263 kW
Go to Step 4
4
Go to Step 6
Repair the wiring harness connectors.
5
10°C (50°F): 5.807.09 kW 110°C (230°F): 0.2310.263 kW
Go to Step 7
Go to Step 8
DAEWOO V121 BL4
AISIN AUTOMATIC TRANSAXLE 5A2 55
Step 6 Action 1. Replace the master TCM. 2. Perform the reproducing test under user condition after confirming no DTC. Is DTC displayed? Value(s) Yes Repair the temporary connection failure of connector (Refer to "Wiring Harness and Connector Inspection" in this section). No Replace the TCM.
7
1. Estimate the failure of the vehicle wiring harness or between connectors. 2. Inspect continuity and short circuit for the vehicle wiring harness and inspect the connection condition between connectors (C3). Refer to "Wiring Harness and Connector Inspection" in this section. Is the condition OK? 1. Estimate the failure of T/M wire or between connectors of TFT sensor. 2. Inspect fluid temperature. Refer to "Unit Inspection" in this section. Is the problem found? 1. Estimate the failure of T/M wire. Inspect continuity and short circuit for the T/M wire and inspect the connection condition between connectors (C3). Refer to "Wiring Harness and Connector Inspection" in this section. Is the condition OK?
Repair the tem- Replace the veporary connechicle harness tion failure of or adjustment connector between connectors
8
Replace TFT sensor
Go to Step 9
9
Repair the temporary connection failure of connector
Replace the T/M wire or adjustment between connectors
DAEWOO V121 BL4
5A2 56IAISIN AUTOMATIC TRANSAXLE
DIAGNOSTIC TROUBLE CODE (DTC) P0717 INPUT SHAFT SPEED (ISS) SENSOR CIRCUIT NO SIGNAL
Conditions for Setting the DTC S This DTC detects no signal of Input Shaft Speed (ISS) sensor circuit for a long period of time. ( Revolution : 0 rpm 10000 rpm). S TCM detects no pulse of ISS sensor while TCM detects 4 pulses of Output Speed Sensor. This detection 1000 times continuously. S D,2,L range selected S Engine revolution is 400 rpm or greater. S DTCs P0751, P0753, P0756, P0758, and P0705 are not set. S Output revolution is 775 rpm or greater. S 25 seconds later after Neutral to Drive shift. S 10 seconds later after changing the gear. 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 S S S No engagement pressure control No 4th gear No selflearning control No timing solenoid control ND
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 history. S The TCM clears the DTC from the TCM history memory after forty consecutive warm up cycles without fault. S TCM detects 250 pulses of ISS while failure detection is not achieved. Cause of Failure S Wiring harness or connector between Input Shaft Speed (ISS) sensor and TCM S ISS sensor S TCM
DAEWOO V121 BL4
AISIN AUTOMATIC TRANSAXLE 5A2 57 DTC P0717 Input Shaft Speed (ISS) Sensor Circuit No Signal
Step 1 Action 1. 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 Diagnostic Trouble Codes Information menu. 7. Clear DTC Information. 8. Perform one vehicle drive cycle. Is the Malfunction Indicator Lamp (MIL) ON? 1. Select Request DTC by Status from the Diagnostic Trouble Codes Information menu. 2. Request DTC by Status. Is DTC P0717 displayed? Value(s) Yes Go to Step 2 No Repair the temporary connection failure of connector (Refer to "Wiring Harness and Connector" in this section.)
2
Go to Step 3
Repair the temporary connection failure of connector (Refer to "Wiring Harness and Connector" in this section.) Go to Step 5
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1. Turn the ignition OFF. 2. Inspect the resistance between the vehicle harness and Input Shaft Speed (ISS) sensor. Refer to"Unit Inspection" in this section. 3. Disconnect the TCM connector (X1) and inspect the resistance between the terminal B6 and B16. Is the measurement within the specified value? 1. Estimate the failure of between the vehicle wiring harness connector and TCM. 2. Inspect the connector. Refer to "Wiring Harness and Connector Inspection" in this section. 3. Inspect the connection condition between the connectors (C1). Is the connection condition OK? 1. Estimate the failure of T/M wire or between the connectors of ISS sensor. 2. Disconnect the ISS sensor connector (X5) and inspect the resistance between terminals 1 and 2. Is the measurement within the specified value?
20°C (68°F): 560680 W
Go to Step 4
4
Go to Step 6
Repair the wiring harness connectors.
5
20°C (68°F): 560680W
Go to Step 7
Replace the ISS sensor
DAEWOO V121 BL4
5A2 58IAISIN AUTOMATIC TRANSAXLE
Step 6 Action 1. Replace the master TCM. 2. Perform the reproducing test under user condition after confirming no DTC. Is DTC displayed? Value(s) Yes Repair the temporary connection failure of connector (Refer to "Wiring Harness and Connector" in this section.) Repair the temporary connection failure of connector No Replace the TCM.
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1. Estimate the failure of T/M wire. 2. Inspect continuity and short circuit for the T/M wire and inspect the connection condition between connectors (C5). Refer to "Wiring Harness and Connector" in this section Is the condition OK?
Replace the T/M wire or adjustment between connectors
DAEWOO V121 BL4
AISIN AUTOMATIC TRANSAXLE 5A2 59
DIAGNOSTIC TROUBLE CODE (DTC) P0722 OUPUT SHAFT SPEED (OSS) SENSOR CIRCUIT NO SIGNAL
Conditions for Setting the DTC S This DTC detects no signal of Output Shaft Speed (OSS) sensor circuit for a long period of time. ( Revolution : 0 rpm 10000 rpm). S TCM detects no pulse of Output Shaft Speed (OSS) sensor while TCM detects 178 pulses of Input Shaft Speed sensor. This detection 500 times continuously. S D,2,L range selected S Input speed is 5 km/h (3 mph) or greater. S DTCs P0751, P0753, P0756, P0758, P0717 and P0705 are not set. S 25 seconds later after Neutral to Drive shift. 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 S S No 4th gear No selflearning control No prevent reverse gear control
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 history. S The TCM clears the DTC from the TCM history memory after forty consecutive warm up cycles without fault. S TCM detects 250 pulses of Output Shaft Speed (OSS) sensor while failure detection is not achieved. Cause of Failure S Wiring harness or connector between Output Shaft Speed (OSS) sensor and TCM S OSS sensor S TCM
DAEWOO V121 BL4
5A2 60IAISIN AUTOMATIC TRANSAXLE DTC P0722 Output Shaft Speed (OSS) sensor Circuit No Signal
Step 1 Action 1. 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 Diagnostic Trouble Codes Information menu. 7. Clear DTC Information. 8. Perform one vehicle drive cycle. Is the Malfunction Indicator Lamp (MIL) ON? 1. Select Request DTC by Status from the Diagnostic Trouble Codes Information menu. 2. Request DTC by Status. Is DTC P0722 displayed? Value(s) Yes Go to Step 2 No Repair the temporary connection failure of connector (Refer to "Wiring Harness and Connector Inspection" in this section.)
2
Go to Step 3
Repair the temporary connection failure of connector (Refer to "Wiring Harness and Connector Inspection" in this section.) Go to Step 5
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1. Turn the ignition OFF. 2. Inspect the voltage between vehicle harness and the Output Shaft Speed (OSS) sensor. 3. Disconnect the connector (X1) of the vehicle harness. 4. Connect the voltmeter to monitor the voltage between terminal B25 and ground. 5. Turn ignition ON and lift up the vehicle. 6. Check the voltage change from approximately 0 v to 12 v when the wheel is turned slowly. Does the measurement change within the specified value? 1. Estimate the failure of between the vehicle wiring harness connector and TCM. 2. Inspect the connector. Refer to "Wiring Harness and Connector Inspection" in this section. 3. Inspect the connection condition between the connectors (C1). Is the connection condition OK? 1. Estimate the failure of T/M wire or between the connectors of OSS sensor. 2. Inspect the OSS sensor. Refer to "Unit Inspection" in this section Is the condition of OSS sensor OK?
012 v
Go to Step 4
4
Go to Step 6
Repair the wiring harness connectors.
5
Go to Step 7
Replace the OSS sensor
DAEWOO V121 BL4
AISIN AUTOMATIC TRANSAXLE 5A2 61
Step 6 Action 1. Replace the master TCM. 2. Perform the reproducing test under user condition after confirming no DTC. Is DTC displayed? Value(s) Yes Repair the temporary connection failure of connector (Refer to "Wiring Harness and Connector Inspection" in this section.) Repair the temporary connection failure of connector No Replace the TCM.
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1. Estimate the failure of T/M wire. 2. Inspect continuity and short circuit for the T/M wire and inspect the connection condition between connectors (C4). Refer to "Wiring Harness and Connector Inspection" in this section. Is the condition OK?
Replace the T/M wire or adjustment between connectors
DAEWOO V121 BL4
5A2 62IAISIN AUTOMATIC TRANSAXLE
DIAGNOSTIC TROUBLE CODE (DTC) P0727 ENGINE SPEED INPUT CIRCUIT NO SIGNAL
Conditions for Setting the DTC S TCM detects that malfunction of engine speed signal for 2 seconds. S No DTCs U2105 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 engine torque reduction control S No lockup S No engagement pressure control S No 4th gear S No selflearning control S No timing solenoid control for ND S TCM judges the engine revolution is 0 rpm. 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 history. S The TCM clears the DTC from the TCM history memory after forty consecutive warm up cycles without fault. Cause of Failure S Wiring harness or connector between ECM and TCM S ECM S TCM
DAEWOO V121 BL4
AISIN AUTOMATIC TRANSAXLE 5A2 63 DTC P0727 Engine Speed Input Circuit No Signal
Step 1 Action 1. 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 Diagnostic Trouble Codes Information menu. 7. Clear DTC Information. 8. Perform one vehicle drive cycle. Is the Malfunction Indicator Lamp (MIL) ON? 1. Select Request DTC by Status from the Diagnostic Trouble Codes Information menu. 2. Request DTC by Status. Is DTC P0727 displayed? 1. Turn the ignition OFF. 2. Disconnect the TCM wiring connector and ECM wiring connector. 3. Measure the resistance between terminal A17 of the TCM wiring connector and terminal 88 of the ECM wiring connector. 4. Measure the resistance between terminal A7 of the TCM wiring connector and terminal 57 of the ECM wiring connector. Is the resistance within the values shown? Repair the malfunctioning terminals as necessary. Is the action complete? 1. Turn the ignition ON. 2. Measure the voltage of terminal A17. 3. Measure the voltage of terminal A7. Is the voltage within the values shown? Repair the malfunctioning terminals as necessary. Is the action complete? 1. Inspect the "Engine Speed". Refer to Section 1F, Diagnosis. Was a problem found? 1. Replace the TCM. 2. Turn the ignition OFF. 3. Turn the ignition ON. 4. Check if P0727 DTC is set. Is the DTC set? Value(s) Yes Go to Step 2 No Repair the temporary connection failure of connector.
2
Go to Step 3
Repair the temporary connection failure of connector. Go to Step 4
3
0W
Go to Step 5
4 5
1114 v
System OK Go to Step 6
Go to Step 7
6 7
Sy