DAEWOO NUBIRA 2004 Service Repair Manual

WATERLEAKS 9I – 3
DAEWOO V–121 BL4
3. Perform the watertest stand leak test. Refer to ”Wa-
tertest Stand Specifications” in this section.
4. If the local water pressure does not allow the re-
quired water pressure of 155 kPa (22.5 psi), moveboth stands closer to the vehicle so that the water
spray overlaps.
Localized Testing (Spot Test)
1. Do localized testing with a water hose or an air
hose.
2. Begin testing by spraying the air or the water at the
base of the suspected leak area. Continue spraying
the air or the water upward until the leak is found.
Water Hose Test
1. Place another person inside the vehicle in order to
detect the location of the leak.
2. Use a water hose without a nozzle.
3. Begin spraying the water at the base of the sus-
pected leak area. Continue spraying the water up-
ward until the leak is found.

9I – 4IWATERLEAKS
DAEWOO V–121 BL4
Air Hose Test
1. Apply soapy water to the outside of the vehicle in
the suspected leak area.
2. Blow air from inside the vehicle. The air pressure
should not exceed 205 kPa (29.7 psi).
3. Determine the location of the leaks from the
bubbles formed in the soapy water.

WATERLEAKS 9I – 5
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
WATERLEAK REPAIR
Some waterleaks around the glass can be repaired with-
out removing the glass.
Important : This type of repair may be used only for ure-
thane– installed glass.
1. Remove the reveal molding in the area of the leak.
It may be necessary to remove the garnish molding
or the trim strip lace in order to locate the leak.
2. While spraying water over the leak area, carefully
push the glass outward in order to determine the
size of the leak.
3. Mark the location of the leak.
4. Use water to clean any dirt from the area. Dry the
area with an air hose.
5. Using a sharp knife, trim off the uneven edges of
the adhesive caulking material around the leak for a
distance of 75 to 100 mm (3 to 4 inches) on both
sides of the leak.
6. Using a sharp knife, trim off the uneven edges of
the adhesive material around the leak 75 to 100
mm (3 to 4 inches) on both sides of the leak.
7. Prime the trimmed area with the primer.

9I – 6IWATERLEAKS
DAEWOO V–121 BL4
8. Allow the primer to dry for 5 minutes.
9. Apply the adhesive over the leak and for a distance
of 75 to 100 mm (3 to 4 inches) on both sides of the
leak.
10. Immediately after applying the adhesive, use a flat
stick or a similar tool to work the adhesive into the
leak area and into the joint between the original ma-
terial and the vehicle body in order to ensure a wa-
tertight seal.
11. Spray warm or hot water over the repaired area in
order to determine if the leak was repaired. Do not
run a heavy stream of water directly on the freshly
applied adhesive.
12. Install the trim strip lace if it was removed.
13. Install the garnish molding if it was removed.
14. Install the reveal molding.
Important : After the completion of any waterleak repair,
retest the area using the watertest stands. Do not use
localized testing procedures on the newly–repaired areas,
as the repair material may dislodge under abnormal pres-
sure.

SECTION : 9J
WINDNOISE
TABLE OF CONTENTS
DIAGNOSIS9J–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Windnoise Diagnosis 9J–1. . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR9J–2 . . . . . . . . . . . . . . . . ON–VEHICLE SERVICE 9J–2. . . . . . . . . . . . . . . . . . . . . .
Windnoise Repair 9J–2. . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS
WINDNOISE DIAGNOSIS
CAUTION : An assistant should drive the vehicle
while the technician checks for the location of the
windnoise, in order to prevent personal injury or ve-
hicle damage.
A test drive in the vehicle is necessary to accurately deter-
mine the location of the windnoise. Often there is a primary
leak and secondary leaks. Failure to repair all leaks will
only reduce the windnoise, not eliminate it.
During the test drive the technician should bring the follow-
ing items to aid in determining the location of the wind-
noise.
S A mechanics stethoscope or vacuum hose
S Masking tape
S Strip caulk
S A china marking pencil
S A screwdriver
Perform the following steps in order to conduct the road
test:
1. Choose a route that includes smooth straight
streets that run in all four directions (north, south,
east, and west).
2. Choose streets with little traffic or noise that would
interfere with the test.
3. Drive the vehicle at the speeds at which the noise
was noticed by the customer or until the noise is
produced. Do not exceed legal speed limits.
4. The windnoise is external if any of the following
conditions occur:
S The windnoise is caused by the wind.S The windnoise can be heard with the door glass
lowered and while the vehicle is being driven.
S The windnoise is eliminated when tape is placed
over various moldings and gaps.
5. Internal windnoise is air leaving the vehicle and
should be repaired in the following manner.
S In order to locate the leak, tape off the body lock
pillar pressure relief valves. This will cause air
pressure to build up inside the vehicle and en-
hance the windnoise.
S Use a stethoscope or a vacuum hose to locate
the leak.
S Temporarily repair the leak with masking tape.
S Continue testing in order to determine if the
noise has been eliminated or if other leaks exist.
S When all leaks have been found, return to the
shop and make permanent repairs with the
proper alignment techniques and sealing materi-
als.

9J – 2IWINDNOISE
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
WINDNOISE REPAIR
Windnoise leak repairs are very similar to waterleak re-
pairs. Refer to Section 9I, Waterleaks. The actual proce-
dure depends on the type of seal being repaired.
Leaks around the door opening weatherstrips do not al-
ways indicate a faulty weatherstrip. A door or window ad-
justment may resolve the condition. Refer to Section 9P,
Doors or Section 9L, Glass and Mirrors.

SECTION : 9K
SQUEAKS AND RATTLES
TABLE OF CONTENTS
DIAGNOSIS9K–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Squeak and Rattle Diagnosis 9K–1. . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR9K–3 . . . . . . . . . . . . . . . ON–VEHICLE SERVICE 9K–3. . . . . . . . . . . . . . . . . . . . .
Squeak and Rattle Repair 9K–3. . . . . . . . . . . . . . . . . . .
DIAGNOSIS
SQUEAK AND RATTLE DIAGNOSIS
Rattle Coming From the Side Rail
ChecksAction
Check the brake lines.S Tap lightly on the brake lines and listen for a rattle.
S Install plastic tie straps to secure the brake lines
tightly together.
Rattle Under Vehicle at Higher RPM
ChecksAction
Check for heat shield contact with the underbody.S Raise the vehicle and perform a visual inspection.
S Bend the heat shield slightly to gain clearance from
the underbody.
Squeak From the Front of the Vehicle in Cold Weather
ChecksAction
Check the front stabilizer shaft insulators.S While the vehicle is cold, perform a test drive and
achieve full front suspension travel by driving through
a dip in the road.
S Remove the insulators and wrap teflon tape around
the stabilizer shaft. Reinstall the insulators over the
tape.
Thump From Rear of Vehicle on Bumps
ChecksAction
Check for a properly secured spare tire in the rear
compartment.S Open the rear compartment and perform a visual
inspection of the spare tire and the tools.
S Tightly secure the spare tire and all tools.
S Perform a road test to verify that the noise is elimi-
nated.

9K – 2ISQUEAKS AND RATTLES
DAEWOO V–121 BL4
Glass Knock Coming From the Rear of the Vehicle When Driving
Over Bumps
ChecksAction
Check for an out–of–adjustment hatchback latch.S Test drive the vehicle in order to verify this condition.
S Loosen the latch nuts and adjust the latch downward.
Rattle Coming From Door
Checks Action
Check the door lock solenoid.S Remove the door trim panel and check if the sole-
noid is loose.
S Tighten the solenoid bolts.
Check for rattling electrical connectors inside the door trim
panel.S Tap on the trim panel and listen for a rattle.
S Remove the trim panel and wrap foam padding
around the connectors as required.
Squeak When Operating Doors
ChecksAction
Check for a lack of lubrication of the door hinge pins.S Operate the doors and listen for squeaks.
S Lubricate the door hinge pins with light oil and coat
with lithium grease.
Squeak Coming From Console When Shifting Manual Transaxle
(Condition Occurs In Cold Weather with a Cold Engine)
Checks Action
Check the manual transaxle control lever lower boot.S Move the control lever between gears and listen for
squeaks.
S Remove the floor console and replace the lower shift
boot or apply talcum powder to the lower shift boot.
Buzz From the Left Side of Instrument Panel
ChecksAction
Check for vibration of the fuse box cover against the instru-
ment panel side trim.S Tap on the cover with a finger and listen for a buzz.
S Apply 6.35 mm (0.250 inch) by 25.4 mm (1.00 inch)
felt pads to the side trim where the cover makes con-
tact.
Squeak Coming From Instrument Cluster Trim Plate
Checks Action
Check for rubbing of the cluster trim plate on the instru-
ment panel.S Test drive the vehicle in order to verify this condition.
S Remove the instrument cluster trim plate and install
felt tape to the edges.

SQUEAKS AND RATTLES 9K – 3
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
SQUEAK AND RATTLE REPAIR
Squeaks and rattles are caused by the unwanted move-
ment between parts of a vehicle. There are three means
to prevent squeaks or rattles.
S Attach the parts securely so that there is no relative
motion during the operation of the vehicle.
S Separate the parts so that there is no contact dur-
ing operation.
S Insulate the parts so that no squeaks or rattles oc-
cur with the movement of the parts. Low uniform
friction surfaces can be used to eliminate ”stick–
slip” motion.

SECTION : 9L
GLASS AND MIRRORS
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
SPECIFICATIONS9L–2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 9L–2. . . . . . . . . . . .
SPECIAL TOOLS9L–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 9L–2. . . . . . . . . . . . . . . . . . . . . . . . .
SCHEMATIC AND ROUTING DIAGRAMS9L–3 . . . . . .
Defogger System 9L–3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Control OSRV (Outside Rear View)
Mirror System 9L–4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS9L–5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing Rear Window Defogger Grid Line 9L–5. . . . . .
Outside Rearview Mirror Defoggers 9L–5. . . . . . . . . . .
Electric Control Outside Rearview Mirrors 9L–6. . . . . .
Folding Mirror Unit 9L–8. . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR9L–10 . . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 9L–10. . . . . . . . . . . . . . . . . . . . .
Windshield 9L–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Window Glass 9L–11. . . . . . . . . . . . . . . . . . . . . . . .
Rear Window Defogger Grid Line Repair 9L–13. . . . . .
Rear Window Defogger Braided Lead Wire
Repair 9L–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Door Glass 9L–15. . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Door Glass 9L–16. . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Door Quarter Glass 9L–16. . . . . . . . . . . . . . . . . . .
Inside Rearview Mirror 9L–17. . . . . . . . . . . . . . . . . . . . .
Outside Rearview Mirrors 9L–18. . . . . . . . . . . . . . . . . . .
Folding Mirrors Unit 9L–18. . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION9L–19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stationary Glass 9L–19. . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Control Heated Outside Rearview
Mirror 9L–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inside Rearview Mirror 9L–19. . . . . . . . . . . . . . . . . . . . .
Folding Mirror Unit 9L–19. . . . . . . . . . . . . . . . . . . . . . . . .