DAEWOO NUBIRA 2004 Service Repair Manual

9R – 10IBODY FRONT END
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
BODY FRONT END
This vehicle has a unitized body with a frame assembly
supporting the engine and the transaxle. The fender pan-
els and the radiator support are also integral parts of the
body.

SECTION : 9S
BODY REAR END
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
SPECIFICATIONS9S–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 9S–1. . . . . . . . . . .
MAINTENANCE AND REPAIR9S–2 . . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 9S–2. . . . . . . . . . . . . . . . . . . . .
Fuel Filler Door 9S–2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filler Door Remote Handle and Cable 9S–2. . . .
Rear Deck Lid 9S–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Deck Lid Torque Rods 9S–5. . . . . . . . . . . . . . . . .
Luggage Compartment Lock Cylinder 9S–5. . . . . . . .
Luggage Compartment Lock Striker 9S–6. . . . . . . . . .
Luggage Compartment Lock 9S–6. . . . . . . . . . . . . . . . Weatherstrip 9S–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hatchback Weatherstrip 9S–7. . . . . . . . . . . . . . . . . . . .
Hatchback Door 9S–8. . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Support Assemblies 9S–8. . . . . . . . . . . . . . . . . . .
Hatchback Door Lock Striker 9S–9. . . . . . . . . . . . . . . .
Hatchback Door Lock 9S–9. . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION9S–10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filler Door 9S–10. . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Deck Lid (Notchback) 9S–10. . . . . . . . . . . . . . . .
Hatchback Door 9S–10. . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Fuel Filler Door Screws4–35
Fuel Filler Door Remote Cable Handle Cover Screw3–27
Fuel Filler Door Remote Cable Handle Screws10–89
Lower B–Pillar Seat Belt Anchor Bolt3828–
Luggage Compartment Lock Cylinder Nuts8–71
Luggage Compartment Lock Screws6–53
Luggage Compartment Lock Striker Bolts8–71
Rear Deck Lid Bolts10–89

9S – 2IBODY REAR END
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
FUEL FILLER DOOR
Removal Procedure
1. Remove the screws and the fuel filler door.
Installation Procedure
Notice : Dissimilar metals in direct contact with each other
may corrode rapidly. Make sure to use the correct fasten-
ers to prevent premature corrosion.
1. Install the fuel filler door with the screws.
Tighten
Tighten the fuel filler door screws to 4 NSm (35 lb–in).
FUEL FILLER DOOR REMOTE
HANDLE AND CABLE
Removal Procedure
1. Open the luggage compartment.
2. Remove the luggage compartment wheelhouse trim
panels and the luggage compartment rear trim pan-
el. Refer to Section 9G, Interior Trim.
3. Disconnect the cable from the fuel filler door.

BODY REAR END 9S – 3
DAEWOO V–121 BL4
4. Remove the lower B–pillar seat belt bolt and the
anchor.
5. Remove the screw and the fuel filler door remote
cable handle cover.
6. Remove the screws and the fuel filler door remote
cable handle.
7. Disconnect the cable from the handle.
8. Remove the driver’s side seat and the rear seats.
Refer to Section 9H, Seats.
9. Remove the left side front and rear rocker panels,
the left side kick panel, and the left side lower B–
pillar trim panel. Refer to Section 9G, InteriorTrim.
10. Reposition the floor carpet on the left side of the
vehicle.
11. Remove the cable.
Installation Procedure
1. Feed the cable from the luggage compartment to
the passenger compartment.
2. Install the floor carpet to its original position.
3. Install the left side front and rear rocker panels, the
left side kick panel, and the left side lower B–pillar
trim panel. Refer to Section 9G, Interior Trim.
4. Install the driver’s side seat and the rear seats. Re-
fer to Section 9H, Seats.
5. Connect the cable to the handle.
Notice : Dissimilar metals in direct contact with each other
may corrode rapidly. Make sure to use the correct fasten-
ers to prevent premature corrosion.
6. Install the fuel filler door remote cable handle with
the screws.
Tighten
Tighten the fuel filler door remote cable handle screws
to 10 NSm (89 lb–in).
Notice : Dissimilar metals in direct contact with each other
may corrode rapidly. Make sure to use the correct fasten-
ers to prevent premature corrosion.
7. Install the fuel filler door remote cable handle cover
with the screw.
Tighten
Tighten the fuel filler door remote cable handle cover
screw to 3 NSm (27 lb–in).

9S – 4IBODY REAR END
DAEWOO V–121 BL4
8. Install the lower B–pillar seat belt anchor with the
bolt.
Tighten
Tighten the lower B–pillar seat belt anchor bolt to 38
NSm (28 lb–ft).
9. Connect the cable to the fuel filler door.
10. Install the luggage compartment wheelhouse trim
panels and the luggage compartment rear trim pan-
el. Refer to Section 9G, Interior Trim.
11. Close the luggage compartment.
REAR DECK LID
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the electrical connector.
3. Remove the electrical harness from the rear deck
lid hinge arm.
4. Remove the bolts and the rear deck lid.
Installation Procedure
Notice : Dissimilar metals in direct contact with each other
may corrode rapidly. Make sure to use the correct fasten-
ers to prevent premature corrosion.
1. Install the rear deck lid with the bolts.
Tighten
Tighten the rear deck lid bolts to 10 NSm (89 lb–in).
2. Install the electrical harness to the rear deck lid
hinge arm.
3. Connect the electrical connector.
4. Connect the negative battery cable.

BODY REAR END 9S – 5
DAEWOO V–121 BL4
REAR DECK LID TORQUE RODS
Removal Procedure
1. Raise and support the deck lid in the open position.
2. Pull the torque rods out of the rear mount.
3. Remove the torque rods from the hinge.
Installation Procedure
1. Install the torque rods into the hinge mount.
2. Extend the torque rods to mount them in the rear
mounting hole.
LUGGAGE COMPARTMENT LOCK
CYLINDER
Removal Procedure
1. Remove the nuts securing the lock cylinder.
2. Disconnect the lock rod.
3. Disconnect the electrical connector.
4. Remove the luggage compartment lock cylinder.
Installation Procedure
1. Install the luggage compartment lock cylinder.
2. Connect the electrical connector.
3. Connect the lock rod.
Notice : Dissimilar metals in direct contact with each other
may corrode rapidly. Make sure to use the correct fasten-
ers to prevent premature corrosion.
4. Install the luggage compartment lock cylinder with
the nuts.
Tighten
Tighten the luggage compartment lock cylinder nut to
8 NSm (71 lb–in).

9S – 6IBODY REAR END
DAEWOO V–121 BL4
LUGGAGE COMPARTMENT LOCK
STRIKER
Removal Procedure
1. Open the luggage compartment.
2. Remove the luggage compartment rear lower cov-
er. Refer to Section 9G, Interior Trim.
3. Remove the bolts securing the lock striker.
4. Pull the lock striker out.
5. Disconnect the lock release cable from the lock
striker.
Installation Procedure
1. Connect the lock release cable.
Notice : Dissimilar metals in direct contact with each other
may corrode rapidly. Make sure to use the correct fasten-
ers to prevent premature corrosion.
2. Install the lock striker with the bolts.
Tighten
Tighten the luggage compartment lock striker bolts to
8 NSm (71 lb–in).
3. Install the luggage compartment rear lower cover.
Refer to Section 9G, Interior Trim.
LUGGAGE COMPARTMENT LOCK
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the luggage compartment lock cover.
3. Disconnect the electrical connector.
4. Remove the screws and the luggage compartment
lock.
5. Disconnect the lock rod.
Installation Procedure
1. Connect the lock rod.
Notice : Dissimilar metals in direct contact with each other
may corrode rapidly. Make sure to use the correct fasten-
ers to prevent premature corrosion.
2. Install the luggage compartment lock with the
screws.
Tighten
Tighten the luggage compartment lock screws to 6
NSm (53 lb–in).
3. Connect the electrical connector.
4. Install the luggage compartment lock cover.
5. Connect the negative battery cable.

BODY REAR END 9S – 7
DAEWOO V–121 BL4
WEATHERSTRIP
Removal Procedure
1. Open the luggage compartment lid.
2. Remove the weatherstrip from around the gutter.
Installation Procedure
1. Install the weatherstrip onto the gutter flange.
2. Inspect the weatherstrip. Make sure that the clinch
is completely seated onto the flange.
3. Using a water hose without a nozzle, test the rear
deck lid to make sure that no leaks are present.
S If there are no leaks present, no further repair is
required.
S If leaks are present, continue with the remainder
of the installation procedure.
J4D39S01
HATCHBACK WEATHERSTRIP
Removal Procedure
1. Open the luggage compartment lid.
2. Remove the luggage compartment rear quarter and
rear trim panels. Refer to Section 9G, Interior Trim.
3. Remove the weatherstrip from around the gutter.
J4D39S01
Installation Procedure
1. Install the weatherstrip onto the gutter flange.
2. Inspect the weatherstrip. Make sure that the clinch
is completely seated onto the flange.
3. Using a water hose without a nozzle, test the rear
deck lid to make sure that no leaks are present.
4. Install the luggage compartment rear quarter and
rear trim panels. Refer to Section 9G, Interior Trim.

9S – 8IBODY REAR END
DAEWOO V–121 BL4
J4D39S02
HATCHBACK DOOR
Removal Procedure
1. Open and suitably support the hatchback door.
2. Disconnect the hatchback door grommet, the elec-
trical connector, and the washer hose.
3. Remove the gas support assemblies from the
hatchback door and the body. Refer to ”Gas Sup-
port Assemblies” in this section.
4. With the aid of another technician, remove the bolts
and the hatchback door from the hinges.
J4D39S02
Installation Procedure
1. With the aid of another technician, install the hatch-
back door to the hinges with the bolts.
Tighten
Tighten the hatchback door hinge bolts to 20 NSm (15
lb–ft).
2. Install the gas support assemblies to the hatchback
door and the body. Refer to ”Gas Support Assem-
blies” in this section.
3. Connect the hatchback door electrical connector,
the washer hose, and the grommet.
4. Close the hatchback door.
GAS SUPPORT ASSEMBLIES
Removal Procedure
1. Open and suitably support the hatchback door.
2. Unscrew and remove the gas support assembly
from the hatchback door and the body.
Installation Procedure
1. Install the gas support assembly onto the hatch-
back door and the body.
Tighten
Tighten the gas support assembly studs to 8 NSm (71
lb–in).
2. Close the hatchback door.

BODY REAR END 9S – 9
DAEWOO V–121 BL4
HATCHBACK DOOR LOCK STRIKER
Removal Procedure
1. Open the hatchback door.
2. Remove the luggage compartment rear trim panel.
Refer to Section 9G, Interior Trim.
3. Remove the screws that secure the lock striker.
4. Disconnect the cable from the lock striker.
Installation Procedure
1. Connect the cable to the lock striker.
2. Install the lock striker with the screws.
Tighten
Tighten the hatchback door lock striker screws to 20
NSm (15 lb–ft).
3. Install the luggage compartment rear trim panel.
Refer to Section 9G, Interior Trim.
4. Close the hatchback door.
J4D39S04
HATCHBACK DOOR LOCK
Removal Procedure
1. Open the hatchback door.
2. Remove the hatchback door lower garnish molding.
Refer to Section 9G, Interior Trim.
3. Remove the screws and the hatchback lock.
4. Disconnect the lock rods and the electrical connec-
tor.
J4D39S04
Installation Procedure
1. Connect the lock rods and the electrical connector.
2. Install the hatchback lock with the screws.
Tighten
Tighten the hatchback door lock screws to 6 NSm (53
lb–in).
3. Install the hatchback door lower garnish molding.
Refer to Section 9G, Interior Trim.
4. Close the hatchback door.