width DAEWOO NUBIRA 2004 Service Owner's Manual

AISIN AUTOMATIC TRANSAXLE 5A2 – 157
DAEWOO V–121 BL4
91. Apply formed in place gasket (FIPG) to the trans-
axle rear cover.
FIPG: three bond 1281 or equivalent
Seal bend width: 1.2 mm (0.047 in.)
92. Install the transaxle rear cover to the transaxle case
with the 9 bolts.
Tighten
Tighten the bolts to 25 NSm (18 lb–ft).
93. Install the counter driven gear assembly to the
transaxle case.
94. Install the differential gear assembly to the trans-
axle case.

5A2 – 160IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
104. Remove any packing material and be careful
not to get oil on the contacting surfaces of the
transaxle housing or transaxle case.
105. Apply FIPG (formed in place gasket) to the
transaxle housing.
FIPG: Three bond 1281 or equivalent.
Seal bend width: 1.2 mm (0.047 in.)
106. Install the transaxle housing to the transaxle
case with the 16 bolts.
Tighten
Tighten the bolts to 29 NSm (22 lb–ft).
S Apply seal packing or equivalent to the 3 bolts
indicated by arrows.
107. Coat a new O–ring with ATF, install it to the
transaxle wire.
108. Install the transaxle wire the to the transaxle
case with the bolt.
Tighten
Tighten the bolts to 5.4 NSm (48 lb–in).

AISIN AUTOMATIC TRANSAXLE 5A2 – 203
DAEWOO V–121 BL4
Upper Valve Body Key
MarkRetainerHeight/Width/Thickness mm (in.)
ACheck valve11.5 (0.453) / 5.0 (0.197) / 3.2 (0.126)
BSecondary regulator valve16.0 (0.630) / 5.0 (0.197) / 3.2 (0.126)
CLock up control valve16.0 (0.630) / 5.0 (0.197) / 3.2 (0.126)
DReverse control valve11.5 (0.453) / 5.0 (0.197) / 3.2 (0.126)

AISIN AUTOMATIC TRANSAXLE 5A2 – 207
DAEWOO V–121 BL4
Lower Valve Body Key
MarkRetainerHeight/Width/Thickness mm (in.)
A4–3 shift timing valve No.136.0 (1.417) / 5.0 (0.197) / 3.2 (0.126)
BLow modulator valve24.0 (0.945) / 5.0 (0.197) / 3.2 (0.126)
C2–3 shift valve10.0 (0.394) / 5.0 (0.197) / 3.2 (0.126)
D1–2 shift valve10.0 (0.394) / 5.0 (0.197) / 3.2 (0.126)
EPrimary regulator valve9.8 (0.386) / 5.2 (0.205) / 3.2 (0.126)
FLock up relay valve16.0 (0.630) / 5.0 (0.197) / 3.2 (0.126)
GSolenoid modulator valve24.0 (0.945) / 5.0 (0.197) / 3.2 (0.126)

9L – 14IGLASS AND MIRRORS
DAEWOO V–121 BL4
5. Buff the grid lines that are to be repaired with steel
wool. Wipe the lines clean using a cloth dampened
with alcohol. Buff and clean about 6 mm (0.25 inch)
beyond each side of the break in the grid line.
6. Attach a grid line repair decal or two strips of tape
above and below the repair areas.
S A repair decal or tape must be used in order to
control the width of the repair areas.
S If a decal is used, the die–cut metered slot must
be the same width as the grid line.
7. Apply the grid repair material to the repair area us-
ing a small wooden stick or a spatula. The grid re-
pair material should be at room temperature.
8. Carefully remove the decal or the tape.
Notice : The grid line repair material must be cured with
heat. In order to avoid heat damage to the interior trim, pro-
tect the trim near the repair area where heat will be ap-
plied.
9. Heat the repair area for 1 to 2 minutes.
10. Hold the heat gun nozzle 25 mm (1 inch) from the
surface. A minimum temperature of 149°C (300°F)
is required.
11. Inspect the grid line repair area. If the repair ap-
pears discolored, apply a coating of tincture of io-
dine to the area using a pipe cleaner or a line
brush. Allow the iodine to dry for about 30 seconds.
Carefully wipe off the excess iodine with a lint–free
cloth.
12. Test the operation of the rear window defogger in
order to verify that the repair was successful.
Important : At least 24 hours is required for complete cur-
ing of the repair materials. The repair area should not be
physically disturbed until after that time.

4–12 FRONTNUBIRA/LACETTI
Note : Use of jigs is recommended for correct positions
and check that the both front longitudinal and wheel-
house are parallel.
S Tack weld the clamped section for temporary installa-
tion.
7. Perform the main welding.
S Weld as much as possible with the jig still mounted.
S Make MIG or gas welds at the butt joints at the front lon-
gitudinal, carefully.
Fig. 19
S Spot weld the wheelhouse with the front longitudinal
flange areas and front panel.
CAUTION : To prevent eye injury and burns when
welding, wear an approved welding helmet, gloves
and safety shoes.
S Perform a trial welding first, and check the welding con-
dition.
S Increase the number of spot by 20% for areas to be spot
welded.
Fig. 20
S Level the weld beads at the longitudinal butt joints area
with disc sander.
S Make the stiffener(Thickness: 2.8 mm Min., Width: 80
mm) according to the form of longitudinal butt joint areasand weld the stiffener at the longitudinal butt joint areas
with MIG welder.
Fig. 21
8. Finish the welding areas.
S Level the gas or MIG welded areas with disc sander.
S Use a hammer and dolly to even out the wheelhouse and
longitudinal flanges for a close fit.
9. Apply the sealer.
S Apply the sealer to the joint areas of the dash panel lower
and floor panel areas.
10. Apply the undercoat.
S Undercoat to the joint and overlapped areas of the front
floor, longitudinal under side and the inside of front, rear
wheelhouse.
11. Apply the paint.
CAUTION
S Ventilate when spraying paint. Most paint contains sub-
stances that are harmful if inhaled or swallowed. Read
the paint label before opening paint container.
S Avoid contact with skin. Wear an approved respirator,
gloves, eye protection and appropriate clothing when
painting.
S Paint is flammable. Store in a safe place, and keep it
away from sparks, flames or cigarettes.
12. Coating the anti–rust agents.
S Coating the anti–rust agents to the end of front panel
side and the front door hinge areas.
13. Install the related parts.
S Clean the passenger compartment.
S Wiring harness, instrument panel and related parts.
S Parts of the passenger compartment.
S Chassis components.
S Engine, radiator and related parts.
S Aircon condenser and related parts.
S Head lamps and fenders.
S Heed, radiator grill, and bumper.
S Others.
S Install in the reverse order in which they were removed.