DAEWOO NUBIRA 2004 Service Repair Manual

2–12WPOSITION OF CONNECTORS AND GROUNDS
S204 (MAGENTA)
S205 (ORANGE) : MR–140/HV–240
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
TCM ”B15” TerC206 ”11” TerTCM ”B6” Ter
PNP S/W ”3” Ter
C206 ”2” Ter
PNP S/W ”5” Ter
BW BW BW BW
PNP S/W ”4” Ter
LgB
LgB
LgB
PNP S/W ”10” Ter
TCM ”B13” Ter
TCM ”B12” Ter
C206 ”6” Ter RL
RL
RL
PNP S/W ”2” Ter
PNP S/W ”1” Ter
C206 ”12” Ter
TCM ”C15” Ter
TCM ”C16” Ter
P P P P LgRLgR LgRLRLR LR
TCM ”B11” Ter
C206 ”7” Ter C206 ”16” Ter
TCM ”C1” Ter
J3B1S007
S301 (BLUE) : NOTCH BACK
S301 (BLUE) : HATCH BACK
S302 (BROWN) : NOTCH BACK
S302 (BROWN) : HATCH BACK

SECTION : 2A
SUSPENSION DIAGNOSIS
TABLE OF CONTENTS
DIAGNOSIS2A–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Diagnosis 2A–1. . . . . . . . . . . . . . . . . . . . . . . . . Torque Steer 2A–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tapered Roller Bearing 2A–6. . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS
GENERAL DIAGNOSIS
Problems in the steering, the suspension, the tires, and
the wheels involve several systems. Consider all systems
when diagnosing a complaint. Some problems, such as
abnormal or excessive tire wear and scuffed tires, may be
the result of hard driving. Always road test the vehicle first.If possible, do this road test with the customer.
Proceed with the following preliminary checks. Correct
any substandard conditions.
Preliminary Checks
ChecksAction
Inspect the tires for improper pressure and uneven wear.Inflate the tires to the proper pressure.
Inspect the joint from the steering column to the steering
gear for loose connections or wear.Tighten the intermediate shaft pinch bolts. Replace the in-
termediate shaft as needed.
Inspect the front and the rear suspension, the steering
gear, and the linkage for loose or damaged parts.Tighten the front and the rear suspension. Tighten the
steering gear mounting bracket bolts. Tighten the coupling
flange pinch bolts. Replace the front and the rear suspen-
sion as needed. Replace the steering gear as needed. Re-
place the intermediate shaft as needed.
Inspect for out–of–round tires.Perform a free runout test. Match–mount the tires.
Inspect for out–of–balance tires, bent wheels, and worn or
loose wheel bearings.Balance the wheels. Replace the wheels. Replace the
wheel bearings.
Check the power steering pump serpentine belt tension.Tighten the power steering pump serpentine belt.
Inspect the power steering system for leaks. Check the
power steering fluid level.Repair any leaks. Perform a power steering gear test. Add
power steering fluid.
Car Lead/Pull
ChecksAction
Inspect for mismatched or uneven tires.Replace the tires.
Inspect for a broken or a sagging spring.Replace the spring.
Inspect for a radial tire lateral force.Check the wheel alignment. Switch the wheels. Replace
the tires as needed.
Check the front–wheel alignment.Align the front wheels.
Inspect for an off–center steering gear.Reseat the pinion valve assembly. Replace the pinion
valve assembly as needed.
Inspect for front–brake dragging.Adjust the front brakes.

2A – 2ISUSPENSION DIAGNOSIS
DAEWOO V–121 BL4
Abnormal or Excessive Tire Wear
ChecksAction
Check the front–wheel and the rear–wheel alignment.Align the front and the rear wheels.
Inspect for excessive toe on the front and the rear wheels.Adjust the toe on the front and the rear wheels.
Inspect for a broken or a sagging spring.Replace the spring.
Inspect for out–of–balance tires.Balance the tires.
Inspect for worn strut dampeners.Replace the strut dampeners.
Check for a failure to rotate tires.Rotate the tires. Replace the tires as needed.
Check for an overloaded vehicle.Maintain the proper load weight.
Inspect for low tire inflation.Inflate the tires to the proper pressure.
Scuffed Tires
ChecksAction
Inspect for incorrect toe on the front and the rear wheels.Adjust the toe on the front and the rear wheels.
Inspect for a twisted or a bent suspension arm.Replace the suspension arm.
Wheel Tramp
ChecksAction
Inspect for an out–of–balance tire or wheel.Balance the tire or the wheel.
Inspect for improper strut dampener action.Replace the strut dampeners.
Shimmy, Shake, or Vibration
ChecksAction
Inspect for an out–of–balance tire or wheel.Balance the tire or the wheel.
Inspect for excessive wheel hub runout.Measure the hub flange runout. Replace the hub as need-
ed.
Inspect for excessive brake drum or brake rotor imbal-
ance.Adjust the brakes. Replace the brake rotor or the brake
drum as needed.
Inspect for worn tie rod ends.Replace the outer tie rods.
Inspect for wheel trim imbalance.Balance the wheel.
Inspect for a worn lower ball joint.Replace the lower ball joint.
Inspect for excessive wheel runout.Measure the wheel runout. Replace the wheel as needed.
Inspect for excessive loaded radial runout on the tire and
wheel assembly.Match–mount the tire and wheel assembly.
Hard Steering
ChecksAction
Check the steering gear preload adjustment.Perform a rack bearing preload adjustment.
Check the hydraulic system. Test the power steering sys-
tem pressure with a gauge.Replace the seals and the hoses as needed.
Inspect for binding or catching in the steering gear.Lubricate the steering gear. Repair or replace the steering
gear as needed.
Inspect for a loose steering gear mounting.Tighten the steering gear mounting bracket nuts.

SUSPENSION DIAGNOSIS 2A – 3
DAEWOO V–121 BL4
Too Much Play in Steering
ChecksAction
Inspect for worn or loose wheel bearings.Tighten the drive axle nut. Replace the wheel bearings as
needed.
Inspect for a loose steering gear mounting.Tighten the steering gear mounting bracket nuts.
Inspect the joint from the column to the steering gear for
loose connections or wear.Tighten the intermediate shaft pinch bolts. Replace the in-
termediate shaft as needed.
Check the steering gear preload adjustment.Perform a rack bearing preload adjustment.
Poor Returnability
ChecksAction
Inspect for lack of lubrication of the ball joints and the tie
rod ends.Replace the ball joints and the outer tie rods.
Inspect for binding in the ball joints.Replace the ball joint.
Inspect for binding in the steering column.Lubricate the steering column. Replace the steering col-
umn as needed.
Check the front–wheel alignment.Align the front wheels.
Check the steering gear preload adjustment.Perform a rack bearing preload adjustment.
Inspect for a sticking valve.Lubricate the pinion valve assembly. Replace the pinion
valve assembly as needed.
Inspect for binding in the intermediate shaft on the steering
gear.Replace the intermediate shaft.
Abnormal Noise, Front Suspension
ChecksAction
Inspect for a lack of lubrication of the ball joints and the tie
rod ends.Replace the ball joints and the outer tie rods.
Inspect for damaged suspension components.Replace the damaged suspension components.
Inspect for worn control arm bushings or tie rod ends.Replace the control arm bushings or the tie rods.
Inspect for a loose stabilizer shaft link.Tighten the stabilizer shaft link.
Inspect for loose wheel bolts.Tighten the wheel bolts.
Inspect for loose suspension bolts or nuts.Tighten the suspension bolts or the nuts.
Inspect for worn strut dampeners or strut mountings.Replace the strut dampeners. Tighten the strut mounting
bolts.
Inspect for an improperly positioned strut spring.Adjust the strut spring to the proper position.
Wander or Poor Steering Ability
ChecksAction
Inspect for mismatched or uneven tires.Replace the tires.
Inspect for lack of lubrication of the ball joints and the tie
rod ends.Replace the ball joints and the outer tie rods.
Inspect for worn strut dampeners.Replace the strut dampeners.
Inspect for a loose stabilizer shaft link.Tighten the stabilizer shaft link.
Inspect for a broken or a sagging spring.Replace the spring.

2A – 4ISUSPENSION DIAGNOSIS
DAEWOO V–121 BL4
Checks Action
Check the steering gear preload adjustment.Perform a rack bearing preload adjustment.
Check the front–wheel and the rear–wheel alignment.Align the front and the rear wheels.
Erratic Steering when Braking
ChecksAction
Inspect for worn or loose wheel bearings.Replace the wheel bearings.
Inspect for a broken or a sagging spring.Replace the spring.
Inspect for a leaking wheel cylinder or caliper.Replace the wheel cylinder or the caliper.
Inspect for warped rotors.Replace the rotors.
Inspect for an incorrect or an uneven caster.If the caster is beyond specifications, check the frame and
repair it as needed.
Low or Uneven Trim Height
ChecksAction
Inspect for a broken or a sagging spring.Replace the spring.
Check for an overloaded vehicle.Maintain the proper load weight.
Inspect for an incorrect or weak spring.Replace the spring.
Ride Too Soft
ChecksAction
Inspect for worn strut dampeners.Replace the strut dampeners.
Inspect for a broken or a sagging spring.Replace the spring.
Ride Too Harsh
ChecksAction
Inspect for incorrect strut dampeners.Replace the strut dampeners.
Inspect for an incorrect spring.Replace the spring.
Body Leans or Sways in Corners
ChecksAction
Inspect for a loose stabilizer shaft link.Tighten the stabilizer shaft link.
Inspect for worn strut dampeners or strut mountings.Replace the strut dampeners. Tighten the strut assembly
mounting bolts.
Check for an overloaded vehicle.Maintain the proper load weight.
Inspect for a broken or a sagging spring.Replace the spring.
Suspension Bottoms
ChecksAction
Inspect for worn strut dampeners.Replace the strut dampeners.
Check for an overloaded vehicle.Maintain the proper load weight.
Inspect for a broken or a sagging spring.Replace the spring.

SUSPENSION DIAGNOSIS 2A – 5
DAEWOO V–121 BL4
Steering Wheel Kickback
ChecksAction
Inspect for air in the power steering system.Purge the power steering system of air.
Inspect for a loose steering gear mounting.Tighten the steering gear mounting bracket nuts.
Inspect the joint from the column to the steering gear for
loose connections or wear.Tighten the intermediate shaft pinch bolts. Replace the in-
termediate shaft as needed.
Inspect for loose tie rod ends.Tighten the tie rod ends. Replace the outer tie rods as
needed.
Inspect for loose or worn wheel bearings.Tighten the drive axle nut. Replace the wheel bearings as
needed.
Steering Wheel Surges or Jerks
ChecksAction
Check the hydraulic system. Test the power steering sys-
tem pressure with a gauge.Replace the seals and the hoses as needed.
Inspect for a sluggish steering gear valve.Clean the pinion valve assembly. Replace the pinion valve
assembly as needed.
Inspect for a loose power steering pump serpentine belt.Adjust the power steering pump serpentine belt.
Cupped Tires
ChecksAction
Check the front–wheel and the rear–wheel alignment.Align the front and the rear wheels.
Inspect for worn strut dampeners.Replace the strut dampeners.
Inspect for worn or loose wheel bearings.Tighten the drive axle nut. Replace the wheel bearings as
needed.
Inspect for excessive tire or wheel runout.Match–mount the tires. Replace the tires as needed. Re-
place the wheels as needed.
Inspect for a worn ball joint.Replace the ball joint.
Check the steering gear preload adjustment.Perform a rack bearing preload adjustment.
TORQUE STEER
A degree of torque steer to the right may be experienced
during the use of heavy throttle on some front–wheel drive
cars with drive axles of unequal length. This torque steer
to the right results from the right drive axle being longer
than the left drive axle, which creates a difference in the
drive axle angle. Cars with intermediate shaft assemblies
have axles of almost equal length.
A difference in the drive axle lengths results in more torque
toe–in in the left front wheel. You will notice the torque toe–
in when the vehicle accelerates from a standing start or at
lower speeds.
Inspection Procedure
1. Place a small piece of tape at the top center of the
steering wheel.2. Note the inches of steering wheel deflection re-
quired to keep the vehicle straight during heavy ac-
celeration.
3. Compare this finding with similar cars.
Factors that may cause torque steer to be more apparent
on a particular vehicle include:
S Variations in the tire and wheel assemblies. This
has the most significant effect on torque steer. A
slightly smaller diameter on the right front tire will
increase a right torque lead.
S Large differences in the right and the left front tire
pressure.
S Looseness in the control arm bushings, the tie rod
assemblies, or the steering gear mounting. This
looseness permits a front wheel to pull forward and
toe–in under a torque greater than the wheel on the
opposite side. A loose suspension component may
result in an opposite lead upon deceleration.

2A – 6ISUSPENSION DIAGNOSIS
DAEWOO V–121 BL4
S A high front trim height. This height would increase
the drive axle angle and could cause wobble at
speeds between 24 to 48 km/h (15 to 30 mph).
S Binding or a tight drive axle joint. A tight drive axle
joint or a high front trim height may also cause a
wobble at speeds between 24 to 48 km/h (15 to 30
mph).
S Incorrect, worn, or loose engine mounts causing
adverse drive angles.
Refer to ”General Diagnosis” in this section for actions to
remedy these problems.
Conditions that may produce an effect similar to torque
steer include:
S Incorrect front or rear alignment.
S Frame misalignment or defect.
S Front suspension damage.
S Incorrectly mounted rear crossmember.
TAPERED ROLLER BEARING
Perform the following test to check for looseness in the
hub and bearing assembly on vehicles equipped with rear
disc brakes:
1. Raise and suitably support the vehicle.
2. Remove the rear wheel. Refer to Section 2E, Tires
and Wheels.
3. Remove the brake disc caliper and the brake rotor.
Refer to Section 4E1, Rear Disc Brakes.4. Mount a dial indicator set with a magnetic base to a
control arm or any other stationary part of the ve-
hicle.
5. Push and pull the wheel hub by hand. If the wheel
hub movement exceeds 0.05 mm (0.002 inch), re-
place the wheel bearing. Refer to Section 2D, Rear
Suspension.
6. Install the brake disc caliper and the brake rotor.
Refer to Section 4E1, Rear Disc Brakes.
7. Install the rear wheel. Refer to Section 2E, Tires
and Wheels.
8. Lower the vehicle.

SECTION : 2B
WHEEL ALIGNMENT
TABLE OF CONTENTS
SPECIFICATIONS2B–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Alignment Specifications 2B–1. . . . . . . . . . . . . .
Fastener Tightening Specifications 2B–1. . . . . . . . . . .
DIAGNOSIS2B–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tire Diagnosis 2B–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radial Tire Lead/Pull 2B–3. . . . . . . . . . . . . . . . . . . . . . .
Vibration Diagnosis 2B–5. . . . . . . . . . . . . . . . . . . . . . . .
Preliminary Inspection 2B–8. . . . . . . . . . . . . . . . . . . . . .
Front Toe Adjustment 2B–8. . . . . . . . . . . . . . . . . . . . . .
Front Camber and Caster Check 2B–8. . . . . . . . . . . . .
Rear Camber Check 2B–8. . . . . . . . . . . . . . . . . . . . . . . Rear Toe Adjustment 2B–9. . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION2B–10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Four Wheel Alignment 2B–10. . . . . . . . . . . . . . . . . . . . .
Toe 2B–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Caster 2B–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camber 2B–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Axis Inclination 2B–10. . . . . . . . . . . . . . . . . . .
Included Angle 2B–10. . . . . . . . . . . . . . . . . . . . . . . . . . .
Scrub Radius 2B–10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setback 2B–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turning Angle 2B–10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS
WHEEL ALIGNMENT SPECIFICATIONS
ApplicationFrontRear
Camber–0°20’ ± 45’–1°00’ ± 45’
Caster4°00’ ± 45’–
Toe–in (No person, full tank)0°00 ± 10’0°12’ ± 10’
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Rear Parallel Link–to–Crossmember Nut9066–

2B – 2IWHEEL ALIGNMENT
DAEWOO V–121 BL4
DIAGNOSIS
TIRE DIAGNOSIS
Irregular and Premature Wear
Irregular and premature tire wear has many causes. Some
of them are incorrect inflation pressures, lack of regular
rotation, poor driving habits, or improper wheel alignment.
If the wheel alignment is reset because of tire wear, always
reset the toe as close to zero degrees as the specification
allows. Refer to ”Rear Toe Adjustment” in this section.
Rotate the tires if:
S The front tire wear is different from the rear.
S The left and right front tire wear is unequal.
S The left and right rear tire wear is unequal.
Check wheel alignment if:
S The left and right front tire wear is unequal.
S The wear is uneven across the tread of either front
tire.
S The front tire treads are scuffed with ”feather”
edges on the side of the tread ribs or blocks.
Tread Wear Indicators
The original equipment tires have built–in tread wear indi-
cators to show when the tires need replacement. These in-
dicators appear as bands when the tire tread depth be-
comes shallow. Tire replacement is recommended when
the indicators appear in three or more grooves at six loca-
tions.
Radial Tire Waddle
Waddle is side–to–side movement at the front or rear of
the vehicle. It is caused by the steel belt not being straight
within the tire, or by excessive lateral runout of the tire or
wheel. It is most noticeable at low speeds, 8 to 48 km/h (5
to 30 mph), but may appear as ride roughness at 80 to 113
km/h (50 to 70 mph).
The vehicle must be road tested to determine which end
of the vehicle has the faulty tire. The rear end of the vehicle
will shake from side to side or ”waddle” if the waddle tire
is on the rear of the vehicle. From the driver’s seat, it feels
as though someone is pushing on the side of the vehicle.
If the faulty tire is on the front of the vehicle, the waddle is
more visual. The front sheet metal appears to be moving
back and forth, and the driver’s seat feels like the pivot
point in the vehicle.
Waddle can be diagnosed using the method of substi–tut-
ing known good tire and wheel assemblies on the problem
vehicle.
1. Road test the vehicle to determine if the waddle is
coming from the front or the rear of the vehicle.
2. Install good tires and wheels from a similar vehicle
in place of those on the offending end of the prob-
lem vehicle. If the source of the waddle is not ob-
vious, change the rear tires.
3. Road test the vehicle. If there is improvement,
install the original tires to find the offending tire. If
there is no improvement, install good tires in place
of all four offending tires.

WHEEL ALIGNMENT 2B – 3
DAEWOO V–121 BL4
4. Install original tires one at a time to find the offend-
ing tire.
RADIAL TIRE LEAD/PULL
Lead/pull is the deviation of the vehicle from a straight pathon a level road with no pressure on the steering wheel.
Lead is usually caused by:
S Incorrect alignment.
S Uneven brake adjustment.
S Tire construction.
The way in which a tire is built can produce lead/pull in the
vehicle. Off–center belts on radial tires can cause the tire
to develop a side force while the vehicle rolls straight down
the road. If one side of the tire has even a little larger diam-
eter than the diameter of the other side, the tire will tend
to roll to one side. Unequal diameters will cause the tire to
develop a side force which can produce vehicle lead/pull.
The radial lead/pull diagnosis chart should be used to de-
termine whether the problem originates from an alignment
problem or from the tires. Part of the lead diagnosis proce-
dure calls for tire rotation that is different from the proper
tire rotation pattern. If a medium– to high–mileage tire is
moved to the other side of the vehicle, be sure to check for
ride roughness. Rear tires will not cause lead/pull.