DAEWOO NUBIRA 2004 Service Repair Manual

2B – 4IWHEEL ALIGNMENT
DAEWOO V–121 BL4
Radial Tire Lead/Pull Diagnosis Chart
StepActionValue(s)YesNo
11. Perform wheel alignment preliminary inspec-
tion.
2. Check the brakes for dragging.
3. Road test the vehicle.
Does the vehicle lead/pull?–Go to Step 2System OK
21. Cross switch the front tire and wheel assem-
blies.
2. Road test the vehicle.
Does the vehicle lead/pull?–Go to Step 3System OK
3Check the front wheel alignment.
Is the alignment within specifications?–Go to Step 4Adjust
alignment
4Compare the front camber and front caster to speci-
fications.
Are they within specifications?–Go to Step 7Go to Step 5
5Check the vehicle frame.
Is the frame bent?–Go to Step 6Go to Step 1
6Straighten the frame.
Is the repair complete?–Go to Step 3–
71. The probable cause is the tires.
2. Switch the left front tire and wheel assembly
with the left rear tire and wheel assembly.
3. Road test the vehicle.
Does the vehicle still lead/pull?–Go to Step 9Go to Step 8
8Switch the left front tire and wheel assembly with the
left rear tire and wheel assembly and replace the left
front tire.
Is the repair complete?–System OKGo to Step 1
91. Switch the right front tire and wheel assembly
with the right rear tire and wheel assembly.
2. Road test the vehicle.
Does the vehicle still lead/pull?–Go to Step 1Go to Step 10
10Switch the right front tire and wheel assembly with
the right rear tire and wheel assembly and replace
the right front tire.
Is the repair complete?–System OKGo to Step 1

WHEEL ALIGNMENT 2B – 5
DAEWOO V–121 BL4
VIBRATION DIAGNOSIS
Wheel imbalance causes most highway speed vibration
problems. A vibration can remain after dynamic balancing
because:
S A tire is out of round.
S A rim is out of round.
S A tire stiffness variation exists.
Measuring tire and wheel free runout will uncover only part
of the problem. All three causes, known as loaded radial
runout, must be checked using method of substituting
known good tire and wheel assemblies on the problem ve-
hicle.
Low–speed vibrations, which occur below 64 km/h (40
mph), are usually caused by runout. High–speed vibra-
tions, which occur above 64 km/h (40 mph), can be caused
by either imbalance or runout.
Preliminary Checks
Prior to performing any work, always road test the car and
perform a careful visual inspection for:
S Obvious tire and wheel runout.
S Obvious drive axle runout.
S Improper tire inflation.
S Incorrect trim height.
S Bent or damaged wheels.
S Debris build–up on the tire or the wheel.
S Irregular or excessive tire wear.
S Improper tire bead seating on the rim.
S Imperfections in the tires, including: tread deforma-
tions, separations, or bulges from impact damage.
Slight sidewall indentations are normal and will not
affect ride quality.
Tire Balancing
Balance is the easiest procedure to perform and should be
done first if the vibration occurs at high speeds. Do an off–
vehicle, two–plane dynamic balance first to correct any im-
balance in the tire and wheel assembly.
An on–vehicle finish balance will correct any brake drum,
rotor, or wheel cover imbalance. If balancing does not cor-
rect the high–speed vibration, or if the vibration occurs at
low speeds, runout is the probable cause.
Runout
Runout can be caused by the tire, the wheel, or the way
the wheel is attached to the vehicle. To investigate the pos-
sibility of wheel runout, refer to the following procedures
as well as the wheel runout diagnosis chart in this section:
1. If runout is suspected, measure the on–vehicle free
lateral and free radial runout of the tire and wheel
assembly. Refer to Section 2E, Tires and Wheels.
Both the free lateral and the free radial runout
should be less than 1.5 mm (0.06 inch). If either
measurement exceeds this number, proceed to
Step 2.
2. Mount the tire and the wheel on a dynamic balanc-
ing machine and remeasure the free lateral and the
free radial runout. Record the amount of the free
lateral and the free radial runout and the location of
the highest measurement. Refer to Section 2E,
Tires and Wheels. If the free radial or the free later-
al runout exceeds 1.3 mm (0.05 inch) at the tire
tread, proceed to Step 4.
3. Measure the wheel runout. Refer to Section 2E,
Tires and Wheels. If the wheel exceeds specifica-
tions, replace it.
4. Deflate the tire and match–mount the high radial
runout point of the tire to the low radial runout point
of the wheel. Reinflate the tire and mount it on the
dynamic balancing machine. Measure and record
the free radial and the free lateral runout and their
locations. In many cases, match mounting the tire
on the wheel will bring the tire and wheel assem-
bly’s free runout into an acceptable range of 1.3
mm (0.05 inch) or less.
5. If the free runout of the tire and wheel assembly is
1.3 mm (0.05 inch) or less when it was measured
off the vehicle, yet exceeds 1.3 mm (0.05 inch)
when measured on the vehicle, the attachment of
the tire and wheel assembly to the hub is the prob-
able cause of the vibration. Rotate the assembly’s
two wheel studs and recheck the runout. Refer
toSection 2E, Tires and Wheels. Several positions
may have to be tried to find the best location for the
studs.
6. If the tire and wheel assembly free runout cannot
be reduced to 1.3 mm (0.05 inch) or less, remove
the assembly.
1) Measure the wheel stud runout using a dial
indicator set with a magnetic base.
2) Zero the dial indicator set button on one stud.
3) Gently lift the set button off the stud. Rotate
the flange to position the next stud against the
dial indicator set.
4) Record the runout of all the studs. The dial in-
dicator should read zero when it is repositioned
on the first stud that was checked.
5) If the runout exceeds 0.76 mm (0.03 inch), the
hub or the hub and bearing assembly should
be replaced.

2B – 6IWHEEL ALIGNMENT
DAEWOO V–121 BL4
Whenever a tire is rotated on the wheel, or whenever a tire
or wheel is replaced, rebalance the assembly.
Wheel Runout Diagnosis Chart
StepActionValue(s)YesNo
1Road test the vehicle to verify the vibration com-
plaint.
Are the customer’s concerns verified?–Go to Step 2System OK
21. Perform a vibration diagnosis preliminary
check.
2. Repair any of the problems found.
Is the vibration still present?–Go to Step 3System OK
3Determine at what speed the vibration is present.
Is the vibration over 64 km/h (40 mph)?–Go to Step 4Go to Step 6
4Perform off–vehicle dynamic wheel balance.
Is the vibration still present?–Go to Step 5System OK
5Perform on–vehicle finish balance.
Is the vibration still present?–Go to Step 6System OK
6Perform free lateral and radial on–vehicle runout
check.
Does the runout match the value specified?1.5mm
(0.06 in.)Go to Step 4Go to Step 7
7Perform free lateral and free radial off–vehicle run-
out check.
Does the runout match the value specified?1.3mm
(0.05 in.)Go to Step 8Go to Step 12
81. Index the tire and wheel assembly on the
wheel studs.
2. Obtain the least amount of runout possible.
Does the runout match the value specified?0.76mm
(0.03 in.)Go to Step 9Go to Step 14
9Perform off–vehicle dynamic wheel balance.
Is the vibration still present?–Go to Step 10System OK
10Perform on–vehicle finish balance.
Is the vibration still present?–Go to Step 11System OK
111. Check for any engine driveline imbalance.
2. Thoroughly inspect the drive axles and the
constant velocity joints.
3. Repair any problems found.
Are the repairs complete?–Go to Step 1–
121. Match–mount the tire on the wheel.
2. Perform free lateral and free radial off–vehicle
runout check.
Does the runout match the value specified?1.5mm
(0.06 in.)Go to Step 9Go to Step 13
131. Dismount the tire from the wheel of the sus-
pected assembly.
2. Measure the runout of the wheel.
Does the runout match the value specified?0.8mm
(0.03 in.)Go to Step 15Go to Step 16
14Measure the hub flange runout.
Does the runout match the value specified?0.76mm
(0.03 in.)Go to Step 9Go to Step 17
15Replace the tire.
Is the repair complete?–Go to Step 1–

WHEEL ALIGNMENT 2B – 7
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
16Replace the wheel.
Is the repair complete?–Go to Step 1–
17Replace the hub.
Is the repair complete?–Go to Step 1–

2B – 8IWHEEL ALIGNMENT
DAEWOO V–121 BL4
PRELIMINARY INSPECTION
ChecksAction
Check the tires for proper inflation pressures and normal
tread wear.Inflate the tires to the proper tire pressure. Replace the
tires as needed.
Check the wheel bearings for looseness.Tighten the axle nut to the proper specification. Replace
the strut wheel bearing as needed.
Check for loose ball joints and tie rod ends.Tighten the ball joints and the tie rods.
Check the runout of the wheels and the tires.Measure and correct the tire runout.
Check the vehicle trim heights.Correct the trim heights. Make the correction before ad-
justing the toe.
Check for loose rack and pinion mounting.Tighten the mounting brackets for the rack and pinion as-
sembly.
Check for improperly operating struts.Replace the strut assembly.
Check for loose control arms.Tighten the control arm attachment bolts. Replace the con-
trol arm bushings as needed.
FRONT TOE ADJUSTMENT
1. Disconnect the outer tie rods from the knuckle as-
semblies. Refer to Section 6C, Power Steering
Gear.
2. Turn the right and the left outer tie rods and the ad-
juster nuts to align the toe to 0.0 ± 0.10 degree.
3. Reconnect the outer tie rods to the knuckle assem-
blies. Refer to Section 6C, Power Steering Gear.
Notice : In this adjustment, the right and the left tie rods
must be equal in length, or the tires will wear unevenly.FRONT CAMBER AND CASTER
CHECK
The front camber and caster are not adjustable. Refer to
”Wheel Alignment Specifications” in this section. Jounce
the bumper three times before measuring the camber or
the caster in order to prevent an incorrect reading. If the
front camber or caster measurements deviate from the
specifications, locate and replace or repair any damaged,
loose, bent, dented, or worn suspension part. If the prob-
lem is body related, repair the body.
REAR CAMBER CHECK
The rear camber is not adjustable. Refer to ”Wheel Align-
ment Specifications” in this section. If the rear camber
deviates from the specification, locate the cause and cor-
rect it. If damaged, loose, bent, dented, or worn suspen-
sion parts are found, they should be repaired or replaced.
If the problem is body related, repair the body.

WHEEL ALIGNMENT 2B – 9
DAEWOO V–121 BL4
REAR TOE ADJUSTMENT
Adjustment Procedure
1. Perform a preliminary inspection before any at-
tempt is made to change or correct the wheel align-
ment factors. Refer to ”Preliminary Inspection” in
this section.
2. Loosen the nuts on the parallel link–to–crossmem-
ber bolts.
3. Rotate the parallel link adjustment bolts until the
preferred rear toe specification is obtained. Refer
to”Wheel Alignment Specifications” in this section
for preferred specifications.
4. Hold the parallel link adjustment bolts and tighten
the parallel link–to–crossmember nuts.
Tighten
Tighten the parallel link–to–crossmember nuts to 90 NSm
(66 lb–ft).

2B – 10IWHEEL ALIGNMENT
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
FOUR WHEEL ALIGNMENT
The first responsibility of engineering is to design safe
steering and suspension systems. Each component must
be strong enough to withstand and absorb extreme pun-
ishment. Both the steering system and the front and the
rear suspension must function geometrically with the body
mass.
The steering and the suspension systems require that the
front wheels self–return and that the tire rolling effort and
the road friction be held to a negligible force in order to al-
low the customer to direct the vehicle with the least effort
and the most comfort.
A complete wheel alignment check should include mea-
surements of the rear toe and camber.
Four–wheel alignment assures that all four wheels will be
running in precisely the same direction.
When the vehicle is geometrically aligned, fuel economy
and tire life are at their peak, and steering and perfor-
mance are maximized.
TOE
Toe–in is the turning in of the tires, while toe–out is the
turning out of the tires from the geometric centerline or
thrust line. The toe ensures parallel rolling of the wheels.
The toe serves to offset the small deflections of the wheel
support system which occur when the vehicle is rolling for-
ward. The specified toe angle is the setting which achieves
0 degrees of toe when the vehicle is moving.
Incorrect toe–in or toe–out will cause tire wear and re-
duced fuel economy. As the individual steering and sus-
pension components wear from vehicle mileage, addition-
al toe will be needed to compensate for the wear.
Always correct the toe dimension last.
CASTER
Caster is the tilting of the uppermost point of the steering
axis either forward or backward from the vertical when
viewed from the side of the vehicle. A backward tilt is posi-
tive, and a forward tilt is negative. Caster influences direc-
tional control of the steering but does not affect tire wear.
Weak springs or overloading a vehicle will affect caster.
One wheel with more positive caster will pull toward the
center of the car. This condition will cause the car to move
or lean toward the side with the least amount of positive
caster. Caster is measured in degrees and is not adjust-
able.
CAMBER
Camber is the tilting of the top of the tire from the vertical
when viewed from the front of the vehicle. When the tires
tilt outward, the camber is positive. When the tires tilt in-
ward, the camber is negative. The camber angle is mea-
sured in degrees from the vertical. Camber influences
both directional control and tire wear.
If the vehicle has too much positive camber, the outside
shoulder of the tire will wear. If the vehicle has too much
negative camber, the inside shoulder of the tire will wear.
Camber is not adjustable.
STEERING AXIS INCLINATION
Steering Axis Inclination (SAI) is the tilt at the top of the
steering knuckle from the vertical. Measure the SAI angle
from the true vertical to a line through the center of the strut
and the lower ball joint as viewed from the front of the ve-
hicle.
SAI helps the vehicle track straight down the road and as-
sists the wheel back into the straight ahead position. SAI
on front wheel drive vehicles should be negative.
INCLUDED ANGLE
The included angle is the angle measured from the cam-
ber angle to the line through the center of the strut and the
lower ball joint as viewed from the front of the vehicle.
The included angle is calculated in degrees. Most align-
ment racks will not measure the included angle directly. To
determine the included angle, subtract the negative or add
the positive camber readings to the Steering Axis Inclina-
tion (SAI).
SCRUB RADIUS
The scrub radius is the distance between true vertical and
the line through the center of the strut and lower ball joint
to the road surface. Scrub radius is built into the design of
the vehicle. Scrub radius is not adjustable.
SETBACK
The setback is the distance in which one front hub and
bearing assembly may be rearward of the other front hub
and bearing assembly. Setback is primarily caused by a
road hazard or vehicle collision.
TURNING ANGLE
The turning angle is the angle of each front wheel to the
vertical when the vehicle is making a turn.

SECTION : 2C
FRONT SUSPENSION
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
SPECIFICATIONS2C–2 . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 2C–2. . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 2C–2. . . . . . . . . . .
SPECIAL TOOLS2C–3 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 2C–3. . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS2C–5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strut Dampener 2C–5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Ball Joint and Knuckle 2C–6. . . . . . . . . . . . . . . . . . . . . .
Excessive Friction Check 2C–6. . . . . . . . . . . . . . . . . . .
COMPONENT LOCATOR2C–7 . . . . . . . . . . . . . . . . . . . .
Front Suspension 2C–7. . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR2C–9 . . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 2C–9. . . . . . . . . . . . . . . . . . . . .
Stabilizer Shaft and Insulators 2C–9. . . . . . . . . . . . . . . Stabilizer Link 2C–10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knuckle Assembly 2C–10. . . . . . . . . . . . . . . . . . . . . . . .
Hub and Bearing 2C–13. . . . . . . . . . . . . . . . . . . . . . . . .
Control Arm 2C–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strut Assembly 2C–16. . . . . . . . . . . . . . . . . . . . . . . . . . .
Crossmember Assembly 2C–18. . . . . . . . . . . . . . . . . . .
UNIT REPAIR 2C–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ball Joint 2C–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Arm Bushings 2C–21. . . . . . . . . . . . . . . . . . . . .
Front Strut Assembly 2C–22. . . . . . . . . . . . . . . . . . . . . .
Knuckle 2C–23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION 2C–25 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Suspension 2C–25. . . . . . . . . . . . . . . . . . . . . . . . .

2C – 2IFRONT SUSPENSION
DAEWOO V–121 BL4
SPECIFICATIONS
GENERAL SPECIFICATIONS
ApplicationTrim Height
Center of Front Wheel to Bottom of Front Wheel Well368 mm (14.4 in.)
Center of Rear Wheel to Bottom of Rear Wheel Well367 mm (14.4 in.)
* CONDITION : Full Fuel in the Tank
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Ball Joint Pinch Bolt Nut6044–
Ball Joint–to–Control Arm Nuts10074–
Front Control Arm–to–Crossmember Bolt12592–
Rear Contral Arm–to–Crossmember Bolt11 081–
Crossmember Link–to–Crossmember Bolt11 484–
Crossmember Link–to–Transaxle Bracket Nut169125–
Drive Axle–to–Hub Caulking Nut300221–
Front Crossmember–to–Body Bolts13096–
Piston Rod Nut7555–
Rear Crossmember–to–Body Bolts196145–
Stabilizer Link–to–Strut Assembly Nut4735–
Stabilizer Shaft–to–Crossmember Clamp Bolts2518–
Stabilizer Shaft–to–Stabilizer Link Nut4735–
Steering Knuckle–to–Strut Assembly Nuts/Bolts12089–
Strut Assembly–to–Body Nut6548–

FRONT SUSPENSION 2C – 3
DAEWOO V–121 BL4
SPECIAL TOOLS
SPECIAL TOOLS TABLE
500–20
Hex Nut
J–36661–2
Forcing Screw
J–37105–B–1
Support Bridge
J–37105–B–3
Hub Adapter
KM–158
Remover/Installer
KM–329–A
Spring Compressor
KM–507–B
Ball Joint Remover
J–37105–B–2
Bearing Adapter