DAEWOO NUBIRA 2004 Service Repair Manual

2C – 4IFRONT SUSPENSION
DAEWOO V–121 BL4
J–42468
Front Strut Mount
Nut Wrench

FRONT SUSPENSION 2C – 5
DAEWOO V–121 BL4
DIAGNOSIS
STRUT DAMPENER
A strut dampener is basically a shock absorber. However, strut dampeners are easier to extend and retract by hand than
are shock absorbers.
Struts Seem Weak
ChecksAction
Check the tire pressures.Adjust the tire pressures to the specifications on the tire
placard.
Check the load conditions under which the vehicle is nor-
mally driven.Consult with the owner to confirm the owner’s understand-
ing of normal load conditions.
Check the compression and rebound effectiveness of the
strut dampener.Quickly push down and then lift up on the corner of the
bumper nearest the strut dampener being tested.
Compare the compression and rebound with those of a
similar vehicle that has an acceptable ride quality.
Replace the strut dampener, if needed.
Struts Are Noisy
ChecksAction
Check the mountings for looseness or damage.Tighten the strut dampener mounting nuts. Replace the
strut dampener, if needed.
Check the compression and rebound effectiveness of the
strut dampener.Quickly push down and then lift up on the corner of the
bumper nearest the strut dampener being tested.
Compare the compression and rebound with those of a
similar vehicle that has an acceptable ride quality.
Replace the strut dampener, if needed.
Leaks
ChecksAction
Check for a slight trace of fluid.The strut dampener is OK.
Check the integrity of the seal cover on the fully extended
strut.Replace the strut dampener.
Check for an excessive amount of fluid on the strut damp-
ener.Replace the strut dampener.

2C – 6IFRONT SUSPENSION
DAEWOO V–121 BL4
BALL JOINT AND KNUCKLE
Ball Joint Inspection
1. Raise the front of the vehicle to allow the front sus-
pension to hang free.
2. Grasp the tire at the top and the bottom.
3. Move the top of the tire in an in–and–out motion.
4. Look for any horizontal movement of the knuckle
relative to the control arm.
5. Ball joints must be replaced under the following
conditions:
S The joint is loose.
S The ball seal is cut.
S The ball stud is disconnected from the knuckle.
S The ball stud is loose at the knuckle.
S The ball stud can be twisted in its socket with
finger pressure.
Ball Stud Inspection
Make sure to check the tightness of the ball stud in the
knuckle boss during each inspection of the ball joint. One
way to inspect the ball stud for wear is to shake the wheel
and feel for movement of the stud end at the knuckle boss.Another way to inspect the ball stud for wear is to check
the fastener torque at the pinch nut. A loose nut can indi-
cate a stressed stud or a hole in the knuckle boss.
Worn or damaged ball joints and knuckles must be re-
placed.
EXCESSIVE FRICTION CHECK
Use the following procedure to check for excessive friction
in the front suspension:
1. Enlist the help of another technician to lift up on the
front bumper, raising the vehicle as high as pos-
sible.
2. Slowly release the bumper, allowing the vehicle to
assume its normal trim height. See ”General Speci-
fications” in this section.
3. Measure the distance from the street level to the
center of the bumper.
4. Push down on the bumper, release slowly, and al-
low the vehicle to assume its normal trim height.
5. Measure the distance from the street level to the
center of the bumper.
6. The difference between the two measurements
should be less than 12.7 mm (0.5 inch). If the differ-
ence exceeds this limit, inspect the control arms,
the struts, and the ball joints for damage or wear.

FRONT SUSPENSION 2C – 7
DAEWOO V–121 BL4
COMPONENT LOCATOR
FRONT SUSPENSION

2C – 8IFRONT SUSPENSION
DAEWOO V–121 BL4
1. Cap
2. Strut Upper Nut
3. Piston Rod Nut
4. Strut Mount
5. Strut Bearing
6. Washer
7. Upper Spring Seat
8. Front Spring Locator
9. Upper Spring Insulator
10. Hollow Bumper
11. Front Coil Spring
12. Lower Spring Insulator
13. Front Strut
14. Steering Knuckle–to–Strut Assembly
15. Nut
16. Steering Knuckle
17. Brake Shield
18. Front Hub Bearing19. Outer Snap Ring
20. Front Hub
21. Front Brake Disc
22. Washer
23. Caulking Nut
24. Stabilizer Clamp Bolt
25. Stabilizer Clamp
26. Stabilizer Clamp Insulator
27. Stabilizer
28. Stabilizer Link Nut
29. Stabilizer Link
30. Front Suspension Crossmember
31. Crossmember Cover
32. Crossmember Cover Bolt
33. Crossmember Bolt
34. Crossmember Nut
35. Control Arm
36. Ball Joint

FRONT SUSPENSION 2C – 9
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
STABILIZER SHAFT AND
INSULATORS
Removal Procedure
1. Raise and suitably support the vehicle.
2. Remove the stabilizer shaft–to–stabilizer link nut.
3. Remove the crossmember. Refer to ”Crossmember
Assembly” in this section.
4. Remove the stabilizer shaft–to–crossmember
clamp bolts.
5. Remove the stabilizer shaft, the stabilizer shaft in-
sulator clamp, and the insulators from the vehicle.
Installation Procedure
1. Install the stabilizer shaft.
2. Install the stabilizer shaft insulator clamps, the sta-
bilizer shaft clamp bolt, and the insulators onto the
crossmember. Do not tighten the bolt.

2C – 10IFRONT SUSPENSION
DAEWOO V–121 BL4
3. Install the stabilizer link onto the stabilizer shaft and
connect them with the stabilizer shaft–to–stabilizer
link nut.
Tighten
S Tighten the stabilizer shaft–to–stabilizer link nut
to 47 NSm (35 lb–ft).
S Tighten the stabilizer shaft–to–crossmember
clamp bolts to 25 NSm (18 lb–ft).
4. Install the front wheels. Refer to Section 2E, Tires
and Wheels.
STABILIZER LINK
Removal Procedure
1. Remove the stabilizer shaft–to–stabilizer link nut.
2. Remove the stabilizer link–to–strut assembly nut.
3. Remove the stabilizer link.
Installation Procedure
1. Install the stabilizer link.
2. Install the stabilizer link–to–strut assembly nut.
Tighten
Tighten the stabilizer link–to–strut assembly nut to 47
NSm (35 lb–ft).
3. Install the stabilizer shaft–to–stabilizer link nut.
Tighten
Tighten the stabilizer shaft–to–stabilizer link nut to 47
NSm (35 lb–ft).
KNUCKLE ASSEMBLY
Tools Required
KM–507–B Ball Joint Remover
Removal Procedure
1. Raise and suitably support the vehicle.
2. Remove the wheel. Refer to Section 2E, Tires and
Wheels.
3. Remove the caulking nut from the axle shaft.

FRONT SUSPENSION 2C – 11
DAEWOO V–121 BL4
4. Remove the brake caliper from the rotor. Support
the caliper so it does not hang from the hydraulic
brake hose. Refer to Section 4D, Front Disc
Brakes.
5. Remove the outer tie rod from the knuckle assem-
bly. Refer to Section 6C, Power Steering Gear.
6. On vehicles equipped with the antilock braking sys-
tem (ABS), disconnect the ABS speed sensor elec-
trical connection from the knuckle.
7. Remove the ball joint pinch bolt and the nut.
8. Separate the knuckle from the ball joint using the
ball joint remover KM–507–B.
9. Remove the nuts from the bolts that connect the
knuckle assembly to the strut assembly.

2C – 12IFRONT SUSPENSION
DAEWOO V–121 BL4
Notice : Do not over extend the axle joints. When either
end of the shaft is disconnected, overextension of the joint
can result in separation of internal components and pos-
sible joint failure. Use drive axle joint seal protectors when-
ever performing service on or near the drive axles. Failure
to do so can cause internal joint or seal damage and result
in possible joint failure.
10. Support the drive axle.
11. Separate the drive axle shaft from the wheel hub.
12. Remove the bolts that connect the knuckle assem-
bly to the strut assembly.
13. Remove the knuckle assembly from the vehicle.
Installation Procedure
1. Install the knuckle assembly onto the vehicle.
2. Install the steering knuckle–to–strut assembly nuts.
Tighten
Tighten the steering knuckle–to–strut assembly nuts
to 120 NSm (89 lb–ft).
3. Connect the drive axle to the front wheel hub.
4. Connect the ball joint to the knuckle assembly.
5. Install the ball joint pinch bolt and the nut.
Tighten
Tighten the ball joint pinch bolt nut to 60 NSm (44 lb–
ft).
6. Connect the ABS speed sensor electrical connec-
tion.

FRONT SUSPENSION 2C – 13
DAEWOO V–121 BL4
7. Connect the outer tie rod to the knuckle assembly.
Refer to Section 6C, Power Steering Gear.
8. Install the brake caliper onto the rotor. Refer to
Section 4D, Front Disc Brakes.
9. Install the caulking nut onto the axle shaft.
Tighten
Tighten the drive axle–to–hub caulking nut to 150
NSm (111 lb–ft). Loosen the nut, then retighten it to
275 NSm (126 lb–ft).
10. Install the wheel. Refer to Section 2E, Tires and
Wheels.
11. Lower the vehicle.
HUB AND BEARING
Tools Required
500–20 Hex Nut
J–36661–2 Forcing Screw
J–37105–B–1 Support Bridge
J–37105–B–2 Bearing Adapter
J–377105–B–3 Hub Adapter
Removal Procedure
1. Remove the drive axle from the front wheel hub.
Refer to ”Knuckle Assembly” in this section.
2. Remove the inner snap ring.
3. Remove the wheel hub with the support bridge
J–37105–B–1, the hub adapter J–377105–B–3, the
hex nut 500–20, and the forcing screw J–36661–2.
4. Remove the brake shield. Refer to Section 4D,
Front Disc Brakes.
5. Remove the outer snap ring.