seats DAEWOO NUBIRA 2004 Service Repair Manual

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TABLE OF CONTENTS
Section 0B General Information
Section 1 Engine
Section 1A General Engine Information
Section 1C1 1.4L/1.6L DOHC Engine Mechanical
Section 1C2 1.8L DOHC Engine Mechanical
Section 1D Engine Cooling
Section 1E Engine Electrical
Section 1F Engine Controls
Section 1G Engine Exhaust
Section 2 Suspension
Section 2A Suspension Diagnosis
Section 2B Wheel Alignment
Section 2C Front Suspension
Section 2D Rear Suspension
Section 2E Tires and Wheels
Section 3 Driveline/Axle
Section 3A Automatic Transaxle Drive Axle
Section 3B Manual Transaxle Drive Axle
Section 4 Brakes
Section 4A Hydraulic Brakes
Section 4B Master Cylinder
Section 4C Power Booster
Section 4D Front Disc Brakes
Section 4E1 Rear Disc Brakes
Section 4E2 Rear Drum Brakes
Section 4F Antilock Brake System
Section 4G Parking Brake
Section 5 Transmission/Transaxle
Section 5A1 ZF 4HP16 Automatic Transaxle
Section 5A2 AISIN Automatic Transaxle
Section 5B Five-Speed Manual Transaxle
Section 5C Clutch
Section 6 Steering
Section 6A Power Steering System
Section 6B Power Steering PumpSection 6C Power Steering Gear
Section 6E Steering Wheel and Column
Section 7 Heating, Ventilation, and Air
Conditioning (HVAC)
Section 7A Heating and Ventilation System
Section 7B Manual Control Heating, Ventilation,
and Air Conditioning System
Section 7D Automatic Temperature Control HVAC
Section 8 Restraints
Section 8A Seat Belts
Section 8B Supplemental Inflatable Restraints
(SIR)
Section 9 Body and Accessories
Section 9A Body Wiring System
Section 9B Lighting Systems
Section 9C Horns
Section 9D Wipers/Washer Systems
Section 9E Instrumentation/Driver Information
Section 9F Audio Systems
Section 9G Interior Trim
Section 9H Seats
Section 9I Waterleaks
Section 9J Windnoise
Section 9K Squeaks and Rattles
Section 9L Glass and Mirrors
Section 9M Exterior Trim
Section 9N Frame and Underbody
Section 9O Bumpers and Fascias
Section 9P Doors
Section 9Q Roof
Section 9R Body Front End
Section 9S Body Rear End
Section 9T1 Remote Keyless Entry and Anti–Theft
System
Section 9T2 Immobilizer Anti–Theft System

0B – 12IGENERAL INFORMATION
DAEWOO V–121 BL4
OWNER INSPECTIONS AND SERVICES
WHLE OPERATING THE VEHICLE
Horn Operation
Blow the horn occasionally tomake sure it works. Check
all the button locations.
Brake System Operation
Be alert for abnormal sounds, increased brake pedal trav-
el or repeated pulling to one side when braking. Also, if the
brake warning light goes on, or flashes, something may be
wrong with part of the brake system.
Exhaust System Operation
Be alert to any changes in the sound of the system or the
smell of the fumes. These are signs that the system may
be leaking or overheating. Have the system inspected and
repaired immediately.
Tires,Wheels and Alignment Operation
Be alert to any vibration of the steering wheel or the seats
at normal highway speeds. This may mean a wheel needs
to be balanced. Also, a pull right or left on a straight, level
road may show the need for a tire pressure adjustment or
a wheel alignment.
Steering System Operation
Be alert to changes in the steering action. An inspection
is needed when the steering wheel is hard to turn or has
too much free play, or if unusual sounds are noticed when
turning or parking.
Headlight Aim
Take note of the light pattern occasionally. Adjust the
headlights if the beams seem improperly aimed.
AT EACH FUEL FILL
A fluid loss in any (except windshield washer) system may
indicate a problem. Have the system inspected and re-
paired immediately.
Engine Oil Level
Check the oil level and add oil if necessary. The best time
to check the engine oil level is when the oil is warm.
1. After stopping the engine, wait a few minutes for
the oil to drain back to the oil pan.
2. Pull out the oil level indicator (dip stick).
3. Wipe it clean, and push the oil level indicator back
down all the way.
4. Pull out the oil level indicator and look at the oil lev-
el on it.
5. Add oil, if needed, to keep the oil level above the
MIN line and within the area labeled ”Operating
Range.” Avoid overfilling the engine, since this may
cause engine damage.
6. Push the indicator all the way back down into the
engine after taking the reading.If you check the oil level when the oil is cold, do not run the
engine first. The cold oil will not drain back to the pan fast
enough to give a true oil level reading.
Engine Coolant Level and Condition
Check the coolant level in the coolant reservoir tank and
add coolant if necessary. Inspect the coolant. Replace
dirty or rusty coolant.
Windshield Washer Fluid Level
Check the washer fluid level in the reservoir. Add fluid if
necessary.
AT LEAST MONTHLY
Tire And Wheel Inspection and Pressure
Check
Check the tires for abnormal wear or damage. Also check
for damaged wheels. Check the tire pressure when the
tires are cold (check the spare also, unless it is a stow-
away). Maintain the recommended pressures that are on
the tire placard that is in the glove box.
Light Operation
Check the operation of the license plate light, the head-
lights (including the high beams), the parking lights, the
fog lights, the taillight, the brake lights, the turn signals, the
backup lights and the hazard warning flasher.
Fluid Leak Check
Periodically inspect the surface beneath the vehicle for
water, oil, fuel or other fluids, after the vehicle has been
parked for a while. Water dripping from the air conditioning
system after use is normal. If you notice fuel leaks or
fumes, find the cause and correct it at once.
AT LEAST TWICE A YEAR
Power Steering System Reservoir Level
Check the power steering fluid level. Keep the power
steering fluid at the proper level. Refer to Section 6A, Pow-
er Steering System.
Brake Master Cylinder Reservoir Level
Check the fluid and keep it at the proper level. A low fluid
level can indicate worn disc brake pads which may need
to be serviced. Check the breather hole in the reservoir
cover to be free from dirt and check for an open passage.
Clutch Pedal Free Travel
Check clutch pedal free travel and adjust as necessary.
Measure the distance from the center of the clutch pedal
to the outer edge of the steering wheel with the clutch ped-
al not depressed. Then measure the distance from the
center of the clutch pedal to the outer edge of the steering
wheel with the clutch pedal fully depressed. The difference
between the two values must be greater than 130 mm
(5.19 inches).
Weather–Strip Lubrication
Apply a thin film silicone grease using a clean cloth.

GENERAL INFORMATION 0B – 15
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
GENERAL REPAIR INSTRUCTIONS
S If a floor jack is used, the following precautions are
recommended.
S Park the vehicle on level ground,
block" the front
or rear wheels, set the jack against the frame, raise
the vehicle and support it with chassis stands and
then perform the service operation.
S Before performing the service operation, disconnect
the negative battery cable in order to reduce the
chance of cable damage and burning due to short–
circuiting.
S Use a cover on the body, the seats and the floor to
protect them against damage and contamination.
S Handle brake fluid and antifreeze solution with care
as they can cause paint damage.
S The use of proper tools, and the recommended es-
sential and available tools where specified, are im-
portant for efficient and reliable performance of the
service repairs.S Use genuine DAEWOO parts.
S Discard used cotter pins, gaskets, O–rings, oil
seals, lock washers and self–locking nuts. Prepare
new ones for installation. Normal function of these
parts cannot be maintained if these parts are re-
used.
S Keep the disassembled parts neatly in groups to
facilitate proper and smooth reassembly.
S Keep attaching bolts and nuts separated, as they
vary in hardness and design depending on the posi-
tion of the installation.
S Clean the parts before inspection or reassembly.
S Also clean the oil parts, etc. Use compressed air to
make certain they are free of restrictions.
S Lubricate rotating and sliding faces of parts with oil
or grease before installation.
S When necessary, use a sealer on gaskets to pre-
vent leakage.
S Carefully observe all specifications for bolt and nut
torques.
S When service operation is completed, make a final
check to be sure service was done properly and the
problem was corrected.

1C1 – 60I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
35. Remove the valves. Maintain the original position of
the valves for installation.
36. Remove the valve stem seals.
Cylinder Head Inspection
1. Clean the sealing surfaces.
2. Inspect the cylinder head gasket and mating sur-
faces for leaks, corrosion, and blowby.
3. Inspect the cylinder head for cracks.
4. Inspect the length and the width of the cylinder
head using a feeler gauge and a straight edge.
5. Check the sealing surfaces for deformation and
warpage. The cylinder head sealing surfaces must
be flat within 0.050 mm (0.002 inch) maximum.
6. Measure the height of the cylinder head from seal-
ing surface to sealing surface. The cylinder head
height should be 134.08 to 134.23 mm. If the cylin-
der head height is less than 134.08 mm, replace
the cylinder head.
7. Inspect all threaded holes for damage.
8. Inspect valve seats for excessive wear and burned
spots.
Valve Inspection
1. Inspect the valve stem tip for wear.
2. Inspect the valve key grooves and the oil seal
grooves for chips and wear.
3. Inspect the valves for burns or cracks.
4. Inspect the valve stem for burrs and scratches.
5. Inspect the valve stem. The valve stem must be
straight.
6. Inspect the valve face for grooving. If the groove is
so deep that refacing the valve would result in a
sharp edge, replace the valve.

1C1 – 62I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
Valve Grind
1. Ensure that there are no crater line burns on the
valve cone.
2. The valve may be reground only two times. Do not
grind the valve stem end.
3. The angle at the valve face is 45 degrees.
4. Inspect the assembly height of the intake valves
and the exhaust valves.
Valve Guide – Ream
1. Measure the diameter of the valve guide using the
gauge MKM–571–B and a commercially available
inside micrometer.
Important : Valve oversizes may already have been fitted
in production.
2. An oversize service code is on the valve guide and
the valve stem end. The following table gives the
correct size, reamer, and production code for each
service.
Size
ReamerProduction
CodeService
Code
Normal––K
0.075KM–8051K1
0.150–2K2
3. Ream the valve guide from the upper side of the
cylinder head to the next oversize.
4. After reaming, cross out the code and emboss the
valve guide with the new code.
Valve Seat – Cut
1. Place the cylinder head on wooden blocks.
2. Cut the intake and the exhaust valve seats using
the guide drift KM–340–7 as follows:
S Valve seat – A 45–degree surface using the cut-
ter KM–340–13.
S Upper correction angle – A 30–degree surface
using the cutter KM–340–13.
S Lower correction angle – A 60–degree surface
using the cutter KM–340–26.
3. Clean the chippings from the cylinder head.

1.8L DOHC ENGINE MECHANICAL 1C2 – 23
DAEWOO V–121 BL4
14. Loosen the camshaft bearing cap bolts in stages of
one–half to one turn.
15. Remove the camshaft bearing cap bolts from the
cylinder head.
16. Remove the camshafts.
17. Remove the seal ring from the camshafts.
Important : The camshaft must detach evenly from the
bearing seats in the front guide bearing.
18. Check the camshaft and bearing seats for wear and
replace them if necessary.
Installation Procedure
Notice : Take extreme care to prevent any scratches,
nicks or damage to the camshafts.
1. Lubricate the camshaft journals and the camshaft
caps with engine oil.
2. Install the intake camshaft.
3. Install the intake camshaft caps in their original
positions.
4. Install the intake camshaft cap bolts.
5. Install the exhaust camshaft.
6. Install the exhaust camshaft caps in their original
positions.
7. Install the exhaust camshaft cap bolts.
8. Tighten the camshaft cap bolts gradually and in the
sequence shown for each camshaft cap.
Tighten
Tighten the camshaft bearing cap bolts to 8 NSm (71
lb–in).
9. Measure the intake camshaft end play and the ex-
haust camshaft end play. Refer to ”Engine Specifi-
cations” in this section.
10. Install the intake camshaft gear.
11. While holding the intake camshaft firmly in place,
install the intake camshaft gear bolt.
Tighten
Tighten the intake camshaft gear bolt to 50 NSm (37
lb–ft) plus 60 degrees and 15 degrees using the angu-
lar torque gauge KM–470–B.

1C2 – 58I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
31. Remove the valves. Maintain the original position of
the valves for installation.
32. Remove the valve stem seals.
Cylinder Head Inspection
1. Clean the sealing surfaces.
2. Inspect the cylinder head gasket and mating sur-
faces for leaks, corrosion, and blowby.
3. Inspect the cylinder head for cracks.
4. Inspect the length and the width of the cylinder
head using a feeler gauge and a straight edge.
5. Check the sealing surfaces for deformation and
warpage. The cylinder head sealing surfaces must
be flat within 0.025 mm (0.001 inch) maximum.
6. Measure the height of the cylinder head from seal-
ing surface to sealing surface. The cylinder head
height should be 133.975 to 134.025 mm (5.274 to
5.276 inches). If the cylinder head height is less
than 133.9 mm (5.271 inches), replace the cylinder
head.
7. Inspect all threaded holes for damage.
8. Inspect valve seats for excessive wear and burned
spots.
Valve Inspection
1. Inspect the valve stem tip for wear.
2. Inspect the valve key grooves and the oil seal
grooves for chips and wear.
3. Inspect the valves for burns or cracks.
4. Inspect the valve stem for burrs and scratches.
5. Inspect the valve stem. The valve stem must be
straight.
6. Inspect the valve face for grooving. If the groove is
so deep that refacing the valve would result in a
sharp edge, replace the valve.
7. Inspect the valve spring. If the valve spring ends
are not parallel, replace the valve spring.

1C2 – 60I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
Valve Grind
1. Ensure that there are no crater line burns on the
valve cone.
2. The valve may be reground only two times. Do not
grind the valve stem end.
3. Ensure that the angle at the valve face is 45 de-
grees.
4. Inspect the assembly height of the intake valves
and the exhaust valves.
Valve Guide – Ream
1. Measure the diameter of the valve guide using
gauge MKM–571–B and a commercially available
inside micrometer.
Important : Valve oversizes may already have been fitted
in production.
2. An oversize service code is on the valve guide and
the valve stem end. The following table gives the
correct size, reamer, and production code for each
service.
Size
ReamerProduction
CodeService
Code
Normal––K
0.075KM–8051K1
0.150–2K2
3. Ream the valve guide from the upper side of the
cylinder head to the next oversize.
4. After reaming, cross out the code and emboss the
valve guide with the new code.
Valve Seat – Cut
1. Place the cylinder head on wooden blocks.
2. Cut the intake and the exhaust valve seats using
the guide drift KM–340–7 as follows:
S Valve seat – A 45–degree surface using the cut-
ter KM–340–13.
S Upper correction angle – A 30–degree surface
using the cutter KM–340–13.
S Lower correction angle – A 60–degree surface
using the cutter KM–340–26.
3. Clean the chippings from the cylinder head.

1.8L DOHC ENGINE MECHANICAL 1C2 – 61
DAEWOO V–121 BL4
4. Inspect the dimension for the valve seat width.
S Intake: 1.2 to 1.4 mm (0.047 to 0.055 inch).
S Exhaust: 1.4 to 1.8 mm (0.055 to 0.070 inch).
5. Inspect the assembly height of the intake valves
and the exhaust valves. If the dimension is exceed-
ed, install new valves. Inspect the assembly height
of the intake valves and the exhaust valves again. If
the valve assembly height is still too large despite
replacing the valves, replace the cylinder head.
Assembly Procedure
1. Coat the valve stems with engine oil.
2. Insert the valves in the cylinder head in their origi-
nal positions.
3. Insert the valve spring seats.
4. Push the accompanying assembly sleeve onto the
valve stem.
5. Insert the new valve stem seat.
6. Carefully drive the valve stem seal onto the stop
with light taps.
7. Install the valve springs in their original positions.
8. Install the valve spring caps.
9. Compress the valve springs with the valve spring
compressor KM–348 and adapter KM–653.
10. Install the valve keys.
11. Remove the valve spring compressor KM–348 and
adapter KM–653.
12. Lubricate the valve tappet adjusters with engine oil.
13. Install the valve tappet adjusters.

ENGINE CONTROLS 1F – 145
DAEWOO V–121 BL4
DIAGNOSTIC TROUBLE CODE (DTC) P0135
FRONT HEATED OXYGEN SENSOR HEATER CIRCUIT
NOT FUNCTIONING
Circuit Description
Heated oxygen sensors (HO2S) are used for fuel control
and post catalyst monitoring. Each HO2S compares the
oxygen content of the surrounding air with the oxygen con-
tent in the exhaust stream. The HO2S must reach operat-
ing temperature to provide an accurate voltage signal. A
heating element inside the HO2S minmizes the time re-
quired for the sensor to reach operating temperature. Volt-
age is provided to the heater by the ignition 1 voltage cir-
cuit through a fuse. With the engine running, ground is
provided to the heater by the HO2S heater low control cir-
cuit, through a low side driver within the engine control
module (ECM). The ECM monitors the current flow
through the heater for diagnosis.
If the ECM detects that the HO2S heater current is above
or blelow a specified range, DTC P0135 seats.
Conditions for Setting the DTC
S DTCs P0106, P0117, P0118, P1017 are not set.
S Engine run time is greater than 30 seconds.
S Filtered O2 heater current is less than 0.1 amps.
Action Taken When the DTC SetsS The Malfunction Indicator Lamp (MIL) will illuminate
after three consecutive trip with a fail.
S The ECM will record operating conditions at the
time the diagnostic fails. This information will be
stored in the Freeze Frame and Failure Records
buffers.
S A history Diagnostic Trouble Code (DTC) is stored.
Conditions for Clearing the MIL/DTC
S The MIL will turn off after three consecutive ignition
cycles in which the diagnostic runs without a fault.
S A history DTC will clear after 40 consecutive warm–
up cycles without a fault.
S DTC(s) can be cleared by using the scan tool.
Diagnostic Aids
An intermittent may be caused by rubbed through wire in-
sulation or a wire contacting the exhaust.
Check for poor connection or damaged harness – inspect
harness connectors for the following conditions:
S Improper mating
S Broken locks
S Improperly formed
S Damaged terminals
S Poor terminal–to–wire connection