ABS DAEWOO NUBIRA 2004 Service Repair Manual

2C – 16IFRONT SUSPENSION
DAEWOO V–121 BL4
5. Install the control arm–to–crossmember bolts.
Tighten
S Tighten the front control arm–to–crossmember
bolt to 125 NSm (92 lb–ft).
S Tighten the rear control arm–to–crossmember
bolt to 110 NSm (81 lb–ft).
6. Install the wheel. Refer to Section 2E, Tires and
Wheels.
7. Lower the vehicle.
STRUT ASSEMBLY
Removal Procedure
1. Remove the strut upper cap and nut.
2. Raise and suitably support the vehicle.
3. Remove the wheel. Refer to Section 2E, Tires and
Wheels.
4. On vehicles equipped with an antilock braking sys-
tem (ABS), disconnect the ABS sensor line from
the strut assembly.
5. Remove the brake line from the securing bracket
on the strut assembly.
6. Disconnect the stabilizer shaft link by removing the
stabilizer link–to–strut assembly nut.

2C – 18IFRONT SUSPENSION
DAEWOO V–121 BL4
3. Connect the stabilizer shaft link to the strut assem-
bly by attaching the stabilizer link–to–strut assem-
bly nut.
Tighten
Tighten the stabilizer link–to–strut assembly nut to 47
NSm (35 lb–ft).
4. Install the brake line to the securing bracket on the
strut assembly.
5. On vehicles equipped with the ABS, connect the
ABS sensor line to the strut assembly.
6. Install the wheel. Refer to Section 2E, Tires and
Wheels.
7. Lower the vehicle.
8. Install the nuts securing the strut assembly to the
body of the vehicle.
Tighten
Tighten the strut assembly–to–body nuts to 65 NSm
(48 lb–ft).
CROSSMEMBER ASSEMBLY
Removal Procedure
1. Raise and suitably support the vehicle.
2. Remove the wheels. Refer to Section 2E, Tires and
Wheels.
3. Remove the nuts and bolts from the steering gear
mounting bracket.
4. Remove the return line bolt from the clip on the
crossmember.
5. Remove the exhaust pipe forward of the catalytic
converter. Refer to Section 1G, Engine Exhaust.
6. Disconnect the tie rod from the knuckle assembly.
Refer to Section 6C, Power Steering Gear.
7. Disconnect the ball joint from the knuckle assembly.
Refer to ”Knuckle Assembly” in this section.
8. Disconnect the stabilizer link from the strut assem-
bly. Refer to ”Stabilizer Link” in this section.
9. Remove the crossmember link–to–transaxle brack-
et nut.
1) Remove the right lower engine mount.
2) Remove the rear transmission mount bracket.

REAR SUSPENSION 2D – 3
DAEWOO V–121 BL4
DIAGNOSIS
EXCESSIVE FRICTION CHECK
Check excessive friction in the rear suspension as follows:
1. With the aid of a helper, lift up on the rear bumper
and raise the vehicle as high as possible. Slowly
release the bumper and allow the car to assume
normal trim height.
2. Measure the distance from the floor to the center of
the bumper.
3. Push down on the bumper, release slowly, and al-
low the car to assume normal trim height.4. Measure the distance from the floor to the center of
the bumper.
The difference between the two measurements should be
less than 12.7 mm (0.50 inch). If the difference exceeds
this limit, inspect the control arms for damage or wear.
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. 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 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.

REAR SUSPENSION 2D – 5
DAEWOO V–121 BL4
1. Strut Mount Lock Nut
2. Strut Assembly–to–Body Nut
3. Strut Mount
4. Upper Spring Seat
5. Rear Spring
6. Strut Dampener Dust Cover
7. Hollow Bumper
8. Lower Spring Insulation Ring
9. Rear Strut Dampener
10. Strut Assembly–to–Knuckle Bolt
11. Strut Assembly–to–Knuckle Nut
12. Spindle Assembly
13. Brake Disc
14. Stabilizer Shaft Clamp Bolt
15. Stabilizer Shaft Clamp16. Stabilizer Shaft Insulator
17. Stabilizer Shaft
18. Stabilizer Shaft–to–Stabilizer Link Nut
19. Stabilizer Link
20. Rear Parallel Link–to–Knuckle Bolt
21. Rear Parallel Link
22. Trailing Link
23. Front Parallel Link
24. Trailing Link Bracket
25. Rear Crossmember–to–body Bolts
26. Rear Crossmember
27. Rear Crossmember Cover
28. Toe–in Adjustment Bolt
29. ABS Wiring Cover
30. Rear Drum

REAR SUSPENSION 2D – 9
DAEWOO V–121 BL4
9. Install the trunk carpeting over the rear strut mount-
ing nuts. For station wagons, remove the panels
that cover the luggage compartment wheelhouse
trim panel (wagon). Refer to Section 9G, Interior
Trim.
KNUCKLE ASSEMBLY
Removal Procedure
1. Raise and suitably support the vehicle.
2. Remove the wheel. Refer to Section 2E, Tires and
Wheels.
3. On vehicles equipped with the antilock braking sys-
tem, remove the ABS speed sensor. Refer to Sec-
tion 4F, Antilock Brake System.
4. On vehicles equipped with rear disc brakes, remove
the rear brake caliper from the knuckle assembly.
Refer to Section 4E1, Rear Disc Brakes.
5. Disconnect the parking brake from the knuckle as-
sembly. Refer to Section 4G, Parking Brake.
6. Disconnect the front parallel link from the knuckle.
Refer to ”Front Parallel Link” in this section.
7. Disconnect the rear parallel link from the knuckle.
Refer to ”Rear Parallel Link” in this section.
8. Disconnect the rear trailing link from the rear
knuckle. Refer to ”Rear Trailing Link” in this sec-
tion.
9. On vehicles equipped with rear drum brakes, re-
move the clip that secures the brake line to the
strut assembly.
10. On vehicles equipped with rear drum brakes, dis-
connect the brake line from the knuckle assembly.
Refer to Section 4E2, Rear Drum Brakes.
11. Remove the rear knuckle–to–strut assembly nuts
and the bolts.
12. Disconnect the brake line from the strut assembly
and remove the rear knuckle from the strut assem-
bly.

2D – 10IREAR SUSPENSION
DAEWOO V–121 BL4
Installation Procedure
1. Install the rear knuckle into the vehicle and install
the brake line into the strut assembly bracket.
2. Install the knuckle–to–strut assembly bolts and
nuts. Do not tighten.
3. Install the clip securing the brake line to the strut
assembly.
4. Tighten the knuckle–to–strut assembly nuts.
Tighten
Tighten the knuckle–to–strut assembly nuts to 100
NSm (74 lb–ft).
5. Connect the rear trailing link to the rear knuckle.
Refer to ”Rear Trailing Link” in this section.
6. Connect the rear parallel link to the knuckle. Refer
to ”Rear Parallel Link” in this section.
7. Connect the front parallel link to the knuckle. Refer
to ”Front Parallel Link” in this section.
8. Connect the parking brake to the knuckle assembly.
Refer to Section 4G, Parking Brake.
9. On vehicles equipped with rear drum brakes, con-
nect the brake line to the knuckle assembly. On
vehicles equipped with rear disc brakes, install the
rear brake caliper onto the knuckle assembly. Refer
to Section 4E1, Rear Disc Brakes.
10. On vehicles equipped with the antilock braking sys-
tem, install the ABS speed sensor. Refer to Section
4F, Antilock Brake System.
11. Install the wheel. Refer to Section 2E, Tires and
Wheels.
12. Lower the vehicle.
TRAILING LINK
Removal Procedure
1. Raise and suitably support the vehicle.
2. Remove the rear trailing link–to–rear knuckle nut.
3. Remove the rear trailing link–to–trailing link bracket
nut and the rear trailing link–to–knuckle bolt.
4. Remove the rear trailing link.

2D – 12IREAR SUSPENSION
DAEWOO V–121 BL4
2. Install the trailing link bracket–to–body bolts.
Tighten
Tighten the trailing link bracket–to–body bolts to 70
NSm (52 lb–ft).
3. Connect the trailing link to the trailing link bracket
by installing the trailing link–to–trailing link bracket
nut and bolt.
Tighten
Tighten the trailing link–to–trailing link bracket nut to
100 NSm (74 lb–ft).
4. Lower the vehicle.
FRONT PARALLEL LINK
Removal Procedure
1. Raise and suitably support the vehicle.
2. Remove the wheel. Refer to Section 2E, Tires and
Wheels.
3. For vehicles equipped with the antilock braking sys-
tem, remove the ABS sensor from the knuckle and
the ABS housing assembly from the front parallel
link.
4. Remove the front parallel link bolt from the rear
crossmember.
5. Remove the front parallel link bolt from the rear
knuckle.
6. Remove the front parallel link.
Installation Procedure
1. Install the front parallel link.
2. Install the front parallel link onto the rear knuckle
with the bolt.
Tighten
Tighten the front parallel link–to–knuckle bolt to 120
NSm (89 lb–ft).
3. Install the front parallel link onto the rear cross–
member with the bolt. Do not tighten.
4. For vehicles equipped with the antilock braking sys-
tem, install the ABS housing assembly onto the
front parallel link and the ABS sensor line into the
knuckle.
5. Install the wheel. Refer to Section 2E, Tires and
Wheels.
6. Perform a rear toe adjustment. Refer to Section 2B,
Wheel Alignment.

SECTION : 4A
HYDRAULIC BRAKES
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
SPECIFICATIONS4A–2 . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifcations 4A–2. . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 4A–2. . . . . . . . . .
COMPONENT LOCATOR4A–3 . . . . . . . . . . . . . . . . . . . .
Brake System (ABS) 4A–3. . . . . . . . . . . . . . . . . . . . . . .
Brake System (NON–ABS) 4A–4. . . . . . . . . . . . . . . . .
DIAGNOSIS4A–5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake System Testing 4A–5. . . . . . . . . . . . . . . . . . . . .
Brake Hose Inspection 4A–5. . . . . . . . . . . . . . . . . . . . .
Warning Lamp Operation 4A–5. . . . . . . . . . . . . . . . . . .
Stop Lamp Warning Circuit Diagnosis 4A–6. . . . . . . . MAINTENANCE AND REPAIR4A–10 . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 4A–10. . . . . . . . . . . . . . . . . . . .
Manual Bleeding the Brakes 4A–10. . . . . . . . . . . . . . .
Pressure Bleeding the Brakes 4A–12. . . . . . . . . . . . . .
Brake Hose Rear 4A–13. . . . . . . . . . . . . . . . . . . . . . . . .
Brake Hose Front 4A–14. . . . . . . . . . . . . . . . . . . . . . . . .
Stoplamp Switch 4A–15. . . . . . . . . . . . . . . . . . . . . . . . .
Brake Pedal 4A–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION4A–17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning Lamp Operation 4A–17. . . . . . . . . . . . . . . . . .

HYDRAULIC BRAKES 4A – 3
DAEWOO V–121 BL4
COMPONENT LOCATOR
BRAKE SYSTEM (ABS)
1. RH Rear Brake Hose
2. RH 3rd Rear Brake Pipe
3. Clip
4. 2nd Rear Brake Pipe (A)
5. 2nd Front Brake Pipe
6. RH Front Brake Hose
7. 2nd Rear Brake Pipe (B)
8. 1st Rear Brake Pipe (A)9. 1st Rear Brake Pipe (B)
10. Front Brake Pipe
11. LH Front Brake Hose
12. LHD Master Cylinder/Booster Assembly
13. ABS Modulator
14. LH Rear Brake Hose
15. LH 3rd Rear Brake Pipe

4A – 4IHYDRAULIC BRAKES
DAEWOO V–121 BL4
BRAKE SYSTEM (NON–ABS)
1. RH Rear Brake Hose
2. RH 3rd Rear Brake Pipe
3. Clip
4. 2nd Rear Brake Pipe
5. 2nd Front Brake Pipe
6. RH Front Brake Hose
7. 2nd Rear Brake Pipe
8. Front Brake Pipe9. LH Front Brake Hose
10. Connector
11. 1st Rear Brake Pipe (A)
12. 1st Front Brake Pipe
13. 1st Rear Brake Pipe (B)
14. LHD Master Cylinder/Booster Assembly
15. LH Rear Brake Hose
16. LH 3rd Rear Brake Pipe