ABS DAEWOO NUBIRA 2004 Service Repair Manual

STEERING WHEEL AND COLUMN 6E – 9
DAEWOO V–121 BL4
3. Install the upper and the lower steering column cov-
er panels. Install the upper and the lower steering
column cover panel screws.
Tighten
Tighten the upper and the lower steering column cov-
er panel screws to 2.5 NSm (22 lb–in).
4. Connect the negative battery cable.
WIPER SWITCH AND LEVER
(Left–Hand Drive Shown, Right–Hand Dirve
Similar)
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the upper and the lower steering column
cover panel screws.
3. Remove the upper and the lower steering column
cover panels.
4. Remove the wiper switch by pushing the tabs on
the top and the bottom of the switch housing.
5. Disconnect the electrical connector from the wiper
switch. Disconnect the cruise control connector, if
equipped.
Installation Procedure
1. Connect the electrical connector to the wiper
switch. Connect the cruise control connector, if
equipped.
2. Install the wiper switch by snapping it into the
switch housing.

6E – 12ISTEERING WHEEL AND COLUMN
DAEWOO V–121 BL4
Important : In order to install the steering wheel correctly,
match–mark the steering column shaft to the steering
wheel.
6. Remove the steering wheel using the steering
wheel puller KM–210–A.
7. Unclip the contact ring from the steering wheel, if
necessary.
Installation Procedure
1. Clip the contact ring on the steering wheel, if nec-
essary.
2. Align the match marks on the steering wheel and
the steering column shaft.
3. Install the retaining clip and a new steering wheel
nut.
Tighten
Tighten the steering wheel nut to 38 NSm (28 lb–ft).
4. Bend the tabs to secure the retaining clip.
5. Connect the horn leads and install the steering
wheel horn cap.
6. Rotate the steering wheel to allow access to the
steering wheel horn cap screw. Install the horn cap
screw.
7. Rotate the steering wheel to allow access to the
other steering wheel horn cap screw. Install the
horn cap screw.
Tighten
Tighten both steering wheel horn cap screws to 4.5
NSm (40 lb–in).
8. Connect the negative battery cable.

STEERING WHEEL AND COLUMN 6E – 13
DAEWOO V–121 BL4
STEERING WHEEL WITH SIR
Tools Required
KM–210–A Steering Wheel Puller
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the SIR module. Refer to Section 8B, Sup-
plemental Inflatable Restraints.
3. Remove the steering wheel nut and the retaining
clip.
Important : In order to install the steering wheel correctly,
match–mark the steering column shaft to the steering
wheel.
4. Remove the steering wheel using the steering
wheel puller KM–210–A.
5. Unclip the contact ring from the steering wheel, if
necessary.
Installation Procedure
1. Clip the contact ring on the steering wheel, if nec-
essary.
Important : In order to correctly install the steering wheel,
match–mark the steering column shaft to the steering
wheel.
2. Align the match marks on the steering wheel and
the steering column shaft. Turn the signal canceling
cam on the wheel to the left.
3. Install the retaining clip and the steering wheel nut.
Tighten
Tighten the steering wheel nut to 38 NSm (28 lb–ft).
4. Bend the tabs to secure the retaining clip.
5. Install the SIR Module. Refer to Section 8B, Sup-
plemental Inflatable Restraints.
6. Connect the negative battery cable.
IGNITION LOCK CYLINDER AND
SWITCH
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the upper and the lower steering column
cover panel by removing the screws.
3. Disconnect the electrical connector for the immobi-
lizer detection coil.

6E – 20ISTEERING WHEEL AND COLUMN
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
STEERING WHEEL AND COLUMN
CAUTION : To ensure the energy–absorbing action of
the steering column, it is important to use only the
specified screws, bolts, and nuts, tightened to the
specified torque.
In addition to the steering function, the steering column
provides safety and security.
The energy–absorbing column is designed to compress in
a front–end collision to lessen the chance of driver injury.
The ignition switch and the lock are mounted on the col-
umn, allowing the ignition and steering operations to be
locked to inhibit theft of the car.
The column levers trigger the turn signals, the headlight
beams, and the windshield washer and wipers.The tilt steering column uses telescopic function to allow
the steering wheel to tilt up and down in and out. This en-
ables the driver to adjust the steering wheel to a comfort-
able position.
Notice : Apply a thin coat of lithium grease to all friction
points when reassembling.
The column may be disassembled and reassembled easi-
ly.IGNITION KEY REMINDER
The ignition key reminder alerts the driver that the key is
still in the ignition when the driver attempts to exit the ve-
hicle.
An internal switch in the ignition lock cylinder supplies bat-
tery voltage to the reminder chime module when all of the
following conditions are true:
S The key is in the ignition switch.
S The ignition is OFF.
S The driver’s door is open.
For information on removal and installation of the reminder
chime module, refer to Section 9E, Instrumentation/Driver
Information.

7A – 16IHEATING AND VENTILATION SYSTEM
DAEWOO V–121 BL4
BLOWER NOISE
StepActionValue(s)YesNo
1Verify the customer’s complaint.
Are the customer’s concerns verified?–Go to Step 2System OK
21. Sit inside the vehicle.
2. Close the doors and the windows.
3. Turn the ignition ON.
4. Start the engine.
5. Set the temperature to full cold.
6. Cycle through the blower speeds, the modes,
and the temperature settings in order to find
the noise.
Is the blower noise constant at high blower speeds
or certain modes, but absent at lower speeds or in
other modes?–Go to Step 11Go to Step 3
3Check for vibrations from the blower motor and fan
assembly at each blower speed by feeling the blower
motor housing.
Did you find excessive vibration?–Go to Step 6Go to Step 4
41. Remove the blower motor and the fan assem-
bly. Refer to ”Blower Motor” in this section.
2. Check for foreign material at the opening of the
blower inlet.
Do you find any foreign material at the blower inlet?–Go to Step 5Go to Step 6
5Remove all foreign material.
Is the repair complete?–System OKGo to Step 6
61. Examine the blower fan for wear spots,
cracked blades, a cracked hub, a loose fan re-
taining nut, or bad alignment.
2. Examine the blower case for wear spots.
Did you find any problem?–Go to Step 7Go to Step 9
7Repair as required.
Is the repair complete?–System OKGo to Step 8
8Replace the motor and the fan assembly.
Is the repair complete?–System OKGo to Step 9
9If the noise is a click/tick or whine, replace the motor.
Is the repair complete?–System OKGo to Step 10
10Reinstall the original motor.
Is the problem still present?–Go to Step 11System OK
111. Set the blower speed on maximum.
2. Check full–hot to full–cold temperature posi-
tions in the defrost, floor, and vent modes.
Is the noise present in the defrost mode only?–Go to Step 12Go to Step 13
121. Check the ducts for obstructions or foreign ma-
terials.
2. Remove any obstructions or foreign materials.
3. Check the floor/defroster door seals.
4. Repair or replace the components, as needed.
Is the repair complete?–System OK–
13Is the noise present in the floor mode only?–Go to Step 12Go to Step 14
14Is the noise present in the vent mode only?–Go to Step 15Go to Step 16

9E – 2IINSTRUMENTATION/DRIVER INFORMATION
DAEWOO V–121 BL4
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Air Deflector Screws2–18
Chime Module Screws4–35
Clock Screws2–18
Cupholder Screws2.5–22
Deposit Box Screws2.5–22
Driver Knee Bolster Bolts10–89
Floor Console Brace Bolts4–35
Floor Console Brace Nuts4–35
HVAC Controls Screws4–35
Instrument Cluster Screws4–35
Instrument Cluster Trim Panel Screws4–35
Instrument Panel End Bolts2015–
Instrument Panel End Screws4–35
Instrument Panel Nuts Above the Steering Column2015–
Instrument Panel Bolts Behind the HVAC Controls4–35
Steering Column Bracket Nut2216–
Steering Column Lower Trim Cover Screws2.5–22
Steering Column U–Clamp Nuts2216–
Steering Column Upper Trim Cover Screws3–27
INSTRUMENT CLUSTER INDICATOR LAMPS
SPECIFICATIONS
Indicator LampColorBulb
ABS WarningAmber14 v 1.4 W
Airbag WarningRed14 v 1.4 W
Battery Charge IndicatorRed14 v 1.4 W
Check EngineAmber14 v 1.4 W
Door Open WarningRed14 v 1.4 W
Engine OverheatRed14 v 1.4 W
Fasten Seat Belt WarningRed14 v 1.4 W
High Beam IndicatorBlue14 v 1.4 W
Low Fuel Level WarningAmber14 v 4 W
Oil Pressure WarningRed14 v 1.4 W
Parking Brake Indicator and Brake Fluid WarningRed14 v 1.4 W
Service Engine Soon WarningAmber14 v 1.4 W
Transaxle Power Mode IndicatorAmber14 v 1.4 W
Turn Signal IndicatorsGreen14 v 1.4 W

SECTION : 9O
BUMPERS AND FASCIAS
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
SPECIFICATIONS9O–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 9O–1. . . . . . . . . . .
MAINTENANCE AND REPAIR9O–2 . . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 9O–2. . . . . . . . . . . . . . . . . . . . .
Front Bumper Fascia 9O–2. . . . . . . . . . . . . . . . . . . . . . .
Front Bumper Energy Absorber 9O–3. . . . . . . . . . . . . . Front Bumper Impact Bar 9O–4. . . . . . . . . . . . . . . . . . .
Notchback Rear Bumper Fascia 9O–4. . . . . . . . . . . . .
Hatchback Rear Bumper Fascia 9O–6. . . . . . . . . . . . .
Rear Bumper Impact Bar 9O–7. . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION9O–9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bumpers 9O–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Fender–to–Fascia Bolts10–89
Fender–to–Fascia Screws2–18
Front Impact Bar Bolts3929–
Lower Fascia Screws2–18
Luggage Compartment Fascia Bolts10–89
Luggage Compartment Fascia Screws2–18
Rear Wheel Well Fascia Bolts2–18

BUMPERS AND FASCIAS 9O – 3
DAEWOO V–121 BL4
Installation Procedure
1. Install the front bumper fascia.
Notice : Dissimilar metals in direct contact with each other
may corrode rapidly. Make sure to use the correct fasten-
ers to prevent premature corrosion.
2. Install the upper fascia screws.
3. Install the lower fascia clips.
4. Install the fender–to–fascia bolts and the screws.
Tighten
Tighten the fender–to–fascia bolts to 10 NSm (89 lb–
in).
Tighten the fender–to–fascia screws to 2 NSm (18 lb–
in).
5. Install the headlamps and the fog lamps. Refer to
Section 9B, Lighting Systems.
6. Install the front wheel well splash shields. Refer to
Section 9B, Lighting Systems.
7. Connect the negative battery cable.
FRONT BUMPER ENERGY
ABSORBER
Removal Procedure
1. Remove the front bumper fascia. Refer to ”Front
Bumper Fascia” in this section.
2. Remove the energy absorber.

9O – 4IBUMPERS AND FASCIAS
DAEWOO V–121 BL4
Installation Procedure
1. Install the energy absorber.
2. Install the front bumper fascia. Refer to ”Front
Bumper Fascia” in this section.
FRONT BUMPER IMPACT BAR
Removal Procedure
1. Disconnect the electrical connector.
2. Remove the front bumper fascia. Refer to ”Front
Bumper Fascia” in this section.
3. Remove the front bumper energy absorber. Refer
to ”Front Bumper Energy Absorber” in this section.
4. Remove the bolts and the front bumper impact bar.
Installation Procedure
Notice : Dissimilar metals in direct contact with each other
may corrode rapidly. Make sure to use the correct fasten-
ers to prevent premature corrosion.
1. Install the front impact bar with the bolts.
Tighten
Tighten the front impact bar bolts to 39 NSm (29 lb–ft).
2. Install the front bumper energy absorber. Refer to
”Front Bumper Energy Absorber” in this section.
3. Install the front bumper fascia. Refer to ”Front
Bumper Fascia” in this section.
4. Connect the electrical connector.
NOTCHBACK REAR BUMPER
FASCIA
Removal Procedure
1. Remove the rear wheels. Refer to Section 2E,
Tires and Wheels.
2. Remove the screws and the mud guards.
3. Remove the screws and the splash shields.
4. Remove the screws behind the fascia.

BUMPERS AND FASCIAS 9O – 9
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
BUMPERS
The bumper systems are designed to sustain a collision
into a fixed barrier at either 8 km/h (5 mph) or 4 km/h (2.5
mph) without damage. After absorbing the energy of a col-lision, the bumper systems restore themselves to their
original positions. The bumpers feature an internal foam
energy absorber and a polymer fascia cover.