nut DAEWOO NUBIRA 2004 Service Repair Manual

MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B – 39
DAEWOO V–121 BL4
3. Align the clutch hub key with the shaft keyway.
Place the clutch drive plate and the hub assembly
onto the compressor shaft.
4. Remove the hub and drive plate remover/installer
J–33013–B center bolt and reverse the body direc-
tion on the center bolt. The body of the hub and
drive plate remover/installer J–33013–B should be
backed off sufficiently to allow the center bolt to be
threaded onto the end of the compressor shaft.
Notice : If the center bolt is threaded fully onto the end of
the compressor shaft, or if the body of the hub and drive
plate remover/installer J–33013–B is held and the center
bolt is rotated, the key will wedge and could break the
clutch drive plate and the hub assembly.
5. Install the hub and drive plate remover/installer
J–33013–B and the bearing onto the clutch drive
plate. Thread the center bolt onto the compressor
shaft.
6. Hold the center bolt with a wrench. Tighten the hex
portion of the hub and drive plate remover/installer
J–33013–B body to press the hub onto the shaft.
Tighten the body several turns.
7. Remove the hub and drive plate remover/installer
J–33013–B and check to see that the clutch hub
key is still in place in the keyway before installing
the clutch drive plate and the hub assembly to its
final position. The air gap between frictional sur-
faces of the clutch drive plate and the clutch pulley
rotor should be 0.38 to 0.64 mm (0.015 to 0.025
inch.).
8. Remove the hub and drive plate remover/installer
J–33013–B. Check for proper positioning of the
clutch hub key. It should be even or slightly above
the clutch hub.
9. Install the shaft nut. Hold the clutch drive plate and
the hub assembly with the clutch hub holding tool
J–33027. Use the shaft nut socket J–33022 and
tighten the nut against the compressor shaft shoul-
der.
Tighten
Tighten the clutch plate and hub assembly retaining
nut to 17 NSm (13 lb–ft).
10. Spin the pulley rotor by hand to verify that the
pulley is not rubbing the clutch drive plate.

7B – 48IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
DAEWOO V–121 BL4
8. With the O–ring in place on the rear of the cylinder
assembly, locate the relief boss for the compressor
guide pin at the 6 o’clock position, directly above
the hole in the side of the rear head. Carefully lower
the cylinder and the front head assembly over the
guide pin to the rear head.
9. Press the cylinder and the compressor housing as-
sembly down onto the rear head using both hands.
10. Add the new through–bolt gasket to the through–
bolts and install it into the compressor assembly.
Four of the through–bolts must thread into the rear
head before removing the alignment rod.
Tighten
Alternately tighten the through–bolts in progressive
torque sequence to 10 NSm (89 lb–in).
11. Add new PAG refrigerant oil as determined in Step
1 of Removal Procedure.
12. Place the shaft nut on the shaft and rotate the com-
pressor shaft several times.
13. Perform a leak test on the compressor. Refer to
”Leak Testing (External)” in this section.
14. Install the clutch coil. Refer to ”Clutch Coil” in this
section.
15. Install the clutch rotor and bearing. Refer to ”Clutch
Rotor and Bearing” in this section.
16. Install the clutch plate and hub assembly. Refer to
”Clutch Plate and Hub Assembly” in this section.
17. Install the compressor. Refer to ”Compressor” in
this section.
18. Evacuate and recharge the A/C system. Refer to
”Discharging, Adding Oil, Evacuating, and Charging
Procedures for A/C System” in this section.
CYLINDER–TO–FRONT HEAD
O–RING
Tools Required
J–34993 Cylinder Alignment Rods
J–35372 Support Block
Removal Procedure
1. Recover the refrigerant. Refer to ”Discharging, Add-
ing Oil, Evacuating, and Charging Procedures for
A/C System” in this section.
2. Remove the compressor. Refer to ”Compressor” in
this section.
3. Drain the oil from compressor into a suitable con-
tainer. Measure and record the amount of oil
drained from the compressor. Discard all used oil.
4. Remove the clutch plate and hub assembly. Refer
to ”Clutch Plate and Hub Assembly” in this section.
5. Remove the clutch rotor and bearing. Refer to
”Clutch Rotor and Bearing” in this section.
6. Remove the clutch coil. Refer to ”Clutch Coil” in
this section.

8B – 8ISUPPLEMENTAL INFLATABLE RESTRAINTS (SIR)
DAEWOO V–121 BL4
SIR DIAGNOSTIC SYSTEM CHECK
Notice : If the vehicle interior has been exposed to exten-
sive water intrusion such as water leaks, driving through
high water, flooding, or other causes, the sensing and
diagnostic module(SDM) and SDM connector may need
to be replaced. With ignition OFF, inspect the area around
the SDM, including the carpet. If any significant soaking or
evidence of previous soaking is detected, the water must
be removed, water damage repaired, and the SDM and
the SDM connector must be replaced. Before attempting
any of these repairs, the supplemental inflatable re-
straints(SIR) must be disabled. Refer to ”Disabling the
SIR” and ”Sensing and Diagnostic Module(SDM)” in this
section for instructions on how to disable the SIR and re-
place the SDM.
The SIR Diagnostic System Check must always be the
starting point for any SIR diagnosis. The Diagnostic Sys-
tem Check reveals diagnostic trouble codes(DTCs)
through the use of scan tool. The diagnostic procedures
used in this section are designed to find any repair SIR
conditions. To get the best results, it is important to use the
diagnostic charts and follow the sequence listed below.
1. Perform the SIR Diagnostic System Check, which
reveal diagnostic trouble codes(DTCs) through theuse of scan tool.. It also checks for proper airbag
indicator operation.
2. Refer to the proper diagnostic chart as directed by
SIR Diagnostic System Check. Bypassing these
procedures may result in extended diagnostic time,
incorrect diagnosis, and incorrect parts replace-
ment.
3. Repeat the SIR Diagnostic System Check after any
repair or diagnostic procedures have been per-
formed to ensure that the repair has been made
correctly and that no other malfunction exists.
Circiut Description
When the ignition switch is first turned to ON, ignition volt-
age is supplied from airbag fuse to find the SDM at input
terminal A1. The SDM responds by flashing the airbag in-
dicator seven times and then turning it off while the SDM
performs tests on the SIR.
Diagnostic Aids
The order in which DTCs are diagnosed is very important.
Failure to diagnose the DTCs in the order specified may
result in extended diagnostic time, incorrect diagnosis,
and incorrect parts replacement.
SIR Diagnostic System Check
CAUTION : The sensing and the diagnosis module
(SDM) can maintain surfficient voltage to deploy the
airbags and pretensioners for 1 minute after the igni-
tion is OFF and the fuse has been removed. If the air-
bags and pretensioners are not disconnected, do not
begin service until one minute has been passed after
disconnecting power to the SDM. Otherwise, injury
could result.
CAUTION : During service procedure, be very careful
when handling the SDM. Never strike or jar the SDM.Never power the supplemental inflatable re-
straints(SIR) when the SDM is not rigidly attached to
the vehicle. All SDM mounting bolts must be carefully
tightened , and the arrow on the SDM must be point
toward the front of the vehicle to ensure proper op-
eration of the SIR. The SDM could be activated if it is
powered when it is not rigidly attached to the vehicle,
resulting in unexpected deployment and possible in-
jury.
Step
ActionValue(s)YesNo
11. Turn the ignition switch ON.
2. Observe the airbag indicator as the ignition is
being turned ON. Does the indicator flash
seven times?–System OKGo to Step 2
21. Turn the ignition to LOCK and remove the key.
2. Connect the scan tool to the data link connec-
tor(DLC). Follow the directions given in the
scan tool manual.
3. Are any DTCs displayed on the scan tool?–Go to the
DTC check
procedureGo to Step 3
3Check the fuse F1 in the interior fuse box.
Is the fuse F1 blown?–Go to Step 4Go to Step 5
4Replace the fuse F1.–––
51. Disconnect the connector C207.
2. Check the wiring shortage between the fuse F1
and the terminal 1 of the connector C207.
3. Is the wiring shorted? Then, repair the wiring.––Go to Step 6

8B – 10ISUPPLEMENTAL INFLATABLE RESTRAINTS (SIR)
DAEWOO V–121 BL4
SENSING AND DIAGNOSTIC MODULE (SDM) INTEGRITY
CHECK
The following diagnostic chart must be used when all cir-
cuitry outside the sensing and diagnostic module (SDM)
has been found to operate properly, as indicated by follow-
ing the appropriate diagnostic trouble code(DTC) chart.
The chart verifies the need for SDM replacement.
Circuit Description
When the SDM recognizes ignition voltage greater than 9
volts at terminal A1 of the SDM, the airbag indicator
flashes seven times to verify operation. At this time the
SDM performs turn–on tests followed by resistance mea-surement tests and continuous monitoring tests.
When malfunction is detected, the SDM sets current DTC
and illuminates the airbag indicator.
When the malfuncation is no longer detected and/or the
ignition switch is cycled, the SDM will clear current DTCs
and move them to a history file, except for the DTCs 51
and sometimes 71. DTCs 51 will not be cleared by scan
tool because these codes require replacement of SDM.
The SDM must be replaced only after the malfunction that
set the DTC has been repaired.
Sensing and Diagnostic Module (SDM) Integrity Check
CAUTION : The sensing and diagnostic module
(SDM) can maimtain sufficient voltage to deploy the
airbags and pretensioners for 1 minute after the igni-
tion is OFF and the fuse has been removed. If the air-
bags and pretensioners are not disconnected, do not
begin service until one minute has passed after dis-
connecting the power to the SDM. Otherwise, injury
could result.
CAUTION : During service procedure, be very careful
when handling the SDM. Never strike or jar the SDM.Never power the supplemental inflatable re-
straints(SIR) when the SDM is not rigidlyattached to
the vehile. All SDM mounting bolts must be carefully
tightened , and the arrow on the SDM must be point
toward the front of the vehicle to ensure proper op-
eration of the SIR. The SDM could be activated if it is
powered when it is not rigidly attached to the vehicle,
resulting in unexpected deployment and possible in-
jury.
Step
ActionValue(s)YesNo
11. Turn the ignition to LOCK and remove the key
2. Connect all SIR components and ensure that
all the components are properly mounted.
3. Ensure that the ignition switch has been OFF
for at least 30 seconds.
4. Observe the airbag indicator as the ignition is
turned ON. Does the indicator lamp flashes
seven times ?–Clear the SIR
DTCs and
go to
”Diagnostic
System Check”Go to Step 2
21. Turn the ignition to LOCK and remove the key.
2. Connect the scan tool to DLC. Follow the direc-
tions given in the scan tool manual.
3. Turn the ignition to ON.
4. Request SIR DTC display with the scan tool. Is
the same DTC displayed that was previous oc-
curred when the SIR Diagnostic System Check
was previously performed?–Go to Step 3.Go to the table
for the DTC in-
dicated.
31. Clear SIR DTCs.
2. Turn the ignition OFF for at least 30 seconds.
3. Observe the airbag indicator as the ignition is
turned ON. Does the indicator lamp flashes
seven times ?–System OKGo to Step4
41. Turn the ignition to LOCK and remove the key.
2. Disconnect the SDM connector.
3. Replace the SDM.
4. Connect the SDM connector and ensure that
all components are properly mounted. Is the
repair complete?–Go to
”Diagnostic
System Check”–

SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR) 8B – 13
DAEWOO V–121 BL4
DTC 1
Driver Airbag Deployment Loop Resistance Is High
CAUTION : The sensing and diagnostic module(SDM)
can maintain sufficient voltage to deploy the airbags
and pretensioners for 1 minute after the ignition is
OFF and the fuse has been removed. If the airbags
and pretensioners are not disconnected, do not be-
gin service until one minute has passed after discon-
necting power to SDM. Otherwise, injury could result.
CAUTION : During service procedure, be very careful
when handling the SDM. Never strike or jar the SDM.Never power the supplemental inflatable re-
straints(SIR) when the SDM is not rigidly attached to
the vehicle. All SDM mounting bolts must be carefully
tightened , and the arrow on the SDM must be point
toward the front of the vehicle to ensure proper op-
eration of the SIR. The SDM could be activated if it is
powered when it is not rigidly attached to the vehicle,
resulting in unexpected deployment and possible in-
jury.
Step
ActionValue(s)YesNo
1Perform the SIR Diagnostic System Check.
Is the SIR Diagnostic System Check completed?–Go to Step 2–
2Visually inspect the connector and the wiring of driv-
er airbag. Is the connector disconnected?–Connect the
connector and
go to Step 1Go to Step 3
31. Confirm the ignition switch ”OFF”.
2. Remove the driver airbag module.
3. Disconnect the connector of SDM wiring.
4. Check the resistance between the terminal
10,11 of SDM and the terminal 1,2 of driver
airbag module. Is the resistance about 0(zero)
?
0 WGo to Step 4Go to Step 5
41. Replace the SDM.
2. Confirm the ignition switch ”ON”.
3. Erase the DTC using scan tool.
4. Perform the SIR Diagnostic System Check.
5. If the DTC is not removable, then replace the
driver airbag module.–––
51. Remove the connector from the clock spring
wiring.
2. Check the resistance between the terminal
10,11 of SDM and the terminal 1,2 of clock
spring. Is the resistance about 0(zero) ?
0 WGo to Step 6Go to Step 7
61. Replace the clock spring–––
71. Replace the airbag wiring.–––

SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR) 8B – 15
DAEWOO V–121 BL4
DTC 2
Driver Airbag Deployment Loop Resistance Is Low
CAUTION : The sensing and diagnostic module(SDM)
can maintain sufficient voltage to deploy the airbags
and pretensioners for 1 minute after the ignition is
OFF and the fuse has been removed. If the airbags
and pretensioners are not disconnected, do not be-
gin service until one minute has passed after discon-
necting power to SDM. Otherwise, injury could result.
CAUTION : During service procedure, be very careful
when handling the SDM. Never strike or jar the SDM.Never power the supplemental inflatable re-
straints(SIR) when the SDM is not rigidly attached to
the vehicle. All SDM mounting bolts must be carefully
tightened , and the arrow on the SDM must be point
toward the front of the vehicle to ensure proper op-
eration of the SIR. The SDM could be activated if it is
powered when it is not rigidly attached to the vehicle,
resulting in unexpected deployment and possible in-
jury.
Step
ActionValue(s)YesNo
11. Confirm the ignition switch ”OFF”.
2. Wait for a minute to discharge the SDM char-
ger.–Go to Step 2–
2Visually inspect the connector and the wiring of driv-
er airbag. Is the airbag wiring damaged?–Replace the
airbag wiring.Go to Step 5
31. Confirm the ignition switch ”OFF”.
2. Remove the driver airbag module.
3. Check the resistance between the terminal 1
and 2 of driver airbag module. Is the resistance
in the specification range?
4. Erase the current DTCs with the scan tool.–Go to Step 4Go to Step 5
41. Replace the SDM.
2. Confirm the ignition switch ”ON”.
3. Erase the DTC using scan tool.
4. Perform the SIR Diagnostic System Check.
5. If the DTC is not removable, then replace the
driver airbag module.–––
51. Remove the connector from the clock spring
wiring.
2. Check the resistance between the terminal 1
and 2 of clock spring. Is the resistance ?Replace the
airbag wiring.Replace the
clock spring.

SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR) 8B – 17
DAEWOO V–121 BL4
DTC 3
Driver Airbag Deployment Loop Is Shorted To Ground
CAUTION : The sensing and diagnostic module(SDM)
can maintain sufficient voltage to deploy the airbags
and pretensioners for 1 minute after the ignition is
OFF and the fuse has been removed. If the airbags
and pretensioners are not disconnected, do not be-
gin service until one minute has passed after discon-
necting power to SDM. Otherwise, injury could result.
CAUTION : During service procedure, be very careful
when handling the SDM. Never strike or jar the SDM.Never power the supplemental inflatable re-
straints(SIR) when the SDM is not rigidly attached to
the vehicle. All SDM mounting bolts must be carefully
tightened , and the arrow on the SDM must be point
toward the front of the vehicle to ensure proper op-
eration of the SIR. The SDM could be activated if it is
powered when it is not rigidly attached to the vehicle,
resulting in unexpected deployment and possible in-
jury.
Step
ActionValue(s)YesNo
11. Confirm the ignition switch ”OFF”.
2. Wait for a minute to discharge the SDM char-
ger.–Go to Step 2–
2Visually inspect the connector and the wiring of driv-
er airbag. Is the airbag wiring damaged?–Replace the
airbag wiring.Go to Step 3
31. Confirm the ignition switch ”OFF”.
2. Remove the driver airbag module.
3. Disconnect the connector of SDM wiring.
4. Check the resistance between the high, low
wiring of driver airbag module and the ground.
Is the resistance 10KΩ?10 KΩGo to Step 4Go to Step 5
41. Replace the SDM.
2. Confirm the ignition switch ”ON”.
3. Erase the DTC using scan tool.
4. Perform the SIR Diagnostic System Check.
5. If the DTC is not removable, then replace the
driver airbag module.–––
51. Remove the connector from the clock spring
wiring.
2. Check the resistance between the high, low
wiring of clock spring and the ground. Is the
resistance in the specification.?–Replace the
clock spring.Replace the
airbag wiring.

SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR) 8B – 19
DAEWOO V–121 BL4
DTC 4
Driver Airbag Deployment Loop Is Shorted To Power
CAUTION : The sensing and diagnostic module(SDM)
can maintain sufficient voltage to deploy the airbags
and pretensioners for 1 minute after the ignition is
OFF and the fuse has been removed. If the airbags
and pretensioners are not disconnected, do not be-
gin service until one minute has passed after discon-
necting power to SDM. Otherwise, injury could result.
CAUTION : During service procedure, be very careful
when handling the SDM. Never strike or jar the SDM.Never power the supplemental inflatable re-
straints(SIR) when the SDM is not rigidly attached to
the vehicle. All SDM mounting bolts must be carefully
tightened , and the arrow on the SDM must be point
toward the front of the vehicle to ensure proper op-
eration of the SIR. The SDM could be activated if it is
powered when it is not rigidly attached to the vehicle,
resulting in unexpected deployment and possible in-
jury.
Step
ActionValue(s)YesNo
11. Confirm the ignition switch ”OFF”.
2. Wait for a minute to discharge the SDM char-
ger.–Go to Step 2–
2Visually inspect the connector and the wiring of driv-
er airbag. Is the airbag wiring damaged?–Replace the
airbag wiring.Go to Step 3
31. Confirm the ignition switch ”OFF”.
2. Remove the driver airbag module.
3. Disconnect the connector of SDM wiring.
4. Check the resistance between the high, low
wiring of driver airbag module and the battery.
Is the resistance 10KΩ?10 KΩGo to Step 4Go to Step 5
41. Replace the SDM.
2. Confirm the ignition switch ”ON”.
3. Erase the DTC using scan tool.
4. Perform the SIR Diagnostic System Check.
5. If the DTC is not removable, then replace the
driver airbag module.–––
51. Remove the connector from the clock spring
wiring.
2. Check the resistance between the high, low
wiring of clock spring and the battery. Is the
resistance 10KΩ?10 KΩReplace the
clock spring.Replace the
airbag wiring.

SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR) 8B – 21
DAEWOO V–121 BL4
DTC 5
Passenger Airbag Deployment Loop Resistance Is High
CAUTION : The sensing and diagnostic module(SDM)
can maintain sufficient voltage to deploy the airbags
and pretensioners for 1minute after the ignition is
OFF and the fuse has been removed. If the airbags
and pretensioners are not disconnected, do not be-
gin service until one minute has passed after discon-
necting power to SDM. Otherwise, injury could result.
CAUTION : During service procedure, be very careful
when handling the SDM. Never strike or jar the SDM.Never power the supplemental inflatable re-
straints(SIR) when the SDM is not rigidly attached to
the vehicle. All SDM mounting bolts must be carefully
tightened , and the arrow on the SDM must be point
toward the front of the vehicle to ensure proper op-
eration of the SIR. The SDM could be activated if it is
powered when it is not rigidly attached to the vehicle,
resulting in unexpected deployment and possible in-
jury.
Step
ActionValue(s)YesNo
1Perform the SRS Diagnostic System Check.
Is the SRS Diagnostic System Check completed?–Go to Step 2–
2Visually inspect the connector and the wiring of pas-
senger airbag.
Is the connector disconnected?–Connect the
connector and
go to Step 1Go to Step 3
31. Confirm the ignition switch ”OFF”.
2. Remove the driver airbag module.
3. Disconnect the connector of SDM wiring.
4. Check the resistance between the terminal
13,14 of SDM and the terminal 1,2 of passen-
ger airbag module. Is the resistance about
0(zero)?
0KWGo to Step 4Replace the
airbag wiring.
41. Replace the SDM.
2. Confirm the ignition switch ”ON”
3. Erase the DTC using scan tool.
4. Perform the SIR diagnostic system check.
Is the DTC removed?–The System is
OK.Go to Step 5
51. Replace the passenger air bag module.
2. Perform the SIR Diagnostic System Check.
Is the DTC removed?–The System is
OK.–

SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR) 8B – 23
DAEWOO V–121 BL4
DTC 6
Passenger Airbag Deployment Loop Resistance Is Low
CAUTION : The sensing and diagnostic module(SDM)
can maintain sufficient voltage to deploy the airbags
and pretensioners for 1 minute after the ignition is
OFF and the fuse has been removed. If the airbags
and pretensioners are not disconnected, do not be-
gin service until one minute has passed after discon-
necting power to SDM. Otherwise, injury could result.
CAUTION : During service procedure, be very careful
when handling the SDM. Never strike or jar the SDM.Never power the supplemental inflatable re-
straints(SIR) when the SDM is not rigidly attached to
the vehicle. All SDM mounting bolts must be carefully
tightened , and the arrow on the SDM must be point
toward the front of the vehicle to ensure proper op-
eration of the SIR. The SDM could be activated if it is
powered when it is not rigidly attached to the vehicle,
resulting in unexpected deployment and possible in-
jury.
Step
ActionValue(s)YesNo
11. Confirm the ignition switch ”OFF”.
2. Wait for a minute to discharge the SDM char-
ger.–Go to Step 2–
2Visually inspect the connector and the wiring of driv-
er belt pretensioner. Is the wiring damaged?–Replace the
wiring.Go to Step 3
31. Confirm the ignition switch ”OFF”.
2. Disconnect the connector of driver belt preten-
sioner.
3. Disconnect the connector of SDM wiring.
4. Check the resistance between the terminal 1
and 2 of driver belt pretensioner. Is the resist-
ance ?ΩGo to Step 4Go to Step 5
41. Replace the SDM.
2. Confirm the ignition switch ”ON”.
3. Erase the DTC using scan tool.
4. Perform the SIR Diagnostic System Check.
5. If the DTC is not removable, then replace the
passenger airbag module.–––
5Replace the airbag wiring.–––