DAEWOO NUBIRA 2004 Service Repair Manual

2C – 24IFRONT SUSPENSION
DAEWOO V–121 BL4
Assembly Procedure
1. Install the brake splash shield. Refer to Section 4D,
Front Disc Brakes.
2. Install the hub and bearing assembly. Refer to ”Hub
and Bearing” in this section.
3. Install the rotor. Refer to Section 4D, Front Disc
Brakes.
4. Install the knuckle assembly onto the vehicle. Refer
to ”Knuckle Assembly” in this section.

FRONT SUSPENSION 2C – 25
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
FRONT SUSPENSION
The front suspension for this vehicle is a combination of
a strut assembly and a knuckle assembly. The strut as-
sembly combines a strut dampener and spring mounted
to the body of the vehicle. The upper end of the strut is iso-
lated by a rubber mount and contains a bearing to allow the
strut to turn. The knuckle is attached to the strut assembly
and pivots on a ball joint bolted to the control arm. The con-
trol arms pivot from the body using rubber bushings.
The ball joint is fastened to the steering knuckle with a
pinch bolt and nut, and to the lower control arm with rivets.
The stabilizer bar interconnects both strut assemblies ofthe vehicle through the stabilizer link and is attached to the
front suspension crossmember. Jounce and rebound
movements affecting one wheel are partially transmitted
to the opposite wheel of the vehicle to stabilize body roll.
When servicing the control arm–to–body attachment and
the stabilizer shaft–to–body insulators, make sure the at-
taching bolts are loose until the control arms are moved to
the trim height, which is curb height. Trim height is the nor-
mal position to which the control arms move when the ve-
hicle is sitting on the ground. Refer to ”General Specifica-
tions” in this section.
The springs in the front suspension of engine family II are
stronger and the strut dampeners heavier than are the
springs and strut dampeners found in the front suspension
of engine family I.

SECTION : 2D
REAR SUSPENSION
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
SPECIFICATIONS2D–2 . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 2D–2. . . . . . . . . . .
SPECIAL TOOLS2D–2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 2D–2. . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS2D–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Excessive Friction Check 2D–3. . . . . . . . . . . . . . . . . . .
Strut Dampener 2D–3. . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPONENT LOCATOR2D–4 . . . . . . . . . . . . . . . . . . . .
Rear Suspension 2D–4. . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR2D–6 . . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 2D–6. . . . . . . . . . . . . . . . . . . . .
Strut Assembly 2D–6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knuckle Assembly 2D–9. . . . . . . . . . . . . . . . . . . . . . . . .
Trailing Link 2D–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trailing Link Bracket 2D–11. . . . . . . . . . . . . . . . . . . . . .
Front Parallel Link 2D–12. . . . . . . . . . . . . . . . . . . . . . . .
Rear Parallel Link 2D–13. . . . . . . . . . . . . . . . . . . . . . . . .
Stabilizer Shaft 2D–13. . . . . . . . . . . . . . . . . . . . . . . . . . .
Stabilizer Link 2D–14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crossmember 2D–14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hub and Bearing Assembly 2D–15. . . . . . . . . . . . . . . .
UNIT REPAIR 2D–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Springs and Insulators 2D–17. . . . . . . . . . . . . . . . . . . . .
Knuckle 2D–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hub and Bearing 2D–19. . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION 2D–20 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Suspension 2D–20. . . . . . . . . . . . . . . . . . . . . . . . .

2D – 2IREAR SUSPENSION
DAEWOO V–121 BL4
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Crossmember–to–Body Bolts11 283–
Strut Dampener–to–Strut Mount Nut7555–
Rear Parallel Link–to–Crossmember Bolt9066–
Front Parallel Link–to–Knuckle Bolt12089–
Fuel Filler Hose Shield Bolt2015–
Knuckle–to–Strut Assembly Nuts10074–
Rear Parallel Link–to–Knuckle Bolt9066–
Rear Trailing Link–to–Trailing Link Bracket Nut10074–
Rear Trailing Link–to–Knuckle Nut150111–
Stabilizer Link–to–Strut Assembly Nut4735–
Stabilizer Shaft Clamp Bolts4030–
Stabilizer Shaft–to–Stabilizer Link Nut4735–
Strut Mount–to–Body Nuts3022–
Trailing Link Bracket–to–Body Bolts7052–
Trailing Link–to–Trailing Link Bracket Nut10074–
Rear Hub Assembly Bolts6548–
SPECIAL TOOLS
SPECIAL TOOLS TABLE
J–42468
Front Strut Mount
Nut WrenchKM–329–A
Spring Compressor

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.

2D – 4IREAR SUSPENSION
DAEWOO V–121 BL4
COMPONENT LOCATOR
REAR SUSPENSION

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

2D – 6IREAR SUSPENSION
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
STRUT ASSEMBLY
Removal Procedure
1. Remove the trunk carpeting that covers the rear
strut mounting nuts. For station wagons, remove
the panels that cover the luggage compartment
wheelhouse trim panel (wagon). Refer to Section
9G, Interior Trim.
2. Remove the rear strut mounting nuts.
3. Raise and suitably support the vehicle.
4. Remove the wheel. Refer to Section 2E, Tires and
Wheels.
5. Disconnect the parking brake. Refer to Section 4G,
Parking Brake.
Important : On vehicles equipped with rear drum brakes,
the brake hose will easily disconnect from the strut assem-
bly as the assembly is being removed from the vehicle. On
vehicles equipped with rear disc brakes, the brake hose
can be disconnected from the strut assembly at any time.
6. Remove the clip that holds the brake hose to the
strut assembly.

REAR SUSPENSION 2D – 7
DAEWOO V–121 BL4
7. Remove the stabilizer link–to–strut assembly nut
and disconnect the stabilizer link from the strut as-
sembly.
8. Remove the knuckle–to–strut assembly nuts and
the bolts.
9. On vehicles equipped with rear drum brakes, lower
the strut assembly and separate the brake line from
the strut assembly.
10. Remove the rear strut assembly from the vehicle.
Installation Procedure
Important : On vehicles equipped with rear drum brakes,
the brake hose will easily connect to the strut assembly as
the assembly is being installed into the vehicle. On ve-
hicles equipped with rear disc brakes, the brake hose can
be connected to the strut assembly at any time after the
strut assembly has been installed into the vehicle.
1. Install the rear strut assembly into the vehicle. On
vehicles equipped with rear drum brakes, secure
the brake line into the holder as the assembly goes
into place.

2D – 8IREAR SUSPENSION
DAEWOO V–121 BL4
2. Secure the strut assembly by loosely attaching the
strut mount–to–body nuts.
3. Install the knuckle–to–strut assembly nuts and
bolts. Do not tighten.
4. Install the clip holding the brake hose to the strut
assembly.
Tighten
Tighten the knuckle–to–strut assembly nuts to 100
NSm (74 lb–ft).
5. Connect the stabilizer link to the strut assembly and
install the stabilizer link–to–strut assembly nut.
Tighten
Tighten the stabilizer link–to–strut assembly nut to 47
NSm (35 lb–ft).
6. Connect the parking brake. Refer to Section 4G,
Parking Brake.
7. Install the wheel. Refer to Section 2E, Tires and
Wheels.
8. Lower the vehicle.
Tighten
Tighten the strut mount–to–body nuts to 30 NSm (22
lb–ft).