alternator DAEWOO NUBIRA 2004 Service Repair Manual

GENERAL INFORMATION 0B – 5
DAEWOO V–121 BL4
Cooling System
Application1.4L DOHC1.6L DOHC1.8L DOHC
Cooling TypeForced Water
Circulation


Radiator TypeCross–flow


Water Pump TypeCentrifugal


Thermostat TypePellet Type


Coolant Capacity7.0L (7.49 qts)7.2L (7.6 qts)7.4L (7.8 qts)
Electric System
Application1.4L DOHC1.6L DOHC1.8L DOHC
Battery12V–55 AH


610 CCA
(Cold Cranking Amps)


Alternator85 Amps
95 Amps
Starter1.2 KW
1.4 KW
No–Load Test @ 12.2
volts
Drive Pinion Speed at :90 Amps Max
Min. 2,600 rpm


85 Amps Max
Min. 2,550 rpm

0B – 10IGENERAL INFORMATION
DAEWOO V–121 BL4
SCHEDULED MAINTENANCE CHARTS
Engine
Maintenance ItemMaintenance Interval
Kilometers or time in months, whichever comes first
x 1,000 km1153045607590105120
x 1,000 miles0.6918273645546372
Months–1224364860728496
Drive belts (Alternator, power steering
and A/C belt)IIII
Engine oil & engine oil filter (1) (3)IRRRRRRRR
Cooling system hose & connectionsIIIIIIII
Engine coolant (3)IIIRIIRII
Fuel filterRR
Fuel line and connectionsIIIIIIII
Air cleaner element (2)IIRIIRII
Spark plugs (1.4D/1.6D)IRIRIRIR
Spark plugs (1.8D)IRIR
Spark plug wiresReplace every 90,000 km(54,000 miles)
EVAP canister, vapor lines & solenoid
valve filterII
PCV systemIIII
Timing beltlRlR
Chart Symbols:
I –Inspect, and if necessary correct, clean, replenish or adjust.
R – Replace or change:
(1) Change the engine oil and oil filter every 7,500 km (4,500 miles) or 6months, whichever comes first, if the vehicle is
operated under any of the following conditions:
S Short distance driving.
S Extensive idling.
S Driving on dusty roads.
(2) Inspect the air cleaner element every 7,500 km (4,500 miles) or 6 months if driving under dusty conditions. If necessary,
correct, clean or replace.
(3) Refer to ”Recommended Fluids And Lubricants”
Note : Check the engine oil and radiator coolant levels every week.

1C1 – 18I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
12. Remove the alternator. Refer to Section 1E, Engine
Electrical.
13. Remove the intake manifold support bracket.
14. Remove the intake manifold retaining bolts/nuts in
the sequence shown.
15. Remove the intake manifold and gasket.
16. Clean the sealing surfaces of the intake manifold
and the cylinder head.
Installation Procedure
1. Install the fule rail.
Tighten
Tighten the fule rail bolts to 25 NSm (18 lb–ft).
2. Install the new intake manifold gasket and intake
manifold.
Tighten
Tighten the intake manifold bolts and nuts to 25 NSm
(18 lb–ft).
3. Install the exhaust gas recirculation(EGR) pipe.
Tighten
Tighten the exhaust gas recirculation(EGR) pipe bolts
to 10 NSm (89 lb–ft).

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 57
DAEWOO V–121 BL4
Symptom ActionPossible Cause
Sealing Ring Selector ShaftS Check sealing ring.
S Replace sealing ring as described in the repair
instruction.
O–ring at Socket OutletS Check O–ring.
S Replace O–ring as described in the repair in-
struction.
O–ring and Speed Sensor ConnectionS Check O–ring.
S Replace O–ring as described in the repair in-
struction.
Oil Leak Incorrectly IdentifiedS No oil leak is possible at this point.
Speed Sensor Itself Is LeakingS Check speed sensor.
S Replace speed sensor as described in the re-
pair instruction.
Hair Line Crack at the Piping in the Con-
nection Area, Sealing Ring Fit in Trans-
axle HousingS Pressurize the line with compressed air and
check it.
S Replace lines as described in the repair in-
struction.
O–ring Defective, IncorrectCheck O–ring.
Replace O–rings as described in the repair instruc-
tion.
Plug LooseCheck the Tightening Torque for the screw plug.
Tighten to torque specified in the repair instruction.
Noise
SymptomPossible CauseAction
NoiseTFT Level Too LowS When the TFT level is too low, the gear wheels
from the transaxle oil pump might generate
noise.
S Check the TFT level as described in the repair
instruction and fill to the proper level.
Monolith in Catalytic Converter Has
BrokenS Check according to the exhaust gas diagnostic
procedure or by shaking the catalytic converter
casing.
S Replace catalytic converter if necessary.
Noise from Auxiliaries (e.g. exhaust
system, alternator, drive shafts.)S Check these components; if necessary, elimi-
nate the faults as described in the repair in-
struction
Noise from Tires or Wheel BearingsS Eliminate fault if necessary
Noise from Planetary GearsS Whistling noise on traction and overrun(in first
gear only)caused by high rotating speeds(func-
tionally unavoidable)
Cumulative Tooth Backlash in the Com-
plete Drive LineS Production status. Customer must be con-
vinced.
Jerky Noise of the Parking Lock (e.g.
when the car is standing on a gradient)S Load–reversal reaction
S Apply the handbrake before selection the park-
ing Lock (position P)

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 69
DAEWOO V–121 BL4
DTC P0562 – System Voltage Low
StepActionValue(s)YesNo
1Perform an On–Board Diagnostic (EOBD) System
Check.
Is the check completed?–Go to Step 2Go to ”On–
Board Diagnos-
tic System
Check”
21. Install the scan tool.
2. Turn the ignition ON and record then clear
DTC(s), then turn ignition OFF.
3. Turn the ignition ON and start the engine.
4. Run the engine to 1,200 rpm.
5. Select system voltage on the scan tool.
6. Drive the vehicle and observe the scan tool for
system voltage.
Is the voltage within the values shown?9–16VGo to Step 4Go to Step 3
31. Disconnect the negative battery cable.
2. Measure the voltage of the battery at the bat-
tery.
Is the voltage within the values shown?9–16VGo to Step 4Go to ”Section
1E, Engine
Electrical”
41. Turn the headlamp ON.
2. Turn the air conditioner ON.
3. Run the engine to 1,200rpm.
4. Observe the scan tool for system voltage.
Is the voltage within the values shown?9–16VGo to Step 6Go to Step 5
51. Turn the ignition OFF.
2. After testing the charging system, repair the
alternator circuit if necessary.
Is the action completed?–System OK–
6The vehicle would not have started if F2 or EF1 were
blown.
Was a problem found?–Go to Step 7Go to Step 8
7Replace the fuse.
Is the replacement complete?–System OK–
81. Turn the ignition ON.
2. Measure the voltage of F2, EF1.
Is the voltage within the values shown?9–16VGo to Step 10Go to Step 9
9Repair the fuse voltage supply lines for an open.
Is the action completed?–System OK–
101. Turn the ignition OFF.
2. Disconnect the TCM wiring connector.
3. Measure the resistance between EF1 fuse and
terminal B3 of the TCM wiring connector.
Is the resistance within the values shown?0ΩGo to Step 12Go to Step 11
11Repair the circuit(between EF1 and terminal B3) for
short to ground and open.
Is the repair completed?–System OK–

5A1 – 72IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
DTC P0563 – System Voltage High
StepActionValue(s)YesNo
1Perform an On–Board Diagnostic (EOBD) System
Check.
Is the check completed?–Go to Step 2Go to ”On–
Board Diagnos-
tic System
Check”
21. Install the scan tool.
2. Turn the ignition ON and record then clear
DTC(s), then turn ignition OFF.
3. Turn the ignition ON and start the engine.
4. Run the engine to 1,200 rpm.
5. Select system voltage on the scan tool.
6. Drive the vehicle and observe the scan tool for
system voltage.
Is the voltage within the values shown?9–16VGo to Step 4Go to Step 3
31. Disconnect the negative battery cable.
2. Measure the voltage of the battery.
Is the voltage within the values shown?9–16VGo to Step 4Go to ”Section
1E, Engine
Electrical”
41. Turn the headlamp ON.
2. Turn the air conditioner ON.
3. Run the engine to 1,200rpm.
4. Observe the scan tool for system voltage.
Is the voltage within the values shown?9–16VGo to Step 6Go to Step 5
51. Turn the ignition OFF.
2. After testing the charging system, repair the
alternator circuit if necessary.
Is the action completed?–System OK–
6Inspect the F2, EF1 fuse for an open.
Was a problem found?–Go to Step 7Go to Step 8
7Replace the fuse if necessary.
Is the replacement complete?–System OK–
81. Turn the ignition ON.
2. Measure the voltage of F2, EF1.
Is the voltage within the values shown?9–16VGo to Step 10Go to Step 9
9Repair the fuse voltage supply lines for an open.
Is the repair completed?–System OK–
101. Turn the ignition OFF.
2. Disconnect the TCM wiring connector.
3. Measure the resistance between EF1 fuse and
terminal B3 of the TCM wiring connector.
Is the resistance within the values shown?0ΩGo to Step 12Go to Step 11
11Repair the circuit(between EF1 and terminal B3) for
a short to ground and open.
Is the repair completed?–System OK–
121. Disconnect the C105 connector and TCM con-
nector.
2. Turn the ignition ON.
3. Measure the voltage of the terminal B3(TCM
wiring connector).
Is the voltage within the values shown?9–16VGo to Step 13Go to Step 14

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 81
DAEWOO V–121 BL4
DTC P0606 – Transaxle Control Module Processor Fault
StepActionValue(s)YesNo
1Perform an On–Board Diagnostic (EOBD) System
Check.
Is the check completed?–Go to Step 2Go to ”On–
Board Diagnos-
tic System
Check”
21. Install the scan tool.
2. Turn the ignition ON and record then clear
DTC(s), then turn ignition OFF.
3. Turn the ignition ON and start the engine.
4. Run the engine to 1,200 rpm.
5. Select system voltage on the scan tool.
6. Drive the vehicle and observe the scan tool for
system voltage.
Is the voltage within the values shown?9–16VGo to Step 4Go to Step 3
31. Disconnect the negative battery cable.
2. Measure the voltage of the battery at the bat-
tery.
Is the voltage within the values shown?9–16VGo to Step 4Go to ”Section
1E, Engine
Electrical”
41. Turn the headlamp ON.
2. Turn the air conditioner ON.
3. Run the engine to 1,200rpm.
4. Observe the scan tool for system voltage.
Is the voltage within the values shown?9–16VGo to Step 6Go to Step 5
51. Turn the ignition OFF.
2. After testing the charging system, repair the
alternator circuit if necessary.
Is the action completed?–System OK–
6The vehicle would not have started if F2 or EF1 were
blown.
Was a problem found?–Go to Step 7Go to Step 8
7Replace the fuse if necessary.
Is the replacement complete?–System OK–
81. Turn the ignition ON.
2. Measure the voltage of F2, EF1.
Is the voltage within the values shown?9–16VGo to Step 10Go to Step 9
9Repair the fuse voltage supply lines for an open.
Is the action completed?–System OK–
101. Turn the ignition OFF.
2. Disconnect the TCM wiring connector.
3. Measure the resistance between EF1 fuse and
terminal B3 of the TCM wiring connector.
Is the resistance within the values shown?0ΩGo to Step 12Go to Step 11
11Repair the circuit(between EF1 and terminal B3) for
short to ground and open.
Is the repair completed?–System OK–

5A2 – 38IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
DTC P0562 System Voltage Low
StepActionValue(s)YesNo
11. Turn the ignition OFF.
2. Install the Scan tool.
3. Turn the ignition ON, with the engine OFF.
4. Run the engine to 600 rpm or greater.
5. Record then clear DTC(s).
6. Select system voltage on the scan tool.
7. Drive the vehicle and observe the scan tool for
either of the flowing conditions:
Is the voltage within the values shown?9–16vGo to Step 4Go to Step 2
21. Disconnect the battery cable.
2. Measure the battery voltage.
Is the voltage within the values shown?9–16vGo to Step 4Go to Step 3
31. Replace the battery.
Is the replacement completed?–System OK–
41. Turn the headlamp ON.
2. Turn the air conditioner ON.
3. Run the engine to 600 rpm or greater.
4. Observe the scan tool for system voltage.
Is the voltage within the values shown?9–16vGo to Step 6Go to Step 5
51. Turn the ignition LOCK.
2. Repair the alternator circuit if necessary.
Is the action completed?–System OK–
6Inspect the EF1,F2 fuse for an open.
Was a problem found?–Go to Step 7Go to Step 8
7Inspect the EF1,F2 fuse for short. Replace the fuse
if necessary.
Is the replacement complete?–System OK–
81. Turn the ignition ON.
2. Measure the voltage of EF1, F2.
Is the voltage within the values shown?9–16vGo to Step 10Go to Step 9
9Repair the fuse voltage supply lines for open.
Is the action completed?–System OK–
101. Turn the ignition LOCK.
2. Disconnect the TCM wiring connector.
3. Measure the resistance between EF1 fuse and
terminal A24 of the TCM wiring connector.
Is the resistance within the values shown?0ΩGo to Step 12Go to Step 11
11Repair the circuit (between EF1 and terminal A24)
for short to ground and open.
Is the repair completed?–System OK–
121. Disconnect the C105 connector and TCM con-
nector.
2. Turn the ignition ON.
3. Measure the voltage of the terminal A24.
Is the voltage within the values shown?9–16vGo to Step 13Go to Step 14
13Repair the circuit from EF1 to terminal A24 of the
TCM for short to battery.
Is the repair completed?–System OK–

AISIN AUTOMATIC TRANSAXLE 5A2 – 41
DAEWOO V–121 BL4
DTC P0563 System Voltage High
StepActionValue(s)YesNo
11. Turn the ignition OFF.
2. Install the Scan tool.
3. Turn the ignition ON, with the engine OFF.
4. Run the engine to 600 rpm or greater.
5. Record then clear DTC(s).
6. Select system voltage on the scan tool.
7. Drive the vehicle and observe the scan tool for
either of the flowing conditions:
Is the voltage within the values shown?9–16vGo to Step 4Go to Step 2
21. Disconnect the battery cable.
2. Measure the battery voltage.
Is the voltage within the values shown?9–16vGo to Step 4Go to Step 3
31. Replace the battery.
Is the replacement completed?–System OK–
41. Turn the headlamp ON.
2. Turn the air conditioner ON.
3. Run the engine to 600 rpm or greater.
4. Observe the scan tool for system voltage.
Is the voltage within the values shown?9–16vGo to Step 6Go to Step 5
51. Turn the ignition LOCK.
2. Repair the alternator circuit if necessary.
Is the action completed?–System OK–
6Inspect the EF1,F2 fuse for an open.
Was a problem found?–Go to Step 7Go to Step 8
7Inspect the EF1,F2 fuse for short. Replace the fuse
if necessary.
Is the replacement complete?–System OK–
81. Turn the ignition ON.
2. Measure the voltage of EF1,F2.
Is the voltage within the values shown?9–16vGo to Step 10Go to Step 9
9Repair the fuse voltage supply lines for open.
Is the action completed?–System OK–
101. Turn the ignition LOCK.
2. Disconnect the TCM wiring connector.
3. Measure the resistance between EF1 fuse and
terminal A24 of the TCM wiring connector.
Is the resistance within the values shown?0ΩGo to Step 12Go to Step 11
11Repair the circuit (between EF1 and terminal A24)
for short to ground and open.
Is the repair completed?–System OK–
121. Disconnect the C105 connector and TCM con-
nector.
2. Turn the ignition ON.
3. Measure the voltage of the terminal A24.
Is the voltage within the values shown?9–16vGo to Step 13Go to Step 14
13Repair the circuit from EF1 to terminal A24 of the
TCM for short to battery.
Is the repair completed?–System OK–

POWER STEERING SYSTEM 6A – 7
DAEWOO V–121 BL4
8. Lower the vehicle.
9. Secure the pressure line with the retaining clip lo-
cated above the alternator.
Tighten
Tighten the pressure line retaining clip bolt to 8 NSm
(71 lb–in).
10. Connect the return and supply line to the fluid res-
ervoir.
11. Connect the pressure line pipe and the supply line
hose to the outlet and inlet connections on the pow-
er steering pump.
Tighten
Tighten the pressure line fitting to 28 NSm (21 lb–ft).
Notice : When adding fluid or making a complete change,
always use DEXRON®–II or III power steering fluid. Fail-
ure to use the proper fluid will cause hose and seal dam-
age and fluid leaks.
12. Fill the fluid reservoir with power steering fluid.
13. Inspect for leaks. If there are leaks, correct the
cause of the leaks and bleed the system. Refer to
”Bleeding the Power Steering System” in this sec-
tion.