hood release DAEWOO NUBIRA 2004 Service Repair Manual

GENERAL INFORMATION 0B – 13
DAEWOO V–121 BL4
EACH TIME THE OIL IS CHANGED
Automatic Transaxle Fluid
Refer to fluid level service procedure of Section 5A, ZF
4HP16 Automatic Transaxle.
Manual Transaxle
Check the fluid level and add fluid as required. Refer to
Section 5B, Five–Speed Manual Transaxle.
Brake System Inspection
This inspection should be done when the wheels are re-
moved for rotation. Inspect the lines and the hoses for
proper hookup, binding, leaks, cracks, chafing, etc. In-
spect the disc brake pads for wear. Inspect the rotors for
surface condition. Also inspect the drum brake linings for
wear and cracks. Inspect other brake parts, including the
drums, the wheels cylinders, the parking brake, etc., at the
same time. Check the parking brake adjustment. Inspect
the brakes more often if habit or conditions result in fre-
quent braking.
Steering, Suspension and Front Drive Axle
Boot And Seal Inspection
Inspect the front and rear suspension and the steering
system for damaged, loose or missing parts, signs of wear
or lack of lubrication. Inspect the power steering lines and
the hoses for proper hookup, binding, leaks, cracks, chaf-
ing, etc. Clean and inspect the drive axle boot and seals
for damage, tears or leakage. Replace the seals if neces-
sary.
Exhaust System Inspection
Inspect the complete system (including the catalytic con-
verter if equipped). Inspect the body near the exhaust sys-
tem. Look for broken, damaged, missing, or out–of–posi-
tion parts as well as open seams, holes, loose
connections, or other conditions which could cause heat
buildup in the floor pan or could let exhaust fumes seep
into the trunk or passenger compartment.
Throttle Linkage Inspection
Inspect the throttle linkage for interference or binding,
damaged, or missing parts. Lubricate all linkage joints and
throttle cable joints, the intermediate throttle shaft bearing,
the return spring at throttle valve assembly, and the accel-
erator pedal sliding face with suitable grease. Check the
throttle cable for free movements.
Engine Drive Belts
Inspect all belts for cracks, fraying, wear and proper ten-
sion. Adjust or replace the belts as needed.
Hood Latch Operation
When opening the hood, note the operation of the secon-
dary latch. It should keep the hood from opening all the
way when the primary latch is released. The hood must
close firmly.
AT LEAST ANNUALLY
Lap and Shoulder Belts Condition and
Operation
Inspect the belt system including: the webbing, the
buckles, the latch plates, the retractor, the guide loops and
the anchors.
Movable Head Restraint Operation
On vehicles with movable head restraints, the restraints
must stay in the desired position.
Spare Tire and Jack Storage
Be alert to rattles in the rear of the vehicle. The spare tire,
all the jacking equipment, and the tools must be securely
stowed at all times. Oil the jack ratchet or the screw mech-
anism after each use.
Key Lock Service
Lubricate the key lock cylinder.
Body Lubrication Service
Lubricate all the body door hinges including the hood, the
fuel door, the rear compartment hinges and the latches,
the glove box and the console doors, and any folding seat
hardware.
Transaxle Neutral Switch Operation on
Automatic Transaxle
CAUTION : Take the following precautions because
the vehicle could move without warning and possibly
cause personal injury or property damage:
S Firmly apply the parking brake and the regular
brakes.
S Do not use the accelerator pedal.
S Be ready to promptly turn off the ignition if the ve-
hicle starts.
On automatic transaxle vehicles, try to start the engine in
each gear. The starter should crank only in P (Park) or N
(Neutral).
Parking Brake and Transaxle P (Park)
Mechanism Operation
CAUTION : In order to reduce the risk of personal in-
jury or property damage, be prepared to apply the reg-
ular brakes promptly if the vehicle begins to move.
Park on a fairly steep hill with enough room for movement
in the downhill direction. To check the parking brake, with
the engine running and the transaxle in N (Neutral), slowly
remove foot pressure from the regular brake pedal (until
only the parking brake is holding the vehicle).
To check the automatic transaxle P (Park) mechanism’s
holding ability, release all brakes after shifting the trans-
axle to P (Park).
Underbody Flushing
Flushing the underbody will remove any corrosive materi-
als used for ice and snow removal and dust control. At
least every spring clean the underbody. First, loosen the
sediment packed in closed areas of the vehicle. Then flush
the underbody with plain water.

0B – 14IGENERAL INFORMATION
DAEWOO V–121 BL4
Engine Cooling System
Inspect the coolant and freeze protection fluid. If the fluid
is dirty or rusty, drain, flush and refill the engine cooling
system with new coolant. Keep the coolant at the proper
mixture in order to ensure proper freeze protection, corro-sion protection and engine operating temperature. Inspect
the hoses. Replace the cracked, swollen, or deteriorated
hoses. Tighten the clamps. Clean the outside of the radia-
tor and the air conditioning condenser. Wash the filler cap
and the neck. Pressure test the cooling system and the
cap in order to help ensure proper operation.
RECOMMENDED FLUIDS AND LUBRICANTS
UsageCapacityFluid/Lubricant
Engine Oil3.75L (4.0 qt) : 1.4L DOHC
3.75L (4.0 qt) : 1.6L DOHC
4.0L (4.2 qt) : 1.8L DOHCAPI SL (ILSAC GF–III) grade or better
SAE 5W–30, SAE10W–30, SAE15W–40
(Cold area : SAE5W–30
Hot area : SAE 15W–40)
Engine Coolant7.0L (7.49 qt) : 1.4L DOHC
7.2L (7.6 qt) : 1.6L DOHC
7.4L (7.8 qt) : 1.8L DOHCMixture of water and good quality ethylene gly-
col base antifreeze (year–round coolant)
Brake Fluid and Clutch Fluid0.5L (0.5 qt)DOT–3 or DOT–4
Power Steering System1.1L (1.2 qt)DEXRON®–III or DEXRON®–IID
Automatic Transaxle5.77 ± 0.2L (6.1 ± 0.2 qts) :
1.6L DOHC (AISIN 81–40LE)ESSO JWS 3309 or ISU DEXRON III
6.9 ± 0.2L (7.3 ± 0.2 qts) :
1.8L DOHC (ZF 4HP16)ESSO LT 71141 or TOTAL ATF H50235
Manual Transaxle1.8L (2.0 qt)Manual Transaxle Fluid
SAE80W (Cold Area : SAE 75W)
Manual Transaxle Shift LinkageAs requiredMultipurpose type grease meeting require-
ments NLGI No. 1 or 2
Key Lock CylindersAs requiredSilicone lubricant
Automatic Transaxle Shift Link-
ageAs requiredEngine oil
Clutch Linkage Pivot PointsAs requiredEngine oil
Floor Shift Linkage PointsAs requiredEngine oil
Hood Latch Assembly
a. Pivots and Spring Anchor
b. Release PawlAs requireda. Engine oil
b. Multipurpose type grease meeting require-
ments NLGI No. 1 or 2
Hood and door hinges
Fuel door hinge
Rear compartment lid hingesAs requiredEngine oil
WeatherstripsAs requiredSilicone grease

4G – 2IPARKING BRAKE
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
PARKING BRAKE ADJUSTMENT
REAR DRUM BRAKES
Adjustment Procedure
1. Adjust the rear brakes. Refer to Section 4E1, Rear
Disc Brakes.
2. Release the parking brake.
3. Raise and suitably support the vehicle.
4. Check the parking brake cables for free movement.
5. Lower the vehicle
6. Remove the parking brake/gearshift console hood.
Refer to Section 9G, Interior Trim.
7. Partially raise the vehicle.
8. Turn the self–locking nut on the parking brake lever
assembly until the wheels are difficult to turn.
9. Back off the nut until the rear wheels are just free to
turn.
10. Lower the vehicle
11. Install the parking brake/gearshift console hood.
Refer to Section 9G, Interior Trim.
PARKING BRAKE ADJUSTMENT
REAR DISC BRAKES
Adjustment Procedure
1. Release the parking brake.
2. Raise and suitably support the vehicle.
3. Remove the rear wheels. Refer to Section 2E, Tires
and Wheels.
4. Remove the caliper and rotor assemblies. Refer to
Section 4E1, Rear Disc Brakes.
5. Remove the brake rotors on each side of the ve-
hicle. Refer to Section 4E1, Rear Disc Brakes.
6. Disconnect the parking brake cable from the back-
plate operating lever on each side of the vehicle.

PARKING BRAKE 4G – 3
DAEWOO V–121 BL4
7. Inspect and replace any parts of doubtful strength
or quality. This can be shown by discoloration from
heat or stress.
8. Using a vernier caliper, adjust the shoe assembly to
167.6 to 167.8 mm (6.60 to 6.61 inches) by turning
the adjuster nut clockwise to increase the diameter.
Measure the shoe assembly diameter as closely as
possible to the center of the lining material.
9. Inspect and install the rotors and calipers. Refer to
Section 4E1, Rear Disc Brakes.
10. Install the parking brake cable to the backplate le-
ver on each side of the vehicle.
11. In the vehicle cabin, pull on the parking brake han-
dle. Stop after hearing two clicks.
12. Turn the rear wheel by hand until the wheel begins
to drag.
13. Release the parking brake.
14. Turn the rear wheel by hand to check the drag. Re-
adjust the cable, if necessary.
15. Repeat the process for the other rear wheel.
16. Lower the vehicle.
PARKING BRAKE LEVER
Removal Procedure
1. Release the parking brake.
2. Remove the parking brake/gearshift console hood.
Refer to Section 9G, Interior Trim.
3. Measure the thread length from the end of the pull
rod to the hex nut.
4. Remove the hex nut.
5. Remove the parking brake warning lamp switch.
Notice : The parking brake switch should be replaced if
the BRAKE warning light in the instrument panel cluster
did not glow when the parking brake was applied with the
ignition switch ON.

PARKING BRAKE 4G – 5
DAEWOO V–121 BL4
PARKING BRAKE CABLE
Removal Procedure
1. Remove the parking brake/gearshift console hood.
Refer to Section 9G, Interior Trim.
2. Release the parking brake lever and the hex nut on
the end of pull rod.
3. Remove the parking brake cable ends from the
equalizer.
4. Raise and suitably support the vehicle.
5. Remove the rear wheels. Refer to Section 2E, Tires
and Wheels.
6. For vehicles with rear drum brakes, remove the det-
ent screw of the rear brake drum and remove the
brake drum.
7. Remove the retaining ring for the parking brake
cable.
8. Remove the plastic sleeve.
9. Remove the parking brake cable from the brake
trailing shoe lever and from the backing plate.

SECTION : 9G
INTERIOR TRIM
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
SPECIFICATIONS9G–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 9G–1. . . . . . . . . . .
SPECIAL TOOLS9G–2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 9G–2. . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR9G–3 . . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 9G–3. . . . . . . . . . . . . . . . . . . . .
Front Door Trim Panel 9G–3. . . . . . . . . . . . . . . . . . . . . .
Rear Door Trim Panel 9G–4. . . . . . . . . . . . . . . . . . . . . .
A–pillar Trim Panel 9G–4. . . . . . . . . . . . . . . . . . . . . . . . .
Upper B–pillar Trim Panel 9G–5. . . . . . . . . . . . . . . . . . .
Lower B–pillar Trim Panel 9G–5. . . . . . . . . . . . . . . . . . .
C–pillar Trim Panel 9G–6. . . . . . . . . . . . . . . . . . . . . . . . .
Deck Lid Sill Plate Cover 9G–6. . . . . . . . . . . . . . . . . . .
Front Rocker Trim Panel 9G–7. . . . . . . . . . . . . . . . . . . .
Rear Rocker Trim Panel 9G–7. . . . . . . . . . . . . . . . . . . .
Front Wheelhouse Trim 9G–8. . . . . . . . . . . . . . . . . . . . .
Rear Wheelhouse Trim 9G–8. . . . . . . . . . . . . . . . . . . . .
Floor Console 9G–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Floor Carpet 9G–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Luggage Compartment Rear Low Cover 9G–11. . . . .
Luggage Compartment Wheelhouse Trim
Panel 9G–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Driver’s Side Knee Bolster 9G–12. . . . . . . . . . . . . . . . .
Hatchback Door Lower Garnish Molding 9G–13. . . . .
Hatchback Door Upper Garnish Molding 9G–14. . . . .
Luggage Compartment Wheelhouse Trim Panel
(HATCHBACK) 9G–14. . . . . . . . . . . . . . . . . . . . . . . . .
Luggage Compartment Rear Trim Panel 9G–14. . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION9G–16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interior Trim Panels 9G–16. . . . . . . . . . . . . . . . . . . . . . .
Pressure Relief Vent 9G–16. . . . . . . . . . . . . . . . . . . . . .
Floor Console 9G–16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Floor Carpet 9G–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Compartment Security Cover
(HATCHBACK) 9G–16. . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Door Trim Panel Screws2.5–22
Driver’s Side Knee Bolster Mounting Bolts10–89
Floor Console Screws2.5–22
Gearshift Housing Bolts8–70
Hood Latch Release Handle Mounting Screw3–27
Seat Belt Anchor Bolt3828–

9G – 12IINTERIOR TRIM
DAEWOO V–121 BL4
LUGGAGE COMPARTMENT
WHEELHOUSE TRIM PANEL
Tools Required
KM–475–B Trim Remover
Removal Procedure
1. Remove the luggage compartment rear panel cov-
er. Refer to ”Luggage Compartment Rear Panel
Cover” in this section.
2. Remove the plastic retaining clips using the trim
remover KM–475–B and reposition the luggage
compartment rear trim panel.
Installation Procedure
1. Install the wheelhouse trim panel with the plastic
clips.
2. Install the luggage compartment rear panel cover.
Refer to ”Luggage Compartment Rear Panel Cover”
in this section.
DRIVER’S SIDE KNEE BOLSTER
Removal Procedure
1. Remove the screws.
2. Separate the hood release cable from the hood
latch release handle.
3. Carefully pull the instrument panel under cover until
the mounting clips are released and the instrument
panel under cover.
4. Remove the bolts from the driver’s side knee bol-
ster.
5. Remove the knee bolster.

INTERIOR TRIM 9G – 13
DAEWOO V–121 BL4
Installation Procedure
1. Install the knee bolster with the bolts.
Tighten
Tighten the driver’s side knee bolster mounting bolts
to 10 NSm (89 lb–in).
2. Install the instrument panel under cover.
3. Connect the hood release cable to the hood latch
release handle.
4. Install the screws.
HATCHBACK DOOR LOWER
GARNISH MOLDING
Tools Required
KM–475–B Trim Remover
Removal Procedure
1. Open the hatchback door.
2. Remove the hatchback door upper garnish molding.
Refer to ”Hatchback Door upper garnish Molding” in
this section.
3. Remove the lower garnish molding clips using the
trim remover KM–475–B.
4. Remove the lower garnish molding.
Installation Procedure
1. Install the lower garnish molding with the clips.
2. Install the hatchback door upper garnish molding.
3. Close the hatchback door.

SECTION : 9R
BODY FRONT END
TABLE OF CONTENTS
SPECIFICATIONS9R–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 9R–1. . . . . . . . . . .
MAINTENANCE AND REPAIR9R–2 . . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 9R–2. . . . . . . . . . . . . . . . . . . . .
Lubrication 9R–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fasteners 9R–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Anticorrosion Materials 9R–2. . . . . . . . . . . . . . . . . . . . .
Front End Sealing 9R–2. . . . . . . . . . . . . . . . . . . . . . . . .
Cowl Vent Grille 9R–2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Hood 9R–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hood Hinges 9R–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hood Prop Rod 9R–4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hood Secondary Latch 9R–4. . . . . . . . . . . . . . . . . . . . .
Hood Latch Release Cable 9R–5. . . . . . . . . . . . . . . . . .
Notchback Radiator Grille 9R–5. . . . . . . . . . . . . . . . . . .
Hatchback Radiator Grille 9R–6. . . . . . . . . . . . . . . . . . .
Front Wheel Well Splash Shield 9R–6. . . . . . . . . . . . .
Fender 9R–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION9R–10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body Front End 9R–10. . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
A–Pillar Fender Bolt10–89
Fender Bolt (Front of Fascia)4–35
Front Bumper Fascia–to–Fender Bolt2.5–22
Hinge Bolts2720–
Hood–to–Hinge Bolts2720–
Hood Latch Bolts8–71
Hood Release Handle Nuts4–35
Lower Fender Bolt10–89
Radiator Grille Nuts4–35
Splash Shield screws2–18
Upper Fender Bolts10–89

BODY FRONT END 9R – 5
DAEWOO V–121 BL4
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. Position the hood latch in the location marked dur-
ing removal.
2. Install the hood latch with the bolts.
Tighten
Tighten the hood latch bolts to 8 NSm (71 lb–in).
HOOD LATCH RELEASE CABLE
(Left–Hand Drive Shown, Right–Hand Drive
Similar)
Removal Procedure
1. Remove the screws and the hood release handle
from the instrument panel.
2. Open the hood.
3. Remove the bolts and the hood latch release.
4. Remove the cable from the hood latch release as-
sembly.
5. Remove the cable from the engine compartment.
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 radiator grille with the screws.
2. Install the cable into the hood latch release handle.
3. Install the hood release handle on the instrument
panel with the screws.
Tighten
Tighten the hood release handle screws to 4 NSm (35
lb–in).
4. Install the cable to the hood latch release assembly.
5. Install the hood latch release assembly with the
bolts.
Tighten
Tighten the hood latch bolts to 8 NSm (71 lb–in).
NOTCHBACK RADIATOR GRILLE
Removal Procedure
1. Open the hood.
2. Remove the screws and clips at lower area of the
radiator grille.