low beam DAEWOO NUBIRA 2004 Service Repair Manual

0B – 12IGENERAL INFORMATION
DAEWOO V–121 BL4
OWNER INSPECTIONS AND SERVICES
WHLE OPERATING THE VEHICLE
Horn Operation
Blow the horn occasionally tomake sure it works. Check
all the button locations.
Brake System Operation
Be alert for abnormal sounds, increased brake pedal trav-
el or repeated pulling to one side when braking. Also, if the
brake warning light goes on, or flashes, something may be
wrong with part of the brake system.
Exhaust System Operation
Be alert to any changes in the sound of the system or the
smell of the fumes. These are signs that the system may
be leaking or overheating. Have the system inspected and
repaired immediately.
Tires,Wheels and Alignment Operation
Be alert to any vibration of the steering wheel or the seats
at normal highway speeds. This may mean a wheel needs
to be balanced. Also, a pull right or left on a straight, level
road may show the need for a tire pressure adjustment or
a wheel alignment.
Steering System Operation
Be alert to changes in the steering action. An inspection
is needed when the steering wheel is hard to turn or has
too much free play, or if unusual sounds are noticed when
turning or parking.
Headlight Aim
Take note of the light pattern occasionally. Adjust the
headlights if the beams seem improperly aimed.
AT EACH FUEL FILL
A fluid loss in any (except windshield washer) system may
indicate a problem. Have the system inspected and re-
paired immediately.
Engine Oil Level
Check the oil level and add oil if necessary. The best time
to check the engine oil level is when the oil is warm.
1. After stopping the engine, wait a few minutes for
the oil to drain back to the oil pan.
2. Pull out the oil level indicator (dip stick).
3. Wipe it clean, and push the oil level indicator back
down all the way.
4. Pull out the oil level indicator and look at the oil lev-
el on it.
5. Add oil, if needed, to keep the oil level above the
MIN line and within the area labeled ”Operating
Range.” Avoid overfilling the engine, since this may
cause engine damage.
6. Push the indicator all the way back down into the
engine after taking the reading.If you check the oil level when the oil is cold, do not run the
engine first. The cold oil will not drain back to the pan fast
enough to give a true oil level reading.
Engine Coolant Level and Condition
Check the coolant level in the coolant reservoir tank and
add coolant if necessary. Inspect the coolant. Replace
dirty or rusty coolant.
Windshield Washer Fluid Level
Check the washer fluid level in the reservoir. Add fluid if
necessary.
AT LEAST MONTHLY
Tire And Wheel Inspection and Pressure
Check
Check the tires for abnormal wear or damage. Also check
for damaged wheels. Check the tire pressure when the
tires are cold (check the spare also, unless it is a stow-
away). Maintain the recommended pressures that are on
the tire placard that is in the glove box.
Light Operation
Check the operation of the license plate light, the head-
lights (including the high beams), the parking lights, the
fog lights, the taillight, the brake lights, the turn signals, the
backup lights and the hazard warning flasher.
Fluid Leak Check
Periodically inspect the surface beneath the vehicle for
water, oil, fuel or other fluids, after the vehicle has been
parked for a while. Water dripping from the air conditioning
system after use is normal. If you notice fuel leaks or
fumes, find the cause and correct it at once.
AT LEAST TWICE A YEAR
Power Steering System Reservoir Level
Check the power steering fluid level. Keep the power
steering fluid at the proper level. Refer to Section 6A, Pow-
er Steering System.
Brake Master Cylinder Reservoir Level
Check the fluid and keep it at the proper level. A low fluid
level can indicate worn disc brake pads which may need
to be serviced. Check the breather hole in the reservoir
cover to be free from dirt and check for an open passage.
Clutch Pedal Free Travel
Check clutch pedal free travel and adjust as necessary.
Measure the distance from the center of the clutch pedal
to the outer edge of the steering wheel with the clutch ped-
al not depressed. Then measure the distance from the
center of the clutch pedal to the outer edge of the steering
wheel with the clutch pedal fully depressed. The difference
between the two values must be greater than 130 mm
(5.19 inches).
Weather–Strip Lubrication
Apply a thin film silicone grease using a clean cloth.

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.

9B – 16ILIGHTING SYSTEMS
DAEWOO V–121 BL4
HEADLAMPS
Low–Beam Headlamps Are Inoperative, High–Beam Headlamps
Are OK
StepActionValue(s)YesNo
1Check fuses Ef20 (left side headlamps) and Ef27
(right side headlamps).
Is fuse Ef20 or Ef27 blown?–Go to Step 2Go to Step 3
21. Check for a short circuit and repair if neces-
sary.
2. Replace the fuse.
Is the repair complete?–System OK–
3Check the voltage at fuses Ef20 and Ef27.
Does the voltage available at fuses Ef20 and Ef27
equal the value specified?11–14 vGo to Step 4Go to Step 9
41. Disconnect both headlamp connectors.
2. Turn the headlamps ON.
3. Select the low beams.
Does the voltage at each headlamp connector termi-
nal 5 equal the value specified?11–14 vGo to Step 6Go to Step 5
5Repair the open circuit between fuses Ef20 or Ef27
and the low beam headlamps.
Is the repair complete?–System OK–
61. Disconnect the headlamp connectors.
2. Connect an ohmmeter between ground and
either headlamp connector terminal 6.
Is the resistance equal to the value specified?0 WGo to Step 8Go to Step 7
7Repair the ground circuit.
Is the repair complete?–System OK–
8Replace the faulty headlamps.
Is the repair complete?–System OK–
91. Disconnect the headlamp switch connector.
2. Select the low beams.
3. Use an ohmmeter to check the continuity be-
tween terminals 6 and 5 of the headlamp
switch.
Does the ohmmeter indicate the value specified?0 WGo to Step 10Go to Step 11
10Replace the headlamp combination switch.
Is the repair complete?–System OK–
11Repair the open circuit between fuses Ef20 and Ef27
and the headlamp switch connector terminal 5.
Is the repair complete?–System OK–

LIGHTING SYSTEMS 9B – 17
DAEWOO V–121 BL4
High–Beam Headlamps Are Inoperative, Low–Beam Headlamps
Are OK
StepActionValue(s)YesNo
1Check the high–beam headlamps in the ”flash–to–
pass” mode.
Do the high–beam headlamps work in the ”flash–to–
pass” mode?–Go to Step 11Go to Step 2
2Check the voltage at the headlamp switch connector
terminal 7.
Does the voltage equal the value specified?11–14 vGo to Step 4Go to Step 3
3Repair the open circuit between the headlamp
switch connector terminal 7 and the fuse Ef2.
Is the repair complete?–System OKGo to Step 4
4Check fuses Ef15.
Is the fuse blown?–Go to Step 5Go to Step 6
51. Check for a short circuit. Repair it if necessary.
2. Replace the fuse.
Is the repair complete?–System OK–
61. Turn the high–beam headlamps ON.
2. Check the voltage at fuses Ef15.
Does the voltage available at fuses Ef15 equal the
value specified?11–14 vGo to Step 7Go to Step 12
71. Turn the high–beam headlamps ON.
2. Check the voltage at headlamp terminal 4 with
high beams selected.
Does the voltage available at the headlamp connec-
tor terminal 4 equal the value specified?11–14 vGo to Step 9Go to Step 8
8Repair the open circuit between fuse EF16 and the
high–beam headlamps.
Is the repair complete?–System OK–
9Replace the faulty headlamps.
Is the repair complete?–System OK–
101. Disconnect the headlamp combination switch
connector.
2. Put the switch in the high–beam position.
3. Use an ohmmeter to check the continuity of the
headlamp switch between terminals 7 and 4.
Does the ohmmeter indicate the specified value?0 WGo to Step 12Go to Step 11
11Replace the headlamp combination switch.
Is the repair complete?–System OK–
12Repair the open circuit between headlamp combina-
tion switch connector (terminal 4) and Ef15.
Is the repair complete?–System OK–

9B – 18ILIGHTING SYSTEMS
DAEWOO V–121 BL4
High–Beam and Low–Beam Headlamps Are Inoperative On Both
Left and Right Sides
StepActionValue(s)YesNo
1Check fuses F6, Ef2, Ef20, Ef27 and Ef15.
Is any fuse blown?–Go to Step 2Go to Step 3
21. Check for a short circuit and repair if neces-
sary.
2. Replace the fuse.
Is the repair complete?–System OK–
31. Turn the low–beam headlamps ON.
2. Check the voltage at fuses Ef20, Ef27 and
Ef15.
Does the voltage at the headlamps equal the value
specified?11–14 vGo to Step 4Go to Step 9
41. Turn the low–beam headlamps ON.
2. Check the voltage at the headlamp connector
terminal 5.
3. Turn the high–beam headlamps ON.
4. Check the voltage at headlamp connector ter-
minal 4.
Does the battery voltage available at the headlamps
equal the value specified?11–14 vGo to Step 6Go to Step 5
5Repair the open circuit between fuses Ef20, Ef27
and Ef15 and the headlamps.
Is the repair complete?–System OK–
6Use an ohmmeter to check between ground and
each headlamp connector terminal 6.
Is the resistance equal to the specified value?0 WGo to Step 8Go to Step 7
7Repair the ground circuit.
Is the repair complete?–System OK–
81. Replace the faulty headlamps.
2. Check the charging system to make sure that
charging voltage is not excessively high. Re-
pair if necessary.
Is the repair complete?–System OK–
9Temporarily substitute the illumination relay in place
of the headlamp relay.
Do the headlamps operate with the substituted
relay?–Go to Step 10Go to Step 11
10Install the illumination relay in its original position,
and install a new headlamp relay.
Is the repair complete?–System OK–
111. With the headlamp relay removed, turn the
headlamp switch to the low–beam position.
2. Use an ohmmeter to check the continuity be-
tween the connector for relay terminal 85 and
ground.
Does the ohmmeter indicate the specified value?
0 WGo to Step 17Go to Step 12

LIGHTING SYSTEMS 9B – 19
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
121. Reinstall the headlamp relay.
2. Check the voltage at the light switch connector
terminal 2.
Does the voltage equal the specified value?11–14 vGo to Step 14Go to Step 13
13Repair the open circuit between headlamp relay ter-
minal 85 and the light switch connector terminal 2.
Is the repair complete?–System OK–
141. Disconnect the light switch connector.
2. Turn the headlamps to the low–beam position.
3. Use an ohmmeter to check the continuity be-
tween terminals 2 and 3 of light switch.
Does the ohmmeter indicate the specified value?
0 WGo to Step 16Go to Step 15
15Replace the light switch.
Is the repair complete?–System OK–
16Repair the open circuit between terminal 3 of light
switch connector and ground.
Is the repair complete?–System OK–
17Check the voltage at headlamp switch connector
terminal 6.
Does the voltage equal the specified value?11–14 vGo to Step 19Go to Step 18
18Repair the open circuit between headlamp switch
connector and terminal 87 of the headlamp relay.
Is the repair complete?–System OK–
191. Disconnect headlamp switch connector.
2. Turn the headlamps to the low–beam position.
3. Connect an ohmmeter between terminals 5
and 6 of headlamp switch connector. Observe
the reading on the ohmmeter.
4. Turn the headlamps to the high–beam position.
5. Connect an ohmmeter between terminals 4
and 6 of the headlamp switch. Observe the
reading on the ohmmeter.
Does the ohmmeter show the specified value for
both of the tests?
0 WGo to Step 20Go to Step 15
20Repair the open circuit between the headlamp
switch and fuses Ef20, Ef27 and Ef15.
Is the repair complete?–System OK–

LIGHTING SYSTEMS 9B – 21
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
141. Turn the low–beam headlamps ON.
2. With the headlamp leveling switch removed for
testing and the electrical connector still con-
nected, check the voltage at the DK GRN wire
at the headlamp leveling switch with the switch
dial set at ”0”.11–14 vGo to Step 16Go to Step 15
15Replace the headlamp leveling switch.
Is the repair complete?–System OK–
161. Turn the low–beam headlamps ON.
2. With the headlamp leveling switch removed for
testing and the electrical connector still con-
nected, check the voltage at the DK GRN wire
at the headlamp leveling switch with the switch
dial set at ”3”.4.5 vGo to Step 17Go to Step 15
17Repair the open DK GRN wire between the head
lamp leveling switch and the headlamp leveling mo-
tors.
Is the repair complete?–System OK–

9B – 46ILITHING SYSTEMS
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
HEADLAMPS–ON REMINDER CHIME
When the headlamp switch is in the headlamps–on or
parking lamps–on position, voltage is applied to the chime
module. When the ignition is in ON, ACC or START, volt-
age is applied through the fuse block to the module. These
two voltages are sensed, and the chime module is not
sounded.
When the ignition is not in ON, ACC or START, the module
loses voltage. The chime module senses change. If the
voltage is still available, it is applied to sound the chime.
The chime can be turned off by turning the headlamp
switch off. The module no longer senses voltage from the
headlamp switch, so the chime module does not sound.
HEADLAMPS
The headlamps are controlled by the multifunction lever
located on the left side of the steering column. They will
come on with the ignition switch in any position. Turning
the headlamp switch to the first position turns on the park-
ing lamps, the license plate lamps and the instrument pan-
el illumination. Turning the switch to the second position
turns on all of the previous lamps and the headlamps.
Turning the switch to the OFF position turns off all the
lamps.
Headlamp high beams and low beams are also controlled
by this lever. When the headlamps are on, pushing the le-
ver away from the driver until the switch clicks changes the
lamp from low beam to high beam. An indicator lamp on
the instrument cluster assembly will come on when the
high beam headlamps are on. To return the headlamps to
low beam, pull the lever toward the driver.
The headlamps must be aimed for proper illumination of
the road. Headlamp aim should be checked whenever a
new headlamp assembly is installed, or whenever service
repairs to the front end area may have disturbed the head-
lamp assembly or its mountings.
DAYTIME RUNNING LAMPS
The Daytime Running Lamps (DRL) will come on when:
S The ignition is ON.
S The light is OFF.
S The parking brake is released.
When the exterior lights are on, the DRL will turn off. To
turn the DRL off when idling, apply the parking brake.
PARKING AND TURN SIGNAL LAMPS
The parking lamps can be turned on by turning the lighting
switch to the first position. The parking lamps can be
turned off by turning the switch to the OFF position.When the turn signals are activated, the front and rear turn
signal lamps flash to signal a turn. The turn signals work
only when the ignition is ON.
The turn signals are controlled by the light switch on the
left side of the steering column. Moving the lever all the
way up or down (past the detent) will turn on the front and
rear turn signals. When the turn is completed, the lever will
return to horizontal and the turn signals will stop flashing.
For changing lanes, or for shallow turns in which the steer-
ing wheel does not turn far enough to cancel the signal,
move the signal lever only to the first detent and hold it
there. When the lever is released, it will return to horizontal
and the turn signals will cancel.
FOG LAMPS
The fog lamp switch is on the instrument panel to the right
of the steering column. To use the fog lamps, first turn on
the headlamps or the parking lamps. Then push the fog
lamp switch. The indicator light in the switch will illuminate
to indicate that the fog lamps are on. Push the switch again
to turn off the fog lamps. The indicator light will then go off.
The fog lamps should not be used as a substitute for the
headlamps.
The fog lamps must be aimed for proper illumination of the
road. Fog lamp aim should be checked when a new bulb
is installed or if service or repairs in the front end area may
have disturbed the fog lamp mountings.
REAR COMBINATION LAMPS
The taillamps, stoplamps, turn signal lamps and backup
lamp are one assembly.
Turning on either the headlamps or the parking lamps will
also turn on the taillamps. When the brake pedal is
pushed, the taillamps will glow brighter to serve as sto-
plamps.
The center high–mounted stoplamp is located in the rear
window and will come on when the brake pedal is pressed.
LICENSE PLATE LAMP
The license plate lamps will come on when the headlamps
or the parking lamps are on. The license plate lamps are
mounted above the license plate.
INTERIOR COURTESY LAMP
The courtesy lamp is located on the headliner just behind
the front seats. The lamp switch has three positions. If the
switch is left in the center position, the lamp will go on
whenever a door is opened and go off when it is closed.
In the ON position, the lamp will stay on until it is turned off.
In the OFF position, the lamp will not come on, even when
a door is opened.
LUGGAGE COMPARTMENT LAMP
The luggage compartment lamp is located under the deck
lid sill plate on the notchback. The lamp is located on the
left–side wheelhouse trim panel on the hatchback. It will
come on whenever the luggage compartment is opened.

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