maintenance DAEWOO NUBIRA 2004 Service Repair Manual

iii
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NUBIRA/LACETTI
Service Manual
(MY2004)
FOREWORD
This manual includes procedures for maintenance, adjustment, service operations, and removal
and installation of components for the NUBIRA/LACETTI vehicle.
When reference is made in this manual to a brand name, number, or specific tool, an equivalent
product may be used in place of the recommended item.
All information, illustrations and specifications contained in this manual are based on the latest
product information available at the time of publication approval. The right is reserved to make
changes at any time without notice.
GM Daewoo Auto & Technology Co., Ltd.
Service Engineering Team
199–1 Cheong Cheon–Dong, Bupyung–Gu, Incheon, Korea
Tel: 82-32-520–2737, 5752
Fax: 82-32-520–4808
E-mail: [email protected]
[email protected]
GM Daewoo Auto & Technology Co., Ltd.
All Rights Reserved
No part of this publication may be reproduced, stored in any retrieval system or transmitted,
in any form or by any means, including but not limited to electronic, mechanical, photocopy-
ing, recording or otherwise, without the prior written permission of GM Daewoo Auto &
Technology Co., Ltd.
Printed in the Republic of Korea

SECTION : 0B
GENERAL INFORMATION
TABLE OF CONTENTS
SPECIFICATIONS0B–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 0B–1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle Dimensions and Weights 0B–6. . . . . . . . . . . .
Standard Bolt Specifications 0B–8. . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR0B–9 . . . . . . . . . . . . . . .
MAINTENANCE AND LUBRICATION 0B–9. . . . . . . . . .
Normal Vehicle Use 0B–9. . . . . . . . . . . . . . . . . . . . . . .
Explanation of Scheduled Maintenance
Services 0B–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scheduled Maintenance Charts 0B–10. . . . . . . . . . . .
OWNER INSPECTIONS AND SERVICES 0B–12. . . . .
Whle Operating The Vehicle 0B–12. . . . . . . . . . . . . . . At Each Fuel Fill 0B–12. . . . . . . . . . . . . . . . . . . . . . . . .
At least Monthly 0B–12. . . . . . . . . . . . . . . . . . . . . . . . . .
At least Twice a Year 0B–12. . . . . . . . . . . . . . . . . . . . .
Each Time The Oil is Changed 0B–13. . . . . . . . . . . . .
At Least Annually 0B–13. . . . . . . . . . . . . . . . . . . . . . . .
Recommended Fluids and Lubricants 0B–14. . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION0B–15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Repair Instructions 0B–15. . . . . . . . . . . . . . . .
GENERAL DESCRIPTION 0B–16. . . . . . . . . . . . . . . . . .
Vehicle and Component Identification 0B–16. . . . . . .
Vehicle Lifting Procedures 0B–21. . . . . . . . . . . . . . . . .
SPECIFICATIONS
TECHNICAL DATA
Performance – Manual Transaxle
Application1.4L DOHC1.6L DOHC1.8L DOHC
Maximum Speed175 km/h (108.7 mph)187 km/h (116.2 mph)194 km/h (120.5 mph)
Minimum Turning Radius5.2 m (17.1 ft)


Performance – Automatic Transaxle
Application1.4L DOHC1.6L DOHC1.8L DOHC
Maximum Speed–175 km/h (108.7 mph)184 km/h (114.3 mph)
Minimum Turning Radius–5.2 m (17.1 ft)

GENERAL INFORMATION 0B – 9
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
MAINTENANCE AND LUBRICATION
NORMAL VEHICLE USE
The maintenance instructions contained in the mainte-
nance schedule are based on the assumption that the ve-
hicle will be used for the following reasons:
S To carry passengers and cargo within the limitation
indicated on the tire placard located on the edge of
the driver’s door.
S To be driven on reasonable road surfaces and with-
in legal operating limits.
EXPLANATION OF SCHEDULED
MAINTENANCE SERVICES
The services listed in the maintenance schedule are fur-
ther explained below. When the following maintenance
services are performed, make sure all the parts are re-
placed and all the necessary repairs are done before driv-
ing the vehicle. Always use the proper fluid and lubricants.
Drive Belt Inspection
When a separate belt drives the power steering pump, the
air conditioning compressor and the generator, inspect it
for cracks, fraying, wear and proper tension. Adjust or re-
place the belt as needed.
Engine Oil and Oil Filter Change
API Classifications of Engine Oil
The International Lubricant Standardization and Approval
Committee (ILSAC) and American Petroleum Institute
classifies engine oils according to their performance quali-
ty. Always use oil rated API–SL (ILSAC GF–III) or better.
Engine Oil Viscosity
Engine oil viscosity (thickness) has an effect on fuel econ-
omy and cold weather operation. Lower viscosity engine
oils can provide better fuel economy and cold weather per-
formance; however, higher temperature weather condi-
tions require higher viscosity engine oils for satisfactory lu-
brication. Using oils of any viscosity other than those
viscosities recommended could result in engine damage.
Cooling System Service
Drain, flush and refill the system with new coolant. Refer
to ”Recommended Fluids And Lubricants” in this section.
Fuel Micro–Filter Replacement
Replace the engine fuel filter every 45,000 km (27,000
miles).
Air Cleaner Element Replacement
Replace the air cleaner element every 45,000 km (27,000
miles).Replace the air cleaner more often under dusty conditions.
Throttle Body Mounting Bolt Torque
Check the torque of the mounting bolts.
Tighten the throttle body mounting bolts to 15 NSm (11 lb–
ft) if necessary.
Spark Plug Replacement
Replace spark plugs with the same type.
Spark Plug Wire Replacement
Clean wires and inspect them for burns, cracks or other
damage. Check the wire boot fit at the DIS module and at
the spark plugs. Replace the wires as needed.
Brake System Service
Check the disc brake pads and the drum brake linings ev-
ery 15,000 km (9,000 miles) or 12 months. Check the pad
and the lining thickness carefully. If the pads or the linings
are not expected to last to the next scheduledmaintenance
service, replace the pads or the linings. Check the breath-
er hole in the brake fluid reservoir cap to be sure it is free
from dirt and the passage is open.
Transaxle Service
The manual transaxle fluid does not require changing. For
automatic transaxles, refer to ”Scheduled Maintenance
Charts” in this section.
Tire and Wheel Inspection and Rotation
Check the tires for abnormal wear or damage. To equalize
wear and obtain maximum tire life, rotate the tires. If irreg-
ular or premature wear exists, check the wheel alignment
and check for damaged wheels. While the tires and
wheels are removed, inspect the brakes. Refer to ”Each
Time The Oil Is Changed” in this section.
Tire Rotation

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.

GENERAL INFORMATION 0B – 11
DAEWOO V–121 BL4
Chassis and Body
Maintenance ItemMaintenance Interval
Kilometers or time in months, whichever comes first
x 1,000 km1153045607590105120
x 1,000 miles0.6918273645546372
Months–1224364860728496
Interior air filter (A/C)RRRRRRRR
Exhaust pipes & mountingsIIIIIIII
Brake/Clutch fluid (1) (4)IIRIRIRIR
Front brake pads and discs(3)IIIIIIII
Rear brake pads & discs or drums and
linings (3)IIIIIIII
Parking brakeIIIIIIIII
Brake line and connections (Including
booster)IIIIIIII
Manual Transaxle Oil *(1)IIIIIIII
Automatic transaxle fluid *(1) (5)IIIIIIII
Tighten chassis and underbody bolts
and nutsIIIIIIII
Tire condition and inflation pressureIIIIIIIII
Wheel alignment (2)Inspect when abnormal condition is noted
Steering wheel and linkageIIIIIIII
Power steering fluid & lines* (1)IIIIIIIII
Drive shaft bootsIIIIIIII
Seat belts, buckles and anchorsIIIIIIII
Lubricate locks, hinges and hood
latchIIIIIIII
Chart Symbols:
I – Inspect and if necessary correct, clean, replenish, or adjust.
R – Replace or change:
(1) Refer to Recommended Fluids And Lubricants.
(2) And if necessary, rotate and balance wheels.
(3) More frequent if operated under severe conditions: short distance driving, extensive idling, frequent low–speed oper-
aion in stop and go traffic, or driving in dusty conditions.
(4) Change the brake/clutch fluid every 15,000 km (9,000 miles), if the vehicle is mainly driven under the following severe
conditions: driving in hilly or mountainous terrain, or towing a trailer/caravan frequently.
(5) 1.8 DOHC model (ZF 4HP16 Automatic Transaxle): Change automatic transaxle fluid every 60,000 Km (36,000 miles)
if the vehicle is mainly driven under any of the following severe conditions:
S In heavy city traffic where the outside temperature regularly reaches 32°C (90°F) or higher, or
S In hilly or mountainous terrain, or
S When doing frequent trailer towing, or
S Uses such as taxi, police or delivery service.

SECTION : 1C1
1.4L/1.6L DOHC ENGINE MECHANICAL
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
SPECIFICATIONS1C1–2 . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Specifications 1C1–2. . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifcations 1C1–5. . . . . . . . . .
SPECIAL TOOLS1C1–7 . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 1C1–7. . . . . . . . . . . . . . . . . . . . . . .
COMPONENT LOCATOR1C1–9 . . . . . . . . . . . . . . . . . . .
Cylinder Head 1C1–9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block 1C1–10. . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake & Exhaust Manifold 1C1–12. . . . . . . . . . . . . . . .
Timing Belt 1C1–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Mounting 1C1–14. . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR1C1–15 . . . . . . . . . . . . .
ON–VEHICLE SERVICE 1C1–15. . . . . . . . . . . . . . . . . . .
Engine Cover 1C1–15. . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft Cover 1C1–15. . . . . . . . . . . . . . . . . . . . . . . . .
Intake Manifold 1C1–16. . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold 1C1–20. . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Gasket 1C1–21. . . . . . . . . . . . . . . .
Camshaft 1C1–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt Check and Adjust 1C1–30. . . . . . . . . . . . .
Timing Belt 1C1–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pan 1C1–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump 1C1–40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Mount 1C1–43. . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft Gears 1C1–45. . . . . . . . . . . . . . . . . . . . . . . . .
Rear Timing Belt Cover 1C1–46. . . . . . . . . . . . . . . . . . .
Engine 1C1–48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistons and Rods 1C1–53. . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR 1C1–58. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Valve Train Components 1C1–58.
Crankshaft 1C1–65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Bearing and Connecting Rod
Beadings – Gauging Plastics 1C1–74. . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION1C1–77 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Gasket 1C1–77. . . . . . . . . . . . . . . .
Crankshaft 1C1–77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt 1C1–77. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump 1C1–77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan 1C1–77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold 1C1–77. . . . . . . . . . . . . . . . . . . . . . . .
Intake Manifold 1C1–77. . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft 1C1–77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 15
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
ENGINE COVER
Removal Procedure
1. Remove the bolts and nuts from the engine cover.
2. Remove the engine cover.
Installation Procedure
1. Position the engine cover on the engine.
2. Install the engine cover bolts and nuts.
Tighten
Tighten the engine cover bolts and nuts to 10 NSm(89
lb–ft).
CAMSHAFT COVER
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the engine cover. Refer to ”Engine” in this
section.
3. Remove the breather hose, ventilation hose and
cam position sensor wiring connector from the cam-
shaft cover.

SECTION : 1C2
1.8L DOHC ENGINE MECHANICAL
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
SPECIFICATIONS1C2–2 . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Specifications 1C2–2. . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifcations 1C2–4. . . . . . . . . .
SPECIAL TOOLS1C2–6 . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 1C2–6. . . . . . . . . . . . . . . . . . . . . . .
COMPONENT LOCATOR1C2–8 . . . . . . . . . . . . . . . . . . .
Upper End 1C2–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower End 1C2–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR1C2–12 . . . . . . . . . . . . .
ON–VEHICLE SERVICE 1C2–12. . . . . . . . . . . . . . . . . . .
Camshaft Cover 1C2–12. . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Gasket 1C2–13. . . . . . . . . . . . . . . .
Camshafts 1C2–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt Check and Adjust 1C2–24. . . . . . . . . . . . .
Timing Belt 1C2–28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan 1C2–32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump 1C2–33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Mount 1C2–37. . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake Manifold 1C2–38. . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Manifold 1C2–41. . . . . . . . . . . . . . . . . . . . . . . .
Camshaft Gears 1C2–43. . . . . . . . . . . . . . . . . . . . . . . . .
Rear Timing Belt Cover 1C2–44. . . . . . . . . . . . . . . . . . .
Engine 1C2–46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistions and Rods 1C2–51. . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR 1C2–56. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Valve Train Components 1C2–56.
Crankshaft 1C2–63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Bearing and Connecting Rod
Beadings – Gauging Plastics 1C2–72. . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION1C2–75 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Gasket 1C2–75. . . . . . . . . . . . . . . .
Crankshaft 1C2–75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt 1C2–75. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump 1C2–75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan 1C2–75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold 1C2–75. . . . . . . . . . . . . . . . . . . . . . . .
Intake Manifold 1C2–75. . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft 1C2–75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1C2 – 12I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
CAMSHAFT COVER
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the breather tube from the valve cover.
3. Disconnect all of the necessary vacuum lines.
4. Remove the spark plug cover bolts.
5. Remove the spark plug cover.
6. Disconnect the ignition wires from the spark plugs.
7. Disconnect the camshaft position sensor connector.
8. Remove the camshaft cover bolts.
9. Remove the camshaft cover.
10. Remove the camshaft cover gasket from the cam-
shaft cover.

SECTION : 1D
ENGINE COOLING
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
SPECIFICATIONS1D–2 . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacity 1D–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 1D–2. . . . . . . . . . .
SPECIAL TOOLS1D–2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 1D–2. . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS1D–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat Test 1D–3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Surge Tank Cap Test 1D–3. . . . . . . . . . . . . . . . . . . . . . .
Cooling System Diagnosis 1D–4. . . . . . . . . . . . . . . . . .
COMPONENT LOCATOR1D–5 . . . . . . . . . . . . . . . . . . . .
Radiator/Fan 1D–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump/Thermostat (1.4L/1.6L DOHC) 1D–6. . .
Water Pump/Thermostat (1.8L DOHC) 1D–7. . . . . . .
MAINTENANCE AND REPAIR1D–8 . . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 1D–8. . . . . . . . . . . . . . . . . . . . . Draining and Refilling the Cooling System 1D–8. . . . .
Thermostat (1.4L/1.6L DOHC) 1D–9. . . . . . . . . . . . . . .
Thermostat (1.8L DOHC) 1D–10. . . . . . . . . . . . . . . . . .
Water Pump 1D–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Cooling Fan – Main or Auxiliary 1D–13. . . . . .
Surge Tank 1D–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator 1D–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION1D–18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Description 1D–18. . . . . . . . . . . . . . . . . . . . . . .
Radiator 1D–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Surge Tank 1D–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump 1D–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat 1D–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Cooling Fan 1D–19. . . . . . . . . . . . . . . . . . . . . . .
Engine Block Heater 1D–19. . . . . . . . . . . . . . . . . . . . . .