remove gear lever DAEWOO NUBIRA 2004 Service Repair Manual

1E – 32IENGINE ELECTRICAL
DAEWOO V–121 BL4
the same cable to the positive terminal on the other
battery. Never connect the other end to the nega-
tive terminal of the discharged battery.
CAUTION : To avoid injury do not attach the cable di-
rectly to the negative terminal of the discharged bat-
tery. Doing so could cause sparks and a possible bat-
tery explosion.
6. Clamp one end of the second cable to the negative
terminal of the booster battery. Make the final con-
nection to a solid engine ground (such as the en-
gine lift bracket) at least 450 millimeters (18 inches)
from the discharged battery.
7. Start the engine of the vehicle with the good bat-
tery. Run the engine at a moderate speed for sever-
al minutes. Then start the engine of the vehicle
which has the discharged battery.
8. Remove the jumper cables by reversing the above
sequence exactly. Remove the negative cable from
the vehicle with the discharged battery first. While
removing each clamp, take care that it does not
touch any other metal while the other end remains
attached.
GENERATOR
The Delco–Remy CS charging system has several mod-
els available, including the CS. The number denotes the
outer diameter in millimeters of the stator lamination.
CS generators are equipped with internal regulators. A
Delta stator, a rectifier bridge, and a rotor with slip rings
and brushes are electrically similar to earlier generators.
A conventional pulley and fan are used. There is no test
hole.
Unlike three–wire generators, the CS may be used with
only two connections: battery positive and an ”L’’ terminal
to the charge indicator lamp.
As with other charging systems, the charge indicator lamp
lights when the ignition switch is turned to RUN, and goes
out when the engine is running. If the charge indicator is
on with the engine running, a charging system defect is in-
dicated. This indicator light will glow at full brilliance for
several kinds of defects as well as when the system volt-
age is too high or too low.The regulator voltage setting varies with temperature and
limits the system voltage by controlling rotor field current.
At high speeds, the on–time may be 10 percent and the
off–time 90 percent. At low speeds, with high electrical
loads, on–time may be 90 percent and the off–time 10 per-
cent.
CHARGING SYSTEM
CS generators use a new type of regulator that incorpo-
rates a diode trio. A Delta stator, a rectifier bridge, and a
rotor with slip rings and brushes are electrically similar to
earlier generators. A conventional pulley and fan are used.
There is no test hole.
STARTER
Wound field starter motors have pole pieces, arranged
around the armature, which are energized by wound field
coils.
Enclosed shift lever cranking motors have the shift lever
mechanism and the solenoid plunger enclosed in the drive
housing, protecting them from exposure to dirt, icy condi-
tions, and splashes.
In the basic circuit, solenoid windings are energized when
the switch is closed. The resulting plunger and shift lever
movement causes the pinion to engage the engine fly-
wheel ring gear. The solenoid main contacts close. Crank-
ing then takes place.
When the engine starts, pinion overrun protects the arma-
ture from excessive speed until the switch is opened, at
which time the return spring causes the pinion to disen-
gage. To prevent excessive overrun, the switch should be
released immediately after the engine starts.
STARTING SYSTEM
The engine electrical system includes the battery, the igni-
tion, the starter, the generator, and all the related wiring.
Diagnostic tables will aid in troubleshooting system faults.
When a fault is traced to a particular component, refer to
that component section of the service manual.
The starting system circuit consists of the battery, the
starter motor, the ignition switch, and all the related electri-
cal wiring. All of these components are connected electri-
cally.

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.

4G – 4IPARKING BRAKE
DAEWOO V–121 BL4
6. Remove the parking brake lever assembly–to–ve-
hicle underbody bolts.
Installation Procedure
Notice : If the parking brake lever is bent or damaged, re-
place the complete parking brake lever assembly, which
includes a new parking brake switch.
1. Fasten the parking brake switch to the parking
brake lever assembly with the screw.
Tighten
Tighten the parking brake switch–to–parking brake
lever screw to 4 NSm (35 lb–in).
2. Install the parking brake lever bolts, and fasten the
parking brake lever assembly to the vehicle under-
body.
Tighten
Tighten the parking brake lever assembly–to–vehicle
underbody bolts to 22 NSm (16 lb–ft).
3. Install the hex nut on the end of pull rod.
4. Check the parking brake adjustment referring to the
original removal adjustment nut measurement tak-
en in the removal procedure. Refer to ”Parking
Brake Adjustment – Rear Drum Brakes” or ”Park-
ing Brake Adjustment – Rear Disc Brakes” in this
section.
5. Install the parking brake/gearshift console hood.
Refer to Section 9G, Interior Trim.

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.

4G – 8IPARKING BRAKE
DAEWOO V–121 BL4
9. Attach the parking brake cable ends to the equaliz-
er.
10. Adjust the hex nut on the end of pull rod. Refer to
”Parking Brake Adjustment” in this section.
11. Install the parking brake/gearshift console hood.
Refer to Section 9G, Interior Trim.
PARKING BRAKE HANDLE
Removal Procedure
1. Remove the parking brake/gearshift console hood,
detaching the parking brake lever boot. Refer to
Section 9G, Interior Trim.
2. Slip the parking brake handle off of the parking
brake lever.
Installation Procedure
1. Push the parking brake handle as far as it will go on
the parking brake lever.
2. Install the parking brake/gearshift console hood
with the parking brake lever boot. Refer to Section
9G, Interior Trim.

5A1 – 46IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
sible, drive the vehicle for a few kilometers (N–D,
N–R, shift until two gear). This will allow the trans-
axle to be within the correct temperature range.
Transaxle fluid level should be checked at tempera-
ture 20 to 45°C (68 to 113°F).
CAUTION : Removal of the fluid filler plug when the
transaxle fluid is hot may cause injury if fluid drains
from the filler hole.
2. Switch off accessories, especially air conditioner,
heater.
3. With the brake pedal pressed, move the gear shift
control lever through the gear ranges, pausing a
few seconds in each range. Return the gearshift
lever to P(Park). Turn the engine OFF.
4. Park the vehicle on a hoist, inspection pit or similar
raised level surface. The vehicle must be level to
obtain a correct fluid level measurement.
5. Place a fluid container below the fluid filler plug.
6. Clean all dirt from around the fluid filler plug.
Remove the fluid filler plug. Clean the filler plug and
check that there is no damage to the ”O” ring.
S If fluid drains through the filler hole the transaxle
may have been overfilled. When the fluid stops
draining the fluid level is correct. Install the fluid
filler plug and tighten it to 45NSm(34 lb–ft).
S If fluid does not drain through the filler hole, the
transaxle fluid level may be low. Lower the ve-
hicle, and start the vehicle in P(Park) with the
parking brake and the brake applied. With the
engine idling, move the gear shift lever through
the gear ranges, pausing a few seconds in each
range and adding the fluid until gear application
is felt. Return the gear shift lever to P(Park).
Turn the engine OFF and raise the vehicle.
Check if the fluid level is aligned with the bottom
of the filler hole. If not, add a small quantity of
fluid to the correct level. Install the fluid filler
plug and tighten it to 45NSm(34 lb–ft).
7. When the fluid level checking procedure is com-
pleted, wipe any fluid around the filler plug with a
rag or shop towel.
Fluid Level Set After Service
1. Depending on the service procedure performed,
add the following amounts of fluid through the filler
plug hole prior to adjusting the fluid level:
Oil pan removal – 4 liters (4.23 quarts)
Converter removal – 2 liters ( 2.11 quarts)
Overhaul – 6.9liters (7.3 quarts)
Oil drain plug removal – 4 liters (4.23 quarts)
2. Follow steps 1 through 4 of the Fluid Level Diagno-
sis Procedure.
3. Clean all dirt from around the fluid filler plug.
Remove the fluid filler plug. Clean the filler plug and
check that there is no damage to the ”O” ring.
4. Lower the vehicle with the filler plug still removed
and start the vehicle in P(Park) with the parking
brake and the brake applied. With the engine idling,move the gear shift lever through the gear ranges,
pausing a few seconds in each range and adding
the fluid until gear application is felt. Then add an
additional 0.5 liters of fluid. Return the gear shift
lever to P(Park). Turn the engine OFF and raise the
vehicle. Install the fluid filler plug and tighten it to
45NSm (34 lb–ft).
5. Drive the vehicle at 2.2 miles(3.5km) to 2.8
miles(4.5 km) with light throttle so that the engine
does not exceed 2500 rpm. This should result in
the transaxle temperature being in the range 20 to
45°C (68 to 11°F). With the brake applied, move
the shift lever through the gear ranges, pausing a
few seconds in each range at the engine idling.
6. Return the gear shift lever to P(Park). Turn the en-
gine OFF and raise the vehicle on the hoist, if appli-
cable, ensuring the vehicle is level. When the three
minutes passed after the engine stopped, remove
the filler plug. Check if the fluid level is aligned with
the bottom of the filler hole. If not, add a small
quantity of fluid to the correct level. Install the fluid
filler plug and tighten it to 45NSm (34 lb–ft).
7. Wipe any fluid around the filler plug with a rag or
shop towel.
Fluid Leak Diagnosis and Repair
The cause of most external leaks can generally be Lo-
cated and repaired with the transaxle in the vehicle.
Methods for Locating Leaks
General Method
1. Verify that the leak is transaxle fluid.
2. Thoroughly clean the suspected leak area.
3. Drive the vehicle for approximately 25 km (15
miles) or until the transaxle reaches normal operat-
ing temperature (88°C, 190°F).
4. Park the vehicle over clean paper or cardboard.
5. Turn the engine OFF and look for fluid spots on the
paper.
6. Make the necessary repairs to correct the leak.
Powder Method
1. Thoroughly clean the suspected leak area.
2. Apply an aerosol type powder (foot powder) to the
suspected leak area.
3. Drive the vehicle for approximately 25 km (15
miles) or until the transaxle reaches normal operat-
ing temperature (88°C, 190°F).
4. Turn the engine OFF.
5. Inspect the suspected leak area and trace the leak
path through the powder to find the source of the
leak.
6. Make the necessary repairs.
Dye and Black Light Method
1. Add dye to the transaxle though the transaxle fluid
filler plug. Follow the manufacturer’s recommenda-
tion for the amount of dye to be used.
2. Use the black light to find the fluid leak.
3. Make the necessary repairs.

5A1 – 190IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
TRANSAXLE FLUID LEVEL
CHECKING PROCEDURE
Tools Required
DW260–070 Plug Remover/Installer
Inspection Procedure
1. Start the engine and allow the engine to idle for
approximately 5 minutes, or, if possible, drive the
vehicle for a few kilometers(miles) to warm the
transaxle fluid. Check the fluid level when the trans-
axle is over 30°C(86°F).
2. Press the brake pedal and move the shift lever
through the gear ranges, pausing a few seconds in
each range. Return the shift lever to the park posi-
tion. (Left–Hand Drive Shown, Right–Hand Drive
Similar.)
3. Raise and suitably support the vehicle.
4. Place a fluid container below the fluid level plug.
CAUTION : Do not remove the fluid level plug if the
transaxle fluid is hot. This may cause injury if the fluid
drains from the plug hole.
5. Remove the fluid level plug using the plug remover/
installer DW260–070. Because the transaxle oper-
ates correctly over a range of levels, fluid may or
may not drain out of the plug hole when the plug is
removed.

AISIN AUTOMATIC TRANSAXLE 5A2 – 117
DAEWOO V–121 BL4
UNIT REPAIR
MAJOR COMPONENT DISASSEMBLY
Tools Required
DW240–020 Brake/Clutch Spring Compressor
DW240–050 Overdrive Brake Adapter
DW240–060–01 Brake Spring Compressor Bolt/Nut
DW240–070 1st & Reverse Brake Adapter
DW240–080 2nd Brake Adapter
DW240–090 Planetary Ring Gear Remover
DW240–150 Transaxle Case Side Bearing Outer Race
Adapter
DW240–170 Adapter Handle
DW260–021–02 Automatic Transaxle Overhaul Fixture
(81–40 LE)
DW260–041 Planetary Ring Gear Nut Removal/Installa-
tion Socket
Disassembly Procedure
1. Remove the transaxle assembly from the vehicle.
Refer to”Transaxle Assembly” in this section.
2. Install the transaxle assembly to the transaxle sup-
port stand using Automatic Transaxle Overhaul Fix-
ture DW260–021–02 (81–40 LE).
3. Remove the nut, washer and control lever.
4. Using a screwdriver, unstake the lock washer.
5. Remove the two bolts and nut and pull out the
transmission range (TR) switch.
6. Remove the two unions the transaxle case.
7. Remove the two O–rings from the unions.

FIVE–SPEED MANUAL TRANSAXLE 5B – 15
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
CHECKING FLUID LEVEL
1. With the vehicle on a level surface and the fluid in
the transaxle cold, remove the filler plug and check
the fluid level. The fluid should come to the bottom
edge of the plug hole.
2. If the level is low, add SAE 80 manual transaxle
fluid through the filler plug hole until the fluid begins
to run out.
3. Reinstall the filler plug and tighten it securely.
4. If the fluid is contaminated, drain the oil after re-
moving the differential gear cover.
SHIFT LINKAGE ADJUSTMENT
(LEFT–HAND DRIVE SHOWN,
RIGHT–HAND DRIVE SIMILAR)
1. Disconnect the negative battery cable.
2. Position the gearshift lever into NEUTRAL.
Important : All the gears must be easy to engage when
the vehicle is stationary, the engine is running, and the
clutch is disengaged.
3. Loosen the rod clamp bolt.