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NUBIRA
Daewoo NUBIRA User Manual
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1C – 6
I
DOHC ENGINE MECHANICAL
DAEWOO
V–121 BL4
SPECIAL TOOLS
SPECIAL T
OOLS T
ABLE
KM–653
Adapter
KM–135
Adapter
KM–805
V
alve Guide Reamer
J–36792
Crankshaft Rear Oil Seal
Installer
MKM–571–B
Gauge
J–28467–B
Engine Assembly Lift
Support
KM–412
Engine Overhaul Stand
KM–348
Spring Compressor
43
45
Table of Contents
Default Chapter
2
Performance – Automatic Transaxle
2
Table of Contents
2
Performance – Manual Transaxle
2
Specifications
2
Engine Data
3
Ignition System Data
3
Manual Transaxle Data
3
Clutch – Manual Transaxle Data
3
Automatic Transaxle Data
4
Brake Data
4
Tire and Wheel Data
4
Steering System Data
5
Suspension Data
5
Fuel System Data
5
Lubricating System Data
5
Cooling System Data
6
Vehicle Dimensions and Weights
6
Standard Bolt Specifications
8
Drive Belt Inspection
9
Engine Oil and Oil Filter Change
9
Explanation of Scheduled Maintenance Services
9
Maintenance and Lubrication
9
Maintenance and Repair
9
Normal Vehicle Use
9
Tire and Wheel Inspection and Rotation
10
Transaxle Service
10
Spark Plug Wire Replacement
10
Brake System Service
10
Scheduled Maintenance Chart - Engine
11
Scheduled Maintenance Chart - Chassis and Body
12
At each Fuel Fill
13
At Least Monthly
13
At Least Twice a Year
13
Owner Inspections and Services
13
At Least Annually
14
Each Time the Oil Is Changed
14
Parking Brake and Transaxle P (PARK) Mechanism Operation
14
Transaxle Neutral Switch Operation on Automatic Transaxle
14
Engine Cooling System
15
Underbody Flushing
15
Recommended Fluids and Lubricants
16
General Description and System Operation
17
General Repair Instructions
17
General Description
18
On Board Refueling Vapor Recovery System
18
Schematic of on Board Refueling Vapor Recovery System
19
Component Locator Diagram
20
Certification Plate
21
Passenger Car VIN
21
Vehicle Identification
21
Certification Label
22
Engraved VIN Location
22
VIN Plate Location
22
Engine Number Plate Location – Family II (2.0L DOHC Engine)
23
Engine Number – Family II (2.0L DOHC Engine)
23
Automatic Transaxle Identification Number Plate
24
Manual Transaxle Identification Number Plate
24
Manual Transaxle Identification Number Plate Location
24
Automatic Transaxle Identification Number Plate Location
25
Vehicle Lifting Procedures
25
Vehicle Lifting Points Diagram
27
Compression Test
28
Diagnosis
28
General Engine Information
28
Oil Pressure Test
29
Black Light and Dye Method
30
Finding the Leak
30
Oil Leak Diagnosis
30
Powder Method
30
Engine Knocks Cold and Continues for Two–Three Minutes And/Or Knock Increases with Engine Torque
31
Knock Diagnosis
31
Repairing the Leak
31
Heavy Knock Hot with Torque Applied
32
Knocks During Initial Start–Up but Lasts Only a few Seconds
33
Light Knock Hot
33
Knocks at Idle Hot
34
Connecting Rod Bearing Noise Symptom
35
Main Bearing Noise
35
Noise Diagnosis
35
Piston Noises
36
Valve Mechanism or Valve Train Noises
37
Cleanliness and Care
38
General Information
38
On-Engine Service
38
Table of Contents
39
DOHC Engine Mechanical
39
Engine Specifications
40
Fastener Tightening Specifications
42
Special Tools Table
44
Component Locator
46
Upper End
46
Lower End
48
DOHC Engine Mechanical: General Description and System Operation
50
Crankshaft
50
Oil Pump
50
Oil Pan
50
Engine Maintenance and Repair. On-Vehicle Service
51
Valve Cover
51
Installation Procedure
52
Cylinder Head and Gasket Removal
53
Cylinder Head and Gasket Cleaning
58
Cylinder Head and Gasket Installation
58
Camshafts Removal
63
Camshafts Installation
64
Timing Belt Check and Adjust - Adjustment Procedure
66
Timing Belt Removal
70
Timing Belt Installation
73
Oil Pan Removal
75
Oil Pan Cleaning
76
Oil Pan Installation
77
Oil Pump Maintenance
78
Engine Oil Pressure Inspection Procedure
78
Oil Pump Removal
79
Removal Procedure
79
Oil Pump Inspection
80
Inspection Procedure
80
Oil Pump Installation
81
Oil Pump 1C-39
81
Cylinder Head and Valve Train Components Disassembly
83
Intake Manifold
83
Cylinder Head Inspection
85
Cylinder Head Cleaning Procedure
86
Valve Inspection
86
Cylinder Head Overhaul
87
Valve Grind
87
Valve Grind–In
87
Valve Guide – Ream
88
Cylinder Head Assembly Procedure
89
Valve Seat – Cut
89
Crankshaft Disassembly
92
Crankshaft Assembly
96
Crankshaft Bearing and Connecting Rod Bearings - Gauging Plastic
103
Inspection Procedure – Crankshaft
103
Inspection Procedure – Connecting Rods
105
Engine Cooling
106
Engine Cooling: Capacity
107
Engine Cooling: Fastener Tightening Specifications
107
Engine Cooling: Special Tools Table
107
Engine Cooling: Diagnosis
108
Surge Tank Cap Test
108
Thermostat Test
108
Cooling System Diagnosis
109
Engine Fails to Reach Normal Operating Temperature or Cool Air from the Heater
109
Engine Overheats
109
Loss of Coolant
109
Radiator/Fan Exploded View
110
Coolant Pump/Thermostat (2.0L DOHC) Exploded View
111
Draining and Refilling the Cooling System
112
Engine Cooling Maintenance and Repair
112
Thermostat Removal
113
Thermostat Installation
114
Coolant Pump Inspection Cleaning Procedure
115
Coolant Pump Removal
115
Coolant Pump Installation
116
Electric Cooling Fan (Main or Auxiliary) Removal
116
Electric Cooling Fan (Main or Auxiliary) Installation
117
Surge Tank Removal
118
Surge Tank Installation
119
Radiator Removal
120
Radiator Installation
121
Engine Coolant Temperature Sensor Installation
122
Engine Coolant Temperature Sensor Removal
122
Cooling System Description
123
Radiator
123
Surge Tank
123
Thermostat
123
A/C off or Non–A/C Model
124
A/C on
124
Coolant Temperature Sensor
124
Engine Block Heater
124
Engine Controls
125
Engine Data Display Tables
128
Specifications
128
EVAP Data Display
130
EGR Data Display
131
Oxygen Sensor Data Display
132
Misfire Data Display
133
Engine Data Display Table Definitions
134
TEC Display Table
134
Engine Controls: Fastener Tightening Specifications
137
Fuel System Specifications
138
Temperature VS Resistance Table
138
Pcm/Ecm Wiring Diagram (1 of 6) (Ipcm-6Kd/Isfi-6Td)
139
Schematic and Routing Diagrams
139
Pcm/Ecm Wiring Diagram (2 of 6) (Ipcm-6Kd/Isfi-6Td)
140
Pcm/Ecm Wiring Diagram (3 of 6) (Ipcm-6Kd/Isfi-6Td)
141
Pcm/Ecm Wiring Diagram (4 of 6) (Ipcm-6Kd/Isfi-6Td)
142
Pcm/Ecm Wiring Diagram (5 of 6) (Ipcm-6Kd/Isfi-6Td)
143
Pcm/Ecm Wiring Diagram (6 of 6) (Ipcm-6Kd/Isfi-6Td)
144
Connector End View (Dohc)
145
Engine Controls: Component Locator
150
Diagnostic Aids
152
Engine Controls: Diagnosis
152
Idle Learn Procedure
152
System Diagnosis
152
On-Board Diagnostic (OBD II) System Check
153
PCM/ECM Output Diagnosis
155
Multiple PCM/ECM Information Sensor DTCS Set
157
Engine Cranks but will Not Run
161
No Malfunction Indicator Lamp
168
Malfunction Indicator Lamp on Steady 1F
171
Fuel Pressure Relief Procedure
173
Fuel System Diagnosis
173
Fuel Pump Relay Circuit Check
176
Diagnostic Trouble Codes
179
Engine Controls: Important Preliminary Checks
179
Intermittents
179
Hard Start
181
Surges or Chuggles
183
Lack of Power, Sluggishness, or Sponginess
186
Detonation/Spark Knock
187
Hesitation, Sag, Stumble
189
Cuts Out, Misses
190
Poor Fuel Economy
192
Rough, Unstable, or Incorrect Idle, Stalling
193
Excessive Exhaust Emissions or Odors
196
Dieseling, Run-On
197
Backfire
198
Engine Controls Maintenance and Repair
199
Fuel Tank Removal
199
Fuel Tank Installation
200
Fuel Pump Installation
201
Fuel Pump Removal
201
Fuel Tank Pressure Sensor Installation
202
Fuel Tank Pressure Sensor Removal
202
Fuel Filter Installation
203
Fuel Filter Removal
203
Fuel Rail and Injectors Removal
204
Fuel Rail and Injectors Installation
205
Fuel Pressure Regulator Removal
206
Engine Coolant Temperature Sensor Removal Procedure
207
Fuel Pressure Regulator Installation
207
Throttle Body Removal
208
Throttle Position Sensor Installation
208
Throttle Position Sensor Removal
208
Throttle Body Installation
210
Heated Oxygen Sensor Removal
211
Oxygen Sensor Installation
211
Oxygen Sensor Removal
211
Heated Oxygen Sensor Installation
212
Idle Air Control Valve Installation
213
Idle Air Control Valve Removal
213
Intake Air Temperature Sensor Installation
213
Intake Air Temperature Sensor Removal
213
Manifold Absolute Pressure Sensor Removal
214
Manifold Absolute Pressure Sensor Installation
215
Exhaust Gas Recirculation Valve Installation
216
Exhaust Gas Recirculation Valve Removal
216
G Sensor Removal
216
Evaporative Emission Canister Installation
217
Evaporative Emission Canister Removal
217
G Sensor Installation
217
Crankshaft Position Sensor Removal
218
Evaporative Emission Canister Purge Solenoid Installation
218
Evaporative Emission Canister Purge Solenoid Removal
218
Crankshaft Position Sensor Installation
219
Camshaft Position Sensor Installation
220
Camshaft Position Sensor Removal
220
Powertrain Control Module/Engine Control Module Removal
221
Electronic Ignition System Ignition Coil Installation
222
Electronic Ignition System Ignition Coil Removal
222
Powertrain Control Module/Engine Control Module Installation
222
Fuel Cutoff Switch Installation
223
Fuel Cutoff Switch Removal
223
Knock Sensor Removal
224
Knock Sensor Installation
225
Camshaft Position Sensor
226
Crankshaft Position Sensor
226
Fuel Control System Operation
226
Ignition System Operation
226
Battery Voltage Correction Mode
227
Clear Flood Mode
227
Evaporative Emission Control System Operation
227
Fuel Cut–Off Mode
227
Catalyst Monitor Oxygen Sensors
228
Engine Coolant Temperature Sensor
228
Evaporative Emission Canister
228
Positive Crankcase
228
Exhaust Gas Recirculation Valve
229
Idle Air Control Valve
229
Intake Air Temperature Sensor
229
Fuel Injector
230
Knock Sensor
230
Manifold Absolute Pressure Sensor
230
Powertrain Control Module/Engine Control Module
230
Fuel Cutoff Switch
231
G Sensor
231
OBD II Serviceability Issues
231
Strategy-Based Diagnostics
231
Class II Serial Data Communications
232
Non–Oem Parts
232
Poor Vehicle Maintenance
232
Severe Vibration
232
Comprehensive Component Monitor Diagnostic Operation
233
On-Board Diagnostics (OBD II)
233
Output Components
233
Passive and Active Diagnostic Tests
233
Common OBD II Terms
234
DTC Types
235
Reading Diagnostic Trouble Codes
235
Special Cases of Type B Diagnostic Tests
235
Type A, Type B, Type C
235
DTC Information Mode
236
DTC Modes
236
DTC Status
236
Last Test Fail
236
History DTC
237
Misfire Monitor Diagnostic Operation
237
Oxygen Sensor Diagnosis
237
Primary System-Based Diagnostics
237
Fuel Trim Cell Diagnostic Weights
238
Fuel Trim System Monitor Diagnostic Operation
238
Misfire Counters
238
Engine Exhaust Specifications
239
Exhaust System Diagram
240
Exhaust System Maintenance and Repair
241
Main Catalytic Converter and Connecting Pipe Removal
241
Main Catalytic Converter and Connecting Pipe Installation
242
Auxiliary Catalytic Converter Removal
243
Auxiliary Catalytic Converter Installation
244
Muffler - Front, Removal
245
Muffler - Front, Installation
246
Muffler - Rear, Removal
247
Muffler - Rear, Installation
248
Catalytic Converters
250
Exhaust System Description
250
Muffler
250
Wiring Diagram for Power Supplies
251
Ignition Switch Circuit
252
Ter Bat + Power Supply Circuit (Passenger Room Fuse Box)
253
15A IGN 2, 15C ACC Power Supply Circuit (Passenger Room Fuse Box)
254
Engine Room Fuse & Relay Circuit
255
Automatic Transaxle Drive Axle Specifications
258
Automatic Transaxle Drive Axle - Special Tools Table
259
Front Drive Axle Diagram
259
Automatic Transaxle Drive Axle Maintenance and Repair
261
Drive Axle Assembly Removal
261
Drive Axle Assembly Installation
263
Outer Joint Seal Installation
265
Outer Joint Seal Removal
265
Inner Tripot Seal Removal
266
Inner Tripot Seal Installation
268
Front Drive Axle - General Description
270
Usage and Capacity of Fuses
271
Engine Compartment Relay and Fuse Box Diagram
272
Passenger Room Fuse Box Diagram
273
Position of Control Unit, Relay and Part Number
274
Hydraulic Brakes Specifications
275
Brake System (ABS) Diagram
277
Brake System (Non-ABS) Diagram
278
Brake Hose Inspection
279
Brake System Testing
279
Hydraulic Brakes - Diagnosis
279
Warning Lamp Operation
279
Brake Lamp Warning Cricuit Diagnosis
280
Hydraulic Brakes Maintenance and Repair
284
Manual Bleeding the Brakes
284
Pressure Bleeding the Brakes
287
Brake Hose Rear Installation
288
Brake Hose Rear Removal
288
Brake Hose Front Removal
289
Brake Hose Front Installation
290
Brake Pedal Removal
291
Stoplamp Switch Installation
291
Stoplamp Switch Removal
291
Brake Pedal Installation
292
Hydraulic Brakes General Description
293
Hydraulic Fluid
293
Master Cylinder Specifications
294
Master Cylinder Assembly Removal
296
Master Cylinder Maintenance and Repair
296
Master Cylinder Assembly Installation
297
Brake Fluid Reservoir Removal
298
Brake Fluid Reservoir Installation
299
Proportioning Valve Installation
300
Proportioning Valve Removal
300
Master Cylinder Disassembly
301
Master Cylinder Overhaul
301
Master Cylinder Assembly
302
Fluid Level Sensor
304
Master Cylinder Description
304
Proportioning Valve
304
Power Booster Functional Check
305
Power Booster Specifications
305
Power Booster Maintenance and Repair
306
Vacuum Hose Installation
306
Vacuum Hose Removal
306
Power Booster Assembly Removal
307
Power Booster Assembly Installation
309
Power Booster Description
311
Front Disc Brakes Specifications
312
Lining Inspection
312
Rotor Inspection
312
Front Disc Brakes Maintenance and Repair
314
Shoe and Lining Removal
314
Caliper Removal
315
Shoe and Lining Installation
315
Caliper Installation
316
Rotor Removal
317
Rotor Installation
318
Splash Shield Removal
318
Splash Shield Installation
319
Caliper Overhaul - Disassembly
320
Caliper Assembly
321
Disc Brake Caliper Assembly Description
322
Rear Disc Brakes Specifications
323
Lining Inspection Steps
324
Rotor Inspection Steps
324
Rear Disc Brakes Maintenance and Repair
325
Shoe and Lining Removal (Rear)
325
Caliper Removal (Rear)
326
Shoe and Lining Installation (Rear)
326
Caliper Installation (Rear)
327
Rotor Removal (Rear)
328
Rotor Installation (Rear)
329
Splash Shield/Backplate and Parking Brake Lever Removal
329
Splash Shield/Backplate and Parking Brake Lever Installation
333
Caliper Overhaul - Disassembly (Rear)
337
Caliper Overhaul - Assembly (Rear)
338
Disc Brake Caliper (Rear)
340
Rear Disc Brakes - General Description and System Operaton
340
Antilock Brake System
341
Antilock Brake System - Special Tools Table
343
Antilock Brake System Specifications
343
ABS Component Locator
344
ABS Circuit Diagram
345
Antilock Brake System - Visual Identification
349
EBCM Connector Face View Diagram
349
EBCM Connector J1 Diagram
349
EBCM Connector J2 Diagram
351
Parking Brake Specifications
352
Parking Brake Adjustment
353
Parking Brake Maintenance and Repair
353
Parking Brake Lever Removal
354
Parking Brake Lever Installation
355
Parking Brake Cable Removal
356
Parking Brake Cable Installation
359
Parking Brake Handle Installation
361
Parking Brake Handle Removal
361
Parking Brake Description
362
Electrical Wiring Diagrams
363
Battery, Ignition Switch, Starter Motor, Alternator & Switch (Clutch (M/T), NSBU (A/T) Diagram
364
Starting & Charging System Diagrams
364
2.0 DOHC Engine Diagram
365
Left "A" Pillar Inside Diagram
365
Position of Connectors and Grounds Diagram
365
Splice Pack Diagram
365
4T40–E Automatic Transaxle
366
4T40–E Automatic Transaxle Specifications
371
End Play Specifications
371
Fluid Capacity
371
Transaxle General Specifications
371
Range Reference
372
4T40-E Gear Ratios
373
Automatic Transaxle Fastener Tightening Specifications
373
Line Pressure
373
Shift Speed
373
Automatic Transaxle - Special Tools Table
375
Automatic Transaxle - Schematic and Routing Diagrams
380
Powertrain Controle Module Diagram
380
Transaxle Identification Information
383
Five-Speed Manual Transaxle
384
Five-Speed Manual Transaxle Specifications
385
Special Tools
386
Five-Speed Manual Transaxle - Special Tools Table
386
Five-Speed Manual Transaxle - Diagnosis
388
Road Travel Noise
388
Transaxle Noise
388
Bearing Noise
388
Isolate Noise
388
Five-Speed Manual Transaxle - Symptom Diagnosis
389
Five-Speed Manual Transaxle - Component Locators
392
Gears and Case Diagram
392
Differential and Case Diagram
394
Shift Linkage Diagram
395
Clutch Specifications
397
Clutch - Special Tools Table
398
Clutch Operation Diagnosis
398
Fails to Release
398
Slipping
398
Grabbing (Chattering)
399
Rattling (Transaxle Click)
399
Release Bearing Noise with Clutch Fully Engaged
399
Pedal Stays on Floor When Disengaged
399
Hydraulic Clutch Components Diagram
400
Clutch Maintenance and Repair
403
Clutch Pedal Removal
403
Clutch Pedal Installation
404
Clutch Pedal Position Switch Removal
405
Clutch Pedal Position Switch Installation
405
Clutch Pedal Position Switch Adjustment
405
Clutch Disc and Related Components Removal
406
Clutch Disc and Related Components Installation
409
Clutch Pedal Adjustment (Hydraulic) Removal
411
Clutch Release Point Adjustment (Hydraulic) Removal
413
Air Bleeding
413
Clutch Master Cylinder Assembly Removal
413
Clutch Master Cylinder Assembly Installation
415
Clutch Release Cylinder Assembly Removal
416
Clutch Release Cylinder Assembly Installation
417
Clutch Master Cylinder Disassembly
417
Clutch Master Cylinder Assembly
418
Clutch Release Cylinder Disassembly
419
Clutch Release Cylinder Assembly
420
Clutch - General Descriptoi and System Operation
421
Driving Members
421
Driven Members
421
Operating Members
421
Heating and Ventilating System Specifications
422
Airflow through Vents with Rear Heating Duct - Diagram
424
Heating and Ventilating System Diagnosis
425
Insufficient Heating or Defrosting
425
Blower Electrical
428
Improper Air Delivery or no Mode Shift
430
Too Much Heat
432
Controls
434
Blower Noise
435
Heating and Ventilating System Maintenance and Repair
437
Temperature Cable Adjustment
437
Temperature Control Cable Removal
437
Temperature Control Cable Installation
438
Control Assembly Removal
439
Conrol Assembly Installation
439
Control Assembly Knob Lighting Removal
440
Control Assembly Knob Lighting Installation
441
Heater/Air Distributor Case Assembly Removal
441
Heater/Air Distributor Case Assembly Installation
443
Blower Motor Removal
444
Blower Motor Installation
444
High-Blower Relay Removal
445
High-Blower Relay Installation
445
Blower Resistor Removal
445
Blower Resistor Installation
446
Heater Hoses Removal
446
Heater Hoses Installation
446
Heater Core Removal
447
Heater Core Installation
447
Rear Heating Duct
448
Heating and Ventilating Sytem Description
449
Rotary Temperature Control Knob
449
Rotary Mode Control Knob
449
Rotary Blower Control Knob
449
Manual Control Heating, Ventilation, and Air Conditioning System
450
Manual Control Heating, Ventilation, and Air Conditioning System Specifications
451
A/C System Charging Capacity
451
Manual Control Heating, Ventilation, and Air Conditioning System - Special Tools Table
452
Manual Control Heating, Ventilation, and Air Conditioning System - Schematic and Routing Diagrams
455
A/C System - Typical, Diagram
455
Airflow - Typical, Diagram
456
A/C Schematic
457
Manual Control Heating, Ventilation, and Air Conditioning System Diagnosis
458
Testing the Refrigerant System
458
Insufficient Cooling "Quick Check" Procedure
458
General Diagnosis
458
A/C Performance Test
459
Pressure-Temperature Relationship of R-134A
460
Leak Testing the Refrigerant System
461
Liquid Leak Detectors
461
Electronic Leak Detectors
461
Testing the Evaporator Core
461
V5 System Air Conditioning Diagnosis
462
Insufficien Cooling Diagnosis
462
Symptom Diagnosis
466
Pressure Test Chart (R-134A System)
466
Low and High Side Pressure Relationship Chart
468
Body Wiring System
469
Schematic and Routing Diagrams (Body Wiring)
469
Wire Color Chart
469
Wires with Tracers
469
Table of Contents
469
Power Distribution Schematic
470
Fuse Block Locator (Engine) Diagram
472
Fuse Block Locator (Passenger Compartment) Diagram
472
Fuse Chart
473
Blower Motor
473
Rear Harness Routing Diagram
475
Front Harness Routing Diagram
476
Floor Harness Routing Diagram
477
Instrument Harness Routing Diagram
478
Door Harness Routing Diagram
479
Lighting Systems
480
Bulb Usage Chart
481
Lighting Systems - Fastening Tightening Specifications
481
Headlamps - on Reminder Chime Circuit Diagram
482
Parking, Tail, Position and License Lamps Circuit Diagram
483
Turn and Hazard Lamps Circuit Diagram
484
Brake and Backup Lamps Circuit Diagram
485
Interior Courtesy Lamp and Luggage Compartment Lamp Circuit Diagram
486
Headlamps Circuit Diagram
487
Daytime Running Lamps Circuit Diagram
488
Fog Lamps Circuit Diagram
489
Lighting Systems Diagnosis
490
Headlamps - on Reminder Chime
490
Headlamp Reminder Chime Is Inoperative
490
Low–Beam Headlamps Are Inoperative, High–Beam Headlamps Are OK
491
High–Beam Headlamps Are Inoperative, Low–Beam Headlamps Are OK
492
High–Beam and Low–Beam Headlamps Are Inoperative on both Left and Right Sides
492
Daytime Running Lamps Do Not Turn on
495
Fog Lamps Do Not Work on Either Side
497
Rear Combination Lamps
498
Exterior Illumination Lamps Do Not Work
498
Stoplamps Do Not Work
501
Center High–Mounted Stoplamp (CHMSL) Does Not Work
502
Backup Lamps Inoperative
503
Turn Signal Lamps and Hazard Lamps Do Not Work
504
Hazard Lamps Do Not Operate, Turn Signals Are OK
506
Interior Courtesy Lamp Inoperative
507
Luggage Compartment Lamp Inoperative
508
Horns Specifications
510
Horn Wiring System Diagram
511
Horns Maintenance and Repair
512
Horns Removal
512
Horns Installation
512
On-Vehicle Service
512
Horns Description
514
General Description and System Operation
514
Wipers/Washer Systems Specifications
515
Wipers/Washer Systems (Notchback) Schematic Diagram
516
Wipers/Washer Systems (Hatchback) Schematic Diagram
517
Diagnosis
518
Wipers/Washer Systems Diagnosis
518
Windshield Wipers Do Not Work at any Speed
518
Wipers Do Not Work on HI Speed, lo Speed OK
519
Wipers Do Not Work on lo Speed, HI Speed OK
519
Wipers Do Not Work on Intermittent (INT), Other Speeds OK
520
Windshield Wipers Do Not Return to Park Position
521
Windshield Washer Inoperative, Wipers Work OK
522
Rear Window Wiper (Hatchback and Wagon) - Diagnostic Aid
523
Rear Window Washer System (Hatchback and Wagon) - Diagnostic Aid
525
Maintenance and Repair
526
Wipers/Washer Systems Maintenance and Repair
526
Windshield Wiper Arm Removal
526
Windshield Wiper Arm Installation
526
Windshield Wiper Motor Removal
526
Windshield Wiper Motor Installation
527
Windshield Wiper Blade (Typical) Removal
528
Windshield Wiper Blade (Typical) Installation
528
Windshield Wiper Blade Insert Removal
528
Windshield Wiper Blade Insert Installation
529
Windshield Washer Reservoir Removal
529
Windshield Washer Reservoir Installation
530
Windshield Washer Pump(S) (Typical) Removal
531
Windshield Washer Pump(S) (Typical) Installation
531
Windshield Washer Nozzles Removal
532
Windshield Washer Nozzles Installation
532
Windshield Washer Hoses (Typical) Removal
532
Windshield Washer Hoses (Typical) Installation
533
Rear Window Wiper Arm Removal
534
Rear Window Wiper Arm Installation
534
Rear Window Wiper Motor (Hatchback) Removal
534
Rear Window Wiper Motor (Hatchback) Installation
535
Rear Window Wiper Motor (Wagon) Removal
535
Rear Window Wiper Motor (Wagon) Installation
536
Rear Window Washer Nozzle (Hatchback) Removal
536
Rear Window Washer Nozzle (Hatchback) Installation
537
General Description and System
538
Windshield Wiper System Description
538
Windshield Washer System Description
538
Rear Window Wiper/Washer System Description
538
Instrument/Driver Information - Maintenance and Repair
539
Cigar Lighter Removal
539
Cigar Lighter Installation
540
Ashtray Removal Procedure
541
Ashtray Installation
541
Cup Holder Removal
542
Cup Holder Installation
543
Glove Box Removal
543
Glove Box Installation
544
Digital Clock Removal
544
Digital Clock Installation
544
Instrument Cluster Removal
545
Instrument Cluster Installation
545
Speedometer/Odometer/Trip Odometer Removal
545
Speedometer/Odometer/Trip Odometer Installation
547
Tachometer Removal
548
Tachometer Installation
548
Fuel Gauge Removal
549
Fuel Gauge Installation
550
Temperature Gauge Removal
550
Temperature Gauge Installation
551
Instrument Cluster Indicator Lamps Removal
552
Instrument Cluster Indicator Lamps Installation
552
Chime Module Removal
552
Chime Module Installation
553
Instrument Panel Removal
553
Instrument Panel Installation
555
Instrument/Driver Information - General Description and System Operation
559
Instrument Cluster
559
Chime Module
559
Trip Odometer
559
Audiosystems Specifications
560
Audiosystems Schematic and Routing Diagrams
561
Audio System Circuit Diagram
561
Audio Systems - Diagnosis
562
Cassette AM/FM Radio Inoperative
562
Cassette Player Inoperative, AM/FM Functions OK
562
AM Does Not Work, FM and Cassette OK
563
FM Radio Does Not Work, am and Cassette OK
563
Front Speakers Distorted or Inoperative, Rest of Audio System OK
564
Rear Speakers Distorted or Inoperative, Rest of Audio System OK
564
Power Antenna Does Not Work
565
Audio Systems Maintenance and Repair
567
Stereo Cassette AM/FM Radio Removal
567
Stereo Cassette AM/FM Radio Installation
567
Front Door Speakers Removal
568
Front Door Speakers Installation
568
Tweeter Speakers Removal
569
Tweeter Speakers Installation
569
Rear Speakers (Notchback) Removal
569
Rear Speakers (Notchback) Installation
570
Rear Speakers (Hatchback) Removal
570
Rear Speakers (Hatchback) Installation
570
Mast Antenna Removal
571
Mast Antenna Installation
571
Roof Antenna Removal
572
Roof Antenna Installation
572
Power Antenna Mast (Notchback) Removal
572
Power Antenna Mast (Notchback) Installation
573
Power Antenna Motor (Notchback) Removal
573
Power Antenna Motor (Notchback) Installation
574
Compact Disc Changer Removal
574
Compact Disc Changer Installation
575
Audio Systems General Description
576
Audio Security System
576
Speakers
576
Tape Player and Cassette Care
576
Exterior Trim Specifications
577
Exterior Trim Maintenance and Repair
578
B-Pillar Molding Removal
578
B-Pillar Molding Installation
578
Quarter Window Molding (Wagon) Removal
578
Quarter Window Molding (Wagon) Installation
579
Roof Molding Removal
579
Roof Molding Installation
579
Mud Guards Removal
580
Mud Guards Installation
580
Exterior Trim General Description
581
Emblems and Lettering
581
Mud Guards
581
Frame and Underbody Specifications
582
Frame and Underbody Maintenance and Repair
583
Alignment Checking
583
Floor Pan Insulators
583
Engine under Cover Removal
584
Engine under Cover Installation
584
Frame and Underbody - General Description and System Operation
586
General Body Construction
586
Engine under Covers
586
Bumpers and Fascias Specifications
587
Bumpers and Fascias Maintenance and Repair
588
Front Bumper Fascia Removal
588
Front Bumper Fascia Installation
590
Front Bumper Energy Absorber Removal
592
Fribt Bumper Energy Absorber Installation
592
Front Bumper Impact Bar Removal
592
Front Bumper Impact Bar Installation
593
Rear Bumper Fascia Removal
594
Rear Bumper Fascia Installation
595
Rear Bumper Energy Absorber Removal
597
Rear Bumper Impact Bar Removal
598
Rear Bumper Impact Bar Installation
598
Bumpers - General Description
600
Doors Specification
601
Power Door Locks Schematic Diagram
603
Power Windows (Front and Rear) Schematic Diagram
604
Schematic and Routing Diagrams 9P-3.
605
Doors: Diagnosis
605
Power Door Locks Do Not Operate at any Door
605
Diagnosis
607
Power Windows Do Not Operate
607
Power Windows (Front and Rear)
607
Maintenance and Repair
609
Doors Maintenance and Repair
609
Front Door Glass Run Removal
609
Front Door Glass Run Installation
609
Rear Door Glass Run Removal
609
Rear Door Glass Run Installation
610
Front Door Secondary Weatherstrip Removal
611
Front Door Secondary Weatherstrip Installation
611
Rear Door Secondary Weatherstrip Removal
611
Rear Door Secondary Weatherstrip Installation
612
Door Lock Striker Removal
612
Door Lock Striker Installation
613
Door Lock Striker Adjustment
613
Front Door Lock Removal
614
Front Door Lock Installation
616
Childproof Rear Door Lock Removal
617
Childproof Rear Door Lock Installation
618
Inside Door Handle Removal
619
Inside Door Handle Installation
619
Inside Lock Rod Removal
619
Inside Lock Rod Installation
620
Outside Door Handle Removal
620
Outside Door Handle Installation
620
Door Lock Cylinder Removal
621
Door Lock Cylinder Installation
621
Power Front Window Regulator Removal
621
Power Front Window Regulator Installation
622
Power Rear Window Regulator Removal
623
Power Rear Window Regulator Installation
623
Manual Rear Window Regulator Removal
624
Manual Rear Window Regulator Installation
624
Manual Rear Window Regulator Handle Removal
625
Manual Rear Window Regulator Handle Installation
625
Front Door Assembly Removal
625
Front Door Assembly Installation
626
Rear Door Assembly Removal
627
Rear Door Assembly Installation
628
Door Hinge Removal
629
Door Hinge Installation
629
Door Hold Open Link Removal
629
Door Hold Open Link Installation
630
Inside Channel Molding Removal
630
Inside Channel Molding Installation
630
Outside Channel Molding Removal
631
Outside Channel Molding Installation
631
Door Weatherstrip Removal
631
Door Weatherstrip Installation
632
Door Seal Trim Removal
632
Door Seal Trim Installation
633
Front Door Opening Weatherstrip Removal
633
Front Door Opening Weatherstrip Installation
634
Rear Door Opening Weatherstrip Removal
634
Rear Door Opening Weatherstrip Installation
634
Doors: General Description
635
Door Lock Striker
635
Power Door Locks
635
Power Windows
635
Roof Specifications
636
Power Sunroof System Schematic Diagram
637
Roof: Diagnosis
638
Power Sunroof Does Not Work
638
Roof Maintenance and Repair
640
Power Sunroof Removal
640
Power Sunroof Installation
641
Roof Rack (Wagon) Removal
643
Roof Rack (Wagon) Installation
643
Formed Headliner Removal
644
Formed Headliner Installation
645
Sun Visors Removal
647
Sun Visors Installation
648
Passenger Assist Handles Removal
648
Passenger Assist Handles Installation
649
Interior Courtesy Lamp/Power Sunroof Control Switch Removal
649
Interior Courtesy Lamp/Power Sunroof Control Switch Installation
650
Roof General Description
651
Power Sunroof
651
Passenger Assist Handles
651
Interior Courtesy Lamp/Power Sunroof Control Switch
651
Coat Hook
651
Body Front End Specifications
652
Body Front End Maintenance and Repair
653
Fasteners
653
Anticorrosion Materials
653
Cowl Vent Grill Removal
653
Cowl Vent Grill Installation
654
Hood Removal
655
Hood Installation
655
Hood Hinges Removal
655
Hood Hinges Installation
656
Hood Prop Rod Removal
656
Hood Prop Rod Installation
656
Hood Secondary Latch Removal
657
Hood Secondary Latch Installation
657
Hood Latch Release Cable Removal
657
Hood Latch Release Cable Installation
658
Radiator Grille Removal
659
Radiator Grille Installation
660
Fender Removal
660
Fender Installation
662
Body Front End General Description
665
Body Rear End Specifications
666
Body Rear End Maintenance and Repair
668
Fuel Filler Door Removal
668
Fuel Filler Door Installation
668
Rear Deck Lid (Notchback) Removal
668
Rear Deck Lid (Notchback) Installation
669
Rear Deck Lid Springs (Notchback) Removal
670
Rear Deck Lid Springs (Notchback) Installation
671
Luggage Compartment Lock Cylinder Removal
671
Luggage Compartment Lock Cylinder Installation
671
Luggage Compartment Lock Striker (Notchback) Removal
672
Luggage Compartment Lock Striker (Notchback) Installation
672
Luggage Compartment Lock (Notchback and Hatchback) Removal
672
Luggage Compartment Lock (Notchback and Hatchback) Installation
673
Weatherstrip Removal
674
Weatherstrip Installation
674
Hatchback Door Removal
674
Hatchback Door Installation
675
Gas Support Assemblies (Hatchback) Removal
675
Gas Support Assemblies (Hatchback) Installation
675
Luggage Compartment Lock Striker (Hatchback) Removal
676
Luggage Compartment Lock Striker (Hatchback) Installation
676
Rear Spoiler (Hatchback) Removal
676
Rear Spoiler (Hatchback) Installation
677
Tailgate (Wagon) Removal
677
Tailgate (Wagon) Installation
677
Gas Support Assemblies (Wagon) Removal
678
Gas Support Assemblies (Wagon) Installation
678
Luggage Compartment Lock Striker (Wagon) Removal
679
Luggage Compartment Lock Striker (Wagon) Installation
679
Rear Deck Lid/Hatchback Door Remote Cable and Handle (Notchback) Removal
680
Rear Deck Lid/Hatchback Door Remote Cable and Handle (Notchback) Installation
681
Fuel Filler Door Remote Cable and Handle Removal
681
Fuel Filler Door Remote Cable and Handle Installation
682
Body Rear End General Description
684
Fuel Filler Door
684
Rear Deck Lid (Notchback)
684
Hatchback Door
684
Immobilizer Anti-Theft System Specifications
685
Immobilizer Anti-Theft System: Special Tools
685
Diagnosis
686
Immobilizer Anti-Theft System: Diagnosis
686
DTC 53 – PCM/ECM Immobilized Error
686
Ignition off Status
686
Key Status Errors
686
Communication between Immobilizer and Test Equipment
687
Immobilizer Anti-Theft System Maintenance and Repair
688
Key Coding Procedure
688
ID Code Reprogramming
688
On-Vehicle Service
688
Transponder
689
Detection Coil Removal
689
Detection Coil Installation
691
Immobilizer Control Unit Removal
692
Immobilizer Control Unit Installation
693
Immobilizer Anti-Theft System Description
694
Electronically Coded Keys
694
Detection Coil
694
Immobilizer Control Unit
694
General Description and System Operation
694
Data Link Connector (DLC)
695
ID Code Handling
695
Serial Data Link
695
Powertrain Control Module (Pcm)/Engine Control Module (ECM)
695
Remote Keyless Entry and Perimeter/Ultrasonic Anti-Theft System Specifications
696
Specifications
697
Remote Keyless Entry and Perimeter/Ultrasonic Anti-Theft System Schematic Diagram
697
Schematic and Routing Diagrams
697
Remote Keyless Entry and Anti-Theft System (2
698
Control Module/Receiver Connector Diagram
699
Wiring Harness Connectors Diagram
699
Remote Keyless Entry and Perimeter/Ultrasonic Anti-Theft System Maintenance and Repair
700
Control Module/Receiver Removal
700
Control Module/Receiver Installation
700
Siren Removal
700
On-Vehicle Service
700
Siren Installation
701
Front Door Tamper Switch Removal
702
Front Door Tamper Switch Installation
702
Rear Deck Lid Tamper Switch Removal
702
Rear Deck Lid Tamper Switch Installation
703
Hood Open Switch Removal
703
Hood Open Switch Installation
704
Password Programming
705
Remote Keyless Entry and Anti-Theft System General Description
706
Remote Locking and Unlocking
706
Security Indicator
706
Intrusion Sensing
706
General Description and System Operation
706
Siren
706
Autolocking (Safety Lock)
707
Control Module/Receiver
707
Fault of Alarm Indication
707
Panic Button
707
Vehicle Locator
707
Cruise Control System Specifications
708
Specifications
709
Schematic and Routing Diagrams
709
Cruise Control System (Automatic Transaxle) (1 of 2)
709
Cruise Control System (Automatic Transaxle) (2 of 2)
710
Cruise Control System (Manual Transaxle) Schematic Diagram
711
Cruise Control System
712
Cruise Control System Diagnosis
713
Cruise Control Does Not Operate
713
Cruise Control System Maintenance and Repair
718
Cruise Control Actuator Removal
718
On-Vehicle Service
718
Cruise Control Actuator Installation
720
Actuator Control Cable Removal
722
Actuator Control Cable Installation
723
Main Switch Removal
724
Main Switch Installation
725
Cruise Control System General Description
726
Cruise Control Actuator
726
Main Switch
726
Lever Switch
726
General Description and System Operation
726
Technical Service Bulletin
728
Parts Information
728
1999 Paint Codes
729
Fuel Level Sensor Diagnostic Procedure
732
Fuel Level Sensor Replacement
734
Rear Hatch Lock Rod Removal
739
Rear Hatch Lock Rod Installation
740
Remote Keyless Entry Transmitter Programming
741
Exploded Views
743
Other manuals for Daewoo NUBIRA
User Manual
685 pages
Manual
184 pages
5
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Daewoo NUBIRA Specifications
General
Brand
Daewoo
Model
NUBIRA
Category
Automobile
Language
English
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