2004 DAEWOO NUBIRA check oil

5A2 – 172IAISIN AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
Tools Required
DW240–020 Brake/Clutch Spring Compressor
DW240–040 Direct Clutch Adapter
Disassembly Procedure
WARNING : USE CAUTION WHEN CHECKING COM-
PONENTS WITH COMPRESSED AIR OR PERSONAL
INJURY MAY RESULT.
1. Install the direct clutch and thrust needle roller
bearing on the oil pump.
2. Using a dial indicator, measure the direct clutch
piston stroke while applying and releasing 392 kPa
(57 psi).of compressed air.
Piston stroke: 0.4
0.8 mm (0.016
0.031 in.)
If the stroke is non–standard, inspect the discs,
plates and flange.
3. Using a screwdriver, remove the snap ring.
4. Remove the flange, 2discs and 2 plates.
5. Place the brake/clutch spring compressor
DW240–020 and direct clutch adapter DW240–040
on the direct clutch return spring and compress.
6. Using a snap ring expander, remove the snap ring.
Notice : Stop the press when the piston return spring is
lowered to the place 1–2 mm (0.039–0.078 in.) from the
snap ring groove, preventing the piston return spring from
being deformed.
Notice : Do not expand the snap ring excessively.

AISIN AUTOMATIC TRANSAXLE 5A2 – 177
DAEWOO V–121 BL4
11. Install the direct clutch on the oil pump.
WARNING : USE CAUTION WHEN CHECKING COM-
PONENTS WITH COMPRESSED AIR OR PERSONAL
INJURY MAY RESULT.
12. Using a dial indicator, measure the direct clutch
piston stroke while applying and releasing 392 kPa
(57 psi) .of compressed air .
Piston stroke: 0.4
0.8 mm (0.016
0.031 in.)
S If the piston stroke is less than the limit of piston
stroke, parts may have been assembled incor-
rectly, so check and reassemble again.
S If the stroke is non–standard, select another
flange.
S There are 3 flanges in different thickness.
S Flange Thickness: mm (in.)
No
ThicknessNoThickness
13.0 (0.118)33.4 (0.134)
23.2 (0.126)

FIVE–SPEED MANUAL TRANSAXLE 5B – 5
DAEWOO V–121 BL4
DIAGNOSIS
ISOLATE NOISE
Identify the cause of any noise before attempting to repair
the clutch, the transaxle, or their related link–ages.
Symptoms of trouble with the clutch or the manual trans-
axle include:
S A great effort required to shift gears.
S The sound of gears clashing and grinding.
S Gear blockout.
Any of these conditions requires a careful analysis. Make
the following checks before disassembling the clutch or
the transaxle for repairs.
Road Travel Noise
Many noises that appear to come from the transaxle may
actually originate with other sources such as the:
S Tires.
S Road surfaces.
S Wheel bearings.
S Engine.
S Exhaust system.
These noises may vary according to the:
S Size of the vehicle.
S Type of the vehicle.
S Amount of insulation used in the body of the ve-
hicle.
Transaxle Noise
Transaxle gears, like any mechanical device, are not ab-
solutely quiet and will make some noise during normal op-
eration.
To verify suspected transaxle noises:
1. Select a smooth, level asphalt road to reduce tire
and resonant body noise.
2. Drive the vehicle far enough to warm up all the lu-
bricants thoroughly.
3. Record the speed and the gear range of the trans-
axle when the noise occurs.
4. Check for noises with the vehicle stopped, but with
the engine running.
5. Determine if the noise occurs while the vehicle op-
erates in:
S Drive – under a light acceleration or a heavy
pull.
S Float – maintaining a constant speed with a light
throttle on a level road.
S Coast – with the transaxle in gear and the
throttle partly or fully closed.
S All of the above.
Bearing Noise
Differential Side Bearing Noise
Differential side bearing noise and wheel bearing noise
can be confused easily. Since side bearings are pre–
loaded, a differential side bearing noise should not dimin-
ish much when the differential/transaxle is run with the
wheels off the ground.
Wheel Bearing Noise
Wheel bearings produce a rough growl or grating sound
that will continue when the vehicle is coasting and the
transaxle is in NEUTRAL. Since wheel bearings are not
pre–loaded, a wheel bearing noise should diminish con-
siderably when the wheels are off the ground.
Other Noise
Brinelling
A brinelled bearing causes a ”knock” or ”click” approxi-
mately every second revolution of the wheel because the
bearing rollers do not travel at the same speed as the
wheel. In operation, the effect is characterized by a low–
pitched noise.
A brinelled bearing is caused by excessive thrust which
pushes the balls up on the pathway and creates a triangu-
lar–shaped spot in the bearing race. A brinelled bearing
can also be caused from pressing one race into position
by applying pressure on the other race.
A false indication of a brinelled bearing occurs as a result
of vibration near the area where the bearing is mounted.
Brinelling is identified by slight indentations, resulting in a
washboard effect in the bearing race.
Lapping
Lapped bearing noise occurs when fine particles of abra-
sive materials such as scale, sand, or emery circulate
through the oil in the vehicle, causing the surfaces of the
roller and the race to wear away. Bearings that wear loose
but remain smooth, without spalling or pitting, are the re-
sult of dirty oil.
Locking
Large particles of foreign material wedged between the
roller and the race usually causes one of the races to turn,
creating noise from a locked bearing. Pre–loading regular
taper roller bearings to a value higher than that specified
also can result in locked bearings
Pitting
Pitting on the rolling surface comes from normal wear and
the introduction of foreign materials.
Spalling
Spalled bearings have flaked or pitted rollers or races
caused by an overload or an incorrect assembly that re-
sults in a misalignment, a cocking of bearings, or adjust-
ments that are too tight.
After completing these checks, refer to the ”Diagnosis
Chart” in this section.

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.

5C – 2ICLUTCH
DAEWOO V–121 BL4
SPECIAL TOOLS
SPECIAL TOOLS TABLE
J–42474
Clutch Arbor
DIAGNOSIS
CLUTCH OPERATION
Intermittent Clutch Operation
ChecksAction
Check for the driver improperly operating the vehicle.Correct the driver’s operation of the vehicle as necessary.
Check for the improper clutch pedal play.Adjust the clutch pedal play.
Check for the insufficient oil or the leak at oil pressure line.Repair the leak or add the oil.
Check for a warped or worn clutch disc.Replace the clutch disc.
Check for worn splines on the input shaft.Repair or Replace the splines on the input shaft.
Check for a weak diaphragm spring.Replace the pressure plate.
Clutch Slipping
ChecksAction
Check for a stuck concentric slave cylinder.Replace the concentric slave cylinder.
Check for improper return of clutch oil.Perform the air bleeding.
Check for a worn clutch disc or oil contamination.Replace the clutch disc.
Check for a warped pressure plate.Replace the pressure plate.

CLUTCH 5C – 3
DAEWOO V–121 BL4
Clutch Vibration
ChecksAction
Check for a contaminated or warped flywheel.Repair or replace the flywheel.
Check for a weak diaphragm spring.Replace the pressure plate.
Check for a oily contamination of clutch disc.Replace the clutch disc.
Check for worn splines on the input shaft.Replace the splines on the input shaft.
Check for a warped pressure plate or flywheel.Replace the pressure plate or flywheel.
Hard Pedal Effort
ChecksAction
Check for bad lubrication of clutch pedal shaft.Apply the grease or repair it.
Check for a clogged pipe.Inspect or replace the clogged pipe.
Check for a stuck concentric slave cylinder.Replace the concentric slave cylinder.
Noise in Clutch Pedal
ChecksAction
Check for insufficient lubrication of clutch pedal bushing.Lubricate the clutch pedal bushing.
Check for interference of clutch pedal return spring.Remove and reinstall the clutch pedal return spring.

CLUTCH 5C – 9
DAEWOO V–121 BL4
4. Remove the clutch disc from the flywheel.
Inspection Procedure
Clutch Disc
1. Visual Inspection
S Inspect the worn or oily contamination on the
clutch surface.
S Inspect the damaged or weakened torsion
spring.
S Inspect the a warped or bent clutch disc. After
inspection, replace new clutch disc, if necessary.
2. Clutch Disc Inspection
S Measure the rivet head depth from the clutch
disc surface.
S Replace the clutch disc if the measured value is
below the limit.
S Rivet Head Depth (Limit) : 0.3 mm (0.012 in)
Inspection Procedure
Pressure Plate
1. Check for a worn diaphragm spring finger.
2. Check for a worn or cracked pressure plate sur-
face.
3. Check for the polluted face by the oil. After inspec-
tion, replace the pressure plate if necessary.

7A – 10IHEATING AND VENTILATION SYSTEM
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
71. Turn the ignition ON.
2. Set the blower switch on 4.
3. Check the blower motor ground.
Is ground OK?–Go to Step 9Go to Step 8
8Repair the blower motor ground.
Is the repair complete?–System OK–
9Check the motor connector with a 12–volt test light.
Does the test light come on?–Go to Step 10Go to Step 11
10Repair the open in the feed wire from the resistor
block to the blower motor.
Is the repair complete?–System OK–
11Use the 12–volt test light to check the power feed
terminal on the blower speed switch.
Does the light come on?–Go to Step 12Go to Step 13
12Replace the blower speed switch.
Is the repair complete?–System OK–
13Repair the open in the power wire from the blower
speed switch to the fuse panel.
Is the repair complete?–System OK–
14Turn the blower on speed 4.
Does the blower fail to operate at speed 4?–Go to Step 15Go to Step 21
15Check fuse EF3 in the engine fuse block.
Is the fuse blown?–Go to Step 16Go to Step 17
161. Turn the ignition ON.
2. Turn the blower motor switch to 4.
3. Use a short detector to locate a possible short
in the following locations:
S Engine fuse panel–to–blower HI relay.
S Blower HI relay–to–blower motor.
4. Repair any short.
5. Replace the EF3 fuse.
Is the repair complete?–System OK–
171. Turn the ignition switch ON.
2. Set the blower switch to 4.
3. Check for 12 volts on the blower HI relay coil
terminal from the blower speed switch terminal
A7.
Is this voltage present?–Go to Step 18Go to Step 19
18Replace the blower speed switch.
Is the repair complete?–System OK–
191. Turn the ignition OFF.
2. Check for opens in the following locations:
S EF3 fuse–to–blower HI relay.
S Blower speed switch–to–blower– HI relay.
S Blower HI relay–to–ground.
S Blower HI relay–to–blower motor.
3. Repair any opens.
Is the repair complete?–System OKGo to Step 20
20Replace the blower HI relay.
Is the repair complete?–System OK–