2004 DAEWOO NUBIRA Service Repair Manual

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Page 1897 of 2643

DAEWOO NUBIRA 2004 Service Repair Manual 5C – 10ICLUTCH
DAEWOO V–121 BL4
Installation Procedure
1. Coat the spline on the clutch disc with multi–pur-
pose grease.
2. Align the pressure plate and the clutch disc onto
the flywheel usi

Page 1898 of 2643

DAEWOO NUBIRA 2004 Service Repair Manual CLUTCH 5C – 11
DAEWOO V–121 BL4
6. Remove the clutch master cylinder nuts.
7. Remove the clutch master cylinder.
Installation Procedure
1. Install the clutch master cylinder and clutch master

Page 1899 of 2643

DAEWOO NUBIRA 2004 Service Repair Manual 5C – 12ICLUTCH
DAEWOO V–121 BL4
5. Install the push rod fixing pin and push rod.
6. Install the locking clip.
7. Bleed the air. Refer to ”Air Bleeding” in this section.
8. Adjust the clut

Page 1900 of 2643

DAEWOO NUBIRA 2004 Service Repair Manual CLUTCH 5C – 13
DAEWOO V–121 BL4
Installation Procedure
1. Install the concentric slave cylinder and the pipe.
2. After installing the pipe screw provisionally, tighten
the concentric slave cyl

Page 1901 of 2643

DAEWOO NUBIRA 2004 Service Repair Manual 5C – 14ICLUTCH
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
DRIVING MEMBERS
The driving members consist of two flat surfaces ma-
chined to a smooth finish. One of these is the rear fa

Page 1902 of 2643

DAEWOO NUBIRA 2004 Service Repair Manual SECTION : 6A
POWER STEERING SYSTEM
TABLE OF CONTENTS
SPECIFICATIONS6A–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 6A–1. . . . . . . . . . .
SPECIAL T

Page 1903 of 2643

DAEWOO NUBIRA 2004 Service Repair Manual 6A – 2IPOWER STEERING SYSTEM
DAEWOO V–121 BL4
DIAGNOSIS
POWER STEERING SYSTEM
PRESSURE TEST
Tools Required
KM–354–B Pressure Test Gauge Kit
Check the fluid pressure as follows to determine whe

6A – 2IPOWER STEERING SYSTEM
DAEWOO V–121 BL4
DIAGNOSIS
POWER STEERING SYSTEM
PRESSURE TEST
Tools Required
KM–354–B Pressure Test Gauge Kit
Check the fluid pressure as follows to determine whether
the trouble is in the pump or the gear unit.
Test Procedure
1. Check the power steering fluid level and the power
steering pump belt tension. Refer to ”Checking and
Adding Fluid” in this section and Section 6B, Power
Steering Pump.
2. Disconnect the high pressure line at the pump. Use
a small container to catch any fluid.
3. Connect the hose of the pressure test gauge kit
KM–354–B to the power steering pressure hose
from the power steering pump.
4. Place the gear selector lever in PARK (automatic
transaxle–equipped vehicles) or NEUTRAL (manual
transaxle–equipped vehicles). Set the parking
brake.
5. Open the gauge valve fully.
6. Start the engine and let it idle.
7. Turn the steering wheel from lock to lock several
times to warm the fluid to operating temperature.
8. Increase the engine speed to 1,500 rpm.
Notice : The power steering pump could be damaged if
the valve is fully closed for more than 5 seconds.
9. Close the gauge valve fully, and read the pressure.
The pump pressure with the valve closed should be
between 8,330 kPa to 8,820 kPa (1,208 psi to
1,279 psi). With electronic variable orifice, the pres-
sure should be between 8,500 kPa to 8,960 kPa
(1,233 psi to 1,299 psi).
10. Immediately open the gauge valve fully.
11. Turn the steering wheel all the way to the left and
the right. If the pressure is within the specified lim-
its, the problem is not in the pump. Check the pow-
er steering gear for leaks.
POWER STEERING SYSTEM LEAK
TEST
General Procedure
Inspect the following:
S The fluid reservoir for overfill.
S Fluid for aeration and overflow.
S The hoses for loose connections.
S The torsion bar, stub shaft and adjuster seals for
leaks.
S The component sealing surfaces for damage.
Important : Verify the exact point of the leak. The point
from which the fluid is dripping is not necessarily the point
at which the system is leaking. When service is required,
clean the leak area upon disassembly, replace the leaking
seal, check the component sealing surfaces for damage
and reset the torque bolt to specifications, where required.
External Leak Check
The purpose of this procedure is to pinpoint the location of
the leak. In some cases, the leak can be easily located, but
seepage–type leaks may be harder to find. To locate seep-
age leaks, use the following method:
1. With the engine off, wipe dry the complete power
steering system.
2. Check the power steering fluid level in the pump’s
reservoir. Adjust the fluid level as necessary. Refer
to ”Checking and Adding Fluid” in this section.
Notice : Do not hold the steering wheel at a stop for any
length of time as this can damage the power steering
pump.
3. Start the engine. Turn the steering wheel counter-
clockwise and clockwise from stop to stop several
times.
4. Find the exact area of the leak and repair it.

Page 1904 of 2643

DAEWOO NUBIRA 2004 Service Repair Manual POWER STEERING SYSTEM 6A – 3
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
BLEEDING THE POWER STEERING
SYSTEM
If the power steering hydraulic system has been serviced,
an accurate

POWER STEERING SYSTEM 6A – 3
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
BLEEDING THE POWER STEERING
SYSTEM
If the power steering hydraulic system has been serviced,
an accurate fluid level reading cannot be obtained until the
air is bled from the system. Follow these steps to bleed the
air from the system.
1. Turn the wheels all the way to the left and add the
power steering fluid to the MIN mark on the fluid
level indicator.
Notice : When adding fluid or making a complete fluid
change, always use DEXRON®–II or III power steering
fluid. Failure to use the proper fluid will cause hose and
seal damage and fluid leaks.
2. Start the engine. With the engine running at fast
idle, recheck the fluid level. If necessary, add fluid
to bring the level up to the MIN mark.
3. Bleed the system by turning the wheels from side to
side without reaching the stop at either end. Keep
the fluid level at the MIN mark. The air must be
eliminated from the fluid before normal steering ac-
tion can be obtained.
4. Return the wheels to the center position. Continue
running the engine for 2 to 3 minutes.
5. Road test the car to be sure the steering functions
normally and is free from noise.
6. Recheck the fluid level as described in steps 1 and
2. Make sure the fluid level is at the MAX mark af-
ter the system has stabilized at its normal operating
temperature. Add fluid as needed.
CHECKING AND ADDING FLUID
Notice : When adding fluid or making a complete fluid
change, always use DEXRON®–II or III power steering
fluid. Failure to use the proper fluid will cause hose and
seal damage and fluid leaks.
1. The power steering fluid level is indicated either by
marks on a see–through fluid reservoir or by marks
on a fluid level indicator on the fluid reservoir cap.
2. If the fluid is warmed up to 66°C (150°F), the fluid
level should be between the MAX and MIN marks.
Add fluid as needed.
3. If the fluid is cool, 21°C (70°F), the fluid level
should be at the MIN mark. Add fluid as needed.

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