2004 DAEWOO NUBIRA clutch

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 face of
the engine flywheel and the other is the pressure plate.
The pressure plate is fitted into a steel cover which is
bolted the flywheel.
DRIVEN MEMBERS
The driven member is the clutch disc with a splined hub.The splined hub is free to slide lengthwise along the
splines of the input shaft and drives the input shaft through
these same splines.
The driving and driven members are held in contact by
spring pressure. This pressure is exerted by a diaphragm
spring in the pressure plate assembly.
OPERATING MEMBERS
The clutch release system consists of the clutch pedal, the
clutch master cylinder, and concentric slave cylinder.
Unlike the former system to release the clutch by the re-
lease lever and release fork, the concentric slave cylinder
type makes the concentric slave cylinder directly perform
the clutch release by the generated pressure through the
clutch pedal operation.

SECTION : 7B
MANUAL CONTROL HEATING, VENTILATION
AND AIR CONDITIONING SYSTEM
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
SPECIFICATIONS7B–2 . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 7B–2. . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 7B–2. . . . . . . . . . .
SPECIAL TOOLS7B–3 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 7B–3. . . . . . . . . . . . . . . . . . . . . . . .
SCHEMATIC AND ROUTING DIAGRAMS7B–6 . . . . .
A/C System – Typical 7B–6. . . . . . . . . . . . . . . . . . . . . .
Manual Control A/C Diagram 7B–7. . . . . . . . . . . . . . . .
DIAGNOSIS7B–8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DIAGNOSIS 7B–8. . . . . . . . . . . . . . . . . . . . . .
Testing the Refrigerant System 7B–8. . . . . . . . . . . . . .
Insufficient Cooling ”Quick Check” Procedure 7B–8. .
A/C Performance Test 7B–9. . . . . . . . . . . . . . . . . . . . . .
Pressure–Temperature Relationship of
R–134A 7B–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Leak Testing Refrigerant System 7B–11. . . . . . . . . . . .
V5 SYSTEM AIR CONDITIONING DIAGNOSIS 7B–12
Insufficient Cooling Diagnosis 7B–12. . . . . . . . . . . . . .
SYMPTOM DIAGNOSIS 7B–16. . . . . . . . . . . . . . . . . . . .
Pressure Test Chart (R–134A System) 7B–16. . . . . .
Low and High Side Pressure Relationship
Chart 7B–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR7B–19 . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 7B–19. . . . . . . . . . . . . . . . . . . .
GENERAL A/C SYSTEM SERVICE
PROCEDURES 7B–19. . . . . . . . . . . . . . . . . . . . . . . . . .
O–Ring Replacement 7B–19. . . . . . . . . . . . . . . . . . . . .
Handling Refrigerant 7B–19. . . . . . . . . . . . . . . . . . . . . .
Handling of Refrigerant Lines and Fittings 7B–19. . . .
Maintaining Chemical Stability in the Refrigeration
System 7B–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Discharging, Adding Oil, Evacuating, and Charging
Procedures for A/C System 7B–20. . . . . . . . . . . . . .
SERVICEABLE COMPONENTS 7B–23. . . . . . . . . . . . . Components Used In Non–A/C Systems 7B–23. . . . .
A/C Pressure Transducer 7B–24. . . . . . . . . . . . . . . . . .
A/C Compressor Relay 7B–24. . . . . . . . . . . . . . . . . . . .
Air Filter 7B–25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A/C Expansion Valve 7B–25. . . . . . . . . . . . . . . . . . . . . .
A/C High–Pressure Pipe Line 7B–26. . . . . . . . . . . . . . .
Evaporator Core 7B–29. . . . . . . . . . . . . . . . . . . . . . . . . .
A/C Suction Hose Assembly 7B–30. . . . . . . . . . . . . . .
A/C Discharge Hose Compressor to
Condenser 7B–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receiver–Dryer 7B–32. . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor 7B–33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condenser 7B–35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR 7B–37. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPONENT LOCATOR 7B–37. . . . . . . . . . . . . . . . . . .
V5 Compressor 7B–37. . . . . . . . . . . . . . . . . . . . . . . . . . .
V5 AIR CONDITIONING COMPRESSOR
OVERHAUL 7B–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Plate and Hub Assembly 7B–38. . . . . . . . . . . .
Clutch Rotor and Bearing 7B–40. . . . . . . . . . . . . . . . . .
Clutch Coil 7B–42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft Seal Replacement 7B–44. . . . . . . . . . . . . . . . . . .
Control Valve Assembly 7B–46. . . . . . . . . . . . . . . . . . .
Rear Head, Gasket, Valve Plate, Reed Plate,
and O–ring 7B–47. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder to Front Head O–ring 7B–48. . . . . . . . . . . . . .
Leak Testing (External) 7B–50. . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION7B–51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION 7B–51. . . . . . . . . . . . . . . . . .
The V5 A/C System 7B–51. . . . . . . . . . . . . . . . . . . . . . .
System Components – Functional 7B–51. . . . . . . . . .
System Components – Control 7B–52. . . . . . . . . . . . .
V5 Compressor – General Description 7B–52. . . . . . .
V5 Compressor – Description of Operation 7B–52. . .

7B – 2IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
DAEWOO V–121 BL4
SPECIFICATIONS
GENERAL SPECIFICATIONS
ApplicationUnitDescription
Compressor–V5
Receiver–Dryer–AL R/DRIER
RefrigerantType–R–134a System
Capacityg640±20 (RHD : 680±20)
Refrigerant Oil in A/C SystemType–Union Carbide 488 PAG OIL
Capacitycc (ml)220
Evaporator Capacity (Airflow rate 8.7 kg/min)Kcal/h6000±10%
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Pressure Transducer7–62
Expansion Valve Stud Bolts8–71
Liquid Pipe Support Clamp Bolts4–35
Liquid Pipe Block–to–Receiver Dryer Retaining Nut1410–
Liquid Pipe Block–to–Expansion Valve Retaining Nut1410–
Refrigerant Discharge Hose Block–to–Condenser Retaining Nut1612–
Refrigerant Discharge Hose Block–to–Compressor Retaining Nut3324–
Evaporator Core Cover Screws1.2–11
Heater Core Housing–to–Evaporator Housing Retaining Screws1.2–11
Suction Hose Block–to–Compressor Retaining Nut3324–
Suction Hose Support Clamp–to–Longitudinal Member Bolt8–71
Suction Hose Support Clamp–to–Engine Bracket Bolt (1.4D, 1.6D only)4–35
Suction Hose Support Clamp–to–Engine Bracket Bolt (1.8D, 2.0D only)1410–
Suction Hose Block–to–Expansion Valve Retaining Nut1410–
(Receiver Dryer) Band Clamp Bolt5–44
Receiver Dryer–to–Condenser Pipe Block Bolt5–44
Upper Compressor–to–Bracket Mounting Bolts (1.4D, 1.6D only)2518–
Lower Compressor–to–Bracket Mounting Bolts (1.4D, 1.6D only)4533–
Front Compressor–to–Bracket Mounting Bolts (1.8D, 2.0D only)3526–
Rear Compressor–to–Bracket Mounting Bolts (1.8D, 2.0D only)2015–
Condenser Mount Bolts4–35
(Compressor) Clutch Plate and Hub Assembly Retaining Nut1713–
(Compressor) Through Bolts10–89

MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B – 5
DAEWOO V–121 BL4
J–33022
Shaft Nut Socket
J–33023–A
Puller Pilot
J–33024
Clutch Coil
Installer Adapter
J–33025
Clutch Coil Puller Legs
J–34992
Compressor
Holding Fixture
J–33027
Clutch Hub
Holding Tool

7B – 8IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
DAEWOO V–121 BL4
DIAGNOSIS
GENERAL DIAGNOSIS
TESTING THE REFRIGERANT
SYSTEM
If you suspect a problem in the refrigerant system, check
for the following conditions:
1. Check the outer surfaces of the radiator and the
condenser cores to be sure that the airflow is not
blocked by dirt, leaves, or other foreign material.
Check between the condenser and the radiator, as
well as all outer surfaces.
2. Check for restrictions or kinks in the condenser
core, the hoses, and the tubes.
3. Check the operation of the blower fan.
4. Check all the air ducts for leaks or restrictions. Low
airflow rate may indicate a restricted evaporator
core.
5. Check for slippage of the compressor clutch.
6. Check the drive belt tension.
INSUFFICIENT COOLING ”QUICK
CHECK” PROCEDURE
Perform the following ”hand–feel” procedure to get a quick
idea of whether the A/C system has the proper charge of
Refrigerant–134a. The air temperature must be above
21°C (70°F) for most models.
1. Warm up engine. Run the engine at idle.
2. Open the hood and all the doors.
3. Turn the A/C switch ON.
4. Set the temperature control to the full cold position.
5. Set the blower speed switch on the maximum
speed setting.
6. ”Hand–feel” the temperature of the evaporator out-
let pipe. The pipe should be cold.
7. Check for other problems. Refer to ”Testing the Re-
frigerant System” in this section.
8. Leak check the system. Refer to ”Leak Testing the
Refrigerant System” in this section. If you find a
leak, discharge the system and repair the leak as
required. After completing the repair, evacuate the
system and charge it.
9. If there is no leak, refer to ”Insufficient Cooling
Diagnosis” in this section.

MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B – 11
DAEWOO V–121 BL4
LEAK TESTING REFRIGERANT
SYSTEM
Test for leaks whenever you suspect a refrigerant leak in
the system. You should also test for leaks whenever you
perform a service operation which results in disturbing the
lines or the connections. Leaks are commonly found at the
refrigerant fittings or at the connections. Leaks are com-
monly caused by the following problems:
S Improper torque.
S Damaged O–ring seals.
S Dirt or lint on the O–ring seals.
Liquid Leak Detectors
Use a liquid leak detector solution on locations such as fit-
tings. Apply the solution to the area in question with the
swab that is supplied with the solution. Look for bubbles
to appear. This will indicate the existence and the location
of any leak.
For areas where this is not practical, such as sections of
the evaporator and the condenser, an electronic leak de-
tector is more useful.
Electronic Leak Detectors
Follow the manufacturer’s instructions for calibration, op-
eration, and maintenance of an electronic leak detector.
Battery condition is especially important to the accuracy
of a portable model. Set the detector to R–134a before be-
ginning the test.
Notice : Electronic leak detectors are sensitive to wind-
shield washing solutions, solvents and cleaners, and cer-
tain vehicle adhesives. Surfaces must be clean to prevent
false readings. Make sure that all surfaces are dry to pre-
vent damage to the detector.
General Testing Instructions
1. Follow the entire path of the refrigerant system.
2. Completely circle each joint at 25 to 50 mm (1 to 2
inches) per second.
3. Hold the probe tip within 6 mm (1/4 inch) of the sur-
face.4. Do not block the air intake.
5. The audible tone changes from 1 to 2 clicks per
second into a solid alarm if there is a leak. Adjust
the balance control to maintain 1 to 2 clicks per
second.
6. Test all of the following areas, even after one leak
has been confirmed:
S Evaporator inlet and outlet.
S Receiver–drier inlet and outlet.
S Condenser inlet and outlet.
S Brazed and welded areas.
S Damaged areas.
S Hose couplings.
S Compressor rear head.
S All fittings and joints.
Testing Service Ports/Access Valves
The sealing caps provide protection for the service ports.
Make sure that these caps are not missing or loose. Al-
ways use the correct cap for each port.
Testing the Evaporator Core
Leaks in the evaporator core are difficult to find. Test the
evaporator core using the following procedure:
1. Run the blower fan at the maximum speed setting
for at least 15 minutes.
2. Turn the blower OFF.
3. Wait for 10 minutes.
4. Remove the blower motor resistor. Refer to Section
7A, Heating and Ventilation System.
5. Insert the leak detector probe as close as possible
to the evaporator core. The detector will indicate a
leak with a solid alarm.
6. Use a flashlight to search for refrigerant oil on the
core surface.
Testing the Compressor Shaft Seal
1. Blow shop air behind and in front of the compressor
clutch/pulley for at least 15 seconds.
2. Wait 1 to 2 minutes.
3. Probe the area in front of the pulley. If the detector
emits a solid alarm, there is a leak.

7B – 12IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
DAEWOO V–121 BL4
V5 SYSTEM AIR CONDITIONING DIAGNOSIS
INSUFFICIENT COOLING DIAGNOSIS
Test Description
The numbers below refer to steps on the diagnostic table.
13. See the Important below.
32. See the Important below.Important : Perform this test under garage conditions with
the air temperature at 21–32°C (70–90°F), and no sun
load. Follow this test carefully for accurate results.
Important : Perform this test exactly as described to ob-
tain accurate results.
Step
ActionValue(s)YesNo
1Record the customer’s complaint.
Can you verify the customer’s complaint?–Go to Step 2System OK
21. Check the A/C fuse.
2. Check the blower fan operation.
3. Check the engine cooling fan operation.
4. Check the A/C compressor belt.
5. Check the A/C condenser for restricted airflow.
6. Check the clutch coil connection.
7. Repair or replace any components as needed.
8. Check the discharge air temperature with the
A/C turned ON.
Is the discharge air temperature normal?At least 7°C
(12°F) below
ambient air
temperatureSystem OKGo to Step 3
31. Turn the ignition switch to LOCK.
2. Connect the high– and the low–pressure
gauges.
Are both pressures within the value specified?69–345 kPa
(10–50 psi)Go to Step 4Go to Step 5
41. Check the A/C system for leaks.
2. Repair any refrigerant leaks as needed.
3. Recover, evacuate, and recharge the A/C sys-
tem.
4. Observe the two pressure gauges.
Are both pressures above the value specified?345 kPa
(50 psi)Go to Step 7–
5Observe the two pressure gauges.
Are both pressures below the value specified?69 kPa
(10 psi)Go to Step 6Go to Step 7
61. Add 0.45 kg (1 pound) of refrigerant R–134a.
2. Check the A/C system for leaks.
3. Repair any refrigerant leaks, as needed.
4. Recover, evacuate, and recharge the A/C sys-
tem.
5. Observe the two pressure gauges.
Are both pressures above the value specified?345 kPa
(50 psi)Go to Step 7–
71. Start the engine and allow it to run at idle.
2. Set the A/C controls to the following positions:
S The A/C switch to the ON.
S The fresh air control switch to fresh air (in-
dicator lamp OFF).
S The blower motor to 4.
S The temperature to full cold.
Does the A/C compressor clutch engage?–Go to Step 8Go to Step 10

MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B – 13
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
81. Check for a knocking noise from the A/C com-
pressor.
2. Cycle the A/C compressor ON and OFF in or-
der to verify the source of the noise.
Do you hear a loud knocking noise?–Go to Step 9Go to Step 13
91. Recover the A/C system refrigerant.
2. Replace the A/C compressor.
3. Evacuate and recharge the A/C system.
4. Check the A/C system for leaks.
Is the compressor running normally?–Go to Step 13–
101. Turn the ignition switch to LOCK.
2. Disconnect the A/C compressor clutch coil con-
nector.
3. Connect a jumper wire from ground to one A/C
compressor clutch coil terminal.
4. Connect a fused jumper wire from the positive
battery terminal to the other A/C compressor
clutch coil terminal.
Does the A/C clutch engage?–Go to Step 11Go to Step 12
11Repair the electrical circuit to the A/C compressor
clutch coil.
Does the A/C clutch engage?–Go to Step 8–
12Replace the A/C compressor clutch coil.
Does the A/C clutch engage?–Go to Step 8–
131. Close all of the vehicle’s windows and doors.
2. Set the A/C controls to the following positions:
S The A/C switch to the ON position.
S The fresh air control switch to fresh air.
S The blower motor to 4.
S The temperature to full cold.
3. Start the engine and allow it to run at idle for 5
minutes.
4. Feel the evaporator inlet and outlet pipes.
Is there a noticeable difference in the temperature of
the evaporator inlet and outlet pipes?–Go to Step 15Go to Step 14
141. Turn the ignition switch to LOCK.
2. Recover the A/C system refrigerant.
3. Examine the high–pressure pipe for an ob-
struction.
4. Examine the expansion valve for an obstruction
or a malfunction.
5. Repair the obstruction or replace the expansion
valve as needed.
6. Evacuate and recharge the A/C system.
7. Check the A/C system for leaks.
8. Note the discharge air temperature with the
A/C ON.
Is the discharge temperature normal?At least 7°C
(12°F) below
ambient air
temperatureGo to Step 15Go to Step 13