2004 DAEWOO NUBIRA section 9G

REAR SUSPENSION 2D – 17
DAEWOO V–121 BL4
UNIT REPAIR
SPRINGS AND INSULATORS
Tools Required
KM–329–A Spring Compressor
Disassembly Procedure
1. Remove the rear strut assembly from the vehicle.
Refer to ”Strut Assembly” in this section.
2. Mount the rear strut assembly into the spring com-
pressor (KM–329–A or DW320–010). Ensure that
the hooks are properly seated.
3. Compress the spring.
4. Remove the lock nut from the strut dampener rod.
5. Remove the rear strut mount.
6. Remove the rear spring upper seat, the dust cover,
and the hollow bumper.
7. Release the spring.
8. Remove the rear spring and the rear spring lower
seat.
Assembly Procedure
1. Install the rear spring lower seat and the rear
spring.
2. Compress the spring.
3. Install the hollow bumper, the dust cover, and the
rear spring upper seat.
4. Install the rear strut mount.

2D – 18IREAR SUSPENSION
DAEWOO V–121 BL4
5. Install the lock nut onto the strut dampener rod.
Tighten
Tighten the ball joint–to–control arm nuts to 100 NSm
(74 lb–ft). Tighten the strut dampener–to–strut mount
nut to 75 NSm (55 lb–ft).
6. Release the spring.
7. Remove the strut assembly from the spring com-
pressor and install the strut assembly into the ve-
hicle. Refer to ”Strut Assembly” in this section.
KNUCKLE
Disassembly Procedure
1. Remove the knuckle from the vehicle. Refer to
”Knuckle Assembly” in this section.
2. Remove the brake drum. Refer to Section 4E2,
Rear Drum Brakes.
3. Remove the wheel hub. Refer to ”Hub and Bearing
Assembly” in this section.
4. On vehicles equipped with rear drum brakes, re-
move the rear drum brake assembly. On vehicles
equipped with rear disc brakes, remove the rear
disc brake assembly. Refer to Section 4E1, Rear
Disc Brakes.
5. Remove the brake splash shield. Refer to Section
4E2, Rear Drum Brakes.
Assembly Procedure
1. Install the brake splash shield. Refer to Section
4E1, Rear Disc Brakes.
2. On vehicles equipped with rear drum brakes, install
the rear drum brake assembly. On vehicles
equipped with rear disc brakes, install the rear disc
brake assembly. Refer to Section 4E1, Rear Disc
Brakes.
3. Install the wheel hub. Refer to ”Hub and Bearing
Assembly” in this section.
4. Install the brake caliper and brake rotor or the
brake drum. Refer to Section 4E1, Rear Disc
Brakes and 4E2, Rear Drum Brakes.
5. Install the knuckle into the vehicle. Refer to
”Knuckle Assembly” in this section.

SECTION : 2E
TIRES AND WHEELS
TABLE OF CONTENTS
SPECIFICATIONS2E–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
Tire Size and Pressure Specifications 2E–1. . . . . . . .
Inflation Pressure Conversion Specifications 2E–2. .
Fastener Tightening Specifications 2E–2. . . . . . . . . . .
DIAGNOSIS2E–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Runout 2E–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR2E–3 . . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 2E–3. . . . . . . . . . . . . . . . . . . . .
Wheel 2E–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
On–Vehicle Balancing 2E–4. . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR 2E–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alloy Wheel Porosity 2E–5. . . . . . . . . . . . . . . . . . . . . . .
Alloy Wheel Refinishing 2E–5. . . . . . . . . . . . . . . . . . . . .
Off–Vehicle Balancing 2E–7. . . . . . . . . . . . . . . . . . . . . . Correcting Non–Uniform Tires 2E–7. . . . . . . . . . . . . . .
Tire and Wheel Match–Mounting 2E–8. . . . . . . . . . . . .
Tire Mounting and Dismounting 2E–8. . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION 2E–9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tire and Wheel Balancing 2E–9. . . . . . . . . . . . . . . . . . .
Tire Chain Usage 2E–9. . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement Tires 2E–10. . . . . . . . . . . . . . . . . . . . . . . .
All Season Tires 2E–10. . . . . . . . . . . . . . . . . . . . . . . . . .
Passenger Metric Sized Tires 2E–10. . . . . . . . . . . . . .
Tire Label 2E–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spare Tire 2E–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheels 2E–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inflation o Tires 2E–11. . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS
TIRE SIZE AND PRESSURE SPECIFICATIONS
Inflation Pressure at Full Load
TiresWheelFrontRear
kPapsikPapsi
175 / 70R145.5J x 14(Steel)2053020530
175 / 70R145.5J x 14(Alloy)2053020530
T125 / 70D154T x 154156041560
185 / 65R145.5J x 14(Steel)2053020530
185 / 65R145.5J x 14(Alloy)2053020530
T125 / 70D154T x 154156041560
195 / 55R156J x 15(Steel)2053020530
195 / 55R156J x 15(Alloy)2053020530
195 / 55R156J x 15
(Alloy, Sporty)2053020530
T125 / 70D154T x 154156041560

TIRES AND WHEELS 2E – 5
DAEWOO V–121 BL4
UNIT REPAIR
ALLOY WHEEL POROSITY
Wheel repairs that use welding, heating or peening are not
approved.
1. Raise and suitably support the vehicle.
2. Remove the wheel. Refer to ”Wheel” in this sec-
tion.
CAUTION : To avoid serious injury, do not stand over
the tire when inflating, because the bead may break
when it snaps over the safety hump. Do not exceed
275 kPa (40 psi) of air pressure in any tire if the beads
are not seated. If 275 kPa (40 psi) of air pressure will
not seat the beads, deflate the tire. Relubricate the
beads. Reinflate the tire. Overinflation may cause the
bead to break and cause serious injury.
3. Locate leaking areas by inflating the tire to 345 kPa
(50 psi) and dipping the tire and wheel assembly
into a water bath.
4. Mark the leak areas and remove the tire from the
wheel.
5. Scuff the inside wheel surface at the leak area with
80–grit sandpaper. Clean the leak area with a gen-
eral–purpose cleaner.
6. Apply a 3.3 mm (0.13 inch) thick layer of adhesive/
sealant to the leak area. Allow it to dry for 12 hours.
7. Install the tire on the wheel. Inflate the tire to 345
kPa (50 psi) and check for leaks as in step 3.
8. Adjust the tire pressure to meet specifications. Re-
fer to ”Tire Size and Pressure Specifications” in
this section.
9. Balance the wheel. Refer to ”Tire and Wheel Bal-
ancing” in this section.
10. Install the wheel. Refer to ”Wheel” in this section.
11. Lower the vehicle.
ALLOY WHEEL REFINISHING
A protective clear or color coating is applied to the surface
of the original equipment cast alloy wheels. Surface deg-
radation can develop if this clear coating is damaged or re-
moved. This can happen at some automatic car wash fa-
cilities that use silicon carbide–tipped tire brushes to clean
white walls and tires. Once the protective coating is dam-
aged, exposure to caustic cleaners or road salt causes fur-
ther surface degradation. The following procedure details
how to strip, clean and recoat alloy wheels.
CAUTION : To avoid serious personal injury, follow
the manufacturer’s recommendations and cautions
when using these materials.
Required materials:
S Amchem Alumi Prep No. 33. Stock No. DX533 or
equivalent cleaning and conditioning chemical for
alloys.

2E – 10ITIRES AND WHEELS
DAEWOO V–121 BL4
turers of tire chains have a specific chain size for each tire
size to ensure a proper fit when the chain is installed. Be
sure to purchase the correct chains for the tires on which
they are to be used. Use rubber adjusters to take up any
slack or clearance in loose chains.
Use of chains may adversely affect vehicle handling.
When tire chains are installed, follow these precautions:
S Adjust speed to road conditions.
S Avoid sharp turns.
S Avoid locked–wheel braking.
To prevent chain damage to the vehicle, install the chains
on the front tires as tightly as possible. Tighten them again
after driving 0.4 to 0.8 kilometer (0.3 to 0.5 mile). The use
of chains on the rear tires is not recommended because
they may contact the vehicle and possibly damage it. If
chains must be used on the rear tires, be sure there is suffi-
cient clearance between the chains and the body. Do not
exceed 70 km/h (45 mph) or the chain manufacturer’s
speed limit, if lower. Avoid large bumps, potholes, severe
turns and any other maneuvers which could cause the
tires to bounce. Follow any other instructions of the chain
manufacturer which do not disagree with the above in-
structions.
REPLACEMENT TIRES
A tire performance criteria (TPC) specification number is
molded in the sidewall near the tire size of all original
equipment tires. This specification number assures that
the tire meets performance standards for traction, endur-
ance, dimensions, noise, handling and rolling resis–tance.
Usually a specific TPC number is assigned to each tire
size.
CAUTION : Do not mix different types of tires on the
same vehicle such as radial, bias and bias–belted
tires except in emergencies, because vehicle han-
dling may be seriously affected and may result in loss
of control.
Use only replacement tires with the same size, load range,
and construction as the original. The use of any other tire
size or construction type may seriously affect ride, han-
dling, speedometer/odometer calibration, vehicle ground
clearance, and tire clearance to the body and the chassis.
This does not apply to the spare tire furnished with the ve-
hicle.
It is recommended that new tires be installed in pairs on
the same axle.
If it is necessary to replace only one tire, pair it with the tire
having the most tread to equalize the braking action.
Although they may appear different in tread design, tires
built by different manufacturers with identical TPC specifi-
cations may be used on the same vehicle.
ALL SEASON TIRES
Most vehicles are now equipped with steel–belted all sea-
son radial tires as standard equipment. These tires qualify
as snow tires, with a 37 percent higher average rating for
snow traction than the non–all season radial tires pre-
viously used. Other performance areas, such as wet trac-
tion, rolling resistance, tread life, and air retention, have
also been improved. This was done by improvements in
both tread design and tread compounds. These tires are
identified by an ”M + S” molded in the tire sidewall following
the size number. The suffix ”MS” is also molded in the side-
wall after the TPC specification number.
The optional handling tires used on some vehicles are not
all season tires. These will not have the ”MS” marking after
the tire size or the TPC specification number.
PASSENGER METRIC SIZED TIRES
All Daewoo vehicles now use Passenger (P) metric sized
tires. P–metric tires are available in two load ranges: stan-
dard load (35 psi maximum) and extra load (41 psi maxi-
mum). Most passenger vehicle tires are standard load.
Most P–metric tire sizes do not have exact corresponding
alphanumeric tire sizes. For example, a P175/70R13 is
not exactly equal in size and load–carrying capacity to an
FR70–13. For this reason, replacement tires should be of
the same TPC specification number as the originals. If P–
metric tires must be replaced with other sizes, consult a
tire dealer. Tire companies can best recommend the clos-
est match of alphanumeric to P–metric sizes within their
own tire lines.
The metric term for measuring tire inflation pressure is the
kilopascal (kPa). Tire pressure may be printed in both kPa
and psi. One psi equals 6.895 kPa.
See the tire label or refer to ”Tire Size and Pressure Speci-
fications” in this section for tire inflation pressures.
TIRE LABEL
The tire label is permanently located on the rear face of the
driver’s door and should be referred to for tire information.
It lists the maximum vehicle load, the tire size (including
the spare tire), and the cold inflation pressure (including
the spare tire).
SPARE TIRE
The notchback and the wagon come equipped with a full–
sized tire on a steel wheel. The hatchback comes
equipped with a reduced–sized temporary tire on a steel
wheel.
WHEELS
Wheels must be replaced if they are bent, dented, have
excessive lateral or radial runout, leak air through welds,
have elongated bolt holes, or if the wheel bolts won’t stay
tight or are heavily rusted. Wheels with excessive runout
may cause vehicle vibration. Replacement wheels must
be equivalent to the original equipment wheels in load ca-

TIRES AND WHEELS 2E – 11
DAEWOO V–121 BL4
pacity, diameter, rim width, offset, and mounting configu-
ration. A wheel of improper size or type may affect wheel
and bearing life, brake cooling, speedometer/odometer
calibration, vehicle ground clearance, and tire clearance
to the body and the chassis. The wheel offset is 49 ± 1 mm
(1.93 ± 0.04 inches). Steel wheels may be identified by a
two– or three–letter code stamped into the rim near the
valve stem. Alloy wheels should have the code, the part
number, and the manufacturer ID cast into the back side.
INFLATION O TIRES
The pressure recommended for any vehicle line is careful-
ly calculated to give a satisfactory ride, handling, tread life,
and load–carrying capacity.
Tire pressure should be checked monthly or before any
extended trip. Check the tires when they are cold, after the
vehicle has sat for 3 hours or more, or has been driven less
than 1 mile. Set the tire pressure to the specifications on
the tire label located on the rear face of the driver’s door.
Tire inflation pressure is also given under ”Tire Size and
Pressure Specifications” in this section.
Valve caps or extensions should be on the valves to keep
dust and water out.
For sustained driving at speeds up to 140 km/h (85 mph),
inflate the tires to the pressure recommended on the tire.
Sustained driving at speeds faster than 140 km/h (85mph), even if permitted by law, is not advised unless the
vehicle has special high–speed tires available from many
tire dealers. Tire pressures may increase as much as 41
kPa (6 psi) when the tires are hot.
Higher than recommended tire pressure can cause
S Hard ride.
S Tire bruising or damage.
S Rapid tread wear at the center of the tire.
Lower than recommended pressure can cause
S Tire squeal on turns.
S Hard steering.
S Rapid and uneven wear on the edges of the tread.
S Tire rim bruises and rupture.
S Tire cord breakage.
S High tire temperatures.
Unequal tire pressures on same axle can cause
S Uneven braking.
S Steering lead.
S Reduced handling.
S Swerve on acceleration.
S Torque steer.

SECTION 3
WIRING DIAGRAM FOR POWER SUPPLIES
CONTENTS
1. IGNITION SWITCH CIRCUIT3–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. 30 TER ”BAT+” POWER SUPPLY CIRCUIT(I.P FUSE BLOCK) 3–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. 15 TER ”IGN 1” POWER SUPPLY CIRCUIT(I.P FUSE BLOCK) 3–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. 15A TER ”IGN2”, 15C TER ”ACC” POWER SUPPLY CIRCUIT(I.P FUSE BLOCK) 3–4. . . . . . . . . . . . . . . . . . . . . .
5. ENGINE FUSE BLOCK & RELAY CIRCUIT 3–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION : 3A
AUTOMATIC TRANSAXLE DRIVE AXLE
TABLE OF CONTENTS
SPECIFICATIONS3A–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 3A–1. . . . . . . . . .
SPECIAL TOOLS3A–2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 3A–2. . . . . . . . . . . . . . . . . . . . . . . .
COMPONENT LOCATOR3A–2 . . . . . . . . . . . . . . . . . . . .
Front Drive Axle 3A–2. . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR3A–4 . . . . . . . . . . . . . . . ON–VEHICLE SERVICE 3A–4. . . . . . . . . . . . . . . . . . . . .
Drive Axle Assembly 3A–4. . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR 3A–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outer Joint Seal 3A–7. . . . . . . . . . . . . . . . . . . . . . . . . .
Inner Tripot Seal 3A–8. . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION3A–10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Drive Axle 3A–10. . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Axle Shaft Caulking Nut300221–
Lower Ball Joint Pinch Bolt and Nut6044–
Tie Rod Nut5541–
Wheel Nuts10074–