2004 DAEWOO NUBIRA maintenance

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–

3A – 4IAUTOMATIC TRANSAXLE DRIVE AXLE
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
DRIVE AXLE ASSEMBLY
Tools Required
KM–507–B Ball Joint Separator
DW340–110 Axle Shaft Remover
Removal Procedure
1. Raise and suitably support the vehicle.
2. Remove the wheels. Refer to Section 2E, Tires
and Wheels.
3. Remove the axle shaft caulking nut. Discard the
nut.
Notice : Use only the recommended tool for separating
the lower ball joint. Failure to use the recommended tool
may cause damage to the ball joint and the seal.
4. Remove the lower ball joint pinch bolt and nut.
5. Separate the steering knuckle from the lower ball
joint using the ball joint separator KM–507–B.
6. Remove the tie rod nut.
Notice : Use only the recommended tool for separating
the tie rod from the knuckle/strut assembly. Failure to use
the recommended tool may cause damage to the knuckle/
strut assembly.
7. Separate the tie rod end using the ball joint separa-
tor KM–507–B.

SECTION : 3B
MANUAL TRANSAXLE DRIVE AXLE
TABLE OF CONTENTS
SPECIFICATIONS3B–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 3B–1. . . . . . . . . .
SPECIAL TOOLS3B–2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 3B–2. . . . . . . . . . . . . . . . . . . . . . . .
COMPONENT LOCATOR3B–2 . . . . . . . . . . . . . . . . . . . .
Front Drive Axle 3B–2. . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR3B–5 . . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 3B–5. . . . . . . . . . . . . . . . . . . . . Drive Axle Assembly 3B–5. . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR 3B–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outer Joint Seal 3B–8. . . . . . . . . . . . . . . . . . . . . . . . . .
Inner Tripot Seal 3B–9. . . . . . . . . . . . . . . . . . . . . . . . . .
Cross Groove Joint Seal 3B–11. . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION3B–13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Drive Axle 3B–13. . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Axle Shaft Caulking Nut300221–
Lower Ball Joint Pinch Bolt and Nut6044–
Tie Rod Nut5541–
Wheel Nuts10074–

MANUAL TRANSAXLE DRIVE AXLE 3B – 5
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
DRIVE AXLE ASSEMBLY
Tools Required
KM–507–B Ball Joint Separator
KM–460–A Axle Shaft Remover
Removal Procedure
1. Raise and suitably support the vehicle.
2. Remove the wheels. Refer to Section 2E, Tires and
Wheels.
3. Remove the axle shaft caulking nut. Discard the
nut.
Notice : Use only the recommended tool for separating
the lower ball joint. Failure to use the recommended tool
may cause damage to the ball joint and the seal.
4. Remove the lower ball joint pinch bolt and nut.
5. Separate the steering knuckle from the lower ball
joint using the ball joint separator KM–507–B.
6. Remove the tie rod nut.
Notice : Use only the recommended tool for separating
the tie rod from the knuckle/strut assembly. Failure to use
the recommended tool may cause damage to the knuckle/
strut assembly.
7. Separate the tie rod end using the ball joint separa-
tor KM–507–B.

SECTION : 4A
HYDRAULIC BRAKES
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
SPECIFICATIONS4A–2 . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifcations 4A–2. . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 4A–2. . . . . . . . . .
COMPONENT LOCATOR4A–3 . . . . . . . . . . . . . . . . . . . .
Brake System (ABS) 4A–3. . . . . . . . . . . . . . . . . . . . . . .
Brake System (NON–ABS) 4A–4. . . . . . . . . . . . . . . . .
DIAGNOSIS4A–5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake System Testing 4A–5. . . . . . . . . . . . . . . . . . . . .
Brake Hose Inspection 4A–5. . . . . . . . . . . . . . . . . . . . .
Warning Lamp Operation 4A–5. . . . . . . . . . . . . . . . . . .
Stop Lamp Warning Circuit Diagnosis 4A–6. . . . . . . . MAINTENANCE AND REPAIR4A–10 . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 4A–10. . . . . . . . . . . . . . . . . . . .
Manual Bleeding the Brakes 4A–10. . . . . . . . . . . . . . .
Pressure Bleeding the Brakes 4A–12. . . . . . . . . . . . . .
Brake Hose Rear 4A–13. . . . . . . . . . . . . . . . . . . . . . . . .
Brake Hose Front 4A–14. . . . . . . . . . . . . . . . . . . . . . . . .
Stoplamp Switch 4A–15. . . . . . . . . . . . . . . . . . . . . . . . .
Brake Pedal 4A–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION4A–17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning Lamp Operation 4A–17. . . . . . . . . . . . . . . . . .

4A – 10IHYDRAULIC BRAKES
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
MANUAL BLEEDING THE BRAKES
(Left–Hand Drive Shown, Right–Hand Drive
Similar)
1. Remove the booster reserve by applying the brakes
several times with the engine OFF until all the re-
serve is depleted.
Important : If the master cylinder is known or suspected
to have air in the bore, then it must be bled before any
wheel cylinder or caliper is bled.
2. Fill the master cylinder reservoir with brake fluid.
Keep the master cylinder at least one–half full of
fluid during the bleeding operation.
3. Disconnect the front brake line(s) at the master cyl-
inder.
4. Allow the brake fluid to fill the master cylinder until it
begins to flow from the front pipe connector port.
5. Connect the front brake line(s) to the master cylin-
der.
Tighten
Tighten the brake lines to 16 NSm (12 lb–ft).

SECTION : 4B
MASTER CYLINDER
TABLE OF CONTENTS
SPECIFICATIONS4B–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 4B–1. . . . . . . . . .
DIAGNOSIS4B–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Brake Proportioning Valve 4B–2. . . . . . . . .
MAINTENANCE AND REPAIR4B–3 . . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 4B–3. . . . . . . . . . . . . . . . . . . . .
Master Cylinder Assembly 4B–3. . . . . . . . . . . . . . . . . . Brake Fluid Reservoir 4B–4. . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR 4B–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Cylinder Overhaul 4B–7. . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION4B–9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Cylinder 4B–9. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Level Sensor 4B–9. . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Brake Lines1612–
Master Cylinder Attaching Nuts1813–
Proportioning Valves2216–

MASTER CYLINDER 4B – 3
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
MASTER CYLINDER ASSEMBLY
(Left–Hand Drive Shown, Right–Hand Drive
Similar)
Removal Procedure
1. Disconnect the electrical connector from the reser-
voir.
2. For vehicles with the ABS braking system, discon-
nect the brake lines from the master cylinder body.
3. For vehicles with the non–ABS braking system, dis-
connect the brake lines from the proportioning
valves.
4. For vehicles with the manual transaxle, disconnect
the clip to the clutch hose connection to the master
cylinder and move the clip out of the way.
5. Remove the clutch hose from the master cylinder if
equipped.
6. Plug the opening to the brake lines to prevent fluid
loss and contamination.
7. Remove the attaching nuts from the power booster.
8. Remove the master cylinder assembly.
9. Drain the brake fluid.