2004 DAEWOO NUBIRA auxiliary battery

SECTION : 1D
ENGINE COOLING
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
SPECIFICATIONS1D–2 . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacity 1D–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 1D–2. . . . . . . . . . .
SPECIAL TOOLS1D–2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 1D–2. . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS1D–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat Test 1D–3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Surge Tank Cap Test 1D–3. . . . . . . . . . . . . . . . . . . . . . .
Cooling System Diagnosis 1D–4. . . . . . . . . . . . . . . . . .
COMPONENT LOCATOR1D–5 . . . . . . . . . . . . . . . . . . . .
Radiator/Fan 1D–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump/Thermostat (1.4L/1.6L DOHC) 1D–6. . .
Water Pump/Thermostat (1.8L DOHC) 1D–7. . . . . . .
MAINTENANCE AND REPAIR1D–8 . . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 1D–8. . . . . . . . . . . . . . . . . . . . . Draining and Refilling the Cooling System 1D–8. . . . .
Thermostat (1.4L/1.6L DOHC) 1D–9. . . . . . . . . . . . . . .
Thermostat (1.8L DOHC) 1D–10. . . . . . . . . . . . . . . . . .
Water Pump 1D–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Cooling Fan – Main or Auxiliary 1D–13. . . . . .
Surge Tank 1D–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator 1D–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION1D–18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Description 1D–18. . . . . . . . . . . . . . . . . . . . . . .
Radiator 1D–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Surge Tank 1D–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump 1D–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat 1D–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Cooling Fan 1D–19. . . . . . . . . . . . . . . . . . . . . . .
Engine Block Heater 1D–19. . . . . . . . . . . . . . . . . . . . . .

ENGINE COOLING 1D – 13
DAEWOO V–121 BL4
ELECTRIC COOLING FAN – MAIN OR
AUXILIARY
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the cooling fan electrical connector.
3. Remove the fan shroud mounting bolts.
4. Lift the fan shroud assembly upward, and remove
the fan shroud assembly from the vehicle.
5. Remove the fan blade from the fan shroud assem-
bly by removing the nut at the center of the fan hub.
6. Turn over the fan shroud assembly.
7. Remove the fan motor retaining screws.
8. Remove the fan motor from the shroud.
Installation Procedure
CAUTION : If a fan blade is bent or damaged in any
way, no attempt should be made to repair or reuse the
damaged part. A bent or damaged fan assembly must
be replaced with a new fan assembly. It is essential
that fan assemblies remain in proper balance. A fan
assembly that is not in proper balance can fail and fly
apart during use, creating extreme danger. Proper
balance cannot be assured on a fan assembly that
has been bent or damaged.
1. Install the fan motor to the shroud.
2. Secure the motor to the shroud with the retaining
screws.

1D – 16IENGINE COOLING
DAEWOO V–121 BL4
RADIATOR
Removal Procedure
1. Disconnect the negative battery cable.
2. Drain the engine cooling system. Refer to ”Draining
and Refilling the Cooling System” in this section.
3. Remove the main and the auxiliary cooling fans.
Refer to ”Electric Cooling Fan – Main or Auxiliary”
in this section.
4. Remove the upper radiator retaining bolt.
5. Remove the upper radiator retaining bracket.
6. Remove the upper radiator hose clamp.
7. Disconnect the upper radiator hose from the radia-
tor.
8. Remove the hose clamp from the surge tank hose
at the radiator.
9. Disconnect the surge tank hose from the radiator.
10. Remove the lower radiator hose clamp.
11. Disconnect the lower radiator hose from the radia-
tor.
12. Disconnect the transaxle cooler pipes from the low-
er radiator tank, if equipped.
13. Remove the bolt and the transaxle pipe support
clamp from the radiator.
14. Remove the radiator from the vehicle.
Important : The radiator still contains a substantial
amount of coolant. Drain the remainder of the coolant from
the radiator into a drain pan.
Installation Procedure
1. Set the radiator into place in the vehicle with the
radiator bottom posts in the rubber shock bumpers.
2. Connect the transaxle cooler pipes to the lower ra-
diator tank, if equipped.
3. Install the transaxle pipe and support clamp to the
radiator with a bolt.
4. Connect the surge tank hose to the radiator.
5. Secure the surge tank hose with a hose clamp.
6. Connect the upper radiator hose and the lower ra-
diator hose to the radiator.
7. Secure each hose with a hose clamp.
8. Position the radiator retainers in place.
9. Install the upper radiator retainer bracket.
10. Install the upper radiator retaining bolt.

ENGINE COOLING 1D – 17
DAEWOO V–121 BL4
11. Install the main and the auxiliary cooling fans. Refer
to ”Electric Cooling Fan – Main or Auxiliary” in this
section.
12. Refill the engine cooling system. Refer to ”Draining
and Refilling the Cooling System” in this section.
13. Connect the negative battery cable.
Tighten
Tighten the radiator retaining bolt to 8 NSm (71 lb–in).

ENGINE CONTROLS 1F – 93
DAEWOO V–121 BL4
ENGINE COOLING FAN CIRCUIT CHECK – DUAL FAN
(1.4L/1.6L DOHC)
Circuit Description
The engine cooling fan circuit operates the main cooling
fan and the auxiliary cooling fan. The cooling fans are con-
trolled by the engine control module (ECM) based on in-
puts from the Engine Coolant Temperature (ECT) sensor
and the Air Conditioning Pressure (ACP) sensor. The
ECM controls the low speed cooling fan operation by inter-
nally grounding the ECM connector terminal 10. This ener-
gizes the low speed cooling fan relay and operates the
main cooling fan and the auxiliary cooling fan at low speed
as the cooling fans are connected in a series circuit. The
ECM controls the high speed cooling fan operation by in-
ternally grounding the ECM connector terminal 10 and the
ECM connector terminal 9 at the same time. This ener-
gizes the low speed cooling fan relay, the high speed cool-
ing fan relay, and the series/parallel cooling fan relay re-
sulting in high speed fan operation as the cooling fans are
now connected in a parallel circuit.
Diagnostic Aids
S If the owner complained of an overheating problem,
it must be determined if the complaint was due to
an actual boil over, or the engine coolant tempera-
ture gauge indicated overheating. If the engine is
overheating and the cooling fans are on, the cooling
system should be checked.
S If the engine fuse block fuses Ef11 become open
(blown) immediately after installation, inspect for a
short to ground in the wiring of the appropriate cir-
cuit. If the fuses become open (blown) when the
cooling fans are to be turned on by the ECM, sus-
pect a faulty cooling fan motor.
S The ECM will turn the cooling fans on at low speed
when the coolant temperature is 97°C (207°F). The
ECM will turn the cooling fans off when the coolant
temperature is 94°C(201°F).
S The ECM will turn the cooling fans on at high speed
when the coolant temperature is 101°C (214°F).
The ECM will change the cooling fans from high
speed to low speed when the coolant temperature
is 98°C (208°F).S The ECM will turn the cooling fans on at low speed
when the A/C system is on. The ECM will change
the cooling fans from low speed to high speed
when the high side A/C pressure is 1882 kPa (273
psi) then return to low speed when the high side
A/C pressure is 1448 kPa (210 psi). When the A/C
system is on, the ECM will change the cooling fans
from low to high speed when the coolant tempera-
ture reaches 117°C (244°F) then return to low
speed when the coolant temperature reaches
11 4°C (237°F).
S The cooling fan circuit can be checked quickly by
disconnecting the ECM connector 2 and grounding
the connector terminal 10. This should create low
speed cooling fan operation with the ignition ON. By
grounding the ECM connector terminals 10 and 9
and turning the ignition ON, high speed cooling fan
operation should be achieved.
Test Description
The number(s) below refer to step(s) on the diagnostic
table.
4. This step, along with step 5, checks for the ability of
the ECM to operate the cooling fans.
8. This step, along with step 9, checks for the ability of
the ECM to operate the cooling fans in response to
A/C pressure readings.
16. After confirming battery voltage and the ECM sup-
plying a ground to the coil side of the cooling fan
relay A, by jumpering connector terminals 30 and
87 it will be determined if the relay is at fault or a
wiring problem is present.
31. This step checks for the presence of battery volt-
age to the main cooling fan when the A/C is on. If
battery voltage is present and the cooling fans are
not operating, the problem is in the ground side of
the cooling fan circuit.
37. By directly grounding the ECM connector terminals
10 and 9, the main and auxiliary cooling fans
should run at high speed.
Engine Cooling Fan Circuit Check – Dual Fan (1.4L/1.6L DOHC)
StepActionValue(s)YesNo
1Perform an On–Board Diagnostic (EOBD) system
check.
Is the check completed?–Go to Step 2Go to
”On–Board
Diagnostic Sys-
tem Check”
21. Check the engine fuse block fuse Ef11.
2. Replace the fuse as needed.
Is the fuse OK?–Go to Step 3Go to
”Diagnostic
Aids”

1F – 96IENGINE CONTROLS
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
20Check the wire between the cooling fan control relay
connector terminal 87A and the auxiliary cooling fan
connector terminal 2 for an open.
Is the problem found?–Go to Step 22Go to Step 21
21Check for an open wire between the auxiliary cooling
fan connector terminal 1 and ground.
Is the problem found?–Go to Step 22Go to Step 29
22Repair the open wire as needed.
Is the repair complete?–System OK–
23Repair the open between the cooling fan relay Low
connector terminal 30 and the fuse Ef11.
Is the repair complete?–System OK–
24Repair the open between the cooling fan relay Low
connector terminal 86 and the ignition switch.
Is the repair complete?–System OK–
25Repair the open wire between the cooling fan relay
Low connector terminal 85 and the ECM connector
terminal 10.
Is the repair complete?–System OK–
26Replace the cooling fan relay Low.
Is the repair complete?–System OK–
27Replace the cooling fan control relay.
Is the repair complete?–System OK–
28Replace the main cooling fan.
Is the repair complete?–System OK–
29Replace the auxiliary cooling fan.
Is the repair complete?–System OK–
30Replace the ECM.
Is the repair complete?–System OK–
311. Turn the ignition OFF.
2. Disconnect the main cooling fan connector.
3. Connect a test light between the main cooling
fan connector termina 2 and ground.
4. Turn the A/C switch ON.
5. Start the engine.
Is the test light on?–Go to Step 32Go to Step 12
321. Turn the ignition OFF.
2. Connect a test light between the main cooling
fan connector terminal 1 and battery positive.
3. Turn the A/C switch ON.
4. Start the engine.
Is the test light on?–Go to Step 28Go to Step 17
331. Turn the ignition OFF.
2. Disconnect the cooling fan relay Hi.
3. Connect a test light between the cooling fan
relay Hi connector terminal 86 and ground.
4. Turn the ignition ON.
Is the test light on?–Go to Step 34Go to Step 44

1F – 98IENGINE CONTROLS
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
411. Connect the cooling fan control relay.
2. Connect a fused jumper between the ECM
connector terminal 9 and ground.
3. Disconnect the cooling fan relay Hi.
4. Connect a fused jumper between the cooling
fan relay Hi connector terminals 30 and 87.
5. Disconnect the low speed cooling fan relay.
6. Connect a fused jumper between the low
speed cooling fan relay connector terminals 30
and 87.
7. Turn the ignition ON.
Do the cooling fans run at high speed?–Go to Step 43Go to Step 42
421. Turn the ignition OFF.
2. Connect a fused jumper between the ECM
connector terminal 9 and ground.
3. Disconnect the cooling fan control relay.
4. Connect a fused jumper between the cooling
fan control relay connector terminals 30 and
87.
5. Connect a fused jumper between the low
speed cooling fan relay connector terminals 30
and 87.
6. Turn the ignition ON.
Do the cooling fans run at high speed?–Go to Step 27–
43Replace the cooling fan relay Hi.
Is the repair complete?–System OK–
44Repair the open wire between the cooling fan relay
Hi connector terminal 86 and the ignition switch.
Is the repair complete?–System OK–
45Repair the open wire between the cooling fan relay
Hi connector terminal 30 and the battery.
Is the repair complete?–System OK–
46Repair the open wire between the cooling fan control
relay connector terminal 85 and the ignition switch
Is the repair complete?–System OK–
47Repair the open wire between the cooling fan control
relay connector terminal 87 and ground.
Is the repair complete?–System OK–
48Repair the open wire between the cooling fan relay
Hi connector terminal 87 and the auxiliary cooling
fan connector terminal 2.
Is the repair complete?–System OK–
49Repair the open wire between the cooling fan control
relay connector terminal 85 and the ECM connector
terminal 9.
Is the repair complete?–System OK–

1F – 100IENGINE CONTROLS
DAEWOO V–121 BL4
ENGINE COOLING FAN CIRCUIT CHECK – DUAL FAN
(1.8L DOHC)
Circuit Description
The engine cooling fan circuit operates the main cooling
fan and the auxiliary cooling fan. The cooling fans are con-
trolled by the engine control module (ECM) based on in-
puts from the Engine Coolant Temperature (ECT) sensor
and the Air Conditioning Pressure (ACP) sensor. The
ECM controls the low speed cooling fan operation by inter-
nally grounding the ECM connector terminal K28. This en-
ergizes the low speed cooling fan relay and operates the
main cooling fan and the auxiliary cooling fan at low speed
as the cooling fans are connected in a series circuit. The
ECM controls the high speed cooling fan operation by in-
ternally grounding the ECM connector terminal K28 and
the ECM connector terminal K12 at the same time. This
energizes the low speed cooling fan relay, the high speed
cooling fan relay, and the series/parallel cooling fan relay
resulting in high speed fan operation as the cooling fans
are now connected in a parallel circuit.
Diagnostic Aids
S If the owner complained of an overheating problem,
it must be determined if the complaint was due to
an actual boil over, or the engine coolant tempera-
ture gauge indicated overheating. If the engine is
overheating and the cooling fans are on, the cooling
system should be checked.
S If the engine fuse block fuses Ef21, Ef6, Ef8 be-
come open (blown) immediately after installation,
inspect for a short to ground in the wiring of the ap-
propriate circuit. If the fuses become open (blown)
when the cooling fans are to be turned on by the
ECM, suspect a faulty cooling fan motor.
S The ECM will turn the cooling fans on at low speed
when the coolant temperature is 97°C (207°F). The
ECM will turn the cooling fans off when the coolant
temperature is 94°C(201°F).
S The ECM will turn the cooling fans on at high speed
when the coolant temperature is 101°C (214°F).
The ECM will change the cooling fans from high
speed to low speed when the coolant temperature
is 98°C (208°F).S The ECM will turn the cooling fans on at low speed
when the A/C system is on. The ECM will change
the cooling fans from low speed to high speed
when the high side A/C pressure is 1882 kPa (273
psi) then return to low speed when the high side
A/C pressure is 1448 kPa (210 psi). When the A/C
system is on, the ECM will change the cooling fans
from low to high speed when the coolant tempera-
ture reaches 117°C (244°F) then return to low
speed when the coolant temperature reaches
11 4°C (237°F).
S The cooling fan circuit can be checked quickly by
disconnecting the ECM connector 2 and grounding
the connector terminal K28. This should create low
speed cooling fan operation with the ignition ON. By
grounding the ECM connector terminals K28 and
K12 and turning the ignition ON, high speed cooling
fan operation should be achieved.
Test Description
The number(s) below refer to step(s) on the diagnostic
table.
4. This step, along with step 5, checks for the ability of
the ECM to operate the cooling fans.
8. This step, along with step 9, checks for the ability of
the ECM to operate the cooling fans in response to
A/C pressure readings.
16. After confirming battery voltage and the ECM sup-
plying a ground to the coil side of the cooling fan
relay A, by jumpering connector terminals 30 and
87 it will be determined if the relay is at fault or a
wiring problem is present.
31. This step checks for the presence of battery volt-
age to the main cooling fan when the A/C is on. If
battery voltage is present and the cooling fans are
not operating, the problem is in the ground side of
the cooling fan circuit.
37. By directly grounding the ECM connector terminals
K28 and K12, the main and auxiliary cooling fans
should run at high speed.
Engine Cooling Fan Circuit Check – Dual Fan (1.8L DOHC)
StepActionValue(s)YesNo
1Perform an On–Board Diagnostic (EOBD) system
check.
Is the check completed?–Go to Step 2Go to
”On–Board
Diagnostic Sys-
tem Check”
21. Check the I/P fuse block fuse F2.
2. Replace the fuse as needed.
Is the fuse OK?–Go to Step 3Go to
”Diagnostic
Aids”