2004 DAEWOO NUBIRA bolt

SECTION : 0B
GENERAL INFORMATION
TABLE OF CONTENTS
SPECIFICATIONS0B–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 0B–1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle Dimensions and Weights 0B–6. . . . . . . . . . . .
Standard Bolt Specifications 0B–8. . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR0B–9 . . . . . . . . . . . . . . .
MAINTENANCE AND LUBRICATION 0B–9. . . . . . . . . .
Normal Vehicle Use 0B–9. . . . . . . . . . . . . . . . . . . . . . .
Explanation of Scheduled Maintenance
Services 0B–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scheduled Maintenance Charts 0B–10. . . . . . . . . . . .
OWNER INSPECTIONS AND SERVICES 0B–12. . . . .
Whle Operating The Vehicle 0B–12. . . . . . . . . . . . . . . At Each Fuel Fill 0B–12. . . . . . . . . . . . . . . . . . . . . . . . .
At least Monthly 0B–12. . . . . . . . . . . . . . . . . . . . . . . . . .
At least Twice a Year 0B–12. . . . . . . . . . . . . . . . . . . . .
Each Time The Oil is Changed 0B–13. . . . . . . . . . . . .
At Least Annually 0B–13. . . . . . . . . . . . . . . . . . . . . . . .
Recommended Fluids and Lubricants 0B–14. . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION0B–15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Repair Instructions 0B–15. . . . . . . . . . . . . . . .
GENERAL DESCRIPTION 0B–16. . . . . . . . . . . . . . . . . .
Vehicle and Component Identification 0B–16. . . . . . .
Vehicle Lifting Procedures 0B–21. . . . . . . . . . . . . . . . .
SPECIFICATIONS
TECHNICAL DATA
Performance – Manual Transaxle
Application1.4L DOHC1.6L DOHC1.8L DOHC
Maximum Speed175 km/h (108.7 mph)187 km/h (116.2 mph)194 km/h (120.5 mph)
Minimum Turning Radius5.2 m (17.1 ft)


Performance – Automatic Transaxle
Application1.4L DOHC1.6L DOHC1.8L DOHC
Maximum Speed–175 km/h (108.7 mph)184 km/h (114.3 mph)
Minimum Turning Radius–5.2 m (17.1 ft)

0B – 8IGENERAL INFORMATION
DAEWOO V–121 BL4
STANDARD BOLT SPECIFICATIONS
Bolt*4T – Low Carbon Steel7T – High Carbon Steel7T – Alloy Steel
M6 X 1.04.1–8.1 NSm (36–72 lb–in)5.4–9.5 NSm (48–84 lb–in)–
M8 X 1.25 8.1–17.6 NSm (72–156 lb–in)12.2–23.0 NSm (108–204 lb–in)16–30 NSm (12–22 lb–ft)
M10 X 1.25 20–34 NSm (15–25 lb–ft)27–46 NSm (20–34 lb–ft)37–62 NSm (27–46 lb–ft)
M10 X 1.5 19–34 NSm (14–25 lb–ft)27–45 NSm (20–33 lb–ft)37–60 NSm (27–44 lb–ft)
M12 X 1.25 49–73 NSm (36–54 lb–ft)61–91 NSm (45–67 lb–ft)76–114 NSm (56–84 lb–ft)
M12 X 1.75 45–69 NSm (33–51 lb–ft)57–84 NSm (42–62 lb–ft)72–107 NSm (53–79 lb–ft)
M14 X 1.5 76–115 NSm (56–85 lb–ft)94–140 NSm (69–103 lb–ft)114–171 NSm (84–126 lb–ft)
M14 X 2.0 72–107 NSm (53–79 lb–ft)88–132 NSm (65–97 lb–ft)107–160 NSm (79–118 lb–ft)
M16 X 1.5 104–157 NSm (77–116 lb–ft)136–203 NSm (100–150 lb–ft)160–240 NSm (118–177 lb–ft)
M16 X 2.0 100–149 NSm (74–110 lb–ft)129–194 NSm (95–143 lb–ft)153–229 NSm (113–169 lb–ft)
M18 X 1.5 151–225 NSm (111–166 lb–ft)195–293 NSm (144–216 lb–ft)229–346 NSm (169–255 lb–ft)
M20 X 1.5 206–311 NSm (152–229 lb–ft)270–405 NSm (199–299 lb–ft)317–476 NSm (234–351 lb–ft)
M22 X 1.5 251–414 NSm (185–305 lb–ft)363–544 NSm (268–401 lb–ft)424–636 NSm (313–469 lb–ft)
M24 X 2.0 359–540 NSm (265–398 lb–ft)431–710 NSm (318–524 lb–ft)555–831 NSm (409–613 lb–ft)
* Diameter X pitch in millimeters

GENERAL INFORMATION 0B – 9
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
MAINTENANCE AND LUBRICATION
NORMAL VEHICLE USE
The maintenance instructions contained in the mainte-
nance schedule are based on the assumption that the ve-
hicle will be used for the following reasons:
S To carry passengers and cargo within the limitation
indicated on the tire placard located on the edge of
the driver’s door.
S To be driven on reasonable road surfaces and with-
in legal operating limits.
EXPLANATION OF SCHEDULED
MAINTENANCE SERVICES
The services listed in the maintenance schedule are fur-
ther explained below. When the following maintenance
services are performed, make sure all the parts are re-
placed and all the necessary repairs are done before driv-
ing the vehicle. Always use the proper fluid and lubricants.
Drive Belt Inspection
When a separate belt drives the power steering pump, the
air conditioning compressor and the generator, inspect it
for cracks, fraying, wear and proper tension. Adjust or re-
place the belt as needed.
Engine Oil and Oil Filter Change
API Classifications of Engine Oil
The International Lubricant Standardization and Approval
Committee (ILSAC) and American Petroleum Institute
classifies engine oils according to their performance quali-
ty. Always use oil rated API–SL (ILSAC GF–III) or better.
Engine Oil Viscosity
Engine oil viscosity (thickness) has an effect on fuel econ-
omy and cold weather operation. Lower viscosity engine
oils can provide better fuel economy and cold weather per-
formance; however, higher temperature weather condi-
tions require higher viscosity engine oils for satisfactory lu-
brication. Using oils of any viscosity other than those
viscosities recommended could result in engine damage.
Cooling System Service
Drain, flush and refill the system with new coolant. Refer
to ”Recommended Fluids And Lubricants” in this section.
Fuel Micro–Filter Replacement
Replace the engine fuel filter every 45,000 km (27,000
miles).
Air Cleaner Element Replacement
Replace the air cleaner element every 45,000 km (27,000
miles).Replace the air cleaner more often under dusty conditions.
Throttle Body Mounting Bolt Torque
Check the torque of the mounting bolts.
Tighten the throttle body mounting bolts to 15 NSm (11 lb–
ft) if necessary.
Spark Plug Replacement
Replace spark plugs with the same type.
Spark Plug Wire Replacement
Clean wires and inspect them for burns, cracks or other
damage. Check the wire boot fit at the DIS module and at
the spark plugs. Replace the wires as needed.
Brake System Service
Check the disc brake pads and the drum brake linings ev-
ery 15,000 km (9,000 miles) or 12 months. Check the pad
and the lining thickness carefully. If the pads or the linings
are not expected to last to the next scheduledmaintenance
service, replace the pads or the linings. Check the breath-
er hole in the brake fluid reservoir cap to be sure it is free
from dirt and the passage is open.
Transaxle Service
The manual transaxle fluid does not require changing. For
automatic transaxles, refer to ”Scheduled Maintenance
Charts” in this section.
Tire and Wheel Inspection and Rotation
Check the tires for abnormal wear or damage. To equalize
wear and obtain maximum tire life, rotate the tires. If irreg-
ular or premature wear exists, check the wheel alignment
and check for damaged wheels. While the tires and
wheels are removed, inspect the brakes. Refer to ”Each
Time The Oil Is Changed” in this section.
Tire Rotation

GENERAL INFORMATION 0B – 11
DAEWOO V–121 BL4
Chassis and Body
Maintenance ItemMaintenance Interval
Kilometers or time in months, whichever comes first
x 1,000 km1153045607590105120
x 1,000 miles0.6918273645546372
Months–1224364860728496
Interior air filter (A/C)RRRRRRRR
Exhaust pipes & mountingsIIIIIIII
Brake/Clutch fluid (1) (4)IIRIRIRIR
Front brake pads and discs(3)IIIIIIII
Rear brake pads & discs or drums and
linings (3)IIIIIIII
Parking brakeIIIIIIIII
Brake line and connections (Including
booster)IIIIIIII
Manual Transaxle Oil *(1)IIIIIIII
Automatic transaxle fluid *(1) (5)IIIIIIII
Tighten chassis and underbody bolts
and nutsIIIIIIII
Tire condition and inflation pressureIIIIIIIII
Wheel alignment (2)Inspect when abnormal condition is noted
Steering wheel and linkageIIIIIIII
Power steering fluid & lines* (1)IIIIIIIII
Drive shaft bootsIIIIIIII
Seat belts, buckles and anchorsIIIIIIII
Lubricate locks, hinges and hood
latchIIIIIIII
Chart Symbols:
I – Inspect and if necessary correct, clean, replenish, or adjust.
R – Replace or change:
(1) Refer to Recommended Fluids And Lubricants.
(2) And if necessary, rotate and balance wheels.
(3) More frequent if operated under severe conditions: short distance driving, extensive idling, frequent low–speed oper-
aion in stop and go traffic, or driving in dusty conditions.
(4) Change the brake/clutch fluid every 15,000 km (9,000 miles), if the vehicle is mainly driven under the following severe
conditions: driving in hilly or mountainous terrain, or towing a trailer/caravan frequently.
(5) 1.8 DOHC model (ZF 4HP16 Automatic Transaxle): Change automatic transaxle fluid every 60,000 Km (36,000 miles)
if the vehicle is mainly driven under any of the following severe conditions:
S In heavy city traffic where the outside temperature regularly reaches 32°C (90°F) or higher, or
S In hilly or mountainous terrain, or
S When doing frequent trailer towing, or
S Uses such as taxi, police or delivery service.

GENERAL INFORMATION 0B – 15
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
GENERAL REPAIR INSTRUCTIONS
S If a floor jack is used, the following precautions are
recommended.
S Park the vehicle on level ground,
block" the front
or rear wheels, set the jack against the frame, raise
the vehicle and support it with chassis stands and
then perform the service operation.
S Before performing the service operation, disconnect
the negative battery cable in order to reduce the
chance of cable damage and burning due to short–
circuiting.
S Use a cover on the body, the seats and the floor to
protect them against damage and contamination.
S Handle brake fluid and antifreeze solution with care
as they can cause paint damage.
S The use of proper tools, and the recommended es-
sential and available tools where specified, are im-
portant for efficient and reliable performance of the
service repairs.S Use genuine DAEWOO parts.
S Discard used cotter pins, gaskets, O–rings, oil
seals, lock washers and self–locking nuts. Prepare
new ones for installation. Normal function of these
parts cannot be maintained if these parts are re-
used.
S Keep the disassembled parts neatly in groups to
facilitate proper and smooth reassembly.
S Keep attaching bolts and nuts separated, as they
vary in hardness and design depending on the posi-
tion of the installation.
S Clean the parts before inspection or reassembly.
S Also clean the oil parts, etc. Use compressed air to
make certain they are free of restrictions.
S Lubricate rotating and sliding faces of parts with oil
or grease before installation.
S When necessary, use a sealer on gaskets to pre-
vent leakage.
S Carefully observe all specifications for bolt and nut
torques.
S When service operation is completed, make a final
check to be sure service was done properly and the
problem was corrected.

GENERAL ENGINE INFORMATION 1A – 5
DAEWOO V–121 BL4
Heavy Knock Hot with Torque Applied
StepActionValue(s)YesNo
1Is there a heavy knock when the engine is hot and
torque is applied?–Go to Step 2System OK
2Inspect the balancer and the pulley hub.
Is the balancer or the pulley hub broken?–Go to Step 3Go to Step 4
3Replace the broken balancer or the pulley hub.
Is the repair complete?–Go to Step 1–
4Inspect the torque converter bolts.
Are the bolts tightened to specified value?45 NSm
(33 lb–ft)Go to Step 5Go to Step 6
5Tighten the torque converter bolts.
Is the repair complete?–Go to Step 1–
6Inspect the accessory belts.
Are the belts too tight or nicked?–Go to Step 7Go to Step 8
7Replace and/or tension the belts to specifications,
as necessary.
Is the repair complete?–Go to Step 1–
8Inspect the exhaust system.
Is the system grounded?–Go to Step 9Go to Step 10
9Reposition the system, as necessary.
Is the repair complete?–Go to Step 1–
10Inspect the flywheel.
Is the flywheel cracked?–Go to Step 11Go to Step 12
11Replace the flywheel.
Is the repair complete?–Go to Step 1–
12Inspect the main bearing clearance.
Is the clearance more than the specified value?0.026~0.046
mm (0.0010~
0.0018 in.)Go to Step 13Go to Step 14
13Replace the main bearings, as necessary.
Is the repair complete?–Go to Step 1–
14Inspect the rod bearing clearance.
Is the clearance more than the specified value?0.019 ~
0.070 mm
(0.0007 ~
0.0028 in.)Go to Step 15System OK
15Replace the rod bearings, as necessary.
Is the repair complete?–Go to Step 1–

1A – 6IGENERAL ENGINE INFORMATION
DAEWOO V–121 BL4
Light Knock Hot
StepActionValue(s)YesNo
1Is there a light knock when the engine is hot?–Go to Step 2System OK
2Is detonation or spark knock evident?–Go to Step 3Go to Step 4
3Check the engine timing and the fuel quality.
Was the problem found?–Go to Step 1–
4Inspect the torque converter bolts.
Are the bolts tightened to the specified value?45 NSm
(33 lb–ft)Go to Step 5Go to Step 6
5Tighten the torque converter bolts.
Is the repair complete?–Go to Step 1–
6Inspect the manifold.
Is there an exhaust leak at the manifold?–Go to Step 7Go to Step 8
7Tighten the bolts or replace the gasket.
Is the repair complete?–Go to Step 1–
8Check the rod bearing clearance.
Is the clearance within the specified value?0.019 ~
0.070 mm
(0.0007 ~
0.0028 in.)Go to Step 9System OK
9Replace the rod bearings, as necessary.
Is the repair complete?–Go to Step 1–
Knocks During Initial Start–Up But Last Only a Few Seconds
StepActionValue(s)YesNo
1Does the engine knock during initial start–up but last
only a few seconds?–Go to Step 2System OK
2Check the engine oil.
Is the proper viscosity oil used in the crankcase?–Go to Step 4Go to Step 3
3Install oil of the proper viscosity for the expected
seasonal temperatures.
Is the repair complete?–Go to Step 1–
4Inspect the hydraulic lifters.
Is there evidence of hydraulic lifter bleed–down?–Go to Step 5Go to Step 6
5Clean, test and replace the lifters, as necessary.
Is the repair complete?*–Go to Step 1–
6Inspect the crankshaft end clearance.
Is the clearance more than specified value?0.1 mm
(0.0039 in.)Go to Step 7Go to Step 8
7Replace the crankshaft thrust bearing.
Is the repair complete?–Go to Step 1–
8Inspect the front main bearing clearance.
Is the clearance more than the specified value?0.026~0.046
mm (0.0010~
0.0018 in.)Go to Step 9System OK
9Replace the worn parts of the front main bearing.
Is the repair complete?–Go to Step 1–
* When the engine is stopped, some valves will be open. Spring pressure against the lifters will tend to bleed lifter down.
Attempts to repair this should be made only if the problem is consistent.
An engine that is only operated for short periods between start–ups may have lifter noise that lasts for a few minutes. This
is a normal condition.

1A – 8IGENERAL ENGINE INFORMATION
DAEWOO V–121 BL4
NOISE DIAGNOSIS
Main Bearing Noise
StepActionValue(s)YesNo
1Are dull thuds or knocks heard with every engine
revolution?–Go to Step 2System OK
2Check the oil pump pressure.
Is the oil pump pressure low?–Go to Oil Pres-
sure TestGo to Step 3
3Inspect the crankshaft end play.
Does the crankshaft end play exceed the specified
value?0.1 mm
(0.0039 in.)Go to Crank-
shaft Replace-
ment Proce-
dureGo to Step 4
4Inspect the crankshaft journals.
Are the crankshaft journals out–of–round?0.004 mm
(0.0002 in.)
max.Go to Crank-
shaft Replace-
ment Proce-
dureGo to Step 5
5Inspect the belt tension.
Does the belt tension exceed the specified value?–Go to Timing
Belt Replace-
ment Proce-
dureGo to Step 6
6Inspect the crankshaft pulley.
Is the crankshaft pulley loose?–Go to Crank-
shaft Replace-
ment Proce-
dureSystem OK
Connecting Rod Bearing Noise Symptom
StepActionValue(s)YesNo
1Is a knock noise heard under all engine speeds?–Go to Step 2System OK
2Inspect the crankshaft connecting rod journal.
Is the crankshaft connecting rod journal worn?–Go to Crank-
shaft Replace-
ment Proce-
dureGo to Step 3
3Check the oil pump pressure.
Is the oil pump pressure low?–Go to Oil Pres-
sure TestGo to Step 4
4Inspect the crankshaft connecting rod journals.
Are the journals out–of–round?–Go to Crank-
shaft Replace-
ment Proce-
dureGo to Step 5
5Inspect the connecting rods.
Is there a misaligned connecting rod?–Go to Pistons
and Rods Re-
placement Pro-
cedureGo to Step 6
6Inspect the connecting rod bolts.
Are the connecting rod bolts torqued properly?–System OKGo to Pistons
and Rods Re-
placement Pro-
cedure