2004 DAEWOO NUBIRA parking brake

i
PERSONAL INJURY CAUTION
Appropriate service methods and proper repair procedures are essential
for the safe, reliable operation of all motor vehicles, as well as for the per-
sonal safety of the person doing the repair. There are many variations in
procedures, techniques, tools and parts for servicing vehicles, as well as
in the skills of the people doing the work. This manual cannot possibly
anticipate all such variations and provide advice or precautions for each.
Anyone who deviates from the instructions provided in this manual must
ensure their own safety and preserve the safety and integrity of the ve-
hicle. The following list contains general precautions that should always
be followed while working on a vehicle.
DSafety stands are required whenever a procedure calls for under-
body work.
DDo not smoke when you work on a vehicle.
DTo prevent serious burns, do not touch any hot metal parts.
DSet the parking brake when you work on the vehicle.
DTurn the ignition switch OFF unless a procedure states otherwise.
DThe engine may operate only in a well-ventilated area.
DAvoid moving parts when the engine is running.
DSafety glasses must be worn for eye protection.

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TABLE OF CONTENTS
Section 0B General Information
Section 1 Engine
Section 1A General Engine Information
Section 1C1 1.4L/1.6L DOHC Engine Mechanical
Section 1C2 1.8L DOHC Engine Mechanical
Section 1D Engine Cooling
Section 1E Engine Electrical
Section 1F Engine Controls
Section 1G Engine Exhaust
Section 2 Suspension
Section 2A Suspension Diagnosis
Section 2B Wheel Alignment
Section 2C Front Suspension
Section 2D Rear Suspension
Section 2E Tires and Wheels
Section 3 Driveline/Axle
Section 3A Automatic Transaxle Drive Axle
Section 3B Manual Transaxle Drive Axle
Section 4 Brakes
Section 4A Hydraulic Brakes
Section 4B Master Cylinder
Section 4C Power Booster
Section 4D Front Disc Brakes
Section 4E1 Rear Disc Brakes
Section 4E2 Rear Drum Brakes
Section 4F Antilock Brake System
Section 4G Parking Brake
Section 5 Transmission/Transaxle
Section 5A1 ZF 4HP16 Automatic Transaxle
Section 5A2 AISIN Automatic Transaxle
Section 5B Five-Speed Manual Transaxle
Section 5C Clutch
Section 6 Steering
Section 6A Power Steering System
Section 6B Power Steering PumpSection 6C Power Steering Gear
Section 6E Steering Wheel and Column
Section 7 Heating, Ventilation, and Air
Conditioning (HVAC)
Section 7A Heating and Ventilation System
Section 7B Manual Control Heating, Ventilation,
and Air Conditioning System
Section 7D Automatic Temperature Control HVAC
Section 8 Restraints
Section 8A Seat Belts
Section 8B Supplemental Inflatable Restraints
(SIR)
Section 9 Body and Accessories
Section 9A Body Wiring System
Section 9B Lighting Systems
Section 9C Horns
Section 9D Wipers/Washer Systems
Section 9E Instrumentation/Driver Information
Section 9F Audio Systems
Section 9G Interior Trim
Section 9H Seats
Section 9I Waterleaks
Section 9J Windnoise
Section 9K Squeaks and Rattles
Section 9L Glass and Mirrors
Section 9M Exterior Trim
Section 9N Frame and Underbody
Section 9O Bumpers and Fascias
Section 9P Doors
Section 9Q Roof
Section 9R Body Front End
Section 9S Body Rear End
Section 9T1 Remote Keyless Entry and Anti–Theft
System
Section 9T2 Immobilizer Anti–Theft System

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.

0B – 12IGENERAL INFORMATION
DAEWOO V–121 BL4
OWNER INSPECTIONS AND SERVICES
WHLE OPERATING THE VEHICLE
Horn Operation
Blow the horn occasionally tomake sure it works. Check
all the button locations.
Brake System Operation
Be alert for abnormal sounds, increased brake pedal trav-
el or repeated pulling to one side when braking. Also, if the
brake warning light goes on, or flashes, something may be
wrong with part of the brake system.
Exhaust System Operation
Be alert to any changes in the sound of the system or the
smell of the fumes. These are signs that the system may
be leaking or overheating. Have the system inspected and
repaired immediately.
Tires,Wheels and Alignment Operation
Be alert to any vibration of the steering wheel or the seats
at normal highway speeds. This may mean a wheel needs
to be balanced. Also, a pull right or left on a straight, level
road may show the need for a tire pressure adjustment or
a wheel alignment.
Steering System Operation
Be alert to changes in the steering action. An inspection
is needed when the steering wheel is hard to turn or has
too much free play, or if unusual sounds are noticed when
turning or parking.
Headlight Aim
Take note of the light pattern occasionally. Adjust the
headlights if the beams seem improperly aimed.
AT EACH FUEL FILL
A fluid loss in any (except windshield washer) system may
indicate a problem. Have the system inspected and re-
paired immediately.
Engine Oil Level
Check the oil level and add oil if necessary. The best time
to check the engine oil level is when the oil is warm.
1. After stopping the engine, wait a few minutes for
the oil to drain back to the oil pan.
2. Pull out the oil level indicator (dip stick).
3. Wipe it clean, and push the oil level indicator back
down all the way.
4. Pull out the oil level indicator and look at the oil lev-
el on it.
5. Add oil, if needed, to keep the oil level above the
MIN line and within the area labeled ”Operating
Range.” Avoid overfilling the engine, since this may
cause engine damage.
6. Push the indicator all the way back down into the
engine after taking the reading.If you check the oil level when the oil is cold, do not run the
engine first. The cold oil will not drain back to the pan fast
enough to give a true oil level reading.
Engine Coolant Level and Condition
Check the coolant level in the coolant reservoir tank and
add coolant if necessary. Inspect the coolant. Replace
dirty or rusty coolant.
Windshield Washer Fluid Level
Check the washer fluid level in the reservoir. Add fluid if
necessary.
AT LEAST MONTHLY
Tire And Wheel Inspection and Pressure
Check
Check the tires for abnormal wear or damage. Also check
for damaged wheels. Check the tire pressure when the
tires are cold (check the spare also, unless it is a stow-
away). Maintain the recommended pressures that are on
the tire placard that is in the glove box.
Light Operation
Check the operation of the license plate light, the head-
lights (including the high beams), the parking lights, the
fog lights, the taillight, the brake lights, the turn signals, the
backup lights and the hazard warning flasher.
Fluid Leak Check
Periodically inspect the surface beneath the vehicle for
water, oil, fuel or other fluids, after the vehicle has been
parked for a while. Water dripping from the air conditioning
system after use is normal. If you notice fuel leaks or
fumes, find the cause and correct it at once.
AT LEAST TWICE A YEAR
Power Steering System Reservoir Level
Check the power steering fluid level. Keep the power
steering fluid at the proper level. Refer to Section 6A, Pow-
er Steering System.
Brake Master Cylinder Reservoir Level
Check the fluid and keep it at the proper level. A low fluid
level can indicate worn disc brake pads which may need
to be serviced. Check the breather hole in the reservoir
cover to be free from dirt and check for an open passage.
Clutch Pedal Free Travel
Check clutch pedal free travel and adjust as necessary.
Measure the distance from the center of the clutch pedal
to the outer edge of the steering wheel with the clutch ped-
al not depressed. Then measure the distance from the
center of the clutch pedal to the outer edge of the steering
wheel with the clutch pedal fully depressed. The difference
between the two values must be greater than 130 mm
(5.19 inches).
Weather–Strip Lubrication
Apply a thin film silicone grease using a clean cloth.

GENERAL INFORMATION 0B – 13
DAEWOO V–121 BL4
EACH TIME THE OIL IS CHANGED
Automatic Transaxle Fluid
Refer to fluid level service procedure of Section 5A, ZF
4HP16 Automatic Transaxle.
Manual Transaxle
Check the fluid level and add fluid as required. Refer to
Section 5B, Five–Speed Manual Transaxle.
Brake System Inspection
This inspection should be done when the wheels are re-
moved for rotation. Inspect the lines and the hoses for
proper hookup, binding, leaks, cracks, chafing, etc. In-
spect the disc brake pads for wear. Inspect the rotors for
surface condition. Also inspect the drum brake linings for
wear and cracks. Inspect other brake parts, including the
drums, the wheels cylinders, the parking brake, etc., at the
same time. Check the parking brake adjustment. Inspect
the brakes more often if habit or conditions result in fre-
quent braking.
Steering, Suspension and Front Drive Axle
Boot And Seal Inspection
Inspect the front and rear suspension and the steering
system for damaged, loose or missing parts, signs of wear
or lack of lubrication. Inspect the power steering lines and
the hoses for proper hookup, binding, leaks, cracks, chaf-
ing, etc. Clean and inspect the drive axle boot and seals
for damage, tears or leakage. Replace the seals if neces-
sary.
Exhaust System Inspection
Inspect the complete system (including the catalytic con-
verter if equipped). Inspect the body near the exhaust sys-
tem. Look for broken, damaged, missing, or out–of–posi-
tion parts as well as open seams, holes, loose
connections, or other conditions which could cause heat
buildup in the floor pan or could let exhaust fumes seep
into the trunk or passenger compartment.
Throttle Linkage Inspection
Inspect the throttle linkage for interference or binding,
damaged, or missing parts. Lubricate all linkage joints and
throttle cable joints, the intermediate throttle shaft bearing,
the return spring at throttle valve assembly, and the accel-
erator pedal sliding face with suitable grease. Check the
throttle cable for free movements.
Engine Drive Belts
Inspect all belts for cracks, fraying, wear and proper ten-
sion. Adjust or replace the belts as needed.
Hood Latch Operation
When opening the hood, note the operation of the secon-
dary latch. It should keep the hood from opening all the
way when the primary latch is released. The hood must
close firmly.
AT LEAST ANNUALLY
Lap and Shoulder Belts Condition and
Operation
Inspect the belt system including: the webbing, the
buckles, the latch plates, the retractor, the guide loops and
the anchors.
Movable Head Restraint Operation
On vehicles with movable head restraints, the restraints
must stay in the desired position.
Spare Tire and Jack Storage
Be alert to rattles in the rear of the vehicle. The spare tire,
all the jacking equipment, and the tools must be securely
stowed at all times. Oil the jack ratchet or the screw mech-
anism after each use.
Key Lock Service
Lubricate the key lock cylinder.
Body Lubrication Service
Lubricate all the body door hinges including the hood, the
fuel door, the rear compartment hinges and the latches,
the glove box and the console doors, and any folding seat
hardware.
Transaxle Neutral Switch Operation on
Automatic Transaxle
CAUTION : Take the following precautions because
the vehicle could move without warning and possibly
cause personal injury or property damage:
S Firmly apply the parking brake and the regular
brakes.
S Do not use the accelerator pedal.
S Be ready to promptly turn off the ignition if the ve-
hicle starts.
On automatic transaxle vehicles, try to start the engine in
each gear. The starter should crank only in P (Park) or N
(Neutral).
Parking Brake and Transaxle P (Park)
Mechanism Operation
CAUTION : In order to reduce the risk of personal in-
jury or property damage, be prepared to apply the reg-
ular brakes promptly if the vehicle begins to move.
Park on a fairly steep hill with enough room for movement
in the downhill direction. To check the parking brake, with
the engine running and the transaxle in N (Neutral), slowly
remove foot pressure from the regular brake pedal (until
only the parking brake is holding the vehicle).
To check the automatic transaxle P (Park) mechanism’s
holding ability, release all brakes after shifting the trans-
axle to P (Park).
Underbody Flushing
Flushing the underbody will remove any corrosive materi-
als used for ice and snow removal and dust control. At
least every spring clean the underbody. First, loosen the
sediment packed in closed areas of the vehicle. Then flush
the underbody with plain water.

ENGINE ELECTRICAL 1E – 31
DAEWOO V–121 BL4
trolyte and the plates are at room temperature. A
battery that is extremely cold may not accept cur-
rent for several hours after starting the charger.
3. Charge the battery until the green dot appears. The
battery should be checked every half–hour while
charging. Tipping or shaking the battery may be
necessary to make the green dot appear.
4. After charging, the battery should be load tested.
Refer to ”Starter Motor” in this section.
CHARGING TIME REQUIRED
The time required to charge a battery will vary depending
upon the following factors:
S Size of Battery – A completely discharged large
heavy–duty battery requires more than twice the re-
charging time as a completely discharged small pas-
senger car battery.
S Temperature – A longer time will be needed to
charge any battery at –18°C (0°F) than at 27°C
(80°F). When a fast charger is connected to a cold
battery, the current accepted by the battery will be
very low at first. The battery will accept a higher cur-
rent rate as the battery warms.
S Charger Capacity – A charger which can supply only
5 amperes will require a much longer charging period
than a charger that can supply 30 amperes or more.
S State–of–Charge – A completely discharged battery
requires more than twice as much charge as a one–
half charged battery. Because the electrolyte is nearly
pure water and a poor conductor in a completely dis-
charged battery, the current accepted by the battery
is very low at first. Later, as the charging current
causes the electrolyte acid content to increase, the
charging current will likewise increase.
CHARGING A COMPLETELY
DISCHARGED BATTERY (OFF THE
VEHICLE)
Unless this procedure is properly followed, a perfectly
good battery may need to be replaced.
The following procedure should be used to recharge a
completely discharged battery:
1. Measure the voltage at the battery terminals with
an accurate voltmeter. If the reading is below 10
volts, the charge current will be very low, and it
could take some time before the battery accepts
the current in excess of a few milliamperes. Refer
to ””Charging Time Required” in this section, which
focuses on the factors affecting both the charging
time required and the rough estimates in the table
below. Such low current may not be detectable on
ammeters available in the field.
2. Set the battery charger on the high setting.Important : Some chargers feature polarity protection cir-
cuitry, which prevents charging unless the charger leads
are correctly connected to the battery terminals. A com-
pletely discharged battery may not have enough voltage
to activate this circuitry, even though the leads are con-
nected properly, making it appear that the battery will not
accept charging current. Therefore, follow the specific
charger manufacturer’s instruction for bypassing or over-
riding the circuitry so that the charger will turn on and
charge a low–voltage battery.
3. Continue to charge the battery until the charge cur-
rent is measurable. Battery chargers vary in the
amount of voltage and current provided. The time
required for the battery to accept a measurable
charge current at various voltages may be as fol-
lows:
Voltage
Hours
16.0 or moreUp to 4 hours
14.0–15.9Up to 8 hours
13.9 or lessUp to 16 hours
S If the charge current is not measurable at the
end of the above charging times, the battery
should be replaced.
S If the charge current is measurable during the
charging time, the battery is good, and charging
should be completed in the normal manner.
Important : It is important to remember that a completely
discharged battery must be recharged for a sufficient num-
ber of ampere hours (AH) to restore the battery to a usable
state. As a general rule, using the reserve capacity rating
(RC) as the number of ampere hours of charge usually
brings the green dot into view.
S If the charge current is still not measurable after
using the charging time calculated by the above
method, the battery should be replaced.
JUMP STARTING PROCEDURE
1. Position the vehicle with the good (charged) battery
so that the jumper cables will reach.
2. Turn off the ignition, all the lights, and all the electri-
cal loads in both vehicles. Leave the hazard flasher
on if jump starting where there may be other traffic
and any other lights needed for the work area.
3. In both vehicles, apply the parking brake firmly.
Notice : To avoid vehicle damage,Make sure the cables
are not on or near pulleys, fans, or other parts that will
move when the engine starts.
4. Shift an automatic transaxle to PARK, or a manual
transaxle to NEUTRAL.
CAUTION : In order to avoid injury, do not use cables
that have loose or missing insulation.
5. Clamp one end of the first jumper cable to the posi-
tive terminal on the battery. Make sure it does not
touch any other metal parts. Clamp the other end of

1F – 30IENGINE CONTROLS
DAEWOO V–121 BL4
DIAGNOSIS
SYSTEM DIAGNOSIS
DIAGNOSTIC AIDS
If an intermittent problem is evident, follow the guidelines
below.
Preliminary Checks
Before using this section you should have already per-
formed the ”On–Board Diagnostic System Check.”
Perform a thorough visual inspection. This inspection can
often lead to correcting a problem without further checks
and can save valuable time. Inspect for the following con-
ditions:
S Engine control module (ECM) grounds for being
clean, tight, and in their proper location.
S Vacuum hoses for splits, kinks, collapsing and prop-
er connections as shown on the Vehicle Emission
Control Information label. Inspect thoroughly for
any type of leak or restriction.
S Air leaks at the throttle body mounting area and the
intake manifold sealing surfaces.
S Ignition wires for cracks, hardness, proper routing,
and carbon tracking.
S Wiring for proper connections.
S Wiring for pinches or cuts.
Diagnostic Trouble Code Tables
Do not use the Diagnostic Trouble Code (DTC) tables to
try to correct an intermittent fault. The fault must be pres-
ent to locate the problem.
Incorrect use of the DTC tables may result in the unneces-
sary replacement of parts.
Faulty Electrical Connections or Wiring
Most intermittent problems are caused by faulty electrical
connections or wiring. Perform a careful inspection of sus-
pect circuits for the following:
S Poor mating of the connector halves.
S Terminals not fully seated in the connector body.
S Improperly formed or damaged terminals. All con-
nector terminals in a problem circuit should be care-
fully inspected, reformed, or replaced to insure con-
tact tension.S Poor terminal–to–wire connection. This requires
removing the terminal from the connector body.
Road Test
If a visual inspection does not find the cause of the prob-
lem, the vehicle can be driven with a voltmeter or a scan
tool connected to a suspected circuit. An abnormal voltage
or scan tool reading will indicate that the problem is in that
circuit.
If there are no wiring or connector problems found and a
DTC was stored for a circuit having a sensor, except for
DTC P0171 and DTC P0172, replace the sensor.
Fuel System
Some intermittent driveability problems can be attributed
to poor fuel quality. If a vehicle is occasionally running
rough, stalling, or otherwise performing badly, ask the cus-
tomer about the following fuel buying habits:
S Do they always buy from the same source? If so,
fuel quality problems can usually be discounted.
S Do they buy their fuel from whichever fuel station
that is advertising the lowest price? If so, check the
fuel tank for signs of debris, water, or other contam-
ination.
IDLE LEARN PROCEDURE
Whenever the battery cables, the engine control module
(ECM), or the ECM fuse is disconnected or replaced, the
following idle learn procedure must be performed:
1. Turn the ignition ON for 5 seconds.
2. Turn the ignition OFF for 5 seconds.
3. Turn the ignition ON for 5 seconds.
4. Start the engine in park/neutral.
5. Allow the engine to run until the engine coolant is
above 185° F (85°C ).
6. Turn the A/C ON for 10 seconds, if equipped.
7. Turn the A/C OFF for 10 seconds, if equipped.
8. If the vehicle is equipped with an automatic trans-
axle, apply the parking brake. While pressing the
brake pedal, place the transaxle in D (drive).
9. Turn the A/C ON for 10 seconds, if equipped.
10. Turn the A/C OFF for 10 seconds, if equipped.
11. Turn the ignition OFF. The idle learn procedure is
complete.

ENGINE CONTROLS 1F – 31
DAEWOO V–121 BL4
TEC (TOOTH ERROR CORRECTION)
LEARN PROCEDURE
When an ECM is reflashed, initialized or replaced, and dri-
veplate of fly wheel has been replaced, follow these proce-
dures to relearn the crankshaft position (CKP) system
variation :
CAUTION : To avoid personal injury when performing
the TEC learn procedure, always set the vehicle park-
ing brake and block the drive wheels. Release the
throttle immediately when the engine starts to decel-
erate. Once the learning procedure is completed, en-
gine control will be learned to the operator, and the
engine will respond to throttle position.1. Stay the gear parking or neutral.
2. Install the scan tool and select ”TEC (Toth Error
Correction) LEARN” menu.
3. Start the engine with A/C off.
4. Keep the engine coolant temperature above 65°C
(149° F)
5. Put the acceleration pedal above 4000 RPM until
the fuel cut–off occurs.
6. Wait 10–15 seconds.
7. Fulfill this procedure again if the scan tool does not
display ”OK” message.
8. Turn the ignition switch OFF.
9. Turn the ignition swtich ON and then clear the DTC
code.