2004 DAEWOO NUBIRA roof

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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

0B – 6IGENERAL INFORMATION
DAEWOO V–121 BL4
VEHICLE DIMENSIONS AND WEIGHTS
Vehicle Dimensions
Application1.4L DOHC1.6L DOHC1.8L DOHC
Overall Length
4 Door
5 Door H/B4,500 mm (177.2 in.)
4,295 mm (169.1 in.)






Overhang :
4 Door
Front
Rear
885 mm (34.8 in.)
1,015 mm (40.0 in.)






5 Door H/B
Front
Rear
902 mm (35.5 in.)
793 mm (31.2 in.)






Overall Width1,725 mm (67.9 in.)


Overall Height1,445 mm (56.9 in.)


Minimum Ground Clear-
ance160 mm (6.3 in.)


Wheel Base2,600 mm (102.4 in.)


Tread :
Front
Rear1,480 mm (58.3 in.)
1,480 mm (58.3 in.)






Vehicle Weights
4 Door
Application1.4L DOHC1.6L DOHC1.8L DOHC
Manual :
Curb Weight :
Standard
Optional1,175 kg (2,590 lb)
1,225 kg (2,701 lb)1,180 kg (2,601 lb)
1,230 kg (2,712 lb)1,210 kg (2,668 lb)
1,260 kg (2,778 lb)
Gross Vehicle Weight1,660 kg (3,660 lb)1,665 kg (3,671 lb)1,695 kg (3,737 lb)
Automatic :
Curb Weight :
Standard
Optional–
–1,190 kg (2,624 lb)
1,240 kg (2,734 lb)1,235 kg (2,723 lb)
1,285 kg (2,833 lb)
Gross Vehicle Weight–1,675 (3,693 lb)1,720 kg (3,792 lb)
Passenger Capacity5


Optional Weight : ABS, Sun Roof, A/C

GENERAL INFORMATION 0B – 7
DAEWOO V–121 BL4
Vehicle Weights
5 Door H/B
Application1.4L DOHC1.6L DOHC1.8L DOHC
Manual :
Curb Weight :
Standard
Optional1,170 kg (2,580 lb)
1,220 kg (2,690 lb)1,175 kg (2,590 lb)
1,225 kg (2,701 lb)1,205 kg (2,657 lb)
1,255 kg (2,767 lb)
Gross Vehicle Weight1,645 kg (3,627 lb)1,650 kg (3,638 lb)1,680 kg (3,704 lb)
Automatic :
Curb Weight :
Standard
Optional–
–1,185 kg (2,612 lb)
1,235 kg (2,723 lb)1,230 kg (2,712 lb)
1,280 kg (2,822 lb)
Gross Vehicle Weight–1,660 kg (3,660 lb)1,705 kg (3,759 lb)
Passenger Capacity5


Optional Weight : ABS, Sun Roof, A/C

POSITION OF CONNECTORS AND GROUNDSW2–3
2) CONNECTOR INFORMATION
Connector
Number
Te r m i n a l
NumberColorConnecting Wiring
HarnessConnector Position
C10121 PinWhiteBody
Engine Fuse BlockEngine Fuse Block
C10211 P i nWhiteBody
Engine Fuse BlockEngine Fuse Block
C10310 PinWhiteEngine
Engine Fuse BlockEngine Fuse Block
C10424 PinWhiteFront
Engine Fuse BlockEngine Fuse Block
C1054 PinWhiteBody
Engine Fuse BlockEngine Fuse Block
C10620 PinWhiteEngine
Engine Fuse BlockEngine Fuse Block
C1072 PinWhiteABS
Engine Fuse BlockEngine Fuse Block
C10824 PinBlackBody
EngineLeft Engine Fuse Block
C1094 PinWhiteEngine
FrontUnder Engine Fuse Block
C11012 PinWhiteABS
BodyBelow Engine Fuse Block
C 1112 PinBlackABS
FrontBelow Engine Fuse Block
C1122 PinBlackFront – HornCenter Cross Member Panel
C11316 PinBlackBody
FrontBehind ECM Bracket
C20176 PinBlackI.P
I.P Fuse BlockI.P Fuse Block
C20289 PinWhiteI.P
BodyLeft CO–Driver Leg Room
C2048 PinWhiteRoof
Body (W/O Rain Sensor)Left CO–Driver Leg Room
C20414 PinWhiteRoof
Body(W/ Rain Sensor)Left CO–Driver Leg Room
C20622 PinWhiteI.P
TCMUpper Driver Leg Room
C2076 PinWhiteAir Bag
I.PUpper Left Driver Leg Room
C20815 PinWhiteI.P
FAT CBehind Glove Box
C20920 PinBlackFAT C
FAT C . A u xBetween Heater Core and
Evaporator Core
C2106 PinWhiteI.P
ConsoleBelow Console Box
C3018 PinWhiteAir Bag
BodyFront SDM
C3024 PinBlackRR. ABS
BodyCenter Rear Cross Member
C35133 PinGrayBody
Front Light DoorUnder CO–Driver A Pillar
C36133 PinGrayBody
Front Right DoorUnder Driver A Pillar
C37112 PinWhiteBody
Rear Light DoorUnder Left B Pillar
C38112 PinWhiteBody
Rear Right DoorUnder Right B Pillar
C401 (N/B)8 PinWhiteTrunk
BodyInside Right Trunk Side Cover
C401 (H/B)6 PinWhiteTrunk
BodyInside Right Trunk Side Cover
C4026 PinWhiteTrunk LID
BodyInside Right Trunk Side Cover
C4036 PinWhiteT/Gate. EXT. – BodyInside Left C Pillar
C4048 PinWhiteT/Gate. EXT. – BodyInside Left C Pillar
C4058 PinWhiteT/Gate. EXT. – T/GateBeside Left Rear Wiper Motor
C4066 PinWhiteT/Gate. EXT. – T/GateBeside Left Rear Wiper Motor
3) GROUND INFORMATION
Ground Number
Wiring HarnessGround Position
G101FrontBehind Left Head Lamp
G102FrontBehind Right Head Lamp
G103BatteryLeft Battery
G104EngineUnder Start Motor
G105BatteryUnder Start Motor
G106ABSBelow EBCM
G107Engine(MR–140/HV–240)Under Start Motor
G201I.PLeft I/P Fuse Block
G202Air BagBehind Left Audio Bracket
G203I.PBehind Left Audio Bracket
G205RoofUpper Driver Leg Room
G301BodyBelow Driver Cross Member Floor Panel
G302BodyBelow Left C Pillar
G303BodyBelow Left CO–Driver Leg Room
G401TrunkCenter Trunk Lower Back Panel
G402T/Gate. EXT.Inside Driver C Pillar
4) SPLICE PACK INFORMATION
Splice Pack Number
ColorWiring HarnessGround Position
S101BlackEngine(MR–140/HV–240)Upper Transmission
S202BlackI.PBehind Cluster
S203RedI.PBehind Audio Mounting
S204MagentaI.PBehind Audio Mounting
S205OrangeTCM (MR–140/HV–240)Upper Driver Leg Room
S301BlueBodyLeft CO–Driver Leg Room
S302BrownBodyLeft CO–Driver Leg Room

POSITION OF CONNECTORS AND GROUNDSW2–9
9) W/H ROOF10) W/H DRIVE DOOR
11) W/H REAR DOOR

USAGE AND CAPACITY OF FUSES IN FUSE BLOCKW4–3
2. I.P FUSE BLOCK
1) POSITION OF FUSE AND RELAY
2) USAGE OF FUSE IN I.P FUSE BLOCK
Power
Supply
ClassificationFuse
NoCapacityUsage
IGN1 (15)Blade TypeF110ASDM
FuseF210ATCM, ECM, Generator, VGIS,VSS
F315AHazard Switch
F410ACluster, Chime Bell, Brake Switch, SSPS Module,
A/C Control Switch
–F5––
IGN2 (15A)F610AA/C Comp. Relay, Defog Relay, Power Window
Relay, Head Lamp Relay
F720ABlower Relay, A/C Control Switch, FATC
F815AElectric Mirror Switch, Folding Mirror, Sun Roof
Module
IGN1 (15)F925AWiper Motor, Wiper Switch
–F10––
IGN1 (15)F1110AEBCM, Oil Feeding Connector
F1210AImmobilizer, Anti Theft Control Unit, Rain Sensor
Unit
30 BAT(+)F1310ATCM
F1415AHazard Switch
F1515AAnti Theft Control Unit
F1610ADLC
ACC (15C)F1710AAudio, Clock
F1815AExtra Power Jack
F1915ACigar Lighter
IGN1 (15)F2010AReverse Lamp Switch, PNP Switch
30 BAT(+)F2115ARear Fog Relay
F2215AClock, FATC, A/C Control Switch
F2315AAudio
F2410AImmobilizer

ELECTRICAL WIRING DIAGRAMSW5–5
14. STOP LAMP, CENTER HIGH MOUNT STOP LAMP (CHMSL) & REVERSE LAMP CIRCUIT 5–102. . . . . . . . . . . .
1) MR–140/HV–240 : NOTCH BACK 5–102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2) MR–140/HV–240 : HATCH BACK 5–104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3) SIRIUS D4 : NOTCH BACK5–106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4) SIRIUS D4 : HATCH BACK5–108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15. TRUNK/TAIL GATE OPEN SWITCH, TRUNK LATCH SWITCH, TRUNK ROOM LAMP & HORN
CIRCUIT5–110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1) DUAL HORN5–110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2) SIGNLE HORN5–112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16. LAMPS(MAP & ROOM) CIRCUIT5–114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1) W/O SUN ROOF & W/ DECAY5–114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2) W/ SUN ROOF & W/ DECAY5–116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3) W/O SUN ROOF & W/O DECAY 5–118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4) W/ SUN ROOF & W/O DECAY5–120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17. CLOCK, CIGAR LIGHTER,ASHTRAY ILLUM. LAMP & EXTRA POWER JACK CIRCUIT 5–122. . . . . . . . . . . . . .
1) M/T5–122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2) A/T5–124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18. CHIME BELL, SEAT BELT & KEY REMIND SWITCH CIRCUIT 5–126. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19. WIPER CIRCUIT5–128 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1) W/O RAIN SENSOR & AIR CONDITIONER : NOTCH BACK 5–128. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2) W/O RAIN SENSOR & AIR CONDITIONER : HATCH BACK 5–130. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3) W/ RAIN SENSOR & AIR CONDITIONER : NOTCH BACK 5–132. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4) W/ RAIN SENSOR & AIR CONDITIONER : HATCH BACK 5–134. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5) W/O RAIN SENSOR & FATC : NOTCH BACK 5–136. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6) W/O RAIN SENSOR & FATC : HATCH BACK 5–138. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7) W/ RAIN SENSOR & FATC : NOTCH BACK 5–140. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8) W/ RAIN SENSOR & FATC : HATCH BACK 5–142. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL WIRING DIAGRAMSW5–7
29. SUN ROOF CIRCUIT5–180 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30. SSPS(SPEED SENSITIVE POWER STEERING) CIRCUIT 5–182. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31. IMMOBILIZER SYSTEM CIRCUIT5–184 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32. ANTI THEFT CONTROL SYSTEM CIRCUIT 5–186. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1) NOTCH BACK5–186 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2) HATCH BACK5–188 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .