2004 DAEWOO NUBIRA wheel nut

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 – 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.

1A – 4IGENERAL ENGINE INFORMATION
DAEWOO V–121 BL4
Repairing the Leak
Once the origin of the leak has been pinpointed and traced
back to its source, the cause of the leak must be deter-
mined in order for it to be repaired properly. If a gasket is
replaced, but the sealing flange is bent, the new gasket will
not repair the leak. The bent flange must be repaired also.
Before attempting to repair a leak, check for the following
conditions and correct them as they may cause a leak.
Gaskets:
S The fluid level/pressure is too high.
S The crankcase ventilation system is malfunctioning.
S The fasteners are improperly tightened or the
threads are dirty or damaged.
S The flanges or the sealing surface is warped.S There are scratches, burrs or other damage to the
sealing surface.
S The gasket is damaged or worn.
S There is cracking or porosity of the component.
S An improper seal was used, (where applicable).
Seals:
S The fluid level/pressure is too high.
S The crankcase ventilation system is malfunctioning.
S The seal bore is damaged, scratched, burred or
nicked.
S The seal is damaged or worn.
S Improper installation is evident.
S There are cracks in the component.
S The shaft surface is scratched, nicked or damaged.
S A loose or worn bearing is causing excess seal
wear.
KNOCK DIAGNOSIS
Definition for Knock
Engine knock refers to various types of engine noise.
Heavy knock is usually very loud and the result of broken
or excessively worn internal engine components. Lightknock is a noticeable noise, but not as loud. Light knock
can be caused by worn internal engine components.
Loose or broken external engine components can also
cause heavy or light knock.
Engine Knocks Cold and Continues for Two–Three Minutes and/or
Knock Increases with Engine Torque
StepActionValue(s)YesNo
1Does the engine knock when it is cold and continue
for two to three minutes or does the knock increase
with torque?–Go to Step 2System OK
2Inspect the flywheel.
Is the flywheel contacting the splash shield?–Go to Step 3Go to Step 4
3Reposition the splash shield.
Is the repair complete?–Go to Step 1–
4Inspect the balancer and the drive pulleys.
Is either the balancer or the drive pulleys loose or
broken?–Go to Step 5Go to Step 6
5Tighten or replace the balancer or the drive pulleys.
Is the repair complete?–Go to Step 1–
6Inspect the piston–to–bore clearance.
Is the clearance more than the specified value?0.030 mm
(0.001 in.)Go to Step 7Go to Step 8
71. Rebore the cylinder and hone to size.
2. Replace the piston.
Is the repair complete?*–Go to Step 1–
8Inspect the connecting rod.
Is the connecting rod bent?–Go to Step 9System OK
9Replace the connecting rod.
Is the repair complete?–Go to Step 1–
* Cold engine piston knock usually disappears when the cylinder is grounded out. Cold engine piston knock, which disap-
pears in about 1.5 minutes, is considered acceptable.

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 5
DAEWOO V–121 BL4
FASTENER TIGHTENING SPECIFCATIONS
ApplicationNSmLb–FtLb–In
Air Cleaner Housing Bolts10–89
Camshaft Cap Bolts1612–
Camshaft Cover Nuts10–89
Connecting Rod Bearing Cap Bolts25
+ 30° + 15°18
+ 30° + 15°–
Coolant Temperature Sensor2015–
Crankshaft Bearing Cap Bolts50
+ 45° + 15°37
+ 45°+ 15°–
Crankshaft Cover Nuts5~8–44~71
Crankshaft Pulley Bolt95 NSm
+ 30° + 15°––
Cylinder Head Bolts (Cylinder Head Mounting Bolts)25 + 70°
+ 70° + 50°18 + 70°
+ 70° + 50°–
Direct Ignition System Coil Mounting Bolts10–89
Direct Ignition System Coil Mounting Bracket Bolts10–89
Engine Mount Attaching Bolts3022–
Engine Mount Bracket Attaching Bolts/Nuts5037–
Exhaust Camshaft Gear Bolt67.549–
Exhaust Flex Pipe–to–Catalytic Converter or Connecting Pipe
Retaining Nut3526–
Exhaust Flex Pipe–to–Exhaust Manifold Retaining Nuts3526–
Exhaust Gas Recirculation Valve Adapter Bolts2518–
Exhaust Manifold Heat Shield Bolts1511–
Exhaust Manifold Retaining Nuts2518–
Flexible Plate Bolts6044–
Flexible Plate Inspection Cover Bolts10–89
Flywheel Bolts35
+ 30° + 15°25
+ 30° + 15°–
Flywheel Inspection Cover Bolts12–106
Front Timing Belt Cover Bolts (Upper and Lower)10–89
Fuel Rail Assembly Retaining Bolts2518–
Fuel Rail Retaining Bolts2518–
Generator Upper Retaining Bolt2015–
Intake Camshaft Gear Bolt67.549–
Intake Manifold Retaining Bolts/Nuts2518–
Intake Manifold Support Bracket Lower Bolt2518–
Intake Manifold Support Bracket Upper Bolts2518–
Lower Front Timing Belt Cover Bolts10–89
Oil Pan Flange Bolts7555–
Oil Pan Retaining Bolts10–89
Oil Pan Drain Plug3526–
OIl Pressure Switch4030–

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 65
DAEWOO V–121 BL4
28. Install the fuel rail assembly with the bolts.
Tighten
Tighten the fuel rail assembly retaining bolts to 25
NSm (18 lb–ft).
29. Install the thermostat housing assembly.
30. Install the thermostat housing mounting bolts.
Tighten
Tighten the thermostat housing mounting bolts to 20
NSm (15 lb–ft).
31. Install the exhaust manifold studs.
32. Install the exhaust manifold gasket.
33. Install the exhaust manifold.
34. Install the exhaust manifold retaining nuts in the
sequence shown.
Tighten
Tighten the exhaust manifold retaining nuts to 25 NSm
(18 lb–ft).
35. Install the exhaust manifold heat shield.
36. Install the exhaust manifold heat shield bolts.
Tighten
Tighten the exhaust manifold heat shield bolts to 15
NSm (11 lb–ft).
37. Install the ECT sensor.
Tighten
Tighten the engine coolant temperature sensor to 20
NSm (15 lb–ft).
38. Install the cylinder head with the intake manifold
and the exhaust manifold attached. Refer to ”Cylin-
der Head and Gasket” in this section.
CRANKSHAFT
Tools Required
KM–412 Engine Overhaul Stand
J–42492 Timing Belt Adjuster
KM–470–B Angular Torque Gauge
J–36792 or KM–635 Crankshaft Rear Oil Seal Installer
Notice : Take extreme care to prevent any scratches,
nicks, or damage to the camshafts.
Disassembly Procedure
1. Remove the engine. Refer to ”Engine” in this sec-
tion.
2. Remove the flywheel or flexible plate bolts.
3. Remove the flywheel or the flexible plate.

1C2 – 4I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
FASTENER TIGHTENING SPECIFCATIONS
ApplicationNSmLb–FtLb–In
Air Cleaner Housing Bolts10–89
Automatic Tensioner Bolt2518–
Camshaft Bearing Bridge and Oil Pan Scraper Bolts20 + 45°15 + 45°–
Camshaft Bearing Cap Bolts8–71
Camshaft Cover Bolts8–71
Charcoal Canister Purge and Exhaust Gas Recirculation Sole-
noid Bracket Bolt5–44
Connecting Rod Bearing Cap Bolts35
+ 45° + 15°26
+ 45° + 15°–
Coolant Bypass Housing and Mounting Bolts1511–
Crankshaft Bearing Cap Bolts50
+ 45° + 15°37
+ 45° + 15°–
Crankshaft Pulley Bolts2015–
Crankshaft Gear Bolt145
+ 30° + 15°107
+ 30° + 15°–
Cylinder Head Bolts25 + 90°
+ 90° + 90°18 + 90°
+ 90° + 90°–
Direct Ignition System Coil and Exhaust Gas Recirculation
Mounting Bracket Bolts2518–
Engine Mount Bracket Retaining Bolts and Nuts5541–
Engine Mount Retaining Bolts4533–
Engine–to–Intake Manifold Support Bracket Bolts2015–
Exhaust Camshaft Gear Bolt50
+ 60° + 15°37
+ 60° + 15°–
Exhaust Flex Pipe–to–Catalytic Converter or Connecting Pipe
Retaining Nuts3526–
Exhaust Flex Pipe–to–Exhaust Manifold Retaining Nuts3526–
Exhaust Manifold Heat Shield Bolts8–71
Exhaust Manifold Retaining Nuts2216–
Flexible Plate Bolts4533–
Flywheel Bolts65
+ 30° + 15°48
+ 30° + 15°–
Front Timing Belt Cover Bolts6–53
Generator–to–Intake Manifold Strap Bracket Bolt2216–
Generator–to–Intake Manifold Support Bracket Bolts3727–
Intake Camshaft Gear Bolt50
+ 60° + 15°37
+ 60° + 15°–
Intake Manifold Retaining Bolt and Nuts2216–
Intake Manifold Support Bracket Lower Bolt2518–
Intake Manifold Support Bracket Upper Bolts2518–
Lower Block Support Bracket and Splash Shield Bolts3526–
Oil Pan Drain Plug3526–
Oil Pan Flange–to–Transaxle Bolts4030–

1.8L DOHC ENGINE MECHANICAL 1C2 – 11
DAEWOO V–121 BL4
1. Connecting Rod
2. Bearing Set
3. Connecting Rod Bolt
4. Piston Ring Set
5. Piston Pin
6. Piston
7. Engine Block
8. Sleeve
9. Water Jacket Cap
10. Bolt (Manual Transaxle)
11. Flywheel (Manual Transaxle)
12. Flexible Plate (Automatic Transaxle)
13. Bolt (Automatic Transaxle)
14. Clamp
15. Hose
16. Clamp
17. Engine Ventilation Pipe
18. Bolt
19. Gasket
20. Needle Sleeve
21. Crankshaft Rear Seal
22. Crankshaft
23. Transmitter Disk
24. Bolt
25. Oil Pan Scraper
26. Oil Pan
27. Drain Plug
28. Washer
29. Bolt
30. Sleeve
31. Gasket
32. Bolt
33. Oil Pump Cover
34. Ring Gear
35. Gear
36. Oil Pressure Switch
37. Washer
38. Washer
39. Oil Duct Outlet Plug
40. Connecting Piece
41. Seal Ring
42. Oil Filter43. Bypass Valve
44. Pressure Relief Valve Plunger
45. Pressure Relief Valve Spring
46. Seal Ring
47. Pressure Relief Valve Plug
48. Seal Ring
49. Bolt
50. Oil Suction Pipe
51. Bolt
52. Rear Timing Belt Cover
53. Bolt
54. Special Bolt
55. Idler Pulley
56. Stud
57. Nut
58. Bolt
59. Tensioner
60. Bolt
61. Thrust Inner Washer
62. Woodruff Key
63. Crankshaft Gear
64. Thrust Outer Washer
65. Bolt
66. Camshaft Drive Belt
67. Gasket
68. Front Timing Belt Cover
69. Bolt
70. Bushing Plug
71. Bushing
72. Oil Gallery Plug
73. Bolt
74. Water Pump
75. Seal Ring
76. Crankshaft Position Sensor
77. Bolt
78. Knock Sensor*
79. Bolt
80. Bolt
81. Crankshaft Bearing Bridge
* : 2.0L DOHC Engine