DAEWOO Nubira 1998 Service Manual

SECTION : 0B

GENERAL INFORMATION

TABLE OF CONTENTS

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 0B–1 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . 0B–1 VEHICLE DIMENSIONS AND WEIGHTS . . . . . 0B–5 STANDARD BOLT SPECIFICATIONS . . . . . . . . 0B–7

MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 0B–8 MAINTENANCE AND LUBRICATION . . . . . . . . . . 0B–8 NORMAL VEHICLE USE . . . . . . . . . . . . . . . . . . . 0B–8

EXPLANATION OF SCHEDULED MAINTENANCE SERVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B–8

SCHEDULED MAINTENANCE CHARTS . . . . 0B–10

OWNER INSPECTIONS AND SERVICES . . . . . 0B–12 WHILE 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–15

GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B–16

GENERAL REPAIR INSTRUCTIONS . . . . . . . 0B–16

GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . 0B–17

ON BOARD REFUELING VAPOR RECOVERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B–17

VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . 0B–20 VEHICLE LIFTING PROCEDURES . . . . . . . . . 0B–24

SPECIFICATIONS

TECHNICAL DATA

Performance – Manual Transaxle

Application	2.0L DOHC
Maximum Speed	195 km/h (122 mph)
Gradeability	0.446 (tan Ø)
Minimum Turning Radius	5.3 m (17 ft)

Performance – Automatic Transaxle

Application	2.0L DOHC
Maximum Speed	190 km/h (119mph)
Gradeability	0.668 (tan Ø)
Minimum Turning Radius	5.3 m (17 ft)

0B – 2 GENERAL INFORMATION

	Engine
Application		2.0L DOHC
Engine Type		Dual Overhead Cam L–4
Bore		86 mm (3.4 in.)
Stroke		86 mm (3.4 in.)
Total Displacement		1 998 cm3 (121.9 in3)
Compression Ratio		9.5µ0.2:1
Maximum Power		96 kW (128.7 bhp)
		(at 5,400 rpm)
Maximum Torque		184 NSm (135.7 lb–ft)
		(at 4,400 rpm)

	Ignition System
Application		2.0L DOHC
Ignition Type		Direct Ignition System
Ignition Timing		8³ BTDC
Ignition Sequence		1–3–4–2
Spark Plug Gap		0.8 mm (0.031 in)
Spark Plug Maker		Bosch
Spark Plug Type		FR8LDC4

	Clutch – Manual Transaxle
Application		2.0L DOHC
Type		Single Dry Plate
Outside Diameter		225 mm (9.0 in.)
Inside Diameter		150 mm (5.9 in.)
Thickness		3.4 mm (0.13 in.)
Fluid Capacity		Common Use; Brake Fluid

	Manual Transaxle
Application		2.2L DOHC
Maker		DWMC
Type or Model		D–20
Gear Ratio:		–
1st		3.545:1
2nd		2.158:1
3rd		1.478:1
4th		1.129:1
5th		0.886:1
Reverse		3.333:1
Final Drive Ratio		3.550:1
Oil Capacity		1.8L (2 qt)

* Puerto Rico only.

		GENERAL INFORMATION 0B – 3
	Automatic Transaxle
Application		2.0L DOHC
Maker		GM
Type or Model		4T40E
Gear Ratio:		–
1st		2.957:1
2nd		1.623:1
3rd		1.000:1
4th		0.682:1
Reverse		2.143:1
Final Drive Ratio		3.910:1
Oil Capacity		11.5L (12 qt)
	Brake
Application		2.0L DOHC
Booster Size:		–
Single		228.6 mm (9 in.)
Master Cylinder Diameter		22.2 mm (0.87 in.)
Booster Ratio		5.0:1
Front Brake:		–
Disc Type		Ventilated
Disc Size		356 mm (14.0 in.)
Rear Brake:		–
Disc:		–
Disc Type		Solid
Disc Size		32 mm (1.3 in.)
Fluid Capacity		0.5L (0.53 qt)
	Tire and Wheel
Application		2.0L DOHC
Standard Tire Size		185/65R14
Temporary Tire Size		T125/70D15
Standard Wheel Size		5.5JX14
Inflation Pressure at Full Load:		–
185/65R14:		––
Front		30 psi
Rear		28 psi
T127/70D15		60 psi

0B – 4 GENERAL INFORMATION

	Steering System
Application		2.0L DOHC
Gear Type		Power Rack and Pinion
Overall Gear Ratio:		–
Manual Steering		–
Power Steering		16:1
Wheel Alignment:		–
Front:		–
Total Toe–In (2 Occupants)		–10′ to +10′
Caster:		–
Power Steering		2³30′ to 3³30′
Camber		–54′ to 6′
Rear:		–
Total Toe–In (2 Occupants)		–3′ to +17′
Camber		–1³35′ to –5′
Oil Capacity		1.0L (1.1 qt)

	Suspension
Application		2.0L DOHC
Front Type		MacPherson Strut
Rear Type		Compound Link

	Fuel System
Application		2.0L DOHC
Fuel Delivery		MPI
Fuel Pump Type		Electric Motor Pump
Fuel Filter Type		Cartridge
Fuel Capacity		52L (13.7 gal)

	Lubricating System
Application		2.0L DOHC
Lubricating Type		Forced Feed
Oil Pump Type		Duocentric Rotor
Oil Filter Type		Cartridge (Full Flow)
Oil Pan Capacity Including Oil Filter		3.8L (4.1 qt)

		GENERAL INFORMATION 0B – 5
	Cooling System
Application		2.0L DOHC
Cooling Type		Forced Water Circulation
Radiator Type		Cross–flow
Water Pump Type		Centrifugal
Thermostat Type		Pellet Type
Coolant Capacity:		–
Manual:		7.0L (7.4 qt)
Automatic:		7.0L (7.4 qt)
	Electric System
Application		2.0L DOHC
Battery (55 AH, M/F)		630 Cold Cranking Amps
Alternator:		85 Amps
Starter (1.4 kW) No Load Test		Minimum 40 Amps
		Maximum 90 Amps
		(at 12.2 volts)

VEHICLE DIMENSIONS AND WEIGHTS

Vehicle Dimensions – Manual and Automatic

Application	2.0L DOHC
Overall Length:	–
4–Door Notchback	4 470 mm (176.0 in.)
4–Door Wagon	4 514 mm (177.7 in.)
5–Door	4 248 mm (167.2 in.)
Overall Width	1 700 mm (66.9 in.)
Overall Height:	–
4–Door Notchback	1 425 mm (56.1 in.)
4–Door Wagon	1 432 mm (56.4 in.)
5–Door	1 425 mm (56.1 in.)
Overall Height:	Overall Height:
4–Door Notchback	1 430 mm (56.2 in.)
4–Door Wagon	1 470 mm (58.0 in.)
5–Door	1 430 mm (56.2 in.)
Minimum Ground Clearance	151 mm (5.9 in.)
Wheel Base	2 570 mm (101.2 in.)
Tread:	–
Front	1 464 mm (57.6 in.)
Rear	1 454 mm (57.2 in.)

0B – 6 GENERAL INFORMATION

Vehicle Weights – 4 Door Notchback

Application	2.0L DOHC
Manual:	–
Curb Weight:	–
Standard	1 164 kg (2,566 lb)
Optional	1 233 kg (2,718 lb)
Gross Vehicle Weight	1 720 kg (3,792 lb)
Automatic:	–
Curb Weight	–
Standard	1 200 kg (2,645 lb)
Optional	1 269 kg (2,797 lb)
Gross Vehicle Weight	1 720 kg (3,792 lb)
Passenger Capacity	5

Vehicle Weights – 4 Door Wagon

Application	2.0L DOHC
Manual:	–
Curb Weight:	–
Standard	1 222 kg (2,694 lb)
Optional	1 291 kg (2,846 lb)
Gross Vehicle Weight	1 860 kg (4,101 lb)
Automatic:	–
Curb Weight	–
Standard	1 258 kg (2,773 lb)
Optional	1 327 kg (2,925 lb)
Gross Vehicle Weight	1 860 kg (4,101 lb)
Passenger Capacity	5

	Vehicle Weights – 5 Door
Application		2.0L DOHC
Manual:		–
Curb Weight:		–
Standard		1 155 kg (2,546 lb)
Optional		1 224 kg (2,698 lb)
Gross Vehicle Weight		1 720 kg (3,792 lb)
Automatic:		–
Curb Weight:		–
Standard		1 191 kg (2,625 lb)
Optional		1 260 kg (2,778 lb)
Gross Vehicle Weight		1 720 kg (3,792 lb)
Passenger Capacity		5

Optional Weight: Air Conditioning, Power Steering, ABS, Sunroof, Airbag.

GENERAL INFORMATION 0B – 7

STANDARD BOLT SPECIFICATIONS

	Bolt*	4T – Low Carbon Steel	7T – High Carbon Steel	7T – Alloy Steel
M6 X 1.0		4.1–8.1 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–	16–30 NSm (12–22 lb–ft)
			in)
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

0B – 8 GENERAL INFORMATION

MAINTENANCE AND REPAIR

MAINTENANCE AND LUBRICATION NORMAL VEHICLE USE

The maintenance instructions contained in the maintenance schedule are based on the assumption that the vehicle 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 side door.

S To be driven on reasonable road surfaces and within legal operating limits.

EXPLANATION OF SCHEDULED MAINTENANCE SERVICES

The services listed in the maintenance schedule are further explained below. When the following maintenance services are performed, make sure all the parts are replaced and all the necessary repairs are done before driving 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 replace 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 quality. Always use oil rated API–SJ (ILSAC GF–II) or better.

Engine Oil Viscosity

Engine oil viscosity (thickness) has an effect on fuel economy and cold weather operation. Lower viscosity engine oils can provide better fuel economy and cold weather performance; however, higher temperature weather conditions require higher viscosity engine oils for satisfactory lubrication. 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.

GENERAL INFORMATION 0B – 9

Fuel Micro–Filter Replacement

Replace the engine fuel filter every 48,000 km (30,000 miles).

The engine fuel filter is located on the center dash panel near the brake booster.

Air Cleaner Element Replacement

Replace the air cleaner element every 48 000 km (30,000 miles).

Replace the air cleaner more often under dusty conditions.

Throttle Body Mounting Bolt Torque

Check the torque of the throttle body mounting bolts. Tighten the throttle body mounting bolts to 17 NSm (13 lb– ft) if necessary.

Spark Plug Replacement

Replace spark plugs with the same type.

–Type: AC Type FR8LDC4 (2.0L DOHC)

–Gap: 0.8 mm (0.031 in.) (2.0L DOHC)

Spark Plug Wire Replacement

Clean the wires and inspect them for burns, cracks, or other damage. Check the wire boot fit at the direct ignition system (DIS) module and at the spark plugs. Replace the wires, as needed.

Brake System Service

Check the disc brake pads or the drum brake linings every 9,600 km (6,000 mi) or 6 months. Check the pad and the lining thickness carefully. If the pads or the linings are not expected to last another 9,600 km (6,000 mi), replace the pads or the linings. Check the breather 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 irregular 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.

0B – 10 GENERAL INFORMATION

SCHEDULED MAINTENANCE CHARTS

Engine

Maintenance Item

Maintenance Interval

Miles (Kilometers) or time inmonths, whichever comes first

x 1,000 miles

6

12

18

24

30

36

42

48

54

60

66

72

78

84

90

96

102

x 1,000 km

9.6

19.2

28.8

38.4

48

57.6

67.2

76.8

86.46

96

105.6

115.2

124.8

134.4

144

153.6

163.2

# Months

6

12

18

24

30

36

42

48

54

60

66

72

78

84

90

96

102

Drive belt (Generator and power

I

I

I

I

I

Steering)

Engine oil & engine oil filter (1)(3)

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

Cooling system hose & connec-

I

I

I

I

I

I

I

I

tions

Engine coolant (3)

I

I

I

I

R

I

I

I

I

R

I

I

I

I

R

I

I

Fuel filter

R*

R*

R*

Fuel line and connections

I*

I*

I*

I*

I*

I*

I*

I*

Air cleaner element (2)

I*

I*

I*

I*

R

I*

I*

I*

I*

R

I*

I*

I*

I*

R

I*

I*

Ignition timing

I*

I*

I*

I*

I*

I*

I*

I*

Spark plugs

I*

R

I*

R

I*

R

Evaporative emission canister &

I*

I*

I*

vapor lines

PCV system

I*

I*

I*

I*

I*

Camshaft

Out of Cali-

Replace every 72,000 miles (115,200 km)

belt(Timimg

fornia

belt)

California

Inspect every 60,000 miles (96,000 km) and 90,000 miles (144,000 km)

Replace every 102,000 miles (163,200 km)

Chart Symbols:

I – Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace. R – Replace or change.

(1)Change the engine oil every 3,000 miles (4,800 kilometers) or 3 months, whichever comes first, if the vehicle is operated under any of the following conditions :

–Short–distance driving.

–Extensive idling.

–Driving on dusty roads.

(2)More frequent maintenance is required if driving under dusty conditions.

(3)Refer to ”Recommended Fluids And Lubricants”

Note : Check the engine oil and radiator coolant levels every week.

* : Replacement or inspection of these emissions components is recommended to be performed at the indicated intervals however, the California Air Resources Board has determined that performing thesemaintenance items are not required to maintained your vehicle emission warranty.

GENERAL INFORMATION 0B – 11

Chassis and Body

Maintenance Item

Maintenance Interval

Miles (Kilometers) or time inmonths, whichever comes first

x 1,000 miles

6

12

18

24

30

36

42

48

54

60

66

72

78

84

90

96

102

x 1,000 km

9.6

19.2

28.8

38.4

48

57.6

67.2

76.8

86.46

96

105.6

115.2

124.8

134.4

144

153.6

163.2

# Months

6

12

18

24

30

36

42

48

54

60

66

72

78

84

90

96

102

Air Filter (A/C) (2)

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

Exhaust pipes & mountings

I*

I*

I*

I*

I*

I*

I*

I*

Brake/Clutch fluid (3)(5)

I

I

R

I

I

R

I

I

R

I

I

R

I

I

R

I

Brake pads & discs(6)

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

Parking brake

I

I

I

I

I

I

I

Brake line & connections (In-

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

cluding booster)

Rear hub bearing & clearance

I

I

I

I

I

I

I

I

Manual Transaxle Oil (3)

I

I

I

I

I

I

I

I

Clutch & brake pedal free play

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

Automatic transaxle fluid* (3) (7)

I

I

I

I

R

I

I

I

Chassis & underbody bolts &

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

nuts, tighten/secure

Tire condition & inflation pres-

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

sure

Wheel alignment (8)

Inspect when abnormal condition is noted.

Tire rotation

Rotate tires every 6,000 miles

Steering wheel & linkage

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

Power steering fluid & lines*

I

I

I

I

I

I

I

I

Drive shaft boots

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

Seat belts, buckles & anchors

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

Lubricate locks, hinges & hood

I

I

I

I

I

I

I

I

latch

Chart Symbols:

I – Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace. R – Replace or change.

(2)More frequent maintenance is required if driving under dusty conditions.

(3)Refer to”Recommended Fluids And Lubricants.”

(5)Change the brake/clutch fluid every 9,000 miles (14,400 kilometers) or 9months, whichever comes first, if the vehicle is operated under any of the following conditions :

–Driving in hilly or mountainous terrain.

(6)More frequent maintenance is required if the vehicle is operated under any of the following conditions:

–Short–distance driving.

–Extensive idling or slow–speed driving in stop–and–go traffic.

–Driving on dusty roads.

(7)Change the automatic transaxle fluid every 50,000miles (80,000 kilometers) if the vehicle is operated under any of the following conditions :

–Driving in hilly or mountainous terrain.

–Driving in heavy city traffic where the outside temperatures regularly reach 32³C (90³F) or higher.

–Driving a taxi, or police or delivery vehicles.

(8)If necessary, rotate and balance the wheels

Note : Check the engine oil and radiator coolant levels every week.

0B – 12 GENERAL INFORMATION

* Replacement or inspection of these emissions components is recommended to be performed at the indicated intervals however, the California Air Resources Board has determined that performing thesemaintenance items are not required to maintained your vehicle emission warranty.

OWNER INSPECTIONS AND

SERVICES

WHILE OPERATING THE VEHICLE

Horn Operation

Blow the horn occasionally to make sure it works. Check all the button locations.

Brake System Operation

Be alert for abnormal sounds, increased brake pedal travel, 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.

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 checking 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.

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 to the right or the 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, has too much free play, or if unusual sounds are noticed when turning or parking.

Headlamp Aim

Take note of the light pattern occasionally. Adjust the headlamps 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 repaired 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 (dipstick).

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 level on it.

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 tire, unless it is a stowaway). Maintain the recommended pressures that are on the tire placard that is on the driver’s side door.

Lamp Operation

Check the operation of the license plate lamp, the headlamps (including the high beams), the parking lamps, the fog lamps, the taillamp, the brake lamps, the turn signals, the backup lamps, and the hazardwarning 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 immediately.

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, Power 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 andmay need to be serviced. Check the breather hole in the reservoir cover that it is free from dirt and check for an open passage.

Clutch Pedal Free Travel

Check clutch pedal free travel and adjust, as necessary, every 16,000 km (10,000 miles). Measure the distance from the center of the clutch pedal to the outer edge of the

GENERAL INFORMATION 0B – 13

steering wheel with the clutch pedal not pressed. Then, measure the distance from the center of the clutch pedal to the outer edge of the steering wheel with the clutch pedal fully pressed. The difference between the two values must be greater than 130 mm (5.1 in.).

Hood Latch Operation

When opening the hood, note the operation of the secondary latch. It should keep the hood from opening all the way when the primary latch is released. The hood must close firmly.

Weatherstrip Lubrication

Apply a thin film of silicone grease using a clean cloth.

EACH TIME THE OIL IS CHANGED

Automatic Transaxle Fluid

Refer to”Transaxle Fluid Level Checking Procedure”in-

Section 5A, 4T40E Automatic Transaxle.

AT LEAST ANNUALLY

Lap and Shoulder Belt Condition and Operation

Inspect the belt system, including the webbing, the buckles, the latch plates, the retractor, the guide loops and the anchors.

Manual Transaxle

Check the fluid level and add fluid, as required. Refer toSection 5B, Five–Speed Manual Transaxle.

Movable Head Restraint Operation

On vehicles with movable head restraints, the restraints must stay in the desired position.

Brake System Inspection

This inspection should be done when the wheels are removed for rotation. Inspect the lines and the hoses for proper hookup, binding, leaks, cracks, chafing, etc. Inspect 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 frequent braking.

Steering, Suspension and Front Drive Axle Boot and Seal Inspection

Inspect the front and the 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 and chafing, etc. Clean and inspect the drive axle boot and seals for damage, tears, or leakage. Replace the seals, if necessary.

Exhaust System Inspection

Inspect the complete system (including the catalytic converter, if equipped). Inspect the body near the exhaust system. Look for broken, damaged, missing, or out of position 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 the throttle valve assembly, and the accelerator pedal sliding face with suitable grease. Check the throttle cable for free movement.

Engine Drive Belts

Inspect all belts for cracks, fraying, wear, and proper tension. Adjust or replace the belts, as needed.

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 mechanism 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 : Adhere to the following precautions. Failuretodosocancauseinjuriesandpropertydamage.

SFirmly apply the parking brake and the regular brakes.

SDo not use the accelerator pedal.

SBe ready to turn the ignition OFF if the vehicle starts.

On automatic transaxle vehicles, try to start the engine in each gear. The starter should crank only in P (PARK) and in N (NEUTRAL).

Parking Brake and Transaxle P (PARK)

Mechanism Operation

CAUTION : To reduce the risk of personal injury or property damage, be prepared to apply the regular brakes if the vehicle begins to move.

Park on a fairly steep hillwith enough roomformovement in the downhill direction. To check the parking brake, with the engine running and the transaxle in N (NEUTRAL), slowly remove foot pressure fromthe 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 transaxle to P (PARK).

0B – 14 GENERAL INFORMATION

Underbody Flushing

Flushing the underbody will remove any corrosive materials 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 underbodywith plainwater.

Engine Cooling System

Inspect the coolant and freeze protection fluid. If the fluid

is dirty or rusty, drain, flush and refill the engine cooling system with new coolant. Keep the coolant at the proper mixture to ensure proper freeze protection, corrosion protection and engine operating temperature. Inspect the hoses. Replace the cracked, swollen, or deteriorated hoses. Tighten the clamps. Clean the outside of the radiator and the air conditioning condenser. Wash the filler cap and the neck. Pressure test the cooling system and the cap to help ensure proper operation.

				GENERAL INFORMATION 0B – 15
	RECOMMENDED FLUIDS AND LUBRICANTS
	USAGE	CAPACITY		FLUID/LUBRICANT
Engine Oil		3.8L (4.1 qt)		ILSAC GF–II (API SJ) grade
				SAE 5W––30, SAE 10W––30
Engine Coolant		7.0L (7.4 qt)	Mixture of water and good quality ethylene glycol–
			base antifreeze (year–round coolant)
Brake and Clutch Fluid		0.5L (0.5 qt)	SSK–221 (DOT–3 and DOT–4 Fluid)
Power Steering System Fluid		1.0L (1.1 qt)	DEXRON±–III, DEXRON± II–D
Automatic Transaxle		11.5L (12.2 qt)	DEXRON±–III
Manual Transaxle		1.8L (2 qt)	Manual Transaxle Fluid ( B0400075, SAE80 or eqi-
			valent; Extremely cold area: SAE 75W)
Manual Transaxle Shift Linkage		As needed	Multipurpose–type grease meeting requirements
			NLGI No. 1 or 2
Key Lock Cylinders		As needed	Silicone lubricant
Automatic Transaxle Shift Link-		As needed	Engine oil
age
Clutch Linkage Pivot Points		As needed	Engine oil
Floor Shift Linkage Points		As needed	Engine oil
Hood Latch Assembly		As needed	1.	Engine oil
1.	Pivots and Spring Anchor		2.	Multipurpose–type grease meeting require-
2.	Release Pawl			ments NLGI No. 1 or 2
Hood and door hinges		As needed	Engine oil
Fuel door hinge
Rear compartment lid hinges
Weatherstripping		As needed	Silicone grease

0B – 16 GENERAL INFORMATION

GENERAL DESCRIPTION AND SYSTEM OPERATION

GENERAL REPAIR INSTRUCTIONS

If a floor jack is used, the following precautions are recommended:

SPark 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.

SBefore performing the service operation, disconnect the negative battery cable to reduce the chance of cable damage and burning due to short–circuiting.

SUse a cover on the body, the seats, and the floor to protect them against damage and contamination.

SHandle brake fluid and antifreeze solution with care as they can cause paint damage.

SThe use of proper tools, and the required special tools where specified, is important for efficient and reliable performance of the service repairs.

SUse genuine DAEWOO parts.

SDiscard used cotter pins, gaskets, O–rings, oil seals, lock washers and self–locking nuts. Prepare new ones for installation. Normal functioning of the vehicle’s components cannot be maintained if these fasteners and seals are reused.

SKeep the disassembled parts to assist in reassembly.

SKeep attaching bolts and nuts separated, as they vary in hardness and design depending on the position of the installation.

SClean the parts before inspection or reassembly.

SClean the oil parts, etc. Use compressed air to make certain they are free of restrictions.

SLubricate rotating and sliding faces of parts with oil or grease before installation.

SWhen necessary, use a sealer on gaskets to prevent leakage.

SCarefully observe all specifications for bolt and nut torques.

When service operation is complete, make a final check to be sure service was done properly and the problem was corrected.

GENERAL INFORMATION 0B – 17

GENERAL DESCRIPTION

ON BOARD REFUELING VAPOR RECOVERY SYSTEM

The NUBIRA 2.0 DOHC model is equipped with an On Board Diagnostic Stage II (OBD–II) system to meet enhanced emission control requirements. Within this OBD–II system, an On Board Refueling Vapor Recorvery (ORVR) system has been developed and equipped to meet enhanced evaporative emission control requirements during vehicle moving, parking, and refueling at gas stations. The Daewoo ORVR system adopts one canister to collect both evaporative vapors during the moving & parking as well as refueling vapor. Collected vapor is consurmed by the engine through the intake manfold during vehicle operation. The mechanism of Daewoo ORVR system to meet the ORVR requirement is to create suction inside filler neck by the aid of fuel flow through a reduced diameter section in the filler pipe.

Therefore, Daewoo ORVR system adopts the so called ”Liquid Trap” or ”Liquid Seal” system that assures the long term durability.

The Daewoo ORVR system provides nozzle compatibility with conventional and stage II vapor recovery nozzle.

The Daewoo ORVR system has been designed to have the following functional features.

STo collect refueling vapors and to route to canister.

STo provide nozzle compatibility with conventional and stage II vapor recovery nozzles.

STo provide fill shut off signal.

STo prevent canister from liquid fuel during normal driving and vehicle rollover.

STo provide fuel tank venting to canister during vehicle operation.

STo protect fuel tank from over–pressure.

STo protect fuel vapor dome from overfill.

Any failures or malfunction of the ORVR system will be identified by OBD–II system and warned through Malfunction Indicator Lamp (MIL) on the instrument cluster.

No special refueling procedures and mainternance on ORVR system are required.

The Daewoo ORVR system and all fuel system components have been designed to prevent the electrostatic discharge phenomenon by adopting mitigation techniques recommended in SAE J1645. Daewoo’s own test procedure (EDS–T–5005) is similar to SAE J1113.

0B – 18 GENERAL INFORMATION

Schematic Of On Board Refueling Vapor Recovery System

1.	Manifold (Intake)		criminator
2.	Canister Purge Valve (Electronic Pwm Control)	9.	Pressure Relief Valve
3.	Service Port	10.	Tank Pressure Transducer (OBD–II)
4.	Integrated Fuel Vapor Storage Canister	11.	Rollover Valve
5.	OBD–II Valve (Solenoid)OBD–II Valve (Solenoid)	12.	2–Way Check Valve
6.	Air Filter	13.	Check Valve
7.	Fuel Tank (Steel)	14.	Fuel Filler Tube (Dynamic Seal During Fill)
8.	Fuel Fill Vent Control Valve & Liquid–Vapor Dis-	15.	Fuel Filler Cap (Pressure–Vacuum Relief)

GENERAL INFORMATION 0B – 19

Component Locator

1.	Fuel Tank	6.	Purge Valve
2.	Filler Tube	7.	Service port
3.	Canister	8.	Fuel Filler Cap
4.	OBD– II Valve	9.	Air Filter

5.Fuel Filter

0B – 20 GENERAL INFORMATION

VEHICLE IDENTIFICATION

Passenger Car VIN

Certification plate

1.Production Date

2.Gross Vehicle Weight Rating

3.Gross Axle Weight Rating Front

4.Gross Axle Weight Rating Rear

5.Vehicle Identification Number

GENERAL INFORMATION 0B – 21

VIN Plate Location

Engraved VIN Location

The vehicle identification number (VIN) plate is attached to the top of the driver’s side of the instrument panel.

The vehicle identification number (VIN) is engraved in the

top of the bulkhead, next to the ABS module.

Certification Label

The Certification Label is attached to the driver’s side B– pillar near door strike.

0B – 22 GENERAL INFORMATION

Engine Number – Family II (2.0L DOHC Engine)

Engine Number Plate Location – Family II

(2.0L DOHC Engine)

The engine number is stamped on the cylinder block under the No. 4 exhaust manifold of the engine.

	GENERAL INFORMATION 0B – 23
Manual Transaxle Identification Number	Automatic Transaxle Identification Number
Plate	Plate

1.Identification Code

2.Sequential Number

Identification	Engine	Gear Ratio
Code
FE	2.0L DOHC	3.545 C/R

Manual Transaxle Identification Number

Plate Location

1.Assembly Plant (Windsor, Canada)

2.Model Year (1996)

3.Broadcast Code

4.Model Name (4T40E)

5.Update Level

6.Sequential Number

7.Manufacturer

8.Part Number

Identification Code	Engine
7ZZR	2.0L DOHC

The manual transaxle identification number is attached to the top of the transaxle case near the engine.

0B – 24 GENERAL INFORMATION

Automatic Transaxle Identification Number

Plate Location

VEHICLE LIFTING PROCEDURES

Notice : To raise the vehicle, place the lifting equipment only at the points indicated. Failure to use these precise positions may result in permanent body deformation. Many dealer service facilities and service stations are equipped with automotive hoists that bear upon some parts of the frame to lift the vehicle. If any other hoist method is used, use special care to avoid damaging the fuel tank, the filler neck, the exhaust system, or the underbody.

The automatic transaxle identification number plate is attached on the rear side of the transaxle near the bulkhead.

GENERAL INFORMATION 0B – 25

0B – 26 GENERAL INFORMATION

Vehicle Lifting Points

SECTION : 1A

GENERAL ENGINE INFORMATION

TABLE OF CONTENTS

DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–1 COMPRESSION TEST . . . . . . . . . . . . . . . . . . . . . 1A–1 OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . 1A–2 OIL LEAK DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . 1A–3 KNOCK DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . 1A–4

DIAGNOSIS

COMPRESSION TEST

Important : Disconnect the Crankshaft Position Sensor (CPS) connector to disable the fuel and the ignition systems.

Test the compression pressure for each cylinder. Low compression pressure may be the fault of the valves or the pistons. The following conditions should be considered when checking the cylinder compression:

SThe engine should be at normal operating temperature.

SThe throttle must be wide open.

SAll the spark plugs should be removed.

SThe battery must be at or near full charge.

1.Place approximately three squirts of oil from a plunger type oiler into each spark plug port.

2.Insert the engine compression gauge into each spark plug port.

NOISE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . .

1A–8

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1A–11 CLEANLINESS AND CARE . . . . . . . . . . . . . . . . 1A–11

ON–ENGINE SERVICE . . . . . . . . . . . . . . . . . . .

1A–11

3.Crank test each cylinder with four to five compression strokes using the starter motor.

4.The lowest reading should not be less than 70% of the highest reading. The compression gauge reading should not be less than 689 kPa (100 psi) for any of the cylinders.

5.Examine the gauge readings obtained after the four ”puffs” per cylinder are obtained from cranking the starter motor. The readings are explained in the following descriptions:

SNormal Condition – Compression builds up quickly and evenly to specified compression on each cylinder.

SPiston Rings Faulty – Compression is low on the first stroke and tends to build up on following strokes, but does not reach normal. The compression pressure improves considerably with the addition of oil into the cylinder.

SValves Faulty – Low compression pressure on the first stroke. The compression pressure does not tend to build up on the following strokes. The compression pressure does not improve much with the addition of oil into the cylinder.

1A – 2 GENERAL ENGINE INFORMATION

OIL PRESSURE TEST

Step	Action	Value(s)	Yes	No
1	Is the oil pressure warning lamp on?		Go to Step 2	System OK
2	Check the oil level in the crankcase.		Go to Step 3	Go to Step 4
	Is the oil level low?
3	Add oil so that the oil level is up to the MAX mark on		Go to Step 1
	the indicator.
	Is the repair complete?
4	Check the idle speed.	825 rpm	Go to Step 5	Go to Step 6
	Is the idle speed below the value specified?
5	Increase the idle speed.		Go to Step 1
	Is the speed increased?
6	Inspect the oil pressure switch.		Go to Step 7	Go to Step 8
	Is the oil pressure switch incorrect or malfunction-
	ing?
7	Install a new oil pressure switch.		Go to Step 1
	Is the repair complete?
8	Inspect the oil pressure gauge.		Go to Step 9	Go to Step 10
	Is the oil pressure gauge incorrect or malfunction-
	ing?
9	Install a new oil pressure gauge.		Go to Step 1
	Is the repair complete?
10	Inspect the engine oil.		Go to Step 11	Go to Step 12
	Is the engine oil in the crankcase diluted or of the im-
	proper viscosity?
11	Install new engine oil of the proper viscosity for the		Go to Step 1
	expected temperatures.
	Is the repair complete?
12	Inspect the oil pump.		Go to Step 13	Go to Step 14
	Is the pump worn or dirty?
13	Replace the oil pump.		Go to Step 1
	Is the repair complete?
14	Inspect the oil filter.		Go to Step 15	Go to Step 16
	Is the oil filter plugged?
15	Install a new oil filter.		Go to Step 1
	Is the repair complete?
16	Inspect the oil pickup screen.		Go to Step 17	Go to Step 18
	Is the oil pickup screen loose or plugged?
17	Tighten or replace the oil pickup screen as neces-		Go to Step 1
	sary.
	Is the repair complete?
18	Inspect the oil pickup tube.		Go to Step 19	Go to Step 20
	Are there any holes in the oil pickup tube?
19	Replace the oil pickup tube.		Go to Step 1
	Is the repair complete?

GENERAL ENGINE INFORMATION 1A – 3

Step	Action	Value(s)	Yes	No
20	Inspect the bearing clearances.	Crankshaft	Go to Step 21	Go to Step 22
	Are the bearing clearances more than the values	0.005 mm
	specified?	(0.0001 in.)
		Connecting
		Rod
		0.0019–0.070
		mm
		(0.0007–0.0025
		in.)
21	Replace the bearing, if necessary.		Go to Step 1
	Is the repair complete?
22	Inspect the oil galleries.		Go to Step 23	Go to Step 24
	Are the oil galleries cracked, porous, or plugged?
23	Repair or replace the engine block.		Go to Step 1
	Is the repair complete?
24	Inspect the gallery plugs.		Go to Step 25	Go to Step 26
	Are any of the gallery plugs missing or installed im-
	properly?
25	Install plugs or repair, as necessary.		Go to Step 1
	Is the repair complete?
26	Inspect the camshaft.		Go to Step 27	System OK
	Is the camshaft worn or is there evidence of poor
	machining?
27	Replace the camshaft.		Go to Step 1
	Is the repair complete?

OIL LEAK DIAGNOSIS

Most fluid oil leaks are easily located and repaired by visually finding the leak and replacing or repairing the necessary parts. On some occasions, a fluid leak may be difficult to locate or repair. The following procedures may help you in locating and repairing most leaks.

Finding the Leak:

1.Identify the fluid. Determine whether it is engine oil,automatic transmission fluid, power steering fluid, etc.

2.Identify where the fluid is leaking from.

1)After running the vehicle at normal operating temperature, park the vehicle over a large sheet of paper.

2)Wait a few minutes.

3)You should be able to find the approximate location of the leak by the drippings on the paper.

3.Visually check around the suspected component. Check around all the gasket mating surfaces for leaks. A mirror is useful for finding leaks in areas that are hard to reach.

4.If the leak still cannot be found, it may be necessary to clean the suspected area with a degreaser, steam or spray solvent.

1)Thoroughly clean the area.

2)Dry the area.

3)Operate the vehicle for several miles at normal operating temperature and varying speeds.

4)After operating the vehicle, visually check the suspected component.

5)If you still cannot locate the leak, try using the powder or black light and dye method.

Powder Method:

1.Clean the suspected area.

2.Apply an aerosol–type powder (such as foot powder) to the suspected area.

3.Operate the vehicle under normal operating conditions.

4.Visually inspect the suspected component. You should be able to trace the leak path over the white powder surface to the source.

Black Light and Dye Method:

A dye and light kit is available for finding leaks. Refer to the manufacturer’s directions when using the kit.

1.Pour the specified amount of dye into the engine oil fill tube.