Daewoo Nubira 2002-2008 Workshop Service Manual for Repair
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🏷️ Basic Information Identification Make: Daewoo Model: Nubira Generation Codes: J100, J150, J200 👋 Introduction Market Position Market Segment: Compact/Small Family Car Competitive Analysis Key Competitors Era: Chevrolet Cruze (later), Ford Focus, Volkswagen Golf, Hyundai Elantra, Kia Spectra, Toyota Corolla, Honda Civic Key Features Model Purpose: Affordable, practical, and relatively well-equipped family car offering a balance of comfort and economy. 📋 Manual Details Coverage Coverage Years: 2002, 2003, 2004, 2005, 2006, 2007, 2008 Page Count Page Count: 1500+ Manual Type Manual Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Systems Covered: Engine, Transmission (Manual & Automatic), Fuel System, Cooling System, Exhaust System, Drivetrain, Suspension, Steering, Brakes, Electrical System, Climate Control, Body & Chassis, Interior Components, Diagnostic Procedures, Troubleshooting Procedures Procedures Included: Maintenance, Adjustments, Lubrication, Removal & Installation, Disassembly & Assembly, Troubleshooting, Diagnostics, Repair Procedures, Component Testing, Tightening Torques, Wear Limits, Fluid Specifications Depth Technical Depth: Comprehensive, from basic maintenance to complete overhaul and diagnostics. Includes special tool references and usage. Diagnostics Diagnostic Trouble Codes DTCs: Covers standard OBD-II diagnostic trouble codes (DTCs), their meanings, and troubleshooting steps. Body And Chassis Body Repair Procedures: Includes procedures for body panel alignment, dent repair, and replacement of common body components. Electrical System Wiring Diagrams: Detailed wiring diagrams for various electrical circuits, including lighting, ignition, charging, and accessories. Cooling System Cooling System Components: Radiator, water pump, thermostat, coolant hoses, fan operation, and bleeding procedures. Exhaust System Exhaust System Components: Exhaust manifold, catalytic converter, mufflers, pipes, and oxygen sensor replacement. Suspension Suspension Components: Front and rear suspension struts, shock absorbers, springs, control arms, ball joints, sway bar links, and wheel bearings. Steering Steering System Components: Steering rack, power steering pump, fluid reservoir, steering column, and tie rod ends. Brakes Brake System Components: Front and rear disc brakes (and drums on rear for some models), brake calipers, pads, rotors, master cylinder, brake lines, and ABS components. Interior Interior Component Repair: Dashboard removal/installation, seat removal, door panel removal, center console, and HVAC system components. Fuel System Fuel System Components: Fuel tank, fuel pump, fuel filter, fuel injectors, fuel pressure regulator, and fuel lines. Torque Values Tightening Torques: Extensive list of specific tightening torques for critical fasteners across all systems. Alignment Wheel Alignment Specifications: Includes camber, caster, toe, and thrust angle specifications for front and rear wheels. Performance Tuning Engine Tuning Info: Information on basic engine tuning and adjustments, but not extensive performance modification guides. Troubleshooting Diagnostic Charts: Flowcharts and tables for systematic troubleshooting of common drivability, electrical, and mechanical issues. Vehicle Systems Climate Control Repair: Covers A/C system components, refrigerant charging, heater core replacement, and blower motor service. Safety Systems Airbag System Service: Information on airbag component replacement and safety precautions for working with SRS systems. Wheels And Tires Wheel And Tire Specifications: Details on wheel bolt patterns, tire sizes, and recommended inflation pressures. Component Identification Part Identification: Illustrations and descriptions to help identify specific components and their locations on the vehicle. Maintenance Procedures Preventive Maintenance: Detailed steps for all routine preventive maintenance tasks. 📊 Manual Specifications File Details File Format: PDF Print Quality: High-quality, printable pages Searchability: Likely searchable text within PDF (depending on source scan quality) Compatibility Operating Systems: Windows, Mac, Linux OS Requirements Software Requirement: Adobe Reader ⚙️ Engine Specifications Primary Engine Engine Options: Likely 1.6L (Ecotec Z16SE/LE), 1.8L (Ecotec Z18XE), and potentially 2.0L (X20SED) gasoline engines, depending on market and specific year. Performance Horsepower Range: Approximately 105 hp (1.6L) to 130 hp (1.8L), with potential variations for the 2.0L. Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Engine Management ECU Type: Likely a GM/Delphi-based Engine Control Unit (ECU) Maintenance Timing Belt Interval: Typically around 60,000-100,000 miles or 4-6 years; consult manual for exact specification. 🔧 Transmission Standard Standard Transmission: 5-speed Manual Transmission Optional Optional Transmission: 4-speed Automatic Transmission Features Transmission Fluid Type: Dexron III/VI for automatic; GL-4 for manual (check manual for specific GM/Dexron specification). 📐 Dimensions Exterior Body Styles: Sedan, Hatchback (5-door), Station Wagon (Wagon) Weights Curb Weight Range: Approximately 2,600 - 3,000 lbs (1,180 - 1,360 kg), depending on body style and engine. 🛡️ Safety Features Ratings NHTSA Ratings Era: Generally average for its class during its production years. Specific ratings may vary by year and testing methodology. Active Features Active Safety Features: Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD) often optional or standard on higher trims. Passive Features Passive Safety Features: Driver and Passenger Front Airbags, Side Airbags (optional on some trims), Seatbelt Pretensioners. 💡 Technology Features Infotainment Infotainment Features Era: Basic AM/FM/CD/Cassette stereo systems were common. Higher trims might have offered optional cassette/CD changers or more advanced speaker systems. Driver Assistance Driver Assistance Features Era: Limited. Cruise control was common. Electronic stability control (ESC) and traction control were rare or non-existent for most models in this era. Connectivity Connectivity...
Extensive list of specific tightening torques for critical fasteners across all systems.
Alignment
Wheel Alignment Specifications:
Includes camber, caster, toe, and thrust angle specifications for front and rear wheels.
Performance Tuning
Engine Tuning Info:
Information on basic engine tuning and adjustments, but not extensive performance modification guides.
Troubleshooting
Diagnostic Charts:
Flowcharts and tables for systematic troubleshooting of common drivability, electrical, and mechanical issues.
Vehicle Systems
Climate Control Repair:
Covers A/C system components, refrigerant charging, heater core replacement, and blower motor service.
Safety Systems
Airbag System Service:
Information on airbag component replacement and safety precautions for working with SRS systems.
Wheels And Tires
Wheel And Tire Specifications:
Details on wheel bolt patterns, tire sizes, and recommended inflation pressures.
Component Identification
Part Identification:
Illustrations and descriptions to help identify specific components and their locations on the vehicle.
Maintenance Procedures
Preventive Maintenance:
Detailed steps for all routine preventive maintenance tasks.
📊 Manual Specifications
File Details
File Format:
PDF
Print Quality:
High-quality, printable pages
Searchability:
Likely searchable text within PDF (depending on source scan quality)
Compatibility
Operating Systems:
Windows, Mac, Linux OS
Requirements
Software Requirement:
Adobe Reader
⚙️ Engine Specifications
Primary Engine
Engine Options:
Likely 1.6L (Ecotec Z16SE/LE), 1.8L (Ecotec Z18XE), and potentially 2.0L (X20SED) gasoline engines, depending on market and specific year.
Performance
Horsepower Range:
Approximately 105 hp (1.6L) to 130 hp (1.8L), with potential variations for the 2.0L.
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Engine Management
ECU Type:
Likely a GM/Delphi-based Engine Control Unit (ECU)
Maintenance
Timing Belt Interval:
Typically around 60,000-100,000 miles or 4-6 years; consult manual for exact specification.
🔧 Transmission
Standard
Standard Transmission:
5-speed Manual Transmission
Optional
Optional Transmission:
4-speed Automatic Transmission
Features
Transmission Fluid Type:
Dexron III/VI for automatic; GL-4 for manual (check manual for specific GM/Dexron specification).
📐 Dimensions
Exterior
Body Styles:
Sedan, Hatchback (5-door), Station Wagon (Wagon)
Weights
Curb Weight Range:
Approximately 2,600 - 3,000 lbs (1,180 - 1,360 kg), depending on body style and engine.
🛡️ Safety Features
Ratings
NHTSA Ratings Era:
Generally average for its class during its production years. Specific ratings may vary by year and testing methodology.
Active Features
Active Safety Features:
Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD) often optional or standard on higher trims.
Passive Features
Passive Safety Features:
Driver and Passenger Front Airbags, Side Airbags (optional on some trims), Seatbelt Pretensioners.
💡 Technology Features
Infotainment
Infotainment Features Era:
Basic AM/FM/CD/Cassette stereo systems were common. Higher trims might have offered optional cassette/CD changers or more advanced speaker systems.
Driver Assistance
Driver Assistance Features Era:
Limited. Cruise control was common. Electronic stability control (ESC) and traction control were rare or non-existent for most models in this era.
Connectivity
Connectivity Features:
Basic connectivity was limited to auxiliary inputs for external audio devices on some later models. No Bluetooth or USB integration typically.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 5,000-7,500 miles or 6-12 months, depending on oil type and driving conditions. Consult manual for precise intervals.
Fluid Specifications
Engine Oil Specification:
API SJ/SL or ACEA A3/B3 or A3/B4, viscosity typically SAE 5W-30 or 10W-40 (verify with manual).
Coolant Specification:
Ethylene glycol based coolant, typically OAT (Organic Acid Technology) or HOAT (Hybrid OAT), often specified as a GM-approved coolant. Dilution 50/50 with distilled water.
Brake Fluid Specification:
DOT 3 or DOT 4
Known Issues
Common Wear Items:
Suspension components (bushings, ball joints), exhaust system corrosion, ignition coils, oxygen sensors, HVAC blower motor resistor, power steering pump leaks.
Potential Electrical Quirks:
Door lock actuators, window regulators, and dashboard illumination can be prone to failure over time.
Technical Specs
Spark Plug Gap:
Typically 0.040 inches (1.0 mm) for most gasoline engines; verify in manual.
Tire Pressure Recommendations:
Varies by tire size and load; typically in the 30-35 PSI range. Refer to the vehicle's door jamb sticker.
📚 Vehicle History
Brand Heritage
Brand Origin:
South Korean automaker, originally part of GM Korea.
Model Evolution
Model Generations:
The 2002-2008 models represent the second generation (J200) of the Daewoo Nubira, which replaced the J100/J150.
Production
Manufacturing Locations:
Primarily South Korea, with some production potentially in other global markets through licensing or joint ventures (e.g., Eastern Europe).
🏆 Awards & Recognition
Recognitions
Historical Performance:
The Daewoo Nubira generally competed in the budget-friendly segment and received mixed reviews. It was often seen as a value proposition rather than a class leader in performance or refinement.
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