Text preview for : en_4j2_2d.pdf part of Daewoo Nubira/Lacetti Also known as: Chevrolet Nubira / Lacetti, Chevrolet Optra Optra5, Suzuki Forenza Reno Covers the 1.4L, 1.6L and 1.8L engine. Year 2004



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SECTION : 2D

REAR SUSPENSION
CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2D­2 Fastener Tightening Specifications . . . . . . . . . . . 2D­2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D­2 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . . 2D­2 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D­3 Excessive Friction Check . . . . . . . . . . . . . . . . . . . 2D­3 Strut Dampener . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D­3 COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . . 2D­4 Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . 2D­4 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 2D­6 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 2D­6 Strut Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D­6 Knuckle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 2D­9 Trailing Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D­10 Trailing Link Bracket . . . . . . . . . . . . . . . . . . . . . . 2D­11 Front Parallel Link . . . . . . . . . . . . . . . . . . . . . . . . 2D­12 Rear Parallel Link . . . . . . . . . . . . . . . . . . . . . . . . . 2D­13 Stabilizer Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D­13 Stabilizer Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D­14 Crossmember . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D­14 Hub and Bearing Assembly . . . . . . . . . . . . . . . . 2D­15 UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D­17 Springs and Insulators . . . . . . . . . . . . . . . . . . . . . 2D­17 Knuckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D­18 Hub and Bearing . . . . . . . . . . . . . . . . . . . . . . . . . 2D­19 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D­20 Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . 2D­20

2D ­ 2IREAR SUSPENSION

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application Crossmember­to­Body Bolts Strut Dampener­to­Strut Mount Nut Rear Parallel Link­to­Crossmember Bolt Front Parallel Link­to­Knuckle Bolt Fuel Filler Hose Shield Bolt Knuckle­to­Strut Assembly Nuts Rear Parallel Link­to­Knuckle Bolt Rear Trailing Link­to­Trailing Link Bracket Nut Rear Trailing Link­to­Knuckle Nut Stabilizer Link­to­Strut Assembly Nut Stabilizer Shaft Clamp Bolts Stabilizer Shaft­to­Stabilizer Link Nut Strut Mount­to­Body Nuts Trailing Link Bracket­to­Body Bolts Trailing Link­to­Trailing Link Bracket Nut Rear Hub Assembly Bolts NSm 112 75 90 120 20 100 90 100 150 47 40 47 30 70 100 65 Lb­Ft 83 55 66 89 15 74 66 74 111 35 30 35 22 52 74 48 Lb­In ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­

SPECIAL TOOLS
SPECIAL TOOLS TABLE

J­42468 Front Strut Mount Nut Wrench

KM­329­A Spring Compressor

DAEWOO V­121 BL4

REAR SUSPENSION 2D ­ 3

DIAGNOSIS
EXCESSIVE FRICTION CHECK
Check excessive friction in the rear suspension as follows: 1. With the aid of a helper, lift up on the rear bumper and raise the vehicle as high as possible. Slowly release the bumper and allow the car to assume normal trim height. Measure the distance from the floor to the center of the bumper. Push down on the bumper, release slowly, and allow the car to assume normal trim height. 4. Measure the distance from the floor to the center of the bumper. The difference between the two measurements should be less than 12.7 mm (0.50 inch). If the difference exceeds this limit, inspect the control arms for damage or wear.

2. 3.

STRUT DAMPENER
A strut dampener is basically a shock absorber. However, strut dampeners are easier to extend and retract by hand than are shock absorbers.

Struts Seem Weak
Checks Check the tire pressures. Check the load conditions under which the vehicle is normally driven. Check the compression and rebound effectiveness of the strut dampener. Action Adjust the tire pressures to the specifications on the tire placard. Consult with the owner to confirm the owner's understanding of normal load conditions. Quickly push down and then lift up on the corner of the bumper nearest the strut dampener being tested. Compare the compression and rebound with those of a similar vehicle that has an acceptable ride quality. Replace the strut dampener, if needed.

Struts Are Noisy
Checks Check the mountings for looseness or damage. Check the compression and rebound effectiveness of the strut dampener. Action Tighten the strut dampener. Replace the strut dampener, if needed. Quickly push down and then lift up on the corner of the bumper nearest the strut dampener being tested. Compare the compression and rebound with those of a similar vehicle that has an acceptable ride quality. Replace the strut dampener, if needed.

Leaks
Checks Check for a slight trace of fluid. Check the seal cover on the fully extended strut. Check for an excessive amount of fluid on the strut dampener. Action The strut dampener is OK. Replace the strut dampener. Replace the strut dampener.

DAEWOO V­121 BL4

2D ­ 4IREAR SUSPENSION

COMPONENT LOCATOR
REAR SUSPENSION

DAEWOO V­121 BL4

REAR SUSPENSION 2D ­ 5
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Strut Mount Lock Nut Strut Assembly­to­Body Nut Strut Mount Upper Spring Seat Rear Spring Strut Dampener Dust Cover Hollow Bumper Lower Spring Insulation Ring Rear Strut Dampener Strut Assembly­to­Knuckle Bolt Strut Assembly­to­Knuckle Nut Spindle Assembly Brake Disc Stabilizer Shaft Clamp Bolt Stabilizer Shaft Clamp 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. Stabilizer Shaft Insulator Stabilizer Shaft Stabilizer Shaft­to­Stabilizer Link Nut Stabilizer Link Rear Parallel Link­to­Knuckle Bolt Rear Parallel Link Trailing Link Front Parallel Link Trailing Link Bracket Rear Crossmember­to­body Bolts Rear Crossmember Rear Crossmember Cover Toe­in Adjustment Bolt ABS Wiring Cover Rear Drum

DAEWOO V­121 BL4

2D ­ 6IREAR SUSPENSION

MAINTENANCE AND REPAIR
ON­VEHICLE SERVICE STRUT ASSEMBLY
Removal Procedure
1. Remove the trunk carpeting that covers the rear strut mounting nuts. For station wagons, remove the panels that cover the luggage compartment wheelhouse trim panel (wagon). Refer to Section 9G, Interior Trim.

2.

Remove the rear strut mounting nuts.

3. 4.

Raise and suitably support the vehicle. Remove the wheel. Refer to Section 2E, Tires and Wheels. 5. Disconnect the parking brake. Refer to Section 4G, Parking Brake. Important : On vehicles equipped with rear drum brakes, the brake hose will easily disconnect from the strut assembly as the assembly is being removed from the vehicle. On vehicles equipped with rear disc brakes, the brake hose can be disconnected from the strut assembly at any time. 6. Remove the clip that holds the brake hose to the strut assembly.

DAEWOO V­121 BL4

REAR SUSPENSION 2D ­ 7
7. Remove the stabilizer link­to­strut assembly nut and disconnect the stabilizer link from the strut assembly.

8. 9.

Remove the knuckle­to­strut assembly nuts and the bolts. On vehicles equipped with rear drum brakes, lower the strut assembly and separate the brake line from the strut assembly.

10. Remove the rear strut assembly from the vehicle.

Installation Procedure
Important : On vehicles equipped with rear drum brakes, the brake hose will easily connect to the strut assembly as the assembly is being installed into the vehicle. On vehicles equipped with rear disc brakes, the brake hose can be connected to the strut assembly at any time after the strut assembly has been installed into the vehicle. 1. Install the rear strut assembly into the vehicle. On vehicles equipped with rear drum brakes, secure the brake line into the holder as the assembly goes into place.

DAEWOO V­121 BL4

2D ­ 8IREAR SUSPENSION
2. 3. Secure the strut assembly by loosely attaching the strut mount­to­body nuts. Install the knuckle­to­strut assembly nuts and bolts. Do not tighten.

4.

Install the clip holding the brake hose to the strut assembly.

Tighten
Tighten the knuckle­to­strut assembly nuts to 100 NSm (74 lb­ft).

5.

Connect the stabilizer link to the strut assembly and install the stabilizer link­to­strut assembly nut.

Tighten
Tighten the stabilizer link­to­strut assembly nut to 47 NSm (35 lb­ft).

6. 7. 8.

Connect the parking brake. Refer to Section 4G, Parking Brake. Install the wheel. Refer to Section 2E, Tires and Wheels. Lower the vehicle.

Tighten
Tighten the strut mount­to­body nuts to 30 NSm (22 lb­ft).

DAEWOO V­121 BL4

REAR SUSPENSION 2D ­ 9
9. Install the trunk carpeting over the rear strut mounting nuts. For station wagons, remove the panels that cover the luggage compartment wheelhouse trim panel (wagon). Refer to Section 9G, Interior Trim.

KNUCKLE ASSEMBLY
Removal Procedure
1. 2. 3. Raise and suitably support the vehicle. Remove the wheel. Refer to Section 2E, Tires and Wheels. On vehicles equipped with the antilock braking system, remove the ABS speed sensor. Refer to Section 4F, Antilock Brake System. On vehicles equipped with rear disc brakes, remove the rear brake caliper from the knuckle assembly. Refer to Section 4E1, Rear Disc Brakes. Disconnect the parking brake from the knuckle assembly. Refer to Section 4G, Parking Brake. Disconnect the front parallel link from the knuckle. Refer to "Front Parallel Link" in this section. Disconnect the rear parallel link from the knuckle. Refer to "Rear Parallel Link" in this section. Disconnect the rear trailing link from the rear knuckle. Refer to "Rear Trailing Link" in this section. On vehicles equipped with rear drum brakes, remove the clip that secures the brake line to the strut assembly.

4.

5. 6. 7. 8.

9.

10. On vehicles equipped with rear drum brakes, disconnect the brake line from the knuckle assembly. Refer to Section 4E2, Rear Drum Brakes. 11. Remove the rear knuckle­to­strut assembly nuts and the bolts. 12. Disconnect the brake line from the strut assembly and remove the rear knuckle from the strut assembly.

DAEWOO V­121 BL4

2D ­ 10IREAR SUSPENSION Installation Procedure
1. 2. 3. Install the rear knuckle into the vehicle and install the brake line into the strut assembly bracket. Install the knuckle­to­strut assembly bolts and nuts. Do not tighten. Install the clip securing the brake line to the strut assembly.

4.

Tighten the knuckle­to­strut assembly nuts.

Tighten
Tighten the knuckle­to­strut assembly nuts to 100 NSm (74 lb­ft). 5. Connect the rear trailing link to the rear knuckle. Refer to "Rear Trailing Link" in this section. 6. Connect the rear parallel link to the knuckle. Refer to "Rear Parallel Link" in this section. 7. Connect the front parallel link to the knuckle. Refer to "Front Parallel Link" in this section. 8. Connect the parking brake to the knuckle assembly. Refer to Section 4G, Parking Brake. 9. On vehicles equipped with rear drum brakes, connect the brake line to the knuckle assembly. On vehicles equipped with rear disc brakes, install the rear brake caliper onto the knuckle assembly. Refer to Section 4E1, Rear Disc Brakes. 10. On vehicles equipped with the antilock braking system, install the ABS speed sensor. Refer to Section 4F, Antilock Brake System. 11. Install the wheel. Refer to Section 2E, Tires and Wheels. 12. Lower the vehicle.

TRAILING LINK
Removal Procedure
1. 2. 3. 4. Raise and suitably support the vehicle. Remove the rear trailing link­to­rear knuckle nut. Remove the rear trailing link­to­trailing link bracket nut and the rear trailing link­to­knuckle bolt. Remove the rear trailing link.

DAEWOO V­121 BL4

REAR SUSPENSION 2D ­ 11 Installation Procedure
1. 2. Install the rear trailing link. Install the rear trailing link bracket nut and the bolt.

Tighten
Tighten the rear trailing link­to­trailing link bracket nut to 100 NSm (74 lb­ft). 3. Install the trailing link­to­knuckle nut.

Tighten
Tighten the rear trailing link­to­knuckle nut to 150 NSm (11 lb­ft). 4. Lower the vehicle.

TRAILING LINK BRACKET
Removal Procedure
1. 2. 3. Raise and suitably support the vehicle. Remove the trailing link­to­trailing link bracket nut and the bolt. Remove the trailing link bracket­to­body bolts.

4.

Remove the trailing link bracket.

Installation Procedure
1. Install the trailing link bracket.

DAEWOO V­121 BL4

2D ­ 12IREAR SUSPENSION
2. Install the trailing link bracket­to­body bolts.

Tighten
3. Tighten the trailing link bracket­to­body bolts to 70 NSm (52 lb­ft). Connect the trailing link to the trailing link bracket by installing the trailing link­to­trailing link bracket nut and bolt.

Tighten
4. Tighten the trailing link­to­trailing link bracket nut to 100 NSm (74 lb­ft). Lower the vehicle.

FRONT PARALLEL LINK
Removal Procedure
1. 2. 3. Raise and suitably support the vehicle. Remove the wheel. Refer to Section 2E, Tires and Wheels. For vehicles equipped with the antilock braking system, remove the ABS sensor from the knuckle and the ABS housing assembly from the front parallel link. Remove the front parallel link bolt from the rear crossmember. Remove the front parallel link bolt from the rear knuckle. Remove the front parallel link.

4. 5. 6.

Installation Procedure
1. 2. Install the front parallel link. Install the front parallel link onto the rear knuckle with the bolt.

Tighten
3. 4. Tighten the front parallel link­to­knuckle bolt to 120 NSm (89 lb­ft). Install the front parallel link onto the rear cross­ member with the bolt. Do not tighten. For vehicles equipped with the antilock braking system, install the ABS housing assembly onto the front parallel link and the ABS sensor line into the knuckle. Install the wheel. Refer to Section 2E, Tires and Wheels. Perform a rear toe adjustment. Refer to Section 2B, Wheel Alignment.

5. 6.

DAEWOO V­121 BL4

REAR SUSPENSION 2D ­ 13

REAR PARALLEL LINK
Removal Procedure
Raise and suitably support the vehicle. Remove the wheel. Refer to Section 2E, Tires and Wheels. Important : Before removing the parallel link­to­crossmember bolt, mark the position of the adjuster cam in relation to the parallel link and the crossmember. This adjuster cam must be placed in the same position when the parallel link is installed on the vehicle to maintain the proper rear toe. 3. Remove the rear parallel link bolt from the rear crossmember. 4. Remove the rear parallel link bolt from the rear knuckle. 5. Remove the rear parallel link. 1. 2.

Installation Procedure
1. 2. Install the rear parallel link. Install the rear parallel link­to­knuckle bolt.

Tighten
3. Tighten the rear parallel link­to­knuckle bolt to 120 NSm (89 lb­ft). Install the rear parallel link onto the rear crossmember. Install the rear parallel link­to­crossmember bolts.

Tighten
4. Tighten the rear parallel link­to­crossmember bolt to 90 NSm (66 lb­ft). Install the wheel. Refer to Section 2E, Tires and Wheels.

STABILIZER SHAFT
Removal Procedure
1. 2. 3. 4. Raise and suitably support the vehicle. Remove the stabilizer shaft clamp bolts. Remove the stabilizer shaft­to­stabilizer link nut. Remove the stabilizer shaft clamps, the insulators, and the stabilizer shaft from the vehicle.

DAEWOO V­121 BL4

2D ­ 14IREAR SUSPENSION Installation Procedure
1. 2. Install the stabilizer shaft, the insulators, and the stabilizer shaft clamps. Install the stabilizer shaft­to­stabilizer link nut.

Tighten
3. Tighten the stabilizer shaft­to­stabilizer link nut to 47 NSm (35 lb­ft). Install the stabilizer shaft clamp bolts.

Tighten
4. Tighten the stabilizer shaft clamp bolts to 40 NSm (30 lb­ft). Lower the vehicle.

STABILIZER LINK
Removal Procedure
1. 2. 3. 4. 5. Raise and suitably support the vehicle. Remove the wheel. Refer to Section 2E, Tires and Wheels. Remove the stabilizer shaft­to­stabilizer link nut. Remove the stabilizer link­to­strut assembly nut. Remove the stabilizer link.

Installation Procedure
1. 2. Install the stabilizer link. Install the stabilizer link­to­strut assembly nut.

Tighten
3. Tighten the stabilizer link­to­strut assembly nut to 47 NSm (35 lb­ft). Install the stabilizer shaft­to­stabilizer link nut.

Tighten
4. 5. Tighten the stabilizer shaft­to­stabilizer link nut to 47 NSm (35 lb­ft). Install the wheel. Refer to Section 2E, Tires and Wheels. Lower the vehicle.

CROSSMEMBER
Removal Procedure
1. 2. Raise and suitably support the vehicle. Remove the front parallel link bolt from the crossmember. Refer to "Front Parallel Link" in this section. Remove the rear parallel link bolt from the crossmember. Refer to "Rear Parallel Link"in this section. Remove the rear wheel speed sensor wiring from the crossmember.

3. 4.

DAEWOO V­121 BL4

REAR SUSPENSION 2D ­ 15
5. 6. Remove the crossmember­to­body bolts. Remove the crossmember.

Installation Procedure
1. 2. Install the crossmember. Install the crossmember­to­body bolts.

Tighten
3. 4. 5. 6. Tighten the crossmember­to­body bolts to 112 NSm (83 lb­ft). Route and install the rear wheel speed sensor wiring. Install the rear parallel link bolt onto the crossmember. Refer to "Rear Parallel Link"in this section. Install the front parallel link bolt onto the crossmember. Refer to "Front Parallel Link" in this section. Lower the vehicle.

HUB AND BEARING ASSEMBLY
Removal Procedure
1. 2. 3. Raise and suitably support the vehicle. Remove the wheel. Refer to Section 2E, Tires and Wheels. On vehicles equipped with rear drum brakes, remove the rear brake drum detent screw and brake drum. Refer to Section 4E2, Rear Drum Brakes. On vehicles equipped with rear disc brakes, remove the rear brake caliper and rear brake disc. Refer to Section 4E1, Rear Disc Brakes. Remove the hub bolts and hub assembly.

4.

5.

DAEWOO V­121 BL4

2D ­ 16IREAR SUSPENSION Installation Procedure
1. Install the hub assembly.

Tighten
2. 3. Tighten the hub assembly bolts to 65 NSm (48 lb­ft). Install the hub nut. On vehicles equipped with rear disc brakes, install the rear brake disc and rear brake caliper. Refer to Section 4E1, Rear Disc Brakes. On vehicles equipped with rear drum brakes, install the rear brake drum and the brake drum detent screw. Refer to Section 4E2, Rear Drum Brakes. Install the wheel. Refer to Section 2E, Tires and Wheels. Lower the vehicle.

4.

5. 6.

DAEWOO V­121 BL4

REAR SUSPENSION 2D ­ 17

UNIT REPAIR SPRINGS AND INSULATORS
Tools Required KM­329­A Spring Compressor

Disassembly Procedure
1. 2. Remove the rear strut assembly from the vehicle. Refer to "Strut Assembly" in this section. Mount the rear strut assembly into the spring compressor (KM­329­A or DW320­010). Ensure that the hooks are properly seated. Compress the spring. Remove the lock nut from the strut dampener rod.

3. 4.

5. 6. 7. 8.

Remove the rear strut mount. Remove the rear spring upper seat, the dust cover, and the hollow bumper. Release the spring. Remove the rear spring and the rear spring lower seat.

Assembly Procedure
1. 2. 3. 4. Install the rear spring lower seat and the rear spring. Compress the spring. Install the hollow bumper, the dust cover, and the rear spring upper seat. Install the rear strut mount.

DAEWOO V­121 BL4

2D ­ 18IREAR SUSPENSION
5. Install the lock nut onto the strut dampener rod.

Tighten
Tighten the ball joint­to­control arm nuts to 100 NSm (74 lb­ft). Tighten the strut dampener­to­strut mount nut to 75 NSm (55 lb­ft). Release the spring. Remove the strut assembly from the spring compressor and install the strut assembly into the vehicle. Refer to "Strut Assembly" in this section.

6. 7.

KNUCKLE
Disassembly Procedure
1. 2. 3. 4. Remove the knuckle from the vehicle. Refer to "Knuckle Assembly" in this section. Remove the brake drum. Refer to Section 4E2, Rear Drum Brakes. Remove the wheel hub. Refer to "Hub and Bearing Assembly" in this section. On vehicles equipped with rear drum brakes, remove the rear drum brake assembly. On vehicles equipped with rear disc brakes, remove the rear disc brake assembly. Refer to Section 4E1, Rear Disc Brakes. Remove the brake splash shield. Refer to Section 4E2, Rear Drum Brakes.

5.

Assembly Procedure
1. 2. Install the brake splash shield. Refer to Section 4E1, Rear Disc Brakes. On vehicles equipped with rear drum brakes, install the rear drum brake assembly. On vehicles equipped with rear disc brakes, install the rear disc brake assembly. Refer to Section 4E1, Rear Disc Brakes. Install the wheel hub. Refer to "Hub and Bearing Assembly" in this section. Install the brake caliper and brake rotor or the brake drum. Refer to Section 4E1, Rear Disc Brakes and 4E2, Rear Drum Brakes. Install the knuckle into the vehicle. Refer to "Knuckle Assembly" in this section.

3. 4.

5.

DAEWOO V­121 BL4

REAR SUSPENSION 2D ­ 19

HUB AND BEARING
The hub bearing is not unit repair serviceable. If the hub bearing is defective, the hub and bearing assembly should be replaced.

DAEWOO V­121 BL4

2D ­ 20IREAR SUSPENSION

GENERAL DESCRIPTION AND SYSTEM OPERATION
REAR SUSPENSION
The rear suspension is fully independent and consists of a crossmember with four parallel links, two trailing links, two strut assemblies with coil springs and insulators, and two knuckles containing the hub and bearing assemblies. The strut assemblies support the weight of the vehicle using coil springs positioned around the strut dampeners.

The coil springs are seated on insulators attached to the upper mount and the lower spring seat of the strut assembly. The parallel links and the trailing link bracket have rubber isolator bushings at each end and are attached to the crossmember and the knuckle. The rear parallel link is attached to the crossmember through adjustment cams that are used to adjust rear toe. The trailing links are attached to the body, through the trailing link bracket, and the bottom of the knuckle. A forged knuckle bolts to each strut assembly. Lateral movement of the knuckle is controlled by the parallel links. Fore and aft movement of the knuckle is controlled by the trailing link.

DAEWOO V­121 BL4