transaxle DAEWOO LACETTI 2004 Service User Guide

1C1 – 6I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
Application Lb–InLb–Ft NSm
Oil Pump Bolts10–89
Oil Pump Rear Cover Bolts8–71
Oil Pump Retaining Bolts10–89
Oil Suction Pipe or Support Bracket Bolts10–89
Rear Timing Belt Cover Bolts10–89
Safety Relief Valve Bolt303022–
Spark Plugs2518–
Thermostat Housing Mounting Bolts2015–
Timing Belt Automatic Tensioner Bolts2518–
Timing Belt Idler Pulley Bolt4030–
Transaxle Bell Housing Bolts7555–
Transaxle Torque Converter Bolts4533–
Upper Front Timing Belt Cover Bolts10–89
Water Pump Retaining Bolts10–89

1C1 – 14I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
ENGINE MOUNTING
1. Rear Power Unit Damping Block
2. Rear Transaxle Mounting Bracket (A/T)
3. Rear Transaxle Mounting Bracket (M/T)
4. Transaxle Mounting Cage
5. Transaxle Mounting Bracket (M/T)6. Transaxle Mounting Bracket (A/T)
7. Engine Undercover
8. Hydro Mounting
9. Engine Mounting Bracket

1C1 – 38I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
OIL PAN
Removal Procedure
1. Disconnect the negative battery cable.
2. Drain the Engine oil from the engine crankcase.
3. Remove the catalytic converter retaining nuts from
the exhaust pipe.
4. Remove the lower crossmember bracket.
5. Remove the exhaust connecting pipe.
6. Remove the oil pan bolts to the transaxle case.
7. Remove the oil pan retaining bolts to the engine
block.
8. Remove the oil pan from the engine block.

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 39
DAEWOO V–121 BL4
Cleaning Procedure
1. Clean the oil pan sealing surface.
2. Clean the engine block sealing surface.
3. Clean the oil pan retaining bolts.
4. Clean the oil pan attaching bolt holes in the engine
block.
Installation Procedure
1. Coat the new oil pan gasket with sealant.
Important : Install the oil pan within 5 minutes after apply-
ing the liquid gasket to the oil pan.
2. Install the oil pan to the engine block.
3. Install the oil pan retaining bolts.
Tighten
Tighten the oil pan retaining bolts to 10 NSm (89 lb–in).
4. Install the oil pan bolts to the transaxle case.
Tighten
Tighten the oil pan to the transaxle case bolts to 31
NSm (23 lb–ft).
5. Install the exhaust connecting pipe.
6. Install the catalytic converter retaining nuts to the
exhaust pipe.
Tighten
Tighten the catalytic converter to exhaust pipe retain-
ing nuts to 40 NSm (30 lb–ft).
7. Install the lower crossmember bracket.
8. Connect the negative battery cable.
9. Install the oil pan drain plug.
Tighten
Tighten the oil pan drain plug to 55 NSm (40 lb–ft).
10. Refill the engine crankcase with engine oil.

1C1 – 50I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
33. Remove the crankshaft pulley bolt.
34. Remove the crankshaft pulley.
35. Disconnect the vacuum lines at the charcoal canis-
ter purge solenoid.
36. Disconnect the electrical connector at the charcoal
canister purge (CCP) solenoid and at the knock
sensor.
37. Disconnect the electrical connector at the oil pres-
sure switch and at the exhaust gas recirculation
(EGR) solenoid.
38. Disconnect the crankshaft position sensor (CPS)
connector.
39. Remove the transaxle torque converter bolts, if au-
tomatic transaxle equipped.
40. Remove the stater motor. Refer to Section 1E, En-
gine Electrical.
41. Remove the transaxle bell housing bolts.
42. Support the transaxle with a floor jack.
43. Install the engine lifting device.
44. Disconnect the right engine mount bracket from the
engine mount and the engine by removing the at-
taching bolts and the nuts.
45. Remove the right engine mount from the engine
block. Refer to ”Engine Mount” in this section.
46. Separate the engine block from the transaxle.
47. Remove the engine.
Installation Procedure
1. Install the engine into the engine compartment.
2. Align the engine alignment pins to the transaxle.
3. Install the transaxle bell housing bolts.
Tighten
Tighten the transaxle bell housing bolts to 75 NSm (55
lb–ft).
4. Install the right engine mount to the engine block.
Refer to ”Engine Mount” in this section.

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 51
DAEWOO V–121 BL4
5. Connect the right engine mount bracket to the en-
gine mount and the engine by installing the attach-
ing bolts and the nuts.
Tighten
Tighten the engine mount bracket attaching bolts and
the nuts to 55 NSm (41 lb–ft).
6. Remove the floor jack used for support of the trans-
axle.
7. Remove the engine lifting device.
8. Install the transaxle torque converter bolts, if auto-
matic transaxle equipped.
Tighten
Tighten the transaxle torque converter bolts to 45
NSm (33 lb–ft).
9. Install the starter motor. Refer to Section 1E, En-
gine Electrical.
10. Connect the vacuum lines at the CCP solenoid.
11. Connect the electrical connector at the CCP sole-
noid and at the knock sensor.
12. Connect the oil pressure switch and the EGR sole-
noid connectors.
13. Install the crankshaft pulley.
14. Install the crankshaft pulley bolt.
Tighten
Tighten the crankshaft pulley bolt to 95 NSm (70 lb–ft)
and retighten 30 degrees plus 15 degrees.
15. Connect the CPS connector.
16. Install the exhaust front pipe.
17. Install the catalytic converter retaining nuts to the
exhaust pipe.
Tighten
Tighten the catalytic converter to exhaust pipe retain-
ing nuts to 35 NSm (26 lb–ft).

1C1 – 74I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
56. Install the engine lifting device.
57. Remove the engine from the engine overhaul stand
KM–412.
58. Install a new crankshaft rear oil seal using the in-
staller J–36792 or KM–635.
59. Install the flywheel or the flexible plate.
60. Install the flywheel or the flexible plate bolts.
Tighten
Tighten the flywheel bolts to 35 NSm (25 lb–ft). Use
the angular torque gauge KM–470–B to tighten the
flywheel bolts another 30 degrees plus 15 degrees. If
the vehicle is equipped with an automatic transaxle,
tighten the flexible plate bolts to 45 NSm (33 lb–ft).
61. Install the engine. Refer to ”Engine” in this section.
CRANKSHAFT BEARINGS AND
CONNECTING ROD BEARINGS –
GAUGING PLASTIC
Tools Required
KM–470–B Angular Torque Gauge
Inspection Procedure – Crankshaft
1. Coat the crankshaft bearings with engine oil.
2. Install the upper crankshaft bearings into the engine
block crankshaft journals.
3. Install the lower crankshaft bearings into the crank-
shaft bearing caps.

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 – 5
DAEWOO V–121 BL4
Application Lb–InLb–Ft NSm
Oil Pan Retaining Bolts10–89
Oil Pressure Switch4030–
Oil Suction Pipe Bolts8–71
Oil Suction Pipe Support Bracket Bolts16–53
Oil Pump Rear Cover Bolts6–53
Oil Pump Retaining Bolts10–89
Pulse Pickup Sensor Disc1310–
Rear Timing Belt Cover Bolts7–62
Safety Relief Valve Bolt3022–
Spark Plug Cover Bolts8–71
Spark Plugs2015–
Thermostat Housing Mounting Bolts1511–
Throttle Cable Bracket Bolts8–71
Timing Belt Automatic Tensioner Bolts2518–
Timing Belt Idler Pulley Bolt2518–
Timing Belt Idler Pulley Nut2518–
Transaxle Bell Housing Bolts7555–
Transaxle Torque Converter Bolts6044–

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