wheel DAEWOO LACETTI 2004 Service User Guide

GENERAL ENGINE INFORMATION 1A – 5
DAEWOO V–121 BL4
Heavy Knock Hot with Torque Applied
StepActionValue(s)YesNo
1Is there a heavy knock when the engine is hot and
torque is applied?–Go to Step 2System OK
2Inspect the balancer and the pulley hub.
Is the balancer or the pulley hub broken?–Go to Step 3Go to Step 4
3Replace the broken balancer or the pulley hub.
Is the repair complete?–Go to Step 1–
4Inspect the torque converter bolts.
Are the bolts tightened to specified value?45 NSm
(33 lb–ft)Go to Step 5Go to Step 6
5Tighten the torque converter bolts.
Is the repair complete?–Go to Step 1–
6Inspect the accessory belts.
Are the belts too tight or nicked?–Go to Step 7Go to Step 8
7Replace and/or tension the belts to specifications,
as necessary.
Is the repair complete?–Go to Step 1–
8Inspect the exhaust system.
Is the system grounded?–Go to Step 9Go to Step 10
9Reposition the system, as necessary.
Is the repair complete?–Go to Step 1–
10Inspect the flywheel.
Is the flywheel cracked?–Go to Step 11Go to Step 12
11Replace the flywheel.
Is the repair complete?–Go to Step 1–
12Inspect the main bearing clearance.
Is the clearance more than the specified value?0.026~0.046
mm (0.0010~
0.0018 in.)Go to Step 13Go to Step 14
13Replace the main bearings, as necessary.
Is the repair complete?–Go to Step 1–
14Inspect the rod bearing clearance.
Is the clearance more than the specified value?0.019 ~
0.070 mm
(0.0007 ~
0.0028 in.)Go to Step 15System OK
15Replace the rod bearings, as necessary.
Is the repair complete?–Go to Step 1–

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 – 11
DAEWOO V–121 BL4
1. Piston Ring Set
2. Piston
3. Piston Pin
4. Connecting Rod
5. Connecting Rod Bearing Set
6. Oil Level Gauge Stick
7. Gauge Stic Tube
8. Sleeve
9. Clutch Housing Sleeve
10. Cylinder Block
11. Plug
12. Gap
13. Bypass Valve
14. Connecting Piece
15. Oil Filter
16. Oil Pump Body Gasket
17. Water Inlet Neck
18. Knock Sensor
19. Fly Wheel (M/T)
20. Flexible Plate (A/T)
21. Shaft Seal Ring
22. Crank Shaft Upper Bearing Set
23. Crank Shaft24. Crank Shaft Lower Bearing Set
25. Transmitter Disc
26. Crankshaft Bearing Cap
27. Oil Pan
28. Threaded Ring
29. Washer
30. Oil Pan Drain Plug
31. Oil Pump
32. Oil Pump Cover
33. Oil Pump Inner Rotor
34. Oil Pump Outer Rotor
35. Oil Pump Plug
36. Shaft Sealing
37. Pressure Relief Valve Plunger
38. Relief Valve Spring
39. Sealing
40. Relief Valve
41. Oil Pressure Switch
42. Sleeve
43. Oil Suction Pipe Bracket
44. Oil Suction Pipe
45. Sealing

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 23
DAEWOO V–121 BL4
12. Remove the all the vaccum hoses from the intake
manifold including brake booster vaccum hose.
13. Remove the ignition cables from the spark plugs.
14. Remove the direct ignition coil(DIS) and the bracket
from the cylinder head.
15. Remove the serpentine accessory drive belt by ro-
tating the tensioner pulley bolt to clockwise using
DW110–080. Refer to Section 6B, Power Steering
Pump.
16. Remove the front passenger side tire. Refer to Sec-
tion 2E, Tires and Wheels.
17. Remove front wheel housing shield.
18. Remove the upper front timing belt cover bolts.
19. Remove the upper front timing belt cover.
20. Align the camshaft gear timing marks.
21. Remove the crank shaft pulley.
22. Remove the lower front timing belt cover bolts and
cover.

1C1 – 28I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
25. Install the timing belt.
26. Rotate the water pump clockwise using the timing
belt adjuster J–42492 to apply tension to the timing
belt.
Tighten
Tighten the water pump retaining bolts to 10 NSm (89
lb–in).
27. Check and adjust the timing belt tension. Refer to
”Timing Belt Check and Adjust” in this section.
28. Install the upper and lower front timing belt covers.
Tighten
Tighten the upper and lower front timing belt covers
bolts to 10 NSm (89 lb–in).
29. Install the crank shaft pulley bolt.
Tighten
Tighten the crank shaft pulley bolt to 95 NSm (70 lb–ft)
and retighten 30 degrees plus 15 degrees.
30. Install the serpentine accessory drive belt. Refer to
Section 6B, Power Steering Pump.
31. Connect the upper radiator hose to the thermostat
housing.
32. Install the front wheel and splash shield. Refer to
Section 2E, Tires and Wheels.
33. Install the air cleaner housing.
Tighten
Tighten the air cleaner housing bolts to 10 NSm (89 lb–
in).
34. Connect the breather tube to the cam shaft cover.
35. Install the crank shaft pulley bolt.
36. Connect the MAT sensor connector.
37. Connect the intake manifold pressure sensor, in-
take air temperature sensor and coolant tempera-
ture sensor connector.

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 31
DAEWOO V–121 BL4
TIMING BELT CHECK AND ADJUST
Tools Required
J–42492 Timing Belt Adjuster
KM–470–B Angular Torque Gauge
Adjustment Procedure
1. Disconnect the negative battery cable.
2. Remove the air cleaner outlet hose from the throttle
body.
3. Remove the breather tube from the camshaft cover.
4. Remove the air cleaner housing bolts.
5. Remove the air cleaner housing.
6. Remove the right front wheel. Refer to Section 2E,
Tires and Wheels.
7. Remove the right front wheel well splash shield.
8. Remove the serpentine accessory drive belt. Refer
to Section 6B, Power Steering Pump.
9. Remove the crankshaft pulley bolt.
10. Remove the crankshaft pulley.
11. Remove the upper front timing belt cover bolts.
12. Remove the upper front timing belt cover.
13. Remove the lower front timing belt cover bolts.
14. Remove the lower front timing belt cover.
15. Install the crankshaft pulley bolt.

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 33
DAEWOO V–121 BL4
25. Using the timing belt adjuster J–42492, rotate the
water pump until the adjust arm pointer of the tim-
ing belt automatic tensioner is aligned with the
pointer on the timing belt automatic tensioner
bracket.
26. Tighten the water pump retaining bolts.
Tighten
Tighten the water pump retaining bolts to 10 NSm (89
lb–in).
27. Remove the crankshaft pulley bolt.
28. Install the upper and lower front timing belt covers.
29. Install the upper and lower front timing belt cover
bolts.
Tighten
Tighten the front timing belt cover bolts to 10 NSm (89
lb–in).
30. Install the crankshaft pulley.
31. Install the crankshaft pulley bolt.
Tighten
Tighten the crankshaft pulley bolt to 95 NSm (70 lb–ft)
and retighten 30 degrees plus 15 degrees.
32. Install the serpentine accessory drive belt. Refer to
Section 6B, Power Steering Pump.
33. Install the right front wheel well splash shield.
34. Install the right front wheel. Refer to Section 2E,
Tires and Wheels.
35. Install the air cleaner housing.
36. Install the air cleaner housing bolts.
Tighten
Tighten the air cleaner housing bolts to 10 NSm (89 lb–
in).

1C1 – 34I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
37. Connect the air cleaner outlet hose to the throttle
body.
38. Connect the breather tube to the camshaft cover.
39. Connect the negative battery cable.
TIMING BELT
Tools Required
J–42492 Timing Belt Adjuster
KM–470–B Angular Torque Gauge
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the air cleaner outlet hose from the
throttle body.
3. Disconnect the breather tube from the camshaft
cover.
4. Remove the air cleaner housing bolts.
5. Remove the air cleaner housing.
6. Remove the right front wheel. Refer to Section 2E,
Tires and Wheels.
7. Remove the right front wheel well splash shield.
8. Remove the serpentine accessory drive belt. Refer
to Section 6B, Power Steering Pump.
9. Remove the crankshaft pulley bolt.
10. Remove the crankshaft pulley.

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 37
DAEWOO V–121 BL4
11. Tighten the water pump retaining bolts.
Tighten
Tighten the water pump retaining bolts to 10 NSm (89
lb–in).
12. Remove the crankshaft pulley bolt.
13. Install the upper and lower front timing belt covers.
14. Install the upper and lower front timing belt cover
bolts.
Tighten
Tighten the front timing belt cover bolts to 10 NSm (89
lb–in).
15. Install the crankshaft pulley.
16. Install the crankshaft pulley bolt.
Tighten
Tighten the crankshaft pulley bolt to 95 NSm (70 lb–ft)
and retighten 30 degrees plus 15 degrees.
17. Install the serpentine accessory drive belt. Refer to
Section 6B, Power Steering Pump.
18. Install the right front wheel well splash shield.
19. Install the right front wheel. Refer to Section 2E,
Tires and Wheels.
20. Install the air cleaner housing.
21. Install the air cleaner housing bolts.
Tighten
Tighten the air cleaner housing bolts to 10 NSm (89 lb–
in).
22. Connect the air cleaner outlet hose to the throttle
body.
23. Connect the breather tube to the camshaft cover.
24. Connect the negative battery cable.

1C1 – 40I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
OIL PUMP
Tools Required
KM–498–B Pressure Gauge
KM–135 Adapter
Engine Oil Pressure Inspection Procedure
1. Remove the right front wheel, wheel well splash
shield and engine undercover.
2. Disconnect the oil pressure switch connector.
3. Install the adapter KM–135 in place of the oil pres-
sure switch.
4. Connect the pressure gauge KM–498–B to the
adapter.
5. Start the engine and check the oil pressure at idle
speed and engine temperature of 80°C (176°F).
The minimum oil pressure should be 30 kPa (4.35
psi).
6. Stop the engine and remove the pressure gauge
KM–498–B and the adapter KM–135.
7. Install the oil pressure switch.
Tighten
Tighten the oil pressure switch to 40 NSm (30 lb–ft).
8. Connect the oil pressure switch connector.
9. Install the right front wheel well splash shield, en-
gine undercover and wheel.
10. Check the oil level. Pour oil until it reaches the full
mark.
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the power steering pump, if equipped. Re-
fer to Section 6A, Power Steering System.
3. Remove the timing belt. Refer to”Timing Belt” in this
section.
4. Remove the rear timing belt cover. Refer to ”Rear
Timing Belt Cover” in this section.
5. Disconnect the oil pressure switch connector.