Section 5 DAEWOO LACETTI 2004 Service Owner's Manual

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 29
DAEWOO V–121 BL4
38. Connect the DIS coil connector.
39. Connect the fuel injector harness connectors.
40. Connect the oxygen sensor connector and the
ECM ground terminal at the intake manifold.
41. Install the fuel pump fuse.
42. Connect the negative battery ground cable.
43. Refill the engine cooling system. Refer to Sec-
tion1D, Engine Cooling.
CAMSHAFTS
Removal Procedure
1. Remove the camshaft cover. Refer to ”Camshaft
Cover” in this section.
2. Remove the timing belt. Refer to ”Timing Belt” in
this section.
Notice : Take extreme care to prevent any scratches,
nicks or damage to the camshafts.
3. While holding the intake camshaft firmly in place,
remove the intake camshaft gear bolt and gear.
4. While holding the exhaust camshaft firmly in place,
remove the exhaust camshaft gear bolt and gear.
5. Remove the camshaft cap bolts gradually in the
sequence shown for each camshaft cap.

1C1 – 30I1.4L/1.6L DOHC ENGINE MECHANICAL
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6. Remove the intake/exhaust camshaft caps. Main-
tain the correct positions for installation.
7. Remove the intake/exhaust camshaft.
Installation Procedure
Notice : Take extreme care to prevent any scratches,
nicks or damage to the camshafts.
1. Lubricate the camshaft journals and the camshaft
caps with engine oil.
2. Install the intake/exhaust camshafts.
3. Install the intake/exhaust camshaft caps in their
original positions.
Tighten
Tighten the intake/exhaust camshaft caps bolts to 16
NSm (12 lb–ft).
4. Measure the intake/exhaust camshaft end play.Ref-
er to the ”Engine Specifications” in this section.
5. Install the intake/exhaust camshaft gear.
6. While holding the intake/exhaust camshafts firmly
in place, install the intake/exhaust camshaft gear
bolts.
Tighten
Tighten the intake/exhaust camshaft gear bolts to
67.5 NSm (49 lb–ft).
7. Install the timing belt. Refer to ”Timing Belt” in this
section.
8. Install the camshaft cover. Refer to ”Camshaft Cov-
er” in this section.

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 31
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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
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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
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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 – 35
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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.
16. Using the crankshaft pulley bolt, rotate the crank-
shaft clockwise until the timing mark on the crank-
shaft gear is aligned with the notch at the bottom of
the rear timing belt cover.
17. Slightly loosen the water pump retaining bolts.
18. Using the timing belt adjuster J–42492, rotate the
water pump counterclockwise to release the tension
on the timing belt.
19. Remove the right engine mount bracket. Refer to
”Engine Mount” in this section.
20. Remove the timing belt.

1C1 – 36I1.4L/1.6L DOHC ENGINE MECHANICAL
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Installation Procedure
1. Align the timing mark on the crankshaft gear with
the notch on the bottom of the rear timing belt cov-
er.
2. Align the timing marks on the camshaft gears.
3. Install the timing belt.
4. Install the right engine mount bracket. Refer to ”En-
gine Mount” in this section.
5. Rotate the water pump clockwise using the timing
belt adjuster J–42492.
6. Rotate the water pump clockwise until the adjust
arm pointer of the timing belt automatic tensioner is
aligned with the notch in the timing belt automatic
tensioner bracket.
7. Tighten the water pump retaining bolts.
8. Rotate the crankshaft two full turns clockwise using
the crankshaft pulley bolt.
9. Loosen the water pump retaining bolts.
10. Rotate the water pump until the adjust arm pointer
of the timing belt automatic tensioner is aligned with
the pointer on the timing belt automatic tensioner
bracket.

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 37
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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
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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.

1C1 – 42I1.4L/1.6L DOHC ENGINE MECHANICAL
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7. Clean the oil pump housing and all the oil pump
parts.
8. Inspect all the oil pump parts for signs of wear. Re-
fer to ”Engine Specifications” in this section. Re-
place the worn oil pump parts.
Notice : Pack the oil pump gear cavity with petroleum jelly
to ensure an oil pump prime, or engine damage could re-
sult.
9. Coat all the oil pump parts with clean engine oil.
Install the oil pump parts.
10. Apply Loctite® 242 to the oil pump rear cover bolts
and install the cover and bolts.
Tighten
Tighten the oil pump rear cover bolts to 8 NSm (71 lb–
in).
11. Install the safety relief valve, spring, washer and
bolt.
Tighten
Tighten the safety relief valve bolt to 30 NSm (22 lb–ft).
Installation Procedure
1. Apply Loctite® 242 to the oil pump bolts and room
temperature vulcanizing (RTV) sealant to the new
oil pump gasket.
2. Install the gasket to the oil pump and install the oil
pump to the engine block with the bolts.
Tighten
Tighten the oil pump bolts to 10 NSm (89 lb–in).
3. Install a new oil pump–to–crankshaft seal. Coat the
lip of the seal with a thin coat of grease.