Timing belt DAEWOO LACETTI 2004 Service Owner's Manual

1C1 – 36I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
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
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.

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 43
DAEWOO V–121 BL4
4. Coat the threads of the oil suction pipe and support
bracket bolts with Loctite® 242.
5. Install the oil suction pipe and bolts.
Tighten
Tighten the oil suction pipe and support bracket bolts
to 10 NSm (89 lb–in).
6. Install the oil pan. Refer to ”Oil Pan” in this section.
7. Connect the oil pressure switch connector.
8. Install the rear timing belt cover. Refer to ”Rear
Timing Belt Cover” in this section.
9. Install the timing belt. Refer to ”Timing Belt” in this
section.
10. Install the power steering pump, if equipped. Refer
to Section 6A, Power Steering System.
11. Connect the negative battery cable.
ENGINE MOUNT
Tools Required
DW110–060 Engine Support Fixture
Removal Procedure
1. Disconnect the negative battery cable.
2. Support the engine assembly using the engine sup-
port fixture DW110–060.
3. Remove the engine mount bracket attaching bolts/
nuts.
4. Remove the front timing belt cover. Refer to ”Timing
Belt” in this section.

1C1 – 44I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
5. Remove the engine mount attaching bolts/nuts.
6. Remove the engine mount.
Installation Procedure
1. Install the engine mount.
2. Install the engine mount retaining bolts.
Tighten
Tighten the engine mount attaching bolts to 30 NSm
(22 lb–ft).
3. Install the front timing belt cover. Refer to ”Timing
Belt” in this section.
4. Install the engine mount bracket attaching bolts/
nuts.
Tighten
Tighten the engine mount bracket attaching bolts/
nuts to 55 NSm (41 lb–ft).
5. Remove engine assembly support fixture
DW110–060.
6. Connect the negative battery cable.

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 45
DAEWOO V–121 BL4
CAMSHAFT GEARS
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the engine cover.
3. Remove the timing belt. Refer to ”Timing Belt” in
this section.
4. Disconnect the ignition wires from the spark plugs.
5. Disconnect the engine ventilation hoses from the
camshaft cover.
6. Remove the camshaft cover bolts.
7. Remove the camshaft cover and the camshaft cov-
er gasket.
Notice : Take extreme care to prevent any scratches,
nicks or damage to the camshafts.
8. While holding the intake camshaft firmly in place,
remove the intake camshaft gear bolt.
9. Remove the intake camshaft gear.
10. While holding the exhaust camshaft firmly in place,
remove the exhaust camshaft gear bolt.
11. Remove the exhaust camshaft gear.
Installation Procedure
Notice : Take extreme care to prevent any scratches,
nicks or damage to the camshafts.
1. Install the intake camshaft gear.
2. While holding the intake camshaft firmly in place,
install the intake camshaft gear bolt.
Tighten
Tighten the intake camshaft gear bolt to 67.5 NSm (49
lb–ft).

1C1 – 46I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
3. Install the exhaust camshaft gear.
4. While holding the exhaust camshaft firmly in place,
install the exhaust camshaft gear bolt.
Tighten
Tighten the exhaust camshaft gear bolt to 67.5 NSm
(49 lb–ft).
5. Apply a small amount of gasket sealant to the cor-
ners of the front camshaft caps and to the top of
the rear camshaft cover–to–cylinder head seal.
6. Install the camshaft cover and the camshaft cover
gasket.
7. Install the camshaft cover bolts.
Tighten
Tighten the camshaft cover nuts to 10 NSm (89 lb–in).
8. Connect the engine ventilation hoses to the cam-
shaft cover.
9. Connect the ignition wires to the spark plugs.
10. Install the timing belt. Refer to ”Timing Belt” in this
section.
11. Install the engine cover. Refer to ”Engine Cover” in
this section.
12. Connect the negative battery cable.
REAR TIMING BELT COVER
Removal Procedure
1. Remove the timing belt and the timing belt cover.
Refer to ”Timing Belt” in this section.
2. Remove the camshaft gears. Refer to ”Camshaft
Gears” in this section.
3. Remove the crankshaft gear.
4. Remove the timing belt automatic tensioner bolts.
5. Remove the timing belt automatic tensioner.

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 47
DAEWOO V–121 BL4
6. Remove the timing belt idler pulley bolt.
7. Remove the timing belt idler pulley.
8. Remove the rear timing belt cover bolts.
9. Remove the rear timing belt cover.
Installation Procedure
1. Install the rear timing belt cover.
2. Install the rear timing belt cover bolts.
Tighten
Tighten the rear timing belt cover bolts to 10 NSm (89
lb–in).
3. Install the timing belt idler pulley.
4. Install the timing belt idler pulley bolt.
Tighten
Tighten the timing belt idler pulley bolt to 40 NSm (30
lb–ft).

1C1 – 48I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
5. Install the timing belt automatic tensioner.
6. Install the timing belt automatic tensioner bolts.
Tighten
Tighten the timing belt automatic tensioner bolts to 25
NSm (18 lb–ft).
7. Install the crankshaft gear.
Notice : Take extreme care to prevent any scratches,
nicks or damage to the camshafts.
8. Install the camshaft gears. Refer to ”Camshaft
Gears” in this section.
9. Install the timing belt and timing belt cover. Refer to
”Timing Belt” in this section.
ENGINE
Removal Procedure
1. Remove the fuel pump fuse.
2. Start the engine. After it stalls, crank the engine for
10 seconds to rid the fuel system of fuel pressure.
3. Remove the hood. Refer to Section 9R, Body Front
End.
4. Drain the engine oil.
5. Disconnect the negative battery cable.
6. Remove the air cleaner outlet hose from the throttle
body and air cleaner housing.
7. Disconnect the breather tubes from the camshaft
cover.
8. Remove the serpentine accessory drive belt. Refer
to Section 6B, Power Steering Pump.
9. Remove the right front wheel. Refer to Section 2E,
Tires and Wheels.
10. Remove the right front wheel well splash shield.
11. Drain the engine coolant. Refer to Section 1D, En-
gine Cooling.
12. Remove the cooling system radiator and the engine
cooling fans. Refer to Section 1D, Engine Cooling.
13. Disconnect the upper radiator hose from the ther-
mostat housing.
14. Disconnect the power steering return hose from the
power steering pump. Refer to Section 6A, Power
Steering System.
15. Disconnect the power steering pressure hose from
the power steering pump. Refer to Section 6A,
Power Steering System.
16. Disconnect the electrical connector at the direct
ignition system (DIS) coil and the electronic control
module (ECM) ground terminal at the intake man-
ifold and at the starter motor.

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 65
DAEWOO V–121 BL4
28. Install the fuel rail assembly with the bolts.
Tighten
Tighten the fuel rail assembly retaining bolts to 25
NSm (18 lb–ft).
29. Install the thermostat housing assembly.
30. Install the thermostat housing mounting bolts.
Tighten
Tighten the thermostat housing mounting bolts to 20
NSm (15 lb–ft).
31. Install the exhaust manifold studs.
32. Install the exhaust manifold gasket.
33. Install the exhaust manifold.
34. Install the exhaust manifold retaining nuts in the
sequence shown.
Tighten
Tighten the exhaust manifold retaining nuts to 25 NSm
(18 lb–ft).
35. Install the exhaust manifold heat shield.
36. Install the exhaust manifold heat shield bolts.
Tighten
Tighten the exhaust manifold heat shield bolts to 15
NSm (11 lb–ft).
37. Install the ECT sensor.
Tighten
Tighten the engine coolant temperature sensor to 20
NSm (15 lb–ft).
38. Install the cylinder head with the intake manifold
and the exhaust manifold attached. Refer to ”Cylin-
der Head and Gasket” in this section.
CRANKSHAFT
Tools Required
KM–412 Engine Overhaul Stand
J–42492 Timing Belt Adjuster
KM–470–B Angular Torque Gauge
J–36792 or KM–635 Crankshaft Rear Oil Seal Installer
Notice : Take extreme care to prevent any scratches,
nicks, or damage to the camshafts.
Disassembly Procedure
1. Remove the engine. Refer to ”Engine” in this sec-
tion.
2. Remove the flywheel or flexible plate bolts.
3. Remove the flywheel or the flexible plate.