egr DAEWOO LACETTI 2004 Service Owner's Manual

1C1 – 76I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
12. Remove the crankshaft bearing caps.
13. Measure the width of the flattened plastic thread of
the plastic gauging using a ruler. (Plastic gauging is
available for different tolerance ranges.)
14. Inspect the bearing clearances for permissible toler-
ance ranges. Refer to ”Engine Specifications” in
this section.
Inspection Procedure – Connecting Rods
1. Coat the connecting rod bearings with engine oil.
2. Install the upper connecting rod bearings into the
connecting rod journals.
3. Install the lower connecting rod bearings into the
connecting rod bearing caps.
Notice : Grease the connecting rod journals and lubricate
the connecting rod bearings slightly so that the plastic
gauging thread does not tear when the connecting rod
bearing caps are removed.
4. Inspect all of the connecting rod bearing clearances
using a commercially available plastic gauging
(ductile plastic threads).
5. Cut the plastic gauging threads to the length of the
bearing width. Lay them axially between the con-
necting rod journals and the connecting rod bear-
ings.
6. Install the connecting rod bearing caps.
7. Install the connecting rod bearing cap bolts.
Tighten
Tighten the connecting rod bearing cap bolts to 25
NSm (18 lb–ft). Using the angular torque gauge
KM–470–B, tighten the connecting rod bearing cap
bolts another 30 degrees plus 15 degrees.
8. Remove the connecting rod bearing caps.
9. Measure the width of the flattened plastic thread of
the plastic gauging using a ruler. (Plastic gauging is
available for different tolerance ranges.)
10. Inspect the bearing clearance for permissible toler-
ance ranges. Refer to ”Engine Specifications” in
this section.

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 77
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
CYLINDER HEAD AND GASKET
The cylinder head is made of an aluminum alloy. The cylin-
der head uses cross–flow intake and exhaust ports. A
spark plug is located in the center of each combustion
chamber. The cylinder head houses the dual camshafts.
CRANKSHAFT
The crankshaft has eight integral weights which are cast
with it for balancing. Oil holes run through the center of the
crankshaft to supply oil to the connecting rods, the bear-
ings, the pistons, and the other components. The end
thrust load is taken by the thrust washers installed at the
center journal.
TIMING BELT
The timing belt coordinates the crankshaft and the dual
overhead camshafts and keeps them synchronized. The
timing belt also turns the water pump. The timing belt and
the pulleys are toothed so that there is no slippage be-
tween them. There are two idler pulleys. An automatic ten-
sioner pulley maintains the timing belt’s correct tension.
The timing belt is made of a tough reinforced rubber similar
to that used on the serpentine accessory drive belt. The
timing belt requires no lubrication.
OIL PUMP
The oil pump draws engine oil from the oil pan and feeds
it under pressure to the various parts of the engine. An oil
strainer is mounted before the inlet of the oil pump to re-
move impurities which could clog or damage the oil pump
or other engine components. When the drive gear rotates,
the driven gear rotates. This causes the space between
the gears to constantly open and narrow, pulling oil in from
the oil pan when the space opens and pumping the oil out
to the engine as it narrows.
At high engine speeds, the oil pump supplies a much high-
er amount of oil than is required for lubrication of the en-
gine. The oil pressure regulator prevents too much oil from
entering the engine lubrication passages. During normal
oil supply, a coil spring and valve keep the bypass closed,
directing all of the oil pumped to the engine. When the
amount of oil being pumped increases, the pressure be-
comes high enough to overcome the force of the spring.This opens the valve of the oil pressure regulator, allowing
the excess oil to flow through the valve and drain back to
the oil pan.
OIL PAN
The engine oil pan is mounted to the bottom of the cylinder
block. The engine oil pan houses the crankcase and is
made of cast metal.
Engine oil is pumped from the oil pan by the oil pump. After
it passes through the oil filter, it is fed through two paths
to lubricate the cylinder block and the cylinder head. In one
path, the oil is pumped through the oil passages in the
crankshaft to the connecting rods, then to the pistons and
the cylinders. It then drains back to the oil pan. In the sec-
ond path, the oil is pumped through the oil passages to the
camshaft. The oil passes through the internal passage-
ways in the camshafts to lubricate the valve assemblies
before draining back to the oil pan.
EXHAUST MANIFOLD
A single four–port, rear–takedown manifold is used with
this engine. The manifold is designed to direct escaping
exhaust gases out of the combustion chambers with a
minimum of back pressure. The oxygen sensor is
mounted to the exhaust manifold.
INTAKE MANIFOLD
The intake manifold has four independent long ports and
uses inertial supercharging to improve engine torque at
low and moderate speeds. The plenum is attached to the
intake manifold.
CAMSHAFTS
This engine is a dual overhead camshaft (DOHC) type,
which means there are two camshafts. One camshaft op-
erates the intake valves, and the other camshaft operates
the exhaust valves. The camshafts sit in journals on the
top of the engine in the cylinder head and are held in place
by camshaft caps. The camshaft journals of the cylinder
head are drilled to create oil passages. Engine oil travels
to the camshafts under pressure where it lubricates each
camshaft journal. The oil returns to the oil pan through
drain holes in the cylinder head. The camshaft lobes are
machined into the solid camshaft to open and close the in-
take and the exhaust valves precisely the correct amount
at the correct time. The camshaft lobes are oiled by splash
action from pressurized oil escaping from the camshaft
journals.

1C2 – 16I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
40. Remove the timing belt idler pulley bolt and nut.
41. Remove the timing belt idler pulleys.
42. Remove the engine mount bolts.
43. Remove the engine mount.
44. Remove the rear timing belt cover bolts.
45. Remove the rear timing belt cover.
46. Remove the exhaust flex pipe retaining nuts at the
exhaust manifold studs.
47. Disconnect all of the necessary vacuum hoses.
48. Disconnect the fuel feed line at the fuel rail.
49. Remove the generator adjusting bracket retaining
bolt and the bracket.
50. Disconnect the coolant hose at the rear cylinder
head and ignition coil exhaust gas recirculation
(EGR) bracket.
51. Disconnect the surge tank coolant hose at the
throttle body.
52. Remove the fuel rail assembly. Refer to Section 1F,
Engine Controls.

1.8L DOHC ENGINE MECHANICAL 1C2 – 17
DAEWOO V–121 BL4
53. Remove the generator–to–intake manifold support
bracket bolts at the cylinder head and the intake
manifold.
54. Remove the generator support bracket.
55. Remove the intake manifold–to–generator strap
bracket bolt and loosen the bolt on the generator.
56. Move the strap clear of the intake manifold.
57. Remove the charcoal canister purge (CCP) and
EGR solenoid bracket bolt and move the bracket
clear.
58. Disconnect the throttle cable at the throttle body
and the intake manifold.
59. Loosen all of the cylinder head bolts gradually and
in the sequence shown.
60. Remove the cylinder head bolts.
61. Remove the cylinder head with the intake manifold
and the exhaust manifold attached.
Notice : Prevent any engine oil or coolant from entering
the cylinders when removing the cylinder head.
62. Remove the cylinder head gasket.
Cleaning Procedure
1. Clean the gasket surfaces of the cylinder head and
the engine block.
2. Make sure the gasket surfaces of the cylinder head
and the engine block are free of nicks and heavy
scratches.
3. Clean the cylinder head bolts.
4. Inspect the cylinder head for warpage. Refer to
”Cylinder Head and Valve Train Components” in
this section.
Installation Procedure
1. Install the cylinder head gasket.
2. Install the cylinder head with the intake manifold
and the exhaust manifold attached.
3. Install the cylinder head bolts.
4. Tighten the cylinder head bolts gradually and in the
sequence shown.

1C2 – 18I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
Tighten
Tighten the cylinder head bolts to 25 NSm (18 lb–ft)
and turn the bolts another 3 turns of 90 degrees using
the angular torque gauge KM–470–B.
5. Connect the throttle cable at the throttle body and
the intake manifold.
6. Install the generator–to–intake manifold support
bracket.
7. Install the intake generator–to–manifold support
bracket bolts.
Tighten
Tighten the generator–to–intake manifold support
bracket bolts to the intake manifold to 37 NSm (27 lb–
ft).
8. Install the intake manifold support bracket bolt to
the generator.
Tighten
Tighten the generator–to–intake manifold support
bracket bolt at the generator to 22 NSm (16 lb–ft).
9. Connect the surge tank coolant hose at the throttle
body.
10. Connect the coolant hose to the rear cylinder head
and ignition coil EGR bracket.
11. Connect the fuel feed line at the fuel rail.
12. Connect the fuel return line at the fuel rail.
13. Connect all of the necessary vacuum hoses.
14. Install the fuel rail assembly. Refer to Section 1F,
Engine Controls.

1.8L DOHC ENGINE MECHANICAL 1C2 – 19
DAEWOO V–121 BL4
15. Install the exhaust flex pipe retaining nuts at the
exhaust manifold studs.
Tighten
Tighten the exhaust flex pipe–to–exhaust manifold
retaining nuts to 35 NSm (26 lb–ft).
16. Install the rear timing belt cover.
17. Install the rear timing belt cover bolts.
Tighten
Tighten the rear timing belt cover bolts to 7 NSm (62
lb–in).
18. Install the engine mount and the retaining bolts.
Tighten
Tighten the engine mount retaining bolts to 45 NSm
(33 lb–ft).
19. Install the timing belt automatic tensioner.
20. Install the timing belt automatic tensioner bolt.
Tighten
Tighten the timing belt automatic tensioner bolts to 25
NSm (18 lb–ft).
21. Install the timing belt idler pulleys.
22. Install the timing belt idler pulley bolt and nut.
Tighten
Tighten the timing belt idler pulley bolt to 25 NSm (18
lb–ft).
23. Install the camshaft gears with the timing marks at
the front.
24. Insert the guide pin of the intake camshaft into the
”IN” bore.
25. Insert the guide pin of the exhaust camshaft into
the ”EX” bore.
26. Install the camshaft gears by counterholding on the
hex of the camshaft with an open–ended wrench.
27. Install the camshaft gear with a new bolt to the
camshaft.
Tighten
Tighten the intake camshaft gear bolt to 50 NSm (37
lb–ft) turn the bolt another 60 degrees and 15 degrees
using the angular torque gauge.
28. While holding the exhaust camshaft firmly in place,
install the exhaust camshaft gear bolt.

1C2 – 20I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
Tighten
Tighten the exhaust camshaft gear bolt to 50 NSm (37
lb–ft) turn the bolt another 60 degrees and 15 degrees
using the angular torque gauge.
29. 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.
30. Install the camshaft cover and the camshaft cover
gasket.
31. Install the camshaft cover washers.
32. Install the camshaft cover bolts.
Tighten
Tighten the camshaft cover bolts to 8 NSm (71 lb–in).
33. Connect the ignition wires to the spark plugs.
34. Install the spark plug cover.
35. Install the spark plug cover bolts.
Tighten
Tighten the spark plug cover bolts to 8 NSm (71 lb–in).
36. Connect the breather tube to the camshaft cover.
37. Align the timing marks on the camshaft gears to the
notches on the camshaft cover, using the intake
gear mark for the intake gear and the exhaust gear
mark for the exhaust gear.
38. Align the mark on the crankshaft gear with the
notch at the bottom of the rear timing belt cover.

1C2 – 22I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
56. Connect the CTS connector.
57. Connect the engine CTS connector.
58. Connect the IAC valve connector.
59. Connect the TPS connector.
60. Install the CCP and the EGR solenoid bracket bolt.
Tighten
Tighten the charcoal canister purge and exhaust gas
recirculation solenoid bracket bolt to 5 NSm (44 lb–in).
61. Connect the DIS coil connector.
62. Connect the O2 sensor connector, if equipped.
63. Connect the ECM ground terminal.
64. Install the fuel pump fuse.
65. Connect the negative battery ground cable.
66. Refill the engine cooling system. Refer to Section
1D, Engine Cooling.
CAMSHAFTS
Removal Procedure
1. Remove the timing belt. Refer to ”Timing Belt” in
this section.
2. Disconnect the breather tube at the camshaft cov-
er.
3. Disconnect the engine ventilation hose at the cam-
shaft cover.
4. Remove the spark plug cover bolts.
5. Remove the spark plug cover.
6. Disconnect the ignition wires from the spark plugs.
7. Remove the camshaft cover bolts.
8. Remove the camshaft cover washers.
9. Remove the camshaft cover and the camshaft cov-
er gasket.
Notice : Take extreme care to prevent any scratches,
nicks or damage to the camshafts.
10. While holding the intake camshaft firmly in place,
remove the intake camshaft gear bolt.
11. Remove the intake camshaft gear.
12. While holding the exhaust camshaft firmly in place,
remove the exhaust camshaft gear bolt.
13. Remove the exhaust camshaft gear.

1.8L DOHC ENGINE MECHANICAL 1C2 – 23
DAEWOO V–121 BL4
14. Loosen the camshaft bearing cap bolts in stages of
one–half to one turn.
15. Remove the camshaft bearing cap bolts from the
cylinder head.
16. Remove the camshafts.
17. Remove the seal ring from the camshafts.
Important : The camshaft must detach evenly from the
bearing seats in the front guide bearing.
18. Check the camshaft and bearing seats for wear and
replace them if necessary.
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 camshaft.
3. Install the intake camshaft caps in their original
positions.
4. Install the intake camshaft cap bolts.
5. Install the exhaust camshaft.
6. Install the exhaust camshaft caps in their original
positions.
7. Install the exhaust camshaft cap bolts.
8. Tighten the camshaft cap bolts gradually and in the
sequence shown for each camshaft cap.
Tighten
Tighten the camshaft bearing cap bolts to 8 NSm (71
lb–in).
9. Measure the intake camshaft end play and the ex-
haust camshaft end play. Refer to ”Engine Specifi-
cations” in this section.
10. Install the intake camshaft gear.
11. While holding the intake camshaft firmly in place,
install the intake camshaft gear bolt.
Tighten
Tighten the intake camshaft gear bolt to 50 NSm (37
lb–ft) plus 60 degrees and 15 degrees using the angu-
lar torque gauge KM–470–B.

1C2 – 24I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
12. Install the exhaust camshaft gear.
13. While holding the exhaust camshaft firmly in place,
install the exhaust camshaft gear bolt.
Tighten
Tighten the exhaust camshaft gear bolt to 50 NSm (37
lb–ft) plus 60 degrees and 15 degrees using the angu-
lar torque gauge KM–470–B.
14. Install the camshaft cover and the camshaft cover
gasket.
15. Install the camshaft cover washers.
16. Install the camshaft cover bolts.
Tighten
Tighten the camshaft cover bolts to 8 NSm (71 lb–in).
17. Connect the ignition wires to the spark plugs.
18. Install the spark plug cover.
19. Install the spark plug cover bolts.
Tighten
Tighten the spark plug cover bolts to 8 NSm (71 lb–in).
20. Connect the breather tube to the camshaft cover.
21. Connect the engine ventilation hose to the cam-
shaft cover.
22. Install the timing belt. Refer to ”Timing Belt” in this
section.
TIMING BELT CHECK AND ADJUST
(Left–Hand Drive Shown, Right–Hand Drive
Similar)
Adjustment Procedure
1. Disconnect the negative battery cable.
2. Disconnect the manifold air temperature (MAT)
sensor connector.
3. Remove the air cleaner outlet hose from the throttle
body.
4. Remove the breather tube from the camshaft cover.