Gear DAEWOO LACETTI 2004 Service Service Manual

1.8L DOHC ENGINE MECHANICAL 1C2 – 37
DAEWOO V–121 BL4
ENGINE MOUNT
Tools Required
J–28467–B Engine Assembly Support Fixture
X–28467–560 Engine Assembly Support Channel
Removal Procedure
1. Disconnect the negative battery cable.
2. Support the engine assembly using the engine as-
sembly support fixture J–28467–B, and the engine
assembly support channel X–28467–560.
3. Disconnect the manifold air temperature (MAT)
sensor connector.
4. Disconnect the air cleaner outlet hose from the
throttle body.
5. Remove the air cleaner housing bolts.
6. Remove the air cleaner housing.
7. Remove the right front splash shield. Refer to Sec-
tion 9R, Body Font End.
8. Remove the engine mount bracket retaining bolts.
9. Remove the engine mount bracket.
10. Remove the serpentine accessory drive belt. Refer
to Section 6B, Power Steering Pump.
11. Remove the front timing belt cover bolts.
12. Align the crankshaft pulley timing mark with the
pointer, and the camshaft gears with the timing
marks on the rear cover, by turning the crankshaft
gear bolt.
13. Loosen the timing belt automatic tensioner bolt.
14. Turn the hex–key tab to relieve belt tension.
15. Remove the timing belt idler pulley bolt and nut.
16. Remove the timing belt idler pulley.
17. Remove the engine mount retaining bolts.
18. Remove the engine mount.
Installation Procedure
1. Install the engine mount.
2. Install the engine mount retaining bolts.
Tighten
Tighten the engine mount retaining bolts to 45 NSm
(33 lb–ft).

1.8L DOHC ENGINE MECHANICAL 1C2 – 43
DAEWOO V–121 BL4
CAMSHAFT GEARS
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the timing belt. Refer to ”Timing Belt” in
this section.
3. Remove the spark plug cover bolts.
4. Remove the spark plug cover.
5. Disconnect the ignition wires from the spark plugs.
6. Disconnect the breather tubes from the camshaft
cover.
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.
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 50 NSm (37
lb–ft) plus 60 degrees and 15 degrees using the angu-
lar torque gauge KM–470–B.

1C2 – 44I1.8L 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 50 NSm (37
lb–ft) plus 60 degrees and 15 degrees using the angu-
lar torque gauge KM–470–B.
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 washers.
8. Install the camshaft cover bolts.
Tighten
Tighten the camshaft cover bolts to 8 NSm (71 lb–in).
9. Connect the crankcase breather tubes to the cam-
shaft cover.
10. Connect the ignition wires to the spark plugs.
11. Install the spark plug cover.
12. Install the spark plug cover bolts.
Tighten
Tighten the spark plug cover bolts to 8 NSm (71 lb–in).
13. Install the timing belt. Refer to ”Timing Belt” in this
section.
14. Connect the negative battery cable.
REAR TIMING BELT COVER
Tools Required
KM–470–B Angular Torque Gauge
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the timing belt. Refer to ”Timing Belt” in
this section.
3. Remove the camshaft gears. Refer to ”Camshaft
Gears” in this section.
4. Remove the timing belt automatic tensioner bolt.
5. Remove the timing belt automatic tensioner.

1.8L DOHC ENGINE MECHANICAL 1C2 – 45
DAEWOO V–121 BL4
6. Remove the timing belt idler pulley bolt and nut.
7. Remove the timing belt idler pulleys.
8. Remove the engine mount retaining bolts.
9. Remove the engine mount.
10. Remove the crankshaft gear bolt.
11. Remove the crankshaft gear.
12. Remove the rear timing belt cover bolts.
13. 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 7 NSm (62
lb–in).
3. Install the engine mount and retaining bolts.
Tighten
Tighten the engine mount retaining bolts to 45 NSm
(33 lb–ft).
4. Install the timing belt idler pulleys.
5. Install the timing belt idler pulley bolt and nut.
Tighten
Tighten the timing belt idler pulley bolt to 25 NSm (18
lb–ft).
Tighten the timing belt idler pulley nut to 25 NSm (18
lb–ft).
6. Install the crankshaft timing belt drive gear and bolt.
Tighten
Tighten the crankshaft gear bolt to 145 NSm (107 lb–
ft) plus 30 degrees and plus 15 degrees using the an-
gular torque gauge KM–470–B.

1C2 – 46I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
7. Install the timing belt automatic tensioner and bolt.
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.
10. Connect the negative battery cable.
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. Discharge the air conditioning (A/C) system, if
equipped. Refer to Section 7B, Manual Control
Heating, Ventilation, and Air Conditioning Systems.
7. Disconnect the manifold air temperature (MAT)
sensor connector.
8. Remove the air cleaner outlet hose from the throttle
body and air cleaner housing.
9. Disconnect the breather tubes from the camshaft
cover.
10. Remove the right front wheel. Refer to Section 2E,
Tires and Wheels.
11. Remove the right front wheel well splash shield.
Refer to Section 9R, Body Font End.
12. Remove the serpentine accessory drive belt. Refer
to Section 6B, Power Steering Pump.
13. Drain the engine coolant. Refer to Section 1D, En-
gine Cooling.
14. Remove the cooling system radiator and the engine
cooling fans. Refer to Section 1D, Engine Cooling.
15. Disconnect the upper radiator hose from the ther-
mostat housing.
16. Disconnect the power steering return hose from the
power steering pump.
17. Disconnect the power steering pressure hose from
the power steering pump.
18. Disconnect the electrical connector at the direct
ignition system (DIS) coil and the electronic control
module (ECM) ground terminal and at the starter
motor.

1C2 – 64I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
6. Remove the front timing belt cover bolts.
7. Remove the front timing belt cover.
8. Remove the crankshaft pulley bolts.
9. Remove the crankshaft pulley.
10. Loosen the timing belt automatic tensioner bolt.
11. Rotate the timing belt automatic tensioner hex–key
clockwise to release the tension.
12. Remove the timing belt idler pulley bolt and nut.
13. Remove the timing belt idler pulleys.
14. Remove the timing belt.
15. Remove the engine mount retaining bolts.
16. Remove the engine mount.
17. Disconnect the breather tubes from the camshaft
cover.
18. Remove the spark plug cover bolts.
19. Remove the spark plug cover.
20. Disconnect the ignition wires from the spark plugs.
21. Remove the camshaft cover bolts.
22. Remove the camshaft cover washers.
23. Remove the camshaft cover and the camshaft cov-
er gasket.
Notice : Take extreme care to prevent any scratches,
nicks or damage to the camshafts.
24. While holding the intake camshaft firmly in place,
remove the intake camshaft bolt.
25. Remove the intake camshaft gear.
26. While holding the exhaust camshaft firmly in place,
remove the exhaust camshaft bolt.
27. Remove the exhaust camshaft gear.

1.8L DOHC ENGINE MECHANICAL 1C2 – 65
DAEWOO V–121 BL4
28. Remove the crankshaft timing belt gear.
29. Remove the rear timing belt cover bolts and cover.
30. Rotate the engine on the engine overhaul stand
KM–412.
31. Remove the oil pan retaining bolts.
32. Remove the oil pan.
33. Remove the oil suction pipe and support bracket
bolts.
34. Remove the oil suction pipe.
35. Remove the crankshaft bearing bridge and oil pan
scraper bolts.
36. Remove the oil pan scraper.
37. Remove the crankshaft bearing bridge bolts.
38. Remove the crankshaft bearing bridge.

1C2 – 70I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
31. Coat the new oil pan gasket with sealant.
32. Install the oil pan gasket to the oil pan.
33. Install the oil pan.
34. Install the oil pan retaining bolts.
Tighten
Tighten the oil pan retaining bolts to 10 NSm (89 lb–in).
35. Rotate the engine on the engine overhaul stand
KM–412.
36. Install the rear timing belt cover.
37. Install the rear timing belt cover bolts.
Tighten
Tighten the rear timing belt cover bolts to 7 NSm (62
lb–in).
38. Install the crankshaft gear and bolt.
Tighten
Tighten the crankshaft gear bolt to 145 NSm (107 lb–
ft) plus 30 degrees plus 15 degrees using the angular
torque gauge KM–470–B.
39. Install the engine mount and retaining bolts.
Tighten
Tighten the engine mount retaining bolts to 45 NSm
(33 lb–ft).
40. Install the timing belt automatic tensioner.
41. Install the timing belt automatic tensioner bolts.
Tighten
Tighten the timing belt automatic tensioner bolts to 25
NSm (18 lb–ft).
42. Install the timing belt idler pulley.
43. Install the timing belt idler pulley bolt and nut.
Tighten
Tighten the timing belt idler pulley nut to 25 NSm (18
lb–ft).

1.8L DOHC ENGINE MECHANICAL 1C2 – 71
DAEWOO V–121 BL4
Notice : Take extreme care to prevent any scratches,
nicks or damage to the camshafts.
44. Install the intake camshaft gear.
45. Install the intake camshaft gear bolt while holding
the intake camshaft firmly in place.
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.
46. Install the exhaust camshaft gear.
47. Install the exhaust camshaft gear bolt while holding
the exhaust camshaft firmly in place.
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.
48. Install the timing belt. Refer to ”Timing Belt” in this
section.
49. Adjust the timing belt tension. Refer to ”Timing Belt
Check and Adjust” in this section.
50. 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.
51. Install the camshaft cover and the camshaft cover
gasket.
52. Install the camshaft cover washers.
53. Install the camshaft cover bolts.
Tighten
Tighten the camshaft cover bolts to 8 NSm (71 lb–in).
54. Connect the ignition wires to the spark plugs.
55. Install the spark plug cover.
56. Install the spark plug cover bolts.
Tighten
Tighten the spark plug cover bolts to 8 NSm (71 lb–in).
57. Connect the breather tube to the camshaft cover.
58. Install the front timing belt cover.
59. Install the front timing belt cover bolts.
Tighten
Tighten the front timing belt cover bolts to 8 NSm (71
lb–in).
60. Install the engine lifting device.
61. Remove the engine from the engine overhaul stand
KM–412.

1.8L DOHC ENGINE MECHANICAL 1C2 – 75
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 coolant 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 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 crankshaft ro-
tates, the oil pump 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 required for lubrication of the engine.
The oil pressure regulator prevents too much oil from en-
tering the engine lubrication passages. During normal oil
supply, a coil spring and valve keep the bypass closed, di-
recting 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 aluminum.
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 cylinder head. In one
path, the oil is pumped through oil passages in the crank-
shaft to the connecting rods, then to the pistons and cylin-
ders. It then drains back to the oil pan. In the second path,
the oil is pumped through passages to the camshaft. The
oil passes through the internal passageways in the cam-
shafts 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
utilizes an inertial supercharging effect to improve engine
torque at low and moderate speeds.
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 cyl-
inder head are drilled for 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 precisely open and
close the intake and the exhaust valves the correct
amount at the correct time. The camshaft lobes are oiled
by splash action from pressurized oil escaping from the
camshaft journals.