Timing belt DAEWOO LACETTI 2004 Service Service Manual

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 – 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.

1.8L DOHC ENGINE MECHANICAL 1C2 – 21
DAEWOO V–121 BL4
39. Install the timing belt.
40. Check and adjust the timing belt tension. Refer to
”Timing Belt Check and Adjust” in this section.
41. Install the front timing belt cover.
42. Install the front timing belt cover bolts.
Tighten
Tighten the front timing belt cover bolts to 6 NSm (53
lb–in).
43. Install the crankshaft pulley.
44. Install the crankshaft pulley bolts.
Tighten
Tighten the crankshaft pulley bolts to 12 NSm (106 lb–
in).
45. Install the right engine mount bracket and retaining
bolts.
Tighten
Tighten the engine mount bracket retaining bolts to 55
NSm (41 lb–ft).
46. Remove the engine assembly lift support
J–28467–B.
47. Install the serpentine accessory drive belt. Refer to
Section 6B, Power Steering Pump.
48. Connect the upper radiator hose to the thermostat
housing.
49. Install the right front wheel well splash shield.
50. Install the right front wheel. Refer to Section 2E,
Tires and Wheels.
51. Install the air cleaner housing.
52. Install the air cleaner housing bolts.
Tighten
Tighten the air cleaner housing bolts to 10 NSm (89 lb–
in).
53. Connect the air cleaner outlet hose to the throttle
body.
54. Connect the breather tube to the camshaft cover.
55. Connect the MAT sensor connector.

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.

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.

1.8L DOHC ENGINE MECHANICAL 1C2 – 25
DAEWOO V–121 BL4
5. Remove the air cleaner housing bolts.
6. Remove the air cleaner housing.
7. Remove the right front wheel. Refer to Section 2E,
Tires and Wheels.
8. Remove the right front wheel well splash shield.
9. Remove the serpentine accessory drive belt. Refer
to Section 6B, Power Steering Pump.
10. Remove the crankshaft pulley bolts.
11. Remove the crankshaft pulley.
12. Remove the right engine mount bracket. Refer to
”Engine Mount” in this section.
13. Remove the front timing belt cover bolts.
14. Remove the front timing belt cover.
15. Rotate the crankshaft at least one full turn clock-
wise using the crankshaft gear bolt.
16. Align the mark on the crankshaft gear with the
notch at the bottom of the rear timing belt cover.

1C2 – 26I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
17. Align the camshaft gear timing marks. Use the ex-
haust gear mark for the exhaust gear and the in-
take gear mark for the intake gear, since the gears
are interchangeable
18. Loosen the automatic tensioner bolt. To relieve the
belt tension, turn the hex–key tab counterclockwise.
19. Rotate the automatic tensioner hex–key tab clock-
wise until the adjust arm pointer of the timing belt
automatic tensioner is aligned with the notch in the
timing belt automatic tensioner bracket.
20. Tighten the automatic tensioner bolt.
21. Rotate the crankshaft two full turns clockwise using
the crankshaft gear bolt.
22. Check the automatic tensioner pointer.
23. When the adjust arm pointer of the timing belt auto-
matic tensioner is aligned with the notch on the tim-
ing belt automatic tensioner bracket, the belt is ten-
sioned correctly.
Tighten
Tighten the automatic tensioner bolt to 25 NSm (18 lb–
ft).

1.8L DOHC ENGINE MECHANICAL 1C2 – 27
DAEWOO V–121 BL4
24. Install the front timing belt cover.
25. Install the front timing belt cover bolts.
Tighten
Tighten the front timing belt cover bolts to 6 NSm (53
lb–in).
26. Install the crankshaft pulley.
27. Install the crankshaft pulley bolt.
Tighten
Tighten the crankshaft pulley bolt to 20 NSm (15 lb–ft).
28. Install the right engine mount bracket. Refer to ”En-
gine Mount” in this section.
29. Install the serpentine accessory drive belt. Refer to
Section 6B, Power Steering Pump.
30. Install the right front wheel well splash shield.
31. Install the right front wheel. Refer to Section 2E,
Tires and Wheels.
32. Install the air cleaner housing.
33. Install the air cleaner housing bolts.
Tighten
Tighten the air cleaner housing bolts to 10 NSm (89 lb–
in).
34. Connect the air cleaner outlet hose to the throttle
body.
35. Connect the breather tube to the camshaft cover.
36. Connect the MAT sensor connector.
37. Connect the negative battery cable.

1C2 – 28I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
TIMING BELT
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the manifold air temperature (MAT)
sensor connector.
3. Disconnect the air cleaner outlet hose from the
throttle body.
4. Disconnect the breather tube from the camshaft
cover.
5. Remove the air cleaner housing bolts.
6. Remove the air cleaner housing.
7. Remove the right front wheel. Refer to Section 2E,
Tires and Wheels.
8. Remove the right front wheel well splash shield.
9. Remove the serpentine accessory drive belt. Refer
to Section 6B, Power Steering Pump.
10. Remove the crankshaft pulley bolts.
11. Remove the crankshaft pulley.
12. Remove the right engine mount bracket. Refer to
”Engine Mount” in this section.
13. Remove the front timing belt cover bolts.
14. Remove the front timing belt cover.