egr DAEWOO LACETTI 2004 Service Repair Manual

i
PERSONAL INJURY CAUTION
Appropriate service methods and proper repair procedures are essential
for the safe, reliable operation of all motor vehicles, as well as for the per-
sonal safety of the person doing the repair. There are many variations in
procedures, techniques, tools and parts for servicing vehicles, as well as
in the skills of the people doing the work. This manual cannot possibly
anticipate all such variations and provide advice or precautions for each.
Anyone who deviates from the instructions provided in this manual must
ensure their own safety and preserve the safety and integrity of the ve-
hicle. The following list contains general precautions that should always
be followed while working on a vehicle.
DSafety stands are required whenever a procedure calls for under-
body work.
DDo not smoke when you work on a vehicle.
DTo prevent serious burns, do not touch any hot metal parts.
DSet the parking brake when you work on the vehicle.
DTurn the ignition switch OFF unless a procedure states otherwise.
DThe engine may operate only in a well-ventilated area.
DAvoid moving parts when the engine is running.
DSafety glasses must be worn for eye protection.

HOW TO USE ELECTRICAL WIRING DIAGRAMW1–3
2. CIRCUIT IDENTIFICATION SYMBOL
IDENTIFICATION
SYMBOLMEANING
CConnector
DDiode
EfFuse in engine room fuse box
FFuse in passenger room fuse box
GGround
SSplice pack(Junction connector)
3. FUNCTION OF POWER SUPPLY LINE (NUMBER)
Power supply NoPower supply condition
15Battery Voltage(B+) supply in Ignition Switch ”ON” and ”ST” (IGN 1)
15ABattery Voltage(B+) supply in Ignition Switch ”ON” (IGN 2)
15CBattery Voltage(B+) supply in Ignition Switch ”ON” and ”ACC”
30Battery Voltage(B+) supply directly regardless of Ignition Switch
31Ground connected to battery(
)
58Battery Voltage(B+) supply in Head Lamp Switch 1st and 2nd step (Illumination circuit)
4. WIRING HARNESS COLOR IDENTIFICATION
AbbreviationColorAbbreviationColor
BrBrownSbSky Blue
GGreenRRed
VVioletLBlue
PPinkYYellow
WWhiteGrGray
OrOrangeBBlack
LgLight Green
5. HOW TO CHECK TERMINAL NUMBER OF CONNECTOR
" Terminal number is given based on Female Terminal Connectorex) Terminal Number 4 of C901 connection

GENERAL ENGINE INFORMATION 1A – 3
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
20Inspect the bearing clearances.
Are the bearing clearances more than the specified
values?Crankshaft
0.026 ~0.046
mm
(0.0010~0.001
8 in.)
Connecting
Rod 0.019 ~
0.070 mm
(0.0007 ~
0.0027 in.)Go to Step 21Go to Step 22
21Replace the bearing, if necessary.
Is the repair complete?–Go to Step 1–
22Inspect the oil galleries.
Are the oil galleries cracked, porous, or plugged?–Go to Step 23Go to Step 24
23Repair or replace the engine block.
Is the repair complete?–Go to Step 1–
24Inspect the gallery plugs.
Are any of the gallery plugs missing or installed im-
properly?–Go to Step 25Go to Step 26
25Install the plugs or repair, as necessary.
Is the repair complete?–Go to Step 1–
26Inspect the camshaft.
Is the camshaft worn or is there evidence of poor
machining?–Go to Step 27System OK
27Replace the camshaft.
Is the repair complete?–Go to Step 1–
OIL LEAK DIAGNOSIS
Most fluid oil leaks are easily located and repaired by visu-
ally finding the leak and replacing or repairing the neces-
sary parts. On some occasions, a fluid leak may be difficult
to locate or repair. The following procedures may help you
in locating and repairing most leaks.
Finding the Leak:
1. Identify the fluid. Determine whether it is engine oil,
automatic transmission fluid, power steering fluid,
etc.
2. Identify where the fluid is leaking from.
1) After running the vehicle at normal operating
temperature, park the vehicle over a large sheet
of paper.
2) Wait a few minutes.
3) Find the approximate location of the leak by the
drippings on the paper.
3. Visually check around the suspected component.
Check around all the gasket mating surfaces for
leaks. A mirror is useful for finding leaks in areas
that are hard to reach.
4. If the leak still cannot be found, it may be neces-
sary to clean the suspected area with a degreaser,
steam, or spray solvent.
1) Thoroughly clean the area.2) Dry the area.
3) Operate the vehicle for several miles at normal
operating temperature and varying speeds.
4) After operating the vehicle, visually check the
suspected component.
5) If you still cannot locate the leak, try using the
powder or black light and dye method.
Powder Method:
1. Clean the suspected area.
2. Apply an aerosol–type powder, (such as foot pow-
der), to the suspected area.
3. Operate the vehicle under normal operating condi-
tions.
4. Visually inspect the suspected component. Trace
the leak path over the white powder surface to the
source.
Black Light and Dye Method:
A dye and light kit is available for finding leaks. Refer to the
manufacturer ’s directions when using the kit.
1. Pour the specified amount of dye into the engine oil
fill tube.
2. Operate the vehicle under normal operating condi-
tions as directed in the kit.
3. Direct the light toward the suspected area. The
dyed fluid will appear as a yellow path leading to
the source.

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 9
DAEWOO V–121 BL4
COMPONENT LOCATOR
CYLINDER HEAD
1. Oil Filler Cap
2. Engine Cover
3. Camshaft Cover
4. Camshaft Cover Gasket
5. Camshaft Cover Bolt
6. Hydraulic Tappet Adjuster
7. Valve Key
8. Valve Spring Cap
9. Valve Spring
10. Valve Stem Seal
11. EGR Vaccum Hose
12. EGR Valve
13. EGR Valve Gasket
14. EGR Valve Adaptor
15. EGR Valve Adaptor Gasket16. Cylinder Head
17. Front Camshaft Cap
18. Valve Guide
19. Plug
20. Freeze Plug
21. Oil Duct Cap
22. Intake Valve
23. Exhaust Valve
24. Cylinder Head Gasket
25. Engine Coolant Temperature Sensor
26. Heat Take Off Pipe
27. Camshaft
28. Camshaft Seal
29. Thermostat

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 17
DAEWOO V–121 BL4
6. Disconnect the intake manifold pressure sensor
connector, attaching bolt and vaccum hose.
7. Disconnect the intake manifold air temperature sen-
sor(MAT) connector and remove the MAT sensor.
8. Remove the intake manifold upper bracket.
9. Remove the fule rail bolt and the fuel rail.
10. Remove the all the vaccum hoses from the intake
manifold including PCV hose and brake booster
vaccum hose.
11. Remove the exhaust gas recirculation(EGR) pipe.

1C1 – 18I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
12. Remove the alternator. Refer to Section 1E, Engine
Electrical.
13. Remove the intake manifold support bracket.
14. Remove the intake manifold retaining bolts/nuts in
the sequence shown.
15. Remove the intake manifold and gasket.
16. Clean the sealing surfaces of the intake manifold
and the cylinder head.
Installation Procedure
1. Install the fule rail.
Tighten
Tighten the fule rail bolts to 25 NSm (18 lb–ft).
2. Install the new intake manifold gasket and intake
manifold.
Tighten
Tighten the intake manifold bolts and nuts to 25 NSm
(18 lb–ft).
3. Install the exhaust gas recirculation(EGR) pipe.
Tighten
Tighten the exhaust gas recirculation(EGR) pipe bolts
to 10 NSm (89 lb–ft).

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 25
DAEWOO V–121 BL4
34. Remove the intake/exhaust manifold. Refer to ”In-
take/Exhaust Manifold” in the section.
35. Remove the cylinder head bolts gradually in the
sequence shown and remove the cylinder head.
Notice : Prevent any engine oil or coolant from entering
the cylinders when removing the cylinder head.
36. Remove the cylinder head gasket.
Cleaning Procedure
1. Clean the gasket sitting surfaces of the cylinder
head and the engine block.
2. Make sure the gasket sitting surfaces of the cylin-
der 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 new cylinder head gasket.
2. Install the intake/exhaust manifold to the cylinder
head. Refer to ”Intake/Exhaust Manifold” in the
section.
3. Install the cylinder head bolts gradually in the se-
quence shown.
Tighten
Tighten the cylinder head bolts to 25 NSm (18 lb–ft)
and retighten the cylinder head bolts 70 degrees plus
70 degrees plus 50 degrees using the angular torque
gauge KM–470–B.
4. Install the right engine mount. Refer to ”Engine
Mount” in this section.

1C1 – 28I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
25. Install the timing belt.
26. Rotate the water pump clockwise using the timing
belt adjuster J–42492 to apply tension to the timing
belt.
Tighten
Tighten the water pump retaining bolts to 10 NSm (89
lb–in).
27. Check and adjust the timing belt tension. Refer to
”Timing Belt Check and Adjust” in this section.
28. Install the upper and lower front timing belt covers.
Tighten
Tighten the upper and lower front timing belt covers
bolts to 10 NSm (89 lb–in).
29. Install the crank shaft pulley bolt.
Tighten
Tighten the crank shaft pulley bolt to 95 NSm (70 lb–ft)
and retighten 30 degrees plus 15 degrees.
30. Install the serpentine accessory drive belt. Refer to
Section 6B, Power Steering Pump.
31. Connect the upper radiator hose to the thermostat
housing.
32. Install the front wheel and splash shield. Refer to
Section 2E, Tires and Wheels.
33. Install the air cleaner housing.
Tighten
Tighten the air cleaner housing bolts to 10 NSm (89 lb–
in).
34. Connect the breather tube to the cam shaft cover.
35. Install the crank shaft pulley bolt.
36. Connect the MAT sensor connector.
37. Connect the intake manifold pressure sensor, in-
take air temperature sensor and coolant tempera-
ture sensor connector.

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 33
DAEWOO V–121 BL4
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).

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.