nut DAEWOO NUBIRA 2004 Service Owners Manual

ENGINE CONTROLS 1F – 529
DAEWOO V–121 BL4
DIAGNOSTIC TROUBLE CODE (DTC) P1112
INTAKE AIR TEMPERATURE INTERMITTENT LOW
VOLTAGE
Circuit Description
The Intake Air Temperature (IAT) sensor is a thermistor
which measures the temperature of the air entering the en-
gine. The Engine Control Module (ECM) applies 5 volts
through a pull–up resistor to the IAT sensor. When the in-
take air is cold, the resistance is high, and the ECM will
monitor a high signal voltage on the IAT signal circuit. If the
intake air is warm, the sensor resistance is lower causing
the ECM to monitor a lower voltage. Diagnostic Trouble
Code (DTC) P1111 will set when the ECM detects an inter-
mittent high signal voltage in the intake air temperature
sensor signal circuit or sensor.
Conditions for Setting the DTC
S IAT is greater than 149°C (300°F).
S DTC P0502 is not set
S Engine has been running for over two minutes.
S Vehicles speed is greater than 50 km/h (31 mph).
Action Taken When the DTC Sets
S The ECM will substitute a default value for IAT.
S The ECM will store conditions which were present
when the DTC set as Failure Records data only.
This information will not be stored as Freeze Frame
data.
S The Malfunction Indicator Lamp (MIL) will not illumi-
nate.
S A history DTC is stored.
Conditions for Clearing the MIL/DTC
S A history DTC will clear after 40 consecutive warm–
up cycles without a fault.
S DTC(s) can be cleared by using the scan tool.S Disconnecting the ECM battery feed for more than
10 seconds.
Diagnostic Aids
Check for the following conditions:
S Poor connection at the ECM. Inspect harness con-
nectors for backed–out terminals, improper mating,
broken locks, improperly formed or damaged termi-
nals, and poor terminal–to–wire connection.
S Damaged harness. Inspect the wiring harness for
damage. If the harness appears to be OK, observe
the IAT display on the scan tool while moving con-
nectors and wiring harnesses related to the IAT
sensor. A change in the IAT display will indicate the
location of the fault.
S Reviewing the Fail Records vehicle mileage since
the diagnostic test last failed may help determine
how often the condition that caused the DTC to be
set occurs. This may assist in diagnosing the condi-
tion.
S Use the Temperature vs. Resistance Values table
to evaluate the possibility of a skewed sensor. Re-
fer to ”Temperature vs. Resistance” in this section.
Test Description
Number(s) below refer to the step number(s) on the Diag-
nostic Chart.
1. The On–Board Diagnostic (EOBD) System Check
prompts the technician to complete some basic
checks and store the freeze frame and failure re-
cords data on the scan tool if applicable. This
creates an electronic copy of the data taken when
the malfunction occurred. The information is then
stored on the scan tool for later reference.

ENGINE CONTROLS 1F – 595
DAEWOO V–121 BL4
9. Disconnect the fuel inlet line and the fuel return line
near the right front of the fuel tank.
10. Remove the Fuel pump. Refer to ”Fuel Pump” in
this section.
11. Remove the parking brake cables support brackets.
12. Support the fuel tank.
13. Remove the fuel tank strap retaining nuts.
14. Remove the fuel tank strap.
15. Carefully lower the fuel tank.
16. Remove the fuel tank.
17. Transfer any parts as needed.
Installation Procedure
1. Raise the fuel tank into position.
2. Install the fuel tank straps.
3. Install the fuel tank strap retaining nuts.
Tighten
Tighten the fuel tank strap retaining nuts to 20 NSm
(15 lb–ft).
4. Install the parking brake cables support bracket.
5. Install the fuel pump. Refer to ”Fuel Pump” in this
section.
6. Connect the fuel outlet line and the fuel return line.

1F – 604IENGINE CONTROLS
DAEWOO V–121 BL4
4. Disconnect the coolant hose from the throttle body.
5. Disconnect the throttle cables by opening the re-
lease slot.
6. Disconnect the main throttle idle actuator (MTIA)
electrical connector.
7. Remove the throttle body bolt and the nuts.
8. Remove the throttle body.
Installation Procedure
1. Install the throttle body assembly to the intake man-
ifold.
2. Install the throttle body retaining nuts and the bolt.
Tighten
Tighten the throttle body retaining nuts and the bolt to
15 NSm (11 lb–ft).
3. Connect the throttle cable.
4. Connect the coolant hoses.
5. Connect the breather hose.
6. Install the intake air tube.
7. Connect the negative battery cable.
THROTTLE BODY (1.8L DOHC)
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the intake air temperature (IAT) sensor
connector.
3. Disconnect the breather hose from the valve cover.
4. Remove the air intake tube.

ENGINE CONTROLS 1F – 605
DAEWOO V–121 BL4
5. Disconnect the throttle cables by opening the
throttle and moving the cable through the release
slot.
6. Disconnect the vacuum hoses from the throttle
body.
7. Disconnect the throttle position (TP) sensor and the
idle air control valve connectors.
8. Disconnect the coolant hoses from the throttle
body.
9. Remove the throttle body retaining nuts.
Notice : Cover the opening of the intake manifold after re-
moving the throttle body assembly. This will prevent any
objects or debris from entering the engine which may
cause damage.
10. Remove the throttle body and discard the gasket.
11. Remove the TP sensor. Refer to ”Throttle Position
Sensor ”in this section.
12. Remove the idle air control (IAC) valve. Refer to
”Idle Air Control Valve ”in this section.
Installation Procedure
Notice : Use care in cleaning old gasket material from ma-
chined aluminum surfaces. Sharp tools may damage seal-
ing surfaces.
1. Clean the gasket mating surface on the intake man-
ifold.
Notice : The throttle body may be cleaned in a cold immer-
sion–type cleaner following disassembly. The TP sensor
and the idle air control valve should not come in contact
with any solvent or cleaner, as they may be damaged.
2. Clean the throttle body.
3. Install the TP sensor. Refer to ” Throttle Position
Sensor ”in this section.
4. Install the IAC valve. Refer to ”Idle Air Control Valve
” in this section.
5. Install the throttle body assembly with a new gasket
to the intake manifold.
6. Install the throttle body retaining nuts.
Tighten
Tighten the throttle body retaining nuts to 10 NSm (89
lb–in).

1F – 618IENGINE CONTROLS
DAEWOO V–121 BL4
CAMSHAFT POSITION SENSOR
(1.4L/1.6L DOHC)
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the engine cover bolts and the nuts.
3. Remove the engine cover.
4. Disconnect the CMP sensor electrical connector.
5. Remove the timing belt front cover. Refer to Sec-
tion 1C, DOHC Engine Mechanical.
6. Remvoe the CMP sensor bolts.
7. Remvoe the CMP sensor from the top.
Installation Procedure
1. Install the camshaft position sensor and bolt.
Tighten
Tighten the camshaft position sensor bolts to 7 NSm
(62 lb–in).
2. Install the timing bolt front cover. Refer to Section
1C, DOHC Engine Mechanical.
3. Connect the CMP sensor electrical connector.
4. Install the engine cover.
5. Connect the negative battery cable.

1F – 620IENGINE CONTROLS
DAEWOO V–121 BL4
ENGINE CONTROL MODULE
(1.4L/1.6L DOHC)
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the engine control module (ECM) wiring
harness connector.
3. Remove the nuts from the engine control module
(ECM) mounting bracket.
4. Remove the engine control module (ECM) mount-
ing bracket with the bolt and the nut.
Installation Procedure
1. Install the engine control module (ECM) mounting
bracket with the bolt and the nut.
Tighten
Tighten the ECM mounting bracket bolt and the nut to
12 NSm (9 lb–ft).
2. Install the engine control module (ECM) with the
nuts.
Tighten
Tighten the engine control module (ECM) nut to 12
NSm (9 lb–ft).

ENGINE CONTROLS 1F – 621
DAEWOO V–121 BL4
ENGINE CONTROL MODULE
(1.8L DOHC)
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the air intake tube and resonator.
3. Disconnect the ECM connectors from the ECM.
4. Remove the engine Control module.
Installation Procedure
1. Connect the ECM connectors to the ECM.
2. Align the ECM into the mounting base.
3. Snap the ECM into its mounting base.
4. Install the ECM trim locks.
5. Install the passenger side kick panel. Refer to Sec-
tion 9G, Interior Trim.
6. Connect the negative battery cable.
7. Perform a crankshaft position system variation
learning procedure. Refer to ”DTC P1336” in this
section.
ELECTRONIC IGNITION SYSTEM
IGNITION COIL (1.4L/1.6L DOHC)
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the electronic ignition (EI) system igni-
tion coil connector.
3. Note the ignition wire location and remove the igni-
tion wire.
4. Remvoe the EI system ignition coil retaining nuts.
5. Remove the EI system ignition coil.
Installation Procedure
1. Install the EI system ignition coil into the mounting
location and install the retaining nuts.
Tighten
Tighten the EI system ignition coil retaining nuts to 10
NSm (89 lb–in).
2. Connect the EI system ignition coil connector.
3. Connect the negative battery cable.

SECTION : 1G
ENGINE EXHAUST
TABLE OF CONTENTS
SPECIFICATIONS1G–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 1G–1. . . . . . . . . .
COMPONENT LOCATOR1G–2 . . . . . . . . . . . . . . . . . . . .
Exhaust System 1G–2. . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR1G–3 . . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 1G–3. . . . . . . . . . . . . . . . . . . . .
Catalytic Converter 1G–3. . . . . . . . . . . . . . . . . . . . . . . . Exhaust Front Pipe 1G–4. . . . . . . . . . . . . . . . . . . . . . . .
Muffler – Front 1G–6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Muffler – Rear 1G–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION1G–9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust System 1G–9. . . . . . . . . . . . . . . . . . . . . . . . . .
Muffler 1G–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Catalytic Converters 1G–9. . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Catalytic Converter–to–Exhaust Manifold Nuts4037–
Exhaust Front Pipe–to–Catalytic Converter Nuts4030–
Exhaust Manifold Cover Bolts1511–
Exhaust Front Pip–to–Front Muffler3022–
Front Muffler–to–Rear Muffler Nuts3022–
Front Bracket–to–Cylinder Block Bolt5037–
Catalytic Converter–to–Underbody Shield2.5–22
Front Muffler–to–Underbody Shield2.5–22
Rear Muffler–to–Underbody Shield2.5–22

ENGINE EXHAUST 1G – 3
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
CATALYTIC CONVERTER
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the oxygen sensor electrical connector.
3. Remove the exhaust manifold cover with the bolts.
4. Remove the catalytic converter upper flange nuts.
Important : The nuts and the stud may unscrew as a unit
because of the high temperature associated with the ex-
hast manifold, but they can be re–used as such
5. Remove the exhaust front pipe mounting bracket
bolt.
6. Remove the nuts from the exhaust front pipe–to–
catalytic converter flange.
7. Remove the catalytic converter and the gasket.
8. Clean the sealing surfaces on the exhaust front
pipe flange and the exhaust manifold.
9. Check the exhaust front pipe and the exhaust man-
ifold for holes, damage, open seams or other dete-
rioration which could permit exhaust fumes to seep
into the passenger compartment.

1G – 4IENGINE EXHAUST
DAEWOO V–121 BL4
Installation Procedure
1. Install the catalytic converter and the gasket to the
exhaust front pipe flange.
Tighten
Tighten the exhaust front pipe–to–catalytic converter
nuts to 40 NSm (30 lb–ft).
Tighten the exhaust front pipe–to–cylinder block bolt
to 50 NSm (37 lb–ft).
2. Install the catalytic converter to exhaust manifold
nuts and the gasket.
Tighten
Tighten the catalytic converter to exhaust manifold
nuts to 40 NSm (30 lb–ft).
3. Install the exhaust manifold conver bolts.
Tighten
Tighten the exhaust manifold cover bolts to 15 NSm
(11 lb–ft).
4. Connect the oxygen sensor electrical connector.
5. Connect the negative battery cable.
EXHAUST FRONT PIPE
Removal Procedure
1. Remove the crossmember lower bracket with the
bolts.