engine DAEWOO NUBIRA 2004 Service Repair Manual

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.

1.8L DOHC ENGINE MECHANICAL 1C2 – 29
DAEWOO V–121 BL4
15. Using the crankshaft gear bolt, rotate the crank-
shaft clockwise until the timing mark on the crank-
shaft gear is aligned with the notch at the bottom of
the rear timing belt cover.
Notice : The camshaft gears must align with the notch on
the camshaft cover or damage to the engine could result.
16. Align the camshaft gears with the notch on the
camshaft cover.
Important : Use the intake gear mark for the intake cam-
shaft gear and the exhaust gear mark for the exhaust cam-
shaft gear since both gears are interchangeable.
17. Remove the timing belt.
18. Loosen the automatic tensioner bolt. Turn the hex–
key tab to relieve belt tension.
Installation Procedure
1. Align the timing mark on the crankshaft gear with
the notch on the bottom of the rear timing belt cov-
er.

1C2 – 30I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
2. Align the timing marks on the camshaft gears, us-
ing the intake gear mark for the intake gear and the
exhaust gear mark for the exhaust gear.
3. Install the timing belt.
4. Turn the hex–key tab in a clockwise direction to
tension the belt. Turn until the pointer aligns with
the notch.
5. Install the automatic tensioner bolt.
Tighten
Tighten the automatic tensioner bolt to 25 NSm (18 lb–
ft).
6. Rotate the crankshaft two full turns clockwise using
the crankshaft pulley bolt.
7. Recheck the automatic tensioner pointer.
8. Install the front timing belt cover.
9. Install the front timing belt cover bolts.
Tighten
Tighten the front timing belt cover bolts to 6 NSm (53
lb–in).
10. Install the right engine mount bracket. Refer to ”En-
gine Mounts” in this section.

1.8L DOHC ENGINE MECHANICAL 1C2 – 31
DAEWOO V–121 BL4
11. Install the crankshaft pulley.
12. Install the crankshaft pulley bolts.
Tighten
Tighten the crankshaft pulley bolts to 20 NSm (15 lb–
ft).
13. Install the serpentine accessory drive belt. Refer to
Section 6B, Power Steering Pump.
14. Install the right front wheel well splash shield. Refer
to Section 9R, Body Front End.
15. Install the right front wheel. Refer to Section 2E,
Tires and Wheels.
16. Install the air cleaner housing.
17. Install the air cleaner housing bolts.
Tighten
Tighten the air cleaner housing bolts to 10 NSm (89 lb–
in).
18. Connect the air cleaner outlet hose to the throttle
body.
19. Connect the breather tube to the camshaft cover.
20. Connect the MAT sensor connector.
21. Connect the negative battery cable.

1C2 – 32I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
OIL PAN
Removal Procedure
1. Disconnect the negative battery cable.
2. Drain the engine oil from the engine crankcase.
3. Remove the exhaust flex pipe retaining nuts from
the exhaust manifold.
4. Remove the exhaust flex pipe retaining nuts from
the catalytic converter or the connecting pipe.
5. Remove the exhaust flex pipe.
6. Remove the oil pan flange–to–transaxle retaining
bolts.
7. Remove the oil pan retaining bolts.
8. Remove the oil pan from the engine block.
Cleaning Procedure
1. Clean the oil pan sealing surface.
2. Clean the engine block sealing surface.
3. Clean the oil pan retaining bolts.
4. Clean the oil pan attaching bolt holes in the engine
block.
5. Clean the oil pan scraper.

1.8L DOHC ENGINE MECHANICAL 1C2 – 33
DAEWOO V–121 BL4
Installation Procedure
1. Coat the new oil pan gasket with sealant.
Important : Install the oil pan within 5 minutes after apply-
ing the liquid gasket to the oil pan.
2. Install the oil pan to the engine block.
3. Install the oil pan retaining bolts.
Tighten
Tighten the oil pan retaining bolts to 10 NSm (89 lb–in).
4. Install the oil pan flange–to–transaxle retaining
bolts.
Tighten
Tighten the oil pan flange–to–transaxle bolts to 40
NSm (30 lb–ft).
5. Install the exhaust flex pipe.
6. Install the exhaust flex pipe retaining nuts to the
exhaust manifold.
Tighten
Tighten the exhaust flex pipe–to–exhaust manifold
retaining nuts to 35 NSm (26 lb–ft).
7. Install the exhaust flex pipe retaining nuts to the
catalytic converter or the connecting pipe.
Tighten
Tighten the exhaust flex pipe–to–catalytic converter
or connecting pipe retaining nuts to 35 NSm (26 lb–ft).
8. Connect the negative battery cable.
9. Install the oil pan drain plug.
Tighten
Tighten the oil pan drain plug to 35 NSm (26 lb–ft).
10. Refill the engine crankcase with engine oil.
OIL PUMP
Tools Required
KM–498–B Pressure Gauge
KM–135 Adapter
Engine Oil Pressure Inspection Procedure
1. Remove the right front wheel well oil pan scraper.
Refer to Section 9R, Body Front End.
2. Disconnect the oil pressure switch connector.

1C2 – 34I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
3. Install the adapter KM–135 in place of the oil pres-
sure switch.
4. Connect the pressure gauge KM–498–B to the
adapter.
5. Start the engine and check the oil pressure at idle
speed and engine temperature of 80°C (176°F).
The minimum oil pressure should be 30 kPa (4.35
psi).
6. Stop the engine and remove the pressure gauge
KM–498–B and the adapter KM–135.
7. Install the oil pressure switch.
Tighten
Tighten the oil pressure switch to 40 NSm (30 lb–ft).
8. Connect the electrical connector to the oil pressure
switch.
9. Install the right front wheel well oil pan scraper. Re-
fer to Section 9R, Body Front End.
10. Check the oil level. Add oil until it reaches the full
mark.
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the timing belt. Refer to ”Timing Belt” in
this section.
3. Remove the rear timing belt cover. Refer to ”Rear
Timing Belt Cover” in this section.
4. Disconnect the oil pressure switch connector.
5. Remove the oil pan. Refer to ”Oil Pan” in this sec-
tion.
6. Remove the oil suction pipe and support bracket
bolts.
7. Remove the oil suction pipe.

1.8L DOHC ENGINE MECHANICAL 1C2 – 35
DAEWOO V–121 BL4
8. Remove the oil pump retaining bolts.
9. Carefully separate the oil pump and gasket from
the engine block and oil pan.
10. Remove the oil pump.
Inspection Procedure
1. Clean the oil pump and the engine block gasket
mating surface areas.
2. Remove the safety relief valve bolt.
3. Remove the safety relief valve and the spring.
4. Remove the oil pump–to–crankshaft seal.
5. Remove the oil pump rear cover bolts.
6. Remove the rear cover.
7. Clean the oil pump housing and all the oil pump
parts.
8. Inspect all the oil pump parts for signs of wear. Re-
fer to ”Engine Specifications” in this section. Re-
place the worn oil pump parts.
Notice : Pack the oil pump gear cavity with petroleum jelly
to ensure an oil pump prime, or engine damage could re-
sult.
9. Coat all the oil pump parts with clean engine oil.
Install the oil pump parts.
10. Apply Loctite® 242 to the oil pump rear cover bolts
and install the cover and bolts.
Tighten
Tighten the oil pump rear cover bolts to 6 NSm (53 lb–
in).
11. Install the safety relief valve, spring, washer and
bolt.
Tighten
Tighten the safety relief valve bolt to 30 NSm (22 lb–ft).

1C2 – 36I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
Installation Procedure
1. Apply Loctite® 242 to the oil pump bolts and room
temperature vulcanizing (RTV) sealant to the new
oil pump gasket.
2. Install the gasket to the oil pump and install the oil
pump to the engine block with the bolts.
Tighten
Tighten the oil pump retaining bolts to 10 NSm (89 lb–
in).
3. Install a new oil pump–to–crankshaft seal. Coat the
lip of the seal with a thin coat of grease.
4. Coat the threads of the oil suction pipe and support
bracket bolts with Loctite® 242.
5. Install the oil suction pipe and the bolts.
Tighten
Tighten the oil suction pipe bolts to 10 NSm (89 lb–in)
and support bracket bolts to 6 NSm (53 lb–in).
6. Install the oil pan. Refer to ”Oil Pan” in this section.
7. Connect the oil pressure switch connector.
8. Install the rear timing belt cover. Refer to ”Rear
Timing Belt Cover” in this section.
9. Install the timing belt. Refer to ”Timing Belt” in this
section.
10. Connect the negative battery cable.

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).