cam shaft sensor DAEWOO NUBIRA 2004 Service User Guide

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 77
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 water 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 accessory 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 drive gear rotates,
the 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 is required for lubrication of the en-
gine. The oil pressure regulator prevents too much oil from
entering the engine lubrication passages. During normal
oil supply, a coil spring and valve keep the bypass closed,
directing 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 metal.
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 the cylinder head. In one
path, the oil is pumped through the oil passages in the
crankshaft to the connecting rods, then to the pistons and
the cylinders. It then drains back to the oil pan. In the sec-
ond path, the oil is pumped through the oil passages to the
camshaft. The oil passes through the internal passage-
ways in the camshafts 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
uses inertial supercharging to improve engine torque at
low and moderate speeds. The plenum is attached to the
intake manifold.
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 cylinder
head are drilled to create 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 open and close the in-
take and the exhaust valves precisely the correct amount
at the correct time. The camshaft lobes are oiled by splash
action from pressurized oil escaping from the camshaft
journals.

1.8L DOHC ENGINE MECHANICAL 1C2 – 9
DAEWOO V–121 BL4
1. Bolt
2. Spark Plug Cover
3. Oil Filler Cap
4. Oil Filler Cap Seal
5. Bolt
6. Camshaft Cover
7. Camshaft Cover Gasket
8. Tappet Adjuster
9. Valve Key
10. Valve Spring Cap
11. Valve Spring
12. Valve Stem Seal
13. Valve Spring Seat
14. Valve Guide
15. Intake Valve Seat Ring
16. Exhaust Valve Seat Ring
17. Intake Valve
18. Exhaust Valve
19. Bolt
20. Front Camshaft Cap
21. Head Bolt
22. Bolt
23. Intermediate Camshaft Cap
24. Exhaust Gas Recirculation Adapter
25. Exhaust Gas Recirculation Adapter Gasket
26. Cylinder Head
27. Exhaust Manifold Gasket28. Exhaust Manifold
29. Nut
30. Exhaust Manifold Heat Shield
31. Cylinder Head Gasket
32. Bolt
33. Thermostat Housing
34. Thermostat Housing Gasket
35. Stud
36. Sleeve
37. Plug
38. Bolt
39. Camshaft Position Sensor
40. Oil Gallery Plug
41. Exhaust Camshaft
42. Seal Ring
43. Camshaft Gear
44. Washer
45. Camshaft Gear Bolt
46. Intake Camshaft
47. Intake Manifold Gasket
48. Intake Manifold
49. Throttle Body Gasket
50. Throttle Body
51. Nut
52. Charcoal Canister Purge Solenoid
53. Exhaust Gas Recirculation Solenoid

1.8L DOHC ENGINE MECHANICAL 1C2 – 11
DAEWOO V–121 BL4
1. Connecting Rod
2. Bearing Set
3. Connecting Rod Bolt
4. Piston Ring Set
5. Piston Pin
6. Piston
7. Engine Block
8. Sleeve
9. Water Jacket Cap
10. Bolt (Manual Transaxle)
11. Flywheel (Manual Transaxle)
12. Flexible Plate (Automatic Transaxle)
13. Bolt (Automatic Transaxle)
14. Clamp
15. Hose
16. Clamp
17. Engine Ventilation Pipe
18. Bolt
19. Gasket
20. Needle Sleeve
21. Crankshaft Rear Seal
22. Crankshaft
23. Transmitter Disk
24. Bolt
25. Oil Pan Scraper
26. Oil Pan
27. Drain Plug
28. Washer
29. Bolt
30. Sleeve
31. Gasket
32. Bolt
33. Oil Pump Cover
34. Ring Gear
35. Gear
36. Oil Pressure Switch
37. Washer
38. Washer
39. Oil Duct Outlet Plug
40. Connecting Piece
41. Seal Ring
42. Oil Filter43. Bypass Valve
44. Pressure Relief Valve Plunger
45. Pressure Relief Valve Spring
46. Seal Ring
47. Pressure Relief Valve Plug
48. Seal Ring
49. Bolt
50. Oil Suction Pipe
51. Bolt
52. Rear Timing Belt Cover
53. Bolt
54. Special Bolt
55. Idler Pulley
56. Stud
57. Nut
58. Bolt
59. Tensioner
60. Bolt
61. Thrust Inner Washer
62. Woodruff Key
63. Crankshaft Gear
64. Thrust Outer Washer
65. Bolt
66. Camshaft Drive Belt
67. Gasket
68. Front Timing Belt Cover
69. Bolt
70. Bushing Plug
71. Bushing
72. Oil Gallery Plug
73. Bolt
74. Water Pump
75. Seal Ring
76. Crankshaft Position Sensor
77. Bolt
78. Knock Sensor*
79. Bolt
80. Bolt
81. Crankshaft Bearing Bridge
* : 2.0L DOHC Engine

1C2 – 12I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
CAMSHAFT COVER
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the breather tube from the valve cover.
3. Disconnect all of the necessary vacuum lines.
4. Remove the spark plug cover bolts.
5. Remove the spark plug cover.
6. Disconnect the ignition wires from the spark plugs.
7. Disconnect the camshaft position sensor connector.
8. Remove the camshaft cover bolts.
9. Remove the camshaft cover.
10. Remove the camshaft cover gasket from the cam-
shaft cover.

1.8L DOHC ENGINE MECHANICAL 1C2 – 13
DAEWOO V–121 BL4
Installation Procedure
1. Apply a small amount of gasket sealant to the cor-
ners of the front camshaft caps and the top of the
rear camshaft cover–to–cylinder head seal.
2. Install the new camshaft cover gasket to the cam-
shaft cover.
3. Install the camshaft cover.
4. Install the camshaft cover bolts.
Tighten
Tighten the camshaft cover bolts to 8 NSm (71 lb–in).
5. Connect the ignition wires to the spark plugs.
6. Install the spark plug cover.
Tighten
Tighten the spark plug cover bolts to 8 NSm (71 lb–in).
7. Install the spark plug cover bolts.
8. Connect the camshaft position sensor connector.
9. Connect all of the necessary vacuum lines.
10. Connect the breather tube to the camshaft cover.
11. Connect the negative battery cable.
CYLINDER HEAD AND GASKET
Tools Required
KM–470–B Angular Torque Gauge
J–28467–B Engine Assembly Support Fixture
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. Disconnect the negative battery cable.
4. Disconnect the electronic control mdule (ECM)
ground terminal.
5. Drain the engine coolant. Refer to Section 1D, En-
gine Cooling.

1C2 – 14I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
6. Disconnect the manifold air temperature (MAT)
sensor connector.
7. Disconnect the breather tube from the camshaft
cover.
8. Disconnect the air cleaner outlet hose from the
throttle body.
9. Disconnect the direct ignition system (DIS) coil con-
nector.
10. Disconnect the oxygen (O2) sensor connector, if
equipped.
11. Disconnect the idle air control (IAC) valve connec-
tor.
12. Disconnect the throttle position sensor (TPS) con-
nector.
13. Disconnect the engine coolant temperature (ECT)
sensor connector.
14. Disconnect the coolant temperature sensor (CTS)
connector.
15. Remove the air cleaner housing bolts.
16. Remove the air cleaner housing.
17. Remove the right front wheel. Refer to Section 2E,
Tires and Wheels.
18. Remove the right front wheel well splash shield.
19. Install the engine assembly support fixture
J–28467–B.
20. Remove the right engine mount bracket and bolts.
21. Disconnect the upper radiator hose at the thermo-
stat housing.
22. Remove the serpentine accessory drive belt. Refer
to Section 6B, Power Steering Pump.
23. Remove the crankshaft pulley bolts.
24. Remove the crankshaft pulley.

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 – 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.