oil DAEWOO NUBIRA 2004 Service User Guide

GENERAL INFORMATION 0B – 15
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
GENERAL REPAIR INSTRUCTIONS
S If a floor jack is used, the following precautions are
recommended.
S Park the vehicle on level ground,
block" the front
or rear wheels, set the jack against the frame, raise
the vehicle and support it with chassis stands and
then perform the service operation.
S Before performing the service operation, disconnect
the negative battery cable in order to reduce the
chance of cable damage and burning due to short–
circuiting.
S Use a cover on the body, the seats and the floor to
protect them against damage and contamination.
S Handle brake fluid and antifreeze solution with care
as they can cause paint damage.
S The use of proper tools, and the recommended es-
sential and available tools where specified, are im-
portant for efficient and reliable performance of the
service repairs.S Use genuine DAEWOO parts.
S Discard used cotter pins, gaskets, O–rings, oil
seals, lock washers and self–locking nuts. Prepare
new ones for installation. Normal function of these
parts cannot be maintained if these parts are re-
used.
S Keep the disassembled parts neatly in groups to
facilitate proper and smooth reassembly.
S Keep attaching bolts and nuts separated, as they
vary in hardness and design depending on the posi-
tion of the installation.
S Clean the parts before inspection or reassembly.
S Also clean the oil parts, etc. Use compressed air to
make certain they are free of restrictions.
S Lubricate rotating and sliding faces of parts with oil
or grease before installation.
S When necessary, use a sealer on gaskets to pre-
vent leakage.
S Carefully observe all specifications for bolt and nut
torques.
S When service operation is completed, make a final
check to be sure service was done properly and the
problem was corrected.

SECTION : 1A
GENERAL ENGINE INFORMATION
TABLE OF CONTENTS
DIAGNOSIS1A–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compression Test 1A–1. . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Test 1A–2. . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Leak Diagnosis 1A–3. . . . . . . . . . . . . . . . . . . . . . . .
Knock Diagnosis 1A–4. . . . . . . . . . . . . . . . . . . . . . . . . . Noise Diagnosis 1A–8. . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION1A–11 . . . . . . . . . . . . . . . . . .
Cleanliness and Care 1A–11. . . . . . . . . . . . . . . . . . . . .
On–Engine Service 1A–11. . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS
COMPRESSION TEST
Important : Disconnect the Crankshaft Position (CKP)
Sensor connector to disable the fuel and the ignition sys-
tems.
Test the compression pressure for each cylinder. Low
compression pressure may be the fault of the valves or the
pistons. The following conditions should be considered
when you check the cylinder compression:
S The engine should be at normal operating tempera-
ture.
S The throttle must be wide open.
S All the spark plugs should be removed.
S The battery must be at or near full charge.
1. Place approximately three squirts of oil from a
plunger– type oiler into each spark plug port.
2. Insert the engine compression gauge into each
spark plug port.
3. Crank test each cylinder with four to five compres-
sion strokes using the starter motor.4. The lowest reading should not be less than 70% of
the highest reading. The compression gauge read-
ing should not be less than 689 kPa (100 psi) for
any of the cylinders.
5. Examine the gauge readings obtained after the four
”puffs” per cylinder are obtained from cranking the
starter motor. The readings are explained in the
following descriptions:
S Normal Condition – Compression builds up quickly
and evenly to the specified compression on each
cylinder.
S Piston Rings Faulty – Compression is low on the
first stroke and tends to build up on following
strokes, but the compression pressure does not
reach normal. The compression pressure improves
considerably with the addition of oil into the cylin-
der.
S Valves Faulty – Low compression pressure on the
first stroke. The compression pressure does not
tend to build up on the following strokes. The com-
pression pressure does not improve much with the
addition of oil into the cylinder.

1A – 2IGENERAL ENGINE INFORMATION
DAEWOO V–121 BL4
OIL PRESSURE TEST
StepActionValue(s)YesNo
1Is the oil pressure warning lamp on?–Go to Step 2System OK
2Check the oil level in the crankcase.
Is the oil level low?–Go to Step 3Go to Step 4
3Add oil so that the oil level is up to the fullmark on the
indicator.
Is the repair complete?–Go to Step 1–
4Check the idle speed.
Is the idle speed below the specified value ?825 rpmGo to Step 5Go to Step 6
5Increase the idle speed.
Is the speed increased?–Go to Step 1–
6Inspect the oil pressure switch.
Is the oil pressure switch incorrect or malfunction-
ing?–Go to Step 7Go to Step 8
7Install a new oil pressure switch.
Is the repair complete?–Go to Step 1–
8Inspect the oil pressure gauge.
Is the oil pressure gauge incorrect or malfunction-
ing?–Go to Step 9Go to Step 10
9Install a new oil pressure gauge.
Is the repair complete?–Go to Step 1–
10Inspect the engine oil.
Is the engine oil in the crankcase diluted or of the im-
proper viscosity?–Go to Step 11Go to Step 12
11Install new engine oil of the proper viscosity for the
expected temperatures.
Is the repair complete?–Go to Step 1–
12Inspect the oil pump.
Is the pump worn or dirty?–Go to Step 13Go to Step 14
13Replace the oil pump.
Is the repair complete?–Go to Step 1–
14Inspect the oil filter.
Is the oil filter plugged?–Go to Step 15Go to Step 16
15Install a new oil filter.
Is the repair complete?–Go to Step 1–
16Inspect the oil pickup screen.
Is the oil pickup screen loose or plugged?–Go to Step 17Go to Step 18
17Tighten or replace the oil pickup screen, as neces-
sary.
Is the repair complete?–Go to Step 1–
18Inspect the oil pickup tube.
Are there any holes in the oil pickup tube?–Go to Step 19Go to Step 20
19Replace the oil pickup tube.
Is the repair complete?–Go to Step 1–

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.

1A – 6IGENERAL ENGINE INFORMATION
DAEWOO V–121 BL4
Light Knock Hot
StepActionValue(s)YesNo
1Is there a light knock when the engine is hot?–Go to Step 2System OK
2Is detonation or spark knock evident?–Go to Step 3Go to Step 4
3Check the engine timing and the fuel quality.
Was the problem found?–Go to Step 1–
4Inspect the torque converter bolts.
Are the bolts tightened to the specified value?45 NSm
(33 lb–ft)Go to Step 5Go to Step 6
5Tighten the torque converter bolts.
Is the repair complete?–Go to Step 1–
6Inspect the manifold.
Is there an exhaust leak at the manifold?–Go to Step 7Go to Step 8
7Tighten the bolts or replace the gasket.
Is the repair complete?–Go to Step 1–
8Check the rod bearing clearance.
Is the clearance within the specified value?0.019 ~
0.070 mm
(0.0007 ~
0.0028 in.)Go to Step 9System OK
9Replace the rod bearings, as necessary.
Is the repair complete?–Go to Step 1–
Knocks During Initial Start–Up But Last Only a Few Seconds
StepActionValue(s)YesNo
1Does the engine knock during initial start–up but last
only a few seconds?–Go to Step 2System OK
2Check the engine oil.
Is the proper viscosity oil used in the crankcase?–Go to Step 4Go to Step 3
3Install oil of the proper viscosity for the expected
seasonal temperatures.
Is the repair complete?–Go to Step 1–
4Inspect the hydraulic lifters.
Is there evidence of hydraulic lifter bleed–down?–Go to Step 5Go to Step 6
5Clean, test and replace the lifters, as necessary.
Is the repair complete?*–Go to Step 1–
6Inspect the crankshaft end clearance.
Is the clearance more than specified value?0.1 mm
(0.0039 in.)Go to Step 7Go to Step 8
7Replace the crankshaft thrust bearing.
Is the repair complete?–Go to Step 1–
8Inspect the front main bearing clearance.
Is the clearance more than the specified value?0.026~0.046
mm (0.0010~
0.0018 in.)Go to Step 9System OK
9Replace the worn parts of the front main bearing.
Is the repair complete?–Go to Step 1–
* When the engine is stopped, some valves will be open. Spring pressure against the lifters will tend to bleed lifter down.
Attempts to repair this should be made only if the problem is consistent.
An engine that is only operated for short periods between start–ups may have lifter noise that lasts for a few minutes. This
is a normal condition.

GENERAL ENGINE INFORMATION 1A – 7
DAEWOO V–121 BL4
Knocks at Idle Hot
StepActionValue(s)YesNo
1Does the engine knock at idle when hot?–Go to Step 2System OK
2Inspect the drive belts.
Are the belts loose or worn?–Go to Step 3Go to Step 4
3Tension or replace the belts, as necessary.
Is the repair complete?–Go to Step 1–
4Inspect the A/C compressor and the generator.
Is either the compressor or the generator faulty?–Go to Step 5Go to Step 6
5Replace the faulty A/C compressor or the generator.
Is the repair complete?–Go to Step 1–
6Inspect the valve train.
Are valve train components faulty?–Go to Step 7Go to Step 8
7Replace the faulty valve train components.
Is the repair complete?–Go to Step 1–
8Check the engine oil.
Is the proper viscosity oil used in the crankcase?–Go to Step 10Go to Step 9
9Install oil of the proper viscosity for the expected
seasonal temperatures.
Is the repair complete?–Go to Step 1–
10Inspect the piston pin clearance.
Is the clearance more than the specified value?0.020 mm
(0.0008 in.)Go to Step 11Go to Step 12
11Replace the piston and the pin.
Is the repair complete?–Go to Step 1–
12Check the connecting rod alignment.
Is the alignment faulty?–Go to Step 13Go to Step 14
13Check and replace rods, as necessary.
Is the repair complete?–Go to Step 1–
14Inspect the piston–to–bore clearance.
Is the clearance within the specified value?0.030 mm
(0.0012 in.)Go to Step 16Go to Step 15
15Hone the bore and fit a new piston.
Is the repair complete?Go to Step 1–
16Inspect the crankshaft balancer.
Is the balancer loose?–Go to Step 17Go to Step 18
17Torque or replace worn parts.
Is the repair complete?–Go to Step 1–
18Check the piston pin offset.
Is the offset at the specified value?0.5 ± 0.1 mm
(0.020 ~ 0.003
in.)
Toward Thrust
SideGo to Step 19System OK
19Install the correct piston.
Is the repair complete?–Go to Step 1–

1A – 8IGENERAL ENGINE INFORMATION
DAEWOO V–121 BL4
NOISE DIAGNOSIS
Main Bearing Noise
StepActionValue(s)YesNo
1Are dull thuds or knocks heard with every engine
revolution?–Go to Step 2System OK
2Check the oil pump pressure.
Is the oil pump pressure low?–Go to Oil Pres-
sure TestGo to Step 3
3Inspect the crankshaft end play.
Does the crankshaft end play exceed the specified
value?0.1 mm
(0.0039 in.)Go to Crank-
shaft Replace-
ment Proce-
dureGo to Step 4
4Inspect the crankshaft journals.
Are the crankshaft journals out–of–round?0.004 mm
(0.0002 in.)
max.Go to Crank-
shaft Replace-
ment Proce-
dureGo to Step 5
5Inspect the belt tension.
Does the belt tension exceed the specified value?–Go to Timing
Belt Replace-
ment Proce-
dureGo to Step 6
6Inspect the crankshaft pulley.
Is the crankshaft pulley loose?–Go to Crank-
shaft Replace-
ment Proce-
dureSystem OK
Connecting Rod Bearing Noise Symptom
StepActionValue(s)YesNo
1Is a knock noise heard under all engine speeds?–Go to Step 2System OK
2Inspect the crankshaft connecting rod journal.
Is the crankshaft connecting rod journal worn?–Go to Crank-
shaft Replace-
ment Proce-
dureGo to Step 3
3Check the oil pump pressure.
Is the oil pump pressure low?–Go to Oil Pres-
sure TestGo to Step 4
4Inspect the crankshaft connecting rod journals.
Are the journals out–of–round?–Go to Crank-
shaft Replace-
ment Proce-
dureGo to Step 5
5Inspect the connecting rods.
Is there a misaligned connecting rod?–Go to Pistons
and Rods Re-
placement Pro-
cedureGo to Step 6
6Inspect the connecting rod bolts.
Are the connecting rod bolts torqued properly?–System OKGo to Pistons
and Rods Re-
placement Pro-
cedure

1A – 10IGENERAL ENGINE INFORMATION
DAEWOO V–121 BL4
Valve Mechanism or Valve Train Noises
StepActionValue(s)YesNo
1Is a light tapping sound heard from the engine?–Go to Step 2System OK
2Inspect the valve springs.
Are the springs weak or broken?–Go to Cylinder
Head and
Valve Train
Components
Replacement
ProcedureGo to Step 3
3Inspect the valves.
Are the valves sticking or warped?–Go to Cylinder
Head and
Valve Train
Components
Replacement
ProcedureGo to Step 4
4Inspect the valve lifters.
Are the valve lifters dirty, stuck or worn?–Go to Cylinder
Head and
Valve Train
Components
Replacement
ProcedureGo to Step 5
5Inspect the camshaft lobes.
Are the camshaft lobes damaged or improperly ma-
chined?–Go to Cam-
shaft Replace-
ment Proce-
dureGo to Step 6
6Check the oil supply to the valve train.
Is the oil supply insufficient or poor?–Go to Cylinder
Head and
Valve Train
Components
Replacement
ProcedureGo to Step 7
7Inspect the valve guides.
Are the valve guides worn?–Go to Cylinder
Head and
Valve Train
Components
Replacement
ProcedureGo to Step 8
8Inspect the valve spring seat.
Is the valve spring seat incorrect?–Go to Cylinder
Head and
Valve Train
Components
Replacement
ProcedureSystem OK

GENERAL ENGINE INFORMATION 1A – 11
DAEWOO V–121 BL4
GENERAL INFORMATION
CLEANLINESS AND CARE
An automobile engine is a combination of many machined,
honed, polished and lapped surfaces with tolerances that
are measured in the ten–thousandths of an inch. When
any internal engine parts are serviced, care and cleanli-
ness are important. A liberal coating of engine oil should
be applied to friction areas during assembly, to protect and
lubricate the surfaces on initial operation. Proper cleaning
and protection of machined surfaces and friction areas is
part of the repair procedure. This is considered standard
shop practice even if not specifically stated.
Whenever valve train components are removed for ser-
vice, they should be kept in order. They should be installed
in the same locations, and with the same mating surfaces,
as when they were removed.Battery cables should be disconnected before any major
work is performed on the engine. Failure to disconnect
cables may result in damage to wire harness or other elec-
trical parts.ON–ENGINE SERVICE
CAUTION : Disconnect the negative battery cable be-
fore removing or installing any electrical unit, or
when a tool or equipment could easily come in con-
tact with exposed electrical terminals. Disconnecting
this cable will help prevent personal injury and dam-
age to the vehicle. The ignition must also be in LOCK
unless otherwise noted.
Notice : Any time the air cleaner is removed, the intake
opening should be covered. This will protect against acci-
dental entrance of foreign material, which could follow the
intake passage into the cylinder and cause extensive
damage when the engine is started.

SECTION : 1C1
1.4L/1.6L DOHC ENGINE MECHANICAL
CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool
or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help
prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
TABLE OF CONTENTS
SPECIFICATIONS1C1–2 . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Specifications 1C1–2. . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifcations 1C1–5. . . . . . . . . .
SPECIAL TOOLS1C1–7 . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 1C1–7. . . . . . . . . . . . . . . . . . . . . . .
COMPONENT LOCATOR1C1–9 . . . . . . . . . . . . . . . . . . .
Cylinder Head 1C1–9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block 1C1–10. . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake & Exhaust Manifold 1C1–12. . . . . . . . . . . . . . . .
Timing Belt 1C1–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Mounting 1C1–14. . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR1C1–15 . . . . . . . . . . . . .
ON–VEHICLE SERVICE 1C1–15. . . . . . . . . . . . . . . . . . .
Engine Cover 1C1–15. . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft Cover 1C1–15. . . . . . . . . . . . . . . . . . . . . . . . .
Intake Manifold 1C1–16. . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold 1C1–20. . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Gasket 1C1–21. . . . . . . . . . . . . . . .
Camshaft 1C1–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt Check and Adjust 1C1–30. . . . . . . . . . . . .
Timing Belt 1C1–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pan 1C1–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump 1C1–40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Mount 1C1–43. . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft Gears 1C1–45. . . . . . . . . . . . . . . . . . . . . . . . .
Rear Timing Belt Cover 1C1–46. . . . . . . . . . . . . . . . . . .
Engine 1C1–48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistons and Rods 1C1–53. . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR 1C1–58. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Valve Train Components 1C1–58.
Crankshaft 1C1–65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Bearing and Connecting Rod
Beadings – Gauging Plastics 1C1–74. . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION1C1–77 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Gasket 1C1–77. . . . . . . . . . . . . . . .
Crankshaft 1C1–77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt 1C1–77. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump 1C1–77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan 1C1–77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold 1C1–77. . . . . . . . . . . . . . . . . . . . . . . .
Intake Manifold 1C1–77. . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft 1C1–77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .