section 7 DAEWOO NUBIRA 2004 Service User Guide

1C1 – 16I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
4. Remove the ignition wires from the spark plug.
5. Remove the camshaft cover bolts and camshaft
cover.
6. Remove the camshaft cover gasket.
Installation Procedure
1. Install the camshaft cover gasket on the camshaft
cover.
2. Position the camshaft cover on the engine block.
3. Install the camshaft cover bolts.
Tighten
Tighten the camshaft cover bolts to 10 NSm(89 lb–ft).
4. Install the ignition wires to the spark plugs and con-
nect the breather hose, ventilation hose and cam
position sensor wiring connector to the canshaft
cover.
5. Install the engine cover.
6. Connect the negative battery cable.
INTAKE MANIFOLD
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 calbe.
4. Drain the engine coolant. Refer to Section 1D, En-
gine Cooling.
5. Remove the engine cover and throttle body. Refer
to Section 1F, Engine Control.

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).

1C1 – 20I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
12. Install the throttle body and engine cover.
13. Refill the engine cooling system. Refer to Section
1D, Engine Cooling.
14. Install the fuel pump fuse and connect the negative
battery cable.
EXHAUST MANIFOLD
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the oxygen sensor connecter.
3. Remove the exhaust manifold heat shield.
4. Remove the exhaust manifold nuts from the pup
converter.
5. Remove the exhaust manifold retaining nuts in the
sequence shown and remove the exhaust manifold.
6. Remove the exhaust manifold gasket.
7. Clean the sealing surfaces of the exhaust manifold
and the cylinder head.

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 21
DAEWOO V–121 BL4
Installation Procedure
1. Install the exhaust manifold and gasket.
2. Install the exhaust manifold retaining nuts and tight-
en in the sequence shown.
Tighten
Tighten the exhaust manifold retaining nuts to 25 NSm
(18 lb–ft).
3. Install the exhaust manifold nuts to the catalytic
converter.
Tighten
Tighten the exhaust manifold nuts to 40 NSm (30 lb–
ft).
4. Install the heat shield.
Tighten
Tighten the the heat shield bolts to 13 NSm (10 lb–ft).
5. Connect the oxygen sensor connecter.
6. Connect the negative battery cable.
CYLINDER HEAD AND GASKET
Tools Required
J–42492 Timing Belt Adjuster
KM–470–B Angular Torque Gauge
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 calbe.
4. Disconnect the electronic control module(ECM)
ground terminal from the intake manifold.
5. Drain the engine coolant. Refer to Section 1D, En-
gine Cooling.

1C1 – 22I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
6. Drain the engine oil and remove the camshaft cov-
er. Refer to this section.
7. Remove the air cleaner housing.
8. Remove the throttle cable and inlet/outlet coolant
hoses.
9. Remove the thermostat upper hose.
10. Remove the intake manifold pressure sensor, in-
take air temperature sensor and coolant tempera-
ture sensor.
11. Remove the intake manifold support bracket.

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 23
DAEWOO V–121 BL4
12. Remove the all the vaccum hoses from the intake
manifold including brake booster vaccum hose.
13. Remove the ignition cables from the spark plugs.
14. Remove the direct ignition coil(DIS) and the bracket
from the cylinder head.
15. Remove the serpentine accessory drive belt by ro-
tating the tensioner pulley bolt to clockwise using
DW110–080. Refer to Section 6B, Power Steering
Pump.
16. Remove the front passenger side tire. Refer to Sec-
tion 2E, Tires and Wheels.
17. Remove front wheel housing shield.
18. Remove the upper front timing belt cover bolts.
19. Remove the upper front timing belt cover.
20. Align the camshaft gear timing marks.
21. Remove the crank shaft pulley.
22. Remove the lower front timing belt cover bolts and
cover.

1C1 – 24I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
23. Slightly loosen the water pump retaining bolts.
24. Rotate the water pump counterclockwise using the
timing belt adjuster J–42492 to relieve the timing
belt tension.
25. Remove the timing belt.Refer to ”Timing Belt” in
this section.
26. Remove the engine mounting bracket.Refer to ”En-
gine Mount” in this section.
27. Remove the camshaft cover. Refer to ”Camshaft
Cover” in this section.
28. While holding the intake camshaft firmly in place,
remove the intake camshaft gear bolt and gear.
29. While holding the exhaust camshaft firmly in place,
remove the exhaust camshaft gear bolt and gear.
Notice : Take extreme care to prevent any scratches,
nicks or damage to the camshafts.
30. Remove the timing belt automatic tensioner.
31. Remove the timing belt idler pulley.
32. Remove the right engine mount. Refer to ”Engine
Mount” in this section.
33. Remove the rear timing belt cover.

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.

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 27
DAEWOO V–121 BL4
15. Install the timing belt automatic tensioner.
Tighten
Tighten the timing belt automatic tensioner bolts to 25
NSm (18 lb–ft).
16. Install the timing belt idler pulley.
Tighten
Tighten the timing belt idler pulley bolt to 25 NSm(18
lb–ft).
Notice : Take extreme care to prevent any scratches,
nicks or damage to the camshafts.
17. Install the intake/exhaust camshaft gear.
Tighten
Tighten the intake/exhaust camshaft gear bolts to
67.5 NSm (49 lb–ft).
18. 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.
19. Install the camshaft cover and the gasket. Refer to
”Camshaft Cover” in this section.
20. Connect the ignition wires to the spark plugs.
21. Install the oil filler cap.
22. Connect the engine ventilation hose to the cam-
shaft cover.
23. Align the timing marks on the camshaft gears.
24. Align the mark on the crank shaft gear with the
notch at the bottom of the rear timing belt cover.

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.