Temperature DAEWOO NUBIRA 2004 Service Owner's 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.

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.

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).

1C2 – 38I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
3. Install the timing belt idler pulleys.
4. Install the timing belt idler pulley bolt and nut.
Tighten
Tighten the timing belt idler pulley bolt and nut to 25
NSm (18 lb–ft).
5. Tension the timing belt by turning the timing belt
automatic tensioner hex–key tab counterclockwise
until the pointer is aligned to the indicator.
Tighten
Tighten the timing belt automatic tensioner bolt to 25
NSm (18 lb–ft).
6. Install the front timing belt cover.
7. Install the front timing belt cover bolts.
Tighten
Tighten the front timing belt cover bolts to 6 NSm (53
lb–in).
8. Install the engine mount bracket and retaining bolts.
Tighten
Tighten the engine mount bracket retaining bolts to 55
NSm (41 lb–ft).
9. Remove the engine assembly support fixture
J–28467–B, and the channel X–28467–560.
10. Install the serpentine accessory drive belt. Refer to
Section 6B, Power Steering Pump.
11. 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 cable.
4. Disconnect the charcoal canister purge (CCP) and
exhaust gas recirculation (EGR) solenoid from the
intake manifold and loosen the bracket bolt.
5. Drain the engine coolant. Refer to Section 1D, En-
gine Cooling.
6. Disconnect the manifold air temperature sensor
(MAT) connector.
7. Disconnect the air cleaner outlet hose from the
throttle body.

1C2 – 46I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
7. Install the timing belt automatic tensioner and bolt.
8. Install the camshaft gears. Refer to ”Camshaft
Gears” in this section.
9. Install the timing belt and timing belt cover. Refer to
”Timing Belt” in this section.
10. Connect the negative battery cable.
ENGINE
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. Remove the hood. Refer to Section 9R, Body Front
End.
4. Drain the engine oil.
5. Disconnect the negative battery cable.
6. Discharge the air conditioning (A/C) system, if
equipped. Refer to Section 7B, Manual Control
Heating, Ventilation, and Air Conditioning Systems.
7. Disconnect the manifold air temperature (MAT)
sensor connector.
8. Remove the air cleaner outlet hose from the throttle
body and air cleaner housing.
9. Disconnect the breather tubes from the camshaft
cover.
10. Remove the right front wheel. Refer to Section 2E,
Tires and Wheels.
11. Remove the right front wheel well splash shield.
Refer to Section 9R, Body Font End.
12. Remove the serpentine accessory drive belt. Refer
to Section 6B, Power Steering Pump.
13. Drain the engine coolant. Refer to Section 1D, En-
gine Cooling.
14. Remove the cooling system radiator and the engine
cooling fans. Refer to Section 1D, Engine Cooling.
15. Disconnect the upper radiator hose from the ther-
mostat housing.
16. Disconnect the power steering return hose from the
power steering pump.
17. Disconnect the power steering pressure hose from
the power steering pump.
18. Disconnect the electrical connector at the direct
ignition system (DIS) coil and the electronic control
module (ECM) ground terminal and at the starter
motor.

1.8L DOHC ENGINE MECHANICAL 1C2 – 47
DAEWOO V–121 BL4
19. Disconnect the oxygen (O2) sensor connector, if
equipped.
20. Disconnect the idle air control (IAC) valve connec-
tor.
21. Disconnect the throttle position sensor (TPS) con-
nector.
22. Disconnect the engine coolant temperature sensor
(CTS) connector.
23. Disconnect the CTS connector.
24. Disconnect the generator voltage regulator connec-
tor and power lead.
25. Disconnect all of the necessary vacuum lines, in-
cluding the brake booster vacuum hose.
26. Disconnect the fuel return line at the fuel rail.
27. Disconnect the fuel feed line at the fuel rail.
28. Remove the fuel rail and injector channel cover as
an assembly. Refer to Section 1F, Engine Controls.
29. Disconnect the throttle cable from the throttle body
and the intake manifold bracket.
30. Disconnect the coolant hose at the throttle body.
31. Disconnect the heater outlet hose at the coolant
pipe.
32. Disconnect the coolant bypass hose from the cylin-
der head.
33. Disconnect the surge tank coolant hose from the
coolant pipe.
34. Disconnect the lower radiator hose from the coolant
pipe.
35. Disconnect the starter solenoid ”S” terminal wire
and power lead.
36. Remove the A/C compressor. Refer to Section 7B,
Manual Control Heating, Ventilation, and Air Condi-
tioning Systems.
37. Remove the exhaust flex pipe retaining nuts from
the exhaust manifold studs.
38. Remove the exhaust flex pipe retaining nuts from
the catalytic converter or the connecting pipe.
39. Remove the exhaust flex pipe.

1.8L DOHC ENGINE MECHANICAL 1C2 – 53
DAEWOO V–121 BL4
8. Inspect the piston for fit to the connecting rod.
9. Inspect the engine block deck surface for flatness
using a straight edge and a feeler gauge. Refer to
”Engine Specifications” in this section.
10. Inspect the bearing bore for concentricity and align-
ment using cylinder bore check gauge J–8087. Re-
fer to ”Engine Specifications” in this section. If the
bearing bore is beyond specifications, replace the
engine block.
11. Inspect the engine block cylinder bore for wear,
runout, ridging and taper using a bore gauge. Refer
to ”Engine Specifications” in this section.
12. Inspect the engine block cylinder bore for glazing.
Lightly hone the cylinder bore as necessary.
Installation Procedure
Important : For ease of installation of the piston pin, the
connecting rod should be heated to 2805C. Heat the upper
connecting rod only. Use commercial thermocolor materi-
al to determine the correct temperature. When the thermo-
color material changes from black to green, the tempera-
ture is correct for installation.
1. Align the notch on the piston and connecting rod so
that the proper sides will be facing the front of the
engine.
2. Install the piston pin guide through the piston and
the connecting rod.
3. Coat the piston pin with clean oil.
4. Install the piston pin into the opposite side of the
piston.
5. Install the piston pin into the piston and connecting
rod assembly using the piston pin service set
KM–427.
6. Select a set of new piston rings.
7. Measure the piston ring gap using a feeler gauge.
Refer to ”Engine Specifications” in this section.
8. Increase the piston ring gap by carefully filing off
excess material if the piston ring gap is below spec-
ifications.

ENGINE COOLING 1D – 3
DAEWOO V–121 BL4
DIAGNOSIS
THERMOSTAT TEST
1. Remove the thermostat from the vehicle. Refer to
”Thermostat” in this section.
2. Make sure the valve spring is tight when the ther-
mostat is fully closed. If the spring is not tight, re-
place the thermostat.
3. Suspend the thermostat and a thermometer in a
pan of 50/50 mixture of ethylene glycol and water.
Do not let the thermostat or the thermometer rest
on the bottom of the pan because the uneven con-
centration of heat on the bottom could result in in-
accurate temperature measurements.
4. Heat the pan on a burner.
5. Use the thermometer to measure the temperature
of the heated solution.
6. The thermostat should begin to open at 87°C
(189°F) and it should be fully open at 102°C
(216°F). If it does not open at these temperatures,
replace the thermostat.
SURGE TANK CAP TEST
Tools Required
KM–471 Adapter
The surge tank cap maintains proper pressure, protects
the system from high pressure by opening a pressure
valve, and protects the coolant hoses from collapsing be-
cause of a vacuum.1. Wash any sludge from the surge tank cap and the
valve seat of the vacuum pressure valve for the
surge tank cap.
2. Check for any damage or deformity to the vacuum
pressure valve for the surge tank cap. If any dam-
age or deformity is found, replace the cap.
3. Install a suitable cooling system pressure tester to
the cap using the adapter KM–471.
4. Pull the vacuum pressure valve open. If the surge
tank cap does not seal properly, replace the surge
tank cap.
5. Pressurize the cap to 90 to 120 kPa (13.1 to 17.4
psi).
6. Wait 10 seconds and check the pressure held by
the tank cap tester.
7. If the pressure held by the cooling system pressure
tester falls below 80 kPa (11.6 psi), replace the
surge tank cap.

1D – 4IENGINE COOLING
DAEWOO V–121 BL4
COOLING SYSTEM DIAGNOSIS
Engine Overheats
ChecksAction
Check for a loss of the coolant.Add the coolant.
Check for a weak coolant solution.Confirm that the coolant solution is a 50/50 mixture of eth-
ylene glycol and water.
Check the front of the radiator for any dirt, any leaves, or
any insects.Clean the front of the radiator.
Check for leakage from the hoses, the coolant pump, the
heater, the thermostat housing, the radiator, the core
plugs, or the head gasket.Replace any damaged components.
Check for a faulty thermostat.Replace a damaged thermostat.
Check for retarded ignition timing.Perform an ECM code diagnosis. Confirm the integrity of
the timing belt.
Check for an improperly operating electric cooling fan.Replace the electric cooling fan.
Check for radiator hoses that are plugged or rotted.Replace any damaged radiator hoses.
Check for a faulty water pump.Replace a faulty water pump.
Check for a faulty surge tank cap.Replace a faulty surge tank cap.
Check for a cylinder head or an engine block that is
cracked or plugged.Repair the damaged cylinder head or the damaged engine
block.
Loss of Coolant
ChecksAction
Check for a leak in the radiator.Replace a damaged radiator.
Check for a leak in the following locations:
S Surge tank.
S Hose.Replace the following parts, as needed:
S Surge tank.
S Hose.
Check for loose or damaged radiator hoses, heater hoses,
and connections.Reseat the hoses.
Replace the hoses or the clamps.
Check for leaks in the coolant pump seal.Replace the coolant pump seal.
Check for leaks in the coolant pump gasket.Replace the coolant pump gasket.
Check for an improper cylinder head torque.Tighten the cylinder head bolts to specifications.
Replace the cylinder head gasket, if needed.
Check for leaks in the following locations:
S Intake manifold.
S Cylinder head gasket.
S Cylinder block plug.
S Heater core.
S Radiator drain plug.Repair or replace any components, as needed, to correct
the leak.
Engine Fails to Reach Normal Operating Temperature or Cool Air
from the Heater
ChecksAction
Check to determine if the thermostat is stuck open or is the
wrong type of thermostat.Install a new thermostat of the correct type and heat range.
Check the coolant level to determine if it is below the MIN
mark on the surge tank.Add sufficient coolant to raise the fluid to the specified
mark on the surge tank.