check engine DAEWOO NUBIRA 2004 Service Owner's Manual

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 73
DAEWOO V–121 BL4
36. Install the crankshaft timing belt gear.
37. Install the timing belt automatic tensioner.
38. Install the timing belt automatic tensioner bolts.
Tighten
Tighten the timing belt automatic tensioner bolts to 25
NSm (18 lb–ft).
39. Install the timing belt idler pulley.
40. Install the timing belt idler pulley bolt.
Tighten
Tighten the timing belt idler pulley bolt to 40 NSm (30
lb–ft).
Notice : Take extreme care to prevent any scratches,
nicks or damage to the camshafts.
41. Install the intake camshaft gear.
42. Install the intake camshaft gear bolt while holding
the intake camshaft firmly in place.
Tighten
Tighten the intake camshaft gear bolt to 67.5 NSm (49
lb–ft).
43. Install the exhaust camshaft gear.
44. Install the exhaust camshaft gear bolt while holding
the exhaust camshaft firmly in place.
Tighten
Tighten the exhaust camshaft gear bolt to 67.5 NSm
(49 lb–ft).
45. Install the timing belt. Refer to ”Timing Belt” in this
section.
46. Adjust the timing belt tension. Refer to ”Timing Belt
Check and Adjust” in this section.
47. Apply a small amount of gasket sealant to the cor-
ners of the front camshaft caps and to the top of
the rear camshaft cover–to–cylinder head seal.
48. Install the camshaft cover and the camshaft cover
gasket.
49. Install the camshaft cover washers.
50. Install the camshaft cover nuts.
Tighten
Tighten the camshaft cover nuts to 10 NSm (89 lb–in).
51. Connect the ignition wires to the spark plugs.
52. Connect the oil filler cap.
53. Connect the engine ventilation hose to the cam-
shaft cover.
54. Install the upper and the lower front timing belt cov-
ers.
55. Install the upper and the lower front timing belt cov-
er bolts.
Tighten
Tighten the upper and the lower front timing belt cover
bolts to 10 NSm (89 lb–in).

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 75
DAEWOO V–121 BL4
4. Install the crankshaft.
5. Inspect the crankshaft end play with the crankshaft
bearings installed.
6. Check for permissible crankshaft end play. Refer to
”Engine Specifications” in this section.
7. With the crankshaft mounted on the front and rear
crankshaft bearings, check the middle crankshaft
journal for permissible out–of–round (runout). Refer
to ”Engine Specifications” in this section.
Notice : Grease the crankshaft journals and lubricate the
crankshaft bearings slightly so that the plastic gauging
thread does not tear when the crankshaft bearing caps are
removed.
8. Inspect all of the crankshaft bearing clearances us-
ing a commercially available plastic gauging (ductile
plastic threads).
9. Cut the plastic gauging threads to the length of the
bearing width. Lay them axially between the crank-
shaft journals and the crankshaft bearings.
10. Install the crankshaft bearing caps.
11. Install the crankshaft bearing cap bolts.
Tighten
Tighten the crankshaft bearing cap bolts to 50 NSm
(37 lb–ft). Using the angular torque gauge
KM–470–B, tighten the crankshaft bearing cap bolts
45 degrees plus 15 degrees.

SECTION : 1C2
1.8L 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
SPECIFICATIONS1C2–2 . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Specifications 1C2–2. . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifcations 1C2–4. . . . . . . . . .
SPECIAL TOOLS1C2–6 . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 1C2–6. . . . . . . . . . . . . . . . . . . . . . .
COMPONENT LOCATOR1C2–8 . . . . . . . . . . . . . . . . . . .
Upper End 1C2–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower End 1C2–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR1C2–12 . . . . . . . . . . . . .
ON–VEHICLE SERVICE 1C2–12. . . . . . . . . . . . . . . . . . .
Camshaft Cover 1C2–12. . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Gasket 1C2–13. . . . . . . . . . . . . . . .
Camshafts 1C2–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt Check and Adjust 1C2–24. . . . . . . . . . . . .
Timing Belt 1C2–28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan 1C2–32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump 1C2–33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Mount 1C2–37. . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake Manifold 1C2–38. . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Manifold 1C2–41. . . . . . . . . . . . . . . . . . . . . . . .
Camshaft Gears 1C2–43. . . . . . . . . . . . . . . . . . . . . . . . .
Rear Timing Belt Cover 1C2–44. . . . . . . . . . . . . . . . . . .
Engine 1C2–46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistions and Rods 1C2–51. . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR 1C2–56. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Valve Train Components 1C2–56.
Crankshaft 1C2–63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Bearing and Connecting Rod
Beadings – Gauging Plastics 1C2–72. . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION1C2–75 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Gasket 1C2–75. . . . . . . . . . . . . . . .
Crankshaft 1C2–75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt 1C2–75. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump 1C2–75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan 1C2–75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold 1C2–75. . . . . . . . . . . . . . . . . . . . . . . .
Intake Manifold 1C2–75. . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft 1C2–75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.8L DOHC ENGINE MECHANICAL 1C2 – 7
DAEWOO V–121 BL4
KM–635
Crankshaft Rear
Oil Seal Installer
KM–427
Piston Pin
Service Set
J–8087
Cylinder Bore
Check Gauge
KM–340–0
Cutter Set
Includes: KM–340–7
Guide Drift
KM–340–13
Cutters
KM–340–26
Cutters
KM–470–B
Angular Torque Gauge
KM–498–B
Pressure Gauge
J–8037
Universal Piston
Ring Compressor

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.

1.8L DOHC ENGINE MECHANICAL 1C2 – 23
DAEWOO V–121 BL4
14. Loosen the camshaft bearing cap bolts in stages of
one–half to one turn.
15. Remove the camshaft bearing cap bolts from the
cylinder head.
16. Remove the camshafts.
17. Remove the seal ring from the camshafts.
Important : The camshaft must detach evenly from the
bearing seats in the front guide bearing.
18. Check the camshaft and bearing seats for wear and
replace them if necessary.
Installation Procedure
Notice : Take extreme care to prevent any scratches,
nicks or damage to the camshafts.
1. Lubricate the camshaft journals and the camshaft
caps with engine oil.
2. Install the intake camshaft.
3. Install the intake camshaft caps in their original
positions.
4. Install the intake camshaft cap bolts.
5. Install the exhaust camshaft.
6. Install the exhaust camshaft caps in their original
positions.
7. Install the exhaust camshaft cap bolts.
8. Tighten the camshaft cap bolts gradually and in the
sequence shown for each camshaft cap.
Tighten
Tighten the camshaft bearing cap bolts to 8 NSm (71
lb–in).
9. Measure the intake camshaft end play and the ex-
haust camshaft end play. Refer to ”Engine Specifi-
cations” in this section.
10. Install the intake camshaft gear.
11. While holding the intake camshaft firmly in place,
install the intake camshaft gear bolt.
Tighten
Tighten the intake camshaft gear bolt to 50 NSm (37
lb–ft) plus 60 degrees and 15 degrees using the angu-
lar torque gauge KM–470–B.

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.

1C2 – 26I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
17. Align the camshaft gear timing marks. Use the ex-
haust gear mark for the exhaust gear and the in-
take gear mark for the intake gear, since the gears
are interchangeable
18. Loosen the automatic tensioner bolt. To relieve the
belt tension, turn the hex–key tab counterclockwise.
19. Rotate the automatic tensioner hex–key tab clock-
wise until the adjust arm pointer of the timing belt
automatic tensioner is aligned with the notch in the
timing belt automatic tensioner bracket.
20. Tighten the automatic tensioner bolt.
21. Rotate the crankshaft two full turns clockwise using
the crankshaft gear bolt.
22. Check the automatic tensioner pointer.
23. When the adjust arm pointer of the timing belt auto-
matic tensioner is aligned with the notch on the tim-
ing belt automatic tensioner bracket, the belt is ten-
sioned correctly.
Tighten
Tighten the automatic tensioner bolt to 25 NSm (18 lb–
ft).

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.

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.