nut DAEWOO NUBIRA 2004 Service Owner's Manual

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 51
DAEWOO V–121 BL4
5. Connect the right engine mount bracket to the en-
gine mount and the engine by installing the attach-
ing bolts and the nuts.
Tighten
Tighten the engine mount bracket attaching bolts and
the nuts to 55 NSm (41 lb–ft).
6. Remove the floor jack used for support of the trans-
axle.
7. Remove the engine lifting device.
8. Install the transaxle torque converter bolts, if auto-
matic transaxle equipped.
Tighten
Tighten the transaxle torque converter bolts to 45
NSm (33 lb–ft).
9. Install the starter motor. Refer to Section 1E, En-
gine Electrical.
10. Connect the vacuum lines at the CCP solenoid.
11. Connect the electrical connector at the CCP sole-
noid and at the knock sensor.
12. Connect the oil pressure switch and the EGR sole-
noid connectors.
13. Install the crankshaft pulley.
14. Install the crankshaft pulley bolt.
Tighten
Tighten the crankshaft pulley bolt to 95 NSm (70 lb–ft)
and retighten 30 degrees plus 15 degrees.
15. Connect the CPS connector.
16. Install the exhaust front pipe.
17. Install the catalytic converter retaining nuts to the
exhaust pipe.
Tighten
Tighten the catalytic converter to exhaust pipe retain-
ing nuts to 35 NSm (26 lb–ft).

1C1 – 58I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
UNIT REPAIR
CYLINDER HEAD AND VALVE TRAIN
COMPONENTS
Tools Required
MKM–571–B Gauge
KM–340–0 Cutter Set
KM–340–7 Guide Drift
KM–340–13 Cutters
KM–340–26 Cutters
KM–348 Valve Spring Compressor
KM–653 Adapter
KM–805 Valve Guide Reamer
Disassembly Procedure
1. Remove the cylinder head with the intake manifold
and the exhaust manifold attached. Refer to ”Cylin-
der Head and Gasket” in this section.
2. Remove the engine coolant temperature sensor.
3. Remove the exhaust manifold heat shield bolts.
4. Remove the exhaust manifold heat shield.
5. Remove the exhaust manifold retaining nuts in the
sequence shown.
6. Remove the exhaust manifold.
7. Remove the exhaust manifold gasket.
8. Remove the exhaust manifold studs.
9. Remove the thermostat housing mounting bolts.
10. Remove the thermostat housing assembly.
11. Remove the fuel rail retaining bolts and the fuel rail
assembly.
12. Remove the intake manifold retaining nuts and re-
taining bolts in the sequence shown.
13. Remove the intake manifold.
14. Remove the intake manifold studs.

1C1 – 64I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
11. Install the intake camshaft.
12. Install the intake camshaft caps in their original
positions.
13. Install the exhaust camshaft.
14. Install the exhaust camshaft caps in their original
positions.
15. Install the camshaft cap bolts.
16. Tighten the camshaft cap bolts gradually and in the
sequence shown for each camshaft cap.
Tighten
Tighten the camshaft cap bolts to 16 NSm (12 lb–ft).
17. Install the spark plugs.
Tighten
Tighten the spark plugs to 25 NSm (18 lb–ft).
18. Install the EGR valve adapter gasket.
19. Install the EGR valve adapter.
20. Install the EGR valve adapter bolts.
Tighten
Tighten the exhaust gas recirculation valve adapter
bolts to 25 NSm (18 lb–ft).
21. Install the DIS coil mounting bracket.
22. Install the DIS coil mounting bracket bolts.
Tighten
Tighten the direct ignition system coil mounting brack-
et bolts to 10 NSm (89 lb–in).
23. Install the DIS coil with the ignition wires attached.
24. Install the DIS coil mounting bolts.
Tighten
Tighten the direct ignition system coil mounting bolts
to 10 NSm (89 lb–in).
25. Install the intake manifold studs.
26. Install the intake manifold.
27. Install the intake manifold retaining nuts and retain-
ing bolts in the sequence shown.
Tighten
Tighten the intake manifold retaining nuts and retain-
ing bolts to 25 NSm (18 lb–ft).

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 65
DAEWOO V–121 BL4
28. Install the fuel rail assembly with the bolts.
Tighten
Tighten the fuel rail assembly retaining bolts to 25
NSm (18 lb–ft).
29. Install the thermostat housing assembly.
30. Install the thermostat housing mounting bolts.
Tighten
Tighten the thermostat housing mounting bolts to 20
NSm (15 lb–ft).
31. Install the exhaust manifold studs.
32. Install the exhaust manifold gasket.
33. Install the exhaust manifold.
34. Install the exhaust manifold retaining nuts in the
sequence shown.
Tighten
Tighten the exhaust manifold retaining nuts to 25 NSm
(18 lb–ft).
35. Install the exhaust manifold heat shield.
36. Install the exhaust manifold heat shield bolts.
Tighten
Tighten the exhaust manifold heat shield bolts to 15
NSm (11 lb–ft).
37. Install the ECT sensor.
Tighten
Tighten the engine coolant temperature sensor to 20
NSm (15 lb–ft).
38. Install the cylinder head with the intake manifold
and the exhaust manifold attached. Refer to ”Cylin-
der Head and Gasket” in this section.
CRANKSHAFT
Tools Required
KM–412 Engine Overhaul Stand
J–42492 Timing Belt Adjuster
KM–470–B Angular Torque Gauge
J–36792 or KM–635 Crankshaft Rear Oil Seal Installer
Notice : Take extreme care to prevent any scratches,
nicks, or damage to the camshafts.
Disassembly Procedure
1. Remove the engine. Refer to ”Engine” in this sec-
tion.
2. Remove the flywheel or flexible plate bolts.
3. Remove the flywheel or the flexible plate.

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 67
DAEWOO V–121 BL4
11. Disconnect the engine ventilation hoses from the
camshaft cover.
12. Disconnect the oil filler cap.
13. Remove the spark plug cover bolts.
14. Remove the spark plug cover.
15. Disconnect the ignition wires from the spark plugs.
16. Remove the camshaft cover nuts.
17. Remove the camshaft cover washers.
18. Remove the camshaft cover and the camshaft cov-
er gasket.
Notice : Take extreme care to prevent any scratches,
nicks or damage to the camshafts.
19. While holding the intake camshaft firmly in place,
remove the intake camshaft bolt.
20. Remove the intake camshaft gear.
21. While holding the exhaust camshaft firmly in place,
remove the exhaust camshaft bolt.
22. Remove the exhaust camshaft gear.
23. Remove the timing belt automatic tensioner bolts.
24. Remove the timing belt automatic tensioner.
25. Remove the timing belt idler pulley bolt.
26. Remove the timing belt idler pulley.
27. Remove the crankshaft timing belt gear.
28. Remove the rear timing belt cover bolts.
29. Remove the rear timing belt cover.

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).

1.8L DOHC ENGINE MECHANICAL 1C2 – 3
DAEWOO V–121 BL4
Application Description
Diameter (All)
Out of Round (Maximum)48.970~ 48.988 mm (1.9279~1.9287 in.)
0.004 mm (0.00015 in.)
Cylinder Head:
Valve Stem Protrusion39.2~39.8 mm (1.54~1.56 in.)
Valve Guide Height13.7~14.0 mm (0.54~0.57 in.)
Overall Height134 ± 0.025 mm (5.2755~0.0009 in.)
Minimum Overall Height After Machining133.9 mm (5.27 in.)
Valve System:
Valve Lash CompensatorsHydraulic Tappet
Seat Runout (Maximum, All)0.03 mm (0.00118 in.)
Face Runout (Maximum, All)0.03 mm (0.00118 in.)
Valve Stem Diameter:
Intake
Exhaust5.945~5.960 mm (0.2341~0.2346 in.)
5.945~5.960 mm (0.2341~0.2346 in.)
Valve Diameter:
Intake
Exhaust32 ± 0.1 mm (1.2598 ± 0.0039 in.)
29 ± 0.1 mm (1.1417 ± 0.0039 in.)
Valve Seat Width:
Intake
Exhaust1.0~1.5 mm (0.039~0.059 in.)
1.7~2.2 mm (0.066~0.086 in.)
Valve Face Angle44°
Valve Guide Inside Diameter7.03~7.05 mm (0.276~0.277 in.)
Oil Pump:
Gear Lash0.10~0.20 mm (0.003~0.007 in.)
Outer Gear to Body0.11~0.19 mm (0.004~0.007 in.)
Outer Gear to Crescent0.40~0.50 mm (0.015~0.019 in.)
Inner Gear to Crescent0.35~0.40 mm (0.013~0.015 in.)
End Clearance0.030~0.10 mm (0.001~0.003 in.)
Sealants and Adhesives:
Rear Main Bearing CapGE p/n RTV 159
Camshaft Carrier to Cylinder HeadHN 1581 (Loctite® 515)
Oil Pan BoltsHN 1256 (Loctite® 242)
Oil Pump BoltsHN 1256 (Loctite® 242)
Oil Pan Pickup Tube BoltsHN 1256 (Loctite® 242)
Oil Gallery PlugHN 1256 (Loctite® 242)
Coolant Jacket Caps and Plugs (Freeze Plugs)HN 1756 (Loctite® 176)
Exhaust Manifold Studs/NutsAnti–seize Compound (HMC Spec HN1325)

1C2 – 4I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
FASTENER TIGHTENING SPECIFCATIONS
ApplicationNSmLb–FtLb–In
Air Cleaner Housing Bolts10–89
Automatic Tensioner Bolt2518–
Camshaft Bearing Bridge and Oil Pan Scraper Bolts20 + 45°15 + 45°–
Camshaft Bearing Cap Bolts8–71
Camshaft Cover Bolts8–71
Charcoal Canister Purge and Exhaust Gas Recirculation Sole-
noid Bracket Bolt5–44
Connecting Rod Bearing Cap Bolts35
+ 45° + 15°26
+ 45° + 15°–
Coolant Bypass Housing and Mounting Bolts1511–
Crankshaft Bearing Cap Bolts50
+ 45° + 15°37
+ 45° + 15°–
Crankshaft Pulley Bolts2015–
Crankshaft Gear Bolt145
+ 30° + 15°107
+ 30° + 15°–
Cylinder Head Bolts25 + 90°
+ 90° + 90°18 + 90°
+ 90° + 90°–
Direct Ignition System Coil and Exhaust Gas Recirculation
Mounting Bracket Bolts2518–
Engine Mount Bracket Retaining Bolts and Nuts5541–
Engine Mount Retaining Bolts4533–
Engine–to–Intake Manifold Support Bracket Bolts2015–
Exhaust Camshaft Gear Bolt50
+ 60° + 15°37
+ 60° + 15°–
Exhaust Flex Pipe–to–Catalytic Converter or Connecting Pipe
Retaining Nuts3526–
Exhaust Flex Pipe–to–Exhaust Manifold Retaining Nuts3526–
Exhaust Manifold Heat Shield Bolts8–71
Exhaust Manifold Retaining Nuts2216–
Flexible Plate Bolts4533–
Flywheel Bolts65
+ 30° + 15°48
+ 30° + 15°–
Front Timing Belt Cover Bolts6–53
Generator–to–Intake Manifold Strap Bracket Bolt2216–
Generator–to–Intake Manifold Support Bracket Bolts3727–
Intake Camshaft Gear Bolt50
+ 60° + 15°37
+ 60° + 15°–
Intake Manifold Retaining Bolt and Nuts2216–
Intake Manifold Support Bracket Lower Bolt2518–
Intake Manifold Support Bracket Upper Bolts2518–
Lower Block Support Bracket and Splash Shield Bolts3526–
Oil Pan Drain Plug3526–
Oil Pan Flange–to–Transaxle Bolts4030–

1.8L DOHC ENGINE MECHANICAL 1C2 – 5
DAEWOO V–121 BL4
Application Lb–InLb–Ft NSm
Oil Pan Retaining Bolts10–89
Oil Pressure Switch4030–
Oil Suction Pipe Bolts8–71
Oil Suction Pipe Support Bracket Bolts16–53
Oil Pump Rear Cover Bolts6–53
Oil Pump Retaining Bolts10–89
Pulse Pickup Sensor Disc1310–
Rear Timing Belt Cover Bolts7–62
Safety Relief Valve Bolt3022–
Spark Plug Cover Bolts8–71
Spark Plugs2015–
Thermostat Housing Mounting Bolts1511–
Throttle Cable Bracket Bolts8–71
Timing Belt Automatic Tensioner Bolts2518–
Timing Belt Idler Pulley Bolt2518–
Timing Belt Idler Pulley Nut2518–
Transaxle Bell Housing Bolts7555–
Transaxle Torque Converter Bolts6044–

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