DAEWOO NUBIRA 2004 Service Repair Manual

ENGINE CONTROLS 1F – 605
DAEWOO V–121 BL4
5. Disconnect the throttle cables by opening the
throttle and moving the cable through the release
slot.
6. Disconnect the vacuum hoses from the throttle
body.
7. Disconnect the throttle position (TP) sensor and the
idle air control valve connectors.
8. Disconnect the coolant hoses from the throttle
body.
9. Remove the throttle body retaining nuts.
Notice : Cover the opening of the intake manifold after re-
moving the throttle body assembly. This will prevent any
objects or debris from entering the engine which may
cause damage.
10. Remove the throttle body and discard the gasket.
11. Remove the TP sensor. Refer to ”Throttle Position
Sensor ”in this section.
12. Remove the idle air control (IAC) valve. Refer to
”Idle Air Control Valve ”in this section.
Installation Procedure
Notice : Use care in cleaning old gasket material from ma-
chined aluminum surfaces. Sharp tools may damage seal-
ing surfaces.
1. Clean the gasket mating surface on the intake man-
ifold.
Notice : The throttle body may be cleaned in a cold immer-
sion–type cleaner following disassembly. The TP sensor
and the idle air control valve should not come in contact
with any solvent or cleaner, as they may be damaged.
2. Clean the throttle body.
3. Install the TP sensor. Refer to ” Throttle Position
Sensor ”in this section.
4. Install the IAC valve. Refer to ”Idle Air Control Valve
” in this section.
5. Install the throttle body assembly with a new gasket
to the intake manifold.
6. Install the throttle body retaining nuts.
Tighten
Tighten the throttle body retaining nuts to 10 NSm (89
lb–in).

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7. Connect the TP sensor connector and the IAC
valve connector.
8. Connect the coolant hoses to the throttle body.
9. Connect the vacuum hoses to the throttle body.
Important : Make sure the throttle/cruise control cables
do not hold the throttle open. With the engine off, check to
see that the accelerator pedal is free.
10. Connect the throttle cable.
11. Install the air intake tube.
12. Connect the breather hose to the valve cover.
13. Connect the IAT sensor connector.
14. Connect the negative battery cable.
15. Fill the cooling system.
FRONT HEATED OXYGEN SENSOR
(HO2S1) (1.4L/1.6L DOHC)
Removal Procedure
1. Disconnect the negative battery cable.
Notice : The oxygen sensor uses a permanently attached
pigtail and connector. This pigtail should not be removed
from the oxygen sensor. Damage or removal of the pigtail
or the connector could affect proper operation of the oxy-
gen sensor. Take care when handling the oxygen sensor.
Do not drop the oxygen sensor.
2. Disconnect the front heated oxygen sensor
(HO2S1) connector.
Notice : The oxygen sensor may be difficult to remove
when engine temperature is below 48°C (120°F). Exces-
sive force may damage threads in the exhaust manifold.
3. Carefully remove the HO2S1 from the exhaust
manifold.
Installation Procedure
Important : A special anti–seize compound is used on the
oxygen sensor threads. This compound consists of a liq-
uid graphite and glass beads. The graphite will burn away,
but the glass beads will remain, making the sensor easier
to remove. New or service sensors will already have the
compound applied to the threads. If a sensor is removed
from any engine and if for any reason it is to be reinstalled,
the threads must have anti–seize compound applied be-
fore reinstallation.
1. Coat the threads of the HO2S1 with an anti–seize
compound, if needed.
2. Install the HO2S1 into the exhaust manifold.
Tighten
Tighten the oxygen sensor to 42 NSm (31 lb–ft).
3. Connect the HO2S1 connector.
4. Connect the negative battery cable.

ENGINE CONTROLS 1F – 607
DAEWOO V–121 BL4
FRONT HEATED OXYGEN SENSOR
(HO2S1) (1.8L DOHC)
Removal Procedure
1. Disconnect the negative battery cable.
Notice : The oxygen sensor (O2S) uses a permanently at-
tached pigtail and connector. This pigtail should not be re-
moved from the O2S. Damage or removal of the pigtail or
the connector could affect proper operation of the O2S.
Take care when handling the O2S. Do not drop the O2S.
2. Disconnect the HO2S1 connector.
Notice : The oxygen sensor may be difficult to remove
when engine temperature is below 118°F (48°C). Exces-
sive force may damage threads in the exhaust manifold.
3. Carefully remove the HO2S1 from the exhaust
manifold.
Installation Procedure
Important : A special anti–seize compound is used on the
oxygen sensor threads. This compound consists of a liq-
uid graphite and glass beads. The graphite will burn away,
but the glass beads will remain, making the sensor easier
to remove. New or serviced sensors will already have the
compound applied to the threads. If a sensor is removed
from any engine and is to be reinstalled, the threads must
have an anti–seize compound applied before reinstalla-
tion.
1. Coat the threads of the HO2S1 with an anti–seize
compound, if needed.
2. Install the HO2S1 into the exhaust manifold.
Tighten
Tighten the oxygen sensor to 42 NSm (31 lb–ft).
3. Connect the HO2S1 connector.
4. Connect the negative battery cable.
REAR HEATED OXYGEN SENSOR
(HO2S2)
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the electrical connector.

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3. Remove the heated oxygen sensor.
Installation Procedure
1. Install the rear heated oxygen sensor.
Tighten
Tighten the heated oxygen sensor to 42 NSm (31 lb–
ft).
2. Connect the electrical connector.
3. Connect the negative battery cable.
INTAKE AIR TEMPERATURE
SENSOR (1.4L/1.6L DOHC)
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the intake air temperature (IAT) sensor
connector.
3. Remove the IAT sensor.

ENGINE CONTROLS 1F – 609
DAEWOO V–121 BL4
Installation Procedure
1. Install the IAT sensor.
Tighten
Tighten the IAT sensor to 22 NSm (16 lb–ft).
2. Connect the IAT sensor connector.
3. Connect the negative battery cable.
INTAKE AIR TEMPERATURE
SENSOR (1.8L DOHC)
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the intake air temperature (IAT) sensor
connector.
3. Remove the IAT sensor by pulling it out of the air
intake tube.
Installation Procedure
1. Install the IAT sensor into the air intake tube.
2. Connect the IAT connector.
3. Connect the negative battery cable.
IDLE AIR CONTROL VALVE
(1.8L DOHC)
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the air intake resonator.
3. Disconnect the idle air control (IAC) valve connec-
tor.
4. Remove the IAC valve retaining bolts.
Notice : On IAC valves that have been in service, do not
push on the valve pintle. The force required to move the
pintle may damage the threads on the worm drive.
5. Remove the IAC valve.

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DAEWOO V–121 BL4
Notice : Do not use methyl ethyl ketone because it can
damage the parts.
6. Clean the IAC valve O–ring seal area, the pintle
valve seat, and the air passage with a suitable fuel
system cleaner.
Installation Procedure
Important : If installing a new IAC valve, be sure to re-
place it with an identical part. The IAC valve pintle shape
and diameter are designed for the specific application.
Measure the distance between the tip of the IAC valve
pintle and the mounting flange. If the distance is greater
than 1.1 inches (28 mm), use finger pressure to slowly re-
tract the pintle. The force required to retract the pintle will
not damage the IAC valve. The purpose of the 1.1–inch
(28–mm) setting is to prevent the IAC pintle from bottom-
ing out on the pintle seat. This 1.1–inch (28–mm) setting
is also an adequate setting for controlled idle on a restart.
1. Lubricate a new O–ring with engine oil. Install the
new O–ring onto the valve.
2. Install the IAC valve into the throttle body.
3. Install the IAC valve retaining bolts.
Tighten
Tighten the idle air control valve retaining bolts to 3
NSm (27 lb–in).
4. Connect the IAC valve connector.
5. Install the air intake resonator.
6. Connect the negative battery cable.
7. Start the engine and check for the proper idle
speed.
MANIFOLD ABSOLUTE PRESSURE
SENSOR (1.4L/1.6L DOHC)
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the manifold Absolute pressure (MAP)
sensor electrical connector.
3. Disconnect the MAP sensor vacuum hose.
4. Remove the MAP sensor bolt.
5. Remove the MAP sensor.

ENGINE CONTROLS 1F – 611
DAEWOO V–121 BL4
Installation Procedure
1. Install the manifold absolute pressure (MAP) sen-
sor with the bolt.
Tighten
Tighten the MAP sensor bolt to 8 NSm (71 lb–in).
2. Connect the MAP sensor vacuum hose.
3. Connect the MAP sensor electrical connector.
4. Connect the negative battery cable.
MANIFOLD ABSOLUTE PRESSURE
SENSOR (1.8L DOHC)
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the fuel rail. Refer to”Fuel Rail and In-
jectors” in this section.
3. Disconnect the manifold absolute pressure (MAP)
sensor connector from the MAP sensor.
4. Remove the MAP sensor retaining bolt.
5. Remove the MAP sensor from the intake manifold.
Installation Procedure
1. Connect the MAP sensor connector to the MAP
sensor.
2. Install the MAP sensor into the intake manifold.
3. Install the MAP sensor retaining bolt.
Tighten
Tighten the MAP sensor retaining bolt to 4 NSm (35
lb–in).
4. Connect the fuel rail. Refer to ”Fuel Rail and Injec-
tors” in this section.
5. Connect the negative battery cable.
EXHAUST GAS RECIRCULATION
VALVE (1.4L/1.6L DOHC)
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the electrical exhaust gas recirculation
valve electrical connector.
3. Remove the EEGR valve retaining bolts.
4. Remove the EEGR valve.

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DAEWOO V–121 BL4
Installation Procedure
1. Install the EEGR valve with the bolts.
Tighten
Tighten the electrical exhaust gas recirculation valve
retaining bolts to 30 NSm (22 lb–ft).
2. Connect the EEGR valve electrical connector.
3. Connect the negative battery cable.
EXHAUST GAS RECIRCULATION
VALVE (1.8L DOHC)
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the vacuum hose from the exhaust gas
recirculation (EGR) valve.
3. Remove the EGR valve retaining bolts.
4. Remove the EGR valve from the electronic ignition
(EI) system ignition coil adapter.
Installation Procedure
1. Clean the EI system ignition coil adapter mating
surface.
2. Install a new EGR valve gasket.
3. Install the EGR valve with the bolts.
Tighten
Tighten the exhaust gas recirculation valve retaining
bolts to 30 NSm (22 lb–ft).
4. Connect the vacuum hose to the EGR valve.
5. Connect the negative battery cable.
KNOCK SENSOR (1.4L/1.6L DOHC)
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the intake manifold support bracket bolts.
3. Remove the intake manifold support bracket.

ENGINE CONTROLS 1F – 613
DAEWOO V–121 BL4
4. Disconnect the knock sensor electrical connector.
5. Remove the knock sensor bolt.
6. Remove the knock sensor.
Installation Procedure
1. Install the knock sensor with the bolt.
Tighten
Tighten the knock sensor bolt to 20 NSm (15 lb–ft).
2. Connect the knock sensor electrical connector.
3. Install the intake manifold support bracket with the
bolts.
Tighten
Tighten the intake manifold support bracket upper
bolts to 25 NSm (18 lb–ft).
Tighten the intake manifold support bracket lower
bolts to 45 NSm (33 lb–ft).
4. Connect the negative battery cable.
KNOCK SENSOR (1.8L DOHC)
Removal Procedure
1. Disconnect the negative battery cable.
2. Raise and suitably support the vehicle.
3. Disconnect electrical connector at the knock sen-
sor.

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DAEWOO V–121 BL4
4. Remove the bolt and the knock sensor.
Installation Procedure
1. Install the knock sensor with the bolt.
Tighten
Tighten the knock sensor bolt to 20 NSm (15 lb–ft).
2. Connect the electrical connector at the knock sen-
sor.
3. Lower the vehicle.
4. Connect the negative battery cable.
EVAPORATIVE EMISSION CANISTER
Removal Procedure
CAUTION : Canister and vacuum hoses contain fuel
vapors. Do not smoke in the area or permit an open
flame.
1. Remove the bolt that secures the canister flange to
the vehicle.
2. Slide the canister out of the track holder.
3. Disconnect the canister fuel vapor hoses.
4. Remove the canister cover.
5. Remove the canister.