TPS DAEWOO NUBIRA 2004 Service Repair Manual

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 49
DAEWOO V–121 BL4
17. Disconnect the oxygen (O2) sensor connector, if
equipped.
18. Disconnect the fuel injector harness connectors.
19. Disconnect the MAT, MAP sensor connectors.
20. Disconnect the throttle position sensor (TPS) con-
nector.
21. Disconnect the generator voltage regulator connec-
tor and power lead.
22. Remove the electrical harness clamp bolt.
23. Disconnect all of the necessary vacuum lines, in-
cluding the brake booster vacuum hose.
24. Disconnect the fuel feed line at the fuel rail.
25. Disconnect the throttle cable from the throttle body
and the intake manifold bracket.
26. Disconnect the surge tank coolant hose at the
throttle body.
27. Disconnect the heater outlet hose at the coolant
pipe.
28. Disconnect the heater inlet hose from the cylinder
head.
29. Disconnect the surge tank coolant hose from the
coolant pipe.
30. Disconnect the lower radiator hose from the coolant
pipe. Disconnect the starter solenoid ”S” terminal
wire. Remove the A/C compressor, if equipped. Re-
fer to Section 7B, Manual Control Heating, Ventila-
tion, and Air Conditioning Systems.
31. Remove the catalytic converter retaining nuts from
the exhaust pipe.
32. Remove the exhaust pipe.

1C1 – 52I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
18. Connect the power steering pressure hose.
19. Connect the power steering return hose.
20. Install the A/C compressor, if equipped. Refer to
Section 7B, Manual Control Heating, Ventilation,
and Air Conditioning Systems.
21. Install the generator. Refer to Section 1E, Engine
Electrical.
22. Install the serpentine accessory drive belt. Refer to
Section 6B, Power Steering Pump.
23. Install the right front wheel well splash shield.
24. Install the right front wheel. Refer to Section 2E,
Tires and Wheels.
25. Connect the fuel feed line to the fuel rail.
26. Connect all of the necessary vacuum lines, includ-
ing the brake booster vacuum hose.
27. Connect the O2 sensor connector, if equipped.
28. Connect the starter solenoid ”S” terminal wire and
power lead.
29. Connect the generator voltage regulator connector
and power lead.
30. Connect the CTS connector.
31. Connect the MAP, MAT sensor connectors.
32. Connect the TPS connector.
33. Install the electrical wiring harness clamp at the
intake manifold support bracket.
34. Connect the fuel injector harness connectors.
35. Connect the electrical connector at the DIS coil and
the ECM ground terminal at the starter.
36. Install the air cleaner outlet hose between the
throttle body and the air cleaner housing.
37. Connect the breather tubes to the camshaft cover.
38. Install the cooling system radiator and the engine
cooling fans. Refer to Section 1D, Engine Cooling.

1C2 – 14I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
6. Disconnect the manifold air temperature (MAT)
sensor connector.
7. Disconnect the breather tube from the camshaft
cover.
8. Disconnect the air cleaner outlet hose from the
throttle body.
9. Disconnect the direct ignition system (DIS) coil con-
nector.
10. Disconnect the oxygen (O2) sensor connector, if
equipped.
11. Disconnect the idle air control (IAC) valve connec-
tor.
12. Disconnect the throttle position sensor (TPS) con-
nector.
13. Disconnect the engine coolant temperature (ECT)
sensor connector.
14. Disconnect the coolant temperature sensor (CTS)
connector.
15. Remove the air cleaner housing bolts.
16. Remove the air cleaner housing.
17. Remove the right front wheel. Refer to Section 2E,
Tires and Wheels.
18. Remove the right front wheel well splash shield.
19. Install the engine assembly support fixture
J–28467–B.
20. Remove the right engine mount bracket and bolts.
21. Disconnect the upper radiator hose at the thermo-
stat housing.
22. Remove the serpentine accessory drive belt. Refer
to Section 6B, Power Steering Pump.
23. Remove the crankshaft pulley bolts.
24. Remove the crankshaft pulley.

1C2 – 22I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
56. Connect the CTS connector.
57. Connect the engine CTS connector.
58. Connect the IAC valve connector.
59. Connect the TPS connector.
60. Install the CCP and the EGR solenoid bracket bolt.
Tighten
Tighten the charcoal canister purge and exhaust gas
recirculation solenoid bracket bolt to 5 NSm (44 lb–in).
61. Connect the DIS coil connector.
62. Connect the O2 sensor connector, if equipped.
63. Connect the ECM ground terminal.
64. Install the fuel pump fuse.
65. Connect the negative battery ground cable.
66. Refill the engine cooling system. Refer to Section
1D, Engine Cooling.
CAMSHAFTS
Removal Procedure
1. Remove the timing belt. Refer to ”Timing Belt” in
this section.
2. Disconnect the breather tube at the camshaft cov-
er.
3. Disconnect the engine ventilation hose at the cam-
shaft cover.
4. Remove the spark plug cover bolts.
5. Remove the spark plug cover.
6. Disconnect the ignition wires from the spark plugs.
7. Remove the camshaft cover bolts.
8. Remove the camshaft cover washers.
9. Remove the camshaft cover and the camshaft cov-
er gasket.
Notice : Take extreme care to prevent any scratches,
nicks or damage to the camshafts.
10. While holding the intake camshaft firmly in place,
remove the intake camshaft gear bolt.
11. Remove the intake camshaft gear.
12. While holding the exhaust camshaft firmly in place,
remove the exhaust camshaft gear bolt.
13. Remove the exhaust camshaft gear.

1.8L DOHC ENGINE MECHANICAL 1C2 – 39
DAEWOO V–121 BL4
8. Disconnect the idle air control (IAC) valve connec-
tor.
9. Disconnect the throttle position sensor (TPS) con-
nector.
10. Disconnect the manifold absolute pressure (MAP)
sensor connector.
11. Disconnect the coolant hoses at the throttle body.
12. Disconnect all of the necessary vacuum hoses, in-
cluding the vacuum hose at the fuel pressure regu-
lator and the brake booster vacuum hose at the
intake manifold.
13. Disconnect the throttle cable from the throttle body
and the intake manifold.
14. Remove the throttle cable bracket bolts from the
intake manifold.
15. Remove the throttle cable bracket.
16. Remove the generator–to–intake manifold strap
bracket bolts and strap.
17. Remove the fuel rail as an assembly. Refer to Sec-
tion 1F, Engine Controls.
18. Remove the generator–to–intake manifold support
bracket bolts.
19. Remove the generator–to–intake manifold support
bracket.
20. Remove the intake manifold support bracket bolt at
the engine block and the intake manifold.
21. Remove the intake manifold support bracket.
22. Remove the intake manifold retaining bolt and nuts
in the sequence shown.
23. Remove the intake manifold.
24. Remove the intake manifold gasket.
25. Clean the sealing surfaces of the intake manifold
and the cylinder head.

1.8L DOHC ENGINE MECHANICAL 1C2 – 41
DAEWOO V–121 BL4
14. Connect the MAP sensor connector.
15. Connect the coolant hoses to the throttle body.
16. Connect the IAC valve connector.
17. Connect the TPS connector.
18. Connect the air cleaner outlet hose to the throttle
body.
19. Connect the MAT sensor connector.
20. Connect the CCP and EGR solenoid at the intake
manifold and tighten the bracket bolt.
Tighten
Tighten the charcoal canister purge and exhaust gas
recirculation solenoid bracket bolt to 5 NSm (44 lb–in).
21. Install the fuel pump fuse.
22. Connect the negative battery cable.
23. Refill the engine cooling system. Refer to Section
1D, Engine Cooling.
EXHAUST MANIFOLD
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the oxygen (O2) sensor connector, if
equipped.
3. Remove the exhaust manifold heat shield bolts.
4. Remove the exhaust manifold heat shield.
5. Remove the exhaust flex pipe retaining nuts from
the exhaust manifold studs.

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.

1C2 – 50I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
18. Install the exhaust flex pipe retaining nuts to the
catalytic converter or the connecting pipe.
Tighten
Tighten the exhaust flex pipe–to–catalytic converter
or connecting pipe retaining nuts to 35 NSm (26 lb–ft).
19. Connect the power steering pressure hose.
20. Connect the power steering return hose.
21. Install the A/C compressor, if equipped. Refer to
Section 7B, Manual Control Heating, Ventilation,
and Air Conditioning System.
22. Install the serpentine accessory drive belt. Refer to
Section 6B, Power Steering Pump.
23. Install the right front wheel well splash shield.
24. Install the right front wheel. Refer to Section 2E,
Tires and Wheels.
25. Connect the fuel feed line to the fuel rail.
26. Connect the fuel return line to fuel rail.
27. Install the fuel rail and injector channel cover as an
assembly. Refer to Section 1F, Engine Controls.
28. Connect all of the necessary vacuum lines including
the brake booster vacuum hose.
29. Connect the O2 sensor connector, if equipped.
30. Connect the starter solenoid ”S” terminal wire and
power lead.
31. Connect the generator voltage regulator connector.
32. Connect the CTS connector.
33. Connect the engine CTS connector.
34. Connect the TPS connector.
35. Connect the IAC valve connector.
36. Connect the MAP sensor connector.
37. Connect the knock sensor, if necessary
38. Connect the electrical connector at the DIS ignition
coil and the ECM ground terminal and at the starter
motor.
39. Install the air cleaner outlet hose between the
throttle body and the air cleaner housing.
40. Connect the breather tubes to the camshaft cover.
41. Connect the MAT sensor connector.
42. Install the cooling system radiator and the engine
cooling fans. Refer to Section 1D, Engine Cooling.

ENGINE CONTROLS 1F – 79
DAEWOO V–121 BL4
IDLE AIR CONTROL SYSTEM CHECK (1.4L/1.6L DOHC)
Circuit Description
The aim of the MTIA (Main Throttle Idle Actuator) is to con-
trol the idle speed with the throttle body itself. The throttle
is motorized for low opening angle (0°C, 19°C). The char-
acteristics of the airflow are not the same for low and high
opening angles. As a matter of fact, the gradient of the
mass air flow function of TPS is lower for small angles that
permits to be more precise during the idle speed control.
Out of idle speed the throttle is actuated mechanically by
a classical bowdencable.
The main throttle idle actuator (MTIA) provides a voltagesignal that changes in relation to the throttle plate angle.
The signal voltage will vary from about nearly 5.0 V at idles
to about 0.2V to 0.4 V at wide–open throttle. The TPS is
one of the most important inputs used by the ECM for fuel
control and other functions such as idle, wide open
throttle, deceleration enleanment, and acceleration en-
richment.
Diagnostic Aids
If the idle is too high, stop the engine. Fully extend the main
throttle idle actuator (MTIA) with a IAC driver. Start the en-
gine. If the idle speed is above 800 rpm, locate and repair
the vacuum leak. Also, check for a binding throttle plate or
throttle linkage or an incorrect base idle setting.

1F – 80IENGINE CONTROLS
DAEWOO V–121 BL4
Idle Air Control System Check (1.4L/1.6L DOHC)
StepActionValue(s)YesNo
1Perform an On–Board Diagnostic (EOBD) System
Check.
Is the system check complete?–Go to Step 2Go to
”On–Board
Diagnostic Sys-
tem Check”
2Turn the ignition switch to ON.
Is the Malfunction Indicator Lamp (MIL) on steady?–Go to Step 4Go to Step 3
3Turn the ignition switch to LOCK.
Connect the scan tool to the DLC.
Turn the Turn the ignition switch to ON.
Are any diagnostic trouble codes (DTCs) displayed?–Go to Step 4Try with
another scan
tool
4Refer to the applicable DTC table.
Is only one DTC identified as valid trouble code
P0122?–Go to Step 5Go to
applicable DTC
table And go to
”Multiple DTC”
51. Connect the scan tool to the DLC.
2. Turn the ignition switch to ON.
3. Press the accelerator pedal while watching
TPS for smooth changes in the voltage.
Does the scan tool show the TPS voltage change
smoothly within the value specified?0.3V–4.8VGo to
”Diagnostic
Aids”Go to Step 6
61. Turn the ignition switch to lock.
2. Disconnect the MTIA connector.
3. Measure the voltage between terminal 2 and 8.
Does the voltage measure within the value speci-
fied?4.8V–5.0VGo to Step 7Go to Step 8
7Connect a fused jumper between the MTIA connec-
tor terminal 2 and terminal 7.
Does the scan tool show the TPS voltage above val-
ue specified?4.8V–5.0VGo to Step 13Go to Step 11
8Measure the voltage between the MTIA connector
2 and ground.
Does the voltage measure within the value speci-
fied?>5.0VGo to Step 9Go to Step 10
91. Turn the ignition switch to lock.
2. Check for an open or low voltage in the wire
between the MTIA connector 8 and ECM con-
nector 19.
Is the problem found?–Go to Step 12Go to Step 14
101. Turn the ignition switch to LOCK.
2. Check for an open or low voltage in the wire
between the MTIA connector 2 and ECM con-
nector 79.
Is the problem found?–Go to Step 12Go to Step 14
111. Turn the ignition switch to LOCK.
2. Check for an open or low voltage in the wire
between the MTIA connector 7 and ECM con-
nector 74.
Is the problem found?–Go to Step 12Go to Step 14