Vacuum DAEWOO NUBIRA 2004 Service Repair Manual

1C1 – 26I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
5. Connect the throttle cable at the throttle body and
the intake manifold.
6. Install the intake manifold support bracket upper
bolts to the intake manifold.
Tighten
Tighten the intake manifold support bracket upper
bolts to the intake manifold to 25 NSm (18 lb–ft).
7. Connect the surge tank coolant hose at the throttle
body.
8. Connect the heater inlet hose to the cylinder head.
9. Install the generator upper retaining bolt.
Tighten
Tighten the generator upper retaining bolt to 20 NSm
(15 lb–ft).
10. Connect the fuel feed line at the fuel rail.
11. Connect all the disconnected vacuum hoses and
the brake booster vacuum hose at the intake man-
ifold.
12. Install the catalytic converter retaining nuts at the
exhaust manifold flange.
Tighten
Tighten the catalytic converter to exhaust manifold
flange nuts to 40 NSm (30 lb–ft).
13. Install the rear timing belt cover.
14. Install the rear timing belt cover bolts.
Tighten
Tighten the rear timing belt cover bolts to 10 NSm (89
lb–in).

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 – 50I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
33. Remove the crankshaft pulley bolt.
34. Remove the crankshaft pulley.
35. Disconnect the vacuum lines at the charcoal canis-
ter purge solenoid.
36. Disconnect the electrical connector at the charcoal
canister purge (CCP) solenoid and at the knock
sensor.
37. Disconnect the electrical connector at the oil pres-
sure switch and at the exhaust gas recirculation
(EGR) solenoid.
38. Disconnect the crankshaft position sensor (CPS)
connector.
39. Remove the transaxle torque converter bolts, if au-
tomatic transaxle equipped.
40. Remove the stater motor. Refer to Section 1E, En-
gine Electrical.
41. Remove the transaxle bell housing bolts.
42. Support the transaxle with a floor jack.
43. Install the engine lifting device.
44. Disconnect the right engine mount bracket from the
engine mount and the engine by removing the at-
taching bolts and the nuts.
45. Remove the right engine mount from the engine
block. Refer to ”Engine Mount” in this section.
46. Separate the engine block from the transaxle.
47. Remove the engine.
Installation Procedure
1. Install the engine into the engine compartment.
2. Align the engine alignment pins to the transaxle.
3. Install the transaxle bell housing bolts.
Tighten
Tighten the transaxle bell housing bolts to 75 NSm (55
lb–ft).
4. Install the right engine mount to the engine block.
Refer to ”Engine Mount” in this section.

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 – 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 – 12I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
CAMSHAFT COVER
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the breather tube from the valve cover.
3. Disconnect all of the necessary vacuum lines.
4. Remove the spark plug cover bolts.
5. Remove the spark plug cover.
6. Disconnect the ignition wires from the spark plugs.
7. Disconnect the camshaft position sensor connector.
8. Remove the camshaft cover bolts.
9. Remove the camshaft cover.
10. Remove the camshaft cover gasket from the cam-
shaft cover.

1.8L DOHC ENGINE MECHANICAL 1C2 – 13
DAEWOO V–121 BL4
Installation Procedure
1. Apply a small amount of gasket sealant to the cor-
ners of the front camshaft caps and the top of the
rear camshaft cover–to–cylinder head seal.
2. Install the new camshaft cover gasket to the cam-
shaft cover.
3. Install the camshaft cover.
4. Install the camshaft cover bolts.
Tighten
Tighten the camshaft cover bolts to 8 NSm (71 lb–in).
5. Connect the ignition wires to the spark plugs.
6. Install the spark plug cover.
Tighten
Tighten the spark plug cover bolts to 8 NSm (71 lb–in).
7. Install the spark plug cover bolts.
8. Connect the camshaft position sensor connector.
9. Connect all of the necessary vacuum lines.
10. Connect the breather tube to the camshaft cover.
11. Connect the negative battery cable.
CYLINDER HEAD AND GASKET
Tools Required
KM–470–B Angular Torque Gauge
J–28467–B Engine Assembly Support Fixture
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 electronic control mdule (ECM)
ground terminal.
5. Drain the engine coolant. Refer to Section 1D, En-
gine Cooling.

1C2 – 16I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
40. Remove the timing belt idler pulley bolt and nut.
41. Remove the timing belt idler pulleys.
42. Remove the engine mount bolts.
43. Remove the engine mount.
44. Remove the rear timing belt cover bolts.
45. Remove the rear timing belt cover.
46. Remove the exhaust flex pipe retaining nuts at the
exhaust manifold studs.
47. Disconnect all of the necessary vacuum hoses.
48. Disconnect the fuel feed line at the fuel rail.
49. Remove the generator adjusting bracket retaining
bolt and the bracket.
50. Disconnect the coolant hose at the rear cylinder
head and ignition coil exhaust gas recirculation
(EGR) bracket.
51. Disconnect the surge tank coolant hose at the
throttle body.
52. Remove the fuel rail assembly. Refer to Section 1F,
Engine Controls.

1C2 – 18I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
Tighten
Tighten the cylinder head bolts to 25 NSm (18 lb–ft)
and turn the bolts another 3 turns of 90 degrees using
the angular torque gauge KM–470–B.
5. Connect the throttle cable at the throttle body and
the intake manifold.
6. Install the generator–to–intake manifold support
bracket.
7. Install the intake generator–to–manifold support
bracket bolts.
Tighten
Tighten the generator–to–intake manifold support
bracket bolts to the intake manifold to 37 NSm (27 lb–
ft).
8. Install the intake manifold support bracket bolt to
the generator.
Tighten
Tighten the generator–to–intake manifold support
bracket bolt at the generator to 22 NSm (16 lb–ft).
9. Connect the surge tank coolant hose at the throttle
body.
10. Connect the coolant hose to the rear cylinder head
and ignition coil EGR bracket.
11. Connect the fuel feed line at the fuel rail.
12. Connect the fuel return line at the fuel rail.
13. Connect all of the necessary vacuum hoses.
14. Install the fuel rail assembly. Refer to Section 1F,
Engine Controls.

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.