width DAEWOO NUBIRA 2004 Service Repair Manual

0B – 6IGENERAL INFORMATION
DAEWOO V–121 BL4
VEHICLE DIMENSIONS AND WEIGHTS
Vehicle Dimensions
Application1.4L DOHC1.6L DOHC1.8L DOHC
Overall Length
4 Door
5 Door H/B4,500 mm (177.2 in.)
4,295 mm (169.1 in.)






Overhang :
4 Door
Front
Rear
885 mm (34.8 in.)
1,015 mm (40.0 in.)






5 Door H/B
Front
Rear
902 mm (35.5 in.)
793 mm (31.2 in.)






Overall Width1,725 mm (67.9 in.)


Overall Height1,445 mm (56.9 in.)


Minimum Ground Clear-
ance160 mm (6.3 in.)


Wheel Base2,600 mm (102.4 in.)


Tread :
Front
Rear1,480 mm (58.3 in.)
1,480 mm (58.3 in.)






Vehicle Weights
4 Door
Application1.4L DOHC1.6L DOHC1.8L DOHC
Manual :
Curb Weight :
Standard
Optional1,175 kg (2,590 lb)
1,225 kg (2,701 lb)1,180 kg (2,601 lb)
1,230 kg (2,712 lb)1,210 kg (2,668 lb)
1,260 kg (2,778 lb)
Gross Vehicle Weight1,660 kg (3,660 lb)1,665 kg (3,671 lb)1,695 kg (3,737 lb)
Automatic :
Curb Weight :
Standard
Optional–
–1,190 kg (2,624 lb)
1,240 kg (2,734 lb)1,235 kg (2,723 lb)
1,285 kg (2,833 lb)
Gross Vehicle Weight–1,675 (3,693 lb)1,720 kg (3,792 lb)
Passenger Capacity5


Optional Weight : ABS, Sun Roof, A/C

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 3
DAEWOO V–121 BL4
ApplicationDescription (Manual and Automatic)
1.4L DOHC1.6L DOHC
Crankshaft:
Main Journal:
Diameter (All)
Taper (Maximum)
Out of Round (Maximum)55 mm (2.71 in.)
0.005 mm (0.0001 in.)
0.004 mm (0.0001 in.)54.982–54.994 mm
(2.164–2.165 in.)
0.005 mm (0.0001 in.)
0.004 mm (0.0001 in.)
Main Bearing Clearance (All)0.026–0.042 mm (0.001–0.002 in.)0.026–0.042 mm (0.001–0.002 in.)
Crankshaft End Play0.1 mm (0.003 in.)0.05–0.28 mm (0.002–0.011 in.)
Connecting Rod Journal:
Diameter (All)43 mm (1.69 in.)
42.971–42.987 mm
(1.691–1.692 in.)
Taper (Maximum)0.005 mm (0.0001 in.)0.005 mm (0.0001 in.)
Out of Round (Maximum)0.004 mm (0.0001 in.)0.004 mm (0.0001 in.)
Rod Bearing Clearance (All)0.019–0.070 mm
(0.0007–0.0028 in.)0.019–0.071 mm
(0.0007–0.0028 in.)
Rod Side Clearance0.070–0.242 mm
(0.0027–0.009 in.)0.070–0.242 mm
(0.0027–0.009 in.)
Valve System:
Valve Lash CompensatorsHydraulicHydraulic
Face Angle (All)45°~45.25°90°~90.5°
Seat Angle (All)44.5°~45°89°~90°
Seat Runout (Maximum, All)0.05 mm (0.002 in.)0.05 mm (0.002 in.)
Face Runout (Maximum, All)0.03 mm (0.0012 in.)0.03 mm (0.0012 in.)
Seat Width:
Intake
Exhaust1.17–1.57 mm (0.046–0.062 in.)
1.4–1.8 mm (0.055–0.071 in.)1.17–1.57 mm (0.046–0.062 in.)
1.4–1.8 mm (0.055–0.071 in.)
Valve Guide Inside Diameter (All)6.00–6.02 mm (0.236–0.237 in.)6.00–6.02 mm (0.236–0.237 in.)
Valve Stem Diameter (All)6 mm (0.236 in.)6 mm (0.236 in.)
Valve Diameter (All):
Intake
Exhaust28.57 mm (1.125 in.)
27.24 mm (1.074 in.)28.6 mm (1.126 in.)
27.2 mm (1.072 in.)
Valve Spring Loads:
Valve Open
Valve Closed580 ± 29N (426 ± 21 lbs)
260 ± 13N (191 ± 9.6 lbs)580–26N (428–19 lbs)
@23.0 mm(0.90 in.)
260”13N(192” 9 lbs) @
32.0mm(1.25 in.)
Valve Spring Free Length41.2 mm (1.622 in.)41.2 mm (1.622 in.)
Oil Pump:
Gap Between Oil Pump Body and Out
Rotor0.400~0.484 mm
(0.0157~0.019 in.)0.400~0.484 mm (0.0157~0.019 in.)
Out Rotor Side Clearance0.045~0.100 mm
(0.0018~0.0039 in.)0.045~0.100 mm (0.02~0.004 in.)

1C1 – 60I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
35. Remove the valves. Maintain the original position of
the valves for installation.
36. Remove the valve stem seals.
Cylinder Head Inspection
1. Clean the sealing surfaces.
2. Inspect the cylinder head gasket and mating sur-
faces for leaks, corrosion, and blowby.
3. Inspect the cylinder head for cracks.
4. Inspect the length and the width of the cylinder
head using a feeler gauge and a straight edge.
5. Check the sealing surfaces for deformation and
warpage. The cylinder head sealing surfaces must
be flat within 0.050 mm (0.002 inch) maximum.
6. Measure the height of the cylinder head from seal-
ing surface to sealing surface. The cylinder head
height should be 134.08 to 134.23 mm. If the cylin-
der head height is less than 134.08 mm, replace
the cylinder head.
7. Inspect all threaded holes for damage.
8. Inspect valve seats for excessive wear and burned
spots.
Valve Inspection
1. Inspect the valve stem tip for wear.
2. Inspect the valve key grooves and the oil seal
grooves for chips and wear.
3. Inspect the valves for burns or cracks.
4. Inspect the valve stem for burrs and scratches.
5. Inspect the valve stem. The valve stem must be
straight.
6. Inspect the valve face for grooving. If the groove is
so deep that refacing the valve would result in a
sharp edge, replace the valve.

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 63
DAEWOO V–121 BL4
4. Inspect the dimension for the valve seat width.
S Intake: 1.17 to 1.57 mm (0.046 to 0.062 inch).
S Exhaust: 1.4 to 1.8 mm (0.055 to 0.071 inch).
5. Inspect the assembly height of the intake valves
and the exhaust valves. If the dimension is exceed-
ed, install new valves. Inspect the assembly height
of the intake valves and the exhaust valves again. If
the valve assembly height is still too large despite
replacing the valves, replace the cylinder head.
Assembly Procedure
1. Install the valve stem seals.
2. Lubricate the valve stems with engine oil.
3. Carefully install the valves in their original positions.
Do not damage the valve stem seals.
4. Install the valve springs in their original positions.
5. Install the valve spring caps.
6. Compress the valve springs with the valve spring
compressor KM–348 and adapter KM–653.
7. Install the valve keys.
8. Remove the valve spring compressor KM–348 and
adapter KM–653.
9. Lubricate the valve tappet adjusters with engine oil.
10. Install the valve tappet adjusters.

1C1 – 70I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
Important : Grease the crankshaft journals and lubri–cate
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 and the bolts.
Tighten
Tighten the crankshaft bearing cap bolts to 50 NSm
(37 lb–ft) plus 45 degrees plus 15 degrees.
11. Remove the crankshaft bearing cap bolts and the
caps.
12. Measure the width of the flattened plastic thread of
the plastic gauging using a ruler. (Plastic gauging is
available for different tolerance ranges.)
13. Inspect the bearing clearance for permissible toler-
ance ranges. Refer to ”Engine Specifications” in
this section.
14. Apply a bead of adhesive sealing compound to the
grooves of the crankshaft bearing caps.
15. Install the crankshaft bearing caps to the engine
block.
16. Tighten the crankshaft bearing caps using new
bolts.
Tighten
Tighten the crankshaft bearing cap bolts to 50 NSm
(37 lb–ft) using a torque wrench. Use the angular
torque gauge KM–470–B to tighten the crankshaft
bearings 45 degrees plus 15 degrees.
Important : Grease the connecting rod journals and lubri-
cate the connecting rod bearings slightly so that the plastic
gauging thread does not tear when the connecting rod
bearing caps are removed.
17. Inspect all of the connecting rod bearing clearances
using a commercially available plastic gauging
(ductile plastic threads).
18. Cut the plastic gauging threads to the length of the
connecting rod bearing width. Lay them axially be-
tween the connecting rod journals and the connect-
ing rod bearings.
19. Install the connecting rod bearing caps.

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 71
DAEWOO V–121 BL4
Tighten
Tighten the connecting rod bearing cap bolts to 25
NSm (18 lb–ft) using a torque wrench. Use the angular
torque gauge KM–470–B to tighten the connecting
rod bearing cap bolts 30 degrees plus 15 degrees.
20. Remove the connecting rod bearing caps.
21. Measure the width of the flattened plastic thread of
the plastic gauging using a ruler. (Plastic gauging is
available for different tolerance ranges.)
22. Inspect the bearing clearance for permissible toler-
ance ranges. Refer to ”Engine Specifications” in
this section.
23. Install the connecting rod bearing caps to the con-
necting rods.
24. Tighten the connecting rod bearing caps using new
bolts.
Tighten
Tighten the connecting rod bearing cap bolts to 25
NSm (18 lb–ft) using a torque wrench. Use the angular
torque gauge KM–470–B to tighten the connecting
rod cap bolts 30 degrees plus 15 degrees.
25. Install the oil pump.
26. Install the oil pump retaining bolts.
Tighten
Tighten the oil pump retaining 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.

1C1 – 76I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
12. Remove the crankshaft bearing caps.
13. Measure the width of the flattened plastic thread of
the plastic gauging using a ruler. (Plastic gauging is
available for different tolerance ranges.)
14. Inspect the bearing clearances for permissible toler-
ance ranges. Refer to ”Engine Specifications” in
this section.
Inspection Procedure – Connecting Rods
1. Coat the connecting rod bearings with engine oil.
2. Install the upper connecting rod bearings into the
connecting rod journals.
3. Install the lower connecting rod bearings into the
connecting rod bearing caps.
Notice : Grease the connecting rod journals and lubricate
the connecting rod bearings slightly so that the plastic
gauging thread does not tear when the connecting rod
bearing caps are removed.
4. Inspect all of the connecting rod bearing clearances
using a commercially available plastic gauging
(ductile plastic threads).
5. Cut the plastic gauging threads to the length of the
bearing width. Lay them axially between the con-
necting rod journals and the connecting rod bear-
ings.
6. Install the connecting rod bearing caps.
7. Install the connecting rod bearing cap bolts.
Tighten
Tighten the connecting rod bearing cap bolts to 25
NSm (18 lb–ft). Using the angular torque gauge
KM–470–B, tighten the connecting rod bearing cap
bolts another 30 degrees plus 15 degrees.
8. Remove the connecting rod bearing caps.
9. Measure the width of the flattened plastic thread of
the plastic gauging using a ruler. (Plastic gauging is
available for different tolerance ranges.)
10. Inspect the bearing clearance for permissible toler-
ance ranges. Refer to ”Engine Specifications” in
this section.

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 – 58I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
31. Remove the valves. Maintain the original position of
the valves for installation.
32. Remove the valve stem seals.
Cylinder Head Inspection
1. Clean the sealing surfaces.
2. Inspect the cylinder head gasket and mating sur-
faces for leaks, corrosion, and blowby.
3. Inspect the cylinder head for cracks.
4. Inspect the length and the width of the cylinder
head using a feeler gauge and a straight edge.
5. Check the sealing surfaces for deformation and
warpage. The cylinder head sealing surfaces must
be flat within 0.025 mm (0.001 inch) maximum.
6. Measure the height of the cylinder head from seal-
ing surface to sealing surface. The cylinder head
height should be 133.975 to 134.025 mm (5.274 to
5.276 inches). If the cylinder head height is less
than 133.9 mm (5.271 inches), replace the cylinder
head.
7. Inspect all threaded holes for damage.
8. Inspect valve seats for excessive wear and burned
spots.
Valve Inspection
1. Inspect the valve stem tip for wear.
2. Inspect the valve key grooves and the oil seal
grooves for chips and wear.
3. Inspect the valves for burns or cracks.
4. Inspect the valve stem for burrs and scratches.
5. Inspect the valve stem. The valve stem must be
straight.
6. Inspect the valve face for grooving. If the groove is
so deep that refacing the valve would result in a
sharp edge, replace the valve.
7. Inspect the valve spring. If the valve spring ends
are not parallel, replace the valve spring.