2004 DAEWOO LACETTI Section 6

1.8L DOHC ENGINE MECHANICAL 1C2 – 35
DAEWOO V–121 BL4
8. Remove the oil pump retaining bolts.
9. Carefully separate the oil pump and gasket from
the engine block and oil pan.
10. Remove the oil pump.
Inspection Procedure
1. Clean the oil pump and the engine block gasket
mating surface areas.
2. Remove the safety relief valve bolt.
3. Remove the safety relief valve and the spring.
4. Remove the oil pump–to–crankshaft seal.
5. Remove the oil pump rear cover bolts.
6. Remove the rear cover.
7. Clean the oil pump housing and all the oil pump
parts.
8. Inspect all the oil pump parts for signs of wear. Re-
fer to ”Engine Specifications” in this section. Re-
place the worn oil pump parts.
Notice : Pack the oil pump gear cavity with petroleum jelly
to ensure an oil pump prime, or engine damage could re-
sult.
9. Coat all the oil pump parts with clean engine oil.
Install the oil pump parts.
10. Apply Loctite® 242 to the oil pump rear cover bolts
and install the cover and bolts.
Tighten
Tighten the oil pump rear cover bolts to 6 NSm (53 lb–
in).
11. Install the safety relief valve, spring, washer and
bolt.
Tighten
Tighten the safety relief valve bolt to 30 NSm (22 lb–ft).

1C2 – 36I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
Installation Procedure
1. Apply Loctite® 242 to the oil pump bolts and room
temperature vulcanizing (RTV) sealant to the new
oil pump gasket.
2. Install the gasket to the oil pump and install the oil
pump to the engine block with the bolts.
Tighten
Tighten the oil pump retaining bolts to 10 NSm (89 lb–
in).
3. Install a new oil pump–to–crankshaft seal. Coat the
lip of the seal with a thin coat of grease.
4. Coat the threads of the oil suction pipe and support
bracket bolts with Loctite® 242.
5. Install the oil suction pipe and the bolts.
Tighten
Tighten the oil suction pipe bolts to 10 NSm (89 lb–in)
and support bracket bolts to 6 NSm (53 lb–in).
6. Install the oil pan. Refer to ”Oil Pan” in this section.
7. Connect the oil pressure switch connector.
8. Install the rear timing belt cover. Refer to ”Rear
Timing Belt Cover” in this section.
9. Install the timing belt. Refer to ”Timing Belt” in this
section.
10. Connect the negative battery cable.

1.8L DOHC ENGINE MECHANICAL 1C2 – 37
DAEWOO V–121 BL4
ENGINE MOUNT
Tools Required
J–28467–B Engine Assembly Support Fixture
X–28467–560 Engine Assembly Support Channel
Removal Procedure
1. Disconnect the negative battery cable.
2. Support the engine assembly using the engine as-
sembly support fixture J–28467–B, and the engine
assembly support channel X–28467–560.
3. Disconnect the manifold air temperature (MAT)
sensor connector.
4. Disconnect the air cleaner outlet hose from the
throttle body.
5. Remove the air cleaner housing bolts.
6. Remove the air cleaner housing.
7. Remove the right front splash shield. Refer to Sec-
tion 9R, Body Font End.
8. Remove the engine mount bracket retaining bolts.
9. Remove the engine mount bracket.
10. Remove the serpentine accessory drive belt. Refer
to Section 6B, Power Steering Pump.
11. Remove the front timing belt cover bolts.
12. Align the crankshaft pulley timing mark with the
pointer, and the camshaft gears with the timing
marks on the rear cover, by turning the crankshaft
gear bolt.
13. Loosen the timing belt automatic tensioner bolt.
14. Turn the hex–key tab to relieve belt tension.
15. Remove the timing belt idler pulley bolt and nut.
16. Remove the timing belt idler pulley.
17. Remove the engine mount retaining bolts.
18. Remove the engine mount.
Installation Procedure
1. Install the engine mount.
2. Install the engine mount retaining bolts.
Tighten
Tighten the engine mount retaining bolts to 45 NSm
(33 lb–ft).

1C2 – 38I1.8L DOHC ENGINE MECHANICAL
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3. Install the timing belt idler pulleys.
4. Install the timing belt idler pulley bolt and nut.
Tighten
Tighten the timing belt idler pulley bolt and nut to 25
NSm (18 lb–ft).
5. Tension the timing belt by turning the timing belt
automatic tensioner hex–key tab counterclockwise
until the pointer is aligned to the indicator.
Tighten
Tighten the timing belt automatic tensioner bolt to 25
NSm (18 lb–ft).
6. Install the front timing belt cover.
7. Install the front timing belt cover bolts.
Tighten
Tighten the front timing belt cover bolts to 6 NSm (53
lb–in).
8. Install the engine mount bracket and retaining bolts.
Tighten
Tighten the engine mount bracket retaining bolts to 55
NSm (41 lb–ft).
9. Remove the engine assembly support fixture
J–28467–B, and the channel X–28467–560.
10. Install the serpentine accessory drive belt. Refer to
Section 6B, Power Steering Pump.
11. Connect the negative battery cable.
INTAKE MANIFOLD
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 charcoal canister purge (CCP) and
exhaust gas recirculation (EGR) solenoid from the
intake manifold and loosen the bracket bolt.
5. Drain the engine coolant. Refer to Section 1D, En-
gine Cooling.
6. Disconnect the manifold air temperature sensor
(MAT) connector.
7. Disconnect the air cleaner outlet hose from the
throttle body.

1C2 – 40I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
Installation Procedure
1. Install the intake manifold gasket.
2. Install the intake manifold.
3. Install the intake manifold retaining bolt and nuts in
the sequence shown.
Tighten
Tighten the intake manifold retaining bolt and nuts to
22 NSm (16 lb–ft).
4. Install the generator–to–intake manifold strap
bracket and bolts.
Tighten
Tighten the generator–to–intake manifold strap
bracket bolts to 22 NSm (16 lb–ft).
5. Install the intake manifold support bracket.
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. Install the intake manifold support bracket lower
bolt to the engine block.
Tighten
Tighten the intake manifold support bracket lower bolt
to the engine block to 25 NSm (18 lb–ft).
8. Install the generator–to–intake manifold support
bracket and bolts.
Tighten
Tighten the generator–to–intake manifold support
bracket bolts to 37 NSm (27 lb–ft).
9. Install the fuel rail and injector cover as an assem-
bly. Refer to Section 1F, Engine Controls.
10. Install the throttle cable bracket.
11. Install the throttle cable bracket bolts.
Tighten
Tighten the throttle cable bracket bolts to 8 NSm (71
lb–in).
12. Connect the throttle cable to the intake manifold
and the throttle body.
13. Connect all of the necessary vacuum lines that
were previously disconnected.

1.8L DOHC ENGINE MECHANICAL 1C2 – 41
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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 – 43
DAEWOO V–121 BL4
CAMSHAFT GEARS
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the timing belt. Refer to ”Timing Belt” in
this section.
3. Remove the spark plug cover bolts.
4. Remove the spark plug cover.
5. Disconnect the ignition wires from the spark plugs.
6. Disconnect the breather tubes from the camshaft
cover.
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.
Installation Procedure
Notice : Take extreme care to prevent any scratches,
nicks or damage to the camshafts.
1. Install the intake camshaft gear.
2. While holding the intake camshaft firmly in place,
install the intake camshaft gear bolt.
Tighten
Tighten the intake camshaft gear bolt to 50 NSm (37
lb–ft) plus 60 degrees and 15 degrees using the angu-
lar torque gauge KM–470–B.

1C2 – 44I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
3. Install the exhaust camshaft gear.
4. While holding the exhaust camshaft firmly in place,
install the exhaust camshaft gear bolt.
Tighten
Tighten the exhaust camshaft gear bolt to 50 NSm (37
lb–ft) plus 60 degrees and 15 degrees using the angu-
lar torque gauge KM–470–B.
5. 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.
6. Install the camshaft cover and the camshaft cover
gasket.
7. Install the camshaft cover washers.
8. Install the camshaft cover bolts.
Tighten
Tighten the camshaft cover bolts to 8 NSm (71 lb–in).
9. Connect the crankcase breather tubes to the cam-
shaft cover.
10. Connect the ignition wires to the spark plugs.
11. Install the spark plug cover.
12. Install the spark plug cover bolts.
Tighten
Tighten the spark plug cover bolts to 8 NSm (71 lb–in).
13. Install the timing belt. Refer to ”Timing Belt” in this
section.
14. Connect the negative battery cable.
REAR TIMING BELT COVER
Tools Required
KM–470–B Angular Torque Gauge
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the timing belt. Refer to ”Timing Belt” in
this section.
3. Remove the camshaft gears. Refer to ”Camshaft
Gears” in this section.
4. Remove the timing belt automatic tensioner bolt.
5. Remove the timing belt automatic tensioner.