2004 DAEWOO LACETTI Section 6

SECTION : 1C1
1.4L/1.6L DOHC ENGINE MECHANICAL
CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool
or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help
prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
TABLE OF CONTENTS
SPECIFICATIONS1C1–2 . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Specifications 1C1–2. . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifcations 1C1–5. . . . . . . . . .
SPECIAL TOOLS1C1–7 . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 1C1–7. . . . . . . . . . . . . . . . . . . . . . .
COMPONENT LOCATOR1C1–9 . . . . . . . . . . . . . . . . . . .
Cylinder Head 1C1–9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block 1C1–10. . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake & Exhaust Manifold 1C1–12. . . . . . . . . . . . . . . .
Timing Belt 1C1–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Mounting 1C1–14. . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR1C1–15 . . . . . . . . . . . . .
ON–VEHICLE SERVICE 1C1–15. . . . . . . . . . . . . . . . . . .
Engine Cover 1C1–15. . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft Cover 1C1–15. . . . . . . . . . . . . . . . . . . . . . . . .
Intake Manifold 1C1–16. . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold 1C1–20. . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Gasket 1C1–21. . . . . . . . . . . . . . . .
Camshaft 1C1–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt Check and Adjust 1C1–30. . . . . . . . . . . . .
Timing Belt 1C1–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pan 1C1–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump 1C1–40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Mount 1C1–43. . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft Gears 1C1–45. . . . . . . . . . . . . . . . . . . . . . . . .
Rear Timing Belt Cover 1C1–46. . . . . . . . . . . . . . . . . . .
Engine 1C1–48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistons and Rods 1C1–53. . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR 1C1–58. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Valve Train Components 1C1–58.
Crankshaft 1C1–65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Bearing and Connecting Rod
Beadings – Gauging Plastics 1C1–74. . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION1C1–77 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Gasket 1C1–77. . . . . . . . . . . . . . . .
Crankshaft 1C1–77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt 1C1–77. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump 1C1–77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan 1C1–77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold 1C1–77. . . . . . . . . . . . . . . . . . . . . . . .
Intake Manifold 1C1–77. . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft 1C1–77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 15
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
ENGINE COVER
Removal Procedure
1. Remove the bolts and nuts from the engine cover.
2. Remove the engine cover.
Installation Procedure
1. Position the engine cover on the engine.
2. Install the engine cover bolts and nuts.
Tighten
Tighten the engine cover bolts and nuts to 10 NSm(89
lb–ft).
CAMSHAFT COVER
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the engine cover. Refer to ”Engine” in this
section.
3. Remove the breather hose, ventilation hose and
cam position sensor wiring connector from the cam-
shaft cover.

1C1 – 16I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
4. Remove the ignition wires from the spark plug.
5. Remove the camshaft cover bolts and camshaft
cover.
6. Remove the camshaft cover gasket.
Installation Procedure
1. Install the camshaft cover gasket on the camshaft
cover.
2. Position the camshaft cover on the engine block.
3. Install the camshaft cover bolts.
Tighten
Tighten the camshaft cover bolts to 10 NSm(89 lb–ft).
4. Install the ignition wires to the spark plugs and con-
nect the breather hose, ventilation hose and cam
position sensor wiring connector to the canshaft
cover.
5. Install the engine cover.
6. 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 calbe.
4. Drain the engine coolant. Refer to Section 1D, En-
gine Cooling.
5. Remove the engine cover and throttle body. Refer
to Section 1F, Engine Control.

1C1 – 18I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
12. Remove the alternator. Refer to Section 1E, Engine
Electrical.
13. Remove the intake manifold support bracket.
14. Remove the intake manifold retaining bolts/nuts in
the sequence shown.
15. Remove the intake manifold and gasket.
16. Clean the sealing surfaces of the intake manifold
and the cylinder head.
Installation Procedure
1. Install the fule rail.
Tighten
Tighten the fule rail bolts to 25 NSm (18 lb–ft).
2. Install the new intake manifold gasket and intake
manifold.
Tighten
Tighten the intake manifold bolts and nuts to 25 NSm
(18 lb–ft).
3. Install the exhaust gas recirculation(EGR) pipe.
Tighten
Tighten the exhaust gas recirculation(EGR) pipe bolts
to 10 NSm (89 lb–ft).

1C1 – 20I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
12. Install the throttle body and engine cover.
13. Refill the engine cooling system. Refer to Section
1D, Engine Cooling.
14. Install the fuel pump fuse and connect the negative
battery cable.
EXHAUST MANIFOLD
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the oxygen sensor connecter.
3. Remove the exhaust manifold heat shield.
4. Remove the exhaust manifold nuts from the pup
converter.
5. Remove the exhaust manifold retaining nuts in the
sequence shown and remove the exhaust manifold.
6. Remove the exhaust manifold gasket.
7. Clean the sealing surfaces of the exhaust manifold
and the cylinder head.

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 21
DAEWOO V–121 BL4
Installation Procedure
1. Install the exhaust manifold and gasket.
2. Install the exhaust manifold retaining nuts and tight-
en in the sequence shown.
Tighten
Tighten the exhaust manifold retaining nuts to 25 NSm
(18 lb–ft).
3. Install the exhaust manifold nuts to the catalytic
converter.
Tighten
Tighten the exhaust manifold nuts to 40 NSm (30 lb–
ft).
4. Install the heat shield.
Tighten
Tighten the the heat shield bolts to 13 NSm (10 lb–ft).
5. Connect the oxygen sensor connecter.
6. Connect the negative battery cable.
CYLINDER HEAD AND GASKET
Tools Required
J–42492 Timing Belt Adjuster
KM–470–B Angular Torque Gauge
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 calbe.
4. Disconnect the electronic control module(ECM)
ground terminal from the intake manifold.
5. Drain the engine coolant. Refer to Section 1D, En-
gine Cooling.

1C1 – 22I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
6. Drain the engine oil and remove the camshaft cov-
er. Refer to this section.
7. Remove the air cleaner housing.
8. Remove the throttle cable and inlet/outlet coolant
hoses.
9. Remove the thermostat upper hose.
10. Remove the intake manifold pressure sensor, in-
take air temperature sensor and coolant tempera-
ture sensor.
11. Remove the intake manifold support bracket.

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 23
DAEWOO V–121 BL4
12. Remove the all the vaccum hoses from the intake
manifold including brake booster vaccum hose.
13. Remove the ignition cables from the spark plugs.
14. Remove the direct ignition coil(DIS) and the bracket
from the cylinder head.
15. Remove the serpentine accessory drive belt by ro-
tating the tensioner pulley bolt to clockwise using
DW110–080. Refer to Section 6B, Power Steering
Pump.
16. Remove the front passenger side tire. Refer to Sec-
tion 2E, Tires and Wheels.
17. Remove front wheel housing shield.
18. Remove the upper front timing belt cover bolts.
19. Remove the upper front timing belt cover.
20. Align the camshaft gear timing marks.
21. Remove the crank shaft pulley.
22. Remove the lower front timing belt cover bolts and
cover.