2004 DAEWOO LACETTI filter

1.8L DOHC ENGINE MECHANICAL 1C2 – 75
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
CYLINDER HEAD AND GASKET
The cylinder head is made of an aluminum alloy. The cylin-
der head uses cross–flow intake and exhaust ports. A
spark plug is located in the center of each combustion
chamber. The cylinder head houses the dual camshafts.
CRANKSHAFT
The crankshaft has eight integral weights which are cast
with it for balancing. Oil holes run through the center of the
crankshaft to supply oil to the connecting rods, the bear-
ings, the pistons, and the other components. The end
thrust load is taken by the thrust washers installed at the
center journal.
TIMING BELT
The timing belt coordinates the crankshaft and the dual
overhead camshafts and keeps them synchronized. The
timing belt also turns the coolant pump. The timing belt
and the pulleys are toothed so that there is no slippage be-
tween them. There are two idler pulleys. An automatic ten-
sioner pulley maintains the timing belt’s correct tension.
The timing belt is made of a tough reinforced rubber similar
to that used on the serpentine drive belt. The timing belt
requires no lubrication.
OIL PUMP
The oil pump draws engine oil from the oil pan and feeds
it under pressure to the various parts of the engine. An oil
strainer is mounted before the inlet of the oil pump to re-
move impurities which could clog or damage the oil pump
or other engine components. When the crankshaft ro-
tates, the oil pump driven gear rotates. This causes the
space between the gears to constantly open and narrow,
pulling oil in from the oil pan when the space opens and
pumping the oil out to the engine as it narrows.
At high engine speeds, the oil pump supplies a much high-
er amount of oil than required for lubrication of the engine.
The oil pressure regulator prevents too much oil from en-
tering the engine lubrication passages. During normal oil
supply, a coil spring and valve keep the bypass closed, di-
recting all of the oil pumped to the engine. When the
amount of oil being pumped increases, the pressure be-
comes high enough to overcome the force of the spring.This opens the valve of the oil pressure regulator, allowing
the excess oil to flow through the valve and drain back to
the oil pan.
OIL PAN
The engine oil pan is mounted to the bottom of the cylinder
block. The engine oil pan houses the crankcase and is
made of cast aluminum.
Engine oil is pumped from the oil pan by the oil pump. After
it passes through the oil filter, it is fed through two paths
to lubricate the cylinder block and cylinder head. In one
path, the oil is pumped through oil passages in the crank-
shaft to the connecting rods, then to the pistons and cylin-
ders. It then drains back to the oil pan. In the second path,
the oil is pumped through passages to the camshaft. The
oil passes through the internal passageways in the cam-
shafts to lubricate the valve assemblies before draining
back to the oil pan.
EXHAUST MANIFOLD
A single four–port, rear–takedown manifold is used with
this engine. The manifold is designed to direct escaping
exhaust gases out of the combustion chambers with a
minimum of back pressure. The oxygen sensor is
mounted to the exhaust manifold.
INTAKE MANIFOLD
The intake manifold has four independent long ports and
utilizes an inertial supercharging effect to improve engine
torque at low and moderate speeds.
CAMSHAFTS
This engine is a dual overhead camshaft (DOHC) type,
which means there are two camshafts. One camshaft op-
erates the intake valves, and the other camshaft operates
the exhaust valves. The camshafts sit in journals on the
top of the engine (in the cylinder head) and are held in
place by camshaft caps. The camshaft journals of the cyl-
inder head are drilled for oil passages. Engine oil travels
to the camshafts under pressure where it lubricates each
camshaft journal. The oil returns to the oil pan through
drain holes in the cylinder head. The camshaft lobes are
machined into the solid camshaft to precisely open and
close the intake and the exhaust valves the correct
amount at the correct time. The camshaft lobes are oiled
by splash action from pressurized oil escaping from the
camshaft journals.

ENGINE CONTROLS 1F – 5
DAEWOO V–121 BL4
SYMPTOM DIAGNOSIS1F–574 . . . . . . . . . . . . . . . . . . .
Important Preliminary Checks 1F–574. . . . . . . . . . . . .
Intermittents 1F–574. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hard Start 1F–576. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Surges or Chuggles 1F–579. . . . . . . . . . . . . . . . . . . . . .
Lack of Power, Sluggishness, or Sponginess 1F–581
Hesitation, Sag, Stumble 1F–583. . . . . . . . . . . . . . . . .
Cuts Out, Misses 1F–584. . . . . . . . . . . . . . . . . . . . . . . .
Poor Fuel Economy 1F–587. . . . . . . . . . . . . . . . . . . . . .
Rough, Unstable, or Incorrect Idle, Stalling 1F–588. .
Excessive Exhaust Emissions or Odors 1F–591. . . . .
Dieseling, Run–On 1F–592. . . . . . . . . . . . . . . . . . . . . . .
Backfire 1F–593. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR1F–594 . . . . . . . . . . . . .
ON–VEHICLE SERVICE 1F–594. . . . . . . . . . . . . . . . . . .
Fuel System Pressure Relief 1F–594. . . . . . . . . . . . . .
Fuel Tank 1F–594. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump 1F–596. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter 1F–597. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Rail and Injectors (1.4L/1.6L DOHC) 1F–598. . .
Fuel Rail and Injectors (1.8L DOHC) 1F–600. . . . . . .
Engine Coolant Temperature Sensor
(1.4L/1.6L DOHC) 1F–602. . . . . . . . . . . . . . . . . . . . . .
Engine Coolant Temperature Sensor
(1.8L DOHC) 1F–602. . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Position Sensor (1.8L DOHC) 1F–603. . . . . .
Throttle Body (1.4L/1.6L DOHC) 1F–603. . . . . . . . . . .
Throttle Body (1.8L DOHC) 1F–604. . . . . . . . . . . . . . .
Front Heated Oxygen Sensor (HO2S 1)
(1.4L/1.6L DOHC) 1F–606. . . . . . . . . . . . . . . . . . . . . .
Front Heated Oxygen Sensor (HO2S 1)
(1.8L DOHC) 1F–607. . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Heated Oxygen Sensor (HO2S 2) 1F–607. . . . .
Intake Air Temperature Sensor
(1.4L/1.6L DOHC) 1F–608. . . . . . . . . . . . . . . . . . . . . .
Intake Air Temperature Sensor (1.8L DOHC) 1F–609
Idle Air Control Valve (1.8L DOHC) 1F–609. . . . . . . . .
Manifold Absolute Pressure Sensor
(1.4L/1.6L DOHC) 1F–610. . . . . . . . . . . . . . . . . . . . . .
Manifold Absolute Pressure Sensor
(1.8L DOHC) 1F–611. . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Gas Recirculation Valve
(1.4L/1.6L DOHC) 1F–611. . . . . . . . . . . . . . . . . . . . . .
Exhaust Gas Recirculation Valve (1.8L DOHC) 1F–612
Knock Sensor (1.4L/1.6L DOHC) 1F–612. . . . . . . . . .
Knock Sensor (1.8L DOHC) 1F–613. . . . . . . . . . . . . . .
Evaporative Emission Canister 1F–614. . . . . . . . . . . . Evaporative Emission Canister Purge Solenoid Valve 1
F–615
Crankshaft Position (CKP) Sensor
(1.4L/1.6L DOHC) 1F–615. . . . . . . . . . . . . . . . . . . . . .
Crankshaft Position (CKP) Sensor
(1.8L DOHC) 1F–616. . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft Position Sensor (1.4L/1.6L DOHC) 1F–618
Camshaft Position Sensor (1.8L DOHC) 1F–619. . . .
Engine Control Module (1.4L/1.6L DOHC) 1F–620. . .
Engine Control Module (1.8L DOHC) 1F–621. . . . . . .
Electronic Ignition System Ignition Coil
(1.4L/1.6L DOHC) 1F–621. . . . . . . . . . . . . . . . . . . . . .
Electronic Ignition System Ignition Coil
(1.8L DOHC) 1F–622. . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION1F–623 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition System Operation 1F–623. . . . . . . . . . . . . . . .
Electronic Ignition System Ignition Coil 1F–623. . . . . .
Crankshaft Position Sensor 1F–623. . . . . . . . . . . . . . .
Camshaft Position Sensor 1F–623. . . . . . . . . . . . . . . .
Idle Air System Operation 1F–623. . . . . . . . . . . . . . . . .
Fuel Control System Operation 1F–623. . . . . . . . . . . .
Evaporative Emission Control System
Operation 1F–624. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evaporative Emission Canister 1F–625. . . . . . . . . . . .
Positive Crankcase Ventilation System
Operation 1F–625. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Coolant Temperature Sensor 1F–625. . . . . . .
Throttle Position Sensor 1F–625. . . . . . . . . . . . . . . . . .
Catalyst Monitor Oxygen Sensors 1F–625. . . . . . . . . .
Exhaust Gas Recirculation Valve 1F–626. . . . . . . . . . .
Intake Air Temperature Sensor 1F–626. . . . . . . . . . . .
Idle Air Control Valve 1F–626. . . . . . . . . . . . . . . . . . . . .
Manifold Absolute Pressure Sensor 1F–626. . . . . . . .
Engine Control Module 1F–627. . . . . . . . . . . . . . . . . . .
Fuel Injector 1F–627. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knock Sensor 1F–627. . . . . . . . . . . . . . . . . . . . . . . . . . .
Rough Road Sensor 1F–627. . . . . . . . . . . . . . . . . . . . .
Strategy–Based Diagnostics 1F–628. . . . . . . . . . . . . .
EOBD Serviceability Issues 1F–628. . . . . . . . . . . . . . .
Serial Data Communications 1F–629. . . . . . . . . . . . . .
On–Board Diagnostic (EOBD) 1F–629. . . . . . . . . . . . .
Comprehensive Component Monitor Diagnostic
Operation 1F–630. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Common EOBD Terms 1F–630. . . . . . . . . . . . . . . . . . .
Reading Diagnostic Trouble Codes 1F–632. . . . . . . . .
Primary System–Based Diagnostics 1F–633. . . . . . . .

1F – 10IENGINE CONTROLS
DAEWOO V–121 BL4
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Camshaft Position Sensor Bolts (1.4L/1.6L DOHC)7–62
Camshaft Position Sensor Bolts (1.8 DOHC)8–71
Crankshaft Position Sensor Retaining Bolt (1.4L/1.6L DOHC)6.5–58
Crankshaft Position Sensor Retaining Bolt (1.8 DOHC)8–71
Electronic Ignition System Ignition Coil Retaining Bolts10–89
Exhaust Gas Recirculation Valve Retaining Bolts3022–
Engine Control Module Bolts12–106
Engine Coolant Temperature Sensor Bolt (1.4L/1.6L DOHC)17.513–
Engine Coolant Temperature Sensor Bolt (1.8 DOHC)2015–
Evaporative Emission Canister Flange Bolt4–35
Evaporative Emission Canister Purge Solenoid Bracket Bolt5–44
Fuel Filter Mounting Bracket Assembly Bolt4–35
Fuel Tank Retaining Bolts2015–
Fuel Rail Retaining Bolts2518–
Idle Air Control Valve Retaining Bolts (1.8 DOHC)3–27
Intake Air Temperature Sensor2216–
Knock Sensor Bolt2015–
Manifold Absolute Pressure Sensor Bolts (1.4L/1.6L DOHC)8–71
Manifold Absolute Pressure Sensor Bolts (1.8 DOHC)4–35
Oxygen Sensor Bolt4231–
Throttle Body Retaining Nuts (1.4L/1.6L DOHC)1511–
Throttle Body Retaining Nuts (1.8 DOHC)10–89
Throttle Position Sensor Retaining Bolts (1.8 DOHC)2–18

1F – 42IENGINE CONTROLS
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
191. Measure the resistance between following ter-
minals:
S Terminal 1 and 2 of ignition coil.
S Terminal 2 and 1 of ignition coil.
Are the resistance within the value specified.
1. Remove the high tension cable.
2. Measure the resistance between second coil.
S Between 1 and 4
S Between 2 and 3
Are the resistance within the value specified.0.9 W
5.3 kWGo to Step 21Go to Step 20
20Replace the EI system ignition coil.
Is the repair complete?–Go to Step 2–
211. Check for any damages or poor connection in
ignition wires and repair as needed.
2. Connect the EI system ignition coil connector
and ECM connector.
3. Check for the presence of spark from all of the
ignition wires.
Is the spark present from all of the ignition wires?–Go to Step 2Go to Step 22
22Replace ECM.
Is the repair complete?–Go to Step 2–
231. Turn the ignition OFF.
2. Connect a fuel pressure gauge.
3. Crank the engine.
Is any fuel pressure present?–Go to Step 26Go to Step 24
241. Turn the ignition OFF.
2. Disconnect the electrical connector at the fuel
pump.
3. Connect a test light between the fuel pump ter-
minals 2 and 3.
4. Turn the ignition ON.
5. With the ignition ON, the test light should light
for the time specified.
Is the test light on?2 sec.Go to Step 25Go to 34
25Replace the fuel pump.
Is the repair complete?–Go to Step 2–
26Is the fuel pressure within the value specified?283–324 kPa
(41–47 psi)Go to Step 27Go to Step 29
27Check the fuel for contamination.
Is the fuel contaminated?–Go to Step 28Go to Step 41
281. Remove the contaminated fuel from the fuel
tank.
2. Clean the fuel tank as needed.
Is the repair complete?–Go to Step 2–
291. Check the fuel filter for restriction.
2. Inspect the fuel lines for kinks and restrictions.
3. Repair or replace as needed.
4. Measure the fuel pressure.
Is the fuel pressure within the value specified?283–324 kPa
(41–47 psi)Go to Step 2Go to Step 30

ENGINE CONTROLS 1F – 43
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
301. Disconnect vacuum line from the fuel pressure
regulator.
2. Inspect the vacuum line for the presence of
fuel.
3. Inspect the fuel pressure regulator vacuum port
for the presence of fuel.
Is any fuel present?–Go to Step 31Go to Step 32
31Replace the fuel pressure regulator.
Is the repair complete?–Go to Step 2–
321. Remove the fuel pump assembly from the fuel
tank.
2. Inspect the fuel pump sender and the fuel cou-
pling hoses for a restriction.
3. Inspect the in–tank fuel filter for restriction.
Is the problem found?–Go to Step 33Go to Step 25
33Replace the fuel pump sender, the in–tank fuel filter,
and/or the fuel coupling hoses as needed.
Is the repair complete?–Go to Step 2–
341. Turn the ignition OFF.
2. Disconnect the electric connector at the fuel
pump.
3. Connect a test light between fuel pump con-
nector terminal 3 and ground.
4. Turn the ignition ON.
5. With the ignition ON, the test light should illumi-
nate for the time specified.
Is the test light on?2 secGo to Step 35Go to Step 36
35Repair the open circuit between the fuel pump con-
nector terminal 2 and ground.
Is the repair complete?–Go to Step 2–
361. Turn the ignition OFF.
2. Disconnect the fuel pump relay.
3. Turn the ignition ON.
4. Measure the voltage at terminal 30 and 86 of
fuel pump relay.
Is the voltage within the value specified?11–14 VGo to Step 38Go to Step 37
37Repair open or short circuit for power supply.
Is the repair complete?–Go to Step 2–
381. Turn the ignition OFF.
2. Disconnect ECM connector.
3. Using an ohmmeter, measure the resistance
between following terminals.
S Terminal 6 of ECM and terminal 85 of fuel
pump relay.
S Terminal 87 of fuel pump relay and terminal
3 of fuel pump.
Does the resistance within the value specified?0 WGo to Step 40Go to Step 39

1F – 50IENGINE CONTROLS
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
35While cranking the engine, measure the voltage at
the EI system ignition coil connector terminal 3 .
Does the voltage fluctuate within the values speci-
fied?0.2–2.0 vGo to Step 39Go to Step 37
36Check for an open in the wire from the EI system
ignition coil connector terminal 1 to the ECM connec-
tor terminal M51.
Is the problem found?–Go to Step 38Go to Step 40
37Check for an open in the wire from the EI system
ignition coil connector terminal 3 to the ECM connec-
tor terminal M1.
Is the problem found?–Go to Step 38Go to Step 40
381. Repair the wiring as needed.
2. Connect the EI system ignition coil connector.
3. Check for the presence of spark from all of the
ignition wires.
Is spark present from all of the ignition wires?–Go to Step 3Go to Step 39
39Replace the EI system ignition coil.
Is the repair complete?–Go to Step 3–
401. Turn the ignition OFF.
2. Replace the ECM.
Is the repair complete?–Go to Step 3–
411. Turn the ignition OFF.
2. Connect a fuel pressure gauge.
3. Crank the engine.
Is any fuel pressure present?–Go to Step 44Go to Step 42
421. Turn the ignition OFF.
2. Disconnect the electrical connector at the fuel
pump.
3. Connect a test light between the fuel pump
connector terminals 3 and 2.
4. Turn the ignition ON.
5. With the ignition ON, the test light should light
for the time specified.
Is the test light on?2 secGo to Step 43Go to Step 53
43Replace the fuel pump.
Is the repair complete?–Go to Step 3–
44Is the fuel pressure within the value specified?283–324 kPa
(41–47 psi)Go to Step 48Go to Step 45
451. Check the fuel filter for a restriction.
2. Inspect the fuel lines for kinks and restrictions.
Is the problem found?–Go to Step 46Go to Step 47
461. Disconnect the vacuum line from the fuel pres-
sure regulator.
2. Inspect the vacuum line for the presence of
fuel.
3. Inspect the fuel pressure regulator vacuum port
for the presence of fuel.
Is any fuel present?283–324 kPa
(41–47 psi)Go to Step 3Go to Step 47

ENGINE CONTROLS 1F – 51
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
471. Disconnect the vacuum line from the fuel pres-
sure regulator.
2. Inspect the vacuum line for the presence of
fuel.
3. Inspect the fuel pressure regulator vacuum port
for the presence of fuel.
Is any fuel presen–Go to Step 50Go to Step 51
48Check the fuel for contamination.
Is the fuel contaminated?–Go to Step 49Go to Step 65
491. Remove the contaminated fuel from the fuel
tank.
2. Clean the fuel tank as needed.
Is the repair complete?–Go to Step 3–
50Replace the fuel pressure regulator.
Is the repair complete?–Go to Step 3–
511. Remove the fuel pump assembly from the fuel
tank.
2. Inspect the fuel pump sender and the fuel cou-
pling hoses for a restriction.
3. Inspect the in–tank fuel filter for a restriction.
Is the problem found?–Go to Step 52Go to Step 43
52Replace the fuel pump sender, the in–tank fuel filter,
and/or the fuel coupling hoses as needed.
Is the repair complete?–Go to Step 3–
531. Turn the ignition OFF.
2. Disconnect the electrical connector at the fuel
pump.
3. Connect a test light between the fuel pump
connector terminal 3 and a known good
ground.
4. Turn the ignition ON.
5. With the ignition ON, the test light should light
for the time specified.
Is the test light on?2 secGo to Step 54Go to Step 55
54Repair the open wire between the fuel pump connec-
tor terminal 2 and ground.
Is the repair complete–Go to Step 3–
551. Turn the ignition OFF.
2. Disconnect the fuel pump relay.
3. Connect a test light between the fuel pump
relay connector terminal 85 and ground.
4. Turn the ignition ON.
Is the test light on?2 secGo to Step 56Go to Step 62
561. Turn the ignition OFF.
2. Connect a test light between the fuel pump
relay connector terminal 86 and battery posi-
tive.
3. Turn the ignition ON.
4. With the ignition ON, the test light should light
for the time specified.
Is the test light on?–Go to Step 57Go to Step 61

ENGINE CONTROLS 1F – 145
DAEWOO V–121 BL4
DIAGNOSTIC TROUBLE CODE (DTC) P0135
FRONT HEATED OXYGEN SENSOR HEATER CIRCUIT
NOT FUNCTIONING
Circuit Description
Heated oxygen sensors (HO2S) are used for fuel control
and post catalyst monitoring. Each HO2S compares the
oxygen content of the surrounding air with the oxygen con-
tent in the exhaust stream. The HO2S must reach operat-
ing temperature to provide an accurate voltage signal. A
heating element inside the HO2S minmizes the time re-
quired for the sensor to reach operating temperature. Volt-
age is provided to the heater by the ignition 1 voltage cir-
cuit through a fuse. With the engine running, ground is
provided to the heater by the HO2S heater low control cir-
cuit, through a low side driver within the engine control
module (ECM). The ECM monitors the current flow
through the heater for diagnosis.
If the ECM detects that the HO2S heater current is above
or blelow a specified range, DTC P0135 seats.
Conditions for Setting the DTC
S DTCs P0106, P0117, P0118, P1017 are not set.
S Engine run time is greater than 30 seconds.
S Filtered O2 heater current is less than 0.1 amps.
Action Taken When the DTC SetsS The Malfunction Indicator Lamp (MIL) will illuminate
after three consecutive trip with a fail.
S The ECM will record operating conditions at the
time the diagnostic fails. This information will be
stored in the Freeze Frame and Failure Records
buffers.
S A history Diagnostic Trouble Code (DTC) is stored.
Conditions for Clearing the MIL/DTC
S The MIL will turn off after three consecutive ignition
cycles in which the diagnostic runs without a fault.
S A history DTC will clear after 40 consecutive warm–
up cycles without a fault.
S DTC(s) can be cleared by using the scan tool.
Diagnostic Aids
An intermittent may be caused by rubbed through wire in-
sulation or a wire contacting the exhaust.
Check for poor connection or damaged harness – inspect
harness connectors for the following conditions:
S Improper mating
S Broken locks
S Improperly formed
S Damaged terminals
S Poor terminal–to–wire connection