2004 DAEWOO LACETTI Service Repair Manual

1.8L DOHC ENGINE MECHANICAL 1C2 – 65
DAEWOO V–121 BL4
28. Remove the crankshaft timing belt gear.
29. Remove the rear timing belt cover bolts and cover.
30. Rotate the engine on the engine overhaul stand
KM–412.
31. Remove the oil pan retaining bolts.
32. Remove the oil pan.
33. Remove the oil suction pipe and support bracket
bolts.
34. Remove the oil suction pipe.
35. Remove the crankshaft bearing bridge and oil pan
scraper bolts.
36. Remove the oil pan scraper.
37. Remove the crankshaft bearing bridge bolts.
38. Remove the crankshaft bearing bridge.

1C2 – 66I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
39. Remove the oil pump retaining bolts.
40. Remove the oil pump.
41. Mark the order of the connecting rod bearing caps.
42. Remove the connecting rod bearing cap bolts for all
of the pistons.
43. Remove the connecting rod bearing caps and the
lower connecting rod bearings.
44. Mark the order of the crankshaft bearing caps.
45. Remove the crankshaft bearing cap bolts.
46. Remove the crankshaft bearing caps and the lower
crankshaft bearings.
47. Remove the crankshaft.
48. Clean the parts, as needed.
Assembly Procedure
1. Coat the crankshaft bearings with engine oil.
2. If replacing the crankshaft, transfer the pulse pickup
sensor disc to the new crankshaft.

1.8L DOHC ENGINE MECHANICAL 1C2 – 67
DAEWOO V–121 BL4
3. Install the crankshaft.
4. Install the lower crankshaft bearings in the bearing
caps.
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.
Important : 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 and the bolts.
Tighten
Tighten the crankshaft bearing cap bolts to 50 NSm
(37 lb–ft) plus 45 degrees and 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.

1C2 – 68I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
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 another 45 degrees and 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.
Tighten
Tighten the connecting rod bearing cap bolts to 35
NSm (26 lb–ft) using a torque wrench. Use the angular
torque gauge KM–470–B to tighten the connecting
rod bearing cap bolts another 45 degrees plus 15 de-
grees.
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.

1.8L DOHC ENGINE MECHANICAL 1C2 – 69
DAEWOO V–121 BL4
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 35
NSm (26 lb–ft) using a torque wrench. Use the angular
torque gauge KM–470–B to tighten the connecting
rod cap bolts another 45 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).
27. Install the crankshaft bearing bridge and bolts.
Tighten
Tighten the crankshaft bearing bridge bolts to 20 NSm
(15 lb–ft) plus 45 degrees using the angular torque
gauge KM–470–B.
28. Install the crankshaft bearing bridge and oil pan
scraper bolts.
Tighten
Tighten the crankshaft bearing bridge and oil scraper
bolts to 20 NSm (15 lb–ft) plus 45 degrees using the
angular torque gauge KM–470–B.
29. Install the oil suction pipe.
30. Install the oil suction pipe and support bracket
bolts.
Tighten
Tighten the oil suction pipe bolts to 8 NSm (81 lb–in)
and oil suction pipe support bracket bolt to 6 NSm (53
lb–in) .

1C2 – 70I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
31. Coat the new oil pan gasket with sealant.
32. Install the oil pan gasket to the oil pan.
33. Install the oil pan.
34. Install the oil pan retaining bolts.
Tighten
Tighten the oil pan retaining bolts to 10 NSm (89 lb–in).
35. Rotate the engine on the engine overhaul stand
KM–412.
36. Install the rear timing belt cover.
37. Install the rear timing belt cover bolts.
Tighten
Tighten the rear timing belt cover bolts to 7 NSm (62
lb–in).
38. Install the crankshaft gear and bolt.
Tighten
Tighten the crankshaft gear bolt to 145 NSm (107 lb–
ft) plus 30 degrees plus 15 degrees using the angular
torque gauge KM–470–B.
39. Install the engine mount and retaining bolts.
Tighten
Tighten the engine mount retaining bolts to 45 NSm
(33 lb–ft).
40. Install the timing belt automatic tensioner.
41. Install the timing belt automatic tensioner bolts.
Tighten
Tighten the timing belt automatic tensioner bolts to 25
NSm (18 lb–ft).
42. Install the timing belt idler pulley.
43. Install the timing belt idler pulley bolt and nut.
Tighten
Tighten the timing belt idler pulley nut to 25 NSm (18
lb–ft).

1.8L DOHC ENGINE MECHANICAL 1C2 – 71
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Notice : Take extreme care to prevent any scratches,
nicks or damage to the camshafts.
44. Install the intake camshaft gear.
45. Install the intake camshaft gear bolt while holding
the intake camshaft firmly in place.
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.
46. Install the exhaust camshaft gear.
47. Install the exhaust camshaft gear bolt while holding
the exhaust camshaft firmly in place.
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.
48. Install the timing belt. Refer to ”Timing Belt” in this
section.
49. Adjust the timing belt tension. Refer to ”Timing Belt
Check and Adjust” in this section.
50. 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.
51. Install the camshaft cover and the camshaft cover
gasket.
52. Install the camshaft cover washers.
53. Install the camshaft cover bolts.
Tighten
Tighten the camshaft cover bolts to 8 NSm (71 lb–in).
54. Connect the ignition wires to the spark plugs.
55. Install the spark plug cover.
56. Install the spark plug cover bolts.
Tighten
Tighten the spark plug cover bolts to 8 NSm (71 lb–in).
57. Connect the breather tube to the camshaft cover.
58. Install the front timing belt cover.
59. Install the front timing belt cover bolts.
Tighten
Tighten the front timing belt cover bolts to 8 NSm (71
lb–in).
60. Install the engine lifting device.
61. Remove the engine from the engine overhaul stand
KM–412.

1C2 – 72I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
62. Install a new crankshaft rear oil seal using installer
J–36792 or KM–635.
63. Install the flywheel or flexible plate.
64. Install the flywheel or the flexible plate bolts.
Tighten
Tighten the flywheel bolts to 65 NSm (48 lb–ft). Use
the angular torque gauge KM–470–B to tighten the
flywheel bolts another 30 degrees plus 15 degrees.
For the automatic transmission, tighten the flexible
plate bolts to 45 NSm (33 lb–ft).
65. Install the engine. Refer to ”Engine” in this section.
CRANKSHAFT BEARINGS AND
CONNECTING ROD BEARINGS –
GAUGING PLASTIC
Tools Required
KM–470–B Angular Torque Gauge
Inspection Procedure – Crankshaft
1. Coat the crankshaft bearings with engine oil.
2. Install the upper crankshaft bearings into the engine
block crankshaft journals.
3. Install the lower crankshaft bearings into the crank-
shaft bearing caps.
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.