2004 DAEWOO LACETTI steering

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 43
DAEWOO V–121 BL4
4. Coat the threads of the oil suction pipe and support
bracket bolts with Loctite® 242.
5. Install the oil suction pipe and bolts.
Tighten
Tighten the oil suction pipe and support bracket bolts
to 10 NSm (89 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. Install the power steering pump, if equipped. Refer
to Section 6A, Power Steering System.
11. Connect the negative battery cable.
ENGINE MOUNT
Tools Required
DW110–060 Engine Support Fixture
Removal Procedure
1. Disconnect the negative battery cable.
2. Support the engine assembly using the engine sup-
port fixture DW110–060.
3. Remove the engine mount bracket attaching bolts/
nuts.
4. Remove the front timing belt cover. Refer to ”Timing
Belt” in this section.

1C1 – 48I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
5. Install the timing belt automatic tensioner.
6. Install the timing belt automatic tensioner bolts.
Tighten
Tighten the timing belt automatic tensioner bolts to 25
NSm (18 lb–ft).
7. Install the crankshaft gear.
Notice : Take extreme care to prevent any scratches,
nicks or damage to the camshafts.
8. Install the camshaft gears. Refer to ”Camshaft
Gears” in this section.
9. Install the timing belt and timing belt cover. Refer to
”Timing Belt” in this section.
ENGINE
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. Remove the hood. Refer to Section 9R, Body Front
End.
4. Drain the engine oil.
5. Disconnect the negative battery cable.
6. Remove the air cleaner outlet hose from the throttle
body and air cleaner housing.
7. Disconnect the breather tubes from the camshaft
cover.
8. Remove the serpentine accessory drive belt. Refer
to Section 6B, Power Steering Pump.
9. Remove the right front wheel. Refer to Section 2E,
Tires and Wheels.
10. Remove the right front wheel well splash shield.
11. Drain the engine coolant. Refer to Section 1D, En-
gine Cooling.
12. Remove the cooling system radiator and the engine
cooling fans. Refer to Section 1D, Engine Cooling.
13. Disconnect the upper radiator hose from the ther-
mostat housing.
14. Disconnect the power steering return hose from the
power steering pump. Refer to Section 6A, Power
Steering System.
15. Disconnect the power steering pressure hose from
the power steering pump. Refer to Section 6A,
Power Steering System.
16. Disconnect the electrical connector at the direct
ignition system (DIS) coil and the electronic control
module (ECM) ground terminal at the intake man-
ifold and at the starter motor.

1C1 – 52I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
18. Connect the power steering pressure hose.
19. Connect the power steering return hose.
20. Install the A/C compressor, if equipped. Refer to
Section 7B, Manual Control Heating, Ventilation,
and Air Conditioning Systems.
21. Install the generator. Refer to Section 1E, Engine
Electrical.
22. Install the serpentine accessory drive belt. Refer to
Section 6B, Power Steering Pump.
23. Install the right front wheel well splash shield.
24. Install the right front wheel. Refer to Section 2E,
Tires and Wheels.
25. Connect the fuel feed line to the fuel rail.
26. Connect all of the necessary vacuum lines, includ-
ing the brake booster vacuum hose.
27. Connect the O2 sensor connector, if equipped.
28. Connect the starter solenoid ”S” terminal wire and
power lead.
29. Connect the generator voltage regulator connector
and power lead.
30. Connect the CTS connector.
31. Connect the MAP, MAT sensor connectors.
32. Connect the TPS connector.
33. Install the electrical wiring harness clamp at the
intake manifold support bracket.
34. Connect the fuel injector harness connectors.
35. Connect the electrical connector at the DIS coil and
the ECM ground terminal at the starter.
36. Install the air cleaner outlet hose between the
throttle body and the air cleaner housing.
37. Connect the breather tubes to the camshaft cover.
38. Install the cooling system radiator and the engine
cooling fans. Refer to Section 1D, Engine Cooling.

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 53
DAEWOO V–121 BL4
39. Connect the lower radiator hose to the coolant pipe.
40. Connect the upper radiator hose to the thermostat
housing.
41. Connect the surge tank coolant hose to the radia-
tor.
42. Connect the heater inlet hose to the cylinder head.
43. Connect the heater outlet hose to the coolant pipe.
44. Connect the coolant surge tank hose to the coolant
pipe.
45. Connect the surge tank coolant hose to the throttle
body.
46. Connect the throttle cable to the throttle body and
the intake manifold bracket.
47. Install the fuel pump fuse.
48. Connect the negative battery cable.
49. Refill the engine crankcase with engine oil.
50. Refill the engine coolant system. Refer to Section
1D, Engine Cooling.
51. Bleed the power steering system. Refer to Section
6A, Power Steering System.
52. Refill the A/C refrigerant system, if equipped. Refer
to Section 7B, Manual Control Heating, Ventilation,
and Air Conditioning System.
53. Install the hood. Refer to Section 9R, Body Front
End.
PISTONS AND RODS
Tools Required
KM–427 Piston Pin Service Set
KM 470–B Angular Torque Gauge
Removal Procedure
1. Remove the cylinder head with the intake manifold
and the exhaust manifold attached. Refer to ”Cylin-
der Head and Gasket” in this section.
2. Remove the oil pan. Refer to ”Oil Pan” in this sec-
tion.
3. Remove the oil suction pipe bolts.
4. Remove the oil suction pipe.
5. Move the piston to the bottom of the piston stroke.
6. Mark the connecting rod cap for position.
7. Remove the connecting rod cap bolts.
8. Remove the connecting rod cap and the lower con-
necting rod bearing.
9. Remove the upper piston connecting rod bearing.
10. Ridge ream the cylinder wall.

1C2 – 14I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
6. Disconnect the manifold air temperature (MAT)
sensor connector.
7. Disconnect the breather tube from the camshaft
cover.
8. Disconnect the air cleaner outlet hose from the
throttle body.
9. Disconnect the direct ignition system (DIS) coil con-
nector.
10. Disconnect the oxygen (O2) sensor connector, if
equipped.
11. Disconnect the idle air control (IAC) valve connec-
tor.
12. Disconnect the throttle position sensor (TPS) con-
nector.
13. Disconnect the engine coolant temperature (ECT)
sensor connector.
14. Disconnect the coolant temperature sensor (CTS)
connector.
15. Remove the air cleaner housing bolts.
16. Remove the air cleaner housing.
17. Remove the right front wheel. Refer to Section 2E,
Tires and Wheels.
18. Remove the right front wheel well splash shield.
19. Install the engine assembly support fixture
J–28467–B.
20. Remove the right engine mount bracket and bolts.
21. Disconnect the upper radiator hose at the thermo-
stat housing.
22. Remove the serpentine accessory drive belt. Refer
to Section 6B, Power Steering Pump.
23. Remove the crankshaft pulley bolts.
24. Remove the crankshaft pulley.

1.8L DOHC ENGINE MECHANICAL 1C2 – 21
DAEWOO V–121 BL4
39. Install the timing belt.
40. Check and adjust the timing belt tension. Refer to
”Timing Belt Check and Adjust” in this section.
41. Install the front timing belt cover.
42. Install the front timing belt cover bolts.
Tighten
Tighten the front timing belt cover bolts to 6 NSm (53
lb–in).
43. Install the crankshaft pulley.
44. Install the crankshaft pulley bolts.
Tighten
Tighten the crankshaft pulley bolts to 12 NSm (106 lb–
in).
45. Install the right engine mount bracket and retaining
bolts.
Tighten
Tighten the engine mount bracket retaining bolts to 55
NSm (41 lb–ft).
46. Remove the engine assembly lift support
J–28467–B.
47. Install the serpentine accessory drive belt. Refer to
Section 6B, Power Steering Pump.
48. Connect the upper radiator hose to the thermostat
housing.
49. Install the right front wheel well splash shield.
50. Install the right front wheel. Refer to Section 2E,
Tires and Wheels.
51. Install the air cleaner housing.
52. Install the air cleaner housing bolts.
Tighten
Tighten the air cleaner housing bolts to 10 NSm (89 lb–
in).
53. Connect the air cleaner outlet hose to the throttle
body.
54. Connect the breather tube to the camshaft cover.
55. Connect the MAT sensor connector.

1.8L DOHC ENGINE MECHANICAL 1C2 – 25
DAEWOO V–121 BL4
5. Remove the air cleaner housing bolts.
6. Remove the air cleaner housing.
7. Remove the right front wheel. Refer to Section 2E,
Tires and Wheels.
8. Remove the right front wheel well splash shield.
9. Remove the serpentine accessory drive belt. Refer
to Section 6B, Power Steering Pump.
10. Remove the crankshaft pulley bolts.
11. Remove the crankshaft pulley.
12. Remove the right engine mount bracket. Refer to
”Engine Mount” in this section.
13. Remove the front timing belt cover bolts.
14. Remove the front timing belt cover.
15. Rotate the crankshaft at least one full turn clock-
wise using the crankshaft gear bolt.
16. Align the mark on the crankshaft gear with the
notch at the bottom of the rear timing belt cover.

1.8L DOHC ENGINE MECHANICAL 1C2 – 27
DAEWOO V–121 BL4
24. Install the front timing belt cover.
25. Install the front timing belt cover bolts.
Tighten
Tighten the front timing belt cover bolts to 6 NSm (53
lb–in).
26. Install the crankshaft pulley.
27. Install the crankshaft pulley bolt.
Tighten
Tighten the crankshaft pulley bolt to 20 NSm (15 lb–ft).
28. Install the right engine mount bracket. Refer to ”En-
gine Mount” in this section.
29. Install the serpentine accessory drive belt. Refer to
Section 6B, Power Steering Pump.
30. Install the right front wheel well splash shield.
31. Install the right front wheel. Refer to Section 2E,
Tires and Wheels.
32. Install the air cleaner housing.
33. Install the air cleaner housing bolts.
Tighten
Tighten the air cleaner housing bolts to 10 NSm (89 lb–
in).
34. Connect the air cleaner outlet hose to the throttle
body.
35. Connect the breather tube to the camshaft cover.
36. Connect the MAT sensor connector.
37. Connect the negative battery cable.