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Page 190 of 2643

DAEWOO NUBIRA 2004 Service Repair Manual 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

Page 191 of 2643

DAEWOO NUBIRA 2004 Service Repair Manual 1.8L DOHC ENGINE MECHANICAL 1C2 – 71
DAEWOO V–121 BL4
Notice : Take extreme care to prevent any scratches,
nicks or damage to the camshafts.
44. Install the intake camshaft gear.
45. Install th

Page 195 of 2643

DAEWOO NUBIRA 2004 Service Repair Manual 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 cr

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.

Page 199 of 2643

DAEWOO NUBIRA 2004 Service Repair Manual 1D – 4IENGINE COOLING
DAEWOO V–121 BL4
COOLING SYSTEM DIAGNOSIS
Engine Overheats
ChecksAction
Check for a loss of the coolant.Add the coolant.
Check for a weak coolant solution.Confirm that the co

1D – 4IENGINE COOLING
DAEWOO V–121 BL4
COOLING SYSTEM DIAGNOSIS
Engine Overheats
ChecksAction
Check for a loss of the coolant.Add the coolant.
Check for a weak coolant solution.Confirm that the coolant solution is a 50/50 mixture of eth-
ylene glycol and water.
Check the front of the radiator for any dirt, any leaves, or
any insects.Clean the front of the radiator.
Check for leakage from the hoses, the coolant pump, the
heater, the thermostat housing, the radiator, the core
plugs, or the head gasket.Replace any damaged components.
Check for a faulty thermostat.Replace a damaged thermostat.
Check for retarded ignition timing.Perform an ECM code diagnosis. Confirm the integrity of
the timing belt.
Check for an improperly operating electric cooling fan.Replace the electric cooling fan.
Check for radiator hoses that are plugged or rotted.Replace any damaged radiator hoses.
Check for a faulty water pump.Replace a faulty water pump.
Check for a faulty surge tank cap.Replace a faulty surge tank cap.
Check for a cylinder head or an engine block that is
cracked or plugged.Repair the damaged cylinder head or the damaged engine
block.
Loss of Coolant
ChecksAction
Check for a leak in the radiator.Replace a damaged radiator.
Check for a leak in the following locations:
S Surge tank.
S Hose.Replace the following parts, as needed:
S Surge tank.
S Hose.
Check for loose or damaged radiator hoses, heater hoses,
and connections.Reseat the hoses.
Replace the hoses or the clamps.
Check for leaks in the coolant pump seal.Replace the coolant pump seal.
Check for leaks in the coolant pump gasket.Replace the coolant pump gasket.
Check for an improper cylinder head torque.Tighten the cylinder head bolts to specifications.
Replace the cylinder head gasket, if needed.
Check for leaks in the following locations:
S Intake manifold.
S Cylinder head gasket.
S Cylinder block plug.
S Heater core.
S Radiator drain plug.Repair or replace any components, as needed, to correct
the leak.
Engine Fails to Reach Normal Operating Temperature or Cool Air
from the Heater
ChecksAction
Check to determine if the thermostat is stuck open or is the
wrong type of thermostat.Install a new thermostat of the correct type and heat range.
Check the coolant level to determine if it is below the MIN
mark on the surge tank.Add sufficient coolant to raise the fluid to the specified
mark on the surge tank.

Page 206 of 2643

DAEWOO NUBIRA 2004 Service Repair Manual ENGINE COOLING 1D – 11
DAEWOO V–121 BL4
Installation Procedure
1. Install the thermostat into the thermostat housing
by pressing the thermostat mounting flange down-
ward and then rotating the

Page 207 of 2643

DAEWOO NUBIRA 2004 Service Repair Manual 1D – 12IENGINE COOLING
DAEWOO V–121 BL4
5. Remove the water pump mounting bolts.
6. Remove the water pump from the engine block.
7. Remove the ring seal from the water pump.
Inspection Cleanin

Page 213 of 2643

DAEWOO NUBIRA 2004 Service Repair Manual 1D – 18IENGINE COOLING
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
GENERAL DESCRIPTION
The cooling system maintains the engine temperature at
an efficient level during all engine ope

1D – 18IENGINE COOLING
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
GENERAL DESCRIPTION
The cooling system maintains the engine temperature at
an efficient level during all engine operating conditions.
When the engine is cold, the cooling system cools the en-
gine slowly or not at all. This slow cooling of the engine al-
lows the engine to warm up quickly.
The cooling system includes a radiator and recovery sub-
system, cooling fans, a thermostat and housing, a coolant
pump, and a coolant pump drive belt. The timing belt
drives the coolant pump.
All components must function properly in order for the
cooling system to operate. The coolant pump draws the
coolant from the radiator. The coolant then circulates
through water jackets in the engine block, the intake man-
ifold, and the cylinder head. When the coolant reaches the
operating temperature of the thermostat, the thermostat
opens. The coolant then goes back to the radiator where
it cools.
This system directs some coolant through the hoses to the
heater core. This provides for heating and defrosting. The
surge tank is connected to the radiator to recover the cool-
ant displaced by expansion from the high temperatures.
The surge tank maintains the correct coolant level.
The cooling system for this vehicle has no radiator cap or
filler neck. The coolant is added to the cooling system
through the surge tank.
RADIATOR
This vehicle has a lightweight tube–and–fin aluminum ra-
diator. Plastic tanks are mounted on the right and the left
sides of the radiator core.
On vehicles equipped with automatic transaxles, the
transaxle fluid cooler lines run through the left radiator
tank. A radiator drain cock is on this radiator.
To drain the cooling system, open the drain cock.
SURGE TANK
The surge tank is a transparent plastic reservoir, similar to
the windshield washer reservoir.
The surge tank is connected to the radiator by a hose and
to the engine cooling system by another hose. As the ve-
hicle is driven, the engine coolant heats and expands. The
portion of the engine coolant displaced by this expansion
flows from the radiator and the engine into the surge tank.
The air trapped in the radiator and the engine is degassed
into the surge tank.When the engine stops, the engine coolant cools and con-
tracts. The displaced engine coolant is then drawn back
into the radiator and the engine. This keeps the radiator
filled with the coolant to the desired level at all times and
increases the cooling efficiency.
Maintain the coolant level between the MIN and the MAX
marks on the surge tank when the system is cold.
WATER PUMP
The belt–driven centrifugal water pump consists of an im-
peller, a drive shaft, and a belt pulley. The water pump is
mounted on the front of the transverse–mounted engine,
and is driven by the timing belt.
The impeller is supported by a completely sealed bearing.
The water pump is serviced as an assembly and, there-
fore, cannot be disassembled.
THERMOSTAT
A wax pellet–type thermostat controls the flow of the en-
gine coolant through the engine cooling system. The ther-
mostat is mounted in the thermostat housing to the front
of the cylinder head.
The thermostat stops the flow of the engine coolant from
the engine to the radiator in order to provide faster warm–
up, and to regulate the coolant temperature. The thermo-
stat remains closed while the engine coolant is cold, pre-
venting circulation of the engine coolant through the
radiator. At this point, the engine coolant is allowed to cir-
culate only throughout the heater core to warm it quickly
and evenly.
As the engine warms, the thermostat opens. This allows
the engine coolant to flow through the radiator, where the
heat is dissipated through the radiator. This opening and
closing of the thermostat permits enough engine coolant
to enter the radiator to keep the engine within proper en-
gine temperature operating limits.
The wax pellet in the thermostat is hermetically sealed in
a metal case. The wax element of the thermostat expands
when it is heated and contracts when it is cooled.
As the vehicle is driven and the engine warms, the engine
coolant temperature increases. When the engine coolant
reaches a specified temperature, the wax pellet element
in the thermostat expands and exerts pressure against the
metal case, forcing the valve open. This allows the engine
coolant to flow through the engine cooling system and cool
the engine.
As the wax pellet cools, the contraction allows a spring to
close the valve.
The thermostat begins to open at 87°C (189°F) and is fully
open at 102°C (216°F). The thermostat closes at 86°C
(187°F).

Page 224 of 2643

DAEWOO NUBIRA 2004 Service Repair Manual 1E – 10IENGINE ELECTRICAL
DAEWOO V–121 BL4
GENRATOR OUTPUT TEST
1. Perform the generator system test. Refer to ”Gen-
erator System Check”in this section.
2. Replace the generator if it fails

1E – 10IENGINE ELECTRICAL
DAEWOO V–121 BL4
GENRATOR OUTPUT TEST
1. Perform the generator system test. Refer to ”Gen-
erator System Check”in this section.
2. Replace the generator if it fails that test. Refer to
”Generator” in the On–Vehicle Service portion of
this section. If it passes the test, perform the on–
vehicle output check which follows.
Important : Always check the generator for output before
assuming that a grounded ”L” terminal circuit has dam-
aged the regulator.
3. Attach a digital multimeter, an ammeter, and a car-
bon pile load to the vehicle.
Important : Be sure the vehicle battery is fully charged,
and the carbon pile load is turned off.
4. With the ignition switch in the OFF position, check
and record the battery voltage.
5. Remove the harness connector from the generator.
6. Turn the ignition to RUN with the engine not run-
ning. Use a digital multimeter to check for voltage in
the harness connector ”L” terminal.
7. The reading should be near the specified battery
voltage of 12 volts. If the voltage is too low, check
the indicator L" terminal circuits for open and
grounded circuits causing voltage loss. Correct any
open wires, terminal connections, etc., as neces-
sary. Refer to”Charging System” in this section.
8. Attach the generator harness connector.
9. Run the engine at a moderate idle, and measure
the voltage across the battery terminals. The read-
ing should be above that recorded in step 14, but
less than 16 volts. If the reading is over 16 volts or
below the previous reading, replace the generator.
Refer to”Generator” in the On–Vehicle Service sec-
tion.
10. Run the engine at a moderate idle, and measure
the generator amperage output.
11. Turn on the carbon pile, and adjust it to obtain the
maximum amps while maintaining the battery volt-
age above 13 volts.
12. If the reading is within 15 amps of the generator’s
rating noted on the generator, the generator is
good. If not, replace the generator. Refer to”Gener-
ator” in the On–Vehicle Service section.
13. With the generator operating at the maximum out-
put, measure the voltage between the generator
housing and the battery negative terminal. The volt-
age drop should be 0.5 volt or less. If the voltage
drop is more than 0.5 volt, check the ground path
from the generator housing to the negative battery
cable.
14. Check, clean, tighten, and recheck all of the ground
connections.
GENERATOR SYSTEM CHECK
When operating normally, the generator indicator lamp will
come on when the ignition is in RUN position and go out
when the engine starts. If the lamp operates abnormally
or if an undercharged or overcharged battery condition oc-
curs, the following procedure may be used to diagnose the
charging system. Remember that an undercharged bat-
tery is often caused by accessories being left on overnight
or by a defective switch that allows a lamp, such as a trunk
or a glove box lamp, to stay on.
Diagnose the generator with the following procedure:
1. Visually check the belt and the wiring.
2. With the ignition in the ON position and the engine
stopped, the charge indicator lamp should be on. If
not, detach the harness at the generator and
ground the ”L” terminal in the harness with a 5–am-
pere jumper lead.
S If the lamp lights, replace the generator. Refer to
”Generator” in the On–Vehicle Service section.
S If the lamp does not light, locate the open circuit
between the ignition switch and the harness
connector. The indicator lamp bulb may be
burned out.
3. With the ignition switch in the ON position and the
engine running at moderate speed, the charge indi-
cator lamp should be off. If not, detach the wiring
harness at the generator.
S If the lamp goes off, replace the generator. Re-
fer to ”Generator” in the On–Vehicle Service
section.
S If the lamp stays on, check for a short to ground
in the harness between the connector and the
indicator lamp.
Important : Always check the generator for output before
assuming that a grounded ”L” terminal circuit has dam-
aged the regulator. Refer to”Generator” in the Unit Repair
section.

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