Page 89 of 2643

1C1 – 46I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
3. Install the exhaust camshaft gear.
4. While holding the exhaust camshaft firmly in place,
install the exhaust camshaft gear bolt.
Tighten
Tighten the exhaust camshaft gear bolt to 67.5 NSm
(49 lb–ft).
5. 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.
6. Install the camshaft cover and the camshaft cover
gasket.
7. Install the camshaft cover bolts.
Tighten
Tighten the camshaft cover nuts to 10 NSm (89 lb–in).
8. Connect the engine ventilation hoses to the cam-
shaft cover.
9. Connect the ignition wires to the spark plugs.
10. Install the timing belt. Refer to ”Timing Belt” in this
section.
11. Install the engine cover. Refer to ”Engine Cover” in
this section.
12. Connect the negative battery cable.
REAR TIMING BELT COVER
Removal Procedure
1. Remove the timing belt and the timing belt cover.
Refer to ”Timing Belt” in this section.
2. Remove the camshaft gears. Refer to ”Camshaft
Gears” in this section.
3. Remove the crankshaft gear.
4. Remove the timing belt automatic tensioner bolts.
5. Remove the timing belt automatic tensioner.
Page 90 of 2643
1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 47
DAEWOO V–121 BL4
6. Remove the timing belt idler pulley bolt.
7. Remove the timing belt idler pulley.
8. Remove the rear timing belt cover bolts.
9. Remove the rear timing belt cover.
Installation Procedure
1. Install the rear timing belt cover.
2. Install the rear timing belt cover bolts.
Tighten
Tighten the rear timing belt cover bolts to 10 NSm (89
lb–in).
3. Install the timing belt idler pulley.
4. Install the timing belt idler pulley bolt.
Tighten
Tighten the timing belt idler pulley bolt to 40 NSm (30
lb–ft).
Page 91 of 2643

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.
Page 92 of 2643

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 49
DAEWOO V–121 BL4
17. Disconnect the oxygen (O2) sensor connector, if
equipped.
18. Disconnect the fuel injector harness connectors.
19. Disconnect the MAT, MAP sensor connectors.
20. Disconnect the throttle position sensor (TPS) con-
nector.
21. Disconnect the generator voltage regulator connec-
tor and power lead.
22. Remove the electrical harness clamp bolt.
23. Disconnect all of the necessary vacuum lines, in-
cluding the brake booster vacuum hose.
24. Disconnect the fuel feed line at the fuel rail.
25. Disconnect the throttle cable from the throttle body
and the intake manifold bracket.
26. Disconnect the surge tank coolant hose at the
throttle body.
27. Disconnect the heater outlet hose at the coolant
pipe.
28. Disconnect the heater inlet hose from the cylinder
head.
29. Disconnect the surge tank coolant hose from the
coolant pipe.
30. Disconnect the lower radiator hose from the coolant
pipe. Disconnect the starter solenoid ”S” terminal
wire. Remove the A/C compressor, if equipped. Re-
fer to Section 7B, Manual Control Heating, Ventila-
tion, and Air Conditioning Systems.
31. Remove the catalytic converter retaining nuts from
the exhaust pipe.
32. Remove the exhaust pipe.
Page 93 of 2643

1C1 – 50I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
33. Remove the crankshaft pulley bolt.
34. Remove the crankshaft pulley.
35. Disconnect the vacuum lines at the charcoal canis-
ter purge solenoid.
36. Disconnect the electrical connector at the charcoal
canister purge (CCP) solenoid and at the knock
sensor.
37. Disconnect the electrical connector at the oil pres-
sure switch and at the exhaust gas recirculation
(EGR) solenoid.
38. Disconnect the crankshaft position sensor (CPS)
connector.
39. Remove the transaxle torque converter bolts, if au-
tomatic transaxle equipped.
40. Remove the stater motor. Refer to Section 1E, En-
gine Electrical.
41. Remove the transaxle bell housing bolts.
42. Support the transaxle with a floor jack.
43. Install the engine lifting device.
44. Disconnect the right engine mount bracket from the
engine mount and the engine by removing the at-
taching bolts and the nuts.
45. Remove the right engine mount from the engine
block. Refer to ”Engine Mount” in this section.
46. Separate the engine block from the transaxle.
47. Remove the engine.
Installation Procedure
1. Install the engine into the engine compartment.
2. Align the engine alignment pins to the transaxle.
3. Install the transaxle bell housing bolts.
Tighten
Tighten the transaxle bell housing bolts to 75 NSm (55
lb–ft).
4. Install the right engine mount to the engine block.
Refer to ”Engine Mount” in this section.
Page 94 of 2643

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 51
DAEWOO V–121 BL4
5. Connect the right engine mount bracket to the en-
gine mount and the engine by installing the attach-
ing bolts and the nuts.
Tighten
Tighten the engine mount bracket attaching bolts and
the nuts to 55 NSm (41 lb–ft).
6. Remove the floor jack used for support of the trans-
axle.
7. Remove the engine lifting device.
8. Install the transaxle torque converter bolts, if auto-
matic transaxle equipped.
Tighten
Tighten the transaxle torque converter bolts to 45
NSm (33 lb–ft).
9. Install the starter motor. Refer to Section 1E, En-
gine Electrical.
10. Connect the vacuum lines at the CCP solenoid.
11. Connect the electrical connector at the CCP sole-
noid and at the knock sensor.
12. Connect the oil pressure switch and the EGR sole-
noid connectors.
13. Install the crankshaft pulley.
14. Install the crankshaft pulley bolt.
Tighten
Tighten the crankshaft pulley bolt to 95 NSm (70 lb–ft)
and retighten 30 degrees plus 15 degrees.
15. Connect the CPS connector.
16. Install the exhaust front pipe.
17. Install the catalytic converter retaining nuts to the
exhaust pipe.
Tighten
Tighten the catalytic converter to exhaust pipe retain-
ing nuts to 35 NSm (26 lb–ft).
Page 95 of 2643

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.
Page 96 of 2643

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.