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1C1 – 20I1.4L/1.6L DOHC ENGINE MECHANICAL
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12. Install the throttle body and engine cover.
13. Refill the engine cooling system. Refer to Section
1D, Engine Cooling.
14. Install the fuel pump fuse and connect the negative
battery cable.
EXHAUST MANIFOLD
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the oxygen sensor connecter.
3. Remove the exhaust manifold heat shield.
4. Remove the exhaust manifold nuts from the pup
converter.
5. Remove the exhaust manifold retaining nuts in the
sequence shown and remove the exhaust manifold.
6. Remove the exhaust manifold gasket.
7. Clean the sealing surfaces of the exhaust manifold
and the cylinder head.
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1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 21
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Installation Procedure
1. Install the exhaust manifold and gasket.
2. Install the exhaust manifold retaining nuts and tight-
en in the sequence shown.
Tighten
Tighten the exhaust manifold retaining nuts to 25 NSm
(18 lb–ft).
3. Install the exhaust manifold nuts to the catalytic
converter.
Tighten
Tighten the exhaust manifold nuts to 40 NSm (30 lb–
ft).
4. Install the heat shield.
Tighten
Tighten the the heat shield bolts to 13 NSm (10 lb–ft).
5. Connect the oxygen sensor connecter.
6. Connect the negative battery cable.
CYLINDER HEAD AND GASKET
Tools Required
J–42492 Timing Belt Adjuster
KM–470–B Angular Torque Gauge
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. Disconnect the negative battery calbe.
4. Disconnect the electronic control module(ECM)
ground terminal from the intake manifold.
5. Drain the engine coolant. Refer to Section 1D, En-
gine Cooling.
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1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 29
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38. Connect the DIS coil connector.
39. Connect the fuel injector harness connectors.
40. Connect the oxygen sensor connector and the
ECM ground terminal at the intake manifold.
41. Install the fuel pump fuse.
42. Connect the negative battery ground cable.
43. Refill the engine cooling system. Refer to Sec-
tion1D, Engine Cooling.
CAMSHAFTS
Removal Procedure
1. Remove the camshaft cover. Refer to ”Camshaft
Cover” in this section.
2. Remove the timing belt. Refer to ”Timing Belt” in
this section.
Notice : Take extreme care to prevent any scratches,
nicks or damage to the camshafts.
3. While holding the intake camshaft firmly in place,
remove the intake camshaft gear bolt and gear.
4. While holding the exhaust camshaft firmly in place,
remove the exhaust camshaft gear bolt and gear.
5. Remove the camshaft cap bolts gradually in the
sequence shown for each camshaft cap.
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1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 31
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TIMING BELT CHECK AND ADJUST
Tools Required
J–42492 Timing Belt Adjuster
KM–470–B Angular Torque Gauge
Adjustment Procedure
1. Disconnect the negative battery cable.
2. Remove the air cleaner outlet hose from the throttle
body.
3. Remove the breather tube from the camshaft cover.
4. Remove the air cleaner housing bolts.
5. Remove the air cleaner housing.
6. Remove the right front wheel. Refer to Section 2E,
Tires and Wheels.
7. Remove the right front wheel well splash shield.
8. Remove the serpentine accessory drive belt. Refer
to Section 6B, Power Steering Pump.
9. Remove the crankshaft pulley bolt.
10. Remove the crankshaft pulley.
11. Remove the upper front timing belt cover bolts.
12. Remove the upper front timing belt cover.
13. Remove the lower front timing belt cover bolts.
14. Remove the lower front timing belt cover.
15. Install the crankshaft pulley bolt.
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1C1 – 34I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
37. Connect the air cleaner outlet hose to the throttle
body.
38. Connect the breather tube to the camshaft cover.
39. Connect the negative battery cable.
TIMING BELT
Tools Required
J–42492 Timing Belt Adjuster
KM–470–B Angular Torque Gauge
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the air cleaner outlet hose from the
throttle body.
3. Disconnect the breather tube from the camshaft
cover.
4. Remove the air cleaner housing bolts.
5. Remove the air cleaner housing.
6. Remove the right front wheel. Refer to Section 2E,
Tires and Wheels.
7. Remove the right front wheel well splash shield.
8. Remove the serpentine accessory drive belt. Refer
to Section 6B, Power Steering Pump.
9. Remove the crankshaft pulley bolt.
10. Remove the crankshaft pulley.
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1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 37
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11. Tighten the water pump retaining bolts.
Tighten
Tighten the water pump retaining bolts to 10 NSm (89
lb–in).
12. Remove the crankshaft pulley bolt.
13. Install the upper and lower front timing belt covers.
14. Install the upper and lower front timing belt cover
bolts.
Tighten
Tighten the front timing belt cover bolts to 10 NSm (89
lb–in).
15. Install the crankshaft pulley.
16. Install the crankshaft pulley bolt.
Tighten
Tighten the crankshaft pulley bolt to 95 NSm (70 lb–ft)
and retighten 30 degrees plus 15 degrees.
17. Install the serpentine accessory drive belt. Refer to
Section 6B, Power Steering Pump.
18. Install the right front wheel well splash shield.
19. Install the right front wheel. Refer to Section 2E,
Tires and Wheels.
20. Install the air cleaner housing.
21. Install the air cleaner housing bolts.
Tighten
Tighten the air cleaner housing bolts to 10 NSm (89 lb–
in).
22. Connect the air cleaner outlet hose to the throttle
body.
23. Connect the breather tube to the camshaft cover.
24. Connect the negative battery cable.
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1C1 – 38I1.4L/1.6L DOHC ENGINE MECHANICAL
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OIL PAN
Removal Procedure
1. Disconnect the negative battery cable.
2. Drain the Engine oil from the engine crankcase.
3. Remove the catalytic converter retaining nuts from
the exhaust pipe.
4. Remove the lower crossmember bracket.
5. Remove the exhaust connecting pipe.
6. Remove the oil pan bolts to the transaxle case.
7. Remove the oil pan retaining bolts to the engine
block.
8. Remove the oil pan from the engine block.
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Cleaning Procedure
1. Clean the oil pan sealing surface.
2. Clean the engine block sealing surface.
3. Clean the oil pan retaining bolts.
4. Clean the oil pan attaching bolt holes in the engine
block.
Installation Procedure
1. Coat the new oil pan gasket with sealant.
Important : Install the oil pan within 5 minutes after apply-
ing the liquid gasket to the oil pan.
2. Install the oil pan to the engine block.
3. Install the oil pan retaining bolts.
Tighten
Tighten the oil pan retaining bolts to 10 NSm (89 lb–in).
4. Install the oil pan bolts to the transaxle case.
Tighten
Tighten the oil pan to the transaxle case bolts to 31
NSm (23 lb–ft).
5. Install the exhaust connecting pipe.
6. Install the catalytic converter retaining nuts to the
exhaust pipe.
Tighten
Tighten the catalytic converter to exhaust pipe retain-
ing nuts to 40 NSm (30 lb–ft).
7. Install the lower crossmember bracket.
8. Connect the negative battery cable.
9. Install the oil pan drain plug.
Tighten
Tighten the oil pan drain plug to 55 NSm (40 lb–ft).
10. Refill the engine crankcase with engine oil.