2004 DAEWOO NUBIRA check engine

1A – 4IGENERAL ENGINE INFORMATION
DAEWOO V–121 BL4
Repairing the Leak
Once the origin of the leak has been pinpointed and traced
back to its source, the cause of the leak must be deter-
mined in order for it to be repaired properly. If a gasket is
replaced, but the sealing flange is bent, the new gasket will
not repair the leak. The bent flange must be repaired also.
Before attempting to repair a leak, check for the following
conditions and correct them as they may cause a leak.
Gaskets:
S The fluid level/pressure is too high.
S The crankcase ventilation system is malfunctioning.
S The fasteners are improperly tightened or the
threads are dirty or damaged.
S The flanges or the sealing surface is warped.S There are scratches, burrs or other damage to the
sealing surface.
S The gasket is damaged or worn.
S There is cracking or porosity of the component.
S An improper seal was used, (where applicable).
Seals:
S The fluid level/pressure is too high.
S The crankcase ventilation system is malfunctioning.
S The seal bore is damaged, scratched, burred or
nicked.
S The seal is damaged or worn.
S Improper installation is evident.
S There are cracks in the component.
S The shaft surface is scratched, nicked or damaged.
S A loose or worn bearing is causing excess seal
wear.
KNOCK DIAGNOSIS
Definition for Knock
Engine knock refers to various types of engine noise.
Heavy knock is usually very loud and the result of broken
or excessively worn internal engine components. Lightknock is a noticeable noise, but not as loud. Light knock
can be caused by worn internal engine components.
Loose or broken external engine components can also
cause heavy or light knock.
Engine Knocks Cold and Continues for Two–Three Minutes and/or
Knock Increases with Engine Torque
StepActionValue(s)YesNo
1Does the engine knock when it is cold and continue
for two to three minutes or does the knock increase
with torque?–Go to Step 2System OK
2Inspect the flywheel.
Is the flywheel contacting the splash shield?–Go to Step 3Go to Step 4
3Reposition the splash shield.
Is the repair complete?–Go to Step 1–
4Inspect the balancer and the drive pulleys.
Is either the balancer or the drive pulleys loose or
broken?–Go to Step 5Go to Step 6
5Tighten or replace the balancer or the drive pulleys.
Is the repair complete?–Go to Step 1–
6Inspect the piston–to–bore clearance.
Is the clearance more than the specified value?0.030 mm
(0.001 in.)Go to Step 7Go to Step 8
71. Rebore the cylinder and hone to size.
2. Replace the piston.
Is the repair complete?*–Go to Step 1–
8Inspect the connecting rod.
Is the connecting rod bent?–Go to Step 9System OK
9Replace the connecting rod.
Is the repair complete?–Go to Step 1–
* Cold engine piston knock usually disappears when the cylinder is grounded out. Cold engine piston knock, which disap-
pears in about 1.5 minutes, is considered acceptable.

1A – 6IGENERAL ENGINE INFORMATION
DAEWOO V–121 BL4
Light Knock Hot
StepActionValue(s)YesNo
1Is there a light knock when the engine is hot?–Go to Step 2System OK
2Is detonation or spark knock evident?–Go to Step 3Go to Step 4
3Check the engine timing and the fuel quality.
Was the problem found?–Go to Step 1–
4Inspect the torque converter bolts.
Are the bolts tightened to the specified value?45 NSm
(33 lb–ft)Go to Step 5Go to Step 6
5Tighten the torque converter bolts.
Is the repair complete?–Go to Step 1–
6Inspect the manifold.
Is there an exhaust leak at the manifold?–Go to Step 7Go to Step 8
7Tighten the bolts or replace the gasket.
Is the repair complete?–Go to Step 1–
8Check the rod bearing clearance.
Is the clearance within the specified value?0.019 ~
0.070 mm
(0.0007 ~
0.0028 in.)Go to Step 9System OK
9Replace the rod bearings, as necessary.
Is the repair complete?–Go to Step 1–
Knocks During Initial Start–Up But Last Only a Few Seconds
StepActionValue(s)YesNo
1Does the engine knock during initial start–up but last
only a few seconds?–Go to Step 2System OK
2Check the engine oil.
Is the proper viscosity oil used in the crankcase?–Go to Step 4Go to Step 3
3Install oil of the proper viscosity for the expected
seasonal temperatures.
Is the repair complete?–Go to Step 1–
4Inspect the hydraulic lifters.
Is there evidence of hydraulic lifter bleed–down?–Go to Step 5Go to Step 6
5Clean, test and replace the lifters, as necessary.
Is the repair complete?*–Go to Step 1–
6Inspect the crankshaft end clearance.
Is the clearance more than specified value?0.1 mm
(0.0039 in.)Go to Step 7Go to Step 8
7Replace the crankshaft thrust bearing.
Is the repair complete?–Go to Step 1–
8Inspect the front main bearing clearance.
Is the clearance more than the specified value?0.026~0.046
mm (0.0010~
0.0018 in.)Go to Step 9System OK
9Replace the worn parts of the front main bearing.
Is the repair complete?–Go to Step 1–
* When the engine is stopped, some valves will be open. Spring pressure against the lifters will tend to bleed lifter down.
Attempts to repair this should be made only if the problem is consistent.
An engine that is only operated for short periods between start–ups may have lifter noise that lasts for a few minutes. This
is a normal condition.

GENERAL ENGINE INFORMATION 1A – 7
DAEWOO V–121 BL4
Knocks at Idle Hot
StepActionValue(s)YesNo
1Does the engine knock at idle when hot?–Go to Step 2System OK
2Inspect the drive belts.
Are the belts loose or worn?–Go to Step 3Go to Step 4
3Tension or replace the belts, as necessary.
Is the repair complete?–Go to Step 1–
4Inspect the A/C compressor and the generator.
Is either the compressor or the generator faulty?–Go to Step 5Go to Step 6
5Replace the faulty A/C compressor or the generator.
Is the repair complete?–Go to Step 1–
6Inspect the valve train.
Are valve train components faulty?–Go to Step 7Go to Step 8
7Replace the faulty valve train components.
Is the repair complete?–Go to Step 1–
8Check the engine oil.
Is the proper viscosity oil used in the crankcase?–Go to Step 10Go to Step 9
9Install oil of the proper viscosity for the expected
seasonal temperatures.
Is the repair complete?–Go to Step 1–
10Inspect the piston pin clearance.
Is the clearance more than the specified value?0.020 mm
(0.0008 in.)Go to Step 11Go to Step 12
11Replace the piston and the pin.
Is the repair complete?–Go to Step 1–
12Check the connecting rod alignment.
Is the alignment faulty?–Go to Step 13Go to Step 14
13Check and replace rods, as necessary.
Is the repair complete?–Go to Step 1–
14Inspect the piston–to–bore clearance.
Is the clearance within the specified value?0.030 mm
(0.0012 in.)Go to Step 16Go to Step 15
15Hone the bore and fit a new piston.
Is the repair complete?Go to Step 1–
16Inspect the crankshaft balancer.
Is the balancer loose?–Go to Step 17Go to Step 18
17Torque or replace worn parts.
Is the repair complete?–Go to Step 1–
18Check the piston pin offset.
Is the offset at the specified value?0.5 ± 0.1 mm
(0.020 ~ 0.003
in.)
Toward Thrust
SideGo to Step 19System OK
19Install the correct piston.
Is the repair complete?–Go to Step 1–

1A – 8IGENERAL ENGINE INFORMATION
DAEWOO V–121 BL4
NOISE DIAGNOSIS
Main Bearing Noise
StepActionValue(s)YesNo
1Are dull thuds or knocks heard with every engine
revolution?–Go to Step 2System OK
2Check the oil pump pressure.
Is the oil pump pressure low?–Go to Oil Pres-
sure TestGo to Step 3
3Inspect the crankshaft end play.
Does the crankshaft end play exceed the specified
value?0.1 mm
(0.0039 in.)Go to Crank-
shaft Replace-
ment Proce-
dureGo to Step 4
4Inspect the crankshaft journals.
Are the crankshaft journals out–of–round?0.004 mm
(0.0002 in.)
max.Go to Crank-
shaft Replace-
ment Proce-
dureGo to Step 5
5Inspect the belt tension.
Does the belt tension exceed the specified value?–Go to Timing
Belt Replace-
ment Proce-
dureGo to Step 6
6Inspect the crankshaft pulley.
Is the crankshaft pulley loose?–Go to Crank-
shaft Replace-
ment Proce-
dureSystem OK
Connecting Rod Bearing Noise Symptom
StepActionValue(s)YesNo
1Is a knock noise heard under all engine speeds?–Go to Step 2System OK
2Inspect the crankshaft connecting rod journal.
Is the crankshaft connecting rod journal worn?–Go to Crank-
shaft Replace-
ment Proce-
dureGo to Step 3
3Check the oil pump pressure.
Is the oil pump pressure low?–Go to Oil Pres-
sure TestGo to Step 4
4Inspect the crankshaft connecting rod journals.
Are the journals out–of–round?–Go to Crank-
shaft Replace-
ment Proce-
dureGo to Step 5
5Inspect the connecting rods.
Is there a misaligned connecting rod?–Go to Pistons
and Rods Re-
placement Pro-
cedureGo to Step 6
6Inspect the connecting rod bolts.
Are the connecting rod bolts torqued properly?–System OKGo to Pistons
and Rods Re-
placement Pro-
cedure

1A – 10IGENERAL ENGINE INFORMATION
DAEWOO V–121 BL4
Valve Mechanism or Valve Train Noises
StepActionValue(s)YesNo
1Is a light tapping sound heard from the engine?–Go to Step 2System OK
2Inspect the valve springs.
Are the springs weak or broken?–Go to Cylinder
Head and
Valve Train
Components
Replacement
ProcedureGo to Step 3
3Inspect the valves.
Are the valves sticking or warped?–Go to Cylinder
Head and
Valve Train
Components
Replacement
ProcedureGo to Step 4
4Inspect the valve lifters.
Are the valve lifters dirty, stuck or worn?–Go to Cylinder
Head and
Valve Train
Components
Replacement
ProcedureGo to Step 5
5Inspect the camshaft lobes.
Are the camshaft lobes damaged or improperly ma-
chined?–Go to Cam-
shaft Replace-
ment Proce-
dureGo to Step 6
6Check the oil supply to the valve train.
Is the oil supply insufficient or poor?–Go to Cylinder
Head and
Valve Train
Components
Replacement
ProcedureGo to Step 7
7Inspect the valve guides.
Are the valve guides worn?–Go to Cylinder
Head and
Valve Train
Components
Replacement
ProcedureGo to Step 8
8Inspect the valve spring seat.
Is the valve spring seat incorrect?–Go to Cylinder
Head and
Valve Train
Components
Replacement
ProcedureSystem OK

SECTION : 1C1
1.4L/1.6L DOHC ENGINE MECHANICAL
CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool
or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help
prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
TABLE OF CONTENTS
SPECIFICATIONS1C1–2 . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Specifications 1C1–2. . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifcations 1C1–5. . . . . . . . . .
SPECIAL TOOLS1C1–7 . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 1C1–7. . . . . . . . . . . . . . . . . . . . . . .
COMPONENT LOCATOR1C1–9 . . . . . . . . . . . . . . . . . . .
Cylinder Head 1C1–9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block 1C1–10. . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake & Exhaust Manifold 1C1–12. . . . . . . . . . . . . . . .
Timing Belt 1C1–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Mounting 1C1–14. . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR1C1–15 . . . . . . . . . . . . .
ON–VEHICLE SERVICE 1C1–15. . . . . . . . . . . . . . . . . . .
Engine Cover 1C1–15. . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft Cover 1C1–15. . . . . . . . . . . . . . . . . . . . . . . . .
Intake Manifold 1C1–16. . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold 1C1–20. . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Gasket 1C1–21. . . . . . . . . . . . . . . .
Camshaft 1C1–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt Check and Adjust 1C1–30. . . . . . . . . . . . .
Timing Belt 1C1–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pan 1C1–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump 1C1–40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Mount 1C1–43. . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft Gears 1C1–45. . . . . . . . . . . . . . . . . . . . . . . . .
Rear Timing Belt Cover 1C1–46. . . . . . . . . . . . . . . . . . .
Engine 1C1–48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistons and Rods 1C1–53. . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR 1C1–58. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Valve Train Components 1C1–58.
Crankshaft 1C1–65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Bearing and Connecting Rod
Beadings – Gauging Plastics 1C1–74. . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION1C1–77 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Gasket 1C1–77. . . . . . . . . . . . . . . .
Crankshaft 1C1–77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt 1C1–77. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump 1C1–77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan 1C1–77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold 1C1–77. . . . . . . . . . . . . . . . . . . . . . . .
Intake Manifold 1C1–77. . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft 1C1–77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1C1 – 28I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
25. Install the timing belt.
26. Rotate the water pump clockwise using the timing
belt adjuster J–42492 to apply tension to the timing
belt.
Tighten
Tighten the water pump retaining bolts to 10 NSm (89
lb–in).
27. Check and adjust the timing belt tension. Refer to
”Timing Belt Check and Adjust” in this section.
28. Install the upper and lower front timing belt covers.
Tighten
Tighten the upper and lower front timing belt covers
bolts to 10 NSm (89 lb–in).
29. Install the crank shaft pulley bolt.
Tighten
Tighten the crank shaft pulley bolt to 95 NSm (70 lb–ft)
and retighten 30 degrees plus 15 degrees.
30. Install the serpentine accessory drive belt. Refer to
Section 6B, Power Steering Pump.
31. Connect the upper radiator hose to the thermostat
housing.
32. Install the front wheel and splash shield. Refer to
Section 2E, Tires and Wheels.
33. Install the air cleaner housing.
Tighten
Tighten the air cleaner housing bolts to 10 NSm (89 lb–
in).
34. Connect the breather tube to the cam shaft cover.
35. Install the crank shaft pulley bolt.
36. Connect the MAT sensor connector.
37. Connect the intake manifold pressure sensor, in-
take air temperature sensor and coolant tempera-
ture sensor connector.

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 31
DAEWOO V–121 BL4
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.