2004 DAEWOO NUBIRA battery

1C1 – 40I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
OIL PUMP
Tools Required
KM–498–B Pressure Gauge
KM–135 Adapter
Engine Oil Pressure Inspection Procedure
1. Remove the right front wheel, wheel well splash
shield and engine undercover.
2. Disconnect the oil pressure switch connector.
3. Install the adapter KM–135 in place of the oil pres-
sure switch.
4. Connect the pressure gauge KM–498–B to the
adapter.
5. Start the engine and check the oil pressure at idle
speed and engine temperature of 80°C (176°F).
The minimum oil pressure should be 30 kPa (4.35
psi).
6. Stop the engine and remove the pressure gauge
KM–498–B and the adapter KM–135.
7. Install the oil pressure switch.
Tighten
Tighten the oil pressure switch to 40 NSm (30 lb–ft).
8. Connect the oil pressure switch connector.
9. Install the right front wheel well splash shield, en-
gine undercover and wheel.
10. Check the oil level. Pour oil until it reaches the full
mark.
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the power steering pump, if equipped. Re-
fer to Section 6A, Power Steering System.
3. Remove the timing belt. Refer to”Timing Belt” in this
section.
4. Remove the rear timing belt cover. Refer to ”Rear
Timing Belt Cover” in this section.
5. Disconnect the oil pressure switch connector.

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 – 44I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
5. Remove the engine mount attaching bolts/nuts.
6. Remove the engine mount.
Installation Procedure
1. Install the engine mount.
2. Install the engine mount retaining bolts.
Tighten
Tighten the engine mount attaching bolts to 30 NSm
(22 lb–ft).
3. Install the front timing belt cover. Refer to ”Timing
Belt” in this section.
4. Install the engine mount bracket attaching bolts/
nuts.
Tighten
Tighten the engine mount bracket attaching bolts/
nuts to 55 NSm (41 lb–ft).
5. Remove engine assembly support fixture
DW110–060.
6. Connect the negative battery cable.

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 45
DAEWOO V–121 BL4
CAMSHAFT GEARS
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the engine cover.
3. Remove the timing belt. Refer to ”Timing Belt” in
this section.
4. Disconnect the ignition wires from the spark plugs.
5. Disconnect the engine ventilation hoses from the
camshaft cover.
6. Remove the camshaft cover bolts.
7. Remove the camshaft cover and the camshaft cov-
er gasket.
Notice : Take extreme care to prevent any scratches,
nicks or damage to the camshafts.
8. While holding the intake camshaft firmly in place,
remove the intake camshaft gear bolt.
9. Remove the intake camshaft gear.
10. While holding the exhaust camshaft firmly in place,
remove the exhaust camshaft gear bolt.
11. Remove the exhaust camshaft gear.
Installation Procedure
Notice : Take extreme care to prevent any scratches,
nicks or damage to the camshafts.
1. Install the intake camshaft gear.
2. While holding the intake camshaft firmly in place,
install the intake camshaft gear bolt.
Tighten
Tighten the intake camshaft gear bolt to 67.5 NSm (49
lb–ft).

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.

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.

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.

SECTION : 1C2
1.8L 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
SPECIFICATIONS1C2–2 . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Specifications 1C2–2. . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifcations 1C2–4. . . . . . . . . .
SPECIAL TOOLS1C2–6 . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 1C2–6. . . . . . . . . . . . . . . . . . . . . . .
COMPONENT LOCATOR1C2–8 . . . . . . . . . . . . . . . . . . .
Upper End 1C2–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower End 1C2–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR1C2–12 . . . . . . . . . . . . .
ON–VEHICLE SERVICE 1C2–12. . . . . . . . . . . . . . . . . . .
Camshaft Cover 1C2–12. . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Gasket 1C2–13. . . . . . . . . . . . . . . .
Camshafts 1C2–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt Check and Adjust 1C2–24. . . . . . . . . . . . .
Timing Belt 1C2–28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan 1C2–32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump 1C2–33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Mount 1C2–37. . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake Manifold 1C2–38. . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Manifold 1C2–41. . . . . . . . . . . . . . . . . . . . . . . .
Camshaft Gears 1C2–43. . . . . . . . . . . . . . . . . . . . . . . . .
Rear Timing Belt Cover 1C2–44. . . . . . . . . . . . . . . . . . .
Engine 1C2–46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistions and Rods 1C2–51. . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR 1C2–56. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Valve Train Components 1C2–56.
Crankshaft 1C2–63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Bearing and Connecting Rod
Beadings – Gauging Plastics 1C2–72. . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION1C2–75 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Gasket 1C2–75. . . . . . . . . . . . . . . .
Crankshaft 1C2–75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt 1C2–75. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump 1C2–75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan 1C2–75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold 1C2–75. . . . . . . . . . . . . . . . . . . . . . . .
Intake Manifold 1C2–75. . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft 1C2–75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .