2004 DAEWOO NUBIRA check engine

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.

1C1 – 60I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
35. Remove the valves. Maintain the original position of
the valves for installation.
36. Remove the valve stem seals.
Cylinder Head Inspection
1. Clean the sealing surfaces.
2. Inspect the cylinder head gasket and mating sur-
faces for leaks, corrosion, and blowby.
3. Inspect the cylinder head for cracks.
4. Inspect the length and the width of the cylinder
head using a feeler gauge and a straight edge.
5. Check the sealing surfaces for deformation and
warpage. The cylinder head sealing surfaces must
be flat within 0.050 mm (0.002 inch) maximum.
6. Measure the height of the cylinder head from seal-
ing surface to sealing surface. The cylinder head
height should be 134.08 to 134.23 mm. If the cylin-
der head height is less than 134.08 mm, replace
the cylinder head.
7. Inspect all threaded holes for damage.
8. Inspect valve seats for excessive wear and burned
spots.
Valve Inspection
1. Inspect the valve stem tip for wear.
2. Inspect the valve key grooves and the oil seal
grooves for chips and wear.
3. Inspect the valves for burns or cracks.
4. Inspect the valve stem for burrs and scratches.
5. Inspect the valve stem. The valve stem must be
straight.
6. Inspect the valve face for grooving. If the groove is
so deep that refacing the valve would result in a
sharp edge, replace the valve.

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 61
DAEWOO V–121 BL4
7. Inspect the valve spring. If the valve spring ends
are not parallel, replace the valve spring.
8. Measure the valve spring height. Refer to ”Engine
Specifications” in this section. If the valve spring
height does not match the specifications, replace
the valve spring.
9. Inspect the valve spring seating surface of the
valve rotators for wear or gouges. Replace as re-
quired.
Cleaning Procedure
1. Clean the cylinder head.
2. Clean the valve guides.
3. Clean all of the threaded holes.
4. Clean the valves of carbon, oil, and varnish.
Cylinder Head Overhaul
Valve Grind–in
1. Lubricate the valve stem using a fine–grained
paste.
2. Lift the valve rhythmically from the seat with a com-
mercially available valve grinding tool in order to
distribute the paste.
3. Check the contact pattern on the valve head and in
the cylinder head.
4. Clean the valves, the valve guides, and the cylinder
head.

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 69
DAEWOO V–121 BL4
41. Mark the order of the crankshaft bearing caps.
42. Remove the crankshaft bearing cap bolts.
43. Remove the crankshaft bearing caps and the lower
crankshaft bearings.
44. Remove the crankshaft.
45. Remove the upper crankshaft bearings.
46. Clean the parts, as needed.
Assembly Procedure
1. Coat the crankshaft bearings with the engine oil.
2. Install the upper crankshaft bearings in the engine
block.
3. Install the crankshaft.
4. Install the lower crankshaft bearings in the bearing
caps.
5. Inspect the crankshaft end play with the crankshaft
bearings installed.
6. Check for permissible crankshaft end play. Refer to
”Engine Specifications” in this section.
7. With the crankshaft mounted on the front and the
rear crankshaft bearings, check the middle crank-
shaft journal for permissible out–of–round (runout).
Refer to ”Engine Specifications” in this section.

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 73
DAEWOO V–121 BL4
36. Install the crankshaft timing belt gear.
37. Install the timing belt automatic tensioner.
38. Install the timing belt automatic tensioner bolts.
Tighten
Tighten the timing belt automatic tensioner bolts to 25
NSm (18 lb–ft).
39. Install the timing belt idler pulley.
40. Install the timing belt idler pulley bolt.
Tighten
Tighten the timing belt idler pulley bolt to 40 NSm (30
lb–ft).
Notice : Take extreme care to prevent any scratches,
nicks or damage to the camshafts.
41. Install the intake camshaft gear.
42. Install the intake camshaft gear bolt while holding
the intake camshaft firmly in place.
Tighten
Tighten the intake camshaft gear bolt to 67.5 NSm (49
lb–ft).
43. Install the exhaust camshaft gear.
44. Install the exhaust camshaft gear bolt while holding
the exhaust camshaft firmly in place.
Tighten
Tighten the exhaust camshaft gear bolt to 67.5 NSm
(49 lb–ft).
45. Install the timing belt. Refer to ”Timing Belt” in this
section.
46. Adjust the timing belt tension. Refer to ”Timing Belt
Check and Adjust” in this section.
47. 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.
48. Install the camshaft cover and the camshaft cover
gasket.
49. Install the camshaft cover washers.
50. Install the camshaft cover nuts.
Tighten
Tighten the camshaft cover nuts to 10 NSm (89 lb–in).
51. Connect the ignition wires to the spark plugs.
52. Connect the oil filler cap.
53. Connect the engine ventilation hose to the cam-
shaft cover.
54. Install the upper and the lower front timing belt cov-
ers.
55. Install the upper and the lower front timing belt cov-
er bolts.
Tighten
Tighten the upper and the lower front timing belt cover
bolts to 10 NSm (89 lb–in).

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 75
DAEWOO V–121 BL4
4. Install the crankshaft.
5. Inspect the crankshaft end play with the crankshaft
bearings installed.
6. Check for permissible crankshaft end play. Refer to
”Engine Specifications” in this section.
7. With the crankshaft mounted on the front and rear
crankshaft bearings, check the middle crankshaft
journal for permissible out–of–round (runout). Refer
to ”Engine Specifications” in this section.
Notice : Grease the crankshaft journals and lubricate the
crankshaft bearings slightly so that the plastic gauging
thread does not tear when the crankshaft bearing caps are
removed.
8. Inspect all of the crankshaft bearing clearances us-
ing a commercially available plastic gauging (ductile
plastic threads).
9. Cut the plastic gauging threads to the length of the
bearing width. Lay them axially between the crank-
shaft journals and the crankshaft bearings.
10. Install the crankshaft bearing caps.
11. Install the crankshaft bearing cap bolts.
Tighten
Tighten the crankshaft bearing cap bolts to 50 NSm
(37 lb–ft). Using the angular torque gauge
KM–470–B, tighten the crankshaft bearing cap bolts
45 degrees plus 15 degrees.

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.8L DOHC ENGINE MECHANICAL 1C2 – 7
DAEWOO V–121 BL4
KM–635
Crankshaft Rear
Oil Seal Installer
KM–427
Piston Pin
Service Set
J–8087
Cylinder Bore
Check Gauge
KM–340–0
Cutter Set
Includes: KM–340–7
Guide Drift
KM–340–13
Cutters
KM–340–26
Cutters
KM–470–B
Angular Torque Gauge
KM–498–B
Pressure Gauge
J–8037
Universal Piston
Ring Compressor