2004 DAEWOO NUBIRA fuel

1C1 – 26I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
5. Connect the throttle cable at the throttle body and
the intake manifold.
6. Install the intake manifold support bracket upper
bolts to the intake manifold.
Tighten
Tighten the intake manifold support bracket upper
bolts to the intake manifold to 25 NSm (18 lb–ft).
7. Connect the surge tank coolant hose at the throttle
body.
8. Connect the heater inlet hose to the cylinder head.
9. Install the generator upper retaining bolt.
Tighten
Tighten the generator upper retaining bolt to 20 NSm
(15 lb–ft).
10. Connect the fuel feed line at the fuel rail.
11. Connect all the disconnected vacuum hoses and
the brake booster vacuum hose at the intake man-
ifold.
12. Install the catalytic converter retaining nuts at the
exhaust manifold flange.
Tighten
Tighten the catalytic converter to exhaust manifold
flange nuts to 40 NSm (30 lb–ft).
13. Install the rear timing belt cover.
14. Install the rear timing belt cover bolts.
Tighten
Tighten the rear timing belt cover bolts to 10 NSm (89
lb–in).

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 29
DAEWOO V–121 BL4
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.

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 – 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.

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.

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.

1C1 – 58I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
UNIT REPAIR
CYLINDER HEAD AND VALVE TRAIN
COMPONENTS
Tools Required
MKM–571–B Gauge
KM–340–0 Cutter Set
KM–340–7 Guide Drift
KM–340–13 Cutters
KM–340–26 Cutters
KM–348 Valve Spring Compressor
KM–653 Adapter
KM–805 Valve Guide Reamer
Disassembly 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 engine coolant temperature sensor.
3. Remove the exhaust manifold heat shield bolts.
4. Remove the exhaust manifold heat shield.
5. Remove the exhaust manifold retaining nuts in the
sequence shown.
6. Remove the exhaust manifold.
7. Remove the exhaust manifold gasket.
8. Remove the exhaust manifold studs.
9. Remove the thermostat housing mounting bolts.
10. Remove the thermostat housing assembly.
11. Remove the fuel rail retaining bolts and the fuel rail
assembly.
12. Remove the intake manifold retaining nuts and re-
taining bolts in the sequence shown.
13. Remove the intake manifold.
14. Remove the intake manifold studs.

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 65
DAEWOO V–121 BL4
28. Install the fuel rail assembly with the bolts.
Tighten
Tighten the fuel rail assembly retaining bolts to 25
NSm (18 lb–ft).
29. Install the thermostat housing assembly.
30. Install the thermostat housing mounting bolts.
Tighten
Tighten the thermostat housing mounting bolts to 20
NSm (15 lb–ft).
31. Install the exhaust manifold studs.
32. Install the exhaust manifold gasket.
33. Install the exhaust manifold.
34. Install the exhaust manifold retaining nuts in the
sequence shown.
Tighten
Tighten the exhaust manifold retaining nuts to 25 NSm
(18 lb–ft).
35. Install the exhaust manifold heat shield.
36. Install the exhaust manifold heat shield bolts.
Tighten
Tighten the exhaust manifold heat shield bolts to 15
NSm (11 lb–ft).
37. Install the ECT sensor.
Tighten
Tighten the engine coolant temperature sensor to 20
NSm (15 lb–ft).
38. Install the cylinder head with the intake manifold
and the exhaust manifold attached. Refer to ”Cylin-
der Head and Gasket” in this section.
CRANKSHAFT
Tools Required
KM–412 Engine Overhaul Stand
J–42492 Timing Belt Adjuster
KM–470–B Angular Torque Gauge
J–36792 or KM–635 Crankshaft Rear Oil Seal Installer
Notice : Take extreme care to prevent any scratches,
nicks, or damage to the camshafts.
Disassembly Procedure
1. Remove the engine. Refer to ”Engine” in this sec-
tion.
2. Remove the flywheel or flexible plate bolts.
3. Remove the flywheel or the flexible plate.