2004 DAEWOO NUBIRA nut

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.

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.

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 – 50I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
33. Remove the crankshaft pulley bolt.
34. Remove the crankshaft pulley.
35. Disconnect the vacuum lines at the charcoal canis-
ter purge solenoid.
36. Disconnect the electrical connector at the charcoal
canister purge (CCP) solenoid and at the knock
sensor.
37. Disconnect the electrical connector at the oil pres-
sure switch and at the exhaust gas recirculation
(EGR) solenoid.
38. Disconnect the crankshaft position sensor (CPS)
connector.
39. Remove the transaxle torque converter bolts, if au-
tomatic transaxle equipped.
40. Remove the stater motor. Refer to Section 1E, En-
gine Electrical.
41. Remove the transaxle bell housing bolts.
42. Support the transaxle with a floor jack.
43. Install the engine lifting device.
44. Disconnect the right engine mount bracket from the
engine mount and the engine by removing the at-
taching bolts and the nuts.
45. Remove the right engine mount from the engine
block. Refer to ”Engine Mount” in this section.
46. Separate the engine block from the transaxle.
47. Remove the engine.
Installation Procedure
1. Install the engine into the engine compartment.
2. Align the engine alignment pins to the transaxle.
3. Install the transaxle bell housing bolts.
Tighten
Tighten the transaxle bell housing bolts to 75 NSm (55
lb–ft).
4. Install the right engine mount to the engine block.
Refer to ”Engine Mount” in this section.

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 51
DAEWOO V–121 BL4
5. Connect the right engine mount bracket to the en-
gine mount and the engine by installing the attach-
ing bolts and the nuts.
Tighten
Tighten the engine mount bracket attaching bolts and
the nuts to 55 NSm (41 lb–ft).
6. Remove the floor jack used for support of the trans-
axle.
7. Remove the engine lifting device.
8. Install the transaxle torque converter bolts, if auto-
matic transaxle equipped.
Tighten
Tighten the transaxle torque converter bolts to 45
NSm (33 lb–ft).
9. Install the starter motor. Refer to Section 1E, En-
gine Electrical.
10. Connect the vacuum lines at the CCP solenoid.
11. Connect the electrical connector at the CCP sole-
noid and at the knock sensor.
12. Connect the oil pressure switch and the EGR sole-
noid connectors.
13. Install the crankshaft pulley.
14. Install the crankshaft pulley bolt.
Tighten
Tighten the crankshaft pulley bolt to 95 NSm (70 lb–ft)
and retighten 30 degrees plus 15 degrees.
15. Connect the CPS connector.
16. Install the exhaust front pipe.
17. Install the catalytic converter retaining nuts to the
exhaust pipe.
Tighten
Tighten the catalytic converter to exhaust pipe retain-
ing nuts to 35 NSm (26 lb–ft).

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.

1C1 – 64I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
11. Install the intake camshaft.
12. Install the intake camshaft caps in their original
positions.
13. Install the exhaust camshaft.
14. Install the exhaust camshaft caps in their original
positions.
15. Install the camshaft cap bolts.
16. Tighten the camshaft cap bolts gradually and in the
sequence shown for each camshaft cap.
Tighten
Tighten the camshaft cap bolts to 16 NSm (12 lb–ft).
17. Install the spark plugs.
Tighten
Tighten the spark plugs to 25 NSm (18 lb–ft).
18. Install the EGR valve adapter gasket.
19. Install the EGR valve adapter.
20. Install the EGR valve adapter bolts.
Tighten
Tighten the exhaust gas recirculation valve adapter
bolts to 25 NSm (18 lb–ft).
21. Install the DIS coil mounting bracket.
22. Install the DIS coil mounting bracket bolts.
Tighten
Tighten the direct ignition system coil mounting brack-
et bolts to 10 NSm (89 lb–in).
23. Install the DIS coil with the ignition wires attached.
24. Install the DIS coil mounting bolts.
Tighten
Tighten the direct ignition system coil mounting bolts
to 10 NSm (89 lb–in).
25. Install the intake manifold studs.
26. Install the intake manifold.
27. Install the intake manifold retaining nuts and retain-
ing bolts in the sequence shown.
Tighten
Tighten the intake manifold retaining nuts and retain-
ing bolts to 25 NSm (18 lb–ft).

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.