2004 DAEWOO NUBIRA lock

1F – 596IENGINE CONTROLS
DAEWOO V–121 BL4
7. Connect the fuel pump harness connector.
8. Connect the fuel vapor line.
9. Connect the fuel tank filler tube.
10. Connect the fuel tank vent tube.
11. Install the fuel tank filler tube clamp at the fuel tank.
12. Install the front muffler. Refer to Section 1G, Ex-
haust System
13. Connect the negative battery cable.
14. Fill the fuel tank.
15. Perform a leak check of the fuel tank and the fuel
line connections.
FUEL PUMP
Removal Procedure
CAUTION : The fuel system is under pressure. To
avoid fuel spillage and the risk of personal injury or
fire, it is necessary to relieve the fuel system pressure
before disconnecting the fuel lines.
1. Relieve the fuel system pressure.
1) Remove the fuel cap.
2) Remove fuel pump fuse Ef18 from the engine
fuse block.
3) Start the engine and allow the engine to stall.
4) Crank the engine for an additional 10 seconds.
2. Disconnect the negative battery cable.
3. Remove the rear seat. Refer to Section 9H, Seats.
4. Remove the fuel pump access cover.
5. Disconnect the electrical connector at the fuel
pump assembly.
6. Disconnect the fuel outlet line.
7. Disconnect the fuel tank return line.

ENGINE CONTROLS 1F – 597
DAEWOO V–121 BL4
8. Turn the lock ring counterclockwise to clear the
tank tabs.
9. Remove the fuel pump assembly from the tank.
Installation Procedure
1. Clean the gasket mating surface on the fuel tank.
2. Position the new gasket in place.
3. Install the fuel pump into the fuel tank in the same
location as removed for ease of line and connector
installation.
4. Position the lock ring in place and turn it clockwise
until it contacts the tank stop.
5. Connect the fuel pump assembly connector.
6. Install the fuel pump outlet line.
7. Install the fuel tank return line.
8. Install the fuel pump access cover.
9. Connect the negative battery cable.
10. Perform an operational check of the fuel pump.
11. Install the rear seat. Refer to Section 9H, Seats.
FUEL FILTER
Removal Procedure
CAUTION : The fuel system is under pressure. To
avoid fuel spillage and the risk of personal injury or
fire, it is necessary to relieve the fuel system pressure
before disconnecting the fuel lines.
1. Relieve the fuel system pressure. Refer to ” Fuel
System Pressure Relief ” in this section.
2. Disconnect the negative battery cable.
3. Remove the fuel filter mounting bracket assembly
bolt.
4. Remove the fuel filter cover.
5. Disconnect the inlet/outlet fuel lines by moving the
line connector lock forward and pulling the hose off
of the fuel filter tube.

1F – 598IENGINE CONTROLS
DAEWOO V–121 BL4
Installation Procedure
1. Install the new fuel filter into the retaining clamp.
Note the flow direction.
2. Install the fuel filter.
3. Connect the inlet/outlet lines. Secure the lines with
the connector lock.
4. Install the fuel filter cover.
5. Install the fuel filter mounting bracket assembly bolt
with the fuel filter ground.
Tighten
Tighten the fuel filter mounting bracket assembly
bolts to 4 NSm (35 lb–ft).
6. Connect the negative battery cable.
7. Perform a leak test of the fuel filter.
FUEL RAIL AND INJECTORS
(1.4L/1.6L DOHC)
Removal Procedure
CAUTION : The fuel system is under pressure. To
avoid fuel spillage and the risk of personal injury or
fire, it is necessary to relieve the fuel system pressure
before disconnecting the fuel lines.
1. Relieve the fuel system pressure. Refer to ”Fuel
Pump”in this section.
2. Disconnect the negative battery cable.
3. Remove the intake manifold bracket bolts.
4. Remove the intake manifold bracket.
5. Disconnect the fuel injector harness connectors.
6. Remove the fuel feed line.
7. Remove the fuel rail mounting bolts.
Notice : Before removal, the fuel rail assembly may be
cleaned with a spray–type cleaner, following package in-
structions. Do not immerse the fuel rails in liquid cleaning
solvent. Use care in removing the fuel rail assembly to pre-
vent damage to the electrical connectors and the injector
spray tips. Prevent dirt and other contaminants from enter-
ing open lines and passages. Fittings should be capped
and holes plugged during service.
Important : If an injector becomes separated from the rail
and remains in the cylinder head, replace the injector O–
ring seals and the retaining clip.

ENGINE CONTROLS 1F – 617
DAEWOO V–121 BL4
5. Remove the accessory mounting bracket by remov-
ing the bolts.
6. Disconnect the crankshaft position (CKP) sensor
connector.
7. Remove the CKP sensor retaining bolt.
8. Gently rotate and remove the CKP sensor from the
engine block.
Installation Procedure
1. Insert the CKP sensor into the engine block.
2. Install the CKP sensor retaining bolt.
Tighten
Tighten the crankshaft position sensor retaining bolt
to 8 NSm (71 lb–in).
3. Connect the CKP sensor connector.
4. Install the accessory mounting bracket with the
bolts.
Tighten
Tighten the accessory mounting bracket bolts to 27
NSm (37 lb–ft).
5. Install the rear A/C mounting bracket.
Tighten
Tighten the rear A/C mounting bracket bolts to 35
NSm (26 lb–ft).
6. Install the A/C compressor. Refer to Section 7D,
Automatic Temperature Control Heating, Ventilation
and Air Conditioning System.
7. Install the power steering pump. Refer to Section
6B, Power Steering Pump.
8. Connect the negative battery cable.

ENGINE CONTROLS 1F – 621
DAEWOO V–121 BL4
ENGINE CONTROL MODULE
(1.8L DOHC)
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the air intake tube and resonator.
3. Disconnect the ECM connectors from the ECM.
4. Remove the engine Control module.
Installation Procedure
1. Connect the ECM connectors to the ECM.
2. Align the ECM into the mounting base.
3. Snap the ECM into its mounting base.
4. Install the ECM trim locks.
5. Install the passenger side kick panel. Refer to Sec-
tion 9G, Interior Trim.
6. Connect the negative battery cable.
7. Perform a crankshaft position system variation
learning procedure. Refer to ”DTC P1336” in this
section.
ELECTRONIC IGNITION SYSTEM
IGNITION COIL (1.4L/1.6L DOHC)
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the electronic ignition (EI) system igni-
tion coil connector.
3. Note the ignition wire location and remove the igni-
tion wire.
4. Remvoe the EI system ignition coil retaining nuts.
5. Remove the EI system ignition coil.
Installation Procedure
1. Install the EI system ignition coil into the mounting
location and install the retaining nuts.
Tighten
Tighten the EI system ignition coil retaining nuts to 10
NSm (89 lb–in).
2. Connect the EI system ignition coil connector.
3. Connect the negative battery cable.

ENGINE CONTROLS 1F – 627
DAEWOO V–121 BL4
A closed throttle on engine coast down produces a rela-
tively low MAP output. MAP is the opposite of vacuum.
When manifold pressure is high, vacuum is low. The MAP
sensor is also used to measure barometric pressure. This
is performed as part of MAP sensor calculations. With the
ignition ON and the engine not running, the engine control
module (ECM) will read the manifold pressure as baromet-
ric pressure and adjust the air/fuel ratio accordingly. This
compensation for altitude allows the system to maintaindriving performance while holding emissions low. The
barometric function will update periodically during steady
driving or under a wide open throttle condition. In the case
of a fault in the barometric portion of the MAP sensor, the
ECM will set to the default value.
A failure in the MAP sensor circuit sets a diagnostic trouble
code P0107 or P0108.
The following tables show the difference between absolute pressure and vacuum related to MAP sensor output, which
appears as the top row of both tables.
MAP
Volts4.94.43.83.32.72.21.71.10.60.30.3
kPa1009080706050403020100
in. Hg29.626.623.720.717.714.811.88.95.92.90
VACUUM
Volts4.94.43.83.32.72.21.71.10.60.30.3
kPa0102030405060708090100
in. Hg02.95.98.911.814.817..720.723.726.729.6
ENGINE CONTROL MODULE
The engine control module (ECM), located inside the pas-
senger kick–panel, is the control center of the fuel injection
system. It constantly looks at the information from various
sensors and controls the systems that affect the vehicle’s
performance. The ECM also performs the diagnostic func-
tions of the system. It can recognize operational problems,
alert the driver through the Malfunction Indicator Lamp
(MIL), and store diagnostic trouble code(s) which identify
problem areas to aid the technician in making repairs.
There are no serviceable parts in the ECM. The calibra-
tions are stored in the ECM in the Programmable Read–
Only Memory (PROM).
The ECM supplies either 5 or 12 volts to power the sensors
or switches. This is done through resistances in the ECM
which are so high in value that a test light will not come on
when connected to the circuit. In some cases, even an or-
dinary shop voltmeter will not give an accurate reading be-
cause its resistance is too low. You must use a digital volt-
meter with a 10 megohm input impedance to get accurate
voltage readings. The ECM controls output circuits such
as the fuel injectors, the idle air control valve, the A/C
clutch relay, etc., by controlling the ground circuit through
transistors or a device called a ”quad–driver.”
FUEL INJECTOR
The Multiport Fuel Injection (MFI) assembly is a solenoid–
operated device controlled by the engine control module
(ECM). It meters pressurized fuel to a single engine cylin-
der. The ECM energizes the fuel injector or the solenoid
to a normally closed ball or pintle valve. This allows fuel toflow into the top of the injector, past the ball or pintle valve,
and through a recessed flow director plate at the injector
outlet.
The director plate has six machined holes that control the
fuel flow, generating a conical spray pattern of finely atom-
ized fuel at the injector tip. Fuel from the tip is directed at
the intake valve, causing it to become further atomized
and vaporized before entering the combustion chamber.
A fuel injector which is stuck partially open will cause a loss
of fuel pressure after the engine is shut down. Also, an ex-
tended crank time will be noticed on some engines. Diesel-
ing can also occur because some fuel can be delivered to
the engine after the ignition is turned OFF.
KNOCK SENSOR
The knock sensor detects abnormal knocking in the en-
gine. The sensor is mounted in the engine block near the
cylinders. The sensor produces an AC output voltage
which increases with the severity of the knock. This signal
is sent to the engine control module (ECM). The ECM then
adjusts the ignition timing to reduce the spark knock.
ROUGH ROAD SENSOR
The engine control module (ECM) receives rough road in-
formation from the VR sensor. The ECM uses the rough
road information to enable or disable the misfire diagnos-
tic. The misfire diagnostic can be greatly affected by
crankshaft speed variations caused by driving on rough
road surfaces. The VR sensor generates rough road infor-
mation by producing a signal which is proportional to the
movement of a small metal bar inside the sensor.
If a fault occurs which causes the ECM to not receive
rough road information between 30 and 80 mph (50 and
132 km/h), DTC P1391 will set.

SECTION : 1G
ENGINE EXHAUST
TABLE OF CONTENTS
SPECIFICATIONS1G–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 1G–1. . . . . . . . . .
COMPONENT LOCATOR1G–2 . . . . . . . . . . . . . . . . . . . .
Exhaust System 1G–2. . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR1G–3 . . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 1G–3. . . . . . . . . . . . . . . . . . . . .
Catalytic Converter 1G–3. . . . . . . . . . . . . . . . . . . . . . . . Exhaust Front Pipe 1G–4. . . . . . . . . . . . . . . . . . . . . . . .
Muffler – Front 1G–6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Muffler – Rear 1G–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION1G–9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust System 1G–9. . . . . . . . . . . . . . . . . . . . . . . . . .
Muffler 1G–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Catalytic Converters 1G–9. . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Catalytic Converter–to–Exhaust Manifold Nuts4037–
Exhaust Front Pipe–to–Catalytic Converter Nuts4030–
Exhaust Manifold Cover Bolts1511–
Exhaust Front Pip–to–Front Muffler3022–
Front Muffler–to–Rear Muffler Nuts3022–
Front Bracket–to–Cylinder Block Bolt5037–
Catalytic Converter–to–Underbody Shield2.5–22
Front Muffler–to–Underbody Shield2.5–22
Rear Muffler–to–Underbody Shield2.5–22

1G – 4IENGINE EXHAUST
DAEWOO V–121 BL4
Installation Procedure
1. Install the catalytic converter and the gasket to the
exhaust front pipe flange.
Tighten
Tighten the exhaust front pipe–to–catalytic converter
nuts to 40 NSm (30 lb–ft).
Tighten the exhaust front pipe–to–cylinder block bolt
to 50 NSm (37 lb–ft).
2. Install the catalytic converter to exhaust manifold
nuts and the gasket.
Tighten
Tighten the catalytic converter to exhaust manifold
nuts to 40 NSm (30 lb–ft).
3. Install the exhaust manifold conver bolts.
Tighten
Tighten the exhaust manifold cover bolts to 15 NSm
(11 lb–ft).
4. Connect the oxygen sensor electrical connector.
5. Connect the negative battery cable.
EXHAUST FRONT PIPE
Removal Procedure
1. Remove the crossmember lower bracket with the
bolts.