2004 DAEWOO NUBIRA gas

1C2 – 38I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
3. Install the timing belt idler pulleys.
4. Install the timing belt idler pulley bolt and nut.
Tighten
Tighten the timing belt idler pulley bolt and nut to 25
NSm (18 lb–ft).
5. Tension the timing belt by turning the timing belt
automatic tensioner hex–key tab counterclockwise
until the pointer is aligned to the indicator.
Tighten
Tighten the timing belt automatic tensioner bolt to 25
NSm (18 lb–ft).
6. Install the front timing belt cover.
7. Install the front timing belt cover bolts.
Tighten
Tighten the front timing belt cover bolts to 6 NSm (53
lb–in).
8. Install the engine mount bracket and retaining bolts.
Tighten
Tighten the engine mount bracket retaining bolts to 55
NSm (41 lb–ft).
9. Remove the engine assembly support fixture
J–28467–B, and the channel X–28467–560.
10. Install the serpentine accessory drive belt. Refer to
Section 6B, Power Steering Pump.
11. Connect the negative battery cable.
INTAKE MANIFOLD
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. Disconnect the negative battery cable.
4. Disconnect the charcoal canister purge (CCP) and
exhaust gas recirculation (EGR) solenoid from the
intake manifold and loosen the bracket bolt.
5. Drain the engine coolant. Refer to Section 1D, En-
gine Cooling.
6. Disconnect the manifold air temperature sensor
(MAT) connector.
7. Disconnect the air cleaner outlet hose from the
throttle body.

1.8L DOHC ENGINE MECHANICAL 1C2 – 39
DAEWOO V–121 BL4
8. Disconnect the idle air control (IAC) valve connec-
tor.
9. Disconnect the throttle position sensor (TPS) con-
nector.
10. Disconnect the manifold absolute pressure (MAP)
sensor connector.
11. Disconnect the coolant hoses at the throttle body.
12. Disconnect all of the necessary vacuum hoses, in-
cluding the vacuum hose at the fuel pressure regu-
lator and the brake booster vacuum hose at the
intake manifold.
13. Disconnect the throttle cable from the throttle body
and the intake manifold.
14. Remove the throttle cable bracket bolts from the
intake manifold.
15. Remove the throttle cable bracket.
16. Remove the generator–to–intake manifold strap
bracket bolts and strap.
17. Remove the fuel rail as an assembly. Refer to Sec-
tion 1F, Engine Controls.
18. Remove the generator–to–intake manifold support
bracket bolts.
19. Remove the generator–to–intake manifold support
bracket.
20. Remove the intake manifold support bracket bolt at
the engine block and the intake manifold.
21. Remove the intake manifold support bracket.
22. Remove the intake manifold retaining bolt and nuts
in the sequence shown.
23. Remove the intake manifold.
24. Remove the intake manifold gasket.
25. Clean the sealing surfaces of the intake manifold
and the cylinder head.

1C2 – 40I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
Installation Procedure
1. Install the intake manifold gasket.
2. Install the intake manifold.
3. Install the intake manifold retaining bolt and nuts in
the sequence shown.
Tighten
Tighten the intake manifold retaining bolt and nuts to
22 NSm (16 lb–ft).
4. Install the generator–to–intake manifold strap
bracket and bolts.
Tighten
Tighten the generator–to–intake manifold strap
bracket bolts to 22 NSm (16 lb–ft).
5. Install the intake manifold support bracket.
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. Install the intake manifold support bracket lower
bolt to the engine block.
Tighten
Tighten the intake manifold support bracket lower bolt
to the engine block to 25 NSm (18 lb–ft).
8. Install the generator–to–intake manifold support
bracket and bolts.
Tighten
Tighten the generator–to–intake manifold support
bracket bolts to 37 NSm (27 lb–ft).
9. Install the fuel rail and injector cover as an assem-
bly. Refer to Section 1F, Engine Controls.
10. Install the throttle cable bracket.
11. Install the throttle cable bracket bolts.
Tighten
Tighten the throttle cable bracket bolts to 8 NSm (71
lb–in).
12. Connect the throttle cable to the intake manifold
and the throttle body.
13. Connect all of the necessary vacuum lines that
were previously disconnected.

1.8L DOHC ENGINE MECHANICAL 1C2 – 41
DAEWOO V–121 BL4
14. Connect the MAP sensor connector.
15. Connect the coolant hoses to the throttle body.
16. Connect the IAC valve connector.
17. Connect the TPS connector.
18. Connect the air cleaner outlet hose to the throttle
body.
19. Connect the MAT sensor connector.
20. Connect the CCP and EGR solenoid at the intake
manifold and tighten the bracket bolt.
Tighten
Tighten the charcoal canister purge and exhaust gas
recirculation solenoid bracket bolt to 5 NSm (44 lb–in).
21. Install the fuel pump fuse.
22. Connect the negative battery cable.
23. Refill the engine cooling system. Refer to Section
1D, Engine Cooling.
EXHAUST MANIFOLD
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the oxygen (O2) sensor connector, if
equipped.
3. Remove the exhaust manifold heat shield bolts.
4. Remove the exhaust manifold heat shield.
5. Remove the exhaust flex pipe retaining nuts from
the exhaust manifold studs.

1C2 – 42I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
6. Remove the exhaust manifold retaining nuts in the
sequence shown.
7. Remove the exhaust manifold.
8. Remove the exhaust manifold gasket.
9. Clean the sealing surfaces of the exhaust manifold
and the cylinder head.
Installation Procedure
1. Install the exhaust manifold gasket.
2. Install the exhaust manifold.
3. Install the exhaust manifold retaining nuts and tight-
en in the sequence shown.
Tighten
Tighten the exhaust manifold retaining nuts 22 NSm
(16 lb–ft).
4. Install the exhaust flex pipe retaining nuts to the
exhaust manifold studs.
Tighten
Tighten the exhaust flex pipe–to–exhaust manifold
retaining nuts to 35 NSm (26 lb–ft).
5. Install the exhaust manifold heat shield.
6. Install the exhaust manifold heat shield bolts.
Tighten
Tighten the exhaust manifold heat shield bolts to 8
NSm (71 lb–in).
7. Connect the O2 sensor connector, if equipped.
8. Connect the negative battery.

1.8L DOHC ENGINE MECHANICAL 1C2 – 43
DAEWOO V–121 BL4
CAMSHAFT GEARS
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the timing belt. Refer to ”Timing Belt” in
this section.
3. Remove the spark plug cover bolts.
4. Remove the spark plug cover.
5. Disconnect the ignition wires from the spark plugs.
6. Disconnect the breather tubes from the camshaft
cover.
7. Remove the camshaft cover bolts.
8. Remove the camshaft cover washers.
9. Remove the camshaft cover and the camshaft cov-
er gasket.
Notice : Take extreme care to prevent any scratches,
nicks or damage to the camshafts.
10. While holding the intake camshaft firmly in place,
remove the intake camshaft gear bolt.
11. Remove the intake camshaft gear.
12. While holding the exhaust camshaft firmly in place,
remove the exhaust camshaft gear bolt.
13. 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 50 NSm (37
lb–ft) plus 60 degrees and 15 degrees using the angu-
lar torque gauge KM–470–B.

1C2 – 44I1.8L 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 50 NSm (37
lb–ft) plus 60 degrees and 15 degrees using the angu-
lar torque gauge KM–470–B.
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 washers.
8. Install the camshaft cover bolts.
Tighten
Tighten the camshaft cover bolts to 8 NSm (71 lb–in).
9. Connect the crankcase breather tubes to the cam-
shaft cover.
10. Connect the ignition wires to the spark plugs.
11. Install the spark plug cover.
12. Install the spark plug cover bolts.
Tighten
Tighten the spark plug cover bolts to 8 NSm (71 lb–in).
13. Install the timing belt. Refer to ”Timing Belt” in this
section.
14. Connect the negative battery cable.
REAR TIMING BELT COVER
Tools Required
KM–470–B Angular Torque Gauge
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the timing belt. Refer to ”Timing Belt” in
this section.
3. Remove the camshaft gears. Refer to ”Camshaft
Gears” in this section.
4. Remove the timing belt automatic tensioner bolt.
5. Remove the timing belt automatic tensioner.

1C2 – 48I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
40. Remove the crankshaft pulley bolts.
41. Remove the crankshaft pulley.
42. Disconnect the vacuum lines at the charcoal canis-
ter purge solenoid.
43. Disconnect the electrical connector at the charcoal
canister purge (CCP) and the exhaust gas recir-
culation (EGR) solenoid.
44. Disconnect the electrical connector at the oil pres-
sure switch.
45. Disconnect the crankshaft position sensor (CPS)
connector.
46. Disconnect the knock sensor connector.
47. Remove the transaxle torque converter bolts, if au-
tomatic transaxle equipped.
48. Remove the transaxle bell housing bolts and the oil
pan flange bolts.
49. Support the transaxle with a floor jack.
50. Install the engine lifting device.
51. Disconnect the right engine mount bracket from the
engine mount by removing the retaining bolt.
52. Remove the right engine mount bracket from the
engine block and frame mount. Refer to Section
5B, Five Speed Manual Transaxle, or Section 5A,
Automatic Transaxle.
53. Separate the engine block from the transaxle. Re-
move 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 oil pan flange–to–transaxle bolts.
Tighten
Tighten the oil pan flange–to–transaxle bolts to 40
NSm (30 lb–ft).