2004 DAEWOO NUBIRA cylinder head

0B – 12IGENERAL INFORMATION
DAEWOO V–121 BL4
OWNER INSPECTIONS AND SERVICES
WHLE OPERATING THE VEHICLE
Horn Operation
Blow the horn occasionally tomake sure it works. Check
all the button locations.
Brake System Operation
Be alert for abnormal sounds, increased brake pedal trav-
el or repeated pulling to one side when braking. Also, if the
brake warning light goes on, or flashes, something may be
wrong with part of the brake system.
Exhaust System Operation
Be alert to any changes in the sound of the system or the
smell of the fumes. These are signs that the system may
be leaking or overheating. Have the system inspected and
repaired immediately.
Tires,Wheels and Alignment Operation
Be alert to any vibration of the steering wheel or the seats
at normal highway speeds. This may mean a wheel needs
to be balanced. Also, a pull right or left on a straight, level
road may show the need for a tire pressure adjustment or
a wheel alignment.
Steering System Operation
Be alert to changes in the steering action. An inspection
is needed when the steering wheel is hard to turn or has
too much free play, or if unusual sounds are noticed when
turning or parking.
Headlight Aim
Take note of the light pattern occasionally. Adjust the
headlights if the beams seem improperly aimed.
AT EACH FUEL FILL
A fluid loss in any (except windshield washer) system may
indicate a problem. Have the system inspected and re-
paired immediately.
Engine Oil Level
Check the oil level and add oil if necessary. The best time
to check the engine oil level is when the oil is warm.
1. After stopping the engine, wait a few minutes for
the oil to drain back to the oil pan.
2. Pull out the oil level indicator (dip stick).
3. Wipe it clean, and push the oil level indicator back
down all the way.
4. Pull out the oil level indicator and look at the oil lev-
el on it.
5. Add oil, if needed, to keep the oil level above the
MIN line and within the area labeled ”Operating
Range.” Avoid overfilling the engine, since this may
cause engine damage.
6. Push the indicator all the way back down into the
engine after taking the reading.If you check the oil level when the oil is cold, do not run the
engine first. The cold oil will not drain back to the pan fast
enough to give a true oil level reading.
Engine Coolant Level and Condition
Check the coolant level in the coolant reservoir tank and
add coolant if necessary. Inspect the coolant. Replace
dirty or rusty coolant.
Windshield Washer Fluid Level
Check the washer fluid level in the reservoir. Add fluid if
necessary.
AT LEAST MONTHLY
Tire And Wheel Inspection and Pressure
Check
Check the tires for abnormal wear or damage. Also check
for damaged wheels. Check the tire pressure when the
tires are cold (check the spare also, unless it is a stow-
away). Maintain the recommended pressures that are on
the tire placard that is in the glove box.
Light Operation
Check the operation of the license plate light, the head-
lights (including the high beams), the parking lights, the
fog lights, the taillight, the brake lights, the turn signals, the
backup lights and the hazard warning flasher.
Fluid Leak Check
Periodically inspect the surface beneath the vehicle for
water, oil, fuel or other fluids, after the vehicle has been
parked for a while. Water dripping from the air conditioning
system after use is normal. If you notice fuel leaks or
fumes, find the cause and correct it at once.
AT LEAST TWICE A YEAR
Power Steering System Reservoir Level
Check the power steering fluid level. Keep the power
steering fluid at the proper level. Refer to Section 6A, Pow-
er Steering System.
Brake Master Cylinder Reservoir Level
Check the fluid and keep it at the proper level. A low fluid
level can indicate worn disc brake pads which may need
to be serviced. Check the breather hole in the reservoir
cover to be free from dirt and check for an open passage.
Clutch Pedal Free Travel
Check clutch pedal free travel and adjust as necessary.
Measure the distance from the center of the clutch pedal
to the outer edge of the steering wheel with the clutch ped-
al not depressed. Then measure the distance from the
center of the clutch pedal to the outer edge of the steering
wheel with the clutch pedal fully depressed. The difference
between the two values must be greater than 130 mm
(5.19 inches).
Weather–Strip Lubrication
Apply a thin film silicone grease using a clean cloth.

GENERAL INFORMATION 0B – 13
DAEWOO V–121 BL4
EACH TIME THE OIL IS CHANGED
Automatic Transaxle Fluid
Refer to fluid level service procedure of Section 5A, ZF
4HP16 Automatic Transaxle.
Manual Transaxle
Check the fluid level and add fluid as required. Refer to
Section 5B, Five–Speed Manual Transaxle.
Brake System Inspection
This inspection should be done when the wheels are re-
moved for rotation. Inspect the lines and the hoses for
proper hookup, binding, leaks, cracks, chafing, etc. In-
spect the disc brake pads for wear. Inspect the rotors for
surface condition. Also inspect the drum brake linings for
wear and cracks. Inspect other brake parts, including the
drums, the wheels cylinders, the parking brake, etc., at the
same time. Check the parking brake adjustment. Inspect
the brakes more often if habit or conditions result in fre-
quent braking.
Steering, Suspension and Front Drive Axle
Boot And Seal Inspection
Inspect the front and rear suspension and the steering
system for damaged, loose or missing parts, signs of wear
or lack of lubrication. Inspect the power steering lines and
the hoses for proper hookup, binding, leaks, cracks, chaf-
ing, etc. Clean and inspect the drive axle boot and seals
for damage, tears or leakage. Replace the seals if neces-
sary.
Exhaust System Inspection
Inspect the complete system (including the catalytic con-
verter if equipped). Inspect the body near the exhaust sys-
tem. Look for broken, damaged, missing, or out–of–posi-
tion parts as well as open seams, holes, loose
connections, or other conditions which could cause heat
buildup in the floor pan or could let exhaust fumes seep
into the trunk or passenger compartment.
Throttle Linkage Inspection
Inspect the throttle linkage for interference or binding,
damaged, or missing parts. Lubricate all linkage joints and
throttle cable joints, the intermediate throttle shaft bearing,
the return spring at throttle valve assembly, and the accel-
erator pedal sliding face with suitable grease. Check the
throttle cable for free movements.
Engine Drive Belts
Inspect all belts for cracks, fraying, wear and proper ten-
sion. Adjust or replace the belts as needed.
Hood Latch Operation
When opening the hood, note the operation of the secon-
dary latch. It should keep the hood from opening all the
way when the primary latch is released. The hood must
close firmly.
AT LEAST ANNUALLY
Lap and Shoulder Belts Condition and
Operation
Inspect the belt system including: the webbing, the
buckles, the latch plates, the retractor, the guide loops and
the anchors.
Movable Head Restraint Operation
On vehicles with movable head restraints, the restraints
must stay in the desired position.
Spare Tire and Jack Storage
Be alert to rattles in the rear of the vehicle. The spare tire,
all the jacking equipment, and the tools must be securely
stowed at all times. Oil the jack ratchet or the screw mech-
anism after each use.
Key Lock Service
Lubricate the key lock cylinder.
Body Lubrication Service
Lubricate all the body door hinges including the hood, the
fuel door, the rear compartment hinges and the latches,
the glove box and the console doors, and any folding seat
hardware.
Transaxle Neutral Switch Operation on
Automatic Transaxle
CAUTION : Take the following precautions because
the vehicle could move without warning and possibly
cause personal injury or property damage:
S Firmly apply the parking brake and the regular
brakes.
S Do not use the accelerator pedal.
S Be ready to promptly turn off the ignition if the ve-
hicle starts.
On automatic transaxle vehicles, try to start the engine in
each gear. The starter should crank only in P (Park) or N
(Neutral).
Parking Brake and Transaxle P (Park)
Mechanism Operation
CAUTION : In order to reduce the risk of personal in-
jury or property damage, be prepared to apply the reg-
ular brakes promptly if the vehicle begins to move.
Park on a fairly steep hill with enough room for movement
in the downhill direction. To check the parking brake, with
the engine running and the transaxle in N (Neutral), slowly
remove foot pressure from the regular brake pedal (until
only the parking brake is holding the vehicle).
To check the automatic transaxle P (Park) mechanism’s
holding ability, release all brakes after shifting the trans-
axle to P (Park).
Underbody Flushing
Flushing the underbody will remove any corrosive materi-
als used for ice and snow removal and dust control. At
least every spring clean the underbody. First, loosen the
sediment packed in closed areas of the vehicle. Then flush
the underbody with plain water.

GENERAL INFORMATION 0B – 17
DAEWOO V–121 BL4
VIN Plate Location
The vehicle identification number (VIN) plate is attached
to the top of the front panel support.
VIN Plate
1. Manufacturer ’s Name
2. Whole Vehicle Type Approval No.
3. VIN (Vehicle Identification No.)
4. GVW
5. Combination Weight (GVW + Braked Trailer
Weight)
6. Maximum Permissible Axle Weight – Front
7. Maximum Permissible Axle Weight – Rear
Engraved VIN Location
The vehicle identification number (VIN) is engraved in the
top of the bulkhead.
Engine Number Location
The engine number is stamped on the cylinder block under
the No. 4 exhaust manifold of the engine.
1.4L/1.6L DOHC Engine
1.8L DOHC Engine

1A – 10IGENERAL ENGINE INFORMATION
DAEWOO V–121 BL4
Valve Mechanism or Valve Train Noises
StepActionValue(s)YesNo
1Is a light tapping sound heard from the engine?–Go to Step 2System OK
2Inspect the valve springs.
Are the springs weak or broken?–Go to Cylinder
Head and
Valve Train
Components
Replacement
ProcedureGo to Step 3
3Inspect the valves.
Are the valves sticking or warped?–Go to Cylinder
Head and
Valve Train
Components
Replacement
ProcedureGo to Step 4
4Inspect the valve lifters.
Are the valve lifters dirty, stuck or worn?–Go to Cylinder
Head and
Valve Train
Components
Replacement
ProcedureGo to Step 5
5Inspect the camshaft lobes.
Are the camshaft lobes damaged or improperly ma-
chined?–Go to Cam-
shaft Replace-
ment Proce-
dureGo to Step 6
6Check the oil supply to the valve train.
Is the oil supply insufficient or poor?–Go to Cylinder
Head and
Valve Train
Components
Replacement
ProcedureGo to Step 7
7Inspect the valve guides.
Are the valve guides worn?–Go to Cylinder
Head and
Valve Train
Components
Replacement
ProcedureGo to Step 8
8Inspect the valve spring seat.
Is the valve spring seat incorrect?–Go to Cylinder
Head and
Valve Train
Components
Replacement
ProcedureSystem OK

SECTION : 1C1
1.4L/1.6L 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
SPECIFICATIONS1C1–2 . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Specifications 1C1–2. . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifcations 1C1–5. . . . . . . . . .
SPECIAL TOOLS1C1–7 . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 1C1–7. . . . . . . . . . . . . . . . . . . . . . .
COMPONENT LOCATOR1C1–9 . . . . . . . . . . . . . . . . . . .
Cylinder Head 1C1–9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block 1C1–10. . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake & Exhaust Manifold 1C1–12. . . . . . . . . . . . . . . .
Timing Belt 1C1–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Mounting 1C1–14. . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR1C1–15 . . . . . . . . . . . . .
ON–VEHICLE SERVICE 1C1–15. . . . . . . . . . . . . . . . . . .
Engine Cover 1C1–15. . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft Cover 1C1–15. . . . . . . . . . . . . . . . . . . . . . . . .
Intake Manifold 1C1–16. . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold 1C1–20. . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Gasket 1C1–21. . . . . . . . . . . . . . . .
Camshaft 1C1–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt Check and Adjust 1C1–30. . . . . . . . . . . . .
Timing Belt 1C1–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pan 1C1–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump 1C1–40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Mount 1C1–43. . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft Gears 1C1–45. . . . . . . . . . . . . . . . . . . . . . . . .
Rear Timing Belt Cover 1C1–46. . . . . . . . . . . . . . . . . . .
Engine 1C1–48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistons and Rods 1C1–53. . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR 1C1–58. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Valve Train Components 1C1–58.
Crankshaft 1C1–65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Bearing and Connecting Rod
Beadings – Gauging Plastics 1C1–74. . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION1C1–77 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Gasket 1C1–77. . . . . . . . . . . . . . . .
Crankshaft 1C1–77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt 1C1–77. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump 1C1–77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan 1C1–77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold 1C1–77. . . . . . . . . . . . . . . . . . . . . . . .
Intake Manifold 1C1–77. . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft 1C1–77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1C1 – 4I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
ApplicationDescription (Manual and Automatic)
1.4L DOHC1.6L DOHC
Inner Rotor Side Clearance0.035~0.085 mm (0.001~0.003 in.)0.035~0.085 mm (0.001~0.003 in.)
Relief Valve Spring Free Length81 mm (3.2 in.)81 mm (3.2 in.)
Sealants and Adhesives:
Rear Main Bearing CapGE p/n RTV 159
Camshaft Carrier to Cylinder HeadHN 1581 (Loctite® 515)
Oil Pan BoltsHN 1256 (Loctite® 242)
Oil Pump BoltsHN 1256 (Loctite® 242)
Oil Pan Pickup Tube BoltsHN 1256 (Loctite® 242)
Oil Gallery PlugHN 1256 (Loctite® 242)
Coolant Jacket Caps and Plugs
(Freeze Plugs)HN 1756 (Loctite® 176)
Exhaust Manifold Studs/NutsAnti–seize Compound (HMC Spec HN1325)

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 5
DAEWOO V–121 BL4
FASTENER TIGHTENING SPECIFCATIONS
ApplicationNSmLb–FtLb–In
Air Cleaner Housing Bolts10–89
Camshaft Cap Bolts1612–
Camshaft Cover Nuts10–89
Connecting Rod Bearing Cap Bolts25
+ 30° + 15°18
+ 30° + 15°–
Coolant Temperature Sensor2015–
Crankshaft Bearing Cap Bolts50
+ 45° + 15°37
+ 45°+ 15°–
Crankshaft Cover Nuts5~8–44~71
Crankshaft Pulley Bolt95 NSm
+ 30° + 15°––
Cylinder Head Bolts (Cylinder Head Mounting Bolts)25 + 70°
+ 70° + 50°18 + 70°
+ 70° + 50°–
Direct Ignition System Coil Mounting Bolts10–89
Direct Ignition System Coil Mounting Bracket Bolts10–89
Engine Mount Attaching Bolts3022–
Engine Mount Bracket Attaching Bolts/Nuts5037–
Exhaust Camshaft Gear Bolt67.549–
Exhaust Flex Pipe–to–Catalytic Converter or Connecting Pipe
Retaining Nut3526–
Exhaust Flex Pipe–to–Exhaust Manifold Retaining Nuts3526–
Exhaust Gas Recirculation Valve Adapter Bolts2518–
Exhaust Manifold Heat Shield Bolts1511–
Exhaust Manifold Retaining Nuts2518–
Flexible Plate Bolts6044–
Flexible Plate Inspection Cover Bolts10–89
Flywheel Bolts35
+ 30° + 15°25
+ 30° + 15°–
Flywheel Inspection Cover Bolts12–106
Front Timing Belt Cover Bolts (Upper and Lower)10–89
Fuel Rail Assembly Retaining Bolts2518–
Fuel Rail Retaining Bolts2518–
Generator Upper Retaining Bolt2015–
Intake Camshaft Gear Bolt67.549–
Intake Manifold Retaining Bolts/Nuts2518–
Intake Manifold Support Bracket Lower Bolt2518–
Intake Manifold Support Bracket Upper Bolts2518–
Lower Front Timing Belt Cover Bolts10–89
Oil Pan Flange Bolts7555–
Oil Pan Retaining Bolts10–89
Oil Pan Drain Plug3526–
OIl Pressure Switch4030–

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 9
DAEWOO V–121 BL4
COMPONENT LOCATOR
CYLINDER HEAD
1. Oil Filler Cap
2. Engine Cover
3. Camshaft Cover
4. Camshaft Cover Gasket
5. Camshaft Cover Bolt
6. Hydraulic Tappet Adjuster
7. Valve Key
8. Valve Spring Cap
9. Valve Spring
10. Valve Stem Seal
11. EGR Vaccum Hose
12. EGR Valve
13. EGR Valve Gasket
14. EGR Valve Adaptor
15. EGR Valve Adaptor Gasket16. Cylinder Head
17. Front Camshaft Cap
18. Valve Guide
19. Plug
20. Freeze Plug
21. Oil Duct Cap
22. Intake Valve
23. Exhaust Valve
24. Cylinder Head Gasket
25. Engine Coolant Temperature Sensor
26. Heat Take Off Pipe
27. Camshaft
28. Camshaft Seal
29. Thermostat