2004 DAEWOO NUBIRA intake

GENERAL ENGINE INFORMATION 1A – 11
DAEWOO V–121 BL4
GENERAL INFORMATION
CLEANLINESS AND CARE
An automobile engine is a combination of many machined,
honed, polished and lapped surfaces with tolerances that
are measured in the ten–thousandths of an inch. When
any internal engine parts are serviced, care and cleanli-
ness are important. A liberal coating of engine oil should
be applied to friction areas during assembly, to protect and
lubricate the surfaces on initial operation. Proper cleaning
and protection of machined surfaces and friction areas is
part of the repair procedure. This is considered standard
shop practice even if not specifically stated.
Whenever valve train components are removed for ser-
vice, they should be kept in order. They should be installed
in the same locations, and with the same mating surfaces,
as when they were removed.Battery cables should be disconnected before any major
work is performed on the engine. Failure to disconnect
cables may result in damage to wire harness or other elec-
trical parts.ON–ENGINE SERVICE
CAUTION : Disconnect the negative battery cable be-
fore removing or installing any electrical unit, or
when a tool or equipment could easily come in con-
tact with exposed electrical terminals. Disconnecting
this cable will help prevent personal injury and dam-
age to the vehicle. The ignition must also be in LOCK
unless otherwise noted.
Notice : Any time the air cleaner is removed, the intake
opening should be covered. This will protect against acci-
dental entrance of foreign material, which could follow the
intake passage into the cylinder and cause extensive
damage when the engine is started.

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 – 2I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
SPECIFICATIONS
ENGINE SPECIFICATIONS
ApplicationDescription (Manual and Automatic)
1.4L DOHC1.6L DOHC
General Data:
Engine TypeF14DF16D
Displacement1399 cm31598 cm3 (97.51 in3)
Bore Stroke77.9 x 73.4 mm (3.01 in. x 2.89 in.)79.0 x 81.5 mm (3.1 in. X 3.21 in.)
Compression Ratio9.5 ± 0.2:19.5 ± 0.2:1
Firing Oder1–3–4–21–3–4–2
Cylinder Bore:
Diameter77.9 mm (3.07 in.)79 mm (3.1 in.)
Out of Round (Maximum)0.0065 mm (0.00025 in.)0.0065 mm (0.00025 in.)
Taper (Maximum)0.07 x 30°0.0065 mm (0.00025 in.)
Pistion:
Diameter77.87 mm (3.07 in.)78.970 mm (3.1090 in.)
Clearance to Bore0.030 mm (0.0012 in.)0.030 mm (0.0012 in.)
Piston Rings:
Ring, End Gap:
Top Compression
2nd Compression0.15–0.30 mm
(0.0059–0.0118 in.)
0.3–0.5 mm (0.0118–0.0197 in.)0.2–0.3 mm (0.008–0.012 in.)
0.5–0.6 mm (0.02–0.024 in.)
Groove Clearance:
Top Compression
2nd Compression0.05–0.09 mm
(0.00197–0.00354 in.)
0.06–0.1 mm
(0.00236–0.00393 in.)0.016 mm (0.0006 in.)
0.066 mm (0.0026 in.)
Piston Pin:
Diameter18.00 mm (0.708 in.)18.00 mm (0.708 in.)
Pin Off–Set0.5 ± 0.1 mm
(0.0197 ± 0.00787 in.)0.7–0.9 mm (0.028–0.036 in.)
Camshaft:
Lift Intake7.2 mm (0.283 in.)8.5 mm (0.335 in.)
Lift Exhaust7.2 mm (0.283 in.)8.5 mm (0.335 in.)
End Play0.1–0.25 mm (0.00394–0.00787 in.)0.10–0.25 mm (0.004–0.0089 in.)
Journal OD:
No. 1
No. 2
No. 3
No. 4
No. 529.94 mm (1.179 in.)
26.94 mm (1.061 in.)
26.94 mm (1.061 in.)
26.94 mm (1.061 in.)
26.94 mm (1.061 in.)30 mm (1.18 in.)
27 mm (1.06 in.)
27 mm (1.06 in.)
27 mm (1.06 in.)
27 mm (1.06 in.)

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 3
DAEWOO V–121 BL4
ApplicationDescription (Manual and Automatic)
1.4L DOHC1.6L DOHC
Crankshaft:
Main Journal:
Diameter (All)
Taper (Maximum)
Out of Round (Maximum)55 mm (2.71 in.)
0.005 mm (0.0001 in.)
0.004 mm (0.0001 in.)54.982–54.994 mm
(2.164–2.165 in.)
0.005 mm (0.0001 in.)
0.004 mm (0.0001 in.)
Main Bearing Clearance (All)0.026–0.042 mm (0.001–0.002 in.)0.026–0.042 mm (0.001–0.002 in.)
Crankshaft End Play0.1 mm (0.003 in.)0.05–0.28 mm (0.002–0.011 in.)
Connecting Rod Journal:
Diameter (All)43 mm (1.69 in.)
42.971–42.987 mm
(1.691–1.692 in.)
Taper (Maximum)0.005 mm (0.0001 in.)0.005 mm (0.0001 in.)
Out of Round (Maximum)0.004 mm (0.0001 in.)0.004 mm (0.0001 in.)
Rod Bearing Clearance (All)0.019–0.070 mm
(0.0007–0.0028 in.)0.019–0.071 mm
(0.0007–0.0028 in.)
Rod Side Clearance0.070–0.242 mm
(0.0027–0.009 in.)0.070–0.242 mm
(0.0027–0.009 in.)
Valve System:
Valve Lash CompensatorsHydraulicHydraulic
Face Angle (All)45°~45.25°90°~90.5°
Seat Angle (All)44.5°~45°89°~90°
Seat Runout (Maximum, All)0.05 mm (0.002 in.)0.05 mm (0.002 in.)
Face Runout (Maximum, All)0.03 mm (0.0012 in.)0.03 mm (0.0012 in.)
Seat Width:
Intake
Exhaust1.17–1.57 mm (0.046–0.062 in.)
1.4–1.8 mm (0.055–0.071 in.)1.17–1.57 mm (0.046–0.062 in.)
1.4–1.8 mm (0.055–0.071 in.)
Valve Guide Inside Diameter (All)6.00–6.02 mm (0.236–0.237 in.)6.00–6.02 mm (0.236–0.237 in.)
Valve Stem Diameter (All)6 mm (0.236 in.)6 mm (0.236 in.)
Valve Diameter (All):
Intake
Exhaust28.57 mm (1.125 in.)
27.24 mm (1.074 in.)28.6 mm (1.126 in.)
27.2 mm (1.072 in.)
Valve Spring Loads:
Valve Open
Valve Closed580 ± 29N (426 ± 21 lbs)
260 ± 13N (191 ± 9.6 lbs)580–26N (428–19 lbs)
@23.0 mm(0.90 in.)
260”13N(192” 9 lbs) @
32.0mm(1.25 in.)
Valve Spring Free Length41.2 mm (1.622 in.)41.2 mm (1.622 in.)
Oil Pump:
Gap Between Oil Pump Body and Out
Rotor0.400~0.484 mm
(0.0157~0.019 in.)0.400~0.484 mm (0.0157~0.019 in.)
Out Rotor Side Clearance0.045~0.100 mm
(0.0018~0.0039 in.)0.045~0.100 mm (0.02~0.004 in.)

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

1C1 – 12I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
INTAKE & EXHAUST MANIFOLD
1. Oxygen Sensor
2. Heat Shield
3. Exhaust Manifold
4. Exhaust Manifold Gasket
5. Intake Manifold
6. Main Throttle Idle Actuator (MTIA) Gasket
7. MTIA
8. Clamp9. Intake Air Tube
10. Breethe Hose
11. Aircleaner Assembly
12. Aircleaner Upper Hosing
13. Aircleaner Eliment
14. Aircleaner Lower Housing
15. Resoinator
16. Air Intet Hose

1C1 – 16I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
4. Remove the ignition wires from the spark plug.
5. Remove the camshaft cover bolts and camshaft
cover.
6. Remove the camshaft cover gasket.
Installation Procedure
1. Install the camshaft cover gasket on the camshaft
cover.
2. Position the camshaft cover on the engine block.
3. Install the camshaft cover bolts.
Tighten
Tighten the camshaft cover bolts to 10 NSm(89 lb–ft).
4. Install the ignition wires to the spark plugs and con-
nect the breather hose, ventilation hose and cam
position sensor wiring connector to the canshaft
cover.
5. Install the engine cover.
6. 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 calbe.
4. Drain the engine coolant. Refer to Section 1D, En-
gine Cooling.
5. Remove the engine cover and throttle body. Refer
to Section 1F, Engine Control.