2004 DAEWOO NUBIRA oil type

0B – 2IGENERAL INFORMATION
DAEWOO V–121 BL4
Engine
Application1.4L DOHC1.6L DOHC1.8L DOHC
Engine TypeDual Overhead Cam L–4


Bore77.9 mm (3.06 in.)79 mm (3.11 in.)81.6 mm (3.21 in.)
Stroke73.4 mm (2.89 in.)81.5 mm (3.21 in.)86 mm (3.38 in.)
Total Displacement1399 cm3 (85.4 in.3)1598 cm3 (97.5 in.3)1799 cm3 (109.7 in3)
Compression Ratio9.5 : 1
9.8 : 1
Maximum Power69.5 kw (93.2 hp)
(at 6,300 rpm)80 kw (107.3 hp)
(at 5,800 rpm)90 kw (120.7 hp)
(at 5,800 rpm)
Maximum Torque131 N_m (96.6 lb–ft)
(at 4,400 rpm)150 NSm (110.6 lb–ft)
(at 4,000 rpm)165 NSm (121.7 lb–ft)
(at 4,000 rpm)
Ignition System
Application1.4L DOHC1.6L DOHC1.8L DOHC
Ignition TypeDirect Ignition System


Ignition Timing (BTDC)4°5°

Ignition Sequence1–3–4–2


Spark Plug Gap1.0 ~ 1.1 mm
(0.039 ~ 0.043 in.)
0.9 ~ 1.1 mm
(0.035 ~ 0.043 in.)
Spark Plug MakerWoojin
Boach
Spark Plug TypeBKR6E–11
FLR8LDCU
Clutch
Application1.4L DOHC1.6L DOHC1.8L DOHC
TypeSingle Dry Plate


Outside Diameter215 mm (8.5 in.)


Inside Diameter145 mm (5.7 in.)


Thickness8.4 mm (0.331 in.)


FluidCommon Use:
Brake Fluid


Manual Transaxle
Application1.4L DOHC1.6L DOHC1.8L DOHC
MakerGMDATGMDAT

Type or ModelD–16 (C/R)D–16 (C/R)

Gear Ratio :
1st
2nd
3rd
4th
5th
Reverse3.818 : 1
2.158 : 1
1.478 : 1
1.129 : 1
0.886 : 1
3.333 : 13.545 : 1
2.158 : 1
1.478 : 1
1.129 : 1
0.886 : 1
3.333 : 1











Final Drive Ratio3.722 : 13.722 : 1

Oil Capacity1.8L (2 qts)

GENERAL INFORMATION 0B – 3
DAEWOO V–121 BL4
Automatic Transaxle
Application1.4L DOHC1.6L DOHC1.8L DOHC
Maker–AISINZF
Type or Model–81–40LE4HP16
Gear Ratio :
1st
2nd
3rd
4th
Reverse–
–
–
–
–2.875:1
1.568:1
1.000:1
0.697:1
2.300:12.719:1
1.487:1
1.000:1
0.717:1
2.529:1
Final Drive Ratio–3.750:13.945:1
Oil Capacity–5.77±0.2L (6.1±0.2 qts)6.9±0.2L (7.3±0.2 qts)
Brake
Application1.4L DOHC1.6L DOHC1.8L DOHC
Booster Size :
Single
Dual241.3 mm (9.5 in.)
177.8 and 203.2 mm
(7 and 8 in.)






Master Cylinder Diameter22.22 mm (0.875 in.)


Booster Ratio5.5 : 1


Front Brake :
Disc Type
Disc SizeVentilated
256 mm (10 in.)






Rear Brake (Drum) :
Drum Inside Diameter
Wheel Cylinder Diame-
ter200 mm (7.9 in.)
20.64 mm (0.813 in.)






Rear Brake (Disc) :
Disc Type
Disc SizeSolid
258 mm (10.2 in.)






Fluid Capacity0.5L (0.5 qts)


Tire and Wheel
Application1.4L DOHC1.6L DOHC1.8L DOHC
Tire Size195/55R15


Standard Wheel Size6Jx15 (Steel)


Optional Wheel Size6Jx15 (Alloy)


Inflation Pressure at Full
Load30 psi (207 kPa)

0B – 4IGENERAL INFORMATION
DAEWOO V–121 BL4
Steering System
Application1.4L DOHC1.6L DOHC1.8L DOHC
Gear TypePower
Rack and Pinion


Overall Gear Ratio
Power Steering16 : 1


Wheel Diameter
W/ Air Bag
W/O Air Bag380 mm (15.0 in.)
370 mm (14.5 in.)






Wheel Alignment :
Front :
Toe–In
Caster
Camber0° ± 10’
4° ± 45’
20’ ± 45’










Rear :
Toe–In
Camber
12’ ± 10’
–1° ± 45’






Oil Capacity1.1L (1.2 qts)


Suspension
Application1.4L DOHC1.6L DOHC1.8L DOHC
Front TypeMacpherson Strut


Rear TypeDual Link


Fuel System
Application1.4L DOHC1.6L DOHC1.8L DOHC
Fuel DeliveryMPI


Fuel Pump TypeElectric Motor Pump


Fuel Filter TypeCartridge


Fuel Capacity60L (15.85 gal)


Lubricating System
Application1.4L DOHC1.6L DOHC1.8L DOHC
Lubricating TypeForced Feed


Oil Pump TypeRotary (Trochoid)


Oil Filter TypeCartridge (Full Flow)


Oil Pan Capacity
Including Oil Filter3.75L (4 qts)
4.0L (4.2 qts)

GENERAL INFORMATION 0B – 9
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
MAINTENANCE AND LUBRICATION
NORMAL VEHICLE USE
The maintenance instructions contained in the mainte-
nance schedule are based on the assumption that the ve-
hicle will be used for the following reasons:
S To carry passengers and cargo within the limitation
indicated on the tire placard located on the edge of
the driver’s door.
S To be driven on reasonable road surfaces and with-
in legal operating limits.
EXPLANATION OF SCHEDULED
MAINTENANCE SERVICES
The services listed in the maintenance schedule are fur-
ther explained below. When the following maintenance
services are performed, make sure all the parts are re-
placed and all the necessary repairs are done before driv-
ing the vehicle. Always use the proper fluid and lubricants.
Drive Belt Inspection
When a separate belt drives the power steering pump, the
air conditioning compressor and the generator, inspect it
for cracks, fraying, wear and proper tension. Adjust or re-
place the belt as needed.
Engine Oil and Oil Filter Change
API Classifications of Engine Oil
The International Lubricant Standardization and Approval
Committee (ILSAC) and American Petroleum Institute
classifies engine oils according to their performance quali-
ty. Always use oil rated API–SL (ILSAC GF–III) or better.
Engine Oil Viscosity
Engine oil viscosity (thickness) has an effect on fuel econ-
omy and cold weather operation. Lower viscosity engine
oils can provide better fuel economy and cold weather per-
formance; however, higher temperature weather condi-
tions require higher viscosity engine oils for satisfactory lu-
brication. Using oils of any viscosity other than those
viscosities recommended could result in engine damage.
Cooling System Service
Drain, flush and refill the system with new coolant. Refer
to ”Recommended Fluids And Lubricants” in this section.
Fuel Micro–Filter Replacement
Replace the engine fuel filter every 45,000 km (27,000
miles).
Air Cleaner Element Replacement
Replace the air cleaner element every 45,000 km (27,000
miles).Replace the air cleaner more often under dusty conditions.
Throttle Body Mounting Bolt Torque
Check the torque of the mounting bolts.
Tighten the throttle body mounting bolts to 15 NSm (11 lb–
ft) if necessary.
Spark Plug Replacement
Replace spark plugs with the same type.
Spark Plug Wire Replacement
Clean wires and inspect them for burns, cracks or other
damage. Check the wire boot fit at the DIS module and at
the spark plugs. Replace the wires as needed.
Brake System Service
Check the disc brake pads and the drum brake linings ev-
ery 15,000 km (9,000 miles) or 12 months. Check the pad
and the lining thickness carefully. If the pads or the linings
are not expected to last to the next scheduledmaintenance
service, replace the pads or the linings. Check the breath-
er hole in the brake fluid reservoir cap to be sure it is free
from dirt and the passage is open.
Transaxle Service
The manual transaxle fluid does not require changing. For
automatic transaxles, refer to ”Scheduled Maintenance
Charts” in this section.
Tire and Wheel Inspection and Rotation
Check the tires for abnormal wear or damage. To equalize
wear and obtain maximum tire life, rotate the tires. If irreg-
ular or premature wear exists, check the wheel alignment
and check for damaged wheels. While the tires and
wheels are removed, inspect the brakes. Refer to ”Each
Time The Oil Is Changed” in this section.
Tire Rotation

0B – 14IGENERAL INFORMATION
DAEWOO V–121 BL4
Engine Cooling System
Inspect the coolant and freeze protection fluid. If the fluid
is dirty or rusty, drain, flush and refill the engine cooling
system with new coolant. Keep the coolant at the proper
mixture in order to ensure proper freeze protection, corro-sion protection and engine operating temperature. Inspect
the hoses. Replace the cracked, swollen, or deteriorated
hoses. Tighten the clamps. Clean the outside of the radia-
tor and the air conditioning condenser. Wash the filler cap
and the neck. Pressure test the cooling system and the
cap in order to help ensure proper operation.
RECOMMENDED FLUIDS AND LUBRICANTS
UsageCapacityFluid/Lubricant
Engine Oil3.75L (4.0 qt) : 1.4L DOHC
3.75L (4.0 qt) : 1.6L DOHC
4.0L (4.2 qt) : 1.8L DOHCAPI SL (ILSAC GF–III) grade or better
SAE 5W–30, SAE10W–30, SAE15W–40
(Cold area : SAE5W–30
Hot area : SAE 15W–40)
Engine Coolant7.0L (7.49 qt) : 1.4L DOHC
7.2L (7.6 qt) : 1.6L DOHC
7.4L (7.8 qt) : 1.8L DOHCMixture of water and good quality ethylene gly-
col base antifreeze (year–round coolant)
Brake Fluid and Clutch Fluid0.5L (0.5 qt)DOT–3 or DOT–4
Power Steering System1.1L (1.2 qt)DEXRON®–III or DEXRON®–IID
Automatic Transaxle5.77 ± 0.2L (6.1 ± 0.2 qts) :
1.6L DOHC (AISIN 81–40LE)ESSO JWS 3309 or ISU DEXRON III
6.9 ± 0.2L (7.3 ± 0.2 qts) :
1.8L DOHC (ZF 4HP16)ESSO LT 71141 or TOTAL ATF H50235
Manual Transaxle1.8L (2.0 qt)Manual Transaxle Fluid
SAE80W (Cold Area : SAE 75W)
Manual Transaxle Shift LinkageAs requiredMultipurpose type grease meeting require-
ments NLGI No. 1 or 2
Key Lock CylindersAs requiredSilicone lubricant
Automatic Transaxle Shift Link-
ageAs requiredEngine oil
Clutch Linkage Pivot PointsAs requiredEngine oil
Floor Shift Linkage PointsAs requiredEngine oil
Hood Latch Assembly
a. Pivots and Spring Anchor
b. Release PawlAs requireda. Engine oil
b. Multipurpose type grease meeting require-
ments NLGI No. 1 or 2
Hood and door hinges
Fuel door hinge
Rear compartment lid hingesAs requiredEngine oil
WeatherstripsAs requiredSilicone grease

SECTION : 1A
GENERAL ENGINE INFORMATION
TABLE OF CONTENTS
DIAGNOSIS1A–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compression Test 1A–1. . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Test 1A–2. . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Leak Diagnosis 1A–3. . . . . . . . . . . . . . . . . . . . . . . .
Knock Diagnosis 1A–4. . . . . . . . . . . . . . . . . . . . . . . . . . Noise Diagnosis 1A–8. . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION1A–11 . . . . . . . . . . . . . . . . . .
Cleanliness and Care 1A–11. . . . . . . . . . . . . . . . . . . . .
On–Engine Service 1A–11. . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS
COMPRESSION TEST
Important : Disconnect the Crankshaft Position (CKP)
Sensor connector to disable the fuel and the ignition sys-
tems.
Test the compression pressure for each cylinder. Low
compression pressure may be the fault of the valves or the
pistons. The following conditions should be considered
when you check the cylinder compression:
S The engine should be at normal operating tempera-
ture.
S The throttle must be wide open.
S All the spark plugs should be removed.
S The battery must be at or near full charge.
1. Place approximately three squirts of oil from a
plunger– type oiler into each spark plug port.
2. Insert the engine compression gauge into each
spark plug port.
3. Crank test each cylinder with four to five compres-
sion strokes using the starter motor.4. The lowest reading should not be less than 70% of
the highest reading. The compression gauge read-
ing should not be less than 689 kPa (100 psi) for
any of the cylinders.
5. Examine the gauge readings obtained after the four
”puffs” per cylinder are obtained from cranking the
starter motor. The readings are explained in the
following descriptions:
S Normal Condition – Compression builds up quickly
and evenly to the specified compression on each
cylinder.
S Piston Rings Faulty – Compression is low on the
first stroke and tends to build up on following
strokes, but the compression pressure does not
reach normal. The compression pressure improves
considerably with the addition of oil into the cylin-
der.
S Valves Faulty – Low compression pressure on the
first stroke. The compression pressure does not
tend to build up on the following strokes. The com-
pression pressure does not improve much with the
addition of oil into the cylinder.

GENERAL ENGINE INFORMATION 1A – 3
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
20Inspect the bearing clearances.
Are the bearing clearances more than the specified
values?Crankshaft
0.026 ~0.046
mm
(0.0010~0.001
8 in.)
Connecting
Rod 0.019 ~
0.070 mm
(0.0007 ~
0.0027 in.)Go to Step 21Go to Step 22
21Replace the bearing, if necessary.
Is the repair complete?–Go to Step 1–
22Inspect the oil galleries.
Are the oil galleries cracked, porous, or plugged?–Go to Step 23Go to Step 24
23Repair or replace the engine block.
Is the repair complete?–Go to Step 1–
24Inspect the gallery plugs.
Are any of the gallery plugs missing or installed im-
properly?–Go to Step 25Go to Step 26
25Install the plugs or repair, as necessary.
Is the repair complete?–Go to Step 1–
26Inspect the camshaft.
Is the camshaft worn or is there evidence of poor
machining?–Go to Step 27System OK
27Replace the camshaft.
Is the repair complete?–Go to Step 1–
OIL LEAK DIAGNOSIS
Most fluid oil leaks are easily located and repaired by visu-
ally finding the leak and replacing or repairing the neces-
sary parts. On some occasions, a fluid leak may be difficult
to locate or repair. The following procedures may help you
in locating and repairing most leaks.
Finding the Leak:
1. Identify the fluid. Determine whether it is engine oil,
automatic transmission fluid, power steering fluid,
etc.
2. Identify where the fluid is leaking from.
1) After running the vehicle at normal operating
temperature, park the vehicle over a large sheet
of paper.
2) Wait a few minutes.
3) Find the approximate location of the leak by the
drippings on the paper.
3. Visually check around the suspected component.
Check around all the gasket mating surfaces for
leaks. A mirror is useful for finding leaks in areas
that are hard to reach.
4. If the leak still cannot be found, it may be neces-
sary to clean the suspected area with a degreaser,
steam, or spray solvent.
1) Thoroughly clean the area.2) Dry the area.
3) Operate the vehicle for several miles at normal
operating temperature and varying speeds.
4) After operating the vehicle, visually check the
suspected component.
5) If you still cannot locate the leak, try using the
powder or black light and dye method.
Powder Method:
1. Clean the suspected area.
2. Apply an aerosol–type powder, (such as foot pow-
der), to the suspected area.
3. Operate the vehicle under normal operating condi-
tions.
4. Visually inspect the suspected component. Trace
the leak path over the white powder surface to the
source.
Black Light and Dye Method:
A dye and light kit is available for finding leaks. Refer to the
manufacturer ’s directions when using the kit.
1. Pour the specified amount of dye into the engine oil
fill tube.
2. Operate the vehicle under normal operating condi-
tions as directed in the kit.
3. Direct the light toward the suspected area. The
dyed fluid will appear as a yellow path leading to
the source.

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 77
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
CYLINDER HEAD AND GASKET
The cylinder head is made of an aluminum alloy. The cylin-
der head uses cross–flow intake and exhaust ports. A
spark plug is located in the center of each combustion
chamber. The cylinder head houses the dual camshafts.
CRANKSHAFT
The crankshaft has eight integral weights which are cast
with it for balancing. Oil holes run through the center of the
crankshaft to supply oil to the connecting rods, the bear-
ings, the pistons, and the other components. The end
thrust load is taken by the thrust washers installed at the
center journal.
TIMING BELT
The timing belt coordinates the crankshaft and the dual
overhead camshafts and keeps them synchronized. The
timing belt also turns the water pump. The timing belt and
the pulleys are toothed so that there is no slippage be-
tween them. There are two idler pulleys. An automatic ten-
sioner pulley maintains the timing belt’s correct tension.
The timing belt is made of a tough reinforced rubber similar
to that used on the serpentine accessory drive belt. The
timing belt requires no lubrication.
OIL PUMP
The oil pump draws engine oil from the oil pan and feeds
it under pressure to the various parts of the engine. An oil
strainer is mounted before the inlet of the oil pump to re-
move impurities which could clog or damage the oil pump
or other engine components. When the drive gear rotates,
the driven gear rotates. This causes the space between
the gears to constantly open and narrow, pulling oil in from
the oil pan when the space opens and pumping the oil out
to the engine as it narrows.
At high engine speeds, the oil pump supplies a much high-
er amount of oil than is required for lubrication of the en-
gine. The oil pressure regulator prevents too much oil from
entering the engine lubrication passages. During normal
oil supply, a coil spring and valve keep the bypass closed,
directing all of the oil pumped to the engine. When the
amount of oil being pumped increases, the pressure be-
comes high enough to overcome the force of the spring.This opens the valve of the oil pressure regulator, allowing
the excess oil to flow through the valve and drain back to
the oil pan.
OIL PAN
The engine oil pan is mounted to the bottom of the cylinder
block. The engine oil pan houses the crankcase and is
made of cast metal.
Engine oil is pumped from the oil pan by the oil pump. After
it passes through the oil filter, it is fed through two paths
to lubricate the cylinder block and the cylinder head. In one
path, the oil is pumped through the oil passages in the
crankshaft to the connecting rods, then to the pistons and
the cylinders. It then drains back to the oil pan. In the sec-
ond path, the oil is pumped through the oil passages to the
camshaft. The oil passes through the internal passage-
ways in the camshafts to lubricate the valve assemblies
before draining back to the oil pan.
EXHAUST MANIFOLD
A single four–port, rear–takedown manifold is used with
this engine. The manifold is designed to direct escaping
exhaust gases out of the combustion chambers with a
minimum of back pressure. The oxygen sensor is
mounted to the exhaust manifold.
INTAKE MANIFOLD
The intake manifold has four independent long ports and
uses inertial supercharging to improve engine torque at
low and moderate speeds. The plenum is attached to the
intake manifold.
CAMSHAFTS
This engine is a dual overhead camshaft (DOHC) type,
which means there are two camshafts. One camshaft op-
erates the intake valves, and the other camshaft operates
the exhaust valves. The camshafts sit in journals on the
top of the engine in the cylinder head and are held in place
by camshaft caps. The camshaft journals of the cylinder
head are drilled to create oil passages. Engine oil travels
to the camshafts under pressure where it lubricates each
camshaft journal. The oil returns to the oil pan through
drain holes in the cylinder head. The camshaft lobes are
machined into the solid camshaft to open and close the in-
take and the exhaust valves precisely the correct amount
at the correct time. The camshaft lobes are oiled by splash
action from pressurized oil escaping from the camshaft
journals.