Daewoo Nubira. Manual - part 157

1C – 86

I

DOHC ENGINE MECHANICAL

DAEWOO V–121 BL4

35.  Install the rear timing belt cover.
36.  Install the rear timing belt cover bolts.

Tighten

Tighten the rear timing belt cover bolts to 7 N

S

m (62

lb–in).

37.  Install the crankshaft timing belt drive gear and the

bolt.

Tighten

Tighten the crankshaft timing belt drive gear bolt to
135 N

S

m (100 lb–ft) plus 30

³

 to 10

³

 using the torque

angular gauge KM–470–B.

38.  Install the engine mount and the retaining bolts.

Tighten

Tighten the engine mount retaining bolts to 60 N

S

m

(44 lb–ft).

39.  Install the timing belt automatic tensioner.
40.  Install the timing belt automatic tensioner bolts.

Tighten

Tighten the timing belt automatic tensioner bolts to 25
N

S

m (18 lb–ft).

41.  Install the timing belt idler pulley.
42.  Install the timing belt idler pulley bolt and nut.

Tighten

Tighten the timing belt idler pulley bolt to 25 N·m (18
lb–ft).

Tighten

Tighten the timing belt idler pulley nut to 25 N

S

m (18

lb–ft).

Notice : Take extreme care to prevent any scratches,
nicks or damage to the camshafts.

43.  Install the intake camshaft gear.
44.  Install the intake camshaft gear bolt while holding

the intake camshaft firmly in place.

Tighten

Tighten the intake camshaft gear bolt to 50 N

S

m (37

lb–ft).

45.  Install the exhaust camshaft gear.
46.  Install the exhaust camshaft gear bolt while holding

the exhaust camshaft firmly in place.

Tighten

Tighten the exhaust camshaft gear bolt to 50 N

S

m (37

lb–ft). Using the angular torque gauge KM–470–B,
tighten the intake and the exhaust camshaft gear
bolts another 60 degrees plus 15 degrees.

DOHC ENGINE MECHANICAL  1C – 87

DAEWOO V–121 BL4

47.  Install the timing belt. Refer to ”Timing Belt” in this

section.

48.  Adjust the timing belt tension. Refer to ”Timing Belt

Check and Adjust” in this section.

49.  Apply a small amount of gasket sealant to the cor-

ners of the front camshaft caps and to the top of
the rear valve cover to cylinder head seal.

50.  Install the valve cover and the valve cover gasket.
51.  Install the valve cover washers.
52.  Install the valve cover bolts.

Tighten

Tighten the valve cover bolts to 8 N

S

m (71 lb–in).

53.  Connect the ignition wires to the spark plugs.
54.  Install the spark plug cover.
55.  Install the spark plug cover bolts.

Tighten

Tighten the spark plug cover bolts to 8 N

S

m (71 lb–in).

56.  Connect the crankcase breather tube to the valve

cover.

57.  Install the front timing belt cover.
58.  Install the front timing belt cover bolts.

Tighten

Tighten the front timing belt cover bolts to 6 N

S

m (53

lb–in).

59.  Install the engine lifting device.
60.  Remove the engine from the engine overhaul stand

KM–412.

61.  Install a new crankshaft rear oil seal using installer

J–36972 (or KM–635).

1C – 88

I

DOHC ENGINE MECHANICAL

DAEWOO V–121 BL4

62.  Install the flywheel or flexible plate.
63.  Install the flywheel or the flexible plate bolts.

Tighten

Tighten the flywheel bolts to 65 N

S

m (48 lb–ft). Use

the angular torque gauge KM–470–B to tighten the
flywheel bolts to 30 degrees plus 15 degrees. For the
automatic transmission, tighten the flexible plate bolts
to 65 N

S

m (48 lb–ft).

64.  Install the engine. Refer to ”Engine”in this section.

CRANKSHAFT BEARINGS AND
CONNECTING ROD BEARINGS –
GAUGING PLASTIC

Tools Required

KM–470–B Angular Torque Gauge

Inspection Procedure – Crankshaft

1.  Coat the crankshaft bearings with engine oil.
2.  Install the upper crankshaft bearings into the engine

block crankshaft journals.

3.  Install the lower crankshaft bearings into the crank-

shaft bearing caps.

4.  Install the crankshaft.
5.  Inspect the crankshaft end play with the crankshaft

bearings installed.

6.  Check for permissible crankshaft end play. Refer to

”Engine Specifications”in this section.

7.  With the crankshaft mounted on the front and rear

crankshaft bearings, check the middle crankshaft
journal for permissible out–of–round (runout). Refer
to ”Engine Specifications”in this section.

DOHC ENGINE MECHANICAL  1C – 89

DAEWOO V–121 BL4

Important : Grease the crankshaft journals and lubricate
the crankshaft bearings slightly so that the plastic gauging
thread does not tear when the crankshaft bearing caps are
removed.

8.  Inspect all of the crankshaft bearing clearances us-

ing a commercially available plastic gauging (ductile
plastic threads).

9.  Cut the plastic gauging threads to the length of the

bearing width. Lay them axially between the crank-
shaft journals and the crankshaft bearings.

10.  Install the crankshaft bearing caps.
11.  Install the crankshaft bearing cap bolts.

Tighten

Tighten the crankshaft bearing cap bolts to 50 N

S

m

(37 lb–ft). Using the angular torque gauge
KM–470–B, tighten the crankshaft bearing cap bolts
to +45 degrees +15 degrees.

12.  Remove the crankshaft bearing caps.
13.  Measure the width of the flattened plastic thread of

the plastic gauging using a ruler. (Plastic gauging is
available for different tolerance ranges.)

14.  Inspect the bearing clearances for permissible toler-

ance ranges. Refer to ”Engine Specifications”in this
section.