Daewoo CIELO EURO III Operator Manual

SECTION 1

ENGINE CIELO EURO III

SECTION 1A

GENERAL ENGINE INFORMATION

TABLE OF CONTENTS

Diagnosis 1A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compression Test 1A-1. . . . . . . . . . . . . . . . . . . . . . . . .

Oil Pressure Test 1A-2. . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Leak Diagnosis 1A-3. . . . . . . . . . . . . . . . . . . . . . . .

Knock Diagnosis 1A-4. . . . . . . . . . . . . . . . . . . . . . . . . .

DIAGNOSIS

COMPRESSION TEST

Important: Disconnect the Crankshaft Position (CKP)

Sensor connector to disable the fuel and the ignition systems.

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:

D The engine should be at normal operating tempera-

ture.

D The throttle must be wide open.

D All the spark plugs should be removed.

D 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 compression strokes using the starter motor.

Noise Diagnosis 1A-8. . . . . . . . . . . . . . . . . . . . . . . . . . .

General Information 1A-11. . . . . . . . . . . . . . . . . . . . . . .

Cleanliness and Care 1A-11. . . . . . . . . . . . . . . . . . . . .

On-Engine Service 1A-11. . . . . . . . . . . . . . . . . . . . . . .

4. The lowest reading should not be less than 70% of the highest reading. The compression gauge reading 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:

D Normal Condition – Compression builds up quickly

and evenly to the specified compression on each cylinder.

D 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 cylinder.

D Valves Faulty – Low compression pressure on the

first stroke. The compression pressure does not tend to build up on the following strokes. The compression pressure does not improve much with the addition of oil into the cylinder.

DAEWOO T-154 BL2,3

1A – 2 GENERAL ENGINE INFORMATION

OIL PRESSURE TEST

Step

Action

Value(s)

Yes

1 Is low or no oil pressure indicated? – Go to Step 2 System OK

Check the oil level in the crankcase. Is the level low?

– Go to Step 3 Go to Step 4

Add oil so that the oil level is up to the full mark on

the indicator. Is the repair complete?

–

Go to Step 1

Check the idle speed. Is the idle speed below the specified value? 825 rpm Go to Step 5 Go to Step 6

Increase the idle speed. Is the speed increased?

– Go to Step 1 –

Inspect the oil pressure switch.

Is the oil pressure switch incorrect or malfunctioning?

–

Go to Step 7 Go to Step 8

Install a new oil pressure switch. Is the repair complete? – Go to Step 1 –

Inspect the oil pressure gauge.

Is the oil pressure gauge incorrect or malfunctioning?

–

Go to Step 9 Go to Step 10

Install a new oil pressure gauge. Is the repair complete? – Go to Step 1 –

Inspect the engine oil.

Is the engine oil in the crankcase diluted or of the improper viscosity?

–

Go to Step 11 Go to Step 12

Install new engine oil of the proper viscosity for the

expected temperatures. Is the repair complete?

–

Go to Step 1

Inspect the oil pump. Is the pump worn or dirty?

– Go to Step 13 Go to Step 14

Replace the oil pump. Is the repair complete? – Go to Step 1 –

Inspect the oil filter. Is the oil filter plugged?

– Go to Step 15 Go to Step 16

Install a new oil filter. Is the repair complete? – Go to Step 1 –

Inspect the oil pickup screen. Is the oil pickup screen loose or plugged?

– Go to Step 17 Go to Step 18

–

Tighten or replace the oil pickup screen, as

necessary. Is the repair complete?

–

Go to Step 1

Inspect the oil pickup tube. Are there any holes in the oil pickup tube? – Go to Step 19 Go to Step 20

Replace the oil pickup tube. Is the repair complete?

– Go to Step 1 –

DAEWOO T-154 BL2,3

GENERAL ENGINE INFORMATION 1A – 3

OIL PRESSURE TEST (CONT’D)

Step

Action

Inspect the bearing clearances. Are the bearing clearances more than the specified

values?

Replace the bearing, if necessary. Is the repair complete? – Go to Step 1 –

Inspect the oil galleries. Are the oil galleries cracked, porous or plugged?

Repair or replace the engine block. Is the repair complete? – Go to Step 1 –

Inspect the gallery plugs. Are any of the gallery plugs missing or installed

improperly?

Install the plugs or repair them, as necessary. Is the repair complete?

Inspect the camshaft. Is the camshaft worn or is there evidence of poor

machining?

Replace the camshaft. Is the repair complete? – Go to Step 1 –

Value(s)

Crankshaft

0.005 mm (0.002 in.)

Connecting

Rod

0.019 X

0.070 mm

(0.0007 X

0.0027 in.)

– Go to Step 23 Go to Step 24

–

– Go to Step 1 –

–

Yes

Go to Step 21 Go to Step 22

Go to Step 25 Go to Step 26

Go to Step 27 System OK

OIL LEAK DIAGNOSIS

Most fluid oil leaks are easily located and repaired by visually finding the leak and replacing or repairing the necessary 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.

2.1. After running the vehicle at normal operating temperature, park the vehicle over a large sheet of paper.

2.2. Wait a few minutes.

2.3. 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 necessary to clean the suspected area with a degreaser, steam, or spray solvent.

4.1. Thoroughly clean the area.

4.2. Dry the area.

4.3. Operate the vehicle for several miles at normal operating temperature and varying speeds.

4.4. After operating the vehicle, visually check the suspected component.

4.5. 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 powder), to the suspected area.

3. Operate the vehicle under normal operating conditions.

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 conditions as directed in the kit.

DAEWOO T-154 BL2,3

1A – 4 GENERAL ENGINE INFORMATION

3. Direct the light toward the suspected area. The dyed fluid will appear as a yellow path leading to the source.

Repairing the Leak

Once the origin of the leak has been pinpointed and traced back to its source, the cause of the leak must be determined in order for it to be repaired properly. If a gasket is replaced, but the sealing flange is bent, the new gasket will not repair the leak. The bent flange must be repaired also. Before attempting to repair a leak, check for the following conditions and correct them as they may cause a leak.

Gaskets:

D The fluid level/pressure is too high.

D The crankcase ventilation system is malfunctioning.

D The fasteners are improperly tightened or the threads

are dirty or damaged.

KNOCK DIAGNOSIS

Definition for Knock

Engine knock refers to various types of engine noise. Heavy knock is usually very loud and the result of broken or excessively worn internal engine components. Light

D The flanges or the sealing surface is warped.

D There are scratches, burrs or other damage to the

sealing surface.

D The gasket is damaged or worn.

D There is cracking or porosity of the component.

D An improper seal was used, (where applicable).

Seals:

D The fluid level/pressure is too high.

D The crankcase ventilation system is malfunctioning.

D The seal bore is damaged, scratched, burred or

nicked.

D The seal is damaged or worn.

D Improper installation is evident.

D There are cracks in the component.

D The shaft surface is scratched, nicked or damaged.

D A loose or worn bearing is causing excess seal wear.

knock is a noticeable noise, but not as loud. Light knock can be caused by worn internal engine components. Loose or broken external engine components can also cause heavy or light knock.

Engine Knocks Cold and Continues for Two-Three Minutes

and/or Knock Increases with Engine Torque

Step

ÜÜ

Does the engine knock when it is cold and continue

ЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬ

for two to three minutes or does the knock increase with torque?

ЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬ

Inspect the flywheel. Is the flywheel contacting the splash shield?

ЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬ

Reposition the splash shield. Is the repair complete?

Inspect the balancer and the drive pulleys.

ЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬ

Is either the balancer or the drive pulleys loose or

ЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬ

broken?

Tighten or replace the balancer or the drive pulleys. Is the repair complete?

ЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬ

Inspect the piston-to-bore clearance. Is the clearance more than the specified value?

ЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬ

1. Rebore the cylinder and hone to size.

ÜÜ

2. Replace the piston.

ЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬ

Is the repair complete?*

Inspect the connecting rod.

ЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬ

Is the connecting rod bent?

Replace the connecting rod.

ЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬ

Is the repair complete?

* Cold engine piston knock usually disappears when the cylinder is grounded out. Cold engine piston knock,

which disappears in about 1.5 minutes, is considered acceptable.

ЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬ

Action

Value(s)

ÜÜÜ

–

ÜÜÜ

–

ÜÜÜ

–

ÜÜÜ

–

ÜÜÜ

–

0.030 mm (0.001 in.)

ÜÜÜ

–

ÜÜÜ

–

ÜÜÜ

–

Yes

ЬЬЬЬЬ

Go to Step 2

ЬЬЬЬЬ

Go to Step 3

ЬЬЬЬЬ

Go to Step 1

ЬЬЬЬЬ

Go to Step 5

ЬЬЬЬЬ

Go to Step 1

Go to Step 7

ЬЬЬЬЬ

Go to Step 1

ЬЬЬЬЬ

Go to Step 9

ЬЬЬЬЬ

Go to Step 1

ÜÜÜÜ

System OK

ÜÜÜÜ

Go to Step 4

ÜÜÜÜ

–

ÜÜÜÜ

Go to Step 6

ÜÜÜÜ

–

Go to Step 8

ÜÜÜÜ

–

ÜÜÜÜ

System OK

ÜÜÜÜ

–

DAEWOO T-154 BL2,3

GENERAL ENGINE INFORMATION 1A – 5

Heavy Knock Hot with Torque Applied

Step

ÜÜ

Action

Is there a heavy knock when the engine is hot and torque is applied?

Inspect the balancer and pulley hub.

ЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬ

Is the balancer or pulley hub broken?

Replace the broken balancer or pulley hub.

ЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬ

Is the repair complete?

Inspect the torque converter bolts.

ЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬ

Are the bolts tightened to the specified value?

Tighten the torque converter bolts.

ЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬ

Is the repair complete?

Inspect the accessory belts. Are the belts too tight or nicked?

ЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬ

Replace and/or tension the belts to specifications, as necessary.

ЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬ

Is the repair complete?

Inspect the exhaust system.

ЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬ

Is the system grounded?

Reposition the system, as necessary.

ЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬ

Is the repair complete?

Inspect the flywheel.

ЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬ

Is the flywheel cracked?

Replace the flywheel. Is the repair complete?

ЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬ

Inspect the main bearing clearance. Is the clearance more than the specified value?

Replace the main bearings, as necessary.

ЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬ

Is the repair complete?

Inspect the rod bearing clearance.

ЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬ

Is the clearance more than the specified value?

ЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬ

Replace the rod bearings, as necessary.

ЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬ

Is the repair complete?

Value(s)

–

ÜÜÜ

–

ÜÜÜ

–

45 NSm

ÜÜÜ

(33 lb-ft)

ÜÜÜ

–

ÜÜÜ

–

ÜÜÜ

–

ÜÜÜ

–

ÜÜÜ

–

ÜÜÜ

0.050 mm (0.002 in.)

ÜÜÜ

–

0.019 X

ÜÜÜ

0.070 mm

(0.0007 X

ÜÜÜ

0.0028 in.)

ÜÜÜ

–

Yes

Go to Step 2

ЬЬЬЬЬ

Go to Step 3

ЬЬЬЬЬ

Go to Step 1

ЬЬЬЬЬ

Go to Step 5

ЬЬЬЬЬ

Go to Step 1

Go to Step 7

ЬЬЬЬЬ

Go to Step 1

ЬЬЬЬЬ

Go to Step 9

ЬЬЬЬЬ

Go to Step 1

ЬЬЬЬЬ

Go to Step 11

Go to Step 1

ЬЬЬЬЬ

Go to Step 13

ЬЬЬЬЬ

Go to Step 1

ЬЬЬЬЬ

Go to Step 15

ЬЬЬЬЬ

Go to Step 1

System OK

ÜÜÜÜ

Go to Step 4

ÜÜÜÜ

–

ÜÜÜÜ

Go to Step 6

ÜÜÜÜ

–

Go to Step 8

ÜÜÜÜ

–

ÜÜÜÜ

Go to Step 10

ÜÜÜÜ

–

ÜÜÜÜ

Go to Step 12

–

ÜÜÜÜ

Go to Step 14

ÜÜÜÜ

–

ÜÜÜÜ

System OK

ÜÜÜÜ

–

DAEWOO T-154 BL2,3

1A – 6 GENERAL ENGINE INFORMATION

Light Knock Hot

Step

ÜÜ

Action

Is there a light knock when the engine is hot?

Is detonation or spark knock evident?

Value(s)

–

Yes

Go to Step 2

Go to Step 3

System OK

Go to Step 4

Check the engine timing and the fuel quality. Was the problem found?

ЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬ

Inspect the torque converter bolts. Are the bolts tightened to the specified value?

–

ÜÜÜ

45 NSm

(33 lb-ft)

Go to Step 1

ЬЬЬЬЬ

ÜÜÜÜ

Go to Step 5 Go to Step 6

–

Tighten the torque converter bolts. Is the repair complete?

– Go to Step 1 –

Inspect the manifold. Is there an exhaust leak at the manifold? – Go to Step 7 Go to Step 8

Tighten the bolts or replace the gasket. Is the repair complete? – Go to Step 1 –

Check the rod bearing clearance. Is the clearance within the specified value?

0.019 X

0.070 mm

(0.0007 X

0.0028 in.) Go to Step 9 System OK

Replace the rod bearings as necessary. Is the repair complete? – Go to Step 1 –

Knocks During Initial Start-Up But Last Only a Few Seconds

Step

Does the engine knock during initial start-up but last only a few seconds?

Check the engine oil. Is the proper viscosity oil used in the crankcase? – Go to Step 4 Go to Step 3

Action

Value(s)

Yes

– Go to Step 2 System OK

Install oil of the proper viscosity for the expected

seasonal temperatures. Is the repair complete?

Inspect the hydraulic lifters. Is there evidence of hydraulic lifter bleed-down? – Go to Step 5 Go to Step 6

Clean, test and replace the lifters, as necessary. Is the repair complete?*

Inspect the crankshaft end clearance. Is the clearance more than specified value?

Replace the crankshaft thrust bearing. Is the repair complete? – Go to Step 1 –

Inspect the front main bearing clearance. Is the clearance more than the specified value?

Replace the worn parts of the front main bearing. Is the repair complete?

–

Go to Step 1

– Go to Step 1 –

0.1 mm

(0.0039 in.)

Go to Step 7 Go to Step 8

0.005 mm

(0.0001 in.)

Go to Step 9 System OK

– Go to Step 1 –

–

* When the engine is stopped, some valves will be open. Spring pressure against the lifters will tend to bleed

lifter down. Attempts to repair this should be made only if the problem is consistent.

ЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬ

An engine that is only operated for short periods between start-ups may have lifter noise that lasts for a few

ЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬЬ

minutes. This is a normal condition.

DAEWOO T-154 BL2,3

GENERAL ENGINE INFORMATION 1A – 7

Knocks at Idle Hot

Step

Action

Value(s)

Yes

1 Does the engine knock at idle when hot? – Go to Step 2 System OK

Inspect the drive belts. Are the belts loose or worn? – Go to Step 3 Go to Step 4

Tension or replace the belts, as necessary. Is the repair complete?

– Go to Step 1 –

Inspect the A/C compressor and the generator. Is either the compressor or the generator faulty? – Go to Step 5 Go to Step 6

Replace the faulty A/C compressor or the generator. Is the repair complete?

– Go to Step 1 –

Inspect the valve train. Are valve train components faulty? – Go to Step 7 Go to Step 8

Replace faulty valve train components. Is the repair complete?

Check the engine oil. Is the proper viscosity oil used in the crankcase?

– Go to Step 1 –

–

Go to Step 10 Go to Step 9

Install oil of the proper viscosity for the expected

seasonal temperatures. Is the repair complete?

Inspect the piston pin clearance. Is the clearance more than the specified value?

–

0.020 mm

(0.0008 in.)

Go to Step 1

Go to Step 11 Go to Step 12

Replace the piston and the pin. Is the repair complete? – Go to Step 1 –

Check the connecting rod alignment. Is the alignment faulty?

– Go to Step 13 Go to Step 14

Check and replace the rods, as necessary. Is the repair complete? – Go to Step 1 –

Inspect the piston-to-bore clearance. Is the clearance within the specified value?

0.030 mm

(0.0012 in.) Go to Step 16 Go to Step 15

Hone the bore and fit a new piston. Is the repair complete?

– Go to Step 1 –

Inspect the crankshaft balancer. Is the balancer loose?

– Go to Step 17 Go to Step 18

Torque or replace worn parts. Is the repair complete? – Go to Step 1 –

Check the piston pin offset. Is the offset at the specified value?

0.5 X 0.7

mm (0.020 X

0.028 in.)

–

Toward Thrust

Side Go to Step 19 System OK

Install the correct piston. Is the repair complete? – Go to Step 1 –

DAEWOO T-154 BL2,3

1A – 8 GENERAL ENGINE INFORMATION

NOISE DIAGNOSIS

Main Bearing Noise

Step

Action

Are dull thuds or knocks heard with every engine revolution? – Go to Step 2 System OK

Check the oil pump pressure. Is the oil pump pressure low?

Inspect the crankshaft end play. Does the crankshaft end play exceed the specified

value?

Inspect the crankshaft journals. Are the crankshaft journals out-of-round?

Inspect the belt tension. Does the belt tension exceed the specified value?

Inspect the crankshaft pulley. Is the crankshaft pulley loose?

Value(s)

–

0.1 mm

(0.0039 in.)

0.004 mm

(0.0002 in.)

max.

–

Yes

Go to Oil

Pressure Test

Go to

Crankshaft

Replacement

Procedure

Go to

Crankshaft

Replacement

Procedure

Go to

Timing Belt

Replacement

Procedure Go to Step 6

Go to

Crankshaft

Replacement

Procedure

Go to Step 3

Go to Step 4

Go to Step 5

System OK

Connecting Rod Bearing Noise Symptom

Step

1 Is a knock noise heard under all engine speeds? – Go to Step 2 System OK

Inspect the crankshaft connecting rod journal.

Is the crankshaft connecting rod journal worn?

Check the oil pump pressure. Is the oil pump pressure low?

Inspect the crankshaft connecting rod journals. Are the journals out of round?

Inspect the connecting rods. Is there a misaligned connecting rod?

Inspect the connecting rod bolts. Are the connecting rod bolts torqued properly?

Action

Value(s)

–

Yes

Go to

Crankshaft

Replacement

Procedure Go to Step 3

Go to

Oil Pressure

Test Go to Step 4

Go to

Crankshaft

Replacement

Procedure Go to Step 5

Go to Pistons

and Rods

Replacement

Procedure Go to Step 6

System OK

Go to Pistons

and Rods

Replacement

Procedure

DAEWOO T-154 BL2,3

GENERAL ENGINE INFORMATION 1A – 9

Piston Noises

Step

Action

Are any of the following noises heard: a sharp double knock when the engine is idling, a light ticking with no load on the engine or a ‘‘slapping’’ noise when the engine is cold?

Inspect the piston pin and the bushing. Is the piston pin or the bushing worn or loose?

Inspect the piston. Is the piston broken or cracked?

Inspect the connecting rods. Is there a misaligned connecting rod?

Inspect the piston position. Is the piston 180_ out of position?

Value(s)

–

Yes

Go to Step 2 System OK

Go to Pistons

and Rods

Replacement

Procedure Go to Step 3

Go to Pistons

and Rods

Replacement

Procedure Go to Step 4

Go to Pistons

and Rods

Replacement

Procedure Go to Step 5

Go to Pistons

and Rods

Replacement

Procedure System OK

DAEWOO T-154 BL2,3

1A – 10 GENERAL ENGINE INFORMATION

Valve Mechanism or Valve Train Noises

Step

Action

Value(s)

Yes

1 Is a light tapping sound heard from the engine? – Go to Step 2 System OK

Inspect the valve springs. Are the springs weak or broken?

–

Go to

Cylinder Head

and Valve Train

Components

Replacement

Procedure Go to Step 3

Inspect the valves. Are the valves sticking or warped?

–

Go to

Cylinder Head

and Valve Train

Components

Replacement

Procedure

Inspect the valve lifters. Are the valve lifters dirty, stuck or worn?

–

Go to

Cylinder Head

and Valve Train

Components

Go to Step 4

Replacement

Procedure Go to Step 5

Inspect the camshaft lobes.

Are the camshaft lobes damaged or improperly machined?

–

Check the oil supply to the valve train. Is the oil supply insufficient or poor?

–

Go to

Camshaft

Replacement

Procedure Go to Step 6

Go to

Cylinder Head

and Valve Train

Components

Replacement

Procedure Go to Step 7

Inspect the valve guides. Are the valve guides worn?

–

Go to

Cylinder Head

and Valve Train

Components

Replacement

Procedure

Inspect the valve spring seat. Is the valve spring seat incorrect?

–

Go to

Cylinder Head

and Valve Train

Components

Go to Step 8

Replacement

Procedure System OK

DAEWOO T-154 BL2,3

GENERAL ENGINE INFORMATION 1A – 11

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 cleanliness 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 service, 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 electrical parts.

ON-ENGINE SERVICE

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.

Notice: Any time the air cleaner is removed, the intake opening should be covered. This will protect against accidental entrance of foreign material, which could follow the intake passage into the cylinder and cause extensive damage when the engine is started.

DAEWOO T-154 BL2,3

BLANK

DAEWOO T-154 BL2,3

SECTION 1B

SOHC ENGINE MECHANI CAL

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

Specifications 1B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Specifications 1B-2. . . . . . . . . . . . . . . . . . . . . .

Fastener Tightening Specifications 1B-4. . . . . . . . . . .

Special Tools 1B-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Tools Table 1B-5. . . . . . . . . . . . . . . . . . . . . . . .

Component Locator 1B-8. . . . . . . . . . . . . . . . . . . . . . . .

Upper End 1B-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lower End 1B-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance and Repair 1B-12. . . . . . . . . . . . . . . . . . .

On-Vehicle Service 1B-12. . . . . . . . . . . . . . . . . . . . . . . . .

Valve Cover 1B-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder Head and Gasket 1B-13. . . . . . . . . . . . . . . . .

Camshaft 1B-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Timing Belt Check and Adjust 1B-31. . . . . . . . . . . . . .

Timing Belt 1B-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Pump 1B-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Pan 1B-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Mount 1B-50. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intake Manifold 1B-52. . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust Manifold 1B-57. . . . . . . . . . . . . . . . . . . . . . . . .

Camshaft Gear 1B-58. . . . . . . . . . . . . . . . . . . . . . . . . .

Rear Timing Belt Cover 1B-60. . . . . . . . . . . . . . . . . . .

Engine 1B-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pistons and Rods 1B-71. . . . . . . . . . . . . . . . . . . . . . . .

Unit Repair 1B-77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder Head and Valve Train

Components 1B-77. . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft 1B-85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft Bearings and Connecting Rod

Bearings – Gauging Plastic 1B-93. . . . . . . . . . . . . .

General Description and System

Operation 1B-96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder Head and Gasket 1B-96. . . . . . . . . . . . . . . . .

Crankshaft 1B-96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Timing Belt 1B-96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Pump 1B-96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Pan 1B-96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust Manifold 1B-96. . . . . . . . . . . . . . . . . . . . . . . . .

Intake Manifold 1B-96. . . . . . . . . . . . . . . . . . . . . . . . . . .

Camshaft 1B-96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust Gas Recirculation Valve 1B-96. . . . . . . . . . .

DAEWOO T-154 BL2,3

1B–2 SOHC ENGINE MECHANICAL

SPECIFICATIONS

ENGINE SPECIFICATIONS

Application Description (Manual and Automatic)

General Data:

Engine Type 4 Cylinder (In-Line) Displacement:

1.5 SOHC 1 498 cm3 (91.44 in3)

Bore Stroke:

1.5 SOHC 76.5 X 81.5 mm (3.01 in. X 3.21 in.) Compression Ratio 9.5 0.2:1 Firing Order 1–3–4–2

Cylinder Bore:

Diameter 76.5 mm (3.01 in.) Out of Round (Maximum) 0.0065 mm (0.00025 in.) Taper (Maximum):

1.5 SOHC 0.0065 mm (0.00025 in.)

Piston:

Diameter 76.470 mm (3.01 in.) Clearance to Bore 0.030 mm (0.0012 in.)

Piston Rings:

Ring, End Gap:Ring, End Gap:

Top Compression 0.3 mm (0.019 in.) 2nd Compression 0.3 mm (0.019 in.)

Groove Clearance:Groove Clearance:

Top Impression 0.02 mm (0.0008 in) 2nd Impression 0.02 mm (0.0008 in.)

Piston Pin:

Diameter 18.000 mm (0.708 in.) Pin Off-Set 0.5 0.7 mm (0.019 0.027 in.)

Camshaft:

Lift Intake:

1.5 SOHC 6.12 mm (0.240 in.) Lift Exhaust 6.12 mm (0.240 in.) End Play 0.09 0.21 mm (0.0035 0.0082 in.) Journal OD:Journal OD:

No. 1 39.445 mm (1.552 in.) No. 2 39.700 mm (1.562 in.) No. 3 39.945 mm (1.572 in.) No. 4 40.200 mm (1.582 in.) No. 5 40.445 mm (1.592 in.)

DAEWOO T-154 BL2,3

SOHC ENGINE MECHANICAL 1B–3

ENGINE SPECIFICATIONS (Cont’d)

Application

Bearing OD:

No. 1 No. 2 No. 3 No. 4 No. 5

Crankshaft:

Main Journal:

Diameter (All) Taper (Maximum) Out of Round (Maximum) Main Bearing Clearance (All) Crankshaft End Play

Connecting Rod Journal:

Diameter (All) Taper (Maximum) Out of Round (Maximum) Rod Bearing Clearance (All) Rod Side Clearance

Valve System:

Valve Lash Compensators Face Angle (All) Seat Angle (All) Seat Runout (Maximum, All) Face Runout (Maximum, All) Seat Width:

Seat Width:

Intake

Exhaust Valve Guide Inside Diameter (All) Valve Stem Diameter (All) Valve Diameter (All):

Valve Diameter (All):

Intake

Exhaust Valve Spring Loads:

Valve Spring Loads:

Valve Open

Valve Closed

Oil Pump:

Gap Between Oil Pump Body and Out Rotor Out Rotor Side Clearance Inner Rotor Side Clearance

ББББББББББББББББ

Relief Valve Spring Free Length

Description (Manual and Automatic)

39.500 mm (1.555 in.)

39.750 mm (1.564 in.)

40.000 mm (1.574 in.)

40.250 mm (1.584 in.)

40.500 mm (1.594 in.)

54.982 54.994 mm (2.164 2.165 in.)

0.005 mm (0.0001 in.)

0.004 mm (0.0001 in.)

0.005 mm (0.0001 in.)

0.1 mm (0.003 in.)

42.971 42.987 mm (1.691 1.692 in.)

0.005 mm (0.0001 in.)

0.004 mm (0.0001 in.)

0.019 0.070 mm (0.0007 0.0027 in.)

0.070 0.242 mm (0.0027 0.009 in.)

Hydraulic

46 46

0.03 mm (0.019 in.)

1.3 1.5 mm (0.051 0.059 in.)

1.6 1.8 mm (0.063 0.071 in. )

7.030 7.050 mm (0.276 0.277 in.) 7 mm (0.275 in.)

38.0 0.15 mm (1.49 0.0059 in.)

31.0 0.15 mm (1.22 0.0059 in.)

625 25 N (461 18 lbs) @ 21.5 mm (0.846 in.) 275 15 N (202 11 lbs) @ 31.5 mm (1.240 in.)

0.400 0.484 mm (0.0157 0.0191 in.)

0.045 0.100 mm (0.0018 0.0039 in.)

ББББББББББББББББ

0.035 0.085 mm (0.0014 0.0033 in.) 81 mm (3.2 in.)

DAEWOO T-154 BL2,3

1B–4 SOHC ENGINE MECHANICAL

FASTENER TIGHTENING SPECIFICATIONS

Application Nm Lb-Ft Lb-In

A/C Compressor Hose Assembly Retaining Bolt 33 24 – A/C Compressor Mounting Bolts 27 20 – A/C Compressor Mounting Bracket Bolts 50 37 – Air Filter Housing Bolts 8 – 71 Alternator Adjusting Bolt 25 18 – Alternator Adjusting Bracket Retaining Bolt 25 18 – Auxiliary Catalytic Converter-to-Exhaust Manifold Nuts

and Bracket Bolts Camshaft Gear Bolt 45 33 – Camshaft Pressure Plate Bolts 10 – 89 Connecting Rod Bearing Cap Bolts 25 + 30 18 + 30 – Coolant Pump Retaining Bolts 10 – 89 Coolant Temperature Sensor 20 15 – Crankshaft Bearing Cap Bolts 50

Crankshaft Pulley Bolt 95

Crankshaft Position Sensor Retaining Bolt 10 – 89 Cylinder Head Bolts (Camshaft Support Housing &

Cylinder Head Mounting Bolts) Electronic Ignition System Ignition Coil Mounting Bolts 10 – 89 Electronic Ignition System Ignition Coil Mounting Plate

Bolts 10 Engine Lift Bracket Bolt 25 18 – Engine Mount Attaching Nuts 40 30 – Engine Mount Bracket Retaining Bolts 60 44 – Engine Mount Bracket-to-Engine Mount Retaining Bolts 60 44 – Exhaust Manifold Heat Shield Bolts 15 11 – Exhaust Manifold Nuts 25 18 – Flexible Plate Bolts 60 44 – Flexible Plate Inspection Cover Bolts 10 – 89 Flywheel Bolts 35

Flywheel Inspection Cover Bolts 12 – 106 Front Muffler-to-Main Catalytic Converter Nuts 30 22 – Fuel Rail Retaining Bolts 25 18 – Intake Manifold Retaining Nuts 25 18 –

40 30 –

+ 45 + 15

+ 45 + 15 –

+ 30 + 15

25 + 70

+ 70 + 30

+ 30 + 15 –

18 + 70

+ 70 + 30

–

+ 30 + 15

+ 30 + 15 –

–

DAEWOO T-154 BL2,3

SOHC ENGINE MECHANICAL 1B–5

FASTENER TIGHTENING SPECIFICATIONS (Con t ’d)

Application Nm Lb-Ft Lb-In

Intake Manifold Support Bracket Retaining Bolts 22 16 – Lower Timing Belt Cover Bolts 10 – 89 Oil Pan Retaining Bolts 10 – 89 Oil Pan Drain Plug 55 41 – Oil Pressure Switch 40 30 – Oil Pump Retaining Bolts 10 – 89 Oil Pump/Pickup Tube and Support Bracket Bolts 10 – 89 Oil Pump Safety Relief Valve Bolt 30 22 – Oil Pump Rear Cover Bolts 6 – 53 Power Steering Pump Mounting Bolts 25 18 – Power Steering Pump Pulley Bolts 25 18 – Rear Timing Belt Cover Bolts 10 – 89 Right Transaxle Brace Bolts 60 44 – Spark Plugs 25 18 – Thermostat Housing Mounting Bolts 20 15 – Throttle Cable Bracket Bolts 8 – 71 Timing Belt Automatic Tensioner Bolt 20 15 – Transaxle Bell Housing Bolts 75 55 – Transaxle Torque Converter Bolts 65 48 – Upper Timing Belt Cover Bolts 10 – 89 Valve Cover Bolts 9 – 80

A102B150

SPECIAL TOOLS

SPECIAL TOOL S TABLE

KM-565-A

Valve Spring

Compressor

J-42492

Timing Belt Adjuster

A102B151

DAEWOO T-154 BL2,3

1B–6 SOHC ENGINE MECHANICAL

SPECIAL TOOLS TABLE (Cont’d)

A102B152

A102B153

KM -263-B

Engine Assembly

Support Fixture

KM-427

Piston Pin Service Set

MKM-571-B

Gauge

KM-254

Valve Guide Reamer

A102B155

KM-255

Valve Guide Reamer

A102B155

KM-340-0

Cutter Set

Includes: KM-340-7

Includes: KM-340-13 Includes: KM-340-26

A102B154

A102B155

KM-253

Valve Guide Reamer

A102B156

KM-348

Valve Spring

Compressor

A102B157

DAEWOO T-154 BL2,3

SOHC ENGINE MECHANICAL 1B–7

SPECIAL TOOLS TABLE (Cont’d)

A102B158

A102B160

KM-419

Distance Gauge

KM-635

Crankshaft Rear Oil

Seal Installer

MKM-412

Engine Overhaul Stand

KM-470-B

Angular Torque Gauge

A102B161

J-36972

Crankshaft Rear Oil

Seal Installer

A102C155

KM-135

Adapter

A102B159

A202B005

B102C044

KM-498-B

Pressure Gauge

DAEWOO T-154 BL2,3

1B–8 SOHC ENGINE MECHANICAL

COMPONENT LOCATOR

UPPER END

A402B001

DAEWOO T-154 BL2,3

SOHC ENGINE MECHANICAL 1B–9

1 Wiring Bracket 2 Bolt 3 Bolt 4 Cap, Bayonet Joint 5 Seal, Bayonet Cap 6 Valve Cover 7 Bolt 8 Throttle Position Sensor 9 Idle Air Control Valve

10 Throttle Body

11 Throttle Body Gasket 12 Nut 13 Engine Coolant Temperature Sensor 14 Intake Manifold 15 Camshaft Position Sensor 16 EGR Valve 17 Bolt 18 EGR Gasket 19 Shaft Seal Ring 20 Camshaft Support 21 Valve Cover Gasket 22 Tube 23 Cylinder Head Bolt 24 Washer 25 Camshaft 26 Camshaft Pressure Plate 27 Bolt 28 Bolt-Stud 29 Intake Manifold Gasket 30 Bolt-Stud 31 Valve Thrust Piece

32 Valve Key 33 Valve Spring Plate 34 Valve Spring 35 Valve Stem Seal 36 Exhaust Valve Spring Seat 37 Valve Guide 38 Cam Follower 39 Cam Follower Lifter 40 Intake Valve Spring Seat 41 Bolt 42 Thermostat Housing 43 Thermostat Housing Seal Ring 44 Thermostat 45 Screw Plug 46 Oil Duct Cap 47 Oil Duct Cap 48 Adapter 49 Coolant Temperature Sensor 50 Exhaust Valve 51 Intake Valve 52 Cylinder Head Oil Duct Sleeve 53 Bolt-Stud 54 Exhaust Manifold Gasket 55 Cylinder Head Gasket 56 Exhaust Manifold 57 Nut 58 Exhaust Oxygen Sensor 59 Exhaust Manifold Heat Shield 60 Bolt 61 EGR Solenoid 62 Bracket

DAEWOO T-154 BL2,3

1B–10 SOHC ENGINE MECHANICAL

LOWER END

A202B006

DAEWOO T-154 BL2,3

SOHC ENGINE MECHANICAL 1B–11

1 Piston Ring Seat 2 Piston 3 Piston Pin 4 Connecting Rod 5 Connecting Rod Bearing Set 6 Connecting Rod Bolt 7 Oil Level Gauge Stick 8 Gauge Stick Tube 9 Connecting Piece

10 Oil Filter

11 Camshaft Pulley Bolt 12 Washer 13 Camshaft Gear 14 Rear Cover Bolt 15 Rear Timing Belt Cover 16 Bolt 17 Coolant Pump 18 Oil Pump 19 Seal Ring 20 Oil Pump Body Gasket 21 Engine Block 22 Bolt 23 Auto Tensioner 24 Bolt 25 Crankshaft Gear 26 Pressure Relief Valve Plunger 27 Spring 28 Oil Pump Seal Ring 29 Bolt Plug 30 Crankshaft Bearing Set 31 Crankshaft 32 Shaft Seal Ring

33 Flywheel (Manual Transaxle) 34 Bolt (Manual Transaxle) 35 Bolt (Automatic Transaxle) 36 Flex Plate (Automatic Transaxle) 37 Bolt 38 Threaded Ring 39 Drain Plug 40 Bolt 41 Oil Pan 42 Main Bearing Cap Bolt 43 Main Bearing 44 Bolt 45 Bracket 46 Oil Pickup Tube 47 Timing Belt 48 Upper Timing Belt Front Cover 49 Bolt 50 Lower Timing Belt Front Cover 51 Crankshaft Pulley 52 Washer 53 Bolt 54 Bolt 55 Bolt 56 Crankshaft Position Sensor 57 Bracket 58 Gear 59 Gear 60 Cover 61 Bolt 62 Seal 63 Knock Sensor

DAEWOO T-154 BL2,3

1B–12 SOHC ENGINE MECHANICAL

MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE

VALVE COVER

Removal Procedure

1. Disconnect the negative battery cable.

2. Disconnect the breather tube from the valve cover.

A402B002

3. Remove the eight bolts from the valve cover.

4. Remove the valve cover.

5. Remove the valve cover gasket.

6. Clean the sealing surfaces of the valve cover and the camshaft housing.

A402B003

Installation Procedure

1. Install the new valve cover gasket and the valve cover.

2. Install the eight bolts to the valve cover.

Tighten

Tighten the valve cover bolts to 9 N m (80 lb-in).

A402B003

DAEWOO T-154 BL2,3

A402B002

SOHC ENGINE MECHANICAL 1B–13

3. Connect the breather tube to the valve cover.

4. Connect the negative battery cable.

CYLINDER HEAD AND GASKET

Tools Required

J-42492 Timing Belt Adjuster KM-470-B Angular Torque Gauge

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 engine control module (ECM) groun terminal from the intake manifold.

A102B001

5. Drain the engine coolant. Refer to Section 1D, Engine Cooling.

6. Disconnect the intake air temperature (IAT) sensor connector.

7. Disconnect the breather tube from the valve cover.

8. Disconnect the air intake tube from the throttle body.

DAEWOO T-154 BL2,3

1B–14 SOHC ENGINE MECHANICAL

A102B092

9. Disconnect the electronic ignition (EI) system ignition coil connector.

10. Disconnect the oxygen (O

) sensor connector.

11. Disconnect the fuel injector harness connectors.

12. Disconnect the idle air control (IAC) valve connector.

13. Disconnect the throttle position (TP) sensor connector.

14. Disconnect the engine coolant temperature (ECT) sensor connector.

15. Disconnect the coolant temperature sensor (CTS) connector.

16. Remove the camshaft position (CMP) sensor.

A102B016

17. Remove the air cleaner housing bolts.

18. Remove the air cleaner housing.

A102B002

DAEWOO T-154 BL2,3

A102B003

SOHC ENGINE MECHANICAL 1B–15

19. Remove the upper timing belt cover bolts.

20. Remove the upper timing belt cover.

21. Align the camshaft gear timing mark to the notch in the rear timing belt cover.

DAEWOO T-154 BL2,3

A102B004

22. Remove the right front wheel. Refer to Section 2E, Tires and Wheels.

23. Remove the right front wheel well splash shield.

24. Remove the A/C compressor drive belt, if equipped.

A102B006

1B–16 SOHC ENGINE MECHANICAL

25. Remove the alternator drive belt.

26. Remove the power steering pump pulley bolts, if equipped.

27. Remove the power steering pump pulley, if equipped.

A102B005

28. Disconnect the fuel return line at the fuel pressure regulator.

29. Disconnect the fuel feed line at the fuel rail.

A402B009

30. Remove the alternator adjusting bolt.

31. Remove the alternator adjusting bracket retaining bolt.

32. Remove the alternator adjusting bracket.

A102B118

DAEWOO T-154 BL2,3

A102B114

SOHC ENGINE MECHANICAL 1B–17

33. Disconnect the upper radiator hose at the thermostat housing.

34. Disconnect the brake booster vacuum hose at the intake manifold.

35. Disconnect all of the necessary vacuum hoses.

36. Remove the crankshaft pulley bolt.

37. Remove the crankshaft pulley.

38. Remove the power steering pump, if equipped. Refer to Section 6B, Power Steering Pump.

39. Install the engine mount bracket-to-engine mount retaining bolt s and tighten the bolts to secure the engine, if the power steering pump was removed.

40. Remove the lower timing belt cover bolts.

41. Remove the lower timing belt cover.

DAEWOO T-154 BL2,3

A102B008

42. Slightly loosen the coolant pump retaining bolts.

43. Rotate the coolant pump counterclockwise using the timing belt adjuster J-42492 to relieve the timing belt tension.

44. Remove the timing belt. Refer to “Timing Belt” in this section.

A102B040

1B–18 SOHC ENGINE MECHANICAL

45. Disconnect the crankcase ventilation tube at the camshaft housing.

A402B004

46. Remove the valve cover bolts.

47. Remove the valve cover and the valve cover gasket.

A102B111

Notice: Take care to prevent any scratches, nicks or

damage to the camshaft.

48. While holding the camshaft firmly in place, remove the camshaft gear bolt.

49. Remove the camshaft gear.

50. Remove the timing belt automatic tensioner bolt.

51. Remove the timing belt automatic tensioner.

52. Remove the rear timing belt cover bolts.

53. Remove the rear timing belt cover.

A102B046

DAEWOO T-154 BL2,3

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