SECTION 1B

SOHC ENGINE MECHANICAL

CAUTION:Disconnectthenegativebatterycablebeforeremovingorinstallinganyelectricalunitorwhena
toolorequipmentcouldeasilycomeincontactwithexposedelectricalterminals.Disconnectingthiscable
willhelppreventpersonalinjuryanddamagetothevehicle.TheignitionmustalsobeinLOCKunless
otherwisenoted.
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-2 Camshaft Gear . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-58
Engine Specifications . . . . . . . . . . . . . . . . . . . . . . 1B-2 Rear Timing Belt Cover . . . . . . . . . . . . . . . . . . . 1B-59
Fastener Tightening Specifications . . . . . . . . . . . 1B-4 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-60
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5 Pistons and Rods . . . . . . . . . . . . . . . . . . . . . . . . 1B-70
Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . . 1B-5 Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-76
Component Locator . . . . . . . . . . . . . . . . . . . . . . . . 1B-8 Cylinder Head and Valve Train
Upper End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-8 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-76
Lower End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-10 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-84
Maintenance and Repair . . . . . . . . . . . . . . . . . . . 1B-12 Crankshaft Bearings and Connecting Rod
Bearings - Gauging Plastic . . . . . . . . . . . . . . 1B-92
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . 1B-12
General Description and System
Valve Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-12
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-95
Cylinder Head and Gasket . . . . . . . . . . . . . . . . . 1B-13
Cylinder Head and Gasket . . . . . . . . . . . . . . . . . 1B-95
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-27
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-95
Timing Belt Check and Adjust . . . . . . . . . . . . . . 1B-31
Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-95
Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-36
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-95
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-42
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-95
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-47
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . 1B-95
Engine Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-49
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-95
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-51
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-95
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . 1B-57
EGR Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-95

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1B -- 2 SOHC ENGINE MECHANICAL

SPECIFICATIONS
ENGINE SPECIFICATIONS
Application Description (Manual and Automatic)
General Data:
Engine Type 4 Cylinder (In-Line)
Displacement:
1.3 SOHC 1 349 cm3 (82.30 in3)
1.5 SOHC 1 498 cm3 (91.44 in3)
Bore Stroke:
1.3 SOHC 76.5 x 73.4 mm (3.01 in. x 2.89 in.)
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):
1.3 SOHC 0
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:
Top Compression 0.3 mm (0.019 in.)
2nd Compression 0.3 mm (0.019 in.)
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 0.5X 0.7 mm (0.019X 0.027 in.)
Camshaft:
Lift Intake:
1.3 SOHC 5.61 mm (0.220 in.)
1.5 SOHC 6.12 mm (0.240 in.)
Lift Exhaust 6.12 mm (0.240 in.)
End Play 0.09X 0.21 mm (0.0035X 0.0082 in.)
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.)

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 SOHC ENGINE MECHANICAL 1B - 3

ENGINE SPECIFICATIONS (Cont’d)

Application Description (Manual and Automatic)
Bearing OD:
No. 1 39.500 mm (1.555 in.)
No. 2 39.750 mm (1.564 in.)
No. 3 40.000 mm (1.574 in.)
No. 4 40.250 mm (1.584 in.)
No. 5 40.500 mm (1.594 in.)
Crankshaft:
Main Journal:
Diameter (All) 54.982X 54.994 mm (2.164X 2.165 in.)
Taper (Maximum) 0.005 mm (0.0001 in.)
Out of Round (Maximum) 0.004 mm (0.0001 in.)
Main Bearing Clearance (All) 0.005 mm (0.0001 in.)
Crankshaft End Play 0.1 mm (0.003 in.)
Connecting Rod Journal:
Diameter (All) 42.971X 42.987 mm (1.691X 1.692 in.)
Taper (Maximum) 0.005 mm (0.0001 in.)
Out of Round (Maximum) 0.004 mm (0.0001 in.)
Rod Bearing Clearance (All) 0.019X 0.070 mm (0.0007X 0.0027 in.)
Rod Side Clearance 0.070X 0.242 mm (0.0027X 0.009 in.)
Valve System:
Valve Lash Compensators Hydraulic
Face Angle (All) 46_
Seat Angle (All) 46_
Seat Runout (Maximum, All) 0.03 mm (0.019 in.)
Face Runout (Maximum, All) 0.03 mm (0.019 in.)
Seat Width:
Intake 1.3X 1.5 mm (0.051X 0.059 in.)
Exhaust 1.6X 1.8 mm (0.063X 0.071 in. )
Valve Guide Inside Diameter (All) 7.030X 7.050 mm (0.276X 0.277 in.)
Valve Stem Diameter (All) 7 mm (0.275 in.)
Valve Diameter (All):
Intake 38.0" 0.15 mm (1.49" 0.0059 in.)
Exhaust 31.0" 0.15 mm (1.22" 0.0059 in.)
Valve Spring Loads:
Valve Open 625" 25 N (461" 18 lbs) @ 21.5 mm (0.846 in.)
Valve Closed 275" 15 N (202" 11 lbs) @ 31.5 mm (1.240 in.)
Oil Pump:
Gap Between Oil Pump Body and Out Rotor 0.400X 0.484 mm (0.0157X 0.0191 in.)
Out Rotor Side Clearance 0.045X 0.100 mm (0.0018X 0.0039 in.)
Inner Rotor Side Clearance 0.035X 0.085 mm (0.0014X 0.0033 in.)
Relief Valve Spring Free Length 81 mm (3.2 in.)

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1B -- 4 SOHC ENGINE MECHANICAL

FASTENER TIGHTENING SPECIFICATIONS

Application NSm 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 36 -
Air Filter Housing Bolts 12 - 106
Alternator Adjusting Bolt 20 15 -
Alternator Adjusting Bracket Retaining Bolt 20 15 -
Camshaft Gear Bolt 45 33 -
Camshaft Pressure Plate Bolts 10 - 89
Connecting Rod Bearing Cap Bolts 25 18
+30_ +15_ +30_ +15_ -
Coolant Pump Retaining Bolts 10 - 89
Coolant Temperature Sensor 20 15 -
Crankshaft Bearing Cap Bolts 50 37
+45_ +15_ +45_ +15_ -
Crankshaft Pulley Bolt 95 70
+30_ +15_ +30_ +15_ -
Crankshaft Position Sensor Retaining Bolt 10 - 89
Cylinder Head Bolts (Camshaft Support Housing & 25 18
Cylinder Head Mounting Bolts) +60_ +60_ +60_ +60_ -
+60_+10_ +60_+10_
DIS Ignition Coil Mounting Bolts 10 - 89
DIS Ignition Coil Mounting Plate Bolts 10 - 89
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 Flex Pipe Bracket Bolts 40 30 -
Exhaust Flex Pipe-to-Catalytic Converter or Connecting
30 22 -
Pipe Retaining Nuts
Exhaust Flex Pipe-to-Exhaust Manifold Retaining Nuts 40 30 -
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 25
+30_ +15_ +30_ +15_ -
Flywheel Inspection Cover Bolts 12 - 106
Fuel Rail Retaining Bolts 25 18 -
Intake Manifold Retaining Nuts 25 18 -
Intake Manifold Support Bracket Retaining Bolts 22 16 -
Lower Timing Belt Cover Bolts 10 - 89

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 SOHC ENGINE MECHANICAL 1B - 5

FASTENER TIGHTENING SPECIFICATIONS (Cont’d)

Application NSm Lb-Ft Lb-In
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 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 45 -
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 45 33 -
Upper Timing Belt Cover Bolts 10 - 89
Valve Cover Bolts 10 - 89

SPECIAL TOOLS
SPECIAL TOOLS TABLE

KM-565-A
J-42492
Valve Spring
Timing Belt Adjuster
Compressor

A102B150 A102B151

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1B -- 6 SOHC ENGINE MECHANICAL

SPECIAL TOOLS TABLE (Cont’d)

J-28467-B
KM-254
Engine Assembly
Valve Guide Reamer
Support Fixture

A102B152 A102B155

KM-427 KM-255
Piston Pin Service Set Valve Guide Reamer

A102B153 A102B155

KM-340-0
Cutter Set
MKM-571-B
Includes: KM-340-7
Gauge
Includes: KM-340-13
Includes: KM-340-26

A102B154 A102B156

KM-348
KM-253
Valve Spring
Valve Guide Reamer
Compressor

A102B155 A102B157

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 SOHC ENGINE MECHANICAL 1B - 7

SPECIAL TOOLS TABLE (Cont’d)

KM-419 KM-470-B
Distance Gauge Angular Torque Gauge

A102B158 A102B161

KM-635 J-36972
Crankshaft Rear Oil Crankshaft Rear Oil
Seal Installer Seal Installer

A102B160 A102C155

MKM-412 KM-135
Engine Overhaul Stand Adapter

A102B159 B102C044

KM-498-B
Pressure Gauge

A202B005

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1B -- 8 SOHC ENGINE MECHANICAL

COMPONENT LOCATOR
UPPER END

A202B007

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 SOHC ENGINE MECHANICAL 1B - 9

1 Wiring Bracket 32 Valve Key

2 Bolt 33 Valve Spring Plate
3 Bolt 34 Valve Spring
4 Cap, Bayonet Joint 35 Valve Stem Seal
5 Seal, Bayonet Cap 36 Exhaust Valve Spring Seat
6 Valve Cover 37 Valve Guide
7 Bolt 38 Cam Follower
8 Throttle Position Sensor 39 Cam Follower Lifter
9 Idle Air Control Valve 40 Intake Valve Spring Seat
10 Throttle Body 41 Bolt
11 Throttle Body Gasket 42 Thermostat Housing
12 Nut 43 Thermostat Housing Seal Ring
13 Engine Coolant Temperature Sensor 44 Thermostat
14 Intake Manifold 45 Screw Plug
15 Vacuum Tube 46 Oil Duct Cap
16 EGR Valve 47 Oil Duct Cap
17 Bolt 48 Adapter
18 EGR Gasket 49 Coolant Temperature Sensor
19 Shaft Seal Ring 50 Exhaust Valve
20 Camshaft Support 51 Intake Valve
21 Valve Cover Gasket 52 Cylinder Head Oil Duct Sleeve
22 Tube 53 Bolt-Stud
23 Cylinder Head Bolt 54 Exhaust Manifold Gasket
24 Washer 55 Cylinder Head Gasket
25 Camshaft 56 Exhaust Manifold
26 Camshaft Pressure Plate 57 Nut
27 Bolt 58 Exhaust Oxygen Sensor
28 Bolt-Stud 59 Exhaust Manifold Heat Shield
29 Intake Manifold Gasket 60 Bolt
30 Bolt-Stud 61 EGR Solenoid
31 Valve Thrust Piece 62 Bracket

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1B -- 10 SOHC ENGINE MECHANICAL

LOWER END

A202B006

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 SOHC ENGINE MECHANICAL 1B - 11

1 Piston Ring Seat 33 Flywheel (Manual Transaxle)

2 Piston 34 Bolt (Manual Transaxle)
3 Piston Pin 35 Bolt (Automatic Transaxle)
4 Connecting Rod 36 Flex Plate (Automatic Transaxle)
5 Connecting Rod Bearing Set 37 Bolt
6 Connecting Rod Bolt 38 Threaded Ring
7 Oil Level Gauge Stick 39 Drain Plug
8 Gauge Stick Tube 40 Bolt
9 Connecting Piece 41 Oil Pan
10 Oil Filter 42 Main Bearing Cap Bolt
11 Camshaft Pulley Bolt 43 Main Bearing
12 Washer 44 Bolt
13 Camshaft Gear 45 Bracket
14 Rear Cover Bolt 46 Oil Pickup Tube
15 Rear Timing Belt Cover 47 Timing Belt
16 Bolt 48 Upper Timing Belt Front Cover
17 Coolant Pump 49 Bolt
18 Oil Pump 50 Lower Timing Belt Front Cover
19 Seal Ring 51 Crankshaft Pulley
20 Oil Pump Body Gasket 52 Washer
21 Engine Block 53 Bolt
22 Bolt 54 Bolt
23 Auto Tensioner 55 Bolt
24 Bolt 56 Crankshaft Position Sensor
25 Crankshaft Gear 57 Bracket
26 Pressure Relief Valve Plunger 58 Gear
27 Spring 59 Gear
28 Oil Pump Seal Ring 60 Cover
29 Bolt Plug 61 Bolt
30 Crankshaft Bearing Set 62 Seal
31 Crankshaft 63 Knock Sensor
32 Shaft Seal Ring

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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.

A102B011

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.

A102B010

Installation Procedure
1. Install the new valve cover gasket and the valve cov-
er.
2. Install the eight bolts to the valve cover.
Tighten
Tighten the valve cover bolts to 10 NSm (89 lb-in).

A102B010

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 SOHC ENGINE MECHANICAL 1B - 13
3. Connect the breather tube to the valve cover.
4. Connect the negative battery cable.

A102B011

CYLINDER HEAD AND GASKET

(Left-Hand Drive Shown, Right Hand
Drive Similar)
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 electronic control module (ECM)
ground terminal from the intake manifold.

A102B012

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

Cooling.
6. Disconnect the manifold air temperature sensor con-
nector.
7. Disconnect the breather tube from the valve cover.
8. Disconnect the air intake tube from the throttle body.

A102B001

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1B -- 14 SOHC ENGINE MECHANICAL
9. Disconnect the direct ignition system (DIS) ignition
coil connector.
10. Disconnect the oxygen sensor connector.
11. Disconnect the fuel injector harness connectors.

A102B092

12. Disconnect the idle air control valve connector.

13. Disconnect the throttle position sensor connector.
14. Disconnect the engine coolant temperature sensor
connector.
15. Disconnect the coolant temperature sensor connec-
tor.

A102B016

16. Remove the air cleaner housing bolts.

17. Remove the air cleaner housing.

A102B002

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 SOHC ENGINE MECHANICAL 1B - 15
18. Remove the upper timing belt cover bolts.
19. Remove the upper timing belt cover.

A102B003

20. Align the camshaft gear timing mark to the notch in

the rear timing belt cover.

A102B004

21. Remove the right front wheel. Refer to Section 2E,

Tires and Wheels.
22. Remove the right front wheel well splash shield.
23. Remove the A/C compressor drive belt, if equipped.

A102B006

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1B -- 16 SOHC ENGINE MECHANICAL
24. Remove the alternator drive belt.
25. Remove the power steering pump pulley bolts, if
equipped.
26. Remove the power steering pump pulley, if
equipped.

A102B005

27. Disconnect the fuel return line at the fuel pressure

regulator.
28. Disconnect the fuel feed line at the fuel rail.

A102B116

29. Remove the alternator adjusting bolt.

30. Remove the alternator adjusting bracket retaining
bolt.
31. Remove the alternator adjusting bracket.

A102B118

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 SOHC ENGINE MECHANICAL 1B - 17
32. Disconnect the upper radiator hose at the thermo-
stat housing.
33. Disconnect the brake booster vacuum hose at the
intake manifold.
34. Disconnect all of the necessary vacuum hoses.

A102B114

35. Remove the crankshaft pulley bolt.

36. Remove the crankshaft pulley.
37. Remove the power steering pump, if equipped. Re-
fer to Section 6B, Power Steering Pump.
38. Install the engine mount bracket-to-engine mount
retaining bolts and tighten the bolts to secure the en-
gine, if the power steering pump was removed.
39. Remove the lower timing belt cover bolts.
40. Remove the lower timing belt cover.

A102B008

41. Slightly loosen the coolant pump retaining bolts.

42. Rotate the coolant pump counterclockwise using the
timing belt adjuster J-42492 to relieve the timing belt
tension.
43. Remove the timing belt. Refer to “Timing Belt” in this
section.

A102B040

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1B -- 18 SOHC ENGINE MECHANICAL
44. Disconnect the crankcase ventilation tube at the
camshaft housing and the electrical connector at the
exhaust gas recirculation (EGR) solenoid.

A102B117

45. Remove the valve cover bolts.

46. Remove the valve cover and the valve cover gasket.
Notice: Take care to prevent any scratches, nicks or
damage to the camshaft.
47. While holding the camshaft firmly in place, remove
the camshaft gear bolt.
48. Remove the camshaft gear.

A102B111

49. Remove the timing belt automatic tensioner bolt.

50. Remove the timing belt automatic tensioner.
51. Remove the rear timing belt cover bolts.
52. Remove the rear timing belt cover.

A102B046

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 SOHC ENGINE MECHANICAL 1B - 19
53. Disconnect the ignition wires at the spark plugs.
54. Remove the retaining nuts from the exhaust flex
pipe at the exhaust manifold flange and the bolts at
the bracket.

A202B004

55. Disconnect the heater inlet hose at the coolant dis-

tributor.
56. Disconnect the surge tank coolant hose at the
throttle body.

A102B119

57. Remove the intake manifold support bracket retain-

ing bolts from the coolant distributor.
58. Disconnect the throttle cable at the throttle body and
the intake manifold.

A102B120

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1B -- 20 SOHC ENGINE MECHANICAL
59. Gradually loosen all of the cylinder head bolts in the
sequence shown.
60. Remove the cylinder head bolts.
61. Remove the camshaft carrier assembly.
Notice: Prevent any engine oil or coolant from entering
the cylinders when removing the cylinder head. Damage
to the engine could result.
62. Remove the cylinder head with the intake manifold
and the exhaust manifold attached.
63. Remove the cylinder head gasket.

A102B121

Cleaning Procedure
1. Clean the gasket surfaces of the cylinder head and
the engine block.
2. Make sure the gasket surfaces of the cylinder head
and the engine block are free of nicks and heavy
scratches.
3. Clean the cylinder head bolts.
4. Inspect the cylinder head for warpage. Refer to “Cyl-
inder Head and Valve Train Components” in this sec-
tion.

A102B122

Installation Procedure
1. Apply a continuous 3 mm (0.12 inch) bead of gasket
maker to the sealing surface of the camshaft carrier.
2. Install the cylinder head gasket.
3. Install the cylinder head with the intake manifold and
the exhaust manifold attached.
4. Install the camshaft carrier assembly.

A102B123

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 SOHC ENGINE MECHANICAL 1B - 21
5. Install the cylinder head bolts in the sequence shown.

A102B124

Tighten
Tighten the cylinder head bolts in the sequence pre-
viously shown to 25 NSm (18 lb-ft) using a torque
wrench. Use the angular torque gauge KM-470-B
to tighten the cylinder head bolts another 60 degrees
plus 60 degrees plus 60 degrees plue 10 degrees.

A102B172

6. Connect the throttle cable at the throttle body and at

the intake manifold.
7. Install the intake manifold support bracket retaining
bolt to the coolant distributor.
Tighten
Tighten the intake manifold support bracket retaining
bolts to 22 NSm (16 lb-ft).

A102B029

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1B -- 22 SOHC ENGINE MECHANICAL
8. Connect the surge tank coolant hose at the throttle
body.
9. Connect the heater inlet hose to the coolant distribu-
tor.

A102B119

10. Install the exhaust flex pipe retaining nuts at the ex-
haust manifold flange and the bolts to the bracket.
Tighten
Tighten the exhaust flex pipe-to-exhaust manifold re-
taining nuts and bracket bolts to 40 NSm (30 lb-ft).

A202B004

11. Connect the ignition wires at the spark plugs.

12. Install the rear timing belt cover.
13. Install the rear timing belt cover bolts.
Tighten
Tighten the rear timing belt cover bolts to 10 NSm
(89 lb-in).
14. Install the timing belt automatic tensioner.
15. Install the timing belt automatic tensioner bolt.
Tighten
Tighten the timing belt automatic tensioner bolt to
20 NSm (15 lb-ft).

A102B046

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 SOHC ENGINE MECHANICAL 1B - 23
Notice: Take extreme care to prevent any scratches,
nicks, or damage to the camshaft. Such damage can im-
pair vehicle operation.
16. Install the camshaft gear.
17. While holding the camshaft firmly in place, install the
camshaft gear bolt.
Tighten
Tighten the camshaft gear bolt to 45 NSm (33 lb-ft).

A102B111

18. Install the valve cover and the valve cover gasket.
19. Install the valve cover bolts.
Tighten
Tighten the valve cover bolts to 10 NSm (89 lb-in).
20. Connect the crankcase ventilation tube to the cam-
shaft housing and connect the EGR solenoid con-
nector.

A102B117

21. Align the mark on the camshaft gear to the notch at

the top of the rear timing belt cover.

A102B004

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1B -- 24 SOHC ENGINE MECHANICAL
22. Align the mark on the crankshaft gear to the notch at
the bottom of the rear timing belt cover.

A102B030

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

section.
24. Check the timing belt tension. Refer to “Timing Belt
Check and Adjust” in this section.
25. Install the lower timing belt cover.
26. Install the lower timing belt cover bolts.
Tighten
Tighten the lower timing belt cover bolts to 10 NSm
(89 lb-in).
27. Install the power steering pump and the bolts, if
equipped. Refer to Section 6B, Power Steering
Pump.
28. Install the engine mount bracket-to-engine mount re-
taining bolts if the power steering pump was installed.
Tighten
Tighten the engine mount bracket-to-engine mount
retaining bolts to 60 NSm (44 lb-ft).
A102B020

29. Install the crankshaft pulley.

30. Install the crankshaft pulley bolt.
Tighten
Tighten the crankshaft pulley bolt to 95 NSm (70 lb-ft)
using a torque wrench. Use the angular torque gauge
KM-470-B to tighten the crankshaft pulley bolt anoth-
er 30 degrees plus 15 degrees.
31. Install the power steering pump pulley, if equipped.
32. Install the power steering pump pulley bolts, if
equipped.
Tighten
Tighten the power steering pump pulley bolts to
25 NSm (18 lb-ft).

A102B005

DAEWOO T-100 BL3

 SOHC ENGINE MECHANICAL 1B - 25
33. Connect all of the vacuum hoses.
34. Connect the brake booster hose at the intake man-
ifold.
35. Connect the upper radiator hose at the thermostat
housing.

A102B114

36. Install the alternator adjusting bracket.

37. Install the alternator adjusting bracket retaining bolt.
Tighten
Tighten the alternator adjusting bracket retaining bolt
to 20 NSm (15 lb-ft).
38. Install the alternator adjusting bolt. Do not tighten.

A102B118

39. Connect the fuel feed line at the fuel rail.

40. Connect the fuel return line at the fuel pressure reg-
ulator.

A102B116

DAEWOO T-100 BL3

1B -- 26 SOHC ENGINE MECHANICAL
41. Install the alternator drive belt.
Tighten
Tighten the alternator adjusting bolt to 20 NSm (15 lb-ft).
42. Install the upper timing belt cover.
43. Install the upper timing belt cover bolts.
Tighten
Tighten the upper timing belt cover bolts to 10 NSm
(89 lb-in).
44. Install the A/C compressor drive belt, as necessary.
45. Install the right front wheel well splash shield.
46. Install the right front wheel. Refer to Section 2E,
Tires and Wheels.

A102B003

47. Install the air filter housing.

48. Install the air filter housing bolts.
Tighten
Tighten the air filter housing bolts to 12 NSm (106 lb-
in).
49. Connect the air intake tube to the throttle body.
50. Connect the breather tube to the valve cover.
51. Connect the manifold air temperature sensor con-
nector.

A102B001

52. Connect the coolant temperature sensor connector.

53. Connect the engine coolant temperature sensor
connector.
54. Connect the idle air control valve connector.
55. Connect the throttle position sensor connector.
56. Connect the DIS ignition coil connector.
57. Connect the fuel injector harness connectors.
58. Connect the oxygen sensor connector.
59. Connect the ECM ground terminal at the intake
manifold.
60. Connect the negative battery cable.
61. Install the fuel pump fuse.
62. Refill the engine cooling system. Refer to Section
1D, Engine Cooling.

A102B016

DAEWOO T-100 BL3

 SOHC ENGINE MECHANICAL 1B - 27

CAMSHAFT
(Left-Hand Drive Shown, Right Hand
Drive Similar)
Tools Required
KM-565-A Valve Spring Compressor
Removal Procedure
1. Remove the timing belt. Refer to “Timing Belt” in this
section.
2. Disconnect the air breather tube at the valve cover.
3. Remove the valve cover bolts.
4. Remove the valve cover.
5. Remove the valve cover gasket.

A102B010

6. Install the valve spring compressor KM-565-A.

Notice: Take extreme care to prevent any scratches,
nicks, or damage to the camshaft. Such damage can im-
pair vehicle operation.
7. Remove the camshaft followers using the valve
spring compressor KM-565-A.

A102B074

8. While holding the camshaft firmly in place, remove

the camshaft gear bolt.
9. Remove the camshaft gear.

A102B111

DAEWOO T-100 BL3

1B -- 28 SOHC ENGINE MECHANICAL
10. Disconnect the positive battery cable from the bat-
tery.
11. Remove the battery and the battery tray. Refer to
Section 1E, Engine Electrical.

A102C034

12. Disconnect the direct ignition system (DIS) ignition

coil connector.
13. Disconnect the DIS ignition wires at the ignition coil.
14. Remove the DIS ignition coil mounting bolts.
15. Remove the DIS ignition coil.

A102B075

16. Remove the DIS ignition coil mounting plate bolts.

17. Remove the DIS ignition coil mounting plate.
18. Remove the camshaft pressure plate bolts.
19. Remove the camshaft pressure plate.

A102B076

DAEWOO T-100 BL3

 SOHC ENGINE MECHANICAL 1B - 29
20. Remove the camshaft.

A102B077

Installation Procedure
1. Install the camshaft.
2. Install the camshaft pressure plate.
3. Install the camshaft pressure plate bolts.
Tighten
Tighten the camshaft pressure plate bolts to 10 NSm
(89 lb-in).

A102B076

4. Measure camshaft end play. Camshaft end play

should be 0.04 to 0.16 mm (.016 to 0.64 inch).
5. Install the DIS ignition coil mounting plate.
6. Install the DIS ignition coil mounting plate bolts.
Tighten
Tighten the DIS ignition coil mounting plate bolts to
10 NSm (89 lb-in).
7. Install the DIS ignition coil.
8. Install the DIS ignition coil mounting bolts.
Tighten
Tighten the DIS ignition coil mounting bolts to 10 NSm
(89 lb-in).
9. Connect the ignition wires at the DIS ignition coil.
10. Connect the DIS ignition coil connector.

A102B075

DAEWOO T-100 BL3

1B -- 30 SOHC ENGINE MECHANICAL
11. Install the battery and the battery tray. Refer to SecĆ
tion 1E, Engine Electrical.
12. Connect the positive battery cable to the battery.

A102C034

Notice: Take extreme care to prevent any scratches,

nicks, or damage to the camshaft. Such damage can im-
pair vehicle operation.
13. Install the camshaft gear.
14. While holding the camshaft firmly in place, install the
camshaft gear bolt.
Tighten
Tighten the camshaft gear bolt to 45 NSm (33 lb-ft).

A102B111

15. Install the camshaft followers using the valve spring

compressor KM-565-A.
16. Remove the tool KM-565-A.

A102B074

DAEWOO T-100 BL3

 SOHC ENGINE MECHANICAL 1B - 31
17. Install the valve cover gasket.
18. Install the valve cover.
19. Install the valve cover bolts.
Tighten
Tighten the valve cover bolts to 10 NSm (89 lb-in).
20. Connect the air breather tube to the valve cover.
21. Install the timing belt. Refer to “Timing Belt” in this
section.

A102B010

TIMING BELT CHECK AND ADJUST

(Left-Hand Drive Shown, Right Hand
Drive Similar)
Tools Required
J-42492 Timing Belt Adjuster
KM-470-B Angular Torque Gauge
Adjustment Procedure
1. Disconnect the negative battery cable.
2. Disconnect the manifold air temperature sensor con-
nector.
3. Disconnect the air intake tube from the throttle body.
4. Disconnect the breather tube from the valve cover.

A102B001

5. Remove the air cleaner housing bolts.

6. Remove the air cleaner housing.
7. Remove the right front wheel. Refer to Section 2E,
Tires and Wheels.
8. Remove the right front wheel well splash shield.

A102B002

DAEWOO T-100 BL3

1B -- 32 SOHC ENGINE MECHANICAL
9. Remove the A/C compressor drive belt, if equipped.
10. Remove the alternator drive belt.
11. Remove the power steering pump pulley bolts, if
equipped.
12. Remove the power steering pump pulley, if
equipped.
13. Remove the power steering pump mounting bolts,
if equipped.
14. Remove the upper timing belt cover bolts.
15. Remove the upper timing belt cover.

A102B003

16. Remove the crankshaft pulley bolt.

17. Remove the crankshaft pulley.

A102B018

18. Remove the lower timing belt cover bolts.

19. Remove the lower timing belt cover.

A102B008

DAEWOO T-100 BL3

 SOHC ENGINE MECHANICAL 1B - 33
20. Install the crankshaft pulley bolt.
21. Rotate the crankshaft at least one full turn clockwise
using the crankshaft pulley bolt.
22. Align the dot on the crankshaft gear to the notch at
the bottom of the rear timing belt cover.

A102B030

23. Align the camshaft gear timing mark to the notch at

the top of the rear timing belt cover.

A102B004

24. Slightly loosen the three coolant pump retaining

bolts.
25. Using the timing belt adjuster J-42492, rotate the
coolant pump clockwise to add the highest tension
to the timing belt.
26. Tighten the coolant pump retaining bolts.

A102B040

DAEWOO T-100 BL3

1B -- 34 SOHC ENGINE MECHANICAL
27. Align the adjust arm hole of the timing belt automatic
tensioner to the hole in the timing belt automatic ten-
sioner bracket.
28. Insert a 4.5 mm driver through the adjust arm hole
and the tensioner bracket hole.
29. Rotate the crankshaft two full turns clockwise using
the crankshaft pulley bolt.
30. Rotate the crankshaft at least one full turn clockwise
using the crankshaft pulley bolt.
31. Remove the driver from the timing belt automatic
tensioner.
32. Loosen the coolant pump retaining bolts.

A102B039

33. Rotate the coolant pump until the adjust arm pointer
of the timing belt automatic tensioner is aligned with
the notch in the timing belt automatic tensioner
bracket.
34. Tighten the coolant pump retaining bolts.
Tighten
Tighten the coolant pump retaining bolts to 10 NSm
(89 lb-in).

A102B041

35. Remove the crankshaft pulley bolt.

36. Install the lower timing belt cover.
37. Install the lower timing belt cover bolts.
Tighten
Tighten the lower timing belt cover bolts to 10 NSm
(89 lb-in).

A102B008

DAEWOO T-100 BL3

 SOHC ENGINE MECHANICAL 1B - 35
38. Install the crankshaft pulley.
39. Install the crankshaft pulley bolt.
Tighten
Tighten the crankshaft pulley bolt to 95 NSm (70 lb-ft)
using a torque wrench. Use the angular torque gauge
KM-470-B to tighten the crankshaft pulley bolt anoth-
er 30 degrees plus 15 degrees.

A102B018

40. Install the upper timing belt cover.

41. Install the upper timing belt cover bolts.
Tighten
Tighten the upper timing belt cover bolts to 10 NSm
(89 lb-in).
42. Install the power steering pump mounting bolts, if
equipped.
Tighten
Tighten the power steering pump mounting bolts to
25 NSm (18 lb-ft).
43. Install the power steering pump pulley, if equipped.
44. Install the power steering pump pulley bolts, if
equipped.
Tighten
Tighten the power steering pump pulley bolts to
A102B005 25 NSm (18 lb-ft).

45. Install the alternator drive belt.

Tighten
Tighten the alternator adjusting bolt to 20 NSm (15 lb-
ft).
46. Install the A/C compressor drive belt, if equipped.
47. Install the right front wheel well splash shield.
48. Install the right front wheel. Refer to Section 2E,
Tires and Wheels.
49. Install the air cleaner housing.
50. Install the air cleaner housing bolts.
Tighten
Tighten the air filter housing bolts to 12 NSm (106 lb-
in).

A102B002

DAEWOO T-100 BL3

1B -- 36 SOHC ENGINE MECHANICAL
51. Connect the air intake tube to the throttle body.
52. Connect the breather tube to the valve cover.
53. Connect the manifold air temperature sensor con-
nector.
54. Connect the negative battery cable.

A102B001

TIMING BELT
(Left-Hand Drive Shown, Right Hand
Drive Similar)
Tools Required
J-42492 Timing Belt Adjuster
KM-470-B Angular Torque Gauge
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the manifold air temperature sensor con-
nector.
3. Disconnect the air intake tube from the throttle body.
4. Disconnect the breather tube from the valve cover.

A102B001

5. Remove the air cleaner housing bolts.

6. Remove the air cleaner housing.
7. Remove the right front wheel. Refer to Section 2E,
Tires and Wheels.
8. Remove the right front wheel well splash shield.

A102B002

DAEWOO T-100 BL3

 SOHC ENGINE MECHANICAL 1B - 37
9. Remove the A/C compressor drive belt, if equipped.
10. Remove the alternator drive belt.
11. Remove the power steering pump, if equipped. Re-
fer to Section 6B, Power Steering Pump.
12. Remove the upper timing belt cover bolts.
13. Remove the upper timing belt cover.

A102B003

14. Remove the crankshaft pulley bolt.

15. Remove the crankshaft pulley.
16. Remove the lower timing belt cover bolts.
17. Remove the lower timing belt cover.

A102B008

18. Install the crankshaft pulley bolt.

19. Using the crankshaft pulley bolt, rotate the crank-
shaft clockwise until the mark on the crankshaft
gear is aligned with the notch at the bottom of the
rear timing belt cover.

A102B030

DAEWOO T-100 BL3

1B -- 38 SOHC ENGINE MECHANICAL
20. Slightly loosen the coolant pump retaining bolts.
21. Using the timing belt adjuster J-42492, rotate the
coolant pump counterclockwise to release the ten-
sion on the timing belt.
22. Remove the timing belt.

A102B040

Installation Procedure
1. Align the mark on the crankshaft gear to the notch on
the bottom of the rear timing belt cover.
2. Align the mark on the camshaft gear to the notch on
the top of the rear timing belt cover.
3. Install the timing belt.

A102B042

4. Using the timing belt adjuster J-42492, rotate the

coolant pump clockwise to add the highest tension to
the timing belt.
5. Tighten the coolant pump retaining bolts.

A102B040

DAEWOO T-100 BL3

 SOHC ENGINE MECHANICAL 1B - 39
6. Align the adjust arm hole of the timing belt automatic
tensioner to the hole in the timing belt automatic ten-
sioner bracket.
7. Insert a 4.5 mm driver through the adjust arm hole
and the tensioner bracket hole.

A102B039

8. Rotate the crankshaft two full turns clockwise using

the crankshaft pulley bolt.
9. Align the mark on the crankshaft gear to the notch at
the bottom of the rear timing belt cover.

A102B030

10. Remove the driver from the timing belt automatic

tensioner.
11. Slightly loosen the three coolant pump retaining
bolts.
12. Using the timing belt adjuster J-42492, rotate the
coolant pump.

A102B040

DAEWOO T-100 BL3

1B -- 40 SOHC ENGINE MECHANICAL
13. Rotate the coolant pump until the adjust arm pointer
of the timing belt automatic tensioner is aligned with
the notch in the timing belt automatic tensioner
bracket.
14. Tighten the coolant pump retaining bolts.
Tighten
Tighten the coolant pump retaining bolts to 10 NSm
(89 lb-in).

A102B041

15. Remove the crankshaft pulley bolt.

16. Install the lower timing belt cover.
17. Install the lower timing belt cover bolts.
Tighten
Tighten the lower timing belt cover bolts to 10 NSm
(89 lb-in).

A102B008

18. Install the crankshaft pulley.

19. Install the crankshaft pulley bolt.
Tighten
Tighten the crankshaft pulley bolt to 95 NSm (70 lb-ft)
using a torque wrench. Using the angular torque
gauge KM-470-B, tighten the crankshaft pulley bolt
another 30 degrees plus 15 degrees.

A102B018

DAEWOO T-100 BL3

 SOHC ENGINE MECHANICAL 1B - 41
20. Install the upper timing belt cover.
21. Install the upper timing belt cover bolts.
Tighten
Tighten the upper timing belt cover bolts to 10 NSm
(89 lb-in).

A102B003

22. Install the power steering pump, if equipped. Refer

to Section 6B, Power Steering Pump.
23. Install the alternator drive belt.
24. Install the A/C compressor drive belt, if equipped.

A102B006

25. Install the right front wheel well splash shield.

26. Install the right front wheel. Refer to Section 2E,
Tires and Wheels.
27. Install the air filter housing.
28. Install the air filter housing bolts.
Tighten
Tighten the air filter housing bolts to 12 NSm (106 lb-in).

A102B002

DAEWOO T-100 BL3

1B -- 42 SOHC ENGINE MECHANICAL
29. Connect the air intake tube to the throttle body.
30. Connect the breather tube to the valve cover.
31. Connect the manifold air temperature sensor con-
nector.
32. Connect the negative battery cable.

A102B001

OIL PUMP
Tools Required
KM-498-B Pressure Gauge
KM-135 Adapter
Engine Oil Pressure Inspection Procedure
1. Remove the right-hand (RH) wheel well splash shield.
2. Remove the oil pressure switch connector.

A102B019

3. Install the adapter KM-135 in place of the oil pressure

switch.
4. Connect the pressure gauge KM-498-B to the adapt-
er.
5. Start the engine and check the oil pressure at idle
speed and an engine temperature of 80_C (176_ F).
Important: The minimum oil pressure should be 30 kPa
(8.88 psi).
6. Stop the engine and remove the oil pressure gauge
and the adapter.

A202B003

DAEWOO T-100 BL3

 SOHC ENGINE MECHANICAL 1B - 43
7. Install the oil pressure switch.
Tighten
Tighten the oil pressure switch to 40 NSm (30 lb-ft).
8. Connect the electrical connector to the oil pressure
switch.
9. Install the RH wheel well splash shield.
10. Check the oil level and fill the oil to the FULL mark.

A102B019

Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the power steering pump, if equipped. Re-
fer to Section 6A, Power Steering System.
3. Remove the timing belt. Refer to “Timing Belt” in this
section.
4. Remove the rear timing belt cover. Refer to “Rear
Timing Belt Cover” in this section.
5. Disconnect the oil pressure switch connector.

A102B019

6. Remove the crankshaft position sensor bolt.

7. Remove the crankshaft position sensor.
8. Remove the oil pan. Refer to “Oil Pan” in this sec-
tion.
9. Remove the oil pump pickup tube and the support
bracket bolts.
10. Remove the oil pump pickup tube.

A102B064

DAEWOO T-100 BL3

1B -- 44 SOHC ENGINE MECHANICAL
11. Remove the oil pump retaining bolts.
12. Carefully separate the oil pump and the gasket from
the engine block and the oil pan.
13. Remove the oil pump.

A102B065

Inspection Procedure
1. Clean the oil pump and the engine block gasket mat-
ing surfaces.
2. Remove the safety relief valve bolt.
3. Remove the safety relief valve and the spring.
4. Remove the oil pump-to-crankshaft seal.

A202B002

5. Remove the oil pump rear cover bolts.

6. Remove the rear cover.

A202B001

DAEWOO T-100 BL3

 SOHC ENGINE MECHANICAL 1B - 45
7. Clean the oil pump housing and all of the parts.
8. Inspect all of the parts for signs of wear. Refer to
“Engine Specifications” in this section.
9. Coat all of the oil pump parts with clean engine oil.
10. Reinstall all of the oil pump parts.
Notice: Pack the oil pump gear cavity with petroleum
jelly to ensure an oil pump prime. Failure to do this can
damage the engine.
11. Install the oil pump rear cover and the bolts.
Tighten
Tighten the oil pump rear cover bolts to 6 NSm (53 lb-
in).
12. Install the safety relief valve, the spring, the washer,
and the bolt.
Tighten
A202B001
Tighten the oil pump safety relief valve bolt to 30 NSm
(22 lb-ft).

Installation Procedure
1. Apply a bead of room temperature vulcanizing (RTV)
sealer to the oil pump gasket.
2. Install a new oil pump gasket to the oil pump.
3. Coat the threads of the oil pump bolts with Loctite[
573.
4. Install the oil pump to the engine block with the bolts.
Tighten
Tighten the oil pump retaining bolts to 10 NSm (89 lb-
in).

A102B065

DAEWOO T-100 BL3

1B -- 46 SOHC ENGINE MECHANICAL
5. Install a new oil pump to the crankshaft shaft seal.
6. Coat the lip of the seal with a thin coat of grease.

A202B002

7. Coat the threads of the oil pump pickup tube and the
support bracket bolts with Loctite[ 573.
8. Install the oil pump pickup tube and the bolts.
Tighten
Tighten the oil pump pickup tube and the support
bracket bolts to 10 NSm (89 lb-in).

A102B064

9. Install the oil pan. Refer to “Oil Pan” in this section.

10. Install the crankshaft position sensor and the bolt.
Tighten
Tighten the crankshaft position sensor retaining bolt
to 10 NSm (89 lb-in).
11. Connect the oil pressure switch connector.
12. Install the rear timing belt cover. Refer to “Rear Tim-
ing Belt Cover” in this section.
13. Install the timing belt. Refer to “Timing Belt” In this
section.
14. Install the power steering pump, if equipped. Refer
to Section 6A, Power Steering System.
15. Connect the negative battery cable.

A102B019

DAEWOO T-100 BL3

 SOHC ENGINE MECHANICAL 1B - 47

OIL PAN
Removal Procedure
1. Disconnect the negative battery cable.
2. Drain the engine oil from the engine crankcase.
3. Remove the exhaust flex pipe retaining nuts from the
exhaust manifold and the bolts from the bracket.
4. Remove the exhaust flex pipe retaining nuts from the
catalytic converter or connecting pipe.
5. Remove the exhaust flex pipe.

A202B004

6. Remove the flywheel or flexible plate inspection cover

bolts.
7. Remove the flywheel or flexible plate inspection cov-
er.

A102B021

8. Remove the oil pan retaining bolts.

9. Remove the oil pan from the engine block.

A102B043

DAEWOO T-100 BL3

1B -- 48 SOHC ENGINE MECHANICAL

Cleaning Procedure
1. Clean the oil pan sealing surface.
2. Clean the engine block sealing surface.
3. Clean the oil pan retaining bolts.
4. Clean the oil pan retaining bolt holes in the engine
block.

A102B044

Installation Procedure
1. Install the oil pan gasket to the oil pan.
2. Install the oil pan to the engine block.
Important: Install the oil pan within 5 minutes after ap-
plying liquid gasket to the oil pan.
3. Install the oil pan retaining bolts.
Tighten
Tighten the oil pan retaining bolts to 10 NSm (89 lb-in).

A102B043

4. Install the flywheel or flexible plate inspection cover.

5. Install the flywheel or flexible plate inspection cover
bolts.
Tighten
Tighten the flywheel inspection cover bolts to 12 NSm
(106 lb-in) or the flexible plate inspection cover bolts
to 10 NSm (89 lb-in).

A102B021

DAEWOO T-100 BL3

 SOHC ENGINE MECHANICAL 1B - 49
6. Install the exhaust flex pipe.
7. Install the exhaust flex pipe to the exhaust manifold
retaining nuts and the bracket bolts.
Tighten
Tighten the exhaust flex pipe-to-exhaust manifold re-
taining nuts and bracket bolts to 40 NSm (30 lb-ft).
8. Install the exhaust flex pipe retaining nuts to the cat-
alytic converter or connecting pipe.
Tighten
Tighten the exhaust flex pipe-to-catalytic converter or
connecting pipe retaining nuts to 30 NSm (22 lb-ft).
9. Connect the negative battery cable.
10. Install the oil pan drain plug.
Tighten
Tighten the oil pan drain plug to 55 NSm (41 lb-ft).
A202B004
11. Refill the engine crankcase with engine oil.

ENGINE MOUNT
Tools Required
J-28467-B Engine Assembly Support Fixture
Removal Procedure
1. Disconnect the negative battery cable.
2. Support the engine assembly using the engine as-
sembly support fixture J-28467-B.

A105B012

DAEWOO T-100 BL3

1B -- 50 SOHC ENGINE MECHANICAL
3. Remove the engine mount bracket retaining bolts.

A102B020

4. Remove the engine mount attaching nuts.

5. Remove the engine mount.

A102B045

Installation Procedure
1. Install the engine mount.
2. Install the engine mount attaching nuts.
Tighten
Tighten the engine mount attaching nuts to 40 NSm
(30 lb-ft).

A102B045

DAEWOO T-100 BL3

 SOHC ENGINE MECHANICAL 1B - 51
3. Install the engine mount bracket retaining bolts.
Tighten
Tighten the engine mount bracket retaining bolts to
60 NSm (44 lb-ft).

A102B020

4. Remove the engine assembly support fixture

J-28467-B.
5. Connect the negative battery cable.

A105B012

INTAKE MANIFOLD
(Left-Hand Drive Shown, Right Hand
Drive Similar)
Removal Procedure
1. Remove the fuel pump fuse.
2. Start the engine. Crank the engine after it stalls for
10 seconds to rid the fuel system of fuel pressure.
3. Disconnect the negative battery cable.
4. Disconnect the electronic control module (ECM)
ground terminal from the intake manifold.

A102B012

DAEWOO T-100 BL3

1B -- 52 SOHC ENGINE MECHANICAL
5. Drain the engine coolant. Refer to Section 1D, EnĆ
gine Cooling.
6. Disconnect the manifold air temperature sensor
connector.
7. Disconnect the air intake tube from the throttle body.

A102B001

8. Disconnect the idle air control valve connector.

9. Disconnect the throttle position sensor connector.
10. Disconnect the engine coolant temperature sensor
connector.

A102B016

11. Disconnect the heater inlet hose from the coolant

distributor beneath the intake manifold.
12. Disconnect the surge tank coolant hose at the
throttle body.
13. Disconnect all of the necessary vacuum hoses, in-
cluding the vacuum hose at the fuel pressure regu-
lator and the brake booster vacuum hose at the
intake manifold.

A102B031

DAEWOO T-100 BL3

 SOHC ENGINE MECHANICAL 1B - 53
14. Disconnect the throttle cable from the throttle body
and the intake manifold.
15. Remove the two throttle cable bracket bolts and the
throttle cable bracket.
16. Disconnect the fuel return line from the fuel pressure
regulator.
17. Disconnect the fuel feed line from the fuel rail.

A102B116

18. Disconnect the fuel injector connectors from the fuel

injectors.
19. Remove the two retaining bolts from the fuel injector
rail.
20. Remove the fuel injector rail and fuel injectors as an
assembly. Refer to Section 1F, Engine Controls.

A102B032

21. Remove the alternator drive belt.

22. Remove the alternator adjusting bracket and the
bolts.

A102B118

DAEWOO T-100 BL3

1B -- 54 SOHC ENGINE MECHANICAL
23. Remove the three intake manifold support bracket
retaining bolts from the coolant distributor and the
engine block.
24. Remove the intake manifold support bracket.

A102B033

25. Remove the intake manifold retaining nuts and the

engine lift bracket bolt in the sequence shown.

A102B036

26. Remove the intake manifold.

27. Remove the intake manifold gasket.
28. Clean the sealing surfaces of the intake manifold
and the cylinder head.

A102B034

DAEWOO T-100 BL3

 SOHC ENGINE MECHANICAL 1B - 55
Installation Procedure
1. Install the intake manifold gasket.
2. Install the intake manifold.
3. Install the intake manifold retaining nuts and the en-
gine lift bracket bolt in the sequence shown.
Tighten
Tighten the intake manifold retaining nuts in the se-
quence shown to 25 NSm (18 lb-ft).
Tighten the engine lift bracket bolt to 25 NSm (18 lb-ft).

A102B035

4. Install the intake manifold support bracket.

5. Install the intake manifold support bracket retaining
bolts.
Tighten
Tighten the intake manifold support bracket retaining
bolts to 22 NSm (16 lb-ft).
6. Install the alternator adjusting bracket and the bolts.
Tighten
Tighten the alternator adjusting bracket retaining
bolts to 20 NSm (15 lb-ft).
7. Install the alternator drive belt.

A102B118

8. Install the fuel rail and the fuel injectors as an assem-

bly. Refer to Section 1F, Engine Controls.
9. Install the fuel rail retaining bolts.
Tighten
Tighten the fuel rail retaining bolts to 25 NSm (18 lb-ft).

A102B032

DAEWOO T-100 BL3

1B -- 56 SOHC ENGINE MECHANICAL
10. Connect the fuel return line to the fuel pressure reg-
ulator.
11. Connect the fuel feed line to the fuel rail.
12. Install the throttle cable bracket and the two throttle
cable bracket bolts.
Tighten
Tighten the throttle cable bracket bolts to 8 NSm
(71 lb-in).
13. Connect the throttle cable to the intake manifold and
the throttle body.

A102B120

14. Connect the fuel injector connectors to the fuel in-

jectors.
15. Connect all of the vacuum lines that were previously
disconnected.
16. Connect the heater inlet hose to the coolant distribu-
tor beneath the intake manifold.
17. Connect the surge tank coolant hose to the throttle
body.
18. Connect the engine coolant temperature sensor
connector.
19. Connect the idle air control valve connector.
20. Connect the throttle position sensor connector.

A102B016

21. Connect the air intake tube to the throttle body.

22. Connect the manifold air temperature sensor con-
nector.
23. Connect the ECM ground terminal to the intake
manifold.
24. Connect the negative battery cable.
25. Install the fuel pump fuse.
26. Refill the engine cooling system. Refer to Section
1D, Engine Cooling.

A102B001

DAEWOO T-100 BL3

 SOHC ENGINE MECHANICAL 1B - 57

EXHAUST MANIFOLD
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the ignition wires from the spark plugs.
3. Disconnect the oxygen sensor.
4. Remove the exhaust manifold heat shield bolts.
5. Remove the exhaust manifold heat shield.
6. Remove the nuts from the exhaust flex pipe flange
and the bracket bolts.

A202B004

7. Remove the eight exhaust manifold nuts in the se-

quence shown.
8. Remove the exhaust manifold.
9. Remove the exhaust manifold gasket.
10. Clean the sealing surfaces of the exhaust manifold
and the cylinder head.

A102B037

Installation Procedure
1. Install the exhaust manifold gasket.
2. Install the exhaust manifold.
3. Install the eight exhaust manifold nuts and torque in
the sequence shown.
Tighten
Tighten the exhaust manifold nuts 25 NSm (18 lb-ft).

A102B038

DAEWOO T-100 BL3

1B -- 58 SOHC ENGINE MECHANICAL
4. Install the exhaust flex pipe-to-exhaust manifold re-
taining nuts and the bracket bolts.
Tighten
Tighten the three exhaust flex pipe-to-exhaust man-
ifold retaining nuts and the bracket bolts to 40 NSm
(30 lb-ft).
5. Install the manifold heat shield.
6. Install the exhaust manifold heat shield bolts.
Tighten
Tighten the exhaust manifold heat shield bolts to
15 NSm (11 lb-ft).
7. Connect the oxygen sensor.
8. Connect the ignition wires to the spark plugs.
9. Connect the negative battery cable.

A202B004

CAMSHAFT GEAR
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the timing belt. Refer to “Timing Belt” in this
section.
3. Remove the valve cover bolts.
4. Remove the valve cover.

A102B010

Notice: Take extreme care to prevent any scratches,

nicks, or damage to the camshaft. Such damage can im-
pair vehicle operation.
5. While holding the camshaft firmly in place, remove
the camshaft gear bolt.
6. Remove the camshaft gear.

A102B111

DAEWOO T-100 BL3

 SOHC ENGINE MECHANICAL 1B - 59
Installation Procedure
Notice: Take extreme care to prevent any scratches,
nicks, or damage to the camshaft. Such damage can im-
pair vehicle operation.
1. Install the camshaft gear.
2. While holding the camshaft firmly in place, install the
camshaft gear bolt.
Tighten
Tighten the camshaft gear bolt to 45 NSm (33 lb-ft).

A102B111

3. Install the valve cover.

4. Install the valve cover bolts.
Tighten
Tighten the valve cover bolts to 10 NSm (89 lb-in).
5. Install the timing belt. Refer to “Timing Belt” in this
section.
6. Connect the negative battery cable.

A102B010

REAR TIMING BELT COVER

Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the timing belt. Refer to “Timing Belt” in this
section.
Notice: Take extreme care to prevent any scratches,
nicks, or damage to the camshaft. Such damage can im-
pair vehicle operation.
3. Remove the camshaft gear. Refer to “Camshaft
Gear” in this section.
4. Remove the timing belt automatic tensioner bolt.
5. Remove the timing belt automatic tensioner.
6. Remove the rear timing belt cover bolts.
7. Remove the rear timing belt cover.
A102B046

DAEWOO T-100 BL3

1B -- 60 SOHC ENGINE MECHANICAL

Installation Procedure
1. Install the rear timing belt cover.
2. Install the rear timing belt cover bolts.
Tighten
Tighten the rear timing belt cover bolts to 10 NSm
(89 lb-in).
3. Install the timing belt automatic tensioner.
4. Install the timing belt automatic tensioner bolt.
Tighten
Tighten the timing belt automatic tensioner bolt to
20 NSm (15 lb-ft).
Notice: Take extreme care to prevent any scratches,
nicks, or damage to the camshaft. Such damage can im-
pair vehicle operation.
A102B041 5. Install the camshaft gear. Refer to “Camshaft Gear”
in this section.
6. Install the timing belt. Refer to “Timing Belt” in this
section.
7. Connect the negative battery cable.

ENGINE
(Left-Hand Drive Shown, Right Hand
Drive Similar)
Tools Required
KM-470-B Angular Torque Gauge
Removal Procedure
Important: On vehicles equipped with a manual trans-
axle, the manual transaxle must be removed before en-
gine removal. Refer to Section 5B, FiveĆSpeed Manual
Transaxle.
1. Remove the fuel pump fuse.
2. Start the engine. Crank the engine after it stalls for
10 seconds to rid the fuel system of fuel pressure.
3. Remove the hood. Refer to Section 9R, Body Front
A102B012
End.
4. Drain the engine oil.
DAEWOO T-100 BL3
 SOHC ENGINE MECHANICAL 1B - 61
5. Disconnect the negative battery cable.
6. Disconnect and separate the battery positive cable.
7. Disconnect the negative battery cable from the ve-
hicle frame.

A102B013

8. Discharge the air conditioning (A/C) system, if

equipped. Refer to Section 7B, Manual Control
Heating, Ventilation, and Air Conditioning System.
9. Disconnect the manifold air temperature sensor
connector.
10. Remove the air intake tube from the throttle body
and the air filter housing.
11. Disconnect the breather tube from the valve cover.

A102B011

12. Remove the right front wheel. Refer to Section 2E,

Tires and Wheels.
13. Remove the right front wheel well splash shield.
14. Remove the A/C compressor drive belt, if equipped.
15. Remove the alternator drive belt.
16. Remove the power steering pump pulley bolts.
17. Remove the power steering pump pulley.

A102B014

DAEWOO T-100 BL3

1B -- 62 SOHC ENGINE MECHANICAL
18. Drain the engine coolant. Refer to Section 1D, EnĆ
gine Cooling.
19. Remove the cooling system radiator and the engine
cooling fans. Refer to Section 1D, Engine Cooling.
20. Disconnect the upper radiator hose from the ther-
mostat housing.
21. Disconnect the coolant surge tank hose from the ra-
diator.
22. Disconnect the power steering return hose from the
power steering pump, if equipped.
23. Drain the power steering system, if equipped.
24. Disconnect the power steering pressure hose from
the power steering pump, if equipped.

A102B015

25. Disconnect the electrical connector at the direct igni-

tion system (DIS) ignition coil, and the engine con-
trol module (ECM) ground terminal at the intake
manifold and at the starter motor.
26. Disconnect the oxygen sensor connector.
27. Disconnect the electrical connectors at the fuel in-
jectors.
28. Disconnect the idle air control valve connector.
29. Disconnect the throttle position sensor connector.
30. Disconnect the engine coolant temperature sensor
connector.
31. Disconnect the coolant temperature sensor connec-
tor and the knock sensor, if equipped.

A102B016

32. Disconnect the alternator voltage regulator connec-

tor.
33. Disconnect all of the necessary vacuum lines, in-
cluding the brake booster vacuum hose.
34. Disconnect the fuel return line at the fuel pressure
regulator.
35. Disconnect the fuel feed line at the fuel rail.
36. Disconnect the throttle cable from the throttle body
and the intake manifold bracket.

A102B116

DAEWOO T-100 BL3

 SOHC ENGINE MECHANICAL 1B - 63
37. Disconnect the surge tank coolant hose at the
throttle body.
38. Disconnect the heater inlet hose from the coolant
distributor.
39. Disconnect the heater outlet hose at the coolant
pipe.
40. Disconnect the surge tank coolant hose from the
coolant pipe.
41. Disconnect the lower radiator hose at the coolant
pipe.

A102B017

42. Disconnect the starter solenoid “S” terminal wire.

43. Remove the A/C compressor hose assembly retain-
ing bolt.
44. Disconnect the A/C compressor hose assembly
from the compressor.
45. Disconnect the A/C compressor coil connector.
46. Remove the A/C compressor mounting bolts.
47. Remove the A/C compressor.
48. Remove the A/C compressor mounting bracket
bolts.
49. Remove the A/C compressor mounting bracket from
the engine block.

A102B025

50. Remove the exhaust flex pipe retaining nuts from

the exhaust manifold.
51. Remove the exhaust flex pipe retaining nuts from
the catalytic converter or connecting pipe.
52. Remove the exhaust flex pipe.
53. Remove the engine crankshaft pulley bolt.
54. Remove the engine crankshaft pulley.

A102B018

DAEWOO T-100 BL3

1B -- 64 SOHC ENGINE MECHANICAL
55. Disconnect the vacuum lines at the charcoal canis-
ter purge and exhaust gas recirculation (EGR) sole-
noid.
56. Disconnect the electrical connector at the charcoal
canister purge solenoid and the knock sensor.
57. Disconnect the electrical connector at the oil pres-
sure switch.
58. Disconnect the crankshaft position sensor connec-
tor.
59. Remove the crankshaft position sensor retaining
bolt.
60. Remove the crankshaft position sensor.
61. Remove the right transaxle brace bolts from the
transmission.

A102B019

62. Remove the flywheel or the flexible plate inspection

cover bolts.
63. Remove the flywheel or the flexible plate inspection
cover.

A102B021

64. Remove the transaxle torque converter bolts on ve-

hicles with an automatic transaxle.

A102B022

DAEWOO T-100 BL3

 SOHC ENGINE MECHANICAL 1B - 65
65. Remove the transaxle bell housing bolts.
66. Support the transaxle with a floor jack.
67. Install the engine lifting device.
68. Disconnect the right engine mount bracket from the
rubber engine mount by removing the two retaining
bolts.
69. Remove the right engine mount bracket from the en-
gine block.
70. Separate the engine block from the transaxle.
71. Remove the engine.
72. Transfer any necessary parts.

A102B020

Installation Procedure
1. Install the engine into engine compartment.
2. Align the transaxle alignment pins to the transaxle.
3. Install the transaxle bell housing bolts.
Tighten
Tighten the transaxle bell housing bolts to 75 NSm
(55 lb-ft).

A102B063

4. Install the right engine mount bracket to the engine

block.
5. Install the right engine mount bracket retaining bolts
to the engine block.
Tighten
Tighten the engine mount bracket retaining bolts to
60 NSm (44 lb-ft).
6. Install the engine mount-to-bracket retaining bolts.
Tighten
Tighten the engine mount bracket-to-engine mount
retaining bolts to 60 NSm (44 lb-ft).
7. Remove the floor jack used for support of the trans-
axle.
8. Remove the engine lifting device.
A102B020

DAEWOO T-100 BL3

1B -- 66 SOHC ENGINE MECHANICAL
9. Install the transaxle torque converter bolts, if the ve-
hicle has an automatic transaxle.
Tighten
Tighten the transaxle torque converter bolts to 45 NSm
(33 lb-ft).

A102B022

10. Install the flywheel or the flexible plate inspection

cover.
11. Install the flywheel or the flexible plate inspection
cover bolts.
Tighten
Tighten the flywheel inspection cover bolts to 12 NSm
(106 lb-in) or the flexible plate inspection cover bolts
to 10 NSm (89 lb-in).
12. Install the right transaxle brace bolts to the trans-
axle.
Tighten
Tighten the right transaxle brace bolts to 60 NSm
(45 lb-ft).
13. Connect the vacuum lines at the charcoal canister
purge and EGR solenoid.
14. Connect the electrical connectors at the charcoal
A102B024
canister purge and EGR solenoids.

15. Connect the oil pressure switch connector.

16. Install the crankshaft pulley.
17. Install the crankshaft pulley bolt.
Tighten
Tighten the crankshaft pulley bolt to 95 NSm (70 lb-ft)
using a torque wrench. Using the angular torque
gauge KM-470-B, tighten the crankshaft pulley bolt
another 30 degrees plus 15 degrees.

A102B018

DAEWOO T-100 BL3

 SOHC ENGINE MECHANICAL 1B - 67
18. Install the crankshaft position sensor and the crank-
shaft position sensor retaining bolt.
Tighten
Tighten the crankshaft position sensor retaining bolt
to 10 NSm (89 lb-in).
19. Connect the crankshaft position sensor connector.
20. Install the exhaust flex pipe.
21. Install the exhaust flex pipe-to-catalytic converter
retaining nuts.
Tighten
Tighten the exhaust flex pipe-to-catalytic converter or
connecting pipe retaining nuts to 30 NSm (22 lb-ft).
22. Install the exhaust flex pipe-to-exhaust manifold re-
taining nuts and the bracket bolts.
A202B004 Tighten
Tighten the exhaust flex pipe to exhaust manifold re-
taining nuts and the bracket bolts to 40 NSm (30 lb-ft).

23. Connect the power steering pressure hose, if

equipped.
24. Connect the power steering return hose, if
equipped.

A102B015

DAEWOO T-100 BL3

1B -- 68 SOHC ENGINE MECHANICAL
25. Install the A/C compressor mounting bracket, if
equipped.
26. Install the A/C compressor mounting bracket bolts, if
equipped.
Tighten
Tighten the A/C compressor mounting bracket bolts
to 50 NSm (36 lb-ft).
27. Install the A/C compressor, if equipped.
28. Install the A/C compressor mounting bolts, if
equipped.
Tighten
Tighten the A/C compressor mounting bolts to 27 NSm
(20 lb-ft).
29. Connect the A/C compressor coil connector.
30. Install the alternator drive belt.
A102B025 31. Install the A/C compressor drive belt, if equipped.

32. Connect the A/C compressor hose assembly and

the A/C compressor hose assembly retaining bolt,
if equipped.
Tighten
Tighten the A/C compressor hose assembly retaining
bolt to 33 NSm (24 lb-ft).
33. Install the power steering pump pulley, if equipped.
34. Install the power steering pump pulley bolts, if
equipped.
Tighten
Tighten the power steering pump pulley bolts to
25 NSm (18 lb-ft).

A102B014

35. Install the right front wheel well splash shield.

36. Install the right front wheel. Refer to Section 2E,
Tires and Wheels
37. Connect the fuel feed line to the fuel rail.
38. Connect the fuel return line to the fuel pressure reg-
ulator.
39. Connect all of the necessary vacuum lines, includ-
ing the brake booster vacuum hose.

A102B116

DAEWOO T-100 BL3

 SOHC ENGINE MECHANICAL 1B - 69
40. Connect the oxygen sensor connector.
41. Connect the starter solenoid “S” terminal wire.
42. Connect the alternator voltage regulator connector.
43. Connect the coolant temperature sensor connector.
44. Connect the engine coolant temperature sensor
connector and the knock sensor connector, if
equipped.
45. Connect the throttle position sensor connector.
46. Connect the idle air control valve connector.

A102B016

47. Connect the electrical connectors at the fuel injec-

tors.
48. Connect the electrical connector at the DIS ignition
coil and the ECM ground terminal at the intake man-
ifold.
49. Install the air intake tube between the throttle body
and the air filter housing.
50. Connect the breather tube to the valve cover.
51. Connect the manifold air temperature sensor con-
nector.

A102B001

52. Install the cooling system radiator and the engine

cooling fans. Refer to Section 1D, Engine Cooling.
53. Connect the lower radiator hose to the coolant pipe.
54. Connect the upper radiator hose to the thermostat
housing.
55. Connect the coolant surge tank hose to the radiator.
56. Connect the heater outlet hose to the coolant pipe.
57. Connect the heater inlet hose to the coolant distribu-
tor.
58. Connect the coolant surge tank hose to the coolant
pipe.
59. Connect the surge tank coolant hose to the throttle
body.

A102B017

DAEWOO T-100 BL3

1B -- 70 SOHC ENGINE MECHANICAL
60. Connect the throttle cable to the throttle body and
the intake manifold bracket.
61. Install the fuel pump fuse.
62. Connect the negative battery cable to the vehicle
frame.
63. Connect the negative battery cable to the battery.
64. Connect and assemble the battery positive cable.
65. Refill the engine crankcase with engine oil.
66. Refill the engine coolant system. Refer to Section
1D, Engine Cooling.
67. Bleed the power steering system as necessary. Re-
fer to Section 6A, Power Steering System.
68. Refill the A/C refrigerant system as necessary. Re-
fer to Section 7B, Manual Control Heating, VentilaĆ
tion, and Air Conditioning System.
69. Install the hood. Refer to Section 9R, Body Front
A102B013
End.

PISTONS AND RODS

Tools Required
KM-427 Piston Pin Service Set
KM 470-B Angular Torque Gauge
Removal Procedure
1. Remove the cylinder head with the intake manifold
and exhaust manifold attached. Refer to “Cylinder
Head and Gasket” in this section.
2. Remove the oil pan. Refer to “Oil Pan” in this sec-
tion.
3. Remove the oil pump/pickup tube bolts.
4. Remove the oil pump/pickup tube.

A102B094

5. Move the piston to the bottom of the piston stroke.

6. Mark the connecting rod cap.
7. Remove the connecting rod cap bolts.
8. Remove the connecting rod cap and lower connect-
ing rod bearing.
9. Remove the upper piston connecting rod bearing.
10. Ridge ream the cylinder wall.

A102B079

DAEWOO T-100 BL3

 SOHC ENGINE MECHANICAL 1B - 71
C a u tio n : U s e c a re w h e n h a n d lin g th e p is to n . W o rn
p is to n rin g s a re s h a rp a n d m a y c a u s e in ju ry .

11. Remove the piston.

12. Use a piston ring expander tool to expand the piston
rings.
13. Remove the piston rings.

A102B080

14. Remove the piston pin from the piston and connect-
ing rod assembly using the piston pin service set
KM-427.
15. Separate the piston from the connecting rod.

A102B081

Inspection Procedure
1. Inspect the connecting rod for bending or twisting. If
the connecting rod is bent or twisted, replace the con-
necting rod.
2. Inspect the connecting rod bearings.
3. Inspect the connecting rod lower end for wear.
4. Inspect the connecting rod upper end for scoring.
5. Inspect the piston for scoring, cracks and wear.
6. Inspect the piston for taper using a micrometer.

A102B087

DAEWOO T-100 BL3

1B -- 72 SOHC ENGINE MECHANICAL
7. Inspect the piston for fit to the connecting rod.

A102B082

8. Inspect the engine block deck surface for flatness

using a straight edge and a feeler gauge. Refer to
“Engine Specifications” in this section.
9. Inspect the bearing bore for concentricity and align-
ment using a bore gauge. Refer to “Engine Specifi-
cations” in this section. If beyond specifications,
replace the engine block.
10. Inspect the engine block cylinder bore for wear, run-
out, ridging and taper using a bore gauge. Refer to
“Engine Specifications” in this section.
11. Inspect the engine block cylinder bore for glazing.
Lightly hone the cylinder bore as necessary.

A102B083

Installation Procedure
1. Align the notch on the piston and connecting rod so
that the proper sides will be facing the front of the en-
gine.
2. Install the piston pin guide through the piston and the
connecting rod.
3. Coat the piston pin with clean oil.
4. Install the piston pin into the opposite side of the pis-
ton.
5. Install the piston pin into the piston and connecting
rod assembly using the piston pin service set
KM-427.

A102B081

DAEWOO T-100 BL3

 SOHC ENGINE MECHANICAL 1B - 73
6. Select a set of new piston rings.
7. Measure the piston ring gap using a feeler gauge.
Refer to “Engine Specifications” in this section.
8. Increase the piston ring gap by carefully filing off ex-
cess material if the piston ring gap is below specifi-
cations.

A102B084

9. Measure the piston ring side clearance using a feel-

er gauge. Refer to “Engine Specifications” in this
section.
10. If the piston ring is too thick, try another piston ring.
11. If no piston ring can be found that fits to specifica-
tions, the piston ring may be ground to size with
emery paper placed on a sheet of glass.

A102B085

12. Install a piston oil ring, the expander, then the sec-
ond piston oil ring to the bottom ring groove of the
piston.
13. Install the second compression ring to the middle
ring groove of the piston.
14. Install the top compression ring to the top ring
groove of the piston.

A102B086

DAEWOO T-100 BL3

1B -- 74 SOHC ENGINE MECHANICAL
15. Use a piston ring expander to install the piston rings.
Do not expand the piston rings beyond the expan-
sion necessary for installation.
16. Stagger the piston oil rings, the oil ring rail gaps, the
second compression ring, and the top compression
ring in relation to the notch on the top of the piston.

A102B089

17. Lubricate the cylinder wall and the piston rings with
clean engine oil.
18. Install the piston using a ring compressor and a
wood handle. Guide the lower connecting rod end to
prevent damaging the crankshaft journal.
19. Install the connecting rod cap and the bearings. Re-
fer to “Crankshaft Bearings and Connecting Rod
Bearings - Gauging Plastic” in this section.

A102B088

20. Install the connecting rod bearing cap bolts.

Tighten
Tighten the connecting rod bearing cap bolts to
25 NSm (18 lb-ft). Using the angular torque gauge
KM-470-B, tighten one turn of 30 degrees plus one
turn of 15 degrees.

A102C151

DAEWOO T-100 BL3

 SOHC ENGINE MECHANICAL 1B - 75
21. Install the oil pump/pickup tube.
22. Install the oil pump/pickup tube bolts.
Tighten
Tighten the oil pump/pickup tube bolts to 10 NSm
(89 lb-in).
23. Install the oil pan. Refer to “Oil Pan” in this section.
24. Install the cylinder head with the intake manifold and
the exhaust manifold attached. Refer to “Cylinder
Head and Gasket” in this section.

A102B094

DAEWOO T-100 BL3

1B -- 76 SOHC ENGINE MECHANICAL

UNIT REPAIR
CYLINDER HEAD AND VALVE TRAIN
COMPONENTS
Tools Required
MKM-571-B Gauge
KM-253 Valve Guide Reamer
KM-254 Valve Guide Reamer
KM-255 Valve Guide Reamer
KM-340-0 Cutter Set
KM-340-7 Guide Drift
KM-340-13 Cutter
KM-340-26 Cutter
KM-348 Valve Spring Compressor
KM-419 Distance Gauge
A102B049
Disassembly Procedure
1. Remove the cylinder head with the intake manifold
and the exhaust manifold attached. Refer to “Cylinder
Head and Gasket” in this section.
2. Remove the coolant temperature sensor.

3. Remove the exhaust manifold heat shield bolts.

4. Remove the exhaust manifold heat shield.
5. Remove the exhaust manifold nuts.
6. Remove the exhaust manifold.
7. Remove the exhaust manifold gasket.
8. Remove the exhaust manifold studs.
9. Remove the spark plugs.

A102B047

DAEWOO T-100 BL3

 SOHC ENGINE MECHANICAL 1B - 77
10. Remove the intake manifold retaining nuts.
11. Remove the intake manifold.
12. Remove the intake manifold gasket.
13. Remove the intake manifold studs.

A102B048

14. Remove the thermostat housing mounting bolts.

15. Remove the thermostat housing.
16. Remove the thermostat and thermostat gasket.

A102B050

17. Using the valve spring compressor KM-348, com-

press the valve springs.
18. Remove the valve keepers.
19. Remove the valve spring cap.
20. Remove the valve springs.
21. Remove the valves.
22. Remove the valve stem oil seals.
23. Remove camshaft carrier alignment pins.

A102B051

DAEWOO T-100 BL3

1B -- 78 SOHC ENGINE MECHANICAL

Cylinder Head Inspection

1. Clean the sealing surfaces.
2. Inspect the cylinder head gasket and the mating sur-
faces for leaks, corrosion, and blowby.
3. Inspect the cylinder head for cracks.
4. Inspect the length and the width of the cylinder head
using a feeler gauge and a straight edge.
5. Check the sealing surfaces for deformation and warp-
age. The cylinder head sealing surfaces must be flat
within .025 mm (.001 inch) maximum.

A102B052

6. Measure the height of the cylinder head from sealing

surface to sealing surface. The cylinder head height
should be 94.70 to 95.65 mm (3.728 to 3.766 inches).
If the cylinder head height is less than 94.70 mm
(3.728 inches), replace the cylinder head.
7. Inspect all threaded holes for damage.
8. Inspect the valve seats for excessive wear and
burned spots.

A102B053

Valve Inspection
1. Inspect valve stem tip wear.
2. Inspect the valve keeper grooves and oil seal grooves
for chips and wear.
3. Inspect the valves for burns or cracks.
4. Inspect the valve stem for burrs and scratches.
5. Inspect the valve stem. The valve stem must be
straight.
6. Inspect the valve face for grooving. If the groove is so
deep the refacing would result in a sharp edge, re-
place the valve.

A102B054

DAEWOO T-100 BL3

 SOHC ENGINE MECHANICAL 1B - 79
7. Inspect the valve spring. If the valve spring ends are
not parallel, replace the valve spring.
8. Measure the valve spring height. Refer to “Engine
Specifications” in this section. If the valve spring
height does not match the specifications, replace the
valve spring.
9. Inspect the valve spring seating surface of the valve
rotators for wear or gouges. Replace as required.

A102B023

Cleaning Procedure
1. Clean the cylinder head.
2. Clean the valve guides.
3. Clean all of the threaded holes.
4. Clean the valves of carbon, oil and varnish.

A102B055

Cylinder Head Overhaul

Valve Grind-in
1. Lubricate the valve stem using a fine-grained paste.
2. Lift the valve rhythmically from the seat with a com-
mercially available valve grinding tool in order to dis-
tribute the paste.

A102B056

DAEWOO T-100 BL3

1B -- 80 SOHC ENGINE MECHANICAL
3. Check the contact pattern on the valve head and in
the cylinder head.
4. Clean the valves, the valve guides, and the cylinder
head.

A102B057

Valve Grind
1. Ensure that there are no crater line burns on the valve
cone.
2. The valve may be reground only two times. Do not
grind the valve stem end.
3. The angle at the valve face angle is 46 degrees.

A102B066

4. Check the valve stem projection using the distance

gauge KM-419.

A102B058

DAEWOO T-100 BL3

 SOHC ENGINE MECHANICAL 1B - 81
Valve Guide Ream
1. Measure the diameter of the valve guide using the
gauge MKM-571-B and a commercially available in-
side micrometer.
Important: Valve oversizes may already have been
fitted in production.
2. An oversize code is on the valve guide and the valve
stem end. The following table gives the correct size,
reamer, and production code for each service code.

Production Service
Size Reamer
Code Code
Normal — — K
0.075 KM-253 1 K1
0.150 KM-254 2 K2
A102B059 0.250 KM-255 — A

3. Ream the valve guide from the upper side of the cylin-
der head to the next oversize. After reaming, cross
out the code and emboss the valve guide with the
new code.

Valve Seat — Cut

1. Place the cylinder head on wooden blocks.
2. Cut the intake and the exhaust valve seats using the
guide drift KM-340-7 as follows:
D Valve seat: a 45-degree side using the cutter
KM-340-13.
D Upper correction angle: a 30-degree side using the
cutter KM-340-13.
D Lower correction angle: a 60-degree side using the
cutter KM-340-26.

A102B060

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1B -- 82 SOHC ENGINE MECHANICAL
3. Clean the chippings from the cylinder head.
4. Inspect the dimension for the proper valve seat width.
D Intake: 1.3 to 1.5 mm (0.051 to 0.059 inch)
D Exhaust: 1.6 to 1.8 mm (0.063 to 0.071 inch)
5. Inspect the valve stem projection using the distance
gauge KM-419.

A102B058

6. If the dimension is exceeded, install new valves and

then check the valve stem projection again. Refer to
“Valve Grind” and “Valve Grind-In” in this section.
7. If the valve stem projection is still too large despite re-
placing the valves, replace the cylinder head.

A102B061

Assembly Procedure
1. Install the camshaft carrier alignment pins.
2. Install the valve stem oil seals.
3. Coat the valves with engine oil.
4. Install the valves.
5. Install the valve springs.
6. Using the valve spring compressor KM-348, com-
press the valve springs.
7. Install the valve keeper.
8. Install the valve spring cap.

A102B051

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 SOHC ENGINE MECHANICAL 1B - 83
9. Install the thermostat and the gasket.
10. Install the thermostat housing.
11. Install the thermostat housing mounting bolts.
Tighten
Tighten the thermostat housing mounting bolts to
20 NSm (15 lb-ft).

A102B050

12. Install the intake manifold studs.

13. Install the intake manifold gasket.
14. Install the intake manifold.
15. Install the intake manifold retaining nuts.
Tighten
Tighten the intake manifold retaining nuts to 25 NSm
(18 lb-ft).

A102B048

16. Install the spark plugs.

Tighten
Tighten the spark plugs to 25 NSm (18 lb-ft).
17. Install the exhaust manifold studs.
18. Install the exhaust manifold gasket.
19. Install the exhaust manifold.
20. Install the exhaust manifold nuts.
Tighten
Tighten the exhaust manifold nuts to 25 NSm (18 lb-ft).

A102B047

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1B -- 84 SOHC ENGINE MECHANICAL
21. Install the exhaust manifold heat shield.
22. Install the exhaust manifold heat shield bolts.
Tighten
Tighten the exhaust manifold heat shield bolts to
15 NSm (11 lb-ft).
23. Install the coolant temperature sensor.
Tighten
Tighten the coolant temperature sensor to 20 NSm
(15 lb-ft).
24. Install the cylinder head with the intake manifold and
the exhaust manifold attached. Refer to “Cylinder
Head and Gasket” in this section.

A102B049

CRANKSHAFT
Tools Required
MKM-412 Engine Overhaul Stand
J-42492 Timing Belt Adjuster
KM-470-B Angular Torque Gauge
J-36792 or KM-635 Crankshaft Rear Oil Seal Installer
Notice: Take extreme care to prevent any scratches,
nicks, or damage to the camshaft. Such damage can im-
pair vehicle operation.
Disassembly Procedure
1. Remove the engine. Refer to ‘‘Engine’’ in this section.
2. Remove the flywheel bolts.
3. Remove the flywheel.
4. Remove the crankshaft rear oil seal.
A102B095
5. Mount the engine assembly on the engine overhaul
stand MKM-412.

DAEWOO T-100 BL3

 SOHC ENGINE MECHANICAL 1B - 85
6. Remove the upper timing belt cover bolts.
7. Remove the upper timing belt cover.
8. Remove the power steering pump mounting bolts.
9. Remove the power steering pump.
10. Remove the lower timing belt cover bolts.
11. Remove the lower timing belt cover.

A102B096

12. Slightly loosen the three coolant pump retaining

bolts.
13. Rotate the coolant pump using timing belt adjuster
J-42492 to remove the tension from the timing belt.
14. Remove the timing belt.

A102B040

15. Remove the valve cover bolts.

16. Remove the valve cover and the valve cover gasket.
Notice: Take extreme care to prevent any scratches,
nicks, or damage to the camshaft. Such damage can im-
pair vehicle operation.
17. While holding the camshaft firmly in place, remove
the camshaft gear bolt.
18. Remove the camshaft gear.

A102B111

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1B -- 86 SOHC ENGINE MECHANICAL
19. Remove the timing belt automatic tensioner bolt.
20. Remove the timing belt automatic tensioner.
21. Remove the rear timing belt cover bolts.
22. Remove the rear timing belt cover.
23. Remove the crankshaft timing belt gear.

A102B093

24. Rotate the engine on the engine overhaul stand

MKM-412.
25. Remove the oil pan retaining bolts.
26. Remove the oil pan.
27. Remove the oil pickup tube bolts.
28. Remove the oil pump pickup tube.

A102B064

29. Remove the oil pump retaining bolts.

30. Remove the oil pump.

A102B065

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 SOHC ENGINE MECHANICAL 1B - 87
31. Mark the order of the rod bearing caps.
32. Remove the connecting rod cap bolts for all of the
pistons.
33. Remove the connecting rod bearing caps and the
lower connecting rod bearings.
34. Remove the upper connecting rod bearings.

A102B067

35. Mark the order of the crankshaft bearing caps.

36. Remove the crankshaft bearing cap bolts.
37. Remove the crankshaft bearing caps.
38. Remove the crankshaft bearings from the crank-
shaft bearing caps.
39. Remove the crankshaft.
40. Remove the crankshaft bearings from the engine
block.
41. Clean the parts, as necessary.

A102B068

Assembly Procedure
1. With crankshaft and bearings in place, plastic gauge
all bearing clearances. Refer to ‘‘Crankshaft Bearings
and Connecting Rod Bearings - Gauging Plastic’’ in
this section.
2. Inspect the crankshaft end play with the crankshaft
bearings installed.
3. Check for permissible crankshaft end play. Refer to
‘‘Engine Specifications’’ in this section.

A102B070

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1B -- 88 SOHC ENGINE MECHANICAL
4. With the crankshaft mounted on the front and the rear
crankshaft bearings, check the middle crankshaft
journal for permissible out-of-round (runout). Refer to
‘‘Engine Specifications’’ in this section.

A102B071

5. Coat the crankshaft bearings with engine oil.

6. Apply a bead of adhesive sealing compound to the
grooves of the rear crankshaft bearing cap.
7. Install the crankshaft bearings in the engine block.
8. Install the crankshaft.

A102B069

9. Install the crankshaft bearings to the crankshaft

bearing caps.
10. Install the crankshaft bearing caps.
Notice: Do not reuse the old crankshaft bearing cap
bolts. Damage to the engine could result.
11. Install new crankshaft bearing cap bolts.
Tighten
Tighten the crankshaft bearing cap bolts to 50 NSm
(37 lb-ft). Using the angular torque gauge KM-470-B,
tighten the crankshaft bearing cap bolts another 45
degrees plus 15 degrees.
12. Install the upper connecting rod bearings to the con-
necting rods.
13. Install the lower connecting rod bearings to the con-
necting rod bearing caps
A102B091

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 SOHC ENGINE MECHANICAL 1B - 89
14. Install the connecting rod bearing caps to the con-
necting rods.
Notice: Do not reuse the old connecting rod bearing cap
bolts. Damage to the engine could result.
15. Install new connecting rod bearing cap bolts.
Tighten
Tighten the connecting rod bearing cap bolts to
25 NSm (18 lb-ft). Using the angular torque gauge
KM-470-B, tighten the connecting rod bearing cap
bolts another 30 degrees plus 15 degrees.

A102C151

16. Install the oil pump.

17. Install the oil pump retaining bolts.
Tighten
Tighten the oil pump retaining bolts to 10 NSm (89 lb-
in).

A102B065

18. Install the oil pump/pickup tube.

19. Install the oil pump/pickup tube bolts.
Tighten
Tighten the oil pump/pickup tube bolts to 10 NSm
(89 lb-in).

A102B064

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1B -- 90 SOHC ENGINE MECHANICAL
20. Install the oil pan gasket to the oil pan.
21. Install the oil pan.
Important: Install the oil pan within 5 minutes after ap-
plying the liquid gasket to the oil pan.
22. Install the oil pan retaining bolts.
Tighten
Tighten the oil pan retaining bolts to 10 NSm (89 lb-in).

A102B043

23. Install the crankshaft timing belt gear.

24. Install the rear timing belt cover.
25. Install the rear timing belt cover bolts.
Tighten
Tighten the rear timing belt cover bolts to 10 NSm
(89 lb-in).
26. Install the timing belt automatic tensioner.
27. Install the timing belt automatic tensioner bolt.
Tighten
Tighten the timing belt automatic tensioner bolt to
20 NSm (15 lb-ft).

A102B093

Notice: Take extreme care to prevent any scratches,

nicks, or damage to the camshaft. Such damage can im-
pair vehicle operation.
28. Install the camshaft gear.
29. Install the camshaft gear bolt while holding the cam-
shaft firmly in place.
Tighten
Tighten the camshaft gear bolt to 45 NSm (33 lb-ft).

A102B111

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 SOHC ENGINE MECHANICAL 1B - 91
30. Install the timing belt.
31. Adjust the timing belt tension. Refer to “Timing Belt
Check and Adjust” in this section.
32. Install the valve cover gasket and the valve cover.
33. Install the valve cover bolts.
Tighten
Tighten the valve cover bolts to 10 NSm (89 lb-in).
34. Install the lower timing belt cover.
35. Install the lower timing belt cover bolts.
Tighten
Tighten the lower timing belt cover bolts to 10 NSm
(89 lb-in).

A102B008

36. Install the power steering pump.

37. Install the power steering pump mounting bolts.
Tighten
Tighten the power steering pump mounting bolts to
25 NSm (18 lb-ft).
38. Install the upper timing belt cover.
39. Install the upper timing belt cover bolts.
Tighten
Tighten the upper timing belt cover bolts to 10 NSm
(89 lb-in).
40. Install the engine lifting device.
41. Dismount the engine from the engine overhaul
stand MKM-412.
42. Install the crankshaft rear oil seal using installer
J36972 J-36972 or KM-635.
A102C152

43. Install the flywheel.

44. Install the flywheel bolts.
Tighten
Tighten the flywheel bolts to 35 NSm (25 lb-ft) using a
torque wrench. Use the angular torque gauge
KM-470-B to tighten the flywheel bolts another 30 de-
grees plus 15 degrees.
45. Install the engine. Refer to “Engine” in this section.

A102B095

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1B -- 92 SOHC ENGINE MECHANICAL

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
A102B070 “Engine Specifications” in this section.

7. With the crankshaft mounted on the front and the rear

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

A102B071

Important: Grease the crankshaft journals and lubricate

the crankshaft bearings slightly so that the plastic gaug-
ing thread does not tear when the crankshaft bearing
caps are removed.
8. Inspect all of the crankshaft bearing clearances using
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.

A102B072

DAEWOO T-100 BL3

 SOHC ENGINE MECHANICAL 1B - 93
10. Install the crankshaft bearing caps.
11. Install the crankshaft bearing cap bolts.
Tighten
Tighten the crankshaft bearing cap bolts to 50 NSm
(37 lb-ft). Using the angular torque gauge KM-470-B,
tighten the crankshaft bearing cap bolts another 45
degrees plus 15 degrees.

A102B091

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.

A102B073

Inspection Procedure - Connecting Rods

1. Coat the connecting rod bearings with engine oil.
Important: Grease the connecting rod journals and lu-
bricate the connecting rod bearings slightly so that the
plastic gauging thread does not tear when the connect-
ing rod bearing caps are removed.
2. Install the upper connecting rod bearings into the con-
necting rod journals.
3. Install the lower connecting rod bearings into the con-
necting rod bearing caps.
4. Inspect all of the connecting rod bearing clearances
using a commercially available plastic gauging (duc-
tile plastic threads).

A102B072

DAEWOO T-100 BL3

1B -- 94 SOHC ENGINE MECHANICAL
5. Cut the plastic gauging threads to the length of the
bearing width. Lay them axially between the con-
necting rod journals and the connecting rod bear-
ings.
6. Install the connecting rod bearing caps.
7. Install the connecting rod bearing cap bolts.
Tighten
Tighten the connecting rod bearing cap bolts to 25
NSm (18 lb-ft). Using the angular torque gauge
KM-470-B, tighten the crankshaft cap bolts another
30 degrees plus 15 degrees.

A102C151

8. Remove the connecting rod bearing caps.

9. Measure the width of the flattened plastic thread of
the plastic gauging using a ruler. (Plastic gauging is
available for different tolerance ranges.)
10. Inspect the bearing clearance for permissible toler-
ance ranges. Refer to “Engine Specifications” in this
section.

A102B073

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 SOHC ENGINE MECHANICAL 1B - 95

GENERAL DESCRIPTION Engine oil is pumped from the oil pan by the oil pump.
After the oil passes through the oil filter, the oil is fed
AND SYSTEM OPERATION 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,
CYLINDER HEAD AND GASKET then to the pistons and the cylinders in the cylinder
The cylinder head is made of an aluminum alloy. The block. The oil then drains back into the oil pan. In the
cylinder head uses crossflow intake and exhaust ports. second path, the oil is pumped through the oil passages
A spark plug is located in the center of each of the com- to the camshaft. The oil passes through the internal pas-
bustion chambers. sageways in the camshafts to lubricate the valve as-
semblies in the cylinder head before draining back into
CRANKSHAFT the oil pan.
The crankshaft is supported by the five main bearings.
The number three bearing is the end thrust bearing. The EXHAUST MANIFOLD
main bearings are lubricated from the oil holes which in- A single four-port, rear-takedown exhaust manifold is
tersect the main oil gallery on the left side of the engine used with this engine. The exhaust manifold is designed
block. to direct the escaping exhaust gases out of the combus-
tion chambers with a minimum of backpressure.
TIMING BELT
The timing belt coordinates the crankshaft and the cam- INTAKE MANIFOLD
shaft and keeps them synchronized. The timing belt also The intake manifold is made of aluminum. The intake
turns the coolant pump. The timing belt and the pulleys manifold is heated by the engine coolant. An air/fuel
are toothed so that there is no slippage between them. mixture is transferred through the intake manifold to the
There is a tension pulley that maintains the correct tim- engine cylinders for combustion.
ing belt tension. The timing belt is made of a tough rein-
forced rubber similar to that used on the serpentine drive
belt. The timing belt requires no lubrication. CAMSHAFT
The cast-iron camshaft is supported by the five bearing
surfaces in an aluminum camshaft carrier located on the
OIL PUMP top of the cylinder head. The camshaft gear is power
The oil pump draws engine oil from the oil pan and feeds driven by the crankshaft, using the timing belt.
it under pressure to the various parts of the engine. An
oil strainer is mounted before the inlet of the oil pump to
remove impurities which could clog or damage the oil EXHAUST GAS RECIRCULATION
pump or the other engine components. When the drive VALVE
gear rotates, the driven gear rotates. This causes the The exhaust gas recirculation (EGR) system is used to
space between the gears to constantly open and nar- lower oxides of nitrogen (NOX) emission levels caused
row, pulling oil in from the oil pan when the space opens by high combustion temperatures. The main element of
and pumping the oil out to the engine as it narrows. the system is the EGR valve which is operated by vacu-
At high engine speeds, the oil pump supplies a much um.
higher amount of oil than required for lubrication of the The EGR valve feeds small amounts of exhaust gas into
engine. The oil pressure regulator prevents too much oil the intake manifold to decrease the combustion temper-
from entering the engine lubrication passages. During ature. The amount of exhaust gas recirculated is con-
normal oil supply, a coil spring and a valve keep the by- trolled by variations in vacuum and exhaust back
pass closed, directing all of the oil pumped to the engine. pressure. If too much exhaust gas enters combustion
When the amount of oil being pumped increases, the will not take place. For this reason, very little exhaust
pressure becomes high enough to overcome the force gas is allowed to pass through the valve, especially at
of the spring. This opens the valve of the oil pressure idle.
regulator, allowing the excess oil to flow through the
The EGR valve is usually open under the following con-
valve and drain back to the oil pan.
ditions:
D Warm engine operation.
OIL PAN
D Above idle speed.
The oil pan is mounted to the bottom of the cylinder
block. The oil pan houses the crankcase and is made of
pressed sheet metal.

DAEWOO T-100 BL3