Nubira 97 1.6 SX Repair Manual? Blown Headgasket

[David_C]

hey guys,

I seem to have blown the head gasket on my Nubira 97 1.6 SX, The coolants seems to be getting into the cylinders, there is a lot of vapor coming out the exhaust once it is warmed up and I can smell and see the coolant on the plugs when i take them out. . Just wondering if anyone has a workshop/repair manual in .PDF for it? I can only find one in some foreign language (Polish i think?).

Thanks guys.

[Daniel]

For the 1.6 DOHC download the Lanos manual.
http://www.daewootech.com/forum/viewtop ... =21&t=5085 .

[Trey05Woo]

Yea if its the dohc 1.6l found in the lanos, then the Lanos FSM will work. I purchased the set from Daewoous.com a while back I paid very little coin for them too less than 60 bucks brand new sealed. They had them on sale.

Just checked the site and in their promotion section they have the 01 FSM for 9.99!!! So yea plus shipping less than 20 bucks wow!

[daewoomofo]

ive got the pdf of the lanos manual. we justneed a reliable place to upload it to so we can have a good sourse for others to get it

[David_C]

Thanks guys, The download link you gave me doesn't seem to work Daniel

I get this error.

Code: Select all

Forbidden, You don't have permission to access /Download/1/20051217/39546/Lanos_Service_Manual.rar on this server.

Daewoomofo can you please upload it to Rapidshare

It would be a great help

[broken]

This manual is for a Daewoo Lanos 1.6 and 1.5

http://rapidshare.com/files/277552533/D ... g.pdf.html

[David_C]

Big thanks mate!

Now hopefully I can get this thing fixed, Ive only ever replaced a head gasket on a SOHC engine before, DOHC Shouldn't be too much harder.

[David_C]

I had a decent go at it today and got a bit done, however I'm stuck on taking the crankshaft pulley bolt off.

I have only ever taken one off before (in a Honda SOHC) and used a special tool to hold the pulley in place but this pulley doesn't seem to have anywhere to put a special tool.

I'm a bit hesitant to stick it in gear and give it a good yank because i don't want to damage anything internal.

The manual plainly states to "remove crankshaft pulley bolt" I wish it was that easy lol.

Any ideas?

[Trey05Woo]

There are various methods you can use. Manual cars in any fwd gear with the e-brake engaged, and some elbow grease will be just fine. You can also use a breaker bar and the starter motor and not break a sweat...

What ever method u use make sure to REMOVE THE CRANKSHAFT POSITION SENSOR FIRST to prevent damaging the sensor.
Becareful once the bolt is removed as the crank pulley will fall right off and can damage the ckp interruptor teeth. Also discard the bolt for a new one it is torque to yield and CANNOT BE REUSED. Also NEVER crank the engine or spin it excessively with the crank pulley removed. The pulley also serves as a lower guide for tne timing belt. Without it the timing belt, or crank gear will spit out and can damage your engine. You will need a degree wheel to re-torque the crank pulley as it goes 70 ft/lbs + 30 degrees + 15 degrees.

Lastly, when you time your engine DO NOT spin it counter clockwise (lefty) this will cause the tensioner to slack and the belt to loosen and possibly jump some teeth on you, as the system is automatic tensioning type, which only maintains tension as the engine spins in its operating direction: clockwise.

[David_C]

Thanks for that info Trey.

Finally got the crank pulley bolt off! I used the starter motor technique with a breaker bar... After I spent half an hour trying to get the thing undone by hand with the breaker bar

Now I need to get the Timing belt/Cam belt off. The manual says i need a J-42492 timing belt adjuster, Where would I get one of these from? Or is there an alternative way?

Also after taking the inlet manifold off I found a hose that leads from the block that is plugged up with a spark plug

Ill take a picture of it tomorrow and post it on here.

[broken]

Very easy to make>>>>>>> The manual says i need a J-42492 timing belt adjuster

[David_C]

Awesome! Cheers, ill get onto it tomorrow!

[Trey05Woo]

And if your like me and hate welding, try www.delnortools.com they sell both versions of the wrench at a reasonable price. I actually prefer the first one pictured its a more comfortable fit and dosent get tangled up with the alternator and mounting bracket.

Your also going to need an 8mm deep 1/4 allen socket to loosen the wp bolts. If your going to replace the belt with a new one I would just advise you to cut the belt off, and once you disassemble the whole front end and have full access to the wp and its bolts, tackle them. They tend to seize, and usually strip the heads making it double work. I always use new wp bolts also...

[David_C]

Found a good piece of aluminum so i think ill make the thing tomorrow.

Heres a pic of the random spark plug that's blocking up a hose.

[Daniel]

Awesome! Cheers, ill get onto it tomorrow!

Depending of water pump type you have (and rear cover) you may prefer a key folded like a "U" or like a "Z".