Text preview for : en_4j2_0b.pdf part of Daewoo Nubira/Lacetti Also known as: Chevrolet Nubira / Lacetti, Chevrolet Optra Optra5, Suzuki Forenza Reno
Covers the 1.4L, 1.6L and 1.8L engine.
Back to : Service Manual - Daewoo L | HomeSECTION : 0BGENERAL INFORMATIONTABLE OF CONTENTSSPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vehicle Dimensions and Weights . . . . . . . . . . . . Standard Bolt Specifications . . . . . . . . . . . . . . . . 0B1 0B1 0B6 0B8 At Each Fuel Fill . . . . . . . . . . . . . . . . . . . . . . . . . At least Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . At least Twice a Year . . . . . . . . . . . . . . . . . . . . . Each Time The Oil is Changed . . . . . . . . . . . . . 0B12 0B12 0B12 0B13MAINTENANCE AND REPAIR . . . . . . . . . . . . . . . 0B9 MAINTENANCE AND LUBRICATION . . . . . . . . . . 0B9 Normal Vehicle Use . . . . . . . . . . . . . . . . . . . . . . . 0B9 Explanation of Scheduled Maintenance Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B9 Scheduled Maintenance Charts . . . . . . . . . . . . 0B10 OWNER INSPECTIONS AND SERVICES . . . . . 0B12 Whle Operating The Vehicle . . . . . . . . . . . . . . . 0B12At Least Annually . . . . . . . . . . . . . . . . . . . . . . . . 0B13 Recommended Fluids and Lubricants . . . . . . . 0B14 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B15 General Repair Instructions . . . . . . . . . . . . . . . . 0B15 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . 0B16 Vehicle and Component Identification . . . . . . . 0B16 Vehicle Lifting Procedures . . . . . . . . . . . . . . . . . 0B21SPECIFICATIONSTECHNICAL DATAPerformance Manual TransaxleApplication Maximum Speed Minimum Turning Radius 1.4L DOHC 175 km/h (108.7 mph) 5.2 m (17.1 ft) 1.6L DOHC 187 km/h (116.2 mph) ² 1.8L DOHC 194 km/h (120.5 mph) ²Performance Automatic TransaxleApplication Maximum Speed Minimum Turning Radius 1.4L DOHC 1.6L DOHC 175 km/h (108.7 mph) 5.2 m (17.1 ft) 1.8L DOHC 184 km/h (114.3 mph) ²0B 2IGENERAL INFORMATION EngineApplication Engine Type Bore Stroke Total Displacement Compression Ratio Maximum Power Maximum Torque 1.4L DOHC Dual Overhead Cam L4 77.9 mm (3.06 in.) 73.4 mm (2.89 in.) 1399 cm3 (85.4 in.3) 9.5 : 1 69.5 kw (93.2 hp) (at 6,300 rpm) 131 N_m (96.6 lbft) (at 4,400 rpm) 1.6L DOHC ² 79 mm (3.11 in.) 81.5 mm (3.21 in.) 1598 cm3 (97.5 in.3) ² 80 kw (107.3 hp) (at 5,800 rpm) 150 NSm (110.6 lbft) (at 4,000 rpm) 1.8L DOHC ² 81.6 mm (3.21 in.) 86 mm (3.38 in.) 1799 cm3 (109.7 in3) 9.8 : 1 90 kw (120.7 hp) (at 5,800 rpm) 165 NSm (121.7 lbft) (at 4,000 rpm)Ignition SystemApplication Ignition Type Ignition Timing (BTDC) Ignition Sequence Spark Plug Gap Spark Plug Maker Spark Plug Type 1.4L DOHC Direct Ignition System 4° 1342 1.0 ~ 1.1 mm (0.039 ~ 0.043 in.) Woojin BKR6E11 1.6L DOHC ² 5° ² ² ² ² 1.8L DOHC ² ² ² 0.9 ~ 1.1 mm (0.035 ~ 0.043 in.) Boach FLR8LDCUClutchApplication Type Outside Diameter Inside Diameter Thickness Fluid 1.4L DOHC Single Dry Plate 215 mm (8.5 in.) 145 mm (5.7 in.) 8.4 mm (0.331 in.) Common Use: Brake Fluid 1.6L DOHC ² ² ² ² ² 1.8L DOHC ² ² ² ² ²Manual TransaxleApplication Maker Type or Model Gear Ratio : 1st 2nd 3rd 4th 5th Reverse Final Drive Ratio Oil Capacity 3.818 : 1 2.158 : 1 1.478 : 1 1.129 : 1 0.886 : 1 3.333 : 1 3.722 : 1 1.8L (2 qts) 3.545 : 1 2.158 : 1 1.478 : 1 1.129 : 1 0.886 : 1 3.333 : 1 3.722 : 1 ² ² ² ² ² ² ² ² ²DAEWOO V121 BL41.4L DOHC GMDAT D16 (C/R)1.6L DOHC GMDAT D16 (C/R)1.8L DOHC ² ²GENERAL INFORMATION 0B 3 Automatic TransaxleApplication Maker Type or Model Gear Ratio : 1st 2nd 3rd 4th Reverse Final Drive Ratio Oil Capacity 2.875:1 1.568:1 1.000:1 0.697:1 2.300:1 3.750:1 5.77±0.2L (6.1±0.2 qts) 2.719:1 1.487:1 1.000:1 0.717:1 2.529:1 3.945:1 6.9±0.2L (7.3±0.2 qts) 1.4L DOHC 1.6L DOHC AISIN 8140LE 1.8L DOHC ZF 4HP16BrakeApplication Booster Size : Single Dual Master Cylinder Diameter Booster Ratio Front Brake : Disc Type Disc Size Rear Brake (Drum) : Drum Inside Diameter Wheel Cylinder Diameter Rear Brake (Disc) : Disc Type Disc Size Fluid Capacity Solid 258 mm (10.2 in.) 0.5L (0.5 qts) ² ² ² ² ² ² 200 mm (7.9 in.) 20.64 mm (0.813 in.) ² ² ² ² Ventilated 256 mm (10 in.) ² ² ² ² 241.3 mm (9.5 in.) 177.8 and 203.2 mm (7 and 8 in.) 22.22 mm (0.875 in.) 5.5 : 1 ² ² ² ² ² ² ² ² 1.4L DOHC 1.6L DOHC 1.8L DOHCTire and WheelApplication Tire Size Standard Wheel Size Optional Wheel Size Inflation Pressure at Full Load 1.4L DOHC 195/55R15 6Jx15 (Steel) 6Jx15 (Alloy) 30 psi (207 kPa) 1.6L DOHC ² ² ² ² 1.8L DOHC ² ² ² ²DAEWOO V121 BL40B 4IGENERAL INFORMATION Steering SystemApplication Gear Type Overall Gear Ratio Power Steering Wheel Diameter W/ Air Bag W/O Air Bag Wheel Alignment : Front : ToeIn Caster Camber Rear : ToeIn Camber Oil Capacity 12' ± 10' 1° ± 45' 1.1L (1.2 qts) ² ² ² ² ² ² 0° ± 10' 4° ± 45' 20' ± 45' ² ² ² ² ² ² 380 mm (15.0 in.) 370 mm (14.5 in.) ² ² ² ² 16 : 1 ² ² 1.4L DOHC Power Rack and Pinion 1.6L DOHC ² 1.8L DOHC ²SuspensionApplication Front Type Rear Type 1.4L DOHC Macpherson Strut Dual Link 1.6L DOHC ² ² 1.8L DOHC ² ²Fuel SystemApplication Fuel Delivery Fuel Pump Type Fuel Filter Type Fuel Capacity 1.4L DOHC MPI Electric Motor Pump Cartridge 60L (15.85 gal) 1.6L DOHC ² ² ² ² 1.8L DOHC ² ² ² ²Lubricating SystemApplication Lubricating Type Oil Pump Type Oil Filter Type Oil Pan Capacity Including Oil Filter 3.75L (4 qts) ² 4.0L (4.2 qts) 1.4L DOHC Forced Feed Rotary (Trochoid) Cartridge (Full Flow) 1.6L DOHC ² ² ² 1.8L DOHC ² ² ²DAEWOO V121 BL4GENERAL INFORMATION 0B 5 Cooling SystemApplication Cooling Type Radiator Type Water Pump Type Thermostat Type Coolant Capacity 1.4L DOHC Forced Water Circulation Crossflow Centrifugal Pellet Type 7.0L (7.49 qts) 1.6L DOHC ² ² ² ² 7.2L (7.6 qts) 1.8L DOHC ² ² ² ² 7.4L (7.8 qts)Electric SystemApplication Battery 1.4L DOHC 12V55 AH 610 CCA (Cold Cranking Amps) Alternator Starter NoLoad Test @ 12.2 volts Drive Pinion Speed at : 85 Amps 1.2 KW 90 Amps Max Min. 2,600 rpm 1.6L DOHC ² ² ² ² ² ² 1.8L DOHC ² ² 95 Amps 1.4 KW 85 Amps Max Min. 2,550 rpmDAEWOO V121 BL40B 6IGENERAL INFORMATIONVEHICLE DIMENSIONS AND WEIGHTSVehicle DimensionsApplication Overall Length 4 Door 5 Door H/B Overhang : 4 Door Front Rear 5 Door H/B Front Rear Overall Width Overall Height Minimum Ground Clearance Wheel Base Tread : Front Rear 1,480 mm (58.3 in.) 1,480 mm (58.3 in.) ² ² ² ² 902 mm (35.5 in.) 793 mm (31.2 in.) 1,725 mm (67.9 in.) 1,445 mm (56.9 in.) 160 mm (6.3 in.) 2,600 mm (102.4 in.) ² ² ² ² ² ² ² ² ² ² ² ² 885 mm (34.8 in.) 1,015 mm (40.0 in.) ² ² ² ² 4,500 mm (177.2 in.) 4,295 mm (169.1 in.) ² ² ² ² 1.4L DOHC 1.6L DOHC 1.8L DOHCVehicle WeightsApplication Manual : Curb Weight : Standard Optional Gross Vehicle Weight Automatic : Curb Weight : Standard Optional Gross Vehicle Weight Passenger Capacity Optional Weight : ABS, Sun Roof, A/C 5 1,175 kg (2,590 lb) 1,225 kg (2,701 lb) 1,660 kg (3,660 lb) 1.4L DOHC4 Door1.6L DOHC 1.8L DOHC1,180 kg (2,601 lb) 1,230 kg (2,712 lb) 1,665 kg (3,671 lb)1,210 kg (2,668 lb) 1,260 kg (2,778 lb) 1,695 kg (3,737 lb)1,190 kg (2,624 lb) 1,240 kg (2,734 lb) 1,675 (3,693 lb) ²1,235 kg (2,723 lb) 1,285 kg (2,833 lb) 1,720 kg (3,792 lb) ²DAEWOO V121 BL4GENERAL INFORMATION 0B 7 Vehicle WeightsApplication Manual : Curb Weight : Standard Optional Gross Vehicle Weight Automatic : Curb Weight : Standard Optional Gross Vehicle Weight Passenger Capacity Optional Weight : ABS, Sun Roof, A/C 5 1,185 kg (2,612 lb) 1,235 kg (2,723 lb) 1,660 kg (3,660 lb) ² 1,230 kg (2,712 lb) 1,280 kg (2,822 lb) 1,705 kg (3,759 lb) ² 1,170 kg (2,580 lb) 1,220 kg (2,690 lb) 1,645 kg (3,627 lb) 1,175 kg (2,590 lb) 1,225 kg (2,701 lb) 1,650 kg (3,638 lb) 1,205 kg (2,657 lb) 1,255 kg (2,767 lb) 1,680 kg (3,704 lb) 1.4L DOHC5 Door H/B1.6L DOHC 1.8L DOHCDAEWOO V121 BL40B 8IGENERAL INFORMATIONSTANDARD BOLT SPECIFICATIONSBolt* M6 X 1.0 M8 X 1.25 M10 X 1.25 M10 X 1.5 M12 X 1.25 M12 X 1.75 M14 X 1.5 M14 X 2.0 M16 X 1.5 M16 X 2.0 M18 X 1.5 M20 X 1.5 M22 X 1.5 M24 X 2.0 4T Low Carbon Steel 4.18.1 NSm (3672 lbin) 8.117.6 NSm (72156 lbin) 2034 NSm (1525 lbft) 1934 NSm (1425 lbft) 4973 NSm (3654 lbft) 4569 NSm (3351 lbft) 76115 NSm (5685 lbft) 72107 NSm (5379 lbft) 104157 NSm (77116 lbft) 100149 NSm (74110 lbft) 151225 NSm (111166 lbft) 206311 NSm (152229 lbft) 251414 NSm (185305 lbft) 359540 NSm (265398 lbft) 7T High Carbon Steel 5.49.5 NSm (4884 lbin) 12.223.0 NSm (108204 lbin) 2746 NSm (2034 lbft) 2745 NSm (2033 lbft) 6191 NSm (4567 lbft) 5784 NSm (4262 lbft) 94140 NSm (69103 lbft) 88132 NSm (6597 lbft) 136203 NSm (100150 lbft) 129194 NSm (95143 lbft) 195293 NSm (144216 lbft) 270405 NSm (199299 lbft) 363544 NSm (268401 lbft) 431710 NSm (318524 lbft) 7T Alloy Steel 1630 NSm (1222 lbft) 3762 NSm (2746 lbft) 3760 NSm (2744 lbft) 76114 NSm (5684 lbft) 72107 NSm (5379 lbft) 114171 NSm (84126 lbft) 107160 NSm (79118 lbft) 160240 NSm (118177 lbft) 153229 NSm (113169 lbft) 229346 NSm (169255 lbft) 317476 NSm (234351 lbft) 424636 NSm (313469 lbft) 555831 NSm (409613 lbft)* Diameter X pitch in millimetersDAEWOO V121 BL4GENERAL INFORMATION 0B 9MAINTENANCE AND REPAIRMAINTENANCE AND LUBRICATION NORMAL VEHICLE USEThe maintenance instructions contained in the maintenance schedule are based on the assumption that the vehicle will be used for the following reasons: S To carry passengers and cargo within the limitation indicated on the tire placard located on the edge of the driver's door. S To be driven on reasonable road surfaces and within legal operating limits. Replace the air cleaner more often under dusty conditions.Throttle Body Mounting Bolt TorqueCheck the torque of the mounting bolts. Tighten the throttle body mounting bolts to 15 NSm (11 lb ft) if necessary.Spark Plug ReplacementReplace spark plugs with the same type.Spark Plug Wire ReplacementClean wires and inspect them for burns, cracks or other damage. Check the wire boot fit at the DIS module and at the spark plugs. Replace the wires as needed.EXPLANATION OF SCHEDULED MAINTENANCE SERVICESThe services listed in the maintenance schedule are further explained below. When the following maintenance services are performed, make sure all the parts are replaced and all the necessary repairs are done before driving the vehicle. Always use the proper fluid and lubricants.Brake System ServiceCheck the disc brake pads and the drum brake linings every 15,000 km (9,000 miles) or 12 months. Check the pad and the lining thickness carefully. If the pads or the linings are not expected to last to the next scheduledmaintenance service, replace the pads or the linings. Check the breather hole in the brake fluid reservoir cap to be sure it is free from dirt and the passage is open.Drive Belt InspectionWhen a separate belt drives the power steering pump, the air conditioning compressor and the generator, inspect it for cracks, fraying, wear and proper tension. Adjust or replace the belt as needed.Transaxle ServiceThe manual transaxle fluid does not require changing. For automatic transaxles, refer to "Scheduled Maintenance Charts" in this section.Engine Oil and Oil Filter ChangeAPI Classifications of Engine Oil The International Lubricant Standardization and Approval Committee (ILSAC) and American Petroleum Institute classifies engine oils according to their performance quality. Always use oil rated APISL (ILSAC GFIII) or better.Tire and Wheel Inspection and RotationCheck the tires for abnormal wear or damage. To equalize wear and obtain maximum tire life, rotate the tires. If irregular or premature wear exists, check the wheel alignment and check for damaged wheels. While the tires and wheels are removed, inspect the brakes. Refer to "Each Time The Oil Is Changed" in this section.Engine Oil ViscosityEngine oil viscosity (thickness) has an effect on fuel economy and cold weather operation. Lower viscosity engine oils can provide better fuel economy and cold weather performance; however, higher temperature weather conditions require higher viscosity engine oils for satisfactory lubrication. Using oils of any viscosity other than those viscosities recommended could result in engine damage.Tire RotationCooling System ServiceDrain, flush and refill the system with new coolant. Refer to "Recommended Fluids And Lubricants" in this section.Fuel MicroFilter ReplacementReplace the engine fuel filter every 45,000 km (27,000 miles).Air Cleaner Element ReplacementReplace the air cleaner element every 45,000 km (27,000 miles).DAEWOO V121 BL40B 10IGENERAL INFORMATIONSCHEDULED MAINTENANCE CHARTSEngineMaintenance Item Maintenance Interval Kilometers or time in months, whichever comes first x 1,000 km x 1,000 miles Months Drive belts (Alternator, power steering and A/C belt) Engine oil & engine oil filter (1) (3) Cooling system hose & connections Engine coolant (3) Fuel filter Fuel line and connections Air cleaner element (2) Spark plugs (1.4D/1.6D) Spark plugs (1.8D) Spark plug wires EVAP canister, vapor lines & solenoid valve filter PCV system Timing belt I l I I I I I R I I I R I I 1 0.6 15 9 12 30 18 24 I R I I R I R R I R I I I R R I I I 45 27 36 60 36 48 I R I I R I I 75 45 60 90 54 72 I R I R R I R R I I I I I I R R R I I 105 63 84 120 72 96 I R I IReplace every 90,000 km(54,000 miles) I I R I I l I RChart Symbols: I Inspect, and if necessary correct, clean, replenish or adjust. R Replace or change: (1) Change the engine oil and oil filter every 7,500 km (4,500 miles) or 6months, whichever comes first, if the vehicle is operated under any of the following conditions: S Short distance driving. S Extensive idling. S Driving on dusty roads. (2) Inspect the air cleaner element every 7,500 km (4,500 miles) or 6 months if driving under dusty conditions. If necessary, correct, clean or replace. (3) Refer to "Recommended Fluids And Lubricants" Note : Check the engine oil and radiator coolant levels every week.DAEWOO V121 BL4GENERAL INFORMATION 0B 11 Chassis and BodyMaintenance Item Maintenance Interval Kilometers or time in months, whichever comes first x 1,000 km x 1,000 miles Months Interior air filter (A/C) Exhaust pipes & mountings Brake/Clutch fluid (1) (4) Front brake pads and discs(3) Rear brake pads & discs or drums and linings (3) Parking brake Brake line and connections (Including booster) Manual Transaxle Oil *(1) Automatic transaxle fluid *(1) (5) Tighten chassis and underbody bolts and nuts Tire condition and inflation pressure Wheel alignment (2) Steering wheel and linkage Power steering fluid & lines* (1) Drive shaft boots Seat belts, buckles and anchors Lubricate locks, hinges and hood latch I I I I I I I I I 1 0.6 15 9 12 R I I I I I I I I I I 30 18 24 R I R I I I I I I I I 45 27 36 R I I I I I I I I I I 60 36 48 R I R I I I I I I I I 75 45 60 R I I I I I I I I I I 90 54 72 R I R I I I I I I I I 105 63 84 R I I I I I I I I I I 120 72 96 R I R I I I I I I I IInspect when abnormal condition is noted I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I IChart Symbols: I Inspect and if necessary correct, clean, replenish, or adjust. R Replace or change: (1) Refer to Recommended Fluids And Lubricants. (2) And if necessary, rotate and balance wheels. (3) More frequent if operated under severe conditions: short distance driving, extensive idling, frequent lowspeed operaion in stop and go traffic, or driving in dusty conditions. (4) Change the brake/clutch fluid every 15,000 km (9,000 miles), if the vehicle is mainly driven under the following severe conditions: driving in hilly or mountainous terrain, or towing a trailer/caravan frequently. (5) 1.8 DOHC model (ZF 4HP16 Automatic Transaxle): Change automatic transaxle fluid every 60,000 Km (36,000 miles) if the vehicle is mainly driven under any of the following severe conditions: S In heavy city traffic where the outside temperature regularly reaches 32°C (90°F) or higher, or S In hilly or mountainous terrain, or S When doing frequent trailer towing, or S Uses such as taxi, police or delivery service.DAEWOO V121 BL40B 12IGENERAL INFORMATIONOWNER INSPECTIONS AND SERVICES WHLE OPERATING THE VEHICLEHorn OperationBlow the horn occasionally tomake sure it works. Check all the button locations. If you check the oil level when the oil is cold, do not run the engine first. The cold oil will not drain back to the pan fast enough to give a true oil level reading.Engine Coolant Level and ConditionCheck the coolant level in the coolant reservoir tank and add coolant if necessary. Inspect the coolant. Replace dirty or rusty coolant.Brake System OperationBe alert for abnormal sounds, increased brake pedal travel or repeated pulling to one side when braking. Also, if the brake warning light goes on, or flashes, something may be wrong with part of the brake system.Windshield Washer Fluid LevelCheck the washer fluid level in the reservoir. Add fluid if necessary.AT LEAST MONTHLYTire And Wheel Inspection and Pressure CheckCheck the tires for abnormal wear or damage. Also check for damaged wheels. Check the tire pressure when the tires are cold (check the spare also, unless it is a stowaway). Maintain the recommended pressures that are on the tire placard that is in the glove box.Exhaust System OperationBe alert to any changes in the sound of the system or the smell of the fumes. These are signs that the system may be leaking or overheating. Have the system inspected and repaired immediately.Tires,Wheels and Alignment OperationBe alert to any vibration of the steering wheel or the seats at normal highway speeds. This may mean a wheel needs to be balanced. Also, a pull right or left on a straight, level road may show the need for a tire pressure adjustment or a wheel alignment.Light OperationCheck the operation of the license plate light, the headlights (including the high beams), the parking lights, the fog lights, the taillight, the brake lights, the turn signals, the backup lights and the hazard warning flasher.Steering System OperationBe alert to changes in the steering action. An inspection is needed when the steering wheel is hard to turn or has too much free play, or if unusual sounds are noticed when turning or parking.Fluid Leak CheckPeriodically inspect the surface beneath the vehicle for water, oil, fuel or other fluids, after the vehicle has been parked for a while. Water dripping from the air conditioning system after use is normal. If you notice fuel leaks or fumes, find the cause and correct it at once.Headlight AimTake note of the light pattern occasionally. Adjust the headlights if the beams seem improperly aimed.AT LEAST TWICE A YEARPower Steering System Reservoir LevelCheck the power steering fluid level. Keep the power steering fluid at the proper level. Refer to Section 6A, Power Steering System.AT EACH FUEL FILLA fluid loss in any (except windshield washer) system may indicate a problem. Have the system inspected and repaired immediately.Brake Master Cylinder Reservoir Level Engine Oil LevelCheck the oil level and add oil if necessary. The best time to check the engine oil level is when the oil is warm. 1. 2. 3. 4. 5. After stopping the engine, wait a few minutes for the oil to drain back to the oil pan. Pull out the oil level indicator (dip stick). Wipe it clean, and push the oil level indicator back down all the way. Pull out the oil level indicator and look at the oil level on it. Add oil, if needed, to keep the oil level above the MIN line and within the area labeled "Operating Range." Avoid overfilling the engine, since this may cause engine damage. Push the indicator all the way back down into the engine after taking the reading. Check the fluid and keep it at the proper level. A low fluid level can indicate worn disc brake pads which may need to be serviced. Check the breather hole in the reservoir cover to be free from dirt and check for an open passage.Clutch Pedal Free TravelCheck clutch pedal free travel and adjust as necessary. Measure the distance from the center of the clutch pedal to the outer edge of the steering wheel with the clutch pedal not depressed. Then measure the distance from the center of the clutch pedal to the outer edge of the steering wheel with the clutch pedal fully depressed. The difference between the two values must be greater than 130 mm (5.19 inches).6.WeatherStrip LubricationApply a thin film silicone grease using a clean cloth.DAEWOO V121 BL4GENERAL INFORMATION 0B 13EACH TIME THE OIL IS CHANGEDAutomatic Transaxle FluidRefer to fluid level service procedure of Section 5A, ZF 4HP16 Automatic Transaxle.AT LEAST ANNUALLYLap and Shoulder Belts Condition and OperationInspect the belt system including: the webbing, the buckles, the latch plates, the retractor, the guide loops and the anchors.Manual TransaxleCheck the fluid level and add fluid as required. Refer to Section 5B, FiveSpeed Manual Transaxle.Movable Head Restraint OperationOn vehicles with movable head restraints, the restraints must stay in the desired position.Brake System InspectionThis inspection should be done when the wheels are removed for rotation. Inspect the lines and the hoses for proper hookup, binding, leaks, cracks, chafing, etc. Inspect the disc brake pads for wear. Inspect the rotors for surface condition. Also inspect the drum brake linings for wear and cracks. Inspect other brake parts, including the drums, the wheels cylinders, the parking brake, etc., at the same time. Check the parking brake adjustment. Inspect the brakes more often if habit or conditions result in frequent braking.Spare Tire and Jack StorageBe alert to rattles in the rear of the vehicle. The spare tire, all the jacking equipment, and the tools must be securely stowed at all times. Oil the jack ratchet or the screw mechanism after each use.Key Lock ServiceLubricate the key lock cylinder.Body Lubrication ServiceLubricate all the body door hinges including the hood, the fuel door, the rear compartment hinges and the latches, the glove box and the console doors, and any folding seat hardware.Steering, Suspension and Front Drive Axle Boot And Seal InspectionInspect the front and rear suspension and the steering system for damaged, loose or missing parts, signs of wear or lack of lubrication. Inspect the power steering lines and the hoses for proper hookup, binding, leaks, cracks, chafing, etc. Clean and inspect the drive axle boot and seals for damage, tears or leakage. Replace the seals if necessary.Transaxle Neutral Switch Operation on Automatic TransaxleCAUTION : Take the following precautions because the vehicle could move without warning and possibly cause personal injury or property damage: S Firmly apply the parking brake and the regular brakes. S Do not use the accelerator pedal. S Be ready to promptly turn off the ignition if the vehicle starts. On automatic transaxle vehicles, try to start the engine in each gear. The starter should crank only in P (Park) or N (Neutral).Exhaust System InspectionInspect the complete system (including the catalytic converter if equipped). Inspect the body near the exhaust system. Look for broken, damaged, missing, or outofposition parts as well as open seams, holes, loose connections, or other conditions which could cause heat buildup in the floor pan or could let exhaust fumes seep into the trunk or passenger compartment.Parking Brake and Transaxle P (Park) Mechanism OperationCAUTION : In order to reduce the risk of personal injury or property damage, be prepared to apply the regular brakes promptly if the vehicle begins to move. Park on a fairly steep hill with enough room for movement in the downhill direction. To check the parking brake, with the engine running and the transaxle in N (Neutral), slowly remove foot pressure from the regular brake pedal (until only the parking brake is holding the vehicle). To check the automatic transaxle P (Park) mechanism's holding ability, release all brakes after shifting the transaxle to P (Park).Throttle Linkage InspectionInspect the throttle linkage for interference or binding, damaged, or missing parts. Lubricate all linkage joints and throttle cable joints, the intermediate throttle shaft bearing, the return spring at throttle valve assembly, and the accelerator pedal sliding face with suitable grease. Check the throttle cable for free movements.Engine Drive BeltsInspect all belts for cracks, fraying, wear and proper tension. Adjust or replace the belts as needed.Underbody Flushing Hood Latch OperationWhen opening the hood, note the operation of the secondary latch. It should keep the hood from opening all the way when the primary latch is released. The hood must close firmly.DAEWOO V121 BL4Flushing the underbody will remove any corrosive materials used for ice and snow removal and dust control. At least every spring clean the underbody. First, loosen the sediment packed in closed areas of the vehicle. Then flush the underbody with plain water.0B 14IGENERAL INFORMATION Engine Cooling SystemInspect the coolant and freeze protection fluid. If the fluid is dirty or rusty, drain, flush and refill the engine cooling system with new coolant. Keep the coolant at the proper mixture in order to ensure proper freeze protection, corrosion protection and engine operating temperature. Inspect the hoses. Replace the cracked, swollen, or deteriorated hoses. Tighten the clamps. Clean the outside of the radiator and the air conditioning condenser. Wash the filler cap and the neck. Pressure test the cooling system and the cap in order to help ensure proper operation.RECOMMENDED FLUIDS AND LUBRICANTSUsage Engine Oil Capacity 3.75L (4.0 qt) : 1.4L DOHC 3.75L (4.0 qt) : 1.6L DOHC 4.0L (4.2 qt) : 1.8L DOHC 7.0L (7.49 qt) : 1.4L DOHC 7.2L (7.6 qt) : 1.6L DOHC 7.4L (7.8 qt) : 1.8L DOHC 0.5L (0.5 qt) 1.1L (1.2 qt) 5.77 ± 0.2L (6.1 ± 0.2 qts) : 1.6L DOHC (AISIN 8140LE) 6.9 ± 0.2L (7.3 ± 0.2 qts) : 1.8L DOHC (ZF 4HP16) Manual Transaxle Manual Transaxle Shift Linkage Key Lock Cylinders Automatic Transaxle Shift Linkage Clutch Linkage Pivot Points Floor Shift Linkage Points Hood Latch Assembly a. Pivots and Spring Anchor b. Release Pawl Hood and door hinges Fuel door hinge Rear compartment lid hinges Weatherstrips 1.8L (2.0 qt) As required As required As required As required As required As required Fluid/Lubricant API SL (ILSAC GFIII) grade or better SAE 5W30, SAE10W30, SAE15W40 (Cold area : SAE5W30 Hot area : SAE 15W40) Mixture of water and good quality ethylene glycol base antifreeze (yearround coolant) DOT3 or DOT4 DEXRON®III or DEXRON®IID ESSO JWS 3309 or ISU DEXRON III ESSO LT 71141 or TOTAL ATF H50235 Manual Transaxle Fluid SAE80W (Cold Area : SAE 75W) Multipurpose type grease meeting requirements NLGI No. 1 or 2 Silicone lubricant Engine oil Engine oil Engine oil a. Engine oil b. Multipurpose type grease meeting requirements NLGI No. 1 or 2 Engine oilEngine CoolantBrake Fluid and Clutch Fluid Power Steering System Automatic TransaxleAs requiredAs requiredSilicone greaseDAEWOO V121 BL4GENERAL INFORMATION 0B 15GENERAL DESCRIPTION AND SYSTEM OPERATIONGENERAL REPAIR INSTRUCTIONSS S If a floor jack is used, the following precautions are recommended. Park the vehicle on level ground, block" the front or rear wheels, set the jack against the frame, raise the vehicle and support it with chassis stands and then perform the service operation. Before performing the service operation, disconnect the negative battery cable in order to reduce the chance of cable damage and burning due to short circuiting. Use a cover on the body, the seats and the floor to protect them against damage and contamination. Handle brake fluid and antifreeze solution with care as they can cause paint damage. The use of proper tools, and the recommended essential and available tools where specified, are important for efficient and reliable performance of the service repairs.S SS SSS S S S S SS S SUse genuine DAEWOO parts. Discard used cotter pins, gaskets, Orings, oil seals, lock washers and selflocking nuts. Prepare new ones for installation. Normal function of these parts cannot be maintained if these parts are reused. Keep the disassembled parts neatly in groups to facilitate proper and smooth reassembly. Keep attaching bolts and nuts separated, as they vary in hardness and design depending on the position of the installation. Clean the parts before inspection or reassembly. Also clean the oil parts, etc. Use compressed air to make certain they are free of restrictions. Lubricate rotating and sliding faces of parts with oil or grease before installation. When necessary, use a sealer on gaskets to prevent leakage. Carefully observe all specifications for bolt and nut torques. When service operation is completed, make a final check to be sure service was done properly and the problem was corrected.DAEWOO V121 BL40B 16IGENERAL INFORMATIONGENERAL DESCRIPTION VEHICLE AND COMPONENT IDENTIFICATIONPassenger Car Vehicle Identification NumberDAEWOO V121 BL4GENERAL INFORMATION 0B 17 Engraved VIN Location VIN Plate LocationThe vehicle identification number (VIN) plate is attached to the top of the front panel support.The vehicle identification number (VIN) is engraved in the top of the bulkhead.Engine Number LocationThe engine number is stamped on the cylinder block under the No. 4 exhaust manifold of the engine. 1.4L/1.6L DOHC EngineVIN Plate1.8L DOHC Engine1. 2. 3. 4. 5. 6. 7.Manufacturer's Name Whole Vehicle Type Approval No. VIN (Vehicle Identification No.) GVW Combination Weight (GVW + Braked Trailer Weight) Maximum Permissible Axle Weight Front Maximum Permissible Axle Weight RearDAEWOO V121 BL40B 18IGENERAL INFORMATION Engine Number Family I (1.4L/1.6L DOHC Engine)Engine Number Family II (1.8L DOHC Engine)DAEWOO V121 BL4GENERAL INFORMATION 0B 19 Manual Transaxle Identification Number Plate (D16) Automatic Transaxle Identification Number Plate (ZF 4HP16)1. 2.Identification Code Sequential Number Identification Code SY CR CV Engine 1.4L DOHC 1.6L DOHC 1.8L DOHC Gear Ratio 3.722 CR 3.722 CR 3.722 CR1. 2. 3. 4.Part Number Sirial Number Model Code Manufactured Nation and Company Part Code AW Engine 1.8L DOHCManual Transaxle Identification Number Plate Location (D16)Automatic Transaxle Identification Number Plate Location (ZF 4HP16)The manual transaxle identification number is attached to the top of the transmission case near the engine.The automatic transaxle identification number plate is attached on the rear bottom side of the transaxle case near the bulk head.DAEWOO V121 BL40B 20IGENERAL INFORMATION Automatic Transaxle Identification Number Plate (AISIN : 8140LE)4. AW's Serial NumberAutomatic Transaxle Identification Number Plate Location (AISIN : 8140LE)1. 2. 3.AW's Lot Number Part ID Code DW's Part NumberThe automatic transaxle identification number plate is attached on the upper side of the transaxle case.DAEWOO V121 BL4GENERAL INFORMATION 0B 21VEHICLE LIFTING PROCEDURESNotice : To raise the vehicle, place the lifting equipment only at the points indicated. Failure to use these precise positions may result in permanent vehicle body deformation. Many dealer service facilities and service stations areequipped with automotive hoists that bear upon some parts of the frame in order to lift the vehicle. If any other hoist method is used, use special care to avoid damaging the fuel tank, the filler neck, the exhaust system, or the underbody.Vehicle Lifting PointsDAEWOO V121 BL40B 22IGENERAL INFORMATION Vehicle Lifting PointsDAEWOO V121 BL4