Text preview for : en_0.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.
Year 2004
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CONTENTS
PAGE
0. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 1 1. ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 2. SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1 3. DRIVE LINE / AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1 4. BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1 5. TRANSMISSION / TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . 5 1 6. STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1 7. HVAC (HEATING, VENTILATION & AIR CONDITIONING) . . . 7 1 8. RESTRAINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1 9. BODY AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1 10. PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 1
GENERAL INFORMATION 0 1
SECTION 0
GENERAL INFORMATION
1. INTRODUCTION
11. PAGE LAYOUT This Labor Time Guide is designed for convenient and accurate use. For fast, efficient location of Labor Operation Codes, a detailed illustration and corresponding Labor Operation Code information is provided.
12. TYPES OF OPERATION Major Operation The Labor Operation Codes consist of seven digits. All operation numbers having "0" in the seventh digit of operation number are classified as "major" operations. A major operation time allowance is sufficient to do the work described as a single operation.
Supplementary Operation (Adds) All operation numbers having an alphabetical letter in the seventh digit of the operation number are classified as "supplementary" operations. These operations cannot be used as a single operation and must be used as additions to the major operation.
13. TIME ALLOWANCES The time allowances published in this guide have been determined by performing the operation a sufficient number of times to establish an average time or to determine that a fair and equitable time has been developed. Standard technician's hand tools and dealer essential and available tools are used in performing time studies. No power operated tools are used for time studies. Procedures outlined in Service Manuals, other Service Publications and standard shop practices are used as a guide when performing the work necessary to establish time allowances.
The time allowance includes the actual time required to perform the operation plus an additional allowance to provide for operating variables. Time allowances include time to remove and reinstall manufacturer options and accessories but do not include time to remove and reinstall special or aftermarket equipment.
"Repair diagnosis" time is included in all published labor time operations when it is required to perform the operation. It is the responsibility of the dealer's qualified service staff to assist technicians in "customer problem analysis" and "symptom diagnosis".
0 2 GENERAL INFORMATION
2. HOW TO READ THIS MANUAL
4
1
2
3
2
1 2
Section
Refer to the main group code in this chapter.
Illustration Number
The illustration number corresponds to the reference number provided in the chart or the facing page.
GENERAL INFORMATION 0 3
7
6
1
ENGINE 1B 19
SOHC ENGINE MECH. CAM SUPPORT & SHAFT (132)
NO. 1 OPERATION DESCRIPTION COVER AND/OR GASKET, CAMSHAFT HOUSING (ONE PIECE) REPLACE CAMSHAFT REPLACE INC : R & I Dis coil, Camshaft gear, Ignition timing adjust.
B * With air conditioning
OPERATION CODE 1322100
S 1.4/ 1.5S 0.3
2
1322300
2.6
132230B
0.1
3
SUPPORT CAMSHAFT REPLACE INC : R & I Dis coil, Camshaft gear, Ignition timing adjust.
B * With air conditioning
1322500
3.4
132250B
0.1
4 5
CAP, OIL FILLER REPLACE OIL SEAL, CAMSHAFT REPLACE
1322700 1322900
0.2 2.3
2 3
Operation Description
3A. Major Operation
3A
3B
4
5
The Operation Description corresponds to each labor operation number, identifies the part or component, and describes what kind of operation is to be performed. 3B. Supplementary Operation The Operation Description corresponding to each operation number identifies the part or component concerned, and describes the additional operation for removing and reinstalling optional equipment (i.e. power steering, air conditioning, etc.), when a major operation is performed on vehicles with optional equipment.
0 4 GENERAL INFORMATION
4
Operation Code
The Operation Code consists of seven digits.
Main group code Basic code Auxiliary code
1) Main Group Code The Main Group Code consists of 3 digits which indicates the area of the vehicle where the repair was performed. 2) Basic Code The Basic Code is a 3digit number specific to each operation. 3) Auxiliary Code The Auxiliary Code indicates the type of repairs as shown below ; Auxiliary Code 0 A B S S S R Supplementary operation Major operation Description
Major Operation The numeric code "0" represents a major operation. Supplementary Operation (ADD) The alpha code "A" "R" represents supplementary work where additional time is required for R & R of optional parts or components which are related to the intended repair (major operation).
GENERAL INFORMATION 0 5
5
Operation Times
The operation times in this manual are provided in hours and tenths of hours (e.g. 1.1 hours for 1 hour and 6 minutes). Enter the operation time on the warranty claim in the same manner.
6
Model Code
This code represents the vehicle model. Vehicle Models S L : : KALOS NUBIRA/LACETTI EVANDA N :
7
Engine Type
This designation represents engine types. 1.2S : 1.3S : 1.5S : 1.8S : 2.0S : 1.4D : 1.6D : 1.8D : 2.0D : 2.2D : 1.2 SOHC Engine 1.3 SOHC Engine 1.5 SOHC Engine 1.8 SOHC Engine 2.0 SOHC Engine 1.4 DOHC Engine 1.6 DOHC Engine 1.8 DOHC Engine 2.0 DOHC Engine 2.2 DOHC Engine
0 6 GENERAL INFORMATION
3. HOW TO USE THIS MANUAL
The operation times in this manual are provided in hours and tenths of hours (e.g. 1.1 hours for 1 hour and 6 minutes). Enter the operation time on the warranty claim in the same manner. Example : (When supplementary work is performed in addition to the intended repair) Model : S (KALOS) Major Operation : Camshaft Replacement
Supplementary Work : With Air Conditioning
Step 1 :
First find SOHC ENGINE MECH. CAM SUPPORT & SHAFT in MAIN GROUP INDEX and then the page (Engine 1B19) for Camshaft.
Step 2 :
On page Engine 1B19, note the Operation Code for Camshaft Replacement.
1322300 132230B
CAMSHAFT REPLACE WITH AIR CONDITIONING Total Operation Time
2.6 0.1 2.7
GENERAL INFORMATION 0 7
ENGINE 1B 19
SOHC ENGINE MECH. CAM SUPPORT & SHAFT (132)
NO. 1 OPERATION DESCRIPTION COVER AND/OR GASKET, CAMSHAFT HOUSING (ONE PIECE) REPLACE CAMSHAFT REPLACE INC : R & I Dis coil, Camshaft gear, Ignition timing adjust.
B * With air conditioning
OPERATION CODE 1322100
S 1.4/ 1.5S 0.3
2
1322300
2.6
132230B
0.1
3
SUPPORT CAMSHAFT REPLACE INC : R & I Dis coil, Camshaft gear, Ignition timing adjust.
B * With air conditioning
1322500
3.4
132250B
0.1
4 5
CAP, OIL FILLER REPLACE OIL SEAL, CAMSHAFT REPLACE
1322700 1322900
0.2 2.3
Major Operation : Supplementary Work : Operation Code Operation Time Total
CAMSHAFT REPLACE WITH AIR CONDITIONING 1322300 & 132230B 2.6 + 0.1 = 2.7
1322300 132230B
2.6 0.1
4. PAINT REPAIR
41. INSTRUCTION The time allowances for paint operations are established on the basis of techniques and material required for high quality work. The basis for determining the paint time allowances is a "Paintable Surface".
0 8 GENERAL INFORMATION
11. All dents have been removed from sheet metal parts and welded parts are restored to their original shape. 12. Welding and soldering joints, overlapping seams formed by partial replacement and surfaces repaired with fillers are completely smooth. 13. And when the painter does not need to apply more than 3 coats of knifeedge putty to the surfaces to be painted. 42. LABOR TIME The time allowances for paint work include all related tasks like material preparation time, actual repair time and material allowances, which are necessary for a proper and professional paint repair. Note that material allowances are converted to hours and are included in the operation time based on the paint process and the size of area to be painted. The material allowances include necessary paint mixing and other items like masking tape, sand paper, cleaning materials, etc. INCLUDES ; moving the vehicle / mixing all materials / color blending / equipment cleaning / color spray sample / repainting time on clear coat / masking / sanding / cleaning / spraying / removing of the masking and polishing. EXCLUDES ; removal and reinstallation of body attaching parts 43. REPAIR TYPE Type COLOR COAT Description PAINT EXPOSED SURFACES Topcoat entire surface, including small dents that have been straightened (without filling in). This operation should be used when correcting painting conditions such as thin paint, color mismatch or surface scratches not extending beyond the prime coat. REFINISH PAINT NEW PART This operation involves sanding out a defect to expose a local area of bare metal, prime locally and then apply color coat. This applies to those paint repairs that require a repair to the prime coat before the color coat is applied. POLISHING POLISH THE SURFACES
44. HOW TO USE OPERATION CODE FOR PARTIAL PAINTING Use the operation code of the relevant part and enter "P" in the PF column of the Daewoo Warranty Claim. For example, if only a portion of a Lanos hood required painting, complete the Daewoo Warranty Claim as follows ;
PF P
OPERATION CODE 9836080
HOUR 0.7
GENERAL INFORMATION 0 9
5. DEFECT CODE
51. NATURE CODES N01 N02 N03 N04 N05 N06 N07 N08 N09 N10 N11 N12 N13 N14 N15 N16 N17 N18 N19 N20 N21 N22 N23 N24 N25 N26 N27 N28 N29 N30 N31 N32 N33 Hard start, no start Poor idle Surge, hesitate, stumble Engine noise, engine knocking noise Choke malfunction Engine stalled (general) Excessive fuel consumption Excessive oil consumption Overheated Shift shock Engine runon Flooded, overflowing Poor acceleration, uneven acceleration Abnormal combustion Lack of engine power Percolation Improper exhaust gas (black smoke, white smoke) Backfire, afterfire Vapor lock Blocked Shuddering, pulsation, vibration, chattering Slippage (slipping) Difficult engagement Difficult disengagement Abnormal shifts Impossible shifts
Squeaking, squealing, abnormal(wind) noise
N34 N35 N36 N37 N38 N39 N40 N41 N42 N43 N44 N45 N46 N47 N48 N49 N50 N51 N52 N53 N54 N55 N56 N57 N58 N59 N60 N61 N62 N63 N64 N65 N66
Fails to reach normal operating temperature RPM too low RPM too high Jumpingout Improper synchronizing Oil diluted Misfire Spongy pedal Unstable steering Excessive shock Poor release Unusual tire wear Misaligned or mismatched Weak Hard to turn Impossible to turn Vehicle bouncing Deteriorated Distortion, rainbow, waving Color mismatched Defective chrome plate, defective painting Rust, corrosion, perforation Glazed Loose, poor fit Bubbles Vehicle vibration Excessive vibration Dead battery Inaccurate (meter, gauge, etc.) Poor sound (horn, radio, etc.) Overcharged, discharged Electrical failures Blown fuse
Dragging Pulls Stalled while driving Stalled while idling Stalled between shifts Stalling during sudden braking
0 10 GENERAL INFORMATION
51. NATURE CODES N67 N68 N69 N70 N71 N72 N73 N74 N75 N76 N77 N78 N80 N82 N83 Warning light on Intermittent operation Pulls to left or right Poor AM reception / interference Oil leak, oil entering Water leak, water entering Leaksother (air, fuel, refrigerant, vacuum) Poor FM reception / interference Radio / CD does not operate properly Tape deck does not operate properly Improper memory Improper volume control Headlamp improperly aimed Loosening, fallingoff, sagged Gas leak, gas entering N84 N85 N86 N87 N88 N90 N91 N92 N93 N94 N95 N96 N97 N98 N99 Improper opening and/or closing Grabs Poor maneuverability Insufficient brake Brake judder Color rainbow, color waving Interference or hitting Inoperative High/low operating effort Special policy Glass cracked Glass broken Glass chipped Glass scratched Undefined
52. CAUSE CODES R01 R02 R03 R04 R05 R06 R07 R08 R09 R10 R11 R12 R13 R14 R15 R16 R17 R18 Scored, scratched or chipped Frozen (Temperature) Peeling, comingoff Rusty, corroded Split, cut or torn Broken or cracked Porous, pin holes, cavity Bent, kinked, twisted, distorted, warped or wrinkled Stripped bolts, holes, nuts Soiled Weakened, loss of tension or resilience (spring, cushion, etc.) Abnormal wear Out of balance Out of round Loose or improper connection Open circuit or short circuit Burned or burned out Grounded or shorted R19 R20 R21 R22 R23 R24 R25 R26 R27 R28 R31 R32 R33 R34 R35 R36 R99 Improperly machined Faulty casting Improper clearance, back lash, free play Lack of lubricants Improper welding or soldering, welding or soldering omitted Improper tightening, fit or assembly Sticks, binds, seized Foreign material, clogged Improper sealing, sealer omitted or skipped Improper adjustment Incorrect part Improperly installed Improperly routed Missing part Flaw in material Contaminants Undefined
GENERAL INFORMATION 0 11
53. PAINT CODES P01 P02 P03 P04 P05 P06 P07 P11 P12 P13 P14 P15 P16 P17 P18 Oversprayed, drip Undersprayed, bare Color mismatched Low Gloss Mottled, cloudy Sags or runs Pin hole Peeling, scaling Orange peel Slow drying Thin no paint Wavy Tape mark, touch mark Chemical damage Acid rain P19 P20 P21 P22 P23 P24 P25 P26 P27 P30 P31 P32 P33 P34 P99 Atmospheric fallout Polishing mark, sanding mark Touch up Dust, dirt Poor welding Rust Blistered Chipped Cracked Surface scratch Scab corrosion Dent Rust perforation Discolored, faded Undefined
6. ABBREVIATIONS
A/C ADJ ASSY A/T AUTO CC CHK CLN CYL DIFF DIST DOHC ECM EGR ETC H/B IAC Air Conditioning Adjust Assembly Automatic Transaxle Automatic Color Coat paint Check Clean Cylinder Differential Distributor Double Overhead Camshaft Electronic Control Module Exhaust Gas Recirculation Others Hatch Back Idle Air Control I/P MAN MAP MAT OH POL PCV PLA REF RPL RPR R&R SOHC M/T VIN VSS Instrument Panel Manual Manifold Absolute Pressure Manifold Air Temperature Overhaul Polishing Positive Crankcase Ventilation Plating Refinish Paint Replace Repair Remove and Reinstall Single Overhead Camshaft Manual Transaxle Vehicle Identification Number Vehicle Speed Sensor
0 12 GENERAL INFORMATION
7. MAIN GROUP CODE
The first 3 digits of the 7 digit code classify the units to be serviced into main roups.
SECTION
1. ENGINE 1B
SUBSECTION
SOHC Engine Mech. 111 113 121 122 123 131 132 133 138 1C DOHC Engine Mech. 111 113 121 122 123 131 132 133 138 1D Engine Cooling 141 143 145 148 1E Engine Electrical 151 154 156 157 158 1F Engine Controls 171 172 173 181 182 186
MAIN GROUP CODE
Engine unit Belt system Engine block Crankshaft & piston Oil pan & pump Cylinder head Cam support & shaft Timing cover Engine & transaxle mount Engine unit Belt system Engine block Crankshaft & piston Oil pan & pump Cylinder head Cam support & shaft Timing cover Engine & transaxle mount Radiator Cooling fan Radiator hose & pipe Thermostat Ignition cable Alternator unit Starter Battery Fuse & relay Fuel tank Fuel line Canister & fuel vacuum Fuel injection Accelerator control Emission control
PAGE
1B1
1C1
1D1
1E1
1F1
GENERAL INFORMATION 0 13
1. ENGINE 1G Engine Intake & Exhaust 191 193 194 195 196 2. SUSPENSION 2C Front Suspension 213 214 215 2D Rear Suspension 231 232 2E 3. DRIVE LINE/ AXLE 4. BRAKES 4A Hydraulic Brakes 425 428 4B Master Cylinder & Power Booster 4D 4E 4F Front Brakes Rear Brakes AntiLock Brake System 445 456 462 465 4G 5. TRANSMISSION/ TRANSAXLE 5A1 Parking Brakes ZF 16HP Auto Transaxle 478 524 525 526 527 Front brake Rear brake ABS system Hydraulic modulator Parking brake ZF 16HP Auto Transaxle I ZF 16HP Auto Transaxle II ZF 16HP Auto Transaxle III ZF 16HP Auto Transaxle IV 4G1 5A11 4D1 4E1 4F1 431 Brake pipe Brake Pedal & Mount Master cylinder & booster 4B1 4A1 3 Tires & Wheel Drive Axle 241 321 Air intake system Intake manifold Exhaust manifold Vacuum hose Exhaust pipe line Knuckle & hub Front shock absorber Control arm Rear axle Rear shock absorber Wheel & wheel cover Axle shaft parts 2E1 31 2D1 2A1 1G1
0 14 GENERAL INFORMATION
SECTION
5. TRANSMISSION/ TRANSAXLE 5A2
SUBSECTION
AISIN Auto Transaxle 531 532 533 534 535 536 537 5B1 Five Speed Manual Transaxle (D16, D20) 561 563 564 565 566 567 569 5B2 Five Speed Manual Transaxle (Y4M) 571 572 573 574 575 5C Clutch 581 582 583
MAIN GROUP CODE
Automatic transaxle Case & related parts Internal powertrain parts Gear assembly Control valve Fluid cooler pipe Auto transaxle controls Manual transaxle Transaxle gear Reverse & counter gear Bearing plate Gear shift cover & fork Differential gear Shift control Manual transaxle Transaxle gear Gear Shift Cover & Fork Differential Gear Shift Control Clutch parts Hydraulic clutch Clutch pedal Power steering gear Power steering pipe line Manual steering gear Steering wheel Steering column cover Steering column Tie rod
PAGE
5A21
5B11
5B21
5C1
6. STEERING
6A
Power Steering System
621 623
6A1
6D 6E
Manual Steering Gear Steering Wheel & Column
635 641 642 643 647
6D1 6E1
GENERAL INFORMATION 0 15
SECTION
7. HVAC (Heating,Ventilation & Air Conditioning) 7B 7A
SUBSECTION
Heating & Ventilation 711 713 714 HVAC Control 732 733 734 735
MAIN GROUP CODE
Air distribution Evaporator Blower Compressor Compressor mount A/C hose & pipe line A/C control switch Front seat belt Rear seat belt Air bag system Immobilizer Wiring harness Front lamp Rear lamp
PAGE
7A1
7B1
8. RESTRAINTS
8A
Seat Belts
812 822
8A1
8B
S. R. S (Supplemental Inflatable Restraints)
832 833 911 916/91 7 918
8B1
9. BODY AND ACCESSORIES
9A 9B
Body Wiring System Lighting System
9A1 9B1
9D
Wiper/Washer System
921 923
Windshield wiper Windshield washer Instrument cluster Electrical parts Antenna Instrument panel Molding & switch Instrument parts Console Front door trim Rear door trim Pillar trim Floor carpet Front seat Rear seat Glass & outside mirrors
9D1
9E 9F
Inst. Driver System Audio & Antitheft System
925 928 929 931 932 933 934 935 936 938 939
9E1 9F1
9G
Interior Trim
9G1
9H
Seats
941 942
9H1
9L
Glass & Mirrors
946
9L1
0 16 GENERAL INFORMATION
SECTION
9. BODY AND ACCESSORIES 9O 9M
SUBSECTION
Exterior Parts 951 952 Bumpers & Fascias 956 957 9P Doors 961A 961B 961C 963A 963B 963C 965 966 967 968 9Q Roof 971 972A 972B 9R Body Front End 973 974 975 976 977 9S Body Rear End Paint 978 981
MAIN GROUP CODE
Emblem & lettering Mud guard Front bumper Rear bumper Front door & lock Front window lifter Front weatherstrip Rear door & lock Rear window lifter Rear weatherstrip Electric door lock Fuel filler lock & quarter window lock Trunk lid lock & tailgate lock Car lock Headlining & roof panel Sunshade & inside mirror Sun roof Hood panel Front panel Fender panel Dash panel & cowl Grille Trunk lid panel & spoiler Paint
PAGE
9M1
9O1
9P1
9Q1
9R1
9S1 101
10. PAINT
10