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. Year 2004



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SECTION : 0B

GENERAL INFORMATION
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 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 0B­13

MAINTENANCE 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 . . . . . . . . . . . . . . . 0B­12

At 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 . . . . . . . . . . . . . . . . . 0B­21

SPECIFICATIONS
TECHNICAL DATA
Performance ­ Manual Transaxle
Application 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) ²

Performance ­ Automatic Transaxle
Application 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) ²

0B ­ 2IGENERAL INFORMATION Engine
Application 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 System
Application 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 FLR8LDCU

Clutch
Application 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 ²

Manual Transaxle
Application 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 ²
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1.4L DOHC GMDAT D­16 (C/R)

1.6L DOHC GMDAT D­16 (C/R)

1.8L DOHC ² ²

GENERAL INFORMATION 0B ­ 3 Automatic Transaxle
Application 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 4HP16

Brake
Application 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 DOHC

Tire and Wheel
Application 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 ²

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0B ­ 4IGENERAL INFORMATION Steering System
Application 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 ²

Suspension
Application Front Type Rear Type 1.4L DOHC Macpherson Strut Dual Link 1.6L DOHC ² ² 1.8L DOHC ² ²

Fuel System
Application 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 ²

Lubricating System
Application 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 ²

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GENERAL INFORMATION 0B ­ 5 Cooling System
Application 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 System
Application 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 rpm

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0B ­ 6IGENERAL INFORMATION

VEHICLE DIMENSIONS AND WEIGHTS
Vehicle Dimensions
Application 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 DOHC

Vehicle Weights
Application 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 DOHC

4 Door
1.6L DOHC 1.8L DOHC

1,180 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) ²

1,235 kg (2,723 lb) 1,285 kg (2,833 lb) 1,720 kg (3,792 lb) ²

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GENERAL INFORMATION 0B ­ 7 Vehicle Weights
Application 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 DOHC

5 Door H/B
1.6L DOHC 1.8L DOHC

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0B ­ 8IGENERAL INFORMATION

STANDARD BOLT SPECIFICATIONS
Bolt* 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 millimeters

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GENERAL INFORMATION 0B ­ 9

MAINTENANCE AND REPAIR
MAINTENANCE AND LUBRICATION NORMAL VEHICLE USE
The 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 Torque
Check the torque of the mounting bolts. Tighten the throttle body mounting bolts to 15 NSm (11 lb­ ft) if necessary.

Spark Plug Replacement
Replace spark plugs with the same type.

Spark Plug Wire Replacement
Clean 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 SERVICES
The 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 Service
Check 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 Inspection
When 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 Service
The manual transaxle fluid does not require changing. For automatic transaxles, refer to "Scheduled Maintenance Charts" in this section.

Engine Oil and Oil Filter Change
API 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 Rotation
Check 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 Viscosity
Engine 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 Rotation

Cooling System Service
Drain, flush and refill the system with new coolant. Refer to "Recommended Fluids And Lubricants" in this section.

Fuel Micro­Filter Replacement
Replace the engine fuel filter every 45,000 km (27,000 miles).

Air Cleaner Element Replacement
Replace the air cleaner element every 45,000 km (27,000 miles).

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0B ­ 10IGENERAL INFORMATION

SCHEDULED MAINTENANCE CHARTS
Engine
Maintenance 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 I

Replace every 90,000 km(54,000 miles) I I R I I l I R

Chart 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.

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GENERAL INFORMATION 0B ­ 11 Chassis and Body
Maintenance 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 I

Inspect 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 I

Chart 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.

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0B ­ 12IGENERAL INFORMATION

OWNER INSPECTIONS AND SERVICES WHLE OPERATING THE VEHICLE
Horn Operation
Blow 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 Condition
Check the coolant level in the coolant reservoir tank and add coolant if necessary. Inspect the coolant. Replace dirty or rusty coolant.

Brake System Operation
Be 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 Level
Check the washer fluid level in the reservoir. Add fluid if necessary.

AT LEAST MONTHLY
Tire And Wheel Inspection and Pressure Check
Check 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 Operation
Be 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 Operation
Be 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 Operation
Check 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 Operation
Be 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 Check
Periodically 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 Aim
Take note of the light pattern occasionally. Adjust the headlights if the beams seem improperly aimed.

AT LEAST TWICE A YEAR
Power Steering System Reservoir Level
Check the power steering fluid level. Keep the power steering fluid at the proper level. Refer to Section 6A, Power Steering System.

AT EACH FUEL FILL
A 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 Level
Check 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 Travel
Check 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 Lubrication
Apply a thin film silicone grease using a clean cloth.
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GENERAL INFORMATION 0B ­ 13

EACH TIME THE OIL IS CHANGED
Automatic Transaxle Fluid
Refer to fluid level service procedure of Section 5A, ZF 4HP16 Automatic Transaxle.

AT LEAST ANNUALLY
Lap and Shoulder Belts Condition and Operation
Inspect the belt system including: the webbing, the buckles, the latch plates, the retractor, the guide loops and the anchors.

Manual Transaxle
Check the fluid level and add fluid as required. Refer to Section 5B, Five­Speed Manual Transaxle.

Movable Head Restraint Operation
On vehicles with movable head restraints, the restraints must stay in the desired position.

Brake System Inspection
This 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 Storage
Be 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 Service
Lubricate the key lock cylinder.

Body Lubrication Service
Lubricate 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 Inspection
Inspect 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 Transaxle
CAUTION : 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 Inspection
Inspect 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 Operation
CAUTION : 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 Inspection
Inspect 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 Belts
Inspect all belts for cracks, fraying, wear and proper tension. Adjust or replace the belts as needed.

Underbody Flushing Hood Latch Operation
When 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.
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Flushing 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 System
Inspect 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 LUBRICANTS
Usage 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 oil

Engine Coolant

Brake Fluid and Clutch Fluid Power Steering System Automatic Transaxle

As required

As required

Silicone grease

DAEWOO V­121 BL4

GENERAL INFORMATION 0B ­ 15

GENERAL DESCRIPTION AND SYSTEM OPERATION
GENERAL REPAIR INSTRUCTIONS
S 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 S

S S

S

S S S S S S

S S S

Use 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 BL4

0B ­ 16IGENERAL INFORMATION

GENERAL DESCRIPTION VEHICLE AND COMPONENT IDENTIFICATION
Passenger Car Vehicle Identification Number

DAEWOO V­121 BL4

GENERAL INFORMATION 0B ­ 17 Engraved VIN Location VIN Plate Location
The 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 Location
The engine number is stamped on the cylinder block under the No. 4 exhaust manifold of the engine. 1.4L/1.6L DOHC Engine

VIN Plate

1.8L DOHC Engine

1. 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 ­ Rear

DAEWOO V­121 BL4

0B ­ 18IGENERAL INFORMATION Engine Number ­ Family I (1.4L/1.6L DOHC Engine)

Engine Number ­ Family II (1.8L DOHC Engine)

DAEWOO V­121 BL4

GENERAL 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 CR

1. 2. 3. 4.

Part Number Sirial Number Model Code Manufactured Nation and Company Part Code AW Engine 1.8L DOHC

Manual 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 BL4

0B ­ 20IGENERAL INFORMATION Automatic Transaxle Identification Number Plate (AISIN : 81­40LE)
4. AW's Serial Number

Automatic Transaxle Identification Number Plate Location (AISIN : 81­40LE)

1. 2. 3.

AW's Lot Number Part ID Code DW's Part Number

The automatic transaxle identification number plate is attached on the upper side of the transaxle case.

DAEWOO V­121 BL4

GENERAL INFORMATION 0B ­ 21

VEHICLE LIFTING PROCEDURES
Notice : 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 are

equipped 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 Points

DAEWOO V­121 BL4

0B ­ 22IGENERAL INFORMATION Vehicle Lifting Points

DAEWOO V­121 BL4