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Daewoo Service Manual

Nubira-Lacetti
Body Repair Manual

Nubira-Lacetti

0. SERVICE NOTICE
1. GENERAL INFORMATION

SECTION 2

2. PREPARATIONS OF BODYWORK
3. WELDING AND TOOLS

ENGINE COMPARTMENT

4. FRONT
5. ROOF, BACK PANEL AND REAR FLOOR PANEL
6. FRAME DOOR OPENING, DOOR AND SIDE PANEL OUTER

1. COMPONENTS CONNECTION LOOSE

7. FENDER, HOOD, TAILGATE AND TRUNK LID


8. BODY DIMENSION
9. SEALING, CAULKING AND DEADNER

Check engine compartment for components which may be loose; kinked or pinched vacuum hoses or electrical
connections, and for any other missing or disconnected components as below.

10. RUST PREVENTION


11. BODY-FRAME REPAIR EQUIPMENT
Electrical Wiring Diagrams
Labour Time Guide
0. General Information
1. Engine
SOHC ENGINE MECHANICAL
DOHC ENGINE MECHANICAL
DOHC ENGINE MECH. - DOHC ENGINE UNIT (111)
DOHC ENGINE MECH. - BELT SYSTEM (113)
DOHC ENGINE MECH.- ENGINE BLOCK (121)
DOHC ENGINE MECH. - CRANKSHAFT & PISTON (122)
DOHC ENGINE MECH. - OIL PAN & PUMP (123)
DOHC ENGINE MECH. - CYLINDER HEAD (131)
DOHC ENGINE MECH. - CAM SUPPORT & SHAFT (132)
DOHC ENGINE MECH. - TIMING COVER (133)
DOHC ENGINE MECH. - ENGINE & TRANSAXLE MOUNT (138)
ENGINE COOLING
ENGINE ELECTRICAL
ENGINE CONTROLS
ENGINE INTAKE & EXHAUST
2. Suspension
3. Driveline Axle
4. Brakes
5. Transmissions/Transaxle
6. Steering
7. (HVAC) Heating, Ventilation, and Air Conditioning
8. Restraints
9. Body and Accessories
10. Paint
Pre-delivery Inspection
FOREWORD
GENERAL INTRODUCTION

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Air Cleaner
Engine oil filter cap
Brake fluid reservoir*
Clutch fluid reservoir*
Coolant reservoir
fuse and relay box
battery
Washer fluid reservoir
Power steering fluid reservoir
Engine oil level dipstick

ENGINE COMPARTMENT
1. COMPONENTS CONNECTION LOOSE

*Kalos, Nubira/Lacetti and Evanda have one reservoir for both the brake and clutch fluid.

2. HOSE AND ELECT. WIRES ROUTING


3. FREENESS OF MOVEMENT OF LINKAGE, VALVES AND OTHER COMPONENTS

4. UNUSUAL NOISES

5. SEEPAGE AND LEAKS AT HOSES AND PIPE CONNECTIONS, ETC.

6. POWER STEERING SYSTEM

7. ENGINE COOLANT PROTECTION

Check engine components for missing or disconnection.


Check electrical connections for loose or misconnection.
Check vacuum hoses for kink, pinch, damage, twist and swelling.
Check hose clamps and pipe connections for leak or loose for following systems.
Fuel system
Cooling system

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8. ALL FLUID LEVELS CHECK


10. BELTS TENSION

Power steering system


Airconditioning system
Check engine components which may be loose.

9. THROTTLE LINKAGE

BODY - ACCESSORIES
UNDER VEHICLE
ROAD TEST
APPEARANCE
ANNEX

If remedy is required, tighten clamps, connections, bolts and nuts, and replace or repair defective hose and its
connections.

2. HOSE AND ELECT. WIRES ROUTING

Service Manual
0. General Information
1. Engine

Check to assure that following hoses and electrical wires are properly routed to provide sufficient clearance with
adjacent moving or hot parts.

GENERAL ENGINE INFORMATION


DIAGNOSIS

GENERAL INFORMATION

1.4L/1.6L DOHC ENGINE MECHANICAL


SPECIFICATIONS
Engine Specifications
Fastener Tightening Specifcations
SPECIAL TOOLS
Special Tools Table

Fuel hose
Airconditioning hose
Vacuum hoses
High-tension cable for ignition system
Electric wires

3. FREENESS OF MOVEMENT OF LINKAGE, VALVES AND OTHER


COMPONENTS

COMPONENT LOCATOR
Cylinder Head

Observe the movement or freeness of movement of linkage, valves and other components.

Cylinder Block
Intake & Exhaust Manifold

Timing Belt
Engine Mounting
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE

Accelerator cable
Check the accelerator cable free play when the engine is warm as follow.
1) Pull the accelerator cable toward the throttle lever.
2) Push the cable away from the throttle lever until the lever begins to move. (free play)
If adjustment is required, refer to "9. Throttle linkage" of this section.

Engine Cover
Camshaft Cover

Intake Manifold

Clutch pedal
Check the clutch pedal free play when depress the clutch pedal.

Exhaust Manifold
Cylinder Head and Gasket

Camshafts
Timing Belt Check and Adjust
Timing Belt
Oil Pan
Oil Pump
Engine Mount
Camshaft Gears
Rear Timing Belt Cover
Engine
Pistons and Rods

UNIT REPAIR
GENERAL DESCRIPTION AND SYSTEM OPERATION
1.8L DOHC ENGINE MECHANICAL

ENGINE COOLING
ENGINE ELECTRICAL

Steering linkage system


The best method for checking condition is with the vehicle on a flat surface and two mechanics
working as a team.
One of the mechanics turns the steering wheel one way and then the other, and checks its function
mounting and condition, also the mounting for the steering column (with or without power
assistance) while the other mechanic checks for play in the following places;
Tie rods (there must be no looseness)
Steering gear mounting on frame
Steering shaft universal joints from steering gear and upwards (there must be no looseness)
Check all clamps for proper mounting and tightness
Starter motor assembly
1) Check that starting switch and contacts are securely fitted.
2) Run starter motor, and check for followings.
Starter motor should crank engine at normal speed.
Starter motor should function without abnormal noise.

ENGINE CONTROLS
ENGINE EXHAUST

Note : Do not run the starter motor too long as this puts a severe strain on the battery.

2. Suspension
3. Driveline Axle
4. Brakes

Engine starting response


Starting the engine, and check if the engine will function normally.

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5. Transmissions/Transaxle
6. Steering

If the engine does not start or if it stops again, check following items. For further informations, refer
to service manual.

7. (HVAC) Heating, Ventilation, and Air Conditioning


8. Restraints

9. Body and Accessories

Ignition system
IAC operation
Sensors and ECM, if necessary

4. UNUSUAL NOISES
Check for unusual noises within engine compartment.
Run the engine and check if there are some unusual noises. If unusual noises are heard, fasten or fix the loosen
parts and adjust the clearance between components.

5. SEEPAGE AND LEAKS AT HOSES AND PIPE CONNECTIONS, ETC.


Visually inspect for seepage and leaks at hoses and pipe connection, seals, gaskets and plugs. Tighten clamps
and connection as necessary.

Fuel system
Airconditioning system
Cooling system
Brake system
Clutch system
Power steering system
Engine assembly
Camshaft support housing
Cylinder head
Cylinder block
Oil pan
Seals for camshaft etc.

6. POWER STEERING SYSTEM


Check power steering gear, lines and hoses for leaks and clearance with adjacent panels, moving or hot parts.
Tighten clamps and connectors as necessary.

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7. ENGINE COOLANT PROTECTION


Test engine coolant protection

The cooling fans are actuated by the ECM using a low-speed cooling fan relay and a high speed cooling
fan relay on non-A/C model or a series/parallel cooling fan relay on A/C model as below;

Description
A/C OFF or Non-A/C model
A/C ON

Cooling fan Operating Mode


Low speed
High speed
Low speed
High speed

<Example: TACUMA(REZZO)>
Fan operating Temp.(C)
ON
OFF
96
93
100
97
when the A/C system id ON
100
97

Check all hoses and connection.


Check for leaks of cooling system as following procedure.
Correct coolant level and run engine at idle speed.
Mount radiator tester on expansion tank instead of screw cap.
Leaks can be recognized by escaping coolant.
If pressure drops or even rises without coolant escaping, this indicates an internal coolant leak in
the engine caused by a defective cylinder head gasket or a crack in the block.

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8. ALL FLUID LEVELS CHECK


Check all fluid levels; engine oil, transmission oil, power steering oil, brake and cooling system.

Engine oil
Engine oil level should be checked with the vehicle standing on level ground (before the operation
of engine). If the engine is running, stop the engine and wait 5 minutes for the oil to drain back to
the oil pan before checking the oil level.
Pull out the oil level indicator (dipstick), wipe and clean it, and reinsert it.
Again pull it out and check that the oil level is within MAX. and MIN. level marks. Also check the oil
on the dipstick for contamination.
The oil should not go above the "Max" mark on the dip-stick, since this may cause engine
damage.

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Automatic Transaxle Fluid (ATF)


The automatic transaxle equipped with ZF 4HP 16 does not have a dipstick. So, check the fluid
level by removing the fluid level plug when the fluid is warmed to approx. 40C after driving the
vehicle for about 10 minutes with the vehicle on a level surface. The fluid level should be up to the
bottom of the plug hole. If the fluid level is low, replenish the ATF until it reaches the bottom of the
plug hole.
Reinstall the filler plug and tighten it securely.

Note : Removal of the fluid level plug when the transaxle fluid is hot may cause injury if fluid drains from
the fluid level plug.

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The automatic transaxle equipped with AISIN 81-40LE or 80-40LE has a dipstick and the fluid level
should be checked when the transaxle reaches normal operting remperature (70C ~ 80C) with the
selector lever in position P after operating the vehicle for about 20 km. Make sure the vehicle is level.
Pull out the dipstick, wipe and clean it, and reinsert it. Again pull it out and check that the fluid level is
between the MIN and the MAX notches of hot area on the dipstick. Also check the oil on the dipstick for
contamination.

Note : Use only special fluid as given in the fluid chart in owner's manual.

ZF 4HP 16 : ESSO LT 71141 or ISU H50235


AISIN 81-40LE or 80-40LE : ESSO JWS 3309 or ISU DEXRON III
Manual Transaxle oil
With the vehicle on a level surface and the fluid in the transaxle cold, remove the filler plug and
check the fluid level. The fluid should come to the bottom edge of the plug hole.
If the level is low, add SAE 80 (1.2S : SAE 75W-85) manual transaxle fluid through the filler plug
hole until the fluid begins to run out.
Reinstall the filler plug and tighten it securely.

Brake/clutch fluid
The fluid level in the container should be between the MIN and MAX mark.
If the level falls below the MIN mark, add the fluid to the MAX mark and tighten the cap securely
afterwards.

Note : Fluid specification DOT 3 or DOT 4

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Coolant
Check the coolant level in surge tank.
The coolant should be full in the radiator and the fluid level should be between the "MIN" and
"MAX" marks on the outside of the surge tank when the engine is cool.
If the level falls below the "MIN" mark, add enough 50/50 water and ethylene glycol anti-freeze
mix to bring level to a little over the "MAX" mark.
For protection in extremely cold weather conditions, use 40% water and 60% ethylene glycol
antifreeze mix.

Note : Do not overfill and remove the coolant surge tank cap when the engine and radiator are hot.
Note : The antifreeze content of the coolant should be maintained at a minimum of 50% and maximum of
60%.

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Windshield washer fluid


Check the windshield washer fluid level in the reservoir tank.
Windshield washer level in the reservoir tank should be at 2/3-3/4 level.

Note : Do not use radiator antifreeze for windshield washer solution. Because this may result in damage
to the paint work.

Power steering oil


Check fluid level with engine turned off.

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The fluid level should be between the MIN and MAX marks on the reservoir.
If it drops to or below the MIN mark, top up with the specified fluid.

Note : Fluid specification DEXRON II D or DEXRON III

9. THROTTLE LINKAGE
Check throttle linkage for interference or binding, damage and freeness at wide open and closed throttle.

Depressing accelerator pedal several times. check the throttle linkage for freeness.

* Allowable limit for flexure of accelerator cable : 2-10 mm (0.08-0.39 inch).

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10. BELTS TENSION

Check that the belt is worn, cracked or frayed.


check tension for following belts and adjust if necessary.

Note : to check belt tension easily, apply moderate thumb pressure (Approx. 10 Kg) midway between
pulleys, and check the deflection. If the belt goes down by 10 mm, it is normal.

Copyright General Motors Daewoo Europe. All rights reserved

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