DAEWOO LACETTI 2004 Service Repair Manual

i
PERSONAL INJURY CAUTION
Appropriate service methods and proper repair procedures are essential
for the safe, reliable operation of all motor vehicles, as well as for the per-
sonal safety of the person doing the repair. There are many variations in
procedures, techniques, tools and parts for servicing vehicles, as well as
in the skills of the people doing the work. This manual cannot possibly
anticipate all such variations and provide advice or precautions for each.
Anyone who deviates from the instructions provided in this manual must
ensure their own safety and preserve the safety and integrity of the ve-
hicle. The following list contains general precautions that should always
be followed while working on a vehicle.
DSafety stands are required whenever a procedure calls for under-
body work.
DDo not smoke when you work on a vehicle.
DTo prevent serious burns, do not touch any hot metal parts.
DSet the parking brake when you work on the vehicle.
DTurn the ignition switch OFF unless a procedure states otherwise.
DThe engine may operate only in a well-ventilated area.
DAvoid moving parts when the engine is running.
DSafety glasses must be worn for eye protection.

ii
00000000
We support voluntary technician certification through the National Institute for Automotive
Service Excellence.

iii
.
NUBIRA/LACETTI
Service Manual
(MY2004)
FOREWORD
This manual includes procedures for maintenance, adjustment, service operations, and removal
and installation of components for the NUBIRA/LACETTI vehicle.
When reference is made in this manual to a brand name, number, or specific tool, an equivalent
product may be used in place of the recommended item.
All information, illustrations and specifications contained in this manual are based on the latest
product information available at the time of publication approval. The right is reserved to make
changes at any time without notice.
GM Daewoo Auto & Technology Co., Ltd.
Service Engineering Team
199–1 Cheong Cheon–Dong, Bupyung–Gu, Incheon, Korea
Tel: 82-32-520–2737, 5752
Fax: 82-32-520–4808
E-mail: [email protected]
[email protected]
GM Daewoo Auto & Technology Co., Ltd.
All Rights Reserved
No part of this publication may be reproduced, stored in any retrieval system or transmitted,
in any form or by any means, including but not limited to electronic, mechanical, photocopy-
ing, recording or otherwise, without the prior written permission of GM Daewoo Auto &
Technology Co., Ltd.
Printed in the Republic of Korea

iv

v
TABLE OF CONTENTS
Section 0B General Information
Section 1 Engine
Section 1A General Engine Information
Section 1C1 1.4L/1.6L DOHC Engine Mechanical
Section 1C2 1.8L DOHC Engine Mechanical
Section 1D Engine Cooling
Section 1E Engine Electrical
Section 1F Engine Controls
Section 1G Engine Exhaust
Section 2 Suspension
Section 2A Suspension Diagnosis
Section 2B Wheel Alignment
Section 2C Front Suspension
Section 2D Rear Suspension
Section 2E Tires and Wheels
Section 3 Driveline/Axle
Section 3A Automatic Transaxle Drive Axle
Section 3B Manual Transaxle Drive Axle
Section 4 Brakes
Section 4A Hydraulic Brakes
Section 4B Master Cylinder
Section 4C Power Booster
Section 4D Front Disc Brakes
Section 4E1 Rear Disc Brakes
Section 4E2 Rear Drum Brakes
Section 4F Antilock Brake System
Section 4G Parking Brake
Section 5 Transmission/Transaxle
Section 5A1 ZF 4HP16 Automatic Transaxle
Section 5A2 AISIN Automatic Transaxle
Section 5B Five-Speed Manual Transaxle
Section 5C Clutch
Section 6 Steering
Section 6A Power Steering System
Section 6B Power Steering PumpSection 6C Power Steering Gear
Section 6E Steering Wheel and Column
Section 7 Heating, Ventilation, and Air
Conditioning (HVAC)
Section 7A Heating and Ventilation System
Section 7B Manual Control Heating, Ventilation,
and Air Conditioning System
Section 7D Automatic Temperature Control HVAC
Section 8 Restraints
Section 8A Seat Belts
Section 8B Supplemental Inflatable Restraints
(SIR)
Section 9 Body and Accessories
Section 9A Body Wiring System
Section 9B Lighting Systems
Section 9C Horns
Section 9D Wipers/Washer Systems
Section 9E Instrumentation/Driver Information
Section 9F Audio Systems
Section 9G Interior Trim
Section 9H Seats
Section 9I Waterleaks
Section 9J Windnoise
Section 9K Squeaks and Rattles
Section 9L Glass and Mirrors
Section 9M Exterior Trim
Section 9N Frame and Underbody
Section 9O Bumpers and Fascias
Section 9P Doors
Section 9Q Roof
Section 9R Body Front End
Section 9S Body Rear End
Section 9T1 Remote Keyless Entry and Anti–Theft
System
Section 9T2 Immobilizer Anti–Theft System

vi

vii
GM DAEWOO PUBLICATION COMMENT FORM
Use this form to advise us of any errors you might find in this publication. We also welcome your suggestions that might
help us improve GM Daewoo publications.
Publication that contains error:
Page number where the error appears:
Figure number where the error appears:
Vehicle application and system identification:
Describe the error found or your suggestion in detail. Please attach additional pages as necessary. Please attach a
copy of illustrations that contain errors.
From: Name
Address Country
Signature Date Phone
Mail To: GM Daewoo Auto & Technology Co., Ltd.
Service Engineering Team
199-1 Cheong Cheon–Dong, Bupyung–Gu,
Incheon, Korea
E–Mail : [email protected] (S.H.Han) or [email protected] (S.G.Lee)

SECTION : 0B
GENERAL INFORMATION
TABLE OF CONTENTS
SPECIFICATIONS0B–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 0B–1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle Dimensions and Weights 0B–6. . . . . . . . . . . .
Standard Bolt Specifications 0B–8. . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR0B–9 . . . . . . . . . . . . . . .
MAINTENANCE AND LUBRICATION 0B–9. . . . . . . . . .
Normal Vehicle Use 0B–9. . . . . . . . . . . . . . . . . . . . . . .
Explanation of Scheduled Maintenance
Services 0B–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scheduled Maintenance Charts 0B–10. . . . . . . . . . . .
OWNER INSPECTIONS AND SERVICES 0B–12. . . . .
Whle Operating The Vehicle 0B–12. . . . . . . . . . . . . . . At Each Fuel Fill 0B–12. . . . . . . . . . . . . . . . . . . . . . . . .
At least Monthly 0B–12. . . . . . . . . . . . . . . . . . . . . . . . . .
At least Twice a Year 0B–12. . . . . . . . . . . . . . . . . . . . .
Each Time The Oil is Changed 0B–13. . . . . . . . . . . . .
At Least Annually 0B–13. . . . . . . . . . . . . . . . . . . . . . . .
Recommended Fluids and Lubricants 0B–14. . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION0B–15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Repair Instructions 0B–15. . . . . . . . . . . . . . . .
GENERAL DESCRIPTION 0B–16. . . . . . . . . . . . . . . . . .
Vehicle and Component Identification 0B–16. . . . . . .
Vehicle Lifting Procedures 0B–21. . . . . . . . . . . . . . . . .
SPECIFICATIONS
TECHNICAL DATA
Performance – Manual Transaxle
Application1.4L DOHC1.6L DOHC1.8L DOHC
Maximum Speed175 km/h (108.7 mph)187 km/h (116.2 mph)194 km/h (120.5 mph)
Minimum Turning Radius5.2 m (17.1 ft)


Performance – Automatic Transaxle
Application1.4L DOHC1.6L DOHC1.8L DOHC
Maximum Speed–175 km/h (108.7 mph)184 km/h (114.3 mph)
Minimum Turning Radius–5.2 m (17.1 ft)

0B – 2IGENERAL INFORMATION
DAEWOO V–121 BL4
Engine
Application1.4L DOHC1.6L DOHC1.8L DOHC
Engine TypeDual Overhead Cam L–4


Bore77.9 mm (3.06 in.)79 mm (3.11 in.)81.6 mm (3.21 in.)
Stroke73.4 mm (2.89 in.)81.5 mm (3.21 in.)86 mm (3.38 in.)
Total Displacement1399 cm3 (85.4 in.3)1598 cm3 (97.5 in.3)1799 cm3 (109.7 in3)
Compression Ratio9.5 : 1
9.8 : 1
Maximum Power69.5 kw (93.2 hp)
(at 6,300 rpm)80 kw (107.3 hp)
(at 5,800 rpm)90 kw (120.7 hp)
(at 5,800 rpm)
Maximum Torque131 N_m (96.6 lb–ft)
(at 4,400 rpm)150 NSm (110.6 lb–ft)
(at 4,000 rpm)165 NSm (121.7 lb–ft)
(at 4,000 rpm)
Ignition System
Application1.4L DOHC1.6L DOHC1.8L DOHC
Ignition TypeDirect Ignition System


Ignition Timing (BTDC)4°5°

Ignition Sequence1–3–4–2


Spark Plug Gap1.0 ~ 1.1 mm
(0.039 ~ 0.043 in.)
0.9 ~ 1.1 mm
(0.035 ~ 0.043 in.)
Spark Plug MakerWoojin
Boach
Spark Plug TypeBKR6E–11
FLR8LDCU
Clutch
Application1.4L DOHC1.6L DOHC1.8L DOHC
TypeSingle Dry Plate


Outside Diameter215 mm (8.5 in.)


Inside Diameter145 mm (5.7 in.)


Thickness8.4 mm (0.331 in.)


FluidCommon Use:
Brake Fluid


Manual Transaxle
Application1.4L DOHC1.6L DOHC1.8L DOHC
MakerGMDATGMDAT

Type or ModelD–16 (C/R)D–16 (C/R)

Gear Ratio :
1st
2nd
3rd
4th
5th
Reverse3.818 : 1
2.158 : 1
1.478 : 1
1.129 : 1
0.886 : 1
3.333 : 13.545 : 1
2.158 : 1
1.478 : 1
1.129 : 1
0.886 : 1
3.333 : 1











Final Drive Ratio3.722 : 13.722 : 1

Oil Capacity1.8L (2 qts)

GENERAL INFORMATION 0B – 3
DAEWOO V–121 BL4
Automatic Transaxle
Application1.4L DOHC1.6L DOHC1.8L DOHC
Maker–AISINZF
Type or Model–81–40LE4HP16
Gear Ratio :
1st
2nd
3rd
4th
Reverse–
–
–
–
–2.875:1
1.568:1
1.000:1
0.697:1
2.300:12.719:1
1.487:1
1.000:1
0.717:1
2.529:1
Final Drive Ratio–3.750:13.945:1
Oil Capacity–5.77±0.2L (6.1±0.2 qts)6.9±0.2L (7.3±0.2 qts)
Brake
Application1.4L DOHC1.6L DOHC1.8L DOHC
Booster Size :
Single
Dual241.3 mm (9.5 in.)
177.8 and 203.2 mm
(7 and 8 in.)






Master Cylinder Diameter22.22 mm (0.875 in.)


Booster Ratio5.5 : 1


Front Brake :
Disc Type
Disc SizeVentilated
256 mm (10 in.)






Rear Brake (Drum) :
Drum Inside Diameter
Wheel Cylinder Diame-
ter200 mm (7.9 in.)
20.64 mm (0.813 in.)






Rear Brake (Disc) :
Disc Type
Disc SizeSolid
258 mm (10.2 in.)






Fluid Capacity0.5L (0.5 qts)


Tire and Wheel
Application1.4L DOHC1.6L DOHC1.8L DOHC
Tire Size195/55R15


Standard Wheel Size6Jx15 (Steel)


Optional Wheel Size6Jx15 (Alloy)


Inflation Pressure at Full
Load30 psi (207 kPa)