ACC DAEWOO LACETTI 2004 Service Repair Manual

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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

GENERAL INFORMATION 0B – 9
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
MAINTENANCE AND LUBRICATION
NORMAL VEHICLE USE
The maintenance instructions contained in the mainte-
nance schedule are based on the assumption that the ve-
hicle 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 with-
in legal operating limits.
EXPLANATION OF SCHEDULED
MAINTENANCE SERVICES
The services listed in the maintenance schedule are fur-
ther explained below. When the following maintenance
services are performed, make sure all the parts are re-
placed and all the necessary repairs are done before driv-
ing the vehicle. Always use the proper fluid and lubricants.
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 re-
place the belt as needed.
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 quali-
ty. Always use oil rated API–SL (ILSAC GF–III) or better.
Engine Oil Viscosity
Engine oil viscosity (thickness) has an effect on fuel econ-
omy and cold weather operation. Lower viscosity engine
oils can provide better fuel economy and cold weather per-
formance; however, higher temperature weather condi-
tions require higher viscosity engine oils for satisfactory lu-
brication. Using oils of any viscosity other than those
viscosities recommended could result in engine damage.
Cooling System Service
Drain, flush and refill the system with new coolant. Refer
to ”Recommended Fluids And Lubricants” in this section.
Fuel Micro–Filter 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).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.
Brake System Service
Check the disc brake pads and the drum brake linings ev-
ery 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 breath-
er hole in the brake fluid reservoir cap to be sure it is free
from dirt and the passage is open.
Transaxle Service
The manual transaxle fluid does not require changing. For
automatic transaxles, refer to ”Scheduled Maintenance
Charts” in this section.
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 irreg-
ular 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.
Tire Rotation

GENERAL INFORMATION 0B – 13
DAEWOO V–121 BL4
EACH TIME THE OIL IS CHANGED
Automatic Transaxle Fluid
Refer to fluid level service procedure of Section 5A, ZF
4HP16 Automatic Transaxle.
Manual Transaxle
Check the fluid level and add fluid as required. Refer to
Section 5B, Five–Speed Manual Transaxle.
Brake System Inspection
This inspection should be done when the wheels are re-
moved for rotation. Inspect the lines and the hoses for
proper hookup, binding, leaks, cracks, chafing, etc. In-
spect 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 fre-
quent braking.
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, chaf-
ing, etc. Clean and inspect the drive axle boot and seals
for damage, tears or leakage. Replace the seals if neces-
sary.
Exhaust System Inspection
Inspect the complete system (including the catalytic con-
verter if equipped). Inspect the body near the exhaust sys-
tem. Look for broken, damaged, missing, or out–of–posi-
tion 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.
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 accel-
erator 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 ten-
sion. Adjust or replace the belts as needed.
Hood Latch Operation
When opening the hood, note the operation of the secon-
dary latch. It should keep the hood from opening all the
way when the primary latch is released. The hood must
close firmly.
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.
Movable Head Restraint Operation
On vehicles with movable head restraints, the restraints
must stay in the desired position.
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 mech-
anism 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.
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 ve-
hicle starts.
On automatic transaxle vehicles, try to start the engine in
each gear. The starter should crank only in P (Park) or N
(Neutral).
Parking Brake and Transaxle P (Park)
Mechanism Operation
CAUTION : In order to reduce the risk of personal in-
jury or property damage, be prepared to apply the reg-
ular 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 trans-
axle to P (Park).
Underbody Flushing
Flushing the underbody will remove any corrosive materi-
als 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.

HOW TO USE ELECTRICAL WIRING DIAGRAMW1–3
2. CIRCUIT IDENTIFICATION SYMBOL
IDENTIFICATION
SYMBOLMEANING
CConnector
DDiode
EfFuse in engine room fuse box
FFuse in passenger room fuse box
GGround
SSplice pack(Junction connector)
3. FUNCTION OF POWER SUPPLY LINE (NUMBER)
Power supply NoPower supply condition
15Battery Voltage(B+) supply in Ignition Switch ”ON” and ”ST” (IGN 1)
15ABattery Voltage(B+) supply in Ignition Switch ”ON” (IGN 2)
15CBattery Voltage(B+) supply in Ignition Switch ”ON” and ”ACC”
30Battery Voltage(B+) supply directly regardless of Ignition Switch
31Ground connected to battery(
)
58Battery Voltage(B+) supply in Head Lamp Switch 1st and 2nd step (Illumination circuit)
4. WIRING HARNESS COLOR IDENTIFICATION
AbbreviationColorAbbreviationColor
BrBrownSbSky Blue
GGreenRRed
VVioletLBlue
PPinkYYellow
WWhiteGrGray
OrOrangeBBlack
LgLight Green
5. HOW TO CHECK TERMINAL NUMBER OF CONNECTOR
" Terminal number is given based on Female Terminal Connectorex) Terminal Number 4 of C901 connection

1A – 4IGENERAL ENGINE INFORMATION
DAEWOO V–121 BL4
Repairing the Leak
Once the origin of the leak has been pinpointed and traced
back to its source, the cause of the leak must be deter-
mined in order for it to be repaired properly. If a gasket is
replaced, but the sealing flange is bent, the new gasket will
not repair the leak. The bent flange must be repaired also.
Before attempting to repair a leak, check for the following
conditions and correct them as they may cause a leak.
Gaskets:
S The fluid level/pressure is too high.
S The crankcase ventilation system is malfunctioning.
S The fasteners are improperly tightened or the
threads are dirty or damaged.
S The flanges or the sealing surface is warped.S There are scratches, burrs or other damage to the
sealing surface.
S The gasket is damaged or worn.
S There is cracking or porosity of the component.
S An improper seal was used, (where applicable).
Seals:
S The fluid level/pressure is too high.
S The crankcase ventilation system is malfunctioning.
S The seal bore is damaged, scratched, burred or
nicked.
S The seal is damaged or worn.
S Improper installation is evident.
S There are cracks in the component.
S The shaft surface is scratched, nicked or damaged.
S A loose or worn bearing is causing excess seal
wear.
KNOCK DIAGNOSIS
Definition for Knock
Engine knock refers to various types of engine noise.
Heavy knock is usually very loud and the result of broken
or excessively worn internal engine components. Lightknock is a noticeable noise, but not as loud. Light knock
can be caused by worn internal engine components.
Loose or broken external engine components can also
cause heavy or light knock.
Engine Knocks Cold and Continues for Two–Three Minutes and/or
Knock Increases with Engine Torque
StepActionValue(s)YesNo
1Does the engine knock when it is cold and continue
for two to three minutes or does the knock increase
with torque?–Go to Step 2System OK
2Inspect the flywheel.
Is the flywheel contacting the splash shield?–Go to Step 3Go to Step 4
3Reposition the splash shield.
Is the repair complete?–Go to Step 1–
4Inspect the balancer and the drive pulleys.
Is either the balancer or the drive pulleys loose or
broken?–Go to Step 5Go to Step 6
5Tighten or replace the balancer or the drive pulleys.
Is the repair complete?–Go to Step 1–
6Inspect the piston–to–bore clearance.
Is the clearance more than the specified value?0.030 mm
(0.001 in.)Go to Step 7Go to Step 8
71. Rebore the cylinder and hone to size.
2. Replace the piston.
Is the repair complete?*–Go to Step 1–
8Inspect the connecting rod.
Is the connecting rod bent?–Go to Step 9System OK
9Replace the connecting rod.
Is the repair complete?–Go to Step 1–
* Cold engine piston knock usually disappears when the cylinder is grounded out. Cold engine piston knock, which disap-
pears in about 1.5 minutes, is considered acceptable.

GENERAL ENGINE INFORMATION 1A – 5
DAEWOO V–121 BL4
Heavy Knock Hot with Torque Applied
StepActionValue(s)YesNo
1Is there a heavy knock when the engine is hot and
torque is applied?–Go to Step 2System OK
2Inspect the balancer and the pulley hub.
Is the balancer or the pulley hub broken?–Go to Step 3Go to Step 4
3Replace the broken balancer or the pulley hub.
Is the repair complete?–Go to Step 1–
4Inspect the torque converter bolts.
Are the bolts tightened to specified value?45 NSm
(33 lb–ft)Go to Step 5Go to Step 6
5Tighten the torque converter bolts.
Is the repair complete?–Go to Step 1–
6Inspect the accessory belts.
Are the belts too tight or nicked?–Go to Step 7Go to Step 8
7Replace and/or tension the belts to specifications,
as necessary.
Is the repair complete?–Go to Step 1–
8Inspect the exhaust system.
Is the system grounded?–Go to Step 9Go to Step 10
9Reposition the system, as necessary.
Is the repair complete?–Go to Step 1–
10Inspect the flywheel.
Is the flywheel cracked?–Go to Step 11Go to Step 12
11Replace the flywheel.
Is the repair complete?–Go to Step 1–
12Inspect the main bearing clearance.
Is the clearance more than the specified value?0.026~0.046
mm (0.0010~
0.0018 in.)Go to Step 13Go to Step 14
13Replace the main bearings, as necessary.
Is the repair complete?–Go to Step 1–
14Inspect the rod bearing clearance.
Is the clearance more than the specified value?0.019 ~
0.070 mm
(0.0007 ~
0.0028 in.)Go to Step 15System OK
15Replace the rod bearings, as necessary.
Is the repair complete?–Go to Step 1–

GENERAL ENGINE INFORMATION 1A – 11
DAEWOO V–121 BL4
GENERAL INFORMATION
CLEANLINESS AND CARE
An automobile engine is a combination of many machined,
honed, polished and lapped surfaces with tolerances that
are measured in the ten–thousandths of an inch. When
any internal engine parts are serviced, care and cleanli-
ness are important. A liberal coating of engine oil should
be applied to friction areas during assembly, to protect and
lubricate the surfaces on initial operation. Proper cleaning
and protection of machined surfaces and friction areas is
part of the repair procedure. This is considered standard
shop practice even if not specifically stated.
Whenever valve train components are removed for ser-
vice, they should be kept in order. They should be installed
in the same locations, and with the same mating surfaces,
as when they were removed.Battery cables should be disconnected before any major
work is performed on the engine. Failure to disconnect
cables may result in damage to wire harness or other elec-
trical parts.ON–ENGINE SERVICE
CAUTION : Disconnect the negative battery cable be-
fore removing or installing any electrical unit, or
when a tool or equipment could easily come in con-
tact with exposed electrical terminals. Disconnecting
this cable will help prevent personal injury and dam-
age to the vehicle. The ignition must also be in LOCK
unless otherwise noted.
Notice : Any time the air cleaner is removed, the intake
opening should be covered. This will protect against acci-
dental entrance of foreign material, which could follow the
intake passage into the cylinder and cause extensive
damage when the engine is started.

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 9
DAEWOO V–121 BL4
COMPONENT LOCATOR
CYLINDER HEAD
1. Oil Filler Cap
2. Engine Cover
3. Camshaft Cover
4. Camshaft Cover Gasket
5. Camshaft Cover Bolt
6. Hydraulic Tappet Adjuster
7. Valve Key
8. Valve Spring Cap
9. Valve Spring
10. Valve Stem Seal
11. EGR Vaccum Hose
12. EGR Valve
13. EGR Valve Gasket
14. EGR Valve Adaptor
15. EGR Valve Adaptor Gasket16. Cylinder Head
17. Front Camshaft Cap
18. Valve Guide
19. Plug
20. Freeze Plug
21. Oil Duct Cap
22. Intake Valve
23. Exhaust Valve
24. Cylinder Head Gasket
25. Engine Coolant Temperature Sensor
26. Heat Take Off Pipe
27. Camshaft
28. Camshaft Seal
29. Thermostat

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 17
DAEWOO V–121 BL4
6. Disconnect the intake manifold pressure sensor
connector, attaching bolt and vaccum hose.
7. Disconnect the intake manifold air temperature sen-
sor(MAT) connector and remove the MAT sensor.
8. Remove the intake manifold upper bracket.
9. Remove the fule rail bolt and the fuel rail.
10. Remove the all the vaccum hoses from the intake
manifold including PCV hose and brake booster
vaccum hose.
11. Remove the exhaust gas recirculation(EGR) pipe.

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 23
DAEWOO V–121 BL4
12. Remove the all the vaccum hoses from the intake
manifold including brake booster vaccum hose.
13. Remove the ignition cables from the spark plugs.
14. Remove the direct ignition coil(DIS) and the bracket
from the cylinder head.
15. Remove the serpentine accessory drive belt by ro-
tating the tensioner pulley bolt to clockwise using
DW110–080. Refer to Section 6B, Power Steering
Pump.
16. Remove the front passenger side tire. Refer to Sec-
tion 2E, Tires and Wheels.
17. Remove front wheel housing shield.
18. Remove the upper front timing belt cover bolts.
19. Remove the upper front timing belt cover.
20. Align the camshaft gear timing marks.
21. Remove the crank shaft pulley.
22. Remove the lower front timing belt cover bolts and
cover.