Lamp DAEWOO LACETTI 2004 Service Repair Manual

0B – 14IGENERAL INFORMATION
DAEWOO V–121 BL4
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, corro-sion protection and engine operating temperature. Inspect
the hoses. Replace the cracked, swollen, or deteriorated
hoses. Tighten the clamps. Clean the outside of the radia-
tor 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
UsageCapacityFluid/Lubricant
Engine Oil3.75L (4.0 qt) : 1.4L DOHC
3.75L (4.0 qt) : 1.6L DOHC
4.0L (4.2 qt) : 1.8L DOHCAPI SL (ILSAC GF–III) grade or better
SAE 5W–30, SAE10W–30, SAE15W–40
(Cold area : SAE5W–30
Hot area : SAE 15W–40)
Engine Coolant7.0L (7.49 qt) : 1.4L DOHC
7.2L (7.6 qt) : 1.6L DOHC
7.4L (7.8 qt) : 1.8L DOHCMixture of water and good quality ethylene gly-
col base antifreeze (year–round coolant)
Brake Fluid and Clutch Fluid0.5L (0.5 qt)DOT–3 or DOT–4
Power Steering System1.1L (1.2 qt)DEXRON®–III or DEXRON®–IID
Automatic Transaxle5.77 ± 0.2L (6.1 ± 0.2 qts) :
1.6L DOHC (AISIN 81–40LE)ESSO JWS 3309 or ISU DEXRON III
6.9 ± 0.2L (7.3 ± 0.2 qts) :
1.8L DOHC (ZF 4HP16)ESSO LT 71141 or TOTAL ATF H50235
Manual Transaxle1.8L (2.0 qt)Manual Transaxle Fluid
SAE80W (Cold Area : SAE 75W)
Manual Transaxle Shift LinkageAs requiredMultipurpose type grease meeting require-
ments NLGI No. 1 or 2
Key Lock CylindersAs requiredSilicone lubricant
Automatic Transaxle Shift Link-
ageAs requiredEngine oil
Clutch Linkage Pivot PointsAs requiredEngine oil
Floor Shift Linkage PointsAs requiredEngine oil
Hood Latch Assembly
a. Pivots and Spring Anchor
b. Release PawlAs requireda. Engine oil
b. Multipurpose type grease meeting require-
ments NLGI No. 1 or 2
Hood and door hinges
Fuel door hinge
Rear compartment lid hingesAs requiredEngine oil
WeatherstripsAs requiredSilicone grease

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 – 2IGENERAL ENGINE INFORMATION
DAEWOO V–121 BL4
OIL PRESSURE TEST
StepActionValue(s)YesNo
1Is the oil pressure warning lamp on?–Go to Step 2System OK
2Check the oil level in the crankcase.
Is the oil level low?–Go to Step 3Go to Step 4
3Add oil so that the oil level is up to the fullmark on the
indicator.
Is the repair complete?–Go to Step 1–
4Check the idle speed.
Is the idle speed below the specified value ?825 rpmGo to Step 5Go to Step 6
5Increase the idle speed.
Is the speed increased?–Go to Step 1–
6Inspect the oil pressure switch.
Is the oil pressure switch incorrect or malfunction-
ing?–Go to Step 7Go to Step 8
7Install a new oil pressure switch.
Is the repair complete?–Go to Step 1–
8Inspect the oil pressure gauge.
Is the oil pressure gauge incorrect or malfunction-
ing?–Go to Step 9Go to Step 10
9Install a new oil pressure gauge.
Is the repair complete?–Go to Step 1–
10Inspect the engine oil.
Is the engine oil in the crankcase diluted or of the im-
proper viscosity?–Go to Step 11Go to Step 12
11Install new engine oil of the proper viscosity for the
expected temperatures.
Is the repair complete?–Go to Step 1–
12Inspect the oil pump.
Is the pump worn or dirty?–Go to Step 13Go to Step 14
13Replace the oil pump.
Is the repair complete?–Go to Step 1–
14Inspect the oil filter.
Is the oil filter plugged?–Go to Step 15Go to Step 16
15Install a new oil filter.
Is the repair complete?–Go to Step 1–
16Inspect the oil pickup screen.
Is the oil pickup screen loose or plugged?–Go to Step 17Go to Step 18
17Tighten or replace the oil pickup screen, as neces-
sary.
Is the repair complete?–Go to Step 1–
18Inspect the oil pickup tube.
Are there any holes in the oil pickup tube?–Go to Step 19Go to Step 20
19Replace the oil pickup tube.
Is the repair complete?–Go to Step 1–

1C1 – 12I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
INTAKE & EXHAUST MANIFOLD
1. Oxygen Sensor
2. Heat Shield
3. Exhaust Manifold
4. Exhaust Manifold Gasket
5. Intake Manifold
6. Main Throttle Idle Actuator (MTIA) Gasket
7. MTIA
8. Clamp9. Intake Air Tube
10. Breethe Hose
11. Aircleaner Assembly
12. Aircleaner Upper Hosing
13. Aircleaner Eliment
14. Aircleaner Lower Housing
15. Resoinator
16. Air Intet Hose

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 49
DAEWOO V–121 BL4
17. Disconnect the oxygen (O2) sensor connector, if
equipped.
18. Disconnect the fuel injector harness connectors.
19. Disconnect the MAT, MAP sensor connectors.
20. Disconnect the throttle position sensor (TPS) con-
nector.
21. Disconnect the generator voltage regulator connec-
tor and power lead.
22. Remove the electrical harness clamp bolt.
23. Disconnect all of the necessary vacuum lines, in-
cluding the brake booster vacuum hose.
24. Disconnect the fuel feed line at the fuel rail.
25. Disconnect the throttle cable from the throttle body
and the intake manifold bracket.
26. Disconnect the surge tank coolant hose at the
throttle body.
27. Disconnect the heater outlet hose at the coolant
pipe.
28. Disconnect the heater inlet hose from the cylinder
head.
29. Disconnect the surge tank coolant hose from the
coolant pipe.
30. Disconnect the lower radiator hose from the coolant
pipe. Disconnect the starter solenoid ”S” terminal
wire. Remove the A/C compressor, if equipped. Re-
fer to Section 7B, Manual Control Heating, Ventila-
tion, and Air Conditioning Systems.
31. Remove the catalytic converter retaining nuts from
the exhaust pipe.
32. Remove the exhaust pipe.

1C1 – 52I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
18. Connect the power steering pressure hose.
19. Connect the power steering return hose.
20. Install the A/C compressor, if equipped. Refer to
Section 7B, Manual Control Heating, Ventilation,
and Air Conditioning Systems.
21. Install the generator. Refer to Section 1E, Engine
Electrical.
22. Install the serpentine accessory drive belt. Refer to
Section 6B, Power Steering Pump.
23. Install the right front wheel well splash shield.
24. Install the right front wheel. Refer to Section 2E,
Tires and Wheels.
25. Connect the fuel feed line to the fuel rail.
26. Connect all of the necessary vacuum lines, includ-
ing the brake booster vacuum hose.
27. Connect the O2 sensor connector, if equipped.
28. Connect the starter solenoid ”S” terminal wire and
power lead.
29. Connect the generator voltage regulator connector
and power lead.
30. Connect the CTS connector.
31. Connect the MAP, MAT sensor connectors.
32. Connect the TPS connector.
33. Install the electrical wiring harness clamp at the
intake manifold support bracket.
34. Connect the fuel injector harness connectors.
35. Connect the electrical connector at the DIS coil and
the ECM ground terminal at the starter.
36. Install the air cleaner outlet hose between the
throttle body and the air cleaner housing.
37. Connect the breather tubes to the camshaft cover.
38. Install the cooling system radiator and the engine
cooling fans. Refer to Section 1D, Engine Cooling.

1.8L DOHC ENGINE MECHANICAL 1C2 – 11
DAEWOO V–121 BL4
1. Connecting Rod
2. Bearing Set
3. Connecting Rod Bolt
4. Piston Ring Set
5. Piston Pin
6. Piston
7. Engine Block
8. Sleeve
9. Water Jacket Cap
10. Bolt (Manual Transaxle)
11. Flywheel (Manual Transaxle)
12. Flexible Plate (Automatic Transaxle)
13. Bolt (Automatic Transaxle)
14. Clamp
15. Hose
16. Clamp
17. Engine Ventilation Pipe
18. Bolt
19. Gasket
20. Needle Sleeve
21. Crankshaft Rear Seal
22. Crankshaft
23. Transmitter Disk
24. Bolt
25. Oil Pan Scraper
26. Oil Pan
27. Drain Plug
28. Washer
29. Bolt
30. Sleeve
31. Gasket
32. Bolt
33. Oil Pump Cover
34. Ring Gear
35. Gear
36. Oil Pressure Switch
37. Washer
38. Washer
39. Oil Duct Outlet Plug
40. Connecting Piece
41. Seal Ring
42. Oil Filter43. Bypass Valve
44. Pressure Relief Valve Plunger
45. Pressure Relief Valve Spring
46. Seal Ring
47. Pressure Relief Valve Plug
48. Seal Ring
49. Bolt
50. Oil Suction Pipe
51. Bolt
52. Rear Timing Belt Cover
53. Bolt
54. Special Bolt
55. Idler Pulley
56. Stud
57. Nut
58. Bolt
59. Tensioner
60. Bolt
61. Thrust Inner Washer
62. Woodruff Key
63. Crankshaft Gear
64. Thrust Outer Washer
65. Bolt
66. Camshaft Drive Belt
67. Gasket
68. Front Timing Belt Cover
69. Bolt
70. Bushing Plug
71. Bushing
72. Oil Gallery Plug
73. Bolt
74. Water Pump
75. Seal Ring
76. Crankshaft Position Sensor
77. Bolt
78. Knock Sensor*
79. Bolt
80. Bolt
81. Crankshaft Bearing Bridge
* : 2.0L DOHC Engine

1D – 4IENGINE COOLING
DAEWOO V–121 BL4
COOLING SYSTEM DIAGNOSIS
Engine Overheats
ChecksAction
Check for a loss of the coolant.Add the coolant.
Check for a weak coolant solution.Confirm that the coolant solution is a 50/50 mixture of eth-
ylene glycol and water.
Check the front of the radiator for any dirt, any leaves, or
any insects.Clean the front of the radiator.
Check for leakage from the hoses, the coolant pump, the
heater, the thermostat housing, the radiator, the core
plugs, or the head gasket.Replace any damaged components.
Check for a faulty thermostat.Replace a damaged thermostat.
Check for retarded ignition timing.Perform an ECM code diagnosis. Confirm the integrity of
the timing belt.
Check for an improperly operating electric cooling fan.Replace the electric cooling fan.
Check for radiator hoses that are plugged or rotted.Replace any damaged radiator hoses.
Check for a faulty water pump.Replace a faulty water pump.
Check for a faulty surge tank cap.Replace a faulty surge tank cap.
Check for a cylinder head or an engine block that is
cracked or plugged.Repair the damaged cylinder head or the damaged engine
block.
Loss of Coolant
ChecksAction
Check for a leak in the radiator.Replace a damaged radiator.
Check for a leak in the following locations:
S Surge tank.
S Hose.Replace the following parts, as needed:
S Surge tank.
S Hose.
Check for loose or damaged radiator hoses, heater hoses,
and connections.Reseat the hoses.
Replace the hoses or the clamps.
Check for leaks in the coolant pump seal.Replace the coolant pump seal.
Check for leaks in the coolant pump gasket.Replace the coolant pump gasket.
Check for an improper cylinder head torque.Tighten the cylinder head bolts to specifications.
Replace the cylinder head gasket, if needed.
Check for leaks in the following locations:
S Intake manifold.
S Cylinder head gasket.
S Cylinder block plug.
S Heater core.
S Radiator drain plug.Repair or replace any components, as needed, to correct
the leak.
Engine Fails to Reach Normal Operating Temperature or Cool Air
from the Heater
ChecksAction
Check to determine if the thermostat is stuck open or is the
wrong type of thermostat.Install a new thermostat of the correct type and heat range.
Check the coolant level to determine if it is below the MIN
mark on the surge tank.Add sufficient coolant to raise the fluid to the specified
mark on the surge tank.

ENGINE COOLING 1D – 5
DAEWOO V–121 BL4
COMPONENT LOCATOR
RADIATOR/FAN
1. Holder Transmission Fluid Pipe (Automatic Trans-
mission Only)
2. Upper Radiator Bumper
3. Front Upper Center Panel
4. Radiator
5. Lower Radiator Bumper6. Spring Clamp
7. Upper Radiator Hose
8. Main Cooling Fan
9. Auxiliary Cooling Fan
10. Drain Cock

ENGINE COOLING 1D – 9
DAEWOO V–121 BL4
THERMOSTAT (1.4L/1.6L DOHC)
Removal Procedure
CAUTION : To prevent personal injury, do not remove
the surge tank cap while the engine and the radiator
are hot because the heat causes the system to remain
under pressure. Scalding fluid and steam may be
blown out under pressure.
1. Drain the coolant. Refer to ”Draining and Refilling
the Cooling System” in this section.
2. Loosen the hose clamp on the upper radiator hose
at the thermostat housing.
3. Disconnect the upper radiator hose from the ther-
mostat housing.
4. Loosen the clamp on the bypass hose.
5. Disconnect the bypass hose from the thermostat
housing.
6. Remove the mounting bolts that hold the thermo-
stat housing to the cylinder head.
7. Remove the thermostat housing from the head.
8. Remove the O–ring seal from the head.
9. Check the valve seat for foreign matter that could
prevent the valve from seating properly.
10. Check the thermostat for proper operation. Refer to
”Thermostat Test” in this section.
11. Clean the thermostat housing and the cylinder head
mating surfaces.
Installation Procedure
1. Coat the sealing surface of a new O–ring seal with
Lubriplater®.
2. Install a new O–ring seal into the recess in the cyl-
inder head.
3. Secure the thermostat housing to the cylinder head
with the mounting bolts.
Tighten
Tighten the thermostat housing mounting bolts to 20
NSm (15 lb–ft).