coolant DAEWOO LACETTI 2004 Service Repair Manual

GENERAL INFORMATION 0B – 5
DAEWOO V–121 BL4
Cooling System
Application1.4L DOHC1.6L DOHC1.8L DOHC
Cooling TypeForced Water
Circulation


Radiator TypeCross–flow


Water Pump TypeCentrifugal


Thermostat TypePellet Type


Coolant Capacity7.0L (7.49 qts)7.2L (7.6 qts)7.4L (7.8 qts)
Electric System
Application1.4L DOHC1.6L DOHC1.8L DOHC
Battery12V–55 AH


610 CCA
(Cold Cranking Amps)


Alternator85 Amps
95 Amps
Starter1.2 KW
1.4 KW
No–Load Test @ 12.2
volts
Drive Pinion Speed at :90 Amps Max
Min. 2,600 rpm


85 Amps Max
Min. 2,550 rpm

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

0B – 10IGENERAL INFORMATION
DAEWOO V–121 BL4
SCHEDULED MAINTENANCE CHARTS
Engine
Maintenance ItemMaintenance Interval
Kilometers or time in months, whichever comes first
x 1,000 km1153045607590105120
x 1,000 miles0.6918273645546372
Months–1224364860728496
Drive belts (Alternator, power steering
and A/C belt)IIII
Engine oil & engine oil filter (1) (3)IRRRRRRRR
Cooling system hose & connectionsIIIIIIII
Engine coolant (3)IIIRIIRII
Fuel filterRR
Fuel line and connectionsIIIIIIII
Air cleaner element (2)IIRIIRII
Spark plugs (1.4D/1.6D)IRIRIRIR
Spark plugs (1.8D)IRIR
Spark plug wiresReplace every 90,000 km(54,000 miles)
EVAP canister, vapor lines & solenoid
valve filterII
PCV systemIIII
Timing beltlRlR
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.

0B – 12IGENERAL INFORMATION
DAEWOO V–121 BL4
OWNER INSPECTIONS AND SERVICES
WHLE OPERATING THE VEHICLE
Horn Operation
Blow the horn occasionally tomake sure it works. Check
all the button locations.
Brake System Operation
Be alert for abnormal sounds, increased brake pedal trav-
el 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.
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.
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.
Headlight Aim
Take note of the light pattern occasionally. Adjust the
headlights if the beams seem improperly aimed.
AT EACH FUEL FILL
A fluid loss in any (except windshield washer) system may
indicate a problem. Have the system inspected and re-
paired immediately.
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. After stopping the engine, wait a few minutes for
the oil to drain back to the oil pan.
2. Pull out the oil level indicator (dip stick).
3. Wipe it clean, and push the oil level indicator back
down all the way.
4. Pull out the oil level indicator and look at the oil lev-
el on it.
5. 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.
6. Push the indicator all the way back down into the
engine after taking the reading.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.
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 stow-
away). Maintain the recommended pressures that are on
the tire placard that is in the glove box.
Light Operation
Check the operation of the license plate light, the head-
lights (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.
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.
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, Pow-
er Steering System.
Brake Master Cylinder Reservoir Level
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 ped-
al 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).
Weather–Strip Lubrication
Apply a thin film silicone grease using a clean cloth.

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

1C1 – 4I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
ApplicationDescription (Manual and Automatic)
1.4L DOHC1.6L DOHC
Inner Rotor Side Clearance0.035~0.085 mm (0.001~0.003 in.)0.035~0.085 mm (0.001~0.003 in.)
Relief Valve Spring Free Length81 mm (3.2 in.)81 mm (3.2 in.)
Sealants and Adhesives:
Rear Main Bearing CapGE p/n RTV 159
Camshaft Carrier to Cylinder HeadHN 1581 (Loctite® 515)
Oil Pan BoltsHN 1256 (Loctite® 242)
Oil Pump BoltsHN 1256 (Loctite® 242)
Oil Pan Pickup Tube BoltsHN 1256 (Loctite® 242)
Oil Gallery PlugHN 1256 (Loctite® 242)
Coolant Jacket Caps and Plugs
(Freeze Plugs)HN 1756 (Loctite® 176)
Exhaust Manifold Studs/NutsAnti–seize Compound (HMC Spec HN1325)

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 5
DAEWOO V–121 BL4
FASTENER TIGHTENING SPECIFCATIONS
ApplicationNSmLb–FtLb–In
Air Cleaner Housing Bolts10–89
Camshaft Cap Bolts1612–
Camshaft Cover Nuts10–89
Connecting Rod Bearing Cap Bolts25
+ 30° + 15°18
+ 30° + 15°–
Coolant Temperature Sensor2015–
Crankshaft Bearing Cap Bolts50
+ 45° + 15°37
+ 45°+ 15°–
Crankshaft Cover Nuts5~8–44~71
Crankshaft Pulley Bolt95 NSm
+ 30° + 15°––
Cylinder Head Bolts (Cylinder Head Mounting Bolts)25 + 70°
+ 70° + 50°18 + 70°
+ 70° + 50°–
Direct Ignition System Coil Mounting Bolts10–89
Direct Ignition System Coil Mounting Bracket Bolts10–89
Engine Mount Attaching Bolts3022–
Engine Mount Bracket Attaching Bolts/Nuts5037–
Exhaust Camshaft Gear Bolt67.549–
Exhaust Flex Pipe–to–Catalytic Converter or Connecting Pipe
Retaining Nut3526–
Exhaust Flex Pipe–to–Exhaust Manifold Retaining Nuts3526–
Exhaust Gas Recirculation Valve Adapter Bolts2518–
Exhaust Manifold Heat Shield Bolts1511–
Exhaust Manifold Retaining Nuts2518–
Flexible Plate Bolts6044–
Flexible Plate Inspection Cover Bolts10–89
Flywheel Bolts35
+ 30° + 15°25
+ 30° + 15°–
Flywheel Inspection Cover Bolts12–106
Front Timing Belt Cover Bolts (Upper and Lower)10–89
Fuel Rail Assembly Retaining Bolts2518–
Fuel Rail Retaining Bolts2518–
Generator Upper Retaining Bolt2015–
Intake Camshaft Gear Bolt67.549–
Intake Manifold Retaining Bolts/Nuts2518–
Intake Manifold Support Bracket Lower Bolt2518–
Intake Manifold Support Bracket Upper Bolts2518–
Lower Front Timing Belt Cover Bolts10–89
Oil Pan Flange Bolts7555–
Oil Pan Retaining Bolts10–89
Oil Pan Drain Plug3526–
OIl Pressure Switch4030–

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

1C1 – 16I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
4. Remove the ignition wires from the spark plug.
5. Remove the camshaft cover bolts and camshaft
cover.
6. Remove the camshaft cover gasket.
Installation Procedure
1. Install the camshaft cover gasket on the camshaft
cover.
2. Position the camshaft cover on the engine block.
3. Install the camshaft cover bolts.
Tighten
Tighten the camshaft cover bolts to 10 NSm(89 lb–ft).
4. Install the ignition wires to the spark plugs and con-
nect the breather hose, ventilation hose and cam
position sensor wiring connector to the canshaft
cover.
5. Install the engine cover.
6. Connect the negative battery cable.
INTAKE MANIFOLD
Removal Procedure
1. Remove the fuel pump fuse.
2. Start the engine. After it stalls, crank the engine for
10 seconds to rid the fuel system of fuel pressure.
3. Disconnect the negative battery calbe.
4. Drain the engine coolant. Refer to Section 1D, En-
gine Cooling.
5. Remove the engine cover and throttle body. Refer
to Section 1F, Engine Control.

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 21
DAEWOO V–121 BL4
Installation Procedure
1. Install the exhaust manifold and gasket.
2. Install the exhaust manifold retaining nuts and tight-
en in the sequence shown.
Tighten
Tighten the exhaust manifold retaining nuts to 25 NSm
(18 lb–ft).
3. Install the exhaust manifold nuts to the catalytic
converter.
Tighten
Tighten the exhaust manifold nuts to 40 NSm (30 lb–
ft).
4. Install the heat shield.
Tighten
Tighten the the heat shield bolts to 13 NSm (10 lb–ft).
5. Connect the oxygen sensor connecter.
6. Connect the negative battery cable.
CYLINDER HEAD AND GASKET
Tools Required
J–42492 Timing Belt Adjuster
KM–470–B Angular Torque Gauge
Removal Procedure
1. Remove the fuel pump fuse.
2. Start the engine. After it stalls, crank the engine for
10 seconds to rid the fuel system of fuel pressure.
3. Disconnect the negative battery calbe.
4. Disconnect the electronic control module(ECM)
ground terminal from the intake manifold.
5. Drain the engine coolant. Refer to Section 1D, En-
gine Cooling.