dimensions DAEWOO LACETTI 2004 Service Repair Manual

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 – 6IGENERAL INFORMATION
DAEWOO V–121 BL4
VEHICLE DIMENSIONS AND WEIGHTS
Vehicle Dimensions
Application1.4L DOHC1.6L DOHC1.8L DOHC
Overall Length
4 Door
5 Door H/B4,500 mm (177.2 in.)
4,295 mm (169.1 in.)






Overhang :
4 Door
Front
Rear
885 mm (34.8 in.)
1,015 mm (40.0 in.)






5 Door H/B
Front
Rear
902 mm (35.5 in.)
793 mm (31.2 in.)






Overall Width1,725 mm (67.9 in.)


Overall Height1,445 mm (56.9 in.)


Minimum Ground Clear-
ance160 mm (6.3 in.)


Wheel Base2,600 mm (102.4 in.)


Tread :
Front
Rear1,480 mm (58.3 in.)
1,480 mm (58.3 in.)






Vehicle Weights
4 Door
Application1.4L DOHC1.6L DOHC1.8L DOHC
Manual :
Curb Weight :
Standard
Optional1,175 kg (2,590 lb)
1,225 kg (2,701 lb)1,180 kg (2,601 lb)
1,230 kg (2,712 lb)1,210 kg (2,668 lb)
1,260 kg (2,778 lb)
Gross Vehicle Weight1,660 kg (3,660 lb)1,665 kg (3,671 lb)1,695 kg (3,737 lb)
Automatic :
Curb Weight :
Standard
Optional–
–1,190 kg (2,624 lb)
1,240 kg (2,734 lb)1,235 kg (2,723 lb)
1,285 kg (2,833 lb)
Gross Vehicle Weight–1,675 (3,693 lb)1,720 kg (3,792 lb)
Passenger Capacity5


Optional Weight : ABS, Sun Roof, A/C

2E – 10ITIRES AND WHEELS
DAEWOO V–121 BL4
turers of tire chains have a specific chain size for each tire
size to ensure a proper fit when the chain is installed. Be
sure to purchase the correct chains for the tires on which
they are to be used. Use rubber adjusters to take up any
slack or clearance in loose chains.
Use of chains may adversely affect vehicle handling.
When tire chains are installed, follow these precautions:
S Adjust speed to road conditions.
S Avoid sharp turns.
S Avoid locked–wheel braking.
To prevent chain damage to the vehicle, install the chains
on the front tires as tightly as possible. Tighten them again
after driving 0.4 to 0.8 kilometer (0.3 to 0.5 mile). The use
of chains on the rear tires is not recommended because
they may contact the vehicle and possibly damage it. If
chains must be used on the rear tires, be sure there is suffi-
cient clearance between the chains and the body. Do not
exceed 70 km/h (45 mph) or the chain manufacturer’s
speed limit, if lower. Avoid large bumps, potholes, severe
turns and any other maneuvers which could cause the
tires to bounce. Follow any other instructions of the chain
manufacturer which do not disagree with the above in-
structions.
REPLACEMENT TIRES
A tire performance criteria (TPC) specification number is
molded in the sidewall near the tire size of all original
equipment tires. This specification number assures that
the tire meets performance standards for traction, endur-
ance, dimensions, noise, handling and rolling resis–tance.
Usually a specific TPC number is assigned to each tire
size.
CAUTION : Do not mix different types of tires on the
same vehicle such as radial, bias and bias–belted
tires except in emergencies, because vehicle han-
dling may be seriously affected and may result in loss
of control.
Use only replacement tires with the same size, load range,
and construction as the original. The use of any other tire
size or construction type may seriously affect ride, han-
dling, speedometer/odometer calibration, vehicle ground
clearance, and tire clearance to the body and the chassis.
This does not apply to the spare tire furnished with the ve-
hicle.
It is recommended that new tires be installed in pairs on
the same axle.
If it is necessary to replace only one tire, pair it with the tire
having the most tread to equalize the braking action.
Although they may appear different in tread design, tires
built by different manufacturers with identical TPC specifi-
cations may be used on the same vehicle.
ALL SEASON TIRES
Most vehicles are now equipped with steel–belted all sea-
son radial tires as standard equipment. These tires qualify
as snow tires, with a 37 percent higher average rating for
snow traction than the non–all season radial tires pre-
viously used. Other performance areas, such as wet trac-
tion, rolling resistance, tread life, and air retention, have
also been improved. This was done by improvements in
both tread design and tread compounds. These tires are
identified by an ”M + S” molded in the tire sidewall following
the size number. The suffix ”MS” is also molded in the side-
wall after the TPC specification number.
The optional handling tires used on some vehicles are not
all season tires. These will not have the ”MS” marking after
the tire size or the TPC specification number.
PASSENGER METRIC SIZED TIRES
All Daewoo vehicles now use Passenger (P) metric sized
tires. P–metric tires are available in two load ranges: stan-
dard load (35 psi maximum) and extra load (41 psi maxi-
mum). Most passenger vehicle tires are standard load.
Most P–metric tire sizes do not have exact corresponding
alphanumeric tire sizes. For example, a P175/70R13 is
not exactly equal in size and load–carrying capacity to an
FR70–13. For this reason, replacement tires should be of
the same TPC specification number as the originals. If P–
metric tires must be replaced with other sizes, consult a
tire dealer. Tire companies can best recommend the clos-
est match of alphanumeric to P–metric sizes within their
own tire lines.
The metric term for measuring tire inflation pressure is the
kilopascal (kPa). Tire pressure may be printed in both kPa
and psi. One psi equals 6.895 kPa.
See the tire label or refer to ”Tire Size and Pressure Speci-
fications” in this section for tire inflation pressures.
TIRE LABEL
The tire label is permanently located on the rear face of the
driver’s door and should be referred to for tire information.
It lists the maximum vehicle load, the tire size (including
the spare tire), and the cold inflation pressure (including
the spare tire).
SPARE TIRE
The notchback and the wagon come equipped with a full–
sized tire on a steel wheel. The hatchback comes
equipped with a reduced–sized temporary tire on a steel
wheel.
WHEELS
Wheels must be replaced if they are bent, dented, have
excessive lateral or radial runout, leak air through welds,
have elongated bolt holes, or if the wheel bolts won’t stay
tight or are heavily rusted. Wheels with excessive runout
may cause vehicle vibration. Replacement wheels must
be equivalent to the original equipment wheels in load ca-

SECTION : 9N
FRAME AND UNDERBODY
TABLE OF CONTENTS
SPECIFICATIONS9N–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 9N–1. . . . . . . . . . .
Notchback Underbody Dimensions 9N–2. . . . . . . . . . .
Hatchback Underbody Dimensions 9N–4. . . . . . . . . . .
MAINTENANCE AND REPAIR9N–6 . . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 9N–6. . . . . . . . . . . . . . . . . . . . . Alignment Checking 9N–6. . . . . . . . . . . . . . . . . . . . . . . .
Floor Pan Insulators 9N–6. . . . . . . . . . . . . . . . . . . . . . . .
Engine Under Covers 9N–7. . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION9N–8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Body Construction 9N–8. . . . . . . . . . . . . . . . .
Engine Under Covers 9N–8. . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Engine Under Cover Bolts3.5–31

9N – 2IFRAME AND UNDERBODY
DAEWOO V–121 BL4
NOTCHBACK UNDERBODY DIMENSIONS

9N – 4IFRAME AND UNDERBODY
DAEWOO V–121 BL4
HATCHBACK UNDERBODY DIMENSIONS

9N – 6IFRAME AND UNDERBODY
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
ALIGNMENT CHECKING
An accurate method of determining the alignment of the
underbody uses a measuring tram gauge. The tram gauge
set used to perform the recommended measuring checks
must include a vertical pointer able to reach 457 mm (18
inches).
Two types of measurements can be made with a tram
gauge: direct point–to–point measurements and mea-
surements calculated on a horizontal plane (datum line)
parallel to the underbody. Point–to–point measurements
are generally taken on steering and suspension engine
compartment parts and simply require the vertical pointers
to be set equally.
For horizontal plane measurements, the vertical pointers
must be set as specified for each point to be measured.
Dimensions–to–gauge holes are measured to the center
of the holes and flush to the adjacent surface metal unless
otherwise specified. It is recommended that the diagonal
dimensions to the cross–body be checked on both sides
in order to verify the dimensional accuracy of the vehicle
underbody.
FLOOR PAN INSULATORS
The floor pan insulators have been designed for the higher
floor pan temperatures that result from the use of the cata-
lytic converter in the exhaust system. Therefore, when
servicing a vehicle, it is essential that any insulators that
may have been disturbed or removed be reinstalled in the
original sequence and location. Also, if an insulator needs
to be replaced, use only the insulation specified for that
location on the floor pan.
When servicing or replacing interior insulators, observe
the following instructions.
S Install the insulators in the original position and se-
quence. Butt the pieces together in order to avoid
gapping or overlapping.
S If it is necessary to replace an insulator, use only
the specified insulation.
S Use the original part to determine the amount of
replacement material required and as a template for
cutting and fitting the new piece to the floor pan.
S When installing the insulator, do not enlarge any
cutouts or holes that are used for the attachment of
interior parts such as the instrument panel or the
floor console.
S Route the cross–body harness for interior parts
over the floor pan insulators. Clip it in the original
location.
S Do not apply spray–on deadeners or trim adhesives
to the top of the floor pan at the area directly over
the catalytic converter or the muffler.

1–12 GENERAL INFORMATIONNUBIRA/LACETTI
10. BODY REPAIR PROCEDURES
No.OperationProcedureRemarks
1InspectionInspect the damaged parts and the extent of damage and make
plans for the repair..
2PreparationPrepare the new parts, special repair tools and others..
3RemovalRemove the related parts for repair..
4Pull outRoughly pull out and straighten the damaged areas..
5Cut and pry offCut off the damaged areas and drills on the spot weld nuggets
and pry off the remaining spot weld flanges..
6Peel offPeel off the undercoat and sealer..
7MoldingMold damaged areas and even out the welding flanges and fill
any holes..
8Set the new partsGrind both sides of the welding section and set the new parts
and tack welds for temporary installation..
9InspectionInspect the dimensions for correct position and preinstall the ex-
terior parts and check the clearances and level differences..
10WeldingPerform a trial welding and the main welding..
11FinishFinish the welding areas and even out the flanges for a close fit..
12SealingApply the sealer to the matching and over lapped surface..
13UndercoatingApply the undercoat to the required areas..
14PaintingApply the paint..
15DeadnerApply the deadner to the designated areas..
16Anti–rust agentsCoating the anti–rust agents to the designated areas..
17InstallationInstall the related parts and rub in grease to the moving parts and
replenish the cooling liquid, oil, aircon gas and others..
18Check and adjustCheck all operations, wheel alignments, leaks, head lamp aim
and others with the specified check sheet..

2–6 PREPARATIONS OF BODYWORK NUBIRA/LACETTI
4. MEASURING SYSTEMS (WITHOUT
SMALL DAMAGE)
S Whenever possible, make judgements and conclusions
based on measurement. Measure the wheel align-
ment(see pages 2–2, 2–3) so as to prevent any future
trouble like unsymmetrical wear of the tires or catchingof the steering wheel.
S If there are any deviations, use a tram tracking gauge
and measure parts of the body.(Below Fig. 5–1)
S If there is any twisting to the body, measure using a
frame centering gauge.(Below Fig. 5–2)
S When measuring body dimensions, use a universal tram
gauge.(Below Fig. 5–3)
.
Fig. 5–1
Fig. 5–2
Fig. 5–3
Fig. 5

NUBIRA/LACETTI ROOF, BACK PANEL AND REAR FLOOR PANEL 5–3
1–2. REPAIR PROCEDURE
1. Remove the related parts.
S Room lamp, door weatherstrip and pillar trims.
S Headlining and wiring harness.
S Wiper, cowl and windshield.
S Rear glass and others.
2. Pull out and straighten the damaged area to approxi-
mately the original shape.
Note : Use heat–resistant protective cover for protect
painting areas, seats, carpets and other parts.
S Attach the car to the frame straightener by tightening the
underbody clamps at the horizontal pinch welds.
S Before cutting off the roof panel, pull them out so that
they are restored to the original shape.
S Do not pull out more than necessary.
S Pull out and straighten the related damaged parts to
approximately their original shape.
Note : Make sure that the right and left pillars are parallel
with the windshield surface. Check the door for proper
opening and closing.
3. Keep the body, level.
S Jack up the body, and place safety stands at the four
designated places of the frame door opening.
4. Cut off the shaded areas of the roof panel.
S Cut the roof weld flanges with a hand saw and snips at
the roof panel and roof frames.
Fig. 2
S Using a chisel, pry off the roof panel along the bold lines
as shown.
S Center punch around the spot weld imprints of the roof
welded flange.
S Drill holes using the spot cutter.
S Using a chisel and a disc sander, pry off the welded
flange from the front, rear body pillar and roof panel.
S Level and finish the burrs of welded flanges with a disc
sander.CAUTION : To prevent eye injury, wear goggles or
safety glasses whenever sanding, cutting, or grind-
ing.
5. Peel off the sealer.
S Peel off the sealer with a steel spatula at the welding
areas of the frame door opening.
6. Mold damaged related parts.
S Use a hammer and dolly to mold damaged areas of the
front, rear body pillar inner and frame door opening.
S Even out the welding flanges with a hammer and dolly
for close fit with the roof panel welding flange.
S Fill any holes drilled by welding.
7. Set the new panels.
S Grind both sides of the welding section of the rail wind-
shield header, support roof panel, frame rear roof panel
and roof panel with a disc sander to remove the paint and
expose the steel plate.
CAUTION : To prevent eye injury, wear goggles or
safety glasses whenever sanding, cutting, or grind-
ing.
S Temporarily set the new three frames and roof panel and
clamp with the vise grips.
Note : Check that the flange surface fit closely. Be care-
ful not to twist or deform the roof panel.
Fig. 3
S Measure the dimensions diagonally at the windshield
area and rear glass area with a tracking gauge or convex
rule as shown to check it for twisting or bending.