torque DAEWOO LACETTI 2004 Service Repair Manual

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 – 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 – 15
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
GENERAL REPAIR INSTRUCTIONS
S If a floor jack is used, the following precautions are
recommended.
S Park the vehicle on level ground,
block" the front
or rear wheels, set the jack against the frame, raise
the vehicle and support it with chassis stands and
then perform the service operation.
S Before performing the service operation, disconnect
the negative battery cable in order to reduce the
chance of cable damage and burning due to short–
circuiting.
S Use a cover on the body, the seats and the floor to
protect them against damage and contamination.
S Handle brake fluid and antifreeze solution with care
as they can cause paint damage.
S The use of proper tools, and the recommended es-
sential and available tools where specified, are im-
portant for efficient and reliable performance of the
service repairs.S Use genuine DAEWOO parts.
S Discard used cotter pins, gaskets, O–rings, oil
seals, lock washers and self–locking nuts. Prepare
new ones for installation. Normal function of these
parts cannot be maintained if these parts are re-
used.
S Keep the disassembled parts neatly in groups to
facilitate proper and smooth reassembly.
S Keep attaching bolts and nuts separated, as they
vary in hardness and design depending on the posi-
tion of the installation.
S Clean the parts before inspection or reassembly.
S Also clean the oil parts, etc. Use compressed air to
make certain they are free of restrictions.
S Lubricate rotating and sliding faces of parts with oil
or grease before installation.
S When necessary, use a sealer on gaskets to pre-
vent leakage.
S Carefully observe all specifications for bolt and nut
torques.
S When service operation is completed, make a final
check to be sure service was done properly and the
problem was corrected.

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–

1A – 6IGENERAL ENGINE INFORMATION
DAEWOO V–121 BL4
Light Knock Hot
StepActionValue(s)YesNo
1Is there a light knock when the engine is hot?–Go to Step 2System OK
2Is detonation or spark knock evident?–Go to Step 3Go to Step 4
3Check the engine timing and the fuel quality.
Was the problem found?–Go to Step 1–
4Inspect the torque converter bolts.
Are the bolts tightened to the 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 manifold.
Is there an exhaust leak at the manifold?–Go to Step 7Go to Step 8
7Tighten the bolts or replace the gasket.
Is the repair complete?–Go to Step 1–
8Check the rod bearing clearance.
Is the clearance within the specified value?0.019 ~
0.070 mm
(0.0007 ~
0.0028 in.)Go to Step 9System OK
9Replace the rod bearings, as necessary.
Is the repair complete?–Go to Step 1–
Knocks During Initial Start–Up But Last Only a Few Seconds
StepActionValue(s)YesNo
1Does the engine knock during initial start–up but last
only a few seconds?–Go to Step 2System OK
2Check the engine oil.
Is the proper viscosity oil used in the crankcase?–Go to Step 4Go to Step 3
3Install oil of the proper viscosity for the expected
seasonal temperatures.
Is the repair complete?–Go to Step 1–
4Inspect the hydraulic lifters.
Is there evidence of hydraulic lifter bleed–down?–Go to Step 5Go to Step 6
5Clean, test and replace the lifters, as necessary.
Is the repair complete?*–Go to Step 1–
6Inspect the crankshaft end clearance.
Is the clearance more than specified value?0.1 mm
(0.0039 in.)Go to Step 7Go to Step 8
7Replace the crankshaft thrust bearing.
Is the repair complete?–Go to Step 1–
8Inspect the front main bearing clearance.
Is the clearance more than the specified value?0.026~0.046
mm (0.0010~
0.0018 in.)Go to Step 9System OK
9Replace the worn parts of the front main bearing.
Is the repair complete?–Go to Step 1–
* When the engine is stopped, some valves will be open. Spring pressure against the lifters will tend to bleed lifter down.
Attempts to repair this should be made only if the problem is consistent.
An engine that is only operated for short periods between start–ups may have lifter noise that lasts for a few minutes. This
is a normal condition.

GENERAL ENGINE INFORMATION 1A – 7
DAEWOO V–121 BL4
Knocks at Idle Hot
StepActionValue(s)YesNo
1Does the engine knock at idle when hot?–Go to Step 2System OK
2Inspect the drive belts.
Are the belts loose or worn?–Go to Step 3Go to Step 4
3Tension or replace the belts, as necessary.
Is the repair complete?–Go to Step 1–
4Inspect the A/C compressor and the generator.
Is either the compressor or the generator faulty?–Go to Step 5Go to Step 6
5Replace the faulty A/C compressor or the generator.
Is the repair complete?–Go to Step 1–
6Inspect the valve train.
Are valve train components faulty?–Go to Step 7Go to Step 8
7Replace the faulty valve train components.
Is the repair complete?–Go to Step 1–
8Check the engine oil.
Is the proper viscosity oil used in the crankcase?–Go to Step 10Go to Step 9
9Install oil of the proper viscosity for the expected
seasonal temperatures.
Is the repair complete?–Go to Step 1–
10Inspect the piston pin clearance.
Is the clearance more than the specified value?0.020 mm
(0.0008 in.)Go to Step 11Go to Step 12
11Replace the piston and the pin.
Is the repair complete?–Go to Step 1–
12Check the connecting rod alignment.
Is the alignment faulty?–Go to Step 13Go to Step 14
13Check and replace rods, as necessary.
Is the repair complete?–Go to Step 1–
14Inspect the piston–to–bore clearance.
Is the clearance within the specified value?0.030 mm
(0.0012 in.)Go to Step 16Go to Step 15
15Hone the bore and fit a new piston.
Is the repair complete?Go to Step 1–
16Inspect the crankshaft balancer.
Is the balancer loose?–Go to Step 17Go to Step 18
17Torque or replace worn parts.
Is the repair complete?–Go to Step 1–
18Check the piston pin offset.
Is the offset at the specified value?0.5 ± 0.1 mm
(0.020 ~ 0.003
in.)
Toward Thrust
SideGo to Step 19System OK
19Install the correct piston.
Is the repair complete?–Go to Step 1–

1A – 8IGENERAL ENGINE INFORMATION
DAEWOO V–121 BL4
NOISE DIAGNOSIS
Main Bearing Noise
StepActionValue(s)YesNo
1Are dull thuds or knocks heard with every engine
revolution?–Go to Step 2System OK
2Check the oil pump pressure.
Is the oil pump pressure low?–Go to Oil Pres-
sure TestGo to Step 3
3Inspect the crankshaft end play.
Does the crankshaft end play exceed the specified
value?0.1 mm
(0.0039 in.)Go to Crank-
shaft Replace-
ment Proce-
dureGo to Step 4
4Inspect the crankshaft journals.
Are the crankshaft journals out–of–round?0.004 mm
(0.0002 in.)
max.Go to Crank-
shaft Replace-
ment Proce-
dureGo to Step 5
5Inspect the belt tension.
Does the belt tension exceed the specified value?–Go to Timing
Belt Replace-
ment Proce-
dureGo to Step 6
6Inspect the crankshaft pulley.
Is the crankshaft pulley loose?–Go to Crank-
shaft Replace-
ment Proce-
dureSystem OK
Connecting Rod Bearing Noise Symptom
StepActionValue(s)YesNo
1Is a knock noise heard under all engine speeds?–Go to Step 2System OK
2Inspect the crankshaft connecting rod journal.
Is the crankshaft connecting rod journal worn?–Go to Crank-
shaft Replace-
ment Proce-
dureGo to Step 3
3Check the oil pump pressure.
Is the oil pump pressure low?–Go to Oil Pres-
sure TestGo to Step 4
4Inspect the crankshaft connecting rod journals.
Are the journals out–of–round?–Go to Crank-
shaft Replace-
ment Proce-
dureGo to Step 5
5Inspect the connecting rods.
Is there a misaligned connecting rod?–Go to Pistons
and Rods Re-
placement Pro-
cedureGo to Step 6
6Inspect the connecting rod bolts.
Are the connecting rod bolts torqued properly?–System OKGo to Pistons
and Rods Re-
placement Pro-
cedure

1C1 – 6I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
Application Lb–InLb–Ft NSm
Oil Pump Bolts10–89
Oil Pump Rear Cover Bolts8–71
Oil Pump Retaining Bolts10–89
Oil Suction Pipe or Support Bracket Bolts10–89
Rear Timing Belt Cover Bolts10–89
Safety Relief Valve Bolt303022–
Spark Plugs2518–
Thermostat Housing Mounting Bolts2015–
Timing Belt Automatic Tensioner Bolts2518–
Timing Belt Idler Pulley Bolt4030–
Transaxle Bell Housing Bolts7555–
Transaxle Torque Converter Bolts4533–
Upper Front Timing Belt Cover Bolts10–89
Water Pump Retaining Bolts10–89

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 7
DAEWOO V–121 BL4
SPECIAL TOOLS
SPECIAL TOOLS TABLE
J–42492
Timing Belt
Adjuster
KM–470–B
Angular Torque
Gauge
J–28467–B
Engine Assembly
Support Fixture
KM–427
Piston Pin
Service Set
KM–571–B
Gauge
KM–340–0
Cutter Set
Includes: KM–340–7
Guide Drift
KM–340–13
Cutters
KM–340–26
Cutters
KM–348
Valve Spring
Compressor
KM–653
Adapter