2004 DAEWOO LACETTI Automatic

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

GENERAL INFORMATION 0B – 19
DAEWOO V–121 BL4
Manual Transaxle Identification Number
Plate (D16)
1. Identification Code
2. Sequential Number
Identification
Code
EngineGear Ratio
SY1.4L DOHC3.722 CR
CR1.6L DOHC3.722 CR
CV1.8L DOHC3.722 CR
Manual Transaxle Identification Number
Plate Location (D16)
The manual transaxle identification number is attached to
the top of the transmission case near the engine.
Automatic Transaxle Identification Number
Plate (ZF 4HP16)
1. Part Number
2. Sirial Number
3. Model Code
4. Manufactured Nation and Company
Part Code
Engine
AW1.8L DOHC
Automatic Transaxle Identification Number
Plate Location (ZF 4HP16)
The automatic transaxle identification number plate is at-
tached on the rear bottom side of the transaxle case near
the bulk head.

0B – 20IGENERAL INFORMATION
DAEWOO V–121 BL4
Automatic Transaxle Identification Number
Plate (AISIN : 81–40LE)
1. AW’s Lot Number
2. Part ID Code
3. DW’s Part Number4. AW’s Serial Number
Automatic Transaxle Identification Number
Plate Location (AISIN : 81–40LE)
The automatic transaxle identification number plate is at-
tached on the upper side of the transaxle case.

GENERAL ENGINE INFORMATION 1A – 3
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
20Inspect the bearing clearances.
Are the bearing clearances more than the specified
values?Crankshaft
0.026 ~0.046
mm
(0.0010~0.001
8 in.)
Connecting
Rod 0.019 ~
0.070 mm
(0.0007 ~
0.0027 in.)Go to Step 21Go to Step 22
21Replace the bearing, if necessary.
Is the repair complete?–Go to Step 1–
22Inspect the oil galleries.
Are the oil galleries cracked, porous, or plugged?–Go to Step 23Go to Step 24
23Repair or replace the engine block.
Is the repair complete?–Go to Step 1–
24Inspect the gallery plugs.
Are any of the gallery plugs missing or installed im-
properly?–Go to Step 25Go to Step 26
25Install the plugs or repair, as necessary.
Is the repair complete?–Go to Step 1–
26Inspect the camshaft.
Is the camshaft worn or is there evidence of poor
machining?–Go to Step 27System OK
27Replace the camshaft.
Is the repair complete?–Go to Step 1–
OIL LEAK DIAGNOSIS
Most fluid oil leaks are easily located and repaired by visu-
ally finding the leak and replacing or repairing the neces-
sary parts. On some occasions, a fluid leak may be difficult
to locate or repair. The following procedures may help you
in locating and repairing most leaks.
Finding the Leak:
1. Identify the fluid. Determine whether it is engine oil,
automatic transmission fluid, power steering fluid,
etc.
2. Identify where the fluid is leaking from.
1) After running the vehicle at normal operating
temperature, park the vehicle over a large sheet
of paper.
2) Wait a few minutes.
3) Find the approximate location of the leak by the
drippings on the paper.
3. Visually check around the suspected component.
Check around all the gasket mating surfaces for
leaks. A mirror is useful for finding leaks in areas
that are hard to reach.
4. If the leak still cannot be found, it may be neces-
sary to clean the suspected area with a degreaser,
steam, or spray solvent.
1) Thoroughly clean the area.2) Dry the area.
3) Operate the vehicle for several miles at normal
operating temperature and varying speeds.
4) After operating the vehicle, visually check the
suspected component.
5) If you still cannot locate the leak, try using the
powder or black light and dye method.
Powder Method:
1. Clean the suspected area.
2. Apply an aerosol–type powder, (such as foot pow-
der), to the suspected area.
3. Operate the vehicle under normal operating condi-
tions.
4. Visually inspect the suspected component. Trace
the leak path over the white powder surface to the
source.
Black Light and Dye Method:
A dye and light kit is available for finding leaks. Refer to the
manufacturer ’s directions when using the kit.
1. Pour the specified amount of dye into the engine oil
fill tube.
2. Operate the vehicle under normal operating condi-
tions as directed in the kit.
3. Direct the light toward the suspected area. The
dyed fluid will appear as a yellow path leading to
the source.

1C1 – 2I1.4L/1.6L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
SPECIFICATIONS
ENGINE SPECIFICATIONS
ApplicationDescription (Manual and Automatic)
1.4L DOHC1.6L DOHC
General Data:
Engine TypeF14DF16D
Displacement1399 cm31598 cm3 (97.51 in3)
Bore Stroke77.9 x 73.4 mm (3.01 in. x 2.89 in.)79.0 x 81.5 mm (3.1 in. X 3.21 in.)
Compression Ratio9.5 ± 0.2:19.5 ± 0.2:1
Firing Oder1–3–4–21–3–4–2
Cylinder Bore:
Diameter77.9 mm (3.07 in.)79 mm (3.1 in.)
Out of Round (Maximum)0.0065 mm (0.00025 in.)0.0065 mm (0.00025 in.)
Taper (Maximum)0.07 x 30°0.0065 mm (0.00025 in.)
Pistion:
Diameter77.87 mm (3.07 in.)78.970 mm (3.1090 in.)
Clearance to Bore0.030 mm (0.0012 in.)0.030 mm (0.0012 in.)
Piston Rings:
Ring, End Gap:
Top Compression
2nd Compression0.15–0.30 mm
(0.0059–0.0118 in.)
0.3–0.5 mm (0.0118–0.0197 in.)0.2–0.3 mm (0.008–0.012 in.)
0.5–0.6 mm (0.02–0.024 in.)
Groove Clearance:
Top Compression
2nd Compression0.05–0.09 mm
(0.00197–0.00354 in.)
0.06–0.1 mm
(0.00236–0.00393 in.)0.016 mm (0.0006 in.)
0.066 mm (0.0026 in.)
Piston Pin:
Diameter18.00 mm (0.708 in.)18.00 mm (0.708 in.)
Pin Off–Set0.5 ± 0.1 mm
(0.0197 ± 0.00787 in.)0.7–0.9 mm (0.028–0.036 in.)
Camshaft:
Lift Intake7.2 mm (0.283 in.)8.5 mm (0.335 in.)
Lift Exhaust7.2 mm (0.283 in.)8.5 mm (0.335 in.)
End Play0.1–0.25 mm (0.00394–0.00787 in.)0.10–0.25 mm (0.004–0.0089 in.)
Journal OD:
No. 1
No. 2
No. 3
No. 4
No. 529.94 mm (1.179 in.)
26.94 mm (1.061 in.)
26.94 mm (1.061 in.)
26.94 mm (1.061 in.)
26.94 mm (1.061 in.)30 mm (1.18 in.)
27 mm (1.06 in.)
27 mm (1.06 in.)
27 mm (1.06 in.)
27 mm (1.06 in.)

1.4L/1.6L DOHC ENGINE MECHANICAL 1C1 – 3
DAEWOO V–121 BL4
ApplicationDescription (Manual and Automatic)
1.4L DOHC1.6L DOHC
Crankshaft:
Main Journal:
Diameter (All)
Taper (Maximum)
Out of Round (Maximum)55 mm (2.71 in.)
0.005 mm (0.0001 in.)
0.004 mm (0.0001 in.)54.982–54.994 mm
(2.164–2.165 in.)
0.005 mm (0.0001 in.)
0.004 mm (0.0001 in.)
Main Bearing Clearance (All)0.026–0.042 mm (0.001–0.002 in.)0.026–0.042 mm (0.001–0.002 in.)
Crankshaft End Play0.1 mm (0.003 in.)0.05–0.28 mm (0.002–0.011 in.)
Connecting Rod Journal:
Diameter (All)43 mm (1.69 in.)
42.971–42.987 mm
(1.691–1.692 in.)
Taper (Maximum)0.005 mm (0.0001 in.)0.005 mm (0.0001 in.)
Out of Round (Maximum)0.004 mm (0.0001 in.)0.004 mm (0.0001 in.)
Rod Bearing Clearance (All)0.019–0.070 mm
(0.0007–0.0028 in.)0.019–0.071 mm
(0.0007–0.0028 in.)
Rod Side Clearance0.070–0.242 mm
(0.0027–0.009 in.)0.070–0.242 mm
(0.0027–0.009 in.)
Valve System:
Valve Lash CompensatorsHydraulicHydraulic
Face Angle (All)45°~45.25°90°~90.5°
Seat Angle (All)44.5°~45°89°~90°
Seat Runout (Maximum, All)0.05 mm (0.002 in.)0.05 mm (0.002 in.)
Face Runout (Maximum, All)0.03 mm (0.0012 in.)0.03 mm (0.0012 in.)
Seat Width:
Intake
Exhaust1.17–1.57 mm (0.046–0.062 in.)
1.4–1.8 mm (0.055–0.071 in.)1.17–1.57 mm (0.046–0.062 in.)
1.4–1.8 mm (0.055–0.071 in.)
Valve Guide Inside Diameter (All)6.00–6.02 mm (0.236–0.237 in.)6.00–6.02 mm (0.236–0.237 in.)
Valve Stem Diameter (All)6 mm (0.236 in.)6 mm (0.236 in.)
Valve Diameter (All):
Intake
Exhaust28.57 mm (1.125 in.)
27.24 mm (1.074 in.)28.6 mm (1.126 in.)
27.2 mm (1.072 in.)
Valve Spring Loads:
Valve Open
Valve Closed580 ± 29N (426 ± 21 lbs)
260 ± 13N (191 ± 9.6 lbs)580–26N (428–19 lbs)
@23.0 mm(0.90 in.)
260”13N(192” 9 lbs) @
32.0mm(1.25 in.)
Valve Spring Free Length41.2 mm (1.622 in.)41.2 mm (1.622 in.)
Oil Pump:
Gap Between Oil Pump Body and Out
Rotor0.400~0.484 mm
(0.0157~0.019 in.)0.400~0.484 mm (0.0157~0.019 in.)
Out Rotor Side Clearance0.045~0.100 mm
(0.0018~0.0039 in.)0.045~0.100 mm (0.02~0.004 in.)

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)

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