2004 DAEWOO LACETTI low oil pressure

GENERAL INFORMATION 0B – 11
DAEWOO V–121 BL4
Chassis and Body
Maintenance ItemMaintenance Interval
Kilometers or time in months, whichever comes first
x 1,000 km1153045607590105120
x 1,000 miles0.6918273645546372
Months–1224364860728496
Interior air filter (A/C)RRRRRRRR
Exhaust pipes & mountingsIIIIIIII
Brake/Clutch fluid (1) (4)IIRIRIRIR
Front brake pads and discs(3)IIIIIIII
Rear brake pads & discs or drums and
linings (3)IIIIIIII
Parking brakeIIIIIIIII
Brake line and connections (Including
booster)IIIIIIII
Manual Transaxle Oil *(1)IIIIIIII
Automatic transaxle fluid *(1) (5)IIIIIIII
Tighten chassis and underbody bolts
and nutsIIIIIIII
Tire condition and inflation pressureIIIIIIIII
Wheel alignment (2)Inspect when abnormal condition is noted
Steering wheel and linkageIIIIIIII
Power steering fluid & lines* (1)IIIIIIIII
Drive shaft bootsIIIIIIII
Seat belts, buckles and anchorsIIIIIIII
Lubricate locks, hinges and hood
latchIIIIIIII
Chart Symbols:
I – Inspect and if necessary correct, clean, replenish, or adjust.
R – Replace or change:
(1) Refer to Recommended Fluids And Lubricants.
(2) And if necessary, rotate and balance wheels.
(3) More frequent if operated under severe conditions: short distance driving, extensive idling, frequent low–speed oper-
aion in stop and go traffic, or driving in dusty conditions.
(4) Change the brake/clutch fluid every 15,000 km (9,000 miles), if the vehicle is mainly driven under the following severe
conditions: driving in hilly or mountainous terrain, or towing a trailer/caravan frequently.
(5) 1.8 DOHC model (ZF 4HP16 Automatic Transaxle): Change automatic transaxle fluid every 60,000 Km (36,000 miles)
if the vehicle is mainly driven under any of the following severe conditions:
S In heavy city traffic where the outside temperature regularly reaches 32°C (90°F) or higher, or
S In hilly or mountainous terrain, or
S When doing frequent trailer towing, or
S Uses such as taxi, police or delivery service.

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.

GENERAL INFORMATION 0B – 13
DAEWOO V–121 BL4
EACH TIME THE OIL IS CHANGED
Automatic Transaxle Fluid
Refer to fluid level service procedure of Section 5A, ZF
4HP16 Automatic Transaxle.
Manual Transaxle
Check the fluid level and add fluid as required. Refer to
Section 5B, Five–Speed Manual Transaxle.
Brake System Inspection
This inspection should be done when the wheels are re-
moved for rotation. Inspect the lines and the hoses for
proper hookup, binding, leaks, cracks, chafing, etc. In-
spect the disc brake pads for wear. Inspect the rotors for
surface condition. Also inspect the drum brake linings for
wear and cracks. Inspect other brake parts, including the
drums, the wheels cylinders, the parking brake, etc., at the
same time. Check the parking brake adjustment. Inspect
the brakes more often if habit or conditions result in fre-
quent braking.
Steering, Suspension and Front Drive Axle
Boot And Seal Inspection
Inspect the front and rear suspension and the steering
system for damaged, loose or missing parts, signs of wear
or lack of lubrication. Inspect the power steering lines and
the hoses for proper hookup, binding, leaks, cracks, chaf-
ing, etc. Clean and inspect the drive axle boot and seals
for damage, tears or leakage. Replace the seals if neces-
sary.
Exhaust System Inspection
Inspect the complete system (including the catalytic con-
verter if equipped). Inspect the body near the exhaust sys-
tem. Look for broken, damaged, missing, or out–of–posi-
tion parts as well as open seams, holes, loose
connections, or other conditions which could cause heat
buildup in the floor pan or could let exhaust fumes seep
into the trunk or passenger compartment.
Throttle Linkage Inspection
Inspect the throttle linkage for interference or binding,
damaged, or missing parts. Lubricate all linkage joints and
throttle cable joints, the intermediate throttle shaft bearing,
the return spring at throttle valve assembly, and the accel-
erator pedal sliding face with suitable grease. Check the
throttle cable for free movements.
Engine Drive Belts
Inspect all belts for cracks, fraying, wear and proper ten-
sion. Adjust or replace the belts as needed.
Hood Latch Operation
When opening the hood, note the operation of the secon-
dary latch. It should keep the hood from opening all the
way when the primary latch is released. The hood must
close firmly.
AT LEAST ANNUALLY
Lap and Shoulder Belts Condition and
Operation
Inspect the belt system including: the webbing, the
buckles, the latch plates, the retractor, the guide loops and
the anchors.
Movable Head Restraint Operation
On vehicles with movable head restraints, the restraints
must stay in the desired position.
Spare Tire and Jack Storage
Be alert to rattles in the rear of the vehicle. The spare tire,
all the jacking equipment, and the tools must be securely
stowed at all times. Oil the jack ratchet or the screw mech-
anism after each use.
Key Lock Service
Lubricate the key lock cylinder.
Body Lubrication Service
Lubricate all the body door hinges including the hood, the
fuel door, the rear compartment hinges and the latches,
the glove box and the console doors, and any folding seat
hardware.
Transaxle Neutral Switch Operation on
Automatic Transaxle
CAUTION : Take the following precautions because
the vehicle could move without warning and possibly
cause personal injury or property damage:
S Firmly apply the parking brake and the regular
brakes.
S Do not use the accelerator pedal.
S Be ready to promptly turn off the ignition if the ve-
hicle starts.
On automatic transaxle vehicles, try to start the engine in
each gear. The starter should crank only in P (Park) or N
(Neutral).
Parking Brake and Transaxle P (Park)
Mechanism Operation
CAUTION : In order to reduce the risk of personal in-
jury or property damage, be prepared to apply the reg-
ular brakes promptly if the vehicle begins to move.
Park on a fairly steep hill with enough room for movement
in the downhill direction. To check the parking brake, with
the engine running and the transaxle in N (Neutral), slowly
remove foot pressure from the regular brake pedal (until
only the parking brake is holding the vehicle).
To check the automatic transaxle P (Park) mechanism’s
holding ability, release all brakes after shifting the trans-
axle to P (Park).
Underbody Flushing
Flushing the underbody will remove any corrosive materi-
als used for ice and snow removal and dust control. At
least every spring clean the underbody. First, loosen the
sediment packed in closed areas of the vehicle. Then flush
the underbody with plain water.

SECTION : 1A
GENERAL ENGINE INFORMATION
TABLE OF CONTENTS
DIAGNOSIS1A–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compression Test 1A–1. . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Test 1A–2. . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Leak Diagnosis 1A–3. . . . . . . . . . . . . . . . . . . . . . . .
Knock Diagnosis 1A–4. . . . . . . . . . . . . . . . . . . . . . . . . . Noise Diagnosis 1A–8. . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION1A–11 . . . . . . . . . . . . . . . . . .
Cleanliness and Care 1A–11. . . . . . . . . . . . . . . . . . . . .
On–Engine Service 1A–11. . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS
COMPRESSION TEST
Important : Disconnect the Crankshaft Position (CKP)
Sensor connector to disable the fuel and the ignition sys-
tems.
Test the compression pressure for each cylinder. Low
compression pressure may be the fault of the valves or the
pistons. The following conditions should be considered
when you check the cylinder compression:
S The engine should be at normal operating tempera-
ture.
S The throttle must be wide open.
S All the spark plugs should be removed.
S The battery must be at or near full charge.
1. Place approximately three squirts of oil from a
plunger– type oiler into each spark plug port.
2. Insert the engine compression gauge into each
spark plug port.
3. Crank test each cylinder with four to five compres-
sion strokes using the starter motor.4. The lowest reading should not be less than 70% of
the highest reading. The compression gauge read-
ing should not be less than 689 kPa (100 psi) for
any of the cylinders.
5. Examine the gauge readings obtained after the four
”puffs” per cylinder are obtained from cranking the
starter motor. The readings are explained in the
following descriptions:
S Normal Condition – Compression builds up quickly
and evenly to the specified compression on each
cylinder.
S Piston Rings Faulty – Compression is low on the
first stroke and tends to build up on following
strokes, but the compression pressure does not
reach normal. The compression pressure improves
considerably with the addition of oil into the cylin-
der.
S Valves Faulty – Low compression pressure on the
first stroke. The compression pressure does not
tend to build up on the following strokes. The com-
pression pressure does not improve much with the
addition of oil into the cylinder.

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–

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

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 – 11
DAEWOO V–121 BL4
1. Piston Ring Set
2. Piston
3. Piston Pin
4. Connecting Rod
5. Connecting Rod Bearing Set
6. Oil Level Gauge Stick
7. Gauge Stic Tube
8. Sleeve
9. Clutch Housing Sleeve
10. Cylinder Block
11. Plug
12. Gap
13. Bypass Valve
14. Connecting Piece
15. Oil Filter
16. Oil Pump Body Gasket
17. Water Inlet Neck
18. Knock Sensor
19. Fly Wheel (M/T)
20. Flexible Plate (A/T)
21. Shaft Seal Ring
22. Crank Shaft Upper Bearing Set
23. Crank Shaft24. Crank Shaft Lower Bearing Set
25. Transmitter Disc
26. Crankshaft Bearing Cap
27. Oil Pan
28. Threaded Ring
29. Washer
30. Oil Pan Drain Plug
31. Oil Pump
32. Oil Pump Cover
33. Oil Pump Inner Rotor
34. Oil Pump Outer Rotor
35. Oil Pump Plug
36. Shaft Sealing
37. Pressure Relief Valve Plunger
38. Relief Valve Spring
39. Sealing
40. Relief Valve
41. Oil Pressure Switch
42. Sleeve
43. Oil Suction Pipe Bracket
44. Oil Suction Pipe
45. Sealing