Page 5 of 2643

v
TABLE OF CONTENTS
Section 0B General Information
Section 1 Engine
Section 1A General Engine Information
Section 1C1 1.4L/1.6L DOHC Engine Mechanical
Section 1C2 1.8L DOHC Engine Mechanical
Section 1D Engine Cooling
Section 1E Engine Electrical
Section 1F Engine Controls
Section 1G Engine Exhaust
Section 2 Suspension
Section 2A Suspension Diagnosis
Section 2B Wheel Alignment
Section 2C Front Suspension
Section 2D Rear Suspension
Section 2E Tires and Wheels
Section 3 Driveline/Axle
Section 3A Automatic Transaxle Drive Axle
Section 3B Manual Transaxle Drive Axle
Section 4 Brakes
Section 4A Hydraulic Brakes
Section 4B Master Cylinder
Section 4C Power Booster
Section 4D Front Disc Brakes
Section 4E1 Rear Disc Brakes
Section 4E2 Rear Drum Brakes
Section 4F Antilock Brake System
Section 4G Parking Brake
Section 5 Transmission/Transaxle
Section 5A1 ZF 4HP16 Automatic Transaxle
Section 5A2 AISIN Automatic Transaxle
Section 5B Five-Speed Manual Transaxle
Section 5C Clutch
Section 6 Steering
Section 6A Power Steering System
Section 6B Power Steering PumpSection 6C Power Steering Gear
Section 6E Steering Wheel and Column
Section 7 Heating, Ventilation, and Air
Conditioning (HVAC)
Section 7A Heating and Ventilation System
Section 7B Manual Control Heating, Ventilation,
and Air Conditioning System
Section 7D Automatic Temperature Control HVAC
Section 8 Restraints
Section 8A Seat Belts
Section 8B Supplemental Inflatable Restraints
(SIR)
Section 9 Body and Accessories
Section 9A Body Wiring System
Section 9B Lighting Systems
Section 9C Horns
Section 9D Wipers/Washer Systems
Section 9E Instrumentation/Driver Information
Section 9F Audio Systems
Section 9G Interior Trim
Section 9H Seats
Section 9I Waterleaks
Section 9J Windnoise
Section 9K Squeaks and Rattles
Section 9L Glass and Mirrors
Section 9M Exterior Trim
Section 9N Frame and Underbody
Section 9O Bumpers and Fascias
Section 9P Doors
Section 9Q Roof
Section 9R Body Front End
Section 9S Body Rear End
Section 9T1 Remote Keyless Entry and Anti–Theft
System
Section 9T2 Immobilizer Anti–Theft System
Page 8 of 2643

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)
Page 9 of 2643

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 : 19.8 : 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 MakerWoojinBoach
Spark Plug TypeBKR6E–11FLR8LDCU
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)
Page 10 of 2643

GENERAL INFORMATION 0B – 3
DAEWOO V–121 BL4
Automatic Transaxle
Application1.4L DOHC1.6L DOHC1.8L DOHC
Maker–AISINZF
Type or Model–81–40LE4HP16
Gear Ratio :
1st
2nd
3rd
4th
Reverse–
–
–
–
–2.875:1
1.568:1
1.000:1
0.697:1
2.300:12.719:1
1.487:1
1.000:1
0.717:1
2.529:1
Final Drive Ratio–3.750:13.945:1
Oil Capacity–5.77±0.2L (6.1±0.2 qts)6.9±0.2L (7.3±0.2 qts)
Brake
Application1.4L DOHC1.6L DOHC1.8L DOHC
Booster Size :
Single
Dual241.3 mm (9.5 in.)
177.8 and 203.2 mm
(7 and 8 in.)
Master Cylinder Diameter22.22 mm (0.875 in.)
Booster Ratio5.5 : 1
Front Brake :
Disc Type
Disc SizeVentilated
256 mm (10 in.)
Rear Brake (Drum) :
Drum Inside Diameter
Wheel Cylinder Diame-
ter200 mm (7.9 in.)
20.64 mm (0.813 in.)
Rear Brake (Disc) :
Disc Type
Disc SizeSolid
258 mm (10.2 in.)
Fluid Capacity0.5L (0.5 qts)
Tire and Wheel
Application1.4L DOHC1.6L DOHC1.8L DOHC
Tire Size195/55R15
Standard Wheel Size6Jx15 (Steel)
Optional Wheel Size6Jx15 (Alloy)
Inflation Pressure at Full
Load30 psi (207 kPa)
Page 11 of 2643
0B – 4IGENERAL INFORMATION
DAEWOO V–121 BL4
Steering System
Application1.4L DOHC1.6L DOHC1.8L DOHC
Gear TypePower
Rack and Pinion
Overall Gear Ratio
Power Steering16 : 1
Wheel Diameter
W/ Air Bag
W/O Air Bag380 mm (15.0 in.)
370 mm (14.5 in.)
Wheel Alignment :
Front :
Toe–In
Caster
Camber0° ± 10’
4° ± 45’
20’ ± 45’
Rear :
Toe–In
Camber
12’ ± 10’
–1° ± 45’
Oil Capacity1.1L (1.2 qts)
Suspension
Application1.4L DOHC1.6L DOHC1.8L DOHC
Front TypeMacpherson Strut
Rear TypeDual Link
Fuel System
Application1.4L DOHC1.6L DOHC1.8L DOHC
Fuel DeliveryMPI
Fuel Pump TypeElectric Motor Pump
Fuel Filter TypeCartridge
Fuel Capacity60L (15.85 gal)
Lubricating System
Application1.4L DOHC1.6L DOHC1.8L DOHC
Lubricating TypeForced Feed
Oil Pump TypeRotary (Trochoid)
Oil Filter TypeCartridge (Full Flow)
Oil Pan Capacity
Including Oil Filter3.75L (4 qts)4.0L (4.2 qts)
Page 12 of 2643
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 Amps95 Amps
Starter1.2 KW1.4 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
Page 13 of 2643

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
Page 14 of 2643
GENERAL INFORMATION 0B – 7
DAEWOO V–121 BL4
Vehicle Weights 5 Door H/B
Application1.4L DOHC1.6L DOHC1.8L DOHC
Manual :
Curb Weight :
Standard
Optional1,170 kg (2,580 lb)
1,220 kg (2,690 lb)1,175 kg (2,590 lb)
1,225 kg (2,701 lb)1,205 kg (2,657 lb)
1,255 kg (2,767 lb)
Gross Vehicle Weight1,645 kg (3,627 lb)1,650 kg (3,638 lb)1,680 kg (3,704 lb)
Automatic :
Curb Weight :
Standard
Optional–
–1,185 kg (2,612 lb)
1,235 kg (2,723 lb)1,230 kg (2,712 lb)
1,280 kg (2,822 lb)
Gross Vehicle Weight–1,660 kg (3,660 lb)1,705 kg (3,759 lb)
Passenger Capacity5
Optional Weight : ABS, Sun Roof, A/C