Daewoo Lanos Full Engine Service Manual

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SECTION 0B
GENERAL INFORMATION
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-1
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B
1
Vehicle Dimensions and Weights . . . . . . . . . . . . 0B
6
Standard Bolt Specifications . . . . . . . . . . . . . . . . 0B
8
Maintenance and Repair . . . . . . . . . . . . . . . . . . . . 0B-9
Maintenance and Lubrication . . . . . . . . . . . . . . . . . . 0B
9
Normal Vehicle Use . . . . . . . . . . . . . . . . . . . . . . . . 0B
9
Explanation of Scheduled Maintenance
Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B
9
Scheduled Maintenance Charts . . . . . . . . . . . . 0B
11
Owner Inspections and Services . . . . . . . . . . . . . 0B
13
While Operating the Vehicle . . . . . . . . . . . . . . . 0B
13
At Each Fuel Fill . . . . . . . . . . . . . . . . . . . . . . . . .

At Least Monthly . . . . . . . . . . . . . . . . . . . . . . . . .
At Least Twice a Year . . . . . . . . . . . . . . . . . . . . .
Each Time the Oil Is Changed . . . . . . . . . . . . . .
At Least Annually . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Fluids and Lubricants . . . . . . .
General Description and System
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Repair Instructions . . . . . . . . . . . . . . . .
General Description . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle and Component Identification . . . . . . .
Vehicle Lifting Procedures . . . . . . . . . . . . . . . . .
0B
13
0B
13
0B
13
0B
14
0B
14
0B
15
0B-16
0B
16
0B
17
0B
17
0B
21
SPECIFICATIONS
TECHNICAL DATA
Performance - Manual Transaxle
Application
1.3L SOHC
1.5L SOHC
1.6L DOHC
166 km/h (103.2 mph)
172 km/h (106.9 mph)
180 km/h (111.8 mph)
Gradeability
0.43 (tan j )
0.5 (tan j )
0.5 (tan j )
Minimum Turning Radius
4.9 m (16 ft)
4.9 m (16 ft)
4.9 m (16 ft)
Maximum Speed
Performance - Automatic Transaxle

Application
1.3L SOHC
1.5L SOHC
1.6L DOHC
Maximum Speed
161 km/h (100.0 mph)
173 km/h (107.5 mph)
Gradeability
0.59 (tan j )
0.59 (tan j )
Minimum Turning Radius
4.9 m (16 ft)
4.9 m (16 ft)
% 2 :$
/7 2 ('
0B - 2 GENERAL INFORMATION
Engine
1.3L SOHC
Manual
1.5L SOHC
Manual and Automatic
1.6L DOHC
Engine Type
Overhead Cam L
4
Overhead Cam L
4
Overhead Cam L
4
Bore
76.5 mm (3.01 in.)
76.5 mm (3.01 in.)
79.0 mm (3.11 in.)
Stroke
73.4 mm (2.89 in.)
81.5 mm (3.21 in.)
81.5 mm (3.21 in.)
Total Displacement
1 349 cm3 (82.3 in3)
1 498 cm3 (91.4 in3)
1 598 cm3 (97.5 in3)
Compression Ratio
9.5:1
9.5:1
9.5:1
55 kw (74 bhp)
(at 5,400 rpm)
115 NSm (85 lb
ft)
(at 3,400 rpm)
63 kw (84 bhp)
(at 5,800 rpm)
130 NSm (96 lb
ft)
(at 3,400 rpm)
77.8 kw (104 bhp)

(at 6,000 rpm)
145.3 NSm (107.17 lb
ft)
(at 3,400 rpm)
Application
Maximum Power
Maximum Torque
Ignition System
1.5L SOHC
1.6L DOHC
Direct Ignition System
10_ (BTDC)
10_ (BTDC)
10_ (BTDC)
1 4
3 2
1 4
3 2
1 4
3 2
0.70
0.80 mm
(0.028
0.031 in.)
0.70
0.80 mm
(0.028
0.031 in.)
1.00
1.10 mm
(0.039
0.043 in.)
Spark Plug Maker
Champion / Woojin
Champion / Woojin
Woojin
Spark Plug Type
RN9YC / BPR6ES
RN9YC / BPR6ES
BKR6E
11
Application
Ignition Type
Ignition Timing
Ignition Sequence
Spark Plug Gap
1.3L SOHC
Manual
Clutch - Manual Transaxle

Application
1.3L SOHC
1.5L SOHC
1.6L DOHC
Type
Single Dry Plate
Single Dry Plate
Single Dry Plate
Outside Diameter
184 mm (7.2 in.)
200 mm (7.9 in.)
215 mm (8.5 in.)
Inside Diameter
127 mm (5.0 in.)
134 mm (5.3 in.)
145 mm (5.7 in.)
7.65 mm (0.301 in.)
7.65 mm (0.301 in.)
7.65 mm (0.301 in.)
Common Use;
Brake Fluid
Common Use;
Brake Fluid
Common Use;
Brake Fluid
Thickness
Fluid
Manual Transaxle
Application
Maker
1.3L SOHC
Wide Ratio
1.5L SOHC
Medium Ratio
1.6L DOHC
Close Ratio
DWMC
DWMC
DWMC
D
16
D
16
D
16
3.545:1
1.952:1
3.545:1
2.048:1
3.545:1
2.158:1
3rd
1.276:1
1.346:1
1.478:1
4th
0.892:1
0.971:1
1.129:1
5th
0.707:1
0.763:1
0.886:1
Reverse
3.333:1
3.333:1
3.333:1
3.944:1
4.176:1
3.722:1
1.8L (2 qt)
1.8L (2 qt)
1.8L (2 qt)
Type or Model
Gear Ratio:
1st
2nd
Final Drive Ratio

Oil Capacity
DAEWOO T BL3
100
GENERAL INFORMATION 0B - 3
Automatic Transaxle
Application
1.3L SOHC
1.5L SOHC
1.6L DOHC
Maker
General Motors
General Motors
Type or Model
4T40E
4T40E
2nd
2.957:1
1.623:1
2.957:1
1.623:1
3rd
1.000:1
1.000:1
4th
0.682:1
0.682:1
Reverse
Gear Ratio:
1st
2.143:1
2.143:1
Final Drive Ratio
3.91:1
3.91:1
Oil Capacity
11.5L (12 qt)
11.5L (12 qt)
1.5L SOHC
1.6L DOHC
Brake
Application
1.3L SOHC
Manual Transaxle
Booster Size
228.6 mm (9.00 in.)
228.6 mm (9.00 in.)
228.6 mm (9.00 in.)
Master Cylinder Diameter
20.64 mm (0.813 in.)
20.64 mm (0.813 in.)
22.22 mm (0.875 in.)
5.0:1
5.0:1
5.0:1
Ventilated
Ventilated
Ventilated
200 mm (7.9 in.)

17.46 mm (0.687 in.)
200 mm (7.9 in.)

17.46 mm (0.687 in.)
200 mm (7.9 in.)

19.05 mm (0.750 in.)
0.5L (0.5 qt)
0.5L (0.5 qt)
0.5L (0.5 qt)
1.3L SOHC
Manual
1.5L SOHC
1.6L DOHC
155/80R13
175/70R13
175/70R13
185/60R14
Standard Wheel Size
5J X 13 (Steel)
5J X 13 (Steel)
5.5J X 14 (Steel)
Optional Wheel Size
5.5J X 14 (Aluminum)
35 psi
32 psi
32 psi
32 psi
Booster Ratio
Front Brake:
Disc Type
Rear Brake:
Drum Inside Diameter
Wheel Cylinder Diameter
Fluid Capacity
Tire and Wheel

Application
Tire Size
Inflation Pressure at Full Load:

155/80R13
175/70R13
185/60R14
DAEWOO T BL3
100
Steering System
Application
Gear Type
Overall Gear Ratio
Manual Steering
Power Steering
Wheel Diameter
Wheel Alignment:
Front:
Toe
In
Caster:
Manual Steering
Power Steering
Camber
Rear:
Toe
In
Camber
Oil Capacity
1.3L SOHC
Manual
1.5L SOHC
Power/Manual
Rack and Pinion
Power/Manual
Rack and Pinion
1.6L DOHC
Power/Manual
Rack and Pinion
24.5:1
16.12:1
16.12:1
16.12:1
380 mm (15.0 in.)
380 mm (15.0 in.)
380 mm (15.0 in.)
- 10i 10i (- 1 1 mm)

+
+
(- 0.04 0.04 in.)
+
- 10i 10i (- 1 1 mm)

+
+
(- 0.04 0.04 in.)
+
- 10i 10i (- 1 1 mm)

+
+
(- 0.04 0.04 in.)
+
30i
2_30i
1_45i
3_45i
1_45i
3_45i
1_45i
3_45i
- 1_10i 20i
+
- 1_10i 20i
+
- 1_10i 20i
+
- 10i 40i (- 1 4 mm)

+
+
(- 0.04 0.16 in.)
+
- 10i 40i (- 1 4 mm)

+
+
(- 0.04 0.16 in.)
+
- 10i 40i (- 1 4 mm)

+
+
(- 0.04 0.16 in.)
+
- 2_10i- 1_10i
- 2_10i- 1_10i
- 2_10i- 1_10i
1.0L (1 qt)
1.0L (1 qt)
1.0L (1 qt)
Suspension
Application
Front type
Rear type
1.3L SOHC
Manual
MacPherson Strut
1.5L SOHC
MacPherson Strut
Compound Link
Compound Link
1.6L DOHC
MacPherson Strut
Compound Link
Fuel System
Application
Fuel Delivery
Fuel Pump Type
Fuel Filter Type
Fuel Capacity
1.3L SOHC
Manual
1.5L SOHC
1.6L DOHC
MPI
MPI
MPI
Electric Motor Pump
Electric Motor Pump
Electric Motor Pump
Cartridge
Cartridge
Cartridge
48L (12.7 gal)
48L (12.7 gal)
48L (12.7 gal)
Lubricating System
Application
Lubricating Type
1.3L SOHC
Manual
1.5L SOHC
1.6L DOHC
Forced Feed
Forced Feed
Forced Feed
Oil Pump Type
Duocentric Rotor
Duocentric Rotor
Duocentric Rotor
Oil Filter Type
Cartridge (Full Flow)
3.75L (4 qt)
3.75L (4 qt)
3.75L (4 qt)
Oil Pan Capacity

Including Oil Filter
DAEWOO T BL3
100
Cooling System
Application
1.3L SOHC
Manual
1.5L SOHC
1.6L DOHC
Manual and Automatic Manual and Automatic
Cooling Type
Forced Water
Circulation
Forced Water
Circulation
Forced Water
Circulation
Radiator Type
Cross
flow
Cross
flow
Cross
flow
Water Pump Type
Centrifugal
Centrifugal
Centrifugal
Thermostat Type
Pellet Type
Pellet Type
Pellet Type
Coolant Capacity:
Standard
7.0L (7 qt)
7.0L (7 qt)
7.0L (7 qt)
Heavy Duty
7.0L (7 qt)
7.0L (7 qt)
7.0L (7 qt)
Electric System
1.3L SOHC
Manual
1.5L SOHC
Manual and
Automatic
1.6L DOHC
General Area
550 Cold
Cranking Amps
550 Cold
Cranking Amps
550 Cold
Cranking Amps
Some
Countries Only
430 Cold
Cranking Amps
430 Cold
Cranking Amps
430 Cold
Cranking Amps
General Area
85 Amps
85 Amps
85 Amps
Hot Area Only
95 Amps
95 Amps
95 Amps
0.8 (kW)
Maximum
53 (Amps)
(at 11.5 Volts)
Maximum
53 (Amps)
(at 11.5 Volts)
Maximum
53 (Amps)
(at 11.5 Volts)
1.4 (kW)
Minimum 40 Amps
Maximum 90 (Amps)
(at 12.2 Volts)
Minimum 40 Amps
Maximum 90 (Amps)
(at 12.2 Volts)
Minimum 40 Amps
Maximum 90 (Amps)
(at 12.2 Volts)
Application
Battery
Alternator
Starter
(No
Load Test
Current Draw)
)
DAEWOO T BL3
100
-
VEHICLE DIMENSIONS AND WEIGHTS

Vehicle Dimensions - Manual and Automatic
Application
1.3L SOHC
1.5L SOHC
1.6L SOHC
4 Door
4 074 mm (160.4 in.)

4 237 mm (166.8 in.)
4 074 mm (160.4 in.)

4 237 mm (166.8 in.)
4 074 mm (160.4 in.)

4 237 mm (166.8 in.)
5 Door
4 074 mm (160.4 in.)
4 074 mm (160.4 in.)
4 074 mm (160.4 in.)
Overhang:
Front:
3 Door
838 mm (33.0 in.)
838 mm (33.0 in.)
838 mm (33.0 in.)
4 Door
838 mm (33.0 in.)
838 mm (33.0 in.)
838 mm (33.0 in.)
5 Door
838 mm (33.0 in.)
838 mm (33.0 in.)
838 mm (33.0 in.)
4 Door
716 mm (28.2 in.)

879 mm (34.6 in.)
716 mm (28.2 in.)

879 mm (34.6 in.)
716 mm (28.2 in.)

879 mm (34.6 in.)
5 Door
716 mm (28.2 in.)
716 mm (28.2 in.)
716 mm (28.2 in.)
Overall Width
1 678 mm (66.1 in.)
1 678 mm (66.1 in.)
1 678 mm (66.1 in.)
Overall Height
1 432 mm (56.4 in.)
1 432 mm (56.4 in.)
1 432 mm (56.4 in.)
160 mm (6.3 in.)
160 mm (6.3 in.)
160 mm (6.3 in.)
2 520 mm (99.2 in.)
2 520 mm (99.2 in.)
2 520 mm (99.2 in.)
1 405 mm (55.3 in.)

1 425 mm (56.1 in.)
1 405 mm (55.3 in.)

1 425 mm (56.1 in.)
1 405 mm (55.3 in.)

1 425 mm (56.1 in.)
Overall Length:
3 Door
Rear:
3 Door
Minimum Ground Clearance

Wheel Base
Tread:
Front
Rear
Vehicle Weights - 3 Door

Application
Manual:
Curb Weight:
Standard
Optional
Gross Vehicle Weight
Automatic:
Curb Weight:
Standard
Optional
Passenger Capacity
1.3L SOHC
1.5L SOHC
1.6L DOHC
1 005 kg (2,216 lb)
1 011 kg (2,229 lb)
1 031 kg (2,273 lb)
1 071 kg (2,361 lb)
1 077 kg (2,374 lb)
1 097 kg (2,418 lb)
1 595 kg (3,516 lb)
1 595 kg (3,516 lb)
1 595 kg (3,516 lb)
1 047 kg (2,308 lb)
1 067 kg (2,352 lb)
1 113 kg (2,454 lb)
1 133 kg (2,498 lb)
1 595 kg (3,516 lb)
1 595 kg (3,516 lb)
DAEWOO T BL3
100
Application
1.3L SOHC
1 122 kg (2,474 lb)
1 595 kg (3,516 lb)
1 595 kg (3,516 lb)
1 072 kg (2,363 lb)
1 092 kg (2,407 lb)
1 138 kg (2,509 lb)
1 158 kg (2,553 lb)
1 595 kg (3,516 lb)
1 595 kg (3,516 lb)
1.3L SOHC
1.5L SOHC
1.5L DOHC
1 015 kg (2,238 lb)
1 021 kg (2,251 lb)
1 041 kg (2,295 lb)
1 081 kg (2,383 lb)
1 087 kg (2,396 lb)
1 107 kg (2,440 lb)
1 595 kg (3,516 lb)
1 595 kg (3,516 lb)
1 595 kg (3,516 lb)
1 057 kg (2,330 lb)
1 077 kg (2,374 lb)
1 123 kg (2,476 lb)
1 143 kg (2,520 lb)
1 595 kg (3,516 lb)
1 595 kg (3,516 lb)

Passenger Capacity
1 102 kg (2,430 lb)
1 595 kg (3,516 lb)
Optional
1 056 kg (2,328 lb)
Automatic:
Curb Weight:
Standard
1 036 kg (2,284 lb)
1 096 kg (2,416 lb)
Optional
1.5L DOHC
1 030 kg (2,271 lb)
Manual:
Curb Weight:
Standard
1.5L SOHC

Application
Manual:
Curb Weight:
Standard
Optional
Automatic:
Curb Weight:
Standard
Optional
Passenger Capacity
Optional Weight:
DAEWOO T BL3
100
Air Conditioner, Power Steering, ABS, Sun Roof, Airbag
-
STANDARD BOLT SPECIFICATIONS

Bolt*
4T - Low Carbon Steel
7T - High Carbon Steel
7T - Alloy Steel
M6 X 1.0
4.1 NSm (36 lb

8.1
72 in)
4.1 NSm (48 lb

9.5
84 in)
M8 X 1.25
8.1
17.6 NSm (72
156 lb
in)
12.2
23.0 NSm (108
204 lb
in)
16 NSm (12 lb
30
22 ft)
M10 X 1.25
20 NSm (15 lb
34
25 ft)
27 NSm (20 lb
46
34 ft)
37 NSm (27 lb
62
46 ft)
M10 X 1.5
19 NSm (14 lb
34
25 ft)
27 NSm (20 lb
45
33 ft)
37 NSm (27 lb
60
44 ft)
M12 X 1.25
49 NSm (36 lb
73
54 ft)
61 NSm (45 lb
91
67 ft)
76 NSm (56 lb
114
84 ft)
M12 X 1.75
45 NSm (33 lb
69
51 ft)
57 NSm (42 lb
84
62 ft)
72
107 NSm (53 lb
79 ft)
M14 X 1.5
76 NSm (56 lb
115
85 ft)
94
140 NSm (69
103 lb
ft)
114
171 NSm (84
126 lb
ft)
M14 X 2.0
72
107 NSm (53 lb
79 ft)
88
132 NSm (65 lb
97 ft)
107
160 NSm (79 lb
118 ft)
M16 X 1.5
104
157 NSm (77 lb
116 ft)
136
203 NSm (100
150 lb
ft)
160
240 NSm (118
177 lb
ft)
M16 X 2.0
100
149 NSm (74 lb
110 ft)
129
194 NSm (95
143 lb
ft)
153
229 NSm (113
169 lb
ft)
M18 X 1.5
151
225 NSm (111
166 lb
ft)
195
293 NSm (144
216 lb
ft)
229
346 NSm (169
255 lb
ft)
M20 X 1.5
206 NSm (152

311
229 lb
ft)
270
405 NSm (199
299 lb
ft)
317
476 NSm (234
351 lb
ft)
M22 X 1.5
251
414 NSm (185
305 lb
ft)
363
544 NSm (268
401 lb
ft)
424
636 NSm (313
469 lb
ft)
M24 X 2.0
359
540 NSm (265
398 lb
ft)
431
710 NSm (318
524 lb
ft)
555
831 NSm (409
613 lb
ft)
*Diameter X pitch in millimeters
A1010010
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-
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
vehicle will be used for the following reasons:
D To carry passengers and cargo within the limitation in
dicated on the tire placard located on the edge of the
driver's door.
D To be driven on reasonable road surfaces and within
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
driving the vehicle. Always use the proper fluid and lubri
cants.
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 sec
`
tion.
Fuel Micro-Filter Replacement

Replace the engine fuel filter every 40,000 km (24,000
miles).
The engine fuel filter is located on the center dash panel
near the brake booster.
Air Cleaner Element Replacement

Replace the air cleaner element every 40,000 km
(24,000 miles).
Replace the air cleaner more often under dusty condi
tions.
Throttle Body Mounting Bolt Torque

Check the torque of the mounting bolts.
Tighten the throttle body mounting bolts to 17 NSm
(12 lb if necessary.
ft)
Spark Plug Replacement
When a separate belt drives the power steering pump,

the air conditioning compressor and the generator, in
spect it for cracks, fraying, wear and proper tension. Ad
just or replace the belt as needed.
Replace spark plugs with same type.

Type: AC Type RN9YC (SOHC)
BPR6ES (SOHC)
BKR6E (DOHC)
11
Gap
0.7 mm (SOHC)
0.8
1.0 mm (DOHC)
1.1
Engine Oil and Oil Filter Change
Spark Plug Wire Replacement
Always use above the API SH grade or ACEA A1/A2/A3

engine oil. The SH designation may be shown alone or
in combination with other designations such as SH/CC,
SH/CD etc.
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.
Engine Oil Viscosity
Check the disc brake pads or the drum brake linings ev

ery 10,000 km (6,000 miles) or 12 months. Check the
pad and the lining thickness carefully. If the pads or the
linings are not expected to last another 10,000 km
(6,000 miles), replace the pads or the linings. Check the
breather hole in the brake fluid reservoir cap to be sure it
is free from dirt and the passage is open.
Drive Belt Inspection
Engine oil viscosity (thickness) has an effect on fuel

economy and cold weather operation. Lower viscosity
engine oils can provide better fuel economy and cold
weather performance; however, higher temperature
weather conditions require higher viscosity engine oils
for satisfactory lubrication. Using oils of any viscosity
DAEWOO T BL3
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Brake System Service
Transaxle Service
Tire Rotation
The manual transaxle fluid does not require changing.

For automatic transaxles, refer to Scheduled Mainte
nance Charts" in this section.
Tire and Wheel Inspection and Rotation

Check the tires for abnormal wear or damage. To equal
ize wear and obtain maximum tire life, rotate the tires. If
irregular 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.
`
A1010009
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-
SCHEDULED MAINTENANCE CHARTS

Engine
Maintenance Item
Maintenance Interval
Kilometers (miles) or time in months, whichever comes first
Kilometers x 1000
10
20
30
40
50
60
70
80
90
100
MIles x 1000
0.6
12
18
24
30
36
42
48
54
60
Months
12
18
24
30
36
42
48
54
60
Drive belts (alternator, power

steering)
Engine oil and oil filter1, 3
Cooling system and hose

connections
Engine coolant3
Fuel filter
Fuel line and connections

Air cleaner element2
I
I
Ignition timing
Spark plugs
DIS Module
I
I
I
I
Camshaft belt
I
I
I
I
R
I
Charcoal canister and vapor lines

PCV system
R
I
I
I
R
I
I
I
I
R
I
I
I
I
I
I
R
I
I
I
Chart Symbols:
I - Inspect and, if necessary, correct, clean, replenish or adjust.
R - Replace or change.
1 If the vehicle is operated under severe conditions, such as short distance driving, extensive idling, or driving in dusty
conditions, change the engine oil and the filter every 5,000 km (3,000 miles) or 3 months, whichever comes first.
2 More frequently if driving in dusty conditions.
3 Refer to Recommended Fluids And Lubricants" in this section.
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Chassis and Body
Maintenance Item
Maintenance Interval
Kilometers (miles) or time in months, whichever comes first
Kilometers x 1000
10
20
30
40
50
60
70
80
90
100
MIles x 1000
0.6
12
18
24
30
36
42
48
54
60
Months
12
18
24
30
36
42
48
54
60
Brake line and connections (in

cluding booster)
Rear hub bearing and clearance
Exhaust pipe and mountings

Brake/Clutch fluid1, 5
Rear brake drums
Front brake pads
and linings3
and discs3
Parking brake
Manual transaxle
oil1
Clutch and brake pedal free play

Automatic transaxle fluid*1, 4
Tighten chassis and underbody

bolts and nuts
Tire condition and inflation pressure
Wheel alignment2
Inspect when abnormal condition is noted
Steering wheel and linkage
Drive shaft boots
Seat belts, buckles and anchors
Lubricate locks, hinges and

hood latch
Power steering fluid and lines*1
Chart Symbols:
I - Inspect and, if necessary, correct, clean, replenish, or adjust.
R - Replace or change.
1 Refer to Recommended Fluids And Lubricants" in this section.
2 And, if necessary, rotate and balance the wheels.
3 More frequently if operated under severe conditions which include the following: short distance driving, extensive
idling, frequent low
speed operation in stop
and traffic, or driving in dusty conditions.
go
4 The automatic transaxle fluid and filter do not require changing, unless operated under any of these conditions:
heavy city driving where the temperature regularly reaches 32_C (90_F) or higher, hilly terrain, frequent trailer tow
ing, or taxi, police or delivery service driving. If operated under any of these conditions, change the fluid and the filter
every 75,000 km (45,000 miles).
5 Change the brake/clutch fluid every 15,000 km (9,000 miles) if the vehicle is mainly driven under the following se
vere conditions: driving in hilly or mountainous terrain, or towing a trailer/caravan frequently.
DAEWOO T BL3
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-
OWNER INSPECTIONS AND

SERVICES
6. Push the indicator all the way back down into the en
gine after taking the reading.
WHILE OPERATING THE VEHICLE
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.
Horn Operation
Engine Coolant Level and Condition
Blow the horn occasionally to make sure it works. Check

all the button locations.
Brake System Operation

Be alert for abnormal sounds, increased brake pedal
travel 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 in
spected 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 pres
sure 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
repaired 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 level
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 en
gine damage.
DAEWOO T BL3
100
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 stowaway). 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 condition
ing 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 5A,
Power 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 pas
sage.
Clutch Pedal Free Travel

Check clutch pedal free travel and adjust as necessary
every 10,000 km (6,000 miles). Measure the distance
from the center of the clutch pedal to the outer edge of
the steering wheel with the clutch pedal 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 inch
es).
Hood Latch Operation
Apply a thin film silicone grease using a clean cloth.
When opening the hood, note the operation of the sec

ondary latch. It should keep the hood from opening all
the way when the primary latch is released. The hood
must close firmly.
EACH TIME THE OIL IS CHANGED
AT LEAST ANNUALLY
Weather-Strip Lubrication
Automatic Transaxle Fluid

Refer to 4T40E fluid level service procedure of Section
3A, 4T40E Automatic Transaxle.
Manual Transaxle
Check the fluid level and add fluid as required. Refer to
Section 3B, 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 re
sult in frequent 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, chafing, etc. Clean and inspect the drive axle
boot and seals for damage, tears or leakage. Replace
the seals if necessary.
Exhaust System Inspection

Inspect the complete system (including the catalytic
converter if equipped). Inspect the body near the ex
haust system. Look for broken, damaged, missing, or
out position parts as well as open seams, holes,
of
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 accelerator 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.
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 se
curely stowed at all times. Oil the jack ratchet or the
screw mechanism 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 possi
bly cause personal injury or property damage:
D Firmly apply the parking brake and the regular
brakes.
D Do not use the accelerator pedal.
D Be ready to promptly turn off the ignition if the vehicle
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 reducetheriskof personal inju
ry or property damage, be prepared to apply the
regular brakes promptly if the vehicle begins to
move.
Park on a fairly steep hill with enough room for move
ment in the downhill direction. To check the parking
DAEWOO T BL3
100
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 mate
rials 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.
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, corrosion protection and engine operating
temperature. Inspect the hoses. Replace the cracked,
swollen, or deteriorated hoses. Tighten the clamps.
Clean the outside of the radiator and the air conditioning
condenser. Wash the filler cap and the neck. Pressure
test the cooling system and the cap in order to help en
sure proper operation.
RECOMMENDED FLUIDS AND LUBRICANTS

Usage
Engine Oil
Engine Coolant
Capacity
3.75L
M/T (1.3L and 1.5L SOHC,

1.6L DOHC) - 7.0L
A/T 1.5L SOHC and 1.6L
DOHC) - 7.0L
Fluid/Lubricant
API SH grade or ACEA A1/A2/A3
SAE 5W SAE 10W
30,
30,
SAE 10W SAE 15W
40,
40
(Cold area: SAE 5W
30
Hot area: SAE 15W
40)
Mixture of water and good quality ethylene
glycol base antifreeze (year
round
coolant)
Brake Fluid and Clutch Fluid
0.5L (0.53 qt)
DOT or DOT
3
4
Power Steering System
1.0L (1.06 qt)
DEXRONR
III
11.5L (12.15 qt)
DEXRONR
III
Automatic Transaxle
Manual Transaxle
1.8L (1.90 qt)
Manual Transaxle Fluid (B0400075,

SAE80 or equivalent)
Manual Transaxle Shift Linkage
As required
Multipurpose type grease meeting

requirements NLGI No. 1 or 2
Key Lock Cylinders
As required
Silicone lubricant
Automatic Transaxle Shift

Linkage
As required
Engine oil
Clutch Linkage Pivot Points
As required
Engine oil
Floor Shift Linkage Points
As required
Engine oil
Hood Latch Assembly

a. Pivots and Spring Anchor
b. Release Pawl
As required
Hood and door hinges

Fuel door hinge
Rear compartment lid hinges
As required
Engine oil
Weatherstrips
As required
Silicone grease
DAEWOO T BL3
100
a. Engine oil
b. Multipurpose type grease meeting
requirements NLGI No. 1 or 2
-
GENERAL DESCRIPTION
AND SYSTEM OPERATION
GENERAL REPAIR INSTRUCTIONS
D If a floor jack is used, the following precautions are
recommended.
D 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.
D Before performing the service operation, disconnect
the negative battery cable in order to reduce the
chance of cable damage and burning due to short
cir
cuiting.
D Use a cover on the body, the seats and the floor to
protect them against damage and contamination.
D Handle brake fluid and antifreeze solution with care
as they can cause paint damage.
D The use of proper tools, and the recommended es
sential and available tools where specified, are impor
tant for efficient and reliable performance of the
service repairs.
D Use genuine DAEWOO parts.

D 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 reused.
D Keep the disassembled parts neatly in groups to facil
itate proper and smooth reassembly.
D Keep attaching bolts and nuts separated, as they
vary in hardness and design depending on the posi
tion of the installation.
D Clean the parts before inspection or reassembly.
D Also clean the oil parts, etc. Use compressed air to
make certain they are free of restrictions.
D Lubricate rotating and sliding faces of parts with oil or
grease before installation.
D When necessary, use a sealer on gaskets to prevent
leakage.
D Carefully observe all specifications for bolt and nut
torques.
D When service operation is completed, make a final
check to be sure service was done properly and the
problem was corrected.
DAEWOO T BL3
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-
GENERAL DESCRIPTION
VEHICLE AND COMPONENT IDENTIFICATION
Passenger Car Vehicle Identification Number
A3010001
DAEWOO T BL3
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VIN Plate
Engraved VIN Location

(Left-Hand Drive Shown, Right-Hand
Drive Similar)
}- 1
-
}- 2
}- 3
}- 4
}- 5
}- 6
-
A1010002
1
2
3
4
5
6
Manufacturer
Vehicle Identification Number
Blank
Vehicle Model
Engine Type
Body Color
A3010006
The vehicle identification number (VIN) is engraved in

the top of the bulkhead, next to the ABS module.
Engine Number Location - SOHC
VIN Plate Location

Drive Similar)
A3010007
A3010005
The engine number is stamped on the cylinder block un

der the No. 4 exhaust manifold of the engine.
The vehicle identification number (VIN) plate is attached

to the top of the bulkhead, next to the wiper motor.
DAEWOO T BL3
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Engine Number
A3010003
DAEWOO T BL3
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Engine Number Location - DOHC
-
Body Identification Number Plate Location

Drive Similar)
A3010008
The engine number is stamped on the cylinder block un

der the No. 4 exhaust manifold of the engine.
Body Identification Number Plate
A3010009
The body identification number plate is attached to the

top of the front panel support.
Manual Transmission Identification

Number Plate
A2010004
1
2
3
4
5
6
7
P/O Number
Check Digit
Drive
Body Type
P/O Date
Sequential Number
Exterior Color
A3010004
1 Identification Code
2 Sequential Number
Identification
Code
VG
Engine
Gear Ratio
1.3L SOHC
3.944 W/R
MA
1.5L SOHC
4.176 M/R
BS
1.6L DOHC
3.722 C/R
DAEWOO T BL3
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Manual Tranaaxle Identification Number
Plate Location
Drive Similar)
Automatic Transaxle Identification

Number Plate Location
A3010011
A3010010
The manual transaxle identification number is attached

to the top of the transmission case near the engine.
Automatic Transmission Identification

Number Plate
A2010006
1
2
3
4
5
6
7
8
Assembly Plant (Windsor, Canada)

Model Year (1996)
Broadcast Code
Model Name (4T40E)
Update Level
Sequential Number
Manufacturer
Part Number
DAEWOO T BL3
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The automatic transaxle identification number plate is at

tached on the rear side of the transmission near the bulk
head.
VEHICLE LIFTING PROCEDURES

Notice: To raise the vehicle, place the lifting equipment
only at the points indicated. Failure to use these precise
positions may result in permanent vehicle body de
formation. Many dealer service facilities and service sta
tions are equipped with automotive hoists that bear
upon some parts of the frame in order to lift the vehicle.
If any other hoist method is used, use special care to
avoid damaging the fuel tank, the filler neck, the exhaust
system, or the underbody.
Vehicle Lifting Points
A1010007
DAEWOO T BL3
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Vehicle Lifting Points
A1010008
DAEWOO T BL3
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SECTION 1
ENGINE
SECTION 1A
GENERAL ENGINE INFORMATION

TABLE OF CONTENTS
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compression Test . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Leak Diagnosis . . . . . . . . . . . . . . . . . . . . . . . .
Knock Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . .
1A-1
1A-1
1A-2
1A-3
1A-4
DIAGNOSIS
COMPRESSION TEST
Important: Disconnect the Crankshaft Position Sensor
(CPS) connector to disable the fuel and the ignition
systems.
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:
D The engine should be at normal operating temperature.
D The throttle must be wide open.
D All the spark plugs should be removed.
D 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.
DAEWOO T-100 BL3
Noise Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-8

General Information . . . . . . . . . . . . . . . . . . . . . . . 1A-11
Cleanliness and Care . . . . . . . . . . . . . . . . . . . . . 1A-11
On-Engine Service . . . . . . . . . . . . . . . . . . . . . . . 1A-11
3. Crank test each cylinder with four to five compression

strokes using the starter motor.
4. The lowest reading should not be less than 70% of
the highest reading. The compression gauge reading
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:
D Normal Condition - Compression builds up quickly
and evenly to specified compression on each cylinder.
D 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 cylinder.
D Valves Faulty - Low compression pressure on the
first stroke. The compression pressure does not tend
to build up on the following strokes. The compression
pressure does not improve much with the addition of
oil into the cylinder.
1A - 2 GENERAL ENGINE INFORMATION
OIL PRESSURE TEST

Step
1
2
3
4
5
6
7
8
9
10
Action
Is low or no oil pressure indicated?
Check the oil level in the crankcase.
Is the level low?
Add oil so that the oil level is up to the full mark on
the indicator.
Is the repair complete?
Check the idle speed.
Is the idle speed below the value specified?
Increase the idle speed.
Is the speed increased?
Inspect the oil pressure switch.
Is the oil pressure switch incorrect or
malfunctioning?
Install a new oil pressure switch.
Inspect the oil pressure gauge.
Is the oil pressure gauge incorrect or
malfunctioning?
Install a new oil pressure gauge.
Inspect the engine oil.
Is the engine oil in the crankcase diluted or of the
improper viscosity?
11
Install new engine oil of the proper viscosity for the

expected temperatures.
12
Inspect the oil pump.

Is the pump worn or dirty?
13
14
15
16
17
18
19
Replace the oil pump.

Inspect the oil filter.
Is the oil filter plugged?
Install a new oil filter.
Inspect the oil pickup screen.
Is the oil pickup screen loose or plugged?
Tighten or replace the oil pickup screen as
necessary.
Inspect the oil pickup tube.
Are there any holes in the oil pickup tube?
Replace the oil pickup tube.
Value(s)
Yes
No
Go to Step 2
System OK
Go to Step 3
Go to Step 4
Go to Step 1
825 rpm
Go to Step 5
Go to Step 6
Go to Step 1
Go to Step 7
Go to Step 8
Go to Step 1
Go to Step 9
Go to Step 10
Go to Step 1
Go to Step 11
Go to Step 12
Go to Step 1
Go to Step 13
Go to Step 14
Go to Step 1
Go to Step 15
Go to Step 16
Go to Step 1
Go to Step 17
Go to Step 18
Go to Step 1
Go to Step 19
Go to Step 20
Go to Step 1
DAEWOO T-100 BL3
GENERAL ENGINE INFORMATION 1A - 3

-
OIL PRESSURE TEST (CONTD)

Step
Action
Value(s)
21
22
23
24
Repair or replace the engine block.

Inspect the gallery plugs.
Are any of the gallery plugs missing or not installed
properly?
25
Install plugs or repair as necessary.

26
Inspect the camshaft.

Is the camshaft worn or is there evidence of poor
machining?
27
Replace the camshaft.

OIL LEAK DIAGNOSIS

Most fluid oil leaks are easily located and repaired by
visually finding the leak and replacing or repairing the
necessary 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.
2.1. After running the vehicle at normal operating
temperature, park the vehicle over a large
sheet of paper.
2.2. Wait a few minutes.
2.3. You should be able to 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 necessary to
clean the suspected area with a degreaser, steam or
spray solvent.
DAEWOO T-100 BL3
Go to Step 22
Go to Step 1
Replace the bearing if necessary.

Inspect the oil galleries.
Are the oil galleries cracked, porous or plugged?
Go to Step 21
20
No
Crankshaft
0.005 mm
(0.002 in.)
Connecting
Rod
0.019 X
0.070 mm
(0.0007 X
0.0027 in.)
Inspect the bearing clearances.

Are the bearing clearances more than the values
specified?
Yes
Go to Step 23
Go to Step 24
Go to Step 1
Go to Step 25
Go to Step 26
Go to Step 1
Go to Step 27
System OK
Go to Step 1
4.1. Clean the area well.

4.2. Dry the area.
4.3. Operate the vehicle for several miles at normal
operating temperature and varying speeds.
4.4. After operating the vehicle, visually check the
suspected component.
4.5. 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 powder)
to the suspected area.
3. Operate the vehicle under normal operating conditions.
4. Visually inspect the suspected component. You should
be able to 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 manufacturers 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 conditions 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.
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
determined 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
D The fluid level/pressure is too high.
D The crankcase ventilation system is malfunctioning.
D The fasteners are tightened improperly or the threads
are dirty or damaged.
D The flanges or the sealing surface is warped.

D There are scratches, burrs or other damage to the
sealing surface.
D The gasket is damaged or worn.
D There is cracking or porosity of the component.
D An improper seal was used (where applicable).
Seals
D The fluid level/pressure is too high.
D The crankcase ventilation system is malfunctioning.
D The seal bore is damaged (scratched, burred or
nicked).
D The seal is damaged or worn.
D Improper installation is evident.
D There are cracks in the component.
D The shaft surface is scratched, nicked or damaged.
D 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. Light
knock 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
Step
Action
Value(s)
Does the engine knock when it is cold and continue

for two to three minutes or does the knock increase
with torque?
Inspect the flywheel.

Is the flywheel contacting the splash shield?
Reposition the splash shield.

Inspect the balancer and the drive pulleys.

Is either the balancer or the drive pulleys loose or
broken?
Tighten or replace the balancer or the drive pulleys.

Inspect the piston-to-bore clearance.

Is the clearance more than the value specified?
1. Rebore the cylinder and hone to size.

2. Replace the piston.
Is the repair complete?*
Inspect the connecting rod.

Is the connecting rod bent?
Yes
No
Go to Step 2
System OK
Go to Step 3
Go to Step 4
Go to Step 1
Go to Step 5
Go to Step 6
Go to Step 1
Go to Step 7
Go to Step 8
0.030 mm
(0.001 in.)
-
Go to Step 1
Replace the connecting rod.

Go to Step 9
System OK
Go to Step 1
* Cold engine piston knock usually disappears when the cylinder is grounded out. Cold engine piston knock,
which disappears in about 1.5 minutes, is considered acceptable.
DAEWOO T-100 BL3

Heavy Knock Hot with Torque Applied
Step
Action
Value(s)
Yes
No
Is there a heavy knock when the engine is hot and

torque is applied?
Go to Step 2
System OK
Go to Step 3
Go to Step 4
Go to Step 1
45 NSm
(33 lb ft)
Go to Step 5
Go to Step 6
Go to Step 1
Go to Step 7
Go to Step 8
2
3
4
5
6
7
8
9
10
11
12
13
14
15
DAEWOO T-100 BL3
Inspect the balancer and pulley hub.

Is the balancer or pulley hub broken?
Replace the broken balancer or pulley hub.
Inspect the torque converter bolts.
Are the bolts tightened to the value specified?
Tighten the torque converter bolts.
Inspect the accessory belts.
Are the belts too tight or nicked?
Replace and/or tension the belts to specifications as
necessary.
Inspect the exhaust system.
Is the system grounded?
Reposition the system as necessary.
Inspect the flywheel.
Is the flywheel cracked?
Replace the flywheel.
Inspect the main bearing clearance.
Replace the main bearings as necessary.
Inspect the rod bearing clearance.
Replace the rod bearings as necessary.
Go to Step 1
Go to Step 9
Go to Step 10
Go to Step 1
Go to Step 11
Go to Step 12
0.050 mm
(0.002 in.)
Go to Step 1
Go to Step 13
Go to Step 14
0.019 X
0.070 mm
(0.0007 X
0.0028 in.)
Go to Step 1
Go to Step 15
System OK
Go to Step 1

Light Knock Hot
Step
Action
Value(s)
Yes
No
Is there a light knock when the engine is hot?
Go to Step 2
System OK
Is detonation or spark knock evident?
Go to Step 3
Go to Step 4
45 NSm
(33 lb ft)
Go to Step 1
Go to Step 5
Go to Step 6
Go to Step 1
Go to Step 7
Go to Step 8
0.019 X
0.070 mm
(0.0007 X
0.0028 in.)
Go to Step 1
Go to Step 9
System OK
Go to Step 1
3
4
5
6
7
Check the engine timing and the fuel quality.

Was the problem found?
Inspect the torque converter bolts.
Are the bolts tightened to the value specified?
Tighten the torque converter bolts.
Inspect the manifold.
Is there an exhaust leak at the manifold?
Tighten the bolts or replace the gasket.
Check the rod bearing clearance.
Is the clearance within the value specified?
Replace the rod bearings as necessary.
Knocks During Initial Start-Up But Lasts Only a Few Seconds

Step
Action
Value(s)
Yes
No
Does the engine knock during initial start-up but last

only a few seconds?
Go to Step 2
System OK
Go to Step 4
Go to Step 3
2
3
4
5
6
7
8
Check the engine oil.

Is the proper viscosity oil used in the crankcase?
Install oil of the proper viscosity for the expected
seasonal temperatures.
Go to Step 1
Inspect the hydraulic lifters.

Is there evidence of hydraulic lifter bleed-down?
Go to Step 5
Go to Step 6
Clean, test and replace the lifters as necessary.

Is the repair complete?*
Inspect the crankshaft end clearance.
Is the clearance more than value specified?
0.1 mm
(0.0039 in.)
Go to Step 1
Go to Step 7
Go to Step 8
Replace the crankshaft thrust bearing.

Inspect the front main bearing clearance.
0.005 mm
(0.0001 in.)
Go to Step 1
Go to Step 9
System OK
Replace the worn parts of the front main bearing.

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 operated for only short periods between start-ups may have lifter noise that lasts for a few
minutes. This is a normal condition.
9
DAEWOO T-100 BL3

Knocks at Idle Hot
Step
Value(s)
Yes
No
Go to Step 2
System OK
Go to Step 3
Go to Step 4
Go to Step 1
Go to Step 5
Go to Step 6
Go to Step 1
Go to Step 7
Go to Step 8
Replace faulty valve train components.

Check the engine oil.
Is the proper viscosity oil used in the crankcase?
Go to Step 1
Go to Step 10
Go to Step 9
Install oil of the proper viscosity for the expected

seasonal temperatures.
10
Inspect the piston pin clearance.

0.020 mm
(0.0008 in.)
Go to Step 11
Go to Step 12
Go to Step 1
Go to Step 13
Go to Step 14
0.030 mm
(0.0012 in.)
Go to Step 1
Go to Step 16
Go to Step 15
Go to Step 1
Go to Step 17
Go to Step 18
Go to Step 1
0.5 X 0.7
mm (0.020 X
0.028 in.)
Toward Thrust
Side
Go to Step 19
System OK
Go to Step 1
1
2
3
4
5
6
7
8
11
12
13
14
15
16
17
18
19
DAEWOO T-100 BL3
Action
Does the engine knock at idle when hot?
Inspect the drive belts.
Are the belts loose or worn?
Tension or replace the belts as necessary.
Inspect the A/C compressor and the generator.
Is either the compressor or the generator faulty?
Replace the faulty A/C compressor or the generator.
Inspect the valve train.
Are valve train components faulty?
Replace the piston and the pin.

Check the connecting rod alignment.
Is the alignment faulty?
Check and replace rods as necessary.
Inspect the piston-to-bore clearance.
Is the clearance within the value specified?
Hone the bore and fit a new piston.
Inspect the crankshaft balancer.
Is the balancer loose?
Torque or replace worn parts.
Check the piston pin offset.
Is the offset at the value specified?
Install the correct piston.

Go to Step 1
NOISE DIAGNOSIS
Main Bearing Noise
Step
1
2
Action
Are dull thuds or knocks heard with every engine
revolution?
Check the oil pump pressure.
Is the oil pump pressure low?
Inspect the crankshaft end play.
Does the crankshaft end play exceed the value
specified?
Inspect the crankshaft journals.
Are the crankshaft journals out-of-round?
Inspect the belt tension.
Does the belt tension exceed the value specified?
Inspect the crankshaft pulley.
Is the crankshaft pulley loose?
Value(s)
Yes
No
System OK
Go to Step 2
Go to Oil
Pressure Test
Go to Step 3
0.1 mm
(0.0039 in.)
Go to
Crankshaft
Replacement
Procedure
Go to Step 4
0.004 mm
(0.0002 in.)
max.
Go to
Crankshaft
Replacement
Procedure
Go to Step 5
Go to
Timing Belt
Replacement
Procedure
Go to Step 6
Go to
Crankshaft
Replacement
Procedure
System OK
Connecting Rod Bearing Noise Symptom

Step
Action
Is a knock noise heard under all engine speeds?
Inspect the crankshaft connecting rod journal.

Is the crankshaft connecting rod journal worn?
Check the oil pump pressure.

Is the oil pump pressure low?
Inspect the crankshaft connecting rod journals.

Are the journals out of round?
Inspect the connecting rods.

Is there a misaligned connecting rod?
Inspect the connecting rod bolts.
Are the connecting rod bolts torqued properly?
Value(s)
Yes
No
Go to Step 2
System OK
Go to
Crankshaft
Replacement
Procedure
Go to Step 3
Go to
Oil Pressure
Test
Go to Step 4
Go to
Crankshaft
Replacement
Procedure
Go to Step 5
Go to Pistons
and Rods
Replacement
Procedure
Go to Step 6
System OK
Go to Pistons
and Rods
Replacement
Procedure
DAEWOO T-100 BL3

Piston Noises
Step
1
DAEWOO T-100 BL3
Action
Are any of the following noises heard: a sharp
double knock when the engine is idling, a light
ticking with no load on the engine or a slapping
noise when the engine is cold?
Inspect the piston pin and bushing.
Is the piston pin or the bushing worn or loose?
Inspect the piston.
Is the piston broken or cracked?
Inspect the connecting rods.
Is there a misaligned connecting rod?
Inspect the piston position.
Is the piston 180_ out of position?
Value(s)
Yes
No
Go to Step 2
System OK
Go to Pistons
and Rods
Replacement
Procedure
Go to Step 3
Go to Pistons
and Rods
Replacement
Procedure
Go to Step 4
Go to Pistons
and Rods
Replacement
Procedure
Go to Step 5
Go to Pistons
and Rods
Replacement
Procedure
System OK

Valve Mechanism or Valve Train Noises
Step
1
Action
Is a light tapping sound heard from the engine?
Inspect the valve springs.
Are the springs weak or broken?
Inspect the valves.

Are the valves sticking or warped?
3
Inspect the valve lifters.

Are the valve lifters dirty, stuck or worn?
4
Inspect the camshaft lobes.

Are the camshaft lobes damaged or improperly
machined?
Check the oil supply to the valve train.
Is the oil supply insufficient or poor?
Inspect the valve guides.

Are the valve guides worn?
7
Inspect the valve spring seat.

Is the valve spring seat incorrect?
8
Value(s)
Yes
No
Go to Step 2
System OK
Go to
Cylinder Head
and Valve Train
Components
Replacement
Procedure
Go to Step 3
Go to
Cylinder Head
and Valve Train
Components
Replacement
Procedure
Go to Step 4
Go to
Cylinder Head
and Valve Train
Components
Replacement
Procedure
Go to Step 5
Go to
Camshaft
Replacement
Procedure
Go to Step 6
Go to
Cylinder Head
and Valve Train
Components
Replacement
Procedure
Go to Step 7
Go to
Cylinder Head
and Valve Train
Components
Replacement
Procedure
Go to Step 8
Go to
Cylinder Head
and Valve Train
Components
Replacement
Procedure
System OK
DAEWOO T-100 BL3

-
GENERAL INFORMATION
CLEANLINESS AND CARE
An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the ten-thousandths of
an inch. When any internal engine parts are serviced,
care and cleanliness are important. A liberal coating of
engine oil should be applied to friction areas during assembly, to protect and lubricate the surfaces on initial
operation. Proper cleaning and protection of machined
surfaces and friction areas is part of the repair procedure. This is considered standard shop practice even if
not specifically stated.
Whenever valve train components are removed for service, they should be kept in order. They should be
installed in the same locations, and with the same mating
surfaces, as when they were removed.
Battery cables should be disconnected before any major
work is performed on the engine. Failure to disconnect
cables may result in damage to wire harness or other
electrical parts.
DAEWOO T-100 BL3
ON-ENGINE SERVICE
C
aution: D
isconnect thenegativebattery cablebe
fore rem
oving or installing any electrical unit, or
whenatool orequipm
entcouldeasilycom
eincon
tact with exposedelectrical term
inals. D
isconnect
ingthiscablewill helpprevent personal injuryand
dam
agetothevehicle. Theignitionm alsobein
ust
LO Kunlessotherwisenoted.
C
Notice: Any time the air cleaner is removed, the intake
opening should be covered. This will protect against accidental entrance of foreign material, which could follow
the intake passage into the cylinder and cause extensive
damage when the engine is started.
SECTION 1B
SOHC ENGINE MECHANICAL

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TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-2
Engine Specifications . . . . . . . . . . . . . . . . . . . . . . 1B-2
Fastener Tightening Specifications . . . . . . . . . . . 1B-4
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5
Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . . 1B-5
Component Locator . . . . . . . . . . . . . . . . . . . . . . . . 1B-8
Upper End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-8
Lower End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-10
Maintenance and Repair . . . . . . . . . . . . . . . . . . . 1B-12
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . 1B-12
Valve Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-12
Cylinder Head and Gasket . . . . . . . . . . . . . . . . . 1B-13
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-27
Timing Belt Check and Adjust . . . . . . . . . . . . . . 1B-31
Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-36
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-42
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-47
Engine Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-49
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-51
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . 1B-57
DAEWOO T-100 BL3
Camshaft Gear . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Timing Belt Cover . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistons and Rods . . . . . . . . . . . . . . . . . . . . . . . .
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Valve Train
Components . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Bearings and Connecting Rod
Bearings - Gauging Plastic . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Gasket . . . . . . . . . . . . . . . . .
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . .
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EGR Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1B-58
1B-59
1B-60
1B-70
1B-76
1B-76
1B-84
1B-92
1B-95
1B-95
1B-95
1B-95
1B-95
1B-95
1B-95
1B-95
1B-95
1B-95
1B - 2 SOHC ENGINE MECHANICAL

-
SPECIFICATIONS
ENGINE SPECIFICATIONS
Application
Description (Manual and Automatic)
General Data:
Engine Type
4 Cylinder (In-Line)
Displacement:
1.3 SOHC
1 349 cm3 (82.30 in3)
1.5 SOHC
1 498 cm3 (91.44 in3)
Bore Stroke:
1.3 SOHC
1.5 SOHC
Compression Ratio
Firing Order
76.5 x 73.4 mm (3.01 in. x 2.89 in.)

76.5 X 81.5 mm (3.01 in. X 3.21 in.)
9.5 $ 0.2:1
1- 3- 4- 2
Cylinder Bore:
Diameter
Out of Round (Maximum)
Taper (Maximum):
1.3 SOHC
1.5 SOHC
76.5 mm (3.01 in.)

0.0065 mm (0.00025 in.)
0
0.0065 mm (0.00025 in.)
Piston:
Diameter
76.470 mm (3.01 in.)
Clearance to Bore
0.030 mm (0.0012 in.)
Piston Rings:
Ring, End Gap:
Top Compression
0.3 mm (0.019 in.)
2nd Compression
0.3 mm (0.019 in.)
Groove Clearance:
Top Impression
0.02 mm (0.0008 in)
2nd Impression
0.02 mm (0.0008 in.)
Piston Pin:
Diameter
Pin Off-Set
18.000 mm (0.708 in.)

0.5X 0.7 mm (0.019X 0.027 in.)
Camshaft:
Lift Intake:
1.3 SOHC
5.61 mm (0.220 in.)
1.5 SOHC
6.12 mm (0.240 in.)
Lift Exhaust
End Play
Journal OD:
No. 1
6.12 mm (0.240 in.)

0.09X 0.21 mm (0.0035X 0.0082 in.)
39.445 mm (1.552 in.)
No. 2
39.700 mm (1.562 in.)
No. 3
39.945 mm (1.572 in.)
No. 4
40.200 mm (1.582 in.)
No. 5
40.445 mm (1.592 in.)

DAEWOO T-100 BL3
SOHC ENGINE MECHANICAL 1B - 3
ENGINE SPECIFICATIONS (Contd)

Application
Bearing OD:
No. 1
Description (Manual and Automatic)

39.500 mm (1.555 in.)
No. 2
39.750 mm (1.564 in.)
No. 3
40.000 mm (1.574 in.)
No. 4
40.250 mm (1.584 in.)
No. 5
40.500 mm (1.594 in.)
Crankshaft:
Main Journal:
Diameter (All)
54.982X 54.994 mm (2.164X 2.165 in.)
Taper (Maximum)
0.005 mm (0.0001 in.)
0.004 mm (0.0001 in.)
Main Bearing Clearance (All)
0.005 mm (0.0001 in.)
Crankshaft End Play
0.1 mm (0.003 in.)
Connecting Rod Journal:

Diameter (All)
42.971X 42.987 mm (1.691X 1.692 in.)
Taper (Maximum)
0.005 mm (0.0001 in.)
0.004 mm (0.0001 in.)
Rod Bearing Clearance (All)
0.019X 0.070 mm (0.0007X 0.0027 in.)
Rod Side Clearance
0.070X 0.242 mm (0.0027X 0.009 in.)
Valve System:
Valve Lash Compensators
Hydraulic
Face Angle (All)
46_
Seat Angle (All)
46_
Seat Runout (Maximum, All)
0.03 mm (0.019 in.)
Face Runout (Maximum, All)
0.03 mm (0.019 in.)
Seat Width:
Intake
1.3X 1.5 mm (0.051X 0.059 in.)
Exhaust
1.6X 1.8 mm (0.063X 0.071 in. )
Valve Guide Inside Diameter (All)

Valve Stem Diameter (All)
Valve Diameter (All):
Intake
Exhaust
Valve Spring Loads:
Valve Open
Valve Closed
7.030X 7.050 mm (0.276X 0.277 in.)

7 mm (0.275 in.)
38.0" 0.15 mm (1.49" 0.0059 in.)
31.0" 0.15 mm (1.22" 0.0059 in.)
625" 25 N (461" 18 lbs) @ 21.5 mm (0.846 in.)
275" 15 N (202" 11 lbs) @ 31.5 mm (1.240 in.)
Oil Pump:
Gap Between Oil Pump Body and Out Rotor
0.400X 0.484 mm (0.0157X 0.0191 in.)
Out Rotor Side Clearance
0.045X 0.100 mm (0.0018X 0.0039 in.)
Inner Rotor Side Clearance
0.035X 0.085 mm (0.0014X 0.0033 in.)
Relief Valve Spring Free Length
DAEWOO T-100 BL3
81 mm (3.2 in.)

-
FASTENER TIGHTENING SPECIFICATIONS

Application
NSm
Lb-Ft
Lb-In
A/C Compressor Hose Assembly Retaining Bolt
33
24
A/C Compressor Mounting Bolts
27
20
A/C Compressor Mounting Bracket Bolts
50
36
Air Filter Housing Bolts
12
106
Alternator Adjusting Bolt
20
15
Alternator Adjusting Bracket Retaining Bolt
20
15
Camshaft Gear Bolt
45
33
Camshaft Pressure Plate Bolts
10
89
25
+30_ +15_
18
+30_ +15_
Coolant Pump Retaining Bolts
10
89
Coolant Temperature Sensor
20
15
Crankshaft Bearing Cap Bolts
50
+45_ +15_
37
+45_ +15_
Crankshaft Pulley Bolt
95
+30_ +15_
70
+30_ +15_
10
89
25
+60_ +60_
+60_+10_
18
+60_ +60_
+60_+10_
DIS Ignition Coil Mounting Bolts
10
89
DIS Ignition Coil Mounting Plate Bolts
10
89
Engine Lift Bracket Bolt
25
18
Engine Mount Attaching Nuts
40
30
Engine Mount Bracket Retaining Bolts
60
44
Engine Mount Bracket-to-Engine Mount Retaining Bolts
60
44
Exhaust Flex Pipe Bracket Bolts
40
30
Exhaust Flex Pipe-to-Catalytic Converter or Connecting

Pipe Retaining Nuts
30
22
Exhaust Flex Pipe-to-Exhaust Manifold Retaining Nuts
40
30
Exhaust Manifold Heat Shield Bolts
15
11
Exhaust Manifold Nuts
25
18
Flexible Plate Bolts
60
44
Flexible Plate Inspection Cover Bolts
10
89
35
+30_ +15_
25
+30_ +15_
Flywheel Inspection Cover Bolts
12
106
Fuel Rail Retaining Bolts
25
18
Intake Manifold Retaining Nuts
25
18
Intake Manifold Support Bracket Retaining Bolts
22
16
Lower Timing Belt Cover Bolts
10
89
Connecting Rod Bearing Cap Bolts
Crankshaft Position Sensor Retaining Bolt

Cylinder Head Bolts (Camshaft Support Housing &
Cylinder Head Mounting Bolts)
Flywheel Bolts
DAEWOO T-100 BL3
FASTENER TIGHTENING SPECIFICATIONS (Contd)

Application
NSm
Lb-Ft
Lb-In
Oil Pan Retaining Bolts
10
89
Oil Pan Drain Plug
55
41
Oil Pressure Switch
40
30
Oil Pump Retaining Bolts
10
89
Oil Pump/Pickup Tube and Support Bracket Bolts
10
89
Oil Pump Safety Relief Valve
30
22
Oil Pump Rear Cover Bolts
53
Power Steering Pump Mounting Bolts
25
18
Power Steering Pump Pulley Bolts
25
18
Rear Timing Belt Cover Bolts
10
89
Right Transaxle Brace Bolts
60
45
Spark Plugs
25
18
Thermostat Housing Mounting Bolts
20
15
Throttle Cable Bracket Bolts
71
Timing Belt Automatic Tensioner Bolt
20
15
Transaxle Bell Housing Bolts
75
55
Transaxle Torque Converter Bolts
45
33
Upper Timing Belt Cover Bolts
10
89
Valve Cover Bolts
10
89
SPECIAL TOOLS
SPECIAL TOOLS TABLE
KM-565-A
Valve Spring
Compressor
A102B150
DAEWOO T-100 BL3
J-42492
Timing Belt Adjuster
A102B151

-
SPECIAL TOOLS TABLE (Contd)
J-28467-B
Engine Assembly
Support Fixture
A102B152
KM-254
Valve Guide Reamer
A102B155
KM-427
Piston Pin Service Set
A102B153
KM-255
Valve Guide Reamer
A102B155
KM-340-0
Cutter Set
Includes: KM-340-7
Includes: KM-340-13
Includes: KM-340-26
MKM-571-B
Gauge
A102B154
A102B156
KM-348
Valve Spring
Compressor
KM-253
Valve Guide Reamer
A102B155
A102B157
DAEWOO T-100 BL3
KM-419
Distance Gauge
A102B158
KM-470-B
Angular Torque Gauge
A102B161
KM-635
Crankshaft Rear Oil
Seal Installer
A102B160
J-36972
Crankshaft Rear Oil
Seal Installer
A102C155
MKM-412
Engine Overhaul Stand
A102B159
B102C044
KM-498-B
Pressure Gauge
A202B005
DAEWOO T-100 BL3
KM-135
Adapter

-
COMPONENT LOCATOR
UPPER END
A202B007
DAEWOO T-100 BL3

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Wiring Bracket
Bolt
Bolt
Cap, Bayonet Joint
Seal, Bayonet Cap
Valve Cover
Bolt
Throttle Position Sensor
Idle Air Control Valve
Throttle Body
Throttle Body Gasket
Nut
Engine Coolant Temperature Sensor
Intake Manifold
Vacuum Tube
EGR Valve
Bolt
EGR Gasket
Shaft Seal Ring
Camshaft Support
Valve Cover Gasket
Tube
Cylinder Head Bolt
Washer
Camshaft
Camshaft Pressure Plate
Bolt
Bolt-Stud
Intake Manifold Gasket
Bolt-Stud
Valve Thrust Piece
DAEWOO T-100 BL3
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
Valve Key
Valve Spring Plate
Valve Spring
Valve Stem Seal
Exhaust Valve Spring Seat
Valve Guide
Cam Follower
Cam Follower Lifter
Intake Valve Spring Seat
Bolt
Thermostat Housing
Thermostat Housing Seal Ring
Thermostat
Screw Plug
Oil Duct Cap
Oil Duct Cap
Adapter
Exhaust Valve
Intake Valve
Cylinder Head Oil Duct Sleeve
Bolt-Stud
Exhaust Manifold Gasket
Cylinder Head Gasket
Exhaust Manifold
Nut
Exhaust Oxygen Sensor
Exhaust Manifold Heat Shield
Bolt
EGR Solenoid
Bracket

-
LOWER END
A202B006
DAEWOO T-100 BL3

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Piston Ring Seat

Piston
Piston Pin
Connecting Rod
Connecting Rod Bearing Set
Connecting Rod Bolt
Oil Level Gauge Stick
Gauge Stick Tube
Connecting Piece
Oil Filter
Camshaft Pulley Bolt
Washer
Camshaft Gear
Rear Cover Bolt
Rear Timing Belt Cover
Bolt
Coolant Pump
Oil Pump
Seal Ring
Oil Pump Body Gasket
Engine Block
Bolt
Auto Tensioner
Bolt
Crankshaft Gear
Pressure Relief Valve Plunger
Spring
Oil Pump Seal Ring
Bolt Plug
Crankshaft Bearing Set
Crankshaft
Shaft Seal Ring
DAEWOO T-100 BL3
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
Flywheel (Manual Transaxle)

Bolt (Manual Transaxle)
Bolt (Automatic Transaxle)
Flex Plate (Automatic Transaxle)
Bolt
Threaded Ring
Drain Plug
Bolt
Oil Pan
Main Bearing Cap Bolt
Main Bearing
Bolt
Bracket
Oil Pickup Tube
Timing Belt
Upper Timing Belt Front Cover
Bolt
Lower Timing Belt Front Cover
Crankshaft Pulley
Washer
Bolt
Bolt
Bolt
Crankshaft Position Sensor
Bracket
Gear
Gear
Cover
Bolt
Seal
Knock Sensor

-

ON-VEHICLE SERVICE
VALVE COVER
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the breather tube from the valve cover.
A102B011
3.
4.
5.
6.
Remove the eight bolts from the valve cover.

Remove the valve cover.
Remove the valve cover gasket.
Clean the sealing surfaces of the valve cover and the
camshaft housing.
A102B010
Installation Procedure
1. Install the new valve cover gasket and the valve cover.
2. Install the eight bolts to the valve cover.
Tighten
Tighten the valve cover bolts to 10 NSm (89 lb-in).
A102B010
DAEWOO T-100 BL3

3. Connect the breather tube to the valve cover.
4. Connect the negative battery cable.
A102B011
CYLINDER HEAD AND GASKET

(Left-Hand Drive Shown, Right Hand
Drive Similar)
Tools Required
J-42492 Timing Belt Adjuster
KM-470-B Angular Torque Gauge
Removal Procedure
1. Remove the fuel pump fuse.
2. Start the engine. After it stalls, crank the engine for 10
seconds to rid the fuel system of fuel pressure.
4. Disconnect the electronic control module (ECM)
ground terminal from the intake manifold.
A102B012
5. Drain the engine coolant. Refer to Section 1D, Engine

Cooling.
6. Disconnect the manifold air temperature sensor connector.
8. Disconnect the air intake tube from the throttle body.
A102B001
DAEWOO T-100 BL3

9. Disconnect the direct ignition system (DIS) ignition
coil connector.
10. Disconnect the oxygen sensor connector.
11. Disconnect the fuel injector harness connectors.
A102B092
12. Disconnect the idle air control valve connector.

13. Disconnect the throttle position sensor connector.
14. Disconnect the engine coolant temperature sensor
connector.
15. Disconnect the coolant temperature sensor connector.
A102B016
16. Remove the air cleaner housing bolts.

17. Remove the air cleaner housing.
A102B002
DAEWOO T-100 BL3

18. Remove the upper timing belt cover bolts.
19. Remove the upper timing belt cover.
A102B003
20. Align the camshaft gear timing mark to the notch in

the rear timing belt cover.
A102B004
21. Remove the right front wheel. Refer to Section 2E,

Tires and Wheels.
22. Remove the right front wheel well splash shield.
23. Remove the A/C compressor drive belt, if equipped.
A102B006
DAEWOO T-100 BL3

24. Remove the alternator drive belt.
25. Remove the power steering pump pulley bolts, if
equipped.
26. Remove the power steering pump pulley, if
equipped.
A102B005
27. Disconnect the fuel return line at the fuel pressure

regulator.
28. Disconnect the fuel feed line at the fuel rail.
A102B116
29. Remove the alternator adjusting bolt.

30. Remove the alternator adjusting bracket retaining
bolt.
31. Remove the alternator adjusting bracket.
A102B118
DAEWOO T-100 BL3

32. Disconnect the upper radiator hose at the thermostat housing.
33. Disconnect the brake booster vacuum hose at the
intake manifold.
34. Disconnect all of the necessary vacuum hoses.
A102B114
35. Remove the crankshaft pulley bolt.

36. Remove the crankshaft pulley.
37. Remove the power steering pump, if equipped. Refer to Section 6B, Power Steering Pump.
38. Install the engine mount bracket-to-engine mount
retaining bolts and tighten the bolts to secure the engine, if the power steering pump was removed.
39. Remove the lower timing belt cover bolts.
40. Remove the lower timing belt cover.
A102B008
41. Slightly loosen the coolant pump retaining bolts.

42. Rotate the coolant pump counterclockwise using the
timing belt adjuster J-42492 to relieve the timing belt
tension.
43. Remove the timing belt. Refer to Timing Belt in this
section.
A102B040
DAEWOO T-100 BL3

44. Disconnect the crankcase ventilation tube at the
camshaft housing and the electrical connector at the
exhaust gas recirculation (EGR) solenoid.
A102B117
45. Remove the valve cover bolts.

46. Remove the valve cover and the valve cover gasket.
Notice: Take care to prevent any scratches, nicks or
damage to the camshaft.
47. While holding the camshaft firmly in place, remove
the camshaft gear bolt.
48. Remove the camshaft gear.
A102B111
49.
50.
51.
52.
Remove the timing belt automatic tensioner bolt.

Remove the timing belt automatic tensioner.
Remove the rear timing belt cover bolts.
Remove the rear timing belt cover.
A102B046
DAEWOO T-100 BL3

53. Disconnect the ignition wires at the spark plugs.
54. Remove the retaining nuts from the exhaust flex
pipe at the exhaust manifold flange and the bolts at
the bracket.
A202B004
55. Disconnect the heater inlet hose at the coolant distributor.

56. Disconnect the surge tank coolant hose at the
throttle body.
A102B119
57. Remove the intake manifold support bracket retaining bolts from the coolant distributor.
58. Disconnect the throttle cable at the throttle body and
the intake manifold.
A102B120
DAEWOO T-100 BL3

59. Gradually loosen all of the cylinder head bolts in the
sequence shown.
60. Remove the cylinder head bolts.
61. Remove the camshaft carrier assembly.
Notice: Prevent any engine oil or coolant from entering
the cylinders when removing the cylinder head. Damage
to the engine could result.
62. Remove the cylinder head with the intake manifold
and the exhaust manifold attached.
63. Remove the cylinder head gasket.
A102B121
Cleaning Procedure
1. Clean the gasket surfaces of the cylinder head and
the engine block.
2. Make sure the gasket surfaces of the cylinder head
and the engine block are free of nicks and heavy
scratches.
3. Clean the cylinder head bolts.
4. Inspect the cylinder head for warpage. Refer to Cylinder Head and Valve Train Components in this section.
A102B122
1. Apply a continuous 3 mm (0.12 inch) bead of gasket
maker to the sealing surface of the camshaft carrier.
2. Install the cylinder head gasket.
3. Install the cylinder head with the intake manifold and
the exhaust manifold attached.
4. Install the camshaft carrier assembly.
A102B123
DAEWOO T-100 BL3

5. Install the cylinder head bolts in the sequence shown.
A102B124
Tighten
Tighten the cylinder head bolts in the sequence previously shown to 25 NSm (18 lb-ft) using a torque
wrench. Use the angular torque gauge KM-470-B
to tighten the cylinder head bolts another 60 degrees
plus 60 degrees plus 60 degrees plue 10 degrees.
A102B172
6. Connect the throttle cable at the throttle body and at

7. Install the intake manifold support bracket retaining
bolt to the coolant distributor.
Tighten
Tighten the intake manifold support bracket retaining
bolts to 22 NSm (16 lb-ft).
A102B029
DAEWOO T-100 BL3

8. Connect the surge tank coolant hose at the throttle
body.
9. Connect the heater inlet hose to the coolant distributor.
A102B119
10. Install the exhaust flex pipe retaining nuts at the exhaust manifold flange and the bolts to the bracket.
Tighten
Tighten the exhaust flex pipe-to-exhaust manifold retaining nuts and bracket bolts to 40 NSm (30 lb-ft).
A202B004
11. Connect the ignition wires at the spark plugs.

12. Install the rear timing belt cover.
13. Install the rear timing belt cover bolts.
Tighten
Tighten the rear timing belt cover bolts to 10 NSm
(89 lb-in).
14. Install the timing belt automatic tensioner.
15. Install the timing belt automatic tensioner bolt.
Tighten
Tighten the timing belt automatic tensioner bolt to
20 NSm (15 lb-ft).
A102B046
DAEWOO T-100 BL3

Notice: Take extreme care to prevent any scratches,
nicks, or damage to the camshaft. Such damage can impair vehicle operation.
16. Install the camshaft gear.
17. While holding the camshaft firmly in place, install the
camshaft gear bolt.
Tighten
Tighten the camshaft gear bolt to 45 NSm (33 lb-ft).
A102B111
18. Install the valve cover and the valve cover gasket.
19. Install the valve cover bolts.
Tighten
20. Connect the crankcase ventilation tube to the camshaft housing and connect the EGR solenoid connector.
A102B117
21. Align the mark on the camshaft gear to the notch at

the top of the rear timing belt cover.
A102B004
DAEWOO T-100 BL3

22. Align the mark on the crankshaft gear to the notch at
the bottom of the rear timing belt cover.
A102B030
23. Install the timing belt. Refer to Timing Belt in this

section.
24. Check the timing belt tension. Refer to Timing Belt
Check and Adjust in this section.
25. Install the lower timing belt cover.
26. Install the lower timing belt cover bolts.
Tighten
Tighten the lower timing belt cover bolts to 10 NSm
(89 lb-in).
27. Install the power steering pump and the bolts, if
equipped. Refer to Section 6B, Power Steering
Pump.
28. Install the engine mount bracket-to-engine mount retaining bolts if the power steering pump was installed.
Tighten
A102B020
Tighten the engine mount bracket-to-engine mount

retaining bolts to 60 NSm (44 lb-ft).
29. Install the crankshaft pulley.
30. Install the crankshaft pulley bolt.
Tighten
Tighten the crankshaft pulley bolt to 95 NSm (70 lb-ft)
using a torque wrench. Use the angular torque gauge
KM-470-B to tighten the crankshaft pulley bolt another 30 degrees plus 15 degrees.
31. Install the power steering pump pulley, if equipped.
32. Install the power steering pump pulley bolts, if
equipped.
Tighten
Tighten the power steering pump pulley bolts to
25 NSm (18 lb-ft).
A102B005
DAEWOO T-100 BL3

33. Connect all of the vacuum hoses.
34. Connect the brake booster hose at the intake manifold.
35. Connect the upper radiator hose at the thermostat
housing.
A102B114
36. Install the alternator adjusting bracket.

37. Install the alternator adjusting bracket retaining bolt.
Tighten
Tighten the alternator adjusting bracket retaining bolt
to 20 NSm (15 lb-ft).
38. Install the alternator adjusting bolt. Do not tighten.
A102B118
39. Connect the fuel feed line at the fuel rail.

40. Connect the fuel return line at the fuel pressure regulator.
A102B116
DAEWOO T-100 BL3

41. Install the alternator drive belt.
Tighten
Tighten the alternator adjusting bolt to 20 NSm (15 lb-ft).
42. Install the upper timing belt cover.
43. Install the upper timing belt cover bolts.
Tighten
Tighten the upper timing belt cover bolts to 10 NSm
(89 lb-in).
44. Install the A/C compressor drive belt, as necessary.
45. Install the right front wheel well splash shield.
46. Install the right front wheel. Refer to Section 2E,
Tires and Wheels.
A102B003
47. Install the air filter housing.

48. Install the air filter housing bolts.
Tighten
Tighten the air filter housing bolts to 12 NSm (106 lbin).
49. Connect the air intake tube to the throttle body.
51. Connect the manifold air temperature sensor connector.
A102B001
52. Connect the coolant temperature sensor connector.

53. Connect the engine coolant temperature sensor
connector.
54. Connect the idle air control valve connector.
55. Connect the throttle position sensor connector.
56. Connect the DIS ignition coil connector.
57. Connect the fuel injector harness connectors.
58. Connect the oxygen sensor connector.
59. Connect the ECM ground terminal at the intake
manifold.
61. Install the fuel pump fuse.
62. Refill the engine cooling system. Refer to Section
1D, Engine Cooling.
A102B016
DAEWOO T-100 BL3
CAMSHAFT
Drive Similar)
Tools Required
KM-565-A Valve Spring Compressor
Removal Procedure
section.
2. Disconnect the air breather tube at the valve cover.
4. Remove the valve cover.
5. Remove the valve cover gasket.
A102B010
6. Install the valve spring compressor KM-565-A.

7. Remove the camshaft followers using the valve
spring compressor KM-565-A.
A102B074

A102B111
DAEWOO T-100 BL3

10. Disconnect the positive battery cable from the battery.
11. Remove the battery and the battery tray. Refer to
Section 1E, Engine Electrical.
A102C034
12. Disconnect the direct ignition system (DIS) ignition

coil connector.
13. Disconnect the DIS ignition wires at the ignition coil.
14. Remove the DIS ignition coil mounting bolts.
15. Remove the DIS ignition coil.
A102B075
16.
17.
18.
19.
Remove the DIS ignition coil mounting plate bolts.

Remove the DIS ignition coil mounting plate.
Remove the camshaft pressure plate bolts.
Remove the camshaft pressure plate.
A102B076
DAEWOO T-100 BL3

20. Remove the camshaft.
A102B077
1. Install the camshaft.
2. Install the camshaft pressure plate.
3. Install the camshaft pressure plate bolts.
Tighten
Tighten the camshaft pressure plate bolts to 10 NSm
(89 lb-in).
A102B076
4. Measure camshaft end play. Camshaft end play

should be 0.04 to 0.16 mm (.016 to 0.64 inch).
5. Install the DIS ignition coil mounting plate.
6. Install the DIS ignition coil mounting plate bolts.
Tighten
Tighten the DIS ignition coil mounting plate bolts to
10 NSm (89 lb-in).
7. Install the DIS ignition coil.
8. Install the DIS ignition coil mounting bolts.
Tighten
Tighten the DIS ignition coil mounting bolts to 10 NSm
(89 lb-in).
9. Connect the ignition wires at the DIS ignition coil.
10. Connect the DIS ignition coil connector.
A102B075
DAEWOO T-100 BL3

11. Install the battery and the battery tray. Refer to Sec
tion 1E, Engine Electrical.
12. Connect the positive battery cable to the battery.
A102C034

camshaft gear bolt.
Tighten
A102B111
15. Install the camshaft followers using the valve spring

compressor KM-565-A.
16. Remove the tool KM-565-A.
A102B074
DAEWOO T-100 BL3

17. Install the valve cover gasket.
18. Install the valve cover.
Tighten
20. Connect the air breather tube to the valve cover.
section.
A102B010
TIMING BELT CHECK AND ADJUST

Drive Similar)
Tools Required
Adjustment Procedure
A102B001

Tires and Wheels.
A102B002
DAEWOO T-100 BL3

equipped.
equipped.
13. Remove the power steering pump mounting bolts,
if equipped.
A102B003

A102B018
18. Remove the lower timing belt cover bolts.

19. Remove the lower timing belt cover.
A102B008
DAEWOO T-100 BL3

21. Rotate the crankshaft at least one full turn clockwise
using the crankshaft pulley bolt.
22. Align the dot on the crankshaft gear to the notch at
A102B030
23. Align the camshaft gear timing mark to the notch at

A102B004
24. Slightly loosen the three coolant pump retaining

bolts.
25. Using the timing belt adjuster J-42492, rotate the
coolant pump clockwise to add the highest tension
to the timing belt.
26. Tighten the coolant pump retaining bolts.
A102B040
DAEWOO T-100 BL3

27. Align the adjust arm hole of the timing belt automatic
tensioner to the hole in the timing belt automatic tensioner bracket.
28. Insert a 4.5 mm driver through the adjust arm hole
and the tensioner bracket hole.
29. Rotate the crankshaft two full turns clockwise using
the crankshaft pulley bolt.
31. Remove the driver from the timing belt automatic
tensioner.
32. Loosen the coolant pump retaining bolts.
A102B039
33. Rotate the coolant pump until the adjust arm pointer
of the timing belt automatic tensioner is aligned with
the notch in the timing belt automatic tensioner
bracket.
Tighten
Tighten the coolant pump retaining bolts to 10 NSm
(89 lb-in).
A102B041

Tighten
(89 lb-in).
A102B008
DAEWOO T-100 BL3

Tighten
using a torque wrench. Use the angular torque gauge
KM-470-B to tighten the crankshaft pulley bolt another 30 degrees plus 15 degrees.
A102B018

Tighten
(89 lb-in).
42. Install the power steering pump mounting bolts, if
equipped.
Tighten
Tighten the power steering pump mounting bolts to
25 NSm (18 lb-ft).
equipped.
Tighten
A102B005

25 NSm (18 lb-ft).
Tighten
Tighten the alternator adjusting bolt to 20 NSm (15 lbft).
46. Install the A/C compressor drive belt, if equipped.
Tires and Wheels.
49. Install the air cleaner housing.
50. Install the air cleaner housing bolts.
Tighten
A102B002
DAEWOO T-100 BL3

A102B001
TIMING BELT
Drive Similar)
Tools Required
Removal Procedure
A102B001

Tires and Wheels.
A102B002
DAEWOO T-100 BL3

A102B003
14.
15.
16.
17.
Remove the crankshaft pulley bolt.

Remove the crankshaft pulley.
Remove the lower timing belt cover bolts.
Remove the lower timing belt cover.
A102B008

19. Using the crankshaft pulley bolt, rotate the crankshaft clockwise until the mark on the crankshaft
gear is aligned with the notch at the bottom of the
rear timing belt cover.
A102B030
DAEWOO T-100 BL3

coolant pump counterclockwise to release the tension on the timing belt.
22. Remove the timing belt.
A102B040
1. Align the mark on the crankshaft gear to the notch on
2. Align the mark on the camshaft gear to the notch on
3. Install the timing belt.
A102B042

coolant pump clockwise to add the highest tension to
the timing belt.
A102B040
DAEWOO T-100 BL3

6. Align the adjust arm hole of the timing belt automatic
tensioner to the hole in the timing belt automatic tensioner bracket.
7. Insert a 4.5 mm driver through the adjust arm hole
and the tensioner bracket hole.
A102B039

A102B030
10. Remove the driver from the timing belt automatic

tensioner.
bolts.
coolant pump.
A102B040
DAEWOO T-100 BL3

the notch in the timing belt automatic tensioner
bracket.
Tighten
(89 lb-in).
A102B041

Tighten
(89 lb-in).
A102B008

Tighten
using a torque wrench. Using the angular torque
gauge KM-470-B, tighten the crankshaft pulley bolt
another 30 degrees plus 15 degrees.
A102B018
DAEWOO T-100 BL3

Tighten
(89 lb-in).
A102B003
22. Install the power steering pump, if equipped. Refer

to Section 6B, Power Steering Pump.
A102B006

Tires and Wheels.
Tighten
Tighten the air filter housing bolts to 12 NSm (106 lb-in).
A102B002
DAEWOO T-100 BL3

A102B001
OIL PUMP
Tools Required
KM-498-B Pressure Gauge
KM-135 Adapter
Engine Oil Pressure Inspection Procedure

1. Remove the right-hand (RH) wheel well splash shield.
2. Remove the oil pressure switch connector.
A102B019
3. Install the adapter KM-135 in place of the oil pressure

switch.
4. Connect the pressure gauge KM-498-B to the adapter.
5. Start the engine and check the oil pressure at idle
speed and an engine temperature of 80_C (176_ F).
Important: The minimum oil pressure should be 30 kPa
(8.88 psi).
6. Stop the engine and remove the oil pressure gauge
and the adapter.
A202B003
DAEWOO T-100 BL3

7. Install the oil pressure switch.
Tighten
Tighten the oil pressure switch to 40 NSm (30 lb-ft).
8. Connect the electrical connector to the oil pressure
switch.
9. Install the RH wheel well splash shield.
10. Check the oil level and fill the oil to the FULL mark.
A102B019
Removal Procedure
2. Remove the power steering pump, if equipped. Refer to Section 6A, Power Steering System.
section.
4. Remove the rear timing belt cover. Refer to Rear
Timing Belt Cover in this section.
5. Disconnect the oil pressure switch connector.
A102B019
6. Remove the crankshaft position sensor bolt.

7. Remove the crankshaft position sensor.
8. Remove the oil pan. Refer to Oil Pan in this section.
9. Remove the oil pump pickup tube and the support
bracket bolts.
10. Remove the oil pump pickup tube.
A102B064
DAEWOO T-100 BL3

11. Remove the oil pump retaining bolts.
12. Carefully separate the oil pump and the gasket from
the engine block and the oil pan.
13. Remove the oil pump.
A102B065
Inspection Procedure
1. Clean the oil pump and the engine block gasket mating surfaces.
2. Remove the safety relief valve bolt.
3. Remove the safety relief valve and the spring.
4. Remove the oil pump-to-crankshaft seal.
A202B002
5. Remove the oil pump rear cover bolts.

6. Remove the rear cover.
A202B001
DAEWOO T-100 BL3

7. Clean the oil pump housing and all of the parts.
8. Inspect all of the parts for signs of wear. Refer to
Engine Specifications in this section.
9. Coat all of the oil pump parts with clean engine oil.
10. Reinstall all of the oil pump parts.
Notice: Pack the oil pump gear cavity with petroleum
jelly to ensure an oil pump prime. Failure to do this can
damage the engine.
11. Install the oil pump rear cover and the bolts.
Tighten
Tighten the oil pump rear cover bolts to 6 NSm (53 lbin).
12. Install the safety relief valve, the spring, the washer,
and the bolt.
A202B001
Tighten
Tighten the oil pump safety relief valve bolt to 30 NSm
(22 lb-ft).
1. Apply a bead of room temperature vulcanizing (RTV)
sealer to the oil pump gasket.
2. Install a new oil pump gasket to the oil pump.
3. Coat the threads of the oil pump bolts with Loctite[
573.
4. Install the oil pump to the engine block with the bolts.
Tighten
Tighten the oil pump retaining bolts to 10 NSm (89 lbin).
A102B065
DAEWOO T-100 BL3

5. Install a new oil pump to the crankshaft shaft seal.
6. Coat the lip of the seal with a thin coat of grease.
A202B002
7. Coat the threads of the oil pump pickup tube and the
support bracket bolts with Loctite[ 573.
8. Install the oil pump pickup tube and the bolts.
Tighten
Tighten the oil pump pickup tube and the support
bracket bolts to 10 NSm (89 lb-in).
A102B064
9. Install the oil pan. Refer to Oil Pan in this section.

10. Install the crankshaft position sensor and the bolt.
Tighten
Tighten the crankshaft position sensor retaining bolt
to 10 NSm (89 lb-in).
11. Connect the oil pressure switch connector.
12. Install the rear timing belt cover. Refer to Rear Timing Belt Cover in this section.
13. Install the timing belt. Refer to Timing Belt In this
section.
to Section 6A, Power Steering System.
A102B019
DAEWOO T-100 BL3
OIL PAN
Removal Procedure
2. Drain the engine oil from the engine crankcase.
3. Remove the exhaust flex pipe retaining nuts from the
exhaust manifold and the bolts from the bracket.
catalytic converter or connecting pipe.
5. Remove the exhaust flex pipe.
A202B004
6. Remove the flywheel or flexible plate inspection cover

bolts.
7. Remove the flywheel or flexible plate inspection cover.
A102B021
8. Remove the oil pan retaining bolts.

9. Remove the oil pan from the engine block.
A102B043
DAEWOO T-100 BL3

Cleaning Procedure
1.
2.
3.
4.
Clean the oil pan sealing surface.

Clean the engine block sealing surface.
Clean the oil pan retaining bolts.
Clean the oil pan retaining bolt holes in the engine
block.
A102B044
1. Install the oil pan gasket to the oil pan.
2. Install the oil pan to the engine block.
Important: Install the oil pan within 5 minutes after applying liquid gasket to the oil pan.
3. Install the oil pan retaining bolts.
Tighten
Tighten the oil pan retaining bolts to 10 NSm (89 lb-in).
A102B043
4. Install the flywheel or flexible plate inspection cover.

5. Install the flywheel or flexible plate inspection cover
bolts.
Tighten
Tighten the flywheel inspection cover bolts to 12 NSm
(106 lb-in) or the flexible plate inspection cover bolts
A102B021
DAEWOO T-100 BL3

6. Install the exhaust flex pipe.
7. Install the exhaust flex pipe to the exhaust manifold
retaining nuts and the bracket bolts.
Tighten
Tighten the exhaust flex pipe-to-exhaust manifold retaining nuts and bracket bolts to 40 NSm (30 lb-ft).
8. Install the exhaust flex pipe retaining nuts to the catalytic converter or connecting pipe.
Tighten
Tighten the exhaust flex pipe-to-catalytic converter or
connecting pipe retaining nuts to 30 NSm (22 lb-ft).
10. Install the oil pan drain plug.
Tighten
A202B004
Tighten the oil pan drain plug to 55 NSm (41 lb-ft).

11. Refill the engine crankcase with engine oil.
ENGINE MOUNT
Tools Required
J-28467-B Engine Assembly Support Fixture
Removal Procedure
2. Support the engine assembly using the engine assembly support fixture J-28467-B.
A105B012
DAEWOO T-100 BL3

3. Remove the engine mount bracket retaining bolts.
A102B020
4. Remove the engine mount attaching nuts.

5. Remove the engine mount.
A102B045
1. Install the engine mount.
2. Install the engine mount attaching nuts.
Tighten
Tighten the engine mount attaching nuts to 40 NSm
(30 lb-ft).
A102B045
DAEWOO T-100 BL3

3. Install the engine mount bracket retaining bolts.
Tighten
Tighten the engine mount bracket retaining bolts to
60 NSm (44 lb-ft).
A102B020
4. Remove the engine assembly support fixture

J-28467-B.
A105B012
INTAKE MANIFOLD
Drive Similar)
Removal Procedure
2. Start the engine. Crank the engine after it stalls for
10 seconds to rid the fuel system of fuel pressure.
4. Disconnect the electronic control module (ECM)
ground terminal from the intake manifold.
A102B012
DAEWOO T-100 BL3

5. Drain the engine coolant. Refer to Section 1D, En
gine Cooling.
6. Disconnect the manifold air temperature sensor
connector.
A102B001

connector.
A102B016
11. Disconnect the heater inlet hose from the coolant

distributor beneath the intake manifold.
throttle body.
13. Disconnect all of the necessary vacuum hoses, including the vacuum hose at the fuel pressure regulator and the brake booster vacuum hose at the
intake manifold.
A102B031
DAEWOO T-100 BL3

14. Disconnect the throttle cable from the throttle body
and the intake manifold.
15. Remove the two throttle cable bracket bolts and the
throttle cable bracket.
16. Disconnect the fuel return line from the fuel pressure
regulator.
17. Disconnect the fuel feed line from the fuel rail.
A102B116
18. Disconnect the fuel injector connectors from the fuel

injectors.
19. Remove the two retaining bolts from the fuel injector
rail.
20. Remove the fuel injector rail and fuel injectors as an
assembly. Refer to Section 1F, Engine Controls.
A102B032

22. Remove the alternator adjusting bracket and the
bolts.
A102B118
DAEWOO T-100 BL3

23. Remove the three intake manifold support bracket
retaining bolts from the coolant distributor and the
engine block.
24. Remove the intake manifold support bracket.
A102B033
25. Remove the intake manifold retaining nuts and the

engine lift bracket bolt in the sequence shown.
A102B036
26. Remove the intake manifold.

27. Remove the intake manifold gasket.
28. Clean the sealing surfaces of the intake manifold
and the cylinder head.
A102B034
DAEWOO T-100 BL3

1. Install the intake manifold gasket.
2. Install the intake manifold.
3. Install the intake manifold retaining nuts and the engine lift bracket bolt in the sequence shown.
Tighten
Tighten the intake manifold retaining nuts in the sequence shown to 25 NSm (18 lb-ft).
Tighten the engine lift bracket bolt to 25 NSm (18 lb-ft).
A102B035
4. Install the intake manifold support bracket.

5. Install the intake manifold support bracket retaining
bolts.
Tighten
Tighten the intake manifold support bracket retaining
6. Install the alternator adjusting bracket and the bolts.
Tighten
Tighten the alternator adjusting bracket retaining
A102B118
8. Install the fuel rail and the fuel injectors as an assembly. Refer to Section 1F, Engine Controls.
9. Install the fuel rail retaining bolts.
Tighten
Tighten the fuel rail retaining bolts to 25 NSm (18 lb-ft).
A102B032
DAEWOO T-100 BL3

10. Connect the fuel return line to the fuel pressure regulator.
11. Connect the fuel feed line to the fuel rail.
12. Install the throttle cable bracket and the two throttle
cable bracket bolts.
Tighten
Tighten the throttle cable bracket bolts to 8 NSm
(71 lb-in).
13. Connect the throttle cable to the intake manifold and
the throttle body.
A102B120
14. Connect the fuel injector connectors to the fuel injectors.

15. Connect all of the vacuum lines that were previously
disconnected.
16. Connect the heater inlet hose to the coolant distributor beneath the intake manifold.
17. Connect the surge tank coolant hose to the throttle
body.
connector.
A102B016

23. Connect the ECM ground terminal to the intake
manifold.
1D, Engine Cooling.
A102B001
DAEWOO T-100 BL3
EXHAUST MANIFOLD
Removal Procedure
1.
2.
3.
4.
5.
6.
Disconnect the negative battery cable.

Disconnect the ignition wires from the spark plugs.
Disconnect the oxygen sensor.
Remove the exhaust manifold heat shield bolts.
Remove the exhaust manifold heat shield.
Remove the nuts from the exhaust flex pipe flange
and the bracket bolts.
A202B004
7. Remove the eight exhaust manifold nuts in the sequence shown.

8. Remove the exhaust manifold.
9. Remove the exhaust manifold gasket.
10. Clean the sealing surfaces of the exhaust manifold
A102B037
1. Install the exhaust manifold gasket.
2. Install the exhaust manifold.
3. Install the eight exhaust manifold nuts and torque in
the sequence shown.
Tighten
Tighten the exhaust manifold nuts 25 NSm (18 lb-ft).
A102B038
DAEWOO T-100 BL3

4. Install the exhaust flex pipe-to-exhaust manifold retaining nuts and the bracket bolts.
Tighten
Tighten the three exhaust flex pipe-to-exhaust manifold retaining nuts and the bracket bolts to 40 NSm
(30 lb-ft).
5. Install the manifold heat shield.
6. Install the exhaust manifold heat shield bolts.
Tighten
Tighten the exhaust manifold heat shield bolts to
15 NSm (11 lb-ft).
7. Connect the oxygen sensor.
8. Connect the ignition wires to the spark plugs.
A202B004
CAMSHAFT GEAR
Removal Procedure
section.
A102B010

A102B111
DAEWOO T-100 BL3

camshaft gear bolt.
Tighten
A102B111

Tighten
section.
A102B010
REAR TIMING BELT COVER

Removal Procedure
section.
3. Remove the camshaft gear. Refer to Camshaft
Gear in this section.
4. Remove the timing belt automatic tensioner bolt.
5. Remove the timing belt automatic tensioner.
6. Remove the rear timing belt cover bolts.
7. Remove the rear timing belt cover.
A102B046
DAEWOO T-100 BL3

Tighten
(89 lb-in).
Tighten
20 NSm (15 lb-ft).
A102B041
5. Install the camshaft gear. Refer to Camshaft Gear

in this section.
section.
ENGINE
Drive Similar)
Tools Required
Removal Procedure
Important: On vehicles equipped with a manual transaxle, the manual transaxle must be removed before engine removal. Refer to Section 5B, Five
Speed Manual
Transaxle.
A102B012

3. Remove the hood. Refer to Section 9R, Body Front
End.
4. Drain the engine oil.
DAEWOO T-100 BL3

6. Disconnect and separate the battery positive cable.
7. Disconnect the negative battery cable from the vehicle frame.
A102B013
8. Discharge the air conditioning (A/C) system, if

equipped. Refer to Section 7B, Manual Control
Heating, Ventilation, and Air Conditioning System.
connector.
10. Remove the air intake tube from the throttle body
and the air filter housing.
A102B011

Tires and Wheels.
13.
14.
15.
16.
17.
A102B014
DAEWOO T-100 BL3
Remove the right front wheel well splash shield.

Remove the A/C compressor drive belt, if equipped.
Remove the alternator drive belt.
Remove the power steering pump pulley bolts.
Remove the power steering pump pulley.

gine Cooling.
19. Remove the cooling system radiator and the engine
cooling fans. Refer to Section 1D, Engine Cooling.
20. Disconnect the upper radiator hose from the thermostat housing.
21. Disconnect the coolant surge tank hose from the radiator.
22. Disconnect the power steering return hose from the
power steering pump, if equipped.
23. Drain the power steering system, if equipped.
24. Disconnect the power steering pressure hose from
the power steering pump, if equipped.
A102B015
25. Disconnect the electrical connector at the direct ignition system (DIS) ignition coil, and the engine control module (ECM) ground terminal at the intake
manifold and at the starter motor.
26. Disconnect the oxygen sensor connector.
27. Disconnect the electrical connectors at the fuel injectors.
connector.
31. Disconnect the coolant temperature sensor connector and the knock sensor, if equipped.
A102B016
32. Disconnect the alternator voltage regulator connector.

33. Disconnect all of the necessary vacuum lines, including the brake booster vacuum hose.
regulator.
and the intake manifold bracket.
A102B116
DAEWOO T-100 BL3

throttle body.
38. Disconnect the heater inlet hose from the coolant
distributor.
39. Disconnect the heater outlet hose at the coolant
pipe.
40. Disconnect the surge tank coolant hose from the
coolant pipe.
41. Disconnect the lower radiator hose at the coolant
pipe.
A102B017
42. Disconnect the starter solenoid S terminal wire.

43. Remove the A/C compressor hose assembly retaining bolt.
44. Disconnect the A/C compressor hose assembly
from the compressor.
45. Disconnect the A/C compressor coil connector.
46. Remove the A/C compressor mounting bolts.
47. Remove the A/C compressor.
48. Remove the A/C compressor mounting bracket
bolts.
49. Remove the A/C compressor mounting bracket from
the engine block.
A102B025
50. Remove the exhaust flex pipe retaining nuts from

the exhaust manifold.
the catalytic converter or connecting pipe.
53. Remove the engine crankshaft pulley bolt.
54. Remove the engine crankshaft pulley.
A102B018
DAEWOO T-100 BL3

55. Disconnect the vacuum lines at the charcoal canister purge and exhaust gas recirculation (EGR) solenoid.
56. Disconnect the electrical connector at the charcoal
canister purge solenoid and the knock sensor.
57. Disconnect the electrical connector at the oil pressure switch.
58. Disconnect the crankshaft position sensor connector.
59. Remove the crankshaft position sensor retaining
bolt.
61. Remove the right transaxle brace bolts from the
transmission.
A102B019
62. Remove the flywheel or the flexible plate inspection

cover bolts.
63. Remove the flywheel or the flexible plate inspection
cover.
A102B021
64. Remove the transaxle torque converter bolts on vehicles with an automatic transaxle.
A102B022
DAEWOO T-100 BL3

65.
66.
67.
68.
69.
70.
71.
72.
Remove the transaxle bell housing bolts.

Support the transaxle with a floor jack.
Install the engine lifting device.
Disconnect the right engine mount bracket from the
rubber engine mount by removing the two retaining
bolts.
Remove the right engine mount bracket from the engine block.
Separate the engine block from the transaxle.
Remove the engine.
Transfer any necessary parts.
A102B020
1. Install the engine into engine compartment.
2. Align the transaxle alignment pins to the transaxle.
3. Install the transaxle bell housing bolts.
Tighten
Tighten the transaxle bell housing bolts to 75 NSm
(55 lb-ft).
A102B063
4. Install the right engine mount bracket to the engine

block.
5. Install the right engine mount bracket retaining bolts
to the engine block.
Tighten
60 NSm (44 lb-ft).
6. Install the engine mount-to-bracket retaining bolts.
Tighten
Tighten the engine mount bracket-to-engine mount
7. Remove the floor jack used for support of the transaxle.
8. Remove the engine lifting device.
A102B020
DAEWOO T-100 BL3

9. Install the transaxle torque converter bolts, if the vehicle has an automatic transaxle.
Tighten
Tighten the transaxle torque converter bolts to 45 NSm
(33 lb-ft).
A102B022
10. Install the flywheel or the flexible plate inspection

cover.
11. Install the flywheel or the flexible plate inspection
cover bolts.
Tighten
12. Install the right transaxle brace bolts to the transaxle.
Tighten
Tighten the right transaxle brace bolts to 60 NSm
(45 lb-ft).
13. Connect the vacuum lines at the charcoal canister
purge and EGR solenoid.
A102B024
14. Connect the electrical connectors at the charcoal

canister purge and EGR solenoids.
Tighten
gauge KM-470-B, tighten the crankshaft pulley bolt
another 30 degrees plus 15 degrees.
A102B018
DAEWOO T-100 BL3

18. Install the crankshaft position sensor and the crankshaft position sensor retaining bolt.
Tighten
19. Connect the crankshaft position sensor connector.
21. Install the exhaust flex pipe-to-catalytic converter
retaining nuts.
Tighten
Tighten the exhaust flex pipe-to-catalytic converter or
connecting pipe retaining nuts to 30 NSm (22 lb-ft).
22. Install the exhaust flex pipe-to-exhaust manifold retaining nuts and the bracket bolts.
A202B004
Tighten
Tighten the exhaust flex pipe to exhaust manifold retaining nuts and the bracket bolts to 40 NSm (30 lb-ft).
23. Connect the power steering pressure hose, if

equipped.
24. Connect the power steering return hose, if
equipped.
A102B015
DAEWOO T-100 BL3

25. Install the A/C compressor mounting bracket, if
equipped.
26. Install the A/C compressor mounting bracket bolts, if
equipped.
Tighten
Tighten the A/C compressor mounting bracket bolts
27. Install the A/C compressor, if equipped.
28. Install the A/C compressor mounting bolts, if
equipped.
Tighten
Tighten the A/C compressor mounting bolts to 27 NSm
(20 lb-ft).
29. Connect the A/C compressor coil connector.
A102B025

32. Connect the A/C compressor hose assembly and
the A/C compressor hose assembly retaining bolt,
if equipped.
Tighten
Tighten the A/C compressor hose assembly retaining
bolt to 33 NSm (24 lb-ft).
equipped.
Tighten
25 NSm (18 lb-ft).
A102B014

Tires and Wheels
38. Connect the fuel return line to the fuel pressure regulator.
39. Connect all of the necessary vacuum lines, including the brake booster vacuum hose.
A102B116
DAEWOO T-100 BL3

40.
41.
42.
43.
44.
Connect the oxygen sensor connector.

Connect the starter solenoid S terminal wire.
Connect the alternator voltage regulator connector.
Connect the coolant temperature sensor connector.
Connect the engine coolant temperature sensor
connector and the knock sensor connector, if
equipped.
A102B016
47. Connect the electrical connectors at the fuel injectors.

48. Connect the electrical connector at the DIS ignition
coil and the ECM ground terminal at the intake manifold.
49. Install the air intake tube between the throttle body
A102B001
52. Install the cooling system radiator and the engine

53. Connect the lower radiator hose to the coolant pipe.
54. Connect the upper radiator hose to the thermostat
housing.
55. Connect the coolant surge tank hose to the radiator.
56. Connect the heater outlet hose to the coolant pipe.
57. Connect the heater inlet hose to the coolant distributor.
58. Connect the coolant surge tank hose to the coolant
pipe.
body.
A102B017
DAEWOO T-100 BL3

-
A102B013
60. Connect the throttle cable to the throttle body and

the intake manifold bracket.
62. Connect the negative battery cable to the vehicle
frame.
63. Connect the negative battery cable to the battery.
64. Connect and assemble the battery positive cable.
66. Refill the engine coolant system. Refer to Section
1D, Engine Cooling.
67. Bleed the power steering system as necessary. Refer to Section 6A, Power Steering System.
68. Refill the A/C refrigerant system as necessary. Refer to Section 7B, Manual Control Heating, Ventila
tion, and Air Conditioning System.
69. Install the hood. Refer to Section 9R, Body Front
End.
PISTONS AND RODS

Tools Required
KM-427 Piston Pin Service Set
KM 470-B Angular Torque Gauge
Removal Procedure
and exhaust manifold attached. Refer to Cylinder
Head and Gasket in this section.
3. Remove the oil pump/pickup tube bolts.
4. Remove the oil pump/pickup tube.
A102B094
5.
6.
7.
8.
Move the piston to the bottom of the piston stroke.

Mark the connecting rod cap.
Remove the connecting rod cap bolts.
Remove the connecting rod cap and lower connecting rod bearing.
9. Remove the upper piston connecting rod bearing.
10. Ridge ream the cylinder wall.
A102B079
DAEWOO T-100 BL3

C a u tio n : U s e c a re w h e n
h a n d lin g th e p is to n . W o rn
p is to n rin g s a re s h a rp a n d m a y c a u s e in ju ry .
11. Remove the piston.

12. Use a piston ring expander tool to expand the piston
rings.
13. Remove the piston rings.
A102B080
14. Remove the piston pin from the piston and connecting rod assembly using the piston pin service set
KM-427.
15. Separate the piston from the connecting rod.
A102B081
1. Inspect the connecting rod for bending or twisting. If
the connecting rod is bent or twisted, replace the connecting rod.
2. Inspect the connecting rod bearings.
3. Inspect the connecting rod lower end for wear.
4. Inspect the connecting rod upper end for scoring.
5. Inspect the piston for scoring, cracks and wear.
6. Inspect the piston for taper using a micrometer.
A102B087
DAEWOO T-100 BL3

7. Inspect the piston for fit to the connecting rod.
A102B082
8. Inspect the engine block deck surface for flatness

using a straight edge and a feeler gauge. Refer to
9. Inspect the bearing bore for concentricity and alignment using a bore gauge. Refer to Engine Specifications in this section. If beyond specifications,
replace the engine block.
10. Inspect the engine block cylinder bore for wear, runout, ridging and taper using a bore gauge. Refer to
11. Inspect the engine block cylinder bore for glazing.
Lightly hone the cylinder bore as necessary.
A102B083
1. Align the notch on the piston and connecting rod so
that the proper sides will be facing the front of the engine.
2. Install the piston pin guide through the piston and the
connecting rod.
3. Coat the piston pin with clean oil.
4. Install the piston pin into the opposite side of the piston.
5. Install the piston pin into the piston and connecting
rod assembly using the piston pin service set
KM-427.
A102B081
DAEWOO T-100 BL3

6. Select a set of new piston rings.
7. Measure the piston ring gap using a feeler gauge.
Refer to Engine Specifications in this section.
8. Increase the piston ring gap by carefully filing off excess material if the piston ring gap is below specifications.
A102B084
9. Measure the piston ring side clearance using a feeler gauge. Refer to Engine Specifications in this
section.
10. If the piston ring is too thick, try another piston ring.
11. If no piston ring can be found that fits to specifications, the piston ring may be ground to size with
emery paper placed on a sheet of glass.
A102B085
12. Install a piston oil ring, the expander, then the second piston oil ring to the bottom ring groove of the
piston.
13. Install the second compression ring to the middle
ring groove of the piston.
14. Install the top compression ring to the top ring
groove of the piston.
A102B086
DAEWOO T-100 BL3

15. Use a piston ring expander to install the piston rings.
Do not expand the piston rings beyond the expansion necessary for installation.
16. Stagger the piston oil rings, the oil ring rail gaps, the
second compression ring, and the top compression
ring in relation to the notch on the top of the piston.
A102B089
17. Lubricate the cylinder wall and the piston rings with
clean engine oil.
18. Install the piston using a ring compressor and a
wood handle. Guide the lower connecting rod end to
prevent damaging the crankshaft journal.
19. Install the connecting rod cap and the bearings. Refer to Crankshaft Bearings and Connecting Rod
Bearings - Gauging Plastic in this section.
A102B088
20. Install the connecting rod bearing cap bolts.
Tighten
Tighten the connecting rod bearing cap bolts to
25 NSm (18 lb-ft). Using the angular torque gauge
KM-470-B, tighten one turn of 30 degrees plus one
turn of 15 degrees.
A102C151
DAEWOO T-100 BL3

21. Install the oil pump/pickup tube.
22. Install the oil pump/pickup tube bolts.
Tighten
Tighten the oil pump/pickup tube bolts to 10 NSm
(89 lb-in).
the exhaust manifold attached. Refer to Cylinder
A102B094
DAEWOO T-100 BL3

-
UNIT REPAIR
CYLINDER HEAD AND VALVE TRAIN
COMPONENTS
A102B049
Tools Required
MKM-571-B Gauge
KM-253 Valve Guide Reamer
KM-340-0 Cutter Set
KM-340-7 Guide Drift
KM-340-13 Cutter
KM-340-26 Cutter
KM-348 Valve Spring Compressor
KM-419 Distance Gauge
Disassembly Procedure
and the exhaust manifold attached. Refer to Cylinder
2. Remove the coolant temperature sensor.
3.
4.
5.
6.
7.
8.
9.

Remove the exhaust manifold nuts.
Remove the exhaust manifold.
Remove the exhaust manifold gasket.
Remove the exhaust manifold studs.
Remove the spark plugs.
A102B047
DAEWOO T-100 BL3

10.
11.
12.
13.
Remove the intake manifold retaining nuts.

Remove the intake manifold.
Remove the intake manifold gasket.
Remove the intake manifold studs.
A102B048
14. Remove the thermostat housing mounting bolts.

15. Remove the thermostat housing.
16. Remove the thermostat and thermostat gasket.
A102B050
17. Using the valve spring compressor KM-348, compress the valve springs.
18.
19.
20.
21.
22.
23.
A102B051
DAEWOO T-100 BL3
Remove the valve keepers.

Remove the valve spring cap.
Remove the valve springs.
Remove the valves.
Remove the valve stem oil seals.
Remove camshaft carrier alignment pins.

Cylinder Head Inspection
1. Clean the sealing surfaces.
2. Inspect the cylinder head gasket and the mating surfaces for leaks, corrosion, and blowby.
3. Inspect the cylinder head for cracks.
4. Inspect the length and the width of the cylinder head
using a feeler gauge and a straight edge.
5. Check the sealing surfaces for deformation and warpage. The cylinder head sealing surfaces must be flat
within .025 mm (.001 inch) maximum.
A102B052
6. Measure the height of the cylinder head from sealing

surface to sealing surface. The cylinder head height
should be 94.70 to 95.65 mm (3.728 to 3.766 inches).
If the cylinder head height is less than 94.70 mm
(3.728 inches), replace the cylinder head.
7. Inspect all threaded holes for damage.
8. Inspect the valve seats for excessive wear and
burned spots.
A102B053
Valve Inspection
1. Inspect valve stem tip wear.
2. Inspect the valve keeper grooves and oil seal grooves
for chips and wear.
3. Inspect the valves for burns or cracks.
4. Inspect the valve stem for burrs and scratches.
5. Inspect the valve stem. The valve stem must be
straight.
6. Inspect the valve face for grooving. If the groove is so
deep the refacing would result in a sharp edge, replace the valve.
A102B054
DAEWOO T-100 BL3

7. Inspect the valve spring. If the valve spring ends are
not parallel, replace the valve spring.
8. Measure the valve spring height. Refer to Engine
Specifications in this section. If the valve spring
height does not match the specifications, replace the
valve spring.
9. Inspect the valve spring seating surface of the valve
rotators for wear or gouges. Replace as required.
A102B023
Cleaning Procedure
1.
2.
3.
4.
Clean the cylinder head.

Clean the valve guides.
Clean all of the threaded holes.
Clean the valves of carbon, oil and varnish.
A102B055
Cylinder Head Overhaul

Valve Grind-in
1. Lubricate the valve stem using a fine-grained paste.
2. Lift the valve rhythmically from the seat with a commercially available valve grinding tool in order to distribute the paste.
A102B056
DAEWOO T-100 BL3

3. Check the contact pattern on the valve head and in
the cylinder head.
4. Clean the valves, the valve guides, and the cylinder
head.
A102B057
Valve Grind
1. Ensure that there are no crater line burns on the valve
cone.
2. The valve may be reground only two times. Do not
grind the valve stem end.
3. The angle at the valve face angle is 46 degrees.
A102B066
4. Check the valve stem projection using the distance

gauge KM-419.
A102B058
DAEWOO T-100 BL3

Valve Guide Ream
1. Measure the diameter of the valve guide using the
gauge MKM-571-B and a commercially available inside micrometer.
Important: Valve oversizes may already have been
fitted in production.
2. An oversize code is on the valve guide and the valve
stem end. The following table gives the correct size,
reamer, and production code for each service code.
Size
Production
Code
Service
Code
Normal
0.075
KM-253
K1
0.150
A102B059
Reamer
KM-254
K2
0.250
KM-255
3. Ream the valve guide from the upper side of the cylinder head to the next oversize. After reaming, cross
out the code and emboss the valve guide with the
new code.
Valve Seat Cut

1. Place the cylinder head on wooden blocks.
2. Cut the intake and the exhaust valve seats using the
guide drift KM-340-7 as follows:
D Valve seat: a 45-degree side using the cutter
KM-340-13.
D Upper correction angle: a 30-degree side using the
cutter KM-340-13.
D Lower correction angle: a 60-degree side using the
cutter KM-340-26.
A102B060
DAEWOO T-100 BL3

3. Clean the chippings from the cylinder head.
4. Inspect the dimension for the proper valve seat width.
D Intake: 1.3 to 1.5 mm (0.051 to 0.059 inch)
D Exhaust: 1.6 to 1.8 mm (0.063 to 0.071 inch)
5. Inspect the valve stem projection using the distance
gauge KM-419.
A102B058
6. If the dimension is exceeded, install new valves and

then check the valve stem projection again. Refer to
Valve Grind and Valve Grind-In in this section.
7. If the valve stem projection is still too large despite replacing the valves, replace the cylinder head.
A102B061
Assembly Procedure
1.
2.
3.
4.
5.
6.
Install the camshaft carrier alignment pins.

Install the valve stem oil seals.
Coat the valves with engine oil.
Install the valves.
Install the valve springs.
Using the valve spring compressor KM-348, compress the valve springs.
7. Install the valve keeper.
8. Install the valve spring cap.
A102B051
DAEWOO T-100 BL3

9. Install the thermostat and the gasket.
10. Install the thermostat housing.
11. Install the thermostat housing mounting bolts.
Tighten
Tighten the thermostat housing mounting bolts to
20 NSm (15 lb-ft).
A102B050
12.
13.
14.
15.
Install the intake manifold studs.

Install the intake manifold gasket.
Install the intake manifold.
Install the intake manifold retaining nuts.
Tighten
Tighten the intake manifold retaining nuts to 25 NSm
(18 lb-ft).
A102B048
16. Install the spark plugs.
Tighten
Tighten the spark plugs to 25 NSm (18 lb-ft).
17. Install the exhaust manifold studs.
20. Install the exhaust manifold nuts.
Tighten
Tighten the exhaust manifold nuts to 25 NSm (18 lb-ft).
A102B047
DAEWOO T-100 BL3

21. Install the exhaust manifold heat shield.
Tighten
15 NSm (11 lb-ft).
23. Install the coolant temperature sensor.
Tighten
Tighten the coolant temperature sensor to 20 NSm
(15 lb-ft).
A102B049
CRANKSHAFT
Tools Required
MKM-412 Engine Overhaul Stand
J-36792 or KM-635 Crankshaft Rear Oil Seal Installer
A102B095
1.
2.
3.
4.
5.
Remove the engine. Refer to Engine in this section.

Remove the flywheel bolts.
Remove the flywheel.
Remove the crankshaft rear oil seal.
Mount the engine assembly on the engine overhaul
stand MKM-412.
DAEWOO T-100 BL3

6.
7.
8.
9.
10.
11.
Remove the upper timing belt cover bolts.

Remove the upper timing belt cover.
Remove the power steering pump mounting bolts.
Remove the power steering pump.
Remove the lower timing belt cover bolts.
Remove the lower timing belt cover.
A102B096

bolts.
13. Rotate the coolant pump using timing belt adjuster
J-42492 to remove the tension from the timing belt.
A102B040

A102B111
DAEWOO T-100 BL3

19.
20.
21.
22.
23.
Remove the timing belt automatic tensioner bolt.

Remove the rear timing belt cover bolts.
Remove the rear timing belt cover.
Remove the crankshaft timing belt gear.
A102B093
24. Rotate the engine on the engine overhaul stand

MKM-412.
26. Remove the oil pan.
27. Remove the oil pickup tube bolts.
A102B064

A102B065
DAEWOO T-100 BL3

31. Mark the order of the rod bearing caps.
32. Remove the connecting rod cap bolts for all of the
pistons.
33. Remove the connecting rod bearing caps and the
lower connecting rod bearings.
34. Remove the upper connecting rod bearings.
A102B067
35.
36.
37.
38.
Mark the order of the crankshaft bearing caps.

Remove the crankshaft bearing cap bolts.
Remove the crankshaft bearing caps.
Remove the crankshaft bearings from the crankshaft bearing caps.
39. Remove the crankshaft.
40. Remove the crankshaft bearings from the engine
block.
41. Clean the parts, as necessary.
A102B068
Assembly Procedure
1. With crankshaft and bearings in place, plastic gauge
all bearing clearances. Refer to Crankshaft Bearings
and Connecting Rod Bearings - Gauging Plastic in
this section.
2. Inspect the crankshaft end play with the crankshaft
bearings installed.
3. Check for permissible crankshaft end play. Refer to
A102B070
DAEWOO T-100 BL3

4. With the crankshaft mounted on the front and the rear
crankshaft bearings, check the middle crankshaft
journal for permissible out-of-round (runout). Refer to
A102B071
5. Coat the crankshaft bearings with engine oil.

6. Apply a bead of adhesive sealing compound to the
grooves of the rear crankshaft bearing cap.
7. Install the crankshaft bearings in the engine block.
8. Install the crankshaft.
A102B069
9. Install the crankshaft bearings to the crankshaft

bearing caps.
10. Install the crankshaft bearing caps.
Notice: Do not reuse the old crankshaft bearing cap
bolts. Damage to the engine could result.
11. Install new crankshaft bearing cap bolts.
Tighten
Tighten the crankshaft bearing cap bolts to 50 NSm
(37 lb-ft). Using the angular torque gauge KM-470-B,
tighten the crankshaft bearing cap bolts another 45
degrees plus 15 degrees.
12. Install the upper connecting rod bearings to the connecting rods.
13. Install the lower connecting rod bearings to the connecting rod bearing caps
A102B091
DAEWOO T-100 BL3

14. Install the connecting rod bearing caps to the connecting rods.
Notice: Do not reuse the old connecting rod bearing cap
bolts. Damage to the engine could result.
15. Install new connecting rod bearing cap bolts.
Tighten
Tighten the connecting rod bearing cap bolts to
25 NSm (18 lb-ft). Using the angular torque gauge
KM-470-B, tighten the connecting rod bearing cap
bolts another 30 degrees plus 15 degrees.
A102C151
16. Install the oil pump.

17. Install the oil pump retaining bolts.
Tighten
A102B065

Tighten
(89 lb-in).
A102B064
DAEWOO T-100 BL3

21. Install the oil pan.
Important: Install the oil pan within 5 minutes after applying the liquid gasket to the oil pan.
Tighten
A102B043
23. Install the crankshaft timing belt gear.

Tighten
(89 lb-in).
Tighten
20 NSm (15 lb-ft).
A102B093

29. Install the camshaft gear bolt while holding the camshaft firmly in place.
Tighten
A102B111
DAEWOO T-100 BL3

31. Adjust the timing belt tension. Refer to Timing Belt
32. Install the valve cover gasket and the valve cover.
Tighten
Tighten
(89 lb-in).
A102B008
36. Install the power steering pump.

37. Install the power steering pump mounting bolts.
Tighten
25 NSm (18 lb-ft).
Tighten
J36972

(89 lb-in).
40. Install the engine lifting device.
41. Dismount the engine from the engine overhaul
stand MKM-412.
42. Install the crankshaft rear oil seal using installer
J-36972 or KM-635.
A102C152
43. Install the flywheel.

44. Install the flywheel bolts.
Tighten
Tighten the flywheel bolts to 35 NSm (25 lb-ft) using a
torque wrench. Use the angular torque gauge
KM-470-B to tighten the flywheel bolts another 30 degrees plus 15 degrees.
45. Install the engine. Refer to Engine in this section.
A102B095
DAEWOO T-100 BL3

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CRANKSHAFT BEARINGS AND

CONNECTING ROD BEARINGS
GAUGING PLASTIC
Tools Required
Inspection Procedure - Crankshaft
A102B070

2. Install the upper crankshaft bearings into the engine
block crankshaft journals.
3. Install the lower crankshaft bearings into the crankshaft bearing caps.
bearings installed.
7. With the crankshaft mounted on the front and the rear
journal for permissible out-of-round (runout). Refer to
A102B071
Important: Grease the crankshaft journals and lubricate

the crankshaft bearings slightly so that the plastic gauging thread does not tear when the crankshaft bearing
caps are removed.
8. Inspect all of the crankshaft bearing clearances using
a commercially available plastic gauging (ductile
plastic threads).
9. Cut the plastic gauging threads to the length of the
bearing width. Lay them axially between the crankshaft journals and the crankshaft bearings.
A102B072
DAEWOO T-100 BL3

11. Install the crankshaft bearing cap bolts.
Tighten
tighten the crankshaft bearing cap bolts another 45
degrees plus 15 degrees.
A102B091
12. Remove the crankshaft bearing caps.

13. Measure the width of the flattened plastic thread of
the plastic gauging using a ruler. (Plastic gauging is
available for different tolerance ranges.)
14. Inspect the bearing clearances for permissible tolerance ranges. Refer to Engine Specifications in this
section.
A102B073
Inspection Procedure - Connecting Rods

1. Coat the connecting rod bearings with engine oil.
Important: Grease the connecting rod journals and lubricate the connecting rod bearings slightly so that the
plastic gauging thread does not tear when the connecting rod bearing caps are removed.
2. Install the upper connecting rod bearings into the connecting rod journals.
3. Install the lower connecting rod bearings into the connecting rod bearing caps.
4. Inspect all of the connecting rod bearing clearances
using a commercially available plastic gauging (ductile plastic threads).
A102B072
DAEWOO T-100 BL3

bearing width. Lay them axially between the connecting rod journals and the connecting rod bearings.
6. Install the connecting rod bearing caps.
Tighten
Tighten the connecting rod bearing cap bolts to 25
NSm (18 lb-ft). Using the angular torque gauge
KM-470-B, tighten the crankshaft cap bolts another
30 degrees plus 15 degrees.
A102C151
8. Remove the connecting rod bearing caps.

10. Inspect the bearing clearance for permissible tolerance ranges. Refer to Engine Specifications in this
section.
A102B073
DAEWOO T-100 BL3
GENERAL DESCRIPTION
The cylinder head is made of an aluminum alloy. The
cylinder head uses crossflow intake and exhaust ports.
A spark plug is located in the center of each of the combustion chambers.
CRANKSHAFT
The crankshaft is supported by the five main bearings.
The number three bearing is the end thrust bearing. The
main bearings are lubricated from the oil holes which intersect the main oil gallery on the left side of the engine
block.
TIMING BELT
The timing belt coordinates the crankshaft and the camshaft and keeps them synchronized. The timing belt also
turns the coolant pump. The timing belt and the pulleys
are toothed so that there is no slippage between them.
There is a tension pulley that maintains the correct timing belt tension. The timing belt is made of a tough reinforced rubber similar to that used on the serpentine drive
belt. The timing belt requires no lubrication.
OIL PUMP
The oil pump draws engine oil from the oil pan and feeds
it under pressure to the various parts of the engine. An
oil strainer is mounted before the inlet of the oil pump to
remove impurities which could clog or damage the oil
pump or the other engine components. When the drive
gear rotates, the driven gear rotates. This causes the
space between the gears to constantly open and narrow, pulling oil in from the oil pan when the space opens
and pumping the oil out to the engine as it narrows.
At high engine speeds, the oil pump supplies a much
higher amount of oil than required for lubrication of the
engine. The oil pressure regulator prevents too much oil
from entering the engine lubrication passages. During
normal oil supply, a coil spring and a valve keep the bypass closed, directing all of the oil pumped to the engine.
When the amount of oil being pumped increases, the
pressure becomes high enough to overcome the force
of the spring. This opens the valve of the oil pressure
regulator, allowing the excess oil to flow through the
valve and drain back to the oil pan.
OIL PAN
The oil pan is mounted to the bottom of the cylinder
block. The oil pan houses the crankcase and is made of
pressed sheet metal.
DAEWOO T-100 BL3
Engine oil is pumped from the oil pan by the oil pump.
After the oil passes through the oil filter, the oil is fed
through two paths to lubricate the cylinder block and the
cylinder head. In one path, the oil is pumped through the
oil passages in the crankshaft to the connecting rods,
then to the pistons and the cylinders in the cylinder
block. The oil then drains back into the oil pan. In the
second path, the oil is pumped through the oil passages
to the camshaft. The oil passes through the internal passageways in the camshafts to lubricate the valve assemblies in the cylinder head before draining back into
the oil pan.
EXHAUST MANIFOLD
A single four-port, rear-takedown exhaust manifold is
used with this engine. The exhaust manifold is designed
to direct the escaping exhaust gases out of the combustion chambers with a minimum of backpressure.
INTAKE MANIFOLD
The intake manifold is made of aluminum. The intake
manifold is heated by the engine coolant. An air/fuel
mixture is transferred through the intake manifold to the
engine cylinders for combustion.
CAMSHAFT
The cast-iron camshaft is supported by the five bearing
surfaces in an aluminum camshaft carrier located on the
top of the cylinder head. The camshaft gear is power
driven by the crankshaft, using the timing belt.
EXHAUST GAS RECIRCULATION

VALVE
The exhaust gas recirculation (EGR) system is used to
lower oxides of nitrogen (NOX) emission levels caused
by high combustion temperatures. The main element of
the system is the EGR valve which is operated by vacuum.
The EGR valve feeds small amounts of exhaust gas into
the intake manifold to decrease the combustion temperature. The amount of exhaust gas recirculated is controlled by variations in vacuum and exhaust back
pressure. If too much exhaust gas enters combustion
will not take place. For this reason, very little exhaust
gas is allowed to pass through the valve, especially at
idle.
The EGR valve is usually open under the following conditions:
D Warm engine operation.
D Above idle speed.
SECTION 1C
DOHC ENGINE MECHANICAL

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TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Specifications . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1C-2
1C-2
1C-4
1C-6
Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . . 1C-6

Component Locator . . . . . . . . . . . . . . . . . . . . . . . . 1C-8
Upper End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-8
Lower End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-10
Maintenance and Repair . . . . . . . . . . . . . . . . . . . 1C-12
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . 1C-12
Valve Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-12
Cylinder Head and Gasket . . . . . . . . . . . . . . . . . 1C-14
Camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-25
Timing Belt Check and Adjust . . . . . . . . . . . . . . 1C-29
Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-33
Engine Oil Pressure Inspection Procedure . . . 1C-39
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-40
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-44
Engine Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-47
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-49
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . 1C-52
DAEWOO T-100 BL3
Camshaft Gears . . . . . . . . . . . . . . . . . . . . . . . . . 1C-55

Rear Timing Belt Cover . . . . . . . . . . . . . . . . . . . 1C-57
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-59
Pistons and Rods . . . . . . . . . . . . . . . . . . . . . . . . 1C-69
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-74
Cylinder Head and Valve Train
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-74
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-84
Crankshaft Bearings and Connecting Rod
Bearings - Gauging Plastic . . . . . . . . . . . . . . 1C-96
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-100
Cylinder Head and Gasket . . . . . . . . . . . . . . . . 1C-100
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-100
Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-100
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-100
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-100
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . 1C-100
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-100
Camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-100
Exhaust Gas Recirculation Valve . . . . . . . . . . 1C-100
1C - 2 DOHC ENGINE MECHANICAL

-
SPECIFICATIONS
ENGINE SPECIFICATIONS
Application
Description (1.6L DOHC)
General Data:
Engine Type
4 Cylinder (In-line)
Displacement
1 598 cm3 (97 51 in3)

(97.51
Bore Stroke
Compression Ratio
Firing Order
79.0 81.5
79 0 X 81 5 mm (3 11 in X 3 21 in )
(3.11 in. 3.21 in.)
9.5$ 0.02:1
1-3-4-2
Cylinder Bore:
Diameter
79.0 mm (3.11 in.)
0.0065 mm (0.00025 in.)
Taper (Maximum)
0.0065
0 0065 mm (0 00025 in )
(0.00025 in.)
Piston:
Diameter
78.970 mm (3.1090 in.)
Clearance to Bore
0.030 mm (0.0012 in.)
Piston Rings:
Ring, End Gap:
Top Compression
0.3 mm (0.019 in.)
2nd Compression
0.3 mm (0.019 in.)
Groove Clearance:
Top Impression
0.02 mm (0.0008 in.)
2nd Impression
0.02 mm (0.0008 in.)
Piston Pin:
Diameter
Pin Off-Set
18.00 mm (0.708 in.)

0.6X 0.8 mm (0.02X 0.03 in.)
Camshaft:
Lift Intake
8.75 mm (0.344 in.)
Lift Exhaust
8.75 mm (0.344 in.)
End Play
Journal OD:
No. 1
0.10X 0.25 mm (0.003X 0.009 in.)

30 mm (1.18 in.)
No. 2
27 mm (1.06 in.)
No. 3
27 mm (1.06 in.)
No. 4
27 mm (1.06 in.)
No. 5
27 mm (1.06 in.)
Crankshaft:
Main Journal:
Diameter (All)
54.982X 54.994 mm (2.164X 2.165 in.)
Taper (Maximum)
0.005 mm (0.0001 in.)
0.004 mm (0.0001 in.)
Main Bearing Clearance (All)
0.005 mm (0.0001 in.)
DAEWOO T-100 BL3
DOHC ENGINE MECHANICAL 1C - 3
ENGINE SPECIFICATIONS (Contd)

Application
Crankshaft End Play
Connecting Rod Journal:
Diameter (All)
Description (1.6L DOHC)

0.01 mm (0.003 in.)
42.971X 42.987 mm (1.691X 1.692 in.)
Taper (Maximum)
0.005 mm (0.0001 in.)
0.004 mm (0.0001 in.)
Rod Bearing Clearance (All)
0.019X 0.070 mm (0.0007X 0.0027 in.)
Rod Side Clearance
0.070X 0.242 mm (0.0027X 0.009 in.)
Valve System:
Valve Lash Compensators
Hydraulic
Face Angle (All)
46_
Seat Angle (All)
46_
Seat Runout (Maximum, All)
0.03 mm (0.019 in.)
Face Runout (Maximum, All)
0.03 mm (0.019 in.)
Seat Width:
Intake
1.17X 1.57 mm (0.046X 0.062 in.)
Exhaust
1.07X 1.47 mm (0.042X 0.058 in.)
Valve Guide Inside Diameter (All)

Valve Stem Diameter (All)
Valve Diameter (All):
Intake
Exhaust
Valve Spring Loads:
Valve Open
Valve Closed
Valve Spring Free Length
6.00X 6.02 mm (0.236X 0.237 in.)

6 mm (0.236 in.)
30.3" 0.12 mm (1.19" 0.0047 in.)
26.0" 0.14 mm (1.02" 0.0055 in.)
580" 26 N (428" 19 lbs) @ 23.0 mm (0.90 in.)
260" 13 N (192" 9 lbs) @ 32.0 mm (1.25 in.)
-
Cylinder Head:
Overall Height
138.18 mm (5.440 in.)
Minimum Height after machining
138.13 mm (5.438 in.)
Distortion
0.1 mm (0.002 in.)
Oil Pump:
Gap Between Oil Pump Body and Out Rotor
0.4X 0.484 mm (0.016X 0.019 in.)
Out Rotor Side Clearance
0.45X 0.100 mm (0.017X 0.003 in.)
Inner Rotor Side Clearance
0.035X 0.085 mm (0.001X 0.003 in.)
Relief Valve Spring Free Length
81 mm (3.188 in.)
Sealants and Adhesives:

Rear Main Bearing Cap
GE p/n RTV 159
Camshaft Carrier to Cylinder Head
HN 1581 (LoctiteR 515)
Oil Pan Bolts
Oil Pump Bolts
Oil Pan Pickup Tube Bolts
Oil Gallery Plug
Coolant Jacket Caps and Plugs (Freeze Plugs)
Exhaust Manifold Studs/Nuts

DAEWOO T-100 BL3
Anti-seize Compound (HMC Spec HN1325)

-

NSm
Lb-Ft
Lb-In
A/C Compressor Hose Assembly Retaining Bolt
Application
33
24
A/C Compressor Mounting Bolts
27
20
A/C Compressor Mounting Bracket Bolts
50
37
Air Filter Housing Bolts
12
106
Alternator Adjusting Bolt
20
15
Alternator Adjusting Bracket Retaining Bolt
20
15
Camshaft Cap Bolts
16
12
67.5
49
25
+30_+15_
18
+30_+15_
Coolant Pump Retaining Bolts
10
89
20
15
Crankshaft Bearing Cap Bolts
50
+45_+15_
37
+45_+15_
95
+30_+15_
70
+30_+15_
10
89
25
+60_+60_
+60_+10_
18
+60_+60_
+60_+10_
DIS Ignition Coil Mounting Bracket Bolts
10
89
DIS Ignition Coil Mounting Bolts
10
89
Engine Mount Bracket Retaining Bolts
60
44
Engine Mount Retaining Nuts
40
30
Engine-Mount-to-Engine-Mount-Bracket Retaining Bolts
60
44
Exhaust Flexible Pipe Bracket Bolts
40
30
Exhaust Flex Pipe-to-Catalytic Converter or Connecting

Pipe Retaining Nuts
30
22
Exhaust Flex Pipe-to-Exhaust Manifold Retaining Nuts
40
30
Exhaust Gas Recirculation Valve Adapter Bolts
25
18
Exhaust Manifold Heat Shield Bolts
15
11
Exhaust Manifold Retaining Nuts
25
18
Flexible Plate Bolts
60
44
Flexible Plate Inspection Cover Bolts
10
89
35
+30_+15_
25
+30_+15_
Flywheel Inspection Cover Bolts
12
106
Front Timing Belt Cover Bolts, Upper and Lower
10
89
25
18
Intake Manifold Retaining Nuts/Bolts
25
18
Intake Manifold Support Bracket Bolts, Upper
25
18
Camshaft Gear Bolt, Intake & Exhaust

Connecting Rod Cap Bolts
Crankshaft Position Sensor Retaining Bolt

Cylinder Head Bolts (Camshaft Support Housing &
Cylinder Head Mounting Bolts)
Flywheel Bolts
DAEWOO T-100 BL3
FASTENER TIGHTENING SPECIFICATIONS (Contd)

NSm
Lb-Ft
Lb-In
Oil Pan Retaining Bolts
Application
10
89
Oil Pressure Switch
40
30
Oil Pump Rear Cover Bolts
53
Oil Pump Retaining Bolts
10
89
Oil Pump Safety Relief Valve
30
22
Oil Pump/Pickup Tube Bolts
10
89
Power Steering Pump Mounting Bolts
25
18
Power Steering Pump Pulley Bolts
25
18
Rear Timing Belt Cover Bolts
10
89
Right Transaxle Brace Bolts
40
30
Spark Plug Cover Bolts
27
Spark Plugs
25
18
Support Bracket Bolt
10
89
Thermostat Housing Mounting Bolts
20
15
Throttle Cable Bracket Bolts
71
Timing Belt Automatic Tensioner Bolts
25
18
Timing Belt Idler Pulley Bolt
40
30
Transaxle Torque Converter Bolts
65
48
Transmission/Transaxle Bell Housing Bolts
75
55
Valve Cover Nuts
10
89
DAEWOO T-100 BL3

-
SPECIAL TOOLS
SPECIAL TOOLS TABLE
J-42492
Timing Belt Adjuster
A102B151
MKM-571-B
Gauge
A102B154
KM-340-0
Cutter Set
Includes: KM-340-7
Includes: KM-340-13
Includes: KM-340-26
KM-470-B
Angular Torque Gauge
A102B161
A102B156
J-28467-B
Engine Assembly
Support Fixture
A102B152
KM-348
Valve Spring
Compressor
A102B157
KM-427
Piston Pin Service Set
A102B153
KM-653
Adapter
A102C153
DAEWOO T-100 BL3
KM-635
Crankshaft Rear Oil
Seal Installer
KM-805
Valve Guide Reamer
A102C154
A102B160
J-36972
Crankshaft Rear Oil
Seal Installer
KM-412
Engine Overhaul Stand
A102B159
A102C155
KM-498-B
Pressure Gauge
A202B005
DAEWOO T-100 BL3
KM-135
Adapter
B102C044

-
COMPONENT LOCATOR
UPPER END
A102C100
DAEWOO T-100 BL3

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
Spark Plug Cover

Oil Cap
Oil Cap Seal
Valve Cover
Valve Cover Nut
Valve Cover Washer
Valve Cover Gasket
Seal
Hydraulic Valve Lash Adjuster
Valve Key
Valve Spring Retainer
Valve Spring
Valve Stem Oil Seal
Valve Cover Stud
Freeze Plug
Exhaust Manifold
Nut
Exhaust Manifold Heat Shield
Oxygen Sensor
Bolt
Bolt
Thermostat Housing
Thermostat Housing Seal
Thermostat
Thermostat Adapter
Thermostat Adapter Seal
Nut
DAEWOO T-100 BL3
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
Washer
Cylinder Head Gasket
Exhaust Valve
Intake Valve
Camshaft Seal
Washer
Camshaft Gear Bolt
Camshaft
Plug
Stud
Engine Coolant Temperature Sensor
Bolt
Front Camshaft Cap
Plug
Valve Guide
Intermediate Camshaft Cap
Washer
Head Bolt
Exhaust Gas Recirculation Pipe
Intake Manifold
Plenum Gasket
Throttle Body
Plenum
Intake Manifold Gasket
Exhaust Manifold Gasket
Cylinder Head

-
LOWER END
A202C006
DAEWOO T-100 BL3

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
Piston Ring Set

Piston
Piston Pin
Connecting Rod
Connecting Rod Bearing Set
Connecting Rod Bolt
Oil Level Gauge Stick
Gauge Stick Tube
Connecting Piece
Oil Filter
Hose Clamp
Engine Ventilation Hose
Engine Ventilation Pipe
Bolt
Oil Separator Gasket
Washer
Crankshaft Pulley
Crankshaft Gear
Rear Timing Belt Cover
Bolt
Coolant Pump
Oil Pump
Engine Block Seal Ring
Oil Pump Body Gasket
Engine Block
Pressure Relief Valve Plunger
Spring
Oil Pump Seal Ring
Bolt Plug
Crankshaft Bearing Set
Crankshaft
Shaft Seal Ring
Flywheel (Manual Transmission)
Bolt (Manual Transmission)
Bolt
Bracket
Bolt
DAEWOO T-100 BL3
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
Crankshaft Position Sensor

Flexible Plate (Automatic Transmission)
Bolt (Automatic Transmission)
Crankshaft Main Bearing Cap
Bolt
Bolt
Knock Sensor
Oil Pan
Threaded Ring
Bolt
Bolt
Bracket
Oil Pickup Tube
Bolt
Bolt
Timing Belt
Cover Seal
Cover
Bolt
Clamp
Bolt
Washer
Cover Bracket
Idler Pulley
Rear Cover Bolt
Bolt
Auto Tensioner
Seal
Bolt
Seal
Gear
Gear
Cover
Bolt
Plug
Oil Pressure Sensor
Intake Manifold Support Bracket
EGR Solenoid

-

ON-VEHICLE SERVICE
VALVE COVER
Drive Similar)
Removal Procedure
1.
2.
3.
4.

Remove the spark plug cover bolts and cover.
Disconnect the breather tube from the valve cover.
Disconnect the crankcase ventilation tube from the
valve cover.
5.
6.
7.
8.
Disconnect all of the necessary vacuum lines.

Remove the valve cover nuts.
Remove the valve cover washers.
A102C006
A102C015

10. Remove the valve cover gasket from the valve cover.
A102C160
DAEWOO T-100 BL3

1. Apply a small amount of gasket sealant to the corners of the front camshaft caps and the top of the
rear valve cover to cylinder head seal.
2. Install the new valve cover gasket to the valve cover.
A102C001
4. Install the valve cover washers.

5. Install the valve cover nuts.
Tighten
Tighten the valve cover nuts to 10 NSm (89 lb-in).
A102C015

7. Install the spark plug cover.
8. Install the spark plug cover bolts.
Tighten
Tighten the spark plug cover bolts to 3 NSm (27 lb-in).
9. Connect all of the necessary vacuum lines.
10. Connect the crankcase ventilation tube to the valve
cover.
A102C006
DAEWOO T-100 BL3

-

Drive Similar)
Tools Required
Removal Procedure
A102B012

2. Start the engine. After it stalls, crank the engine after it stalls for 10 seconds to rid the fuel system of
fuel pressure.
4. Disconnect the ECM ground terminal from the intake manifold.
gine Cooling.
connector.
A102C002
9.
10.
11.
12.
Disconnect the DIS ignition coil connector.

Disconnect the oxygen sensor connector.
Disconnect the fuel injector harness connectors.
Disconnect the idle air control valve connector.

connector.
A102C016
DAEWOO T-100 BL3

16. Remove the air filter housing bolts.
17. Remove the air filter housing.
Tires and Wheels.
19. Remove the right front splash shield.
A102C161
20. Disconnect the upper radiator hose at the thermostat housing.

22. Remove the alternator adjusting bolt and the alternator drive belt.
equipped.
Important: Push the engine assembly toward the battery
to remove the power steering pump pulley.
24. Remove the power steering pump pulley, if equipped.
A102B006
27.
28.
29.
30.
Remove the upper front timing belt cover bolts.

Remove the upper front timing belt cover.
Remove the lower front timing belt cover bolts.
Remove the lower front timing belt cover.
32. Install the engine-mount-to-engine-mount-bracket
retaining bolts and tighten the bolts to secure the engine if the power steering was removed.
Tighten
Tighten the engine-mount-to-engine-mount-bracket
33. Align the camshaft gear timing marks.
A102C003
DAEWOO T-100 BL3

35. Rotate the coolant pump counterclockwise using the
timing belt adjuster J-42492 to relieve the timing belt
tension.
section.
A102C004

valve cover.
38. Remove the spark plug cover bolts.
39. Remove the spark plug cover.
40. Disconnect the ignition wires from the spark plugs.
41. Remove the valve cover nuts.
42. Remove the valve cover washers.
A102C015

nicks or damage to the camshafts.
44. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt.
45. Remove the intake camshaft gear.
46. While holding the exhaust camshaft firmly in place,
remove the exhaust camshaft gear bolt.
47. Remove the exhaust camshaft gear.
A102C017
DAEWOO T-100 BL3

48. Remove the timing belt automatic tensioner bolts.
A102C018
50. Remove the timing belt idler pulley bolt.

51. Remove the timing belt idler pulley.
A102C019

A102C005
DAEWOO T-100 BL3

54. Remove the exhaust flex pipe retaining nuts at the
exhaust manifold studs and the bolts at the bracket.
55. Disconnect all of the necessary vacuum hoses.
A202B004

regulator.
58. Remove the alternator adjusting bracket retaining
bolt and the bracket.
59. Disconnect the heater inlet hose at the cylinder
head.
throttle body.
A102C020
61. Remove the upper intake manifold support bracket

bolts.
A102C021
DAEWOO T-100 BL3

62. Disconnect the throttle cable at the throttle body and
63. Loosen all of the cylinder head bolts gradually and in
the sequence shown.
64. Remove the cylinder head bolts.
and the exhaust manifold attached.
Notice: Prevent any engine oil or coolant from entering
the cylinders when removing the cylinder heads.
66. Remove the cylinder head gasket.
A102C022
Cleaning Procedure
1. Clean the gasket surfaces of the cylinder head and
the engine block.
2. Make sure the gasket surfaces of the cylinder head
and the engine block are free of nicks and heavy
scratches.
3. Clean the cylinder head bolts.
4. Inspect the cylinder head for warpage. Refer to Cylinder HeadandValve Train Componentsin this section.
A102C023
1. Install the cylinder head gasket.

the exhaust manifold attached.
3. Install the cylinder head bolts.
4. Tighten the cylinder head bolts gradually and in the
sequence shown.
Tighten
Tighten the cylinder head bolts to 25 NSm (18 lb-ft).
Adjust the bolts to 60 degrees +60 degrees +60 degrees + 10 degrees using the angular torque gauge
KM-470-B.
A102C156
DAEWOO T-100 BL3

5. Connect the throttle cable at the throttle body and
6. Install the intake manifold support bracket upper
bolts to the intake manifold.
Tighten
Tighten the intake manifold support bracket upper
bolts to the intake manifold to 25 NSm (18 lb-ft).
7. Connect the surge tank coolant hose at the throttle
body.
8. Connect the heater inlet hose to the cylinder head.
A102C021
9. Install the alternator adjusting bracket with the bolt.
Tighten
Tighten the alternator adjusting bracket retaining bolt
10. Connect the fuel feed line at the fuel rail.
11. Connect the fuel return line at the fuel rail.
12. Connect all of the necessary vacuum hoses.
A102C020
13. Install the exhaust flex pipe retaining nuts at the exhaust manifold flange and the bolts at the bracket.
Tighten
Tighten the exhaust flex pipe retaining nuts and
bracket bolts to 40 NSm (30 lb-ft).
Tighten
(89 lb-in).
A102C005
DAEWOO T-100 BL3

17. Install the timing belt automatic tensioner bolts.
Tighten
Tighten the timing belt automatic tensioner bolts to
25 NSm (18 lb-ft).
18. Install the timing belt idler pulley.
19. Install the timing belt idler pulley bolt.
Tighten
Tighten the timing belt idler pulley bolt to 40 NSm
(30 lb-ft).
A102C018

20. Install the intake camshaft gear.
21. While holding the intake camshaft firmly in place,
install the intake camshaft gear bolt.
Tighten
Tighten the intake camshaft gear bolt to 67.5 NSm
(49 lb-ft).
A102C024
22. Install the exhaust camshaft gear.

install the exhaust camshaft gear bolt.
Tighten
Tighten the exhaust camshaft gear bolt to 67.5 NSm
(49 lb-ft).
A102C017
DAEWOO T-100 BL3

24. Apply a small amount of gasket sealant to the
corners of the front camshaft caps, and the top of
the rear valve cover to cylinder head seal.
Tighten
A102C162

Tighten
cover.
32. Align the timing marks on the camshaft gears.
A102C003

A102C008
DAEWOO T-100 BL3

35. Rotate the coolant pump clockwise using the timing
belt adjuster J-42492 to apply tension to the timing
belt.
Tighten
(89 lb-in).
36. Check and adjust the timing belt tension. Refer to
Timing Belt Check and Adjust in this section.
A102C004

38. Install the engine-mount-bracket-to-engine-mount
retaining bolts if the power steering pump was
installed.
Tighten
Tighten the engine-mount-bracket-to-engine-mount
39. Install the upper and lower front timing belt cover.
40. Install the upper and lower front timing belt cover
bolts.
Tighten
A102C007
Tighten the upper and lower front timing belt cover

bolts to 10 NSm (89 lb-in).
Tighten
gauge KM-470-B, tighten the crankshaft pulley bolt to
30 degrees +15 degrees.
DAEWOO T-100 BL3

equipped.
Tighten
25 NSm (18 lb-ft).
46. Install the alternator adjusting bolt.
Tighten
A102B006
Tighten the alternator adjusting bolt to 20 NSm (15 lbft).

housing.
49. Install the right front splash shield.
Tires and Wheels.
Tighten
A102C057

connector.
A102C016
DAEWOO T-100 BL3

60.
61.
62.
63.
Connect the DIS ignition coil connector.

Connect the fuel injector harness connectors.
Connect the ECM ground terminal at the intake
manifold.
65. Connect the negative battery ground cable.
1D, Engine Cooling.
A102B012
CAMSHAFTS
Drive Similar)
Removal Procedure
section.
2. Disconnect the air breather tube at the valve cover.
valve cover.
A102C006
6.
7.
8.
9.
A102C015
DAEWOO T-100 BL3

Remove the valve cover nuts.
Remove the valve cover washers.
Remove the valve cover and the valve cover gasket.

A102C017
14. Remove the camshaft cap bolts gradually and in the

sequence shown for each camshaft cap.
A102C026
15. Remove the intake camshaft caps. Maintain the

correct positions for installation.
16. Remove the intake camshaft.
17. Remove the exhaust camshaft caps. Maintain the
18. Remove the exhaust camshaft.
A102C025
DAEWOO T-100 BL3

1. Lubricate the camshaft journals and the camshaft
caps with engine oil.
2. Install the intake camshaft.
3. Install the intake camshaft caps in their original
positions.
4. Install the intake camshaft cap bolts.
5. Install the exhaust camshaft.
6. Install the exhaust camshaft caps in their original
positions.
7. Install the exhaust camshaft cap bolts.
A102C025
8. Tighten the camshaft cap bolts gradually and in the

Tighten
Tighten the camshaft cap bolts to 16 NSm (12 lb-ft).
A102C026
9. Measure the intake camshaft end play and the exhaust camshaft end play. Refer to Engine Specifications in this section.
Tighten
(49 lb-ft).
A102C024
DAEWOO T-100 BL3

Tighten
(49 lb-ft).
A102C017
Tighten
A102C015

Tighten
20. Connect the air breather tube to the valve cover.
cover.
section.
A102C006
DAEWOO T-100 BL3
TIMING BELT CHECK AND ADJUST

Drive Similar)
Tools Required
Adjustment Procedure
connector.
3. Remove the air intake tube from the throttle body.
4. Remove the breather tube from the valve cover.
A102C002

Tires and Wheels.
A102C161

equipped.
Important: Push the engine assembly toward the
battery to remove the power steering pump pulley.
12. Remove the power steering pump pulley,
equipped.
A102B006
DAEWOO T-100 BL3
if

15.
16.
17.
18.
19.

Remove the power steering pump mounting bolts, if
equipped.
A102C007

A102C008
23. Align the camshaft gear timing marks.
A102C003
DAEWOO T-100 BL3

belt adjuster J-42492.
A102C004
26. Rotate the coolant pump clockwise until the adjust

arm pointer of the timing belt automatic tensioner
is aligned to the notch in the timing belt automatic
tensioner bracket.
A102C009

the crankshaft pulley.
A102C027
DAEWOO T-100 BL3

coolant pump until the adjust arm pointer of the
timing belt automatic tensioner is aligned with the
pointer on the timing belt automatic tensioner bracket.
A102C010
Tighten
(89 lb-in).
equipped.
Tighten
25 NSm (18 lb-ft).
bolts.
Tighten
A102C007
Tighten the upper and lower front timing belt cover bolts
Tighten
equipped.
Tighten
Tighten the power steering pump pulley bolts to 25 NSm
(18 lb-ft).
A102B006
DAEWOO T-100 BL3

Tires and Wheels.
Tighten
A102C161

A102C002
TIMING BELT
Drive Similar)
Tools Required
Removal Procedure
connector.
A102C057
DAEWOO T-100 BL3

Tires and Wheels.
A102C161

equipped.
equipped.
A102B006
15.
16.
17.
18.

19. Remove the power steering pump mounting bolts, if

equipped.
A102C007
DAEWOO T-100 BL3

21. Using the crankshaft pulley bolt, rotate the crankshaft clockwise until the timing mark on the crankshaft gear is aligned with the notch at the bottom of
the rear timing belt cover.
A102C008

coolant pump counterclockwise to release the tension on the timing belt.
A102C004
Important: Remove the timing belt behind the power

steering pump.
A102C012
DAEWOO T-100 BL3

1. Align the timing mark on the crankshaft gear to the
notch on the bottom of the rear timing belt cover.
A102C008
2. Align the timing marks on the camshaft gears.
A102C163
Important: Insert the timing belt behind the power

steering pump.
A102C003
DAEWOO T-100 BL3

belt adjuster J-42492.
A102C004
5. Rotate the coolant pump clockwise until the adjust

arm pointer of the timing belt automatic tensioner is
aligned to the notch in the timing belt automatic
tensioner bracket.
A102C009

the pointer on the timing belt automatic tensioner
bracket.
A102C010
DAEWOO T-100 BL3

Tighten
(89 lb-in).
A102C027

equipped.
Tighten
Tighten the power steering mounting bolts to 25 NSm
(18 lb-ft).
bolts.
Tighten
Tighten the upper and lower front timing belt cover bolts
A102C007

Tighten
A102B018
DAEWOO T-100 BL3

equipped.
Tighten
25 NSm (18 lb-ft).
Tires and Wheels.
A102B006

Tighten
Tighten the air filter housing bolts to 12 NSm (106 lb-in).
A102C057
ENGINE OIL PRESSURE INSPECTION

PROCEDURE
Tools Required
KM-498-B Pressure Gauge
KM-135 Adapter
1. Remove the front, right-hand wheel well splash
shield.
A102B019
DAEWOO T-100 BL3

3. Install the adapter KM-135 in place of the oil pressure switch.
4. Connect the pressure gauge KM-498-B to the
adapter.
5. Start the engine and check the oil pressure at idle
speed and engine temperature of 80_C (176_F).
The minimum oil pressure should be 30 kPa
(8.88 psi).
6. Turn the engine OFF and remove the oil pressure
gauge and adapter.
A202B003
7. Install the oil pressure switch.
Tighten
Tighten the oil pressure switch to 40 NSm (30 lb-ft).
9. Install the lower front, right-hand wheel well splash
shield.
10. Check the oil level and fill to the full mark.
A102B019
OIL PUMP
Removal Procedure
2. Remove the power steering pump, if equipped. Refer
section.
4. Remove the rear timing belt cover. Refer to Rear
A102B019
DAEWOO T-100 BL3

6. Remove the crankshaft position sensor bolt.
9. Remove the oil pump pickup tube and the support
bracket bolts.
A102B064

12. Carefully separate the oil pump and the gasket from
the engine block and the oil pan.
A102B065
1. Clean the oil pump and the engine block gasket
mating surfaces.
2. Remove the safety relief valve bolt.
3. Remove the safety relief valve and the spring.
4. Remove the oil pump-to-crankshaft seal.
A202B002
DAEWOO T-100 BL3

5. Remove the oil pump rear cover bolts.
6. Remove the rear cover.
A202B001
7. Clean the oil pump housing and all of the parts of the
oil pump housing.
8. Inspect all of the parts for signs of wear. Refer to
9. Coat all of the oil pump parts with clean engine oil
and reinstall them.
Notice: Pack the oil pump gear cavity with petroleum
jelly to ensure an oil pump prime, or engine damage
could result.
10. Apply LoctiteR 242 to the rear cover bolts and install
the rear oil pump cover with the bolts.
Tighten
Tighten the rear cover bolts to 6 NSm (53 lb-in).
11. Install the safety relief valve, the spring, the washer,
and the bolt.
A202B001
Tighten
Tighten the safety relief valve bolt to 30 NSm (22 lb-ft).
DAEWOO T-100 BL3

1. Apply Loctite[ 242 to the oil pump bolts and room

temperature vulcanizing (RTV) (sealer) sealant to the
new oil pump gasket.
2. Install the gasket to the oil pump and install the oil
pump to the engine block with the retaining bolts.
Tighten
A102B065
3. Install a new oil pump-to-crankshaft seal. Coat the lip

of the seal with a thin coat of grease.
A202B002
4. Coat the threads of the oil pump pickup tube and

support bracket bolts with LoctiteR 242.
5. Install the oil pump pickup tube and bolts.
Tighten
Tighten the oil pump pickup tube and the support
bracket bolts to 10 NSm (89 lb-in).
A102B064
DAEWOO T-100 BL3

7. Install the crankshaft position sensor and the bolt.
Tighten
9. Install the rear timing belt cover. Refer to Rear
11. Install the timing belt. Refer to Timing Belt In this
section.
A102B019
OIL PAN
Removal Procedure
Tires and Wheels.
4. Drain the engine oil from the engine crankcase.
exhaust manifold and the bolts at the bracket.
catalytic converter or the connecting pipe.
A202B004
8. Remove the flywheel or flexible plate inspection cover

bolts.
9. Remove the flywheel or flexible plate inspection cover.
A102B021
DAEWOO T-100 BL3

11. Remove the oil pan from the engine block.
12. Remove the oil pan gasket from the oil pan.
A102B043
Cleaning Procedure
1.
2.
3.
4.
Clean the oil pan sealing surface.

Clean the engine block sealing surface.
Clean the oil pan retaining bolts.
Clean the oil pan attaching bolt holes in the engine
block.
A102B044
2. Install the oil pan to the engine block.
Tighten
A102B043
DAEWOO T-100 BL3

bolts.
Tighten
A102B021

7. Install the exhaust flex pipe retaining nuts to the exhaust manifold and the exhaust pipe bracket bolts.
Tighten
Tighten the exhaust flex pipe retaining nuts to the exhaust manifold and the exhaust pipe bracket bolts to
40 NSm (30 lb-ft).
8. Install the exhaust flex pipe retaining nuts to the
catalytic converter or the connecting pipe.
Tighten
Tighten the exhaust flex pipe retaining nuts to the
catalytic converter or the connecting pipe to 30 NSm
(22 lb-ft).
A202B004

Tires and Wheels.
A102C034
DAEWOO T-100 BL3
ENGINE MOUNT
Tools Required
J-28467-B Engine Assembly Lift Support
Removal Procedure
1.
2.
3.
4.

Remove the upper radiator cover.
Remove the right front splash shield.
Support the engine assembly using the engine assembly lift support J-28467-B.
A102C150
5. Remove the engine mount bracket retaining bolts.
A102B020
6. Remove the engine mount retaining nuts.

7. Lower the engine.
8. Remove the engine mount.
A102C172
DAEWOO T-100 BL3

1. Install the engine mount.
2. Raise the engine.
3. Install the engine mount retaining nuts.
Tighten
Tighten the engine mount retaining nuts to 40 NSm
(30 lb-ft).
A102C172
4. Install the engine mount bracket retaining bolts.
Tighten
60 NSm (44 lb-ft).
A102B020
5.
6.
7.
8.
Remove engine assembly lift support J-28467-B.

Install the right front splash shield.
Install the upper radiator cover.
Connect the negative battery cable.
A102C150
DAEWOO T-100 BL3
INTAKE MANIFOLD
Removal Procedure
4. Disconnect the ECM ground terminal from the intake manifold.
gine Cooling.
A102B012

connector.
A102C002

connector.
12. Disconnect the heater inlet hose from the cylinder
head.
throttle body.
A102C016
DAEWOO T-100 BL3

14. Disconnect all of the necessary vacuum hoses, including the vacuum hose at the fuel pressure
regulator and the brake booster vacuum hose at
and the intake manifold.
16. Remove the throttle cable bracket bolts from the intake manifold.
17. Remove the throttle cable bracket.
A102C032
18. Remove the fuel injector rail and fuel injectors as an

assembly. Refer to Section 1F, Engine Controls.
19. Remove the alternator. Refer to Section 1E, Engine
Electrical.
20. Remove the intake manifold support bracket bolts.
21. Remove the intake manifold support bracket.
A102C021
22. Remove the intake manifold retaining bolts/nuts in

the sequence shown.
25. Clean the sealing surfaces of the intake manifold
A102C030
DAEWOO T-100 BL3

1. Install the intake manifold gasket.
2. Install the intake manifold.
3. Install the intake manifold retaining bolts/nuts in the
sequence shown.
Tighten
Tighten the intake manifold retaining bolts to 25 NSm
(18 lb-ft).
A102C031
4. Install the intake manifold support bracket.

5. Install the intake manifold support bracket upper
bolts to the intake manifold.
Tighten
Tighten the intake manifold support bracket bolts to
25 NSm (18 lb-ft).
6. Install the intake manifold support bracket lower bolt
to the engine block.
Tighten
Tighten the intake manifold support bracket lower bolt
to the engine block to 40 NSm (30 lb-ft).
7. Install the alternator. Refer to Section 1E, Engine
Electrical.
A102C021
8. Install the fuel rail and fuel injectors as an assembly.

Refer to Section 1F, Engine Controls.
9. Install the throttle cable bracket.
10. Install the throttle cable bracket bolts.
Tighten
Tighten the throttle cable bracket bolts to 8 NSm
(71 lb-in).
11. Connect the throttle cable to the intake manifold and
the throttle body.
12. Connect all of the necessary vacuum lines that were
previously disconnected.
A102C032
DAEWOO T-100 BL3

body.
connector.
A102C016

21. Connect the ECM ground terminal to the intake
manifold.
1D, Engine Cooling.
A102C002
EXHAUST MANIFOLD
Removal Procedure
1.
2.
3.
4.

A102C035
DAEWOO T-100 BL3

exhaust manifold studs.
A202B004
6. Remove the exhaust manifold retaining nuts in the

sequence shown.
9. Clean the sealing surfaces of the exhaust manifold
A102C036
3. Install the exhaust manifold retaining nuts and tighten
in the sequence shown.
Tighten
Tighten the exhaust manifold retaining nuts 25 NSm
(18 lb-ft).
A102C037
DAEWOO T-100 BL3

4. Install the exhaust flex pipe retaining nuts to the exhaust manifold studs.
Tighten
Tighten the exhaust flex pipe retaining nuts to 40 NSm
(30 lb-ft).
A202B004

Tighten
15 NSm (11 lb-ft).
A102C035
7. Connect the oxygen sensor connector.

A102C034
DAEWOO T-100 BL3
CAMSHAFT GEARS
Drive Similar)
Removal Procedure
section.
6. Disconnect the crankcase ventilation tubes from the
valve cover.
A102C006

A102C015

A102C017
DAEWOO T-100 BL3

Tighten
(49 lb-ft).
A102C024

Tighten
(49 lb-ft).
A102C017

corners of the front camshaft caps and the top of
Tighten
A102C015
DAEWOO T-100 BL3

9. Connect the crankcase ventilation tubes to the valve
cover.
Tighten
section.
A102C006
REAR TIMING BELT COVER

Removal Procedure
1. Remove the timing belt and the timing belt cover. Refer to Timing Belt in this section.
2. Remove the camshaft gears. Refer to Camshaft
Gears in this section.
3. Remove the crankshaft gear.
4. Remove the timing belt automatic tensioner bolts.
A102C018
6. Remove the timing belt idler pulley bolt.

7. Remove the timing belt idler pulley.
A102C019
DAEWOO T-100 BL3

A102C005
Tighten
(89 lb-in).
A102C005

Tighten
(30 lb-ft).
A102C019
DAEWOO T-100 BL3

Tighten
25 NSm (18 lb-ft).
7. Install the crankshaft gear.
8. Install the camshaft gears. Refer to Camshaft
Gears in this section.
9. Install the timing belt and timing belt cover. Refer to
Timing Belt in this section.
A102C018
ENGINE
Tools Required
Removal Procedure
Important: On vehicles equipped with manual transaxle, the manual transaxle must be removed before
the engine is removed. Refer to Section 5B, Manual
Transaxle.
3. Remove the hood. Refer to Section 9R, Body Front
End.
4. Drain the engine oil.
A102B012

6. Disconnect and separate the positive battery cable.
7. Disconnect the negative battery cable from the vehicle frame.
A102B013
DAEWOO T-100 BL3

8. Discharge the air conditioning system, if equipped.
Refer to Section 7B, Manual Control Heating,
Ventilation, and Air Conditioning System.
connector.
10. Remove the air intake tube from the throttle body
and air filter housing.
11. Disconnect the breather tubes from the valve cover.
A102C002

Tires and Wheels.
16. Remove the power steering pump pulley bolts.
17. Remove the power steering pump pulley.
A102B006

gine Cooling.
19. Remove the cooling system radiator and the engine
21. Disconnect the power steering return hose from the
power steering pump, if equipped. Refer to Section
6A, Power Steering System.
22. Disconnect the power steering pressure hose from
the power steering pump, if equipped. Refer to
Section 6A, Power Steering System.
23. Disconnect the electrical connector at the DIS
ignition coil and the ECM ground terminal at the intake manifold and at the starter motor.
A102C164
DAEWOO T-100 BL3

24.
25.
26.
27.
28.

Disconnect the fuel injector harness connectors.
Disconnect the idle air control valve connector.
Disconnect the throttle position sensor connector.
Disconnect the engine coolant temperature sensor
connector.
30. Disconnect the alternator voltage regulator connector.
A102C016
31. Disconnect all of the necessary vacuum lines including the brake booster vacuum hose.
regulator.
A102C020

and the intake manifold bracket.
throttle body.
36. Disconnect the heater outlet hose at the coolant
pipe.
37. Disconnect the heater inlet hose from the cylinder
head.
38. Disconnect the surge tank coolant hose from the
coolant pipe.
39. Disconnect the lower radiator hose from the coolant
pipe.
A102C014
DAEWOO T-100 BL3

40. Disconnect the starter solenoid S terminal wire.
41. Remove the A/C compressor hose assembly retaining bolt.
42. Disconnect the A/C compressor hose assembly
from the compressor.
43. Disconnect the electrical connector at the A/C
compressor coil.
44. Remove the A/C compressor mounting bolts.
45. Remove the A/C compressor.
46. Remove the A/C compressor mounting bracket
bolts from the engine block.
47. Remove the A/C compressor mounting bracket.
A102B025

the exhaust manifold studs and the bolts at the
bracket.
the catalytic converter or the connecting pipe.
A202B004

53. Disconnect the vacuum lines at the charcoal canister purge and exhaust gas recirculation (EGR)
solenoid.
54. Disconnect the electrical connector at the charcoal
canister purge and EGR solenoid.
55. Disconnect the electrical connector at the oil pressure switch.
56. Disconnect the crankshaft position sensor and the
knock sensor connectors.
57. Remove the crankshaft position sensor retaining bolt.
A102B019
DAEWOO T-100 BL3

59. Remove the right transaxle brace bolts from the
transmission.
60. Remove the flywheel or flexible plate inspection
cover bolts.
61. Remove the flywheel or flexible plate inspection
cover.
A102B021
62. Remove the transaxle torque converter bolts, if automatic transaxle equipped.
63. Remove the transmission/transaxle bell housing bolts.
64. Support the transmission with a floor jack.
A102B022
66. Disconnect the right engine mount bracket from the

engine mount by removing the retaining bolts.
67. Remove the right engine mount bracket from the engine block.
68. Separate the engine block from the transmission.
69. Remove the engine.
A102B020
DAEWOO T-100 BL3

1. Install the engine into the engine compartment.
2. Align the engine alignment pins to the transmission.
3. Install the transmission/transaxle bell housing bolts.
Tighten
Tighten the transmission/transaxle bell housing bolts
A102C165
4. Install the right engine mount bracket to the engine

block.
5. Install the right engine mount bracket retaining bolts.
Tighten
Tighten the right engine mount bracket retaining bolts
6. Connect the right engine mount bracket to the engine
mount by installing the two retaining bolts.
Tighten
Tighten the right engine mount-to-engine mount
bracket retaining bolts to 60 NSm (44 lb-ft).
A102B020
7. Remove the floor jack used for support of the transmission.

8. Remove the engine lifting device.
9. Install the transaxle torque converter bolts, if automatic transaxle equipped.
Tighten
Tighten the transaxle torque converter bolts to 65 NSm
(48 lb-ft).
A102B022
DAEWOO T-100 BL3

bolts.
Tighten
12. Install the right transaxle brace bolts to the transmission.
Tighten
Tighten the right transaxle brace bolts to 40 NSm
(30 lb-ft).
A102C166
13. Connect the vacuum lines at the charcoal canister

14. Connect the electrical connector charcoal canister
Tighten
A102B018
18. Install the crankshaft position sensor and the crankshaft position sensor retaining bolt.
Tighten
19. Connect the crankshaft position sensor and the
knock sensor connectors.
21. Install the exhaust flex pipe retaining nuts to the exhaust manifold studs and the bolts at the bracket.
Tighten
Tighten the exhaust flex pipe retaining nuts and the
bolts at the bracket to 40 NSm (30 lb-ft).
A202B004
DAEWOO T-100 BL3

22. Install the exhaust flex pipe retaining nuts to the
catalytic converter.
Tighten
Tighten the exhaust flex pipe retaining nuts to the
catalytic converter on the connecting pipe or the connecting pipe to 30 NSm (22 lb-ft).
23. Connect the power steering pressure hose, if
equipped. Refer to Section 6A, Power Steering
System.
24. Connect the power steering return hose, if equipped.
Refer to Section 6A, Power Steering System.
25. Install the A/C compressor mounting bracket, if
equipped.
26. Install the A/C compressor mounting bracket bolts, if
equipped.
A12C167A
Tighten
Tighten the A/C compressor mounting brackets bolts
27. Install the A/C compressor, if equipped.

28. Install the A/C compressor mounting bolts, if
equipped.
Tighten
Tighten the A/C compressor mounting bolts to
27 NSm (20 lb-ft).
A102B025
DAEWOO T-100 BL3

29. Connect the A/C compressor coil connector, if
equipped.
32. Connect the A/C compressor hose assembly and
the A/C compressor hose assembly retaining bolt, if
equipped.
Tighten
Tighten the A/C compressor hose assembly retaining
bolt to 33 NSm (24 lb-ft).
A102B006

equipped.
Tighten
25 NSm (18 lb-ft).
Tires and Wheels.
38. Connect the fuel return line to the fuel pressure
regulator.
A102C020
39. Connect all of the necessary vacuum lines including

the brake booster vacuum hose.
40.
41.
42.
43.
44.

Connect the starter solenoid S terminal wire.
Connect the alternator voltage regulator connector.
Connect the coolant temperature sensor connector.
Connect the engine coolant temperature sensor
connector.
A102C016
DAEWOO T-100 BL3

47. Connect the fuel injector harness connectors.
48. Connect the electrical connector at the DIS ignition
coil and the ECM ground terminal at the intake
manifold and the starter motor.
49. Install the air intake tube between the throttle body
50. Connect the breather tubes to the valve cover.
52. Install the cooling system radiator and the engine
A102C057
53. Connect the lower radiator hose to the coolant pipe.

housing.
56. Connect the heater outlet hose to the coolant pipe.
57. Connect the coolant surge tank hose to the coolant
pipe.
body.
A102C014
59. Connect the throttle cable to the throttle body and

the intake manifold bracket.
61. Connect the negative battery cable to the vehicle
frame.
63. Connect and assemble the positive battery cable.
A102C034

65. Refill the engine coolant system. Refer to Section
1D, Engine Cooling.
66. Bleed the power steering system, if equipped. Refer
to Section 6A, Power Steering System.
67. Refill the A/C refrigerant system, if equipped. Refer
to Section 7B, Manual Control Heating, Ventilation,
and Air Conditioning System.
68. Installthe hood. RefertoSection9R, Body Front End.
DAEWOO T-100 BL3
PISTONS AND RODS

Tools Required
KM-427 Piston Pin Service Set
KM 470-B Angular Torque Gauge
Removal Procedure
and exhaust manifold attached. Refer to Cylinder
2. Remove the oil pan. Refer to Oil Panin this section.
3. Remove the oil pump/pickup tube bolts.
4. Remove the oil pump/pickup tube.
A102B094
5.
6.
7.
8.
Move the piston to the bottom of the piston stroke.

Mark the connecting rod cap for position.
Remove the connecting rod cap bolts.
Remove the connecting rod cap and lower connecting rod bearing.
9. Remove the upper piston connecting rod bearing.
10. Ridge ream the cylinder wall.
A102B079
C a u tio n : U s e c a re w h e n
h a n d lin g th e p is to n . W o rn
p is to n rin g s a re s h a rp a n d m a y c a u s e in ju ry .
11. Remove the piston.

12. Use a piston ring expander tool to expand the piston
rings.
13. Remove the piston rings.
A102B080
DAEWOO T-100 BL3

14. Remove the piston pin from the piston and connecting rod assembly using the piston pin service set
KM-427.
15. Separate the piston from the connecting rod.
A102B081
1. Inspect the connecting rod for bending or twisting. If
the connecting rod is bent or twisted, replace the
connecting rod.
2. Inspect the connecting rod bearings.
3. Inspect the connecting rod lower end for wear.
4. Inspect the connecting rod upper end for scoring.
5. Inspect the crankshaft rod bearing journal for wear.
Refer to Engine Specifications in this section.
6. Inspect the piston for scoring, cracks, and wear.
7. Inspect the piston for taper using a micrometer.
A102B087
8. Inspect the piston for fit to the connecting rod.
A102B082
DAEWOO T-100 BL3

9. Inspect the engine block deck surface for flatness
using a straight edge and a feeler gauge. Refer to
10. Inspect the bearing bore for concentricity and alignment using a bore gauge. Refer to Engine Specifications in this section. If the bearing bore is beyond
specifications, replace the engine block.
11. Inspect the engine block cylinder bore for wear,
runout, ridging and taper using a bore gauge. Refer
to Engine Specifications in this section.
12. Inspect the engine block cylinder bore for glazing.
Lightly hone the cylinder bore as necessary.
A102B083
1. Align the notch on the piston and connecting rod so
that the proper sides will be facing the front of the engine.
2. Install the piston pin guide through the piston and the
connecting rod.
3. Coat the piston pin with clean oil.
4. Install the piston pin into the opposite side of the
piston.
5. Install the piston pin into the piston and connecting
rod assembly using the piston pin service set
KM-427.
A102B081
6. Select a set of new piston rings.

7. Measure the piston ring gap using a feeler gauge. Refer to Engine Specifications in this section.
8. Increase the piston ring gap by carefully filing off excess material if the piston ring gap is below specifications.
A102B084
DAEWOO T-100 BL3

9. Measure the piston ring side clearance using a feeler gauge. Refer to Engine Specifications in this
section.
10. If the piston ring is too thick, try another piston ring.
11. If no piston ring can be found that fits to specifications, the piston ring may be ground to size with
emery paper placed on a sheet of glass.
A102C055
12. Install a piston oil ring, the expander, then the

second piston oil ring to the bottom ring groove of
the piston.
13. Install the second compression ring to the middle
ring groove of the piston.
14. Install the top compression ring to the top ring
groove of the piston.
A102C168
15. Use a piston ring expander to install the piston rings.

Do not expand the piston rings beyond the expansion necessary for installation.
16. Stagger the piston oil rings, the oil ring rail gaps, the
second compression ring, and the top compression
ring in relation to the notch on the top of the piston.
A102C058
DAEWOO T-100 BL3

17. Lubricate the cylinder wall and the piston rings with
clean engine oil.
18. Install the piston using a ring compressor and a
wood handle. Guide the lower connecting rod end to
prevent damaging the crankshaft journal.
19. Install the connecting rod cap and bearings. Refer to
Crankshaft Bearings and Connecting Rod Bearings
- Gauging Plastic in this section.
A102B088
20. Install the connecting rod cap bolts.
Tighten
Tighten the connecting rod cap bolts to 25 NSm
(18 lb-ft). Using the angular torque gauge KM 470-B,
tighten the bolts one turn of 30 degrees plus one turn
of 15 degrees.
A102C151

Tighten
Tighten the oil pickup tube bolts to 10 NSm (89 lb-in).
exhaust manifold attached. Refer to Cylinder Head
and Gasket in this section.
A102B094
DAEWOO T-100 BL3

-
UNIT REPAIR
CYLINDER HEAD AND VALVE TRAIN
COMPONENTS
Tools Required
MKM-571-B Gauge
KM-340-0 Cutter Set
KM-340-7 Guide Drift
KM-340-13 Cutters
KM-340-26 Cutters
KM-348 Valve Spring Compressor
KM-653 Adapter
KM-805 Reamer
A102C040

and the exhaust manifold attached. Refer to Cylinder Head and Gasket in this section.
2. Remove the coolant temperature sensor.
3. Remove the exhaust manifold heat shield bolts.
4. Remove the exhaust manifold heat shield.
5. Remove the exhaust manifold retaining nuts in the
sequence shown.
8. Remove the exhaust manifold studs.
9. Remove the thermostat housing mounting bolts.

10. Remove the thermostat housing assembly.
11. Remove the fuel rail retaining bolts and the fuel rail
assembly.
A102C042
DAEWOO T-100 BL3

12. Remove the intake manifold retaining nuts and retaining bolts in the sequence shown.
15. Remove the intake manifold studs.
A102C030
16. Remove the DIS ignition coil mounting bolts.

17. Remove the DIS ignition coil with the ignition wires
attached.
18. Remove the DIS ignition coil mounting bracket bolts.
19. Remove the DIS ignition coil mounting bracket.
20. Remove the exhaust gas recirculation valve adapter
bolts.
21. Remove the exhaust gas recirculation valve adapter.
22. Remove the exhaust gas recirculation valve adapter
gasket.
23. Remove the spark plugs.
A102C043
24. Remove the camshaft cap bolts gradually and in the

A102C053
DAEWOO T-100 BL3

25. Remove the intake camshaft caps. Maintain the
26. Remove the intake camshaft.
27. Remove the intake valve lash adjusters.
28. Remove the exhaust camshaft caps. Maintain the
29. Remove the exhaust camshaft.
30. Remove the exhaust valve lash adjusters.
A102C056
31. Compress the valve springs with the valve spring

compressor KM-348 and the adapter KM-653.
32. Remove the valve retainers.
33. Remove the valve spring compressor KM-348 and
the adapter KM-653.
34. Remove the valve spring caps.
35. Remove the valve springs. Maintain the original
position of the valves springs for installation.
A102C044
36. Remove the valves. Maintain the original position of

the valves for installation.
37. Remove the valve stem seals.
A102C048
DAEWOO T-100 BL3

Cylinder Head Inspection
1. Clean the sealing surfaces.
2. Inspect the cylinder head gasket and mating surfaces
for leaks, corrosion and blow-by.
3. Inspect the cylinder head for cracks.
4. Inspect the length and width of the cylinder head using a feeler gauge and a straight edge.
5. Check the sealing surfaces for deformation and warpage. The cylinder head sealing surfaces must be flat
within 0.050 mm (0.002 inch) maximum.
A102C046
6. Measure the height of the cylinder head from sealing

surface to sealing surface. The cylinder head height
should be 138.13 to 138.18 mm (5.438 to 5.440 inches). If the cylinder head height is less than
138.13 mm (5.438 inches), replace the cylinder head.
7. Inspect all threaded holes for damage.
8. Valve seats for excessive wear and burned spots.
A102C045
Valve Inspection
1. Inspect the valve stem tip for wear.
2. Inspect the valve retainer grooves and the oil seal
grooves for chips and wear.
3. Inspect the valves for burns or cracks.
4. Inspect the valve stem for burrs and scratches.
5. Inspect the valve stem. The valve stem must be
straight.
6. Inspect the valve face for grooving. If the groove is so
deep that refacing the valve would result in a sharp
edge, replace the valve.
A102B054
DAEWOO T-100 BL3

7. Inspect the valve spring. If the valve spring ends are
not parallel, replace the valve spring.
8. Measure the valve spring height. Refer to Engine
Specifications in this section. If the valve spring
height does not match the specifications, replace the
valve spring.
9. Inspect the valve spring seating surface of the valve
rotators for wear or gouges. Replace as required.
A102B023
Cleaning Procedure
1.
2.
3.
4.
Clean the cylinder head.

Clean the valve guides.
Clean all of the threaded holes.
Clean the valves of carbon, oil and varnish.
A102C047
Cylinder Head Overhaul

Valve Grind-in
1. Lubricate the valve stem using a fine-grained paste.
2. Lift the valve rhythmically from the seat with a
commercially-available valve grinding tool in order to
distribute the paste.
A102C049
DAEWOO T-100 BL3

3. Check the contact pattern on the valve head and in
the cylinder head.
4. Clean the valves, the valve guides, and the cylinder
head.
A102B057
Valve Grind
1. Ensure that there are no crater line burns on the valve
cone.
2. The valve may be reground only two times. Do not
grind the valve stem end.
3. The angle at the valve face is 45 degrees.
4. Inspect the assembly height of the intake valves and
the exhaust valves.
A102B066
Valve Guide - Ream

1. Measure the diameter of the valve guide using gauge
MKM-571-B and a commercially-available inside micrometer.
A102C050
DAEWOO T-100 BL3

Important: Valve oversizes may already have been
fitted in production.
2. An oversize service code is on the valve guide and
the valve stem end. The following table gives the
correct size, reamer, and production code for each
service.
Size
Reamer
Production
Code
Service
Code
Normal
0.075
KM-805
K1
K2
0.150
A102C051
A102B060
3. Ream the valve guide from the upper side of the cylinder head to the next oversize.
4. After reaming, cross out the code and emboss the
valve guide with the new code.
Valve Seat - Cut
1. Place the cylinder head on wooden blocks.
2. Cut the intake and the exhaust valve seats using the
guide drift KM-340-7 as follows:
D Valve seat: * 45 degrees side using the cutter
KM-340-13.
D Upper correction angle: * 30 degrees side using
the cutter KM-340-13.
D Lower Correction Angle: * 60 degrees using cutter
KM-340-26.
3. Clean the chippings from the cylinder head.
4. Inspect the dimension for the valve seat width.
D Intake: 1.17 to 1.57 mm (0.046 to 0.062 inch).
D Exhaust: 1.07 to 1.47 mm (0.042 to 0.058 inch).
5. Inspect the assembly height of the intake valves and
the exhaust valves.
6. If the dimension is exceeded, install new valves. Inspect the assembly height of the intake valves and
the exhaust valves again.
7. If the valve assembly height is still too large despite
replacing the valves, replace the cylinder head.
DAEWOO T-100 BL3

Assembly Procedure
1. Install the valve stem seals.
2. Lubricate the valve stems with engine oil.
3. Carefully install the valves in their original positions.
Do not damage the valve stem seals.
4. Install the valve springs in their original positions.
5. Install the valve spring caps.
A102C052
6. Compress the valve springs with the valve spring

compressor KM-348 and adapter KM-653.
7. Install the valve retainers.
8. Remove the valve spring compressor KM-348 and
adapter KM-653.
A102C044
9. Lubricate the valve lash adjusters with engine oil.

10. Install the valve lash adjusters.
A102C056
DAEWOO T-100 BL3

11. Install the intake camshaft.
12. Install the intake camshaft caps in their original positions.
13. Install the exhaust camshaft.
14. Install the exhaust camshaft caps in their original
positions.
15. Install the camshaft cap bolts.
16. Tighten the camshaft cap bolts gradually and in the
Tighten
Tighten the camshaft cap bolts to 16 NSm (12 lb-ft).
A102C053
17. Install the spark plugs.
Tighten
Tighten the spark plugs to 25 NSm (18 lb-ft).
18. Install the exhaust gas recirculation valve adapter
gasket.
19. Install the exhaust gas recirculation valve adapter.
20. Install the exhaust gas recirculation valve adapter
bolts.
Tighten
Tighten the exhaust gas recirculation valve adapter
21. Install the DIS ignition coil mounting bracket.
22. Install the DIS ignition coil mounting bracket bolts.
Tighten
A102C043
Tighten the DIS ignition coil mounting bracket bolts to

10 NSm (89 lb-in).
23. Install the DIS ignition coil with the ignition wires attached.
24. Install the DIS ignition coil mounting bolts.
Tighten
Tighten the DIS ignition coil mounting bolts to 10 NSm
(89 lb-in).
DAEWOO T-100 BL3

25.
26.
27.
28.
Install the intake manifold studs.

Install the intake manifold gasket.
Install the intake manifold.
Install the intake manifold retaining nuts and
retaining bolts in the sequence shown.
Tighten
Tighten the intake manifold retaining nuts and
A102C031
29. Install the fuel rail assembly with the bolts.
Tighten
Tighten the fuel rail retaining bolts to 25 NSm (18 lbft).
30. Install the thermostat housing assembly.
31. Install the thermostat housing mounting bolts.
Tighten
20 NSm (15 lb-ft).
A102C042
32.
33.
34.
35.
Install the exhaust manifold studs.

Install the exhaust manifold gasket.
Install the exhaust manifold.
Install the exhaust manifold retaining nuts in the sequence shown.
Tighten
Tighten the exhaust manifold retaining nuts to 25 NSm
(18 lb-ft).
Tighten
15 NSm (11 lb-ft).
A102C041
DAEWOO T-100 BL3

38. Install the coolant temperature sensor.
Tighten
Tighten the coolant temperature sensor to 20 NSm
(15 lb-ft).
A102C169
CRANKSHAFT
Tools Required
KM-412 Engine Overhaul Stand
J-36792 Crankshaft Rear Oil Seal Installer (or KM-635)
nicks, or damage to the camshafts.
1. Remove the engine. Refer to Engine in this section.
2. Remove the flywheel or flexible plate bolts.
3. Remove the flywheel or the flexible plate.
A102B095
4. Remove the crankshaft rear oil seal.

5. Mount the engine assembly on the engine overhaul
stand KM-412.
A102C170
DAEWOO T-100 BL3

6. Remove the upper and lower front timing belt cover
bolts.
7. Remove the upper and lower front timing belt cover.
A102C007
8. Remove the power steering pump mounting bolts, if

equipped.
9. Remove the power steering pump, if equipped.
A102C157
A102C027
DAEWOO T-100 BL3

11. Rotate the coolant pump using the timing belt adjuster J-42942 to remove the tension from the timing
belt.
A102C004
13. Disconnect the crankcase ventilation tubes from the

valve cover.
A102C015

20. While holding the intake camshaft firmly in place, remove the intake camshaft bolt.
remove the exhaust camshaft bolt.
A102C017
DAEWOO T-100 BL3

24.
25.
26.
27.
Remove the timing belt automatic tensioner bolts.

Remove the timing belt idler pulley bolt.
Remove the timing belt idler pulley.
A102C018
28. Remove the crankshaft timing belt gear.

A102C005
31. Rotate the engine on the engine overhaul stand

KM-412.
A102C158
DAEWOO T-100 BL3

32.
33.
34.
35.
Remove the oil pan retaining bolts.

Remove the oil pan.
Remove the oil pickup tube bolts.
Remove the oil pickup tube.
A102B064

A102B065
38. Mark the order of the connecting rod bearing caps.

39. Remove the connecting rod bearing cap bolts for all
of the pistons.
40. Remove the connecting rod bearing caps and the
lower connecting rod bearings.
41. Remove the upper connecting rod bearings.
A102B067
DAEWOO T-100 BL3

42. Mark the order of the crankshaft bearing caps.
43. Remove the crankshaft bearing cap bolts.
44. Remove the crankshaft bearing caps and the lower
crankshaft bearings.
45. Remove the crankshaft.
46. Remove the upper crankshaft bearings.
47. Clean any necessary parts.
A102B068
Assembly Procedure
2. Install the upper crankshaft bearings in the engine
block.
A102B069

4. Install the lower crankshaft bearings in the bearing
caps.
bearings installed.
A102B070
DAEWOO T-100 BL3

7. With the crankshaft mounted on the front and rear
journal for permissible out-of-round (runout). Refer
A102B071
Important: Grease the crankshaft journals and lubricate

caps are removed.
8. Inspect all of the crankshaft bearing clearances using a commercially available plastic gauging
(ductile plastic threads).
10. Install the crankshaft bearing caps and the bolts.
Tighten
(37 lb-ft) 45 degrees +15 degrees.
A102B072
11. Remove the crankshaft bearing cap bolts and the

caps.
section.
A102B073
DAEWOO T-100 BL3

14. Apply a bead of adhesive sealing compound to the
grooves of the crankshaft bearing caps.
15. Install the crankshaft bearing caps to the engine
block.
16. Tighten the crankshaft bearing caps using new
bolts.
Tighten
(37 lb-ft) using a torque wrench. Use the angular
torque gauge KM-470-B to tighten the crankshaft
bearings 45 degrees +15 degrees.
A102B091
Important: Grease the connecting rod journals and lubricate the connecting rod bearings slightly so that the
using a commercially available plastic gauging
18. Cut the plastic gauging threads to the length of
the connecting rod bearing width. Lay them axially
between the connecting rod journals and the connecting rod bearings.
Tighten
A102B072
Tighten the connecting rod bearing cap bolts to 25

NSm (18 lb-ft) using a torque wrench. Use the angular
torque gauge KM-470-B to tighten the connecting rod
bearing cap bolts to 30 degrees +15 degrees.
section.
A102B073
DAEWOO T-100 BL3

23. Install the connecting rod bearing caps to the connecting rods.
24. Tighten the connecting rod bearing caps using new
bolts.
Tighten
Tighten the connecting rod bearing cap bolts to 25 NSm
(18 lb-ft) using a torque wrench. Use the angular
torque gauge KM-470-B to tighten the connecting rod
cap bolts to 30 degrees +15 degrees.
A102C151
25. Install the oil pump.

26. Install the oil pump retaining bolts.
Tighten
A102B065

Tighten
(89 lb-in).
A102B064
DAEWOO T-100 BL3

30. Install the oil pan.
Tighten
A102B043
32. Rotate the engine on the engine assembly stand

KM-412.
A102C158

Tighten
(89 lb-in).
A102C005
DAEWOO T-100 BL3

35. Install the crankshaft timing belt gear.
Tighten
25 NSm (18 lb-ft).
Tighten
(30 lb-ft).
A102C019

41. Install the intake camshaft gear bolt while holding
the intake camshaft firmly in place.
Tighten
(49 lb-ft).
43. Install the exhaust camshaft gear bolt while holding
the exhaust camshaft firmly in place.
Tighten
Tighten the exhaust camshaft bolt to 67.5 NSm (49 lbft).
A102C017

section.
45. Adjust the timing belt tension. Refer to Timing Belt
corners of the front camshaft caps and the top of
Tighten
A102C015
DAEWOO T-100 BL3

Tighten
cover.
bolts.
Tighten
A102C007
Tighten the upper and lower front timing belt cover

56. Install the power steering pump, if equipped.
57. Install the power steering pump mounting bolts.
Tighten
25 NSm (18 lb-ft).

59. Remove the engine from the engine assembly stand
KM-412.
A102C171
DAEWOO T-100 BL3

60. Install a new crankshaft rear oil seal using installer
J-36972 (or KM-635).
J- 36972
A102C152
61. Install the flywheel or flexible plate.

62. Install the flywheel or the flexible plate bolts.
Tighten
Tighten the flywheel bolts to 35 NSm (25 lb-ft). Use
the angular torque gauge KM-470-B to tighten the
flywheel bolts to 30 degrees + 15 degrees. For the
manual transmission, tighten the flexible plate bolts to
60 NSm (44 lb-ft).
63. Install the engine. Refer to Engine in this section.
A102C159
CRANKSHAFT BEARINGS AND

CONNECTING ROD BEARINGS
GAUGING PLASTIC
Tools Required
Inspection Procedure - Crankshaft

-
A102B070

2. Install the upper crankshaft bearings into the engine
block crankshaft journals.
3. Install the lower crankshaft bearings into the crankshaft bearing caps.
bearings installed.
DAEWOO T-100 BL3

7. With the crankshaft mounted on the front and rear
journal for permissible out-of-round (runout). Refer
A102B071
Notice: Grease the crankshaft journals and lubricate

caps are removed.
8. Inspect all of the crankshaft bearing clearances using a commercially available plastic gauging
A102B072

11. Install the crankshaft bearing cap bolts.
Tighten
tighten the crankshaft bearing cap bolts to 45 degrees
+15 degrees.
A102B091
DAEWOO T-100 BL3

12. Remove the crankshaft bearing caps.
14. Inspect the bearing clearances for permissible tolerance ranges. Refer to Engine Specifications in this
section.
A102B073
Inspection Procedure - Connecting Rods

1. Coat the connecting rod bearings with engine oil.
2. Install the upper connecting rod bearings into the
connecting rod journals.
3. Install the lower connecting rod bearings into the
connecting rod bearing caps.
Notice: Grease the connecting rod journals and lubricate the connecting rod bearings slightly so that the
using a commercially available plastic gauging
A102B072

bearing width. Lay them axially between the connecting rod journals and the connecting rod bearings.
Tighten
Tighten the connecting rod cap bolts to 25 NSm
tighten the connecting rod cap bolts to 30 degrees
+15 degrees.
A102C151
DAEWOO T-100 BL3

section.
A102B073
DAEWOO T-100 BL3

-
GENERAL DESCRIPTION
The cylinder head is made of an aluminum alloy. The

cylinder head uses crossflow intake and exhaust ports.
A spark plug is located in the center of each combustion
chamber. The cylinder head houses the dual camshafts.
CRANKSHAFT
The crankshaft has eight integral weights which are cast

with it for balancing. Oil holes run through the center of
the crankshaft to supply oil to the connecting rods, the
bearings, the pistons, and the other components. The
end thrust load is taken by the thrust washers installed
at the center journal.
TIMING BELT
The timing belt coordinates the crankshaft and the dual

overhead camshafts and keeps them synchronized. The
timing belt also turns the coolant pump. The timing belt
and the pulleys are toothed so that there is no slippage
between them. There are two idler pulleys. An automatic
tensioner pulley maintains the timing belts correct
tension. The timing belt is made of a tough reinforced
rubber similar to that used on the serpentine drive belt.
The timing belt requires no lubrication.
OIL PUMP
The oil pump draws engine oil from the oil pan and feeds
it under pressure to the various parts of the engine. An
oil strainer is mounted before the inlet of the oil pump to
remove impurities which could clog or damage the oil
pump or other engine components. When the drive gear
rotates, the driven gear rotates. This causes the space
between the gears to constantly open and narrow,
pulling oil in from the oil pan when the space opens and
pumping the oil out to the engine as it narrows.
At high engine speeds, the oil pump supplies a much
higher amount of oil than required for lubrication of the
engine. The oil pressure regulator prevents too much oil
from entering the engine lubrication passages. During
normal oil supply, a coil spring and valve keeps the bypass closed, directing all of the oil pumped to the engine.
When the amount of oil being pumped increases, the
pressure becomes high enough to overcome the force
of the spring. This opens the valve of the oil pressure
regulator, allowing the excess oil to flow through the
valve and drain back to the oil pan.
OIL PAN
The engine oil pan is mounted to the bottom of the cylinder block. The engine oil pan houses the crankcase and
is made of pressed sheet metal.
Engine oil is pumped from the oil pan by the oil pump.
After it passes through the oil filter, it is fed through two
paths to lubricate the cylinder block and cylinder head.
In one path, the oil is pumped through oil passages in

the crankshaft to the connecting rods, then to the
pistons and cylinders. It then drains back to the oil pan.
In the second path, the oil is pumped through passages
to the camshaft. The oil passes through the internal
passageways in the camshafts to lubricate the valve assemblies before draining back to the oil pan.
EXHAUST MANIFOLD
A single four-port, rear-takedown manifold is used with

this engine. The manifold is designed to direct escaping
exhaust gases out of the combustion chambers with
a minimum of backpressure. The oxygen sensor is
mounted to the exhaust manifold.
INTAKE MANIFOLD
The intake manifold has four independent long ports and

utilizes an inertial supercharging effect to improve engine torque at low and moderate speeds. The plenum is
attached to the intake manifold.
CAMSHAFTS
This engine is a dual over head camshaft (DOHC) type,

which means there are two camshafts. One camshaft
operates the intake valves, and the other camshaft operates the exhaust valves. The camshafts sit in journals
on the top of the engine (in the cylinder head) and are
held in place by camshaft caps. The camshaft
journals of the cylinder head are drilled for oil passages.
Engine oil travels to the camshafts under pressure
where it lubricates each camshaft journal. The oil returns to the oil pan through drain holes in the cylinder
head. The camshaft lobes are machined into the solid
camshaft to precisely open and close the intake and the
exhaust valves the correct amount at the correct time.
The camshaft lobes are oiled by splash action from
pressurized oil escaping the camshaft journals.
EXHAUST GAS RECIRCULATION

VALVE
The exhaust gas recirculation (EGR) system is used to

lower oxides of nitrogen (NOX) emission levels caused
by high combustion temperatures. The main element of
the system is the EGR valve which is operated by vacuum.
The EGR valve feeds small amounts of exhaust gas into
the intake manifold to decrease the combustion temperature. The amount of exhaust gas recirculated is controlled by variations in vacuum and exhaust back
pressure. If too much exhaust gas enters, combustion
will not take place. For this reason, very little exhaust
gas is allowed to pass through the valve, especially at
idle.
The EGR valve is usually open under the following conditions:
D Warm engine operation.
D Above idle speed.
DAEWOO T-100 BL3
SECTION 1D
ENGINE COOLING
n
o ewente.
thr is o d
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1D-1
1D-1
1D-2
1D-2
Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . .

Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat Test . . . . . . . . . . . . . . . . . . . . . . . . . . .
Surge Tank Cap Test . . . . . . . . . . . . . . . . . . . . . . .
Cooling System Diagnosis . . . . . . . . . . . . . . . . . .
Component Locator . . . . . . . . . . . . . . . . . . . . . . . .
Radiator/Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant Pump/Thermostat (DOHC) . . . . . . . . . .
Coolant Pump/Thermostat (SOHC) . . . . . . . . . .
Maintenance and Repair . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining and Refilling the Cooling System . . . .
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1D-2
1D-3
1D-3
1D-3
1D-4
1D-5
1D-5
1D-6
1D-7
1D-8
1D-8
1D-8
1D-9
Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Cooling Fan - Main . . . . . . . . . . . . . . . .
Electric Cooling Fan - Auxiliary . . . . . . . . . . . . .
Surge Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Coolant Temperature Sensor . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Description . . . . . . . . . . . . . . . . . . . . . .
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Surge Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Cooling Fan . . . . . . . . . . . . . . . . . . . . . .
Engine Coolant Temperature Sensor . . . . . . . .
Engine Block Heater . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS
CAPACITY
Application
Coolant in the Cooling System (SOHC MPFI System)
Coolant in the Cooling System (DOHC MPFI System)
DAEWOO T-100 BL3
Description
7.0L (1.85 gal) for automatic transaxle
7.0L (1.85 gal) for manual transaxle
7.1L (1.88 gal) for automatic transaxle
7.2L (1.90 gal) for manual transaxle
1D-11
1D-12
1D-14
1D-16
1D-16
1D-19
1D-21
1D-21
1D-21
1D-21
1D-21
1D-21
1D-22
1D-22
1D-22
1D - 2 ENGINE COOLING
-

Application
NSm
Lb-Ft
Lb-In
Coolant Pump Mounting Bolts
10
89
Electric Cooling Fan (Auxiliary) Motor Retaining Nuts
3.2
28
35
3.2
28
Electric Cooling Fan (Main) Motor Retaining Screws
35
Electric Cooling Fan Assembly (Auxiliary) Mounting

Bolts
35
Electric Cooling Fan Assembly (Main) Mounting Bolts
35
Engine Coolant Temperature Sensor (DOHC)
20
15
Engine Coolant Temperature Sensor (SOHC)
20
15
Negative Battery Terminal Retainer Bolt
15
11
Radiator Retaining Bolt (Upper Left)
35
Radiator Retaining Bolt (Upper Right)
35
Surge Tank Attaching Nuts
35
Thermostat Housing Mounting Bolts (DOHC)
20
15
Thermostat Housing Mounting Bolts (SOHC)
20
15
Transmission Cooler Pipe Bolt (Lower)
12
106
Transmission Cooler Pipe Bolt (Upper)
12
106
Electric Cooling Fan (Auxiliary) Retaining Nut

Electric Cooling Fan (Main) Motor Nut
SPECIAL TOOLS
SPECIAL TOOLS TABLE
KM-471
Adapter
A102D020
DAEWOO T-100 BL3
ENGINE COOLING 1D - 3
-
DIAGNOSIS
THERMOSTAT TEST
1. Remove the thermostat from the vehicle. Refer to
Thermostat in this section.
2. Make sure the valve spring is tight when the thermostat is fully closed. If the spring is not tight, replace the
thermostat.
3. Suspend the thermostat and a thermometer in a pan
of 50/50 mixture of ethylene glycol and water. Do not
let the thermostat or the thermometer rest on the
bottom of the pan because the uneven concentration
of heat on the bottom could result in inaccurate temperature measurements.
4. Heat the pan on a burner.
5. Use the thermometer to measure the temperature of
the heated solution.
6. The thermostat should begin to open at 87_C (189_F)
and it should be fully open at 102_C (226_F). If it does
not open at these temperatures, replace the thermostat.
2. Check for any damage or deformity to the vacuum

pressure valve for the surge tank cap. If any damage
or deformity is found, replace the cap.
3. Install a suitable cooling system pressure tester to the
cap using the KM-471 Adapter.
4. Pull the vacuum pressure valve to the open position.
If the surge tank cap does not seal properly, replace
the surge tank cap.
5. Pressurize the cap to 90 to 120 kPa (13 to 17 psi).
6. Wait 10 seconds and check the pressure held by the
tank cap tester.
SURGE TANK CAP TEST

SPECIAL TOOLS
KM-471 Adapter
The surge tank cap maintains proper pressure, protects
the system from high-pressure by opening a pressurevalve, and protects the coolant hoses from collapsing
because of a vacuum.
1. Wash any sludge from the surge tank cap and the
valve seat of the vacuum pressure valve for the surge
tank cap.
DAEWOO T-100 BL3
A102D021
7. If the pressure held by the cooling system pressure

tester falls below 80 kPa (11.6 psi) replace the surge
tank cap.
-
COOLING SYSTEM DIAGNOSIS

Engine Overheats
Checks
Action
Check for a loss of the coolant.
Add the coolant.
Check for a weak coolant solution.
Confirm that the coolant solution is a 50/50 mixture of

ethylene glycol and water.
Check the front of the radiator for any dirt, any leaves,
or any insects.
Clean the front of the radiator.
Check for leakage from the hoses, the coolant pump,

the heater, the thermostat housing, the radiator, the
core plugs, or the head gasket.
Replace any damaged components.
Check for a faulty thermostat.
Replace a damaged thermostat.
Check for retarded ignition timing.
Perform an ECM code diagnosis. Confirm the integrity

of the timing belt.
Check for an improperly operating electric cooling fan.
Replace the electric cooling fan.
Check for radiator hoses that are plugged or rotted.
Replace any damaged radiator hoses.
Check for a faulty water pump.
Replace a faulty water pump.
Check for a faulty surge tank cap.
Replace a faulty surge tank cap.
Check for a cylinder head or an engine block that is

cracked or plugged.
Repair the damaged cylinder head or the damaged

engine block.
Loss of Coolant
Checks
Action
Check for a leak in the radiator.
Replace a damaged radiator.
Check for a leak in the

D Surge tank.
D Hose.
Replace the
D Surge tank.
D Hose.
Check for loose or damaged

D Radiator hoses.
D Heater hoses.
D Connections.
Reseat the hoses.

Replace the hoses or the clamps.
Check for leaks in the coolant pump seal.
Replace the coolant pump seal.
Check for leaks in the coolant pump gasket.
Replace the coolant pump gasket.
Check for an improper cylinder head torque.
Tighten the cylinder head bolts to specifications.

Replace the cylinder head gasket, if needed.
Repair or replace any components, as needed to correct the leak.
Check for leaks in the

D Intake manifold.
D Cylinder head gasket.
D Cylinder block plug.
D Heater core.
D Radiator drain plug.
DAEWOO T-100 BL3
Engine Fails to Reach Normal Operating Temperature
or
Cool Air from the Heater
Checks
Action
Check to determine if the thermostat is

D Stuck open.
D The wrong type of thermostat.
Install a new thermostat of the correct type and heat

range.
Check the coolant level to determine if it is below the

MIN mark on the surge tank.
Add sufficient coolant to raise the fluid to the specified

mark on the surge tank.
COMPONENT LOCATOR
RADIATOR/FAN
A102D019
1 Bolt
2 Main Cooling Fan
3 Holder Transmission Fluid Pipe (Automatic
Transmission Only)
4 Radiator
DAEWOO T-100 BL3
5
6
7
8
9
Upper Radiator Hose

Spring Clamp
Auxiliary Cooling Fan (Air Conditioning Only)
Radiator Bumper
Drain Cock
-
COOLANT PUMP/THERMOSTAT (DOHC)
A102D030
1
2
3
4
6
Cylinder Block Seal Ring

Seal Ring
Thermostat Adapter
Thermostat
Seal Ring
6
7
8
9
Thermostat Housing
Bolt
Bolt
Water Pump
DAEWOO T-100 BL3
-
COOLANT PUMP/THERMOSTAT (SOHC)
A102D027
1
2
3
4
Thermostat Housing Bolt

Thermostat Housing
Seal Ring
Thermostat
DAEWOO T-100 BL3
5 Water Pump Mounting Bolts

6 Water Pump
7 O-Ring
-

ON-VEHICLE SERVICE
DRAINING AND REFILLING THE
COOLING SYSTEM
C
aution: D not rem the surge tank cap while
o
ove
theengineand theradiator arehot. Scaldingfluid
andsteamm
aybeblownout underpressure.
1. Place a pan below the vehicle to catch the draining
coolant.
2. Remove the surge tank cap.
3. Unplug the drain cock.
A102D001
C a u tio n :
D is p o s e
o f
th e
u sed
c o o la n t
to
u sed
c o o la n t h o ld in g ta n k to b e p ic k e d u p w ith th e u s e d
o il fo r d is p o s a l. N e v e r p o u r th e u s e d c o o la n t d o w n
th e d ra in . E th y le n e g ly c o l a n tifre e z e is a n e x tre m e ly
to x ic c h e m ic a l. D is p o s in g
te m
o f it in to
th e s e w e r s y s
o r th e g ro u n d w a te r c a n c o n ta m in a te th e lo c a l
e n v iro n m e n t.
A102D029
4. Catch the escaping fluid in a drain pan.

5. Remove all sludge and dirt from inside the surge
tank. Refer to Surge Tank in this section.
6. Plug the drain cock.
7. Add the clean water to the surge tank.
8. Fill the tank slowly so that the upper reservoir hose
remains above the water line. This allows the air inside the cooling system to escape.
9. Start the engine.
10. Run the engine until the thermostat opens. You can
tell the thermostat is open when both radiator hoses
are hot to the touch.
11. Stop the engine.
12. Repeat steps 1 through 9 until the drained water is
clear and free of coolant and rust.
Notice: Never use an antifreeze mixture more concentrated than 60 percent antifreeze to 40 percent water.
The solution freezing point increases above this concentration.
13. Fill the cooling system through the surge tank with a
mixture of ethylene glycol antifreeze and water. The
mixture must be at least 50 percent antifreeze, but
not more than 60 percent antifreeze for cold weather
operation.
14. Fill the surge tank to the specified MAX fill mark on
the outside of the tank.
A102D017
DAEWOO T-100 BL3
-
THERMOSTAT
Single Overhead Cam Engine
Removal Procedure
Caution: To prevent personal injury, do not remove
thesurgetank cap whiletheengineand theradiator
are hot because the heat causes the system to re
main under pressure. Scalding fluid and steammay
be blown out under pressure.
A102D002
1. Drain the coolant. Refer to Draining and Refilling

the Cooling System in this section.
2. Remove the rear timing belt cover. Refer to Section
1B, SOHC Engine Mechanical.
3. Loosen the hose clamp on the upper radiator hose
at the thermostat housing.
5. Remove the mounting bolts that hold the thermostat
housing to the cylinder head.
6. Remove the thermostat housing from the head.
7. Remove the thermostat from its recess in the cylinder head.
8. Inspect the valve seat for foreign matter that could
prevent the valve from seating properly.
9. Inspect the thermostat for proper operation. Refer to
Thermostat Test in this section.
10. Clean the thermostat housing and the cylinder head
mating surfaces.
A102D014
1. Install the thermostat into the cylinder head recess.
2. Install the thermostat housing.
3. Secure the thermostat housing to the cylinder head
with the mounting bolts.
Tighten
20 NSm (15 lb-ft).
A102D040
DAEWOO T-100 BL3

housing.
5. Secure the upper radiator hose to the thermostat
housing with a hose clamp.
6. Install the rear timing belt cover. Refer to Section
1B, SOHC Engine Mechanical.
7. Refill the engine cooling system. Refer to Draining
and Refilling the Cooling System in this section.
Dual Overhead Cam Engine
Removal Procedure
are still hot because the heat causes the system to
remain under pressure. Scalding fluid and steam
may be blown out under pressure.
1. Drain the coolant. Refer to Draining and Refilling
2. Loosen the hose clamp on the upper radiator hose
at the thermostat housing.
A102D003
4. Loosen the clamp on the bypass hose.

5. Disconnect the bypass hose from the thermostat
adapter.
6. Remove the mounting bolts holding the thermostat
housing to the cylinder head.
7. Remove the thermostat housing from the head.
8. Remove the O-ring seal from the head.
9. Separate the thermostat cover from the thermostat
adapter.
10. Remove the thermostat from its recess in the thermostat adapter.
11. Check the valve seat for foreign matter that could
prevent the valve from seating properly.
12. Check the thermostat for proper operation. Refer to
Thermostat Test in this section.
13. Clean the thermostat housing and cylinder head
mating surfaces.
A102D004
1. Install the thermostat into the thermostat adapter recess.
2. Assemble the thermostat cover over the thermostat
adapter.
3. Coat the sealing surface of a new O-ring seal with Lubriplater.
A102D018
DAEWOO T-100 BL3
4. Install a new O-ring seal into the recess in the cylinder head.
5. Secure the thermostat housing to the cylinder head
with the mounting bolts.
Tighten
20 NSm (15 lb-ft).
6. Connect the bypass hose to the thermostat adapter.
7. Secure the bypass hose with a hose clamp.
housing.
9. Secure the upper radiator hose to the thermostat
housing with a hose clamp.
A102D004
COOLANT PUMP
Removal Procedure
1. Drain the engine cooling system to a level below the
thermostat housing. Refer to Draining and Refilling
2. Remove the rear timing belt cover. Refer to Section
1B, SOHC Engine Mechanical, or Section 1C, DOHC
Engine Mechanical.
3. Remove the coolant pump mounting bolts.
4. Remove the coolant pump from the cylinder block.
5. Remove the ring seal from coolant pump.
A102D005
Inspection and Cleaning Procedure

1. Inspect the coolant pump body for cracks and leaks.
2. Inspect the coolant pump bearing for play or abnormal noise.
3. Inspect the coolant pump pulley for excessive wear. If
the coolant pump is defective, replace the coolant
pump as a unit.
4. Clean the mating surfaces of the coolant pump and
cylinder block.
A102D041
DAEWOO T-100 BL3
1. Install a new ring seal to the coolant pump.
2. Coat the sealing surface of the ring seal with Lubriplater.
3. Install the coolant pump to the engine block.
4. Secure the coolant pump to the engine block with the
mounting bolts.
Tighten
Tighten the coolant pump mounting bolts to 10 NSm
(89 lb-in).
5. Install the rear timing belt cover. Refer to Section 1B,
DOHC Engine Mechanical.
A102D042
ELECTRIC COOLING FAN - MAIN

Removal Procedure
2. Remove the hood support rod bracket.
A102D023
3. Disconnect the cooling fan electrical connector.

4. Remove the fan shroud mounting bolts.
5. Lift the fan shroud assembly upward, and remove the
fan shroud assembly from the vehicle.
6. Remove the fan blade from the fan motor by removing the nut at the center of the fan hub.
A102D006
DAEWOO T-100 BL3
7. Remove the fan motor retaining screws.
8. Remove the fan motor from the shroud.
A102D007
Caution: If a fan blade is bent or damaged in any
way, no attempt should be made to repair or reuse
the damaged part. A bent or damaged fan assembly
must be replaced with a new fan assembly. It is es
sential that fan assemblies remain in proper bal
ance. A fan assembly that is not in proper balance
can fail and fly apart during use, creating extreme
danger. Proper balance cannot be assured on a fan
assembly that has been bent or damaged.
1. Install the fan motor to the shroud.
2. Secure the motor to the shroud with the retaining
screws.
Tighten
A102D007
Tighten the fan motor retaining screws to 4 NSm

(35 lb-in).
3. Install the fan to the motor with the single nut in the
center of the fan hub.
Tighten
Tighten the fan motor nut to 3.2 NSm (28 lb-in).
A102D006
DAEWOO T-100 BL3
4. Install the electric cooling fan shroud assembly to the
radiator.
Important: Be careful to seat the mounting post on the
fan shroud into the socket at the radiator left tank. Be
sure to slip the tab at the bottom edge of the shroud into
the retaining clip near the center of the radiator.
5. Secure the shroud to the top of the radiator with the
mounting bolts.
Tighten
Tighten the electric cooling fan assembly mounting
6. Install the electrical connector to the cooling fan.
7. Install the hood support rod bracket.
A102D023
ELECTRIC COOLING FAN AUXILIARY

Removal Procedure
1.
2.
3.
4.

Disconnect the cooling fan electrical connector.
Remove the fan shroud mounting bolts.
Lift the fan shroud assembly upward, and remove the
fan shroud assembly from the vehicle.
5. Remove the fan motor nuts that secure the fan motor
to the shroud.
A102D026
6. Remove the fan motor from the shroud.

7. Remove the fan retaining nut which secures the fan
to the motor.
A102D008
DAEWOO T-100 BL3
Caution: If a fan blade is bent or damaged in any
way, no attempt should be made to repair or reuse
the damaged part. A bent or damaged fan assembly
must be replaced with a new fan assembly. It is es
sential that fan assemblies remain in proper bal
ance. A fan assembly that is not in proper balance
can fail and fly apart during use, creating
an extremely dangerous condition. Proper balance
cannot be assured on a fan assembly that has been
bent or damaged.
1. Install the fan to the motor.
2. Attach the fan retaining nut.
Tighten
A102D008
Tighten the fan retaining nut to 4 NSm (35 lb-in).

3. Attach the fan motor to the shroud.
4. Secure the fan motor to the shroud with the retaining
nuts.
Tighten
Tighten the fan motor retaining nuts to 3.2 NSm
(28 lb-in).
5. Install the electric cooling fan assembly to the radiator.
6. Be careful to seat the mounting post on the fan
shroud into the socket at the radiator right tank.
7. Also be sure to slip the bottom edge of the shroud
into the retaining clip near the center of the radiator.
8. Secure the shroud to the top of the radiator with the
mounting bolts.
Tighten
Tighten the electric cooling fan assembly mounting
A102D026
DAEWOO T-100 BL3
9. Install the electrical connector to the cooling fan.

-
SURGE TANK
Removal Procedure
are hot, because the heat causes the system to re
main under pressure. Scalding fluid and steammay
be blown out under pressure.
1. Drain the engine coolant to below the level of the
surge tank.
2. Loosen the overflow hose clamps and disconnect the
overflow hoses from the surge tank.
3. Remove the tank attaching nuts.
4. Remove the tank from the vehicle.
5. Clean the inside and the outside of the surge tank and
the surge tank cap with soap and water.
6. Rinse the surge tank and the cap thoroughly.
A102D017
1. Install the surge tank to the vehicle.
2. Secure the surge tank with the attaching nuts.
Tighten
Tighten the surge tank attaching nuts to 4 NSm (35 lbin).
3. Connect the overflow hoses to the surge tank.
4. Secure the overflow hoses to the surge tank with the
hose clamps.
5. Fill the surge tank with the coolant to the center ridge,
or the MAX mark.
A102D043
RADIATOR
Removal Procedure
2. Drain the engine cooling system. Refer to Draining
3. Remove the hood support rod bracket.
A102D023
DAEWOO T-100 BL3
4. Remove the main cooling fan. Refer to Electric
Cooling Fan - Main in this section.
5. Remove the auxiliary cooling fan, if equipped. Refer
to Electric Cooling Fan - Auxiliary in this section.
6. Remove the lower radiator hose clamp.
7. Disconnect the lower radiator hose from the radiator.
8. Remove the upper radiator hose clamp.
9. Disconnect the upper radiator hose from the radiator.
A102D025
10. Remove the hose clamp from the surge tank hose at
the radiator.
11. Disconnect the surge tank hose from the radiator.
12. Disconnect the upper and lower transmission cooler
hoses from the pipes at the left radiator tank, if
equipped.
13. Remove the left upper radiator retaining bolt.
14. Remove the left upper radiator retaining bracket.
A102D011
15. Remove the right upper radiator retaining bolt.

16. Remove the right upper radiator retaining bracket.
17. Remove the radiator from the vehicle.
Important: The radiator still contains a substantial
amount of coolant. Drain the remainder of the coolant
from the radiator into a drain pan.
A102D022
DAEWOO T-100 BL3
1. If installing a new radiator, remove the transmission

cooler pipes from the old radiator and install them
onto the left tank of the new radiator.
2. Install the upper transmission cooler pipe to the radiator and secure the pipe with a pipe bolt.
Tighten
Tighten the upper transmission cooler pipe bolt to
12 NSm (106 lb-in).
3. Install the pipe holder as it was in the old radiator.
4. Install the lower transmission cooler pipe to the radiator and secure the pipe with a pipe bolt.
Tighten
A102D012
Tighten the lower transmission cooler pipe bolt to

12 NSm (106 lb-in).
5. Set the radiator into place in the vehicle with the radiator bottom posts in the rubber shock bumpers.
6. Position the radiator retainers in place.
7. Install the right upper radiator retainer bracket.
8. Install the right upper radiator retaining bolt.
Tighten
Tighten the right upper radiator retaining bolt to 4 NSm
(35 lb-in).
A102D022
9. Install the left upper radiator retainer bracket.

10. Install the left upper radiator retaining bolt.
Tighten
Tighten the left upper radiator retaining bolt to 4 NSm
(35 lb-in).
A102D011
DAEWOO T-100 BL3
11. Connect the transmission cooler hoses to the pipes,
if equipped.
12. Connect the surge tank hose to the radiator.
13. Secure the surge tank hose with a hose clamp.
14. Connect the upper radiator hose and the lower radiator hose to the radiator.
A102D025
15. Secure each hose with a hose clamp.

16. Install the main cooling fan. Refer to Electric Cooling Fan - Main in this section.
17. Install the auxiliary cooling fan, if equipped. Refer to
Electric Cooling Fan - Auxiliary in this section.
19. Install the hood support bracket.
A102D023
ENGINE COOLANT TEMPERATURE

SENSOR
Single Overhead Cam Engine
Removal Procedure
2. Drain the coolant below the engine coolant temperature sensor level.
3. Disconnect the electrical connector from the engine
coolant temperature sensor.
4. Remove the temperature sensor from the intake
manifold.
A102D013
DAEWOO T-100 BL3
1. Install the engine coolant temperature sensor into the
threaded hole in the intake manifold.
Tighten
Tighten the engine coolant temperature sensor to
20 NSm (15 lb-ft).
2. Connect the electrical connector to the engine coolant temperature sensor.
3. Refill the coolant system. Refer to Draining and Refilling the Cooling System in this section.
A102D044
Dual Overhead Cam Engine

Removal Procedure
1. Disconnect the negative battery table.
2. Drain the coolant below the engine coolant temperature sensor level.
3. Disconnect the electrical connector from the engine
coolant temperature sensor.
4. Remove the temperature sensor from the cylinder
head.
A102D045
1. Install the engine coolant temperature sensor into the
threaded hole in the cylinder head.
Tighten
Tighten the engine coolant temperature sensor to
20 NSm (15 lb-ft).
2. Connect the electrical connector to the engine coolant temperature sensor.
3. Refill the coolant system. Refer to Draining and Refilling the Cooling System in this section.
A102D016
DAEWOO T-100 BL3
-
GENERAL DESCRIPTION
GENERAL DESCRIPTION
The cooling system maintains the engine temperature at
an efficient level during all engine operating conditions.
When the engine is cold the cooling system cools the
engine slowly or not at all. This slow cooling of the engine allows the engine to warm up quickly.
The cooling system includes a radiator and recovery
subsystem, cooling fans, a thermostat and housing, a
coolant pump, and a coolant pump drive belt. The timing
belt drives the coolant pump.
All components must function properly in order for the
cooling system to operate. The coolant pump draws the
coolant from the radiator. The coolant then circulates
through water jackets in the engine block, the intake
manifold, and the cylinder head. When the coolant
reaches the operating temperature of the thermostat,
the thermostat opens. The coolant then goes back to the
radiator where it cools.
This system directs some coolant through the hoses to
the heater core. This provides for heating and defrosting. The surge tank is connected to the radiator to recover the coolant displaced by expansion from the high
temperatures. The surge tank maintains the correct
coolant level.
The cooling system for this vehicle has no radiator cap
or filler neck. The coolant is added to the cooling system
through the surge tank.
RADIATOR
This vehicle has a lightweight tube-and-fin aluminum radiator. Plastic tanks are mounted on the right and the left
sides of the radiator core.
On vehicles equipped with automatic transaxles, the
transaxle fluid cooler lines run through the left radiator
tank. A radiator drain cock is on this radiator.
To drain the cooling system, open the drain cock.
SURGE TANK
The surge tank is a transparent plastic reservoir, similar
to the windshield washer reservoir.
The surge tank is connected to the radiator by a hose
and to the engine cooling system by another hose. As
the vehicle is driven, the engine coolant heats and expands. The portion of the engine coolant displaced by
this expansion flows from the radiator and the engine
into the surge tank. The air trapped in the radiator and
the engine is degassed into the surge tank.
DAEWOO T-100 BL3
When the engine is stops, the engine coolant cools and

contracts. The displaced engine coolant is then drawn
back into the radiator and the engine. This keeps the radiator filled with the coolant to the desired level at all
times and increases the cooling efficiency.
Maintain the coolant level between the MIN and the
MAX marks on the surge tank when the system is cold.
COOLANT PUMP
The belt-driven centrifugal coolant pump consists of an
impeller, a drive shaft, and a belt pulley. The coolant
pump is mounted on the front of the transverse-mounted
engine, and is driven by the timing belt.
The impellerissupportedby a completely sealedbearing.
The coolant pump is serviced as an assembly and,
therefore, cannot be disassembled.
THERMOSTAT
A wax pellet-type thermostat controls the flow of the engine coolant through the engine cooling system. The
thermostat is mounted in the thermostat housing to the
front of the cylinder head.
The thermostat stops the flow of the engine coolant from
the engine to the radiator in order to provide faster
warm-up, and to regulate the coolant temperature. The
thermostat remains closed while the engine coolant is
cold, preventing circulation of the engine coolant
through the radiator. At this point, the engine coolant is
allowed to circulate only throughout the heater core to
warm it quickly and evenly.
As the engine warms, the thermostat opens. This allows
the engine coolant to flow through the radiator, where
the heat is dissipated through the radiator. This opening
and closing of the thermostat permits enough engine
coolant to enter the radiator to keep the engine within
proper engine temperature operating limits.
The wax pellet in the thermostat is hermetically sealed in
a metal case. The wax element of the thermostat expands when it is heated and contracts when it is cooled.
As the vehicle is driven and the engine warms, the engine coolant temperature increases. When the engine
coolant reaches a specified temperature, the wax pellet
element in the thermostat expands and exerts pressure
against the metal case, forcing the valve open. This allows the engine coolant to flow through the engine cooling system and cool the engine.
As the wax pellet cools, the contraction allows a spring
to close the valve.
The thermostat begins to open at 87_C (189_F) and is
fully open at 102_C (226_F). The thermostat closes at
86_C (187_F).
-
ELECTRIC COOLING FAN

C
aution:Keephands,tools,andclothingawayfrom
theenginecoolingfanstohelpprevent personal in
jury. ThisfaniselectricandcanturnO
Nwhetheror
not theengineisrunning.
C
aution: If a fan blade is bent or dam
aged in any
way, noattem shouldbem
pt
adetorepair or reuse
thedam
agedpart. Abent ordam
agedfanassem
bly
shouldalwaysbereplacedwithanewone.
D The ECM will change the cooling fan(Is) from high

speed to low speed at 94_C (201_F) and turn the
cooling fans off at 90_C (194_F).
The cooling fans are mounted behind the radiator in the

engine compartment. The electric cooling fans increase
the flow of air across the radiator fins and across the
condenser on air conditioner (A/C)-equipped vehicles.
This helps to speed cooling when the vehicle is at idle or
moving at low speeds.
The main fan size is 320 mm (12.6 inches) in diameter
with five blades to aid the air flow through the radiator
and the condenser. An electric motor attached to the radiator support drives the fan.
A/C models have two fans - the main fan, and the auxiliary fan. The auxiliary fan is 250 mm (9.8 inches) in diameter. Non-A/C models have only the main fan.
ENGINE COOLANT TEMPERATURE

SENSOR
A/C OFF or Non-A/C Model

D The cooling fan(s) are actuated by the electronic control module (ECM) using a low speed cooling fan
relay and a high speed cooling fan relay. On A/C
equipped vehicles, a series/parallel cooling fan relay
is also used.
D The ECM will turn the cooling fan(s) on at low speed
when the coolant temperature reaches 93_C (199_F)
and high speed at 97_C (207_F).
A/C ON
D The ECM will turn the cooling fans on at low speed
when the A/C system is on. The ECM will change to
high speed when the coolant temperature reaches
97_C (207_F) or highside A/C pressure reaches
1 882 kPa (273 psi).
The engine coolant temperature sensor controls the instrument panel temperature indicator. The engine coolant temperature sensor is located on the intake manifold
near the throttle body on an SOHC engine, and on the
cylinder head, under the intake manifold on a DOHC engine.
ENGINE BLOCK HEATER

The vehicle is designed to accept an engine block heater. The engine block heater helps warm the engine for
improved cold weather starting. It can also help reduce
fuel consumption when a cold engine is warming up.
The engine block heater utilizes an existing expansion
plug for installation and is located under the intake manifold.
Contact your Daewoo dealer for further information or
installation.
DAEWOO T-100 BL3
SECTION 1E
ENGINE ELECTRICAL
n
o ewente.
thr is o d
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-1
Starter Specifications . . . . . . . . . . . . . . . . . . . . . . 1E-1
Generator Specifications . . . . . . . . . . . . . . . . . . . 1E-2
Battery Specifications . . . . . . . . . . . . . . . . . . . . . . 1E-2
Fastener Tightening Specifications . . . . . . . . . . . 1E-2
Schematic and Routing Diagrams . . . . . . . . . . . 1E-3
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-3
Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-4
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-5
No Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-5
Starter Motor Noise . . . . . . . . . . . . . . . . . . . . . . . . 1E-9
Battery Load Test . . . . . . . . . . . . . . . . . . . . . . . . . 1E-9
Generator Output Test . . . . . . . . . . . . . . . . . . . . 1E-10
Generator System Check . . . . . . . . . . . . . . . . . . 1E-10
Maintenance and Repair . . . . . . . . . . . . . . . . . . . 1E-11
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . 1E-11
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-11
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-15
Battery/Battery Tray . . . . . . . . . . . . . . . . . . . . . . 1E-16
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-19
Starter Motor (0.8 Kilowatts) . . . . . . . . . . . . . . .

Starter Motor (1.4 Kilowatts) . . . . . . . . . . . . . . .
Generator (C5-121D) . . . . . . . . . . . . . . . . . . . . .
Generator (C5-128D) . . . . . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reserve Capacity . . . . . . . . . . . . . . . . . . . . . . . .
Cold Cranking Amperage . . . . . . . . . . . . . . . . . .
Built-In Hydrometer . . . . . . . . . . . . . . . . . . . . . . .
Charging Procedure . . . . . . . . . . . . . . . . . . . . . .
Charging Time Required . . . . . . . . . . . . . . . . . . .
Charging a Completely Discharged Battery
(Off the Vehicle) . . . . . . . . . . . . . . . . . . . . . . . .
Jump Starting Procedure . . . . . . . . . . . . . . . . . .
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging System . . . . . . . . . . . . . . . . . . . . . . . . .
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS
STARTER SPECIFICATIONS
Application
Starter 0.8 Kilowatts
No Load Test @ 10 volts
Drive Pinion Speed at:
Solenoid
Hold in
Hold-in Windings @ 10 volts
Pull-in Windings @ 10 volts
Starter 1.4 Kilowatts
No Load Test @ 12.2 volts
Drive Pinion Speed at:
Solenoid
Hold in
Hold-in Windings @ 10 volts
Pull-in Windings @ 10 volts
DAEWOO T-100 BL3
Description
Minimum 60 - Maximum 98 amps
6,000-12,000 rpm
13 19
13-19 amps
59-79 amps
Minimum 40 - Maximum 90 amps
3,200-4,800 rpm
13 19
13-19 amps
59-79 amps
1E-19
1E-28
1E-40
1E-47
1E-55
1E-55
1E-55
1E-55
1E-55
1E-55
1E-55
1E-56
1E-56
1E-56
1E-57
1E-57
1E-57
1E-57
1E - 2 ENGINE ELECTRICAL
-
GENERATOR SPECIFICATIONS
Application
Description
Types
CS-121D CS-128D
BATTERY SPECIFICATIONS
Application
Description
L4 Engine
Cold Cranking Amps
550 amps
RC (Minimum)
90 minutes
Load Test
270 amps
Replacement
85B-60
Minimum Voltage:
9.6
9.4
9.1
8.8
8.5
8.0
Estimated Temperature:
21 C (70 F)
21_C (70_F)
20 C (68 F)
20_C (68_F)
0 C (32 F)
0_C (32_F)
* 10_C (14_F)
(
)
* 18_C (0.4_F)
(
)
Below * 18_C (Below 0_F)

Application
NSm
Lb-Ft
Lb-In
Battery Cable Nuts
15
11
Battery Carrier Tray Lower Bolts
20
15
Battery Carrier Tray Upper Bolts
20
15
Battery Retainer Clamp-to-Battery Rod Nuts
44
20
15
Generator Battery Lead Connector Nut
15
11
Generator Drive End Bearing Nut (CS-121D)
81
60
Generator Drive End Nut (CS-128D)
100
74
Generator Lower Bracket-to-Generator
20
15
Generator Shackle Bracket Bolt
20
15
Generator Through-Bolts (CS-121D)
10
89
Generator Through-Bolts (C5-128D)
25
18
Starter End Frame-to-Brush Holder Assembly Bolts

(0.8 Kilowatts)
27
Starter Field Connector Nut
71
Starter Mounting Studs
43
32
Starter Solenoid Assembly Screws
71
Starter Solenoid-to-Ignition Terminal Nut
53
Starter Through-Bolts
53
Starter Solenoid Terminal-to-Battery Cable Nut
62
DAEWOO T-100 BL3
ENGINE ELECTRICAL 1E - 3
-
STARTING SYSTEM
SCHEMATIC AND ROUTING DIAGRAMS
A202E007
DAEWOO T-100 BL3
CHARGING SYSTEM
-
A202E008
DAEWOO T-100 BL3
-
DIAGNOSIS
NO CRANK
Step
Action
Value(s)
Yes
No
Go to Step 2
Go to Step 8
Go to Step 3
Go to
Charging
Procedure
1. Turn the headlamps ON.

2. Turn the dome lamps ON.
3. Turn the key to START.
Do the lights dim or go out?
Check the battery state of charge.

Is the green eye showing from the built-in
hydrometer?
1. Connect the voltmeter positive lead to the positive

battery terminal.
2. Connect the voltmeter negative lead to the
negative battery terminal.
3. Turn the ignition to START.
Does the voltmeter indicate the value specified?
<9.6 v
Go to Charging
Procedure
Go to Step 4

2. Connect the voltmeter positive lead to the engine
block.
3. Place the ignition in the START position.
>0.5 v
Go to Step 5
Go to Step 6
1. Clean and tighten the negative battery cable

connections both at the battery end and at the
ground end.
2. Replace the cable if needed.
1. Connect the voltmeter positive lead to the starter

B terminal.
3. Check the cranking voltage.
7
8
9
10
11
12
DAEWOO T-100 BL3
Clean, tighten, or replace the positive battery cable.

Check system fuse EF3 in the engine fuse block.
Is fuse EF3 blown?
Replace system fuse EF3.
Check the connection at the starter S terminal.
Is the connection in good condition?
Repair the starter S terminal.
1. Connect the voltmeter positive lead to the starter
S terminal.
4. Read the voltage present at the S terminal.
Does the voltmeter indicate the specified value?
System OK
<9 v
-
>7 v
Go to Step 7
System OK
Go to Step 9
System OK
Go to Step 12
System OK
Go to Step 13
Go to Step 13
Go to Step 10
Go to Step 11
-
Go to Step 14
-
NO CRANK (Contd)
Step
13
14
15
16
17
18
19
Action
Repair or replace the starter.
Turn on the heater blower.
Does the blower operate?
1. Disconnect connector C201.
2. Connect the voltmeter positive lead to terminal
1 of connector C201.
3. Connect the voltmeter negative terminal to
ground.
Repair the open in the RED/WHT wire from fuse
EF3 to Connector C201.
Check the contacts of terminal 1 on connector C201.
Are the contacts OK?
Repair the faulty contact of connector C201.
1. Reconnect connector C201.
2. Disconnect the ignition switch connector.
5 of the ignition switch connector.
4. Connect the voltmeter negative terminal to
ground.
Value(s)
-
12 v
-
11-14 v
Yes
System OK
No
-
Go to Step 24
Go to Step 15
Go to Step 17
Go to Step 16
System OK
Go to Step 19
System OK
Go to Step 21
Go to Step 18
-
Go to Step 20
Repair the open in the RED/WHT wire from terminal

1 of connector C201 to terminal 5 of the ignition
switch connector.
21
Check the contacts of terminal 5 of the ignition

switch connector.
Are the contacts OK?
22
Repair the faulty contact of the ignition switch

connector.
23
Replace the ignition switch.

24
Does the vehicle have an automatic transmission?
Go to Step 25
Go to Step 35
25
1. Disconnect the Park/Neutral switch connector.

2. Connect the voltmeter positive lead to the
Park/Neutral switch connector terminal E,
connected to the RED/BLK wire.
<7 v
Go to Step 26
Go to Step 31
Check continuity between the Park/Neutral switch

connector terminal G, connected to the RED wire,
and the Park/Neutral switch connector terminal E,
connected to the RED/BLK wire.
Does the ohmmeter indicate the specified value?
0W
Go to Step 27
Go to Step 30
20
26
System OK
Go to Step 23
System OK
System OK
Go to Step 22
-
DAEWOO T-100 BL3
-
NO CRANK (Contd)
Step
Action
Value(s)
Repair the faulty terminal.

29
Repair the open in the RED wire between terminal G

of the Park/Neutral switch connector and the starter
S terminal.
30
Replace the Park/Neutral switch.

31
1. Reconnect the Park/Neutral switch.

10 of connector C104 on the ECM/ABS harness.
4. Connect the voltmeter negative lead to ground.
5. Turn the ignition switch to START.
Go to Step 29
28
No
Go to Step 28
Check the condition of terminals E and G on both

the Park/Neutral switch connector and on the
Park/Neutral switch.
Are any of these terminals faulty?
Yes
27
32
33
34
35
36
37
Check terminal 10 on both sides of connector C104.

Is one of them faulty?
Repair the open in the RED/BLK wire from terminal
10 of connector C104 to terminal E of the
Park/Neutral switch.
10 of connector C104 on the ECM/ABS harness.
38
Repair the open in the RED wire from terminal 10 of

connector C104 to the starter S terminal.
39

14 of connector C210 on the I/P harness.
40
41
DAEWOO T-100 BL3

System OK
System OK
12 v
-
System OK
Go to Step 32
Go to Step 39
Go to Step 33
Go to Step 34
System OK
System OK
12 v
-
12 v
-
Go to Step 36
Go to Step 39
Go to Step 37
Go to Step 38
System OK
System OK
Go to Step 40
Go to Step 43
Go to Step 41
Go to Step 42
System OK
-
NO CRANK (Contd)
Step
Action
Value(s)
42
Repair the open in the RED wire from terminal 14 of

connector C210 to terminal 10 of connector C104.
43
1. Disconnect the ignition switch connector.

2. Connect the voltmeter positive lead to terminal ST
of the ignition switch.
44
45
46
47
Replace the ignition switch.

Check terminal ST on the ignition switch and
terminal 3 of the ignition switch connector.
Are the terminals in good condition?
12 v
-
Repair the open in RED wire between terminal 3 of

the ignition switch connector and terminal 14 of
connector C210.
System OK
Go to Step 45
System OK
Go to Step 46

Yes
No
-
Go to Step 44
-
Go to Step 47
-
System OK
System OK
DAEWOO T-100 BL3
-
STARTER MOTOR NOISE

To correct starter motor noise during starting, use the following procedure:
Checks
Action
Check for a high-pitched whine during cranking, before

the engine fires. The engine cranks and fires properly.
The distance is too great between the starter pinion

and the flywheel. Shimming the starter toward the
flywheel is required.
Check for a high-pitched whine after the engine fires,

as the key is being released. The engine cranks and
fires properly. This intermittent complaint is often
diagnosed as starter hang-in or solenoid weak.
The distance is too small between the starter pinion

and the flywheel. Shimming the starter away from the
flywheel is required.
Check for a loud whoop after the engine fires but

while the starter is still held engaged. The sound is like
a siren if the engine is revved while the starter is
engaged.
The most probable cause is a defective clutch. A new

clutch will often correct this problem.
Check for a rumble, a growl, or, in severe cases, a

knock as the starter is coasting down to a stop after
starting the engine.
The most probable cause is a bent or an unbalanced

starter armature. A new armature will often correct this
problem.
If the complaint is noise, correction can be achieved by

proper shimming as follows:
1. Check for a bent or a worn flywheel.
2. Start the engine and carefully touch the outside diameter of the rotating flywheel ring gear with chalk or a
crayon to show the high point of the tooth runout.
Turn the engine OFF and rotate the flywheel so that
the marked teeth are in the area of the starter pinion
gear.
3. Disconnect the negative battery cable to prevent the
cranking of the engine.
4. Check the pinion-to-flywheel clearance by using a
wire gauge of 0.5 mm (0.02 inch) minimum thickness
or diameter. Center a pinion tooth between two flywheel teeth and the gauge. Do not gauge in the corners, where a misleading larger dimension may be
observed. If the clearance is under this minimum,
shimming the starter away from the flywheel is required.
5. If the clearance approaches 1.5 mm (0.06 inch) or
more, shimming the starter toward the flywheel is required. This condition is generally the cause of broken flywheel teeth or a broken starter housing. Shim
the starter toward the flywheel by shimming only the
outboard starter mounting pad. A shim of 0.40 mm
(0.016 inch) thickness at this location will decrease
the
clearance
by
approximately
0.30 mm
(0.012 inch). If normal starter shims are not available,
plain washers or other suitable material may be used
as shims.
DAEWOO T-100 BL3
BATTERY LOAD TEST

1. Check the battery for obvious damage, such as a
cracked or broken case or cover, which could permit
the loss of electrolyte. If damage is obvious, replace
the battery.
Caution: Do not charge the battery if the hydrometer
is clear or light yellow. Instead, replace the battery. If
the battery feels hot or if violent gassing or spewing
of electrolyte through the vent hole occurs, discontin
ue charging or reduce the charging rate to avoid inju
ry.
2. Check the hydrometer. If the green dot is visible, go to
the load test procedure. If the indicator is dark but
green is not visible, charge the battery. For charging a
battery removed from the vehicle, refer to Charging a
Completely Discharged Battery (Off the Vehicle) in
this section.
3. Connect a voltmeter and a battery load tester across
the battery terminals.
4. Apply a 300-ampere load for 15 seconds to remove
any surface charge from the battery.
5. Remove the load.
6. Wait 15 seconds to let the battery recover, and apply
a 270-ampere load.
Important: The battery temperature must be estimated
by touch and by the temperature condition the battery
has been exposed to for the preceding few hours.
7. If the voltage does not drop below the minimum
listed, the battery is good and should be reinstalled. If
the voltage is less than the minimum listed, replace
the battery. Refer to Battery Specifications in this
section.
-
GENERATOR OUTPUT TEST

1. Perform the generator system test. Refer to Generator System Check in this section.
2. Replace the generator if it fails that test. Refer to
Generator in the On-Vehicle Service section. If it
passes the test, perform the on-vehicle output
check which follows.
Important: Always check the generator for output before assuming that a grounded L terminal circuit has
damaged the regulator.
3. Attach a digital multimeter, an ammeter, and a carbon pile load to the vehicle.
Important: Be sure the vehicle battery is fully charged,
and the carbon pile load is turned off.
4. With the ignition switch in the OFF position, check
and record the battery voltage.
5. Remove the harness connector from the generator.
6. Turn the ignition switch to the RUN position with the
engine not running. Use a digital multimeter to
check for voltage in the harness connector L terminal.
7. The reading should be near the specified battery
voltage of 12 volts. If the voltage is too low, check
the indicator L terminal circuits for open and
grounded circuits causing voltage loss. Correct any
open wires, terminal connections, etc., as necessary. Refer to Charging System in this section.
8. Attach the generator harness connector.
9. Run the engine at a moderate idle, and measure the
voltage across the battery terminals. The reading
should be above that recorded in Step 14 but less
than 16 volts. If the reading is over 16 volts or below
the previous reading, replace the generator. Refer to
Generator in the On-Vehicle Service section.
10. Run the engine at a moderate idle, and measure the
generator amperage output.
11. Turn on the carbon pile, and adjust it to obtain the
maximum amps while maintaining the battery voltage above 13 volts.
12. If the reading is within 15 amps of the generators
rating noted on the generator, the generator is good.
If not, replace the generator. Refer to Generator
in the On-Vehicle Service section.
13. With the generator operating at the maximum output, measure the voltage between the generator
housing and the battery negative terminal. The voltage drop should be 0.5 volt or less. If the voltage
drop is more than 0.5 volt, check the ground path
from the generator housing to the negative battery
cable.
14. Check, clean, tighten, and recheck all of the ground
connections.
C102E009
GENERATOR SYSTEM CHECK

When operating normally, the generator indicator lamp
will come on when the ignition switch is in the RUN position and go out when the engine starts. If the lamp operates abnormally or if an undercharged or overcharged
battery condition occurs, the following procedure may
be used to diagnose the charging system. Remember
that an undercharged battery is often caused by accessories being left on overnight or by a defective switch
that allows a lamp, such as a trunk or glove box lamp, to
stay on.
Diagnose the generator with the following procedure:
1. Visually check the belt and wiring.
2. With the ignition switch in the ON position and the engine stopped, the charge indicator lamp should be on.
If not, detach the harness at the generator and
ground the L terminal in the harness with a fused,
5-ampere jumper lead.
D If the lamp lights, replace the generator. Refer to
D If the lamp does not light, locate the open circuit
between the ignition switch and the harness connector. The indicator lamp bulb may be burned out.
3. With the ignition switch in the ON position and the engine running at moderate speed, the charge indicator
lamp should be off. If not, detach the wiring harness
at the generator.
D If the lamp goes off, replace the generator. Refer to
D If the lamp stays on, check for a short to ground in
the harness between the connector and the indicator lamp.
Important: Always check the generator for output before assuming that a grounded L terminal circuit has
damaged the regulator. Refer to Generator in the Unit
Repair section.
DAEWOO T-100 BL3
-

ON-VEHICLE SERVICE
GENERATOR
Removal Procedure
2. Disconnect the manifold air temperature (MAT) sensor electrical connector from the air intake tube.
A202E001
3. Remove the breather tube clamp and all other clamps

to remove the air intake tube.
A202E002
4. Remove the battery harness connector nut from the

generator.
A102E232
DAEWOO T-100 BL3
5. Remove the generator shackle bracket bolt and the
washer.
6. Remove the serpentine accessory drive belt. For vehicles equipped with power steering and air conditioning, refer to Section 6B, Power Steering Pump for belt
removal.
A202E003
7. Remove the bolt and the retaining clamp of the harness.
A202E004
8. For vehicles with the SOHC engine, remove the nuts

and the washers which hold the generator lower
bracket-to-generator bolts.
A102E234
DAEWOO T-100 BL3
9. For vehicles with the DOHC engine, remove the
throttle body. Refer to Section 1F, Engine Controls.
10. Remove the fuel rail mounting bolts.
Notice: Take extreme care not to damage the fuel injector O-rings to prevent fuel leaks when the fuel rail is reseated.
11. Unseat the fuel rails from the cylinder head, and
slightly push the fuel rail assembly clear of the cylinder head in the direction of the master cylinder.
12. Remove the nut and the washers which hold the
generator lower bracket-to-generator bolt.
13. Carefully remove the generator.
A102E254
1. Install the generator at the generator lower bracket

and insert the generator bolts.
2. Install the nuts and the washers on the generator lower bracket-to-generator bolts (SOHC engine is
shown).
Tighten
Tighten the generator lower bracket-to-generator

nuts to 20 NSm (15 lb-ft).
A102E234
3. Install the serpentine accessory drive belt on vehicles

not equipped with power steering and air conditioning.
4. Secure the generator to the shackle bracket with the
bolt (SOHC engine is shown). For vehicles equipped
with power steering and air conditioning, refer to Sec
tion 6B, Power Steering Pump.
Tighten
Tighten the generator shackle bracket bolt to 20 NSm
(15 lb-ft).
A102E231
DAEWOO T-100 BL3
5. Connect the harness connector to the back of the
generator.
6. Install the generator lead to the battery and fasten
the lead with the nut.
Tighten
Tighten the generator battery lead connector nut to
15 NSm (11 lb-ft).
7. Lubricate the injector O-rings on the DOHC engine
with engine oil.
8. Install the fuel rail assembly.
Tighten
Tighten the fuel rail retaining bolts to 20 NSm (15 lbft).
9. Install the throttle body. Refer to Section 1F, Engine
Controls.
A102E232
10. Install the harness retaining clamp bolt.
A202E004
11. Install the air intake tube and the connector.
A202E002
DAEWOO T-100 BL3
12. Install the MAT electrical connector to the air intake
tube.
A202E001
STARTER
Removal Procedure
1. Remove the nut that secures the starter ground wire
to the mounting stud.
2. Remove the ground wire.
3. Remove the lower and then the upper starter stud/
weld nut assemblies. (The lower stud/weld nut assembly is shown.)
B202E005
4. Remove the starter solenoid nuts to disconnect the

electrical cables.
5. Remove the starter assembly.
A102E236
DAEWOO T-100 BL3
1. Place the starter assembly in position using an assistant to prop up the starter to aid in fastening the upper
mounting stud with the weld nut.
2. Install the upper and the lower starter mounting studs
with the weld nuts.
Tighten
Tighten the starter mounting studs to 43 NSm (32 lbft).
B202E005
3. Position the starter electrical wires on the solenoid

terminals.
4. Position the ground wire on the lower stud.
5. Install the starter solenoid nuts.
Tighten
Tighten the starter solenoid terminal-to-battery cable
terminal nut to 7 NSm (62 lb-in).
Tighten the starter solenoid terminal-to-ignition terminal nut to 6 NSm (53 lb-in).
6. Install the ground wire nut.
Tighten
Tighten the ground wire terminal to the point at which
it meets the nut. Then tighten the ground wire terminal an additional quarter turn.
A102E236
BATTERY/BATTERY TRAY
Removal Procedure
1. Disconnect the negative battery cable and then disconnect the positive battery cable.
2. Remove the nuts from the battery rods that fasten the
battery hold-down bar clamp.
A102E241
DAEWOO T-100 BL3
3. Check the battery carrier tray for obvious cracks or
damage. Detach the carrier tray if necessary by removing the upper and the lower bolts.
A202E005
1. Install the battery carrier by fastening the carrier tray
upper and lower bolts.
Tighten
Tighten the battery carrier tray upper and lower bolts
A202E005
2. Install the battery into the tray.

3. Fasten the bar clamp to the battery by loosely attaching the battery rods from the battery tray cutouts
through the bar clamp holes, and loosely tightening
the nuts.
Tighten
Tighten the battery retainer clamp-to-battery rod nuts
A102E241
DAEWOO T-100 BL3
4. Connect the negative and the positive battery cables.
Tighten
Tighten the battery cable nuts to 15 NSm (11 lb-ft).
A102E240
DAEWOO T-100 BL3
-
UNIT REPAIR
STARTER MOTOR (0.8 KILOWATTS)
1. Remove the starter. Refer to Starter in this section.
2. Remove the starter through-bolts.
A302E002
3. Remove the field connector nut. Disconnect the field

connector.
A302E003
4. Pry off the commutator end frame/brush/brush holder

assembly from the field frame.
5. Remove the bolts that secure the end frame to the
brush/brush holder assembly.
6. Inspect the brushes, the pop-out springs, and the
plastic spring retainers for wear and damage. Replace the parts, if necessary.
A302E004
DAEWOO T-100 BL3
7. Check the armature to see if it turns freely. If the armature does not turn freely, break down the assembly
beginning with Step 9. Otherwise, give the armature a
no-load test.
A302E005
Important: If the specified current draw does not include the solenoid, deduct from the armature reading
the specified current draw of the solenoid hold-in winding.
Notice: Complete the testing in a minimum amount of
time to prevent overheating and damaging the solenoid.
A102E219
8. To begin the no-load test, close the switch and

compare the rpm, the current, and the voltage readings with the specifications. Refer to Starter Specifications in this section. Make disconnections only
with the switch open. Use the test results as follows:
8.1. Rated current draw and no-load speed indicate a normal condition for the starter motor.
8.2. Low free speed and high current draw indicate
too much friction (tight, dirty, or worn bearings, or a bent armature shaft), a shorted armature, or a shorted armature and fields.
8.3. Failure to operate with high current draw indicates a direct ground in the terminal or fields,
or frozen bearings.
8.4. Failure to operate with no current draw indicates an open field circuit, open armature
coils, broken brush springs, worn brushes,
high insulation between the commutator bars,
or other causes which will prevent good contact between the brushes and the commutator.
8.5. Low no-load speed and low current indicate
high internal resistance and high current
draw, which usually means shorted fields.
A102E219
DAEWOO T-100 BL3
9. Separate the field frame from the armature assembly.
A302E006
10. Remove the solenoid assembly screws.
A102E226
11. Rotate the solenoid and remove it along with the

plunger return spring.
A102E247
DAEWOO T-100 BL3
Important: If the solenoid is not removed from the starting motor, the connector strap terminals must be removed from the terminal on the solenoid before making
these tests.
12. Test the solenoid windings by checking the current
draw.
12.1. Check the hold-in windings by connecting
an ammeter in series with a 12-volt battery,
the switch terminal, and to ground.
12.2. Connect the carbon pile across the battery.
12.3. Adjust the voltage to 10 volts. The ammeter
reading should be 13 to 19 amperes.
A102E221
Important: Current will decrease as the windings heat

up. Current draw readings that are over specifications
indicate shorted turns or a ground in the windings of the
solenoid Both conditions require replacement of the solenoid. Current draw readings that are under specifications indicate excessive resistance. No reading
indicates an open circuit.
13. Check both windings, connecting them as in the preceding test.
13.1. Ground the solenoid motor terminal.
13.2. Adjust the voltage to 10 volts. The ammeter
reading should be 59 to 79 amperes.
13.3. Check the connections and replace the solenoid, if needed.
A102E221
14. Remove the plunger with the boot and the shift lever
assembly.
A302E007
DAEWOO T-100 BL3
15. Remove the armature assembly from the starter
housing.
A302E008
16. Disassemble the shaft assembly by separating the

bushing from the shaft.
17. Remove the collar and the locking ring from the
groove on the shaft.
A102E220
18. Remove the pinion stop and the drive from the shaft.
A102E248
DAEWOO T-100 BL3
-
A302E008
19. Inspect the armature shaft, the collar, and the pinion
for discoloration, damage, or wear. Replace the
parts, as needed.
20. Inspect the armature commutator. If the commutator is rough, it should be turned down. The outside
diameter of the commutator must measure at least
41.91 mm (1.650 inches) after it is undercut or
turned. Do not turn out-of-round commutators.
21. Inspect the points where the armature conductors
join the commutator bars. Make sure the armature
conductors and the commutator bars have a good
connection. A burned commutator bar is usually evidence of a poor connection.
22. If test equipment is available, check the armature for
short circuits by placing it on a growler and holding a
saw blade over the armature core while the armature is rotated. If the saw blade vibrates, replace the
armature.
23. Recheck the armature after cleaning between the
commutator bars. If the saw blade vibrates, replace
the armature.
Assembly Procedure
1. Clean all of the starter motor parts, but do not use
grease-dissolving solvents for cleaning the armature
and the field coils.
2. Lubricate the drive and the bushings.
3. If proceeding with just the reassembly of the solenoid,
perform Steps 4 and 5.
4. If the starter and the solenoid were fully disassembled, begin reassembly by installing the shift lever assembly with the plunger and the boot.
A302E007
DAEWOO T-100 BL3
5. Position the solenoid assembly and the return spring
against the plunger, applying the sealer to the solenoid flange.
A102E247
6. Fasten the solenoid assembly with the screws.
Tighten
Tighten the starter solenoid assembly screws to
8 NSm (71 lb-in).
A102E226
7. Install the drive and the pinion stop on the armature

shaft.
A102E248
DAEWOO T-100 BL3
8. Install the lock ring into the groove on the armature
shaft.
9. Insert the collar.
A102E220
10. Install the field frame.
A302E006
11. With new brushes positioned in the brush holder assembly, measure the inside diameter of the brush
holder assembly.
12. Insert the brush holder assembly on a plastic, steel,
or wooden dowel about the same diameter as the inside diameter of the brush holder assembly.
A302E009
DAEWOO T-100 BL3
13. Position the end of the dowel with the armature
commutator end. Slide the brush holder assembly
onto the armature.
14. Install the end frame on the brush holder assembly
with the bolts.
Tighten
Tighten the starter end frame-to-brush holder assembly bolts to 3 NSm (27 lb-in).
A302E010
15. Install the starter through-bolts.
Tighten
Tighten the starter through-bolts to 6 NSm (53 lb-in).
A302E002
16. Install the starter field coil connection to the starter

terminal and fasten it with the nut.
Tighten
Tighten the starter field connector nut to 8 NSm (71 lbin).
A302E011
DAEWOO T-100 BL3
Important: The pinion clearance must be correct to prevent the buttons on the shift lever yoke from rubbing on
the clutch collar during cranking.
17. When the solenoid is replaced, it is necessary to
check the pinion clearance.
A302E001
18. Disconnect the motor field coil connector from the

solenoid motor terminal and carefully insulate the
connector.
19. Connect one 12-volt battery lead to the solenoid
switch terminal and the other to the starter frame.
20. Flash a jumper lead momentarily from the solenoid
motor terminal to the starter frame, allowing the pinion to shift in the cranking position, where it will remain until the battery is disconnected.
Important: A means for adjusting the pinion clearance
is not provided on the starter motor. If the clearance
does not fall within the limits, check for improper installation and replace all worn parts.
A102E227
21. Push the pinion back as far as possible to take up

any movement, and check the clearance with a feeler gauge. The clearance should be 0.25 to 3.56 mm
(0.01 to 0.14 inch).
STARTER MOTOR (1.4 KILOWATTS)

1. Remove the starter. Refer to Starter, in this section.
2. Remove the starter through-bolts.
A102E239
DAEWOO T-100 BL3
3. Remove the commutator end frame/brush holder assembly.
4. Inspect the brushes, the pop-out springs, and the
brush holders for wear and damage. Replace the assembly, if necessary.
A102E215
Important: This test should be made for each ground or

insulated brush to ensure continuity through both
brushes and leads. If the lamp fails to light, the field coil
is open and will require replacement.
5. For only those starters having a shunt coil connection, use a test lamp, placing one lead on the shunt
coil terminal while connecting the other lead to a
ground brush or an insulated brush.
A102E216
6. When testing a series coil for ground, separate the

series and the shunt coil strap terminals during the
test.
6.1 With the strap terminals not touching the case
or the other ground, using a test lamp, placing
one lead on the grounded brush holder and
the other lead on either insulated brush.
6.2 If the lamp is lit, a grounded series coil is indicated and must be repaired or replaced.
6.3 Test for an open circuit on each insulated
brush by placing one lead on the series coil
terminal and the other lead on the insulated
brush.
6.4 If the test lamp is not lit, the series coil is open
and will require repair or replacement.
A102E217
DAEWOO T-100 BL3
7. Check the armature to see if it turns freely. If the armature does not turn freely, break down the assembly
immediately, starting with Step 14. Otherwise, give
the armature a no-load test.
A102E218
Notice: Complete the testing in a minimum amount of

time to prevent overheating and damaging the solenoid.
Important: If the specified current draw does not include the solenoid, deduct from the armature reading
the specified current draw of the solenoid hold-in winding.
A102E219
8. To begin the no-load test, close the switch and

compare the rpm, the current, and the voltage readings with the specifications. Refer to Starter Specifications in this section. Make disconnections only
with the switch open. Use the test results as follows:
8.1 Rated current draw and no-load speed indicate a normal condition for the starter motor.
8.2 Low free speed and high current draw indicate
too much friction from tight, dirty, or worn
bearings, or a bent armature shaft, a shorted
armature, or a shorted armature or fields.
8.3 Failure to operate with high current draw indicates a direct ground in the terminal or fields,
or frozen bearings.
8.4 Failure to operate with no current draw indicates an open field circuit, open armature
coils, broken brush springs, worn brushes,
high insulation between the commutator bars,
or other causes which would prevent good
contact between the brushes and the commutator.
8.5 Low no-load speed and low current indicate
high internal resistance and high current
draw, which usually mean shorted fields.
A102E219
DAEWOO T-100 BL3
9. Remove the solenoid assembly screws.
A102E226
10. Remove the field connector nut. Disconnect the field

connector.
A102E243
11. Rotate the solenoid 90 degrees and remove it along

with the plunger return spring.
A102E247
DAEWOO T-100 BL3
Important: If the solenoid is not removed from the starting motor, the connector strap terminals must be removed from the terminal on the solenoid before making
these tests.
12. Test the solenoid windings by checking the current
draw.
12.1 Check the hold-in windings by connecting
an ammeter in series with a 12-volt battery,
the switch terminal, and to ground.
12.2 Connect the carbon pile across the battery.
12.3 Adjust the voltage to 12.2 volts. The ammeter reading should be 12 to 21 amperes.
A102E221
Important: Current will decrease as the windings heat

up. Current draw readings that are over specifications
indicate shorted turns or a ground in the windings of the
solenoid. Both conditions require replacement of the solenoid. Current draw readings that are under specifications indicate excessive resistance. No reading
indicates an open circuit.
13. Check both windings, connecting them according to
the preceding test.
13.1 Ground the solenoid motor terminal.
13.2 Adjust the voltage to 12.2 volts. The ammeter reading should be 60 to 90 amperes.
13.3 Check the connections and replace the solenoid, if necessary.
A102E221
14. Slide the field frame with the enclosed armature assembly away from the starter assembly.
15. Remove the shield.
A102E222
DAEWOO T-100 BL3
16. Separate the field frame from the armature.
A102E242
A102E223
17. Inspect the shaft, the bearing, and the pinion for discoloration, damage, or wear. Replace, if necessary.
18. Inspect the armature commutator. If the commutator is rough, it should be turned down. The outside
diameter of the commutator must measure at least
41.91 mm (1.650 inches) after it is undercut or
turned. Do not turn out-of-round commutators.
19. Inspect the points where the armature conductors
join the commutator bars. Make sure they have a
good connection. A burned commutator bar is usually evidence of a poor connection.
20. If test equipment is available, check the armature for
short circuits by placing it on a growler, and holding
back a saw blade over the armature core while the
armature is rotated. If the saw blade vibrates, replace the armature.
21. Recheck the armature after cleaning between the
commutator bars. If the saw blade vibrates, replace
the armature.
22. Remove the gears, the bushings, and the washer.
23. Remove the cushion and the driveshaft assembly
from the starter housing.
A202E006
DAEWOO T-100 BL3
24. Disassemble the driveshaft assembly by first separating the needle bearing from the driveshaft.
25. Remove the collar and the locking ring from the
groove in the driveshaft.
A102E220
26. Remove the pinion stop and the drive from the driveshaft.
A102E248
27. Remove the gear support and the collar from the driveshaft.
C302E016
DAEWOO T-100 BL3
28. If not done in the previous steps, remove the screws
that hold the solenoid assembly into the housing,
and remove the nut from the field coil connector.
A102E226
29. Rotate the solenoid 90 degrees and remove it along

with the return spring.
A102E247
30. Remove the plunger with the boot and the shift lever
assembly. Test the solenoid windings, if not done in
Step 12.
A302E007
DAEWOO T-100 BL3
Important: The pinion clearance must be correct to prevent the buttons on the shift lever yoke from rubbing on
the clutch collar during the cranking.
31. When the starter motor is disassembled and the solenoid is replaced, it is necessary to check the pinion
clearance when the starter is reassembled.
A102E237
32. Disconnect the motor field coil connector from the

solenoid motor terminal and carefully insulate the
connector.
33. Connect one 12-volt battery lead to the solenoid
switch terminal and the other to the starter frame.
34. Flash a jumper lead momentarily from the solenoid
motor terminal to the starter frame, allowing shifting
of the pinion in the cranking position, where it will remain until the battery is disconnected.
Important: A means for adjusting the pinion clearance
is not provided on the starter motor. If the clearance
does not fall within the limits, check for improper installation and replace all worn parts.
A102E227
35. Push the pinion back as far as possible to take up

any movement, and check the clearance with a feeler gauge. The clearance should be 0.25 to 3.56 mm
(0.01 to 0.14 inch).
Assembly Procedure
1. Clean all of the starter motor parts, but do not use
grease-dissolving solvents for cleaning the armature
and the field coils.
2. Lubricate the gears with lubricant. (Begin at Step 7 if
proceeding with just the reassembly of the solenoid.)
3. If full disassembly of the starter and the solenoid was
performed, begin reassembly by placing the gear
support and the collar on the driveshaft assembly.
C302E016
DAEWOO T-100 BL3
4. Install the drive and the pinion stop on the driveshaft.
A102E248
5. Install the lock ring into the groove on the driveshaft

and insert the collar.
6. Install the needle bearing.
A102E220
7. Install the shift lever assembly with the plunger and

the boot.
A302E007
DAEWOO T-100 BL3
8. Lubricate the gears with lubricant and install the driveshaft assembly with the bushing and the washer
on the gear end.
9. Install the cushion and the gears.
A102E224
10. Lubricate the drive end of the armature shaft with lubricant and install the new gear and the bearing, if
necessary.
A102E223
11. Position the solenoid assembly and the return spring

against the plunger, applying sealer to the solenoid
flange.
A102E247
DAEWOO T-100 BL3
12. Fasten the solenoid assembly with the screws.
Tighten
Tighten the starter solenoid assembly screws to
8 NSm (71 lb-in).
13. Install the field coil connection to the starter terminal. Install the nut.
Tighten
Tighten the starter field connector nut to 8 NSm
(71 lb-in).
A102E226
14. Position the armature assembly into the field frame.

15. Place the shield on the armature and the field frame
assembly.
16. Install the armature and the field frame assembly
with the shield into the starter housing.
A102E222
17. Position the commutator end frame/brush holder assembly, lining up the end frame holes with the
through-bolt holes in the housing.
A102E215
DAEWOO T-100 BL3
18. Install the starter through-bolts.
19. Install the starter. Refer to Starter in this section.
Tighten
Tighten the starter through-bolts to 6 NSm (53 lb-in).
20. Refer to Starter in this section.
A102E239
GENERATOR (C5-121D)
1. Remove the generator. Refer to Generator in the
On-Vehicle Service section.
2. Mark a match line that cannot easily be removed on
the end frame to make assembly easier.
3. Pry off the plastic cover to expose the stator connections.
A102E201
Notice: If the stator connections are not welded, melt

the lead. Avoid excessive heating, as it can damage the
diodes in the rectifier bridge.
4. Remove the stator connections from the rectifier
bridge terminals by unsoldering or cutting the wires.
A102E258
DAEWOO T-100 BL3
5. Remove the generator through-bolts.
A102E203
Important: The fastening torque of this nut is 81 NSm

(60 lb-ft) and may not normally be unfastened using
hand strength.
6. Move to the drive end of the generator and remove
the drive end bearing nut.
A102E251
7. Remove the pulley and the collars.
A102E259
DAEWOO T-100 BL3
8. Test the rotor for an open circuit by using the ohmmeter with the drive end frame assembled. The
reading should be sufficiently high, or the rotor must
be replaced.
A102E252
9. Test the rotor for open and short circuits. The reading should be 1.7 to 2.3 ohms, or the rotor should be
replaced.
A102E205
10. Remove the drive end frame from the shaft.

11. For vehicles with an internal generator fan, remove
the drive end frame and the fan.
A102E206
DAEWOO T-100 BL3
12. Remove the rotor assembly.
A102E207
13. Remove the stator.

14. Test the stator for an open circuit using the ohmmeter.
A102E208
15. Pry off the baffle.

16. Remove the rectifier/regulator/brush holder assembly screws.
17. Remove the brush holder assembly and the regulator, cutting the terminal between the regulator and
the rectifier bridge.
Important: If the brush can be reused, reassemble the
brush to the holder with the retaining pin, after cleaning
the brush with a soft, clean cloth.
A102E256
DAEWOO T-100 BL3
18. Test the rectifier bridge by connecting the ohmmeter
terminals to the bridge and the heat sink.
A102E211
19. Retest by connecting the ohmmeter terminals in reverse.
A102E204
20. Replace the rectifier bridge, if each reading is the

same.
21. Test the remaining two diodes after the above procedure.
Notice: Some kinds of digital ohmmeters are not suited
for the test of the bridge diode. In this case, consult the
manufacturer regarding the test capacity.
22. Test the diodes by connecting the ohmmeter terminals to the bridge terminal and the base plate. If the
reading is the same, the rectifier bridge should be
replaced.
A102E211
DAEWOO T-100 BL3
23. Remove the ring in the slip ring end frame.
A102E212
Assembly Procedure
1. Install the new ring in the slip ring end frame.
2. Push the new bearing outer lace into the bottom of
the end frame casting.
A102E257
3. Solder the brush holder terminal to the regulator terminal, if removed.

4. Fix the brush holder with the retainer pin, and solder
the regulator/brush holder assembled terminal to the
rectifier terminal.
5. Apply silicone grease between the bridge and the end
frame for radiation purposes.
6. Fasten the screws holding the rectifier regulator/
brush holder assembly to the end frame.
7. Punch the new baffle with the pin into the brush.
A102E256
DAEWOO T-100 BL3
8. Install the stator.
A102E213
Notice: Take care to prevent damage to the vehicle by

protecting the diode in the rectifier bridge from excessive heat while soldering or welding.
9. Solder or weld the connectors of the rectifier bridge.
A102E202
10. Install the outside cover.
A102E201
DAEWOO T-100 BL3
11. Position the rotor assembly shaft with the drive end
frame in the slip ring end assembly until the gap between the outer lace and the end frame casting is
1.9 mm (0.075 inch).
12. Install the generator through-bolts.
Tighten
Tighten the generator through-bolts to 10 NSm (89 lbin).
A102E203
13. Position the fan, the collars, and the pulley on the
rotor shaft and secure with the nut.
Tighten
Tighten the generator drive end bearing nut to 81 NSm
(60 lb-ft).
14. Install the generator. Refer to Generator in the OnVehicle Service section.
A102E251
GENERATOR (CS-128D)
1. Remove the generator. Refer to Generator in this
section.
2. Remove the driveshaft nut.
A102E251
DAEWOO T-100 BL3
3. Remove the pulley and the collar from the driveshaft.
C302E002
4. Pry off the plastic cover that encloses the rectifier and
the regulator/brush holder assemblies.
5. Inspect the cover for damage.
C302E014
6. Remove the generator through-bolts.
C302E003
DAEWOO T-100 BL3
7. Remove the bolts that fasten the rectifier assembly
and the regulator assembly to the slip ring end frame.
C302E004
8. To remove the regulator/brush holder and the rectifier

assemblies, first melt the solder of the lead that connects the regulator/brush holder assembly to the rectifier assembly. Then melt the lead to the stator,
followed by the other rectifier assembly leads to the
stator (as shown).
C302E005
9. Test each of the three diodes of the rectifier assembly

for continuity. Connect the ohmmeter probes on each
side of the diode. Retest by connecting the ohmmeter
probes in reverse. If the readings are the same, replace the rectifier.
C302E006
DAEWOO T-100 BL3
10. Mark a line perpendicular to the crack between the
case of the drive end frame and that of the slip ring
end frame.
11. Pry open the drive end frame from the slip ring end
frame.
12. Remove the collar.
C302E007
13. Remove the fan.
C302E008
14. Separate the rotor from the slip ring end frame.
C302E009
DAEWOO T-100 BL3
15. Using an ohmmeter, test the stator for ground. If the
reading is low, replace the stator.
16. Check the stator for an open circuit by placing the
probes on two terminals. If the reading is high (infinite), replace the stator.
C302E010
17. Using an ohmmeter, test the rotor for an open circuit. Check for continuity between the slip rings.
Standard resistance (cold) is 2.8 to 3.0 ohms. If
there is no continuity, replace the rotor.
C302E011
18. Using an ohmmeter, inspect the rotor for ground.

Check for continuity between the rotor and the slip
ring. If there is no continuity between the rotor and
the slip ring, replace the rotor.
C302E012
DAEWOO T-100 BL3
Assembly Procedure
1. Check the bearing on the fan side of the rotor assembly. Replace the bearing if it is rough or worn, especially if the generator is diagnosed as having a noisy
bearing with the vehicle running.
2. If required, install a new bearing and insert the bearing retainer on the rotor assembly shaft.
C302E013
3. Press the rotor assembly onto the end frame.

4. Install the fan on the rotor shaft.
C302E008
5. Install the collar.
C302E007
DAEWOO T-100 BL3
6. Install the slip ring end frame assembly by lining up
the terminal ends of the stator with the end frame
cover holes, and then lining up the marks that were
made on the drive end frame case and the slip ring
end frame case before the two cases were separated.
7. Install the generator through-bolts.
Tighten
Tighten the generator through-bolts to 25 NSm (18 lbft).
C302E003
8. Install the rectifier assembly by first soldering its terminals to the stator terminal ends.
9. If the brushes are worn, solder the terminal of the
new brush holder assembly to the regulator assembly.
C302E015
10. Solder the terminal of the regulator/brush holder assembly to the rectifier assembly.
11. Fasten the rectifier and the regulator/brush holder
assemblies to the slip ring end frame with the bolts.
Tighten
Tighten the rectifier and the regulator/brush holder
assembly bolts to the point at which they are touching
their respective mounting plates. Then tighten the
bolts with an additional quarter turn.
C302E004
DAEWOO T-100 BL3
12. Snap in the cover.
13. Install the collar and the pulley on the drive end
shaft.
C302E002
14. Install the drive end nut.
Tighten
Tighten the generator drive end nut to 100 NSm
(74 lb-ft).
15. Install the generator in the vehicle. Refer to Generator in this section.
A102E251
DAEWOO T-100 BL3
-
GENERAL DESCRIPTION
BATTERY
The battery has three major functions in the electrical
system. First, the battery provides a source of energy
for cranking the engine. Second, the battery acts as a
voltage stabilizer for the electrical system. Finally, the
battery can, for a limited time, provide energy when the
electrical demand exceeds the output of the generator.
The sealed battery is standard on all cars. There are no
vent plugs in the cover. The battery is completely
sealed, except for two small vent holes in the sides.
These vent holes allow the small amount of gas produced in the battery to escape.
The sealed battery has the following advantages over
conventional batteries:
D No water need be added for the life of the battery.
D It is protected against overcharge. If too much voltage is applied to the battery, it will not accept as much
current as a conventional battery. In a conventional
battery, the excess voltage will still try to charge the
battery, leading to gassing, which causes liquid loss.
D It is not as liable to self-discharge as a conventional
battery. This is particularly important when a battery
is left standing for long periods of time.
D It has more power available in a lighter and a smaller
case.
RATINGS
A battery has two ratings: (1) A reserve capacity rating
designated at 27_C (81_F), which is the time a fully
charged battery will provide 25 amperes current flow at
or above 10.5 volts; (2) A cold cranking amp rating determined under testing at -18_C (0_F), which indicates
the cranking load capacity.
RESERVE CAPACITY
The reserve capacity is the maximum length of time it is
possible to travel at night with the minimum electrical
load and no generator output. Expressed in minutes, reserve capacity (or RC rating) is the time required for a
fully charged battery, at a temperature of 27_C (81_F)
and being discharged at a current of 25 amperes, to
reach a terminal voltage of 10.5 volts.
COLD CRANKING AMPERAGE

The cold cranking amperage test is expressed at a battery temperature of -18_C (0_F). The current rating is
the minimum amperage, which must be maintained by
the battery for 30 seconds at the specified temperature,
while meeting a minimum voltage requirement of
7.2 volts. This rating is a measure of cold cranking capacity.
DAEWOO T-100 BL3
The battery is not designed to last indefinitely. However,

with proper care, the battery will provide many years of
service.
If the battery tests well, but fails to perform satisfactorily
in service for no apparent reason, the following factors
may point to the cause of the trouble:
D Vehicle accessories left on overnight.
D Slow average driving speeds used for short periods.
D The vehicles electrical load is more than the generator output, particularly with the addition of aftermarket
equipment.
D Defects in the charging system, such as electrical
shorts, a slipping generator belt, a faulty generator, or
a faulty voltage regulator.
D Battery abuse, including failure to keep the battery
cable terminals clean and tight, or a loose battery
hold-down.
D Mechanical problems such as shorted or pinched
wires in the electrical system.
BUILT-IN HYDROMETER
The sealed battery has a built-in, temperature-compensated hydrometer in the top of the battery. This hydrometer is to be used with the following diagnostic
procedure:
1. When observing the hydrometer, make sure that the
battery has a clean top.
2. Under normal operation, two indications can be observed:
D GREEN DOT VISIBLE - Any green appearance is
interpreted as a green dot, meaning the battery is
ready for testing.
D DARK GREEN DOT IS NOT VISIBLE - If there is
a cranking complaint, the battery should be tested.
The charging and electrical systems should also
be checked at this time.
3. Occasionally, a third condition may appear:
D CLEAR OR BRIGHT YELLOW - This means the
fluid level is below the bottom of the hydrometer.
This may have been caused by excessive or prolonged charging, a broken case, excessive tipping,
or normal battery wear. Finding a battery in this
condition may indicate high charging by a faulty
charging system. Therefore, the charging and the
electrical systems may need to be checked if a
cranking complaint exists. If the cranking complaint is caused by the battery, replace the battery.
CHARGING PROCEDURE
1. Batteries with the green dot showing do not require
charging unless they have just been discharged, such
as in cranking a vehicle.
2. When charging sealed-terminal batteries out of the
vehicle, install the adapter kit. Make sure all the char-
ger connections are clean and tight. For best results,
batteries should be charged while the electrolyte and
the plates are at room temperature. A battery that is
extremely cold may not accept current for several
hours after starting the charger.
3. Charge the battery until the green dot appears. The
battery should be checked every half-hour while
charging. Tipping or shaking the battery may be necessary to make the green dot appear.
4. After charging, the battery should be load tested. Refer to Starter Motor in this section.
CHARGING TIME REQUIRED

The time required to charge a battery will vary depending upon the following factors:
D Size of Battery - A completely discharged large
heavy-duty battery requires more than twice the recharging as a completely discharged small passenger
car battery.
D Temperature - A longer time will be needed to
charge any battery at -18_C (0_F) than at 27_C
(81_F). When a fast charger is connected to a cold
battery, the current accepted by the battery will be
very low at first. The battery will accept a higher current rate as the battery warms.
D Charger Capacity - A charger which can supply only
5 amperes will require a much longer charging period
than a charger that can supply 30 amperes or more.
D State-of-Charge - A completely discharged battery
requires more than twice as much charge as a onehalf charged battery. Because the electrolyte is nearly
pure water and a poor conductor in a completely discharged battery, the current accepted by the battery
is very low at first. Later, as the charging current
causes the electrolyte acid content to increase, the
charging current will likewise increase.
CHARGING A COMPLETELY
DISCHARGED BATTERY
(OFF THE VEHICLE)
Unless this procedure is properly followed, a perfectly
good battery may be needlessly replaced.
The following procedure should be used to recharge a
completely discharged battery:
1. Measure the voltage at the battery terminals with an
accurate voltmeter. If the reading is below 10 volts,
the charge current will be very low, and it could take
some time before the battery accepts the current in
excess of a few milliamperes. Refer to Charging
Time Required in this section, which focuses on the
factors affecting both the charging time required and
the rough estimates in the table below. Such low current may not be detectable on ammeters available in
the field.
2. Set the battery charger on the high setting.
Important: Some chargers feature polarity protection

circuitry, which prevents charging unless the charger
leads are correctly connected to the battery terminals. A
completely discharged battery may not have enough
voltage to activate this circuitry, even though the leads
are connected properly, making it appear that the battery will not accept charging current. Therefore, follow
the specific charger manufacturers instruction for bypassing or overriding the circuitry so that the charger will
turn on and charge a low-voltage battery.
3. Battery chargers vary in the amount of voltage and
current provided. The time required for the battery to
accept a measurable charge current at various voltages may be as follows:
Voltage
Hours
16.0 or more
Up to 4 hours
14.0-15.9
Up to 8 hours
13.9 or less
Up to 16 hours
D If the charge current is not measurable at the end

of the above charging times, the battery should be
replaced.
D If the charge current is measurable during the
charging time, the battery is good, and charging
should be completed in the normal manner.
Important: It is important to remember that a completely discharged battery must be recharged for a sufficient
number of ampere hours (AH) to restore the battery to a
usable state. As a general rule, using the reserve capacity rating (RC) as the number of ampere hours of charge
usually brings the green dot into view.
D If the charge current is still not measurable after
using the charging time calculated by the above
method, the battery should be replaced.
D If the charge current is measurable during the
charging time, the battery is good, and charging
should be completed in the normal manner.
JUMP STARTING PROCEDURE

1. Position the vehicle with the good (charged) battery
so that the jumper cables will reach from one battery
to the other.
2. Turn off the ignition, all the lights, and all the electrical
loads in both vehicles. Leave the hazard flasher on if
there may be other traffic and any other lights needed
for the work area.
3. In both vehicles, apply the parking brake firmly.
Notice: Make sure the cables are not on or near pulleys,
fans, or other parts that will move when the engine
starts, damaging the parts.
4. Shift an automatic transaxle to Park (P), or a manual
transaxle to Neutral (N).
DAEWOO T-100 BL3
C
a u t i o n :
i n g
n o t
i n s u l a t i o n ,
u s e
o r
c a b l e s
i n j u r y
t h a t
c o u l d
h a v e
l o o s e
o r
i s s
r e s u l t .
5. Clamp one end of the first jumper cable to the positive

terminal on the battery. Make sure it does not touch
any other metal parts. Clamp the other end of the
same cable to the positive terminal on the other battery. Never connect the other end to the negative terminal of the discharged battery.
Caution: Do not attach the cable directly to the neg
ative terminal of the discharged battery. Doing so
could cause sparks and a possible battery explo
sion, possibly resulting in personal injury.
6. Clamp one end of the second cable to the negative
terminal of the booster battery. Make the final connection to a solid engine ground, such as the engine
lift bracket, at least 450 millimeters (18 inches) from
the discharged battery.
7. Start the engine of the vehicle with the good battery.
Run the engine at a moderate speed for several minutes. Then start the engine of the vehicle which has
the discharged battery.
8. Remove the jumper cables by reversing the above
sequence exactly. Remove the negative cable from
the vehicle with the discharged battery first. While removing each clamp, take care that it does not touch
any other metal while the other end remains attached.
GENERATOR
The Delco-Remy CS charging system has several models available, including the CS-121D and the CS-128D.
The number denotes the outer diameter in millimeters of
the stator lamination.
CS generators are equipped with internal regulators. A
Delta stator, a rectifier bridge, and a rotor with slip rings
and brushes are electrically similar to earlier generators.
A conventional pulley and a fan are used. There is no
test hole.
Unlike three-wire generators, the CS-121D and the
CS-128D may be used with only two connections: battery positive and an L terminal to the charge indicator
lamp.
As with other charging systems, the charge indicator
lamp lights when the ignition switch is turned to ON, and
goes out when the engine is running. If the charge indicator is on with the engine running, a charging system
defect is indicated. This indicator light will glow at full
brilliance for several kinds of defects, as well as when
the system voltage is too high or too low.
The regulator voltage setting varies with the temperature and limits the system voltage by controlling the rotor
DAEWOO T-100 BL3
field current. The regulator switches rotor field current

on and off at a fixed frequency of about 400 hertz. By
varying the on-/off-time time, correct average field current for proper system voltage control is obtained. At
high speeds, the on-time may be 10 percent and the offtime 90 percent. At low speeds, with high electrical
loads, the on-time may be 90 percent and the off-time
10 percent.
CHARGING SYSTEM
The Delco-Remy CS charging system has several models available, including the CS-121D and the CS-128D.
The number denotes the outer diameter in millimeters of
the stator laminations.
CS generators use a new type of regulator that incorporates a diode trio. A Delta stator, a rectifier bridge, and a
rotor with slip rings and brushes are electrically similar to
earlier generators. A conventional pulley and a fan are
used. There is no test hole.
STARTER
Wound field starter motors have pole pieces, arranged
around the armature, which are energized by wound
field coils.
Enclosed shift lever cranking motors have the shift lever
mechanism and the solenoid plunger enclosed in the
drive housing, protecting them from exposure to dirt, icy
conditions, and splashes.
In the basic circuit, solenoid windings are energized
when the switch is closed. The resulting plunger and
shift lever movement causes the pinion to engage the
engine flywheel ring gear. The solenoid main contacts
close. Cranking then takes place.
When the engine starts, pinion overrun protects the armature from excessive speed until the switch is opened,
at which time the return spring causes the pinion to disengage. To prevent excessive overrun, the switch
should be released immediately after the engine starts.
STARTING SYSTEM
The engine electrical system includes the battery, the
ignition, the starter, the generator, and all the related wiring. Diagnostic tables will aid in troubleshooting system
faults. When a fault is traced to a particular component,
refer to that component section of the service manual.
The starting system circuit consists of the battery, the
starter motor, the ignition switch, and all the related electrical wiring. All of these components are connected
electrically.
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Daewoo Lanos Full Engine Service Manual

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www.carburetor-manual.

Also Visit my website for 7 FREE Download Manuals starting

"The ABC's of Carburetion"

file:///C|/Documents%20and%20Settings/Tim/Desktop/carburetor-manual-welcome/index.htm[4/25/2009 11:42:20 AM]

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At Each Fuel Fill . . . . . . . . . . . . . . . . . . . . . . . . .

166 km/h (103.2 mph)

172 km/h (106.9 mph)

180 km/h (111.8 mph)

Minimum Turning Radius

4.9 m (16 ft)

4.9 m (16 ft)

4.9 m (16 ft)

Performance - Automatic Transaxle

161 km/h (100.0 mph)

173 km/h (107.5 mph)

Minimum Turning Radius

4.9 m (16 ft)

4.9 m (16 ft)

76.5 mm (3.01 in.)

76.5 mm (3.01 in.)

79.0 mm (3.11 in.)

73.4 mm (2.89 in.)

81.5 mm (3.21 in.)

81.5 mm (3.21 in.)

1 349 cm3 (82.3 in3)

1 498 cm3 (91.4 in3)

1 598 cm3 (97.5 in3)

77.8 kw (104 bhp)

Direct Ignition System

Direct Ignition System

Direct Ignition System

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