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SECTION 0

GENERAL INFORMATION

1. INTRODUCTION

1-1. PAGE LAYOUT

This Labor Time Guide is designed for convenient and accurate use. For fast, efficient location of Labor Operation Codes, a detailed illustration and corresponding Labor Operation Code information is provided.

1-2. TYPES OF OPERATION

Major Operation

The Labor Operation Codes consist of seven digits. All operation numbers having "0" in the seventh digit of operation number are classified as "major" operations. A major operation time allowance is sufficient to do the work described as a single operation.

Supplementary Operation (Adds)

All operation numbers having an alphabetical letter in the seventh digit of the operation number are classified as "supplementary" operations. These operations cannot be used as a single operation and must be used as additions to the major operation.

1-3. TIME ALLOWANCES

The time allowances published in this guide have been determined by performing the operation a sufficient number of times to establish an average time or to determine that a fair and equitable time has been developed. Standard technician's hand tools and dealer essential and available tools are used in performing time studies. No power operated tools are used for time studies. Procedures outlined in Service Manuals, other Service Publications and standard shop practices are used as a guide when performing the work necessary to establish time allowances.
The time allowance includes the actual time required to perform the operation plus an additional allowance to provide for operating variables. Time allowances include time to remove and reinstall manufacturer options and accessories but do not include time to remove and reinstall special or aftermarket equipment.
"Repair diagnosis" time is included in all published labor time operations when it is required to perform the operation. It is the responsibility of the dealer's qualified service staff to assist technicians in "customer problem analysis" and "symptom diagnosis".

2. HOW TO READ THIS MANUAL


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Section

Refer to the main group code in this chapter.

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Illustration Number

The illustration number corresponds to the reference number provided in the chart or the facing page.

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Operation Description

3A. Major Operation

The Operation Description corresponds to each labor operation number, identifies the part or component, and describes what kind of operation is to be performed.

3B. Supplementary Operation

The Operation Description corresponding to each operation number identifies the part or component concerned, and describes the additional operation for removing and reinstalling optional equipment (i.e. power steering, air conditioning, etc.), when a major operation is performed on vehicles with optional equipment.

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Operation Code

The Operation Code consists of seven digits.

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1) Main Group Code

The Main Group Code consists of 3 digits which indicates the area of the vehicle where the repair was performed.

2) Basic Code

The Basic Code is a 3-digit number specific to each operation.

3) Auxiliary Code

The Auxiliary Code indicates the type of repairs as shown below ;
Auxiliary Code
Description
0
Major operation
A
Supplementary operation
B
R

Major Operation

The numeric code "0" represents a major operation.

Supplementary Operation (ADD)

The alpha code "A" - "R" represents supplementary work where additional time is required for R & R of optional parts or components which are related to the intended repair (major operation).

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Operation Times

The operation times in this manual are provided in hours and tenths of hours (e.g. 1.1 hours for 1 hour and 6 minutes).
Enter the operation time on the warranty claim in the same manner.

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Model Code

This code represents the vehicle model.
Vehicle Models
S : AVEO/BARINA/Aveo, Epica, Nubira/Lacetti
N : LACETTI/NUBIRA/OPTRA/VIVA/FORENZA
L : EVANDA/EPICA

Engine Type

This designation represents engine types.
1.2S : 1.2 SOHC Engine
1.2D : 1.2 DOHC Engine
1.4S : 1.4 SOHC Engine
1.5S : 1.5 SOHC Engine
1.4D : 1.4 DOHC Engine
1.6D : 1.6 DOHC Engine (FAM 1)
1.6D : 1.6 DOHC Engine (GEN 3)
1.8D : 1.8 DOHC Engine
2.0D : 2.0 DOHC Engine
2.0XK: L6 2.0 DOHC Engine
2.5XK: L6 2.5 DOHC Engine
2.0DSL : 2.0 DIESEL Engine

3. HOW TO USE THIS MANUAL

The operation times in this manual are provided in hours and tenths of hours (e.g. 1.1 hours for 1 hour and 6 minutes).
Enter the operation time on the warranty claim in the same manner.
Example: (When supplementary work is performed in addition to the intended repair)
Model : S (Aveo, Epica, Nubira/Lacetti)
Major Operation : Camshaft Replacement
Supplementary Work : With Air Conditioning
Step 1 : First find SOHC ENGINE MECH. - CAM SUPPORT & SHAFT in MAIN GROUP INDEX and then the page (Engine 1B-19) for Camshaft.
Step 2 : On page Engine 1B-19, note the Operation Code for Camshaft Replacement.
. 1322300
. CAMSHAFT - REPLACE
. 2.6
. 132230B
. WITH AIR CONDITIONING
. 0.1
.
. Total Operation Time
. 2.7

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4. PAINT REPAIR

4-1. INSTRUCTION

The time allowances for paint operations are established on the basis of techniques and material required for high quality work.
The basis for determining the paint time allowances is a "Paintable Surface".
1-1. All dents have been removed from sheet metal parts and welded parts are restored to their original shape.
1-2. Welding and soldering joints, overlapping seams formed by partial replacement and surfaces repaired with fillers are completely smooth.
1-3. And when the painter does not need to apply more than 3 coats of knife-edge putty to the surfaces to be painted.

4-2. LABOR TIME

The time allowances for paint work include all related tasks like material preparation time, actual repair time and material allowances, which are necessary for a proper and professional paint repair. Note that material allowances are converted to hours and are included in the operation time based on the paint process and the size of area to be painted.
The material allowances include necessary paint mixing and other items like masking tape, sand paper, cleaning materials, etc.
INCLUDES ; moving the vehicle / mixing all materials / color blending / equipment cleaning / color spray sample / repainting time on clear coat / masking / sanding / cleaning / spraying / removing of the masking and polishing.
EXCLUDES ; removal and reinstallation of body attaching parts

4-3. REPAIR TYPE

Type
Description
COLOR COAT
. PAINT EXPOSED SURFACES
Top-coat entire surface, including small dents that have been straightened (without filling in). This operation should be used when correcting painting conditions such as thin paint, color mismatch or surface scratches not extending beyond the prime coat.
REFINISH
. PAINT NEW PART
This operation involves sanding out a defect to expose a local area of bare metal, prime locally and then apply color coat.
This applies to those paint repairs that require a repair to the prime coat before the color coat is applied.
POLISHING
. POLISH THE SURFACES

4-4. HOW TO USE OPERATION CODE FOR PARTIAL PAINTING

Use the operation code of the relevant part and enter "P" in the PF column of the Daewoo Warranty Claim. For example, if only a portion of a Lanos hood required painting, complete the Daewoo Warranty Claim as follows ;
. PF
. OPERATION CODE
. HOUR
. P
. 9836080
. 0.7

5. DEFECT CODE

5-1. NATURE CODES

N01
Hard start, no start
N02
Poor idle
N03
Surge, hesitate, stumble
N04
Engine noise, engine knocking noise
N05
Choke malfunction
N06
Engine stalled (general)
N07
Excessive fuel consumption
N08
Excessive oil consumption
N09
Overheated
N10
Shift shock
N11
Engine run-on
N12
Flooded, overflowing
N13
Poor acceleration, uneven acceleration
N14
Abnormal combustion
N15
Lack of engine power
N16
Percolation
N17
Improper exhaust gas (black smoke, white smoke)
N18
Backfire, afterfire
N19
Vapor lock
N20
Blocked
N21
Shuddering, pulsation, vibration, chattering
N22
Slippage (slipping)
N23
Difficult engagement
N24
Difficult disengagement
N25
Abnormal shifts
N26
Impossible shifts
N27
Squeaking, squealing, abnormal(wind) noise
N28
Dragging
N29
Pulls
N30
Stalled while driving
N31
Stalled while idling
N32
Stalled between shifts
N33
Stalling during sudden braking
N34
Fails to reach normal operating temperature
N35
RPM too low
N36
RPM too high
N37
Jumping-out
N38
Improper synchronizing
N39
Oil diluted
N40
Misfire
N41
Spongy pedal
N42
Unstable steering
N43
Excessive shock
N44
Poor release
N45
Unusual tire wear
N46
Misaligned or mismatched
N47
Weak
N48
Hard to turn
N49
Impossible to turn
N50
Vehicle bouncing
N51
Deteriorated
N52
Distortion, rainbow, waving
N53
Color mismatched
N54
Defective chrome plate, defective painting
N55
Rust, corrosion, perforation
N56
Glazed
N57
Loose, poor fit
N58
Bubbles
N59
Vehicle vibration
N60
Excessive vibration
N61
Dead battery
N62
Inaccurate (meter, gauge, etc.)
N63
Poor sound (horn, radio, etc.)
N64
Overcharged, discharged
N65
Electrical failures
N66
Blown fuse
N67
Warning light on
N68
Intermittent operation
N69
Pulls to left or right
N70
Poor AM reception / interference
N71
Oil leak, oil entering
N72
Water leak, water entering
N73
Leaks-other (air, fuel, refrigerant, vacuum)
N74
Poor FM reception / interference
N75
Radio / CD does not operate properly
N76
Tape deck does not operate properly
N77
Improper memory
N78
Improper volume control
N80
Headlamp improperly aimed
N82
Loosening, falling-off, sagged
N83
Gas leak, gas entering
N84
Improper opening and/or closing
N85
Grabs
N86
Poor maneuverability
N87
Insufficient brake
N88
Brake judder
N90
Color rainbow, color waving
N91
Interference or hitting
N92
Inoperative
N93
High/low operating effort
N94
Special policy
N95
Glass cracked
N96
Glass broken
N97
Glass chipped
N98
Glass scratched
N99
Undefined

5-2. CAUSE CODES

R01
Scored, scratched or chipped
R02
Frozen (Temperature)
R03
Peeling, coming-off
R04
Rusty, corroded
R05
Split, cut or torn
R06
Broken or cracked
R07
Porous, pin holes, cavity
R08
Bent, kinked, twisted, distorted, warped or wrinkled
R09
Stripped - bolts, holes, nuts
R10
Soiled
R11
Weakened, loss of tension or resilience (spring, cushion, etc.)
R12
Abnormal wear
R13
Out of balance
R14
Out of round
R15
Loose or improper connection
R16
Open circuit or short circuit
R17
Burned or burned out
R18
Grounded or shorted
R19
Improperly machined
R20
Faulty casting
R21
Improper clearance, back lash, free play
R22
Lack of lubricants
R23
Improper welding or soldering, welding or soldering omitted
R24
Improper tightening, fit or assembly
R25
Sticks, binds, seized
R26
Foreign material, clogged
R27
Improper sealing, sealer omitted or skipped
R28
Improper adjustment
R31
Incorrect part
R32
Improperly installed
R33
Improperly routed
R34
Missing part
R35
Flaw in material
R36
Contaminants
R99
Undefined

5-3. PAINT CODES

P01
Oversprayed, drip
P02
Undersprayed, bare
P03
Color mismatched
P04
Low Gloss
P05
Mottled, cloudy
P06
Sags or runs
P07
Pin hole
P11
Peeling, scaling
P12
Orange peel
P13
Slow drying
P14
Thin no paint
P15
Wavy
P16
Tape mark, touch mark
P17
Chemical damage
P18
Acid rain
P19
Atmospheric fallout
P20
Polishing mark, sanding mark
P21
Touch up
P22
Dust, dirt
P23
Poor welding
P24
Rust
P25
Blistered
P26
Chipped
P27
Cracked
P30
Surface scratch
P31
Scab corrosion
P32
Dent
P33
Rust perforation
P34
Discolored, faded
P99
Undefined

6. ABBREVIATIONS

A/C
Air Conditioning
ADJ
Adjust
ASSY
Assembly
A/T
Automatic Transaxle
AUTO
Automatic
CC
Color Coat paint
CHK
Check
CLN
Clean
CYL
Cylinder
DIFF
Differential
DIST
Distributor
DOHC
Double Overhead Camshaft
ECM
Electronic Control Module
EGR
Exhaust Gas Recirculation
ETC
Others
H/B
Hatch Back
IAC
Idle Air Control
I/P
Instrument Panel
MAN
Manual
MAP
Manifold Absolute Pressure
MAT
Manifold Air Temperature
OH
Overhaul
POL
Polishing
PCV
Positive Crankcase Ventilation
PLA
Plating
REF
Refinish Paint
RPL
Replace
RPR
Repair
R&R
Remove and Reinstall
SOHC
Single Overhead Camshaft
M/T
Manual Transaxle
VIN
Vehicle Identification Number
VSS
Vehicle Speed Sensor

7. MAIN GROUP CODE

The first 3 digits of the 7 digit code classify the units to be serviced into main roups.
SECTION
SUB-SECTION
MAIN GROUP CODE
PAGE
1. ENGINE
1B1
Gasoline SOHC Engine Mech.
111
Engine unit
1B1-1
113
Belt system
121
Engine block
122
Crankshaft & piston
123
Oil pan & pump
131
Cylinder head
132
Cam support & shaft
133
Timing cover
138
Engine & transaxle mount
1B2
Diesel SOHC Engine Mech.
111
Engine unit
1B2-1
113
Belt system
121
Engine block
122
Crankshaft & piston
123
Oil pan & pump
131
Cylinder head
132
Cam support & shaft
133
Timing cover
138
Engine & transaxle mount
1C
DOHC Engine Mech.
111
Engine unit
1C-1
113
Belt system
121
Engine block
122
Crankshaft & piston
123
Oil pan & pump
131
Cylinder head
132
Cam support & shaft
133
Timing cover
138
Engine & transaxle mount
1D1
Gasoline Engine Cooling
141
Radiator
1D1-1
143
Cooling fan
145
Radiator hose & pipe
148
Thermostat
1. ENGINE
1D2
Diesel Engine Cooling
141
Radiator
1D2-1
143
Cooling fan
145
Radiator hose & pipe
148
Thermostat
1E1
Gasoline Engine Electrical
151
Ignition cable
1E1-1
154
Alternator unit
156
Starter
157
Battery
158
Fuse & relay
1E2
Diesel Engine Electrical
151
Ignition cable
1E2-1
154
Alternator unit
156
Starter
157
Battery
158
Fuse & relay
1F1
Gasoline Engine Controls
171
Fuel tank
1F1-1
172
Fuel line
173
Canister & fuel vacuum
181
Fuel injection
182
Accelerator control
186
Emission control
1F2
Diesel Engine Controls
171
Fuel tank
1F2-1
172
Fuel line
173
Canister & fuel vacuum
181
Fuel injection
182
Accelerator control
186
Emission control
1G1
Gasoline Engine Intake & Exhaust
191
Air intake system
1G1-1
193
Intake manifold
194
Exhaust manifold
195
Vacuum hose
196
Exhaust pipe line
1G2
Gasoline Engine Intake & Exhaust
191
Air intake system
1G2-1
193
Intake manifold
194
Exhaust manifold
195
Vacuum hose
196
Exhaust pipe line
2. SUSPENSION
2C
Front Suspension
213
Knuckle & hub
2A-1
214
Front shock absorber
215
Control arm
2D
Rear Suspension
231
Rear axle
2D-1
232
Rear shock absorber
2E
Tires & Wheel
241
Wheel & wheel cover
2E-1
242
TPMS
3. DRIVE LINE/AXLE
3
Drive Axle
321
Axle shaft parts
3-1
4. BRAKES
4A
Hydraulic Brakes
425
Brake pipe
4A-1
428
Brake Pedal & Mount
4B
Master Cylinder & Power Booster
431
Master cylinder & booster
4B-1
4D
Front Brakes
445
Front brake
4D-1
4E
Rear Brakes
456
Rear brake
4E-1
4F
Anti-Lock Brake System
462
ABS system
4F-1
465
Hydraulic modulator
4G
Parking Brakes
478
Parking brake
4G-1
5. TRANSMISSION/TRANSAXLE
5A1
ZF 16HP Auto Transaxle
524
ZF 16HP Auto Transaxle I
5A1-1
525
ZF 16HP Auto Transaxle II
526
ZF 16HP Auto Transaxle III
527
ZF 16HP Auto Transaxle IV
5. TRANSMISSION/TRANSAXLE
5A2
AISIN Auto Transaxle (4 Speeds)
531
Automatic transaxle
5A2-1
532
Case & related parts
533
Internal powertrain parts
534
Gear assembly
535
Control valve
536
Fluid cooler pipe
537
Auto transaxle controls
5A3
AISIN Auto Transaxle (5 Speeds)
531
Automatic transaxle
5A3-1
532
Case & related parts
533
Internal powertrain parts
534
Gear assembly
535
Control valve
536
Fluid cooler pipe
537
Auto transaxle controls
5A4
AISIN Auto Transaxle (6 Speeds)
541
Case & related parts
5A4-1
542
Transmission Case Assenbly
543
Drive Link Assenbly
544
Control Valve Body Assenbly
545
Low/Reverse & Clutch Assenbly
546
Input, Output & Reaction Gearsets
547
Park System Components
548
Auto transaxle controls
5B1
Five Speed Manual Transaxle (D16, D20)
561
Manual transaxle
5B1-1
563
Transaxle gear
564
Reverse & counter gear
565
Bearing plate
566
Gear shift cover & fork
567
Differential gear
569
Shift control
5B2
Five Speed Manual Transaxle (Y4M)
561
Manual transaxle
5B2-1
563
Transaxle gear
566
Gear Shift Cover & Fork
567
Differential Gear
569
Shift Control
5. TRANSMISSION/TRANSAXLE
5C
Clutch
581
Clutch parts
5C-1
582
Hydraulic clutch
583
Clutch pedal
6. STEERING
6A
Power Steering System
621
Power steering gear
6A-1
623
Power steering pipe line
6D
Manual Steering Gear
635
Manual steering gear
6D-1
6E
Steering Wheel & Column
641
Steering wheel
6E-1
642
Steering column cover
643
Steering column
647
Tie rod
7. HVAC (Heating,Ventilation & Air Conditioning)
7A
Heating & Ventilation
711
Air distribution
7A-1
713
Evaporator
714
Blower
7B
HVAC Control
732
Compressor
7B-1
733
Compressor mount
734
A/C hose & pipe line
735
A/C control switch
8. RESTRAINTS
8A
Seat Belts
812
Front seat belt
8A-1
822
Rear seat belt
8B
S. R. S (Supplemental Inflatable Restraints)
832
Air bag system
8B-1
833
Immobilizer
9. BODY AND ACCESSORIES
9A
Body Wiring System
911
Wiring harness
9A-1
9B
Lighting System
916/
Front lamp
9B-1
917
Rear lamp
918
.
9D
Wiper/Washer System
921
Windshield wiper
9D-1
923
Windshield washer
9E
Inst. Driver System
925
Instrument cluster
9E-1
9F
Audio & Anti-theft System
928
Electrical parts
9F-1
929
Antenna
9. BODY AND ACCESSORIES
9G
Interior Trim
931
Instrument panel
9G-1
932
Molding & switch
933
Instrument parts
934
Console
935
Front door trim
936
Rear door trim
938
Pillar trim
939
Floor carpet
9H
Seats
941
Front seat
9H-1
942
Rear seat
9L
Glass & Mirrors
946
Glass & outside mirrors
9L-1
9M
Exterior Parts
951
Emblem & lettering
9M-1
952
Mud guard
9O
Bumpers & Fascias
956
Front bumper
9O-1
957
Rear bumper
9P
Doors
961A
Front door & lock
9P-1
961B
Front window lifter
961C
Front weatherstrip
963A
Rear door & lock
963B
Rear window lifter
963C
Rear weatherstrip
965
Electric door lock
966
Fuel filler lock & quarter window lock
967
Trunk lid lock & tailgate lock
968
Car lock
9Q
Roof
971
Headlining & roof panel
9Q-1
972A
Sunshade & inside mirror
972B
Sun roof
9R
Body Front End
973
Hood panel
9R-1
974
Front panel
975
Fender panel
976
Dash panel & cowl
977
Grille
9S
Body Rear End
978
Trunk lid panel & spoiler
9S-1
10. PAINT
10
Paint
981
Paint
10-1


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