Service Manual2007 Aveo, Epica, Nubira/Lacetti GENERAL INFORMATION

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

Section

Refer to the main group code in this chapter.

Illustration Number

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

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.

Operation Code

The Operation Code consists of seven digits.

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).

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.

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

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
COLOR COAT	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
REFINISH	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
	2D	Rear Suspension	232	Rear shock absorber	2D-1
	2E	Tires & Wheel	241	Wheel & wheel cover	2E-1
	2E	Tires & Wheel	242	TPMS	2E-1
3. DRIVE LINE/AXLE	3	Drive Axle	321	Axle shaft parts	3-1
4. BRAKES	4A	Hydraulic Brakes	425	Brake pipe	4A-1
	4A	Hydraulic Brakes	428	Brake Pedal & Mount	4A-1
	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
	4F	Anti-Lock Brake System	465	Hydraulic modulator	4F-1
	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
	6A	Power Steering System	623	Power steering pipe line	6A-1
	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
	8A	Seat Belts	822	Rear seat belt	8A-1
	8B	S. R. S (Supplemental Inflatable Restraints)	832	Air bag system	8B-1
	8B	S. R. S (Supplemental Inflatable Restraints)	833	Immobilizer	8B-1
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
	9D	Wiper/Washer System	923	Windshield washer	9D-1
	9E	Inst. Driver System	925	Instrument cluster	9E-1
	9F	Audio & Anti-theft System	928	Electrical parts	9F-1
	9F	Audio & Anti-theft System	929	Antenna	9F-1
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
	9H	Seats	942	Rear seat	9H-1
	9L	Glass & Mirrors	946	Glass & outside mirrors	9L-1
	9M	Exterior Parts	951	Emblem & lettering	9M-1
	9M	Exterior Parts	952	Mud guard	9M-1
	9O	Bumpers & Fascias	956	Front bumper	9O-1
	9O	Bumpers & Fascias	957	Rear bumper	9O-1
	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