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Daewoo Tico 1991-2001 Workshop Service Manual for Repair

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The Daewoo Tico, produced between 1991 and 2001, is a compact city car recognized for its affordability, fuel efficiency, and maneuverability in urban environments. Adapted from the second-generation Suzuki Alto platform, this model, often identified by its KLY3 chassis code and the F8CV engine, offered a simple yet functional design. Primarily sold in Europe, Asia, and Oceania, the Tico's appeal lay in its economical operation and straightforward mechanicals, making it a practical choice for budget-conscious buyers and a competitor to vehicles like the Suzuki Alto and Hyundai Atos. This workshop service manual provides comprehensive guidance for the maintenance, diagnosis, and repair of the Daewoo Tico. Covering all major systems including the powertrain, drivetrain, chassis, electrical components, and body, this 322-page manual details everything from routine scheduled maintenance and fluid changes to complex component overhauls and troubleshooting. It is an essential resource for owners and technicians alike, offering detailed procedures, technical specifications, and diagnostic information to ensure the Tico remains in optimal working condition. 🏷️ Basic Information Identification Make: Daewoo Model: Tico Years Covered: 1991-2001 Codes Chassis Code: KLY3 Engine Code Common: F8CV (Suzuki Alto variant) 👋 Introduction Market Position Segment: City Car / Kei Car (adapted for international markets) Competitive Analysis Key Competitors: Suzuki Alto, Hyundai Atos, Kia Pride, Daihatsu Cuore, Fiat Cinquecento/Seicento Key Features Vehicle Appeal: Affordable, fuel-efficient, compact size for urban maneuverability, simple mechanicals. Manual Utility Value Proposition: Essential for owners and independent repair shops for accurate diagnosis, maintenance, and repair of the Daewoo Tico. 📋 Manual Details Coverage Areas Primary Regions Of Sale: Europe, Asia, Oceania Page Count Total Pages: 322 Manual Type Type: Workshop Service Manual / Repair Manual Language Language: English (assumed based on product description format, typically international market manuals) Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, cooling system, lubrication system, exhaust system Drivetrain: Clutch, manual transmission, driveshafts, differential Chassis: Suspension (front and rear), steering system, braking system Electrical: Battery, charging system, starting system, lighting, instrumentation, wiring diagrams, body electrical components Body: Body exterior, interior trim, doors, windows, seats, HVAC (Heating, Ventilation, and Air Conditioning) system Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, lubrication Diagnostics: Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (DTCs) if applicable Repair: Component removal and installation, overhaul procedures for major components Specifications: Torque specifications, clearances, measurements, electrical values Technical Depth Depth: Comprehensive, covering routine maintenance to major repairs and component overhauls. Includes detailed diagrams and troubleshooting. 📊 Manual Specifications File Format File Type: PDF Print Quality Quality: High-resolution scans, suitable for printing. Assumed professional quality for a workshop manual. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 3-cylinder, 4-stroke, naturally aspirated gasoline Displacement: 796 cc (0.8 L) Bore X Stroke: 68.5 mm x 72.0 mm (typical for F8CV) Compression Ratio: 9.3:1 (typical) Performance Horsepower: Approx. 38-41 PS (28-30 kW) at ~5500 rpm (varies by market and emission standards) Torque: Approx. 58-60 Nm (43-44 lb-ft) at ~3500 rpm (varies by market) Fuel System Induction Type: Carburetor (early models) or Multi-point Fuel Injection (later models, often with single-point injection for cost savings) Fuel Type: Unleaded Gasoline (Octane rating typically 91 RON) Lubrication Oil Capacity: Approx. 2.7 Liters (2.9 US Quarts) with filter change Cooling Coolant Capacity: Approx. 4.0 Liters (4.2 US Quarts) 🔧 Transmission Standard Transmission Type: 5-speed manual transmission Optional Transmission Type: 3-speed automatic transmission (less common, often optional in certain markets) Features Clutch Type: Dry single plate clutch Transmission Fluid Type: GL-4 SAE 75W-90 or SAE 80W-90 (Check manual for specific viscosity and API rating) 📐 Dimensions Exterior Length: Approx. 3,335 mm (131.3 inches) Width: Approx. 1,410 mm (55.5 inches) Height: Approx. 1,400 mm (55.1 inches) Wheelbase: Approx. 2,175 mm (85.6 inches) Ground Clearance: Approx. 150 mm (5.9 inches) Weights Curb Weight: Approx. 680-720 kg (1,499-1,587 lbs) Gross Vehicle Weight Rating: Approx. 1,150 kg (2,535 lbs) 🛡️ Safety Features Ratings Crash Test Performance: Generally considered poor by modern standards, typical for its class and era. Lacks advanced safety features. Active Features ABS: Optional on some later models, not standard Traction Control: Not available Passive Features Airbags: Driver airbag optional on some models, passenger airbag not available Seatbelts: Front 3-point, rear 2-point lap belts Body Structure: Unibody construction with basic crumple zones 💡 Technology Features Infotainment Audio System: Basic AM/FM radio, often with cassette player. CD player was rare/unavailable. Dashboard Features: Basic analogue gauges: speedometer, tachometer (optional), fuel gauge, temperature gauge. Warning lights. Driver Assistance Cruise Control: Not available Connectivity Bluetooth Integration: Not available 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 km (3,000 miles) or 6 months, whichever comes first (typical for the era). Air Filter Replacement: Every 15,000 km (9,000 miles) or 12 months. Spark Plug Replacement: Every 20,000 km (12,000 miles) or 18 months....
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Daewoo Tico 1991-2001 Workshop Service Manual for RepairDaewoo Tico 1991-2001 Workshop Service Manual for RepairDaewoo Tico 1991-2001 Workshop Service Manual for RepairDaewoo Tico 1991-2001 Workshop Service Manual for Repair
The Daewoo Tico, produced between 1991 and 2001, is a compact city car recognized for its affordability, fuel efficiency, and maneuverability in urban environments. Adapted from the second-generation Suzuki Alto platform, this model, often identified by its KLY3 chassis code and the F8CV engine, offered a simple yet functional design. Primarily sold in Europe, Asia, and Oceania, the Tico's appeal lay in its economical operation and straightforward mechanicals, making it a practical choice for budget-conscious buyers and a competitor to vehicles like the Suzuki Alto and Hyundai Atos. This workshop service manual provides comprehensive guidance for the maintenance, diagnosis, and repair of the Daewoo Tico. Covering all major systems including the powertrain, drivetrain, chassis, electrical components, and body, this 322-page manual details everything from routine scheduled maintenance and fluid changes to complex component overhauls and troubleshooting. It is an essential resource for owners and technicians alike, offering detailed procedures, technical specifications, and diagnostic information to ensure the Tico remains in optimal working condition.
🏷️ Basic Information
Identification
Make:
Daewoo
Model:
Tico
Years Covered:
1991-2001
Codes
Chassis Code:
KLY3
Engine Code Common:
F8CV (Suzuki Alto variant)
👋 Introduction
Market Position
Segment:
City Car / Kei Car (adapted for international markets)
Competitive Analysis
Key Competitors:
Suzuki Alto, Hyundai Atos, Kia Pride, Daihatsu Cuore, Fiat Cinquecento/Seicento
Key Features
Vehicle Appeal:
Affordable, fuel-efficient, compact size for urban maneuverability, simple mechanicals.
Manual Utility
Value Proposition:
Essential for owners and independent repair shops for accurate diagnosis, maintenance, and repair of the Daewoo Tico.
📋 Manual Details
Coverage Areas
Primary Regions Of Sale:
Europe, Asia, Oceania
Page Count
Total Pages:
322
Manual Type
Type:
Workshop Service Manual / Repair Manual
Language
Language:
English (assumed based on product description format, typically international market manuals)
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, cooling system, lubrication system, exhaust system
Drivetrain:
Clutch, manual transmission, driveshafts, differential
Chassis:
Suspension (front and rear), steering system, braking system
Electrical:
Battery, charging system, starting system, lighting, instrumentation, wiring diagrams, body electrical components
Body:
Body exterior, interior trim, doors, windows, seats, HVAC (Heating, Ventilation, and Air Conditioning) system
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, lubrication
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (DTCs) if applicable
Repair:
Component removal and installation, overhaul procedures for major components
Specifications:
Torque specifications, clearances, measurements, electrical values
Technical Depth
Depth:
Comprehensive, covering routine maintenance to major repairs and component overhauls. Includes detailed diagrams and troubleshooting.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Quality:
High-resolution scans, suitable for printing. Assumed professional quality for a workshop manual.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
3-cylinder, 4-stroke, naturally aspirated gasoline
Displacement:
796 cc (0.8 L)
Bore X Stroke:
68.5 mm x 72.0 mm (typical for F8CV)
Compression Ratio:
9.3:1 (typical)
Performance
Horsepower:
Approx. 38-41 PS (28-30 kW) at ~5500 rpm (varies by market and emission standards)
Torque:
Approx. 58-60 Nm (43-44 lb-ft) at ~3500 rpm (varies by market)
Fuel System
Induction Type:
Carburetor (early models) or Multi-point Fuel Injection (later models, often with single-point injection for cost savings)
Fuel Type:
Unleaded Gasoline (Octane rating typically 91 RON)
Lubrication
Oil Capacity:
Approx. 2.7 Liters (2.9 US Quarts) with filter change
Cooling
Coolant Capacity:
Approx. 4.0 Liters (4.2 US Quarts)
🔧 Transmission
Standard
Transmission Type:
5-speed manual transmission
Optional
Transmission Type:
3-speed automatic transmission (less common, often optional in certain markets)
Features
Clutch Type:
Dry single plate clutch
Transmission Fluid Type:
GL-4 SAE 75W-90 or SAE 80W-90 (Check manual for specific viscosity and API rating)
📐 Dimensions
Exterior
Length:
Approx. 3,335 mm (131.3 inches)
Width:
Approx. 1,410 mm (55.5 inches)
Height:
Approx. 1,400 mm (55.1 inches)
Wheelbase:
Approx. 2,175 mm (85.6 inches)
Ground Clearance:
Approx. 150 mm (5.9 inches)
Weights
Curb Weight:
Approx. 680-720 kg (1,499-1,587 lbs)
Gross Vehicle Weight Rating:
Approx. 1,150 kg (2,535 lbs)
🛡️ Safety Features
Ratings
Crash Test Performance:
Generally considered poor by modern standards, typical for its class and era. Lacks advanced safety features.
Active Features
ABS:
Optional on some later models, not standard
Traction Control:
Not available
Passive Features
Airbags:
Driver airbag optional on some models, passenger airbag not available
Seatbelts:
Front 3-point, rear 2-point lap belts
Body Structure:
Unibody construction with basic crumple zones
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio, often with cassette player. CD player was rare/unavailable.
Dashboard Features:
Basic analogue gauges: speedometer, tachometer (optional), fuel gauge, temperature gauge. Warning lights.
Driver Assistance
Cruise Control:
Not available
Connectivity
Bluetooth Integration:
Not available
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 km (3,000 miles) or 6 months, whichever comes first (typical for the era).
Air Filter Replacement:
Every 15,000 km (9,000 miles) or 12 months.
Spark Plug Replacement:
Every 20,000 km (12,000 miles) or 18 months.
Timing Belt Replacement:
Every 80,000 km (50,000 miles) or 5 years. Crucial to prevent catastrophic engine damage due to interference design (verify with manual).
Fluid Specifications
Engine Oil Specification:
API SG or higher, SAE 10W-30 or 10W-40 (check manual for specific climate recommendations).
Coolant Specification:
Ethylene Glycol based coolant, typically a 50/50 mix with distilled water. (Check manual for specific additive type).
Brake Fluid Specification:
DOT 3 or DOT 4 (Check manual for precise specification).
Known Issues
Common Wear Items:
Clutch wear, starter motor issues, alternator bearing failure, rust on wheel arches and sills, exhaust system corrosion.
Engine Management:
Carburetor tuning issues (if applicable), fuel pump reliability, ignition coil failure.
Electrical Systems:
Wiring harness degradation, intermittent function of lights and accessories due to age and corrosion.
📚 Vehicle History
Brand Heritage
Parent Company:
Daewoo Motors (originally part of Saehan Motor Company, later acquired by GM)
Model Evolution
Development Basis:
Based on the Suzuki Alto (second generation, platform designation SS80/SS110), licensed or developed in partnership with Suzuki.
Updates:
Minor cosmetic updates and powertrain refinements over its production run, with some markets receiving fuel-injected versions towards the end of the 1990s.
Production
Manufacturing Location:
South Korea
Production Years:
1991-2001 (with some regional variations)
🏆 Awards & Recognition
Recognitions
Industry Awards:
No significant industry awards documented for this model. Primarily known for its affordability and economy.
Ratings
Fuel Economy Ratings:
Excellent fuel economy, typically ranging from 5.0-6.5 L/100 km (36-47 MPG US) combined, depending on driving conditions and transmission.
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