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Chevrolet Lacetti/Nubria 2004 Service Repair Manual

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🏷️ Basic Information Identification Make: Chevrolet Model: Lacetti/Nubira Model Year: 2004 Common Names: Chevrolet Lacetti, Chevrolet Nubira, Daewoo Lacetti, Daewoo Nubira, Holden Viva, Suzuki Forenza, Suzuki Verona Codes Platform: J200 👋 Introduction Market Position Segment: Compact car (C-segment) Target Audience: Budget-conscious buyers seeking reliable and practical transportation Competitive Analysis Key Competitors: Ford Focus, Honda Civic, Toyota Corolla, Hyundai Elantra, Kia Spectra Key Features Design Philosophy: Practicality, affordability, and straightforward engineering Value Proposition: Offers a comfortable ride, decent interior space, and a straightforward driving experience at a competitive price point 📋 Manual Details Coverage Areas Market Coverage: Global (Europe, Asia, North America, Australia) Body Styles Covered: Sedan, Hatchback (3-door and 5-door), Wagon Page Count Estimated Page Count: ~1500-2000 Manual Type Manual Type: Service and Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, valve train, pistons, crankshaft, lubrication system, cooling system, fuel system (mechanical components) Engine Management: ECU, ignition system, fuel injection system (EFI), emissions control systems, diagnostic trouble codes (DTCs) Transmission Manual: Clutch, gearbox assembly, gearshift linkage, overhaul procedures Transmission Automatic: Automatic transmission assembly, hydraulic control, torque converter, overhaul procedures, electronic control Drivetrain: Front-wheel drive axle shafts, CV joints, differential Suspension: Front suspension (MacPherson struts), rear suspension (independent trailing arm/multi-link depending on model), shock absorbers, springs, bushings Steering: Power steering system (hydraulic), steering rack, column, tie rods Brakes: Front disc brakes, rear drum/disc brakes, ABS system, brake lines, master cylinder, power booster Electrical System: Battery, charging system (alternator, regulator), starting system (starter motor), lighting (headlights, taillights, interior), fuses, relays, wiring diagrams Body And Chassis: Body panels, doors, windows, locks, interior trim, chassis components, rust prevention HVAC: Heating, ventilation, air conditioning system components, refrigerant handling Exhaust System: Exhaust manifolds, catalytic converter, mufflers, pipes Procedures Included Routine Maintenance: Oil and filter changes, air filter replacement, spark plug replacement, fluid level checks and top-offs, belt inspection and replacement Component Removal Installation: Detailed instructions for removing and installing major and minor components across all systems Troubleshooting: Diagnostic procedures for common drivability issues, electrical faults, and mechanical problems Rebuild Procedures: Complete overhaul instructions for engines, transmissions, and other major assemblies Adjustment Procedures: Wheel alignment, clutch adjustment, parking brake adjustment Diagnostic Codes: Interpretation and troubleshooting steps for OBD-II diagnostic trouble codes (DTCs) Technical Depth Diagnostic Capabilities: Advanced diagnostic procedures utilizing scan tools and diagnostic flowcharts Repair Complexity: Covers from basic DIY repairs to complex engine and transmission rebuilds Electrical Diagrams: Comprehensive, detailed, and accurate wiring diagrams for all electrical systems Torque Specifications: Precise torque values for all critical fasteners Special Tools: Identification and usage of specialized tools required for specific repairs 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Fully searchable text content for quick information retrieval Page Layout: Printable pages, optimized for digital viewing on computers and tablets Print Quality Image Resolution: High-resolution for clear diagrams, illustrations, and photographs Binding Type Binding Type: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code 1: T18SED (1.8L DOHC) Engine Displacement 1: 1799 cc Engine Configuration 1: Inline 4-cylinder Engine Aspirated 1: Naturally Aspirated Engine Valvetrain 1: DOHC, 16 valves Engine Bore X Stroke 1: 80.5 mm x 88.3 mm Engine Compression Ratio 1: 9.5:1 Engine Horsepower 1: 121 hp (90 kW) @ 5800 rpm Engine Torque 1: 165 Nm (122 lb-ft) @ 4000 rpm Alternative Engine Engine Code 2: F16D3 (1.6L DOHC) Engine Displacement 2: 1598 cc Engine Horsepower 2: 109 hp (81 kW) @ 5800 rpm Engine Torque 2: 150 Nm (111 lb-ft) @ 3200 rpm Fuel System Fuel Type: Unleaded Gasoline Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Tank Capacity: 55 Liters (14.5 US gallons) 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Transmission Optional Transmission Type Optional: 4-speed Automatic Transmission Features Clutch Type: Hydraulically Actuated, Dry Single Plate Automatic Transmission Features: Electronically controlled, Lock-up torque converter 📐 Dimensions Exterior Wheelbase: 2600 mm (102.4 in) Length Sedan: 4515 mm (177.8 in) Length Hatchback 5Dr: 4270 mm (168.1 in) Length Hatchback 3Dr: 4170 mm (164.2 in) Length Wagon: 4495 mm (177.0 in) Width: 1725 mm (67.9 in) Height Sedan Wagon: 1445 mm (56.9 in) Height Hatchback: 1440 mm (56.7 in) Track Width Front: 1480 mm (58.3 in) Track Width Rear: 1470 mm (57.9 in) Interior Passenger Volume: ~94.0 cu ft (2662 L) Cargo Cargo Volume Sedan: ~16.6 cu ft (470 L) Cargo Volume Hatchback: ~13.7 cu ft (388 L) to rear seats Cargo Volume Wagon: ~17.7 cu ft (500 L) to rear seats Weights Curb Weight Min: ~1220 kg (2690 lbs) Gross Vehicle Weight Rating Gvwr: ~1770 kg (3902 lbs) 🛡️ Safety Features Ratings NHTSA Frontal Crash Driver: Not Rated/4 Stars (model dependent) NHTSA Frontal Crash Passenger: Not Rated/4 Stars (model dependent) IIHS Front Crash: Acceptable (model dependent) Active Features ABS: Optional (Standard...
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Chevrolet Lacetti/Nubria 2004 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Chevrolet
Model:
Lacetti/Nubira
Model Year:
2004
Common Names:
Chevrolet Lacetti, Chevrolet Nubira, Daewoo Lacetti, Daewoo Nubira, Holden Viva, Suzuki Forenza, Suzuki Verona
Codes
Platform:
J200
👋 Introduction
Market Position
Segment:
Compact car (C-segment)
Target Audience:
Budget-conscious buyers seeking reliable and practical transportation
Competitive Analysis
Key Competitors:
Ford Focus, Honda Civic, Toyota Corolla, Hyundai Elantra, Kia Spectra
Key Features
Design Philosophy:
Practicality, affordability, and straightforward engineering
Value Proposition:
Offers a comfortable ride, decent interior space, and a straightforward driving experience at a competitive price point
📋 Manual Details
Coverage Areas
Market Coverage:
Global (Europe, Asia, North America, Australia)
Body Styles Covered:
Sedan, Hatchback (3-door and 5-door), Wagon
Page Count
Estimated Page Count:
~1500-2000
Manual Type
Manual Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, valve train, pistons, crankshaft, lubrication system, cooling system, fuel system (mechanical components)
Engine Management:
ECU, ignition system, fuel injection system (EFI), emissions control systems, diagnostic trouble codes (DTCs)
Transmission Manual:
Clutch, gearbox assembly, gearshift linkage, overhaul procedures
Transmission Automatic:
Automatic transmission assembly, hydraulic control, torque converter, overhaul procedures, electronic control
Drivetrain:
Front-wheel drive axle shafts, CV joints, differential
Suspension:
Front suspension (MacPherson struts), rear suspension (independent trailing arm/multi-link depending on model), shock absorbers, springs, bushings
Steering:
Power steering system (hydraulic), steering rack, column, tie rods
Brakes:
Front disc brakes, rear drum/disc brakes, ABS system, brake lines, master cylinder, power booster
Electrical System:
Battery, charging system (alternator, regulator), starting system (starter motor), lighting (headlights, taillights, interior), fuses, relays, wiring diagrams
Body And Chassis:
Body panels, doors, windows, locks, interior trim, chassis components, rust prevention
HVAC:
Heating, ventilation, air conditioning system components, refrigerant handling
Exhaust System:
Exhaust manifolds, catalytic converter, mufflers, pipes
Procedures Included
Routine Maintenance:
Oil and filter changes, air filter replacement, spark plug replacement, fluid level checks and top-offs, belt inspection and replacement
Component Removal Installation:
Detailed instructions for removing and installing major and minor components across all systems
Troubleshooting:
Diagnostic procedures for common drivability issues, electrical faults, and mechanical problems
Rebuild Procedures:
Complete overhaul instructions for engines, transmissions, and other major assemblies
Adjustment Procedures:
Wheel alignment, clutch adjustment, parking brake adjustment
Diagnostic Codes:
Interpretation and troubleshooting steps for OBD-II diagnostic trouble codes (DTCs)
Technical Depth
Diagnostic Capabilities:
Advanced diagnostic procedures utilizing scan tools and diagnostic flowcharts
Repair Complexity:
Covers from basic DIY repairs to complex engine and transmission rebuilds
Electrical Diagrams:
Comprehensive, detailed, and accurate wiring diagrams for all electrical systems
Torque Specifications:
Precise torque values for all critical fasteners
Special Tools:
Identification and usage of specialized tools required for specific repairs
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Fully searchable text content for quick information retrieval
Page Layout:
Printable pages, optimized for digital viewing on computers and tablets
Print Quality
Image Resolution:
High-resolution for clear diagrams, illustrations, and photographs
Binding Type
Binding Type:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
T18SED (1.8L DOHC)
Engine Displacement 1:
1799 cc
Engine Configuration 1:
Inline 4-cylinder
Engine Aspirated 1:
Naturally Aspirated
Engine Valvetrain 1:
DOHC, 16 valves
Engine Bore X Stroke 1:
80.5 mm x 88.3 mm
Engine Compression Ratio 1:
9.5:1
Engine Horsepower 1:
121 hp (90 kW) @ 5800 rpm
Engine Torque 1:
165 Nm (122 lb-ft) @ 4000 rpm
Alternative Engine
Engine Code 2:
F16D3 (1.6L DOHC)
Engine Displacement 2:
1598 cc
Engine Horsepower 2:
109 hp (81 kW) @ 5800 rpm
Engine Torque 2:
150 Nm (111 lb-ft) @ 3200 rpm
Fuel System
Fuel Type:
Unleaded Gasoline
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Tank Capacity:
55 Liters (14.5 US gallons)
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transmission
Optional
Transmission Type Optional:
4-speed Automatic Transmission
Features
Clutch Type:
Hydraulically Actuated, Dry Single Plate
Automatic Transmission Features:
Electronically controlled, Lock-up torque converter
📐 Dimensions
Exterior
Wheelbase:
2600 mm (102.4 in)
Length Sedan:
4515 mm (177.8 in)
Length Hatchback 5Dr:
4270 mm (168.1 in)
Length Hatchback 3Dr:
4170 mm (164.2 in)
Length Wagon:
4495 mm (177.0 in)
Width:
1725 mm (67.9 in)
Height Sedan Wagon:
1445 mm (56.9 in)
Height Hatchback:
1440 mm (56.7 in)
Track Width Front:
1480 mm (58.3 in)
Track Width Rear:
1470 mm (57.9 in)
Interior
Passenger Volume:
~94.0 cu ft (2662 L)
Cargo
Cargo Volume Sedan:
~16.6 cu ft (470 L)
Cargo Volume Hatchback:
~13.7 cu ft (388 L) to rear seats
Cargo Volume Wagon:
~17.7 cu ft (500 L) to rear seats
Weights
Curb Weight Min:
~1220 kg (2690 lbs)
Gross Vehicle Weight Rating Gvwr:
~1770 kg (3902 lbs)
🛡️ Safety Features
Ratings
NHTSA Frontal Crash Driver:
Not Rated/4 Stars (model dependent)
NHTSA Frontal Crash Passenger:
Not Rated/4 Stars (model dependent)
IIHS Front Crash:
Acceptable (model dependent)
Active Features
ABS:
Optional (Standard on higher trims/certain markets)
Electronic Brakeforce Distribution Ebd:
Often paired with ABS
Passive Features
Airbags Front:
Driver and front passenger airbags
Airbags Side:
Optional front side airbags
Seatbelts:
3-point front and rear seatbelts, pretensioners and load limiters for front seats
Child Seat Anchors:
LATCH/ISOFIX
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with CD player, 4-6 speakers
Display:
Basic digital display for radio and clock
Connectivity:
Auxiliary input jack (optional/later models)
Driver Assistance
Cruise Control:
Available on higher trims
Parking Sensors:
Not commonly available
🔧 Maintenance
Service Intervals
Engine Oil And Filter:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first
Engine Air Filter:
Every 30,000 miles (48,000 km)
Cabin Air Filter:
Every 15,000 miles (24,000 km) or annually
Spark Plugs:
Every 60,000 miles (96,000 km) (iridium type)
Coolant Replacement:
Every 5 years or 100,000 miles (160,000 km)
Automatic Transmission Fluid:
Every 60,000 miles (96,000 km) (service interval, fluid type dependent)
Timing Belt:
Every 60,000 miles (96,000 km) or 4 years (critical replacement)
Fluid Specifications
Engine Oil Type:
API SM/SN, SAE 5W-30 (check owner's manual for specific viscosity recommendations)
Engine Oil Capacity:
Approx. 4.0 Liters (4.2 US quarts) with filter change
Coolant Type:
GM Dex-Cool (Orange) or equivalent (50/50 mix with distilled water)
Brake Fluid:
DOT 3 or DOT 4
Power Steering Fluid:
GM Power Steering Fluid or Dexron III/VI ATF
Automatic Transmission Fluid:
Dexron III / Dexron VI
Known Issues
Engine Mounts:
Premature wear leading to vibration and noise.
Suspension Components:
Wear in bushings and ball joints, especially on higher mileage vehicles, leading to clunks and poor handling.
Timing Belt:
Critical component failure can cause catastrophic engine damage. Adherence to replacement schedule is vital.
Electrical Connectors:
Corrosion or loose connections in various harnesses can cause intermittent electrical issues.
Oxygen Sensors:
Can become fouled or fail, affecting fuel economy and emissions.
Clutch Assembly:
Wear can lead to slipping or difficulty engaging gears, especially on manual transmissions.
📚 Vehicle History
Brand Heritage
Origin:
Daewoo Motor Co., Ltd. (South Korea)
Model Evolution
Predecessor:
Daewoo Nubira (first generation)
Development:
Developed by Daewoo Motors and styled by Pininfarina. Acquired by General Motors in 2002.
Rebadging:
Rebadged and sold as Chevrolet Lacetti/Nubira globally, Holden Viva in Australia, and Suzuki Forenza/Verona in North America.
Production
Production Start Year:
2002 (as Daewoo), 2004 (as Chevrolet globally)
Manufacturing Locations:
South Korea (Bupyong), Egypt, Poland, Russia, Vietnam
Production End Year:
2008 (replaced by Chevrolet Cruze)
🏆 Awards & Recognition
Recognitions
Design Award Mention:
Exterior styling praised for its clean lines and Pininfarina design influence.
Ratings
Fuel Economy Rating Avg:
Approximately 24 MPG city / 32 MPG highway (1.8L, manual transmission), varies by model and driving conditions.
Certifications
Emissions Standards:
Meets Euro 3/4 and EPA emission standards applicable to the market of sale.
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