Daewoo Tico Service Repair Workshop Manual download

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🏷️ Basic Information Identification Make: Daewoo Model: Tico Generation Generation Name: First Generation (KLYJ) Codes Chassis Code: KLYJ 👋 Introduction Market Position Vehicle Segment: City car, kei car homologue (in some markets). Designed for affordability, economy, and maneuverability in urban environments. Competitive Analysis Key Competitors: Suzuki Alto, Kia Pride (later models), Hyundai Excel, Fiat Cinquecento/Seicento, Ford Festiva. Key Features Design Philosophy: Compact footprint, fuel efficiency, low cost of ownership, simple mechanicals, cheerful styling. Target Audience: First-time car buyers, budget-conscious consumers, drivers seeking economical urban transport. 📋 Manual Details Coverage Areas Model Years Covered: 1995-2001 (Estimated, Tico production spanned various years and markets. Specific years vary by manual edition.) Market Coverage: Primarily Europe, Asia, and other export markets. May include details relevant to specific regional variants. Page Count Estimated Page Count: 500-800 Pages (Typical for a comprehensive service manual of this era) Manual Type Manual Type: Service and Repair Workshop Manual Language Language: English (Likely primary language of download, may contain translated sections or diagrams understandable across languages) Format Digital Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, overhaul, component testing, lubrication system, cooling system, fuel system, ignition system, emissions control. Transmission: Manual transmission (and potentially automatic if offered in some markets), clutch system, gearbox overhaul, maintenance, troubleshooting. Drivetrain: Front-wheel drive system, axles, differential, driveshafts, CV joints. Suspension: Front and rear suspension components, shock absorbers, springs, bushings, alignment specifications. Steering: Steering column, steering rack, power steering system (if equipped), troubleshooting. Brakes: Front disc brakes, rear drum brakes, hydraulic system, brake fluid specifications, bleeding procedures, component replacement. Electrical System: Battery, charging system (alternator), starting system (starter motor), lighting system, fuses, relays, wiring diagrams, body control modules. Fuel System: Fuel tank, fuel pump, fuel filter, carburetor (for earlier models) or fuel injection system (later models), troubleshooting. Cooling System: Radiator, fan, water pump, thermostat, coolant specifications, capacity. Exhaust System: Exhaust manifold, catalytic converter, mufflers, pipes, hangers, gaskets. Body And Chassis: Body panels, doors, hood, trunk, interior trim, chassis components, rust repair considerations. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug replacement, air filter replacement, brake fluid flush, coolant flush, drive belt inspection/replacement. Engine Repair: Engine rebuild, piston ring replacement, valve adjustments, cylinder head gasket replacement, timing belt/chain replacement. Transmission Repair: Clutch replacement, transmission fluid change, gearbox overhaul, synchronizer replacement. Brake System Repair: Brake pad/shoe replacement, rotor/drum replacement, caliper/wheel cylinder overhaul, brake line repair/replacement. Electrical Troubleshooting: Diagnosing electrical faults using wiring diagrams, testing components, common electrical issues. Suspension And Steering Repair: Replacement of tie rods, ball joints, control arm bushings, steering rack seals. Diagnostic Procedures: Troubleshooting flowcharts, symptom-based diagnostics for engine, transmission, and other systems. Heating And Air Conditioning: Component identification, basic troubleshooting, refrigerant handling (if applicable), component replacement (blower motor, heater core). Technical Depth Depth Of Coverage: Comprehensive from basic owner maintenance to in-depth mechanical and electrical repair. Includes specifications for torque values, clearances, and testing parameters. Diagnostic Capabilities: Detailed symptom-to-cause troubleshooting guides, component testing procedures, and diagnostic trouble code (DTC) interpretation (if applicable to the vehicle's systems). Rebuild Procedures: Complete overhaul instructions for major components like the engine and transmission, including disassembly, cleaning, inspection, and reassembly steps. 📊 Manual Specifications File Format PDF Quality: High-resolution scans or digital creation, ensuring clarity of text and diagrams. Searchable text functionality is common in well-prepared PDFs. Printability: Designed for printing, with standard page sizes and orientation. High-quality print output is expected. Binding Type Binding Type: N/A (Digital Download - PDF) Paper Type Paper Type: N/A (Digital Download - PDF) ⚙️ Engine Specifications Primary Engine Engine Code: F8C (Common for 796cc models) Displacement: 796 cc (0.8 Liters) Configuration: Inline 3-cylinder, SOHC Bore X Stroke: 68.5 mm x 72.0 mm (Typical for F8C) Compression Ratio: 9.3:1 (Typical) Performance Horsepower: 39-41 PS (approx. 38-40 bhp) @ 5500 rpm (depending on market and emissions regulations) Torque: 63 Nm (approx. 46 lb-ft) @ 3500 rpm (depending on market and emissions regulations) Fuel System Fuel Delivery: Carburetor (e.g., Hitachi, Mikuni) for most models; some later versions may have basic multi-point fuel injection (MPI). Fuel Type: Unleaded Gasoline Engine Management Ignition Type: Distributor-based electronic ignition (most models) ECU Type: Basic engine control unit (ECU) for fuel injection and ignition timing on FI models. 🔧 Transmission Standard Transmission Type: 5-Speed Manual Optional Transmission Type: 3-Speed Automatic (less common, often for specific markets) Features Clutch Type: Dry single plate (manual transmission) Final Drive Ratio: Typically around 4.1:1 for manual, may vary slightly. 📐 Dimensions Exterior Length: Approx. 3,300 - 3,380 mm (130 - 133 inches) Width: Approx. 1,400 - 1,440 mm (55 - 57 inches) Height: Approx. 1,400 - 1,430 mm (55 - 56 inches) Wheelbase: Approx. 2,175 mm (85.6 inches) Ground Clearance: Approx. 150 mm (5.9 inches) Weights Curb Weight: Approx. 700 - 750 kg (1540 - 1650 lbs) Gross Vehicle Weight Rating: Approx. 1,100 - 1,200 kg (2425...

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Description

🏷️ Basic Information

Identification

Make:

Daewoo

Model:

Generation

Generation Name:

First Generation (KLYJ)

Codes

Chassis Code:

👋 Introduction

Market Position

Vehicle Segment:

City car, kei car homologue (in some markets). Designed for affordability, economy, and maneuverability in urban environments.

Competitive Analysis

Key Competitors:

Suzuki Alto, Kia Pride (later models), Hyundai Excel, Fiat Cinquecento/Seicento, Ford Festiva.

Key Features

Design Philosophy:

Compact footprint, fuel efficiency, low cost of ownership, simple mechanicals, cheerful styling.

Target Audience:

First-time car buyers, budget-conscious consumers, drivers seeking economical urban transport.

📋 Manual Details

Coverage Areas

Model Years Covered:

1995-2001 (Estimated, Tico production spanned various years and markets. Specific years vary by manual edition.)

Market Coverage:

Primarily Europe, Asia, and other export markets. May include details relevant to specific regional variants.

Page Count

Estimated Page Count:

500-800 Pages (Typical for a comprehensive service manual of this era)

Manual Type

Manual Type:

Service and Repair Workshop Manual

Language

Language:

English (Likely primary language of download, may contain translated sections or diagrams understandable across languages)

Format

Digital Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Engine:

Detailed diagnostics, overhaul, component testing, lubrication system, cooling system, fuel system, ignition system, emissions control.

Transmission:

Manual transmission (and potentially automatic if offered in some markets), clutch system, gearbox overhaul, maintenance, troubleshooting.

Drivetrain:

Front-wheel drive system, axles, differential, driveshafts, CV joints.

Suspension:

Front and rear suspension components, shock absorbers, springs, bushings, alignment specifications.

Steering:

Steering column, steering rack, power steering system (if equipped), troubleshooting.

Brakes:

Front disc brakes, rear drum brakes, hydraulic system, brake fluid specifications, bleeding procedures, component replacement.

Electrical System:

Battery, charging system (alternator), starting system (starter motor), lighting system, fuses, relays, wiring diagrams, body control modules.

Fuel System:

Fuel tank, fuel pump, fuel filter, carburetor (for earlier models) or fuel injection system (later models), troubleshooting.

Cooling System:

Radiator, fan, water pump, thermostat, coolant specifications, capacity.

Exhaust System:

Exhaust manifold, catalytic converter, mufflers, pipes, hangers, gaskets.

Body And Chassis:

Body panels, doors, hood, trunk, interior trim, chassis components, rust repair considerations.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug replacement, air filter replacement, brake fluid flush, coolant flush, drive belt inspection/replacement.

Engine Repair:

Engine rebuild, piston ring replacement, valve adjustments, cylinder head gasket replacement, timing belt/chain replacement.

Transmission Repair:

Clutch replacement, transmission fluid change, gearbox overhaul, synchronizer replacement.

Brake System Repair:

Brake pad/shoe replacement, rotor/drum replacement, caliper/wheel cylinder overhaul, brake line repair/replacement.

Electrical Troubleshooting:

Diagnosing electrical faults using wiring diagrams, testing components, common electrical issues.

Suspension And Steering Repair:

Replacement of tie rods, ball joints, control arm bushings, steering rack seals.

Diagnostic Procedures:

Troubleshooting flowcharts, symptom-based diagnostics for engine, transmission, and other systems.

Heating And Air Conditioning:

Component identification, basic troubleshooting, refrigerant handling (if applicable), component replacement (blower motor, heater core).

Technical Depth

Depth Of Coverage:

Comprehensive from basic owner maintenance to in-depth mechanical and electrical repair. Includes specifications for torque values, clearances, and testing parameters.

Diagnostic Capabilities:

Detailed symptom-to-cause troubleshooting guides, component testing procedures, and diagnostic trouble code (DTC) interpretation (if applicable to the vehicle's systems).

Rebuild Procedures:

Complete overhaul instructions for major components like the engine and transmission, including disassembly, cleaning, inspection, and reassembly steps.

📊 Manual Specifications

File Format

PDF Quality:

High-resolution scans or digital creation, ensuring clarity of text and diagrams. Searchable text functionality is common in well-prepared PDFs.

Printability:

Designed for printing, with standard page sizes and orientation. High-quality print output is expected.

Binding Type

Binding Type:

N/A (Digital Download - PDF)

Paper Type

Paper Type:

N/A (Digital Download - PDF)

⚙️ Engine Specifications

Primary Engine

Engine Code:

F8C (Common for 796cc models)

Displacement:

796 cc (0.8 Liters)

Configuration:

Inline 3-cylinder, SOHC

Bore X Stroke:

68.5 mm x 72.0 mm (Typical for F8C)

Compression Ratio:

9.3:1 (Typical)

Performance

Horsepower:

39-41 PS (approx. 38-40 bhp) @ 5500 rpm (depending on market and emissions regulations)

Torque:

63 Nm (approx. 46 lb-ft) @ 3500 rpm (depending on market and emissions regulations)

Fuel System

Fuel Delivery:

Carburetor (e.g., Hitachi, Mikuni) for most models; some later versions may have basic multi-point fuel injection (MPI).

Fuel Type:

Unleaded Gasoline

Engine Management

Ignition Type:

Distributor-based electronic ignition (most models)

ECU Type:

Basic engine control unit (ECU) for fuel injection and ignition timing on FI models.

🔧 Transmission

Standard

Transmission Type:

5-Speed Manual

Optional

Transmission Type:

3-Speed Automatic (less common, often for specific markets)

Features

Clutch Type:

Dry single plate (manual transmission)

Final Drive Ratio:

Typically around 4.1:1 for manual, may vary slightly.

📐 Dimensions

Exterior

Length:

Approx. 3,300 - 3,380 mm (130 - 133 inches)

Width:

Approx. 1,400 - 1,440 mm (55 - 57 inches)

Height:

Approx. 1,400 - 1,430 mm (55 - 56 inches)

Wheelbase:

Approx. 2,175 mm (85.6 inches)

Ground Clearance:

Approx. 150 mm (5.9 inches)

Weights

Curb Weight:

Approx. 700 - 750 kg (1540 - 1650 lbs)

Gross Vehicle Weight Rating:

Approx. 1,100 - 1,200 kg (2425 - 2645 lbs)

🛡️ Safety Features

Ratings

Crash Test Ratings:

Limited availability of formal crash test data for this model in many markets. Expected to be basic due to era and segment. Likely no modern NCAP ratings.

Active Features

Anti Lock Braking System:

Optional or not available on base models.

Electronic Stability Control:

Not available.

Passive Features

Airbags:

Driver's airbag standard on later models/higher trims. Passenger airbag generally not available.

Seatbelts:

Three-point front seatbelts, two-point rear seatbelts (early models) or three-point (later models).

Body Structure:

Reinforced passenger safety cell (typical design of the era).

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM radio with cassette player or single-CD player. Simple speaker setup.

Driver Assistance

Parking Assistance:

No parking sensors or rearview cameras. Relies on driver's spatial awareness.

Connectivity

Bluetooth Integration:

Not available. Aftermarket solutions would be required.

🔧 Maintenance

Service Intervals

Engine Oil And Filter:

Every 5,000 - 7,500 km (3,000 - 5,000 miles) or 6-12 months, whichever comes first.

Air Filter:

Every 15,000 - 20,000 km (9,000 - 12,000 miles) or annually.

Spark Plugs:

Every 20,000 - 30,000 km (12,000 - 18,000 miles) or 2 years, depending on plug type.

Coolant Flush:

Every 30,000 - 40,000 km (18,000 - 24,000 miles) or 2-3 years.

Brake Fluid Flush:

Every 24 months, regardless of mileage.

Timing Belt Replacement:

Crucial: Check manual for specific interval, typically around 60,000 - 90,000 km (36,000 - 54,000 miles) or 4-5 years. Failure can cause catastrophic engine damage.

Fluid Specifications

Engine Oil Type:

API SG or higher, SAE 10W-30 or 10W-40 (check manual for climate-specific recommendations).

Engine Oil Capacity:

Approx. 3.0 - 3.3 Liters (with filter change)

Coolant Type:

Ethylene glycol-based, permanent type antifreeze (e.g., Dex-Cool compatible or similar specification).

Transmission Fluid Type Manual:

API GL-4, SAE 75W-90 or 80W-90 gear oil.

Transmission Fluid Type Auto:

Dexron II or equivalent automatic transmission fluid (ATF).

Brake Fluid Type:

DOT 3 or DOT 4.

Known Issues

Engine Performance:

Weak low-end torque, sensitivity to carburetor adjustment, potential for oil leaks from seals (e.g., valve cover, crank seals) with age.

Electrical Reliability:

Can experience minor electrical gremlins: headlight switch issues, intermittent wipers, corrosion on connectors. Check grounds.

Suspension Wear:

Worn control arm bushings, ball joints, and tie rod ends can lead to vague steering and premature tire wear.

Rust And Corrosion:

Common issue, especially in areas with road salt. Check sills, wheel arches, floor pans, and subframes.

Clutch Wear:

Clutch can wear out, especially with aggressive driving. Clutch pedal adjustment may be needed.

Cooling System Leaks:

Radiator, hoses, and water pump are prone to leaks with age.

📚 Vehicle History

Brand Heritage

Daewoo Origins:

Daewoo Motors was a South Korean automobile manufacturer founded in 1982. It was part of the Daewoo Group conglomerate. Daewoo vehicles were often based on designs licensed from other manufacturers (e.g., Suzuki, Isuzu, GM).

Model Evolution

Tico Development:

The Daewoo Tico was a rebadged version of the Suzuki Alto (seventh generation, CA71V series). It was designed and initially produced by Suzuki in Japan and then manufactured by Daewoo in South Korea starting in 1991.

Production Period:

1991-2001 in South Korea. Production also occurred in other countries under different names or licenses.

Production

Manufacturing Locations:

South Korea (Changwon), Poland (FSO Daewoo), Romania (Oltena/Daewoo), Uzbekistan (UzDaewooAuto as Nexia/Matiz based models, but Tico was also produced).