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Daewoo Espero 1991 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Daewoo Model: Espero Year: 1991 Country Of Origin: South Korea Codes Vin Country Code: 9 👋 Introduction Market Position Segment: Compact/Mid-size Sedan Target Audience: Owners seeking to perform maintenance and repairs, DIY enthusiasts, independent repair shops Competitive Analysis Key Competitors: Opel Vectra A, Ford Sierra, Nissan Primera, Toyota Camry (early models) Key Features Design Influence: Styling influenced by Italdesign Giugiaro, shared platform with Opel Vectra A Value Proposition: Affordable European-inspired styling and engineering for its era. 📋 Manual Details Coverage Areas Engine Coverage: All petrol engines Transmission Coverage: Manual and Automatic transmissions Chassis Coverage: Suspension, steering, brakes, body Electrical Coverage: Complete electrical system, wiring diagrams Bodywork Coverage: Exterior and interior components, repair procedures Page Count Estimated Pages: 500+ Manual Type Type: Full Service and Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine (block, cylinder head, pistons, crankshaft, camshaft), fuel system, ignition system, cooling system, lubrication system, exhaust system, transmission (clutch, gearbox, torque converter, final drive) Chassis And Suspension: Front suspension (MacPherson strut), rear suspension (multi-link), steering system (power steering, steering column), brake system (front discs, rear drums/discs, ABS components), wheel bearings, drive axles Electrical And Electronics: Battery, charging system (alternator), starting system (starter motor), lighting system (headlights, taillights, interior lights), instrumentation, wipers and washers, horn, power windows, central locking, engine control unit (ECU) and related sensors, diagnostic procedures Body And Interior: Body panels, doors, hood, trunk, bumpers, glass, interior trim, seats, dashboard, HVAC system (air conditioning, heating, ventilation), fuel tank, exhaust system routing Procedures Included Maintenance: Oil and filter changes, air filter replacement, spark plug replacement, coolant flush, brake fluid replacement, belt inspection and replacement, tire rotation, general lubrication Repair And Rebuild: Engine overhaul, cylinder head gasket replacement, transmission overhaul, clutch replacement, brake caliper overhaul, suspension component replacement, starter motor/alternator repair, fuel injector cleaning/replacement Diagnostics And Troubleshooting: System-specific troubleshooting guides, diagnostic trouble codes (DTCs) for ECU, electrical fault finding using wiring diagrams, performance issue diagnosis Technical Depth Depth: Comprehensive from basic scheduled maintenance to full engine and transmission rebuilds, including detailed diagnostic procedures and electrical schematics. 📊 Manual Specifications File Format File Type: PDF Searchability: Text-searchable PDF for easy information retrieval Print Quality Resolution: High-resolution for clear diagrams and text Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code Typical: C16NZ, C18NZ, C20NE (Opel derived) Engine Type: Inline 4-cylinder, SOHC/DOHC (depending on variant) Displacement 1.6L: 1598 cc Displacement 1.8L: 1796 cc Displacement 2.0L: 1998 cc Performance 1.6L Horsepower 1.6L: 75 PS (74 hp; 55 kW) Torque 1.6L: 124 Nm (91 lb-ft) Performance 1.8L Horsepower 1.8L: 90 PS (89 hp; 66 kW) Torque 1.8L: 140 Nm (103 lb-ft) Performance 2.0L Horsepower 2.0L: 115 PS (113 hp; 85 kW) Torque 2.0L: 170 Nm (125 lb-ft) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Petrol (Octane rating as per manual recommendation) Ignition System Ignition Type: Electronic Ignition (Distributorless or Distributor-based depending on specific engine) Cooling System Cooling Type: Liquid-cooled, pressurized system with fan Lubrication System Oil Capacity Approx: 3.5 - 4.5 Liters (check specific engine) 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Optional Transmission Type Optional: 4-speed Automatic Features Clutch Type: Hydraulically operated single dry plate clutch Automatic Transmission Features: Torque converter, P-R-N-D-2-1 shift pattern, potentially electronic control depending on specific model. Fluid Specifications Manual Transmission Fluid: API GL-4, SAE 75W-90 or 80W-90 (verify with manual) Automatic Transmission Fluid: Dexron II or equivalent (verify with manual) 📐 Dimensions Exterior Length Length: Approx. 4570 mm (179.9 in) Exterior Width Width: Approx. 1735 mm (68.3 in) Exterior Height Height: Approx. 1415 mm (55.7 in) Wheelbase Wheelbase: Approx. 2600 mm (102.4 in) Track Front Front Track: Approx. 1460 mm (57.5 in) Track Rear Rear Track: Approx. 1440 mm (56.7 in) Weights Curb Curb Weight Approx: 1250 - 1350 kg (2756 - 2976 lbs) depending on engine/transmission Cargo Trunk Volume Trunk Capacity Approx: 470 Liters (16.6 cu ft) Wheels And Tires Wheel Size Standard: 14-inch or 15-inch alloy or steel wheels Tire Size Standard: 185/70R14 or 195/60R15 (verify with manual) Bolt Pattern: 4x100mm Center Bore: 56.1 mm 🛡️ Safety Features Ratings Crash Test Results: Limited official data for 1991 models; equivalent European models (Opel Vectra A) generally performed moderately in contemporary crash tests. Active Features ABS: Optional Anti-lock Braking System (ABS) available on higher trims/later models Brake Bias System: Load-sensing proportioning valve on rear brakes Passive Features Seatbelts: Front 3-point inertia-reel seatbelts, rear lap belts (3-point optional/standard on some trims) Airbags: Driver airbag optional on later models, not standard on 1991 models. Side Impact Beams: Reinforced door beams 💡 Technology Features Infotainment Audio System: Factory fitted radio/cassette player, potential for CD player integration on higher trims. Basic speaker setup. Display Technology: Analog gauges and indicator lights for instrumentation....
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Daewoo Espero 1991 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Daewoo
Model:
Espero
Year:
1991
Country Of Origin:
South Korea
Codes
Vin Country Code:
9
👋 Introduction
Market Position
Segment:
Compact/Mid-size Sedan
Target Audience:
Owners seeking to perform maintenance and repairs, DIY enthusiasts, independent repair shops
Competitive Analysis
Key Competitors:
Opel Vectra A, Ford Sierra, Nissan Primera, Toyota Camry (early models)
Key Features
Design Influence:
Styling influenced by Italdesign Giugiaro, shared platform with Opel Vectra A
Value Proposition:
Affordable European-inspired styling and engineering for its era.
📋 Manual Details
Coverage Areas
Engine Coverage:
All petrol engines
Transmission Coverage:
Manual and Automatic transmissions
Chassis Coverage:
Suspension, steering, brakes, body
Electrical Coverage:
Complete electrical system, wiring diagrams
Bodywork Coverage:
Exterior and interior components, repair procedures
Page Count
Estimated Pages:
500+
Manual Type
Type:
Full Service and Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (block, cylinder head, pistons, crankshaft, camshaft), fuel system, ignition system, cooling system, lubrication system, exhaust system, transmission (clutch, gearbox, torque converter, final drive)
Chassis And Suspension:
Front suspension (MacPherson strut), rear suspension (multi-link), steering system (power steering, steering column), brake system (front discs, rear drums/discs, ABS components), wheel bearings, drive axles
Electrical And Electronics:
Battery, charging system (alternator), starting system (starter motor), lighting system (headlights, taillights, interior lights), instrumentation, wipers and washers, horn, power windows, central locking, engine control unit (ECU) and related sensors, diagnostic procedures
Body And Interior:
Body panels, doors, hood, trunk, bumpers, glass, interior trim, seats, dashboard, HVAC system (air conditioning, heating, ventilation), fuel tank, exhaust system routing
Procedures Included
Maintenance:
Oil and filter changes, air filter replacement, spark plug replacement, coolant flush, brake fluid replacement, belt inspection and replacement, tire rotation, general lubrication
Repair And Rebuild:
Engine overhaul, cylinder head gasket replacement, transmission overhaul, clutch replacement, brake caliper overhaul, suspension component replacement, starter motor/alternator repair, fuel injector cleaning/replacement
Diagnostics And Troubleshooting:
System-specific troubleshooting guides, diagnostic trouble codes (DTCs) for ECU, electrical fault finding using wiring diagrams, performance issue diagnosis
Technical Depth
Depth:
Comprehensive from basic scheduled maintenance to full engine and transmission rebuilds, including detailed diagnostic procedures and electrical schematics.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable PDF for easy information retrieval
Print Quality
Resolution:
High-resolution for clear diagrams and text
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code Typical:
C16NZ, C18NZ, C20NE (Opel derived)
Engine Type:
Inline 4-cylinder, SOHC/DOHC (depending on variant)
Displacement 1.6L:
1598 cc
Displacement 1.8L:
1796 cc
Displacement 2.0L:
1998 cc
Performance 1.6L
Horsepower 1.6L:
75 PS (74 hp; 55 kW)
Torque 1.6L:
124 Nm (91 lb-ft)
Performance 1.8L
Horsepower 1.8L:
90 PS (89 hp; 66 kW)
Torque 1.8L:
140 Nm (103 lb-ft)
Performance 2.0L
Horsepower 2.0L:
115 PS (113 hp; 85 kW)
Torque 2.0L:
170 Nm (125 lb-ft)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Petrol (Octane rating as per manual recommendation)
Ignition System
Ignition Type:
Electronic Ignition (Distributorless or Distributor-based depending on specific engine)
Cooling System
Cooling Type:
Liquid-cooled, pressurized system with fan
Lubrication System
Oil Capacity Approx:
3.5 - 4.5 Liters (check specific engine)
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual
Optional
Transmission Type Optional:
4-speed Automatic
Features
Clutch Type:
Hydraulically operated single dry plate clutch
Automatic Transmission Features:
Torque converter, P-R-N-D-2-1 shift pattern, potentially electronic control depending on specific model.
Fluid Specifications
Manual Transmission Fluid:
API GL-4, SAE 75W-90 or 80W-90 (verify with manual)
Automatic Transmission Fluid:
Dexron II or equivalent (verify with manual)
📐 Dimensions
Exterior Length
Length:
Approx. 4570 mm (179.9 in)
Exterior Width
Width:
Approx. 1735 mm (68.3 in)
Exterior Height
Height:
Approx. 1415 mm (55.7 in)
Wheelbase
Wheelbase:
Approx. 2600 mm (102.4 in)
Track Front
Front Track:
Approx. 1460 mm (57.5 in)
Track Rear
Rear Track:
Approx. 1440 mm (56.7 in)
Weights Curb
Curb Weight Approx:
1250 - 1350 kg (2756 - 2976 lbs) depending on engine/transmission
Cargo Trunk Volume
Trunk Capacity Approx:
470 Liters (16.6 cu ft)
Wheels And Tires
Wheel Size Standard:
14-inch or 15-inch alloy or steel wheels
Tire Size Standard:
185/70R14 or 195/60R15 (verify with manual)
Bolt Pattern:
4x100mm
Center Bore:
56.1 mm
🛡️ Safety Features
Ratings
Crash Test Results:
Limited official data for 1991 models; equivalent European models (Opel Vectra A) generally performed moderately in contemporary crash tests.
Active Features
ABS:
Optional Anti-lock Braking System (ABS) available on higher trims/later models
Brake Bias System:
Load-sensing proportioning valve on rear brakes
Passive Features
Seatbelts:
Front 3-point inertia-reel seatbelts, rear lap belts (3-point optional/standard on some trims)
Airbags:
Driver airbag optional on later models, not standard on 1991 models.
Side Impact Beams:
Reinforced door beams
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette player, potential for CD player integration on higher trims. Basic speaker setup.
Display Technology:
Analog gauges and indicator lights for instrumentation. No central display for infotainment.
Driver Assistance
Cruise Control:
Optional cruise control available on some variants.
Connectivity
Connectivity Features:
Limited to factory audio system, no Bluetooth or USB connectivity.
🔧 Maintenance
Service Intervals Oil
Oil Change Interval:
Every 10,000 km or 6 months, whichever comes first (verify with manual)
Service Intervals Filters
Air Filter Replacement Interval:
Every 20,000 km or 12 months (verify with manual)
Fuel Filter Replacement Interval:
Every 40,000 km or 24 months (verify with manual)
Service Intervals Fluids
Coolant Replacement Interval:
Every 40,000 km or 24 months (verify with manual)
Brake Fluid Replacement Interval:
Every 24 months, regardless of mileage (verify with manual)
Fluid Specifications Engine Oil
Engine Oil Viscosity:
SAE 10W-30 or 10W-40 (API SG/SH or higher, verify with manual)
Fluid Specifications Coolant
Coolant Type:
Ethylene glycol based antifreeze (e.g., Dexcool equivalent for long-life or standard green coolant, verify with manual)
Known Issues
Electrical System:
Corrosion in connectors, premature failure of headlight/taillight bulbs, issues with power window regulators, intermittent dashboard warning lights.
Engine:
Oil leaks from valve cover gasket and oil pan, potential carbon buildup on intake valves, thermostat housing leaks, distributor O-ring leaks.
Suspension And Steering:
Wear in front control arm bushings, worn tie rod ends, premature front wheel bearing failure, power steering fluid leaks.
Exhaust System:
Corrosion of exhaust pipes and muffler, catalytic converter failure.
HVAC System:
Leaking AC evaporator core, heater core issues, degradation of vacuum lines for HVAC controls.
📚 Vehicle History
Brand Heritage
Daewoo Automotive:
South Korean manufacturer, established by Daewoo Group. Known for licensing technology and producing vehicles based on GM and Isuzu platforms.
Model Evolution
Espero Introduction:
Introduced in 1990 as Daewoo's flagship sedan, designed by Italdesign Giugiaro. Replaced the Daewoo Espero.
Platform Sharing:
Based on the GM 'V' platform, shared with the Opel Vectra A.
Production
Production Years:
1990-1997
Manufacturing Locations:
South Korea (main), also assembled in other countries.
Market Presence
Key Export Markets:
Europe, Australia, Canada, and other global markets.
🏆 Awards & Recognition
Recognitions
General Reputation:
While not a recipient of major awards, the Daewoo Espero was noted for its styling and value proposition in its segment during the early 1990s.
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