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DAEWOO REZZO 2000-2008 Service Repair Manual

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🏷️ Basic Information Identification Make: Daewoo Model: Rezzo Model Alias: Tacuma Generation: First Generation Codes Model Code: U100 👋 Introduction Market Position Vehicle Segment: Compact MPV (Multi-Purpose Vehicle) / Minivan Competitive Analysis Key Competitors: Opel Zafira, Renault Scenic, Ford Focus C-Max, Volkswagen Golf Plus Key Features Design Philosophy: Practicality, spaciousness, and affordability, targeting families and individuals needing versatile transport. Body Styles: Primarily a 5-door MPV, often with 7-seat configurations available. 📋 Manual Details Coverage Areas Manual Type: Factory Service Manual / Repair Manual Language: English Format: Digital (Likely PDF) Page Count Estimated Page Count: 1000+ 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul and repair procedures for all engine variants, including cylinder head, pistons, crankshaft, camshafts, and timing components. Engine Performance: Fuel injection system, ignition system, emissions control, cooling system, lubrication system, turbocharging (if applicable). Transmission Manual: Repair, overhaul, and adjustment procedures for manual transmissions, including clutch, gearbox, and driveline components. Transmission Automatic: Diagnostic, repair, and overhaul procedures for automatic transmissions, including torque converter, valve body, and internal components. Brakes: Detailed information on hydraulic systems, ABS (Anti-lock Braking System), brake pads, rotors, calipers, and parking brake mechanisms. Suspension: Front and rear suspension systems, including shock absorbers, struts, springs, control arms, ball joints, and bushings. Steering: Power steering system diagnosis, repair, and component replacement, including steering rack, pump, and lines. Electrical System: Comprehensive wiring diagrams, component testing, diagnosis of lighting, charging system, starting system, and accessories. Body And Chassis: Body panel removal and installation, structural repair, door mechanisms, glass replacement, interior trim. HVAC: Heating, Ventilation, and Air Conditioning system diagnosis, recharge, component replacement (compressor, condenser, evaporator). Safety Systems: Airbag system diagnosis and replacement, seatbelt mechanisms, SRS (Supplemental Restraint System) components. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement. Diagnostic Procedures: Step-by-step troubleshooting guides for common and uncommon issues across all vehicle systems, including fault code interpretation. Component Replacement: Detailed instructions for replacing individual components such as alternators, starters, water pumps, fuel pumps, sensors, and actuators. Engine Rebuild: Instructions for complete engine disassembly, inspection, measurement, machining, and reassembly. Transmission Rebuild: Detailed steps for the overhaul of both manual and automatic transmissions, including torque specifications for critical fasteners. Brake System Service: Brake bleeding procedures, caliper rebuild, rotor and pad replacement, ABS sensor replacement. Suspension And Steering Repair: Replacement of ball joints, tie rod ends, bushings, control arms, and steering rack. Electrical Troubleshooting: Diagnosis of electrical faults using multimeters, oscilloscopes, and interpretation of wiring schematics. Bodywork And Cosmetics: Procedures for panel alignment, dent repair, paint touch-up, and interior component removal/installation. Technical Depth Depth Of Information: Comprehensive, covering everything from basic fluid changes to complete engine and transmission overhauls. Includes diagnostic trees and specifications. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely searchable text content for quick information retrieval. Print Quality Image Resolution: High-resolution diagrams and illustrations for clarity. Binding Type Physical Format Consideration: If printed, typically spiral-bound or perfect-bound for ease of use in a workshop environment. Paper Type Physical Format Consideration: If printed, often on durable, coated paper to withstand workshop conditions. ⚙️ Engine Specifications Primary Engine Engine Displacement 1: 1.6 Liters (1598 cc) Engine Type 1: Inline 4-cylinder, DOHC, 16-valve Engine Code 1: F16D3 (GM Family II) Horsepower 1: Approx. 105 PS (77 kW) @ 6000 RPM Torque 1: Approx. 145 Nm (107 lb-ft) @ 3200 RPM Alternative Engine Engine Displacement 2: 2.0 Liters (1998 cc) Engine Type 2: Inline 4-cylinder, DOHC, 16-valve Engine Code 2: X20D1 (GM Family II) Horsepower 2: Approx. 120-130 PS (88-96 kW) @ 5600 RPM Torque 2: Approx. 175-185 Nm (129-136 lb-ft) @ 4000 RPM Performance Fuel Type: Unleaded Gasoline Fuel System Fuel Delivery: Electronic Fuel Injection (MPI) 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Optional Transmission Type Optional: 4-speed Automatic Features Transmission Fluid Spec Auto: Dexron III/VI (or equivalent) 📐 Dimensions Exterior Length: Approx. 4300 mm (169.3 in) Width: Approx. 1760 mm (69.3 in) Height: Approx. 1670 mm (65.7 in) Wheelbase: Approx. 2600 mm (102.4 in) Interior Seating Capacity: 5 or 7 Seats Cargo Cargo Volume Rear Seats Up: Variable, depending on seat configuration (e.g., approx. 300-400 liters with 3rd row folded) Weights Curb Weight: Approx. 1350-1450 kg (2976-3197 lbs) Gross Vehicle Weight Rating: Approx. 1900-2000 kg (4189-4409 lbs) 🛡️ Safety Features Ratings Crash Test Results: Varies by region and testing authority; generally considered to have average safety for its class and era. Specific Euro NCAP or NHTSA ratings should be verified for the target market. Active Features ABS: Standard on most models, optional on base trims. E-Brake: Mechanical parking brake. Passive Features Airbags Driver Passenger: Standard dual front airbags. Side Airbags Curtain Airbags: Optional or standard on higher trims. Seatbelts: 3-point seatbelts with pre-tensioners for front occupants. 💡 Technology Features Infotainment Head Unit: Factory fitted radio/cassette/CD player, often with basic...
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DAEWOO REZZO 2000-2008 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Daewoo
Model:
Rezzo
Model Alias:
Tacuma
Generation:
First Generation
Codes
Model Code:
U100
👋 Introduction
Market Position
Vehicle Segment:
Compact MPV (Multi-Purpose Vehicle) / Minivan
Competitive Analysis
Key Competitors:
Opel Zafira, Renault Scenic, Ford Focus C-Max, Volkswagen Golf Plus
Key Features
Design Philosophy:
Practicality, spaciousness, and affordability, targeting families and individuals needing versatile transport.
Body Styles:
Primarily a 5-door MPV, often with 7-seat configurations available.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Manual / Repair Manual
Language:
English
Format:
Digital (Likely PDF)
Page Count
Estimated Page Count:
1000+
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul and repair procedures for all engine variants, including cylinder head, pistons, crankshaft, camshafts, and timing components.
Engine Performance:
Fuel injection system, ignition system, emissions control, cooling system, lubrication system, turbocharging (if applicable).
Transmission Manual:
Repair, overhaul, and adjustment procedures for manual transmissions, including clutch, gearbox, and driveline components.
Transmission Automatic:
Diagnostic, repair, and overhaul procedures for automatic transmissions, including torque converter, valve body, and internal components.
Brakes:
Detailed information on hydraulic systems, ABS (Anti-lock Braking System), brake pads, rotors, calipers, and parking brake mechanisms.
Suspension:
Front and rear suspension systems, including shock absorbers, struts, springs, control arms, ball joints, and bushings.
Steering:
Power steering system diagnosis, repair, and component replacement, including steering rack, pump, and lines.
Electrical System:
Comprehensive wiring diagrams, component testing, diagnosis of lighting, charging system, starting system, and accessories.
Body And Chassis:
Body panel removal and installation, structural repair, door mechanisms, glass replacement, interior trim.
HVAC:
Heating, Ventilation, and Air Conditioning system diagnosis, recharge, component replacement (compressor, condenser, evaporator).
Safety Systems:
Airbag system diagnosis and replacement, seatbelt mechanisms, SRS (Supplemental Restraint System) components.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement.
Diagnostic Procedures:
Step-by-step troubleshooting guides for common and uncommon issues across all vehicle systems, including fault code interpretation.
Component Replacement:
Detailed instructions for replacing individual components such as alternators, starters, water pumps, fuel pumps, sensors, and actuators.
Engine Rebuild:
Instructions for complete engine disassembly, inspection, measurement, machining, and reassembly.
Transmission Rebuild:
Detailed steps for the overhaul of both manual and automatic transmissions, including torque specifications for critical fasteners.
Brake System Service:
Brake bleeding procedures, caliper rebuild, rotor and pad replacement, ABS sensor replacement.
Suspension And Steering Repair:
Replacement of ball joints, tie rod ends, bushings, control arms, and steering rack.
Electrical Troubleshooting:
Diagnosis of electrical faults using multimeters, oscilloscopes, and interpretation of wiring schematics.
Bodywork And Cosmetics:
Procedures for panel alignment, dent repair, paint touch-up, and interior component removal/installation.
Technical Depth
Depth Of Information:
Comprehensive, covering everything from basic fluid changes to complete engine and transmission overhauls. Includes diagnostic trees and specifications.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely searchable text content for quick information retrieval.
Print Quality
Image Resolution:
High-resolution diagrams and illustrations for clarity.
Binding Type
Physical Format Consideration:
If printed, typically spiral-bound or perfect-bound for ease of use in a workshop environment.
Paper Type
Physical Format Consideration:
If printed, often on durable, coated paper to withstand workshop conditions.
⚙️ Engine Specifications
Primary Engine
Engine Displacement 1:
1.6 Liters (1598 cc)
Engine Type 1:
Inline 4-cylinder, DOHC, 16-valve
Engine Code 1:
F16D3 (GM Family II)
Horsepower 1:
Approx. 105 PS (77 kW) @ 6000 RPM
Torque 1:
Approx. 145 Nm (107 lb-ft) @ 3200 RPM
Alternative Engine
Engine Displacement 2:
2.0 Liters (1998 cc)
Engine Type 2:
Inline 4-cylinder, DOHC, 16-valve
Engine Code 2:
X20D1 (GM Family II)
Horsepower 2:
Approx. 120-130 PS (88-96 kW) @ 5600 RPM
Torque 2:
Approx. 175-185 Nm (129-136 lb-ft) @ 4000 RPM
Performance
Fuel Type:
Unleaded Gasoline
Fuel System
Fuel Delivery:
Electronic Fuel Injection (MPI)
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual
Optional
Transmission Type Optional:
4-speed Automatic
Features
Transmission Fluid Spec Auto:
Dexron III/VI (or equivalent)
📐 Dimensions
Exterior
Length:
Approx. 4300 mm (169.3 in)
Width:
Approx. 1760 mm (69.3 in)
Height:
Approx. 1670 mm (65.7 in)
Wheelbase:
Approx. 2600 mm (102.4 in)
Interior
Seating Capacity:
5 or 7 Seats
Cargo
Cargo Volume Rear Seats Up:
Variable, depending on seat configuration (e.g., approx. 300-400 liters with 3rd row folded)
Weights
Curb Weight:
Approx. 1350-1450 kg (2976-3197 lbs)
Gross Vehicle Weight Rating:
Approx. 1900-2000 kg (4189-4409 lbs)
🛡️ Safety Features
Ratings
Crash Test Results:
Varies by region and testing authority; generally considered to have average safety for its class and era. Specific Euro NCAP or NHTSA ratings should be verified for the target market.
Active Features
ABS:
Standard on most models, optional on base trims.
E-Brake:
Mechanical parking brake.
Passive Features
Airbags Driver Passenger:
Standard dual front airbags.
Side Airbags Curtain Airbags:
Optional or standard on higher trims.
Seatbelts:
3-point seatbelts with pre-tensioners for front occupants.
💡 Technology Features
Infotainment
Head Unit:
Factory fitted radio/cassette/CD player, often with basic digital display.
Speaker System:
Basic 4-6 speaker setup.
Driver Assistance
Cruise Control:
Available on higher trim levels.
Parking Sensors:
Rarely fitted as standard, potentially an aftermarket addition.
Connectivity
Aux Input:
Uncommon on early models, might be a rare factory option or aftermarket addition.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500-10,000 miles (12,000-15,000 km) or 6-12 months, whichever comes first. Refer to specific mileage and driving conditions in manual.
Engine Air Filter:
Inspect every 15,000 miles (24,000 km), replace as needed or every 30,000 miles (48,000 km).
Spark Plugs:
Replace every 60,000-100,000 miles (96,000-160,000 km) depending on material (e.g., Iridium).
Timing Belt Replacement:
Crucial for 1.6L and 2.0L engines. Typically recommended every 60,000 miles (96,000 km) or 4-5 years. Failure can cause catastrophic engine damage.
Fluid Specifications
Engine Oil Spec:
API SM/SN or ACEA A3/B4, SAE 5W-30 or 10W-40 (check owner's manual for specific viscosity based on climate).
Coolant Spec:
Ethylene glycol based coolant, G11 or G12 standard (often a pink/red or blue coolant).
Brake Fluid Spec:
DOT 3 or DOT 4
Known Issues
Engine Mounts:
Wear and tear leading to vibrations, especially under load.
Suspension Components:
Early wear on bushings, ball joints, and tie rod ends due to road conditions.
Ignition Coils:
Occasional failure leading to misfires.
Exhaust System:
Rust and corrosion, especially in humid climates.
Window Regulators:
Plastic components can become brittle and break.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
South Korea
Brand Status:
Acquired by General Motors in 2002; Daewoo brand phased out in many markets.
Model Evolution
Introduction Year:
2000
Discontinuation Year:
2008
Platform Sharing:
Based on GM's global compact platform, sharing components with other GM and Daewoo models.
Production
Manufacturing Locations:
Primarily South Korea (GM Daewoo Auto & Technology Company)
🏆 Awards & Recognition
Recognitions
Awards Received:
No widely publicized major awards for this specific model. It was known for its value proposition and practicality rather than performance or critical acclaim.
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