Daewoo Sens 1999 Service Repair Manual

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🏷️ Basic Information Identification Make: Daewoo Model: Sens Year: 1999 Market Segment: Subcompact/Compact Car Codes Chassis Code: T100 (common for Daewoo Nexia/Cielo platform) 👋 Introduction Market Position Market Niche: Budget-friendly subcompact/compact car, targeting emerging markets and value-conscious consumers. Competitive Analysis Competitors 1999: Hyundai Accent, Kia Sephia, Chevrolet Aveo (later models), Ford Fiesta (certain markets), Volkswagen Polo (certain markets). Key Features Design Philosophy: Practical, economical, and functional design emphasizing affordability and ease of maintenance. Target Audience: First-time car buyers, students, small families, and individuals seeking reliable basic transportation. 📋 Manual Details Coverage Areas Manual Type: Service and Repair Manual Language: English Format: PDF Download Page Count Estimated Page Count: 300-400 (typical for a comprehensive service manual) 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed overhaul, disassembly, assembly, inspection, and repair procedures for the engine block, cylinder head, pistons, crankshaft, camshafts, valve train, and lubrication system. Engine Fuel System: Fuel injection system (EFI), fuel pump, injectors, fuel pressure regulator, fuel filter replacement, and diagnostic procedures. Engine Ignition System: Ignition timing, spark plugs, ignition coils, distributor (if applicable), ECU control, and diagnostic procedures. Cooling System: Radiator, water pump, thermostat, cooling fans, coolant hoses, and bleeding procedures. Exhaust System: Exhaust manifold, catalytic converter, muffler, exhaust pipes, and emissions control components. Transmission Manual: Clutch operation, clutch replacement, gearbox disassembly, assembly, and maintenance for manual transmissions. Transmission Automatic: Automatic transmission operation, fluid checks, filter replacement, and general maintenance (if applicable to the model variant). Drivetrain: Front-wheel drive system, drive shafts, CV joints, and differential maintenance. Suspension System: Front and rear suspension components (struts, shock absorbers, control arms, bushings), alignment specifications, and wheel bearing replacement. Steering System: Power steering system, steering rack, tie rods, and steering column maintenance. Brake System: Hydraulic system, brake fluid specifications, master cylinder, brake calipers, pads, rotors, drums, parking brake, and ABS components (if equipped). Electrical System: Battery, charging system (alternator), starting system (starter motor), fuses, relays, and wiring diagrams. Lighting System: Headlights, taillights, interior lights, turn signals, and bulb replacement. Instrument Panel Gauges: Dashboard indicators, gauges, warning lights, and their functions. Climate Control System: HVAC system, blower motor, heater core, A/C system components, refrigerant, and cabin air filter replacement. Body Exterior: Body panels, doors, hood, trunk, bumpers, glass replacement, and door mechanisms. Body Interior: Seats, upholstery, dashboard trim, door panels, and interior trim components. Safety Systems: Seat belts, airbags (if equipped), and chassis structural integrity. Procedures Included Routine Maintenance: Oil changes, filter replacements (oil, air, fuel, cabin), fluid checks and top-offs, spark plug replacement, belt inspection and replacement. Troubleshooting: Diagnostic procedures for common engine, transmission, electrical, and mechanical issues, including symptom-based troubleshooting guides. Repair Procedures: Step-by-step instructions for component removal, installation, and repair across all major vehicle systems. Diagnostic Codes: OBD-II (On-Board Diagnostics II) code interpretation and troubleshooting (if applicable to the 1999 model year). Electrical Diagnostics: Use of multimeters, interpreting wiring diagrams, and diagnosing electrical faults. Torque Specifications: Detailed torque values for critical fasteners during assembly and disassembly. Special Tools: Identification and usage instructions for specialized tools required for certain repairs. Technical Depth Depth Level: Comprehensive, covering everything from basic maintenance to major component overhaul and diagnostics. Diagnostic Capabilities: Advanced diagnostic strategies, including symptom analysis and component testing. Rebuild Instructions: Detailed instructions for engine and transmission rebuilds, including specifications for machining and clearances. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF for efficient information retrieval. Printability: Printable pages for offline use and workshop reference. Print Quality Image Resolution: High-resolution for clear diagrams, illustrations, and photographs. Binding Type Digital Binding: N/A (Digital Download) Paper Type Digital Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: G15MF (commonly associated with the T100 platform's 1.5L engine) Engine Type: Inline 4-cylinder, SOHC (Single Overhead Camshaft), naturally aspirated Displacement: 1.5 Liters (1498 cc) Bore X Stroke: 76.6 mm x 82.0 mm (typical for G15MF) Compression Ratio: 9.0:1 (typical for G15MF) Performance Horsepower: Approx. 70-75 HP @ 5400 RPM (varies by market and tune) Torque: Approx. 120-125 Nm @ 3000-3500 RPM (varies by market and tune) Fuel System Fuel Delivery: Multi-point Electronic Fuel Injection (MPI-EFI) Fuel Type: Unleaded Gasoline Octane Rating: 91-95 RON (Research Octane Number) Lubrication System Oil Capacity: Approx. 3.5 Liters (3.7 US Quarts) with filter change Oil Specification: API SG/SH or higher, SAE 10W-30 or 10W-40 (depending on climate) 🔧 Transmission Standard Transmission Type: 5-speed Manual Transmission Optional Transmission Type: 3-speed Automatic Transmission (likely available on certain trims/markets) Features Clutch Type: Dry single-plate clutch Transmission Fluid Manual: GL-4 SAE 75W-90 or 80W-90 gear oil Transmission Fluid Automatic: Dexron III ATF (Automatic Transmission Fluid) (if applicable) 📐 Dimensions Exterior Length: Approx. 3900-4000 mm (varies by body style: hatchback/sedan) Width: Approx. 1600-1650 mm Height: Approx. 1380-1420 mm Wheelbase: Approx. 2470 mm Wheel Bolt Pattern: 4x100 Tire Sizes: 175/70 R13 or 185/60 R14 (common sizes for the class) Weights Curb Weight:...

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Type: Car

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Sku: 16629

Collecties: ALL Daewoo

Beschikbaarheid: Op voorraad

Labels: 1999 Car Daewoo Sens

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Description

🏷️ Basic Information

Identification

Make:

Daewoo

Model:

Year:

Market Segment:

Subcompact/Compact Car

Codes

Chassis Code:

T100 (common for Daewoo Nexia/Cielo platform)

👋 Introduction

Market Position

Market Niche:

Budget-friendly subcompact/compact car, targeting emerging markets and value-conscious consumers.

Competitive Analysis

Competitors 1999:

Hyundai Accent, Kia Sephia, Chevrolet Aveo (later models), Ford Fiesta (certain markets), Volkswagen Polo (certain markets).

Key Features

Design Philosophy:

Practical, economical, and functional design emphasizing affordability and ease of maintenance.

Target Audience:

First-time car buyers, students, small families, and individuals seeking reliable basic transportation.

📋 Manual Details

Coverage Areas

Manual Type:

Service and Repair Manual

Language:

English

Format:

PDF Download

Page Count

Estimated Page Count:

300-400 (typical for a comprehensive service manual)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed overhaul, disassembly, assembly, inspection, and repair procedures for the engine block, cylinder head, pistons, crankshaft, camshafts, valve train, and lubrication system.

Engine Fuel System:

Fuel injection system (EFI), fuel pump, injectors, fuel pressure regulator, fuel filter replacement, and diagnostic procedures.

Engine Ignition System:

Ignition timing, spark plugs, ignition coils, distributor (if applicable), ECU control, and diagnostic procedures.

Cooling System:

Radiator, water pump, thermostat, cooling fans, coolant hoses, and bleeding procedures.

Exhaust System:

Exhaust manifold, catalytic converter, muffler, exhaust pipes, and emissions control components.

Transmission Manual:

Clutch operation, clutch replacement, gearbox disassembly, assembly, and maintenance for manual transmissions.

Transmission Automatic:

Automatic transmission operation, fluid checks, filter replacement, and general maintenance (if applicable to the model variant).

Drivetrain:

Front-wheel drive system, drive shafts, CV joints, and differential maintenance.

Suspension System:

Front and rear suspension components (struts, shock absorbers, control arms, bushings), alignment specifications, and wheel bearing replacement.

Steering System:

Power steering system, steering rack, tie rods, and steering column maintenance.

Brake System:

Hydraulic system, brake fluid specifications, master cylinder, brake calipers, pads, rotors, drums, parking brake, and ABS components (if equipped).

Electrical System:

Battery, charging system (alternator), starting system (starter motor), fuses, relays, and wiring diagrams.

Lighting System:

Headlights, taillights, interior lights, turn signals, and bulb replacement.

Instrument Panel Gauges:

Dashboard indicators, gauges, warning lights, and their functions.

Climate Control System:

HVAC system, blower motor, heater core, A/C system components, refrigerant, and cabin air filter replacement.

Body Exterior:

Body panels, doors, hood, trunk, bumpers, glass replacement, and door mechanisms.

Body Interior:

Seats, upholstery, dashboard trim, door panels, and interior trim components.

Safety Systems:

Seat belts, airbags (if equipped), and chassis structural integrity.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements (oil, air, fuel, cabin), fluid checks and top-offs, spark plug replacement, belt inspection and replacement.

Troubleshooting:

Diagnostic procedures for common engine, transmission, electrical, and mechanical issues, including symptom-based troubleshooting guides.

Repair Procedures:

Step-by-step instructions for component removal, installation, and repair across all major vehicle systems.

Diagnostic Codes:

OBD-II (On-Board Diagnostics II) code interpretation and troubleshooting (if applicable to the 1999 model year).

Electrical Diagnostics:

Use of multimeters, interpreting wiring diagrams, and diagnosing electrical faults.

Torque Specifications:

Detailed torque values for critical fasteners during assembly and disassembly.

Special Tools:

Identification and usage instructions for specialized tools required for certain repairs.

Technical Depth

Depth Level:

Comprehensive, covering everything from basic maintenance to major component overhaul and diagnostics.

Diagnostic Capabilities:

Advanced diagnostic strategies, including symptom analysis and component testing.

Rebuild Instructions:

Detailed instructions for engine and transmission rebuilds, including specifications for machining and clearances.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable PDF for efficient information retrieval.

Printability:

Printable pages for offline use and workshop reference.

Print Quality

Image Resolution:

High-resolution for clear diagrams, illustrations, and photographs.

Binding Type

Digital Binding:

N/A (Digital Download)

Paper Type

Digital Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

G15MF (commonly associated with the T100 platform's 1.5L engine)

Engine Type:

Inline 4-cylinder, SOHC (Single Overhead Camshaft), naturally aspirated

Displacement:

1.5 Liters (1498 cc)

Bore X Stroke:

76.6 mm x 82.0 mm (typical for G15MF)

Compression Ratio:

9.0:1 (typical for G15MF)

Performance

Horsepower:

Approx. 70-75 HP @ 5400 RPM (varies by market and tune)

Torque:

Approx. 120-125 Nm @ 3000-3500 RPM (varies by market and tune)

Fuel System

Fuel Delivery:

Multi-point Electronic Fuel Injection (MPI-EFI)

Fuel Type:

Unleaded Gasoline

Octane Rating:

91-95 RON (Research Octane Number)

Lubrication System

Oil Capacity:

Approx. 3.5 Liters (3.7 US Quarts) with filter change

Oil Specification:

API SG/SH or higher, SAE 10W-30 or 10W-40 (depending on climate)

🔧 Transmission

Standard

Transmission Type:

5-speed Manual Transmission

Optional

Transmission Type:

3-speed Automatic Transmission (likely available on certain trims/markets)

Features

Clutch Type:

Dry single-plate clutch

Transmission Fluid Manual:

GL-4 SAE 75W-90 or 80W-90 gear oil

Transmission Fluid Automatic:

Dexron III ATF (Automatic Transmission Fluid) (if applicable)

📐 Dimensions

Exterior

Length:

Approx. 3900-4000 mm (varies by body style: hatchback/sedan)

Width:

Approx. 1600-1650 mm

Height:

Approx. 1380-1420 mm

Wheelbase:

Approx. 2470 mm

Wheel Bolt Pattern:

4x100

Tire Sizes:

175/70 R13 or 185/60 R14 (common sizes for the class)

Weights

Curb Weight:

Approx. 950-1050 kg (depending on trim and transmission)

🛡️ Safety Features

Ratings

Crash Test Results:

Limited publicly available official crash test data for this specific model in major markets. Likely to be basic by modern standards.

Active Features

Optional Anti-lock Braking System (ABS) may be available on higher trims.

Passive Features

Airbags:

Driver and passenger airbags likely optional or standard on higher trims.

Seat Belts:

Three-point seat belts for front occupants, two-point or three-point for rear (depending on seating position).

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM radio with cassette player, possibly an optional CD player on higher trims. Likely 2-4 speaker system.

Driver Assistance

Cruise Control:

Optional on some higher trim levels.

Anti Lock Brakes:

Optional ABS system for enhanced braking control.

Connectivity

Auxiliary Inputs:

Unlikely to have standard auxiliary or USB inputs; aftermarket solutions would be required.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, whichever comes first.

Oil Filter Replacement:

Replace with every oil change.

Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on driving conditions.

Fuel Filter Replacement:

Every 30,000-50,000 miles (48,000-80,000 km).

Spark Plug Replacement:

Every 30,000-60,000 miles (48,000-96,000 km) using appropriate spark plugs.

Coolant Flush:

Every 2-3 years or 30,000-50,000 miles (48,000-80,000 km).

Brake Fluid Flush:

Every 2-3 years.

Timing Belt Replacement:

Crucial! Daewoo engines of this era often use timing belts. Replacement typically every 60,000-90,000 miles (96,000-144,000 km) or 5-7 years. **Failure to replace can cause catastrophic engine damage.** The manual will specify the exact interval and procedure.

Fluid Specifications

Coolant:

Ethylene glycol based coolant, typically a 50/50 mix with distilled water. Check manual for specific type (e.g., Dex-Cool compatible or conventional green coolant).

Brake Fluid:

DOT 3 or DOT 4.

Known Issues

Engine Mounts:

Degradation of engine and transmission mounts leading to increased vibration.

Electrical Connectors:

Corrosion or loose connections in wiring harnesses, particularly ground points, can cause intermittent electrical issues.

Exhaust System Rust:

Susceptibility to rust and corrosion on exhaust components in certain climates.

Suspension Bushings:

Wear and tear on suspension bushings leading to knocking noises and imprecise handling.

Radiator Leaks:

Aging radiators can develop leaks over time.

Clutch Wear:

Normal wear and tear on the clutch assembly, especially with high mileage or aggressive driving.

📚 Vehicle History

Brand Heritage

Daewoo Motors:

Daewoo Motor Company was a South Korean automobile manufacturer, established in 1982. It produced a range of vehicles based on licensed designs from other manufacturers, including General Motors and Suzuki, before facing financial difficulties and eventually being acquired by General Motors.

Model Evolution

Daewoo Sens Lineage:

The Daewoo Sens is essentially a rebadged version of the Daewoo Cielo, which itself was a development of the Daewoo Nexia, originally based on the Opel Kadett E platform. The Sens was part of Daewoo's strategy to offer competitive vehicles in various market segments.

Production

Production Period:

The Daewoo Sens was produced around the late 1990s, coinciding with the lifespan of the Cielo/Nexia models.

Manufacturing Locations:

Primarily South Korea, with potential assembly in other Daewoo international facilities.

🏆 Awards & Recognition

Recognitions

Brand Awards:

Daewoo as a brand received mixed reviews during its operation. Specific awards for the Sens or its platform counterparts are not widely documented in major automotive publications.