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Daewoo Tico 1991-2001 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Daewoo Model: Tico Model Generation: First Generation Chassis Code: KLY3 👋 Introduction Market Position Segment: Microcar / City Car Target Audience: Urban commuters, budget-conscious buyers, first-time car owners Competitive Analysis Key Competitors: Suzuki Alto, Kia Pride, Hyundai Pony, Fiat Cinquecento Key Features Design Philosophy: Compact, fuel-efficient, affordable, functional city car Distinctive Aspects: Characterful rounded styling, surprisingly spacious interior for its size, nimble handling. 📋 Manual Details Coverage Areas Vehicle Years: 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001 Market Regions: Global (primarily Asia, Europe) Page Count Estimated Page Count: 1500+ Manual Type Manual Type: Factory Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, tuning, components (pistons, rings, bearings, cylinder head, valves, camshafts, crankshaft) Engine Management: Fuel injection system (EFI), ignition system, sensors, actuators, ECU diagnostics, emissions control Transmission: Manual transmission (5-speed), clutch system, driveline components Chassis And Suspension: Front and rear suspension (MacPherson struts), steering system, wheel alignment specifications Braking System: Front disc brakes, rear drum brakes, hydraulic system, parking brake Electrical System: Charging system (alternator, battery), starting system, lighting (headlights, taillights, interior), power windows, wipers, horn Body And Trim: Exterior body panels, interior trim, doors, windows, locks, seats, body sealing HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair Procedures Included Routine Maintenance: Oil change, filter replacement, spark plug replacement, fluid checks and changes, belt inspection and adjustment Troubleshooting: System-specific diagnostic charts, symptom-based troubleshooting guides, fault code interpretation Repair And Rebuild: Detailed step-by-step instructions for component removal, repair, and reinstallation Diagnostics: On-board diagnostics (OBD-I relevant for some early models/markets), electrical circuit diagrams, pressure and vacuum testing Specifications And Tolerances: Torque values, clearances, measurements for engine, chassis, and body components Technical Depth Depth Of Coverage: Comprehensive, suitable for professional technicians and advanced DIY enthusiasts 📊 Manual Specifications File Format File Format Details: Searchable PDF with high-resolution scanned pages, enabling easy navigation and printing. Print Quality Print Quality: High-quality scans ensuring clarity of diagrams, text, and illustrations. Binding Type Binding Type: N/A (Digital PDF Download) Paper Type Paper Type: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Engine Code: F8C (or similar designation depending on market) Engine Type: Inline 3-cylinder, naturally aspirated Displacement: 796 cc (0.8 L) Performance Horsepower: Approx. 39-41 PS (29-30 kW) @ 5500 rpm Torque: Approx. 59-60 Nm (43-44 lb-ft) @ 3200-3500 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline (Petrol) Engine Components Bore X Stroke: 68.5 mm x 72.0 mm (estimated) Compression Ratio: 9.2:1 (estimated) Cooling System Cooling Type: Water-cooled, pressurized system 🔧 Transmission Standard Transmission Type: 5-speed Manual Optional Optional Transmission: N/A (primarily manual) Features Clutch Type: Dry, single-plate diaphragm spring clutch Gear Ratios Final Drive Ratio: Approx. 4.375:1 (common) 📐 Dimensions Exterior Length: 3,295 mm (129.7 in) Width: 1,400 mm (55.1 in) Height: 1,385 mm (54.5 in) Wheelbase: 2,150 mm (84.6 in) Weights Curb Weight: Approx. 680-720 kg (1,499-1,587 lbs) Gross Vehicle Weight: Approx. 1,100 kg (2,425 lbs) Cargo Trunk Volume: Limited, expandable with rear seats folded 🛡️ Safety Features Ratings Crash Test Results: Limited availability of official global ratings due to vehicle class and era; generally considered basic safety for its segment. Active Features Brakes: Front ventilated discs, rear drums. Anti-lock Braking System (ABS) typically not standard, may be an option on later models or specific trims. Passive Features Seatbelts: Standard front seatbelts, often 3-point with pre-tensioners. Rear seatbelts vary by market. Airbags: Driver airbag typically standard on later models; passenger airbag rare. Body Structure: Designed with crumple zones, though capabilities are relative to its microcar class. 💡 Technology Features Infotainment Audio System: Basic AM/FM radio with cassette player, optional CD player on higher trims or later models. Dashboard Features: Analog gauges for speedometer, tachometer (optional), fuel level, engine temperature; warning lights. Driver Assistance ABS Availability: Optional, not standard across all models/years. Connectivity Connectivity Options: Limited to basic audio connectivity; no modern Bluetooth or USB integration from the factory. 🔧 Maintenance Service Intervals Engine Oil Change: Every 5,000 km (3,000 miles) or 6 months, whichever comes first. Air Filter Replacement: Every 15,000 km (9,000 miles) or 12 months. Spark Plug Replacement: Every 30,000 km (18,000 miles) or 24 months (using specified type). Coolant Change: Every 20,000 km (12,000 miles) or 24 months. Fluid Specifications Engine Oil Type: API SG or SH, SAE 10W-30 or 10W-40 recommended for most climates. Engine Oil Capacity: Approx. 3.0 liters (3.2 US quarts) with filter change. Coolant Type: Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. Transmission Fluid Type: API GL-4, SAE 75W-90 or 80W-90 gear oil. Brake Fluid Type: DOT 3 Known Issues Common Wear Items: Clutch wear, suspension bushings, engine mounts, exhaust system corrosion. Electrical Gremlins: Occasional issues with dashboard warning lights, minor electrical connections due to...
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Daewoo Tico 1991-2001 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Daewoo
Model:
Tico
Model Generation:
First Generation
Chassis Code:
KLY3
👋 Introduction
Market Position
Segment:
Microcar / City Car
Target Audience:
Urban commuters, budget-conscious buyers, first-time car owners
Competitive Analysis
Key Competitors:
Suzuki Alto, Kia Pride, Hyundai Pony, Fiat Cinquecento
Key Features
Design Philosophy:
Compact, fuel-efficient, affordable, functional city car
Distinctive Aspects:
Characterful rounded styling, surprisingly spacious interior for its size, nimble handling.
📋 Manual Details
Coverage Areas
Vehicle Years:
1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001
Market Regions:
Global (primarily Asia, Europe)
Page Count
Estimated Page Count:
1500+
Manual Type
Manual Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete engine overhaul, tuning, components (pistons, rings, bearings, cylinder head, valves, camshafts, crankshaft)
Engine Management:
Fuel injection system (EFI), ignition system, sensors, actuators, ECU diagnostics, emissions control
Transmission:
Manual transmission (5-speed), clutch system, driveline components
Chassis And Suspension:
Front and rear suspension (MacPherson struts), steering system, wheel alignment specifications
Braking System:
Front disc brakes, rear drum brakes, hydraulic system, parking brake
Electrical System:
Charging system (alternator, battery), starting system, lighting (headlights, taillights, interior), power windows, wipers, horn
Body And Trim:
Exterior body panels, interior trim, doors, windows, locks, seats, body sealing
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair
Procedures Included
Routine Maintenance:
Oil change, filter replacement, spark plug replacement, fluid checks and changes, belt inspection and adjustment
Troubleshooting:
System-specific diagnostic charts, symptom-based troubleshooting guides, fault code interpretation
Repair And Rebuild:
Detailed step-by-step instructions for component removal, repair, and reinstallation
Diagnostics:
On-board diagnostics (OBD-I relevant for some early models/markets), electrical circuit diagrams, pressure and vacuum testing
Specifications And Tolerances:
Torque values, clearances, measurements for engine, chassis, and body components
Technical Depth
Depth Of Coverage:
Comprehensive, suitable for professional technicians and advanced DIY enthusiasts
📊 Manual Specifications
File Format
File Format Details:
Searchable PDF with high-resolution scanned pages, enabling easy navigation and printing.
Print Quality
Print Quality:
High-quality scans ensuring clarity of diagrams, text, and illustrations.
Binding Type
Binding Type:
N/A (Digital PDF Download)
Paper Type
Paper Type:
N/A (Digital PDF Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
F8C (or similar designation depending on market)
Engine Type:
Inline 3-cylinder, naturally aspirated
Displacement:
796 cc (0.8 L)
Performance
Horsepower:
Approx. 39-41 PS (29-30 kW) @ 5500 rpm
Torque:
Approx. 59-60 Nm (43-44 lb-ft) @ 3200-3500 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (Petrol)
Engine Components
Bore X Stroke:
68.5 mm x 72.0 mm (estimated)
Compression Ratio:
9.2:1 (estimated)
Cooling System
Cooling Type:
Water-cooled, pressurized system
🔧 Transmission
Standard
Transmission Type:
5-speed Manual
Optional
Optional Transmission:
N/A (primarily manual)
Features
Clutch Type:
Dry, single-plate diaphragm spring clutch
Gear Ratios
Final Drive Ratio:
Approx. 4.375:1 (common)
📐 Dimensions
Exterior
Length:
3,295 mm (129.7 in)
Width:
1,400 mm (55.1 in)
Height:
1,385 mm (54.5 in)
Wheelbase:
2,150 mm (84.6 in)
Weights
Curb Weight:
Approx. 680-720 kg (1,499-1,587 lbs)
Gross Vehicle Weight:
Approx. 1,100 kg (2,425 lbs)
Cargo
Trunk Volume:
Limited, expandable with rear seats folded
🛡️ Safety Features
Ratings
Crash Test Results:
Limited availability of official global ratings due to vehicle class and era; generally considered basic safety for its segment.
Active Features
Brakes:
Front ventilated discs, rear drums. Anti-lock Braking System (ABS) typically not standard, may be an option on later models or specific trims.
Passive Features
Seatbelts:
Standard front seatbelts, often 3-point with pre-tensioners. Rear seatbelts vary by market.
Airbags:
Driver airbag typically standard on later models; passenger airbag rare.
Body Structure:
Designed with crumple zones, though capabilities are relative to its microcar class.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with cassette player, optional CD player on higher trims or later models.
Dashboard Features:
Analog gauges for speedometer, tachometer (optional), fuel level, engine temperature; warning lights.
Driver Assistance
ABS Availability:
Optional, not standard across all models/years.
Connectivity
Connectivity Options:
Limited to basic audio connectivity; no modern Bluetooth or USB integration from the factory.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000 km (3,000 miles) or 6 months, whichever comes first.
Air Filter Replacement:
Every 15,000 km (9,000 miles) or 12 months.
Spark Plug Replacement:
Every 30,000 km (18,000 miles) or 24 months (using specified type).
Coolant Change:
Every 20,000 km (12,000 miles) or 24 months.
Fluid Specifications
Engine Oil Type:
API SG or SH, SAE 10W-30 or 10W-40 recommended for most climates.
Engine Oil Capacity:
Approx. 3.0 liters (3.2 US quarts) with filter change.
Coolant Type:
Ethylene glycol-based coolant, typically a 50/50 mix with distilled water.
Transmission Fluid Type:
API GL-4, SAE 75W-90 or 80W-90 gear oil.
Brake Fluid Type:
DOT 3
Known Issues
Common Wear Items:
Clutch wear, suspension bushings, engine mounts, exhaust system corrosion.
Electrical Gremlins:
Occasional issues with dashboard warning lights, minor electrical connections due to age/vibration.
Rust Prone Areas:
Wheel arches, sills, floor pans, particularly in humid or winter environments.
📚 Vehicle History
Brand Heritage
Parent Company:
Daewoo Motor Company (South Korea)
Daewoo Context:
Part of Daewoo's strategy to enter and compete in the small, affordable car segment globally.
Model Evolution
Development Basis:
Developed in partnership with Suzuki, sharing platform elements with the Suzuki Alto.
Facelifts:
Received minor styling updates and feature additions throughout its production run.
Production
Production Years:
1991-2001
Manufacturing Locations:
South Korea (primarily), assembly plants in other countries depending on market distribution.
🏆 Awards & Recognition
Recognitions
Industry Recognition:
Not widely recognized with major international awards. Praised for affordability and urban practicality in its launch markets.
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