Daewoo Fino 1991 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Daewoo Model: Fino Year: 1991 Codes Chassis Code General: Often referred to by internal Daewoo designations, specific chassis codes are rare in common documentation. 👋 Introduction Market Position Vehicle Segment: Subcompact hatchback/sedan, popular in its time for affordability and basic transportation. Target Audience: First-time car buyers, budget-conscious consumers, and those seeking simple, reliable transportation. Competitive Analysis Key Competitors 1991: Hyundai Excel, Kia Pride (Ford Festiva), Suzuki Swift/Geo Metro, Toyota Tercel. Key Features Design Philosophy: Emphasis on practicality, fuel efficiency, and low manufacturing costs, often with styling influenced by Japanese compact car design of the era. Availability Of Service Data: This manual provides critical, often hard-to-find, technical data essential for maintaining and repairing the Daewoo Fino. 📋 Manual Details Coverage Areas Models Covered: All Daewoo Fino models, including all engine, trim, and transmission variants. Page Count Estimated Page Count: Comprehensive, likely exceeding 500 pages for a full workshop manual. Manual Type Manual Type: Workshop Repair Service Manual Language Language: English (based on typical market distribution for such manuals). Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, cylinder head, block, pistons, crankshaft, camshaft, valve train, cooling system, lubrication system, fuel injection system (mechanical and electronic components). Engine Management: Ignition system, sensor diagnostics (MAP, TPS, ECT, Knock), actuator control, ECU (Engine Control Unit) function and troubleshooting. Transmission: Manual and Automatic transmission service, clutch system, gearbox overhaul, torque converter, shifting mechanisms. Drivetrain: Front-wheel drive system, drive shafts, CV joints, differential. Suspension: Front and rear suspension systems, shock absorbers, springs, control arms, bushings, steering knuckles, alignment specifications. Steering: Power steering system, steering rack, tie rods, steering column, lubrication, bleeding procedures. Brakes: Front and rear disc/drum brake systems, hydraulic circuits, brake fluid, master cylinder, calipers, wheel cylinders, parking brake, ABS (if equipped). Electrical System: Battery, charging system (alternator, regulator), starting system (starter motor), lighting (headlights, taillights, interior), fuses, relays, wiring diagrams, component locations. HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system components, refrigerant charging, compressor, condenser, evaporator, blower motor, ducting. Body And Chassis: Body panel removal and installation, doors, hood, trunk, bumpers, glass, interior trim, chassis components. Diagnostic Troubleshooting: Systematic fault finding procedures for all major systems, including common symptoms and their causes. Procedures Included Routine Maintenance: Oil changes, filter replacements (oil, air, fuel), spark plug replacement, coolant flushes, brake fluid changes, lubrication points. Engine Overhaul: Complete engine rebuild procedures, including torque specifications, clearances, and assembly sequences. Transmission Repair: Detailed steps for repairing manual and automatic transmissions, including clutch replacement and gearbox rebuilding. Brake System Repair: Brake pad/shoe replacement, caliper/wheel cylinder overhaul, rotor/drum machining or replacement, bleeding procedures. Suspension And Steering Repair: Replacement of wear items like ball joints, tie rod ends, bushings, shock absorbers, and steering rack repair. Electrical Component Replacement: Installation and removal of starter motors, alternators, ignition coils, sensors, and other electrical components. HVAC Service: Refrigerant system evacuation and charging, component replacement, leak detection. Body Repair: Procedures for panel alignment, door mechanism adjustments, glass replacement. Troubleshooting Guides: Step-by-step diagnostic trees for identifying and resolving common automotive problems. Technical Depth Depth Of Coverage: Comprehensive from basic preventative maintenance to full engine and transmission rebuilds, including detailed diagnostic procedures and specifications. Diagnostic Tools Required: Covers standard hand tools, specialized engine tools, multimeter for electrical diagnostics, and potentially basic scan tools for ECU codes. Wiring Diagrams: Detailed electrical wiring diagrams for all vehicle systems, crucial for accurate troubleshooting. Torque Specifications: Extensive listing of all critical torque specifications for engine, chassis, and component assembly. Clearances And Tolerances: Precise measurements for engine component clearances, bearing tolerances, and other critical assembly parameters. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely contains searchable text, allowing for quick access to specific information. Print Quality Digital Quality: High-resolution digital reproduction suitable for on-screen viewing and printing. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 3-cylinder or 4-cylinder gasoline engines, typically carbureted or early multi-point fuel injection. Displacement Common: Approximately 0.8L to 1.5L (e.g., G12S - 1.2L, G13S - 1.3L). Performance Horsepower Range: Typically 50-70 hp depending on engine displacement and tuning. Torque Range: Typically 70-90 Nm depending on engine displacement. Fuel System Fuel Delivery: Carburetor (early models) or Electronic Fuel Injection (EFI) with multi-point injection (MPI). Fuel Type: Unleaded Gasoline Engine Management Ignition System: Distributor-based ignition system with electronic ignition control. 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Transmission Optional Transmission Type Optional: 3-speed Automatic Transmission Features Clutch Type: Dry single-plate clutch (manual transmission) Transmission Fluid Spec: Refer to manual for specific GL ratings for manual and ATF type for automatic. Typically API GL-4 for manual. 📐 Dimensions Exterior Body Styles: 3-door Hatchback, 5-door Hatchback, 4-door Sedan. Wheelbase Approx: 2300-2400 mm (model dependent) Weights Curb Weight Approx: 750-900 kg (model and trim dependent) 🛡️...

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Description

🏷️ Basic Information

Identification

Make:

Daewoo

Model:

Year:

Codes

Chassis Code General:

Often referred to by internal Daewoo designations, specific chassis codes are rare in common documentation.

👋 Introduction

Market Position

Vehicle Segment:

Subcompact hatchback/sedan, popular in its time for affordability and basic transportation.

Target Audience:

First-time car buyers, budget-conscious consumers, and those seeking simple, reliable transportation.

Competitive Analysis

Key Competitors 1991:

Hyundai Excel, Kia Pride (Ford Festiva), Suzuki Swift/Geo Metro, Toyota Tercel.

Key Features

Design Philosophy:

Emphasis on practicality, fuel efficiency, and low manufacturing costs, often with styling influenced by Japanese compact car design of the era.

Availability Of Service Data:

This manual provides critical, often hard-to-find, technical data essential for maintaining and repairing the Daewoo Fino.

📋 Manual Details

Coverage Areas

Models Covered:

All Daewoo Fino models, including all engine, trim, and transmission variants.

Page Count

Estimated Page Count:

Comprehensive, likely exceeding 500 pages for a full workshop manual.

Manual Type

Manual Type:

Workshop Repair Service Manual

Language

Language:

English (based on typical market distribution for such manuals).

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, cylinder head, block, pistons, crankshaft, camshaft, valve train, cooling system, lubrication system, fuel injection system (mechanical and electronic components).

Engine Management:

Ignition system, sensor diagnostics (MAP, TPS, ECT, Knock), actuator control, ECU (Engine Control Unit) function and troubleshooting.

Transmission:

Manual and Automatic transmission service, clutch system, gearbox overhaul, torque converter, shifting mechanisms.

Drivetrain:

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

Suspension:

Front and rear suspension systems, shock absorbers, springs, control arms, bushings, steering knuckles, alignment specifications.

Steering:

Power steering system, steering rack, tie rods, steering column, lubrication, bleeding procedures.

Brakes:

Front and rear disc/drum brake systems, hydraulic circuits, brake fluid, master cylinder, calipers, wheel cylinders, parking brake, ABS (if equipped).

Electrical System:

Battery, charging system (alternator, regulator), starting system (starter motor), lighting (headlights, taillights, interior), fuses, relays, wiring diagrams, component locations.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system components, refrigerant charging, compressor, condenser, evaporator, blower motor, ducting.

Body And Chassis:

Body panel removal and installation, doors, hood, trunk, bumpers, glass, interior trim, chassis components.

Diagnostic Troubleshooting:

Systematic fault finding procedures for all major systems, including common symptoms and their causes.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements (oil, air, fuel), spark plug replacement, coolant flushes, brake fluid changes, lubrication points.

Engine Overhaul:

Complete engine rebuild procedures, including torque specifications, clearances, and assembly sequences.

Transmission Repair:

Detailed steps for repairing manual and automatic transmissions, including clutch replacement and gearbox rebuilding.

Brake System Repair:

Brake pad/shoe replacement, caliper/wheel cylinder overhaul, rotor/drum machining or replacement, bleeding procedures.

Suspension And Steering Repair:

Replacement of wear items like ball joints, tie rod ends, bushings, shock absorbers, and steering rack repair.

Electrical Component Replacement:

Installation and removal of starter motors, alternators, ignition coils, sensors, and other electrical components.

HVAC Service:

Refrigerant system evacuation and charging, component replacement, leak detection.

Body Repair:

Procedures for panel alignment, door mechanism adjustments, glass replacement.

Troubleshooting Guides:

Step-by-step diagnostic trees for identifying and resolving common automotive problems.

Technical Depth

Depth Of Coverage:

Comprehensive from basic preventative maintenance to full engine and transmission rebuilds, including detailed diagnostic procedures and specifications.

Diagnostic Tools Required:

Covers standard hand tools, specialized engine tools, multimeter for electrical diagnostics, and potentially basic scan tools for ECU codes.

Wiring Diagrams:

Detailed electrical wiring diagrams for all vehicle systems, crucial for accurate troubleshooting.

Torque Specifications:

Extensive listing of all critical torque specifications for engine, chassis, and component assembly.

Clearances And Tolerances:

Precise measurements for engine component clearances, bearing tolerances, and other critical assembly parameters.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely contains searchable text, allowing for quick access to specific information.

Print Quality

Digital Quality:

High-resolution digital reproduction suitable for on-screen viewing and printing.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline 3-cylinder or 4-cylinder gasoline engines, typically carbureted or early multi-point fuel injection.

Displacement Common:

Approximately 0.8L to 1.5L (e.g., G12S - 1.2L, G13S - 1.3L).

Performance

Horsepower Range:

Typically 50-70 hp depending on engine displacement and tuning.

Torque Range:

Typically 70-90 Nm depending on engine displacement.

Fuel System

Fuel Delivery:

Carburetor (early models) or Electronic Fuel Injection (EFI) with multi-point injection (MPI).

Fuel Type:

Unleaded Gasoline

Engine Management

Ignition System:

Distributor-based ignition system with electronic ignition control.

🔧 Transmission

Standard

Transmission Type Standard:

5-speed Manual Transmission

Optional

Transmission Type Optional:

3-speed Automatic Transmission

Features

Clutch Type:

Dry single-plate clutch (manual transmission)

Transmission Fluid Spec:

Refer to manual for specific GL ratings for manual and ATF type for automatic. Typically API GL-4 for manual.

📐 Dimensions

Exterior

Body Styles:

3-door Hatchback, 5-door Hatchback, 4-door Sedan.

Wheelbase Approx:

2300-2400 mm (model dependent)

Weights

Curb Weight Approx:

750-900 kg (model and trim dependent)

🛡️ Safety Features

Ratings

Crash Test Data:

Limited official crash test data from reputable agencies for this specific model and year. Focus is on mechanical safety systems.

Active Features

Active Safety Features:

Standard braking system, potentially optional ABS on later or higher trim models, though unlikely for base 1991.

Passive Features

Passive Safety Features:

Seat belts, reinforced passenger cell (design based on contemporary standards), energy-absorbing steering column.

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM radio with cassette player. Likely a single-DIN unit. Speaker count typically 2 or 4.

Driver Assistance

Driver Assistance Features:

Minimal to none. Focus is on fundamental driving dynamics. No electronic driver aids expected.

Connectivity

Connectivity Options:

None. No provisions for Bluetooth, USB, or smartphone integration.

🔧 Maintenance

Service Intervals

Oil Change Interval Approx:

Every 5,000 - 7,500 km or 6 months, whichever comes first.

Air Filter Replacement Interval Approx:

Every 15,000 - 20,000 km or annually.

Spark Plug Replacement Interval Approx:

Every 30,000 - 40,000 km.

Timing Belt Replacement Interval Approx:

Crucial! Typically 60,000 - 90,000 km or 4-5 years. Failure can cause catastrophic engine damage.

Fluid Specifications

Engine Oil Spec:

API SF or SG, SAE 10W-30 or 10W-40 (verify with manual, viscosity may vary based on climate).

Coolant Spec:

Ethylene Glycol based antifreeze, mixed 50/50 with distilled water. Refer to manual for specific type and color.

Brake Fluid Spec:

DOT 3 or DOT 4 brake fluid (verify with manual).

Known Issues

Common Wear Items:

Clutch wear, suspension bushings, CV joints, exhaust system corrosion, fuel pump reliability (especially with age).

Electrical Gremlins:

Age-related issues with wiring insulation, connectors, and grounds can lead to intermittent faults.

Rust And Corrosion:

As with many vehicles of this era, rust can be a significant issue, particularly in areas with harsh winters or high humidity. Check wheel wells, rocker panels, and subframes.

📚 Vehicle History

Brand Heritage

Daewoo History Context:

Daewoo Motors was a South Korean automobile manufacturer that existed from 1982 to 2011. It was known for producing small to medium-sized cars, often based on licensed designs from other manufacturers.

Model Evolution

Fino Development:

The Daewoo Fino was a rebadged version of the Suzuki Fronte/Alto models, particularly the fifth generation (CM11/CM21). It represented Daewoo's entry into the small car market.

Production

Production Period:

Introduced in South Korea around the late 1980s, with 1991 being a specific model year within its production run.

Manufacturing Locations:

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

🏆 Awards & Recognition

Recognitions

Automotive Awards:

The Daewoo Fino itself did not receive specific prestigious automotive awards. Its market success was more tied to its affordability and accessibility as a basic transportation option.

Ratings

Reliability Ratings:

Reliability is generally considered average for its class and era. Proper maintenance is key to longevity. Refer to specific consumer reports or owner forums for anecdotal data.