DAEWOO REZZO 2000-2008 Service Repair Manual

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The Daewoo Rezzo, also known as the Tacuma (model code U100), is a compact MPV that was produced from 2000 to 2008. Designed with practicality, spaciousness, and affordability in mind,...

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Taper: Car

Distributeur:

UGS: 97554

Mots clés: 2000 2001 2002 2003 2004 2005 2006 2007 2008 Car Daewoo REZZO

Variantes de produits

Description

The Daewoo Rezzo, also known as the Tacuma (model code U100), is a compact MPV that was produced from 2000 to 2008. Designed with practicality, spaciousness, and affordability in mind, it primarily features a 5-door body style and was often available with 5 or 7 seats, making it a versatile option for families. The Rezzo was built on GM's global compact platform and offered with either a 1.6-liter or a 2.0-liter gasoline engine, paired with a 5-speed manual or an optional 4-speed automatic transmission. Its design philosophy emphasized functionality, positioning it as a value-oriented competitor against models like the Opel Zafira and Renault Scenic. This comprehensive factory service manual provides detailed information for the maintenance and repair of the Daewoo Rezzo/Tacuma. It covers a wide array of systems, including engine mechanicals and performance, manual and automatic transmissions, brakes, suspension, steering, and the electrical system. The manual also details procedures for body and chassis work, HVAC, and safety systems. Within its extensive scope, owners and technicians will find step-by-step instructions for routine maintenance, diagnostic procedures, component replacement, engine and transmission rebuilds, and specific system servicing. This resource is designed to assist in keeping the vehicle in optimal condition and to facilitate accurate troubleshooting and repair.

🏷️ Basic Information

Identification

Make:

Daewoo

Model:

Rezzo

Model Alias:

Tacuma

Generation:

First Generation

Codes

Model Code:

👋 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:

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

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:

Discontinuation Year:

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.