Daewoo Tico 1996 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Daewoo Model: Tico Year: 1996 Chassis Code: KL1V Codes Engine Code Common: F8CV 👋 Introduction Market Position Vehicle Segment: City car / Kei car (subcompact)...

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Distributeur:

UGS: 27143

Mots clés: 1996 Car Daewoo Tico

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Daewoo

Model:

Year:

Chassis Code:

Codes

Engine Code Common:

👋 Introduction

Market Position

Vehicle Segment:

City car / Kei car (subcompact)

Target Demographic:

Urban commuters, budget-conscious buyers, first-time car owners.

Competitive Analysis

Key Competitors Era:

Suzuki Alto, Kia Pride, Hyundai Excel, Daihatsu Copen (for spirit, not direct class).

Key Features

Vehicle Philosophy:

Compact, fuel-efficient, affordable transportation with a distinctive European-influenced styling.

📋 Manual Details

Coverage Areas

Manual Type:

Factory Service Repair Manual

Language:

English

Format:

PDF Download

Page Count

Page Count Estimated:

Hundreds of pages (exact count not specified, typical for factory manuals)

Manual Type

Manual Scope:

Complete Official Factory Manual

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, cylinder head, block assembly, pistons, crankshaft, camshafts, timing system.

Fuel System:

Fuel pump, injectors, fuel filter, fuel lines, pressure regulator.

Ignition System:

Spark plugs, ignition coils, distributor (if applicable), ECU ignition control.

Cooling System:

Radiator, water pump, thermostat, coolant hoses, fan operation.

Exhaust System:

Exhaust manifold, catalytic converter, muffler, pipes, O2 sensors.

Transmission Manual:

Clutch system, gearbox overhaul, gear shift mechanism, driveshafts.

Transmission Automatic:

Less common for Tico, but if present, torque converter, gearbox operation, fluid management.

Brakes:

Hydraulic system, master cylinder, brake lines, calipers, pads, rotors, parking brake.

Steering:

Steering column, steering rack, tie rods, power steering pump (if equipped).

Suspension:

Front struts, rear shock absorbers, control arms, bushings, springs.

Electrical System:

Battery, alternator, starter motor, wiring diagrams, fuses, relays.

Lighting System:

Headlights, taillights, turn signals, interior lighting, bulb specifications.

HVAC:

Air conditioning system, heater core, blower motor, controls, refrigerant handling.

Body And Chassis:

Body panel removal/installation, door mechanisms, glass, seals, underbody coatings.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug checks, fluid level checks, tire rotations.

Troubleshooting:

Diagnostic procedures for common faults, symptom-based repair guides.

Engine Repair:

Component removal, inspection, repair, and reassembly for all engine parts.

Transmission Repair:

Gearbox disassembly, inspection, parts replacement, and reassembly.

Brake System Repair:

Brake pad replacement, rotor machining/replacement, caliper overhaul, bleeding procedures.

Electrical Diagnostics:

Using wiring diagrams for fault finding, testing circuits, component testing.

Suspension And Steering Repair:

Alignment procedures, component replacement, diagnosis of noise and handling issues.

HVAC System Repair:

Refrigerant handling, leak detection, component replacement, system charging.

Body Panel Repair:

Dent removal, panel replacement, rust repair techniques.

Technical Depth

Depth Level:

Comprehensive rebuild and repair procedures

Diagnostic Capabilities:

Detailed diagnostic flowcharts and troubleshooting trees

Specifications Accuracy:

Includes precise torque values, clearances, and tolerances

📊 Manual Specifications

File Format

File Type:

Searchable Text:

Implied, as it's a factory PDF, allowing for text search

Print Quality

Printability:

Designed for printing, allowing individual page printing or full document

Binding Type

Binding Type Digital:

N/A (Digital download)

Paper Type

Paper Type Digital:

N/A (Digital download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Three-cylinder, four-stroke, naturally aspirated gasoline

Displacement:

796 cc (0.8 L)

Bore X Stroke:

68.5 mm x 72.0 mm

Compression Ratio:

9.3:1

Valvetrain:

SOHC (Single Overhead Camshaft), 12 valves (4 valves per cylinder)

Performance

Horsepower:

Approx. 38-41 PS (28-30 kW) at around 5500 rpm (depending on market/tuning)

Torque:

Approx. 55-60 Nm (41-44 lb-ft) at around 3000-3500 rpm

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI) or Carburetor (early models/specific markets)

Fuel Type:

Unleaded gasoline

Engine Management

Ignition Type:

Electronic ignition system (Distributorless Ignition System - DIS, or with distributor on some variants)

Cooling System

Cooling Type:

Water-cooled, pressurized system

Lubrication System

Oil Capacity:

Approx. 3.0 - 3.5 Liters (with filter change)

Oil Specification:

API SG/SH or higher, SAE 10W-30 or 10W-40 (refer to manual for exact spec)

🔧 Transmission

Standard

Transmission Type Standard:

5-speed manual transmission

Optional

Transmission Type Optional:

3-speed automatic transmission (less common)

Features

Clutch Type:

Dry single plate, hydraulically operated

Fluid Specification

Manual Transmission Fluid:

API GL-4, SAE 75W-85 or 75W-90 (refer to manual for exact spec)

Fluid Capacity

Manual Transmission Capacity:

Approx. 2.0 Liters

📐 Dimensions

Exterior

Length:

Approx. 3,340 mm

Width:

Approx. 1,495 mm

Height:

Approx. 1,435 mm

Wheelbase:

Approx. 2,300 mm

Ground Clearance:

Approx. 150 mm

Weights

Curb Weight:

Approx. 700-750 kg (depending on equipment)

Gross Vehicle Weight Rating:

Approx. 1100 kg

Wheels Tires

Wheel Size Standard:

13 inches (steel wheels)

Tire Size Standard:

145/70 R13 or 155/65 R13

Bolt Pattern:

4x100

🛡️ Safety Features

Ratings

Crash Test Results:

Limited official crash test data available for this era/segment, likely not subjected to modern stringent tests.

Active Features

Optional on higher trims or specific markets.

Passive Features

Airbags:

Driver airbag standard on many models; passenger airbag optional or not available.

Seatbelts:

Three-point front seatbelts, two-point rear seatbelts (center rear may vary).

💡 Technology Features

Infotainment

Radio System:

Basic AM/FM radio, possibly with cassette player. CD player was rare.

Speakers:

Typically 2 or 4 speakers.

Driver Assistance

Power Steering:

Optional on higher trims, generally not standard.

Air Conditioning:

Optional feature, commonly installed as an aftermarket upgrade.

Connectivity

Connectivity Features:

None (basic vehicle of its era).

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 7,500 - 10,000 km or 6-12 months (whichever comes first), refer to manual.

Oil Filter Replacement:

With every oil change.

Air Filter Replacement:

Every 20,000 - 30,000 km.

Spark Plug Replacement:

Every 30,000 - 40,000 km (depending on plug type).

Transmission Fluid Change:

Every 40,000 - 60,000 km (manual), Every 30,000 - 50,000 km (automatic, if equipped).

Coolant Replacement:

Every 40,000 - 60,000 km or 2-3 years.

Fluid Specifications

Brake Fluid Specification:

DOT 3 or DOT 4.

Coolant Specification:

Ethylene glycol-based antifreeze, typically 50/50 mix with distilled water.

Known Issues

Common Problems Engine:

Oil leaks, thermostat failures, carbon buildup due to short trips, timing belt wear (if not DOHC).

Common Problems Electrical:

Corrosion in connectors, aging wiring harness, starter motor issues.

Common Problems Suspension:

Worn bushings, premature shock absorber failure, noisy suspension components.

Common Problems Rust:

Prone to rust on wheel arches, sills, and door bottoms, especially in humid or coastal climates.

Fluid Capacities

Coolant Capacity:

Approx. 4.5 Liters

Filter Part Numbers

Oil Filter Example:

Mann-Filter W712/1, Mahle OC 205 (Cross-reference required for exact fitment).

📚 Vehicle History

Brand Heritage

Daewoo Origins:

Daewoo Motor Company was a South Korean automobile manufacturer founded in 1982, later acquired by GM.

Model Evolution

Tico Development:

The Tico was based on the Suzuki Alto (fourth generation, CA71/72V) platform, licensed from Suzuki.

Tico Introduction Year:

Production

Production Period:

1991-2001

Manufacturing Locations:

South Korea (Changwon), Uzbekistan (as Daewoo Damas/Matiz)

🏆 Awards & Recognition

Recognitions

Industry Awards:

No significant industry awards are widely documented for the Daewoo Tico, but it was a popular budget choice in its markets.

Ratings

Fuel Economy Rating:

Excellent for its class, typically 5-6 L/100km combined.