Daewoo Tico 1997 Factory Service Repair Manual

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The Daewoo Tico is a subcompact city car produced in 1997, known for its compact size, maneuverability, and fuel efficiency, making it an economical choice for urban commuting and budget-conscious...

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Type: Car

Vendor:

Sku: 80570

Tags: 1997 Car Daewoo Tico

Product variants

Description

The Daewoo Tico is a subcompact city car produced in 1997, known for its compact size, maneuverability, and fuel efficiency, making it an economical choice for urban commuting and budget-conscious buyers. This model, based on the Suzuki Alto platform, features simple mechanicals and was designed to offer affordable transportation. Its engineering prioritizes practicality and low operating costs, positioning it as a straightforward option in the competitive city car segment of its era. This service repair manual provides comprehensive technical information for the Daewoo Tico. It covers essential areas including engine mechanicals, transmission systems, brakes, suspension, steering, and the electrical system. The manual details routine and scheduled maintenance, diagnostic procedures, and repair instructions for all major components and systems, offering factory-level detail for owners and technicians. Its purpose is to facilitate the proper upkeep and repair of the vehicle, ensuring its continued operation and longevity.

🏷️ Basic Information

Identification

Make:

Daewoo

Model:

Year:

Codes

Model Code:

Unknown (Specific to Daewoo Tico 1997)

Chassis Code:

Unknown (Specific to Daewoo Tico 1997)

👋 Introduction

Market Position

Segment:

Subcompact City Car

Target Audience:

Budget-conscious urban commuters, first-time car buyers, economical transportation seekers.

Competitive Analysis

Key Competitors:

Suzuki Alto, Kia Pride, Hyundai Excel, various city cars from Japanese manufacturers of the era.

Key Features

Vehicle Attributes:

Compact size for maneuverability, fuel efficiency, low purchase price, simple mechanicals.

Manual Value Proposition:

Provides essential factory-level technical data for maintaining and repairing the Daewoo Tico, enabling cost-effective ownership.

📋 Manual Details

Coverage Areas

Engine:

Transmission:

Brakes:

Suspension:

Steering:

Electrical System:

Body And Chassis:

Heating And Air Conditioning:

Fuel System:

Exhaust System:

Cooling System:

Interior Components:

Troubleshooting:

Wiring Diagrams:

Page Count

Estimated Pages:

Hundreds (specific count not provided, but described as 'complete' and 'hundreds of pages')

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English (Assumed from product description)

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, component testing, diagnosis, and repair of engine block, cylinder head, pistons, crankshaft, camshafts, valves, timing systems.

Engine Performance:

Ignition system, fuel delivery, emission controls, intake and exhaust systems, diagnostics for performance issues.

Transmission Manual:

Clutch, gearbox operation, gear replacement, bearing inspection, shift mechanism, fluid service.

Transmission Automatic:

Internal components, torque converter, valve body, hydraulic systems, electronic controls (if applicable), fluid service.

Braking System:

Hydraulic system, brake lines, master cylinder, brake boosters, caliper/wheel cylinder overhaul, brake pad/shoe replacement, rotor/drum servicing, parking brake.

Suspension System:

Front and rear suspension components, shock absorbers, struts, coil springs, control arms, ball joints, bushings, wheel bearing service.

Steering System:

Steering gear box, power steering pump, hoses, steering column, tie rods, steering linkage, alignment procedures.

Electrical System Power:

Battery, alternator, starter motor, charging system diagnostics.

Electrical System Lighting:

Headlights, taillights, interior lights, indicator lights, bulb specifications, wiring repair.

Electrical System Accessories:

Wipers, horn, power windows, door locks, radio, accessory circuits.

Body And Chassis Structure:

Body panels, frame components, door mechanisms, hood, trunk, bumper repair and adjustment.

HVAC System:

Evaporator, condenser, compressor, refrigerant lines, blower motor, heater core, control panel diagnosis and repair.

Fuel System Components:

Fuel tank, fuel pump, fuel filter, fuel injectors, fuel lines, fuel pressure testing.

Exhaust System Components:

Exhaust manifold, catalytic converter, muffler, exhaust pipes, hangers, gasket replacement.

Cooling System Components:

Radiator, coolant hoses, thermostat, water pump, cooling fan, coolant specifications.

Interior Trim:

Seat removal/installation, dashboard components, interior paneling, carpet, headliner.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections.

Scheduled Maintenance:

Detailed service intervals for all major components and systems.

Diagnostic Procedures:

Step-by-step troubleshooting guides for common and complex issues across all vehicle systems.

Repair Procedures:

Comprehensive instructions for component removal, repair, reassembly, and adjustment.

Engine Rebuild:

Detailed procedures for engine disassembly, cleaning, inspection, component replacement, and reassembly.

Transmission Rebuild:

Instructions for complete transmission disassembly, overhaul, and reassembly.

Brake System Overhaul:

Detailed steps for replacing brake pads, rotors, calipers, and bleeding the brake system.

Suspension Component Replacement:

Guidance on replacing struts, shocks, control arms, and other suspension parts.

Electrical Troubleshooting:

Utilizing wiring diagrams to diagnose and repair electrical faults.

Body Repair:

Procedures for panel alignment, door adjustments, and minor bodywork.

Air Conditioning Service:

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

Wheel Alignment:

Specifications and procedures for front and rear wheel alignment.

Technical Depth

Depth:

Comprehensive factory-level detail suitable for professional technicians and advanced DIY enthusiasts.

Diagnostic Charts:

Inclusion of diagnostic flowcharts and symptom-based troubleshooting tables.

Torque Specifications:

Detailed torque values for all fasteners critical to engine, chassis, and transmission components.

Clearances And Tolerances:

Specifications for component clearances and assembly tolerances during rebuilds.

Special Tools:

Identification and usage instructions for any specialized tools required for specific procedures.

📊 Manual Specifications

File Format

Format:

PDF (Portable Document Format)

Searchable:

Likely searchable text within the PDF, enabling quick content discovery.

Print Quality

Quality:

High-quality scans or digital original, suitable for printing individual pages or the entire document.

Binding Type

Binding:

N/A (Digital PDF format, printing is user-dependent)

Paper Type

Paper Type:

N/A (Digital PDF format, printing is user-dependent)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline 3-cylinder, 4-stroke

Displacement:

796 cc (0.8 L)

Bore X Stroke:

68.5 mm x 72.0 mm

Compression Ratio:

9.3:1 (Typical for this engine)

Valvetrain:

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

Performance

Horsepower:

Approx. 37-41 PS (27-30 kW) at 5500 rpm (Varies by specific market/tuning)

Torque:

Approx. 56-60 Nm (41-44 lb-ft) at 3000 rpm (Varies by specific market/tuning)

Fuel System

Fuel Delivery:

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

Fuel Type:

Unleaded Gasoline (Octane rating to be specified in manual)

Cooling System

Cooling Method:

Liquid-cooled

Ignition System

Ignition Type:

Electronic Ignition (Distributorless or Distributor type depending on market/variant)

🔧 Transmission

Standard

Type:

5-speed Manual Transmission

Optional

Type:

3-speed Automatic Transmission (Less common)

Features

Drive Layout:

Front-Wheel Drive (FWD)

Fluid Specifications

Manual Transmission Fluid:

API GL-4 SAE 75W-90 or SAE 80W-90 (Refer to manual for exact specification and capacity)

Automatic Transmission Fluid:

Dexron III or equivalent (Refer to manual for exact specification and capacity)

📐 Dimensions

Exterior

Length:

Approx. 3,340 mm (131.1 in)

Width:

Approx. 1,495 mm (58.9 in)

Height:

Approx. 1,400 mm (55.1 in)

Wheelbase:

Approx. 2,315 mm (91.1 in)

Weights

Curb Weight:

Approx. 700-750 kg (1543-1653 lbs) (Varies by equipment)

Gross Vehicle Weight Rating:

Typically around 1100-1200 kg (Refer to manual for exact GVWR)

Cargo

Cargo Volume:

Limited, designed primarily for passenger transport; rear seats are often foldable for increased capacity.

🛡️ Safety Features

Ratings

Crash Test Results:

Limited official safety ratings available for this model from major agencies like NHTSA or Euro NCAP due to its market and era. Likely basic structural integrity for its class.

Active Features

Optional or not available on all models.

Traction Control:

Not typically available.

Passive Features

Airbags:

Driver airbag (standard on many models), Passenger airbag (optional or not available).

Seatbelts:

Standard three-point seatbelts for front occupants, lap belts for rear. Pre-tensioners may be present on some variants.

Body Structure:

Reinforced safety cage and crumple zones designed to meet standards of the time.

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM radio, often with a cassette player. CD players were rare or aftermarket.

Display:

Analog gauges for speed, RPM, fuel, and temperature. No central display screen.

Driver Assistance

Features:

Minimal; primarily focused on basic mechanical operation. No advanced driver assistance systems (ADAS) present.

Connectivity

Features:

No factory-installed Bluetooth, USB ports, or smartphone integration.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 5,000 km (3,000 miles) or 6 months, whichever comes first (Check manual for specific recommendations).

Oil Filter Replacement:

At every engine oil change.

Air Filter Replacement:

Every 10,000 - 15,000 km (6,000 - 9,000 miles).

Spark Plug Replacement:

Every 20,000 - 30,000 km (12,000 - 18,000 miles).

Coolant Flush:

Every 2 years or 40,000 km (24,000 miles).

Transmission Fluid Change:

Manual: Every 40,000 km (24,000 miles). Automatic: Every 30,000 km (18,000 miles) or as specified.

Fluid Specifications

Engine Oil:

API SG/SH or higher, SAE 10W-30 or 10W-40 (Refer to manual for precise viscosity and capacity).

Coolant:

Ethylene glycol based coolant (50% mixture with distilled water), Green or Orange type (Refer to manual for specific type and capacity).

Brake Fluid:

DOT 3 or DOT 4 (Refer to manual for exact specification and capacity).

Power Steering Fluid:

If equipped, typically Dexron II/III or ATF (Refer to manual).

Known Issues

Engine Performance:

Potential for rough idling or misfires due to carburetor or early fuel injection system issues, vacuum leaks.

Electrical System:

Corrosion in connectors, aging wiring harnesses, issues with alternator or starter due to age.

Suspension And Steering:

Wear in ball joints, tie rod ends, and bushings due to the vehicle's age and basic suspension design.

Rust And Corrosion:

Common in older vehicles, particularly in areas exposed to salt or moisture. Check for rust on body panels, sills, and undercarriage.

Cooling System:

Leaking hoses, thermostat failure, or radiator blockages due to age.

📚 Vehicle History

Brand Heritage

Brand Origin:

Daewoo Motor Company was a South Korean automotive manufacturer, established in 1982 and later acquired by General Motors.

Model Evolution

Development:

The Tico was developed as a successor to the Daewoo Matiz (which was originally designed by Italdesign Giugiaro and sold as the Daewoo Tico in some markets). The Tico itself was based on the Japanese Suzuki Alto platform, licensed from Suzuki.

1997 Model Year:

Represents a specific iteration within the Tico's production run. Minor updates and feature changes may have occurred from earlier or later years.

Production

Production Period:

1991-2001 (Original Daewoo Tico/Fino)

Manufacturing Locations:

Primarily South Korea, with some assembly also taking place in other countries.

🏆 Awards & Recognition

Recognitions

Awards:

The Daewoo Tico did not receive significant industry awards for performance or luxury. Its recognition was primarily as an affordable and economical urban transport solution in its target markets.