DAEWOO T-154 BL2,3
SECTION 1
ENGINE CIELO EURO III
SECTION 1A
GENERAL ENGINE INFORMATION
TABLE OF CONTENTS
Diagnosis 1A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compression Test 1A-1 . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Test 1A-2 . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Leak Diagnosis 1A-3 . . . . . . . . . . . . . . . . . . . . . . . .
Knock Diagnosis 1A-4 . . . . . . . . . . . . . . . . . . . . . . . . . .
Noise Diagnosis 1A-8 . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information 1A-11 . . . . . . . . . . . . . . . . . . . . . . .
Cleanliness and Care 1A-11 . . . . . . . . . . . . . . . . . . . . .
On-Engine Service 1A-11 . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS
COMPRESSION TEST
Important: Disconnect the Crankshaft Position (CKP)
Sensor connector to disable the fuel and the ignition
systems.
Test the compression pressure for each cylinder. Low
compression pressure may be the fault of the valves or
the pistons. The following conditions should be consid-
ered when you check the cylinder compression:
D The engine should be at normal operating tempera-
ture.
D The throttle must be wide open.
D All the spark plugs should be removed.
D The battery must be at or near full charge.
1. Place approximately three squirts of oil from a plung-
er-type oiler into each spark plug port.
2. Insert the engine compression gauge into each spark
plug port.
3. Crank test each cylinder with four to five compression
strokes using the starter motor.
4. The lowest reading should not be less than 70% of
the highest reading. The compression gauge reading
should not be less than 689 kPa (100 psi) for any of
the cylinders.
5. Examine the gauge readings obtained after the four
‘‘puffs’’ per cylinder are obtained from cranking the
starter motor. The readings are explained in the follow-
ing descriptions:
D Normal Condition – Compression builds up quickly
and evenly to the specified compression on each cylin-
der.
D Piston Rings Faulty – Compression is low on the first
stroke and tends to build up on following strokes, but
the compression pressure does not reach normal. The
compression pressure improves considerably with the
addition of oil into the cylinder.
D Valves Faulty – Low compression pressure on the
first stroke. The compression pressure does not tend
to build up on the following strokes. The compression
pressure does not improve much with the addition of
oil into the cylinder.
1A–2 GENERAL ENGINE INFORMATION
DAEWOO T-154 BL2,3
OIL PRESSURE TEST
Step Action Value(s) Yes No
1 Is low or no oil pressure indicated? – Go to Step 2 System OK
2
Check the oil level in the crankcase.
Is the level low? – Go to Step 3 Go to Step 4
3
Add oil so that the oil level is up to the full mark on
the indicator.
Is the repair complete?
–
Go to Step 1
–
4
Check the idle speed.
Is the idle speed below the specified value? 825 rpm Go to Step 5 Go to Step 6
5
Increase the idle speed.
Is the speed increased? – Go to Step 1 –
6
Inspect the oil pressure switch.
Is the oil pressure switch incorrect or
malfunctioning?
–
Go to Step 7 Go to Step 8
7
Install a new oil pressure switch.
Is the repair complete? – Go to Step 1 –
8
Inspect the oil pressure gauge.
Is the oil pressure gauge incorrect or
malfunctioning?
–
Go to Step 9 Go to Step 10
9
Install a new oil pressure gauge.
Is the repair complete? – Go to Step 1 –
10
Inspect the engine oil.
Is the engine oil in the crankcase diluted or of the
improper viscosity?
–
Go to Step 11 Go to Step 12
11
Install new engine oil of the proper viscosity for the
expected temperatures.
Is the repair complete?
–
Go to Step 1
–
12
Inspect the oil pump.
Is the pump worn or dirty? – Go to Step 13 Go to Step 14
13
Replace the oil pump.
Is the repair complete? – Go to Step 1 –
14
Inspect the oil filter.
Is the oil filter plugged? – Go to Step 15 Go to Step 16
15
Install a new oil filter.
Is the repair complete? – Go to Step 1 –
16
Inspect the oil pickup screen.
Is the oil pickup screen loose or plugged? – Go to Step 17 Go to Step 18
17
Tighten or replace the oil pickup screen, as
necessary.
Is the repair complete?
–
Go to Step 1
–
18
Inspect the oil pickup tube.
Are there any holes in the oil pickup tube? – Go to Step 19 Go to Step 20
19
Replace the oil pickup tube.
Is the repair complete? – Go to Step 1 –
GENERAL ENGINE INFORMATION 1A–3
DAEWOO T-154 BL2,3
OIL PRESSURE TEST (CONT’D)
Step Action Value(s) Yes No
20
Inspect the bearing clearances.
Are the bearing clearances more than the specified
values?
Crankshaft
0.005 mm
(0.002 in.)
Connecting
Rod
0.019 X
0.070 mm
(0.0007 X
0.0027 in.) Go to Step 21 Go to Step 22
21
Replace the bearing, if necessary.
Is the repair complete? – Go to Step 1 –
22
Inspect the oil galleries.
Are the oil galleries cracked, porous or plugged? – Go to Step 23 Go to Step 24
23
Repair or replace the engine block.
Is the repair complete? – Go to Step 1 –
24
Inspect the gallery plugs.
Are any of the gallery plugs missing or installed
improperly?
–
Go to Step 25 Go to Step 26
25
Install the plugs or repair them, as necessary.
Is the repair complete? – Go to Step 1 –
26
Inspect the camshaft.
Is the camshaft worn or is there evidence of poor
machining?
–
Go to Step 27 System OK
27
Replace the camshaft.
Is the repair complete? – Go to Step 1 –
OIL LEAK DIAGNOSIS
Most fluid oil leaks are easily located and repaired by
visually finding the leak and replacing or repairing the
necessary parts. On some occasions, a fluid leak may
be difficult to locate or repair. The following procedures
may help you in locating and repairing most leaks.
Finding the Leak:
1. Identify the fluid. Determine whether it is engine oil,
automatic transmission fluid, power steering fluid, etc.
2. Identify where the fluid is leaking from.
2.1. After running the vehicle at normal operating
temperature, park the vehicle over a large
sheet of paper.
2.2. Wait a few minutes.
2.3. Find the approximate location of the leak by
the drippings on the paper.
3. Visually check around the suspected component.
Check around all the gasket mating surfaces for
leaks. A mirror is useful for finding leaks in areas that
are hard to reach.
4. If the leak still cannot be found, it may be necessary to
clean the suspected area with a degreaser, steam, or
spray solvent.
4.1. Thoroughly clean the area.
4.2. Dry the area.
4.3. Operate the vehicle for several miles at normal
operating temperature and varying speeds.
4.4. After operating the vehicle, visually check the
suspected component.
4.5. If you still cannot locate the leak, try using the
powder or black light and dye method.
Powder Method:
1. Clean the suspected area.
2. Apply an aerosol-type powder, (such as foot powder),
to the suspected area.
3. Operate the vehicle under normal operating conditions.
4. Visually inspect the suspected component. Trace the
leak path over the white powder surface to the source.
Black Light and Dye Method:
A dye and light kit is available for finding leaks. Refer to
the manufacturer’s directions when using the kit.
1. Pour the specified amount of dye into the engine oil fill
tube.
2. Operate the vehicle under normal operating condi-
tions as directed in the kit.
1A–4 GENERAL ENGINE INFORMATION
DAEWOO T-154 BL2,3
3. Direct the light toward the suspected area. The dyed
fluid will appear as a yellow path leading to the
source.
Repairing the Leak
Once the origin of the leak has been pinpointed and
traced back to its source, the cause of the leak must be
determined in order for it to be repaired properly. If a
gasket is replaced, but the sealing flange is bent, the
new gasket will not repair the leak. The bent flange must
be repaired also. Before attempting to repair a leak,
check for the following conditions and correct them as
they may cause a leak.
Gaskets:
D The fluid level/pressure is too high.
D The crankcase ventilation system is malfunctioning.
D The fasteners are improperly tightened or the threads
are dirty or damaged.
D The flanges or the sealing surface is warped.
D There are scratches, burrs or other damage to the
sealing surface.
D The gasket is damaged or worn.
D There is cracking or porosity of the component.
D An improper seal was used, (where applicable).
Seals:
D The fluid level/pressure is too high.
D The crankcase ventilation system is malfunctioning.
D The seal bore is damaged, scratched, burred or
nicked.
D The seal is damaged or worn.
D Improper installation is evident.
D There are cracks in the component.
D The shaft surface is scratched, nicked or damaged.
D A loose or worn bearing is causing excess seal wear.
KNOCK DIAGNOSIS
Definition for Knock
Engine knock refers to various types of engine noise.
Heavy knock is usually very loud and the result of broken
or excessively worn internal engine components. Light
knock is a noticeable noise, but not as loud. Light knock
can be caused by worn internal engine components.
Loose or broken external engine components can also
cause heavy or light knock.
Engine Knocks Cold and Continues for Two-Three Minutes
and/or Knock Increases with Engine Torque
Step Action Value(s) Yes No
1
Does the engine knock when it is cold and continue
for two to three minutes or does the knock increase
with torque?
–
Go to Step 2 System OK
2
Inspect the flywheel.
Is the flywheel contacting the splash shield? – Go to Step 3 Go to Step 4
3
Reposition the splash shield.
Is the repair complete? – Go to Step 1 –
4
Inspect the balancer and the drive pulleys.
Is either the balancer or the drive pulleys loose or
broken?
–
Go to Step 5 Go to Step 6
5
Tighten or replace the balancer or the drive pulleys.
Is the repair complete? – Go to Step 1 –
6
Inspect the piston-to-bore clearance.
Is the clearance more than the specified value?
0.030 mm
(0.001 in.)
Go to Step 7 Go to Step 8
7
1. Rebore the cylinder and hone to size.
2. Replace the piston.
Is the repair complete?*
–
Go to Step 1
–
8
Inspect the connecting rod.
Is the connecting rod bent? – Go to Step 9 System OK
9
Replace the connecting rod.
Is the repair complete? – Go to Step 1 –
* Cold engine piston knock usually disappears when the cylinder is grounded out. Cold engine piston knock,
which disappears in about 1.5 minutes, is considered acceptable.
GENERAL ENGINE INFORMATION 1A–5
DAEWOO T-154 BL2,3
Heavy Knock Hot with Torque Applied
Step Action Value(s) Yes No
1
Is there a heavy knock when the engine is hot and
torque is applied? – Go to Step 2 System OK
2
Inspect the balancer and pulley hub.
Is the balancer or pulley hub broken? – Go to Step 3 Go to Step 4
3
Replace the broken balancer or pulley hub.
Is the repair complete? – Go to Step 1 –
4
Inspect the torque converter bolts.
Are the bolts tightened to the specified value?
45 NSm
(33 lb-ft)
Go to Step 5 Go to Step 6
5
Tighten the torque converter bolts.
Is the repair complete? – Go to Step 1 –
6
Inspect the accessory belts.
Are the belts too tight or nicked? – Go to Step 7 Go to Step 8
7
Replace and/or tension the belts to specifications, as
necessary.
Is the repair complete?
–
Go to Step 1
–
8
Inspect the exhaust system.
Is the system grounded? – Go to Step 9 Go to Step 10
9
Reposition the system, as necessary.
Is the repair complete? – Go to Step 1 –
10
Inspect the flywheel.
Is the flywheel cracked? – Go to Step 11 Go to Step 12
11
Replace the flywheel.
Is the repair complete? – Go to Step 1 –
12
Inspect the main bearing clearance.
Is the clearance more than the specified value?
0.050 mm
(0.002 in.)
Go to Step 13 Go to Step 14
13
Replace the main bearings, as necessary.
Is the repair complete? – Go to Step 1 –
14
Inspect the rod bearing clearance.
Is the clearance more than the specified value?
0.019 X
0.070 mm
(0.0007 X
0.0028 in.) Go to Step 15 System OK
15
Replace the rod bearings, as necessary.
Is the repair complete? – Go to Step 1 –
1A–6 GENERAL ENGINE INFORMATION
DAEWOO T-154 BL2,3
Light Knock Hot
Step Action Value(s) Yes No
1 Is there a light knock when the engine is hot? – Go to Step 2 System OK
2 Is detonation or spark knock evident? – Go to Step 3 Go to Step 4
3
Check the engine timing and the fuel quality.
Was the problem found? – Go to Step 1 –
4
Inspect the torque converter bolts.
Are the bolts tightened to the specified value?
45 NSm
(33 lb-ft)
Go to Step 5 Go to Step 6
5
Tighten the torque converter bolts.
Is the repair complete? – Go to Step 1 –
6
Inspect the manifold.
Is there an exhaust leak at the manifold? – Go to Step 7 Go to Step 8
7
Tighten the bolts or replace the gasket.
Is the repair complete? – Go to Step 1 –
8
Check the rod bearing clearance.
Is the clearance within the specified value?
0.019 X
0.070 mm
(0.0007 X
0.0028 in.) Go to Step 9 System OK
9
Replace the rod bearings as necessary.
Is the repair complete? – Go to Step 1 –
Knocks During Initial Start-Up But Last Only a Few Seconds
Step Action Value(s) Yes No
1
Does the engine knock during initial start-up but last
only a few seconds? – Go to Step 2 System OK
2
Check the engine oil.
Is the proper viscosity oil used in the crankcase? – Go to Step 4 Go to Step 3
3
Install oil of the proper viscosity for the expected
seasonal temperatures.
Is the repair complete?
–
Go to Step 1
–
4
Inspect the hydraulic lifters.
Is there evidence of hydraulic lifter bleed-down? – Go to Step 5 Go to Step 6
5
Clean, test and replace the lifters, as necessary.
Is the repair complete?* – Go to Step 1 –
6
Inspect the crankshaft end clearance.
Is the clearance more than specified value?
0.1 mm
(0.0039 in.)
Go to Step 7 Go to Step 8
7
Replace the crankshaft thrust bearing.
Is the repair complete? – Go to Step 1 –
8
Inspect the front main bearing clearance.
Is the clearance more than the specified value?
0.005 mm
(0.0001 in.)
Go to Step 9 System OK
9
Replace the worn parts of the front main bearing.
Is the repair complete? – Go to Step 1 –
* When the engine is stopped, some valves will be open. Spring pressure against the lifters will tend to bleed
lifter down. Attempts to repair this should be made only if the problem is consistent.
An engine that is only operated for short periods between start-ups may have lifter noise that lasts for a few
minutes. This is a normal condition.
GENERAL ENGINE INFORMATION 1A–7
DAEWOO T-154 BL2,3
Knocks at Idle Hot
Step Action Value(s) Yes No
1 Does the engine knock at idle when hot? – Go to Step 2 System OK
2
Inspect the drive belts.
Are the belts loose or worn? – Go to Step 3 Go to Step 4
3
Tension or replace the belts, as necessary.
Is the repair complete? – Go to Step 1 –
4
Inspect the A/C compressor and the generator.
Is either the compressor or the generator faulty? – Go to Step 5 Go to Step 6
5
Replace the faulty A/C compressor or the generator.
Is the repair complete? – Go to Step 1 –
6
Inspect the valve train.
Are valve train components faulty? – Go to Step 7 Go to Step 8
7
Replace faulty valve train components.
Is the repair complete? – Go to Step 1 –
8
Check the engine oil.
Is the proper viscosity oil used in the crankcase?
–
Go to Step 10 Go to Step 9
9
Install oil of the proper viscosity for the expected
seasonal temperatures.
Is the repair complete?
–
Go to Step 1
–
10
Inspect the piston pin clearance.
Is the clearance more than the specified value?
0.020 mm
(0.0008 in.)
Go to Step 11 Go to Step 12
11
Replace the piston and the pin.
Is the repair complete? – Go to Step 1 –
12
Check the connecting rod alignment.
Is the alignment faulty? – Go to Step 13 Go to Step 14
13
Check and replace the rods, as necessary.
Is the repair complete? – Go to Step 1 –
14
Inspect the piston-to-bore clearance.
Is the clearance within the specified value?
0.030 mm
(0.0012 in.) Go to Step 16 Go to Step 15
15
Hone the bore and fit a new piston.
Is the repair complete? – Go to Step 1 –
16
Inspect the crankshaft balancer.
Is the balancer loose? – Go to Step 17 Go to Step 18
17
Torque or replace worn parts.
Is the repair complete? – Go to Step 1 –
18
Check the piston pin offset.
Is the offset at the specified value?
0.5 X 0.7
mm (0.020 X
0.028 in.)
Toward Thrust
Side Go to Step 19 System OK
19
Install the correct piston.
Is the repair complete? – Go to Step 1 –
1A–8 GENERAL ENGINE INFORMATION
DAEWOO T-154 BL2,3
NOISE DIAGNOSIS
Main Bearing Noise
Step Action Value(s) Yes No
1
Are dull thuds or knocks heard with every engine
revolution? – Go to Step 2 System OK
2
Check the oil pump pressure.
Is the oil pump pressure low?
–
Go to Oil
Pressure Test Go to Step 3
3
Inspect the crankshaft end play.
Does the crankshaft end play exceed the specified
value?
0.1 mm
(0.0039 in.)
Go to
Crankshaft
Replacement
Procedure Go to Step 4
4
Inspect the crankshaft journals.
Are the crankshaft journals out-of-round?
0.004 mm
(0.0002 in.)
max.
Go to
Crankshaft
Replacement
Procedure Go to Step 5
5
Inspect the belt tension.
Does the belt tension exceed the specified value?
–
Go to
Timing Belt
Replacement
Procedure Go to Step 6
6
Inspect the crankshaft pulley.
Is the crankshaft pulley loose?
–
Go to
Crankshaft
Replacement
Procedure System OK
Connecting Rod Bearing Noise Symptom
Step Action Value(s) Yes No
1 Is a knock noise heard under all engine speeds? – Go to Step 2 System OK
2
Inspect the crankshaft connecting rod journal.
Is the crankshaft connecting rod journal worn?
–
Go to
Crankshaft
Replacement
Procedure Go to Step 3
3
Check the oil pump pressure.
Is the oil pump pressure low?
–
Go to
Oil Pressure
Test Go to Step 4
4
Inspect the crankshaft connecting rod journals.
Are the journals out of round?
–
Go to
Crankshaft
Replacement
Procedure Go to Step 5
5
Inspect the connecting rods.
Is there a misaligned connecting rod?
–
Go to Pistons
and Rods
Replacement
Procedure Go to Step 6
6
Inspect the connecting rod bolts.
Are the connecting rod bolts torqued properly?
–
System OK
Go to Pistons
and Rods
Replacement
Procedure
GENERAL ENGINE INFORMATION 1A–9
DAEWOO T-154 BL2,3
Piston Noises
Step Action Value(s) Yes No
1
Are any of the following noises heard: a sharp
double knock when the engine is idling, a light
ticking with no load on the engine or a ‘‘slapping’’
noise when the engine is cold?
–
Go to Step 2 System OK
2
Inspect the piston pin and the bushing.
Is the piston pin or the bushing worn or loose?
–
Go to Pistons
and Rods
Replacement
Procedure Go to Step 3
3
Inspect the piston.
Is the piston broken or cracked?
–
Go to Pistons
and Rods
Replacement
Procedure Go to Step 4
4
Inspect the connecting rods.
Is there a misaligned connecting rod?
–
Go to Pistons
and Rods
Replacement
Procedure Go to Step 5
5
Inspect the piston position.
Is the piston 180_ out of position?
–
Go to Pistons
and Rods
Replacement
Procedure System OK
1A – 10 GENERAL ENGINE INFORMATION
DAEWOO T-154 BL2,3
Valve Mechanism or Valve Train Noises
Step Action Value(s) Yes No
1 Is a light tapping sound heard from the engine? – Go to Step 2 System OK
2
Inspect the valve springs.
Are the springs weak or broken?
–
Go to
Cylinder Head
and Valve Train
Components
Replacement
Procedure Go to Step 3
3
Inspect the valves.
Are the valves sticking or warped?
–
Go to
Cylinder Head
and Valve Train
Components
Replacement
Procedure Go to Step 4
4
Inspect the valve lifters.
Are the valve lifters dirty, stuck or worn?
–
Go to
Cylinder Head
and Valve Train
Components
Replacement
Procedure Go to Step 5
5
Inspect the camshaft lobes.
Are the camshaft lobes damaged or improperly
machined? –
Go to
Camshaft
Replacement
Procedure Go to Step 6
6
Check the oil supply to the valve train.
Is the oil supply insufficient or poor?
–
Go to
Cylinder Head
and Valve Train
Components
Replacement
Procedure Go to Step 7
7
Inspect the valve guides.
Are the valve guides worn?
–
Go to
Cylinder Head
and Valve Train
Components
Replacement
Procedure Go to Step 8
8
Inspect the valve spring seat.
Is the valve spring seat incorrect?
–
Go to
Cylinder Head
and Valve Train
Components
Replacement
Procedure System OK
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DAEWOO CIELO 3 Engine Workshop Manual
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Description
All models and repairs are covered from A-Z in this workshop service repair manual. It includes detailed mechanical and electrical repair procedures, along with plenty of pictures and diagrams. You can print off only the pages you need, and it will never time out or expire. This manual is suitable for both professional mechanics and DIY enthusiasts.
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This manual provides a comprehensive layout format covering all repair procedures in great detail. It will enhance your understanding of all the parts and repair procedures, enabling you to perform your own servicing and repairs.
All models for the specified years and engine types are included. This Service Repair Workshop Manual is specific to the mentioned model and is the same type of manual that your local dealer/mechanic would use.
Every repair procedure, service repair, and maintenance, etc., is covered in this manual.
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