DAEWOO LACETTI 2004 Service Repair Manual

5C – 4ICLUTCH
DAEWOO V–121 BL4
COMPONENT LOCATOR
CLUTCH COMPONENTS
1. Clutch Pedal
2. Bolt
3. Nut
4. Lock Nut
5. Clutch Pedal Buffer
6. Nut
7. Clutch Pedal Brace8. E–Ring
9. Pin
10. E–Ring
11. Clutch Master Cylinder
12. Clutch Pedal Shaft
13. Turn–over Spring

CLUTCH 5C – 5
DAEWOO V–121 BL4
1. Clutch Master Cylinder
2. Nut
3. Gasket
4. Clip
5. Reservoir Hose
6. Clutch Master Cylinder Pipe
7. Clip
8. Clip
9. Bracket10. Bolt
11. Concentric Slave Cylinder
12. Concentric Slave Cylinder Pipe
13. Bolt
14. Clip
15. Hose
16. Pressure Plate
17. Clutch Disc
18. Bolt

5C – 6ICLUTCH
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
CLUTCH PEDAL
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the return spring from the clutch pedal.
3. Remove the clip and the pedal mounting shaft.
4. Remove the locking clip and push rod fixing pin.
5. Remove the push rod from the clutch pedal.
6. Remove the clutch pedal.
Installation Procedure
1. Install the clutch pedal.
2. Coat the push rod with multi–purpose grease.
3. Install the push rod to the clutch pedal.
4. Install the locking clip and push rod fixing pin.

CLUTCH 5C – 7
DAEWOO V–121 BL4
5. Coat the pedal mounting shaft with multi–purpose
grease.
6. Install the clip and the pedal mounting shaft.
7. Connect the return spring to the clutch pedal.
8. Adjust the clutch pedal play. Refer to ”Clutch Pedal
Adjustment” in this section.
9. Connect the negative battery cable.
CLUTCH PEDAL ADJUSTMENT
Adjustment Procedure
1. Determine the clutch pedal play. Depress the clutch
pedal lightly with your hand and measure the dis-
tance when you feel resistance.
2. Adjust the clutch pedal play. Loosen the locknut
and turn the pushrod. Clutch pedal play should
measure 6 to 12 mm (0.2 to 0.5 inch). Tighten the
locknut after adjustment.
3. Measure the clutch pedal travel. Press the clutch
pedal all the way to the floor. Measure from the
starting position to the ending position.
4. Adjust the clutch pedal travel. Loosen the locknut
and turn the bolt. Clutch pedal travel should mea-
sure 130 to 140 mm (5.1 to 5.5 inches). Tighten the
locknut after adjustment.

5C – 8ICLUTCH
DAEWOO V–121 BL4
CLUTCH RELEASE POINT
ADJUSTMENT
Adjustment Procedure
1. Apply the parking brake.
2. Run the engine at idle speed.
3. While you move the shift lever into the reverse
position, depress the clutch pedal slowly and mea-
sure the distance between the point when gear
noise is not heard and the point the clutch pedal is
completely depressed. The distance should be 30
to 40 mm (1.2 to 1.6 inches).
4. If the distance is not within the specified value,
check the following:
S Clutch pedal height
S Clutch pedal play
S Air in the system
S Clutch cover and disc pressure plate
AIR BLEEDING
Bleed the hydraulic system to remove the air which en-
tered when the pipes were disconnected for repairs. The
clutch/brake fluid in the clutch/brake reservoir must be
maintained at the MIN level or higher during air bleeding.
1. Attach a vinyl hose to the bleeder plug. Place the
other end of the vinyl tube in a glass container half–
filled with brake fluid.
2. Slowly pump the clutch pedal several times.
3. While you press the clutch pedal, loosen the bleed-
er screw until the fluid starts to run out. Close the
bleeder screw.
4. Repeat Step 3 until there are no air bubbles in the
fluid.
5. Fill the reservoir with brake fluid up to the proper
level.
PRESSURE PLATE AND CLUTCH
DISC
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the transaxle from the vehicle. Refer to
Section 5B, Five–Speed Manual Transaxle.
3. Remove the pressure plate bolts and the pressure
plate.
Important : Support the pressure plate when you remove
the last bolt.

CLUTCH 5C – 9
DAEWOO V–121 BL4
4. Remove the clutch disc from the flywheel.
Inspection Procedure
Clutch Disc
1. Visual Inspection
S Inspect the worn or oily contamination on the
clutch surface.
S Inspect the damaged or weakened torsion
spring.
S Inspect the a warped or bent clutch disc. After
inspection, replace new clutch disc, if necessary.
2. Clutch Disc Inspection
S Measure the rivet head depth from the clutch
disc surface.
S Replace the clutch disc if the measured value is
below the limit.
S Rivet Head Depth (Limit) : 0.3 mm (0.012 in)
Inspection Procedure
Pressure Plate
1. Check for a worn diaphragm spring finger.
2. Check for a worn or cracked pressure plate sur-
face.
3. Check for the polluted face by the oil. After inspec-
tion, replace the pressure plate if necessary.

5C – 10ICLUTCH
DAEWOO V–121 BL4
Installation Procedure
1. Coat the spline on the clutch disc with multi–pur-
pose grease.
2. Align the pressure plate and the clutch disc onto
the flywheel using the clutch arbor J–42474.
3. Install the pressure plate bolts.
Tighten
Tighten the bolts to 15 NSm (11 lb–ft).
4. Remove the clutch arbor J–42474.
5. Install the transaxle into the vehicle. Refer to Sec-
tion 5B, Five–Speed Manual Transaxle.
6. Connect the negative battery cable.
CLUTCH MASTER CYLINDER
ASSEMBLY
Removal Procedure
Before disconnecting the reservoir tank hose, remove the
clutch/brake fluid from the reservoir tank.
1. Remove the locking clip.
2. Remove the push rod fixing pin and push rod.
3. Disconnect the hose clamp on the master cylinder.
4. Disconnect the master cylinder hose.
5. Remove the master cylinder pipe.

CLUTCH 5C – 11
DAEWOO V–121 BL4
6. Remove the clutch master cylinder nuts.
7. Remove the clutch master cylinder.
Installation Procedure
1. Install the clutch master cylinder and clutch master
cylinder nuts.
Tighten
Tighten the clutch master cylinder nuts to 22 NSm (16
lb–ft).
2. Install the master cylinder pipe.
3. Connect the master cylinder hose.
4. Connect the hose clamp on the master cylinder.

5C – 12ICLUTCH
DAEWOO V–121 BL4
5. Install the push rod fixing pin and push rod.
6. Install the locking clip.
7. Bleed the air. Refer to ”Air Bleeding” in this section.
8. Adjust the clutch pedal. Refer to ”Clutch Pedal Ad-
justment” in this section.
9. Fill the reservoir with clutch/brake fluid up to the
proper level.
CONCENTRIC SLAVE CYLINDER
Removal Procedure
1. Remove the transaxle from the vehicle. Refer to
Section 5B, Five–Speed Manual Transaxle.
2. Remove the concentric slave cylinder retaining
bolts.
3. Disconnect the concentric slave cylinder pipe from
the concentric slave cylinder.
Notice : When removing the bushing, Make sure not to re-
move it with excessive force.
4. Remove the bushing from the concentric slave cyl-
inder pipe in the transaxle housing.
5. Remove the concentric slave cylinder pipe.
Notice : For removal or installation, Make sure not to sep-
arate oil seal fixing spring from the back side of the con-
centric slave cylinder.
6. Remove the O–ring and the concentric slave cylin-
der.

CLUTCH 5C – 13
DAEWOO V–121 BL4
Installation Procedure
1. Install the concentric slave cylinder and the pipe.
2. After installing the pipe screw provisionally, tighten
the concentric slave cylinder retaining bolts.
Tighten
Tighten the concentric slave cylinder retaining bolts to
7 NSm ( 62 lb–in).
3. Tighten the pipe screw.
Tighten
Tighten the pipe screw to 15 NSm (11 lb–ft).
4. Install the bushing onto the transaxle housing.
5. Connect the pipe with bushing.
6. Install the transaxle into the vehicle. Refer to Sec-
tion 5B, Five–Speed Manual Transaxle.