boot DAEWOO LACETTI 2004 Service User Guide

FRONT DISC BRAKES 4D – 7
DAEWOO V–121 BL4
6. Remove the bleeder valve protector and the bleed-
er valve.
Assembly Procedure
1. Clean all the parts in denatured alcohol or brake
fluid. Dry the parts with unlubricated compressed
air and blow out all the passages in the housing
and the bleeder valve.
2. Inspect the piston and the caliper for scoring, nicks,
and corrosion. Replace the components if these
elements are found.
3. Inspect the caliper bleeder valve.
Important : Do not remove material from the piston or the
caliper bore.
4. Lubricate a new piston inner seal.
5. Install the piston inner seal into the caliper housing
groove. Make sure the seal is not twisted.
6. Install the outer piston dust seal in the groove.
7. Lubricate the piston with brake fluid.
8. Push the piston inward until it is properly seated.
9. Coat the pins with rubber grease and install the
boots.
10. Install the caliper bleeder valve and the protector.
Tighten
Tighten the caliper bleeder valve to 8 NSm (71 lb–in).
11. Connect the brake pads and the pad springs.
Important : Make sure the pad springs are properly
installed.

4E2 – 10IREAR DRUM BRAKES
DAEWOO V–121 BL4
UNIT REPAIR
WHEEL CYLINDER
Disassembly Procedure
1. Remove the wheel cylinder assembly from the
backing plate. Refer to ”Wheel Cylinder Assembly”
in this section.
2. Twist off the boots, the pistons, and the seals from
each end of the wheel cylinder.
3. Remove the spring assembly.
4. Remove the bleeder cap and the bleeder valve.
Assembly Procedure
1. Inspect the wheel cylinder bore and the pistons for
scoring, nicks, corrosion, and wear.
2. Use a crocus cloth to polish out light corrosion in
the wheel cylinder bore.
Important : If the bore will not clean up with a crocus cloth,
replace the assembly.
3. Clean all the parts in clean denatured alcohol or
brake fluid. Dry all the parts with unlubricated com-
pressed air and lubricate the new seals, the pis-
tons, and the wheel cylinder bore with clean brake
fluid before assembly.
4. Thinly coat all the parts except the dust caps with
brake cylinder fluid.
5. Fasten the bleeder valve and the cap to the wheel
cylinder.

REAR DRUM BRAKES 4E2 – 11
DAEWOO V–121 BL4
6. Attach to the wheel cylinder the spring assembly,
followed by the pistons, the seals, and the boots.
7. Inspect the pistons for free movement.
8. Install the wheel cylinder assembly. Refer to ”Wheel
Cylinder Assembly” in this section.

4G – 8IPARKING BRAKE
DAEWOO V–121 BL4
9. Attach the parking brake cable ends to the equaliz-
er.
10. Adjust the hex nut on the end of pull rod. Refer to
”Parking Brake Adjustment” in this section.
11. Install the parking brake/gearshift console hood.
Refer to Section 9G, Interior Trim.
PARKING BRAKE HANDLE
Removal Procedure
1. Remove the parking brake/gearshift console hood,
detaching the parking brake lever boot. Refer to
Section 9G, Interior Trim.
2. Slip the parking brake handle off of the parking
brake lever.
Installation Procedure
1. Push the parking brake handle as far as it will go on
the parking brake lever.
2. Install the parking brake/gearshift console hood
with the parking brake lever boot. Refer to Section
9G, Interior Trim.

5B – 16IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
4. Remove the adjustment hole plug from the shift
lever cover.
5. Turn the gearshift rod and fully insert a 5 mm (0.2
inch) gauge pin into the adjustment hole.
6. Remove the boot from the console.
7. Pull the boot upward to expose the shift control le-
ver mechanism.
8. Position the gearshift lever close to left side of the
NEUTRAL position.
9. Insert a 5 mm (0.2 inch) gauge pin into the holes to
align the gearshift lever with the gearshift lever
housing.
10. Tighten the rod clamp bolt.
Tighten
Tighten the rod clamp bolt to 14 NSm (124 lb–in).
11. Remove .the 5 mm (0.2 inch) gauge pin from the
adjustment hole.
12. Install the adjustment hole plug.
13. Remove the 5 mm (0.2 inch) gauge pin from the
gearshift lever.
14. Install the boot to the console.
15. Connect the negative battery cable.

FIVE–SPEED MANUAL TRANSAXLE 5B – 17
DAEWOO V–121 BL4
GEARSHIFT LEVER
(LEFT–HAND DRIVE SHOWN,
RIGHT–HAND DRIVE SIMILAR)
Removal Procedure
1. Disconnect the negative battery cable.
2. Position the gearshift lever into NEUTRAL.
3. Disconnect the boot from the console cover.
4. Lift the console cover upward to expose the shift
control lever mechanism.
5. Rotate the gearshift lever stop clamp and remove it.
6. Remove the gearshift lever from the gearshift lever
shaft.
Installation Procedure
1. Install the gearshift lever into the gearshift lever
shaft.
2. Install the gearshift lever stop clamp.
3. Rotate the gearshift lever stop clamp to secure it.
4. Lower the boot and connect it to the console cover.
5. Connect the negative battery cable.

SECTION : 6C
POWER STEERING GEAR
CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool
or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help
prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
TABLE OF CONTENTS
SPECIFICATIONS6C–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 6C–1. . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 6C–2. . . . . . . . . . .
SPECIAL TOOLS6C–2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 6C–2. . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS6C–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Rack and Pinion Steering Gear 6C–3. . . . . . . .
Power Rack and Pinion Steering Gear Bench
Testing 6C–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speed Sensitive Power Steering System 6C–6. . . . . .
Speed Sensitive Power Steering System Operating
With Full Assist At All Times 6C–7. . . . . . . . . . . . . . .
Speed Sensitive Power Steering System Operating
with Decreased Assist At All Times 6C–9. . . . . . . . .
MAINTENANCE AND REPAIR6C–11 . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 6C–11. . . . . . . . . . . . . . . . . . . .
Rack and Pinion Assembly 6C–11. . . . . . . . . . . . . . . . . Outer Tie Rod 6C–14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dust Boot 6C–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Straight–Ahead Check 6C–16. . . . . . . . . . . . . . . . . . . .
Intermediate Shaft and Dash Seal 6C–17. . . . . . . . . .
Hydraulic Cylinder Lines 6C–20. . . . . . . . . . . . . . . . . . .
Speed Sensitive Power Steering Control
Module 6C–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR 6C–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rack and Pinion 6C–22. . . . . . . . . . . . . . . . . . . . . . . . . .
Stub Shaft Seals and Upper and Lower
Bearing 6C–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rack Bearing 6C–29. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rack Bearing Preload Adjustment 6C–30. . . . . . . . . . .
Valve and Pinion 6C–30. . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION6C–33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Rack and Pinion 6C–33. . . . . . . . . . . . . . . . . . . .
Speed Sensitive Power Steering System 6C–33. . . . .
SPECIFICATIONS
GENERAL SPECIFICATIONS
ApplicationDescription
Capacity1.1 Liter (1.16 qt)
LubricantPower Steering Fluid DEXRON®–II or III

POWER STEERING GEAR 6C – 15
DAEWOO V–121 BL4
4. Loosen the outer tie rod adjusting nut and remove
the outer tie rod by twisting it off the inner tie rod.
Installation Procedure
1. Reposition the adjusting nut to the marks on the
inner tie rod.
2. Install the outer tie rod by twisting it onto the inner
tie rod.
3. Connect the outer tie rod to the steering knuckle.
4. Perform a front toe adjustment. Refer to Section
2B, Wheel Alignment.
5. Tighten the adjusting nut.
Tighten
Tighten the outer tie rod adjusting nut to 64 NSm (47
lb–ft).
6. Install the outer tie rod nut.
Tighten
Tighten the outer tie rod nut to 50 NSm (37 lb–ft).
7. Install the wheel. Refer to Section 2E, Tires and
Wheels.
DUST BOOT
Tools Required
KM–J–22610 Installer
Removal Procedure
1. Raise and suitably support the vehicle.
2. Remove the wheel. Refer to Section 2E, Tires and
Wheels.
3. Remove the outer tie rod. Refer to ”Outer Tie Rod”
in this section.
4. Remove the dust boot retaining clamps.
5. Remove the dust boot.

6C – 16IPOWER STEERING GEAR
DAEWOO V–121 BL4
Installation Procedure
1. Install the dust boot.
2. Install the tie rod end dust boot retaining clamp.
Install the cylinder end dust boot retaining clamp
with the installer KM–J–22610.
3. Install the outer tie rod. Refer to ”Outer Tie Rod” in
this section.
4. Install the wheel. Refer to Section 2E, Tires and
Wheels.
5. Lower the vehicle.
STRAIGHT–AHEAD CHECK
After all the necessary operations on the steering gear are
completed (removing and installing, disassembling and
assembling), check the exact straight–ahead position of
the steering in each case.
With the vehicle on the floor, place the steering wheel in
the straight–ahead position. Mark the centerline of both
tires on the floor. Turn the steering wheel all the way to the
right and mark the new centerline of both tires on the floor.

6C – 22IPOWER STEERING GEAR
DAEWOO V–121 BL4
UNIT REPAIR
RACK AND PINION
Tools Required
KM–J–22610 Installer
Disassembly Procedure
1. Remove the rack and pinion steering assembly
from the vehicle. Refer to ”Rack and Pinion Assem-
bly” in this section.
2. Remove the valve and pinion assembly from the
rack and pinion steering assembly. Refer to ”Valve
and Pinion” in this section.
3. Remove the rack bearing assembly from the rack
and pinion steering assembly. Refer to ”Rack Bear-
ing” in this section.
4. Mark the threads on the inner tie rod to aid in re-
positioning the adjusting nut.
5. Loosen the adjusting nut and remove the outer tie
rod nut and the adjusting nut.
6. Remove the dust boot retaining clamps.
7. Remove the dust boot.