acc DAEWOO LACETTI 2004 Service Repair Manual

5B – 6IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
SYMPTOM DIAGNOSIS
ChecksAction
Check for a knock at low speeds.S Replace any worn drive axle CV joints.
S Replace any worn side gear hub.
Check for a noise most pronounced on turns.S Correct any abnormalities in the differential gear.
Check for a clunk upon acceleration or deceleration.S Tighten any loose engine mounts.
S Replace any worn drive axle inboard joints.
S Replace any worn differential pinion shaft in the
case.
S Replace any worn side gear hub in the case.
Check for a clunking noise in turns.S Replace any worn outboard CV joint.
Check for a vibration.S Replace any rough wheel bearing.
S Replace any bent drive axle shaft.
S Replace any out–of–round tires.
S Balance any unbalanced tire.
S Replace any worn CV joint in the drive axle shaft.
S Correct an excessive drive axle angle by adjusting
the trim height.
Check for a noise in the NEUTRAL gear with the engine
running.S Replace any worn cluster bearing shaft.
S Replace any worn clutch–release bearing.
S Replace any worn input shaft cluster gears.
S Replace any worn first–gear/bearing.
S Replace any worn second–gear/bearing.
S Replace any worn third–gear/bearing.
S Replace any worn fourth–gear/bearing.
S Replace any worn fifth–gear/bearing.
S Replace any worn mainshaft bearings.
Check for a noise in the first gear (1) only.S Replace any chipped, scored, or worn first–gear
constant mesh gears.
S Replace any worn first–second gear synchronizer.
S Replace any worn first–gear/bearing.
S Replace any worn differential–gear/bearing.
S Replace any worn–ring gear.
S Adjust, repair, or replace the shift lever and the rods.
Check for a noise in the second gear (2) only.S Replace any chipped, scored, or worn second–gear
constant mesh gears.
S Replace any worn first–second gear synchronizer.
S Replace any worn second–gear/bearing.
S Replace any worn differential–gear/bearing.
S Replace any worn–ring gear.
S Adjust, repair, or replace the shift lever and the rods.
Check for a noise in the third gear (3) only.S Replace any chipped, scored, or worn third–gear
constant mesh gears.
S Replace any worn third–fourth gear synchronizer.
S Replace any worn third–gear/bearing.
S Replace any worn differential–gear/bearing.
S Replace any worn–ring gear.
S Adjust, repair, or replace the shift lever and the rods.

FIVE–SPEED MANUAL TRANSAXLE 5B – 63
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
FIVE–SPEED MANUAL TRANSAXLE
This five–speed transaxle assembly is a transmission of
constant–mesh design.
Combined in the assembly are:
S All forward gears.
S The reverse gear.
S The differential output.
The basic components of the five–speed transaxle as-
sembly units are the:
S Transaxle case.
S Input shaft.
S Input shaft gears.S Output shaft.
S Output shaft gears.
S Ring gear and differential assembly.
Forward Gear
Shifting to a forward gear is accomplished through a com-
bination of synchronizers with blocker rings controlled by
sliding shift forks.
Reverse Gear
Reverse gear is not synchronized and uses a sliding idler
gear arrangement.
Differential Assembly
The differential is a conventional arrangement of gears
that is supported by tapered roller bearings. The final out-
put gear turns the ring gear and differential assembly
which turns the drive axle shafts.

POWER STEERING SYSTEM 6A – 3
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
BLEEDING THE POWER STEERING
SYSTEM
If the power steering hydraulic system has been serviced,
an accurate fluid level reading cannot be obtained until the
air is bled from the system. Follow these steps to bleed the
air from the system.
1. Turn the wheels all the way to the left and add the
power steering fluid to the MIN mark on the fluid
level indicator.
Notice : When adding fluid or making a complete fluid
change, always use DEXRON®–II or III power steering
fluid. Failure to use the proper fluid will cause hose and
seal damage and fluid leaks.
2. Start the engine. With the engine running at fast
idle, recheck the fluid level. If necessary, add fluid
to bring the level up to the MIN mark.
3. Bleed the system by turning the wheels from side to
side without reaching the stop at either end. Keep
the fluid level at the MIN mark. The air must be
eliminated from the fluid before normal steering ac-
tion can be obtained.
4. Return the wheels to the center position. Continue
running the engine for 2 to 3 minutes.
5. Road test the car to be sure the steering functions
normally and is free from noise.
6. Recheck the fluid level as described in steps 1 and
2. Make sure the fluid level is at the MAX mark af-
ter the system has stabilized at its normal operating
temperature. Add fluid as needed.
CHECKING AND ADDING FLUID
Notice : When adding fluid or making a complete fluid
change, always use DEXRON®–II or III power steering
fluid. Failure to use the proper fluid will cause hose and
seal damage and fluid leaks.
1. The power steering fluid level is indicated either by
marks on a see–through fluid reservoir or by marks
on a fluid level indicator on the fluid reservoir cap.
2. If the fluid is warmed up to 66°C (150°F), the fluid
level should be between the MAX and MIN marks.
Add fluid as needed.
3. If the fluid is cool, 21°C (70°F), the fluid level
should be at the MIN mark. Add fluid as needed.

SECTION : 6B
POWER STEERING PUMP
TABLE OF CONTENTS
SPECIFICATIONS6B–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 6B–1. . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 6B–1. . . . . . . . . . .
DIAGNOSIS6B–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Steering Pump Diagnosis 6B–2. . . . . . . . . . . . .
MAINTENANCE AND REPAIR6B–3 . . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 6B–3. . . . . . . . . . . . . . . . . . . . . Serpentine Accessory Drive Belt 6B–3. . . . . . . . . . . . .
Pump Assembly 6B–4. . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR 6B–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump 6B–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION6B–8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Steering Pump 6B–8. . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS
GENERAL SPECIFICATIONS
ApplicationDescription
LubricantPower Steering Fluid DEXRON®–II or III
Pressure
– without EVO8330 kPa ~ 8820 kPa (1208 psi ~ 1279 psi)
– with EVO8500 kPa ~ 8960 kPa (1233 psi ~ 1299 psi)
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Air Filter Housing Assembly Bolts6–53
High–Pressure Hose Fitting2821–
Power Steering Pump Bolts2518–
Right Side Power Steering Pump Bracket Bolts3526–

6B – 2IPOWER STEERING PUMP
DAEWOO V–121 BL4
DIAGNOSIS
POWER STEERING PUMP DIAGNOSIS
Foaming or Milky Power Steering Fluid (Air in Fluid)
ChecksAction
Check for internal leakage in the power steering pump,
causing an overflow.Repair the internal pump leakage.
Bleed the system.
Check for a low fluid level.Repair the internal pump leakage.
Bleed the system.
Cold temperatures will cause the air bubbles in the system
if the fluid level is low.
Low Pressure Due to Power Steering Pump
ChecksAction
Check for an external leakage of the power steering pump
at the seals.Replace the seals.
Repair the leak.
Bleed the system.
Check for a worn serpentine accessory drive belt.Replace the serpentine accessory drive belt.
Low Pressure Due to Power Steering Gear
ChecksAction
Check for a scored housing bore.Replace the housing bore.
Check for leakage at the valve rings or the seals.Repair the leak.
Bleed the system.
Groaning Noise in the Power Steering Pump
ChecksAction
Check for air in the power steering fluid.Perform the checks listed in ”Foaming or Milky Power
Steering Fluid (Air in Fluid)” above.
Check for a low level of power steering fluid.Repair any internal or external leaks.
Bleed the system.
Check for a loose mounting of the power steering pump.Tighten the pump mounting to specifications.

POWER STEERING PUMP 6B – 3
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
SERPENTINE ACCESSORY DRIVE
BELT
Removal Procedure
1. Remove the air filter housing assembly bolts and
the air intake tube.
2. Remove the air filter housing assembly from the
vehicle.
3. Use a wrench to turn the tensioner bolt clockwise,
compressing the tensioner, and releasing the ten-
sion on the serpentine accessory drive belt.
4. Remove the serpentine accessory drive belt.

6B – 4IPOWER STEERING PUMP
DAEWOO V–121 BL4
Installation Procedure
1. Use a wrench to turn the tensioner bolt clockwise,
compressing the tensioner, and releasing the ten-
sion on the serpentine accessory drive belt.
2. With the wrench in place on the tensioner bolt, loop
the serpentine accessory drive belt loosely over the
pulleys.
3. Slip the belt over the tensioner.
4. Remove the wrench from the tensioner bolt and the
belt will tighten itself.
5. Install the air filter housing assembly into the ve-
hicle.
6. Install the air intake tube and the air filter housing
assembly bolts.
Tighten
Tighten the air filter housing assembly bolts to 6 NSm
(53 lb–in).
PUMP ASSEMBLY
Removal Procedure
1. Remove the serpentine accessory drive belt. Refer
to ”Serpentine Accessory Drive Belt” in this sec-
tion.
2. Disconnect the electrical connector at the Electronc
Vaariable Orifice (EVO) solenoid actuator.

6B – 6IPOWER STEERING PUMP
DAEWOO V–121 BL4
3. Connect the supply hose to the power steering
pump.
4. Connect the high–pressure hose fitting to the power
steering pump.
Tighten
Tighten the high–pressure hose fitting to 28 NSm (21
lb–ft).
5. Connect the electrical connector at the Electronic
Variable Orifice (EVO) solenoid actuator.
6. Install the serpentine accessory drive belt. Refer to
”Serpentine Accessory Drive Belt” in this section.
7. Refill the power steering fluid. Refer to Section 6A,
Power Steering System.
8. Bleed the power steering system. Refer to Section
6A, Power Steering System.

6B – 8IPOWER STEERING PUMP
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
POWER STEERING PUMP
The power steering pump is a multivaned hydraulic pump.
The serpentine accessory drive belt on the engine drives
the power steering pump.The power steering pump provides the hydraulic pressure
to the power steering gear.
The power steering gear uses the hydraulic pressure to
assist in steering the vehicle.
The power steering system uses a remote reservoir in or-
der to make available more space in the engine compart-
ment.

6C – 18IPOWER STEERING GEAR
DAEWOO V–121 BL4
3. Turn the steering wheel so that the upper pinch bolt
is accessible. Remove the upper pinch bolt from
the universal joint on the intermediate shaft.
4. Remove the nuts from the dash seal retaining ring
and remove the dash seal retaining ring.
5. Remove the coupling from the power steering gear
and pull the intermediate shaft out of the engine
compartment.
Installation Procedure
1. Install the intermediate shaft into the vehicle.