DAEWOO LACETTI 2004 Service Repair Manual

ENGINE ELECTRICAL 1E – 17
DAEWOO V–121 BL4
UNIT REPAIR
STARTER MOTOR
Disassembly Procedure
1. Remove the starter. Refer to ”Starter” in this sec-
tion.
2. Remove the starter through–bolts.
3. Remove the commutator end frame and brush
holder assembly.
4. Inspect the brushes, the pop–out springs, and the
brush holders for wear and damage. Replace the
assembly, if needed.
5. Check the armature to see if it turns freely. If the
armature does not turn freely, break down the as-
sembly immediately, starting with Step 14. Other-
wise, give the armature a no–load test.
Notice : Complete the testing in a minimum amount of
time to prevent overheating and damaging the solenoid.
Important : If the specified current draw does not include
the solenoid, deduct from the armature reading the speci-
fied current draw of the solenoid hold–in winding.
6. To begin the no–load test, close the switch and
compare the rpm, the current, and the voltage read-
ings with the specifications. Refer to ”Starter Speci-
fications” in this section. Make disconnections only
with the switch open. Use the test results as fol-
lows:

1E – 18IENGINE ELECTRICAL
DAEWOO V–121 BL4
1) Rated current draw and no–load speed indicate
a normal condition for the starter motor.
2) Low rpm combined with high current draw is an
indication of excessive friction caused by tight,
dirty, or worn bearings; a bent armature shaft;
a shorted armature; or a shorted field coils.
3) Failure to operate with high current draw indi-
cates a direct ground in the terminal or fields,
or ”frozen” bearings.
4) Failure to operate with no current draw indi-
cates an open field circuit, open armature coils,
broken brush springs, worn brushes, high in-
sulation between the commutator bars, or oth-
er causes which would prevent good contact
between the brushes and the commutator.
5) Low, no–load speed and low current indicate
high internal resistance and high current draw,
which usually mean shorted fields.
7. Remove the solenoid assembly screws.
8. Remove the field connector nut. Disconnect the
field connector.

ENGINE ELECTRICAL 1E – 19
DAEWOO V–121 BL4
9. Remove the plunger return spring.
Important : If the solenoid is not removed from the starting
motor, the connector strap terminals must be removed
from the terminal on the solenoid before making these
tests.
10. Test the solenoid windings by checking the current
draw.
1) Check the hold–in windings by connecting an
ammeter in series with a 12–volt battery, the
switch terminal, and to ground.
2) Connect the carbon pile across the battery.
3) Adjust the voltage to 10 volts. The ammeter
reading should be 13 to 19 amperes.Current will
decrease as the windings heat up. Current draw
readings that are over specifications indicate
shorted turns or a ground in the windings of the
solenoid. Both conditions require replacement of
the solenoid. Current draw readings that are un-
der specifications indicate excessive resistance.
No reading indicates an open circuit.
Important : Current will decrease as the windings heat up.
Current draw readings that are over specifications indicate
shorted turns or a ground in the windings of the solenoid.
Both conditions require replacement of the solenoid. Cur-
rent draw readings that are under specifications indicate
excessive resistance. No reading indicates an open cir-
cuit.
11. Check both windings, connecting them according to
the preceding test.
1) Ground the solenoid motor terminal.
2) Adjust the voltage to 10 volts. The ammeter
reading should be 59 to 79 amperes.
3) Check the connections and replace the sole-
noid, if necessary.

1E – 20IENGINE ELECTRICAL
DAEWOO V–121 BL4
12. Slide the field frame with enclosed armature as-
sembly away from the starter assembly.
13. Remove the shield.
14. Separate the field frame from the armature.
15. Inspect the shaft and the pinion for discoloration,
damage, or wear. Replace, if necessary.
16. Inspect the armature commutator. If the commuta-
tor is rough, it should be turned down. The outside
diameter of the commutator must measure at least
26.9 – 27.1mm (1.059 – 1.067 in.) after it is under-
cut or turned. Do not turn out–of–round commuta-
tors.
17. Inspect the points where the armature conductors
join the commutator bars. Make sure they have a
good connection. A burned commutator bar is usu-
ally evidence of a poor connection.
18. If test equipment is available, check the armature
for short circuits by placing it on a growler, and
holding back a saw blade over the armature core
while the armature is rotated. If the saw blade vi-
brates, replace the armature.
19. Recheck the armature after cleaning between the
commutator bars. If the saw blade vibrates, replace
the armature.

ENGINE ELECTRICAL 1E – 21
DAEWOO V–121 BL4
20. Remove the locking ring from the groove in the dri-
veshaft.
21. Remove the pinion stop and the drive from the dri-
veshaft.
22. If not done in the previous steps, remove the
screws that hold the solenoid assembly into the
housing, and remove the nut from the field coil con-
nector.
23. Rotate the solenoid 90 degrees and remove it along
with the return spring.

1E – 22IENGINE ELECTRICAL
DAEWOO V–121 BL4
24. Remove the plunger with the boot and the shift le-
ver assembly. Test the solenoid windings, if not
done in Step 11.
Important : The pinion clearance must be correct to pre-
vent the buttons on the shift lever yoke from rubbing on the
clutch collar during the cranking.
25. When the starter motor is disassembled and the
solenoid is replaced, it is necessary to check the
pinion clearance.
26. Disconnect the motor field coil connector from the
solenoid motor terminal and carefully insulate the
connector.
27. Connect one 12–volt battery lead to the solenoid
switch terminal and the other to the starter frame.
28. Flash a jumper lead momentarily from the solenoid
motor terminal to the starter frame, allowing shifting
of the pinion in the cranking position, where it will
remain until the battery is disconnected.
Important : A means for adjusting the pinion clearance is
not provided on the starter motor. If the clearance does not
fall within the limits, check for improper installation and re-
place all worn parts.
29. Push the pinion back as far as possible to take up
any movement, and check the clearance with a
feeler gauge. The clearance should be 0.25 to 3.56
mm (0.01 to 0.14 inch).
Assembly Procedure
1. Install the drive and the pinion stop on the drive-
shaft.

ENGINE ELECTRICAL 1E – 23
DAEWOO V–121 BL4
2. Install the lock ring into the groove on the driveshaft
and insert the collar.
3. Install the shift lever, washer and the cushion.
4. Lubricate the drive end of the armature shaft with
lubricant.
5. Position the solenoid assembly.

1E – 24IENGINE ELECTRICAL
DAEWOO V–121 BL4
6. Fasten the solenoid assembly with the screws.
Tighten
Tighten the starter solenoid assembly screws to 8
NSm (71 lb–in).
7. Install the field coil connection to the starter termi-
nal. Install the nut.
Tighten
Tighten the starter field coil connector nut to 8 NSm
(71 lb–in).
8. Position the armature assembly into the field frame.
9. Place the shield on the armature and field frame
assembly.
10. Install the armature and field frame assembly with
the shield into the starter housing.
11. Position the commutator end frame/brush holder
assembly, lining up the end frame holes with the
through–bolt holes in the housing.
12. Install the starter through–bolts.
13. Install the starter. Refer to ”Starter”in this section.
Tighten
Tighten the starter through–bolts to 6 NSm (53 lb–in).

ENGINE ELECTRICAL 1E – 25
DAEWOO V–121 BL4
GENERATOR
Disassembly Procedure
1. Remove the generator. Refer to ”Generator”in the
On–Vehicle Service section.
2. Mark a match line that cannot easily be removed on
the end frame to make assembly easier.
3. Pry off the plastic cover to expose the stator con-
nections.
Notice : If the stator connections are not welded, melt the
lead. Avoid excessive heating, as it can damage the
diodes in the rectifier bridge.
4. Remove the stator connections from the rectifier
bridge terminals by cutting the wires.
5. Pry off the baffle.
6. Remove the rectifier/regulator/brush holder assem-
bly screws.
7. Remove the brush holder assembly and the regula-
tor.
Important : If the brush can be reused, reassmble the
brush to the holder with the retaining pin, after cleaning the
brush with a soft, clean cloth.
8. Test the rectifier bridge by connecting the ohmme-
ter terminals to the brdge and the heat sink.

1E – 26IENGINE ELECTRICAL
DAEWOO V–121 BL4
9. Retest by connecting the ohmmeter terminals in
reverse.
10. Replace the rectifier bridge, if each reading is the
same.
11. Test the remaining two diodes after the above pro-
cedure.
Notice : Some kinds of digital ohmmeters are not suited
for the test of the bridge diode. In this case, consult the
manufacturer regarding the test capacity.
12. Test the diodes by connecting the ohmmeter termi-
nals to the bridge terminal and the base plate. If the
reading is the same, the rectifier bridge should be
replaced.
13. Remove the generator through – bolts.
Important : The fastening torque of this nut is 81 NSm (60
lb–ft) and may not normally be unfastened using hand
strength.
14. Move to the drive end of the generator and remove
the drive end bearing nut.
15. Remove the pulley and the collars.