transaxle DAEWOO LACETTI 2004 Service Owner's Manual

1C2 – 32I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
OIL PAN
Removal Procedure
1. Disconnect the negative battery cable.
2. Drain the engine oil from the engine crankcase.
3. Remove the exhaust flex pipe retaining nuts from
the exhaust manifold.
4. Remove the exhaust flex pipe retaining nuts from
the catalytic converter or the connecting pipe.
5. Remove the exhaust flex pipe.
6. Remove the oil pan flange–to–transaxle retaining
bolts.
7. Remove the oil pan retaining bolts.
8. Remove the oil pan from the engine block.
Cleaning Procedure
1. Clean the oil pan sealing surface.
2. Clean the engine block sealing surface.
3. Clean the oil pan retaining bolts.
4. Clean the oil pan attaching bolt holes in the engine
block.
5. Clean the oil pan scraper.

1.8L DOHC ENGINE MECHANICAL 1C2 – 33
DAEWOO V–121 BL4
Installation Procedure
1. Coat the new oil pan gasket with sealant.
Important : Install the oil pan within 5 minutes after apply-
ing the liquid gasket to the oil pan.
2. Install the oil pan to the engine block.
3. Install the oil pan retaining bolts.
Tighten
Tighten the oil pan retaining bolts to 10 NSm (89 lb–in).
4. Install the oil pan flange–to–transaxle retaining
bolts.
Tighten
Tighten the oil pan flange–to–transaxle bolts to 40
NSm (30 lb–ft).
5. Install the exhaust flex pipe.
6. Install the exhaust flex pipe retaining nuts to the
exhaust manifold.
Tighten
Tighten the exhaust flex pipe–to–exhaust manifold
retaining nuts to 35 NSm (26 lb–ft).
7. Install the exhaust flex pipe retaining nuts to the
catalytic converter or the connecting pipe.
Tighten
Tighten the exhaust flex pipe–to–catalytic converter
or connecting pipe retaining nuts to 35 NSm (26 lb–ft).
8. Connect the negative battery cable.
9. Install the oil pan drain plug.
Tighten
Tighten the oil pan drain plug to 35 NSm (26 lb–ft).
10. Refill the engine crankcase with engine oil.
OIL PUMP
Tools Required
KM–498–B Pressure Gauge
KM–135 Adapter
Engine Oil Pressure Inspection Procedure
1. Remove the right front wheel well oil pan scraper.
Refer to Section 9R, Body Front End.
2. Disconnect the oil pressure switch connector.

1C2 – 48I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
40. Remove the crankshaft pulley bolts.
41. Remove the crankshaft pulley.
42. Disconnect the vacuum lines at the charcoal canis-
ter purge solenoid.
43. Disconnect the electrical connector at the charcoal
canister purge (CCP) and the exhaust gas recir-
culation (EGR) solenoid.
44. Disconnect the electrical connector at the oil pres-
sure switch.
45. Disconnect the crankshaft position sensor (CPS)
connector.
46. Disconnect the knock sensor connector.
47. Remove the transaxle torque converter bolts, if au-
tomatic transaxle equipped.
48. Remove the transaxle bell housing bolts and the oil
pan flange bolts.
49. Support the transaxle with a floor jack.
50. Install the engine lifting device.
51. Disconnect the right engine mount bracket from the
engine mount by removing the retaining bolt.
52. Remove the right engine mount bracket from the
engine block and frame mount. Refer to Section
5B, Five Speed Manual Transaxle, or Section 5A,
Automatic Transaxle.
53. Separate the engine block from the transaxle. Re-
move the engine.
Installation Procedure
1. Install the engine into the engine compartment.
2. Align the engine alignment pins to the transaxle.
3. Install the transaxle bell housing bolts.
Tighten
Tighten the transaxle bell housing bolts to 75 NSm (55
lb–ft).
4. Install the oil pan flange–to–transaxle bolts.
Tighten
Tighten the oil pan flange–to–transaxle bolts to 40
NSm (30 lb–ft).

1.8L DOHC ENGINE MECHANICAL 1C2 – 49
DAEWOO V–121 BL4
5. Install the right engine mount to the engine block
mount and the frame mount.
6. Install the right engine mount bracket retaining bolts
and nuts.
Tighten
Tighten the engine mount bracket retaining bolts and
nuts to 55 NSm (41 lb–ft).
7. Remove the floor jack used for support of the trans-
mission.
8. Remove the engine lifting device.
9. Install the transaxle torque converter bolts, if auto-
matic transaxle equipped.
Tighten
Tighten the transaxle torque converter bolts to 60
NSm (44 lb–ft).
10. Connect the vacuum lines at the CCP solenoid.
11. Connect the electrical connector to the CCP and
the EGR solenoid.
12. Connect the oil pressure switch connector.
13. Install the crankshaft pulley.
14. Install the crankshaft pulley bolts.
Tighten
Tighten the crankshaft pulley bolts to 20 NSm (15 lb–
ft) using a torque wrench.
15. Connect the CPS connector.
16. Install the exhaust flex pipe.
17. Install the exhaust flex pipe retaining nuts to the
exhaust manifold studs.
Tighten
Tighten the exhaust flex pipe–to–exhaust manifold
retaining nuts to 35 NSm (26 lb–ft).

1D – 2IENGINE COOLING
DAEWOO V–121 BL4
SPECIFICATIONS
CAPACITY
ApplicationDescription
Coolant in the Cooling System
(1.4L/1.6L DOHC MPFI System)7.0L (1.85 gal) for automatic transaxle
7.0L (1.85 gal) for manual transaxle
Coolant in the Cooling System
(1.8L DOHC MPFI System)7.1L (1.88 gal) for automatic transaxle
7.1L (1.88 gal) for manual transaxle
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Water Pump Mounting Bolts (1.4L/1.6L DOHC)10–89
Water Pump Mounting Bolts (1.8L DOHC)2518–
Fan Assembly Mounting Bolts4–35
Fan Motor Nut3.2–28
Fan Motor Retaining Screws4–35
Radiator Retaining Bolts, Upper Left and Upper Right8–71
Surge Tank Attaching Bolt5–44
Thermostat Housing Mounting Bolts (1.6L DOHC)2015–
Thermostat Housing Mounting Bolts (1.8L DOHC)1511–
SPECIAL TOOLS
SPECIAL TOOLS TABLE
KM–471
Adapter

1D – 16IENGINE COOLING
DAEWOO V–121 BL4
RADIATOR
Removal Procedure
1. Disconnect the negative battery cable.
2. Drain the engine cooling system. Refer to ”Draining
and Refilling the Cooling System” in this section.
3. Remove the main and the auxiliary cooling fans.
Refer to ”Electric Cooling Fan – Main or Auxiliary”
in this section.
4. Remove the upper radiator retaining bolt.
5. Remove the upper radiator retaining bracket.
6. Remove the upper radiator hose clamp.
7. Disconnect the upper radiator hose from the radia-
tor.
8. Remove the hose clamp from the surge tank hose
at the radiator.
9. Disconnect the surge tank hose from the radiator.
10. Remove the lower radiator hose clamp.
11. Disconnect the lower radiator hose from the radia-
tor.
12. Disconnect the transaxle cooler pipes from the low-
er radiator tank, if equipped.
13. Remove the bolt and the transaxle pipe support
clamp from the radiator.
14. Remove the radiator from the vehicle.
Important : The radiator still contains a substantial
amount of coolant. Drain the remainder of the coolant from
the radiator into a drain pan.
Installation Procedure
1. Set the radiator into place in the vehicle with the
radiator bottom posts in the rubber shock bumpers.
2. Connect the transaxle cooler pipes to the lower ra-
diator tank, if equipped.
3. Install the transaxle pipe and support clamp to the
radiator with a bolt.
4. Connect the surge tank hose to the radiator.
5. Secure the surge tank hose with a hose clamp.
6. Connect the upper radiator hose and the lower ra-
diator hose to the radiator.
7. Secure each hose with a hose clamp.
8. Position the radiator retainers in place.
9. Install the upper radiator retainer bracket.
10. Install the upper radiator retaining bolt.

1D – 18IENGINE COOLING
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
GENERAL DESCRIPTION
The cooling system maintains the engine temperature at
an efficient level during all engine operating conditions.
When the engine is cold, the cooling system cools the en-
gine slowly or not at all. This slow cooling of the engine al-
lows the engine to warm up quickly.
The cooling system includes a radiator and recovery sub-
system, cooling fans, a thermostat and housing, a coolant
pump, and a coolant pump drive belt. The timing belt
drives the coolant pump.
All components must function properly in order for the
cooling system to operate. The coolant pump draws the
coolant from the radiator. The coolant then circulates
through water jackets in the engine block, the intake man-
ifold, and the cylinder head. When the coolant reaches the
operating temperature of the thermostat, the thermostat
opens. The coolant then goes back to the radiator where
it cools.
This system directs some coolant through the hoses to the
heater core. This provides for heating and defrosting. The
surge tank is connected to the radiator to recover the cool-
ant displaced by expansion from the high temperatures.
The surge tank maintains the correct coolant level.
The cooling system for this vehicle has no radiator cap or
filler neck. The coolant is added to the cooling system
through the surge tank.
RADIATOR
This vehicle has a lightweight tube–and–fin aluminum ra-
diator. Plastic tanks are mounted on the right and the left
sides of the radiator core.
On vehicles equipped with automatic transaxles, the
transaxle fluid cooler lines run through the left radiator
tank. A radiator drain cock is on this radiator.
To drain the cooling system, open the drain cock.
SURGE TANK
The surge tank is a transparent plastic reservoir, similar to
the windshield washer reservoir.
The surge tank is connected to the radiator by a hose and
to the engine cooling system by another hose. As the ve-
hicle is driven, the engine coolant heats and expands. The
portion of the engine coolant displaced by this expansion
flows from the radiator and the engine into the surge tank.
The air trapped in the radiator and the engine is degassed
into the surge tank.When the engine stops, the engine coolant cools and con-
tracts. The displaced engine coolant is then drawn back
into the radiator and the engine. This keeps the radiator
filled with the coolant to the desired level at all times and
increases the cooling efficiency.
Maintain the coolant level between the MIN and the MAX
marks on the surge tank when the system is cold.
WATER PUMP
The belt–driven centrifugal water pump consists of an im-
peller, a drive shaft, and a belt pulley. The water pump is
mounted on the front of the transverse–mounted engine,
and is driven by the timing belt.
The impeller is supported by a completely sealed bearing.
The water pump is serviced as an assembly and, there-
fore, cannot be disassembled.
THERMOSTAT
A wax pellet–type thermostat controls the flow of the en-
gine coolant through the engine cooling system. The ther-
mostat is mounted in the thermostat housing to the front
of the cylinder head.
The thermostat stops the flow of the engine coolant from
the engine to the radiator in order to provide faster warm–
up, and to regulate the coolant temperature. The thermo-
stat remains closed while the engine coolant is cold, pre-
venting circulation of the engine coolant through the
radiator. At this point, the engine coolant is allowed to cir-
culate only throughout the heater core to warm it quickly
and evenly.
As the engine warms, the thermostat opens. This allows
the engine coolant to flow through the radiator, where the
heat is dissipated through the radiator. This opening and
closing of the thermostat permits enough engine coolant
to enter the radiator to keep the engine within proper en-
gine temperature operating limits.
The wax pellet in the thermostat is hermetically sealed in
a metal case. The wax element of the thermostat expands
when it is heated and contracts when it is cooled.
As the vehicle is driven and the engine warms, the engine
coolant temperature increases. When the engine coolant
reaches a specified temperature, the wax pellet element
in the thermostat expands and exerts pressure against the
metal case, forcing the valve open. This allows the engine
coolant to flow through the engine cooling system and cool
the engine.
As the wax pellet cools, the contraction allows a spring to
close the valve.
The thermostat begins to open at 87°C (189°F) and is fully
open at 102°C (216°F). The thermostat closes at 86°C
(187°F).

ENGINE ELECTRICAL 1E – 3
DAEWOO V–121 BL4
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Battery Cable Nuts5–44
Battery Carrier Tray Lower, Side and Upper Bolts2015–
Battery Retainer Clamp–to–Battery Rod Nuts5–44
Generator Drive End Bearing Nut8160–
Generator Lower Bracket–to–Engine Block Bolts (1.8L Engine)3727–
Generator Lower Bracket–to–Generator Nut (1.4L/1.6L Engine)2518–
Generator Through–Bolts10–89
Generator–to–Intake Manifold and Cylinder Head Support
Bracket Bolts (1.8L Engine)3727–
Generator–to–Intake Manifold Strap Bracket Bolt (1.8L Engine)2216–
Generator Upper Support Bracket Bolt (1.4L/1.6L Engine)2015–
Intake Manifold–to–Cylinder Body Strap Bracket Bolts (Over
Starter)2216–
Starter Field Connector Nut12–106
Starter Lower Mounting Stud Ground Wire Nut12–106
Starter Mounting Studs/Nuts (1.4L/1.6L Engine)2518–
Starter Solenoid Assembly Screws8–71
Starter Solenoid Terminal–to–Battery Cable Terminal Nut5.5–49
Starter Solenoid Terminal–to–Ignition Solenoid Terminal Nut5.5–49
Starter Through–Bolts6–53
Starter–to–Engine Block Mounting Bolt (1.8L Engine)4533–
Starter–to–Engine Transaxle Mounting Bolt (1.8L Engine)5037–

1E – 6IENGINE ELECTRICAL
DAEWOO V–121 BL4
DIAGNOSIS
NO CRANK
StepActionValue(s)YesNo
11. Turn the headlamps ON.
2. Turn the dome lamps ON.
3. Turn the ignition to START.
Did the lights dim or go out?–Go to Step 2Go to Step 8
2Check the battery state of charge.
Is the green eye showing from the built–in hydrome-
ter?–Go to Step 3Go to
”Charging Pro-
cedure”
31. Connect the voltmeter positive lead to the posi-
tive battery terminal.
2. Connect the voltmeter negative lead to the
negative battery terminal.
3. Turn the ignition to START.
Does the voltmeter indicate the value specified?< 9.6 vGo to
”Charging Pro-
cedure”Go to Step 4
41. Connect the voltmeter negative lead to the
negative battery terminal.
2. Connect the positive voltmeter lead to the en-
gine block.
Does the voltmeter indicate the value specified?> 0.5 vGo to Step 5Go to Step 6
5Clean, tighten, or replace the negative battery cable.
Is the repair complete?–System OK–
61. Connect the voltmeter positive lead to the start-
er ”B+” terminal.
2. Connect the voltmeter negative lead to the
negative battery terminal.
Does the voltmeter indicate the value specified?< 9 vGo to Step 7Go to Step 13
7Clean, tighten, or replace the positive battery cable.
Is the repair complete?–System OK–
8Inspect the engine fuse block fuse Ef5.
Is the fuse OK?–Go to Step 10Go to Step 9
9Inspect the engine fuse block fuse Ef4.
Is the fuse OK?–System OK–
10Check the connection at the starter ”ST” terminal.
Is the connection OK?–Go to Step 12Go to Step 11
11Clean or tighten the connection as needed.
Is the repair complete?–System OK–
121. Connect the voltmeter positive lead to the start-
er ”ST” terminal.
2. Connect the voltmeter negative lead to the
negative battery terminal.
3. Turn the ignition to START.
Does the voltmeter indicate the value specified?< 7 vGo to Step 13Go to Step 14
13Repair or replace the starter as needed.
Is the repair complete?–System OK–
14Determine the type of transaxle on the vehicle.
Is the vehicle equipped with an automatic transaxle?–Go to Step 15Go to Step 32

1E – 14IENGINE ELECTRICAL
DAEWOO V–121 BL4
10. Install the air cleaner outlet hose and connect the
MAT electrical connector.
11. Connect the negative battery cable.
STARTER
Removal Procedure
1. Remove the nut which secures the starter ground
wire to the lower mounting stud and remove the
ground wire.
2. Remove the lower starter stud/weld nut assembly
(1.4L/1.6L engine).
3. For vehicles equipped with the 1.8L engine, remove
the starter–to–engine block mounting bolt and the
starter–to–transmission mounting bolt.
4. Remove the starter solenoid nuts to disconnect the
electrical cable.
5. Remove the starter assembly.
Installation Procedure
1. Place the starter assembly in position using an as-
sistant to prop up the starter to aid in screwing in
the upper stud with the weld nut.
2. Install the upper and the lower starter mounting
bolts.
Tighten
Tighten the starter mounting studs to 23 NSm (16 lb
ft).
3. Install the starter mounting bolts (1.8L engine).
Tighten
Tighten the starter–to–engine block mounting bolt to
45 NSm (33 lb–ft) and the starter–to–engine transaxle
mounting bolt to 50 NSm (37 lb–ft).