Section 5 DAEWOO LACETTI 2004 Service Repair Manual

5B – 62IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
31. Bolt the gearshift lever cover to the fixture KM–552.
32. Position the fixture into the base KM–113–2.
33. Install the gearshift rod, the shift finger lever, and
the gearshift lever pin.
34. Install the snap ring, the bushing, the spring, and
the intermediate lever.
35. Remove the gearshift lever cover from the base
KM–113–2 and the fixture KM–552.
36. Shift the transaxle into NEUTRAL.
37. Install the gearshift lever cover and the gearshift
lever cover bolts.
Tighten
Tighten the gearshift lever cover bolts to 22 NSm (16
lb–ft).
38. Install the transaxle cover and the transaxle cover
bolts.
Tighten
Tighten the transaxle cover bolts to 18 NSm (13 lb–ft).
39. Install the transaxle into the vehicle. Refer to
”Transaxle Assembly” in this section.

SECTION : 5C
CLUTCH
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
SPECIFICATIONS5C–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 5C–1. . . . . . . . . . .
SPECIAL TOOLS5C–2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 5C–2. . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS5C–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Operation 5C–2. . . . . . . . . . . . . . . . . . . . . . . . . .
COMPONENT LOCATOR5C–4 . . . . . . . . . . . . . . . . . . . .
Clutch Components 5C–4. . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR5C–6 . . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 5C–6. . . . . . . . . . . . . . . . . . . . .
Clutch Pedal 5C–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Pedal Adjustment 5C–7. . . . . . . . . . . . . . . . . . . .
Clutch Release Point Adjustment 5C–8. . . . . . . . . . . .
Air Bleeding 5C–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Plate and Clutch Disc 5C–8. . . . . . . . . . . . . .
Clutch Master Cylinder Assembly 5C–10. . . . . . . . . . .
Concentric Slave Cylinder 5C–12. . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION5C–14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Driving Members 5C–14. . . . . . . . . . . . . . . . . . . . . . . . .
Driven Members 5C–14. . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Members 5C–14. . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Clutch Master Cylinder nuts2216–
Concentric Slave Cylinder Retaining Bolts7–62
Concentric Slave Cylinder–to–Clutch Oil Pipe Screw1511–
Pressure Plate–to–Flywheel Bolts1511–

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.

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.

SECTION : 6A
POWER STEERING SYSTEM
TABLE OF CONTENTS
SPECIFICATIONS6A–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 6A–1. . . . . . . . . . .
SPECIAL TOOLS6A–1 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 6A–1. . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS6A–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Steering System Pressure Test 6A–2. . . . . . . .
Power Steering System Leak Test 6A–2. . . . . . . . . . .
MAINTENANCE AND REPAIR6A–3 . . . . . . . . . . . . . . . ON–VEHICLE SERVICE 6A–3. . . . . . . . . . . . . . . . . . . . .
Bleeding the Power Steering System 6A–3. . . . . . . . .
Checking and Adding Fluid 6A–3. . . . . . . . . . . . . . . . . .
Fluid Reservoir 6A–4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hoses and Pipes 6A–4. . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION6A–8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Steering System 6A–8. . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Power Steering Pump Pressure Line Fitting2821–
Return Line Clip Bolts8–71
Steering Gear Inlet and Outlet Pipe Fittings2821–
SPECIAL TOOLS
SPECIAL TOOLS TABLE
KM–354–B
Pressure Test
Gauge Kit

6A – 2IPOWER STEERING SYSTEM
DAEWOO V–121 BL4
DIAGNOSIS
POWER STEERING SYSTEM
PRESSURE TEST
Tools Required
KM–354–B Pressure Test Gauge Kit
Check the fluid pressure as follows to determine whether
the trouble is in the pump or the gear unit.
Test Procedure
1. Check the power steering fluid level and the power
steering pump belt tension. Refer to ”Checking and
Adding Fluid” in this section and Section 6B, Power
Steering Pump.
2. Disconnect the high pressure line at the pump. Use
a small container to catch any fluid.
3. Connect the hose of the pressure test gauge kit
KM–354–B to the power steering pressure hose
from the power steering pump.
4. Place the gear selector lever in PARK (automatic
transaxle–equipped vehicles) or NEUTRAL (manual
transaxle–equipped vehicles). Set the parking
brake.
5. Open the gauge valve fully.
6. Start the engine and let it idle.
7. Turn the steering wheel from lock to lock several
times to warm the fluid to operating temperature.
8. Increase the engine speed to 1,500 rpm.
Notice : The power steering pump could be damaged if
the valve is fully closed for more than 5 seconds.
9. Close the gauge valve fully, and read the pressure.
The pump pressure with the valve closed should be
between 8,330 kPa to 8,820 kPa (1,208 psi to
1,279 psi). With electronic variable orifice, the pres-
sure should be between 8,500 kPa to 8,960 kPa
(1,233 psi to 1,299 psi).
10. Immediately open the gauge valve fully.
11. Turn the steering wheel all the way to the left and
the right. If the pressure is within the specified lim-
its, the problem is not in the pump. Check the pow-
er steering gear for leaks.
POWER STEERING SYSTEM LEAK
TEST
General Procedure
Inspect the following:
S The fluid reservoir for overfill.
S Fluid for aeration and overflow.
S The hoses for loose connections.
S The torsion bar, stub shaft and adjuster seals for
leaks.
S The component sealing surfaces for damage.
Important : Verify the exact point of the leak. The point
from which the fluid is dripping is not necessarily the point
at which the system is leaking. When service is required,
clean the leak area upon disassembly, replace the leaking
seal, check the component sealing surfaces for damage
and reset the torque bolt to specifications, where required.
External Leak Check
The purpose of this procedure is to pinpoint the location of
the leak. In some cases, the leak can be easily located, but
seepage–type leaks may be harder to find. To locate seep-
age leaks, use the following method:
1. With the engine off, wipe dry the complete power
steering system.
2. Check the power steering fluid level in the pump’s
reservoir. Adjust the fluid level as necessary. Refer
to ”Checking and Adding Fluid” in this section.
Notice : Do not hold the steering wheel at a stop for any
length of time as this can damage the power steering
pump.
3. Start the engine. Turn the steering wheel counter-
clockwise and clockwise from stop to stop several
times.
4. Find the exact area of the leak and repair it.

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 – 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.

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