Lamp DAEWOO LACETTI 2004 Service Repair Manual

FIVE–SPEED MANUAL TRANSAXLE 5B – 19
DAEWOO V–121 BL4
Installation Procedure
1. Coat the O–ring with petroleum jelly.
2. Install the speedometer–driven gear and the
speedometer housing.
3. Install the speedometer housing retaining bolt.
Tighten
Tighten the speedometer housing retaining bolt to 4
NSm (35 lb–in).
4. Connect the speedometer speed sensor electrical
connector.
SHIFT LINKAGE ASSEMBLY
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the rod clamp. Refer to ”Shift Linkage Ad-
justment” in this section.
3. Remove the clip and the bolt from universal joint.
4. Separate the universal joint from the transaxle.
5. Remove the fixing shaft pin and separate the link-
age connection part from the transaxle rear mount-
ing bracket.
6. Remove the shift linkage assembly.

5B – 20IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
Installation Procedure
1. Install the shift linkage assembly.
2. Install the fixing shaft pin and connect the linkage
connection part to the transaxle rear mounting
bracket.
3. Install the universal joint to the transaxle.
4. Install the clip and the bolt from universal joint.
5. Install the rod clamp. Refer to ”Shift Linkage Adjust-
ment” in this section.
6. Adjust the shift linkage. Refer to ”Shift Linkage Ad-
justment” in this section.
7. Connect the negative battery cable.
DRIVE AXLE SEAL
Tools Required
KM–519 Ring Installer
Removal Procedure
Notice : Do not damage the bearing adjusting ring with the
pry bar.
1. Remove the drive axle from the transaxle. Refer to
Section 3B, Manual Transaxle Drive Axle.
2. Remove the drive axle seal by lifting the outer lip of
the seal with a pry bar.
Installation Procedure
1. Install the new drive axle seal using the ring install-
er KM–519 and a hammer.
2. Coat the seal lip with the transaxle fluid.
3. Install the drive. Refer to Section 3B, Manual Trans-
axle Drive Axle.

FIVE–SPEED MANUAL TRANSAXLE 5B – 21
DAEWOO V–121 BL4
TRANSAXLE ASSEMBLY
Tools Required
J–28467–B Engine Support Fixture
Removal Procedure
1. Install the engine support fixture J–28467–B.
2. Remove the battery and battery tray. Refer to Sec-
tion 1E, ENGINE ELETRICAL.
3. Remove the shift linkage assembly. Refer to ”Shift
Linkage Adjustment” in this section.
4. Remove the drive axle shaft. Refer to Section 3B,
Manual Transaxle Drive Axle.
5. Disconnect the backup lamp switch electrical con-
nector.
6. Disconnect the speedometer speed sensor electri-
cal connector.
7. Remove the pin and the clutch release cylinder
pipe.
8. Remove the damping block connection nut and
bolt.
9. Remove the three rear mounting bracket bolts.
10. Remove the rear mounting bracket from the trans-
axle.

FIVE–SPEED MANUAL TRANSAXLE 5B – 25
DAEWOO V–121 BL4
11. Connect the clutch release cylinder pipe.
12. Connect the speedometer speed sensor electrical
connector.
13. Connect the backup lamp switch electrical connec-
tor.
14. Remove the engine support fixture J–28467–B.
15. Install the drive axle shaft. Refer to Section 3B,
Manual Transaxle Drive Axle.
16. Install the shift linkage assembly. Refer to ”Shift
Linkage Assembly” in this section.
17. Install the battery and battery tray. Refer to Section
1E, ENGINE ELETRICAL.
18. Inspect the fluid level. Refer to ”Checking Fluid Lev-
el” in this section.

5B – 48IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
HOUSING CASE
Disassembly Procedure
1. Remove the transaxle from the vehicle. Refer to
”Transaxle Assembly” in this section.
2. Remove the shift lever cover bolts and the shift le-
ver cover. Do not disassemble the shift lever cover.
3. Remove the transaxle cover bolts and the transaxle
cover.
4. Remove the bearing plate bolts and the bearing
plate, with the shafts attached. Do not disassemble
the shafts.
5. Remove the differential from the transaxle housing.
Do not disassemble the differential. Refer to ”Differ-
ential” in this section.
6. Remove the backup lamp switch from the transaxle
housing.

FIVE–SPEED MANUAL TRANSAXLE 5B – 49
DAEWOO V–121 BL4
7. Remove the clutch–release bearing and the clutch–
release bearing guide. Refer to Section 5C, Clutch.
8. Remove the speedometer–driven gear bolt and the
speedometer–driven gear from the transaxle hous-
ing.
Assembly Procedure
1. Install the speedometer–driven gear bolt and the
speedometer–driven gear into the transaxle hous-
ing.
Tighten
Tighten the speedometer–driven gear bolt to 5 NSm
(44 lb–in)
2. Install the clutch–release bearing guide and the
clutch–release bearing. Refer to Section 5C,
Clutch.
3. Install the backup lamp switch into the transaxle
housing.
Tighten
Tighten the backup lamp switch to 20 NSm (15 lb–ft).
4. Install the differential into the transaxle housing.
Refer to ”Differential” in this section.
5. Install the bearing plate, with the shafts attached.
6. Install the bearing plate bolts.
Tighten
Tighten the bearing plate bolts to 22 NSm (16 lb–ft).

5C – 10ICLUTCH
DAEWOO V–121 BL4
Installation Procedure
1. Coat the spline on the clutch disc with multi–pur-
pose grease.
2. Align the pressure plate and the clutch disc onto
the flywheel using the clutch arbor J–42474.
3. Install the pressure plate bolts.
Tighten
Tighten the bolts to 15 NSm (11 lb–ft).
4. Remove the clutch arbor J–42474.
5. Install the transaxle into the vehicle. Refer to Sec-
tion 5B, Five–Speed Manual Transaxle.
6. Connect the negative battery cable.
CLUTCH MASTER CYLINDER
ASSEMBLY
Removal Procedure
Before disconnecting the reservoir tank hose, remove the
clutch/brake fluid from the reservoir tank.
1. Remove the locking clip.
2. Remove the push rod fixing pin and push rod.
3. Disconnect the hose clamp on the master cylinder.
4. Disconnect the master cylinder hose.
5. Remove the master cylinder pipe.

CLUTCH 5C – 11
DAEWOO V–121 BL4
6. Remove the clutch master cylinder nuts.
7. Remove the clutch master cylinder.
Installation Procedure
1. Install the clutch master cylinder and clutch master
cylinder nuts.
Tighten
Tighten the clutch master cylinder nuts to 22 NSm (16
lb–ft).
2. Install the master cylinder pipe.
3. Connect the master cylinder hose.
4. Connect the hose clamp on the master cylinder.

6A – 4IPOWER STEERING SYSTEM
DAEWOO V–121 BL4
FLUID RESERVOIR
Removal Procedure
1. Siphon the power steering fluid from the fluid reser-
voir.
2. Loosen the hose clamps and remove both hoses
from the fluid reservoir.
3. Remove the fluid reservoir nuts.
Installation Procedure
1. Attach the fluid reservoir to the fluid reservoir brack-
et.
2. Fix the fluid reservoir with the nuts.
Tighten
Tighten the fluid reservoir nuts to 10 NSm.
3. Connect both hoses to the fluid reservoir and se-
cure the hose clamps.
Notice : When adding fluid or making a complete change,
always use DEXRON®–II or III power steering fluid. Fail-
ure to use the proper fluid will cause hose and seal dam-
age and fluid leaks.
4. Fill the fluid reservoir with power steering fluid.
5. Inspect for leaks. If there are leaks, correct the
cause of the leaks and bleed the system. Refer to
”Bleeding the Power Steering System” in this sec-
tion.
HOSES AND PIPES
Power Steering Pump Hoses and Pipes
(Left–Hand Drive Shown, Right–Hand Drive
Similar)
Removal Procedure
1. Siphon the power steering fluid from the fluid reser-
voir.
2. Disconnect the pressure line pipe and the supply
line hose from the inlet and outlet connections on
the power steering pump.

POWER STEERING GEAR 6C – 9
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
23Repair the open, short to ground, short to B+, or poor
terminal contact between terminal 14 of the SSPS
control module connector and terminal 2 of the
steering wheel rotation sensor connector.
Is the repair complete?–System OK–
241. Turn the ignition OFF.
2. Connect the SSPS control module.
3. Connect the steering wheel rotation sensor.
4. Turn the ignition ON.
5. Backprobe with a voltmeter from terminal 5 on
the control module connector to the ground.
6. Rotate the steering wheel quickly in both direc-
tions.
Does the voltage show an increase and decrease
from the specified value?
3 VGo to Step 25Go to Step 26
25Replace the SSPS control module.
Is the repair complete?–System OK–
26Replace the steering wheel rotation sensor.
Is the repair complete?–System OK–
SPEED SENSITIVE POWER STEERING SYSTEM
OPERATING WITH DECREASED ASSIST AT ALL TIMES
StepActionValue(s)YesNo
1Check the speedometer.
Is speedometer inoperative?–Go to
Section5,
TransaxleGo to Step 2
2Disconnect the EVO solenoid actuator at the power
steering pump.
Is the symptom still present?–Go to
Section 6A,
Power Steering
SystemGo to Step 3
3Replace the speed sensitive poser steering (SSPS)
control module.
Is repair complete?–System OK–
General Operation
The control module self–diagnoses SSPS system. If there
is any malfunction, the warning lamp comes ON and at the
same time a trouble code is set. The trouble code can be
retrieved or cleared only by SCANTOOL.
In normal condition, If the ignition is turned on, the warning
lamp comes on for the first 2 sec and out. During this 2 sec,
the control module is diagnosing SSPS system, so a driver
can feel a little heavy steering effort.
If the warning lamp stays on after the 2 sec or comes on
afterward, it means there is a malfunction and a related
trouble code is recorded.
The warning lamp once come on does not go off even if the
malfunction is cleared. It goes off after ignition is turned off
and on without a malfunction.However the trouble code still remains in the control mod-
ule.