engine electrical DAEWOO LACETTI 2004 Service Service Manual

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.

ENGINE ELECTRICAL 1E – 27
DAEWOO V–121 BL4
16. Test the rotor for an open circuit using the ohmme-
ter with the drive end frame assembled. The read-
ing should be sufficiently high, or the rotor must be
replaced.
17. Test the rotor for open and short circuits. The read-
ing should be 1.7 to 2.3 ohms, or the rotor should
be replaced.
18. Remove the drive end frame from the shaft.
19. For vehicles with an internal generator fan, remove
the drive end frame and the fan.
20. Remove the rotor assembly.

1E – 28IENGINE ELECTRICAL
DAEWOO V–121 BL4
21. Remove the stator.
22. Test the stator for an open circuit using the ohmme-
ter.
23. Remove the ring in the slip ring end frame.
Assembly Procedure
1. Install the new ring in the slip ring end frame.
2. Install the stator.

ENGINE ELECTRICAL 1E – 29
DAEWOO V–121 BL4
3. Position the rotor assembly shaft with the drive end
frame in the slip ring end assembly until the gap
between the outer lace and the end frame casting
is 1.9 mm (0.075 inch).
4. Install the generator through–bolts.
Tighten
Tighten the generator through–bolts to 10 NSm (89 lb–
in).
5. Position the fan, the collars, and the pulley on the
rotor shaft and secure with the nut.
Tighten
Tighten the generator drive end bearing nut to 81 NSm
(60 lb–ft).
6. Install the generator. Refer to ”Generator”in the
On–Vehicle Service section.
7. Weld the brush holder terminal to the regulator ter-
minal, if removed.
8. Fix the brush holder with the retainer pin, and weld
the regulator/brush holder assembled terminal to
the rectifier terminal.
9. Apply silicone grease between the bridge and the
end frame for radiation purposes.
10. Fasten the screws holding the rectifier regulator/
brush holder assembly to the end frame.
11. Punch the new baffle with the pin into the brush.
Notice : Take care to prevent damage to the vehicle by
protecting the diode in the rectifier bridge from excessive
heat while welding.
12. Weld the connectors of the rectifier bridge.