Transaxle DAEWOO LACETTI 2004 Service Manual Online

3B – 8IMANUAL TRANSAXLE DRIVE AXLE
DAEWOO V–121 BL4
UNIT REPAIR
OUTER JOINT SEAL
Tools Required
J–8059 Snap Ring Pliers
J–35566 Seal Clamp Pliers
Removal Procedure
1. Remove the drive axle from the vehicle. Refer to
”Drive Axle Assembly” in this section.
2. Remove the large seal retaining clamp. Discard the
clamp.
3. Remove the small seal retaining clamp. Discard the
clamp.
4. Degrease the joint.
5. Spread the snap ring using the snap ring pliers
J–8059 and remove the outer joint the axle shaft.
CAUTION : Do not remove the axle shaft from the out-
er joint assembly or disassemble the outer joint as-
sembly. Parts are match fit and cannot be serviced se-
parately.Improper reassembly will adversely affect
both performance and safety.
6. Remove the seal from the joint assembly.
Installation Procedure
1. Install the seal onto the axle shaft.
2. Spread the snap ring using the snap ring pliers
J–8059 and remove the outer joint the axle shaft.
3. Fill the joint seal with 110 to 130 g (3.9 to 4.6
ounces) of the recommended grease. Repack the
joint with 110 to 130 g (3.9 to 4.6 ounces) of the
recommended grease.
S 1.8 DOHC : 120 to 140g (4.2 to 4.9 ounces)
4. Install a new large seal retaining clamp and a new
small seal retaining clamp.
5. Crimp the new small seal retaining clamp and the
new large seal retaining clamp using the seal clamp
pliers J–35566.
6. Install the drive axle shaft to the vehicle. Refer to
”Drive Axle Assembly” in this section.

MANUAL TRANSAXLE DRIVE AXLE 3B – 9
DAEWOO V–121 BL4
INNER TRIPOT SEAL
Tools Required
J–35566 Snap Ring Pliers
J–8059 Snap Ring Pliers
Removal Procedure
1. Remove the drive axle from the vehicle. Refer to
”Drive Axle” in this section.
2. Remove the large seal retaining clamp. Discard the
clamp.
3. Remove the small seal retaining clamp. Discard the
clamp.
4. Separate the joint housing from the boot.
5. Degrease the tripot assembly.
6. Remove the shaft retaining ring using the snap ring
pliers J–8059.
7. Remove the tripot and the tripot joint retaining ring
from the axle shaft.
8. Remove the tripot joint seal from the axle shaft.

3B – 10IMANUAL TRANSAXLE DRIVE AXLE
DAEWOO V–121 BL4
Installation Procedure
Tools Required
J–8059 Snap Ring Pliers
J–35566 Seal Clamp Pliers
1. Install a new small seal retaining clamp onto the
seal.
2. Install the seal onto the axle shaft.
3. Install the shaft retaining ring onto the axle shaft
using the snap ring pliers J–8059.
4. Fill the tripot housing with 195 to 215 g (6.9 to 7.6
ounces) of the recommended grease. Repack the
tripot with 195 to 215 g (6.9 to 7.6 ounces) of the
recommended grease.
5. Install the boot to the joint housing.
6. Install a new large seal retaining clamp. Crimp the
large seal retaining clamp using the seal clamp pli-
ers J–35566.
7. Crimp the new small seal retaining clamp using the
seal clamp pliers J–35566.
8. Install the drive axle shaft to the vehicle. Refer to
”Drive Axle Assembly” in this section.

MANUAL TRANSAXLE DRIVE AXLE 3B – 11
DAEWOO V–121 BL4
CROSS GROOVE JOINT SEAL
Tools Required
J–35566 Seal Clamp Pliers
J–8059 Snap Ring Pliers
Removal Procedure
1. Remove the large seal retaing clamp.Discard the
clamp.
2. Remove the small seal retaining clamp. Discard the
clamp.
3. Degrease the joint.
4. Remove the shaft retaining ring using the snap ring
pilers J–8059.
5. Remove the axle shaft from the joint assembly.
CAUTION : The ball retainer is staked in position and
must not be disassmbled. Cross groove joint internal
parts are match fit and cannot be serviced separately.
Improper reassembly will adversely affect both per-
formance and safety.
6. Remove the seal from the joint assembly.
Installation Procedure
1. Install a new small seal retaining clamp onto the
seal. Do not crimp.
2. Install the seal onto the axle shaft.
3. Install the joint assembly onto the axle shaft.

3B – 12IMANUAL TRANSAXLE DRIVE AXLE
DAEWOO V–121 BL4
4. Install the shaft retaining ring using the snap ring
pilers J–8059.
5. Fill the joint assembly with 120 to 140 g (4.2 to 4.9
ounces) of the recommended grease. Repack the
tripot with 120 to 140 g (4.2 to 4.9 ounces) of the
recommended grease.
6. Install the a new large seal retaining clamp.
7. Crimp the new large seal retaining clamp using the
seal clamp pliers J–35566.
8. Crimp the new small retaining clamp using the seal
clamp pliers J–35566.

MANUAL TRANSAXLE DRIVE AXLE 3B – 13
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
FRONT DRIVE AXLE
General Description
Drive axles are flexible shaft assemblies that transmit a
rotational force from the transaxle to the front–wheel as-
semblies. Each axle assembly consists of an innerconstant–velocity joint and an outer constant–velocity
joint connected to an axle shaft. The inner joint is com-
pletely flexible and has the ability to move in and out. The
outer joint is also flexible, but it cannot move in and out.
The drive axles use one type of outboard joint and two
types of inboard joints.

MASTER CYLINDER 4B – 3
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
MASTER CYLINDER ASSEMBLY
(Left–Hand Drive Shown, Right–Hand Drive
Similar)
Removal Procedure
1. Disconnect the electrical connector from the reser-
voir.
2. For vehicles with the ABS braking system, discon-
nect the brake lines from the master cylinder body.
3. For vehicles with the non–ABS braking system, dis-
connect the brake lines from the proportioning
valves.
4. For vehicles with the manual transaxle, disconnect
the clip to the clutch hose connection to the master
cylinder and move the clip out of the way.
5. Remove the clutch hose from the master cylinder if
equipped.
6. Plug the opening to the brake lines to prevent fluid
loss and contamination.
7. Remove the attaching nuts from the power booster.
8. Remove the master cylinder assembly.
9. Drain the brake fluid.

4B – 4IMASTER CYLINDER
DAEWOO V–121 BL4
Installation Procedure
1. Install the master cylinder assembly with the new
attaching nuts.
Tighten
Tighten the master cylinder attaching nuts to 18 NSm
(13 lb–ft).
2. For vehicles with the ABS braking system (as
shown), connect the brake lines to the cylinder
body.
3. For vehicles with the non–ABS braking system,
connect the brake lines to the proportioning valves.
Tighten
Tighten the brake lines to 16 NSm (12 lb–ft).
4. For vehicles with the manual transaxle, connect the
clip to the clutch hose connection to the master cyl-
inder reservoir if equipped.
5. Connect the electrical connector.
6. Add brake fluid.
7. Check for leaks and recheck the fluid level.
8. Bleed the brake system. Refer to Section 4A, Hy-
draulic Brakes.
BRAKE FLUID RESERVOIR
Removal Procedure
Important : Remove the reservoir only when replacing a
damaged or a leaking reservoir.
1. Disconnect the electrical connector from the reser-
voir.

MASTER CYLINDER 4B – 5
DAEWOO V–121 BL4
2. For vehicles with the manual transaxle, disconnect
the clip to the clutch hose connection to the master
cylinder, and move the clip out of the way.
3. Remove the clutch hose from the master cylinder.
4. Gently pry upwards with a screwdriver to release
the reservoir.
5. Tilt the reservoir and pull it upward in order to re-
move it.
6. Remove the reservoir seals from the master cylin-
der body.
Installation Procedure
1. Lubricate the new seals with clean brake fluid.
Install the seals into the cylinder body.
2. Install the reservoir on the master cylinder body.
3. For vehicles with the manual transaxle, connect the
clip to the clutch hose connection to the master cyl-
inder.

ELECTRICAL WIRING DIAGRAMSW5–3
4. ECM (ENGINE CONTROL MODULE) : SIRIUS D4 5–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1) BATTERY POWER SUPPLY, GROUND, EI SYSTEM & CKP SENSOR CIRCUIT 5–34. . . . . . . . . . . . . . . . . . . . .
2) FUEL PUMP, INJECTOR, FUEL CONNECTOR & CMP SENSOR CIRCUIT 5–36. . . . . . . . . . . . . . . . . . . . . . . . .
3) MTIA, SENSOR(ECT, KNOCK, IAT, MAP, ACP & HO2S) & POWER STEERING PRESSURE SWITCH
CIRCUIT : EOBD5–38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4) MTIA, SENSOR(ECT, KNOCK, IAT, MAP, ACP & O2) & POWER STEERING PRESSURE SWITCH
CIRCUIT : NON EOBD5–40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5) EEGR VALVE, VR SENSOR, CLUSTER & FUEL PUMP CIRCUIT : EOBD 5–42. . . . . . . . . . . . . . . . . . . . . . . . . .
6) EGR VALVE, CLUSTER & FUEL PUMP CIRCUIT: NON EOBD 5–44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7) EVAP CANISTER PURGE SOLENOID, VGIS, CLUSTER, VSS, TCM & RON SWITCH CIRCUIT 5–46. . . . . . .
8) DLC, MIL LAMP & IMMOBILIZER CONTROL CIRCUIT 5–48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. TCM (TRANSMISSION CONTROL MODULE) : MR–140/HV–240 5–50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1) POWER SUPPLY, GROUND, PNP SWITCH, BRAKE SWITCH & SOLENOID VALVE CIRCUIT 5–50. . . . . . . .
2) SENSOR(INPUT SPEED,OUTPUT SPEED, TRANSMISSION FLUID TEMP.), CLUSTER, DLC, ECM &
HOLD MODE SWITCH CIRCUIT5–52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3) PNP SWITCH & CLUSTER CIRCUIT 5–54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. TCM (TRANSMISSION CONTROL MODULE) : SIRIUS D4 5–56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1) POWER SUPPLY, GROUND, PNP SWITCH, CLUSTER & ECM CIRCUIT : NOTCH BACK 5–56. . . . . . . . . . . .
2) POWER SUPPLY, GROUND, PNP SWITCH, CLUSTER & ECM CIRCUIT : HATCH BACK 5–58. . . . . . . . . . . .
3) BRAKE SWITCH, BTSI SOLENOID, ISS SENSOR & TRANSAXLE CIRCUIT 5–60. . . . . . . . . . . . . . . . . . . . . . . .
4) HOLD MODE SWITCH, VSS & DLC CIRCUIT 5–62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7. AIR CONDITIONER5–64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1) AIR CONDITIONER CONTROL SWITCH, BLOWER MOTOR RESISTER & BLOWER MOTOR
CIRCUIT5–64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2) AIR CONDITIONER CONTROL, INTAKE MOTOR SWITCH & AIR CONDITIONER COMPRESSOR
CIRCUIT5–66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .