brake rotor DAEWOO LACETTI 2004 Service Repair Manual

GENERAL INFORMATION 0B – 13
DAEWOO V–121 BL4
EACH TIME THE OIL IS CHANGED
Automatic Transaxle Fluid
Refer to fluid level service procedure of Section 5A, ZF
4HP16 Automatic Transaxle.
Manual Transaxle
Check the fluid level and add fluid as required. Refer to
Section 5B, Five–Speed Manual Transaxle.
Brake System Inspection
This inspection should be done when the wheels are re-
moved for rotation. Inspect the lines and the hoses for
proper hookup, binding, leaks, cracks, chafing, etc. In-
spect the disc brake pads for wear. Inspect the rotors for
surface condition. Also inspect the drum brake linings for
wear and cracks. Inspect other brake parts, including the
drums, the wheels cylinders, the parking brake, etc., at the
same time. Check the parking brake adjustment. Inspect
the brakes more often if habit or conditions result in fre-
quent braking.
Steering, Suspension and Front Drive Axle
Boot And Seal Inspection
Inspect the front and rear suspension and the steering
system for damaged, loose or missing parts, signs of wear
or lack of lubrication. Inspect the power steering lines and
the hoses for proper hookup, binding, leaks, cracks, chaf-
ing, etc. Clean and inspect the drive axle boot and seals
for damage, tears or leakage. Replace the seals if neces-
sary.
Exhaust System Inspection
Inspect the complete system (including the catalytic con-
verter if equipped). Inspect the body near the exhaust sys-
tem. Look for broken, damaged, missing, or out–of–posi-
tion parts as well as open seams, holes, loose
connections, or other conditions which could cause heat
buildup in the floor pan or could let exhaust fumes seep
into the trunk or passenger compartment.
Throttle Linkage Inspection
Inspect the throttle linkage for interference or binding,
damaged, or missing parts. Lubricate all linkage joints and
throttle cable joints, the intermediate throttle shaft bearing,
the return spring at throttle valve assembly, and the accel-
erator pedal sliding face with suitable grease. Check the
throttle cable for free movements.
Engine Drive Belts
Inspect all belts for cracks, fraying, wear and proper ten-
sion. Adjust or replace the belts as needed.
Hood Latch Operation
When opening the hood, note the operation of the secon-
dary latch. It should keep the hood from opening all the
way when the primary latch is released. The hood must
close firmly.
AT LEAST ANNUALLY
Lap and Shoulder Belts Condition and
Operation
Inspect the belt system including: the webbing, the
buckles, the latch plates, the retractor, the guide loops and
the anchors.
Movable Head Restraint Operation
On vehicles with movable head restraints, the restraints
must stay in the desired position.
Spare Tire and Jack Storage
Be alert to rattles in the rear of the vehicle. The spare tire,
all the jacking equipment, and the tools must be securely
stowed at all times. Oil the jack ratchet or the screw mech-
anism after each use.
Key Lock Service
Lubricate the key lock cylinder.
Body Lubrication Service
Lubricate all the body door hinges including the hood, the
fuel door, the rear compartment hinges and the latches,
the glove box and the console doors, and any folding seat
hardware.
Transaxle Neutral Switch Operation on
Automatic Transaxle
CAUTION : Take the following precautions because
the vehicle could move without warning and possibly
cause personal injury or property damage:
S Firmly apply the parking brake and the regular
brakes.
S Do not use the accelerator pedal.
S Be ready to promptly turn off the ignition if the ve-
hicle starts.
On automatic transaxle vehicles, try to start the engine in
each gear. The starter should crank only in P (Park) or N
(Neutral).
Parking Brake and Transaxle P (Park)
Mechanism Operation
CAUTION : In order to reduce the risk of personal in-
jury or property damage, be prepared to apply the reg-
ular brakes promptly if the vehicle begins to move.
Park on a fairly steep hill with enough room for movement
in the downhill direction. To check the parking brake, with
the engine running and the transaxle in N (Neutral), slowly
remove foot pressure from the regular brake pedal (until
only the parking brake is holding the vehicle).
To check the automatic transaxle P (Park) mechanism’s
holding ability, release all brakes after shifting the trans-
axle to P (Park).
Underbody Flushing
Flushing the underbody will remove any corrosive materi-
als used for ice and snow removal and dust control. At
least every spring clean the underbody. First, loosen the
sediment packed in closed areas of the vehicle. Then flush
the underbody with plain water.

2A – 2ISUSPENSION DIAGNOSIS
DAEWOO V–121 BL4
Abnormal or Excessive Tire Wear
ChecksAction
Check the front–wheel and the rear–wheel alignment.Align the front and the rear wheels.
Inspect for excessive toe on the front and the rear wheels.Adjust the toe on the front and the rear wheels.
Inspect for a broken or a sagging spring.Replace the spring.
Inspect for out–of–balance tires.Balance the tires.
Inspect for worn strut dampeners.Replace the strut dampeners.
Check for a failure to rotate tires.Rotate the tires. Replace the tires as needed.
Check for an overloaded vehicle.Maintain the proper load weight.
Inspect for low tire inflation.Inflate the tires to the proper pressure.
Scuffed Tires
ChecksAction
Inspect for incorrect toe on the front and the rear wheels.Adjust the toe on the front and the rear wheels.
Inspect for a twisted or a bent suspension arm.Replace the suspension arm.
Wheel Tramp
ChecksAction
Inspect for an out–of–balance tire or wheel.Balance the tire or the wheel.
Inspect for improper strut dampener action.Replace the strut dampeners.
Shimmy, Shake, or Vibration
ChecksAction
Inspect for an out–of–balance tire or wheel.Balance the tire or the wheel.
Inspect for excessive wheel hub runout.Measure the hub flange runout. Replace the hub as need-
ed.
Inspect for excessive brake drum or brake rotor imbal-
ance.Adjust the brakes. Replace the brake rotor or the brake
drum as needed.
Inspect for worn tie rod ends.Replace the outer tie rods.
Inspect for wheel trim imbalance.Balance the wheel.
Inspect for a worn lower ball joint.Replace the lower ball joint.
Inspect for excessive wheel runout.Measure the wheel runout. Replace the wheel as needed.
Inspect for excessive loaded radial runout on the tire and
wheel assembly.Match–mount the tire and wheel assembly.
Hard Steering
ChecksAction
Check the steering gear preload adjustment.Perform a rack bearing preload adjustment.
Check the hydraulic system. Test the power steering sys-
tem pressure with a gauge.Replace the seals and the hoses as needed.
Inspect for binding or catching in the steering gear.Lubricate the steering gear. Repair or replace the steering
gear as needed.
Inspect for a loose steering gear mounting.Tighten the steering gear mounting bracket nuts.

2A – 6ISUSPENSION DIAGNOSIS
DAEWOO V–121 BL4
S A high front trim height. This height would increase
the drive axle angle and could cause wobble at
speeds between 24 to 48 km/h (15 to 30 mph).
S Binding or a tight drive axle joint. A tight drive axle
joint or a high front trim height may also cause a
wobble at speeds between 24 to 48 km/h (15 to 30
mph).
S Incorrect, worn, or loose engine mounts causing
adverse drive angles.
Refer to ”General Diagnosis” in this section for actions to
remedy these problems.
Conditions that may produce an effect similar to torque
steer include:
S Incorrect front or rear alignment.
S Frame misalignment or defect.
S Front suspension damage.
S Incorrectly mounted rear crossmember.
TAPERED ROLLER BEARING
Perform the following test to check for looseness in the
hub and bearing assembly on vehicles equipped with rear
disc brakes:
1. Raise and suitably support the vehicle.
2. Remove the rear wheel. Refer to Section 2E, Tires
and Wheels.
3. Remove the brake disc caliper and the brake rotor.
Refer to Section 4E1, Rear Disc Brakes.4. Mount a dial indicator set with a magnetic base to a
control arm or any other stationary part of the ve-
hicle.
5. Push and pull the wheel hub by hand. If the wheel
hub movement exceeds 0.05 mm (0.002 inch), re-
place the wheel bearing. Refer to Section 2D, Rear
Suspension.
6. Install the brake disc caliper and the brake rotor.
Refer to Section 4E1, Rear Disc Brakes.
7. Install the rear wheel. Refer to Section 2E, Tires
and Wheels.
8. Lower the vehicle.

WHEEL ALIGNMENT 2B – 5
DAEWOO V–121 BL4
VIBRATION DIAGNOSIS
Wheel imbalance causes most highway speed vibration
problems. A vibration can remain after dynamic balancing
because:
S A tire is out of round.
S A rim is out of round.
S A tire stiffness variation exists.
Measuring tire and wheel free runout will uncover only part
of the problem. All three causes, known as loaded radial
runout, must be checked using method of substituting
known good tire and wheel assemblies on the problem ve-
hicle.
Low–speed vibrations, which occur below 64 km/h (40
mph), are usually caused by runout. High–speed vibra-
tions, which occur above 64 km/h (40 mph), can be caused
by either imbalance or runout.
Preliminary Checks
Prior to performing any work, always road test the car and
perform a careful visual inspection for:
S Obvious tire and wheel runout.
S Obvious drive axle runout.
S Improper tire inflation.
S Incorrect trim height.
S Bent or damaged wheels.
S Debris build–up on the tire or the wheel.
S Irregular or excessive tire wear.
S Improper tire bead seating on the rim.
S Imperfections in the tires, including: tread deforma-
tions, separations, or bulges from impact damage.
Slight sidewall indentations are normal and will not
affect ride quality.
Tire Balancing
Balance is the easiest procedure to perform and should be
done first if the vibration occurs at high speeds. Do an off–
vehicle, two–plane dynamic balance first to correct any im-
balance in the tire and wheel assembly.
An on–vehicle finish balance will correct any brake drum,
rotor, or wheel cover imbalance. If balancing does not cor-
rect the high–speed vibration, or if the vibration occurs at
low speeds, runout is the probable cause.
Runout
Runout can be caused by the tire, the wheel, or the way
the wheel is attached to the vehicle. To investigate the pos-
sibility of wheel runout, refer to the following procedures
as well as the wheel runout diagnosis chart in this section:
1. If runout is suspected, measure the on–vehicle free
lateral and free radial runout of the tire and wheel
assembly. Refer to Section 2E, Tires and Wheels.
Both the free lateral and the free radial runout
should be less than 1.5 mm (0.06 inch). If either
measurement exceeds this number, proceed to
Step 2.
2. Mount the tire and the wheel on a dynamic balanc-
ing machine and remeasure the free lateral and the
free radial runout. Record the amount of the free
lateral and the free radial runout and the location of
the highest measurement. Refer to Section 2E,
Tires and Wheels. If the free radial or the free later-
al runout exceeds 1.3 mm (0.05 inch) at the tire
tread, proceed to Step 4.
3. Measure the wheel runout. Refer to Section 2E,
Tires and Wheels. If the wheel exceeds specifica-
tions, replace it.
4. Deflate the tire and match–mount the high radial
runout point of the tire to the low radial runout point
of the wheel. Reinflate the tire and mount it on the
dynamic balancing machine. Measure and record
the free radial and the free lateral runout and their
locations. In many cases, match mounting the tire
on the wheel will bring the tire and wheel assem-
bly’s free runout into an acceptable range of 1.3
mm (0.05 inch) or less.
5. If the free runout of the tire and wheel assembly is
1.3 mm (0.05 inch) or less when it was measured
off the vehicle, yet exceeds 1.3 mm (0.05 inch)
when measured on the vehicle, the attachment of
the tire and wheel assembly to the hub is the prob-
able cause of the vibration. Rotate the assembly’s
two wheel studs and recheck the runout. Refer
toSection 2E, Tires and Wheels. Several positions
may have to be tried to find the best location for the
studs.
6. If the tire and wheel assembly free runout cannot
be reduced to 1.3 mm (0.05 inch) or less, remove
the assembly.
1) Measure the wheel stud runout using a dial
indicator set with a magnetic base.
2) Zero the dial indicator set button on one stud.
3) Gently lift the set button off the stud. Rotate
the flange to position the next stud against the
dial indicator set.
4) Record the runout of all the studs. The dial in-
dicator should read zero when it is repositioned
on the first stud that was checked.
5) If the runout exceeds 0.76 mm (0.03 inch), the
hub or the hub and bearing assembly should
be replaced.

FRONT SUSPENSION 2C – 11
DAEWOO V–121 BL4
4. Remove the brake caliper from the rotor. Support
the caliper so it does not hang from the hydraulic
brake hose. Refer to Section 4D, Front Disc
Brakes.
5. Remove the outer tie rod from the knuckle assem-
bly. Refer to Section 6C, Power Steering Gear.
6. On vehicles equipped with the antilock braking sys-
tem (ABS), disconnect the ABS speed sensor elec-
trical connection from the knuckle.
7. Remove the ball joint pinch bolt and the nut.
8. Separate the knuckle from the ball joint using the
ball joint remover KM–507–B.
9. Remove the nuts from the bolts that connect the
knuckle assembly to the strut assembly.

FRONT SUSPENSION 2C – 13
DAEWOO V–121 BL4
7. Connect the outer tie rod to the knuckle assembly.
Refer to Section 6C, Power Steering Gear.
8. Install the brake caliper onto the rotor. Refer to
Section 4D, Front Disc Brakes.
9. Install the caulking nut onto the axle shaft.
Tighten
Tighten the drive axle–to–hub caulking nut to 150
NSm (111 lb–ft). Loosen the nut, then retighten it to
275 NSm (126 lb–ft).
10. Install the wheel. Refer to Section 2E, Tires and
Wheels.
11. Lower the vehicle.
HUB AND BEARING
Tools Required
500–20 Hex Nut
J–36661–2 Forcing Screw
J–37105–B–1 Support Bridge
J–37105–B–2 Bearing Adapter
J–377105–B–3 Hub Adapter
Removal Procedure
1. Remove the drive axle from the front wheel hub.
Refer to ”Knuckle Assembly” in this section.
2. Remove the inner snap ring.
3. Remove the wheel hub with the support bridge
J–37105–B–1, the hub adapter J–377105–B–3, the
hex nut 500–20, and the forcing screw J–36661–2.
4. Remove the brake shield. Refer to Section 4D,
Front Disc Brakes.
5. Remove the outer snap ring.

FRONT SUSPENSION 2C – 23
DAEWOO V–121 BL4
Important : Record the position of the front spring locator
relative to the strut assembly–to–knuckle bracket. Place
the front spring locator back in the same position during
assembly.
5. Remove the upper strut mount, the mount bearing,
the upper spring seat, the upper ring insulator, and
the hollow bumper.
6. Release the spring.
7. Remove the spring and the lower ring insulator.
Assembly Procedure
1. Install the lower ring insulator and the spring.
2. Compress the spring using the spring compressor
KM–329–A.
3. Install the hollow bumper, the upper ring insulator,
the front spring locator, the upper spring seat, the
upper strut mount, and the mount bearing. Be sure
the upper spring seat is clipped to the front spring
locator.
4. Install the piston rod nut.
Tighten
Tighten the piston rod nut to 75 NSm (55 lb–ft).
5. Release the spring compresser KM–329–A
KNUCKLE
Disassembly Procedure
1. Remove the knuckle assembly from the vehicle.
Refer to ”Knuckle Assembly” in this section.
2. Remove the rotor. Refer to Section 4D, Front Disc
Brakes.
3. Remove the hub and bearing assembly. Refer to
”Hub and Bearing” in this section.
4. Remove the brake splash shield. Refer to Section
4D, Front Disc Brakes.

2C – 24IFRONT SUSPENSION
DAEWOO V–121 BL4
Assembly Procedure
1. Install the brake splash shield. Refer to Section 4D,
Front Disc Brakes.
2. Install the hub and bearing assembly. Refer to ”Hub
and Bearing” in this section.
3. Install the rotor. Refer to Section 4D, Front Disc
Brakes.
4. Install the knuckle assembly onto the vehicle. Refer
to ”Knuckle Assembly” in this section.

2D – 18IREAR SUSPENSION
DAEWOO V–121 BL4
5. Install the lock nut onto the strut dampener rod.
Tighten
Tighten the ball joint–to–control arm nuts to 100 NSm
(74 lb–ft). Tighten the strut dampener–to–strut mount
nut to 75 NSm (55 lb–ft).
6. Release the spring.
7. Remove the strut assembly from the spring com-
pressor and install the strut assembly into the ve-
hicle. Refer to ”Strut Assembly” in this section.
KNUCKLE
Disassembly Procedure
1. Remove the knuckle from the vehicle. Refer to
”Knuckle Assembly” in this section.
2. Remove the brake drum. Refer to Section 4E2,
Rear Drum Brakes.
3. Remove the wheel hub. Refer to ”Hub and Bearing
Assembly” in this section.
4. On vehicles equipped with rear drum brakes, re-
move the rear drum brake assembly. On vehicles
equipped with rear disc brakes, remove the rear
disc brake assembly. Refer to Section 4E1, Rear
Disc Brakes.
5. Remove the brake splash shield. Refer to Section
4E2, Rear Drum Brakes.
Assembly Procedure
1. Install the brake splash shield. Refer to Section
4E1, Rear Disc Brakes.
2. On vehicles equipped with rear drum brakes, install
the rear drum brake assembly. On vehicles
equipped with rear disc brakes, install the rear disc
brake assembly. Refer to Section 4E1, Rear Disc
Brakes.
3. Install the wheel hub. Refer to ”Hub and Bearing
Assembly” in this section.
4. Install the brake caliper and brake rotor or the
brake drum. Refer to Section 4E1, Rear Disc
Brakes and 4E2, Rear Drum Brakes.
5. Install the knuckle into the vehicle. Refer to
”Knuckle Assembly” in this section.

TIRES AND WHEELS 2E – 3
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
WHEEL
Removal Procedure
1. Loosen the wheel bolts.
2. Raise and suitably support the vehicle.
3. Remove the wheel bolts.
Notice : Never use heat to loosen a tight wheel. It can
shorten the life of the wheel, the wheel nuts and the wheel
bearings. Excessive force, such as hammering the wheel
or tire, can also cause damage and is not recommended.
Slight tapping of the wheel sidewall with one’s hand or with
a rubber mallet is acceptable.
4. Remove the wheel.
Difficulty in removing the wheels from the vehicle can be
due to foreign material or to a tight fit between the wheel
centerhole and the hub or the rotor. These wheels can be
removed by
5. Retightening the wheel bolts on the affected wheel
and then loosening the wheel bolts by two turns.
6. Lowering the vehicle and rocking it from side to side
as hard as possible, using one or more person’s
body weight to loosen the wheel.
7. Raising the vehicle and removing the wheel.
CAUTION : Do not allow the penetrating oil to get on
the vertical surfaces between the wheel and the drum
(or rotor) because penetrating oil in this area could
cause the wheel to work loose as the vehicle is driven,
resulting in loss of control and an injury accident.
Penetrating oil is not effective in removing tight wheels. If
it is used, however, apply it sparingly and only to the
wheel’s centerhole area.
Installation Procedure
Notice : Before installing the wheels, remove any buildup
of corrosion on the wheel mounting surface and the brake
drum or the rotor mounting surface by scraping and brush-
ing them with a wire brush. Installing the wheels without
good metal–to–metal contact at the mounting surfaces
can cause the wheel nuts to loosen, which can later allow
a wheel to come off while the vehicle is moving. Wheel
bolts must be tightened in sequence and to the proper
torque to avoid bending the wheel, the brake drum or the
rotor.
1. Mount the wheel.
2. Install the wheel bolts in the sequence shown. Do
not tighten the wheel bolts.
3. Lower the vehicle.
Tighten
Tighten the wheel bolts to 100 NSm (74 lb–ft).