five speed DAEWOO LACETTI 2004 Service Repair Manual

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TABLE OF CONTENTS
Section 0B General Information
Section 1 Engine
Section 1A General Engine Information
Section 1C1 1.4L/1.6L DOHC Engine Mechanical
Section 1C2 1.8L DOHC Engine Mechanical
Section 1D Engine Cooling
Section 1E Engine Electrical
Section 1F Engine Controls
Section 1G Engine Exhaust
Section 2 Suspension
Section 2A Suspension Diagnosis
Section 2B Wheel Alignment
Section 2C Front Suspension
Section 2D Rear Suspension
Section 2E Tires and Wheels
Section 3 Driveline/Axle
Section 3A Automatic Transaxle Drive Axle
Section 3B Manual Transaxle Drive Axle
Section 4 Brakes
Section 4A Hydraulic Brakes
Section 4B Master Cylinder
Section 4C Power Booster
Section 4D Front Disc Brakes
Section 4E1 Rear Disc Brakes
Section 4E2 Rear Drum Brakes
Section 4F Antilock Brake System
Section 4G Parking Brake
Section 5 Transmission/Transaxle
Section 5A1 ZF 4HP16 Automatic Transaxle
Section 5A2 AISIN Automatic Transaxle
Section 5B Five-Speed Manual Transaxle
Section 5C Clutch
Section 6 Steering
Section 6A Power Steering System
Section 6B Power Steering PumpSection 6C Power Steering Gear
Section 6E Steering Wheel and Column
Section 7 Heating, Ventilation, and Air
Conditioning (HVAC)
Section 7A Heating and Ventilation System
Section 7B Manual Control Heating, Ventilation,
and Air Conditioning System
Section 7D Automatic Temperature Control HVAC
Section 8 Restraints
Section 8A Seat Belts
Section 8B Supplemental Inflatable Restraints
(SIR)
Section 9 Body and Accessories
Section 9A Body Wiring System
Section 9B Lighting Systems
Section 9C Horns
Section 9D Wipers/Washer Systems
Section 9E Instrumentation/Driver Information
Section 9F Audio Systems
Section 9G Interior Trim
Section 9H Seats
Section 9I Waterleaks
Section 9J Windnoise
Section 9K Squeaks and Rattles
Section 9L Glass and Mirrors
Section 9M Exterior Trim
Section 9N Frame and Underbody
Section 9O Bumpers and Fascias
Section 9P Doors
Section 9Q Roof
Section 9R Body Front End
Section 9S Body Rear End
Section 9T1 Remote Keyless Entry and Anti–Theft
System
Section 9T2 Immobilizer Anti–Theft System

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.

1C2 – 48I1.8L DOHC ENGINE MECHANICAL
DAEWOO V–121 BL4
40. Remove the crankshaft pulley bolts.
41. Remove the crankshaft pulley.
42. Disconnect the vacuum lines at the charcoal canis-
ter purge solenoid.
43. Disconnect the electrical connector at the charcoal
canister purge (CCP) and the exhaust gas recir-
culation (EGR) solenoid.
44. Disconnect the electrical connector at the oil pres-
sure switch.
45. Disconnect the crankshaft position sensor (CPS)
connector.
46. Disconnect the knock sensor connector.
47. Remove the transaxle torque converter bolts, if au-
tomatic transaxle equipped.
48. Remove the transaxle bell housing bolts and the oil
pan flange bolts.
49. Support the transaxle with a floor jack.
50. Install the engine lifting device.
51. Disconnect the right engine mount bracket from the
engine mount by removing the retaining bolt.
52. Remove the right engine mount bracket from the
engine block and frame mount. Refer to Section
5B, Five Speed Manual Transaxle, or Section 5A,
Automatic Transaxle.
53. Separate the engine block from the transaxle. Re-
move the engine.
Installation Procedure
1. Install the engine into the engine compartment.
2. Align the engine alignment pins to the transaxle.
3. Install the transaxle bell housing bolts.
Tighten
Tighten the transaxle bell housing bolts to 75 NSm (55
lb–ft).
4. Install the oil pan flange–to–transaxle bolts.
Tighten
Tighten the oil pan flange–to–transaxle bolts to 40
NSm (30 lb–ft).

ENGINE COOLING 1D – 19
DAEWOO V–121 BL4
ELECTRIC COOLING FAN
CAUTION : Keep hands, tools, and clothing away
from the engine cooling fans to help prevent personal
injury. This fan is electric and can turn ON whether or
not the engine is running.
CAUTION : If a fan blade is bent or damaged in any
way, no attempt should be made to repair or reuse the
damaged part. A bent or damaged fan assembly
should always be replaced with a new one. Failure to
do so can result in personal injury.
The cooling fans are mounted behind the radiator in the
engine compartment. The electric cooling fans increase
the flow of air across the radiator fins and across the con-
denser on air condition (A/C)–equipped vehicles. This
helps to speed cooling when the vehicle is at idle or moving
at low speeds.
1.4L DOHC engine fan size is 340mm (13.4 in.) and
1.6L/1.8L DOHC engine main fan size is 300 mm (11.8
inches) in diameter with five blades to aid the air flow
through the radiator and the condenser. An electric motor
attached to the radiator support drives the fan.
A/C models have two fans – the main fan and the auxiliary
fan. The auxiliary fan is 300 mm (11.8 inches) in diameter.
Non–A/C models have only the main fan.
A/C OFF or Non–A/C Model (1.4L/1.6L)
S The cooling fans are actuated by the electronic
control module (ECM) using a low–speed cooling
fan relay and a high–speed cooling fan relay. On
A/C–equipped vehicles, a series/parallel cooling fan
relay is also used.
S The ECM will turn the cooling fans on at low speed
when the coolant temperature reaches 97.5°C
(207.5°F) and the cooling fans off at 95.25°C
(203.4°F).
A/C OFF or Non–A/C Model (1.8L)
S The cooling fans are actuated by the electronic
control module (ECM) using a low–speed cooling
fan relay and a high–speed cooling fan relay. On
A/C–equipped vehicles, a series/parallel cooling fan
relay is also used.
S The ECM will turn the cooling fans on at low speed
when the coolant temperature reaches 93°C
(199°F) and the cooling fans off at 90°C (194°F).
A/C ON (1.4L/1.6L)
S The ECM will turn the cooling fans on at low speed
when the A/C system is on. The ECM will change
to high speed when the coolant temperature reach-
es 101.25°C (214°F) or the high side A/C pressure
reaches 1859 kPa (270 psi).
S The cooling fans will return to low speed when the
coolant temperature reaches 99°C (210°F) and the
high side A/C pressure reaches 1449 kPa (210 psi).
A/C ON (1.8L)
S The ECM will turn the cooling fans on at low speed
when the A/C system is on. The ECM will change
to high speed when the coolant temperature reach-
es 97°C (207°F) or the high side A/C pressure
reaches 1859 kPa (270 psi).
S The cooling fans will return to low speed when the
coolant temperature reaches 94°C (201°F) and the
high side A/C pressure reaches 1449 kPa (210 psi).
ENGINE BLOCK HEATER
The vehicle is designed to accept an engine block heater
that helps to warm the engine and to improve starting in
cold weather. It also can help to reduce fuel consumption
while a cold engine warms up.
The engine block heater is located under the intake man-
ifold and uses an existing expansion plug for installation.

MANUAL TRANSAXLE DRIVE AXLE 3B – 7
DAEWOO V–121 BL4
6. Loosely install a new axle shaft caulking nut. Al-
ways use a new nut.
7. Install the wheels. Loosely install the nuts. Refer to
Section 2E, Tires and Wheels.
8. Lower the vehicle to the floor.
Tighten
Tighten the wheel nuts to 100 NSm (74 lb–ft).
9. Tighten the axle shaft caulking nut to 300 NSm (221
lb–ft).
10. Peen the caulking nut with a punch and a hammer
until the nut is locked into place on the axle shaft
hub.
11. Refill the transaxle fluid to the proper level. Refer to
Section 5B, Five–Speed Manual Transaxle.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 117
DAEWOO V–121 BL4
S The TCM will record operating conditions at the
time the diagnostic fails. This information will be
stored in the Failure Records buffer.
S Adopt Emergency/ Substitute mode and constant
4th gear.
S High line pressure
Conditions for Clearing the MIL/DTC
S The MIL will turn OFF when the malfunction hasnot occurred after three–ignition cycle.
S A history DTC will clear after 40 consecutive warm
up cycles without a fault.
S Using a scan tool can clear history DTCs.
Diagnostic Aids
S Check for intermittent input speed sensor or output
speed sensor circuit problems.
S Check for possible incorrect calibration.
DTC P0731 – Gear 1 Incorrect Ratio
StepActionValue(s)YesNo
1Perform an On–Board Diagnostic (EOBD) System
Check.
Is the check completed?–Go to Step 2Go to ”On–
Board Diagnos-
tic System
Check”
2Visually inspect the transaxle cooling system for
fluid leaks.
Was condition found and corrected?–Go to Step 7Go to Step 3
3Has the transaxle fluid checking procedure been
performed?–Go to Step 4Go to Trans-
axle fluid check
procedures
41. Using the scan tool record each transaxle drive
range.
2. Drive the vehicle in transaxle gear ranges 1,2,3
and D with TP greater than 15% and vehicle
speed greater than 16km/h(10mph) for five
seconds.
Does commanded gear ratio match ranges as
shown?1st = 2.719
2nd = 1.487
3rd = 1.000
4th = 0.717Refer to Diag-
nostic AidsGo to Step 5
5Perform line pressure check.
Was the condition found and corrected?–Go to Step 7Go to Step 6
6Check for possible clutch slippage.
Was the condition found and corrected?–Go to Step 7–
71. After the repair, use a scan tool
clear info"
function and road test the vehicle.
2. Review the
DTC info".
Has the last test failed or is the current DTC dis-
played?Replace trans-
axle assemblyRepair verified
exit DTC chart

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 119
DAEWOO V–121 BL4
S The TCM will record operating conditions at the
time the diagnostic fails. This information will be
stored in the Failure Records buffer.
S Adopt Emergency/ Substitute mode and constant
3rd gear.
S High line pressure
Conditions for Clearing the MIL/DTC
S The MIL will turn OFF when the malfunction hasnot occurred after three–ignition cycle.
S A history DTC will clear after 40 consecutive warm
up cycles without a fault.
S Using a scan tool can clear history DTCs.
Diagnostic Aids
S Check for intermittent input speed sensor or output
speed sensor circuit problems.
S Check for possible incorrect calibration.
DTC P0732 – Gear 2 Incorrect Ratio
StepActionValue(s)YesNo
1Perform an On–Board Diagnostic (EOBD) System
Check.
Is the check completed?–Go to Step 2Go to ”On–
Board Diagnos-
tic System
Check”
2Visually inspect the transaxle cooling system for
fluid leaks.
Was condition found and corrected?–Go to Step 7Go to Step 3
3Has the transaxle fluid checking procedure been
performed?–Go to Step 4Go to Trans-
axle fluid check
procedures
41. Using the scan tool record each transaxle drive
range.
2. Drive the vehicle in transaxle gear ranges 1,2,3
and D with TP greater than 15% and vehicle
speed greater than 16km/h(10mph) for five
seconds.
Does commanded gear ratio match ranges as
shown?1st = 2.719
2nd = 1.487
3rd = 1.000
4th = 0.717Refer to Diag-
nostic AidsGo to Step 5
5Perform line pressure check.
Was the condition found and corrected?–Go to Step 7Go to Step 6
6Check for possible clutch slippage.
Was the condition found and corrected?–Go to Step 7–
71. After the repair, use a scan tool
clear info"
function and road test the vehicle.
2. Review the
DTC info".
Has the last test failed or is the current DTC dis-
played?Replace trans-
axle assemblyRepair verified
exit DTC chart

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 121
DAEWOO V–121 BL4
S The TCM will record operating conditions at the
time the diagnostic fails. This information will be
stored in the Failure Records buffer.
S Adopt Emergency/ Substitute mode and constant
4th gear.
S High line pressure
Conditions for Clearing the MIL/DTC
S The MIL will turn OFF when the malfunction hasnot occurred after three–ignition cycle.
S A history DTC will clear after 40 consecutive warm
up cycles without a fault.
S Using a scan tool can clear history DTCs.
Diagnostic Aids
S Check for intermittent input speed sensor or output
speed sensor circuit problems.
S Check for possible incorrect calibration.
DTC P0733 – Gear 3 Incorrect Ratio
StepActionValue(s)YesNo
1Perform an On–Board Diagnostic (EOBD) System
Check.
Is the check completed?–Go to Step 2Go to ”On–
Board Diagnos-
tic System
Check”
2Visually inspect the transaxle cooling system for
fluid leaks.
Was condition found and corrected?–Go to Step 7Go to Step 3
3Has the transaxle fluid checking procedure been
performed?–Go to Step 4Go to Trans-
axle fluid check
procedures
41. Using the scan tool record each transaxle drive
range.
2. Drive the vehicle in transaxle gear ranges 1,2,3
and D with TP greater than 15% and vehicle
speed greater than 16km/h(10mph) for five
seconds.
Does commanded gear ratio match ranges as
shown?1st = 2.719
2nd = 1.487
3rd = 1.000
4th = 0.717Refer to Diag-
nostic AidsGo to Step 5
5Perform line pressure check.
Was the condition found and corrected?–Go to Step 7Go to Step 6
6Check for possible clutch slippage.
Was the condition found and corrected?–Go to Step 7–
71. After the repair, use a scan tool
clear info"
function and road test the vehicle.
2. Review the
DTC info".
Has the last test failed or is the current DTC dis-
played?Replace trans-
axle assemblyRepair verified
exit DTC chart

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 123
DAEWOO V–121 BL4
S The TCM will record operating conditions at the
time the diagnostic fails. This information will be
stored in the Failure Records buffer.
S Adopt Emergency/ Substitute mode and constant
4th gear by hydraulic control.
S After ignition OFF/ON : 3rd gear by hydraulic con-
trol. Possible P, R and N also possible.
S High line pressure
Conditions for Clearing the MIL/DTCS The MIL will turn OFF when the malfunction has
not occurred after three–ignition cycle.
S A history DTC will clear after 40 consecutive warm
up cycles without a fault.
S Using a scan tool can clear history DTCs.
Diagnostic Aids
S Check for intermittent input speed sensor or output
speed sensor circuit problems.
S Check for possible incorrect calibration.
DTC P0734 – Gear 4 Incorrect Ratio
StepActionValue(s)YesNo
1Perform an On–Board Diagnostic (EOBD) System
Check.
Is the check completed?–Go to Step 2Go to ”On–
Board Diagnos-
tic System
Check”
2Visually inspect the transaxle cooling system for
fluid leaks.
Was condition found and corrected?–Go to Step 7Go to Step 3
3Has the transaxle fluid checking procedure been
performed?–Go to Step 4Go to Trans-
axle fluid check
procedures
41. Using the scan tool record each transaxle drive
range.
2. Drive the vehicle in transaxle gear ranges 1,2,3
and D with TP greater than 15% and vehicle
speed greater than 16km/h(10mph) for five
seconds.
Does commanded gear ratio match ranges as
shown?1st = 2.719
2nd = 1.487
3rd = 1.000
4th = 0.717Refer to Diag-
nostic AidsGo to Step 5
5Perform line pressure check.
Was the condition found and corrected?–Go to Step 7Go to Step 6
6Check for possible clutch slippage.
Was the condition found and corrected?–Go to Step 7–
71. After the repair, use a scan tool
clear info"
function and road test the vehicle.
2. Review the
DTC info".
Has the last test failed or is the current DTC dis-
played?Replace trans-
axle assemblyRepair verified
exit DTC chart

SECTION : 5B
FIVE–SPEED MANUAL TRANSAXLE
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
SPECIFICATIONS5B–2 . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 5B–2. . . . . . . . . . .
SPECIAL TOOLS5B–3 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 5B–3. . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS5B–5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Isolate Noise 5B–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symptom Diagnosis 5B–6. . . . . . . . . . . . . . . . . . . . . . . .
COMPONENT LOCATORS5B–9 . . . . . . . . . . . . . . . . . .
Gears and Case 5B–9. . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Plate 5B–11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Gear 5B–12. . . . . . . . . . . . . . . . . . . . . . . . . .
Shift Linkage 5B–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR5B–15 . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 5B–15. . . . . . . . . . . . . . . . . . . .
Checking Fluid Level 5B–15. . . . . . . . . . . . . . . . . . . . . .
Shift Linkage Adjustment 5B–15. . . . . . . . . . . . . . . . . . Gearshift Lever 5B–17. . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearshift Lever Housing 5B–18. . . . . . . . . . . . . . . . . . .
Speedometer Driven Gear 5B–18. . . . . . . . . . . . . . . . .
Shift Linkage Assembly 5B–19. . . . . . . . . . . . . . . . . . . .
Drive Axle Seal 5B–20. . . . . . . . . . . . . . . . . . . . . . . . . . .
Transaxle Assembly 5B–21. . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR 5B–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Major Component Disassembly 5B–26. . . . . . . . . . . . .
Input Shaft and Cluster Gear 5B–35. . . . . . . . . . . . . . .
Mainshaft 5B–37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing Case 5B–48. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential 5B–50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Major Component Assembly 5B–56. . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION5B–63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Five–Speed Manual Transaxle 5B–63. . . . . . . . . . . . . .