2004 DAEWOO LACETTI Iat

FIVE–SPEED MANUAL TRANSAXLE 5B – 27
DAEWOO V–121 BL4
5. Bolt the gearshift lever cover to the fixture KM–552.
6. Position the fixture KM–552 into the base
KM–113–2.
7. Remove the snap ring, the bushing, the spring, and
the intermediate lever.
8. Remove the shift finger lever pin.
9. Remove the gearshift rod and the shift finger lever.

5B – 62IFIVE–SPEED MANUAL TRANSAXLE
DAEWOO V–121 BL4
31. Bolt the gearshift lever cover to the fixture KM–552.
32. Position the fixture into the base KM–113–2.
33. Install the gearshift rod, the shift finger lever, and
the gearshift lever pin.
34. Install the snap ring, the bushing, the spring, and
the intermediate lever.
35. Remove the gearshift lever cover from the base
KM–113–2 and the fixture KM–552.
36. Shift the transaxle into NEUTRAL.
37. Install the gearshift lever cover and the gearshift
lever cover bolts.
Tighten
Tighten the gearshift lever cover bolts to 22 NSm (16
lb–ft).
38. Install the transaxle cover and the transaxle cover
bolts.
Tighten
Tighten the transaxle cover bolts to 18 NSm (13 lb–ft).
39. Install the transaxle into the vehicle. Refer to
”Transaxle Assembly” in this section.

6A – 2IPOWER STEERING SYSTEM
DAEWOO V–121 BL4
DIAGNOSIS
POWER STEERING SYSTEM
PRESSURE TEST
Tools Required
KM–354–B Pressure Test Gauge Kit
Check the fluid pressure as follows to determine whether
the trouble is in the pump or the gear unit.
Test Procedure
1. Check the power steering fluid level and the power
steering pump belt tension. Refer to ”Checking and
Adding Fluid” in this section and Section 6B, Power
Steering Pump.
2. Disconnect the high pressure line at the pump. Use
a small container to catch any fluid.
3. Connect the hose of the pressure test gauge kit
KM–354–B to the power steering pressure hose
from the power steering pump.
4. Place the gear selector lever in PARK (automatic
transaxle–equipped vehicles) or NEUTRAL (manual
transaxle–equipped vehicles). Set the parking
brake.
5. Open the gauge valve fully.
6. Start the engine and let it idle.
7. Turn the steering wheel from lock to lock several
times to warm the fluid to operating temperature.
8. Increase the engine speed to 1,500 rpm.
Notice : The power steering pump could be damaged if
the valve is fully closed for more than 5 seconds.
9. Close the gauge valve fully, and read the pressure.
The pump pressure with the valve closed should be
between 8,330 kPa to 8,820 kPa (1,208 psi to
1,279 psi). With electronic variable orifice, the pres-
sure should be between 8,500 kPa to 8,960 kPa
(1,233 psi to 1,299 psi).
10. Immediately open the gauge valve fully.
11. Turn the steering wheel all the way to the left and
the right. If the pressure is within the specified lim-
its, the problem is not in the pump. Check the pow-
er steering gear for leaks.
POWER STEERING SYSTEM LEAK
TEST
General Procedure
Inspect the following:
S The fluid reservoir for overfill.
S Fluid for aeration and overflow.
S The hoses for loose connections.
S The torsion bar, stub shaft and adjuster seals for
leaks.
S The component sealing surfaces for damage.
Important : Verify the exact point of the leak. The point
from which the fluid is dripping is not necessarily the point
at which the system is leaking. When service is required,
clean the leak area upon disassembly, replace the leaking
seal, check the component sealing surfaces for damage
and reset the torque bolt to specifications, where required.
External Leak Check
The purpose of this procedure is to pinpoint the location of
the leak. In some cases, the leak can be easily located, but
seepage–type leaks may be harder to find. To locate seep-
age leaks, use the following method:
1. With the engine off, wipe dry the complete power
steering system.
2. Check the power steering fluid level in the pump’s
reservoir. Adjust the fluid level as necessary. Refer
to ”Checking and Adding Fluid” in this section.
Notice : Do not hold the steering wheel at a stop for any
length of time as this can damage the power steering
pump.
3. Start the engine. Turn the steering wheel counter-
clockwise and clockwise from stop to stop several
times.
4. Find the exact area of the leak and repair it.

6A – 6IPOWER STEERING SYSTEM
DAEWOO V–121 BL4
9. Remove the bolts from each of the two clips on the
radiator.
10. Remove all the hoses and pipes from the vehicle.
11. Lower the vehicle.
Installation Procedure
1. Route the pressure line from the power steering
pump to the power steering gear.
2. Raise and suitably support the vehicle.
3. Route the return line from the fluid reservoir to the
power steering gear.
4. Install the two bolts on the radiator.
Tighten
Tighten the return line clip bolts to 8 NSm (71 lb–in).
5. Install the return line into the clip on the crossmem-
ber.
Tighten
Tighten the return line clip bolt to 8 NSm (71 lb–in).
6. Connect the return line to the power steering gear
outlet.
Tighten
Tighten the return line fitting to 28 NSm (21 lb–ft).
7. Connect the pressure line to the power steering
gear inlet.
Tighten
Tighten the pressure line fitting to 28 NSm (21 lb–ft).

SECTION : 6C
POWER STEERING GEAR
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
SPECIFICATIONS6C–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 6C–1. . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 6C–2. . . . . . . . . . .
SPECIAL TOOLS6C–2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 6C–2. . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS6C–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Rack and Pinion Steering Gear 6C–3. . . . . . . .
Power Rack and Pinion Steering Gear Bench
Testing 6C–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speed Sensitive Power Steering System 6C–6. . . . . .
Speed Sensitive Power Steering System Operating
With Full Assist At All Times 6C–7. . . . . . . . . . . . . . .
Speed Sensitive Power Steering System Operating
with Decreased Assist At All Times 6C–9. . . . . . . . .
MAINTENANCE AND REPAIR6C–11 . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 6C–11. . . . . . . . . . . . . . . . . . . .
Rack and Pinion Assembly 6C–11. . . . . . . . . . . . . . . . . Outer Tie Rod 6C–14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dust Boot 6C–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Straight–Ahead Check 6C–16. . . . . . . . . . . . . . . . . . . .
Intermediate Shaft and Dash Seal 6C–17. . . . . . . . . .
Hydraulic Cylinder Lines 6C–20. . . . . . . . . . . . . . . . . . .
Speed Sensitive Power Steering Control
Module 6C–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR 6C–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rack and Pinion 6C–22. . . . . . . . . . . . . . . . . . . . . . . . . .
Stub Shaft Seals and Upper and Lower
Bearing 6C–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rack Bearing 6C–29. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rack Bearing Preload Adjustment 6C–30. . . . . . . . . . .
Valve and Pinion 6C–30. . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION6C–33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Rack and Pinion 6C–33. . . . . . . . . . . . . . . . . . . .
Speed Sensitive Power Steering System 6C–33. . . . .
SPECIFICATIONS
GENERAL SPECIFICATIONS
ApplicationDescription
Capacity1.1 Liter (1.16 qt)
LubricantPower Steering Fluid DEXRON®–II or III

6C – 2IPOWER STEERING GEAR
DAEWOO V–121 BL4
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Adjuster Plug12–106
Adjuster Plug Locknut7556–
Control Module Bracket Bolts7–62
Dash Seal Retaining Ring Nuts7–62
Hydraulic Cylinder Line Fittings – Cylinder End2821–
Hydraulic Cylinder Line Fittings – Valve End1813–
Inner Tie Rod10074–
Intermediate Shaft Pinch Bolts2518–
Outer Tie Rod Adjusting Nut6447–
Outer Tie Rod Nuts5037–
Pinion Locknut3022–
Pinion Preload1–9
Steering Gear Inlet and Outlet Pipe Fittings2821–
Steering Gear Mounting Bracket Nuts and Bolts6044–
Transaxle Center Bracket–to–Engine Bolt8059–
SPECIAL TOOLS
SPECIAL TOOLS TABLE
KM–507–B
Ball Joint Remover
KM–J–26610
Installer
J–42459
Rack Guide Spring
Cap Wrench

POWER STEERING GEAR 6C – 3
DAEWOO V–121 BL4
DIAGNOSIS
POWER RACK AND PINION STEERING GEAR
Hissing Noise
ChecksAction
Check the intermediate shaft joints for looseness.Tighten the intermediate shaft joints.
Check the power steering hose for contact with other com-
ponents.Be sure the power steering hose is correctly fitted into the
hose clips.
Rattling Noise in Steering Gear
ChecksAction
Check the power steering hose for contact with the body.Be sure the power steering hose is correctly fitted into the
hose clips.
Check the steering gear for insufficient lubrication.Lubricate the steering gear.
Check the steering gear mounting for improper installa-
tion.Tighten the steering gear mounting bracket nuts and bolts.
Check the outer tie rods for improper installation.Tighten the outer tie rod joints. Replace the outer tie rods.
Poor Return of Steering Wheel to Center
ChecksAction
Check the steering wheel for contact with the turn signal
housing.Adjust the turn signal housing.
Check the intermediate shaft joints for binding or loose-
ness.Replace the intermediate shaft.
Check the power steering pump flow control valve for
sticking and improper alignment.Replace the power steering pump.
Check the wheel alignment.Align the wheels.
Check the wheel bearings for wear or damage.Replace the wheel bearings.
Check the intermediate shaft joints for improper installa-
tion.Adjust the intermediate shaft between the steering gear
and the steering column.
Replace the intermediate shaft.
Check the outer tie rods and the ball joints for binding or
looseness.Tighten the tie rods and the ball joints. Replace the tie rods
and the ball joints.
Check the steering gear adjustments.Perform a straight–ahead check.
Check the steering column shaft seal for rubbing on the
shaft.Replace the dash seal.
Check the steering shaft bearings for binding.Replace the stub shaft bearings.
Momentary Increase in Effort When Turning the Wheel Quickly
ChecksAction
Check the power steering pump for internal leaks.Replace the power steering pump.
Check the hoses for damage or restricted flow.Replace the power steering hoses and/or pipes.
Check the power steering fluid level.Fill the power steering fluid reservoir.
Check the power steering pump flow control valve for
sticking and improper operation.Replace the power steering pump.

6C – 4IPOWER STEERING GEAR
DAEWOO V–121 BL4
Steering Surges or Jerks When Turning with Engine Running
ChecksAction
Check the power steering pump for insufficient pressure.Replace the power steering pump.
Check the power steering pump flow control valve for
sticking and improper operation.Replace the power steering pump.
Check the power steering pump serpentine belt for slip-
page.Tighten the power steering serpentine belt.
Check for air contamination in the power steering system.Bleed the power steering system.
Steering Vibrates During Low Speed or Static Steering
ChecksAction
Check for air contamination in the power steering system.Bleed the power steering system.
Check the power steering pump serpentine belt for loose-
ness.Tighten the power steering serpentine belt.
Excessive Wheel Kickback or Loose Steering
ChecksAction
Check for air contamination in the power steering system.Bleed the power steering system.
Check the wheel bearings for wear or damage.Replace the wheel bearings.
Check the steering gear mounting for improper installa-
tion.Tighten the steering gear mounting bracket nuts and bolts.
Check the intermediate shaft joints for improper installa-
tion.Adjust the intermediate shaft between the steering gear
and the steering column.
Replace the intermediate shaft.
Check the outer tie rods and ball joints for looseness.Tighten the tie rods and the ball joints. Replace the tie rods
and the ball joints.
Hard Steering or Lack of Assist (Especially During Parking)
ChecksAction
Adjust the intermediate shaft between the steering gear
and the steering column. Replace the coupling flange.Adjust the steering coupling flange on the steering gear
and the steering column. Replace the coupling flange as
needed.
Check the power steering pump flow control valve for
sticking and improper installation.Replace the power steering pump.
Check the power steering pump for insufficient pressure.Replace the power steering pump.
Check the power steering pump for internal leaks.Replace the power steering pump.
Check for a loose or a worn intermediate shaft.Tighten the intermediate shaft. Replace the intermediate
shaft as needed.
Check the power steering pump serpentine belt tension.Tighten the power steering serpentine belt.