2004 DAEWOO LACETTI clock

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.

POWER STEERING PUMP 6B – 3
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
SERPENTINE ACCESSORY DRIVE
BELT
Removal Procedure
1. Remove the air filter housing assembly bolts and
the air intake tube.
2. Remove the air filter housing assembly from the
vehicle.
3. Use a wrench to turn the tensioner bolt clockwise,
compressing the tensioner, and releasing the ten-
sion on the serpentine accessory drive belt.
4. Remove the serpentine accessory drive belt.

6B – 4IPOWER STEERING PUMP
DAEWOO V–121 BL4
Installation Procedure
1. Use a wrench to turn the tensioner bolt clockwise,
compressing the tensioner, and releasing the ten-
sion on the serpentine accessory drive belt.
2. With the wrench in place on the tensioner bolt, loop
the serpentine accessory drive belt loosely over the
pulleys.
3. Slip the belt over the tensioner.
4. Remove the wrench from the tensioner bolt and the
belt will tighten itself.
5. Install the air filter housing assembly into the ve-
hicle.
6. Install the air intake tube and the air filter housing
assembly bolts.
Tighten
Tighten the air filter housing assembly bolts to 6 NSm
(53 lb–in).
PUMP ASSEMBLY
Removal Procedure
1. Remove the serpentine accessory drive belt. Refer
to ”Serpentine Accessory Drive Belt” in this sec-
tion.
2. Disconnect the electrical connector at the Electronc
Vaariable Orifice (EVO) solenoid actuator.

POWER STEERING GEAR 6C – 29
DAEWOO V–121 BL4
RACK BEARING
Tools Required
J–42459 Rack Guide Spring Cap Wrench
Disassembly Procedure
1. Remove the rack and pinion steering assembly
from the vehicle. Refer to ”Rack and Pinion Assem-
bly” in this section.
2. Remove the adjuster plug locknut from the adjuster
plug, and remove the adjuster plug from the hous-
ing with the rack guide spring cap wrench J–42459,
or with a 19 mm allen wrench.
3. Remove the adjuster spring and the rack bearing.
Assembly Procedure
1. Coat the rack bearing, the adjuster spring and the
adjuster plug with lithium–based grease and install
them into the housing.
2. With the rack centered, turn the adjuster plug clock-
wise until a torque of 7 NSm (62 lb–in) is obtained,
then back it off by 30 to 40 degrees. Check the pin-
ion torque. Maximum pinion preloaded torque is 1
NSm (9 lb–in).
3. Thread the locknut on the adjuster plug and tighten
it.
Tighten
Tighten the adjuster plug locknut to 75 NSm (56 lb–ft)
while holding the adjuster plug stationary with the rack
guide spring cap wrench J–42459 or with a 19 mm al-
len wrench.
4. Install the rack and pinion assembly. Refer to ”Rack
and Pinion Assembly” in this section.

6C – 30IPOWER STEERING GEAR
DAEWOO V–121 BL4
RACK BEARING PRELOAD
ADJUSTMENT
Adjustment Procedure
1. Raise and suitably support the vehicle.
2. Center the steering wheel.
3. Remove the power steering gear. Refer to ”Rack
and Pinion Assembly” in this section.
4. Loosen the locknut and turn the adjuster plug clock-
wise until a torque of 7 NSm (62 lb–in) is obtained,
then loosen it by 30 to 40 degrees. Check the pin-
ion torque. Maximum pinion preloaded torque is 1
NSm (9 lb–in).
5. Tighten the locknut on the adjuster plug while hold-
ing the adjuster plug stationary.
6. Install the power steering gear. Refer to ”Rack and
Pinion Assembly” in this section.
7. Be sure to check the returnability of the steering
wheel to center position after adjustment.
Tighten
Tighten the adjuster plug locknut to 75 NSm (56 lb–ft).
VALVE AND PINION
Disassembly Procedure
1. Remove the rack and pinion steering assembly
from the vehicle. Refer to ”Rack and Pinion Assem-
bly” in this section.
2. Remove the dust cover from the lower end of the
housing.
Notice : If the stub shaft is not held, damage to the pinion
teeth will occur.
3. While holding the stub shaft, remove the locknut
from the pinion.

7B – 40IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
DAEWOO V–121 BL4
11. Remove the compressor from the bench vise and
remove the J–34992 compressor holding fixture
from the compressor.
12. Install the compressor. Refer to ”Compressor” in
this section.
CLUTCH ROTOR AND BEARING
Tools Required
J–6083 Snap Ring Pliers
J–9398–A Bearing Remover
J–9481 Bearing Installer
J–33020 Pulley Puller
J–33023–A Puller Pilot
J–33019 Bearing Staking Tool Set
Includes: J–33019–1 Bearing Staking Guide
Includes: J–33019–2 Bearing Staking Pin
Includes: J–33019–1 Bearing Staking Guide
J–33017 Pulley Rotor and Bearing Installer
J–8433–1 Puller Crossbar
J–34992 Compressor Holding Fixture
J–8092 Driver Handle
J–8433–3 Forcing Screw
Disassembly Procedure
1. Disconnect the negative battery cable.
2. Recover the refrigerant. Refer to ”Discharging,
Adding Oil, Evacuating, and Charging for A/C Sys-
tem” in this section.
3. Remove the compressor. Refer to ”Compressor” in
this section.
4. Remove the clutch drive plate and hub assembly.
Refer to ”Clutch Plate and Hub Assembly” in this
section.
5. Remove the pulley rotor and bearing assembly re-
taining ring using the snap ring pliers J–6083.
6. With the compressor mounted to the compressor
holding fixture J–34992, install the pulley puller
J–33020 into the inner circle of slots in the pulley
rotor. Turn the pulley puller J–33020 clockwise in
the slots to engage the puller tangs with the seg-
ments between the slots in the rotor.
7. Hold the pulley puller J–33020 in place and tighten
the puller bolt against the compressor shaft to re-
move the pulley rotor and bearing assembly.

7B – 44IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
DAEWOO V–121 BL4
SHAFT SEAL REPLACEMENT
Tools Required
J–5403 Snap Ring Pliers
J–9553–1 O–Ring Remover
J–23128–A Seal Seat Remover/Installer
J–33011 O–Ring Installer
J–34614 Shaft Seal Protector
Important : A shaft seal should not be replaced because
a small amount of oil is found on the adjacent surface. The
seal is designed to leak some oil for lubrication purposes.
A shaft seal should be changed only when a large amount
of sprayed oil is found and then only after actual refrigerant
leakage is found by using an approved leak detection pro-
cedure. Refer to ”Leak Testing the Refrigerant System” in
this section.
Should a compressor shaft seal ever have to be replaced,
the receiver–dryer in this system must also be removed
from the vehicle. The oil in the receiver–dryer must then
be drained, measured and replaced. Refer to ”Discharg-
ing, Adding Oil, Evacuating, and Charging Procedures for
A/C System” in this section.
Removal Procedure
1. Disconnect the negative battery cable.
2. Recover the refrigerant. Refer to ”Discharging, Add-
ing Oil, Evacuating, and Charging Procedures for
A/C System” in this section.
3. Loosen and reposition the compressor in the
mounting brackets.
4. Remove the clutch drive plate and hub assembly
from the compressor. Refer to ”Clutch Plate and
Hub Assembly” in this section.
5. Use the snap ring pliers J–5403 to remove the shaft
seal retaining ring.
Notice : Any dirt or foreign material that enters the com-
pressor may cause damage.
6. Thoroughly clean the inside of the compressor
housing area surrounding the shaft, the exposed
portion of the seal, the shaft itself, and the O–ring
groove.
7. Fully engage the knurled tangs of the seal seat re-
mover/installer J–23128–A into the recessed por-
tion of the seal by turning the handle clockwise.
Remove and discard the seal from the compressor
with a rotating–pulling motion. The handle should
be hand–tightened securely. Do not use a wrench
or pliers to tighten the handle.

MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B – 47
DAEWOO V–121 BL4
REAR HEAD, GASKET, VALVE
PLATE, REED PLATE, AND O–RING
Tools Required
J–34993 Cylinder Alignment Rods
Removal Procedure
1. Recover the refrigerant. Refer to ”Discharging, Add-
ing Oil, Evacuating, and Charging Procedures for
A/C System” in this section.
2. Discharge the A/C system. Refer to ”Discharging,
Adding Oil, Evacuating, and Charging Procedures
for A/C System” in this section.
3. Remove the compressor. Refer to ”Compressor” in
this section.
4. Drain the oil from compressor into a suitable con-
tainer. Measure and record the amount of oil
drained from the compressor. Discard the used oil.
5. Remove the clutch plate and hub assembly. Refer
to ”Clutch Plate and Hub Assembly” in this section.
6. Remove the clutch rotor and bearing. Refer to
”Clutch Rotor and Bearing” in this section.
7. Remove the clutch coil. Refer to ”Clutch Coil” in
this section.
8. Remove the compressor through–bolts. Remove
and discard the gaskets.
9. Using a wooden block and a plastic–headed ham-
mer, tap around the edge of the rear head to disen-
gage the head from the compressor cylinder. Sepa-
rate the rear head, the head gasket, the rear valve
plate, the suction reed plate, and the cylinder–to–
rear head O–ring. Discard the head gasket and the
O–ring.
Installation Procedure
1. Place the rear head on a clean, flat surface. Posi-
tion the head with the control valve at the 6 o’clock
position.
2. Install the cylinder alignment rods J–34993 in the
mounting holes at the 11 o’clock and the 5 o’clock
positions.
3. Install the head gasket over the cylinder alignment
rods J–34993 with the elongated hole at the upper
left pin (the 11 o’clock position).
4. Install the rear head valve plate over the guide pins
with the elongated hole at the upper left pin. Lower
the rear head valve plate into place.
5. Install the suction reed plate over the cylinder align-
ment rods J–34993. Remove the alignment rod at
the 5 o’clock position.
6. Lubricate the cylinder to the new rear head O–ring
with clean polyalkaline glycol (PAG) refrigerant oil.
7. Install the O–ring in the cylinder O–ring groove. The
O–ring seal surface of the head may be lubricated
to ease assembly.