2004 DAEWOO LACETTI transaxle

CLUTCH 5C – 13
DAEWOO V–121 BL4
Installation Procedure
1. Install the concentric slave cylinder and the pipe.
2. After installing the pipe screw provisionally, tighten
the concentric slave cylinder retaining bolts.
Tighten
Tighten the concentric slave cylinder retaining bolts to
7 NSm ( 62 lb–in).
3. Tighten the pipe screw.
Tighten
Tighten the pipe screw to 15 NSm (11 lb–ft).
4. Install the bushing onto the transaxle housing.
5. Connect the pipe with bushing.
6. Install the transaxle into the vehicle. Refer to Sec-
tion 5B, Five–Speed Manual Transaxle.

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.

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 – 7
DAEWOO V–121 BL4
SPEED SENSITIVE POWER STEERING SYSTEM
OPERATING WITH FULL ASSIST AT ALL TIMES
StepActionValue(s)YesNo
1Perform an initial inspection of the power steering
system.
Is the system operational?–Go to Step 2Go to
Section 6A,
Power Steering
System
2Check the speedometer.
Is the speedometer inoperative?–Go to
Section5,
TransaxleGo to Step 3
3Check the diagnostic trouble codes at the engine
control module (ECM).
Is the ECM code 24 set?–Go to
Section1F,
Engine
ControlsGo to Step 4
41. Turn the ignition ON.
2. Disconnect the electronic variable orifice (EVO)
solenoid actuator electrical connector at the
power steering pump.
3. Probe terminal 1 of the EVO actuator connec-
tor with a voltmeter.
Does the voltmeter display the specified value?–Go to Step 6Go to Step 5
5Repair the open or short in the circuit between termi-
nal 1 of the EVO solenoid actuator electrical connec-
tor and terminal 2 on the speed sensitive power
steering (SSPS) control module connector.
Is the repair complete?–System OK–
61. Remove the EVO solenoid actuator from the
power steering pump.
2. Turn the actuator upside down to position the
pintle.
3. Stimulate the actuator by connecting it to the
battery.
Does the actuator click?–Go to Step 8Go to Step 7
7Replace the EVO solenoid actuator.
Is the repair complete?–System OK–
81. Turn the ignition OFF.
2. Remove the SSPS control module from the
control module bracket.
3. Disconnect the SSPS control module connec-
tor.
4. Connect a test light from terminal 8 on the
SSPS control module connector to the ground.
5. Turn the ignition ON.
Is the test light on?–Go to Step 14Go to Step 9
9Check the ignition fuse.
Is the ignition fuse open?–Go to Step 10Go to Step 11
10Replace the ignition fuse.
Is the repair complete?–System OK–
11Check for an open or short in the circuit between ter-
minal 8 of the control module connector and the I/P
fuse block.
Is the connection faulty?–Go to Step 12Go to Step 13

POWER STEERING GEAR 6C – 9
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
23Repair the open, short to ground, short to B+, or poor
terminal contact between terminal 14 of the SSPS
control module connector and terminal 2 of the
steering wheel rotation sensor connector.
Is the repair complete?–System OK–
241. Turn the ignition OFF.
2. Connect the SSPS control module.
3. Connect the steering wheel rotation sensor.
4. Turn the ignition ON.
5. Backprobe with a voltmeter from terminal 5 on
the control module connector to the ground.
6. Rotate the steering wheel quickly in both direc-
tions.
Does the voltage show an increase and decrease
from the specified value?
3 VGo to Step 25Go to Step 26
25Replace the SSPS control module.
Is the repair complete?–System OK–
26Replace the steering wheel rotation sensor.
Is the repair complete?–System OK–
SPEED SENSITIVE POWER STEERING SYSTEM
OPERATING WITH DECREASED ASSIST AT ALL TIMES
StepActionValue(s)YesNo
1Check the speedometer.
Is speedometer inoperative?–Go to
Section5,
TransaxleGo to Step 2
2Disconnect the EVO solenoid actuator at the power
steering pump.
Is the symptom still present?–Go to
Section 6A,
Power Steering
SystemGo to Step 3
3Replace the speed sensitive poser steering (SSPS)
control module.
Is repair complete?–System OK–
General Operation
The control module self–diagnoses SSPS system. If there
is any malfunction, the warning lamp comes ON and at the
same time a trouble code is set. The trouble code can be
retrieved or cleared only by SCANTOOL.
In normal condition, If the ignition is turned on, the warning
lamp comes on for the first 2 sec and out. During this 2 sec,
the control module is diagnosing SSPS system, so a driver
can feel a little heavy steering effort.
If the warning lamp stays on after the 2 sec or comes on
afterward, it means there is a malfunction and a related
trouble code is recorded.
The warning lamp once come on does not go off even if the
malfunction is cleared. It goes off after ignition is turned off
and on without a malfunction.However the trouble code still remains in the control mod-
ule.

6C – 12IPOWER STEERING GEAR
DAEWOO V–121 BL4
9. Remove the outer tie rod nuts and disconnect the
tie rod ends from the strut assembly using the ball
joint remover KM–507–B.
10. Remove the crossmember assembly. Refer to Sec-
tion 2C, Front Suspension.
11. On vehicles equipped with an automatic transaxle,
remove the transaxle center bracket. Refer to Sec-
tion 5A, Automatic Transaxle.
12. On vehicles equipped with a manual transaxle, re-
move the bolts securing the transaxle center brack-
et to the transaxle and the engine. Move the trans-
axle center bracket out of the way.
13. Remove the nuts and bolts from the steering gear
mounting bracket.
14. Remove the return line from the clip on the cross-
member.
15. Disconnect the rack and pinion assembly from the
crossmember assembly.
Installation Procedure
1. Install the rack and pinion assembly on the cross-
member. The steering gear must be in a straight–
ahead position, and the steering wheel spokes
must be vertical and pointing to the left. Align the
marks on the shafts to ensure proper positioning.
Seat the stub shaft into the intermediate shaft.

POWER STEERING GEAR 6C – 13
DAEWOO V–121 BL4
2. Install the bolts and nuts on the steering gear
mounting bracket.
Tighten
Tighten the steering gear mounting bracket bolts and
nuts to 60 NSm (44 lb–ft).
3. Install the return line into the clip on the crossmem-
ber.
Tighten
Tightem the return line clip bolt to 8 NSm (71 lb–in).
4. On vehicles equipped with a manual transaxle,
position the transaxle center bracket in place and
install the bolts securing the bracket to the engine
and the transaxle.
Tighten
Tighten the transaxle center bracket–to–transaxle
bolts and the transaxle center bracket–to–engine bolt
to 80 NSm (59 lb–ft).
5. On vehicles equipped with an automatic transaxle,
install the transaxle center bracket. Refer to Section
5A, Automatic Transaxle.
6. Install the crossmember. Refer to Section 2C, Front
Suspension.
7. Connect the tie rod ends to the strut assembly.
8. Install the outer tie rod nuts.
Tighten
Tighten the outer tie rod nuts to 50 NSm (37 lb–ft).

9B – 26ILIGHTING SYSTEMS
DAEWOO V–121 BL4
Backup Lamps Inoperative
StepActionValue(s)YesNo
11. Block the wheels.
2. Apply the parking brake to prevent the vehicle
from moving.
3. Turn the ignition on.
4. Put the transaxle in reverse (R).
5. Remove one of the backup lamps from its
socket.
6. Test the lamp socket positive terminal with a
voltmeter.
Does the battery voltage available at the backup
lamp socket positive terminal equal the specified
value?11–14 vGo to Step 3Go to Step 2
2Repair the open circuit between fuse F20 and the
backup lamps.
Is the repair complete?–System OK–
3Connect an ohmmeter between ground and the neg-
ative terminal at the bulb socket.
Is the resistance equal to the specified value?0 WGo to Step 4Go to Step 5
4Replace the faulty backup lamps.
Is the repair complete?–System OK–
51. Reinstall the backup lamps.
2. Disconnect the electrical connector at the re-
verse switch. (On automatic transaxle (A/T)
vehicles, disconnect the neutral safety/backup
switch.)
3. Turn the ignition on.
4. Put the transaxle in R.
5. Use a voltmeter to check for the reverse switch
terminal 1. (On A/T vehicles, test terminal 7 of
the neutral safety/backup switch).
Does the battery voltage available at terminal 1 (or
terminal 7, if equipped with A/T) equal the specified
value?11–14 vGo to Step 7Go to Step 6
6Repair the open circuit between the backup lamps
and the, reverse switch (or the neutral safety/backup
switch if equipped with A/T).
Is the repair complete?–System OK–
71. Put the transaxle in R.
2. Use an ohmmeter to check the continuity be-
tween reverse switch terminal 1 and terminal 2
(terminals 7 and 8 on the neutral safety/backup
switch, if equipped with A/T).
Does the continuity between terminals 1 and 2 (ter-
minals 7 and 8, if equipped with A/T) equal the speci-
fied value?0 WGo to Step 9Go to Step 8