SERVICE TRAINING MANUAL

Chassis /
Optional
Lanos (New)
DAEWOO
DAEWOO MOTOR CO., LTD
CONTENTS
I.Chassis...... 5
I I . ABS ( Bosch) . . 39
III.Air Conditioner..75
I V. SI R Syst em. . . 93
V.Keyless Entry/ Anti Theft System..113
VI.Immobilizer System..123
1. Clutch.... 5

2. Transaxle....... 7

3. Brake...... 13

4. Suspension.............. 23

5. Power Steering........25

TABLE OF CONTENTS
I. Chassis
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5
GENERAL INFORMATION CLUTCH
Clutch
1.4L SOHC 1.5 SOHC 1.6L DOHC
Disc type Single Dry Plate Single Dry Plate Single Dry Plate
Outside diameter (mm) 184 200 215
Inside diameter (mm) 127 134 145
Thickness (mm) 7.65 7.65 7.65
130mm 130mm 130mm
30 - 40 30 - 40 30 - 40
Pedal Travel (A)
Clearance between pedal and Floor just
before clutch connection (B)
Application
Clutch Disc
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CLUTCH COMPONENTS CLUTCH
1. Clutch disc
2. Pressure plate
3. Release bearing
4. Release shaft
5. Release shaft bushing (No.1)
6. Release shaft bushing (No.2)
7. Release shaft seal
8. Release arm
9. Clutch cable adjusting nut
10. Clutch Cable
11. Clutch pedal

Clutch master cylinder & release cylinder in exploded view
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GENERAL INFORMATION
Wide ratio Close ratio
DWMC DWMC DWMC DWMC
D - 16 D - 16 D - 16 D - 16
1st 3.545 3.545 3.545 3.545
2nd 1.952 2.048 1.952 2.158
3rd 1.276 1.346 1.276 1.478
4th 0.892 0.971 0.892 1.129
5th 0.707 0.763 0.707 0.886
REV 3.333 3.333 3.333 3.333
W/Europe 4.176 4.176 4.176 3.722
General Area 3.944 4.176 3.944 3.722
1.8 L 1.8 L 1.8 L 1.8 L
Maker
Type or Model
Final drive
ratio
Fluid change is not required Maintenance interval
Gear ratio
Oil capcity (L)
1.6L DOHC
Application
1.4L SOHC
Wide Ratio
1.5L SOHC
Medium Ratio
TRANSAXLE
Manual transaxle
Specification
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8
SHIFT LINKAGE TRANSAXLE
1. Gearshift lever knob
2. Gearshift lever boot
3. Gearshift lever
4. Gearshift lever stop clamp
5. Gearshift lever shaft
6. Gearshift lever stop bushing
7. Gearshift lever stop bushing
8.Bolt
9. Gearshift housing
10. Shift rod clamp bolt
11. Washer
12. Clamp
13. Linkage adjuster bolt
14. Gearshift control rod
15. Linkage ball socket
16. Circlip ring
17. Linkage reverse lever
18. Gearshift boot
19. Bushing
20. Bushing
21. Rod U-joint bushing
22. Clip
23. Gearshift rod
24. Shift finger lever
25. Cover bolt
26. Intermediate lever
27. Shift lever thrust spring
28. Bushing
29. Snap ring
30. Oil filler plug
31. Oil filler plug
Shift Linkage
31. Oil filler plug
32. Gearshift lever cover
33. Pin
34. Bolt
35. Gearshift adjuster linkage
36. Shift reverse pivot bolt
37. Boot
38. Gearshift tube
39. Bushing
40. Gearshift tube bearing
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DIFFERENTIAL & CASE TRANSAXLE
Differential and Case
1. Speedometer driven gear
2. Sea;
3. Hex bolt
4. Bearing plate
5. Washer
6. Bolt
7. Seal
8. Seal
9. Bearing adjusting ring
10. Side bearing race
11. Housing cover gasket
12. Differential cover
13. Bolt
14. Differential bearing
15. Pinion gear shart1.
16. Differential housing
17. Thrust washer
18. Side gear
19. Washer
20. Pinion gear
21. Ring gear
22. Speedometer drive gear
23. Bolt
24. Pinion side bearing retainer
25. Right side bearing retainer
26. Seal
27. Retainer bolt
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TRANSAXLE GEAR IN EXPLODED VIEW TRANSAXLE
Manual transaxle gear
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TRANSAXLE GEAR IN EXPLODED VIEW TRANSAXLE
Manual transaxle gear
1. Case
2. Mainshaft bearing
3. Fourth gear
4. Synchronizer blocking ring
5. Synchronizer sleeve
6. Pin
7. Third-Fourth gearshift fork
8. Third-Fourth gearshift shaft
9. Spring
10. Key
11. Third-Fourth synchronizer gear
12. Synchronizer blocking ring
13. Third gear
14. Second gear
15. First-Second gear blocking ring
16. First-Second gearshift shaft
17. First-Second gearshift shaft
18. Synchronizer hub sleeve
19. Synchronizer spring
20. Key
21. First-Second synchronizer gear
22. Snap ring
23. Outer blocking ring
24. First gear
25. First gear needle bearing
26. Mainshaft wear plate
27. Snap ring
28. Mainshaft bearing
29. Shift rod plug (21.5mm)
30. Spring
31. Shift rod lock pin
32. Bearing plate
33. Shift rod plug
34. Detent rod bolt
35. Bolt
36. Bolt
37. Support
38. Fifth gearshift fork
39. Pin
40. Fifth gear connector
41. Shoe
42. Key
43 Snap ring
44. Gasket
45. Cover
46. Bolt
47. Plug
48. Bolt
49. Screw
50. Synchronizer gear
51. Spring
52. Synchronizer blocking ring
53. Synchronizer blocking ring
54. Mainshaft driven fifth gear
55. Ring
56. Thrust washer
57. Ring
58. Input drive fifth gear
59. Bolt
60. Cluster gear snap ring
61. Screw
62. Cluster shaft bearing
63. Ring
64. Input shaft cluster gear
65. Ball
66. Reverse idler gear shaft
67. Reverse idler gear
68. Washer
69. Reverse gear fork shaft
70. Reverse gearshift
71. Input drive shaft
72. Bolt
73. Fifth-gear pawl
74. Fifth gear needle bearing
75. First-gear needle bearing
76. Main driven shaft
77. Fifth gearshift lever
78. Hex plug
79. Gasket
80. Reverse lamp switch
81. Input shaft bearing
82. Second gear needle bearing
83. Third gear needle bearing
84. Fourth-gear needle bearing
85. Washer
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12
SPECIAL TOOLS TRANSAXLE
Special tools
KM -113-2
Base
KM -334
Install sleeve
KM-553-A
Fifth-gear puller
J-22888-20A
Bearing puller
J-28469-A
Engine-support
fixture
J-36633
Snap ring retainer
J-6125-B
Slide hammer
J-22912-01
Universal bearing
puller
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GENERAL INFORMATION BRAKE
1.3L SOHC 1.5L SOHC 1.6L DOHC
228.6 228.6 228.6
5.0 : 1 5.0 : 1 5.0 : 1
Master
cylinder
20.64 20.64 22.22
Front brake Ventilated Ventilated Ventilated
Inside
diameter(mm)
200 200 200
Wheel cylinder
diameter (mm)
17.46 17.46 19.05
DOT-3 or DOT-4 DOT-3 or DOT-4 DOT-3 or DOT-4
0.5 L 0.5 L 0.5 L
Fluid
Booster
Specification
Capacity
Rear
brake
Application
Bore Diameter (mm)
Disc type
Size (mm)
Ratio
Drum
type
Brake system
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BRAKE FRONT BRAKE
Front brake
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FRONT BRAKE BRAKE
Front brake
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REAR BRAKE (DRUM)
IN EXPLODED VIEW
BRAKE
Rear brake (Drum)
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PARKING BRAKE IN EXPLODED VIEW BRAKE
Parking brake
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MASTER CYLINDER & BOOSTER
IN EXPLODED VIEW
BRAKE
Master cylinder & Booster
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BRAKE PEDAL IN EXPLODED VIEW BRAKE
Brake pedal
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BRAKE PIPE LINE (NON ABS)
IN EXPLODED VIEW
BRAKE
Brake pipe line ( Non ABS)
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BRAKE
BRAKE PIPE LINE (ABS)
IN EXPLODED VIEW
Brake pipe line (ABS)
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ROTOR INSPECTION
Thickness variation can be checked by
measuring the thickness of the rotor at four or
more points around the circumference of the
rotor. All measurements must be made at the
same distance in from the edge of the rotor.
If the thickness of the rotor is below 10mm
replace the brake rotor
Notice : Permissible lateral runout is a
maximum 0.05mm. If lateral runout exceeds
the specification, ensure there is no dirt
between the rotor and the hub and that
contact surface are smooth and free from
burrs,
1. Position the transaxle in NEUTRAL
2. Remove the rotor.
3. Fasten the brake rotor to the wheel hub
with two wheel bolts
4. Fasten a dial indicator to the brake caliper
5. Set the gauge probe tip to approximately
10mm from the outer edge of the brake rotor,
perpendicular to the disc and under slight
preload.
6. Remove the dial indicator and connecting
wheel bolts to the hub
Important : Since accurate control of the
rotor tolerances is necessary for proper
performance of the disc brakes, refinishing of
the rotor should be done only with precision
equipment
6. Refinish the rotor, if required, with precision
equipment. Discard the rotor if it fails to meet
the above specifications after refinishing.
7. Install the rotor
BRAKE
Rotor inspection
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GENERAL INFORMATION SUSPENSION
1.4L SOHC 1.5L SOHC 1.6L DOHC
10' 10' 10' 10' 10' 10'
Manual Steering 30'-2
o
30' - -
Power Steering 1
o
45' -3
o
45' 1
o
45' -3
o
45' 1
o
45' -3
o
45'
-1
o
10' -+20' -1
o
10' -+20' -1
o
10' -+20'
-10' -+ 40' -10' -+ 40' -10' -+ 40'
-2
o
10' - -1
o
10' -2
o
10' - -1
o
10' -2
o
10' - -1
o
10'
1.0 L 1.0 L 1.0 L Oil Capacity
Front Caster
Application
Toe-in ( 2 occupants)
Rear
Camber
Toe-in
Camber
Suspension
Wheel alignment
Application 1.4L SOHC 1.5L SOHC 1.6L DOHC
Front Macpherson Strut Macpherson Strut Macpherson Strut
Rear Compound Link Compound Link Compound Link
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FRONT / REAR SHOCK ABSORBER
IN EXPLODED VIEW
SUSPENSION
Front / Rear Suspension
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GENERAL INFORMATION
POWER
STEERING
1.4L SOHC 1.5L SOHC 1.6L DOHC
Rack & Pinion Rack & Pinion Rack & Pinion
24.5 : 1 - -
16.12 : 1 16.12 : 1 16.12 : 1
DEXRON-III DEXRON-III DEXRON-III
1.0 liter 1.0 liter 1.0 liter
Application
Power steering
pump
Type
Overall gear
ratio
Manual steering
Power steering
Capacity
Lubricant
Specification
Power steering
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POWER STEERING SYSTEM
POWER
STEERING
The power steering system is the system equipped with a hydraulic booster that
reduces the forces required to operate the steering wheel.
The power steering system consists of the following three major parts;
1. Pump : Generates hydraulic pressure of the power.
2, Control valve : Switches the oil passage to the power cylinder according to the
rotational direction of the steering wheel.
3. Power cylinder : Moves the piston in the cylinder right of left with hydraulic
force, and thereby assists the steering wheel operation.

Power steering system operation.
When the steering wheel is turned counter-clockwise (clockwise), hydraulic
pressure from the pump is shifted by the control valve and drawn into the power
cylinder piston is moved by the hydraulic pressure to the left; this assists the
steering wheel can be operated with a light force.
Power steering system
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POWER STEERING OIL PUMP
POWER
STEERING
Pump
Generally, there are two types of the pump
used for the power steering system.
Gear type pump
As the gears turn, fluid in the chamber (A)
enters the tooth groove of each gear and
flows along the inner circumference of the
pump to the chamber(B)
As the two gears engage in the chamber (B),
fluid in the tooth grooves is disengaged to
the control valve.
Power steering oil pump
(Control valve side)
Rotational direction of gear
Flow of fluid
Rotational direction of gear
Flow of fluid
Vane- type pump
The vane-type pump consists of the oval
cam ring, rotor and the vanes that rotate
while being pushed on the inner
circumference of the cam ring by the
centrifugal force of the rotor.
As the rotor turns and the volume of a vane
chamber increases; The fluid is discharged
to the control valve.
This intake / discharge operation is
performed at the top and bottom sections of
the drawling shown to the right; in other
words, each vane chamber performs two
intake/discharge operations for every
rotation of the rotor.

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CONTROL VALVE UNIT
POWER
STEERING
The valve unit consists of the two sections:
When the steering wheel is turned, the torsion bar twists according to the reaction force
of the road surface, when in turn produces the gap between the input shaft and valve.
The oil passage diameter changes according to this gap and, thereby, the flow volume is
controlled.
The input shaft and pinion shaft are engaged by the loose splines preventing the torsion
bar to be twisted more than the set angle.
Control valve unit
Torsion bar
Point shaft
Input shaft
Valve
To right power cylinder
From pump
To left power cylinder
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OPERATION OF
THE CONTROL VALVE
POWER
STEERING
The input shaft is in the neutral position
and fluid from the pump returns to the
reservoir through the rotary valve
When the steering wheel is not operated
When the steering wheel is operated
When the steering wheel is turned
counterclockwise, the input shaft
turns counter clockwise, too, opening
the passage of the power cylinder
side.
Fluid form the pump flows through the
rotary valve to the power cylinder
chamber (A). Fluid in the chamber (B)
is discharged by the piston and
returns to the reservoir.
When the steering wheel is turned
clockwise, the input shaft turns
clockwise, too, opening the valve
passage of the power cylinder
chamber (B) side.
Such operation is made through the
three portion on the circumference of
the input shaft and valve,that are
interconnected with the oil passages.
Power cylinder
(Neutral)
Power cylinder
(When operation)
Chamber
A
Chamber
B

Rotation direction
Flow of fluid (Return)
Flow of fluid (Intake)
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STEERING COLUMN
IN EXPLODED VIEW
POWER
STEERING
Steering column
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31
STEERING COLUMN (TILT)
IN EXPLODED VIEW
POWER
STEERING
Steering column (Tilt)
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STEERING GEAR UNIT
IN EXPLODED VIEW
POWER
STEERING
Steering gear unit
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POWER STEERING GEAR PARTS
IN EXPLODED VIEW
POWER
STEERING
Power steering gear parts
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POWER STEERING PIPE
IN EXPLODED VIEW
POWER
STEERING
Power steering pipe
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PRESSURE TEST
POWER
STEERING
Check the fluid pressure as follows to determine
whether the trouble is in the pump or the gear unit
1. Check the power steering fluid level and the pump drive
belt tension.
2. Disconnect the high pressure line at the pump. Use a
small container to catch any fluid
3.Connect the hose of the pressure the gauge kit(KM-354-
B) to the power steering pressure hose from the power
steering pump
4. Place the gear selector lever in PARK or NEUTRAL.
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 keep the normal operating
temperature.
8. Increase the engine speed to 1,500rpm
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
7088kPa to 8619kPa
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 limits, the
problem is not in the pump.
Check the power steering gear for leaks
Power Steering System Pressure test
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BLEEDING
POWER
STEERING
If the power steering hydraulic system has been
serviced, an accurate fluid level reading cannot be
obtained until the air is bled form the system
1. Turn the wheels all the way to the left and ad the power
steering fluid to the MIN mark on the fluid level indicator
Notice : When adding fluid or making a complete fluid,
always use DEXRON-III power steering fluid. Failure to
use the proper fluid will cause hose and seal damage and
fluid leaks
2. Start the engine. With the engine running at fast idle,
recheck the fluid level. If necessary, add fluid to bring the
level up to the MIN mark.
3. Bleed the system by turning the wheels from side to
side without reaching the stop at either end. Keep the fluid
level at the MIN mark. The air must be eliminated form the
fluid before normal steering action can be obtained.
4. Retune the wheels to the center position. Continue
running the engine for 2 to 3 minutes
5. Road test the car to be sure the steering functions
normally and is free from noise
6. Recheck the fluid level as described in step 1and 2.
Make sure the fluid level is at the MAX mark after the
system has stabilized at its normal operating temperature.
Add fluid as needed
Bleeding The Power Steering System