SERVICE TRAINING MANUAL

Chassis /Optional

Lanos (New)

DAEWOO DAEWOO MOTOR CO., LTD

CONTENTS

I.Chassis……...……………...…………………… 5

II.ABS (Bosch)…………………….……….…39

III.Air Conditioner……………………..………75

IV.SIR System………………………….……..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

6

T - 150GENERAL INFORMATIONCLUTCH

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 justbefore clutch connection (B)

Application

Clutch Disc

7

T - 150CLUTCH COMPONENTSCLUTCH

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

8

T - 150GENERAL 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 driveratio

Fluid change is not requiredMaintenance interval

Gear ratio

Oil capcity (L)

1.6L DOHCApplication

1.4L SOHCWide Ratio

1.5L SOHCMedium Ratio

TRANSAXLE

Manual transaxle

Specification

9

T - 150SHIFT LINKAGETRANSAXLE

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 housing10. Shift rod clamp bolt11. Washer12. Clamp13. Linkage adjuster bolt14. Gearshift control rod15. Linkage ball socket16. Circlip ring17. Linkage reverse lever18. Gearshift boot19. Bushing20. Bushing21. Rod U-joint bushing22. Clip23. Gearshift rod24. Shift finger lever25. Cover bolt26. Intermediate lever27. Shift lever thrust spring28. Bushing29. Snap ring30. Oil filler plug31. Oil filler plug

Shift Linkage

31. Oil filler plug32. Gearshift lever cover33. Pin34. Bolt

35. Gearshift adjuster linkage36. Shift reverse pivot bolt37. Boot38. Gearshift tube39. Bushing40. Gearshift tube bearing

10

T - 150DIFFERENTIAL & CASETRANSAXLE

Differential and Case

1. Speedometer driven gear2. Sea;3. Hex bolt4. Bearing plate5. Washer6. Bolt7. Seal8. Seal9. Bearing adjusting ring10. Side bearing race11. Housing cover gasket12. Differential cover13. Bolt14. Differential bearing

15. Pinion gear shart1.16. Differential housing17. Thrust washer18. Side gear19. Washer20. Pinion gear21. Ring gear22. Speedometer drive gear23. Bolt24. Pinion side bearing retainer25. Right side bearing retainer26. Seal27. Retainer bolt

11

T - 150TRANSAXLE GEAR IN EXPLODED VIEWTRANSAXLE

Manual transaxle gear

12

T - 150TRANSAXLE GEAR IN EXPLODED VIEWTRANSAXLE

Manual transaxle gear

1. Case2. Mainshaft bearing3. Fourth gear4. Synchronizer blocking ring5. Synchronizer sleeve6. Pin7. Third-Fourth gearshift fork8. Third-Fourth gearshift shaft9. Spring10. Key11. Third-Fourth synchronizer gear12. Synchronizer blocking ring13. Third gear14. Second gear15. First-Second gear blocking ring16. First-Second gearshift shaft17. First-Second gearshift shaft18. Synchronizer hub sleeve19. Synchronizer spring20. Key21. First-Second synchronizer gear22. Snap ring23. Outer blocking ring24. First gear25. First gear needle bearing26. Mainshaft wear plate27. Snap ring28. Mainshaft bearing29. Shift rod plug (21.5mm)30. Spring31. Shift rod lock pin32. Bearing plate33. Shift rod plug34. Detent rod bolt35. Bolt36. Bolt37. Support38. Fifth gearshift fork39. Pin40. Fifth gear connector41. Shoe42. Key43 Snap ring

44. Gasket45. Cover46. Bolt47. Plug48. Bolt49. Screw50. Synchronizer gear51. Spring52. Synchronizer blocking ring53. Synchronizer blocking ring54. Mainshaft driven fifth gear55. Ring56. Thrust washer57. Ring58. Input drive fifth gear59. Bolt60. Cluster gear snap ring61. Screw62. Cluster shaft bearing63. Ring64. Input shaft cluster gear65. Ball66. Reverse idler gear shaft67. Reverse idler gear68. Washer69. Reverse gear fork shaft70. Reverse gearshift 71. Input drive shaft72. Bolt73. Fifth-gear pawl74. Fifth gear needle bearing75. First-gear needle bearing76. Main driven shaft77. Fifth gearshift lever78. Hex plug79. Gasket80. Reverse lamp switch81. Input shaft bearing82. Second gear needle bearing83. Third gear needle bearing84. Fourth-gear needle bearing85. Washer

13

T - 150SPECIAL TOOLSTRANSAXLE

Special tools

KM -113-2Base

KM -334Install sleeve

KM-553-AFifth-gear puller

J-22888-20ABearing puller

J-28469-AEngine-support

fixture

J-36633Snap ring retainer

J-6125-BSlide hammer

J-22912-01Universal bearing

puller

14

T - 150GENERAL INFORMATIONBRAKE

1.3L SOHC 1.5L SOHC 1.6L DOHC

228.6 228.6 228.6

5.0 : 1 5.0 : 1 5.0 : 1

Mastercylinder

20.64 20.64 22.22

Front brake Ventilated Ventilated Ventilated

Insidediameter(mm)

200 200 200

Wheel cylinderdiameter (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

Rearbrake

Application

Bore Diameter (mm)

Disc type

Size (mm)

Ratio

Drumtype

Brake system

15

T - 150BRAKE FRONT BRAKE

Front brake

16

T - 150FRONT BRAKEBRAKE

Front brake

17

T - 150REAR BRAKE (DRUM)IN EXPLODED VIEW

BRAKE

Rear brake (Drum)

18

T - 150PARKING BRAKE IN EXPLODED VIEWBRAKE

Parking brake

19

T - 150MASTER CYLINDER & BOOSTER

IN EXPLODED VIEWBRAKE

Master cylinder & Booster

20

T - 150BRAKE PEDAL IN EXPLODED VIEWBRAKE

Brake pedal

21

T - 150BRAKE PIPE LINE (NON ABS)

IN EXPLODED VIEWBRAKE

Brake pipe line ( Non ABS)

22

T - 150BRAKE BRAKE PIPE LINE (ABS) IN EXPLODED VIEW

Brake pipe line (ABS)

23

T - 150ROTOR INSPECTION

Thickness variation can be checked by meas

uring 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 re

place the brake rotor

Notice : Permissible lateral runout is a maxim

um 0.05mm. If lateral runout exceeds the spe

cification, 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 wit

h two wheel bolts

4. Fasten a dial indicator to the brake caliper

5. Set the gauge probe tip to approximately 1

0mm from the outer edge of the brake rotor, p

erpendicular to the disc and under slight prelo

ad.

6. Remove the dial indicator and connecting

wheel bolts to the hub

Important : Since accurate control of the roto

r tolerances is necessary for proper performa

nce of the disc brakes, refinishing of the rotor

should be done only with precision equipment

6. Refinish the rotor, if required, with precisio

n equipment. Discard the rotor if it fails to me

et the above specifications after refinishing.

7. Install the rotor

BRAKE

Rotor inspection

24

T - 150GENERAL INFORMATIONSUSPENSION

1.4L SOHC 1.5L SOHC 1.6L DOHC

10' ± 10' 10' ± 10' 10' ± 10'

Manual Steering 30'-2o 30' - -

Power Steering 1o 45' -3o 45' 1o 45' -3o 45' 1o 45' -3o 45'

-1o 10' -+20' -1o 10' -+20' -1o 10' -+20'

-10' -+ 40' -10' -+ 40' -10' -+ 40'

-2o 10' - -1o 10' -2o 10' - -1o 10' -2o 10' - -1o 10'

1.0 L 1.0 L 1.0 LOil 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

25

T - 150FRONT / REAR SHOCK ABSORBER

IN EXPLODED VIEWSUSPENSION

Front / Rear Suspension

26

T - 150GENERAL INFORMATIONPOWER

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 steeringpump

Type

Overall gearratio

Manual steering

Power steering

Capacity

Lubricant

Specification

Power steering

27

T - 150POWER STEERING SYSTEMPOWER

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

28

T - 150POWER STEERING OIL PUMPPOWER

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.

29

T - 150CONTROL VALVE UNITPOWER

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

30

T - 150OPERATION OF

THE CONTROL VALVEPOWER

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)

ChamberA

ChamberB

Rotation direction

Flow of fluid (Return)Flow of fluid (Intake)

31

T - 150STEERING COLUMN IN EXPLODED VIEW

POWER STEERING

Steering column

32

T - 150STEERING COLUMN (TILT)

IN EXPLODED VIEWPOWER

STEERING

Steering column (Tilt)

33

T - 150STEERING GEAR UNIT

IN EXPLODED VIEWPOWER

STEERING

Steering gear unit

34

T - 150POWER STEERING GEAR PARTS

IN EXPLODED VIEWPOWER

STEERING

Power steering gear parts

35

T - 150POWER STEERING PIPE

IN EXPLODED VIEWPOWER

STEERING

Power steering pipe

36

T - 150PRESSURE TESTPOWER

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

37

T - 150BLEEDINGPOWER

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