new lanos1 chassis(0-36)
TRANSCRIPT
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