2003 DAEWOO MATIZ boot

MANUAL STEERING GEAR 6D–9
DAEWOO M-150 BL2
D105B507

Coat the greases on the tie rod to ease removal
(3).

Remove the boot (4).
D105B508
Installation Procedure
1. Install the rack and pinion boot with the clamp and the
wire clamp.
2. Install the tie rod end nut.
3. Install the tie rod end. Refer to “Tie Rod End” in this
section.
D105B509
D105B510
RACK AND PINION STEERING GEAR
ASSEMBLY
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Remove the intermediate shaft lower pinch bolt. Re-
fer to Section 6E, Steering Wheel and Column.
2. Remove the wheels. Refer to Section 2E, Tires and
Wheels.
3. Disconnect the tie rod end from the steering knuckle.
Refer to “Tie Rod End” in this section.
4. Remove the front exhaust pipe nuts. Refer to Section
1G, Engine Exhaust.
5. Remove the steering gear assembly from the vehicle.

Remove the steering gear bracket bolts (1).

Remove the steering gear bracket (2).

Remove the steering gear assembly.

Remove the packing (3).

MANUAL STEERING GEAR 6D–11
DAEWOO M-150 BL2
UNIT REPAIR
D105B701
TIE ROD END BOOT
Disassembly Procedure
1. Remove the tie rod end. Refer to “Tie Rod End” in this
section.
2. Remove the tie rod end boot.
a. Tie rod end boot.
D105B702
Assembly procedure
Important : Coat the grease inside of the boot.
1. Install the boot to the tie rod end.
2. Install the tie rod end wire clamp.
3. Install the tie rod end. Refer to “Tie Rod End” in this
section.
D105B703
RACK AND PINION
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Disassembly Procedure
1. Remove the rack and pinion steering assembly from
the vehicle. Refer to “Rock and Pinion Assembly” in
this section.
2. Remove the rack and pinion boot.

Remove the tie rod end. Refer to “Tie Rod End” in
this section (1).

Remove the tie rod lock nut (2).

Remove the rack and pinion boot clamp (3).

Cut off the rack and pinion boot wire (4).

6D –12 MANUAL STEERING GEAR
DAEWOO M-150 BL2
D105B704

Coat the greases on the tie rod (5).

Remove the rack and pinion boot (6).
D105B705
3. Remove the tie rod

Pull the rack gear perfectly from the steering gear
housing by turning the pinion gear (1).

Disconnect the shock damper ring from the tie rod
ball joint (2).
D15B706A

Vise the rack gear (3).
Important: Clothe the rack gear with a cloth before vis-
ing the rack gear.
Notice: Do not vise the rack gear over two teeth face.
D105B707

Remove the tie rod (4).

Remove the shock damper ring (5).

6D –14 MANUAL STEERING GEAR
DAEWOO M-150 BL2
D105B712
Inspection Procedure
1. Inspect the rack gear deformation and damage.

Set the V–block on the plate (1).

Set the rack gear on the V–block (2).

Check the rack gear for deformation using a dial
gauge (3).

Inspect the rack gear for wear and damage (4).
D105B713
2. Inspect the pinion and bearing assembly damage.

Inspect the pinion gear for wear and damage (1).

Inspect the bearing for loose and operation (2).
D105B714
3. Inspect the tie rod end boot and the rack and pinion
boot for damage.

Inspect the tie rod end boot for crack and wear (1).

Inspect the rack and pinion boot for crack and wear
(2).
D105B715
4. Inspect the steering gear housing for crack, deforma-
tion and wear.
a. Steering gear housing.

6D –16 MANUAL STEERING GEAR
DAEWOO M-150 BL2
D15B720A
5. Install the tie rod.

Install the shock damper ring to the rack gear (1).

Vise the rack gear (2).
Important : Clothe the rack gear with a cloth before vis-
ing the rack gear.
Notice: Do not vise the rack gear above two teeth face.

Coat the teeth face of the tie rod with Loctitte.

Install the tie rod (3).
Tighten
Tighten the tie rod to 80–120 Nm (59–89 lb-ft).
D105B721
6. Install the shock damper ring to the tie rod ball joint.
a. Tie rod ball joint.

Coat the tie rod ball joint with grease.
D105B722
7. Install the rack and pinion boot.

Install the rack and pinion boot (1).

Install the rack and pinion boot wire clamp (2).

Install the rack and pinion boot clamp (3).
8. Install the tie rod end. Refer to “Tie Rod End” in this
sections.
9. Install the rack and pinion steering gear assembly to
the vehicle. Refer to “Rack and Pinion Steering
Gear Assembly” in this section.
10. Adjust the free load of the steering gear. Refer to
“Diagnosis” in this section.

INTERIOR TRIM 9G–3
DAEWOO M-150 BL2
COMPONENT LOCATOR
INTERIOR TRIM
D19E402A
1. A–Pillar Trim Panel
2. B–Pillar Upper Trim Panel
3. C–Pillar Trim Panel
4. Front Rocker Trim Panel
5. B–Pillar Lower Trim Panel
6. Rear Rocker Trim Panel
7. Rear Parcel Side Shelf8. Wheel House Trim Panel
9. Floor Console
10. Parking Brake Cable Cover
11. Console Cover Assembly
12. Deposit Box
13. Console Boot Assembly

INTERIOR TRIM 9G–15
DAEWOO M-150 BL2
D19E573A
FLOOR CONSOLE
Removal Procedure
1. Remove the floor console screws.
D19E575A
2. Remove the gear shift lever boot cover and the floor
console.

Remove the gear shift lever boot cover (1).

Remove the screws (2).

Remove the floor console (3).
D19E576A
Installation Procedure
1. Install the floor console.
2. Install the gear shift lever boot cover to the floor con-
sole.
3. Tighten the floor console screws.
D109E577
PARKING BRAKE CABLE COVER
Removal Procedure
1. Remove the parking brake cable cover.

Remove the screw (1).

Remove the cable cover (2).

9K – 2 SQUEAKS AND RATTLES
DAEWOO M-150 BL2
SQUEAK AND RATTLE DIAGNOSIS (Cont’d)
ConditionProbable CauseCorrection
Squeak Coming From
Console When Shifting
Manual Transaxle
(Condition Occurs In
Cold Weather with a
Cold Engine)
The faulty manual transaxle
control lever lower boot.
Move the control lever between gears and
listen for squeaks.

Remove the floor console and replace the
lower shift boot or apply talcum powder to
the lower shift boot.
Squeak Coming From
Instrument Cluster Trim
Plate
Rubbing of the cluster trim plate
on the instrument panel.
Test drive the vehicle in order to verify this
condition.

Remove the instrument cluster trim plate and
install felt tape to the edges.