2003 DAEWOO MATIZ steering wheel

3B –4 MANUAL TRANSAXLE DRIVE AXLE
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
Condition Probable Cause Correction
Noise
Bent drive axle shaft.
Replace drive axle.





Worn the spline of drive axle shaft or joint
shaft.


Replace drive axle.

Worn joint by grease leakage.
Replace drive axle.
Steering Wheel
Bent drive axle shaft.
Replace drive axle.


Vibration


Worn the spline of drive axle shaft or joint
shaft.


Replace drive axle.
Car Lead / Pull
Worn joint by grease leakage.
Replace drive axle.
Boot Leak
Poor assembly of boot clamp.
Replace boot clamp.

Torn boot.
Replace Boot.

FRONT DISC BRAKES 4D–7
DAEWOO M-150 BL2
D107B504
CALIPER ASSEMBLY
Removal Procedure
1. Remove the front wheels. Refer to Section 2E, Tires
and Wheels.
2. Remove the caliper assembly.

Remove the brake hose coupling bolt (1).

Plug the opening in the brake hose to prevent fluid
loss and contamination.

Remove the caliper mounting bolts (2).
D17B505B
Installation Procedure
1. Install the caliper assembly with the bolts (1).
Tighten
Tighten the caliper–to–steering knuckle bolts to 95
Nm (70 lb-ft).
2. Connect the brake hose (2).
Tighten
Tighten the brake hose inlet fitting–to–coupling bolt to
25.5 Nm (19.1 lb-ft).
3. Install the front wheels. Refer to Section 2E, Tires
and Wheels.
4. Bleed the brake system. Refer to Section 4A, Hy-
draulic Brakes.
D117B506
ROTOR
Removal Procedure
1. Remove the steering knuckle. Refer to Section 2C,
Front Suspension.
2. Remove the rotor bolts from the front wheel hub.
3. Remove the rotor. Refer to Section 2C, Front Sus-
pension.
D17B507A
Installation Procedure
1. Install the rotor to the front wheel hub by tightening
the detent bolts.
Tighten
Tighten the rotor–to–front wheel hub detent bolts to
65 Nm (48 lb-ft).
2. Install the steering knuckle. Refer to Section 2C, Front
Suspension.

6C – 2 POWER STEERING GEAR
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
POWER RACK AND PINION
The power rack and pinion steering system has a rotary
control valve which directs the hydraulic fluid coming
from the hydraulic pump to one side or the other side of
the rack piston. The integral rack piston is attached to
the rack. The rack piston converts hydraulic pressure to
a linear force which moves the rack left or right. The
force is then transmitted through the tie rods and the tierod ends to the steering knuckles, which turn the
wheels.
If hydraulic assist is not available, manual control is
maintained. However, under these conditions, more
steering effort is required. The movement of the steering
wheel is transferred to the pinion. The movement of the
pinion is then transferred through the pinion teeth, which
meshs with the teeth on the rack, causing the rack to
move.

POWER STEERING GEAR 6C–3
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
POWER RACK AND PINION STERING GEAR
ConditionProbable CauseCorrection
Hissing Noise
Loose steering coupling joints.
Tighten the steering coupling
joints.

Improperly contacted the power
steering hose with other
components.
Fit the power steerng hose into
the hose clips correctly.
Rattling Noise in Steering Gear
Improperly contacted the power
steering line with the body.
Fix the steering line correctly.

Insufficient lubricant.
Lubricate the steering gear.

Loose steering gear mounting.
Tighten the steering gear
mounting bracket bolts.

Improperly installed tie rod ends.
Tighten the tie rod joints and
replace the tie rod end as needed.
Poor Return of Steering Wheel
to Center
Improperly contacted the steering
wheel with the turn signal housing.
Adjust the turn signal housing.

Improper binding or looseness of
steering coupling.
Replace the intermediate shaft.

Stuck and improperly aligned
power steering pump flow control
valve.
Replace the power steering pump.

Improper binding or looseness of
tie rods and ball joints.
Tighten the tie rods and the ball
joints. Replace the tie rods and
the ball joints as needed.

Poor adjustments of the steering
gear.
Perform a straight-ahead check.
Momentary Increase in Effect
When Turning the Wheel
Internal leaks of the power
steering pump.
Replace the power steering pump.
Quickly
The damage or restricted flow of
the hoses.
Replace the power steering hoses
and pipes.

Insufficient power steering fluid.
Fill the power steering fluid
reservoir.

Stuck and improperly operated
power steering pump flow control
valve.
Replace the power steering pump.
Steering Surges or Jerks When
Turning with Engine Running
Insufficient pressure of the power
steering pump.
Replace the power steering pump.

Stuck and improperly operated
power steering pump flow control
valve.
Replace the power steering pump.

The slippage of the pump drive
belt.
Tighten the pump drive belt.

Contaminated air in the power
steering system.
Bleed the power steering system.

6C –4 POWER STEERING GEAR
DAEWOO M-150 BL2
POWER RACK AND PINION STERING GEAR (Cont’d)
ConditionProbable CauseCorrection
Excessive Wheel Kickback or
Loose Steering
Contaminated air in the power
steering system.
Bleed the power steering system.

Worn or damaged wheel bearings.
Replace the wheel bearings.

Loose steering gear mounting.
Tighten the steering gear
mounting bracket bolts.

Improperly installed steering
gear-to-intermediate shaft joints.
Tighten the joint bolt.

Loose tie rods and ball joints.
Tighten the tie rods and the ball
joints.

Replace the tie rods and the ball
joints as needed.
Hard Steering or Lack of Assist
(Especially During Parking)
Stuck and improperly installed
power steering pump flow control
valve.
Replace the power steering pump.

Insufficient pressure of the power
steering pump.
Replace the power steering pump.

Internal leaks of power steering
pump.
Replace the power steering pump.

Improper tension of the pump
drive belt.
Adjust the pump drive belt
tension.

POWER STEERING GEAR 6C–5
DAEWOO M-150 BL2
ADJUST THE FREE LOAD OF THE
STEERING GEAR
1. Place the steering wheel in the straight-ahead posi-
tion.
2. Raise and suitably support the vehicle.
3. Remove the adjust plug locknut.
4. Check the torque of the adjuster plug.
5. Check the torque is below the specification value or
the measured torque is over the specification value,
adjust the tightening torque.

Place the rack gear in the straight-ahead position.

Tighten the adjust plug to 10 Nm (89 lb-in).

Turn the steering wheel all the way to the right and
the left about 5 times repeatedly.

Place the rack gear in the straight-ahead position.

Loosen the adjust plug.
D105C302

Tighten the adjust plug to 4.5–5.5 Nm (40–49 lb-
in).

Loosen the adjust plug to 67.5.
6. Tighten the adjust plug locknut.

6C –6 POWER STEERING GEAR
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
RACK AND PINION 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 wheel. Refer to Section 2E, Tires and
Wheels.
3. Remove the tie rod ends. Refer to Section 6D, Manu-
al Steering Gear.
4. Remove the front exhaust pipe nuts. Refer to Section
1G, Engine Exhaust.
D105C534
5. Remove the rack and pinion assembly.

Disconnect the return line pipe from the steering
gear (1).

Disconnect the pressure inlet line pipe from the
steering gear (2).

Plug the opening in the power steering pipe line to
prevent fluid loss and contamination.
D105C535

Remove the power steering gear retaining bracket
tighten bolts (3).

Remove the power steering gear retaining bracket
(4).
Important: After moving the gear toward the passenger
side and pulling the gear of the driver side into the un-
derbody hole, remove the steering gear.

DAEWOO M-150 BL2
SECTION 6D
MANUAL STEERING GEAR
CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise
noted.
TABLE OF CONTENTS
Description and Operation 6D-2. . . . . . . . . . . . . . . . . .
Manual Rack and Pinion 6D-2. . . . . . . . . . . . . . . . . . . .
Component Locator 6D-3. . . . . . . . . . . . . . . . . . . . . . . .
Manual Rack and Pinion Steering Gear 6D-3. . . . . . .
Diagnostic Information and Procedures 6D-4. . . . .
Manual Rack and Pinion Steering Gear 6D-4. . . . . . .
Straight-Ahead Check 6D-5. . . . . . . . . . . . . . . . . . . . . .
Steering Wheel Restoration 6D-6. . . . . . . . . . . . . . . . .
Check The Turning Resistance of the
Tie Rod End or Tie Rod 6D-6. . . . . . . . . . . . . . . . . . . .
Adjust the Free Load of the Steering Gear 6D-6. . . .
Repair Instructions 6D-7. . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service 6D-7. . . . . . . . . . . . . . . . . . . . . . . . . .
Tie Rod End 6D-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rack and Pinion Boot 6D-8. . . . . . . . . . . . . . . . . . . . . .
Rack and Pinion Steering Gear Assembly 6D-9. . . .
Unit Repair 6D-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tie Rod End Boot 6D-11. . . . . . . . . . . . . . . . . . . . . . . .
Rack and Pinion 6D-11. . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 6D-17. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 6D-17. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 6D-17. . . . . . . . . .
Special Tools and Equipment 6D-18. . . . . . . . . . . . . .
Special Tools Table 6D-18. . . . . . . . . . . . . . . . . . . . . . .