2003 DAEWOO MATIZ steering

POWER STEERING GEAR 6C–7
DAEWOO M-150 BL2
D105C536
6. Remove the packing (5).
D15C537A
Installation Procedure
1. Install in the reverse order of removal.
2. Install the power steering gear bracket with the bolt.
Tighten
Tighten the bracket bolts to 50–55 Nm (36–41 lb-ft).
D15C512A
21–35 Nm21–35 Nm3. Connect the steering pipe. Refer to Section 6A, Pow-
er Steering System.
Tighten
Tighten the power steering pressure line fitting (1) to
21–35 Nm (16–25 lb-ft) (1).
Tighten the return line fitting to 21–35 Nm (16–25 lb-
ft) (2).
Important: When adding fluid or making a complete
fluid change, always use DEXRON II or III power
steering fluid. Failure to use the proper fluid will cause
hose and seal change and fluid leaks.
4. Fill the fluid reservoir with power steering fluid.
5. Inspect for leaks. If there are leaks, correct the cause
of the leaks and bleed the system. Refer to Section
6A, Power Steering System.
POWER STEERING GEAR RACK
AND PINION BOOT
Refer to Section 6D, Manual Steering Gear.

6C –8 POWER STEERING GEAR
DAEWOO M-150 BL2
UNIT REPAIR
TIE ROD END BOOT
Refer to Section 6D, Manual Steering Gear.
D105C701
HYDRAULIC CYLINDER LINES
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Disassembly Procedure
1. Remove the rack and pinion steering assembly from
the vehicle. Refer to “Rack and Pinion Assembly” in
this section.
2. Disconnect the cylinder lines from the rack and pinion
housing.

Remove the fitting (1).

Remove the fitting (2).
D15C715A
Assembly Procedure
1. Connect the cylinder lines to the rack and pinion
housing.
2. Install the power steering line fittings at the pinion
valve end.
Tighten
Tighten the power steering line fittings to 25–35 Nm
(18–25 lb-ft) (1).
3. Install the power steering line fittings at the cylinder
end.
Tighten
Tighten the power steering line fittings to 25–35 Nm
(18–25 lb-ft) (2).
4. Install the rack and pinion steering assembly to the
vehicle. Refer to “Rack and Pinion Assembly” in this
section.

POWER STEERING GEAR 6C–9
DAEWOO M-150 BL2
D105C702
RACK AND PINION STEERING GEAR
ASSEMBLY
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Disassembly Procedure
1. Remove the rack and pinion steering assembly from
the vehicle. Refer to “Rack and Pinion Assembly” in
this section.
2. Remove the rack bearing.

Remove the adjuster plug locknut (1).

Remove the adjuster plug (2).

Remove the adjuster spring (3).
D105C703
3. Remove the steering pinion.

Remove the dust cap (1).

Remove the retaining ring (2).
D105C704

Remove the steering pinion dust cap (3).

Remove the steering pinion locknut (4).
Notice: If the stub shaft is not held, damage to the pin-
ion teeth will occur. While holding the stub shaft, remove
the locknut from the pinion.
D105C705

Remove the steering pinion from the pinion bear-
ing by hitting the pinion with the flated drift and
hammer (5).

6C –10 POWER STEERING GEAR
DAEWOO M-150 BL2
D105C706
Important: Hit the drift using a hammer when the lower
pinion is vertical with the drift.

Remove the bearing by hitting the bearing with the
flated drift and rubber hammer (6).
D105C707

Remove the pinion shaft seal (7).

Remove the needle bearing (8).

Remove the retaining ring (9).
Important: The power steering gear housing and the
rack gear in this vehicle is not serviceable as unit.
The faulty parts must be replaced as whole units.
D105C708
Inspection Procedure
1. Inspect the tie rod ends and the ball joints for dam-
age. Refer to Section 6D, Manual Steering Gear.
2. Inspect the tie rod ends and the rack/pinion boot for
cracks or abnormal wear. Refer to Section 6D, Manu-
al Steering Gear.
3. Inspect the metal part for damage.

Inspect the pinion gear for damage or wear (1).
D105C709

Inspect the rack gear for damage or wear (2).

Inspect the steering gear housing for damage or
wear(3).

POWER STEERING GEAR 6C–11
DAEWOO M-150 BL2
D105C710
4. Inspect the bearings and the seal for damage.

Inspect the pinion shaft seal for leaks and wear (1).

Inspect the needle bearing for wear (2).

Inspect the pinion bearing for wear (3).
5. The faulty parts must be replaced.
D105C711
Assembly Procedrue
1. Install the steering pinion gear.

Install the retaining ring (1).

Install the needle bearing (2).

Install the pinion shaft seal using a drift (3).
D105C712
40–50 Nm2. Install the steering pinion locknut (4).
Tighten
Tighten the pinion locknut to 40–50 Nm (30–36 lb-ft).
D15C713A
45–55 Nm3. Install the dust cap (5).
Tighten
Tighten the dust cap to 45–55 Nm (33–41 lb-ft).
4. Install the retaining ring (6).
5. Install the plastic dust cap (7).

6C –12 POWER STEERING GEAR
DAEWOO M-150 BL2
D105C714
6. Install the rack bearing.

Install the adjuster spring (1).

Tighten the adjuster plug (2).

Tighten the plug locknut (3).
7. Install the rack and pinion steering assembly to the
vehicle. Refer to “ Rack and Pinion Assembly ” in this
section.

POWER STEERING GEAR 6C–13
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS
ApplicationDescription
Power Steering FluidPower Steering Fluid DEXRON-II or DEXRON-III
Capacity1.0 L (1.056 qt)
TypeRack and Pinion
Overall Gear Ratio15.7 : 1
Power Steering Angle144, 155Inside39.5± 2
TireOutside33.5± 2
175 TireInside34.9± 2
Outside30.5± 2
GreaseRackPOLYUREAS
Ball JointSYNTHETICS OILS & LI SOAPS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNmLb-FtLb-In
Power Steering Gear Bracket Bolt50–5536–41–
Power Steering Gear Pinion Nut40–5030–36–
Power Steering Gear Pinion Dust Cover45–5533–41–
Power Steering Gear Pressure Line Fitting25–3518–25–
Power Steering Oil Pressure Pipe Fitting (Gear Side)21–3516–25–
Power Steering Gear Ajuster PlugRefer to “DIAGNOSIS” in this section.

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. . . . . . . . . . . . . . . . . . . . . . .