2003 DAEWOO MATIZ steering

6D –10 MANUAL STEERING GEAR
DAEWOO M-150 BL2
D15B511A
Installation Procedure
1. Install the mounting to the steering gear assembly.
2. Install the steering gear assembly.
3. Install the steering gear bracket with the bolts.
Tighten
Tighten the steering gear bracket bolts to 50–55 Nm
(36–41 lb-ft).
4. Install the front exhaust pipe nuts. Refer to Section
1G, Engine Exhaust.
5. Connect the tie rod end to the steering knuckle. Refer
to “Tie Rod End” in this section.
6. Install the wheels. Refer to Section 2E, Tires and
Wheels.
7. Install the intermediate shaft lower pinch bolt. Refer
to Section 6E, Steering Wheel and Column.

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).

MANUAL STEERING GEAR 6D–13
DAEWOO M-150 BL2
D105B708
4. Remove the rack bearing.

Remove the adjuster plug (1).

Remove the adjuster spring (2).
D105B709
5. Remove the pinion and bearing assembly.

Remove the dust cover (1).

Remove the pinion plug (2).
Important: Do not reuse the removed pinion plug.
D105B710

Remove the pinion and bearing assembly (3).
D105B711
6. Remove the rack gear toward the driver side of the
steering gear.
a. Rack gear.
Notice: Remove the rack gear toward the driver side of
the steering gear to prevent the bulk head in the steering
gear housing from damaging in installing and removing
the rack gear.

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.

MANUAL STEERING GEAR 6D–15
DAEWOO M-150 BL2
D105B716
5. Inspect the tie rod end ball joint and tie rod ball joint
for damage.

Inspect the tie rod end ball joint for operation (1).

Inspect the tie rod ball joint for operation and tie rod
deformation (2).
6. After inspecting the parts, replace the defected parts.
D105B717
Assembly Procedure
Important: Coat the all turn, contact and rub surface
with grease.
1. Clean the all parts removed.
2. Install the rack gear.

Coat the rack gear with grease (1).

Insert the rack gear carefully (2).
D15B718A
3. Install the pinion and bearing assembly.

Set the rack in balance (1).

Coat the pinion and bearing assembly and steering
gear housing surface with grease.

Install the pinion and bearing assembly (2).

Coat the pinion plug with Loctitte.

Install the pinion plug (3).
Tighten
Tighten the pinion plug to 40–60 Nm (30–44 lb-ft).

Install the dust cover (4).
D105B719
4. Install the rack bearing.

Coat the rack bearing with grease.

Install the rack bearing (1).

Install the adjuster spring (2).

Tighten the adjuster plug softly (3).

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.

MANUAL STEERING GEAR 6D–17
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Description
Type Rack and Pinion
Overall Gear Ratio 21 : 1
Inside39.5 ± 2 145,155 Tire
Outside

33.5 ± 2 Steering Angle Inside 34.9 ± 2 175 Tire Outside 30.5 ± 2 Rack Gear POLYUREAS Lubricant Ball Joint SYNTHETICS OILS & LI SOAPS Locktite Type DAC SPEC ADHESIVE SEALANT #520414
FASTENER TIGHTENING SPECIFICATIONS
Application Nm Lb-Ft Lb-In Tie Rod End Castellated Nut 30 – 55 21 – 41 – Tie Rod End Lock Nut 35 – 55 25 – 41 – Steering Gear Bracket Bolts 50 – 55 36 – 41 – Tie Rod–to–Rack Gear 80 – 120 59 – 89 – Pinion Plug 40 – 60 30 – 44 – Pinion Preload Refer to “Diagnosis” in this section.