2003 DAEWOO MATIZ Service Repair Manual

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

6D – 2 MANUAL STEERING GEAR
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
MANUAL RACK AND PINION
The manual rack and pinion steering system consists of
two main components: the rack and the pinion. The mo-
tion of the pinion is transferred through the pinion teeth
that mesh with the teeth on the rack, which moves the
rack. The force is then transmitted through the arms on
the struts, which turn the wheels.

MANUAL STEERING GEAR 6D–3
DAEWOO M-150 BL2
COMPONENT LOCATOR
MANUAL RACK AND PINION STEERING GEAR
(Left–Hand Drive Shown, Right–Hand Drive Similar)
D105B401
1. Manual Steering Gear
2. Steering Gear Bracket
3. Cotter Pin
4. Castellated Nut
5. Tie Rod End
6. Tie Rod End Lock Nut
7. Rack and Pinion Boot Clamp
8. Rack and Pinion Boot
9. Rack and Pinion Boot Wire Clamp
10. Tie Rod
11. Shock Damper Ring
12. Steering Rack Gear13. Bulkhead Retainer
14. Bulkhead Bushing
15. Steering Gear Housing
16. Steering Gear Bracket Bushing
17. Packing
18. Dust Cover
19. Pinion Plug
20. Steering Pinion Gear
21. Roller Bearing
22. Rack Bearing
23. Adjuster Spring
24. Adjuster Plug

6D –4 MANUAL STEERING GEAR
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
MANUAL RACK AND PINION STEERING GEAR
ConditionProbable CauseCorrection
Excessive Play or
Poor adjustment of steering gear.
Perform straight–ahead check.
Looseness in the
Steering System
Improperly installed tie rods.
Tighten the tie rods.

Improper and insufficient lubrication.
Lubricate the rack and pinion
assembly.
Rattling Noise in the
Steering Gear

Improperly installed steering gear mounting.
Tighten the steering gear mounting
bolts.

Improperly installed tie rods.
Tighten the tie rods.