2004 DAEWOO NUBIRA steering

SECTION : 6C
POWER 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 LOCK unless otherwise noted.
TABLE OF CONTENTS
SPECIFICATIONS6C–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 6C–1. . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 6C–2. . . . . . . . . . .
SPECIAL TOOLS6C–2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Table 6C–2. . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS6C–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Rack and Pinion Steering Gear 6C–3. . . . . . . .
Power Rack and Pinion Steering Gear Bench
Testing 6C–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speed Sensitive Power Steering System 6C–6. . . . . .
Speed Sensitive Power Steering System Operating
With Full Assist At All Times 6C–7. . . . . . . . . . . . . . .
Speed Sensitive Power Steering System Operating
with Decreased Assist At All Times 6C–9. . . . . . . . .
MAINTENANCE AND REPAIR6C–11 . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 6C–11. . . . . . . . . . . . . . . . . . . .
Rack and Pinion Assembly 6C–11. . . . . . . . . . . . . . . . . Outer Tie Rod 6C–14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dust Boot 6C–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Straight–Ahead Check 6C–16. . . . . . . . . . . . . . . . . . . .
Intermediate Shaft and Dash Seal 6C–17. . . . . . . . . .
Hydraulic Cylinder Lines 6C–20. . . . . . . . . . . . . . . . . . .
Speed Sensitive Power Steering Control
Module 6C–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR 6C–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rack and Pinion 6C–22. . . . . . . . . . . . . . . . . . . . . . . . . .
Stub Shaft Seals and Upper and Lower
Bearing 6C–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rack Bearing 6C–29. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rack Bearing Preload Adjustment 6C–30. . . . . . . . . . .
Valve and Pinion 6C–30. . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION6C–33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Rack and Pinion 6C–33. . . . . . . . . . . . . . . . . . . .
Speed Sensitive Power Steering System 6C–33. . . . .
SPECIFICATIONS
GENERAL SPECIFICATIONS
ApplicationDescription
Capacity1.1 Liter (1.16 qt)
LubricantPower Steering Fluid DEXRON®–II or III

6C – 2IPOWER STEERING GEAR
DAEWOO V–121 BL4
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Adjuster Plug12–106
Adjuster Plug Locknut7556–
Control Module Bracket Bolts7–62
Dash Seal Retaining Ring Nuts7–62
Hydraulic Cylinder Line Fittings – Cylinder End2821–
Hydraulic Cylinder Line Fittings – Valve End1813–
Inner Tie Rod10074–
Intermediate Shaft Pinch Bolts2518–
Outer Tie Rod Adjusting Nut6447–
Outer Tie Rod Nuts5037–
Pinion Locknut3022–
Pinion Preload1–9
Steering Gear Inlet and Outlet Pipe Fittings2821–
Steering Gear Mounting Bracket Nuts and Bolts6044–
Transaxle Center Bracket–to–Engine Bolt8059–
SPECIAL TOOLS
SPECIAL TOOLS TABLE
KM–507–B
Ball Joint Remover
KM–J–26610
Installer
J–42459
Rack Guide Spring
Cap Wrench

POWER STEERING GEAR 6C – 3
DAEWOO V–121 BL4
DIAGNOSIS
POWER RACK AND PINION STEERING GEAR
Hissing Noise
ChecksAction
Check the intermediate shaft joints for looseness.Tighten the intermediate shaft joints.
Check the power steering hose for contact with other com-
ponents.Be sure the power steering hose is correctly fitted into the
hose clips.
Rattling Noise in Steering Gear
ChecksAction
Check the power steering hose for contact with the body.Be sure the power steering hose is correctly fitted into the
hose clips.
Check the steering gear for insufficient lubrication.Lubricate the steering gear.
Check the steering gear mounting for improper installa-
tion.Tighten the steering gear mounting bracket nuts and bolts.
Check the outer tie rods for improper installation.Tighten the outer tie rod joints. Replace the outer tie rods.
Poor Return of Steering Wheel to Center
ChecksAction
Check the steering wheel for contact with the turn signal
housing.Adjust the turn signal housing.
Check the intermediate shaft joints for binding or loose-
ness.Replace the intermediate shaft.
Check the power steering pump flow control valve for
sticking and improper alignment.Replace the power steering pump.
Check the wheel alignment.Align the wheels.
Check the wheel bearings for wear or damage.Replace the wheel bearings.
Check the intermediate shaft joints for improper installa-
tion.Adjust the intermediate shaft between the steering gear
and the steering column.
Replace the intermediate shaft.
Check the outer tie rods and the ball joints for binding or
looseness.Tighten the tie rods and the ball joints. Replace the tie rods
and the ball joints.
Check the steering gear adjustments.Perform a straight–ahead check.
Check the steering column shaft seal for rubbing on the
shaft.Replace the dash seal.
Check the steering shaft bearings for binding.Replace the stub shaft bearings.
Momentary Increase in Effort When Turning the Wheel Quickly
ChecksAction
Check the power steering pump for internal leaks.Replace the power steering pump.
Check the hoses for damage or restricted flow.Replace the power steering hoses and/or pipes.
Check the power steering fluid level.Fill the power steering fluid reservoir.
Check the power steering pump flow control valve for
sticking and improper operation.Replace the power steering pump.

6C – 4IPOWER STEERING GEAR
DAEWOO V–121 BL4
Steering Surges or Jerks When Turning with Engine Running
ChecksAction
Check the power steering pump for insufficient pressure.Replace the power steering pump.
Check the power steering pump flow control valve for
sticking and improper operation.Replace the power steering pump.
Check the power steering pump serpentine belt for slip-
page.Tighten the power steering serpentine belt.
Check for air contamination in the power steering system.Bleed the power steering system.
Steering Vibrates During Low Speed or Static Steering
ChecksAction
Check for air contamination in the power steering system.Bleed the power steering system.
Check the power steering pump serpentine belt for loose-
ness.Tighten the power steering serpentine belt.
Excessive Wheel Kickback or Loose Steering
ChecksAction
Check for air contamination in the power steering system.Bleed the power steering system.
Check the wheel bearings for wear or damage.Replace the wheel bearings.
Check the steering gear mounting for improper installa-
tion.Tighten the steering gear mounting bracket nuts and bolts.
Check the intermediate shaft joints for improper installa-
tion.Adjust the intermediate shaft between the steering gear
and the steering column.
Replace the intermediate shaft.
Check the outer tie rods and ball joints for looseness.Tighten the tie rods and the ball joints. Replace the tie rods
and the ball joints.
Hard Steering or Lack of Assist (Especially During Parking)
ChecksAction
Adjust the intermediate shaft between the steering gear
and the steering column. Replace the coupling flange.Adjust the steering coupling flange on the steering gear
and the steering column. Replace the coupling flange as
needed.
Check the power steering pump flow control valve for
sticking and improper installation.Replace the power steering pump.
Check the power steering pump for insufficient pressure.Replace the power steering pump.
Check the power steering pump for internal leaks.Replace the power steering pump.
Check for a loose or a worn intermediate shaft.Tighten the intermediate shaft. Replace the intermediate
shaft as needed.
Check the power steering pump serpentine belt tension.Tighten the power steering serpentine belt.

POWER STEERING GEAR 6C – 5
DAEWOO V–121 BL4
POWER RACK AND PINION
STEERING GEAR BENCH TESTING
Removal, Setup and Testing Procedure
Notice : Pressure checks or pressure and flow checks
may also be conducted using this set–up.
1. Disconnect and remove the power steering gear.
Refer to ”Rack and Pinion Assembly” in this sec-
tion.
2. Place the power steering gear on a bench next to
the vehicle.
3. Disconnect the pressure line at the point where the
hose connects to the pipe. Extend this line in order
to reach the power steering gear on the bench.
4. Disconnect the return line from the the power steer-
ing fluid reservoir. Extend this line in order to reach
the power steering gear on the bench.
5. Connect the power steering pipes to the power
steering gear.6. Start the engine and allow it to idle for 10 seconds.
7. Check the power steering fluid level. Refer to Sec-
tion 6A, Power Steering System.
8. Start the engine and turn the rack and pinion stub
shaft to a full turn in each direction. Hold the shaft
against each stop for 5 seconds.
9. Inspect for possible leak points. Refer to Section
6A, Power Steering System.
Installation Procedure
1. Stop the engine.
2. Disconnect the power steering pipes from the pow-
er steering gear.
3. Remove the extensions and reconnect the pressure
and return lines.
4. Install and connect the power steering gear. Refer
to ”Rack and Pinion Assembly” in this section.
5. Start the engine and stay idle for 10 seconds.
6. Check the power steering fluid level. Refer to Sec-
tion 6A, Power Steering System.

6C – 6IPOWER STEERING GEAR
DAEWOO V–121 BL4
SPEED SENSITIVE POWER STEERING SYSTEM

POWER STEERING GEAR 6C – 7
DAEWOO V–121 BL4
SPEED SENSITIVE POWER STEERING SYSTEM
OPERATING WITH FULL ASSIST AT ALL TIMES
StepActionValue(s)YesNo
1Perform an initial inspection of the power steering
system.
Is the system operational?–Go to Step 2Go to
Section 6A,
Power Steering
System
2Check the speedometer.
Is the speedometer inoperative?–Go to
Section5,
TransaxleGo to Step 3
3Check the diagnostic trouble codes at the engine
control module (ECM).
Is the ECM code 24 set?–Go to
Section1F,
Engine
ControlsGo to Step 4
41. Turn the ignition ON.
2. Disconnect the electronic variable orifice (EVO)
solenoid actuator electrical connector at the
power steering pump.
3. Probe terminal 1 of the EVO actuator connec-
tor with a voltmeter.
Does the voltmeter display the specified value?–Go to Step 6Go to Step 5
5Repair the open or short in the circuit between termi-
nal 1 of the EVO solenoid actuator electrical connec-
tor and terminal 2 on the speed sensitive power
steering (SSPS) control module connector.
Is the repair complete?–System OK–
61. Remove the EVO solenoid actuator from the
power steering pump.
2. Turn the actuator upside down to position the
pintle.
3. Stimulate the actuator by connecting it to the
battery.
Does the actuator click?–Go to Step 8Go to Step 7
7Replace the EVO solenoid actuator.
Is the repair complete?–System OK–
81. Turn the ignition OFF.
2. Remove the SSPS control module from the
control module bracket.
3. Disconnect the SSPS control module connec-
tor.
4. Connect a test light from terminal 8 on the
SSPS control module connector to the ground.
5. Turn the ignition ON.
Is the test light on?–Go to Step 14Go to Step 9
9Check the ignition fuse.
Is the ignition fuse open?–Go to Step 10Go to Step 11
10Replace the ignition fuse.
Is the repair complete?–System OK–
11Check for an open or short in the circuit between ter-
minal 8 of the control module connector and the I/P
fuse block.
Is the connection faulty?–Go to Step 12Go to Step 13

6C – 8IPOWER STEERING GEAR
DAEWOO V–121 BL4
StepNo Yes Value(s) Action
12Repair the open or short in the circuit between termi-
nal 8 of the SSPS control module connector and the
I/P fuse block.
Is the repair complete?–System OK–
13Repair the power feed to the ignition fuse F2.
Is the repair complete?–System OK–
141. Turn the ignition OFF.
2. Connect a test light from terminal 10 of the
SSPS control module connector to B+.
Is the test light on?–Go to Step 16Go to Step 15
15Repair the open in the ground circuit between termi-
nal 10 of the SSPS control module connector and
G203.
Is the repair complete?–System OK–
16Check for a short to B+ or an open in the circuit be-
tween terminal 1 of the SSPS control module con-
nector and terminal B of the EVO solenoid actuator
connector.
Is the connection faulty?–Go to Step 17Go to Step 18
17Repair the short to B+ or an open in the circuit be-
tween terminal 1 of the SSPS control module con-
nector and terminal 2 of the EVO solenoid actuator
connector.
Is the repair complete?–System OK–
181. Disconnect the steering wheel rotation sensor.
2. Turn the ignition ON.
3. Check for an open, short to ground, short to
B+, or poor terminal contact between terminal
5 of the SSPS control module connector and
terminal 1 of the steering wheel rotation sensor
connector.
Is the connection faulty?–Go to Step 19Go to Step 20
19Repair the open, short to ground, short to B+, or poor
terminal contact between terminal 5 of the SSPS
control module connector and terminal 1 of the
steering wheel rotation sensor connector.
Is the repair complete?–System OK–
20Check for an open between terminal 3 of the SSPS
control module connector and terminal 3 of the
steering wheel rotation sensor connector.
Is the connection faulty?–Go to Step 21Go to Step 22
21Repair the open between terminal 3 of the SSPS
control module connector and terminal 3 of the
steering wheel rotation sensor connector.
Is the repair complete?–System OK–
22Check for an open, short to ground, short to B+, or
poor terminal contact between terminal 14 of the
SSPS control module connector and terminal 2 of
the steering wheel rotation sensor connector.
Is the connection faulty?–Go to Step 23Go to Step 24