2004 DAEWOO NUBIRA steering

POWER STEERING GEAR 6C – 25
DAEWOO V–121 BL4
5. Install the cylinder end dust boot retaining clamps
with the installer KM–J–22610.
6. Install the tie rod end boot retaining clamps.
7. Reposition the adjusting nut to the marks on the
inner tie rod and install the outer tie rod by twisting
it onto the inner tie rod.
8. Perform a front toe adjustment. Refer to Section
2B, Wheel Alignment.
9. Tighten the adjusting nut.
Tighten
Tighten the outer tie rod adjusting nut to 64 NSm (47
lb–ft).
10. Install the rack bearing assembly into the rack and
pinion steering assembly. Refer to ”Rack Bearing”
in this section.
11. Install the valve and pinion assembly into the rack
and pinion steering assembly. Refer to ”Valve and
Pinion” in this section.
12. Install the rack and pinion steering assembly into
the vehicle. Refer to ”Rack and Pinion Assembly”
in this section.

6C – 26IPOWER STEERING GEAR
DAEWOO V–121 BL4
STUB SHAFT SEALS AND UPPER
AND LOWER BEARING
Disassembly Procedure
1. Remove the rack and pinion steering assembly
from the vehicle. Refer to ”Rack and Pinion Assem-
bly” in this section.
2. Remove the dust cover from the lower end of the
housing.
Notice : If the stub shaft is not held, damage to the pinion
teeth will occur.
3. While holding the stub shaft with a wrench, remove
the locknut from the pinion.
4. With the gear centered, mark the location of the
stub shaft notch on the housing to aid in properly
installing the valve and pinion assembly.
5. Remove the stub shaft retaining ring and, using an
arbor press, press on the threaded end of the pin-
ion until it is possible to remove the pinion and
valve assembly from the housing.

POWER STEERING GEAR 6C – 27
DAEWOO V–121 BL4
6. Remove the stub shaft dust seal the stub shaft
bearing annulus assembly and the valve assembly
from the housing. Discard the stub shaft dust seal.
7. Remove the lower valve assembly bearing and the
bushing.
8. Remove the lower bearing assembly retaining ring
and press the lower bearing assembly from the low-
er end of the housing.
Assembly Procedure
Notice : Coat all the seals with power steering fluid to en-
sure proper sealing.
1. Install the lower bearing assembly and the lower
bearing assembly retaining ring into the lower end
of the housing.

6C – 28IPOWER STEERING GEAR
DAEWOO V–121 BL4
2. Install the lower valve assembly bearing and the
bushing.
3. Center the rack in the housing.
4. Install the the valve assembly, the stub shaft bear-
ing annulus assembly and a new stub shaft dust
seal into the housing.
Important : When the valve and pinion assembly is fully
seated in the housing, be sure that the notch in the stub
shaft and the mark on the housing line up.
Notice : If the stub shaft is not held, damage to the pinion
teeth will occur.
5. While holding the stub shaft, install the locknut onto
the pinion shaft.
Tighten
Tighten the pinion locknut to 30 NSm (22 lb–ft).
6. Replace the dust cover onto the housing.
7. Install the rack and pinion steering assembly. Refer
to ”Rack and Pinion Assembly” in this section.

POWER STEERING GEAR 6C – 29
DAEWOO V–121 BL4
RACK BEARING
Tools Required
J–42459 Rack Guide Spring Cap Wrench
Disassembly Procedure
1. Remove the rack and pinion steering assembly
from the vehicle. Refer to ”Rack and Pinion Assem-
bly” in this section.
2. Remove the adjuster plug locknut from the adjuster
plug, and remove the adjuster plug from the hous-
ing with the rack guide spring cap wrench J–42459,
or with a 19 mm allen wrench.
3. Remove the adjuster spring and the rack bearing.
Assembly Procedure
1. Coat the rack bearing, the adjuster spring and the
adjuster plug with lithium–based grease and install
them into the housing.
2. With the rack centered, turn the adjuster plug clock-
wise until a torque of 7 NSm (62 lb–in) is obtained,
then back it off by 30 to 40 degrees. Check the pin-
ion torque. Maximum pinion preloaded torque is 1
NSm (9 lb–in).
3. Thread the locknut on the adjuster plug and tighten
it.
Tighten
Tighten the adjuster plug locknut to 75 NSm (56 lb–ft)
while holding the adjuster plug stationary with the rack
guide spring cap wrench J–42459 or with a 19 mm al-
len wrench.
4. Install the rack and pinion assembly. Refer to ”Rack
and Pinion Assembly” in this section.

6C – 30IPOWER STEERING GEAR
DAEWOO V–121 BL4
RACK BEARING PRELOAD
ADJUSTMENT
Adjustment Procedure
1. Raise and suitably support the vehicle.
2. Center the steering wheel.
3. Remove the power steering gear. Refer to ”Rack
and Pinion Assembly” in this section.
4. Loosen the locknut and turn the adjuster plug clock-
wise until a torque of 7 NSm (62 lb–in) is obtained,
then loosen it by 30 to 40 degrees. Check the pin-
ion torque. Maximum pinion preloaded torque is 1
NSm (9 lb–in).
5. Tighten the locknut on the adjuster plug while hold-
ing the adjuster plug stationary.
6. Install the power steering gear. Refer to ”Rack and
Pinion Assembly” in this section.
7. Be sure to check the returnability of the steering
wheel to center position after adjustment.
Tighten
Tighten the adjuster plug locknut to 75 NSm (56 lb–ft).
VALVE AND PINION
Disassembly Procedure
1. Remove the rack and pinion steering assembly
from the vehicle. Refer to ”Rack and Pinion Assem-
bly” in this section.
2. Remove the dust cover from the lower end of the
housing.
Notice : If the stub shaft is not held, damage to the pinion
teeth will occur.
3. While holding the stub shaft, remove the locknut
from the pinion.

POWER STEERING GEAR 6C – 31
DAEWOO V–121 BL4
4. With the gear centered, mark the location of the
stub shaft notch on the housing to aid in properly
installing the pinion and valve assembly.
5. Remove the upper housing retaining ring and, using
an arbor press, press on the threaded end of the
pinion until it is possible to remove the valve and
pinion assembly from the housing.
6. Remove the stub shaft dust seal, the stub shaft
bearing annulus assembly and the valve and pinion
assembly from the housing.
7. Inspect the valve body rings for wear or damage.
Replace the valve body rings as needed. Coat the
rings with power steering fluid before installation.
8. Remove the lower pinion valve seal and bushing.
Discard the seal.

6C – 32IPOWER STEERING GEAR
DAEWOO V–121 BL4
Assembly Procedure
Notice : Coat all of the seals and bushings with power
steering fluid to ensure proper sealing.
1. Install the bushing and a new lower pinion valve
seal.
Important : When the valve and pinion assembly is fully
seated in the housing, be sure the notch in the stub shaft
and the mark on the housing line up. If this is not done the
vehicle will not pass the straight–ahead check and will
have poor steering performance.
2. Install the valve and pinion assembly, the stub shaft
bearing annulus assembly and the stub shaft dust
seal.
Notice : If the stub shaft is not held, damage to the pinion
teeth will occur.
3. While holding the stub shaft, tighten the locknut
onto the pinion shaft.
Tighten
Tighten the pinion locknut to 30 NSm (22 lb–ft).
4. Replace the dust cover onto the housing.
5. Install the rack and pinion steering assembly. Refer
to ”Rack and Pinion Assembly” in this section.
6. Perform the straight–ahead check. Refer to
”Straight–Ahead Check” in this section.