DAEWOO LACETTI 2004 Service Repair Manual

6C – 14IPOWER STEERING GEAR
DAEWOO V–121 BL4
9. Install the lower intermediate shaft pinch bolt.
Tighten
Tighten the lower intermediate shaft pinch bolt to 25
NSm (18 lb–ft).
10. Connect the power steering gear fluid inlet and out-
let pipe.
Tighten
Tighten the steering gear inlet and outlet pipe fitting
to 28 NSm (21 lb–ft).
11. Perform a front toe adjustment. Refer to Section
2B, Wheel Alignment.
12. Install the wheels. Refer to Section 2E, Tires and
Wheels.
13. Lower the vehicle.
14. Do a straight–ahead check. Refer to ”Straight–
Ahead Check” in this section.
Notice : When adding fluid or making a complete fluid
change, always use power steering fluid DEXRON®–II or
III or equivalent. Failure to use the proper fluid will cause
hose and seal damage and fluid leaks.
15. Refill the power steering system and check for
leaks. If leaks are found, correct the cause of the
leak and bleed the system. Refer to Section 6A,
Power Steering System.
16. Connect the negative battery cable.
OUTER TIE ROD
Tools Required
KM–507–B Ball Joint Remover
Removal Procedure
1. Remove the wheel. Refer to Section 2E, Tires and
Wheels.
2. Mark the threads on the inner tie rod to aid in re-
positioning the adjusting nut.
3. Remove the outer tie rod nut and disconnect the
outer tie rod from the steering knuckle using the
ball joint remover KM–507–B.

POWER STEERING GEAR 6C – 15
DAEWOO V–121 BL4
4. Loosen the outer tie rod adjusting nut and remove
the outer tie rod by twisting it off the inner tie rod.
Installation Procedure
1. Reposition the adjusting nut to the marks on the
inner tie rod.
2. Install the outer tie rod by twisting it onto the inner
tie rod.
3. Connect the outer tie rod to the steering knuckle.
4. Perform a front toe adjustment. Refer to Section
2B, Wheel Alignment.
5. Tighten the adjusting nut.
Tighten
Tighten the outer tie rod adjusting nut to 64 NSm (47
lb–ft).
6. Install the outer tie rod nut.
Tighten
Tighten the outer tie rod nut to 50 NSm (37 lb–ft).
7. Install the wheel. Refer to Section 2E, Tires and
Wheels.
DUST BOOT
Tools Required
KM–J–22610 Installer
Removal Procedure
1. Raise and suitably support the vehicle.
2. Remove the wheel. Refer to Section 2E, Tires and
Wheels.
3. Remove the outer tie rod. Refer to ”Outer Tie Rod”
in this section.
4. Remove the dust boot retaining clamps.
5. Remove the dust boot.

6C – 16IPOWER STEERING GEAR
DAEWOO V–121 BL4
Installation Procedure
1. Install the dust boot.
2. Install the tie rod end dust boot retaining clamp.
Install the cylinder end dust boot retaining clamp
with the installer KM–J–22610.
3. Install the outer tie rod. Refer to ”Outer Tie Rod” in
this section.
4. Install the wheel. Refer to Section 2E, Tires and
Wheels.
5. Lower the vehicle.
STRAIGHT–AHEAD CHECK
After all the necessary operations on the steering gear are
completed (removing and installing, disassembling and
assembling), check the exact straight–ahead position of
the steering in each case.
With the vehicle on the floor, place the steering wheel in
the straight–ahead position. Mark the centerline of both
tires on the floor. Turn the steering wheel all the way to the
right and mark the new centerline of both tires on the floor.

POWER STEERING GEAR 6C – 17
DAEWOO V–121 BL4
Straight–Ahead Check Table
StepActionValue(s)YesNo
1Place the steering wheel in the straight–
ahead position.
Is the wheel in the correct position?–Go to
Step 2–
2Is the lower intermediate shaft pinch bolt lying
parallel to the steering gear?–Go to
Step 3Go to
Step 4
3Is the steering wheel off center by more than
5 degrees?–Go to
Step 5Go to
Step 6
4The pinion is displaced on the rack. The steer-
ing pinion position must be corrected.
Is the repair complete?–Go to
Step 2–
5Remove steering wheel and center on the
spindle splines.
Is the repair complete?–Go to
Step 3–
6Turn the steering wheel all the way to the
right. Measure the inner and the outer angles
of the tire centerline compared to the straight–
ahead centerline. Are the angles within speci-
fications?Inner
angle:
37.5°
Outer
angle: 31°System
OKGo to
Step 7
7The rack assembly was not assembled cor-
rectly.
Repair as needed.
Is the repair complete?–Go to
Step 6–
INTERMEDIATE SHAFT AND DASH
SEAL
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Turn the steering wheel until it is horizontal, with the
spokes pointing down. This is the straight–ahead
position. Make a mark on the stub shaft housing
that lines up with a mark on the intermediate shaft
lower universal joint. This mark will be used for
proper alignment during installation.
2. Remove the lower pinch bolt from the universal joint
on the intermediate shaft.

6C – 18IPOWER STEERING GEAR
DAEWOO V–121 BL4
3. Turn the steering wheel so that the upper pinch bolt
is accessible. Remove the upper pinch bolt from
the universal joint on the intermediate shaft.
4. Remove the nuts from the dash seal retaining ring
and remove the dash seal retaining ring.
5. Remove the coupling from the power steering gear
and pull the intermediate shaft out of the engine
compartment.
Installation Procedure
1. Install the intermediate shaft into the vehicle.

POWER STEERING GEAR 6C – 19
DAEWOO V–121 BL4
2. Install the dash seal retaining ring with the nuts.
Tighten
Tighten the dash seal retaining ring nuts to 7 NSm (62
lb–in).
Important : When attaching the upper universal joint, the
steering wheel must be placed in the straight–ahead posi-
tion with the spokes pointing down.
3. Attach the upper universal joint of the intermediate
shaft onto the steering column.
4. Install the pinch bolt into the upper universal joint
on the intermediate shaft and tighten the bolt.
Tighten
Tighten the upper intermediate shaft pinch bolt to 22
NSm (16 lb–ft).
Important : When attaching the lower universal joint, the
marks on the intermediate shaft and on the stub shaft
should line up.
5. Attach the lower universal joint of the intermediate
shaft onto the steering gear stub shaft.
Important : When installing the lower intermediate shaft
pinch bolt, make sure the bolt goes through the universal
joint on the side of the stub shaft with the notch. If you have
trouble seating the universal joint completely down onto
the stub shaft, rotate the steering wheel slightly while
pushing down on the universal joint.
6. Install the bolt into the lower universal joint on the
intermediate shaft and tighten the bolt.
Tighten
Tighten the lower intermediate shaft pinch bolt to 22
NSm (16 lb–ft).

6C – 20IPOWER STEERING GEAR
DAEWOO V–121 BL4
HYDRAULIC CYLINDER LINES
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Siphon the power steering fluid from the fluid reser-
voir.
2. Raise and suitably support the vehicle.
3. Disconnect the power steering gear hydraulic cylin-
der pipes from the power steering gear at the valve
end. Replace the O–ring seals as needed.
4. Disconnect the power steering gear hydraulic cylin-
der pipes from the power steering gear at the cylin-
der end.
5. Remove the steering gear hydraulic cylinder pipes
from the vehicle.
Installation Procedure
1. Lubricate any new O–ring seals with power steering
fluid.
2. Place the O–ring seals into the housing and install
the steering gear hydraulic cylinder pipes.
3. Connect the power steering gear hydraulic cylinder
pipes to the power steering gear at the valve end.
Tighten
Tighten the hydraulic cylinder line fittings at the valve
end to 18 NSm (13 lb–ft).
4. Connect the power steering gear hydraulic cylinder
pipes to the power steering gear at the cylinder
end.
Tighten
Tighten the hydraulic cylinder line fittings at the cylin-
der end to 28 NSm (21 lb–ft).
5. Lower the vehicle.
Notice : When adding fluid or making a complete change,
always use DEXRON®–II or III power steering fluid. Fail-
ure to use the proper fluid will cause hose and seal dam-
age and fluid leaks.

POWER STEERING GEAR 6C – 21
DAEWOO V–121 BL4
6. Fill the fluid reservoir with power steering fluid.
7. Inspect for leaks. If there are leaks, correct the
cause of the leaks and bleed the system. Refer to
”Bleeding the Power Steering System” in this sec-
tion.
SPEED SENSITIVE POWER
STEERING CONTROL MODULE
Removal Procedure
1. Disconnect negative battery cable.
2. Remove the glove box. Refer to Section 9G, Interi-
or Trim.
3. Slide the speed sensitive power steering (SSPS)
control module off from the control module bracket.
4. Disconnect the electrical connector from the SSPS
control module.
Installation Procedure
1. Connect the electrical connector to the SSPS con-
trol module.
2. Slide the SSPS control module onto the SSPS con-
trol module bracket.
3. Install the ashtray. Refer to Section 9G, Interior
Trim.
4. Connect the negative battery cable.

6C – 22IPOWER STEERING GEAR
DAEWOO V–121 BL4
UNIT REPAIR
RACK AND PINION
Tools Required
KM–J–22610 Installer
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 valve and pinion assembly from the
rack and pinion steering assembly. Refer to ”Valve
and Pinion” in this section.
3. Remove the rack bearing assembly from the rack
and pinion steering assembly. Refer to ”Rack Bear-
ing” in this section.
4. Mark the threads on the inner tie rod to aid in re-
positioning the adjusting nut.
5. Loosen the adjusting nut and remove the outer tie
rod nut and the adjusting nut.
6. Remove the dust boot retaining clamps.
7. Remove the dust boot.

POWER STEERING GEAR 6C – 23
DAEWOO V–121 BL4
8. Push back the plastic retainer protecting the con-
nection between the inner tie rod and the power
steering gear rack.
9. Counterhold the pinion–side inner tie rod and re-
move the cylinder–side inner tie rod.
10. Place a rag over the rack, counterhold the rack as-
sembly on the teeth with a wrench, and remove the
pinion–side inner tie rod.
Important : The retaining ring can be released by insert-
ing a small screwdriver through the hole in the side of the
housing.
11. Remove the bulkhead inner cylinder retaining ring
the bulkhead inner cylinder and the rack.