DAEWOO MATIZ 2003 Service Repair Manual

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.

6D –18 MANUAL STEERING GEAR
DAEWOO M-150 BL2
SPECIAL TOOLS AND EQUIPMENT
SPECIAL TOOLS TABLE
D105B101
KM–507–B
Ball Joint Remover

DAEWOO M-150 BL2
SECTION 6E
STEERING WHEEL AND COLUMN
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 6E-2. . . . . . . . . . . . . . . . . .
Steering Wheel and Column 6E-2. . . . . . . . . . . . . . . .
Component Locator 6E-3. . . . . . . . . . . . . . . . . . . . . . . .
Steering Wheel and Column 6E-3. . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 6E-4. . . . .
Steering Column Diagnosis 6E-4. . . . . . . . . . . . . . . . .
Repair Instructions 6E-7. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 6E-7. . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Wheel 6E-7. . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Column Cover 6E-8. . . . . . . . . . . . . . . . . . . .
Turn Signal Switch and Lever/
Wiper Switch and Lever 6E-8. . . . . . . . . . . . . . . . . .
Ignition Switch 6E-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition Lock Cylinder and Switch
with Immobilizer 6E-9. . . . . . . . . . . . . . . . . . . . . . . . .
Switch Housing 6E-10. . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Column 6E-11. . . . . . . . . . . . . . . . . . . . . . . . .
Intermediate Shaft cover and
Intermediate Shaft 6E-12. . . . . . . . . . . . . . . . . . . . . .
Unit Repair 6E-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Steering Column 6E-13. . . . . . . . . . . . . . . . .
Specifications 6E-15. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 6E-15. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 6E-15. . . . . . . . . .
Special Tools and Equipment 6E-16. . . . . . . . . . . . . .
Special Tools Table 6E-16. . . . . . . . . . . . . . . . . . . . . . .

6E – 2 STEERING WHEEL AND COLUMN
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
STEERING WHEEL AND COLUMN
In addition to the steering function, the steering column
provides safety and security.
Caution: To ensure energy-absorbing action, it is
important to use only the specified screws, bolts,
and nuts, tightened to the specified torque.
The energy-absorbing column is designed to compress
in a front-end collision to lessen the chance of driver in-
jury.
The ignition switch and the lock are mounted on the col-
umn, allowing the ignition and steering operations to be
locked to inhibit theft of the car.
The column levers trigger the turn signals, the headlight
beams, and the windshield washer and wipers.
Notice: Apply a thin coat of lithium grease to all friction
points when reassembling to ensure proper operation.
The column may be easily disassembled and assembled.
D15A001A

Safety Device
A. Steering Column Upper Bracket.
B. Steering Column.
C. Steering Column Shaft.

STEERING WHEEL AND COLUMN 6E–3
DAEWOO M-150 BL2
COMPONENT LOCATOR
STEERING WHEEL AND COLUMN
D15A401A
1. Horn Cover (Airbag Module)
2. Steering Wheel Nut
3. Locking Plate
4. Steering Wheel
5. Steering Column Upper Cover
6. Steering Column Lower Cover
7. Turn Signal Switch
8. Windshield Wiper Switch
9. Steering Column Assembly
10. Retaining Ring
11. Washer
12. Spring
13. Switch Housing
14. Bolt15. Support Bolt
16. Steering Column Housing
17. Steering Column Jacket
18. Ignition Switch Retaining Screw
19. Ignition Switch
20. Steering Lock Housing Assembly
21. Steering Column Shaft
22. Pinch Bolt
23. Intermediate Shaft
24. Steering Column Upper Nut
25. Steering Column Lower Nut

6E –4 STEERING WHEEL AND COLUMN
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
STEERING COLUMN DIAGNOSIS
Lock System
ConditionProbable CauseCorrection
Lock System Will Not
Damaged lock cylinder.
Replace the lock cylinder.
Unlock
The lack of free movement for the ignition
switch.
Lubricate the ignition switch.

Improper binding or damaged steering
column housing.
Remove the steering shaft and clear
the steering column housing.

Replace the steering column
housing as needed.
Lock System Will Not
Damaged lock cylinder.
Replace the lock cylinder.
Lock
The lack of free movement for the ignition
switch.
Lubricate the ignition switch.

Improper binding or damaged steering
column housing.
Remove the steering shaft and clear
the steering column housing.

Replace the steering column
housing as needed.
High Lock Effort
Damaged lock cylinder.
Replace the lock cylinder.

The lack of free movement for the ignition
switch.
Lubricate the ignition switch.

Extreme misalignment of the housing to the
cover.
Realign the cover on the housing.

Replace the cover as needed.
Key Cannot Be
The ignition switch to be set incorrectly.
Reset the ignition switch.
Removed in the B
Position
Damaged lock cylinder.
Replace the lock cylinder.
Column
ConditionProbable CauseCorrection
Noise in the Column
Improperly installed intermediate shaft–to–
column joints.
Tighten the coupling pinch bolts.

Replace the intermediate shaft as
needed.

Column misalignment.
Replace the alignment spacer.

The lack of lubrication for the joint.
Lubricate the joint.

The lack of lubrication for the steering shaft.
Lubricate the steering shaft bearing.

Improperly seated shaft lock snap ring.
Adjust the shaft lock snap ring.

Replace the shaft lock snap ring as
needed.

Improperly installed intermediate shaft
pinch bolt.
Tighten the pinch bolt.
High Steering Shaft
Column misalignment.
Replace the alignment spacer.
Effort
A damaged bearing.
Replace the steering column
housing.

The lack of free movement for the steering
shaft universal joint.
Lubricate the steering shaft
universal joint.

Replace the steering column shaft
as needed.

STEERING WHEEL AND COLUMN 6E–5
DAEWOO M-150 BL2
Column (Cont’d)
ConditionProbable CauseCorrection
Lash in the Steering
Column
Improperly installed steering column
bracket mounting nuts.
Tighten the steering column bracket
mounting nuts.

Loose steering column housing–to–steering
column jacket support bolts.
Tighten the support bolts.
Loose Steering
Wheel
The bearing to be seated incorrectly in the
housing.
Correctly seat the bearing.

Replace the column housing as
needed.

Loose steering column housing support
bolts.
Tighten the steering column housing
support bolts.
Turn Signal / Dimmer Switch
ConditionProbable CauseCorrection
Turn Signal Will Not
Stay in the Turn
Position
An improperly installed turn signal switch.
Remove and inspect the turn signal
switch.

Reinstall the switch.

The broken or missing components for the
cancelling mechanism.
Replace the turn signal switch.

Foreign material in the turn signal switch
housing.
Remove any foreign material.
Turn Signal Will Not
Cancel
Broken or missing components for the
cancelling mechanism.
Replace the turn signal switch.
Turn Signal/Dimmer
Switch Difficult to
Operate
Improperly installed turn signal/dimmer
switch and turn signal/dimmer switch lever.
Remove and inspect the turn
signal/dimmer switch and
signal/dimmer switch lever.

Reinstall the signal/dimmer switch
and signal/dimmer switch lever.

Foreign material in the signal/dimmer
switch housing.
Remove any foreign material.
Turn Signal Will Not
Indicate Lane
A broken lane change pressure pad or a
broken spring hanger.
Replace the turn signal switch.
Change
The improper functioning of the lane
change spring.
Replace the turn signal switch.

Improperly installed turn signal switch.
Replace the turn signal switch.
No Turn Signal
An inoperative turn signal flasher.
Replace the blinker unit.
Lamps
A faulty turn signal switch.
Replace the turn signal switch.

Improperly connected chassis–to–column
connector.
Reconnect the chassis–to–column
connector.
Turn Indicator Lamps
On, But Not Flashing
An inoperative blinker unit.
Replace the blinker unit.
Front or Rear Turn
Signal Lamps Not
Flashing
An inoperative blinker unit.
Replace the blinker unit.
Turn Signal Lamps
Flash Very Slowly
An inoperative blinker unit.
Replace the blinker unit.

6E –6 STEERING WHEEL AND COLUMN
DAEWOO M-150 BL2
Ignition Switch
ConditionProbable CauseCorrection
Electrical System Will
Damaged ignition switch.
Replace the ignition switch.
Not Function
Improperly installed ignition switch.
Remove and inspect the ignition
switch.

Reinstall the ignition switch.

Improperly installed ignition switch electrical
connector.
Reconnect the ignition switch
electrical connector.

Replace the ignition switch electrical
connector.
Ignition Switch Will
Damaged ignition switch.
Replace the ignition switch.
Not Turn
Improperly installed ignition switch.
Remove and inspect the ignition
switch.

Reinstall the ignition switch.
Wiper Switch Lever
ConditionProbable CauseCorrection
Switch Inoperative :
Damaged wiper switch.
Replace the wiper switch.
No I, Low, High, Int
or Wash
Improperly installed wiper switch.
Remove and inspect the wiper
switch.

Reinstall the wiper switch.