power steering DAEWOO MATIZ 2003 Service User Guide

2C –8 FRONT SUSPENSION
DAEWOO M-150 BL2
D16B504A
70–90 Nm
Installation Procedure
1. Install the strut assembly to the vehicle with the strut
assembly–to–strut bracket bolts.
Tighten
Tighten the strut assembly–to–strut bracket bolts to
70–90 Nm (52–66 lb-ft).
2. Connect the brake hose to the bracket.
3. Install the ABS front speed sensor electrical wire to
the bracket, if applicable.
D16B505A
18–28 Nm
18–28 Nm4. Install the wheel. Refer to Section 2E, Tires and
Wheels.
5. Lower the vehicle.
6. Install the nuts.

Install the nuts at passenger side (1).
Tighten
Tighten the nuts to 18–28 Nm (13–21 lb-ft).

Install the nuts at driver side (2).
Tighten
Tighten the nuts to 18–28 Nm (13–21 lb-ft).
7. Install the power steering fluid reservoir.
8. Install the fuse box and bolt.
D106B506
KNUCKLE ASSEMBLY
Tools Required
KM 507–B Ball Joint Remover
Removal Procedure
1. Remove the caulking nut.

Straighten the bent flange caulking nut (1).

Remove the caulking nut (2).

Remove the washer (3).
2. Remove the wheel. Refer to Section 2E, Tires and
Wheels.
D105B501
3. Separate the tie rod end from the knuckle assembly.

Remove the cotter pin (1).

Remove the castellated nut (2).

Install the ball joint remover KM 507–B.

Separate the tie rod end from the knuckle assem-
bly using a ball joint remover KM 507–B (3).

FRONT SUSPENSION 2C–13
DAEWOO M-150 BL2
D106B523

Remove the strut bar bolts at driver side (4).
Important: When removing the bolts using the tool,
do not contact the battery terminal.

Remove the strut bar at passenger side
D16B524B
Installation Procedure
1. Install the strut bar to the vehicle.

Install the strut bar at passenger side.

Install the strut bar bolts at driver side (1).
Important: When installing the bolts using the tool, do
not contact the battery terminal.

Install the strut bar bolts at passenger side (2).

Install the A/C low pressure pipe bracket–to–strut
bar nut.
Tighten
Tighten the strut bar bolts to 35–55 Nm (25–41 lb-ft).

Install the purge control valve to the strut bar.
D106B525
CROSSMEMBER
Removal Procedure
1. Remove the transaxle under cover. Refer to Section
5B, Five–Speed Manual Transaxle.
2. Remove the front under longitudinal frame. Refer to
“Stabilizer Shaft” in this section.
3. Remove the damping bush bolt and nut.
D106B526
4. Disconnect the power steering pressure line from the
crossmember. Refer to Section 6B, Power Steering
Pump.
5. Remove the crossmember from the vehicle.

Place support jack under the crossmember.

Remove the bumper fascia screws.

Remove the rear bolts (1).

Remove the side bolts (2).

Lower the support jack and remove the crossmem-
ber from the vehicle.

DAEWOO M-150 BL2
SECTION 6B
POWER STEERING PUMP
TABLE OF CONTENTS
Description and Operation 6B-2. . . . . . . . . . . . . . . . . .
Power Steering Pump 6B-2. . . . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 6B-3. . . . .
Power Steering Pump 6B-3. . . . . . . . . . . . . . . . . . . . . .
Repair Instructions 6B-4. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 6B-4. . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Drive Belt 6B-4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Drive Pulley 6B-5. . . . . . . . . . . . . . . . . . . . . . . . . Pump Assembly 6B-5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Repair 6B-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump 6B-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 6B-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 6B-8. . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 6B-8. . . . . . . . . . .
Special Tools and Equipment 6B-9. . . . . . . . . . . . . . .
Special Tools Table 6B-9. . . . . . . . . . . . . . . . . . . . . . . .

6B – 2 POWER STEERING PUMP
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
POWER STEERING PUMP
The pump has a remote fluid reservoir. A pressure-relief
valve inside the flow control valve limits pump pressure.

POWER STEERING PUMP 6B–3
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
POWER STEERING PUMP
ConditionProbable CauseCorrection
Foaming, Milky
Power Steering Fluid,
Insufficient power steering fluid level.
Fill the power steering fluid
reservoir.
Low Fluid Level, and
Possible Low
Contaminated air in the power steering
fluid.
Bleed the power steering system.
Pressure

Internal leaks and overflow of the power
steering pump.
Replace the power steering pump.

Leaks of the power steering pump housing
and the soft plug.
Replace the power steering pump.
Low Pressure Due to
Steering Pump
Stuck and improperly operated power
steering pump flow control valve.
Replace the power steering pump.

Worn power steering pump seats.
Replace the power steering pump.

Scores, cracks, or breaks of the pressure
plate, the pump ring, the thrust plate, and
the rotor.
Replace the power steering pump.

Sticking of the vanes in the rotor slots.
Replace the power steering pump.

Internal leaks and overflow of the power
steering pump.
Replace the power steering pump.
Growling Noise in
Steering Pump
Restricted flow of the pump hoses and the
steering gear pipes.
Clean out the pipes and the hoses.

Replace the pipes and the hoses as
needed.

Scores, cracks, or breaks of the pressure
plate, the pump ring, the thrust plate, and
the rotor.
Replace the power steering pump.

Improperly contacted power steering hose
with the body.
Secure the pump hose in a clamp
away from the body.

Insufficient power steering fluid level.
Fill the power steering pump
reservoir.
Ratting Noise in the
Steering Pump
Contaminated air in the power steering
fluid.
Bleed the power steering system.

Improperly contacted power steering hose
with the body.
Secure the pump hose in a clamp
away from the body.

Insufficient power steering fluid level.
Fill the power steering pump
reservoir.

Improperly installed pump mounting.
Tighten the power steering pump
attachment bolts.
Swishing Noise in the
Steering Pump
Damaged power steering pump flow control
valve.
Replace the power steering pump.
Whining Noise in the
Scores of the pressure plate and the vanes.
Replace the power steering pump.
Steering Pump
Scores of the pump shaft bearing
Replace the power steering pump.

6B –4 POWER STEERING PUMP
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
D105C524
PUMP DRIVE BELT
Removal Procedure
1. Remove the front passenger side headlamp. Refer to
Section 9B, Lighting Systems.
2. Remove the pump drive belt.

Loosen the rear bracket adjusting bolt (1).

Loosen the bolt (2).
D105C525

Loosen the front bracket adjusting bolts (3).

Push the pump forward (4).
18–22 Nm
20–24 Nm
20–24 Nm
D15C526A
Installation Procedure
1. Install the pump drive belt with the bolts.
Tighten

Tighten the front bracket adjusting bolt to 18–22
Nm (13–16 lb-ft) (1).

Tighten the rear bracket adjusting bolt to 20–24
Nm (15–18 lb-ft) (2).

Tighten the power steering pump bolt to 20–24
Nm (15–18 lb-ft) (3).
2. Install the front passenger side headlamp. Refer to
Section 9B, Lighting Systems.

POWER STEERING PUMP 6B–5
DAEWOO M-150 BL2
D105C527
PUMP DRIVE PULLEY
Tools Required
DW310–020 Power Steering Pulley Remove Holder
Removal Procedure
1. Remove the front passenger side headlamp.
Refer to Section 9B, Lighting Systems.
2. Remove the steering pump pulley.

Remove the pump drive belt. Refer to “Pump Drive
Belt” in this section.

Fix the pulley using the power steering pulley re-
move holder DW310–020 (1).

Remove the pump drive pulley nut (2).
55–69 Nm
D15C528A
Installation Procedure
1. Install the pump drive pulley. Install the steering pump
pulley nut.
2. Install the pump drive belt.
3. Tighten the steering pump pulley nut using the power
steering pulley remove holder DW310–020.
Tighten
Tighten the steering pump pulley nuts to 55–69 Nm
(41–51 lb-ft).
4. Install the front passenger side headlamp.
Refer to Section 9B, Lighting Systems.
D105C529
PUMP ASSEMBLY
Removal Procedure
1.Remove the front passenger side headlamp.
Refer to Section 9B, Lighting Systems.
2. Disconnect the pipe line from the pump.

Disconnect the supply line pipe hose (1).

Disconnect the pressure line pipe fitting (2).
D105C530
3. Remove the power steering pump.

Remove the pump drive belt. Refer to “Pump Drive
Belt” in this section.

Disconnect the power steering pressure switch
connector (1). Refer to Section 6A, Power Steering
Systems.

Remove the bolts (2).

6B –6 POWER STEERING PUMP
DAEWOO M-150 BL2
D105C531

Remove the bolt (3).
18–22 Nm
D15C532A
Installation Procedure
1. Install the power steering pump with the bolt.
Tighten
Tighten the bolt to 18–22 Nm (13–16 lb-ft).
2. Connect the power steering pressure switch connec-
tor. Refer to Section 6A, Power Steering System.
3. Install the pump drive belt. Refer to “Pump Drive Belt”
in this section.
20–24 Nm
20–24 Nm 21–35 Nm
D15C533A
4. Install the bolts.
Tighten

Tighten the rear bracket adjusting bolt to 20–24
Nm (15–18 lb-ft) (1).

Tighten the power steering bolt to 20–24 Nm
(15–18 lb-ft) (2).
5. Connect the pressure line pipe to the outlet connec-
tion on the steering pump.
Tighten
Tighten the pressure line pipe fitting to 21–35 Nm
(16–26 lb-ft) (3).
6. Install the front passenger side headlamp.
Refer to Section 9B, Lighting Systems.
Notice: When adding fluid or making a complete fluid
change, always use DEXRON-II or DEXRON-III pow-
er steering fluid. Failure to use the proper fluid will cause
hose and seal damage and fluid leaks.
7. Refill the pump with new fluid and bleed the air from
the system. Refer to Section 6A, Bleeding the Power
Steering System.
8. Inspect for leaks. If leaks are found, correct the cause
of the leak and bleed the system.

POWER STEERING PUMP 6B–7
DAEWOO M-150 BL2
UNIT REPAIR
PUMP
The power steering pump in this vehicle is not service-
able. A faulty pump must be replaced.

6B –8 POWER STEERING PUMP
DAEWOO M-150 BL2
SPECIFICATIONS
GENERAL SPECIFICATIONS

Application

Description
Lubricant

Power Steering Fluid DEXRON-II, DEXRON-III
Capacity

1.0 Liter (1.056 qt)
Type

Vane
FASTENER TIGHTENING SPECIFICATIONS
Application Nm Lb-Ft Lb-In
Power Steering Pump Bolt 20 – 24 15 – 18 –
Power Steering Pump Front Bracket Bolt 20 – 24 15 – 18 –
Power Steering Pump Front Bracket Adjusting Bolt 18 – 22 13 – 16 –
Power Steering Pump Rear Bracket Upper Bolt 35 – 45 26 – 33 –
Power Steering Pump Rear Bracket Lower Bolt 20 – 24 15 – 18 –
Power Steering Pump Rear Bracket Adjusting Bolt20 – 2415 – 18–
Power Steering Pump Pulley Nut55 – 6941– 51–
Power Steering Oil Pressure Line Fitting21 – 3516 – 26–