boot DAEWOO MATIZ 2003 Service Owner's Manual

6C –10 POWER STEERING GEAR
DAEWOO M-150 BL2
D105C706
Important: Hit the drift using a hammer when the lower
pinion is vertical with the drift.

Remove the bearing by hitting the bearing with the
flated drift and rubber hammer (6).
D105C707

Remove the pinion shaft seal (7).

Remove the needle bearing (8).

Remove the retaining ring (9).
Important: The power steering gear housing and the
rack gear in this vehicle is not serviceable as unit.
The faulty parts must be replaced as whole units.
D105C708
Inspection Procedure
1. Inspect the tie rod ends and the ball joints for dam-
age. Refer to Section 6D, Manual Steering Gear.
2. Inspect the tie rod ends and the rack/pinion boot for
cracks or abnormal wear. Refer to Section 6D, Manu-
al Steering Gear.
3. Inspect the metal part for damage.

Inspect the pinion gear for damage or wear (1).
D105C709

Inspect the rack gear for damage or wear (2).

Inspect the steering gear housing for damage or
wear(3).

DAEWOO M-150 BL2
SECTION 6D
MANUAL 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 B unless otherwise
noted.
TABLE OF CONTENTS
Description and Operation 6D-2. . . . . . . . . . . . . . . . . .
Manual Rack and Pinion 6D-2. . . . . . . . . . . . . . . . . . . .
Component Locator 6D-3. . . . . . . . . . . . . . . . . . . . . . . .
Manual Rack and Pinion Steering Gear 6D-3. . . . . . .
Diagnostic Information and Procedures 6D-4. . . . .
Manual Rack and Pinion Steering Gear 6D-4. . . . . . .
Straight-Ahead Check 6D-5. . . . . . . . . . . . . . . . . . . . . .
Steering Wheel Restoration 6D-6. . . . . . . . . . . . . . . . .
Check The Turning Resistance of the
Tie Rod End or Tie Rod 6D-6. . . . . . . . . . . . . . . . . . . .
Adjust the Free Load of the Steering Gear 6D-6. . . .
Repair Instructions 6D-7. . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service 6D-7. . . . . . . . . . . . . . . . . . . . . . . . . .
Tie Rod End 6D-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rack and Pinion Boot 6D-8. . . . . . . . . . . . . . . . . . . . . .
Rack and Pinion Steering Gear Assembly 6D-9. . . .
Unit Repair 6D-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tie Rod End Boot 6D-11. . . . . . . . . . . . . . . . . . . . . . . .
Rack and Pinion 6D-11. . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 6D-17. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 6D-17. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 6D-17. . . . . . . . . .
Special Tools and Equipment 6D-18. . . . . . . . . . . . . .
Special Tools Table 6D-18. . . . . . . . . . . . . . . . . . . . . . .

MANUAL STEERING GEAR 6D–3
DAEWOO M-150 BL2
COMPONENT LOCATOR
MANUAL RACK AND PINION STEERING GEAR
(Left–Hand Drive Shown, Right–Hand Drive Similar)
D105B401
1. Manual Steering Gear
2. Steering Gear Bracket
3. Cotter Pin
4. Castellated Nut
5. Tie Rod End
6. Tie Rod End Lock Nut
7. Rack and Pinion Boot Clamp
8. Rack and Pinion Boot
9. Rack and Pinion Boot Wire Clamp
10. Tie Rod
11. Shock Damper Ring
12. Steering Rack Gear13. Bulkhead Retainer
14. Bulkhead Bushing
15. Steering Gear Housing
16. Steering Gear Bracket Bushing
17. Packing
18. Dust Cover
19. Pinion Plug
20. Steering Pinion Gear
21. Roller Bearing
22. Rack Bearing
23. Adjuster Spring
24. Adjuster Plug

6D –8 MANUAL STEERING GEAR
DAEWOO M-150 BL2
D15B504B
Installation Procedure
1. Install the tie rod end.
2. Install the tie rod lock nut (1).
Tighten
Tighten the tie rod end lock nut to 35–55 Nm (25–41
lb-ft).
3. Connect the tie rod end to the knuckle.
4. Install the tie rod end castellated nut (2).
Tighten
Tighten the castellated nut to 30–55 Nm (21–41 lb-
ft).
5. Install the split pin.
6. Install the wheel. Refer to Section 2E, Tires and
Wheels.
7. Make the toe–in adjustment by turning the tie rod ad-
juster. Refer to Section 2B, Wheel Alignment.
D105B505
RACK AND PINON BOOT
Removal Procedure
1. Remove the tie rod end. Refer to “Tie Rod End” in this
section.
2. Remove the tie rod end lock nut.
D105B506
3. Remove the rack and pinion boot.

Remove the boot clamp (1).

Cut off the boot wire clamp (2).

MANUAL STEERING GEAR 6D–9
DAEWOO M-150 BL2
D105B507

Coat the greases on the tie rod to ease removal
(3).

Remove the boot (4).
D105B508
Installation Procedure
1. Install the rack and pinion boot with the clamp and the
wire clamp.
2. Install the tie rod end nut.
3. Install the tie rod end. Refer to “Tie Rod End” in this
section.
D105B509
D105B510
RACK AND PINION STEERING GEAR
ASSEMBLY
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Removal Procedure
1. Remove the intermediate shaft lower pinch bolt. Re-
fer to Section 6E, Steering Wheel and Column.
2. Remove the wheels. Refer to Section 2E, Tires and
Wheels.
3. Disconnect the tie rod end from the steering knuckle.
Refer to “Tie Rod End” in this section.
4. Remove the front exhaust pipe nuts. Refer to Section
1G, Engine Exhaust.
5. Remove the steering gear assembly from the vehicle.

Remove the steering gear bracket bolts (1).

Remove the steering gear bracket (2).

Remove the steering gear assembly.

Remove the packing (3).

MANUAL STEERING GEAR 6D–11
DAEWOO M-150 BL2
UNIT REPAIR
D105B701
TIE ROD END BOOT
Disassembly Procedure
1. Remove the tie rod end. Refer to “Tie Rod End” in this
section.
2. Remove the tie rod end boot.
a. Tie rod end boot.
D105B702
Assembly procedure
Important : Coat the grease inside of the boot.
1. Install the boot to the tie rod end.
2. Install the tie rod end wire clamp.
3. Install the tie rod end. Refer to “Tie Rod End” in this
section.
D105B703
RACK AND PINION
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Disassembly Procedure
1. Remove the rack and pinion steering assembly from
the vehicle. Refer to “Rock and Pinion Assembly” in
this section.
2. Remove the rack and pinion boot.

Remove the tie rod end. Refer to “Tie Rod End” in
this section (1).

Remove the tie rod lock nut (2).

Remove the rack and pinion boot clamp (3).

Cut off the rack and pinion boot wire (4).

6D –12 MANUAL STEERING GEAR
DAEWOO M-150 BL2
D105B704

Coat the greases on the tie rod (5).

Remove the rack and pinion boot (6).
D105B705
3. Remove the tie rod

Pull the rack gear perfectly from the steering gear
housing by turning the pinion gear (1).

Disconnect the shock damper ring from the tie rod
ball joint (2).
D15B706A

Vise the rack gear (3).
Important: Clothe the rack gear with a cloth before vis-
ing the rack gear.
Notice: Do not vise the rack gear over two teeth face.
D105B707

Remove the tie rod (4).

Remove the shock damper ring (5).

6D –14 MANUAL STEERING GEAR
DAEWOO M-150 BL2
D105B712
Inspection Procedure
1. Inspect the rack gear deformation and damage.

Set the V–block on the plate (1).

Set the rack gear on the V–block (2).

Check the rack gear for deformation using a dial
gauge (3).

Inspect the rack gear for wear and damage (4).
D105B713
2. Inspect the pinion and bearing assembly damage.

Inspect the pinion gear for wear and damage (1).

Inspect the bearing for loose and operation (2).
D105B714
3. Inspect the tie rod end boot and the rack and pinion
boot for damage.

Inspect the tie rod end boot for crack and wear (1).

Inspect the rack and pinion boot for crack and wear
(2).
D105B715
4. Inspect the steering gear housing for crack, deforma-
tion and wear.
a. Steering gear housing.

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.

INTERIOR TRIM 9G–3
DAEWOO M-150 BL2
COMPONENT LOCATOR
INTERIOR TRIM
D19E402A
1. A–Pillar Trim Panel
2. B–Pillar Upper Trim Panel
3. C–Pillar Trim Panel
4. Front Rocker Trim Panel
5. B–Pillar Lower Trim Panel
6. Rear Rocker Trim Panel
7. Rear Parcel Side Shelf8. Wheel House Trim Panel
9. Floor Console
10. Parking Brake Cable Cover
11. Console Cover Assembly
12. Deposit Box
13. Console Boot Assembly