power steering DAEWOO MATIZ 2003 Service Owner's Manual

POWER STEERING PUMP 6B–9
DAEWOO M-150 BL2
SPECIAL TOOLS AND EQUIPMENT
SPECIAL TOOLS TABLE
D105C101
DW310–020
Power Steering Pulley
Remove Holder

DAEWOO M-150 BL2
SECTION 6C
POWER 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 6C-2. . . . . . . . . . . . . . . . . .
Power Rack and Pinion 6C-2. . . . . . . . . . . . . . . . . . . .
Diagnostic Information and Procedures 6C-3. . . . .
Power Rack and Pinion Steering Gear 6C-3. . . . . . .
Adjust the Free Load of the Steering Gear 6C-5. . .
Repair Instructions 6C-6. . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service 6C-6. . . . . . . . . . . . . . . . . . . . . . . . . .
Rack and Pinion Assembly 6C-6. . . . . . . . . . . . . . . . .
Power Steering Gear Rack and Pinion Boot 6C-7. . . Unit Repair 6C-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tie Rod End Boot 6C-8. . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Cylinder Lines 6C-8. . . . . . . . . . . . . . . . . . . .
Rack and Pinion Steering Gear 6C-9. . . . . . . . . . . . . .
Assembly
Specifications 6C-13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 6C-13. . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 6C-13. . . . . . . . . .

6C – 2 POWER STEERING GEAR
DAEWOO M-150 BL2
DESCRIPTION AND OPERATION
POWER RACK AND PINION
The power rack and pinion steering system has a rotary
control valve which directs the hydraulic fluid coming
from the hydraulic pump to one side or the other side of
the rack piston. The integral rack piston is attached to
the rack. The rack piston converts hydraulic pressure to
a linear force which moves the rack left or right. The
force is then transmitted through the tie rods and the tierod ends to the steering knuckles, which turn the
wheels.
If hydraulic assist is not available, manual control is
maintained. However, under these conditions, more
steering effort is required. The movement of the steering
wheel is transferred to the pinion. The movement of the
pinion is then transferred through the pinion teeth, which
meshs with the teeth on the rack, causing the rack to
move.

POWER STEERING GEAR 6C–3
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
POWER RACK AND PINION STERING GEAR
ConditionProbable CauseCorrection
Hissing Noise
Loose steering coupling joints.
Tighten the steering coupling
joints.

Improperly contacted the power
steering hose with other
components.
Fit the power steerng hose into
the hose clips correctly.
Rattling Noise in Steering Gear
Improperly contacted the power
steering line with the body.
Fix the steering line correctly.

Insufficient lubricant.
Lubricate the steering gear.

Loose steering gear mounting.
Tighten the steering gear
mounting bracket bolts.

Improperly installed tie rod ends.
Tighten the tie rod joints and
replace the tie rod end as needed.
Poor Return of Steering Wheel
to Center
Improperly contacted the steering
wheel with the turn signal housing.
Adjust the turn signal housing.

Improper binding or looseness of
steering coupling.
Replace the intermediate shaft.

Stuck and improperly aligned
power steering pump flow control
valve.
Replace the power steering pump.

Improper binding or looseness of
tie rods and ball joints.
Tighten the tie rods and the ball
joints. Replace the tie rods and
the ball joints as needed.

Poor adjustments of the steering
gear.
Perform a straight-ahead check.
Momentary Increase in Effect
When Turning the Wheel
Internal leaks of the power
steering pump.
Replace the power steering pump.
Quickly
The damage or restricted flow of
the hoses.
Replace the power steering hoses
and pipes.

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

Stuck and improperly operated
power steering pump flow control
valve.
Replace the power steering pump.
Steering Surges or Jerks When
Turning with Engine Running
Insufficient pressure of the power
steering pump.
Replace the power steering pump.

Stuck and improperly operated
power steering pump flow control
valve.
Replace the power steering pump.

The slippage of the pump drive
belt.
Tighten the pump drive belt.

Contaminated air in the power
steering system.
Bleed the power steering system.

6C –4 POWER STEERING GEAR
DAEWOO M-150 BL2
POWER RACK AND PINION STERING GEAR (Cont’d)
ConditionProbable CauseCorrection
Excessive Wheel Kickback or
Loose Steering
Contaminated air in the power
steering system.
Bleed the power steering system.

Worn or damaged wheel bearings.
Replace the wheel bearings.

Loose steering gear mounting.
Tighten the steering gear
mounting bracket bolts.

Improperly installed steering
gear-to-intermediate shaft joints.
Tighten the joint bolt.

Loose tie rods and ball joints.
Tighten the tie rods and the ball
joints.

Replace the tie rods and the ball
joints as needed.
Hard Steering or Lack of Assist
(Especially During Parking)
Stuck and improperly installed
power steering pump flow control
valve.
Replace the power steering pump.

Insufficient pressure of the power
steering pump.
Replace the power steering pump.

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

Improper tension of the pump
drive belt.
Adjust the pump drive belt
tension.

POWER STEERING GEAR 6C–5
DAEWOO M-150 BL2
ADJUST THE FREE LOAD OF THE
STEERING GEAR
1. Place the steering wheel in the straight-ahead posi-
tion.
2. Raise and suitably support the vehicle.
3. Remove the adjust plug locknut.
4. Check the torque of the adjuster plug.
5. Check the torque is below the specification value or
the measured torque is over the specification value,
adjust the tightening torque.

Place the rack gear in the straight-ahead position.

Tighten the adjust plug to 10 Nm (89 lb-in).

Turn the steering wheel all the way to the right and
the left about 5 times repeatedly.

Place the rack gear in the straight-ahead position.

Loosen the adjust plug.
D105C302

Tighten the adjust plug to 4.5–5.5 Nm (40–49 lb-
in).

Loosen the adjust plug to 67.5.
6. Tighten the adjust plug locknut.

6C –6 POWER STEERING GEAR
DAEWOO M-150 BL2
REPAIR INSTRUCTIONS
ON–VEHICLE SERVICE
RACK AND PINION 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 wheel. Refer to Section 2E, Tires and
Wheels.
3. Remove the tie rod ends. Refer to Section 6D, Manu-
al Steering Gear.
4. Remove the front exhaust pipe nuts. Refer to Section
1G, Engine Exhaust.
D105C534
5. Remove the rack and pinion assembly.

Disconnect the return line pipe from the steering
gear (1).

Disconnect the pressure inlet line pipe from the
steering gear (2).

Plug the opening in the power steering pipe line to
prevent fluid loss and contamination.
D105C535

Remove the power steering gear retaining bracket
tighten bolts (3).

Remove the power steering gear retaining bracket
(4).
Important: After moving the gear toward the passenger
side and pulling the gear of the driver side into the un-
derbody hole, remove the steering gear.

POWER STEERING GEAR 6C–7
DAEWOO M-150 BL2
D105C536
6. Remove the packing (5).
D15C537A
Installation Procedure
1. Install in the reverse order of removal.
2. Install the power steering gear bracket with the bolt.
Tighten
Tighten the bracket bolts to 50–55 Nm (36–41 lb-ft).
D15C512A
21–35 Nm21–35 Nm3. Connect the steering pipe. Refer to Section 6A, Pow-
er Steering System.
Tighten
Tighten the power steering pressure line fitting (1) to
21–35 Nm (16–25 lb-ft) (1).
Tighten the return line fitting to 21–35 Nm (16–25 lb-
ft) (2).
Important: When adding fluid or making a complete
fluid change, always use DEXRON II or III power
steering fluid. Failure to use the proper fluid will cause
hose and seal change and fluid leaks.
4. Fill the fluid reservoir with power steering fluid.
5. Inspect for leaks. If there are leaks, correct the cause
of the leaks and bleed the system. Refer to Section
6A, Power Steering System.
POWER STEERING GEAR RACK
AND PINION BOOT
Refer to Section 6D, Manual Steering Gear.

6C –8 POWER STEERING GEAR
DAEWOO M-150 BL2
UNIT REPAIR
TIE ROD END BOOT
Refer to Section 6D, Manual Steering Gear.
D105C701
HYDRAULIC CYLINDER LINES
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Disassembly Procedure
1. Remove the rack and pinion steering assembly from
the vehicle. Refer to “Rack and Pinion Assembly” in
this section.
2. Disconnect the cylinder lines from the rack and pinion
housing.

Remove the fitting (1).

Remove the fitting (2).
D15C715A
Assembly Procedure
1. Connect the cylinder lines to the rack and pinion
housing.
2. Install the power steering line fittings at the pinion
valve end.
Tighten
Tighten the power steering line fittings to 25–35 Nm
(18–25 lb-ft) (1).
3. Install the power steering line fittings at the cylinder
end.
Tighten
Tighten the power steering line fittings to 25–35 Nm
(18–25 lb-ft) (2).
4. Install the rack and pinion steering assembly to the
vehicle. Refer to “Rack and Pinion Assembly” in this
section.

POWER STEERING GEAR 6C–9
DAEWOO M-150 BL2
D105C702
RACK AND PINION STEERING GEAR
ASSEMBLY
(Left–Hand Drive Shown, Right–Hand
Drive Similar)
Disassembly Procedure
1. Remove the rack and pinion steering assembly from
the vehicle. Refer to “Rack and Pinion Assembly” in
this section.
2. Remove the rack bearing.

Remove the adjuster plug locknut (1).

Remove the adjuster plug (2).

Remove the adjuster spring (3).
D105C703
3. Remove the steering pinion.

Remove the dust cap (1).

Remove the retaining ring (2).
D105C704

Remove the steering pinion dust cap (3).

Remove the steering pinion locknut (4).
Notice: If the stub shaft is not held, damage to the pin-
ion teeth will occur. While holding the stub shaft, remove
the locknut from the pinion.
D105C705

Remove the steering pinion from the pinion bear-
ing by hitting the pinion with the flated drift and
hammer (5).