6 Steering – Daewoo Matiz Service Manual
Contents
1. D15C528A D105C530 DAEWOO M 150 BL2 POWER STEERING PUMP 6B 5 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 e Remove the pump drive belt Refer to Pump Drive Belt in this section e Fix the pulley using the power steering pulley re move holder DW310 020 1 e Remove the pump drive pulley nut 2 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 Nem 41 51 lb ft 4 Install the front passenger side headlamp Refer to Section 9B Lighting Systems 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 e Disconnect the supply line pipe hose 1 e Disconnect the pressure line pipe fitting 2 3 Remove the power steering pump e Remove the pump drive belt Refer to Pump Drive Belt in this section e Disconnect the power steering pressure switch connector 1 Refer to Section 6A Power Steering Systems e Remove the bolts 2 6B 6 POWER STEERING PUMP D105C5312. without SIR 1 e Straighten the bending locking plate 2 e Remove the nut 3 e Remove the locking plate 4 e In order to install the steering wheel correctly match mark the steering column shaft to the steering wheel 5 e Remove the steering wheel using the steering wheel puller DW310 010 6 Important Be careful not to hit the top of steering col umn shaft with hammer during repair work Installation Procedure 1 Install the SIR module Refer to Section 8B Supple mental Inflatable Restraints For vehicle with SIR Important Align the match marks on the steering wheel and the steering column shaft 2 Install the steering wheel with the nut and the locking plate Tighten Tighten the steering wheel nut to 23 33 Nem 17 24 lb ft Bend the tabs to secure the locking plate Install the steering wheel horn cover For vehicle without SIR Connect the negative battery cable 6E 8 STEERING WHEEL AND COLUMN D105A504 D105A507 STEERING COLUMN COVER Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Remove the screws 2 Remove the steering column lower and upper cover Installation Procedure 1 Install the steering column lower and upper cover with the screws TURN SIGNAL SWITCH AND LEVER WIPER SWITCH AND LEVER Left Hand Drive Shown Right Hand Drive Similar Removal Procedure Disconnect the negative battery cabl
3. As D15C532A D15C533A e Remove the bolt 3 Installation Procedure 1 Install the power steering pump with the bolt Tighten Tighten the bolt to 18 22 Nem 13 16 lb ft Connect the power steering pressure switch connec tor Refer to Section 6A Power Steering System Install the pump drive belt Refer to Pump Drive Belt in this section Install the bolts Tighten e Tighten the rear bracket adjusting bolt to 20 24 Nem 15 18 lb ft 1 e Tighten the power steering bolt to 20 24 Nem 15 18 lb ft 2 Connect the pressure line pipe to the outlet connec tion on the steering pump Tighten Tighten the pressure line pipe fitting to 21 35 Nem 16 26 lb ft 3 Install the front passenger side headlamp Refer to Section 9B Lighting Systems Notice When adding fluid or making a complete fluid change always use DEXRONS I 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 Inspect for leaks If leaks are found correct the cause of the leak and bleed the system DAEWOO M 150 BL2 DAEWOO M 150 BL2 POWER STEERING PUMP 6B 7 UNIT REPAIR PUMP The power steering pump in this vehicle is not service able A faulty pump must be replaced 6B 8 POWER STEERIN
4. Bulkhead Retainer 2 Steering Gear Bracket 14 Bulkhead Bushing 3 Cotter Pin 15 Steering Gear Housing 4 Castellated Nut 16 Steering Gear Bracket Bushing 5 Tie Rod End 17 Packing 6 Tie Rod End Lock Nut 18 Dust Cover 7 Rack and Pinion Boot Clamp 19 Pinion Plug 8 Rack and Pinion Boot 20 Steering Pinion Gear 9 Rack and Pinion Boot Wire Clamp 21 Roller Bearing 10 Tie Rod 22 Rack Bearing 11 Shock Damper Ring 23 Adjuster Spring 12 Steering Rack Gear 24 Adjuster Plug DAEWOO M 150 BL2 6D 4 MANUAL STEERING GEAR DIAGNOSTIC INFORMATION AND PROCEDURES MANUAL RACK AND PINION STEERING GEAR Condition Probable Cause Correction Excessive Play or e Poor adjustment of steering gear e Perform straight ahead check Looseness in the Steering System Improperly installed tie rods e Tighten the tie rods e Lubricate the rack and pinion e Improper and insufficient lubrication assembly e Tighten the steering gear mounting bolts e Improperly installed tie rods e Tighten the tie rods Rattling Noise in the Steering Gear e Improperly installed steering gear mounting DAEWOO M 150 BL2 MANUAL STEERING GEAR 6D 5 STRAIGHT AHEAD CHECK After all the necessary operations on the steering gear Outside Angle t Inside Angle are completed 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
5. 12 lb in by loosening the adjust plug to 0 90 DAEWOO M 150 BL2 MANUAL STEERING GEAR 6D 7 REPAIR INSTRUCTIONS ON VEHICLE SERVICE D105B501 lt a o O TAN D105B502 D105B503 DAEWOO M 150 BL2 TIE ROD END Tools Required KM 507 B Ball Joint Remover Removal Procedure a4 N ao Remove the wheel Refer to Section 2E Tires and wheels Disconnect the tie rod and from the steering knuckle e Remove the cotter pin 1 e Remove the castellated nut 2 e Use a ball joint remover KM 507 B separate the tie rod end 3 Remove the tie rod end e Mark the tie rod tie rod end lock nut and tie rod end 1 e Loosen the tie rod end lock nut anticlockwise 2 e Loosen the tie rod end 3 6D 8 MANUAL STEERING GEAR EI AR MA 30 55 Nm OO AL Are gt E EN 7 EE 6 San N P COAT AG D15B504B D105B505 N ASN D105B506 Installation Procedure ND A 9 O UI N Install the tie rod end Install the tie rod lock nut 1 Tighten Tighten the tie rod end lock nut to 35 55 Nem 25 41 lb ft Connect the tie rod end to the knuckle Install the tie rod end castellated nut 2 Tighten Tighten the castellated nut to 30 55 Nem 21 41 Ib ft Install the split pin Install the wheel Refer to Section 2E Tires and Wheels Ma
6. Nem 16 25 lb ft 1 Tighten the return line fitting to 21 35 Nem 16 25 Ib ft 2 Important When adding fluid or making a complete fluid change always use DEXRON II or II 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 UNIT REPAIR D105C701 D15C715A TIE ROD END BOOT Refer to Section 6D Manual Steering Gear 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 e Remove the fitting 1 e Remove the fitting 2 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 Nem 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 Nem 18 25 lb ft 2 4 Install th
7. e The lack of lubrication for the steering shaft Lubricate the steering shaft bearing e Improperly seated shaft lock snap ring e Adjust the shaft lock snap ring e Replace the shaft lock snap ring as needed e Improperly installed intermediate shaft e Tighten the pinch bolt pinch bolt High Steering Shaft e Column misalignment e Replace the alignment spacer Effort e A damaged bearing e Replace the steering column housing e The lack of free movement for the steering e Lubricate the steering shaft shaft universal joint universal joint e Replace the steering column shaft as needed DAEWOO M 150 BL2 STEERING WHEEL AND COLUMN 6E 5 Column Cont d Lash in the Steering e Improperly installed steering column e Tighten the steering column bracket Column bracket mounting nuts mounting nuts e Loose steering column housing to steering Tighten the support bolts column jacket support bolts Loose Steering e The bearing to be seated incorrectly in the e Correctly seat the bearing Wheel housing e Replace the column housing as needed e Loose steering column housing support e Tighten the steering column housing bolts support bolts Turn Signal Dimmer Switch Turn Signal Will Not e An improperly installed turn signal switch e Remove and inspect the turn signal Stay in the Turn switch Position e Reinstall the switch e The broken or missing components for the e Replace the turn signal switch c
8. 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 Application Specified Valve 145 155 37 5 41 5 Inside Angle D105B301 EE 145 155 31 5 35 5 Straight Ahead Check Table Step Action Value s Yes No Place the steering wheel in the straight ahead posi tion Is the wheel in the correct position The pinion is displaced on the rack The steering pinion position must be corrected Is the repair complete Go to Step 2 Remove steering wheel and center on the spindle splines Is the repair complete Go to Step 2 Turn the steering wheel all the way to the right Mea Refer to sure the inner and the outer angles of the tire cent Straight erline compared to the straight ahead centerline Do Anead Check the angles match the value specified in this section System OK Go to Step 6 The rack assembly was not assembled correctly Repair as needed Is the repair complete Go to Step 5 DAEWOO M 150 BL2 6D 6 MANUAL STEERING GEAR STEERING WHEEL RESTORATION 1 Turn the steering wheel fast to the right and left and turn it slowly as the same way 2 Check if the steering wheel restoration for the wheel turning to right and the one to the leit are same 3 Turn the steering wheel to 90 about 1 2 seconds and loosen the steering wheel during the low speed driving 4 If the steering wheel restores a
9. power e Replace the power steering pump When Turning the Wheel steering pump Quickly e The damage or restricted flow of e Replace the power steering hoses the hoses and pipes Insufficient power steering fluid e Fill the power steering fluid reservoir e Stuck and improperly operated power steering pump flow control valve e Replace the power steering pump e Replace the power steering pump Steering Surges or Jerks When Turning with Engine Running e Insufficient pressure of the power steering pump e Stuck and improperly operated power steering pump flow control valve e Replace the power steering pump e The slippage of the pump drive e Tighten the pump drive belt belt e Contaminated air in the power e Bleed the power steering system steering system DAEWOO M 150 BL2 6C 4 POWER STEERING GEAR POWER RACK AND PINION STERING GEAR Cont d Probable Cause Excessive Wheel Kickback or e Contaminated air in the power e Bleed the power steering system Loose Steering steering system e Worn or damaged wheel bearings Replace the wheel bearings Loose steering gear mounting e Tighten the steering gear mounting bracket bolts e Improperly installed steering e Tighten the joint bolt gear to intermediate shaft joints Loose tie rods and ball joints e Tighten the tie rods and the ball joints e Replace the tie rods and the ball joints as needed Hard Steerin
10. rack gear carefully 2 3 Install the pinion and bearing assembly e Set the rack in balance 1 e Coat the pinion and bearing assembly and steering gear housing surface with grease e Install the pinion and bearing assembly 2 e Coat the pinion plug with Loctitte e Install the pinion plug 3 Tighten Tighten the pinion plug to 40 60 Nem 30 44 lb ft e Install the dust cover 4 4 Install the rack bearing e Coat the rack bearing with grease Install the rack bearing 1 e Install the adjuster spring 2 e Tighten the adjuster plug softly 3 6D 16 MANUAL STEERING GEAR 5 Install the tie rod e 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 e Coat the teeth face of the tie rod with Loctitte e Install the tie rod 8 Tighten Tighten the tie rod to 80 120 Nem 59 89 lb ft D15B720A 6 Install the shock damper ring to the tie rod ball joint a Tie rod ball joint e Coat the tie rod ball joint with grease D105B721 7 Install the rack and pinion boot e Install the rack and pinion boot 1 e Install the rack and pinion boot wire clamp 2 e 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
11. 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 D105B722 DAEWOO M 150 BL2 MANUAL STEERING GEAR 6D 17 SPECIFICATIONS GENERAL SPECIFICATIONS Application Description Rack and Pinion Overall Gear Ratio 145 155 Tire 39 5 2 Steering Angle ae Re Rack Gear Ball Joint Locktite Type FASTENER TIGHTENING SPECIFICATIONS Application O n O EER ige Tie Rod End Castellated Nut 30 55 21 41 TieRodEndloekNut 85 85 esra N S Steering Gear Bracket Bolts 50 55 36 41 Tie Rod to Rack Gear 80 0 59 89 O Pinion Plug 40 60 30 44 Pinion Preload Refer to Diagnosis in this section DAEWOO M 150 BL2 6D 18 MANUAL STEERING GEAR SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS TABLE KM 507 B Ball Joint Remover D105B101 SECTION 6E STEERING WHEEL AND COLUMN CAUTION Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or eguipment 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 TABLE OF CONTENTS noted Description and Operation 6E 2 Steering Wheel and Column 6E 2 Component Locator 0 00 6E 3 Ste
12. 6D 10 MANUAL STEERING GEAR Installation Procedure 1 Install the mounting to the steering gear assembly 2 Install the steering gear assembly 3 Install the steering gear bracket with the bolts Tighten Tighten the steering gear bracket bolts to 50 55 Nem 36 41 lb ft 4 Install the front exhaust pipe nuts Refer to Section 1G Engine Exhaust 5 Connect the tie rod end to the steering knuckle Refer to Tie Rod End in this section 6 Install the wheels Refer to Section 2E Tires and Wheels 7 Install the intermediate shaft lower pinch bolt Refer to Section 6E Steering Wheel and Column AAS WA BORAN TONNAN D15B511A DAEWOO M 150 BL2 DAEWOO M 150 BL2 MANUAL STEERING GEAR 6D 11 UNIT REPAIR D105B701 D105B702 D105B703 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 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 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
13. DIAGNOSIS Lock System Lock System Will Not Damaged lock cylinder e Replace the lock cylinder DOER e The lack of free movement for the ignition e Lubricate the ignition switch switch e Improper binding or damaged steering e Remove the steering shaft and clear column housing the steering column housing e Replace the steering column housing as needed Lock System Will Not Damaged lock cylinder e Replace the lock cylinder men e The lack of free movement for the ignition e Lubricate the ignition switch switch e Improper binding or damaged steering e Remove the steering shaft and clear column housing the steering column housing e Replace the steering column housing as needed High Lock Effort e Damaged lock cylinder e Replace the lock cylinder The lack of free movement for the ignition e Lubricate the ignition switch switch e Extreme misalignment of the housing to the Realign the cover on the housing cover e Replace the cover as needed Key Cannot Be e The ignition switch to be set incorrectly e Reset the ignition switch Removed in the B Position e Damaged lock cylinder e Replace the lock cylinder Column Noise in the Column e Improperly installed intermediate shaft to Tighten the coupling pinch bolts column joints e Replace the intermediate shaft as needed e Column misalignment e Replace the alignment spacer e The lack of lubrication for the joint e Lubricate the joint
14. G PUMP SPECIFICATIONS GENERAL SPECIFICATIONS TT Lubricant Power Steering Fluid DEXRON II DEXRON III Capacity 1 0 Liter 1 056 at Type Vane FASTENER TIGHTENING SPECIFICATIONS OE Rgsieten n ten se Power Steering Pump Bolt 20 24 15 18 Power Steering Pump Front Bracket Bolt 20 24 15 18 mr EN Power Steering Pump Front Bracket Adjusting Bolt 18 22 13 16 Power Steering Pump Rear Bracket Upper Bolt 35 45 26 33 mr Power Steering Pump Rear Bracket Lower Bolt 20 24 15 18 mr Power Steering Pump Rear Bracket Adjusting Bolt 20 24 15 18 Power Steering Pump Pulley Nut 55 69 41 51 Es Power Steering Oil Pressure Line Fitting 21 385 16 26 es DAEWOO M 150 BL2 POWER STEERING PUMP 6B 9 SPECIAL TOOLS AND EGUIPMENT SPECIAL TOOLS TABLE DW310 020 Power Steering Pulley Remove Holder D105C101 SECTION 6C POWER STEERING GEAR CAUTION Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or eguipment 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 Unit Repair EE sn EE EG Ee ee eee 6C 8 Power Rack and Pinion 0 6C 2 Tie Rod End Boot ee seen eee 6C 8 Diagnostic Informat
15. SECTION 6B POWER STEERING PUMP TABLE OF CONTENTS Description and Operation 6B 2 Power Steering Pump 200005 6B 2 Diagnostic Information and Procedures 6B 3 Power Steering Pump 0 2005 6B 3 Repair Instructions 020000ees 6B 4 On Vehicle Service 0 0 cece eee 6B 4 Pump Drive Belt 0000s eee eee 6B 4 Pump Drive Pulley 0e sees 6B 5 DAEWOO M 150 BL2 Pump Assembly 00 cee ee eee eee 6B 5 Unit Repalf tk aie whee ered he week RE RE Meg eens Ate 6B 7 PUMP s sd ES aileron Ge SE aie ER Ee bib EE te 6B 7 Specifications 0 cece eee eee 6B 8 General Specifications 005 6B 8 Fastener Tightening Specifications 6B 8 Special Tools and Equipment 6B 9 Special Tools Table 0000 eee 6B 9 6B 2 POWER STEERING PUMP 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 DAEWOO M 150 BL2 POWER STEERING PUMP 6B 3 DIAGNOSTIC INFORMATION AND PROCEDURES POWER STEERING PUMP Condition Probable Cause Correction Foaming Milky e Insufficient power steering fluid level e Fill the power steering fluid Power Steering Fluid reservoir Low Fluid Level and e Contaminated air in the power steering e Bleed the power steering system Possible Low fluid Pressu
16. ancelling mechanism e Foreign material in the turn signal switch e Remove any foreign material housing Turn Signal Will Not e Broken or missing components for the e Replace the turn signal switch Cancel cancelling mechanism Turn Signal Dimmer e Improperly installed turn signal dimmer e Remove and inspect the turn Switch Difficult to switch and turn signal dimmer switch lever signal dimmer switch and Operate signal dimmer switch lever Reinstall the signal dimmer switch and signal dimmer switch lever e Foreign material in the signal dimmer e Remove any foreign material switch housing Turn Signal Will Not e A broken lane change pressure pad or a e Replace the turn signal switch Indicate Lane broken spring hanger Change e The improper functioning of the lane e Replace the turn signal switch change spring e Improperly installed turn signal switch e Replace the turn signal switch No Turn Signal e An inoperative turn signal flasher e Replace the blinker unit Lamps e A faulty turn signal switch e Replace the turn signal switch e Improperly connected chassis to column e Reconnect the chassis to column connector connector Turn Indicator Lamps An inoperative blinker unit e Replace the blinker unit On But Not Flashing Front or Rear Turn e An inoperative blinker unit e Replace the blinker unit Signal Lamps Not Flashing Turn Signal Lamps e An inoperative blinker unit e Replace the blinker unit Flash Ve
17. ausing the rack to move DAEWOO M 150 BL2 POWER STEERING GEAR 6C 3 DIAGNOSTIC INFORMATION AND PROCEDURES POWER RACK AND PINION STERING GEAR Condition Probable Cause Correction e Tighten the steering coupling joints e Fit the power steerng hose into the hose clips correctly Hissing Noise e Loose steering coupling joints Improperly contacted the power steering hose with other components e Improperly contacted the power steering line with the body e Insufficient lubricant e Lubricate the steering gear Rattling Noise in Steering Gear e Fix the steering line correctly Loose steering gear mounting e Tighten the steering gear mounting bracket bolts e Improperly installed tie rod ends e Tighten the tie rod joints and replace the tie rod end as needed Poor Return of Steering Wheel e Improperly contacted the steering e Adjust the turn signal housing to Center wheel with the turn signal housing e Improper binding or looseness of e Replace the intermediate shaft steering coupling e Stuck and improperly aligned e Replace the power steering pump power steering pump flow control valve e Improper binding or looseness of e Tighten the tie rods and the ball tie rods and ball joints joints Replace the tie rods and the ball joints as needed e Poor adjustments of the steering e Perform a straight ahead check gear Momentary Increase in Effect Internal leaks of the
18. bove 70 the steer ing wheel restoration is OK 5 If the restoration is poor check the tire pressure steering gear preload and steering gear operation And repair the fault CHECK THE TURNING RESISTANCE OF THE TIE ROD END OR TIE ROD 1 Turn the ball joint of the tie rod end or the tie rod about 10 times 2 Use a spring balance to check the turning resistance of each ball joint D105B302 Application Specified Value 0 49 3 43 Nem Tie Rod End Ball Joint 4 5 30 Ib in 0 49 3 43 Nem Tie Rod Ball Joint 4 5 30 Ib in 3 If the values exceed the specified values replace the tie rod end or the tie rod 4 But If the ball joint of the tie rod end or the tie rod falls down of itself replace it 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 Check the torque of the adjuster plug 4 When the measured torque is below the specification value or the measured torque is over the specification value adjust the tightening torque e Place the rack gear in the straight ahead position e Tighten the adjust plug to 95 Nem 70 lb ft e 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 Tighten the adjust plug to 8 Nem 71 Ib in ao Set the torque in the 0 8 1 3 Nem 8
19. d 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 e Safety Device A Steering Column Upper Bracket B Steering Column C Steering Column Shaft DAEWOO M 150 BL2 STEERING WHEEL AND COLUMN 6E 3 COMPONENT LOCATOR STEERING WHEEL AND COLUMN D15A401A 1 Horn Cover Airbag Module 15 Support Bolt 2 Steering Wheel Nut 16 Steering Column Housing 3 Locking Plate 17 Steering Column Jacket 4 Steering Wheel 18 Ignition Switch Retaining Screw 5 Steering Column Upper Cover 19 Ignition Switch 6 Steering Column Lower Cover 20 Steering Lock Housing Assembly 7 Turn Signal Switch 21 Steering Column Shaft 8 Windshield Wiper Switch 22 Pinch Bolt 9 Steering Column Assembly 23 Intermediate Shaft 10 Retaining Ring 24 Steering Column Upper Nut 11 Washer 25 Steering Column Lower Nut 12 Spring 13 Switch Housing 14 Bolt DAEWOO M 150 BL2 6E 4 STEERING WHEEL AND COLUMN DIAGNOSTIC INFORMATION AND PROCEDURES STEERING COLUMN
20. e 2 Remove the steering column cover Refer to Steer ing Column Cover in this section 3 Remove the turn signal switch e Disconnect the turn signal switch by pushing the locking from the switch housing 1 e Disconnect the connector 2 _ A Remove the wiper switch e Disconnect the wiper switch by pushing the locking from the switch housing 1 e Disconnect the connector 2 DAEWOO M 150 BL2 D105A509 D105A510 D105A511 DAEWOO M 150 BL2 STEERING WHEEL AND COLUMN 6E 9 Installation Procedure 1 Install the wiper switch 2 Install the turn signal switch 3 Install the steering column cover Refer to Steering Column Cover in this section 4 Connect the negative battery cable IGNITION SWITCH Removal Procedure 1 Disconnect the negative battery cable 2 Remove the steering wheel Refer to Steering Wheel in this section 3 Remove the ignition switch e Disconnect the electrical connector 1 e Remove the screw 2 Installation Procedure 1 Connect the electrical connector 2 Install the ignition switch with the screw 3 Install the steering wheel Refer to Steering Wheel in this section 4 Connect the negative battery cable IGNITION LOCK CYLINDER WITH IMMOBILIZER Left Hand Drive Shown Right Hand Drive Similar Removal Procedure Remove the steering wheel Refer to Steeri
21. e rack and pinion steering assembly to the vehicle Refer to Rack and Pinion Assembly in this section DAEWOO M 150 BL2 DAEWOO M 150 BL2 D105C703 D105C704 D105C705 POWER STEERING GEAR 6C 9 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 e Remove the adjuster plug locknut 1 e Remove the adjuster plug 2 e Remove the adjuster spring 3 3 Remove the steering pinion e Remove the dust cap 1 e Remove the retaining ring 2 e Remove the steering pinion dust cap 3 e 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 e Remove the steering pinion from the pinion bear ing by hitting the pinion with the flated drift and hammer 5 6C 10 POWER STEERING GEAR Important Hit the drift using a hammer when the lower pinion is vertical with the drift e Remove the bearing by hitting the bearing with the flated drift and rubber hammer 6 D105C706 e Remove the pinion shaft seal 7 e Remove the needle bearing 8 e Remove the retaining ring 9 Important The power steering gear housing and the rack gear in this vehicle is no
22. ering Wheel and Column 6E 3 Diagnostic Information and Procedures 6E 4 Steering Column Diagnosis 6E 4 Repair Instructions sie as sak ea Rek Ra Ee 6E 7 On Vehicle Service 0 0c e eee eee 6E 7 Steering Wheel 0 0 cece ene 6E 7 Steering Column Cover 000000s 6E 8 Turn Signal Switch and Lever Wiper Switch and Lever 6E 8 Ignition Switch 0 0c eee eee eee 6E 9 DAEWOO M 150 BL2 Ignition Lock Cylinder and Switch with Immobilizer 2220005 6E 9 Switch Housing 0eee eee eee 6E 10 Steering Column 00 cee e eee 6E 11 Intermediate Shaft cover and Intermediate Shaft 05 6E 12 Unit Repair EE EE GE ee ek ee ee ee 6E 13 Standard Steering Column 6E 13 SpecificationS iss a ee eee 6E 15 General Specifications 6E 15 Fastener Tightening Specifications 6E 15 Special Tools and Equipment 6E 16 Special Tools Table 2 0005 6E 16 6E 2 STEERING WHEEL AND COLUMN 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 designe
23. g or Lack of Assist Stuck and improperly installed e Replace the power steering pump Especially During Parking power steering pump flow control valve e Insufficient pressure of the power e Replace the power steering pump steering pump e Internal leaks of power steering e Replace the power steering pump pump e Improper tension of the pump e Adjust the pump drive belt drive belt tension 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 Nem 89 Ib 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 DAEWOO M 150 BL2 POWER STEERING GEAR 6C 5 e Tighten the adjust plug to 4 5 5 5 Nem 40 49 Ib in e Loosen the adjust plug to 67 5 6 Tighten the adjust plug locknut 6C 6 POWER STEERING GEAR REPAIR INSTRUCTIONS ON VEHICLE SERVICE RACK AND PINION ASSEMBLY Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Remove the intermediate shaft lo
24. ing e Install the adjuster spring 1 e Tighten the adjuster plug 2 e Tighten the plug locknut 3 7 Install the rack and pinion steering assembly to the vehicle Refer to Rack and Pinion Assembly in this section D105C714 DAEWOO M 150 BL2 POWER STEERING GEAR 6C 13 SPECIFICATIONS GENERAL SPECIFICATIONS Capacity 1 0L 1 056 qt FASTENER TIGHTENING SPECIFICATIONS Power Steering Gear Bracket Bolt 50 55 36 41 ae Power Steering Gear Pinion Nut 40 50 30 36 Power Steering Gear Pinion Dust Cover Power Steering Gear Pressure Line Fitting 25 35 18 25 EE Power Steering Oil Pressure Pipe Fitting Gear Side 21 35 16 25 C a Power Steering Gear Ajuster Plug Refer to DIAGNOSIS in this section 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 eguipment 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 On Vehicle Service 00 EE ee eee 6D 7 Manual Rack and Pinion 6D 2 Tie Rod End 0 0 0 c eee eee eee 6D 7 Component Locator 0 005 6D 3 Rack and Pinion Boot 6D 8 Manual Rac
25. ing in installing and removing the rack gear 6D 14 MANUAL STEERING GEAR Inspection Procedure 1 Inspect the rack gear deformation and damage e Set the V block on the plate 1 e Set the rack gear on the V block 2 e Check the rack gear for deformation using a dial gauge 3 e Inspect the rack gear for wear and damage 4 D105B712 2 Inspect the pinion and bearing assembly damage e Inspect the pinion gear for wear and damage 1 e Inspect the bearing for loose and operation 2 D105B713 3 Inspect the tie rod end boot and the rack and pinion boot for damage e Inspect the tie rod end boot for crack and wear 1 e Inspect the rack and pinion boot for crack and wear 2 D105B714 4 Inspect the steering gear housing for crack deforma tion and wear a Steering gear housing D105B715 DAEWOO M 150 BL2 NA O D105B716 D105B717 D15B718A D105B719 DAEWOO M 150 BL2 MANUAL STEERING GEAR 6D 15 5 Inspect the tie rod end ball joint and tie rod ball joint for damage e Inspect the tie rod end ball joint for operation 1 e Inspect the tie rod ball joint for operation and tie rod deformation 2 6 After inspecting the parts replace the defected parts Assembly Procedure Important Coat the all turn contact and rub surface with grease 1 Clean the all parts removed 2 Install the rack gear e Coat the rack gear with grease 1 e Insert the
26. ion and Procedures 6C 3 Hydraulic Cylinder Lines 6C 8 Power Rack and Pinion Steering Gear 6C 3 Rack and Pinion Steering Gear 6C 9 Adjust the Free Load of the Steering Gear 6C 5 Assembly Repair Instructions ss seek ee RR RR RE 6C 6 Specifications ies s kk cece eee eee eee 6C 13 On Vehicle Service 000e cece eee 6C 6 General Specifications 6C 13 Rack and Pinion Assembly 6C 6 Fastener Tightening Specifications 6C 13 Power Steering Gear Rack and Pinion Boot 6C 7 DAEWOO M 150 BL2 6C 2 POWER STEERING GEAR 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 tie rod 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 c
27. k and Pinion Steering Gear 6D 3 Rack and Pinion Steering Gear Assembly 6D 9 Diagnostic Information and Procedures 6D 4 Unit Repair 0 0 0 2 eee eee eee 6D 11 Manual Rack and Pinion Steering Gear 6D 4 Tie Rod End Boot 2 00055 6D 11 Straight Ahead Check EE EE 6D 5 Rack and Pinion EE EE EE EE EE ee ee ee 6D 11 Steering Wheel Restoration 6D 6 Specifications 2 c cece eee eee 6D 17 Check The Turning Resistance of the General Specifications 6D 17 Tie Rod End or Tie Rod 5 6D 6 Fastener Tightening Specifications 6D 17 Adjust the Free Load of the Steering Gear 6D 6 Special Tools and Equipment 6D 18 Repair Instructions 0eee EER 6D 7 Special Tools Table DAEWOO M 150 BL2 6D 2 MANUAL STEERING GEAR DESCRIPTION AND OPERATION MANUAL RACK AND PINION The manual rack and pinion steering system consists of two main components the rack and the pinion The mo tion of the pinion is transferred through the pinion teeth that mesh with the teeth on the rack which moves the rack The force is then transmitted through the arms on the struts which turn the wheels DAEWOO M 150 BL2 MANUAL STEERING GEAR 6D 3 COMPONENT LOCATOR MANUAL RACK AND PINION STEERING GEAR Left Hand Drive Shown Right Hand Drive Similar lt 20 22 23 24 D105B401 1 Manual Steering Gear 13
28. ke the toe in adjustment by turning the tie rod ad juster Refer to Section 2B Wheel Alignment RACK AND PINON BOOT Removal Procedure 1 2 Remove the tie rod end Refer to Tie Rod End in this section Remove the tie rod end lock nut 3 Remove the rack and pinion boot e Remove the boot clamp 1 e Cut off the boot wire clamp 2 DAEWOO M 150 BL2 MANUAL STEERING GEAR 6D 9 e Coat the greases on the tie rod to ease removal 3 e Remove the boot 4 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 BS Al nN 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 e Remove the steering gear bracket bolts 1 e Remove the steering gear bracket 2 e Remove the steering gear assembly e Remove the packing 3 SEBPEPBRAR HE AAS D105B509 D105B510 DAEWOO M 150 BL2
29. ng Wheel in this section Disconnect the electrical connector for the immobiliz er detection coil Remove the lock cylinder e With the key in the ignition turn to the position des ignated 1 a4 N Co 6E 10 STEERING WHEEL AND COLUMN D105A511 D105A512 D105A513 D105A514 e Remove the lock cylinder by pressing down the detent spring with a 2 5MM allen wrench or other suitable tool and pulling the lock cylinder out of the switch cylinder housing 2 Installation Procedure Important To install the ignition lock cylinder the igni tion position should be designated I 1 Install the ignition lock cylinder 2 Connect the electrical connector for the immobilizer detection coil 3 Install the steering wheel Refer to Steering Wheel in this section SWITCH HOUSING Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Remove the steering wheel Refer to Steering Wheel in this section 2 Remove the turn signal switch and windshield wiper switch Refer to Turn Signal Switch and Lever Wiper Switch and Lever in this section 3 Remove the switch housing e Disconnect the horn electrical connector 1 e Remove the screws retaining the switch housing 2 Installation Procedure 1 Install the switch housing with the screws 2 Connect the horn electrical connector 3 Install the turn signal switch and windshield wiper switch Refer t
30. o Turn Signal Switch and Lever Wiper switch and Lever in this section 4 Install the steering wheel Refer to Steering Wheel in this section DAEWOO M 150 BL2 Q D105A516 D15A517B D15A518B DAEWOO M 150 BL2 STEERING WHEEL AND COLUMN 6E 11 STEERING COLUMN Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Remove the steering wheel Refer to Steering Wheel in this section Caution Disconnect the negative battery cable and let the vehicle sit for 1 minute to deactivate the air bag For vehicle with SIR 2 Remove the turn signal switch and wiper switch Re fer to Turn Signal Switch and Lever Wiper Switch and Lever in this section 3 Remove the switch housing Refer to Switch Hous ing in this section 4 Remove the ignition switch Refer to Ignition Switch in this section 5 Remove the ignition lock cylinder Refer to Ignition Lock Cylinder in this section 6 Remove the steering column e Match mark on the intermediate shaft and the steering column shaft 1 e Remove the intermediate shaft upper pinch bolt 2 e Remove the steering column lower nuts 3 e Remove the steering column upper nuts 4 Installation Procedure Important Align the match mark on the intermediate shaft and the steering column shaft 1 Install the steering column e Install the intermediate shaft
31. ody e Insufficient power steering fluid level e Fill the power steering pump reservoir e Improperly installed pump mounting e Tighten the power steering pump attachment bolts Swishing Noise in the Damaged power steering pump flow control Replace the power steering pump Steering Pump valve Whining Noise in the e Scores of the pressure plate and the vanes Replace the power steering pump Steering Pump e Scores of the pump shaft bearing e Replace the power steering pump DAEWOO M 150 BL2 6B 4 POWER STEERING PUMP REPAIR INSTRUCTIONS ON VEHICLE SERVICE PUMP DRIVE BELT Removal Procedure 1 Remove the front passenger side headlamp Refer to Section 9B Lighting Systems 2 Remove the pump drive belt e Loosen the rear bracket adjusting bolt 1 e Loosen the bolt 2 e Loosen the front bracket adjusting bolts 3 e Push the pump forward 4 D105C525 Installation Procedure 1 Install the pump drive belt with the bolts Tighten ee e Tighten the front bracket adjusting bolt to 18 22 Nem 13 16 lb ft 1 N e Tighten the rear bracket adjusting bolt to 20 24 FRY Nem 15 18 lb ft 2 e Tighten the power steering pump bolt to 20 24 20 24 nee Nem 15 18 lb ft 3 Install the front passenger side headlamp Refer to AU a Section 9B Lighting Systems N D15C526A DAEWOO M 150 BL2 IE es DS sod lt Dw310 020 SD lt 4 a TT D105C527
32. otice Check the lower pinch bolt position correctly D15A521A DAEWOO M 150 BL2 D105A701 D15A702A D15A703A DAEWOO M 150 BL2 STEERING WHEEL AND COLUMN 6E 13 UNIT REPAIR STANDARD STEERING COLUMN Disassembly Procedure 1 Remove the steering column from the vehicle Refer to Steering Column in this section Caution Be careful not to impact on the steering column shaft Plastic sleeve may be broken that is installed to secure the driver at the accident 2 Remove the steering column shaft from the steering column Remove the retaining ring 1 Remove the washer 2 Remove the spring 3 Remove the washer 4 Remove the locking of the alignment spacer 5 Push strongly the steering column shaft downward 6 6E 14 STEERING WHEEL AND COLUMN Assembly Procedure Important Position the alignment spacer on the lower column shaft to install the spacer in the steering column jacket easily 1 Install the steering column shaft to the steering col umn e Position the locking of the alignment spacer on the groove of the steering column e Install the washer Install the spring e Install the washer e Install the retaining ring 2 Install the steering column to the vehicle Refer to Steering Wheel in this section D15A704A DAEWOO M 150 BL2 STEERING WHEEL AND COLUMN GE 15 SPECIFICATIONS GENERAL SPECIFICATIONS Application Unit Desc
33. re e Internal leaks and overflow of the power e Replace the power steering pump steering pump e Leaks of the power steering pump housing Replace the power steering pump and the soft plug Low Pressure Due to Stuck and improperly operated power e Replace the power steering pump Steering Pump steering pump flow control valve e Worn power steering pump seats e Replace the power steering pump e Scores cracks or breaks of the pressure e Replace the power steering pump plate the pump ring the thrust plate and the rotor e Sticking of the vanes in the rotor slots e Replace the power steering pump e Internal leaks and overflow of the power e Replace the power steering pump steering pump Growling Noise in e Restricted flow of the pump hoses and the e Clean out the pipes and the hoses Steering Pump steering gear pipes e Replace the pipes and the hoses as needed e Scores cracks or breaks of the pressure e Replace the power steering pump plate the pump ring the thrust plate and the rotor e Improperly contacted power steering hose e Secure the pump hose in a clamp with the body away from the body e Insufficient power steering fluid level e Fill the power steering pump reservoir Ratting Noise in the e Contaminated air in the power steering e Bleed the power steering system Steering Pump fluid e Improperly contacted power steering hose e Secure the pump hose in a clamp with the body away from the b
34. ription With Airbag mm 380 14 96 m in 14 Steering Wheel Without Airbag mm in 370 14 57 in 0 20 0 40 79 Free Play Engine Stop mm in DAEWOO M 150 BL2 6E 16 STEERING WHEEL AND COLUMN SPECIAL TOOLS AND EGUIPMENT SPECIAL TOOLS TABLE DW310 010 Steering Wheel Puller D105A101
35. ry Slowly DAEWOO M 150 BL2 6E 6 STEERING WHEEL AND COLUMN Ignition Switch Electrical System Will Damaged ignition switch e Replace the ignition switch On Funeion e Improperly installed ignition switch e Remove and inspect the ignition switch e Reinstall the ignition switch e Improperly installed ignition switch electrical Reconnect the ignition switch connector electrical connector e Replace the ignition switch electrical connector Ignition Switch Will e Damaged ignition switch e Replace the ignition switch por Tarn e Improperly installed ignition switch e Remove and inspect the ignition switch e Reinstall the ignition switch Wiper Switch Lever Switch Inoperative e Damaged wiper switch e Replace the wiper switch No I Low High Int e Improperly installed wiper switch e Remove and inspect the wiper or Wash switch Reinstall the wiper switch DAEWOO M 150 BL2 STEERING WHEEL AND COLUMN 6E 7 REPAIR INSTRUCTIONS ON VEHICLE SERVICE D105A501 D15A503A DAEWOO M 150 BL2 STEERING WHEEL Left Hand Drive Shown Right Hand Drive Similar Tools Required DW310 010 Steering Wheel Puller Removal Procedure 1 Disconnect the negative battery cable 2 Remove the SIR module Refer to Section 8B Sup plemental Inflatable Restraints For vehicle with SIR Remove the steering wheel Remove the steering wheel horn cover For vehicle
36. t serviceable as unit The faulty parts must be replaced as whole units D105C707 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 e Inspect the pinion gear for damage or wear 1 D105C708 e Inspect the rack gear for damage or wear 2 e Inspect the steering gear housing for damage or wear 3 D105C709 DAEWOO M 150 BL2 D105C710 D105C711 D105C712 45 55 Nem D15C713A DAEWOO M 150 BL2 POWER STEERING GEAR 6C 11 4 Inspect the bearings and the seal for damage e Inspect the pinion shaft seal for leaks and wear 1 e Inspect the needle bearing for wear 2 e Inspect the pinion bearing for wear 3 5 The faulty parts must be replaced Assembly Procedrue 1 Install the steering pinion gear Install the retaining ring 1 e Install the needle bearing 2 e Install the pinion shaft seal using a drift 3 2 Install the steering pinion locknut 4 Tighten Tighten the pinion locknut to 40 50 Nem 30 36 lb ft 3 Install the dust cap 5 Tighten Tighten the dust cap to 45 55 Nem 33 41 lb ft 4 Install the retaining ring 6 5 Install the plastic dust cap 7 6C 12 POWER STEERING GEAR 6 Install the rack bear
37. the rack and pinion boot Remove the tie rod end Refer to Tie Rod End in this section 1 e Remove the tie rod lock nut 2 e Remove the rack and pinion boot clamp 3 e Cut off the rack and pinion boot wire 4 6D 12 MANUAL STEERING GEAR D105B704 D105B705 D15B706A D105B707 e Coat the greases on the tie rod 5 e Remove the rack and pinion boot 6 3 Remove the tie rod e Pull the rack gear perfectly from the steering gear housing by turning the pinion gear 1 e Disconnect the shock damper ring from the tie rod ball joint 2 e 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 e Remove the tie rod 4 e Remove the shock damper ring 5 DAEWOO M 150 BL2 DAEWOO M 150 BL2 D105B708 D105B709 D105B710 D105B711 MANUAL STEERING GEAR 6D 13 4 Remove the rack bearing e Remove the adjuster plug 1 e Remove the adjuster spring 2 5 Remove the pinion and bearing assembly e Remove the dust cover 1 e Remove the pinion plug 2 Important Do not reuse the removed pinion plug e Remove the pinion and bearing assembly 3 6 Remove the rack gear toward the driver side of the steering gear a Rack gear Notice Remove the rack gear toward the driver side of the steering gear to prevent the bulk head in the steering gear housing from damag
38. upper pinch bolt 1 Tighten Tighten the pinch bolt to 21 29 Nem 16 22 lb ft Install the steering column lower nuts 2 Tighten Tighten the nuts to 15 20 Nem 11 15 lb ft e Install the steering column upper nuts 3 Tighten Tighten the nuts to 15 20 Nem 11 15 lb ft 2 Install the ignition lock cylinder Refer to Ignition Lock Cylinder in this section 3 Install the ignition switch Refer to Ignition Switch in this section 4 Install the switch housing Refer to Switch Housing in this section 5 Install the turn signal switch and wiper switch Refer to Turn Signal Switch and Lever Wiper Switch and Lever in this section 6 Install the steering wheel Refer to Steering Wheel in this section 6E 12 STEERING WHEEL AND COLUMN INTERMEDIATE SHAFT COVER AND INTERMEDIATE SHAFT Left Hand Drive Shown Right Hand Drive Similar Removal Procedure 1 Remove the intermediate shaft In order to install the intermediate shaft correctly match mark the intermediate shaft to the steering column 1 e Remove the intermediate shaft upper pinch bolt D105A520 2 e Remove the intermediate shaft lower pinch bolt 3 Installation Procedure 1 Install the intermediate shaft with the bolts Tighten e Tighten the intermediate shaft lower pinch bolt to 21 29 Nem 16 22 lb ft 1 e Tighten the intermediate shaft upper pinch bolt to 21 29 Nem 16 22 lb ft 2 N
39. wer 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 5 Remove the rack and pinion assembly e Disconnect the return line pipe from the steering gear 1 e Disconnect the pressure inlet line pipe from the steering gear 2 e Plug the opening in the power steering pipe line to prevent fluid loss and contamination e Remove the power steering gear retaining bracket tighten bolts 3 ai r e Remove the power steering gear retaining bracket Oe 4 ci P EE i heel AE Important After moving the gear toward the passenger O12 DS Ns Ve 0 side and pulling the gear of the driver side into the un UAE derbody hole remove the steering gear A We D105C535 DAEWOO M 150 BL2 D105C536 D15C512A DAEWOO M 150 BL2 POWER STEERING GEAR 6C 7 6 Remove the packing 5 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 Nem 36 41 lb ft 3 Connect the steering pipe Refer to Section 6A Pow er Steering System Tighten Tighten the power steering pressure line fitting 1 to 21 35
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