Daewoo Matiz (2003 year). Manual - part 175

POWER STEERING GEAR  6C – 5

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.

D

Place the rack gear in the straight-ahead position.

D

Tighten the adjust plug to 10 N

S

m (89 lb-in).

D

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

D

Place the rack gear in the straight-ahead position.

D

Loosen the adjust plug.

D105C302

D

Tighten the adjust plug to 4.5–5.5 N

S

m (40–49 lb-

in).

D

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 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.

D

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

D

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

D

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

D105C535

D

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

D

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

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 N

S

m (36–41 lb-ft).

D15C512A

21–35 N

S

m

21–35 N

S

m

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 N

S

m (16–25 lb-ft) (1).

Tighten the return line fitting to 21–35 N

S

m (16–25 lb-

ft) (2).

Important: When adding fluid or making a complete
fluid change, always use DEXRON

R 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

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.

D

Remove the fitting (1).

D

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 N

S

m

(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 N

S

m

(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.