Text preview for : en_4j2_6c.pdf part of Daewoo Nubira/Lacetti Also known as: Chevrolet Nubira / Lacetti, Chevrolet Optra Optra5, Suzuki Forenza Reno
Covers the 1.4L, 1.6L and 1.8L engine.
Year 2004
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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 LOCK unless otherwise noted.
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 6C1 General Specifications . . . . . . . . . . . . . . . . . . . . . 6C1 Fastener Tightening Specifications . . . . . . . . . . . 6C2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C2 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . . 6C2 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C3 Power Rack and Pinion Steering Gear . . . . . . . . 6C3 Power Rack and Pinion Steering Gear Bench Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C5 Speed Sensitive Power Steering System . . . . . . 6C6 Speed Sensitive Power Steering System Operating With Full Assist At All Times . . . . . . . . . . . . . . . 6C7 Speed Sensitive Power Steering System Operating with Decreased Assist At All Times . . . . . . . . . 6C9 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . 6C11 ONVEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 6C11 Rack and Pinion Assembly . . . . . . . . . . . . . . . . . 6C11 Outer Tie Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dust Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . StraightAhead Check . . . . . . . . . . . . . . . . . . . . Intermediate Shaft and Dash Seal . . . . . . . . . . Hydraulic Cylinder Lines . . . . . . . . . . . . . . . . . . . Speed Sensitive Power Steering Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rack and Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . 6C14 6C15 6C16 6C17 6C20 6C21 6C22 6C22
Stub Shaft Seals and Upper and Lower Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C26 Rack Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C29 Rack Bearing Preload Adjustment . . . . . . . . . . . 6C30 Valve and Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . 6C30 GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C33 Power Rack and Pinion . . . . . . . . . . . . . . . . . . . . 6C33 Speed Sensitive Power Steering System . . . . . 6C33
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Capacity Lubricant 1.1 Liter (1.16 qt) Power Steering Fluid DEXRON®II or III Description
6C 2IPOWER STEERING GEAR
FASTENER TIGHTENING SPECIFICATIONS
Application Adjuster Plug Adjuster Plug Locknut Control Module Bracket Bolts Dash Seal Retaining Ring Nuts Hydraulic Cylinder Line Fittings Cylinder End Hydraulic Cylinder Line Fittings Valve End Inner Tie Rod Intermediate Shaft Pinch Bolts Outer Tie Rod Adjusting Nut Outer Tie Rod Nuts Pinion Locknut Pinion Preload Steering Gear Inlet and Outlet Pipe Fittings Steering Gear Mounting Bracket Nuts and Bolts Transaxle Center BrackettoEngine Bolt NSm 12 75 7 7 28 18 100 25 64 50 30 1 28 60 80 LbFt 56 21 13 74 18 47 37 22 21 44 59 LbIn 106 62 62 9
SPECIAL TOOLS
SPECIAL TOOLS TABLE
KM507B Ball Joint Remover
J42459 Rack Guide Spring Cap Wrench
KMJ26610 Installer
DAEWOO V121 BL4
POWER STEERING GEAR 6C 3
DIAGNOSIS
POWER RACK AND PINION STEERING GEAR
Hissing Noise
Checks Check the intermediate shaft joints for looseness. Check the power steering hose for contact with other components. Action Tighten the intermediate shaft joints. Be sure the power steering hose is correctly fitted into the hose clips.
Rattling Noise in Steering Gear
Checks Check the power steering hose for contact with the body. Check the steering gear for insufficient lubrication. Check the steering gear mounting for improper installation. Check the outer tie rods for improper installation. Action Be sure the power steering hose is correctly fitted into the hose clips. Lubricate the steering gear. Tighten the steering gear mounting bracket nuts and bolts. Tighten the outer tie rod joints. Replace the outer tie rods.
Poor Return of Steering Wheel to Center
Checks Check the steering wheel for contact with the turn signal housing. Check the intermediate shaft joints for binding or looseness. Check the power steering pump flow control valve for sticking and improper alignment. Check the wheel alignment. Check the wheel bearings for wear or damage. Check the intermediate shaft joints for improper installation. Check the outer tie rods and the ball joints for binding or looseness. Check the steering gear adjustments. Check the steering column shaft seal for rubbing on the shaft. Check the steering shaft bearings for binding. Action Adjust the turn signal housing. Replace the intermediate shaft. Replace the power steering pump. Align the wheels. Replace the wheel bearings. Adjust the intermediate shaft between the steering gear and the steering column. Replace the intermediate shaft. Tighten the tie rods and the ball joints. Replace the tie rods and the ball joints. Perform a straightahead check. Replace the dash seal. Replace the stub shaft bearings.
Momentary Increase in Effort When Turning the Wheel Quickly
Checks Check the power steering pump for internal leaks. Check the hoses for damage or restricted flow. Check the power steering fluid level. Check the power steering pump flow control valve for sticking and improper operation.
DAEWOO V121 BL4
Action Replace the power steering pump. Replace the power steering hoses and/or pipes. Fill the power steering fluid reservoir. Replace the power steering pump.
6C 4IPOWER STEERING GEAR Steering Surges or Jerks When Turning with Engine Running
Checks Check the power steering pump for insufficient pressure. Check the power steering pump flow control valve for sticking and improper operation. Check the power steering pump serpentine belt for slippage. Check for air contamination in the power steering system. Action Replace the power steering pump. Replace the power steering pump. Tighten the power steering serpentine belt. Bleed the power steering system.
Steering Vibrates During Low Speed or Static Steering
Checks Check for air contamination in the power steering system. Check the power steering pump serpentine belt for looseness. Action Bleed the power steering system. Tighten the power steering serpentine belt.
Excessive Wheel Kickback or Loose Steering
Checks Check for air contamination in the power steering system. Check the wheel bearings for wear or damage. Check the steering gear mounting for improper installation. Check the intermediate shaft joints for improper installation. Check the outer tie rods and ball joints for looseness. Action Bleed the power steering system. Replace the wheel bearings. Tighten the steering gear mounting bracket nuts and bolts. Adjust the intermediate shaft between the steering gear and the steering column. Replace the intermediate shaft. Tighten the tie rods and the ball joints. Replace the tie rods and the ball joints.
Hard Steering or Lack of Assist (Especially During Parking)
Checks Adjust the intermediate shaft between the steering gear and the steering column. Replace the coupling flange. Check the power steering pump flow control valve for sticking and improper installation. Check the power steering pump for insufficient pressure. Check the power steering pump for internal leaks. Check for a loose or a worn intermediate shaft. Check the power steering pump serpentine belt tension. Action Adjust the steering coupling flange on the steering gear and the steering column. Replace the coupling flange as needed. Replace the power steering pump. Replace the power steering pump. Replace the power steering pump. Tighten the intermediate shaft. Replace the intermediate shaft as needed. Tighten the power steering serpentine belt.
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POWER STEERING GEAR 6C 5
POWER RACK AND PINION STEERING GEAR BENCH TESTING
Removal, Setup and Testing Procedure
Notice : Pressure checks or pressure and flow checks may also be conducted using this setup. 1. Disconnect and remove the power steering gear. Refer to "Rack and Pinion Assembly" in this section. Place the power steering gear on a bench next to the vehicle. Disconnect the pressure line at the point where the hose connects to the pipe. Extend this line in order to reach the power steering gear on the bench. Disconnect the return line from the the power steering fluid reservoir. Extend this line in order to reach the power steering gear on the bench. Connect the power steering pipes to the power steering gear.
6. 7. 8.
9.
Start the engine and allow it to idle for 10 seconds. Check the power steering fluid level. Refer to Section 6A, Power Steering System. Start the engine and turn the rack and pinion stub shaft to a full turn in each direction. Hold the shaft against each stop for 5 seconds. Inspect for possible leak points. Refer to Section 6A, Power Steering System.
Installation Procedure
1. 2. 3. 4. 5. 6. Stop the engine. Disconnect the power steering pipes from the power steering gear. Remove the extensions and reconnect the pressure and return lines. Install and connect the power steering gear. Refer to "Rack and Pinion Assembly" in this section. Start the engine and stay idle for 10 seconds. Check the power steering fluid level. Refer to Section 6A, Power Steering System.
2. 3.
4.
5.
DAEWOO V121 BL4
6C 6IPOWER STEERING GEAR
SPEED SENSITIVE POWER STEERING SYSTEM
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POWER STEERING GEAR 6C 7
SPEED SENSITIVE POWER STEERING SYSTEM OPERATING WITH FULL ASSIST AT ALL TIMES
Step 1 Action Perform an initial inspection of the power steering system. Is the system operational? Check the speedometer. Is the speedometer inoperative? Check the diagnostic trouble codes at the engine control module (ECM). Is the ECM code 24 set? 1. Turn the ignition ON. 2. Disconnect the electronic variable orifice (EVO) solenoid actuator electrical connector at the power steering pump. 3. Probe terminal 1 of the EVO actuator connector with a voltmeter. Does the voltmeter display the specified value? Repair the open or short in the circuit between terminal 1 of the EVO solenoid actuator electrical connector and terminal 2 on the speed sensitive power steering (SSPS) control module connector. Is the repair complete? 1. Remove the EVO solenoid actuator from the power steering pump. 2. Turn the actuator upside down to position the pintle. 3. Stimulate the actuator by connecting it to the battery. Does the actuator click? Replace the EVO solenoid actuator. Is the repair complete? 1. Turn the ignition OFF. 2. Remove the SSPS control module from the control module bracket. 3. Disconnect the SSPS control module connector. 4. Connect a test light from terminal 8 on the SSPS control module connector to the ground. 5. Turn the ignition ON. Is the test light on? Check the ignition fuse. Is the ignition fuse open? Replace the ignition fuse. Is the repair complete? Check for an open or short in the circuit between terminal 8 of the control module connector and the I/P fuse block. Is the connection faulty? Value(s) Yes Go to Step 2 No Go to Section 6A, Power Steering System Go to Step 3
2
Go to Section5, Transaxle Go to Section1F, Engine Controls Go to Step 6
3
Go to Step 4
4
Go to Step 5
5
System OK
6
Go to Step 8
Go to Step 7
7 8
System OK Go to Step 14
Go to Step 9
9 10 11
Go to Step 10 System OK Go to Step 12
Go to Step 11 Go to Step 13
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6C 8IPOWER STEERING GEAR
Step 12 Action Repair the open or short in the circuit between terminal 8 of the SSPS control module connector and the I/P fuse block. Is the repair complete? Repair the power feed to the ignition fuse F2. Is the repair complete? 1. Turn the ignition OFF. 2. Connect a test light from terminal 10 of the SSPS control module connector to B+. Is the test light on? Repair the open in the ground circuit between terminal 10 of the SSPS control module connector and G203. Is the repair complete? Check for a short to B+ or an open in the circuit between terminal 1 of the SSPS control module connector and terminal B of the EVO solenoid actuator connector. Is the connection faulty? Repair the short to B+ or an open in the circuit between terminal 1 of the SSPS control module connector and terminal 2 of the EVO solenoid actuator connector. Is the repair complete? 1. Disconnect the steering wheel rotation sensor. 2. Turn the ignition ON. 3. Check for an open, short to ground, short to B+, or poor terminal contact between terminal 5 of the SSPS control module connector and terminal 1 of the steering wheel rotation sensor connector. Is the connection faulty? Repair the open, short to ground, short to B+, or poor terminal contact between terminal 5 of the SSPS control module connector and terminal 1 of the steering wheel rotation sensor connector. Is the repair complete? Check for an open between terminal 3 of the SSPS control module connector and terminal 3 of the steering wheel rotation sensor connector. Is the connection faulty? Repair the open between terminal 3 of the SSPS control module connector and terminal 3 of the steering wheel rotation sensor connector. Is the repair complete? Check for an open, short to ground, short to B+, or poor terminal contact between terminal 14 of the SSPS control module connector and terminal 2 of the steering wheel rotation sensor connector. Is the connection faulty? Value(s) Yes System OK No
13 14
System OK Go to Step 16
Go to Step 15
15
System OK
16
Go to Step 17
Go to Step 18
17
System OK
18
Go to Step 19
Go to Step 20
19
System OK
20
Go to Step 21
Go to Step 22
21
System OK
22
Go to Step 23
Go to Step 24
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POWER STEERING GEAR 6C 9
Step 23 Action Repair the open, short to ground, short to B+, or poor terminal contact between terminal 14 of the SSPS control module connector and terminal 2 of the steering wheel rotation sensor connector. Is the repair complete? 1. 2. 3. 4. 5. Turn the ignition OFF. Connect the SSPS control module. Connect the steering wheel rotation sensor. Turn the ignition ON. Backprobe with a voltmeter from terminal 5 on the control module connector to the ground. 6. Rotate the steering wheel quickly in both directions. Does the voltage show an increase and decrease from the specified value? Replace the SSPS control module. Is the repair complete? Replace the steering wheel rotation sensor. Is the repair complete? Value(s) Yes System OK No
24
[3V
Go to Step 25
Go to Step 26
25 26
System OK System OK
SPEED SENSITIVE POWER STEERING SYSTEM OPERATING WITH DECREASED ASSIST AT ALL TIMES
Step 1 Action Check the speedometer. Is speedometer inoperative? Disconnect the EVO solenoid actuator at the power steering pump. Is the symptom still present? Replace the speed sensitive poser steering (SSPS) control module. Is repair complete? Value(s) Yes Go to Section5, Transaxle Go to Section 6A, Power Steering System System OK No Go to Step 2
2
Go to Step 3
3
General Operation
The control module selfdiagnoses SSPS system. If there is any malfunction, the warning lamp comes ON and at the same time a trouble code is set. The trouble code can be retrieved or cleared only by SCANTOOL. In normal condition, If the ignition is turned on, the warning lamp comes on for the first 2 sec and out. During this 2 sec, the control module is diagnosing SSPS system, so a driver can feel a little heavy steering effort. If the warning lamp stays on after the 2 sec or comes on afterward, it means there is a malfunction and a related trouble code is recorded. The warning lamp once come on does not go off even if the malfunction is cleared. It goes off after ignition is turned off and on without a malfunction.
However the trouble code still remains in the control module.
DAEWOO V121 BL4
6C 10IPOWER STEERING GEAR Trouble Code
DTC 01 02 03 04 05 06 07 08 Trouble Actuator circuit open Actuator HI to LO short Actuator circuit short to B+ Actuator HI short to Ground Actuator LO short to Ground Steering Wheel Speed Sensor Open Steering Wheel Speed Sensor short to 5V Battey Voltage Out of Range (9~16 V) Warning lamp ON, Actuator Off Default Action
DAEWOO V121 BL4
POWER STEERING GEAR 6C 11
MAINTENANCE AND REPAIR
ONVEHICLE SERVICE RACK AND PINION ASSEMBLY
(LeftHand Drive Shown, RightHand Drive Similar)
Tools Required KM507B Ball Joint Remover
Removal Procedure
1. 2. 3. 4. Disconnect the negative battery cable. Raise and suitably support the vehicle. Remove the wheels. Refer to Section 2E, Tires and Wheels. Disconnect the power steering gear fluid outlet pipe. Place a drain pan under the steering gear to catch the power steering fluid. Disconnect the power steering gear fluid inlet pipe. Position the steering gear straight ahead by turning the steering wheel until the steering wheel spokes are vertical and pointed to the left. Scribe a mark on the stub shaft housing that lines up with a mark on the intermediate shaft lower coupling.
5. 6.
7.
8.
Remove the intermediate shaft pinch bolt.
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6C 12IPOWER STEERING GEAR
9. Remove the outer tie rod nuts and disconnect the tie rod ends from the strut assembly using the ball joint remover KM507B. 10. Remove the crossmember assembly. Refer to Section 2C, Front Suspension. 11. On vehicles equipped with an automatic transaxle, remove the transaxle center bracket. Refer to Section 5A, Automatic Transaxle. 12. On vehicles equipped with a manual transaxle, remove the bolts securing the transaxle center bracket to the transaxle and the engine. Move the transaxle center bracket out of the way.
13. Remove the nuts and bolts from the steering gear mounting bracket.
14. Remove the return line from the clip on the crossmember. 15. Disconnect the rack and pinion assembly from the crossmember assembly.
Installation Procedure
1. Install the rack and pinion assembly on the crossmember. The steering gear must be in a straight ahead position, and the steering wheel spokes must be vertical and pointing to the left. Align the marks on the shafts to ensure proper positioning. Seat the stub shaft into the intermediate shaft.
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POWER STEERING GEAR 6C 13
2. Install the bolts and nuts on the steering gear mounting bracket.
Tighten
Tighten the steering gear mounting bracket bolts and nuts to 60 NSm (44 lbft).
3.
Install the return line into the clip on the crossmember.
Tighten
4. Tightem the return line clip bolt to 8 NSm (71 lbin). On vehicles equipped with a manual transaxle, position the transaxle center bracket in place and install the bolts securing the bracket to the engine and the transaxle.
Tighten
Tighten the transaxle center brackettotransaxle bolts and the transaxle center brackettoengine bolt to 80 NSm (59 lbft). On vehicles equipped with an automatic transaxle, install the transaxle center bracket. Refer to Section 5A, Automatic Transaxle. Install the crossmember. Refer to Section 2C, Front Suspension. Connect the tie rod ends to the strut assembly. Install the outer tie rod nuts.
5.
6. 7. 8.
Tighten
Tighten the outer tie rod nuts to 50 NSm (37 lbft).
DAEWOO V121 BL4
6C 14IPOWER STEERING GEAR
9. Install the lower intermediate shaft pinch bolt.
Tighten
Tighten the lower intermediate shaft pinch bolt to 25 NSm (18 lbft).
10. Connect the power steering gear fluid inlet and outlet pipe.
Tighten
Tighten the steering gear inlet and outlet pipe fitting to 28 NSm (21 lbft). 11. Perform a front toe adjustment. Refer to Section 2B, Wheel Alignment. 12. Install the wheels. Refer to Section 2E, Tires and Wheels. 13. Lower the vehicle. 14. Do a straightahead check. Refer to "Straight Ahead Check" in this section. Notice : When adding fluid or making a complete fluid change, always use power steering fluid DEXRON®II or III or equivalent. Failure to use the proper fluid will cause hose and seal damage and fluid leaks. 15. Refill the power steering system and check for leaks. If leaks are found, correct the cause of the leak and bleed the system. Refer to Section 6A, Power Steering System. 16. Connect the negative battery cable.
OUTER TIE ROD
Tools Required KM507B Ball Joint Remover
Removal Procedure
1. 2. 3. Remove the wheel. Refer to Section 2E, Tires and Wheels. Mark the threads on the inner tie rod to aid in repositioning the adjusting nut. Remove the outer tie rod nut and disconnect the outer tie rod from the steering knuckle using the ball joint remover KM507B.
DAEWOO V121 BL4
POWER STEERING GEAR 6C 15
4. Loosen the outer tie rod adjusting nut and remove the outer tie rod by twisting it off the inner tie rod.
Installation Procedure
1. 2. Reposition the adjusting nut to the marks on the inner tie rod. Install the outer tie rod by twisting it onto the inner tie rod.
3. 4. 5.
Connect the outer tie rod to the steering knuckle. Perform a front toe adjustment. Refer to Section 2B, Wheel Alignment. Tighten the adjusting nut.
Tighten
Tighten the outer tie rod adjusting nut to 64 NSm (47 lbft). 6. Install the outer tie rod nut.
Tighten
Tighten the outer tie rod nut to 50 NSm (37 lbft). 7. Install the wheel. Refer to Section 2E, Tires and Wheels.
DUST BOOT
Tools Required KMJ22610 Installer
Removal Procedure
1. 2. 3. 4. 5. Raise and suitably support the vehicle. Remove the wheel. Refer to Section 2E, Tires and Wheels. Remove the outer tie rod. Refer to "Outer Tie Rod" in this section. Remove the dust boot retaining clamps. Remove the dust boot.
DAEWOO V121 BL4
6C 16IPOWER STEERING GEAR Installation Procedure
1. 2. Install the dust boot. Install the tie rod end dust boot retaining clamp. Install the cylinder end dust boot retaining clamp with the installer KMJ22610. Install the outer tie rod. Refer to "Outer Tie Rod" in this section. Install the wheel. Refer to Section 2E, Tires and Wheels. Lower the vehicle.
3. 4. 5.
STRAIGHTAHEAD CHECK
After all the necessary operations on the steering gear are completed (removing and installing, disassembling and assembling), check the exact straightahead position of the steering in each case. With the vehicle on the floor, place the steering wheel in the straightahead position. Mark the centerline 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.
DAEWOO V121 BL4
POWER STEERING GEAR 6C 17 StraightAhead Check Table
Step 1 Action Place the steering wheel in the straight ahead position. Is the wheel in the correct position? Is the lower intermediate shaft pinch bolt lying parallel to the steering gear? Is the steering wheel off center by more than 5 degrees? The pinion is displaced on the rack. The steering pinion position must be corrected. Is the repair complete? Remove steering wheel and center on the spindle splines. Is the repair complete? Turn the steering wheel all the way to the right. Measure the inner and the outer angles of the tire centerline compared to the straight ahead centerline. Are the angles within specifications? The rack assembly was not assembled correctly. Repair as needed. Is the repair complete? Value(s) Yes Go to Step 2 Go to Step 3 Go to Step 5 Go to Step 2 Go to Step 3 System OK No
2 3 4
Go to Step 4 Go to Step 6
5
6
Inner angle: 37.5° Outer angle: 31°
Go to Step 7
7
Go to Step 6
INTERMEDIATE SHAFT AND DASH SEAL
(LeftHand Drive Shown, RightHand Drive Similar) Removal Procedure
1. Turn the steering wheel until it is horizontal, with the spokes pointing down. This is the straightahead position. Make a mark on the stub shaft housing that lines up with a mark on the intermediate shaft lower universal joint. This mark will be used for proper alignment during installation. Remove the lower pinch bolt from the universal joint on the intermediate shaft.
2.
DAEWOO V121 BL4
6C 18IPOWER STEERING GEAR
3. Turn the steering wheel so that the upper pinch bolt is accessible. Remove the upper pinch bolt from the universal joint on the intermediate shaft.
4.
Remove the nuts from the dash seal retaining ring and remove the dash seal retaining ring.
5.
Remove the coupling from the power steering gear and pull the intermediate shaft out of the engine compartment.
Installation Procedure
1. Install the intermediate shaft into the vehicle.
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POWER STEERING GEAR 6C 19
2. Install the dash seal retaining ring with the nuts.
Tighten
Tighten the dash seal retaining ring nuts to 7 NSm (62 lbin).
Important : When attaching the upper universal joint, the steering wheel must be placed in the straightahead position with the spokes pointing down. 3. Attach the upper universal joint of the intermediate shaft onto the steering column. 4. Install the pinch bolt into the upper universal joint on the intermediate shaft and tighten the bolt.
Tighten
Tighten the upper intermediate shaft pinch bolt to 22 NSm (16 lbft).
Important : When attaching the lower universal joint, the marks on the intermediate shaft and on the stub shaft should line up. 5. Attach the lower universal joint of the intermediate shaft onto the steering gear stub shaft.
Important : When installing the lower intermediate shaft pinch bolt, make sure the bolt goes through the universal joint on the side of the stub shaft with the notch. If you have trouble seating the universal joint completely down onto the stub shaft, rotate the steering wheel slightly while pushing down on the universal joint. 6. Install the bolt into the lower universal joint on the intermediate shaft and tighten the bolt.
Tighten
Tighten the lower intermediate shaft pinch bolt to 22 NSm (16 lbft).
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6C 20IPOWER STEERING GEAR
HYDRAULIC CYLINDER LINES
(LeftHand Drive Shown, RightHand Drive Similar) Removal Procedure
1. 2. 3. Siphon the power steering fluid from the fluid reservoir. Raise and suitably support the vehicle. Disconnect the power steering gear hydraulic cylinder pipes from the power steering gear at the valve end. Replace the Oring seals as needed. Disconnect the power steering gear hydraulic cylinder pipes from the power steering gear at the cylinder end. Remove the steering gear hydraulic cylinder pipes from the vehicle.
4.
5.
Installation Procedure
1. 2. 3. Lubricate any new Oring seals with power steering fluid. Place the Oring seals into the housing and install the steering gear hydraulic cylinder pipes. Connect the power steering gear hydraulic cylinder pipes to the power steering gear at the valve end.
Tighten
Tighten the hydraulic cylinder line fittings at the valve end to 18 NSm (13 lbft).
4.
Connect the power steering gear hydraulic cylinder pipes to the power steering gear at the cylinder end.
Tighten
Tighten the hydraulic cylinder line fittings at the cylinder end to 28 NSm (21 lbft). 5. Lower the vehicle. Notice : When adding fluid or making a complete change, always use DEXRON®II or III power steering fluid. Failure to use the proper fluid will cause hose and seal damage and fluid leaks.
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POWER STEERING GEAR 6C 21
6. 7. Fill the fluid reservoir with power steering fluid. Inspect for leaks. If there are leaks, correct the cause of the leaks and bleed the system. Refer to "Bleeding the Power Steering System" in this section.
SPEED SENSITIVE POWER STEERING CONTROL MODULE
Removal Procedure
1. 2. 3. 4. Disconnect negative battery cable. Remove the glove box. Refer to Section 9G, Interior Trim. Slide the speed sensitive power steering (SSPS) control module off from the control module bracket. Disconnect the electrical connector from the SSPS control module.
Installation Procedure
1. 2. 3. 4. Connect the electrical connector to the SSPS control module. Slide the SSPS control module onto the SSPS control module bracket. Install the ashtray. Refer to Section 9G, Interior Trim. Connect the negative battery cable.
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6C 22IPOWER STEERING GEAR
UNIT REPAIR RACK AND PINION
Tools Required KMJ22610 Installer
Disassembly Procedure
1. Remove the rack and pinion steering assembly from the vehicle. Refer to "Rack and Pinion Assembly" in this section. Remove the valve and pinion assembly from the rack and pinion steering assembly. Refer to "Valve and Pinion" in this section. Remove the rack bearing assembly from the rack and pinion steering assembly. Refer to "Rack Bearing" in this section. Mark the threads on the inner tie rod to aid in repositioning the adjusting nut. Loosen the adjusting nut and remove the outer tie rod nut and the adjusting nut. Remove the dust boot retaining clamps.
2.
3.
4. 5. 6.
7.
Remove the dust boot.
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POWER STEERING GEAR 6C 23
8. Push back the plastic retainer protecting the connection between the inner tie rod and the power steering gear rack.
9.
Counterhold the pinionside inner tie rod and remove the cylinderside inner tie rod.
10. Place a rag over the rack, counterhold the rack assembly on the teeth with a wrench, and remove the pinionside inner tie rod.
Important : The retaining ring can be released by inserting a small screwdriver through the hole in the side of the housing. 11. Remove the bulkhead inner cylinder retaining ring the bulkhead inner cylinder and the rack.
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6C 24IPOWER STEERING GEAR Assembly Procedure
Notice : Coat all the seals with power steering fluid to ensure proper sealing. 1. Install the rack, the bulkhead inner cylinder and the bulkhead inner cylinder retaining ring.
Notice : To prevent the inner tie rods from loosening, use Loctite® 242 (or equivalent) on both inner tie rod connections to secure them to the rack shaft. Important : The right and left inner tie rods are unequal in length. Be sure to install the correct inner tie rod on the proper side of the power steering gear. 2. Firmly seat the inner tie rods against the rack and tighten both ends simultaneously.
Tighten
Tighten the inner tie rods to 100 NSm (74 lbft).
3.
Push the plastic retainer back onto the connection between the inner tie rod and the power steering gear rack.
4.
Install the dust boot.
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POWER STEERING GEAR 6C 25
5. Install the cylinder end dust boot retaining clamps with the installer KMJ22610.
6.
Install the tie rod end boot retaining clamps.
7.
8. 9.
Reposition the adjusting nut to the marks on the inner tie rod and install the outer tie rod by twisting it onto the inner tie rod. Perform a front toe adjustment. Refer to Section 2B, Wheel Alignment. Tighten the adjusting nut.
Tighten
Tighten the outer tie rod adjusting nut to 64 NSm (47 lbft). 10. Install the rack bearing assembly into the rack and pinion steering assembly. Refer to "Rack Bearing" in this section. 11. Install the valve and pinion assembly into the rack and pinion steering assembly. Refer to "Valve and Pinion" in this section. 12. Install the rack and pinion steering assembly into the vehicle. Refer to "Rack and Pinion Assembly" in this section.
DAEWOO V121 BL4
6C 26IPOWER STEERING GEAR
STUB SHAFT SEALS AND UPPER AND LOWER BEARING
Disassembly Procedure
1. Remove the rack and pinion steering assembly from the vehicle. Refer to "Rack and Pinion Assembly" in this section. Remove the dust cover from the lower end of the housing.
2.
Notice : If the stub shaft is not held, damage to the pinion teeth will occur. 3. While holding the stub shaft with a wrench, remove the locknut from the pinion.
4.
With the gear centered, mark the location of the stub shaft notch on the housing to aid in properly installing the valve and pinion assembly.
5.
Remove the stub shaft retaining ring and, using an arbor press, press on the threaded end of the pinion until it is possible to remove the pinion and valve assembly from the housing.
DAEWOO V121 BL4
POWER STEERING GEAR 6C 27
6. Remove the stub shaft dust seal the stub shaft bearing annulus assembly and the valve assembly from the housing. Discard the stub shaft dust seal.
7.
Remove the lower valve assembly bearing and the bushing.
8.
Remove the lower bearing assembly retaining ring and press the lower bearing assembly from the lower end of the housing.
Assembly Procedure
Notice : Coat all the seals with power steering fluid to ensure proper sealing. 1. Install the lower bearing assembly and the lower bearing assembly retaining ring into the lower end of the housing.
DAEWOO V121 BL4
6C 28IPOWER STEERING GEAR
2. Install the lower valve assembly bearing and the bushing.
3. 4.
Center the rack in the housing. Install the the valve assembly, the stub shaft bearing annulus assembly and a new stub shaft dust seal into the housing.
Important : When the valve and pinion assembly is fully seated in the housing, be sure that the notch in the stub shaft and the mark on the housing line up. Notice : If the stub shaft is not held, damage to the pinion teeth will occur. 5. While holding the stub shaft, install the locknut onto the pinion shaft.
Tighten
Tighten the pinion locknut to 30 NSm (22 lbft).
6. 7.
Replace the dust cover onto the housing. Install the rack and pinion steering assembly. Refer to "Rack and Pinion Assembly" in this section.
DAEWOO V121 BL4
POWER STEERING GEAR 6C 29
RACK BEARING
Tools Required J42459 Rack Guide Spring Cap Wrench
Disassembly Procedure
1. Remove the rack and pinion steering assembly from the vehicle. Refer to "Rack and Pinion Assembly" in this section. Remove the adjuster plug locknut from the adjuster plug, and remove the adjuster plug from the housing with the rack guide spring cap wrench J42459, or with a 19 mm allen wrench. Remove the adjuster spring and the rack bearing.
2.
3.
Assembly Procedure
1. Coat the rack bearing, the adjuster spring and the adjuster plug with lithiumbased grease and install them into the housing.
2.
3.
With the rack centered, turn the adjuster plug clockwise until a torque of 7 NSm (62 lbin) is obtained, then back it off by 30 to 40 degrees. Check the pinion torque. Maximum pinion preloaded torque is 1 NSm (9 lbin). Thread the locknut on the adjuster plug and tighten it.
Tighten
Tighten the adjuster plug locknut to 75 NSm (56 lbft) while holding the adjuster plug stationary with the rack guide spring cap wrench J42459 or with a 19 mm allen wrench. Install the rack and pinion assembly. Refer to "Rack and Pinion Assembly" in this section.
4.
DAEWOO V121 BL4
6C 30IPOWER STEERING GEAR
RACK BEARING PRELOAD ADJUSTMENT
Adjustment Procedure
1. 2. 3. 4. Raise and suitably support the vehicle. Center the steering wheel. Remove the power steering gear. Refer to "Rack and Pinion Assembly" in this section. Loosen the locknut and turn the adjuster plug clockwise until a torque of 7 NSm (62 lbin) is obtained, then loosen it by 30 to 40 degrees. Check the pinion torque. Maximum pinion preloaded torque is 1 NSm (9 lbin). Tighten the locknut on the adjuster plug while holding the adjuster plug stationary. Install the power steering gear. Refer to "Rack and Pinion Assembly" in this section. Be sure to check the returnability of the steering wheel to center position after adjustment.
5. 6. 7.
Tighten
Tighten the adjuster plug locknut to 75 NSm (56 lbft).
VALVE AND PINION
Disassembly Procedure
1. Remove the rack and pinion steering assembly from the vehicle. Refer to "Rack and Pinion Assembly" in this section. Remove the dust cover from the lower end of the housing.
2.
Notice : If the stub shaft is not held, damage to the pinion teeth will occur. 3. While holding the stub shaft, remove the locknut from the pinion.
DAEWOO V121 BL4
POWER STEERING GEAR 6C 31
4. With the gear centered, mark the location of the stub shaft notch on the housing to aid in properly installing the pinion and valve assembly.
5.
Remove the upper housing retaining ring and, using an arbor press, press on the threaded end of the pinion until it is possible to remove the valve and pinion assembly from the housing.
6.
Remove the stub shaft dust seal, the stub shaft bearing annulus assembly and the valve and pinion assembly from the housing.
7.
8.
Inspect the valve body rings for wear or damage. Replace the valve body rings as needed. Coat the rings with power steering fluid before installation. Remove the lower pinion valve seal and bushing. Discard the seal.
DAEWOO V121 BL4
6C 32IPOWER STEERING GEAR Assembly Procedure
Notice : Coat all of the seals and bushings with power steering fluid to ensure proper sealing. 1. Install the bushing and a new lower pinion valve seal.
Important : When the valve and pinion assembly is fully seated in the housing, be sure the notch in the stub shaft and the mark on the housing line up. If this is not done the vehicle will not pass the straightahead check and will have poor steering performance. 2. Install the valve and pinion assembly, the stub shaft bearing annulus assembly and the stub shaft dust seal.
Notice : If the stub shaft is not held, damage to the pinion teeth will occur. 3. While holding the stub shaft, tighten the locknut onto the pinion shaft.
Tighten
Tighten the pinion locknut to 30 NSm (22 lbft).
4. 5. 6.
Replace the dust cover onto the housing. Install the rack and pinion steering assembly. Refer to "Rack and Pinion Assembly" in this section. Perform the straightahead check. Refer to "StraightAhead Check" in this section.
DAEWOO V121 BL4
POWER STEERING GEAR 6C 33
GENERAL DESCRIPTION AND SYSTEM OPERATION
POWER RACK AND PINION
The power rack and pinion steering system has a rotary control valve that directs 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 that moves the rack left or right. That force is then transmitted through the tie rods to the steering knuckles, which turn the wheels. If power rack and pinion steering is not available, manual rack and pinion control is used; however, with this system, more steering effort is required. The movement of the steering wheel is transferred to the pinion. The rotary movement of the pinion is then transferred through the pinion threads, which mesh with teeth on the rack, thereby causing the rack to move in a linear direction. A vanetype of hydraulic pump provides hydraulic pressure for both steering systems.
As the vehicle speed increases, current from the SSPS control module increases, and the pintle blocks more and more of the orifice.
Steering Wheel Rotation Sensor
The steering wheel rotation sensor is located at the end of the steering column housing and is used to send a signal to the controller when abrupt or evasive steering maneuvers are needed.
Power Steering Pressure Hose
SSPS vehicles have a specific pressure hose assembly which includes an inline check valve in the rack and pinion assembly. This reduces the amount of steering wheel "kick" when driving over irregular road surfaces while operating at speeds with reduced flow rate and pressure.
Power Rack and Pinion
Except for differences in valve machining, the design of the SSPS power rack and pinion assembly is the same as for the a nonSSPS system. The steering wheel movement is transferred to the pinion via the intermediate shaft. The pinion moves the rack left or right through meshing the pinion and the rack teeth. The force is then transmitted through the tie rods and steering knuckle to steer the wheels. The power rack and pinion steering system has a rotary control valve which directs the hydraulic fluid from the power steering pump to one side or the other side of the rack piston. The piston is attached to the rack and uses hydraulic pressure to move the rack left or right. The rotary control valve regulates the degree of assist by responding to the driver's torque input. If hydraulic assist is not available, manual control is maintained. However, under this condition, more steering effort is required.
SPEED SENSITIVE POWER STEERING SYSTEM
The speed sensitive power steering (SSPS) system varies the driver effort required to steer as the vehicle speed changes. At low speeds, the system provides maximum power assist for easy turning and parking maneuvers. At higher speeds, the steering power is reduced to provide the driver with firmer steering and directional stability. The SSPS system accomplishes this by reducing the amount of power steering fluid flow from the power steering pump to the power steering gear as the vehicle speed increases. When the vehicle is stationary, the SSPS system provides maximum fluid flow to the steering gear. As the vehicle speed increases, the fluid flow to the steering gear is decreased.
Power Steering Pump
The standard vanetype pump, which provides hydraulic pressure for the system, incorporates a special discharge fitting to hold the EVO actuator.
Control Module
The SSPS control module processes the vehicle speed information from the engine control module (ECM) and uses the steering wheel rotation sensor to provide a control signal to the electronic variable orifice (EVO) actuator located on the power steering pump.
System Operation
System operation originates with input from the vehicle speed sensor via the engine control module to the SSPS control module. The SSPS control module sends a signal to the SSPS actuator to vary the rate of fluid flow output by the power steering pump.
Circuit Operation Electronic Variable Orifice (EVO) Actuator
The electronic variable orifice (EVO) actuator is located on the power steering pump and contains a solenoid operated pintle valve. Fluid leaving the pump passes through an orifice in the actuator tip. When the EVO actuator is powered by the SSPS control module, the pintle moves into the orifice and reduces the power steering fluid flow.
DAEWOO V121 BL4
The SSPS system uses inputs from the speed sensor and steering wheel rotation sensor to the SSPS controller to determine the desired amount of power steering assist. The SSPS control module constantly compares the amount of current flowing through the EVO actuator to the desired current it has calculated. The EVO actuator has a pintle that moves in and out of an orifice, regulating power
6C 34IPOWER STEERING GEAR
steering fluid flow. The SSPS control module can change the amount of current flowing through the EVO actuator by varying the output duty cycle. If the EVO actuator is disconnected, the pintle will be pulled out of the orifice for maximum power steering assist. The SSPS control module has the ability to detect faults in the steering wheel rotation sensor, the EVO actuator, or the circuitry to those components. Any default detected will cause the power steering assist to remain at maximum with the pintle in its normally retracted position for all speeds. When the system is operating normally, increasing the vehicle speed will decrease power steering assist, allowing the driver to have improved road feel and directional stability. When sudden steering wheel turns are made, as in evasive maneuvers, they are detected by the SSPS control module through the steering wheel rotation sensor. When detected, the SSPS control module reduces current to the EVO actuator, allowing greater power steering assist. SSPS (Speed Sensitive Power Steering) is to control power steering effort properly according to varying conditions for both convenience and safety. At low speed or standstill, power steering effort becomes light to provide easy steering. On the contrary, at high speed, power steering effort becomes heavy to provide stable steering. SSPS offered to LACETTI is EVO (Electric Variable Orifice) type, which controls steering effort by modulating pressurized fluid supply to the steering unit from the power steering pump.
Steering wheel rotation sensor is installed at the bottom of the steering column. This sensor detects steering wheel rotation which is used to calculate the angle speed of the steering wheel by SSPS module. If the angle speed was big enough for intervention into nor-
mal steering force control during high vehicle speed, which means a driver made an evasive steering maneuver to avoid an accident, SSPS module would supply enough steering support. The sensor consists of a variable resistor.
DAEWOO V121 BL4
POWER STEERING GEAR 6C 35
1. 2. 3. 4. 1.
Steering Wheel SSPS control module Steering Wheel Rotation Sensor Steering Column Remove SSPS connector TERMINAL A´C B´C VOLTAGE 4.8 5.2 V 0.5 4.5 V
2. 3.
Checking procedure is as follows;
4.
Turn the ignition ON Try to measure 5V across A and C terminals. If you fail, it might be A, C wiring open or short, or SSPS module malfunction. Check if B+ and B are supplied to terminal 8" and 10" respectively. RESISTANCE 9.0 10 KW 0.7 12 KW CONDITION Idle Steering
DAEWOO V121 BL4
6C 36IPOWER STEERING GEAR
The flow control actuator is installed on the outlet of the conventional vein type of the power steering pump. The actuator modulates fluid flow to the steering gear from the pump by current control from the SSPS module. At low speed, small current is supplied to the actuator. Then the actuator modulates flow high and steering effort becomes light. At high speed, On the contrary, big current to the actuator. Low fluid flow and heavy steering effort. If there happens an actuator malfunction, by default its pintle valve opens the orifice 100% to supply light steering effort. The maximum pumping pressure with SSPS option is 74.4~81.6 kg/cm2. If you try to measure voltage at the actuator terminal with the connector removed, you can measure 6.5V.
VEHICLE SPEED (KPH) 0 60 100 140 160
CURRENT (mA) 0 50 400 650 700
DAEWOO V121 BL4
POWER STEERING GEAR 6C 37
[Vehicle Speed Actuator Current Relation] SOLENOID RESISTANCE The control module is installed on the right side of the audio and can be accessible after the glove box is removed. It receives signals from the vehicle speed sensor and the steering wheel rotation sensor and processes them to decide proper fluid flow through the actuator. It also has a selfdiagnosis. If it detects any malfunction, it starts default mode, which is basically actuator full open for light steering effort. 13 W
TERMINAL 1 2 3 4 5 6 7 8 9 10 11 12 13 14
COLOR SB V BW Gr GW P Br BW L SB
FUNCTION Actuator Low Actuator High Steering Wheel Sensor Ground Not used Steering Wheel Sensor 5V ref. VSS Not Used IGN ON Warning Lamp Ground Not Used Not Used Diagnosis Steering Wheel Sensor Signal
DAEWOO V121 BL4