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Steering System General Description .................................................... Specifications ............................................... General Diagnostics and Tests .................... Adjustment ....................................................

Manual Steering System ST -2 ST -11 ST -14 ST -26

Steering Column and Shaft Components Location .................................. Components ................................................. Removal ....................................................... Installation .................................................... Inspection .....................................................

Power Steering System ST -29 ST -30 ST -31 ST -33 ST -34

Steering Linkage Components ................................................. Drag Link Disassembly ............................................ Reassembly ............................................ Tie Rod Disassembly ............................................ Inspection ................................................ Reassembly ............................................

Manual Steering Gear Box Components ............................................ ST -41 Disassembly ............................................ ST -42 Reassembly ............................................ ST -43

ST -35 ST -37 ST -38 ST -39 ST -39 ST -40

Power Steering Gear Box Components ............................................ Disassembly ............................................ Reassembly ............................................ Inspection ................................................ Power Steering Oil Pump Components ............................................ Disassembly ............................................ Inspection ................................................ Reassembly ............................................

ST -46 ST -47 ST -48 ST -48 ST -50 ST -51 ST -53 ST -53

General Description The steering system allows the driver to freely change the vehicle's direction of travel. The steering force applied to the steering wheel is transmitted to the knuckle arm via the steering shaft, steering gear, pitman arm, and the drag link so as to steer the vehicle. LHD Type

SUDSTA003L

1. Steering wheel 2. Column and shaft assembly 3. Steering gear box 4. Drag link 5. Pitman arm

6. Knuckle arm 7. Tie rod 8. Tie rod end 9. Tie rod arm

RHD Tyep

SUDSTA004L

1. Steering wheel 2. Column and shaft assembly 3. Steering gear box 4. Drag link 5. Pitman arm

6. Knuckle arm 7. Tie rod 8. Tie rod end 9. Tie rod arm

Steering Wheel and Shaft The steering wheel is designed to ensure an optimum steering effort and feel. It is connected to the steering shaft by serration and taper boss. The steering shaft is designed so strong as to withstand twisting and bending force. It is coupled with the gear assembly with a joint assembly. The telescopic tilt steering shaft provided with two joint assemblies and a shaft end spline allows the driver to select an optimum driving position.

EMTST5002A

Steering Linkage 1. Drag Link Assembly The drag link connects the pitman arm at the steering gear end to the knuckle arm at the front wheel so as to transmit the movement of pitman arm to the knuckle arm. A coil spring is used in the ball joints installed at the end portion of drag link for buffering the vibration of the front wheels.

SUDSTA005L

1. End plug 2. Ball seat B 3. Pitman arm 4. Ball seat A 5. Coil spring 6. Drag link 7. Knuckle arm

2. Tie Rod Assembly The tie rod assembly is connected to the both ends of the knuckle arms. The ball joint taper attaches the tie-rod end to the knuckle arm with a nut. A right-handed screw and left-handed screw are used at the right and left ends, respectively, for the tie rod to tie-rod end joints, allowing easy adjustment of toe-in.

EMTST5005A

EMTST5004A

Steering Type)

Gear

Assembly

2. The ball tube has a shape, in which a pipe bent into a U shape and split into two parts, and then the divided parts merged again. Both ends are tongued to receive balls easily. When the balls reach the end, they are received by the tongue entering into the tube so as to go back into the first groove inside the ball nut. The ball-nut rack is in mesh with the cross shaft tilted in 6° allowing backlash adjustment.

(Recirculating-ball

1. The recirculating-ball type steering gear is a system in which a ball nut is filled with a number of balls which roll along groove between the worm teeth provided on the end of the main shaft and the grooves inside the ball nut in order to transmit the turning forces of the main shaft via the ball nut to the cross shaft. Rolling motion of the balls dramatically reduces the friction forces. When balls reach the end, they enter ball tubes which take them back into the first groove inside of the ball nut. The worm teeth and ball nut are made by grinding method precisely. Balls are confined between the external and internal threads; i.e., the ball nut attaches to the worm via the balls. This involves a change of friction from sliding into rolling, allowing the mechanism to withstand a greater load.

EMTST5006A

Power Steering Gear

SUDSTA006L

1. Gear housing 2. Steel ball 3. Circulator 4. Cross shaft 5. Needle bearing 6. Side cover

7. Adjusting bolt 8. Adjusting plate 9. Needle bearing 10. Input shaft 11. Ball bearing 12. Valve housing

The power steering unit uses a small rotary valve machined to close tolerances and a torsion bar that ensures smooth andlight steering reaction at low speeds. Furthermore, the torsion bar size is matched to the input shaft control edge shape toprovide stabilized steering action from low to high speeds.The power steering is an integral type. It comprises of the power transmitting system sending the steering force to straightdirection (ball screw unit, cross shaft), the fluid control valve (valve body, valve housing, sleeve) and the force generating multicylinder (gear housing). Ball screw unit comprises of rack piston, main shaft, input shaft, torsion bar and steel ball. The ball screw has lots of ball bearings to reduce friction between torsion bar and rack piston. Steering torque is transmitted to cross shaft via torsion bar, main

13. Angular bearing 14. Torsion bar 15. Rack piston 16. Main shaft 17. Angular bearing 18. End cover shaft and rack piston. And the load from tire is transmitted to main shaft then the torsion bar istwisted by the reaction force from input shaft. When the turning of input shaft stops, the reaction of torsion bar returns inputshaft to approach starting point.

1. For straight-ahead position

SUDSTA007L

1. Gear housing 2. Cross shaft 3. Input shaft 4. Left cylinder 5. Main shaft 6. Rack piston If no steering torque is applied from the steering wheel, the input shaft stays in neutral. In this condition, oil goes through the gap between the input shaft and sleeve holes so that the oil fed under pressure of the oil pump returns to the oil tank withoutflowing to the left and right cylinder chambers.

7. Right cylinder 8. Torsion bar 9. Sleeve 10. Input shaft 11. Sleeve

2. During a right turn

4. When hydraulic circuit fails

When the steering wheel is turned clockwise, the load from tires acts on the main shaft so as to twist the torsion bar. As a result, the input shaft turns to clockwise direction.As the shaft turns, the axial clearance becomes narrow to restrict the oil inflow, and then the oil pressure in the left cylinder chamber increases. Then the oil in the right cylinder chamber is returned to the oil tank. As a result, the rack piston receives thrust in the right direction so as the cross shaft to turn in counter-clockwise direction. The force that has twisted the torsionbar during steering is transmitted to the steering wheel as a steering reaction which gives the driver a sense of steering response.

Even the hydraulic circuit fails, the input shaft stopper comes in direct contact with the slot in the big end of main shaft to transmit the steering force, allowing manual steering for safety.

EMTST5011A

EMTST5009A

3. During a left turn The operation is just opposite to the operation generated during the right turn.These descriptions are based on the L.H.D. models

EMTST5010A

Oil Pump 1. Pump

EMTST5012A

The oil discharged under pressure goes to the control valve that varies the flow rate. The valve spool is moved by thepressure difference in the valve so that the oil returns back to the suction port of the oil pump.When the steering wheel is turned to the lock end shutting off the oil passage, the relief valve is activated so as to return the oil back to the pump suction port, as with the control valve. 2. Flow control valve

EMTST5013A

While the engine is idling, the oil is fed from the pump discharge port via the orifice A1 to the power steering unit.As the engine speed goes up, the delivery rate of the pump increases. Then, as the force P1 overcomes the flow control spring set tension, the

spool valve is moving so that the excessive oil returns to the suction port and a constant flow rate is maintained.

3. Relief valve

EMTST5014A

As the pressure is over the maximum value, the relief valve is open to prevent the excessive pressure from being generated in the hydraulic circuit when the steering wheel is locked or the circuit gets clogged.The internal pressure of the circuit is being applied to the steel ball built into the spool valve through the orifice A2. If a pressure over the maximum [94-99 kgf/cm²] is applied to the steel ball, it overcomes the relief spring set tension pushingthe steel ball so that the oil returns back to the pump suction port, thereby the internal pressure is kept under the maximum level.

Specifications Item Steering wheel

Power steering gear

Power steering oil pump

Specification Type

2-spoke

O.D. (Outer Diameter)

Power : Ø410 , Manual : Ø430

Type

Integral (ball-nut type)

Gear ratio

22.6

Cross shaft operating angle

Left 45°or more Right 43°or more

Maximum operating pressure

120 kg/㎠

Set fluid flow rate

7 lit./min.

Type

Vane pump

Delivery rate

10.5 cc

Relief set pressure

94~99 bar, 103~108 bar

Speed range

600~6500 rpm

Direction of rotation

Clockwise (as viewed from gear side)

Fluid

PSFⅢ

Service Standards Description Steering wheel play(Straight-ahead direction, on wheel periphery)

Nominal Value (Basi Limit c diameter in [ ]) 0 to 25

50

Correction and remarks Adjust with gearbox adjusting screw

Cross shaft T-groove to adjusting screw clearance

0.1 or less

Tie rod runout

Less than 2

2

Cross shaft to steering gear housing (bushing) clearance

[32] 0.01 to 0.06

0.1

Replace steering gearhousing

Cross shaft to side cover (bushing) clearance

[32] 0.01 to 0.06

0.1

Replace side cover

Manual steering gear

Main shaft starting torque N·m (kgf ·m) with cross shaft removed after installation overall Power steering gear

Adjust with adjusting plate

33 to 59 (4 to 6) 59 to 88 (6 to 9)

Correct or replace

Adjust with adjusting plate

Main shaft O.D.

22.55 to 22.6

22.35 Replace ball screw unit

Gearbox cylinder to rack piston clearance

0.02 to 0.09

0.15

Play in cross shaft in axial direction with respect to adjusting bolt

0

0.1

Cross shaft O.D. Power steering oil pu- Cam ring wear mp

[35] -0.008 to +0.008

Replace ball screw unit

Adjust with adjuster plate

34.96 Replace Replace if your fingernail catches ridge

Less than 0.1

-

-

0.05

Replace

14.010 to 14.016

0.03

Replace

-

0.05

Replace

Rotor groove to vane clearance

0.01

0.06

Replace as cartridge assembly

Spring free length

36.5

33.5

Replace

V-belt tension

4.6

Body cover wear, ridge Cover to relief valve clearance Wear depth of shaft seal lip

Adjust with oil pump

Tighten Torque Table Tightening Torque Description Nm

Kgf·m

Lb-ft

Steering wheel nut

39~49

4~5

28.9~36.1

Column support bolt

17~25

1.7~2.6

12.2~18.8

Steering gear and steering shaft connecting bolt and nut

53~65

5.4~6.6

39~47.7

Steering gear assembly bolt and nut

69~83

7~8.5

50.6~61.4

125~165

13~17

94~122.9

Tie-rod end clamp nut

20~29

2~3

14.4~21.6

Tie-rod end and knuckle arm nut

69~115

7~12

50.6~86.7

Steering shaft clamp bolt tightening nut

34~54

3.5~5.5

25.3~39.7

End cover bolt

44~54

4.5~5.5

32.5~39.7

Side cover nut

15~24

1.5~2.4

10.8~17.3

Adjusting screw nut

25~32

2.5~3.3

18~23.8

Oil plug tightening

15~25

1.5~2.5

10.8~18

Valve house clamping nut

45~55

4.5~5.5

32.5~39.7

End cover nut

180~230

18~23

130.1~166.3

Side cover clamping nut

75~190

7.5~19

54.2~137.4

Adjusting bolt clamping lock nut

30~40

3~4

21.6~28.9

Oil pump attaching bolt

18~22

1.8~2.2

13~15.9

Suction connector attaching bolt

6~10

0.6~1.0

4.3~7.2

Discharge connector

40~60

4~6

28.9~43.3

Discharge eye connector attaching bolt

16~24

1.6~2.4

11.5~17.3

Pulley clamping nut

30~40

3~4

21.6~28.9

Center bolt

48

4.8

34.7

Adjusting bolt

41

4.1

29.6

Power steering gear and pipe connecting outer (Return)

40~50

4~5

28.9~36.1

Power steering gear and pipe connecting inner (suction)

30~40

3~4

21.6~28.9

Hose connecting clip

30~40

3~4

21.6~28.9

Pitman arm nut

Manual steering gear

Power steering gear

Power steering pump

General Diagnostics and Tests Manual Steering system

EMTST5047A

EMTST5048A

EMTST5049A

EMTST5050A

EMTST5051A

Power Steering system

EMTST5052A

EMTST5053A

EMTST5054A

EMTST5055A

EMTST5056A

EMTST5057A

EMTST5058A

Adjustment

Checking Steering Angle (Manual/power)

CHECKING STEERING WHEEL FREE PLAY (Manual / power)

1. Place the front wheel on a turning radius gauge and measure the steering angle.

1. Start the engine with the steering wheel in the straight ahead position, apply a force of 5 N (1.1 Ib) to the steering wheel in the peripheral direction.

Standard value : Wheel angle Inner wheel : 31.5°±33.5° Outer wheel : 42˚~44°

2. Measure the play at the circumference of the steering weel Standard value : Steering wheel free play : 0 ~ 25 mm

APIE101B KPSE010A

3. If the free play exceeds the standard value, inspect the connection between the steering shaft and tie rod ends.

2. If the measured value does not meet the standard value, adjust the linkage.

Replacing Power Steering Fluid 1. Jack up the front wheels of the car and support them with jackstands. 2. Disconnect the return hose from the oil reservoir and plug the oil reservoir. 3. Connect a hose to the disconnected return hose, and drain the oil into a container. 4. While operating the starter motor intermittently, turn the steering wheel all the way to the left and then to the right several times to drain the fluid. 5. Connect the return hose and fix it with a clip. 6. Fill the power steering fluid reservoir with the specified fluid. 7. Start the engine.Check for fluid leaks from the hose, then stop the engine. 8. Pour the fluid into the bottom of the oil filter in the power steering fluid reservoir. 9. Bleed the air.

Air Bleeding (Power steering system) 1. Fill the power steering fluid reservoir up to the "MAX" position with specified fluid.

Oil Pump system)

Pressure

Test

(Power

steering

1. Connect the special tool between the pump and the pressure hose. 2. Bleed the air, and then start the engine and turn the steering wheel several times, measure the fluid temperature by Temperature gauge so that the fluid temperature can rise to approximately 50~60℃. 3. Discharge oil pressure measurement.Close the stop valve of the oil pressure gauge at idling engine and measure the oil pressure to confirm that it is within the standard value. Specified value : 10 ㎏/㎠ or less 4. Oil pump pressure relief pressure test. 1) Increase the engine speed at 1500~1600 rpm.

KMTST5013B

2. Jack up the front wheels. 3. Turn the steering wheel all the way to the left and then to the right five or six times. NOTICE When bleeding fluid, replenish with the fluid so that the level dose not fall below the bottom of the filter. 4. Start the engine (idling). 5. Turn the steering wheel to the left and then to the right, until there are no air bubbles in the oil reservoir. 6. Confirm that the fluid is not milky and that the level is between "MAX" and "MIN" mark on the reservoir. 7. Check that there is a little change in the fluid level when the steering wheel is turned left and right. NOTICE If the fluid level varies 5mm (0.2 in.) or more, bleed the system again. If the fluid level suddenly rises after stopping the engine, further bleeding is required. Incomplete bleeding will produce a chattering sound in the pump and noise in the flow control value, and deteriorate durability of the pump.

2) Close the stop valve of the oil pressure gauge and measure MAX. oil pressure. Relief oil pressure : 94~99 ㎏/㎠, 103~108 ㎏/㎠ 5. Remove the oil pressure gauge with stop value and tighten the pressure hose to the specified torque. Tightening torque : 30~40Nm (3~4kgf·m) 21.7~28.9 lb-ft 6. Bleed the air from the system.

Adjustment of oil pump V-belt 1. Tighten the adjusting bolt(A) until a proper tension is achieved to V-belt of oil pump. Control the adjusting bolt(A)

EMTST5015A

2. To adjust the belt tension, a deflection(B) of belt should be 4 ~ 6mm when pressing the belt(A) with 10kgf·force.

EMTST5016A

3. After adjusting tension of belt, tighten the nut(C) with the specified torque. The specified torque : 22.3~40 Nm (2.72 ~ 4.08kgf·m, 19.7~29.5 lb-ft)

Steering Column And Shaft COMPONENTS LOCATION

SUDSTA008L

1. Steering wheel 2. Column support 3. Dust cover •

Installation is disassembly

the

reverse

procedure

of

the

Components

SUDSTA009L

1. Lever 2. Screw 3. Screw 4. Bolt

5. Spacer 6. Lever 7. Wave washer 8. Spring

9. Collar 10. Lever 11. Column support 12. Steering column

13. Cable band 14. Dust "A" cover 15. Dust "B" cover 16. Dust "C" cover

5. Remove the tilt lever(A) and the column cover(B)

Removal 1. Disconnect the (－) battery cable

(LHD Type)

2. Remove the horn pad(A) from the steering wheel. 3. Remove the steering wheel nut(B) 4. Mark the matchmark(C) on the steering shaft and the wheel, and then remove the steering wheel. (LHD Type)

EMTST03B

(RHD Type)

EMTST02B

(RHD Type)

SUDSTA502L

SUDSTA501L

6. Disconnect the multi－function switch harness connector(A) and remove the multi－function switch(B). (LHD Type)

EMTST05B

(RHD Type)

EMST04B

(RHD Type)

SUDSTA504L

8. Remove the key cylinder mounting bolt and the key cylinder assembly(A) 9. Remove the tilt adjuster bolt(B) SUDSTA503L

(LHD Type)

7. Disconnect the engine stop cable(A) from the lever(B) (LHD Type)

EMST06B

(RHD Type)

12.Remove the gear box(A) and the steering shaft mounting bolt pin(B) NOTICE Mark a matchmark on the gear box and steering shaft. (LHD Type)

SUDSTA505L

10.Remove the return spring(A) 11.Remove the steering shaft cover(B) (LHD Type) EMST08B

(RHD Type)

EMST07B

(RHD Type) SUDSTA002L

13.Remove the steering shaft.

Installation 1. The installation is performed in the reverse order of the removal. 2. Align the marks on the steering wheel and column shaft for reinstallation when installing the steering wheel. Align the marks on the gear box and steering shaft for reinstallation when installing the steering shaft.

SUDSTA001L

Inspection 1. Check the steering column shaft for damage and deformations. 2. Check the connecting parts for enough clearance, damaged portion and proper operation.

SUDSTA010L

1. Steering shaft 2. Column 3. Dust seal cap 4. Universial joint assembly

Steering Linkage Components (LHD Type)

SUDSTA011L

Disassembly sequence 1. Split pin 2. Nut 3. Tie rod assembly 4. Tie rod end 5. Knuckle arm 6. Split pin 7. Nut

8. Drag link 9. Dust cap 10. King pin shim 11. King pin 12. Knuckle 13. Front axle

(RHD Type)

SUDSTA012L

Disassembly sequence 1. Split pin 2. Nut 3. Tie rod assembly 4. Tie rod end 5. Knuckle arm 6. Split pin 7. Nut

8. Drag link 9. Dust cap 10. King pin shim 11. King pin 12. Knuckle 13. Front axle

Drag Link Disassembly

SUDSTA013L

Disassembly sequence 1. Split pin 2. End plug 3. Spring 4. Ball seat B 5. Ball seat A 6. Grease seat A

7. Split pin 8. End plug 9. Ball seat A 10. Ball seat B 11. Spring 12. Grease seat B 13. Drag link

Reassembly

EMTST5022A

To fit the end plugs in position on both the pitman arm and knuckle arm ends, first fully tighten, back off a half turn, and secure with a split pin. Face the split pin head outward.

Tie Rod Disassembly

SUDSTA014L

Disassembly sequence 1. Split pin 2. Slotted nut

3. Washer 4. Clip

5. Dust seal 6. Tie-rod end assembly

Inspection 1. Measurement of Tie Rod Runout Nominal value (mm)

Less than 2

Limit (mm)

2

EMTST5024A

7. Large head bolt 8. Tie rod

Reassembly

SUDSTA015L

1. Split pin 2. Slotted nut 3. Washer 4. Dust seal 5. Clip 6. Tie-rod end assembly 7. Large head bolt 8. Tie rod

Manual Steering System Manual Steering Gear Box Components

SUDSTA016L

Disassembly sequence 1. Pitman arm 2. Side cover 3. Adjusting plate 4. Adjusting screw

10. Ball bearing 11. Oil seal 12. Steering gear housing 13. Oil seal 14. Oil plug

5. Cross shaft 6. Dust cover 7. End cover 8. End cover shim *9. Main shaft

The part marked with * must be inspected before disassembly.

•

For disassembly of parts with an encircled number, see Disassembly given later.

NOTICE Do not disassemble the steering gear housing and bushing in the side cover.

•

Do not disassemble the ball nut from the main shaft.

2. Removal of Pitman Arm

Disassembly NOTICE Measurement of Starting Torque of Main Shaft

•

Remove the nut that secures the pitman arm and remove the pitman arm.

Before disassembling the cross shaft to remove it, measure the starting torgue to be served the torgue as reference when reassemble it.

•

Use pitman arm puller for the special tool.

EMTST5038A

3. Removal of Cross Shaft EMTST5036A

1. Draining of Gear Oil

•

With the ball nut moved to the center of the gearbox, remove the cross shaft.

Remove the oil plug to drain gear oil.

EMTST5039A EMTST5037A

Reassembly

EMTST5040A

1. Selection of end cover shim and measurement of starting torque 1) With the main shaft and end cover installed in the steering gear housing, measure the end cover to steering gear housing clearance with a thickness gauge. The clearance is the shim thickness to be selected.

2) Install the end cover shim selected and tighten the end cover to the specified torque. Then, adjust shim to satisty with the specified starting torque.

End cover shim thickness Thickness(mm) 0.05 0.06 0.07 0.10 0.20 EMTST5042A

0.30 2. Selection of adjusting plate

0.50

Fit the adjusting screw into the T-groove in the cross shaft and select the adjusting plate to obtain a clearance of 0.1 mm or less. Adjusting plate thickness Thickness (mm) 1.95 2.00 2.05 2.10 2.15

EMTST5041A

EMTST5043A

3. Installation of pitman arm

2) Adjustment of main shaft starting torque

To install the pitman arm, ensure that the V-groove in the pitman arm lines up the groove that in the cross shaft.

After reassembly, measure again the main shaft starting torque to ensure that it is up to specifications. To adjust the torque, loosen the nut "X" and turn the adjusting screw.

EMTST5044A

4. Adjustment after reassembly EMTST5046A

1) Topping up with the Gear oil With being the steering gear in the installed position, top up with gear oil SAE #90 or the equivalent

EMTST5045A

Power Steering System Power Steering Gear Box Components

SUDSTA017L

Disassembly sequence 1. Pitman arm 2. Dust cover 3. Oil seal 4. Jam nut 5. Side cover

6. Needle bearing 7. U-packing 8. Cross shaft 9. Adjusting bolt 10. Adjusting plate

11. Dust cover 12. Valve housing assembly 13. Angular contact bearing 14. Bearing 15. Oil seal

*16. Ball screw unit 17. Lock screw 18. Gearbox 19. Needle bearing 20. U-Packing

Inspection of the part marked with * must be made before disassembly. For disassembly of parts with an encircled number, see Disassembly given later.

•

NOTICE O-rings, oil seals, seal rings, and other rubber parts must be replaced with new ones whenever they are

disas sembled. •

Make sure that the alignment mark on cross shaft end face in perpendicular to the main shaft axis.

•

Use treated oil and compressed air to remove dirt from metal parts.

•

Keep disassembled of parts to not be damaged.

Disassembly NOTICE Inspection before Disassembly 1. Turn input shaft clockwise and counterclockwise to discharge oil from the cylinder. At the time, check discharged oil for contamination 2. Measure the starting torque of the input shaft.

EMTST5062A

3. Disassembly of cross shaft from side cover

EMTST5060A

1. Removal of Pitman Arm

EMTST5063A

4. Removal of Valve Housing and Ball Screw Unit

EMTST5061A

2. Removal of Cross Shaft and Side Cover Becareful that the cross shaft serration does damage to other parts. EMTST5064A

Reassembly

EMTST5065A

2. Installation of Cross Shaft Into Side Cover

INSPECTION 1. Measurement of Input Shaft Starting Torque Starting torgue : 29~69 N cm (3~7 kgf·cm, 2.2~5.1 lb-ft)

EMTST5066A

After installation, make sure that the input shaft turns approximately 5.5 turns. If not, it means that the neutral position is not reached. Reinsert the shaft.

EMTST5067A

3. Measurement of Overall Starting Torque Measure the starting torque by turning the input shaft approximately 1/4 turn in clockwise and counterclockwise directions. If the specified value is not obtained, adjust with the adjusting bolt. Starting torgue : 49~98 N cm (5~10 kgf·cm, 3.6~7.2 lb-ft)

5. Backlash Adjustment of Cross Shaft With gears meshed in neutral position, measure the backlash at pitman arm end. Use adjusting bolt for adjustment. NOTICE After the backlash has been adjusted, move the pitman arm to make sure that the rack piston moves smoothly throughout the entire range of operating angle.

EMTST5068A

4. Installation of Oil Seal EMTST5070A

EMTST5069A

Power Steering Oil Pump Components

SUDSTA018L

1. Mounting bolt 2. Oil pump cover assembly 3. Gasket 4. Lock pin 5. Cam ring 6. Rotor 7. Vain 8. Oil pump side plate 9. O-ring (Outer) 10. O-ring (Inter) 11. Side plate spring

12. Front housing 13. Connecting assembly 14. Mounting bolt 15. Suction pipe 16. Oil seal 17. Drive shaft 18. Dust spacer 19. Snap ring 20. Pulley 21. Pulley nut

Disassembly

6. Remove the inner and outer O-ring.

1. Remove the suction pipe and the O-ring after removing two bolts from the oil pump body.

7. Remove the side plate spring. •

NOTICE Lise a new gasket and O-ring at assembling.

KPKA050B

2. Remove 4 bolts and the oil pump cover assembly. 3. Remove the cam ring.

KPKA055B

8. Supports the pulley with the metal plate (brass petal or aluminum) after fixing in the vice.

4. Remove the rotor and the vain. 5. Remove the oil pump side plate.

Remove the spring washer and pulley nut.

KPKA046B

KPKA056C

9. Pull and draw out the pulley.

12.Remove the oil seal from oil pump body.

10.Remove the snap ring(A) of shaft by using snap ring plier. Then remove dust spacer(B).

KPKA059B

KPKA270B

11.Knock the rotor side of shaft lightly with the hammer and pull out the shaft.

13.Disconnect the connector from oil pump body and pull out the flow control value and the flow control spring. 14.Remove the O-ring from connector. •

CAUTION Never disassemble the flow control.

KPKA058B KPKA060B

2. Install the oil seal to the pump body by SST.

Inspection 1. Inspect the free length of flow control spring. Free length of flow control spring : 36.5mm

KPKA061B

KPQE911B

3. Insert the shaft assembly(C) softly and install the spacer(B) and snap ring(A)

2. Inspect the power of flow control valve. 3. Check the shaft for wear and damage. 4. Check the V-belt for wear and deterioration. 5. Check the groove of rotor vain for wear. 6. Inspect the contact surface of the cam ring and the vain for wear. 7. Check the vain for damage. 8. Check the contact surface between the side plate(or surface of pump cover) and shaft for stripes wear.

Reassembly 1. Install the flow control spring, flow control valve and connector. KPKA062B

KPKA060B KPKA270B

4. Install the steering pump gear.

8. Install the rotor. 9. Install the vain as its round side is toward an outer side.

KPKA056C

5. Install the spring and inner O-ring. 6. Install the outer O-ring(C) and the oil pump side plate(A)

KMTST5034

10.Install the gasket and oil pump cover assembly. 11.Install the suction pipe and the O-ring.

KMTST5032

7. Insert the lock pin into the groove of front housing and install the cam ring with proper direction.

EMTST5073A

KMTST5035