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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/cm] 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 : 410 , Manual : 430

Type

Integral (ball-nut type)

Gear ratio

22.6

Cross shaft operating angle

Left 45or more


Right 43or 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

PSF

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

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 Nm (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

0.1

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

Kgfm

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 : 31.533.5
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 (3~4kgfm)
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
10kgfforce.

EMTST5016A

3. After adjusting tension of belt, tighten the nut(C) with


the specified torque.
The specified torque : 22.3~40 Nm
(2.72 ~ 4.08kgfm, 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 multifunction switch harness


connector(A) and remove the multifunction
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)

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 kgfcm, 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 kgfcm, 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