GENERAL MANUAL STEERING SYSTEM

MANUAL STEERING GEAR BOX

STEERING COLUMN AND SHAFT
POWER STEERING SYSTEM
STEERING LINKAGE POWER STEERING GEAR BOX
DRAG LINK POWER STEERING OIL PUMP
TIE ROD
ST -2 STEERING SYSTEM

GENERAL 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.
DESCRIPTION E0EF8DD7

The steering system allows the driver to freely change the

vehicle’s direction of travel. The steering force applied to

8
4

7
1. Steering wheel
2. Column and shaft assembly
3. Steering gear box
4. Drag link
5. Pitman arm 6
6. Knuckle arm
7. Tie rod
8. Tie rod end
9. Tie rod arm

EMTST5001A
GENERAL ST -3

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 as-
sembly. The telescopic tilt steering shaft provided with two
joint assemblies and a shaft end spline allows the driver to
select an optimum driving position.

Steering shaft

Steering gear

EMTST5002A
ST -4 STEERING SYSTEM

STEERING LINKAGE transmit the movement of pitman arm to the knuckle

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

1 2 6

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

EMTST5003A
GENERAL ST -5

2. Tie Rod Assembly 2. The ball tube has a shape, in which a pipe bent into
The tie rod assembly is connected to the both ends a U shape and split into two parts, and then the di-
of the knuckle arms. The ball joint taper attaches vided parts merged again. Both ends are tongued to
the tie-rod end to the knuckle arm with a nut. A receive balls easily. When the balls reach the end,
right-handed screw and left-handed screw are used they are received by the tongue entering into the tube
at the right and left ends, respectively, for the tie rod to so as to go back into the first groove inside the ball
tie-rod end joints, allowing easy adjustment of toe-in. nut. The ball-nut rack is in mesh with the cross shaft
tilted in 6 allowing backlash adjustment.

Tie rod
Ball joint Backlash large

Cross shaft

Ball nut
Cross shaft
Tie-rod end
Backlash small
EMTST5004A

EMTST5006A
STEERING GEAR ASSEMBLY
(RECIRCULATING-BALL TYPE)

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 be-
tween 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.

Main shaft

Tube
Cross shaft

EMTST5005A
ST -6 STEERING SYSTEM

POWER STEERING GEAR

2
3
1

5
4
6

8 7
9

1. Gear housing 10. Input shaft

2. Steel ball 11. Ball bearing
3. Circulator 12. Valve housing
4. Cross shaft 13. Angular bearing
5. Needle bearing 14. Torsion bar
6. Side cover 15. Rack piston
7. Adjusting bolt 16. Main shaft
8. Adjusting plate 17. Angular bearing
9. Needle bearing 18. End cover

EMTST5007A

The power steering unit uses a small rotary valve ma- the turning of input shaft stops, the reaction of torsion bar
chined to close tolerances and a torsion bar that ensures returns inputshaft to approach starting point.
smooth andlight steering reaction at low speeds. Further-
more, the torsion bar size is matched to the input shaft con-
trol 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 hous-
ing). 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 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
GENERAL ST -7

1. For straight-ahead position

2
1

10

11

5 8
9
4 6 7

1. Gear housing 7. Right cylinder

2. Cross shaft 8. Torsion bar
3. Input shaft 9. Sleeve
4. Left cylinder 10. Input shaft
5. Main shaft 11. Sleeve
6. Rack piston

EMTST5008A

If no steering torque is applied from the steering

wheel, the input shaft stays in neutral. In this condi-
tion, 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.
ST -8 STEERING SYSTEM

2. During a right turn 4. When hydraulic circuit fails

When the steering wheel is turned clockwise, the load Even the hydraulic circuit fails, the input shaft stopper
from tires acts on the main shaft so as to twist the tor- comes in direct contact with the slot in the big end
sion bar. As a result, the input shaft turns to clockwise of main shaft to transmit the steering force, allowing
direction.As the shaft turns, the axial clearance be- manual steering for safety.
comes 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 Main shaft
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 Torsion bar
the steering wheel as a steering reaction which gives
the driver a sense of steering response.
Input shaft

N
: Stopper angle
OUT

N EMTST5011A

Left cylinder chamber Right cylinder chamber

Rack piston

EMTST5009A

3. During a left turn

The operation is just opposite to the operation gen-
erated during the right turn.These descriptions are
based on the L.H.D. models

N
OUT

EMTST5010A
GENERAL ST -9

OIL PUMP

1. Pump

Transfer From oil reservoir

Cam ring
Rotation

Flow control valve

Suction Suction

Rotor
Shaft
Vane Transfer

EMTST5012A

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

P1 Orifice A1
Relief spring
P2

From oil pump To power steering gear

P2 Pump suction port

Flow control spring

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 over-
comes 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.
ST -10 STEERING SYSTEM

3. Relief valve

Spool
Steel ball
Orifice A2

B chamber From oil pump To power steering gear

Relief spring Pump suction port

EMTST5014A

As the pressure is over the maximum value, the

relief valve is open to prevent the excessive pres-
sure 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.
GENERAL ST -11

SPECIFICATIONS E12471BC

Item Specification
Steering wheel Type 2-spoke
O.D. (Outer Diameter) Power : Ø410 , Manual : Ø430
Manual steering gear Type Ball-nut type
Gear ratio 26.5 to 30.5
Cross shaft operating angle 46 or more (Left)
43 or more (Right)
Power steering gear Type Integral (ball-nut type)
Gear ratio 22.6
Cross shaft operating angle Left 46 or more
Right 42 or more
Maximum operating pressure 94~99 kg/ ㎠
Set fluid flow rate 7 lit./min.
Power steering oil pump Type Vane pump
Delivery rate 9.6 cc/rev
Relief set pressure 94~99 kg/ ㎠
Speed range 600~6500 rpm
Direction of rotation Clockwise (as viewed from pulley side)
Fluid PSFⅢ
ST -12 STEERING SYSTEM

SERVICE STANDARDS

Nominal Value
Correction and
Description (Basic diameter Limit
remarks
in [ ])
Steering wheel play(Straight-ahead direction, Adjust with gearbox
0 to 25 50
on wheel periphery) adjusting screw
Adjust with adjusting
Cross shaft T-groove to adjusting screw clearance 0.1 or less
plate
Tie rod runout Less than 2 2 Correct or replace
Manual steering gear Cross shaft to steering gear Replace steering
[32] 0.01 to 0.06 0.1
housing (bushing) clearance gearhousing
Cross shaft to side cover
[32] 0.01 to 0.06 0.1 Replace side cover
(bushing) clearance

Main shaft starting torque N·m

(kgf·m) with cross shaft removed
after installation overall
33 to 59 (4 to 6) Adjust with adjusting
59 to 88 (6 to 9) plate
Power steering gear 22.35 Replace ball screw
Main shaft O.D. [22.5] -0.05 to 0
unit
Gearbox cylinder to rack 0.02 to 0.09 0.15 Replace ball screw
piston clearance unit
Play in cross shaft in axial 0 0.1
Adjust with adjuster
direction with respect to
plate
adjusting bolt
Cross shaft O.D. [35] -0.008 to +0.008 34.96 Replace
Power steering oil Cam ring wear Replace if your
pump - - fingernail catches
ridge
Body cover wear, ridge 0.05 Replace
Cover to relief valve clearance [14] 0.01 to 0.016 0.03 Replace
Wear depth of shaft seal lip 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 Adjust with oil pump
GENERAL ST -13

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
Pitman arm nut 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

Manual Side cover nut 15~24 1.5~2.4 10.8~17.3

steering gear 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

Power steering End cover nut 180~230 18~23 130.1~166.3

gear 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
Power steering
Discharge eye connector attaching bolt 16~24 1.6~2.4 11.5~17.3
pump
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
ST -14 STEERING SYSTEM

GENERAL DIAGNOSTICS AND

TESTS E1BFE644
MANUAL STEERING SYSTEM

Hard steering

YES
Is steering gear binding?
NO
YES
Are ball bearings damaged? Replace bearings
NO
YES
Is ball nut s ball worn? Replace ball nut assembly

YES
Is steering mechanism binding?
NO
Is universal joint excessively YES Replace shaft assembly or
worn, damaged, or poorly lubricate
lubricated?
NO
YES
Is link deformed? Replace link

YES
Is front axle defective?

YES
Is kingpin poorly lubricated? Lubricate
NO

Is front wheel alignment YES

(toe-in, camber, caster) Correct wheel alignment
improper?
NO
YES
Is front tire pressure low? Inflate properly
NO
YES
Is thrust bearing damaged? Replace bearing

EMTST5047A
GENERAL ST -15

Uneven steering due to exces-

sive play in steering wheel

Is steering gear mechanism YES

defective?
NO
Are ball nut assembly rack and YES Replace ball nut assembly
gear worn? and cross shaft
NO
YES Replace gear housing and
Is cross shaft bushing worn?
side cover
NO
YES
Is ball nut’s ball worn? Replace ball nut assembly

YES
Is steering linkage defective?
NO
Is there excessive play in univer- YES Replace shaft assembly if prob-
sal joint? lem persists after packing grease
NO

Is there excessive play in drag YES Replace knuckle arm, pitman

link ball stud? arm, or drag link end
NO

Is there excessive play in tie-rod YES

Replace tie-rod end
end ball stud?

YES
Is front axle defective?
NO
YES
Is wheel hub bearing worn? Replace bearing
NO
YES
Is kingpin or bushing worn? Replace king pin or bushing

YES
Is there any other trouble?

YES
Does vehicle pull to one side Adjust or replace lining
during braking?

EMTST5048A
ST -16 STEERING SYSTEM

Vehicle pulls to one side during

driving

Are front axle and steering sys- YES

tem defective?
NO YES
Is wheel alignment improper? Correct
NO
YES
Is front axle deformed? Replace axle
NO

Is wheel hub bearing worn or YES

damaged? Replace bearing
NO
YES
Is kingpin worn or damaged? Replace kingpin or bushing
NO

Is center of steering wheel turn YES

to right and left shifted? Correct

YES
Is there any other trouble?

Is chassis spring sagging or YES

Replace
broken?
NO

Does vehicle pull to one side YES

Adjust or replace lining
when braking?
NO

Is tire pressure uneven at right YES

Inflate properly
and left?
NO

Is there excessive difference in YES

Replace tires
wear between RH and LH tires?
NO

Is there a difference in O.D. be- YES Change tire for the one of the
tween RH and LH tires? same O.D.
NO

Is there excessive difference in YES

wheelbase between RH and LH Correct wheelbase
tires?
NO
YES
Is rear axle housing bent? Replace axle housing

EMTST5049A
GENERAL ST -17

Steering kickback

Is front axle assembly YES

defective?
NO
Is kingpin to bushing clearance YES
excessive? Replace kingpin or bushing
NO

Is wheel hub bearing worn or YES

deteriorated? Replace bearing
NO

Is wheel alignment (especially YES

camber and caster) improper? Correct wheel alignment
NO

Is there excessive play in YES

Replace drag link or tie-rod end
knuckle arm or tie-rod ball stud?
NO

Is tire inflation excessively YES

Inflate properly
uneven?
NO

Are knuckle arm, tie-rod arm, YES

Tighten parts to specification
back plate, and knuckle left loose?
NO

Is U-bolt nut of front spring left YES

Tighten to specification
loose?
NO

Do front tires run out or are static YES

Correct wheel balance
and dynamic balance incorrect?

Continued on next page

EMTST5050A
ST -18 STEERING SYSTEM

Continued from previous page

YES
Is steering system defective?
NO
Is ball nut to cross gear play YES
improper? Adjust
NO
YES
Is worm shaft bearing worn? Replace bearing
NO

Is there excessive play in drag YES Replace knuckle arm, pitman

link ball stud? arm or drag link
NO

Are cross shaft and bushing YES Replace gear housing and
worn? side cover
NO

Are ball and ball groove worn of YES

Replace ball nut assembly
the ball nut?
YES
Is there any other trouble?

Is propeller shaft runout YES

Correct or replace
excessive?
NO

Are reduction pinion and gear da- YES Replace pinion and gear, or
maged and in improper meshing? correct tooth contact
NO
YES
Is tire runout excessive? Correct or replace

EMTST5051A
GENERAL ST -19

POWER STEERING SYSTEM

Defective power steering gear

train

Hard steering

NG NG
Hard in both direction Low pressure due to oil leaks Tighten points of leakage or
OK OK replace seal and O-ring

NG
Defective valve Check and correct valve or
OK replace ball screw set

Damaged or contaminated rack NG Check hydraulic oil for

piston contaminants; check and correct
box internal surface and rank pis-
ton sliding surface; or replace ball
screw set

NG NG
Hard especially at center Improperly adjusted rack Adjust main shaft starting torque
OK meshing starting torque

NG NG
Excessive difference in steering Clogged hydraulic circuit Check and correct circuit or
effort between right and left turn replace ball screw unit
OK

NG NG
Hard especially at idle Air trapped due to shortage of oil Bleed the system and then
OK add hydraulic oil

NG NG
Hard especially when the wheel Defective valve Check and correct circuit or
starts to be turned replace ball screw unit

Continued on next page

EMTST5052A
ST -20 STEERING SYSTEM

Continued from previous page

NG
Causes other than power Defective oil pump Correct or replace oil pump
steering gear
OK

NG
Clogged pipings Correct or replace pipings
OK

NG
Oil pump drive belt slipping Adjust V-belt tension or
OK replace V-belt

NG
Steering linkage joints short of Lubricate joints
lubrication
OK

NG
Insufficient front tire inflation Inflate properly
OK

NG
Improper front wheel alignment Measure wheel alignment
Continued on next page and correct as required.

EMTST5053A
GENERAL ST -21

Continued from previous page

Steering kickback

NG NG
Defective power steering gear Damaged valve control edge or Replace ball screw set
OK shock-absorbing O-ring
OK

NG
Improper hydraulic oil in power Replace oil with specified one
steering system

NG NG
Causes other than power Tire pressure imbalance Inflate properly
steering gear OK

NG
Ball joint wear Disassemble and replace
OK

NG
Worn kingpin or kingpin bushing Disassemble and replace

Continued on next page

EMTST5054A
ST -22 STEERING SYSTEM

Continued from previous page

Improper return in action of

steering wheel

NG NG
Both during right and left turn Improperly adjusted rack Adjust main shaft starting torque
OK meshing starting torque
OK

NG NG
Improper return only during right Clogged hydraulic circuit Check and correct circuit or
or left turn OK replace ball screw unit
OK

NG NG
Causes other than power Clogged pipings Correct or replace pipings
steering gear OK

NG
Improper front wheel alignment Measure wheel alignment
and adjust as required

Car wander due to excessive

play in steering wheel

NG NG
Defective power steering gear Ball joint wear Tighten adjusting bolt to eliminate
OK OK play in gear or replace cross shaft
Replace as ball screw set

NG
Damaged valve control edge or Replace wheel bearing
shock-absorbing O-ring

NG NG
Causes other than power Tire pressure imbalance Replace wheel bearing
steering gear OK

NG
Ball joint wear Tighten to specification or
Continued on next page replace defective parts

EMTST5055A
GENERAL ST -23

Continued from previous page

Smaller steering angle or

different angle between right and
left turn
OK

NG NG
Defective power steering gear Improper pitman arm installed Correct
angle
OK

Cause other than power steering NG Improperly adjusted knuckle NG Using turning radius gauge,
gear stopper bolt adjust knuckle stopper bolt to
obtain correct steering angle for
right and left turn.

Oil leaks

NG NG
Defective power steering gear Oil leaking from gearbox Tighten the point of leakage
OK or replace O-ring and seal

Causes other than power NG Clamping nuts at pipings and NG Tighten to specifications or
steering gear joints left loose replace
OK

NG
Oil leaks from reservoir tank due Keep correct level
to excessive oil level
OK

Oil leaking from reservoir due to NG Bleed the system and keep
air trapped correct oil level

EMTST5056A
ST -24 STEERING SYSTEM

Defective power steering oil pump

Improper oil pump pressure

YES NG
Does maximum pressure exceed Defective gear pump Disassemble, check and correct;
specification? or replace defective parts
NO

NG NG
Collapsed or clogged oil line Correct or replace pipings

OK

Unusual noise, vibration

NG NG
Rumbling Air trapped in oil pump Check oil level and hose clips;
OK OK bleed; or replace oil pump

NG
Seizure inside oil pump Replace oil pump

NG NG
Squeaking Loose belt (slipping noise) Adjust belt tension or replace belt
OK OK

NG
Seizure inside oil pump Replace oil pump

Continued on next page

EMTST5057A
GENERAL ST -25

Continued from previous page

OK

NG NG
Roaring Pump bracket or attaching bolt Retighten
OK left loose

NG
*Defective pump unit Replace oil pump
* Oil pump may develop slight roaring noise but that indicates no problem
(especially in case of stationary steering)

Oil leaks

NG NG
Oil pump Defective oil pump housing Disassemble and check, and
replace if defective parts

NG
Defective O-ring and oil seal Disassemble and check, and
replace if defective

NG
Nut left loose Retighten

NG NG
Oil reservoir Poorly welded pipes Braze or replace parts

Overflow Bleed and correct oil level

EMTST5058A
ST -26 STEERING SYSTEM

ADJUSTMENT EB5FC8ED

CHECKING STEERING WHEEL FREE PLAY

(MANUAL / POWER)

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.

2. Measure the play at the circumference of the steering

weel A

Standard value :
Steering wheel free play : 0 ~ 25 mm
APIE101B

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.
0~25mm
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.

EMTST5059A
4. While operating the starter motor intermittently, turn
the steering wheel all the way to the left and then to
3. If the free play exceeds the standard value, inspect the right several times to drain the fluid.
the connection between the steering shaft and tie rod
ends. 5. Connect the return hose and fix it with a clip.

CHECKING STEERING ANGLE (MANUAL/POWER) 6. Fill the power steering fluid reservoir with the specified
fluid.
1. Place the front wheel on a turning radius gauge and
measure the steering angle. 7. Start the engine.Check for fluid leaks from the hose,
then stop the engine.
Standard value :
Wheel angle 8. Pour the fluid into the bottom of the oil filter in the
Inner wheel : 31.5 ~33.5 power steering fluid reservoir.
Outer wheel : 42˚ ~44˚
9. Bleed the air.
GENERAL ST -27

AIR BLEEDING (POWER STEERING SYSTEM) 3. Discharge oil pressure measurement.Close the stop
valve of the oil pressure gauge at idling engine and
1. Fill the power steering fluid reservoir up to the "MAX" measure the oil pressure to confirm that it is within
position with specified fluid. the standard value.

Specified value : 10 ㎏/㎠ or less

4. Oil pump pressure relief pressure test.

MAX

1) Increase the engine speed at 1500~1600 rpm.

MIN

2) Close the stop valve of the oil pressure gauge

and measure MAX. oil pressure.

Relief oil pressure : 94~99 ㎏/㎠

5. Remove the oil pressure gauge with stop value and

tighten the pressure hose to the specified torque.
KMTST5013B
Tightening torque : 30~40Nm (3~4kgf·m)
2. Jack up the front wheels. 21.7~28.9 lb-ft

3. Turn the steering wheel all the way to the left and then
to the right five or six times. 6. Bleed the air from the system.

ADJUSTMENT OF OIL PUMP V-BELT

NOTE
1. Tighten the adjusting bolt(A) until a proper tension is
When bleeding fluid, replenish with the fluid so that
achieved to V-belt of oil pump.
the level dose not fall below the bottom of the filter.
Control the adjusting bolt(A)
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.

NOTE
If the fluid level varies 5mm (0.2 in.) or more, bleed A
the system again. If the fluid level suddenly rises af-
ter stopping the engine, further bleeding is required.
EMTST5015A
Incomplete bleeding will produce a chattering sound
in the pump and noise in the flow control value, and
deteriorate durability of the pump.
OIL PUMP PRESSURE TEST (POWER STEERING
SYSTEM)

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 tem-
perature by Temperature gauge so that the fluid tem-
perature can rise to approximately 50~60℃.
ST -28 STEERING SYSTEM

2. To adjust the belt tension, a deflection(B) of belt

should be 4 ~ 6mm when pressing the belt(A) with
10kgf·force.

10kgf
A

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 ST -29

STEERING COLUMN AND

SHAFT
COMPONENTS EEC32B66

6
7

11

5
10

3
4
2
1

9 7

8 12

14

13
1. Lever
2. Screw
3. Screw
4. Bolt
5. Spacer
6. Lever
15
7. Wave washer
8. Spring
9. Collar 16
10. Lever
11. Column support
12. Steering column
13. Cable band
14. Dust "A" cover
15. Dust "B" cover
16. Dust "C" cover

EMTST5017A
ST -30 STEERING SYSTEM

REMOVAL EDC6BE3E 6. Disconnect the multi－function switch harness con-

nector(A) and remove the multi－function switch(B).
1. Disconnect the (－) battery cable

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.
A

A
B
B

EMST04B

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

C B

EMTST02B

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

EMTST05B

A
8. Remove the key cylinder mounting bolt and the key
cylinder assembly(A)

9. Remove the tilt adjuster bolt(B)

A
EMTST03B

EMST06B
STEERING COLUMN AND SHAFT ST -31

10. Remove the return spring(A)

11. Remove the steering shaft cover(B)

EMST07B

12. Remove the gear box(A) and the steering shaft

mounting bolt pin(B)

NOTE
Mark a matchmark on the gear box and steering shaft.

EMST08B

13. Remove the steering shaft.

ST -32 STEERING SYSTEM

INSPECTION EFAFB579 2. Check the connecting parts for enough clearance,

damaged portion and proper operation.
1. Check the steering column shaft for damage and de-
formations.

Axial play of steering shaft to column

1
Normal value : 0.2mm or less

Spline shaft joint play in rotating direction service

limit than 15 in angle
3

Joint play in rotating direction of flange tube.

Service limit than 15 in angle

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

EMTST5018A
STEERING COLUMN AND SHAFT ST -33

INSTALLATION E1D0BDD6

Apply grease

34.3~53.9
(3.5~5.5, 25.3~39.8)
3

Welding point

Adjusting screw
(for adjustment of steering
wheel play)

53~65
(5.4~6.6, 39.1~47.7)

Apply grease

16.7~25.5
(1.7~2.6, 12.3~18.8) Apply grease

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

Installation is the reverse procedure of the disassembly

Tightening Torque : Nm (kgf.m, Ib-ft)

EMTST5019A
ST -34 STEERING SYSTEM

STEERING LINKAGE
COMPONENTS E8ECCDBC

9
10

11 1
12
8
5
13
12 2

7
5
4

6
3
Disassembly sequence
1. Split pin
2. Nut
3. Tie rod assembly
4. Tie rod end 4
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

EMTST5020A
STEERING LINKAGE ST -35

DRAG LINK

DISASSEMBLY EE6F74E8

Damage 8 7 Not reusable

Wear 9
Wear 10
Cracks, deterioration 11
Cracks 12

13

Cracks 6

14 Ball stud
5 Wear
4 Wear
3 Cracks, deterioration
2 Damage
1 Not reusable

Disassembly sequence
1. Split pin 8. End plug
2. End plug 9. Ball seat A
3. Spring 10. Ball seat B
4. Ball seat B 11. Spring
5. Ball seat A 12. Grease seat B
6. Grease seat A 13. Drag link
7. Split pin

EMTST5021A
ST -36 STEERING SYSTEM

REASSEMBLY EEB76D8A

Position FL marks toward the front of vehicle

12
6
2 4 3 13 9

1,7

10
5 11
Pack with chassis grease

Reassembly sequence
13 6 5 4 3 2 1 12 11 10 9 8 7

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.
STEERING LINKAGE ST -37

TIE ROD

DISASSEMBLY EA0ACED6

1
2
3
4

6
8
Cracks and
Disassembly sequence deterioration
1. Split pin of clip
2. Slotted nut
3. Washer 7 Excessive thread wear
4. Clip
5. Dust seal Runout
6. Tie-rod end assembly NV : Less than 2
7. Large head bolt L:2
8. Tie rod

L ..... Limit
NV ... Nominal Value

EMTST5023A

INSPECTION E722CE07

1. Measurement of Tie Rod Runout

Nominal value (mm) Less than 2

Limit (mm) 2

Approx. 40 mm Approx. 40 mm

EMTST5024A
ST -38 STEERING SYSTEM

REASSEMBLY E4392DCE

Difference of this dimension

X between right and left sides:

1 Within 1.5 mm
(one screw thread)
2

3
Pack with 19.6~29.4
chassis grease (2~3, 14.5~21.7)

1. Split pin 6 Reassembly sequence

2. Slotted nut
7
3. Washer 8 7
X
4. Dust seal 6 5 4 3 2 1
5. Clip Fix right and left tie rod ends
6. Tie-rod end assembly with their axes X-X in parallel
7. Large head bolt with each other.
8. Tie rod

Tightening Torque : Nm (kgf.m, Ib-ft)

EMTST5025A
MANUAL STEERING SYSTEM ST -39

MANUAL STEERING
SYSTEM

MANUAL STEERING GEAR BOX

COMPONENTS E8E2DFC9

Main shaft starting torque

Before
After removal
disassembly
of cross shaft
(Overall)
N cm (kgf cm)
N cm (kgf cm)
59 to 88 39 to 59
(6 to 9) (4 to 6) Clearance

6 NV
1 14 L
[BD]
13
Wear of ball joint [32]
12 0.1
0.01 to 0.06

5
2

Wear 11
Corrosion, dent 10

4
9 3
With mainshaft held vertically, make sure Adjusting screw to cross
that ball nut falls down smoothly without shaft T-groove clearance
excessive play under its own weight NV 0.1 or less
Adjust with adjusting plate
Clearance
Corrosion, dent 10 NV
L
[BD]
8
[30]
0.1
7 0.01 to 0.06
Disassembly sequence
1. Pitman arm
2. Side cover
3. Adjusting plate
4. Adjusting screw
5. Cross shaft
6. Dust cover
7. End cover
8. End cover shim The part marked with * must be inspected before disassembly.
*9. Main shaft For disassembly of parts with an encircled number,
10. Ball bearing see Disassembly given later.
11. Oil seal
12. Steering gear housing NOTE:
13. Oil seal Do not disassemble the steering gear housing and bushing in the side cover.
14. Oil plug Do not disassemble the ball nut from the main shaft.

EMTST5035A
ST -40 STEERING SYSTEM

DISASSEMBLY E4573DAC 2. Removal of Pitman Arm

• Remove the nut that secures the pitman arm and
NOTE remove the pitman arm.
• Use pitman arm puller for the special tool.
Measurement of Starting Torque of Main Shaft
Before disassembling the cross shaft to remove it,
measure the starting torgue to be served the torgue
as reference when reassemble it. Pitman Arm Puller

Starting Torque
Measuring Socket

EMTST5038A

3. Removal of Cross Shaft

• With the ball nut moved to the center of the gear-
EMTST5036A
box, remove the cross shaft.
1. Draining of Gear Oil
Remove the oil plug to drain gear oil.

EMTST5039A

EMTST5037A
MANUAL STEERING SYSTEM ST -41

REASSEMBLY ECBD8994

Apply fluid packing

15~24 Pack with grease
125~165
(13~17) (1.5~2.4)

25~32
(2.5~3.3) 6
[Apply fluid packing
12
to threaded portion of nut]
5 14
9
15~25
(1.5~2.5)
4 11
10

3
13
8
2 Apply fluid
packing

1
10
7

44~54
Reassembly sequence (4.5~5.5)

12 8 7 5 13 4 3 2 1 6 14
9 10 11

For reassembly of parts with an encircled number, see

Reassembly given later.

Tightening Torque : Nm (kgf.m)

EMTST5040A
ST -42 STEERING SYSTEM

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.

End cover shim thickness

Thickness(mm)
0.05
0.06
EMTST5042A
0.07
2. Selection of adjusting plate
0.10
Fit the adjusting screw into the T-groove in the cross
0.20 shaft and select the adjusting plate to obtain a clear-
0.30 ance of 0.1 mm or less.
Adjusting plate thickness
0.50
Thickness (mm)
1.95
2.00
2.05
2.10
2.15

Thickness gauge

EMTST5041A

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.

EMTST5043A
MANUAL STEERING SYSTEM ST -43

3. Installation of pitman arm 2) Adjustment of main shaft starting torque

To install the pitman arm, ensure that the V-groove in After reassembly, measure again the main shaft
the pitman arm lines up the groove that in the cross starting torque to ensure that it is up to specifica-
shaft. tions.
To adjust the torque, loosen the nut “ X” and
turn the adjusting screw.
Pitman arm

Adjusting screw

Nut "X"

Cross shaft

EMTST5044A

4. Adjustment after reassembly EMTST5046A

1) Topping up with the Gear oil

With being the steering gear in the installed po-
sition, top up with gear oil SAE #90 or the equiv-
alent

EMTST5045A
ST -44 STEERING SYSTEM

POWER STEERING SYSTEM

POWER STEERING GEAR BOX

COMPONENTS EBBF16D0

11 Shaft O.D.
NV [22.5] 0
[BD] -0.05
12 L 22.35
Gear box cylinder to unit
clearance
Aging, damage 15 NV 0.02 to 0.09
Turning condition 14 L 0.15

Turning condition 13
16
17
1 Wear of ball joints
2
3
Turning condition
Aging, damage 7 6
Aging,
5 damage

18
4

20 Aging, damage
19 Turning condition

8 Wear of O.D.
9 NV [35] -0.08
10 +0.08
[BD]
Excessive play in L 34.96
BD ..... Basic diameter axial direction
Inspection of the part marked with * must be made
L ....... Limit NV 0 before disassembly.
NV ..... Nominal value L 0.1 For disassembly of parts with an encircled number,
see Disassembly given later.
Disassembly sequence
1. Pitman arm 12. Valve housing assembly NOTE:
2. Dust cover 13. Angular contact bearing O-rings, oil seals, seal rings, and other rub-
3. Oil seal 14. Bearing ber parts must be replaced with new ones
4. Jam nut 15. Oil seal whenever they are disas sembled.
5. Side cover *16. Ball screw unit Make sure that the alignment mark on cross
6. Needle bearing 17. Lock screw shaft end face in perpendicular to the main
7. U-packing 18. Gearbox shaft axis.
8. Cross shaft 19. Needle bearing Use treated oil and compressed air to remove
9. Adjusting bolt 20. U-Packing dirt from metal parts.
10. Adjusting plate Keep disassembled of parts to not be damaged.
11. Dust cover

EMTST5033A
POWER STEERING SYSTEM ST -45

DISASSEMBLY EC90D497

NOTE
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

Starting torque
49 to 98 Nm
(5 to 10 kgf•m)

EMTST5060A

1. Removal of Pitman Arm

Pitman arm puller

EMTST5063A

4. Removal of Valve Housing and Ball Screw Unit

Pitman arm

EMTST5061A

2. Removal of Cross Shaft and Side Cover

Becareful that the cross shaft serration does damage
to other parts.

EMTST5064A
ST -46 STEERING SYSTEM

REASSEMBLY E441A49F

74~98 (7.5~10, 54.3~72.3)

11
20 15
14
12
3 6
2 13
8 7
5

16
9

1 10 4
22 21
17
3~4
19

Reassembly sequence
NOTE:
22 21 When installing the seal ring, do not stretch it exces
20 11 3 2 1 sively
During installation, be careful to prevent O-ring and
12 15 14 13
oil seals, from damage.
5 7 6 With the ballscrew in neutral, insert the cross shaft
4 and side cover into position.
10 9 8

Tightening Torque : Nm (kgf.m, Ib-ft)

EMTST5065A

1. Measurement of Input Shaft Starting Torque After installation, make sure that the input shaft turns
approximately 5.5 turns. If not, it means that the neu-
Starting torgue : 29~69 N cm (3~7 kgf·cm, 2.2~5.1 lb-ft) tral position is not reached. Reinsert the shaft.

EMTST5067A
EMTST5066A

2. Installation of Cross Shaft Into Side Cover

POWER STEERING SYSTEM ST -47

3. Measurement of Overall Starting Torque

Measure the starting torque by turning the input shaft
approximately 1/4 turn in clockwise and counterclock- Adjusting bolt
wise 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)

At front end
0~0.8 mm

Pitman arm

EMTST5070A

Adjusting bolt

EMTST5068A

4. Installation of Oil Seal

EMTST5069A

5. Backlash Adjustment of Cross Shaft

With gears meshed in neutral position, measure the
backlash at pitman arm end. Use adjusting bolt for
adjustment.

NOTE
After the backlash has been adjusted, move the pit-
man arm to make sure that the rack piston moves
smoothly throughout the entire range of operating an-
gle.
ST -48 STEERING SYSTEM

POWER STEERING OIL PUMP

COMPONENTS EE68018D

20 21

15 18
13

14

10 19

17
7
16
6
4

12
11
2

9
8
1. Mounting bolt 11. Side plate spring
2. Oil pump cover assembly 12. Front housing
5 3. Gasket 13. Connecting assembly
4. Lock pin 14. Mounting bolt
3 5. Cam ring 15. Suction pipe
6. Rotor 16. Oil seal
7. Vain 17. Drive shaft
1
8. Oil pump side plate 18. Dust spacer
9. O-ring (Outer) 19. Snap ring
10. O-ring (Inter) 20. Pulley
21. Pulley nut

EMTST5072A
POWER STEERING SYSTEM ST -49

DISASSEMBLY E09F7D59

1. Remove the suction pipe and the O-ring after remov-

ing two bolts from the oil pump body.

KPKA055B

8. Supports the pulley with the metal plate (brass petal

or aluminum) after fixing in the vice.
Remove the spring washer and pulley nut.
KPKA050B

2. Remove 4 bolts and the oil pump cover assembly.

3. Remove the cam ring.

4. Remove the rotor and the vain.

5. Remove the oil pump side plate.

KPKA056C

9. Pull and draw out the pulley.

10. Remove the snap ring(A) of shaft by using snap ring

plier.
Then remove dust spacer(B).

KPKA046B
A
6. Remove the inner and outer O-ring.
B
7. Remove the side plate spring.

NOTE
• Lise a new gasket and O-ring at assembling.

KPKA270B
ST -50 STEERING SYSTEM

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

KPKA060B

KPKA058B
INSPECTION EF6528F2

12. Remove the oil seal from oil pump body. 1. Inspect the free length of flow control spring.

Free length of flow control spring : 36.5mm

KPKA059B

13. Disconnect the connector from oil pump body and pull
KPQE911B
out the flow control value and the flow control spring.
2. Inspect the power of flow control valve.
14. Remove the O-ring from connector.
3. Check the shaft for wear and damage.
CAUTION
4. Check the V-belt for wear and deterioration.
• Never disassemble the flow control.
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.
POWER STEERING SYSTEM ST -51

REASSEMBLY EBC7306E

1. Install the flow control spring, flow control valve and A

connector.
B

KPKA270B

4. Install the steering pump gear.

KPKA060B

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

KPKA056C

5. Install the spring and inner O-ring.

6. Install the outer O-ring(C) and the oil pump side

KPKA061B plate(A)

3. Insert the shaft assembly(C) softly and install the

spacer(B) and snap ring(A) A
B

KMTST5032

KPKA062B
ST -52 STEERING SYSTEM

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

Front housing side

Oil pump cover side

EMTST5073A

8. Install the rotor.

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

side.

KMTST5034

10. Install the gasket and oil pump cover assembly.

11. Install the suction pipe and the O-ring.

KMTST5035