Steering System

GENERAL POWER STEERING GEAR BOX

POWER STEERING HOSES
STEERING COLUMN & SHAFT POWER STEERING OIL PUMP
STEERING COLUMN／SHAFT
EPS (ELECTRONIC POWER STEERING)
MECHANICAL POWER STEERING SYS- SYSTEM
TEM
ST -2 STEERING SYSTEM

GENERAL
SPECIFICATIONS E52E8BEB

Item Specifications
Column and shaft Shaft and joint type Collapsible, crossjoint with tilt column
Steering gear type Rack and pinion
Rack stroke mm 146
Tilt stroke(Manual/Power) ±7
Tele stroke(Manual/Power) 30mm
Oil pump 3.3L/3.8L Type Vane type
Displacement 9.6 cc/rev
Relief pressure 100 ± 4 kgf/㎠
Steering angle Inner 37.68 ± 2
Outer 30.71
Tie rod end ball joint starting torque 30kg·cm or less
GENERAL ST -3

TIGHTENING TORQUE EC7E7013

Items Nm kgf·m lb-ft

Steering Steering column to column member
13 ~ 18 1.3 ~ 1.8 9.4 ~ 13
column and mounting (upper)
shaft
Steering column to column member
13 ~ 18 1.3 ~ 1.8 9.4 ~ 13
mounting (lower)
Steering column dust cover mounting bolt 13 ~ 18 1.3 ~ 1.8 9.4 ~ 13
Steering wheel lock nut 40 ~ 50 4 ~ 5 28.9 ~ 36.1
Joint assembly(upper) 15 ~ 20 1.5 ~ 2.0 10.8 ~ 14.4
Joint assembly(lower) 18 ~ 25 1.8 ~ 2.5 13 ~ 18
Steering gear Wheel nut 90 ~ 110 9 ~ 11 66 ~ 81
box
Pressure hose to gear box 12 ~ 18 1.2 ~ 1.8 8.6 ~ 13
Return tube to gear box 12 ~ 18 1.2 ~ 1.8 8.6 ~ 13
Tie rod end lock nut 50 ~ 55 5.0 ~ 5.5 36.1 ~ 39.7
Pinion and valve assembly to self locking nut 20 ~ 30 2 ~ 3 14.4 ~ 21.6
Yoke plug lock nut 50 ~ 70 5 ~ 7 36.1 ~ 50.6
Tie rod end self locking nut 24 ~ 34 2.4 ~ 3.4 17.3 ~ 24.5
Mounting bracket to crossmember 140 ~ 160 14 ~ 16 101 ~ 118
Steering gear box Mounting 45 ~ 55 4.5 ~ 5.5 33 ~ 39.7
Oil pump Pressure hose to oil pump 55 ~ 65 5.5 ~ 6.5 39.7 ~ 47
Oil pump mounting bolt [3.3L],[3.8L] 35 ~ 55 3.5 ~ 5.5 25.3 ~ 39.7
Pump cover to pump body 18 ~ 22 1.8 ~ 2.2 13 ~ 15.9
Suction connector to oil pump body 6 ~ 10 0.6 ~ 1 4.3 ~ 7.2
Flow control valve connector to pump body 55 ~ 65 5.5 ~ 6.5 39.7 ~ 47
Steering hoses Oil reservoir bracket mounting bolt 4 ~ 6 0.4 ~ 0.6 2.8 ~ 4.3
and oil reservoir
Cooler tube clamp mounting bolt 4 ~ 6 0.4 ~ 0.6 2.8 ~ 4.3
Tube clip and tube bracket 4 ~ 6 0.4 ~ 0.6 2.8 ~ 4.3
Pressure hose bracket mounting bolt 4 ~ 6 0.4 ~ 0.6 2.8 ~ 4.3
Hose clamp 4 ~ 6 0.4 ~ 0.6 2.8 ~ 4.3

LUBRICANTS

Items Specified lubircant Quantity

Steering column bearing Multipurpose grease SAE J310a, NLGI No.2 As required
Steering gear box rack, pinion
Multipurpose grease SAE J310a, NLGI No.2 As required
gear part
Bellows Silicone grease As required
Oil pump Power steering fluid (PSF-3) As required
Power steering fluid Power steering fluid (PSF-3) 1.0 lit
Tie rod end ball joint SUNLIGHT MB-2 4g
ST -4 STEERING SYSTEM

SPECIAL TOOLS E215AE3F

Tool (Number and Name) Illustration Use

09222-32100 Installation of the oil pump oil seal
Valve stem oil seal installer

EPRF001B

09555-21000 Removal and installation of the oil seal

Bar (Use with 09573-33100, 09573-
33000,09573-21000)

EPRF001D

09561-11001 Removal of steering wheel

Steering wheel puller

EPRF001E

09568-4A000 Separation of the tie rod end bail joint

Tie rod end puller

KPRE103I

09572-21000 Measurement of the oil pressure

Oil pressure gauge (Use with 09572-22100, 09572-21200)

EPRF001F
GENERAL ST -5

09572-21200 Measurement of the oil pressure

Oil pressure gauge adapter (Use with 09572-21000, 09572-22100)

EPRF001G

09572-22100 Measurement of the oil pressure

Oil pressure gauge adapter (Use with 09572-21000, 09572-21200)

EPRF001H

09573-21100 Installation of the back up washer and oil seal

Oil seal installer (Use with 09753-21000,09573-33100,
09555-21000)

EPRF001I

09573-33100 Removal and installation of the oil seal

Oil seal guide (Use with 09573-21000, 09573-
33000,09555-21000)

EPRF001K

09432-21600 Installing the pinion gear bearing

Braring installer

APJF001K
ST -6 STEERING SYSTEM

09434-14200 Installing the gear box oil seal

Counter shaft bearing installer

APJF001M

09565-11100 Measuring the pinion shaft preload

Preload socket

APJF001A
GENERAL ST -7

TROUBLESHOOTING E80E87DD

Symptom Probable cause Remedy

Excessive play in Loose yoke plug Retighten
steering
Loose steering gear mounting bolts Retighten
Loose or worn tie rod end Retighten or replace as necessary
Steering wheel V-belt slippage Readjust
operation is not
Damaged V-belt Replace
smooth (Insufficient
power assist) Low fluid level Replenish
Air in the fluid Bleed air
Twisted or damaged hoses Correct the routing or replace
Insufficient oil pump pressure Repair or replace the oil pump
Sticky flow control valve Replace
Excessive internal oil pump leakage Replace the damaged parts
Excessive oil leaks from rack and
Replace the damaged parts
pinion in gear box
Distorted or damaged gear box or
Replace
valve body seals
Steering wheel does Excessive turning resistance of tierod end Replace
not return properly
Yoke plug excessively tight Adjust
Tie rod and/or ball joint cannot turn smoothly Replace
Loose mounting of gear box mounting bracket
Retighten
Worn steering shaft joint and/or
Worn steering shaft joint and/or body grommet Correct or replace
Distorted rack Replace
Damaged pinion bearing Replace
Twisted or damaged hoses Reposition or replace
Damaged oil pressure control valve Replace
Damaged oil pump input shaft bearing Replace
Noise Hissing Noise in Steering Gear
There is some noise with all power steering systems. One of the most common is a
hissing sound when the steering wheel is turned and the car is not moving. This noise
will be most evident when turning the wheel while the brakes are being applied. There
is no relationship between this noise and steering performance. Do not replace the
valve unless the "hissing" noise becomes extreme. A replaced valve will also make
a slight noise, and is not always a solution for the condition.
Rattling or chucking Interference with hoses from vehicle body Reposition
noise in the rack
Loose gear box bracket Retighten
and pinion
Loose tie rod end and/or ball joint Retighten
Worn tie rod and/or ball joint Replace
Noise in the oil pump Low fluid level Replenish
Air in the fluid Bleed air
Loose pump mounting bolts Retighten
ST -8 STEERING SYSTEM

SERVICE ADJUSTMENT CHECKING STEERING ANGLE

PROCEDURE EF4B5EEB 1. Place the front wheel on a turning radius gauge and
measure the steering angle.
CHECKING STEERING WHEEL FREE PLAY

1. Start the engine and with the steering wheel in the Standard value :
straight ahead position. Wheel angle
Inside wheel 39.17 ±2
2. Measure the play while turning the steering wheel to Outside wheel 31.56
the left and right.
2. If the measured value is not within the standard value,
Standard value : adjust the toe and inspect again.
Steering wheel free play : 30 mm (1.1 in)

EPRF010A

KPBF010C
CHECKING THE TIE ROD END BALL JOINT
3. If the play exceeds the standard value, inspect the STARTING TORQUE
connection between the steering shaft and tie rod
1. Disconnect tie rod and knuckle with the special tool
ends.
(09568-4A000).

09568-4A000

KPBF010E
GENERAL ST -9

2. Shake the ball joint stud several times to check for

looseness.

Tie rod end ball joint starting torque :

30 kg·cm or less

KPBF010G

CHECKING POWER STEERING BELT TENSION

Refer to EM group(Timing system).

CHECKING POWER STEERING FLUID LEVEL
KPBF010F
1. Position the vehicle on a level surface.
3. If the starting torque exceeds the upper limit of the
standard value, replace the tie rod end. 2. Start the engine. With the vehicle kept stationary, turn
the steering wheel several times continuously to raise
4. Even if the starting torque is below the lower limit of the fluid temperature to 50-60℃ (122-140℉).
the standard value, check the play of the ball joint and
replace if necessary. 3. With the engine at idle, turn the steering wheel fully
clockwise and counter-clockwise several times.
CHECKING STEERING WHEEL RETURN
4. Make sure that there is no foaming or cloudiness in
1. The force required to turn the steering wheel and the the reservoir fluid.
wheel return should be the same for both moderate
and sharp turns.

2. When the steering wheel is turned 90˚ and held for

a couple of seconds while the vehicle is being driven
at 20-30 kph (12-19 mph), the steering wheel should
return at least 20˚ from its central position when it is
released.

NOTE
If the steering wheel is turned very quickly, steering
may be momentarily difficult. This is not a malfunc-
tion because the oil pump output will be somewhat
decreased.
ST -10 STEERING SYSTEM

5. Stop the engine and check for any difference in fluid AIR BLEEDING
level between a stationary and a running engine.
1. Disconnect the high tension cable, and while oper-
ating the starting motor intermittently (for 15-20 sec-
NOTE onds), turn the steering wheel all the way to the left
1. If the fluid level varies 5 mm (0.2 in) or more, and then to the right five or six times.
bleed the system again.
2. If the fluid level suddenly rises after stopping the NOTE
engine, further bleeding is required.
3. Incomplete bleeding will produce a chattering 1. During air bleeding, replenish the fluid supply so
sound in the pump and noise in the flow control that the level never falls below the lower position
valve, and lead to decreased durability of the of the filter.
pump. 2. If air bleeding is done while the vehicle is idling,
the air will be broken up and absorbed into the
fluid. Be sure to do the bleeding only while crank-
ing.
3. Connect the high tension cable, and start the en-
gine(idling).
4. Turn the steering wheel to the left and the right
until there are no air bubbles in the oil reservoir.
MAX
MIN CAUTION
Do not hold the steering wheel turned all the way
to either side for more than ten seconds.

5. Confirm that the fluid is not milky, and that the

level isup to the position specified on the level
gauge.
6. Confirm that there is little change in the surface
KPBF010H o the fluid when the steering wheel is turned left
and right.
REPLACING POWER STEERING FLUID
CAUTION
1. Jack up the front wheels and support them with jack-
stands. 1. If the surface of the fluid changes consider-
ably, air bleeding should be done again.
2. Disconnect the return hose from the oil reservoir and 2. If the fluid level rises suddenly when the en-
plug the oil reservoir. gine is stopped, it indicates that there is still
air in the system.
3. Connect a vinyl hose to the disconnected return hose, 3. If there is air in the system, a jingling noise
and drain the oil into a container. may be heard from the pump and the control
valve may also produce unusual noises. Air
in the system will shorten the life of the pump
4. Disconnect the high-tension cable at the ignition coil
and other parts.
side. 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 hoses, then fill the oil reservoir with
the specified fluid.

6. Start the engine. Check for oil leakage.

7. Stop the engine.

8. Bleed the system.

Power steering fluid type : PSF-3

Total quantity : Approx 1.0 liter
GENERAL ST -11

Oil pressure gauge

(09572-21000)
Temperture Shut-off valve
MAX gauge (close)
Oil pump
relief presure
5mm
Adapter
(09572-21200,
09572-22100)
MIN
Pressure
hose

Reservor Oil pump

KPBF010J

OIL PUMP PRESSURE TEST (OIL PUMP RELIEF

PRESSURE) Oil pressure
gauge adapter
(09572-22100)
1. Disconnect the pressure hose from the oil pump.
Connect the special tool between the oil pump and
pressure hose as illustrated.

2. Bleed the air, and then start the engine and turn the EPRF002B

steering wheel several times so that the fluid temper-

ature rises to approximately 50℃ (122℉). 5. Remove the special tools, and tighten the pressure
hose to the specified torque.
3. Set the engine speed to 1,000 rpm.
Tightening Torque Nm(kgf·m, lb-ft) :
4. Close the shut-off valve of the special tool and mea- 55 ~ 65(5.5 ~ 6.5, 39.7 ~ 47)
sure the fluid pressure to confirm that it is within the
range.
6. Bleed the system.
standard vaule :
Relief pressure: 90 +3/-2 kgf/㎠

CAUTION
Don’ t keep the shut-off valve on the pressure
gauge closed for longer than seconds.
ST -12 STEERING SYSTEM

STEERING COLUMN &

SHAFT
STEERING COLUMN／SHAFT

COMPONENTS EE8A2FB4

18 ~ 25 (1.8 ~ 2.5, 13 ~ 18)

TORQUE : Nm (kgf.m, lb-ft)

1. Steering wheel 5. Steering colum shaft assembly

2. Key lock assembly 6. Steering column upper shroud
3. Dust cover assembly 7. Steering column lower shroud
4. Universal joint assembly 8. Multifunction switch
EPBF500A
STEERING COLUMN & SHAFT ST -13

REMOVAL E8272C54

1. Disconnect the negative (-) terminal(A) from the bat-

tery.

EPBF500K

09561-11001

APIE102B

2. Loosen the tapping screws and lift up the horn pad

and remove it.

3. Remove the lock nut and the washer.

CAUTION
Before doing these procedures, see the SRS sec-
tion (RT Group. Only for vehicle equipped with EPBF500L
SRS).

EPBF500W

EPBF500X

4. Remove the steering wheel with (09561-11001).

CAUTION
Do not hammer on the steering wheel to remove
it may cause the damage to the collapsible mech-
anism.
ST -14 STEERING SYSTEM

5. Remove the lower cover(A). [RHD]

[LHD]
A

EPBF500N

EPBF500M 6. Remove the steering column lower and upper

shrouds.

EPBF500O
STEERING COLUMN & SHAFT ST -15

7. Disconnect the connectors and remove the multifunc- 9. Remove the dust cover mounting bolts.
tion switch.
[LHD]

B A

EPBF500P

KPBF101H
8. Remove the bolts securing the coupling and universal
joint. Pull out the universal joint from the gear box. [RHD]

[LHD]

EPRF700G

KHBF140F
10. Remove the steering column mounting bolts (4bolts).
[RHD]
B
A

KPBF101I

EPBF500Q
11. Remove the steering column and shaft with the uni-
versal joint and cover.
ST -16 STEERING SYSTEM

DISASSEMBLY EB261A91 UNIVERSAL JOINT ASSEMBLY

KEY LOCK ASSEMBLY 1. Remove the bolt(A) connecting the universal joint as-
sembly(B) and the steering column and shaft assem-
1. If it is necessary to remove the key lock assembly(A), bly(C).
use a punch to make a groove on the head of the
special bolt(B), and then use a screwdriver to remove
the key lock assembly mounting bracket(C).
C

A
C
B

KPBF111C
A
2. Remove the universal joint assembly(A) from the
KPBF111A steering column and shaft assembly(B).

2. Disassemble the key lock assembly(A) from the steer-

ing column and shaft assembly(B).
B
A
B

KPBF111D
A
3. Reassembly is reverse of disassembly.
KPBF111B

3. Reassembly is reverse of disassembly.

STEERING COLUMN & SHAFT ST -17

INSPECTION E1CCD66E 3. Install the dust cover mounting nuts(A).

1. Check the steering shaft for damage, play and round- Tightening Torque Nm(kgf·m, lb-ft) :
movement. 13 ~ 18(1.3 ~ 1.8, 9.4 ~ 13)

2. Check the upper and lower bearing for wear or dam-

[LHD]
age.

3. Check the joints for excessive play, damage or rough-

movement.

4. Check the tilt bracket for cracks or damage.

5. Check the cover or boot for damage. A

6. Check that the steering lock mechanism operate-

sproperly. If necessary, replace.

REASSEMBLY EEAA2192

1. Reassembly is reverse of the removal.

2. Make parallel the steering shaft’s groove to the hookof KPBF101H

the steering lock, when installing the steering lock-

[RHD]
assembly.

INSTALLATION EFEECD62

1. Before installation, grease the inner side of the bear-

ing, the boot, and the dust cover

2. Install the steering column mounting bolts(A) and

nuts(B)

Tightening Torque Nm(kgf·m, lb-ft) :

13 ~ 18(1.3 ~ 1.8, 9.4 ~ 13)

CAUTION
Connect the universal joint to the pinion shaft of EPRF700G
the gear box in advance.

KPBF101I
ST -18 STEERING SYSTEM

4. Install the connecting bolt(A) between the universal 5. Install the multifunction switch(B) mounting screws(A)
joint and the pinion shaft. and the connectors.

Tightening Torque Nm(kgf·m, lb-ft) :

18 ~ 25(1.8 ~ 2.5, 13 ~ 18) B A

[LHD]

EPBF500P

6. Install the steering column lower(A) and upper(B)

shrouds.

KHBF140F
C

[RHD]

EPBF500O

EPBF500Q
STEERING COLUMN & SHAFT ST -19

7. Install the crush pad lower cover(A). NOTE

[LHD] Check that the front wheels is in the right direction in
advance.
A

EPBF500K

9. Install the two steering wheel cover(A) bolts by using

the hexagon wrench.

A
EPBF500Y

[RHD]

EPBF500X

EPBF500W

10. Connect the negative (-) terminal(A) to the battery.

EPBF500Z

8. Install the steering wheel locking nut(A).

Tightening Torque Nm(kgf·m, lb-ft) :

40 ~ 50(4 ~ 5, 28.9 ~ 36.1)

APIE102B
ST -20 STEERING SYSTEM

MECHANICAL POWER
STEERING SYSTEM
COMPONENTS E401C9A1

[LHD]

3
4

5
1
2

[RHD]
4

1. Bellows 4. Valve body assembly

2. Rack housing 5. Tie rod assembly
3. Feed tube 6. Lock nut
EPBF500V
MECHANICAL POWER STEERING SYSTEM ST -21

POWER STEERING GEAR BOX

COMPONENTS E15DDC7A

[LHD] 12

3
2

11 8
4

5 6

9
16
10

14

15
17

13
18

19

20

21

22
23

1. Feed tube 9. Rack support spring 17. Bellows clip

2. Valve body housing 10. Rack support yoke 18. Bellows
3. Bolt 11. Rack housing 19. Bellows band
4. Oil seal 12. Power steering gear box mounting clamp 20. Tie rod
5. Pinion valve assembly 13. Oil seal 21. Circlip
6. Oil seal 14. Rack 22. Oil seal
7. Yoke plug 15. Tie rod end 23. Rack stopper
8. Lock nut 16. Lock nut
EPRF700P
ST -22 STEERING SYSTEM

[RHD] 12

3
2

8 11
4

6 5

9
16
10

14

15
17

13
18

19

20

21

22
23

1. Feed tube 9. Rack support spring 17. Bellows clip

2. Valve body housing 10. Rack support yoke 18. Bellows
3. Bolt 11. Rack housing 19. Bellows band
4. Oil seal 12. Power steering gear box mounting clamp 20. Tie rod
5. Pinion valve assembly 13. Oil seal 21. Circlip
6. Oil seal 14. Rack 22. Oil seal
7. Yoke plug 15. Tie rod end 23. Rack stopper
8. Lock nut 16. Lock nut
EPRF700Q
MECHANICAL POWER STEERING SYSTEM ST -23

REMOVAL E54305AB 5. Remove the pressure sensor connector(A) from the

pressure hose
1. Loosen the wheel nuts slightly.
Raise the front of the vehicle, and make sure it is
securely supported.

2. Remove the front wheel and tire(A) from front hub(B).

KPBF222A

6. Remove the nut(B) from the stabilizer bar link(A).

EIRF101A
B

CAUTION A

Be careful not to damage the hub bolts(C) then

remove the front wheel and tire(A).

3. Drain the power steering fluid.

4. Disconnect the pressure hose and the retrun tube.

KHRE110B

7. Using the specil tool(09568-4A000) disconnect the tie

rod end from the knuckle arm.

KPBF211A

EPBF500G
ST -24 STEERING SYSTEM

10. Remove the joint assembly connecting bolt.

[LHD]

09568-4A000

KHBF105B

8. Remove the lower arm mounting bolts(A).

KHBF140F

[RHD]

KHBF140D

9. Remove the front fork and the knuckle ball joint from
the front lower arm.
EPBF500Q

11. Remove the connecting bolts of front and rear roll

stopper.

KHBF140E
A

CAUTION
Be careful not to damage to the aluminium lower KHBF301A

arm.
MECHANICAL POWER STEERING SYSTEM ST -25

12. Remove the mounting bolts(10EA) of cross member [RHD]

complete assembly.

EPRF700L

KHBF301C CAUTION
When removing the gear box, pull it out carefully
13. Remove the heat protecting cover(A) mounting
and slowly to avoid damaging the boots.
bolts(B).
15. Disconnect the pressure hose and the retrun tube.

[LHD]

A
KPBF201E

KPBF301D
14. Remove the steering gear box mounting bolts and re-
move the steering gear box assembly and the mount- [RHD]
ing rubber.

[LHD]

EPRF700K

KPRE301E
ST -26 STEERING SYSTEM

DISASSEMBLY E6CAB1AD 4. Remove the bellows clip(A).

1. Remove the tie rod end(B) from the tie rod(A).

A
B

EPKE013I

KPBF202A 5. Pull the bellows out toward the tie rod.

2. Remove the dust cover(B) from the ball joint(A). NOTE

Check for rust on the rack when the bellows are re-
placed.
B
6. Remove the feed tube(A) from the rack housing.

EPBF500H

3. Remove the bellows band(A).

APHE006H

7. While moving the rack slowly, drain the fluid from ther-
A
ack housing.

KPBF006F
MECHANICAL POWER STEERING SYSTEM ST -27

8. Unstake the tab washer(A) which fixes the tie rod(B) 11. Remove the yoke plug(B) with a 14mm socket(A).
and rack(C) with a chisel.

KPBF006L

EPKE037A
12. Remove the lock nut(D), yoke plug(C), rack support
9. Remove the tie rod(B) from the rack(A). spring(B) and rack support yoke(A) from the gear box.

CAUTION
Remove the tie rod(B) from the rack(A), takingcare
not to twist the rack.

APJF005L

KPBF006J

10. Remove the yoke plug locking nut(A).

KPBF006K
ST -28 STEERING SYSTEM

13. When the end of the circlip comes out of the notched- 16. Remove the O-ring(A) from the rack bushing(B).
hole of the housing rack cylinder, turn the rack stopper
counterclockwise and remove the circlip.

CAUTION
Be careful not to damage the rack.

EPKE013T

17. Remove the oil seal(B) from the rack bushing(A).

EPKE013Q

14. When the end of the circlip comes out of the notched
hole of the housing rack cylinder, turn the rack stopper
counterclockwise and remove the circlip.

EPKE013U

18. Remove the valve body from the valve body housing
with a soft hammer.

EPKE013R

CAUTION
Be careful not to damage the rack.

15. Remove the rack bushing and rack from the rack
housing.

EPKE210A

19. Using the special tool, remove the oil seal and ball-
bearing from the valve body housing.
MECHANICAL POWER STEERING SYSTEM ST -29

20. Remove the oil seal and O-ring from the rack housing. 2. Pinion valve

1) Check for pinion gear tooth face damage or wear.

CAUTION
Be careful not to damage the pinion valve cylin- 2) Check for oil seal contact surface damage.
derinside of the rack housing.
3) Check for seal ring damage or wear.
21. Using the special tool(09573-33100,
09555-21000),remove the oil seal(A) from the rack 4) Check for oil seal damage or wear.
housing.

CAUTION
Be careful not to damage the rack cylinder insid-
eof the rack housing.

09573-33100
Back-up washer

APJF013Z

3. Bearing
A
09555-21000 1) Check for seizure or abnormal noise during
abearing rotation.
EPRF210B
2) Check for excessive play.

INSPECTION EA7CDA9B
3) Check for missing needle bearing rollers.

4. Others
1. Rack
1) Check for damage of the rack housing cylinder
1) Check for rack tooth face damage or wear.
bore.
2) Check for oil seal contact surface damage.
2) Check for boot damage, cracking or aging.
3) Check for rack bending or twisting.

4) Check for oil seal ring damage or wear.

5) Check for oil seal damage or wear.

Vent hole

LPJF006C
ST -30 STEERING SYSTEM

REASSEMBLY EA4ABAC8 6. Apply the specified grease to the rack teeth.

1. Apply the specified fluid to the entire surface of the Recommended grease
rack oil seal. Multipurpose grease SAE J310a NLGI No.2

Recommended fluid : PSF-3

NOTE

2. Install the backup washer and oil seal(A) to the spec- Do not plug the vent hole(A) in the rack with grease.
ified position in the rack housing.

09573-33100

APJF014E

7. Insert the rack(A) into the rack housing(B) and install

KPBF007F the rack bushing(C).

3. Apply the specified fluid to the entire surface of the

rack bushing oil seal.

Recommended fluid : PSF-3

4. Install the oil seal(A) in the rack bushing(B).

EPKE230I

EPKE230B

5. Apply the specified fluid to the entire surface of the

O-ring and install it in the rack bushing.
MECHANICAL POWER STEERING SYSTEM ST -31

8. Push in the rack stopper until the circlip groove of the 10. After applying the specified fluid and grease to the
rack stopper is aligned with the notched hole of the pinion valve assembly(A), install it in the rack housing
rack housing. Then, install the circlip while turning assembly.
the rack stopper.

CAUTION
The circlip should not be visible through the
notched hole of the rack housing.

EPKE230E
Slot
11. After applying the specified fluid to the oil seal, install it
inthe rack housing and fix the valve body assembly(A)
circlip position
and O-ring in the gear box(B).

EPBF500C

9. Using special Tool(09432–21600), install the oil seal

and the ball bearing in the valve body(A).

APHE007F

APGE008G
ST -32 STEERING SYSTEM

12. Install the rack support yoke(A), rack support 14. Tighten the feed tube(A) to the specified torque and
spring(B), yoke plug(C) and lock nut(D) in the order- install the mounting rubber using adhesive.
shown in the illustration. Apply semi-drying sealantto
the threaded section of the yoke plug before instal-
lation.

APHE006H

15. Apply the specified grease to the bellows mounting

APJF005L position (fitting groove) of the tie rod.

13. With the rack placed in the center position, attach the Recommended grease : Silicone grease
yoke plug to the rack housing. Tighten the yokeplug to
12 Nm (120 kg·cm, 8.9 lb·ft), with a 14mm socket(A).
Loosen the yoke plug approximately from 30 to 60
and tighten the yoke nut to the specified torque.

Tightening Torque Nm(kgf·m, lb-ft) :

50 ~ 70(5 ~ 7, 37 ~ 52)

APGE008C

16. Install the new attaching band to the bellows.

NOTE
When the bellows are installed, a new band must
APHE007I
beused.

17. Install the bellows in position, taking care not to twist

it.
MECHANICAL POWER STEERING SYSTEM ST -33

18. Fill the dust cover inner side and lip with the specified 20. Check for total pinion preload.
grease, and fix the dust cover in position with the clip
ring attached in the groove of the tie rod end.

Recommended grease
A : POLY LUB GLY 801K or equivalent
B : SHOWA SUNLIGHT MB2 or equivalent
Dust cover inner side and lip : THREE BOND

APHE006B

INSTALLATION E5D30F7E

NOTE
Be sure to connect between a tube and a hose
EPKE043A asshown in the illustration.

19. Install the tie rod(A) to the tie rod end(B).

+3
30

APJF009A

A
1. Installation is reverse of removal.
B
TIGHTENING TORQUE Nm(kgf·m, lb-ft)
Pressure hose to gear box :
12~18(1.2~1.8, 8.6~13)
KPBF202A Return tube to gear box :
12~18(1.2~1.8, 8.6~13)
Tie rod end lock nut :
50~55(5~5.5, 36.1~39.7)
Pinion and valve assembly to self locking nut :
20~30(2~3, 14.4~21.6)
lock nut :
50~70(5~7, 36.1~50.6)
Tie rod end self locking nut :
24~34(2.4~3.4, 17.3~24.5)
Mounting bracket to crossmember :
60~80(6~8, 43.3~57.8)

2. After installation, bleed the air in the power steering

system(See page ST-10).
ST -34 STEERING SYSTEM

POWER STEERING HOSES

COMPONENTS E1AFD16E

1. Power steering oil reservoir 5. Power steering gear box

2. Suction hose 6. Return tube
3. Oil pump 7. Cooler tube
4. Pressure hose
EPBF500D
MECHANICAL POWER STEERING SYSTEM ST -35

REMOVAL E1AFEC1C 4. Remove the return tube and hose.

While installing the tube and hose assembly, be sure to [LHD]

align white marks on each fitting.

White line

KPBF301A

KPBF304D
PRESSURE HOSE, TUBE AND RETURN TUBE,
HOSE
[RHD]
1. Remove the mounting clamps from the pressure tube-
and the return tube.
[LHD]

EPRF700O

KPBF302B
INSTALLATION E5DC84CE

2. Remove the pitting of both the pressure tube and the

return tube from the gear box. Installation is the reverse of removal.

3. Remove the pressure hose and tube. NOTE

• Install the return tube and hoses so that they
arenot twisted and it does not come in contact
withany other parts.
• After installation, air bleed the system.

KPBF303C
ST -36 STEERING SYSTEM

POWER STEERING OIL PUMP

COMPONENTS EBC21FCC

55 ~ 65(5.5 ~ 6.5, 39.7 ~ 47)

13

14
12

11

10

9
8
7

5
18 ~ 22
(1.8 ~ 2.2, 13 ~ 15.9) 4

2 15
1

6 ~ 10
(0.6 ~1, 4.3 ~ 7.2)

18 ~ 22
(1.8 ~ 2.2, 13 ~ 15.9)

TORQUE : Nm (kgf.m, lb-ft)

1. Rear cover 6. Cam ring 11. Flow control spring

2. Snap ring 7. Front side plate 12. Flow control valve
3. Gasket 8. O-ring (Outer) 13. Connector
4. Vanes 9. O-ring (Inner) 14. Pulley
5. Rotor 10. Front housing 15. Suction pipe
EPBF500E
MECHANICAL POWER STEERING SYSTEM ST -37

REMOVAL E64E3B0B 4. Remove the powersteering oil pump assembly by re-

moving the three bolts as shown below.
1. Remove the pressure hose from the oil pump and
the suction hose from the suction pipe, then drain the
powersteering oil.

A B

KPBF401D
B

KPBF211A
DISASSEMBLY E41A4D99

2. Release the tension of the powersteering V-type 1. Remove the bolts from the oil pump body, and then
beltby lifting the auto-tensioner pulley. remove the suction pipe and O-ring.

KPBF401B KPBF402A

3. Remove the V-type belt from the pulley of the power- 2. Remove the power steering oil pump rear cover(A)
steering oil pump. and the O-ring(B) by removing the four bolts.

KPBF412A
ST -38 STEERING SYSTEM

3. Remove the cam ring. 6. Remove the oil pump side plate.

KPBF412D KPBF412E

4. Remove the cam ring. 7. Remove the inner O-ring and outer O-ring.

A A

KPBF412B KPBF412F

5. Remove the rotor and vanes. 8. Remove the pulley and the shaft(A).

KPBF412C KPBF412G
MECHANICAL POWER STEERING SYSTEM ST -39

9. Remove the oil seal from the oil pump body. INSPECTION EA05A7C8

1. Check that the flow control valve is not bent.

2. Check the shaft for wear and damage.

A

3. Check the V-belt for wear and deterioration.

4. Check the grooves of the rotor and vanes for stratified

abrasion.

5. Check the contact surface of the cam ring and vanes

for stratified abrasion.

6. Check vanes for damage.

7. Check that there is no striped wear in the side plate or

KPBF402D contacting part between the shaft and the pump cover
surface.
10. Remove the connector from the oil pump body, and
take out the flow control valve and the flow control
spring. REASSEMBLY EC78610A

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

and the connector in to the pump body.
A

A
B

C
B

KPBF412H

11. Remove the O-ring from the connector.

KPBF412H

CAUTION
2. Install the oil seal in the pump body by using the spe-
Do not disassemble the flow control valve. cial tool(09222-32100).

09222-32100

KPBF404B
ST -40 STEERING SYSTEM

3. Install the pump pulley. 6. After inserting the lock pin into the groove of the front
housing, install the camring attending to the direction.

KPBF412G

KPBF404F
4. Install the outer(A) and inner(B) O-rings
7. Install the rotor.

A
B

KPBF414D
KPBF414E

5. Install the side plate(A).

8. Install the vanes.

KPBF412E
KPBF414F
MECHANICAL POWER STEERING SYSTEM ST -41

10. Install the suction pipe and O-ring.

Roter
Vanes
Tightening Torque Nm(kgf·m, lb-ft) :
6 ~ 10(0.6 ~ 1, 4.3 ~ 7.2)

A
EPRF401D

9. After installing the O-ring(A) and the snap ring(C), in-

stall the rear cover assembly(B). B

Tightening Torque Nm(kgf·m, lb-ft) : KPBF414H

18 ~ 22(1.8 ~ 2.2, 13 ~ 15.9)

KPBF424G

KPBF414G
ST -42 STEERING SYSTEM

INSTALLATION EBFE3F36 5. Add power steering fluid (PSF-3).

1. Install the oil pump to the oil pump bracket. 6. Air bleed the system.

Tightening Torque Nm(kgf·m, lb-ft) : 7. Check the oil pump pressure.

35 ~ 55(3.5 ~ 5.5, 25.3 ~ 39.7)

A B

KPBF401D

2. Install the "V"-type belt by pulling the auto tensioner.

3. Install the suction hose.

CAUTION
Install the pressure hose to the oil pump.

4. Install the pressure hose to the oil pump.

Tightening Torque Nm(kgf·m, lb-ft) :

55 ~ 65(5.5 ~ 6.5, 39.7 ~ 47)

NOTE
Install the pressure hose being careful so that it does
not twist and come in contact with other components.

KPBF211A
EPS (ELECTRONIC POWER STEERING) SYSTEM ST -43

EPS (ELECTRONIC POWER

STEERING) SYSTEM
GENERAL E7A2FF5F

The electronic power steering (EPS) system includes the same components of conventional power steering system.

Sloenoid valve

Vehicle speed sensor

TPS Control unit PUMP

EPRF503A

EPS performs the conventional power steering function in case a failure has occurred in the system. EPS electronically
controls the current to the solenoid of by-pass valve by inputting sensor’s signals to control the hydraulic amount in
cylinder chamber and thereby varying the steering effort versus the hydraulic pressure according to vehicle speed.
In addition, it has a solenoid valve on power steering gear box, and a control unit underneath the audio of the
center facia. To control the oil flow of steering gear box, a solenoid is provided and it functions by the current
from control module which receives signals from VSS (Vehicle Speed Sensor) and TPS.
ST -44 STEERING SYSTEM

REMOVAL AND INSTALLATION EED98798

The removal and installation procedure is the same as that of conventional power steering system except for
the solenoid valve components and EPS control module. Refer to the following figures.

KPBF500D
EPS (ELECTRONIC POWER STEERING) SYSTEM ST -45

ELECTRONIC POWER STEERING

CONTROL MODULE E8F19C24

1 2 3 4
5 6 7 8

PIN LAYOUT
PIN NO. DESCRIPTION

1 Solenoid

2 Solenoid

3 Sensor signal from vehicle speed sensor

4 IG2

5 Data link connector

6 Sensor signal from TPS

7 -

8 Ground

EPBF500I
 ST -46
HOT IN ON
See Power PASSENGER
Distribution COMPARTMENT
JUNCTION 1 E39
BLOCK
ELECRONIC
FUSE 4 PHOTO 32 POWER
10A STEERING
CIRCUIT SIAGRAM

See Passenger SOLENOID

Compartment PHOTO 20
Fuse Details 2 E39
18 I/P-A
0.5O 0.5B
EAABCA6A

27 20 EM01
0.3R PHOTO 63
0.3O 0.3B

4 2 1 M70

ON input Solenoid(-) Solenoid(+) ELECTRONIC

POWER
STEERING
Vehicle speed MODULE
Ground input TPS Diagnosis PHOTO 54
8 3 6 5 M70
0.3O
11 M86 0.3Lg 0.3Gr
JOINT
See Vehicle CONNECTOR
Speed Sensor PHOTO 58 13 21 EM01 PHOTO 63
15 M86
With With
0.3B 0.3Y 0.5Lg ESP ABS

15 EM21 PHOTO 29

0.5Y

21 JE01 0.5O 0.5L 0.5P

25 JE02
ENGINE
COMPARTMENT
JUNCTION
BLOCK
PHOTO 7
17 83 JC01 11 E41 11 E22
0.5P 0.5P 0.5Br/B

3 C12 53 85 C44 1 M05

VEHICLE PCM ESP ABS DATA LINK
SPEED PHOTO 22 CONTROL CONTROL CONNECTOR
SENSOR MODULE MODULE PHOTO 31
G20 PHOTO 57 PHOTO 21 PHOTO 24 PHOTO 24
STEERING SYSTEM

E2RF057A
EPS (ELECTRONIC POWER STEERING) SYSTEM ST -47

TROUBLESHOOTING E7A90FA2

NOTE
For checking procedures for each problem, refer to
the flow-chart type of troubleshooting guide on the
following page.

Trouble symptom 1
NOTE
Steering effort remains light at
1. Check to be made by using the scan tool or test lamp.
moderate and high speeds
2. Refer to the circuit diagram for terminal numbers at the harness
side of the E.P.S control module.

Does the stationary steering ef-

fort change within the
standard value ?
Standard value : No Repair the steering gear box or
Malfunction of E.P.S. solenoid
E.P.S. replace the E.P.S. solenoid
2.4 N (2.5 kg, 5.1 lbs) Max.

Yes

Is the function of the vehicle No

speed sensor normal? Replace vehicle speed sensor

Yes Repair the connector connection

or repair the harness (Connect
the connector, or repair the harn-
ess between the vehicle speed
sensor and the control module

EPRF502A
ST -48 STEERING SYSTEM

Trouble symptom 2

No flow of solenoid current (large

steering effort required to turn st-
eering wheel fully) when the igni-
tion switch is at the ON position.

Is fuse for control module power NO Harness short-circuit (harness Repair the harness or replace
supply OK? damage, etc.) the fuse.

Yes

Disconnect the connector

of the control module;
check with the ignition
switch at the ON position

Is the voltage approximately 12V

Damaged or disconnected wirin
measured between earth and NO
-g of harness between fuse and Repair the harness
control module harness side con
control module terminal No. 5.
-nector terminal No. 5?

Yes

Disconnect the connector

Disconnect the battery
for the E. P. S. solenoid
negative (-) terminal and
valve within the engine
check
compartment and check.

Is there continuity between contr Is there continuity betweentwo

NO NO Damaged or disconnected wir-
-ol module harness side connec terminals of the connector at
-tor No. 2 and No. 3 ? ing of E.P.S. solenoid valve coil.
the steering wheel?
Yes Yes
Replace the solenoid valve or
repair the connector connection.

Damaged or disconnected wir-

ing of harness between control Repair the harness or connec-
module and E.P.S. solenoid val tor connection.
-ve connector.
SEE NEXT PAGE

EPRF502B
EPS (ELECTRONIC POWER STEERING) SYSTEM ST -49

CONTINUED FROM PREVI-

OUS PAGE

Yes

During the continuity check as

de-scribed above, was approx-
imately 5.7 to 7.7W of resist- No Poor E.P.S. solenoid valve con- Repair the E.P.S. solenoid valve
ance [at 20 C (68 F)] measur- nector contact. connector contact.
ed between terminal No. 2 and
terminal No. 3?

Yes

No Poor control module connector Check the control module con-

contact, or control module ma- nector contact part; or replace
lfunction. the control module.

EPRF502C

Measure
DTC Trouble Condition Disposal
time
C1101 Voltage over IG[V] ＞ 17V 1sec Solenoid control stop 10V ＜ IG[V] ＜ 16V
C1102 Voltage under IG[V] ＞ 8V 1sec Solenoid control stop 10V ＜ IG[V] ＜ 16V
Vehicle speed TPS ＞ 30% over and Vehicle speed :
C1212 60sec Vehicle speed ＞ 5km/h
sensor vehiclespeed 0km/h 80km/h
EEPROM Read/Write fail
C1604 ECU error 1sec Solenoid control stop IGN ON/OFF
andPWM management error

Measure voltage ＞ 1.28A 1sec

Solenoid Solenoid disconnection 1sec

C2230 Solenoid control stop Power ON reset
current error Target voltage-
Measuervoltage ＞ 0.2A 2sec
and IG[V] ＞ 13V
ST -50 STEERING SYSTEM

DTC C1101 BATTERY VOLTAGE HIGH

COMPONENT LOCATION E97277B3

Power steering
oil pump

EPRF602A

GENERAL DESCRIPTION EBF87DB7

EPS CM precisely controls the EPS solenoid’s current, according to the vehicle speed. The value of the controlled current,
according to voltage changes, are minute, and power is provided by IG2. EPS CM does monitor IG2 voltage to monitor
excessive rises and drops in voltage. Current control is limited which prevents, damage to the EPS CM due to over-
voltage, and operation of the EPS CM at low voltage.

DTC DESCRIPTION EA850CB5

Trouble code occurs when high voltage is caused by a fault in the charging system or IG2 power circuit. EPS CM prohibits
solenoid current control by monitoring IG2 battery voltage of EPS CM.

DTC DETECTING CONDITION EEEE98F3

Item Detecting Condition Possible cause

DTC strategy Voltage monitoring

Enable conditions IG key "ON"
Threshold value IG2 ＞ 17V - Open in ground circuit
- Contact resistance in
Diagnosis time 1 sec
connections.
Prohibit solenoid ’s current control ( 0 A ) - Faulty battery voltage
Restoration condition : 10V ＜ IG2(V) ＜ 16V
Fail safe
⇒ When the voltage is restored to normal from over
voltage, restart solenoid’s current control.
EPS (ELECTRONIC POWER STEERING) SYSTEM ST -51

MONITOR SCANTOOL DATA E16E12F3

1. Connect scantool to Data Link Connector(DLC).

2. Start engine and turn the headight and the heatwire on.

3. Monitor the "BATTERY VOLTAGE" parameter on the scantool.

4. Maintaining ENG. RPM at 2,500RPM(idle) over 2 minutes.

■ Specification

IG Key ON ENG. ON
Bat. Voltage Approx. 11.8V~12.5V Approx. 12.5V~14.5V

Fig1 Battery voltage current data (normal) Fig2 Battery voltage signal waveform (normal)

BPCE601B

5. Is parameter within specifications?

YES

⇒ Fault is intermittent and caused either by poor contact in connectors or wiring harness, or it has been repaired
and EPS CM memory is not cleared yet. Thoroughly check all connectors (and connections) for looseness, bending,
corrosion, contamination, deterioration, and/or damage. Repair or replace as necessary and then go to "Verification
of Vehicle Repair" procedure.

NO

⇒ Go to "W/Harness Inspection" procedure.

ST -52 STEERING SYSTEM

TERMINAL AND CONNECTOR INSPECTION EDCEDFBB

1. Many malfunctions in the electrical system are caused by poor harness and terminals. Faults can also be caused by
interference from other electrical systems, and mechanical or chemical damage.

2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination,deterioration, or
damage.

3. Has a problem been found?

YES

⇒ Repair as necessary and then go to "Verification of Vehicle Repair" procedure.

NO

⇒ Go to ""Charging System Inspection"" procedure.

CHARGING SYSTEM INSPECTION EA9BFA1A

1. Engine "ON", headight and heatwire "ON".

2. Measure voltage between terminal (+) and (-) of battery maintaining ENG. RPM at 2,500RPM(idle) over 2 minutes.

■ Specification

IG Key ON ENG. ON
Bat. Voltage Approx. 11.8V~12.5V Approx. 12.5V~14.5V

3. Is the measured voltage within specifications?

YES

⇒ Go to "Power Circuit Inspection" procedure.

NO

⇒ Thoroughly check connectors for looseness,poor connection, bending, corrosion, contamination, deterioration, or
damage from battery to alternator and fault in charging system.
Repair as necessary and then go to "Verification of Vehicle Repair" procedure.
EPS (ELECTRONIC POWER STEERING) SYSTEM ST -53

POWER CIRCUIT INSPECTION EBCF3E95

1. Ignition "OFF".

2. Disconnect EPS CM connector.

3. Engine "ON", headight and heatwire "ON".

4. Measure voltage between terminal "4" of EPS CM harness connector and chassis ground maintaining ENG. RPM at
2,500RPM(idle) over 2 minutes.

■ Specification

IG Key ON ENG. ON
Bat. Voltage Approx. 11.8V~12.5V Approx. 12.5V~14.5V

< N-01 > 1. EPS solenoid "+"

2. EPS solenoid "-"
3. Vehicle speed
4. IG 2
v 4

8
O
3

7
O/B
2

6
L
1

5
G
5. OBD
B BR/B Y
* 6. TPS PWM
8. Ground

BPCE601C

5. Is the measured voltage within specifications?

YES

⇒ Go to "Ground Circuit Inspection" procedure.

NO

⇒Thoroughly check all connectors (and connections) for looseness, bending, corrosion, contamination, deterioration,
and/or damage.
Repair as necessary and then go to "Verification of Vehicle Repair" procedure.
ST -54 STEERING SYSTEM

GROUND CIRCUIT INSPECTION E3BAD232

1. Ignition "OFF".

2. Disconnect EPS CM connector.

3. Measure resistance between terminal "8" of EPS CM harness connector and chassis ground.

■ Specification : Approx. 0 Ω

< N-01 >

1. EPS solenoid "+"
2. EPS solenoid "-"
4
O
3
O/B
2
L
1
G
3. Vehicle speed
4. IG 2
v 8
B
7

*
6
BR/B
5
Y
5. OBD
6. TPS PWM
8. Ground

BPCE601D

4. Is the measured resistance within specifications?

YES

⇒ Substitute with a known-good EPS CM and check for proper operation.

If the problem is corrected,replace EPS CM and then go to "Verification of Vehicle Repair" procedure.

NO

⇒ Check for open or contact resistance in ground harness.

Repair as necessary and then go to "Verification of Vehicle Repair" procedure.

VERIFICATION OF VEHICLE REPAIR ED1D3D48

After a repair, it is essential to verify that the fault has been corrected.

1. Connect scantool and select "Diagnostic Trouble Codes(DTCs)" mode.

2. Using a scantool, Clear DTC.

3. Operate the vehicle within DTC Enable conditions in General information.

4. Are any DTCs present ?

YES

⇒ Go to the applicable troubleshooting procedure.

NO

⇒ System performing to specification at this time.

EPS (ELECTRONIC POWER STEERING) SYSTEM ST -55

DTC C1102 BATTERY VOLTAGE LOW

COMPONENT LOCATION EFA63D86

Refer to DTC C1101

GENERAL DESCRIPTION EE97FC3D

Refer to DTC C1101

DTC DESCRIPTION E02BBE82

Refer to DTC C1101

DTC DETECTING CONDITION ECF85A0B

Item Detecting Condition Possible cause

DTC strategy Voltage check

- Open/short in power.
Enable conditions IG key "ON" - Contact resistance in
connections.
Threshold value IG2 ＜ 8V - Poor contact of fail-safe
Diagnosis time 1 sec relay.
- Faulty charging system.
Prohibit current control of EPS solenoid ( 0 A )
- Low idle rpm.
Restoration condition : 10V ＜ IG2(V) ＜ 16V
Fail safe - Loose alternator belt
⇒ When the voltage is restored to normal from low
tension.
voltage, restart solenoid’s current control "

MONITOR SCANTOOL DATA E17D2FAC

Refer to DTC C1101

TERMINAL AND CONNECTOR INSPECTION EA41C87A

1. Many malfunctions in the electrical system are caused by poor harness and terminals.
Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage.

2. Thoroughly check all connectors (and connections) for looseness, bending, corrosion, contamination, deterioration,
and/or damage.

3. Has a problem been found?

YES

⇒ Repair as necessary and then go to "Verification of Vehicle Repair" procedure.

NO

⇒ Go to "Charging System Inspection" procedure.

ST -56 STEERING SYSTEM

CHARGING SYSTEM INSPECTION EA3B2FDC

1. Engine "ON", headight and heatwire "ON".

2. Measure voltage between terminal (+) and (-) of battery maintaining ENG. RPM at 2,500RPM(idle) over 2 minutes.

■ Specification

IG Key ON ENG. ON
Bat. Voltage Approx. 11.8V~12.5V Approx. 12.5V~14.5V

3. Is the measured voltage within specifications?

YES

⇒ Go to "Power Circuit Inspection" procedure.

NO

⇒ Check for fault in charging system and check for tension of alternator drive belt, ENG.idle rpm or open/short in
harness from battery to alternator.
Repair as necessary and then go to "Verification of Vehicle Repair" procedure.

POWER CIRCUIT INSPECTION EEAA20E1

1. Ignition "OFF".

2. Disconnect EPS CM connector.

3. Engine "ON", headight and heatwire "ON".

4. Measure voltage between terminal "4" of EPS CM harness connector and chassis ground maintaining ENG. RPM at
2,500RPM(idle) over 2 minutes.

■ Specification

IG Key ON ENG. ON
Bat. Voltage Approx. 11.8V~12.5V Approx. 12.5V~14.5V

< N-01 > 1. EPS solenoid "+"

2. EPS solenoid "-"
3. Vehicle speed
4. IG 2
v 4

8
O
3

7
O/B
2

6
L
1

5
G
5. OBD
B BR/B Y
* 6. TPS PWM
8. Ground

BPCE601C
EPS (ELECTRONIC POWER STEERING) SYSTEM ST -57

5. Is the measured voltage within specifications?

YES

⇒ Substitute with a known-good EPS CM and check for proper operation.

If the problem is corrected, replace EPS CM and then go to "Verification of Vehicle Repair" procedure.

NO

⇒ Check for open/short to ground in power harness.

Repair as necessary and then go to "Verification of Vehicle Repair" procedure.
ST -58 STEERING SYSTEM

DTC C1212 VEHICLE SPEED SENSOR

COMPONENT LOCATION E2E0C30B

Heat protector

EPRF602E

GENERAL DESCRIPTION ED23CCD1

Speed sensor is a sensor which applies a principal of Hall-effect and is located at speedmeter driven gear of transaxle.
If output shaft of transaxle rotates, the rotation of Rotor which has 4 teeth inside the sensor generate a hall effect and
outputs the digital pulse. EPS CM detects vehicle speed based on digital pulse signal and controls amount of current t of
solenoid valve which controls driving force of steering wheel.

DTC DESCRIPTION EA61B55B

Trouble code occurs when a faulty circuit related to the sensor is detected or when an open/short is detected in the speed
sensor circuit. EPS CM detect trouble code and sets solenoid current values according to corresponding 80kph(48mph)
values, to reserve driving stability.

DTC DETECTING CONDITION E6F1FDC2

Item Detecting Condition Possible cause

DTC strategy Signal check

- Open/short in power
Enable conditions IG key "ON" circuit
- Open/short in signal
Threshold value TPS PWM ＞ 30% vehicle speed ＜ 0 kph(0mph) circuit
Diagnosis time 60 sec - Open in ground circuit
- Contact resistance in
Fixing solenoid current value corresponding
connections.
to 80kph(48mph)
Fail safe - Faulty circuit to use VSS
Restoration : Normal vehicle speed 5kph(0.8mph)
- Faulty sensor
of input for 1sec
EPS (ELECTRONIC POWER STEERING) SYSTEM ST -59

SIGNAL WAVEFORM E08D60EC

Fig1 Driving (Vehicle speed sensor output) Fig2 TPS PWM (idle) Fig3 TPS PWM (acceleration)

Fig1) Driving : Vehicle speed sensor output 8.0~12.5V(HIGH SIGNAL) or 0.2~0.5V(LOW SIGNAL), as the vehicle
moves, the 50% of digital duty wave is ouput. ( As vehicle speed increase, Hz increase)
Fig2) Engine RPM signal at idle (TPS PWM duty 10%)
Fig3) Engine RPM signal at acceleration (TPS PWM duty 45%)

BPCE603B

MONITOR SCANTOOL DATA E62D0229

1. Connect scantool to Data Link Connector(DLC).

2. Start engine and monitor the "VEHICLE SPEED SENSOR" parameter on the scantool.

3. Drive the vehicle approx.80kph(48mph) watching the speedometer on the instrument panel.

■ Specification : [Current data value - speedometer value] ≤ [ ± 10 % ]

Fig1 Sensor current data (normal) Fig2 Sensor current data (abnormal)

BPCE603C
ST -60 STEERING SYSTEM

4. Is parameter within specifications?

YES

⇒ Fault is intermittent and caused either by poor contact in connectors or wiring harness, or it has been repaired
and EPS CM memory is not cleared yet. Thoroughly check all connectors (and connections) for looseness, bending,
corrosion, contamination, deterioration, and/or damage. Repair or replace as necessary and then go to "Verification
of Vehicle Repair" procedure.

NO

⇒ Go to "W/Harness Inspection" procedure.

TERMINAL AND CONNECTOR INSPECTION EAAC1E11

1. Many malfunctions in the electrical system are caused by poor harness and terminals.
Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage.

2. Thoroughly check all connectors (and connections) for looseness, bending, corrosion, contamination, deterioration,
and/or damage.

3. Has a problem been found?

YES

⇒ Repair as necessary and then go to "Verification of Vehicle Repair" procedure.

NO

⇒ Check DTC on engine, A/T and other systems which use VSS.
▶ If DTC is detected DTC only in EPS, go to "Signal Circuit Inspection" procedure.
▶ If DTC is detected DTC in other systems also, remove speedometer driven gear and check damage of gear.
→ If Speedometer driven gear is damaged, change it and then go to "Verification of Vehicle Repair" procedure.
→ If Speedometer driven gear is normal, go to "Power Circuit Inspection" procedure.

POWER CIRCUIT INSPECTION EC9977DA

1. Ignition "OFF".

2. Disconnect vehicle speed sensor connector.

3. Engine "ON".

4. Measure voltage between terminal "1" of vehicle speed sensor harness connector and chassis ground.

■ Specification : Approx. B+
EPS (ELECTRONIC POWER STEERING) SYSTEM ST -61

< N-03 >

2 1
B O
3
1. Power supply
L
2. Sensor Ground
v 3. Sensor signal

BPCE603D

5. Is the measured voltage within specifications?

YES

⇒ Go to "Ground Circuit Inspection" procedure.

NO

⇒ Check for open/short to ground in power harness.

Repair as necessary and then go to "Verification of Vehicle Repair" procedure.

GROUND CIRCUIT INSPECTION EE715553

1. Ignition "OFF".

2. Disconnect vehicle speed sensor connector.

3. Measure resistance between terminal "2" of Vehicle speed sensor harness connector and chassis ground.

■ Specification : Approx. 0 Ω

< N-03 >

2 1
B O
3
1. Power supply
L
2. Sensor Ground
3. Sensor signal

EPRF603E
ST -62 STEERING SYSTEM

4. Is the measured resistance within specifications?

YES

⇒ Go to "Signal Circuit Inspection" procedure.

NO

⇒ Check for open/short to power in ground harness.

Repair as necessary and then go to "Verification of Vehicle Repair" procedure.

SIGNAL CIRCUIT INSPECTION EBDBEE5D

1. Ignition "OFF".

2. Connect Scantool to Data Link Connector(DLC).

3. Start engine and select "SCOPEMETER FUNCTION" on scantool.

4. Drive the vehicle and measure output signal between terminal "3" of EPS CM harness connector and chassis ground.
■ Specification : Refer to ’Signal Waveform’

< N-01 > 1.EPS solenoid (+)

2.EPS solenoid (-)
3.Vehicle speed
4 3 2 1
4.IG 2
O O/B L G
5.OBD
8 7 6 5
B
* BR/B Y 6.TPS PWM
7.Space
8.Ground

BPCE603F

5. Is vehicle speed sensor output signal within specifications?

YES

⇒ Substitute with a known-good EPS CM and check for proper operation.

If the problem is corrected, replace EPS CM and then go to "Verification of Vehicle Repair" procedure.

NO

⇒ Check for open/short to ground in signal circuit and other systems which use VSS.
Repair as necessary and then go to "Verification of Vehicle Repair" procedure.
If a problem hasn’t found, go to "Component Inspection" procedure.
EPS (ELECTRONIC POWER STEERING) SYSTEM ST -63

COMPONENT INSPECTION EFEA3BCD

1. Ignition "OFF".

2. Connect Scantool to Data Link Connector(DLC).

3. Start engine and select "SCOPEMETER FUNCTION" on scantool.

4. Drive the vehicle and measure output signal between terminal "3" of Vehicle speed sensor harness connector and
chasiss ground.

< N-03 >

2 1
B O
3
1. Power supply
L
2. Sensor Ground
3. Sensor signal

BPCE603G

■ Specification : Refer to ’Signal Waveform’

5. Is vehicle speed sensor output signal within specifications?

YES

⇒Thoroughly check all connectors (and connections) for looseness, bending, corrosion, contamination, deterioration,
and/or damage.
Repair or replace as necessary and then go to "Verification of Vehicle Repair" procedure.

NO

⇒ Check vehicle speed sensor for contamination, deterioration, or damage.

Substitute with a known-good vehicle speed sensor and check for proper operation.
If the problem is corrected, replace vehicle speed sensor and then go to "Verification of Vehicle Repair" procedure.
ST -64 STEERING SYSTEM

DTC C1604 ECU HARDWARE ERROR

COMPONENT LOCATION EADC45EC

EPBF500J

GENERAL DESCRIPTION E1F86DC4

EPS has a solenoid valve on power steering gear box, and a EPS CM underneath the audio center facia. EPS CM which
receives signals from VSS (Vehicle Speed Sensor) and TPS controls the oil flow of steering gear box.
EPS CM performs the conventional power steering function in case a failure has occurred in the system.
EPS CM electronically controls the current to the solenoid of by-pass valve by inputting sensor’s signals to control the
hydraulic amount in cylinder chamber and thereby varying the steering effort versus the hydraulic pressure according to
vehicle speed.

DTC DESCRIPTION E1A7C0D3

This DTC is about general error of inside EPS CM. If this DTC is set, check unstable power or excessive surge influx by
faulty power supply and chassis ground.

DTC DETECTING CONDITION EAC60287

Item Detecting Condition Possible cause

DTC strategy Voltage monitoring

Enable conditions IG key "ON"
- Contact resistance in
EEPROM read/write
Threshold value ground circuit.
failPWM managerment error
- Surge in power circuit.
Diagnosis time 1 sec - Faulty EPS CM
Prohibit solenoid current control ( 0 A )
Fail safe
IG2 ON/OFF
EPS (ELECTRONIC POWER STEERING) SYSTEM ST -65

SCHEMATIC DIAGRAM E8DCCF83

EPS [CONNECTION INFORMATION]

N-02 N-01
1 1 5 M70 Connected to Fuction
2 ECU
2 1 N-01 terminal 1 Solenoid(+)
B-01
6 A30
2 N-02 terminal 2 Solenoid(-)
N-03
3 3 7 3 N-03 terminal 3 Vehicle speed
2 4 IG SWITCH Power(IG2)
1 4 8
5 - DTC
IG2 6 B-01 terminal A30 TPS
8 - Ground

N-01 N-02 N-03

2 1
4 3 2 1
O L G B O
O/B 2 1
L G 3
8 7 6 5 L
B BR/B Y
*

BPCE604B

MONITOR SCANTOOL DATA E5C9C4C4

1. Ignition "OFF" and connect scantool to Data Link Connector(DLC).

2. Ignition "ON" Engine "OFF".

3. Select "DIAGNOSTIC TROUBLE CODES" mode and monitor "Diagnostic Trouble Code".

4. Clear DTC and drive the vehicle within DTC Enable conditions in General Information.

BPCE604C
ST -66 STEERING SYSTEM

5. Is "C1604" present ?

YES

⇒ Fault is intermittent and caused either by poor contact in connectors or wiring harness, or it has been repaired
and EPS CM memory is not cleared yet. Thoroughly check all connectors (and connections) for looseness, bending,
corrosion, contamination, deterioration, and/or damage.
Repair or replace as necessary and then go to "Verification of Vehicle Repair" procedure.

NO

⇒ Go to "W/Harness Inspection" procedure.

TERMINAL AND CONNECTOR INSPECTION E4AFFCBF

1. Many malfunctions in the electrical system are caused by poor harness and terminals.
Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage.

2. Thoroughly check all connectors (and connections) for looseness, bending, corrosion, contamination, deterioration,
and/or damage.

3. Has a problem been found?

YES

⇒ Repair as necessary and then go to "Verification of Vehicle Repair" procedure.

NO

⇒ Go to "Power Circuit Inspection" procedure.

POWER CIRCUIT INSPECTION EFB0DC3F

1. Ignition "OFF".

2. Connect Scantool to Data Link Connector(DLC) and start engine.

3. Select "SCOPEMETER FUNCTION" on scantool and accelerate engine.

4. Measure output signal between terminal "4"of EPS CM harness connector and chassis ground with switching
(A/C,headlight etc.).

■ Specification : Surge always must not happen when turn IG key ON, OFF with turn the electricity device ON, OFF.
EPS (ELECTRONIC POWER STEERING) SYSTEM ST -67

< N-01 > 1. EPS solenoid "+"

2. EPS solenoid "-"
3. Vehicle speed
4
O
3
O/B
2
L
1
G
4. IG 2
8
B
7 6
BR/B
5
Y
5. OBD
* 6. TPS PWM
8. Ground

BPCE604E

5. Is the resistance measured within specifications?

YES

⇒Go to "Ground in power harness" procedure.

NO

⇒ Check for contact resistance in connections or open in power harness.

Repair as necessary and then go to "Verification of Vehicle Repair" procedure.

GROUND CIRCUIT INSPECTION E165624A

1.CHECK FOR OPEN IN GROUND HARNESS

1. Ignition "OFF".

2. Disconnect EPS CM connector.

3. Measure resistance between terminal "8" of EPS CM harness connector and chassis ground.

■ Specification : Approx. 0 Ω

< N-01 >

1. EPS solenoid "+"
2. EPS solenoid "-"
4
O
3
O/B
2
L
1
G
3. Vehicle speed
8 7 6 5 4. IG 2
B BR/B Y
* 5. OBD
6. TPS PWM
8. Ground

BPCE604F
ST -68 STEERING SYSTEM

4. Is the resistance measured within specifications?

YES

⇒ Go to "Check for earthing in ground harness" as below.

NO

⇒ Check for open or contact resistance in ground harness.

Repair as necessary and then go to "Verification of Vehicle Repair" procedure.
2.CHECK FOR EARTHING IN GROUND HARNESS

1. Ignition "OFF".

2. Connect Scantool to Data Link Connector(DLC) and start engine.

3. Select "SCOPEMETER FUNCTION" on scantool and accelerate engine.

4. Measure output signal between terminal "8" of EPS CM harness connector and chassis ground with switching
(A/C,headlight etc.).

■ Specification : Surge always must not happen when turn IG key ON, OFF with turn the electricity device ON, OFF.

< N-01 >

1. EPS solenoid "+"
2. EPS solenoid "-"
4
O
3 2 1 3. Vehicle speed
O/B L G
8 7 6 5 4. IG 2
B BR/B Y
* 5. OBD
6. TPS PWM
8. Ground

BPCE604H

5. Is the output signal within specifications?

YES

⇒ Go to "Component Inspection " procedure.

NO

⇒ Check for open or poor earthing in ground harness.

Repair as necessary and then go to "Verification of Vehicle Repair" procedure.
EPS (ELECTRONIC POWER STEERING) SYSTEM ST -69

COMPONENT INSPECTION EAF9F5FA

1. Connect scantool and select "Diagnostic Trouble Codes(DTCs)" mode.

2. Clear DTC.

3. Drive the vehicle within DTC Enable conditions in General information.

4. Are any DTCs present ?

YES

⇒ Check EPS CM for damage or sticking by the naked eye. Substitute with a known-good EPS CM and check for
proper operation.
If the problem is corrected, replace EPS CM and then go to "Verification of vehicle Repair" procedure.

NO

⇒ Substitute with a known-good EPS CM and check for proper operation.

If the problem is corrected, replace EPS CM and then go to "Verification of Vehicle Repair" procedure.
ST -70 STEERING SYSTEM

DTC C2230 SOLENID

COMPONENT LOCATION E5DDAE5D

Power steering
gear box

EPRF602S

GENERAL DESCRIPTION E8C48A9C

EPS CM controls current amounts to the solenoid valve which adjust driving force of steering wheel, based on vehicle
speed information recieved from the vehicle speed sensor. The EPS solenoid maintains proper steering force by adjusting
fluid amounts into the EPS valvebody according to current values.

Solenoid control current Vs Vehicle speed

( Vehicle speed increase, solenoid current value is decreased )

BPCE605B

DTC DESCRIPTION EC1B81DD

If an open/short is detected in the solenoid circuit. or current value is under/over, while EPS CM is monitoring solenoid’s
current, EPS CM sets this trouble and the current value will be controlled "0".
EPS (ELECTRONIC POWER STEERING) SYSTEM ST -71

DTC DETECTING CONDITION EE4A56AC

Item Detecting Condition Possible Cause

DTC Strategy Current check
Enable Conditions IG key "ON"
Threshold Value Diagnostic Time - Open/short in power circuit
1 sec and control circuit
Measuer current ＞ 1.28A
- Contact resistance in
Solenoid open 1 sec connections.
- Faulty solenoid
[target current-measure current] ＞ 0.2A and IG(V) ＞13V 2 sec
Prohibit solenoid ’s current control ( 0 A )
Fail Safe
Restoration condition : Power ON reset

SPECIFICATION EBAC1F6B

Solenoid resistance Frequency Duty

5.7~7.7Ω [at 20℃(68℉)] 125/333 Hz 5~95%

SIGNAL WAVEFORM ED9EF678

Fig1 Idle Fig2 Vehicle speed increase

Fig 1) Normal signal waveform which is the current control at idle (1A).
Fig 2) Signal waveform which is the current decrease by vehicle speed increase.

BPCE605C

MONITOR SCANTOOL DATA EF5A65FC

1. Ignition "OFF" and connect scantool to Data Link Connector(DLC).

2. Ignition "ON" Engine "OFF".

3. Select "DIAGNOSTIC TROUBLE CODES" mode and monitor "Diagnostic Trouble Codes(DTCs)".
ST -72 STEERING SYSTEM

Fig1 Diagnostic Trouble Code (abnormal) Fig2 Sensor current data (abnormal)

BPCE605D

4. Is parameter within specifications?

YES

⇒ Fault is intermittent and caused either by poor contact in connectors or wiring harness, or it has been repaired
and EPS CM memory is not cleared yet. Thoroughly check all connectors (and connections) for looseness, bending,
corrosion, contamination, deterioration, and/or damage.
Repair or replace as necessary and then go to "Verification of Vehicle Repair" procedure.

NO

⇒ Go to "W/Harness Inspection" procedure.

TERMINAL AND CONNECTOR INSPECTION EB026EB9

1. Many malfunctions in the electrical system are caused by poor harness and terminals. Faults can also be caused by
interference from other electrical systems, and mechanical or chemical damage.

2. Thoroughly check all connectors (and connections) for looseness, bending, corrosion, contamination, deterioration,
and/or damage.

3. Has a problem been found?

YES

⇒ Repair as necessary and then go to "Verification of Vehicle Repair" procedure.

NO

⇒ Go to "Power Circuit Inspection" procedure.

EPS (ELECTRONIC POWER STEERING) SYSTEM ST -73

POWER CIRCUIT INSPECTION E2A9DBA7

1. Ignition "OFF".

2. Disconnect solenoid connector.

3. Engine "ON".

4. Measure voltage between terminal "1" of solenoid harness connector and chassis ground.

■ Specification : Approx. B+

< N-02 >

2 1
L G

1.Solenoid (+)
2.Solenoid (-)

BPCE605E

5. Is the voltage measured within specifications?

YES

⇒ Go to "Control Circuit Inspection" procedure.

NO

⇒ Measure voltage between terminal "1" of EPS CM harness connector and chassis ground in above condition.

■ Specification : Approx. B+

< N-01 > 1. EPS solenoid "+"

2. EPS solenoid "-"
3. Vehicle speed
4

8
O
3

7
O/B
2

6
L
1

5
G
v 4. IG 2
B BR/B Y 5. OBD
*
6. TPS PWM
8. Ground

BPCE605F

▶ If it is normal, Check for open/short to ground or control harness in power harness. Repair as necessary and then
go to "Verification of Vehicle Repair" procedure.
ST -74 STEERING SYSTEM

▶ If it is abnormal, substitute with a known-good EPS CM and check for proper operation. If the problem is corrected,
replace EPS CM and then go to "Verification of Vehicle Repair" procedure.

CONTROL CIRCUIT INSPECTION EC16C8C9

1. Ignition "OFF".

2. Disconnect solenoid connector and EPS CM connector.

3. Measure resistance between terminal "2"of solenoid harness connector and terminal "2" of EPS CM harness con-
nector.

■ Specification : Approx. 0 Ω

< N-01 > < N-02 >

4 3 2 1 2 1
O O/B L G L G
8 7 6 5
B BR/B Y
*
1.EPS solenoid (+) 5.OBD 1.Solenoid (+)
2.EPS solenoid (-) 6.TPS PWM 2.Solenoid (-)
3.Vehicle speed 7.Space
4.IG 2 8.Ground

BPCE605G

4. Is the measured resistance within specifications?

YES

⇒ Check for short to ground in control harness.

▶ If it is normal, go to "Component Inspection" procedure.
▶ If it is abnormal, repair as necessary and then go to "Verification of Vehicle Repair" procedure.

NO

⇒ Check for open/short to ground in control harness.

Repair as necessary and then go to "Verification of Vehicle Repair" procedure.

COMPONENT INSPECTION E5D9BAB3

CHECK EPS SOLENOID

1. Ignition "OFF".

2. Disconnect EPS solenoid connector.

3. Measure resistance between terminal "2" and terminal "1" of solenoid harness connector(To sensor side).

■ Specification : 5.7~7.7Ω [at 20℃(68℉)]

EPS (ELECTRONIC POWER STEERING) SYSTEM ST -75

< N-02 >

2 1
L G
1.Solenoid (+)
2.Solenoid (-)

BPCE605H

4. Is the measured resistance within specifications?

YES

1) Ignition "OFF".

2) Connect Scantool to Data Link Connector(DLC) and then Engine "ON ".

3) Select "SCOPEMETER FUNCTION" on scantool.

4) Measure output signal between terminal "1" of EPS solenoid harness connector and chassis ground.

■ Specification : Refer to ’Signal Waveform’

⇒ If it is normal, substitute with a known-good EPS CM and check for proper operation.
If the problem is corrected, replace EPS CM and then go to ""Verification of Vehicle Repair"" procedure.
⇒ If it is abnormal, check EPS solenoid for contamination, deterioration, or damage.
Substitute with a known-good EPS solenoid and check for proper operation.
If the problem is corrected, replace EPS solenoid and then go to "Verification of Vehicle Repair" procedure.

< N-02 >

2 1 1.Solenoid (+)
L G
2.Solenoid (-)

BPCE605I

NO

⇒ Check EPS solenoid for contamination, deterioration, or damage.

Substitute with a known-good EPS solenoid and check for proper operation.
If the problem is corrected, replace EPS solenoid and then go to "Verification of Vehicle Repair" procedure.