General Information

SPECIFICATIONS
Items Specifications
Steering wheel diameter (Outer) 386mm
Power steering gear box
Steering gear type Rack and pinion
Steering gear ratio ∞
Rack stroke 81mm x 2
Oil pump
Oil pump type Vane type
Displacement 9.6 cc/rev

SERVICE SPECIFICATIONS
Items Specifications
Steering wheel free play mm 30
Steering gear angle
Inner wheel 37.15° ± 2°

Outer wheel 32.05° ± 2°

Stationary steering effort kg (lbs) 3.3 (7.3)
Drive belt tension mm (in) 6-7 (0.236-0.275)
Oil pump pressure kg/cm² (psi)
Gauge hose valve closed-General 89-95 (1,265-1,351)
Gauge hose valve closed-EPS 79-85 (1,123-1,208)
Gauge hose valve opened 4-6 (56-85)
Power steering oil liter PSF-3 (0.85-0.9)
SPECIAL SERVICE TOOLS
Tool (Number and name) Illustration Use
Valve stem oil seal installer Installation of the pinion gear bearing
(09222 - 21100)

Front oil seal installer Installation of the pinion gear oil seal
(09431 - 11000)

Bearing installer Installation of the pinion gear bearing

(09432 - 21601)

Oil pressure gauge Measurement of the oil pump pressure

(09572-21000)

Power steering oil pressure

gauge adapter (Pump side)
(09572-33100)

Power steering oil pressure

gauge adapter (Hose side)
(09572-21200)
 Tool (Number and name) Illustration Use
Yoke plug torque wrench so- Removal, installation and adjustment of steeri-
cket ng gear yoke plug
(09565 - 31300)

Ball joint remover Separation of the tie rod end ball joint
(0K670 - 321 - 019)
TROUBLESHOOTING
Symptom Probable cause Remedy
Steering wheel return malfunction Incorrect tire pressure Adjust the tire pressure
Steering operation is "hard" Incorrect tire pressure Adjust the tire pressure
Loose belt Adjust the belt tension
Damaged belt Replace the belt
Low fluid level Refill fluid
Air in fluid line Bleed the system
Steering wheel pulls to one side Twisted hose Correct the hose routing or replace the
hoses
Incorrect mounting of the steering gear Retighten
box on the crossmember
Fluid leakage Check the fluid leakage and retighten or
replace
Incorrect wheel alignment (especially ca- Adjust the wheel alignment
ster)
Malfunction of gear box Check and replace the gear box if neces-
sary
Malfunction of oil pump Check the oil pump pressure and repair
oil pump
Excessive steering wheel play Adjust the steering wheel play
Insufficient tire inflation pressure Adjust the tire pressure
Unevenly worn or deformed tire Rotate the wheel or replace the tire
Dragging brake Adjust
Deteriorated or broken front spring Replace
Deformed knuckle arm Replace
Poor wheel alignment Adjust the wheel alignment
Damaged wheel bearing Replace
Deformed or loose lower arm Retighten or replace
Loose linkage joints Retighten
Malfunction of ball joints (Too small ball j Replace
oint starting torque)
Deteriorated or broken lower arm bushin- Replace
g
Incorrect installation or internal damage Correct or replace
in gear
Malfunction of shock absorber Replace
 Symptom Probable cause Remedy
Steering wheel vibrates Insufficient tire inflation pressure Adjust the tire pressure
Unevenly worn or deformed tire(s) Rotate the wheels or replace the tire(s)
Loose hub nut Retighten
Excessive runout, or unbalance of tire a- Adjust the wheel balance or replace
nd wheel
Poor wheel alignment Adjust the wheel alignment
Damaged wheel bearing Replace
Deformed or loose lower arm Retighten or replace
Deformed linkage Repair or replace
Loose linkage joints Retighten
Malfunction of ball joints (Too small ball j Replace
oint starting torque)
Malfunction of front suspension Check and adjust; replace the parts if ne-
cessary
Incorrect installation or internal damage Correct or replace
in gear box
Malfunctioning of shock absorber Replace
Road shock is felt in steering whe- Insufficient steering wheel play Adjust the steering wheel play
el
Insufficient tire inflation pressure Adjust the tire pressure
Unevenly worn or deformed tire(s) Rotate the wheels or replace the tire(s)
Malfunction of shock absorber Replace
Poor recovery of steering wheel to Insufficient tire inflation pressure Adjust the tire pressure
straight ahead position
Stuck or damaged ball joint Replace
Improper wheel alignment angles Adjust the wheel alignment
Rattling noise Loose installation of oil pump or gear bo- Retighten the oil pump and gear box
x
Steering linkage looseness or play Retighten or replace the steering linkage
Loose oil pump pulley nut Retighten the oil pump pulley nut
Interference around column or between Correct or replace the pressure hose an-
pressure hose and other parts d the parts around the column
Abnormal noise inside the gear box and Replace the gear box or oil pump
oil pump
Strident noise Air sucked into oil pump Check the oil level and hose clips; bleed
the system or replace the oil pump
Seizure inside oil pump Replace the oil pump
Squealing noise 1) Loose belt Adjust the belt tension
Seizure inside oil pump Replace the oil pump
 Symptom Probable cause Remedy
Hissing noise Air sucked into oil pump Check the oil level and hose clips; bleed
the system
Damage to the gear box port section Replace the gear box
Malfunction of return hose Replace the hose
Whistling noise Malfunction of gear box port section Replace the gear box
Droning noise Loose mounting bolt on oil pump or oil p- Retighten the pump bracket and pump i-
ump bracket nstalling bolt
Poor condition of oil pump body 2) Replace the oil pump
Squealing noise 2) Malfunction of steering stopper contact Check and adjust the steering stopper
Interference of wheel with vehicle body Adjust the steering angle
Interference of steering shaft and joint a- Reposition the interfering parts
ssembly with other parts
Malfunction of gear box Replace the gear box
Shuddering vibration 3) Air suction Bleed the system
Malfunction of gear box Replace the gear box
Oil leakage from hose connection Improperly tightened flare nut Check, repair or replace
Incorrectly inserted hose
Improperly clamped hose
Oil leakage from hose assembly Damaged or clogged hose Replace
Hose connector malfunction
Oil leakage from oil reservoir Leaking reservoir Replace
Overflow Bleed the system or adjust the oil level
Oil leakage from oil pump Malfunction of oil pump housing Replace the oil pump
Malfunction of O-ring and/or oil seal Replace the O-ring and oil seal
Oil leakage from gear box Malfunction of gear box housing (includi- Replace the gear box
ng leakage from air hole)
Malfunction of O-ring and/or oil seal Replace the O-ring and oil seal

NOTICE or asphalt surface. A very slight amount of vibration

1. A squealing noise may be heard just after very cold is not a malfunction.
engine start (-20°C or less), caused by fluid
characteristics at extreme low temperatures. This is
not a malfunction.
2. A slight "beat noise" is produced by the oil pump;
this is not a malfunction. (This noise occurs
particularly when a stationary steering effort is
made.)
3. A slight vibration may be felt when a stationary
steering effort is made due to the condition of the
road surface. To check whether the vibration actually
exists or not, test-drive the vehicle on a dry concrete
DTC LIST (EPS)
DTC PROBABLE CAUSE REMEDY
C1001 EPS ECU failure Replace EPS ECU
Solenoid short to ground Check connection condition of solenoid or harness
C1017 Solenoid short to battery Check connection condition of solenoid or harness
Solenoid short or open Check or replace solenoid
C1012 Vehicle acceleration or deceleration excess Check vehicle sensor
C1011 Battery voltage under 10V Check battery voltage or charge
C1014 Lamp short or open circuit Check lamp short or open circuit
SERVICE ADJUSTMENT PROCEDURES STATIONARY STEERING EFFORT CHECK
STEERING WHEEL FREE PLAY CHECK (POWER STEERING)
1. With the engine stationary and the steering wheel in 1. Place the vehicle on a level surface and place the
the straight-ahead position, apply a force of 0.5 kg steering wheel in the straight-ahead position.
(1.1 lbs.) to the steering wheel in the peripheral 2. Set the engine speed to 1,000 rpm.
direction. 3. Measure the tangential force with a spring balance by
Standard value : 30 mm or less turning the steering wheel clockwise and
counterclockwise one and a half turns.
Standard value : 3.3 kg (7.31 lbs) or less
4. If the stationary steering effort exceeds the standard
value, check for belt slackness, damage, insufficient
oil, air mixed into oil, collapsed or twisted hoses, etc.,
and repair if found.

APAC006A

2. If the measured value exceeds the standard value.

Inspect contact of the steering shaft and tie rod ball
joints.
STEERING ANGLE CHECK
1. Place the front wheel on a turning radius gauge and
measure the steering angle.
LPAC006C
STANDARD VALUE
CHECKING OF THE STEERING WHEEL RETURN
Inner wheel 37.15° ± 2° TO CENTER (POWER STEERING)
Outer wheel 32.05° ± 2° To check for the return of steering wheel to Center, carry
out drive test and check the following points.
1. Make gentle and sharp turns and check to get a feel
for that there is no appreciable difference in steering
effort and return to Center between right and left
turns.
2. Drive at a speed of about 35 km/h turn the steering
wheel 90° clockwise or counterclockwise, and release
the wheel a second or two later, if the wheel returns
more than 70°, the return may be considered good.
NOTICE
APAC006B When the steering wheel is turned abruptly,
1. If the measured value is not within the standard momentary hard steering might result, but this does
value, adjust the toe-in and inspect again. not mean any problem. It is caused by low oil pump
delivery during idling.
NOTICE
After adjusting the tie rod, assemble the bellows so
they are not twisted.
FLUID LEVEL CHECK (POWER STEERING) FLUID REPLACEMENT (POWER STEERING)
1. Park the vehicle on a flat, level surface, start the 1. Raise the front wheels on a jack, and then support
engine, and then turn the steering wheel several them with rigid racks.
times to raise the temperature of the fluid to 2. Disconnect the return hose connection.
approximately 50° - 60° C.
3. Connect a vinyl hose to the return hose, and drain
the oil into a container.
4. On vehicles with a patrol engine, disconnect the high
tension cable. On vehicles with a diesel engine,
remove the fuel cut valve connector attached to the
injection pump.
While operating the starter motor intermittently, turn
the steering wheel all the way to the left and right
several times to drain all of the fluid.
5. Connect the return hoses securely, and then secure it
APAC006E with the clip.
2. With the engine running, turn the wheel all the way to 6. Fill the oil reservoir with the specified fluid up to the
the left and right several times. lower position of the filter, and then bleed the air.
3. Check the fluid in the oil reservoir for foaming or Specified fluid : PSF-3
milkiness.
BLEEDING
4. Check the difference of the fluid level when the 1. Jack up the front wheels and support them by using a
engine is stopped, and while it is running. If the fluid rigid rack.
level changes considerably, air bleeding should be
2. Manually turn the oil pump pulley a few times.
done.
3. Turn the steering wheel all the way to the left and to
the right five or six times.
4. On vehicles with a patrol engine, disconnect the high
tension cable. On vehicles with a diesel engine,
remove the fuel cut valve connector attached to the
injection pump.
While operating the starter motor intermittently, turn
the steering wheel all the way to the left and right five
or six times (for 15 to 20 seconds).
CAUTION
LPAC006D
• During air bleeding, replenish the fluid supply
so that the level never falls below the lower
position of the filter.
• If air bleeding is done while engine is
running, the air will be broken up and
absorbed into the fluid; be sure to do the
bleeding only while cranking.
5. On vehicles with a patrol engine, connect the ignition
cable. On vehicles with a diesel engine, connect the
fuel cut valve connector attached to the injection
pump. Start the engine (idling).
6. Turn the steering wheel to the left and right until there
are no air bubbles in the oil reservoir.
7. Confirm that the fluid is not milky, and that the level is
up to the specified position on the level gauge.
8. Confirm that there is very little change in the fluid OIL PUMP PRESSURE TEST CHECKING
level when the steering wheel is turned left and right. THE OIL PUMP RELIEF PRESSURE
9. Check whether or not the change in the fluid level is 1. Disconnect the pressure hose from the oil pump, and
within 5 mm (0.20 in.) when the engine is stopped then connect the special tools.
and when it is running.
2. Bleed the air, and then turn the steering wheel
several times while the vehicle is not moving so that
the temperature of the fluid rises to approximately
50-60° C (122-140° F).
3. Start the engine and idle it at 1,000 ± 100 rpm.
4. Fully close the shut-off valve of the pressure gauge
and measure the oil pump relief pressure to confirm
that it is within the standard value range.
Standard value : 89 - 95 kg/cm²(1,265 - 1,351 psi)

LPAC007A

CAUTION
• If the change of the fluid level is 5 mm (0.20
in.) or more, the air has not been completely
bled from the system, and thus must be bled
completely.
• If the fluid level rises suddenly after the
engine is stopped, the air has not been
completely bled.
• If air bleeding is not complete, there will be
abnormal noises from the pump and the
flow-control valve, and this condition could
cause a lessening of the life of the pump, etc.

LPAC008A

CAUTION
Pressure gauge shut off valve must not remain
closed for more than 10 seconds.
5. If it is not within the standard value, replace the oil
pump.
6. Remove the special tools, and then tighten the
pressure hose to the specified torque.
Tightening torque :
55-65 N·m (5.5- 6.5 kg-m, 39 - 47 lb-ft)
7. Bleed the system.
CHECKING THE PRESSURE UNDER NO-LOAD CHECKING POWER STEERING BELT
CONDITIONS TENSION
1. Disconnect the pressure hose from the oil pump, and 1. Press the V-belt, applying a pressure of 98 N (10 kg,
then connect the special tools. 22 lb) at the specified point, and measure the
2. Bleed the air, and then turn the steering wheel deflection to confirm that it is within the standard
several times while the vehicle is not moving so that value range.
the temperature of the fluid raise to approximately V-belt deflection [Standard value]
50-60° C (122-140° F). 6-7 mm (0.236 - 0.275 in.)
3. Start the engine and idle it at 1,000 ± 100 rpm.
4. Check whether or not the hydraulic pressure is the
standard value when no-load conditions are created
by fully opening the shut-off valve of the pressure
gauge.
Standard value : 4 - 6 kg/cm² (56 - 85 psi)

LPAC009A

LPAC008B LPAC009C

5. If it is not within the standard value, the probable 2. Install the belt. Loosen the adjusting bolt A or flange
cause is a malfunction of the oil line or steering gear nut and then adjust the tension of the belt with
box, so check these parts and repair as necessary. adjusting bolt B.
6. Remove the special tools, and then tighten the After that, tighten the adjusting bolt or flange nut to
pressure hose to the specified torque. the specified value.
7. Bleed the system. NOTICE
• When adjusting tension of the belt, tighten the
adjusting bolt and flange nut temporarily so that
the pulley does not lean to one side, then adjust
the tension.
 LPAC009B

LPAC009D

NOTICE
• It is not necessary in case of 2.5D engine to
adjust belt tension. (Refer to EM Group).
Steering Column & Shaft
Steering Column-Shaft
Components
 LPAC010A

Removal 4. After aligning the marks on the steering shaft and

1. Disconnect the negative (-) terminal from the battery. wheel, remove the steering wheel.
CAUTION
Do not hammer on the steering wheel to remove
it; it may damage the steering column.
5. After removing the three screws in the illustration,
remove the steering column upper and lower
shrouds.

LPAC005C

2. After removing the two hexagon-bolts in the

illustration, remove the driver' s airbag module.
APAC011E

6. After removing the screws in the illustration, remove

the clock spring.

APAC011B

3. Remove the steering wheel lock nut.

APAC011Z

7. Remove the connectors from the multifunction switch

and the multifunction switch.

APAC011C
 APAC011F

8. Remove the lower crash pad.

APAC011H
APAC011I
9. Remove the bolt connecting the steering column
shaft assembly with the intermediate upper shaft, and 12.Remove the bolt tightening the intermediate upper
then separate them apart. shaft and intermediate lower shaft, and then separate
them apart.
13.After removing the bolt connecting the steering gear
box with the intermediate lower shaft, separate the
intermediate lower shaft from the gear box.

APAC011J

10.After removing the four mounting bolts, remove the

APAC011M
steering column shaft assembly.
CAUTION
Keep the neutral-range to prevent the damage of
the clock spring inner cable when you handlethe
steering wheel.
Inspection
1. Check the steering column shaft for damage and
deformation.
2. Check the connections for play, damage and smooth
operation.
3. Check the ball joint bearing for wear and damage.
APAC011K

11.Remove the four mounting bolts in the dust cover

assembly.
Assembly
Assembly is the reverse of removal.
Disassembly and reassembly
1. If it is necessary to remove the key lock assembly,
use a pinch to make a groove on the head of the
special bolt, and then use a screwdriver to remove
the key lock assembly mounting bracket.

APAC013A

2. Disassemble the key lock assembly from the steering

column shaft.

APAC013B

3. Reassembly is the reverse of disassembly.

Hydraulic Power Steering System
Power Steering Gear Box
POWER STEERING GEAR BOX
COMPONENTS
 LPAC014A

REMOVAL 5. Remove the steering gear box mounting bolts and

1. Drain the power steering fluid. remove the steering gear box assembly together with
mounting rubber.
2. Disconnect the pressure tube and return tube.
Tightening torque : CAUTION
32- 48 N·m (3.2 - 4.8 kg-m, 23 - 34 lb-ft) When removing the gear box, pull it out carefully
and slowly to avoid damaging the boot.
Tightening torque :
1) 122 - 158 N·m (12.2 - 15.8 kg-m, 88 - 114 lb-ft)
2) 75 - 95 N·m (7.5 - 9.5 kg-m, 54 - 68 lb-ft)

APAC015E

3. Remove the joint assembly connecting bolt.

LHAC010D

DISASSEMBLY
1. Remove the feed tube.

APAC011M

CAUTION
Keep the neutral-range to prevent the damage of
the clock spring inner cable when you handlethe
steering wheel.
APAC015C
4. Using the special tool (0K670-321-019), disconnect
the tie rod end from the knuckle arm. 2. Remove the tie rod end from the tie rod.

Tightening torque :
70 - 80 N·m (7.0 - 8.0 kg-m, 50 - 57 lb-ft)

APAC016A

3. Remove the dust cover from the ball joint.

APAC015B
 APAC016B APAC016E

4. Remove the bellows band. 9. Remove the tie rod from the rack.
CAUTION
Remove the tie rod from the rack, taking care not
to twist the rack.

APAC016C

5. Remove the bellows clip. Pull the bellows out toward

the tie rod.
NOTICE APAC016F

Check for rust on the rack when the bellows are 10.Remove the yoke plug lock nut.
replaced.
6. Remove the feed tube from the rack housing.

APAC016G

11.Using the special tool (09565-31300), remove the

APAC016D yoke plug.
7. While moving the rack slowly, drain the fluid from the
rack housing.
8. Unstake the tab washer which fixes the tie rod and
rack with a chisel.
 APAC016H

12.Remove the rack support spring, yoke support and

bushing from the gear box.

LPAC016L

19.When the end of the circlip comes out from the

notched hole of the housing rack cylinder, turn the
LPAC016I rack stopper counter clockwise and remove the
13.Remove the end plug and self-locking nut. circlip.
CAUTION
Do not damage the rack when disassembling.

APAC016J

14.Detach the dust seal.

LPAC016M
15.Remove the snap ring with snap ring pliers.
16.Remove bolts mounting the valve assembly to the 20.Remove the rack stopper, rack bushing and rack from
rack housing. the rack housing by moving it toward the piston side.

17.Remove the pinion and valve assembly together with CAUTION

the oil seal (upper) using a soft hammer. When the rack has been removed, be sure to
replace the housing side oil seal with a new one.

APAC016K
APAC016N
18.Turn the rack stopper clockwise until the end of the
circlip comes out of the slot in the gear housing. 21.Remove the O-ring from the rack bushing.
 APAC016O APAC017A

22.Remove the oil seal from the rack bushing. 3. Bearing

1) Check for seizure or abnormal noise during
bearing rotation
2) Check for excessive play
3) Check for missing needle bearing rollers
4. Others
1) Check for damage of the rack housing cylinder
bore
2) Check for boot damage, cracking or ageing
ASSEMBLY
APAC016P
1. Apply the specified fluid to the entire surface of the oil
INSPECTION seal.
1. Rack Recommended fluid : Power steering fluid (PSF-3)
1) Check for rack tooth face damage or wear
2. Using the special tool (09431-11000), install the oil
2) Check for oil seal contact surface damage or seal to the specified position in the rack housing.
wear
CAUTION
3) Check for bending or twisting of rack
1. Note the direction of the oil seal.
4) Check for oil seal ring damage or wear
2. Use a new oil seal.
5) Check for oil seal damage or wear

LPAC018A
APAC017B
3. Apply the specified fluid to the entire surface of the
2. Pinion valve rack bushing oil seal.
1) Check for pinion gear tooth face damage or wear
Recommended fluid : Power steering fluid (PSF-3)
2) Check for oil seal contact surface damage
4. Install the oil seal in the rack bushing.
3) Check for seal ring damage or wear
5. Apply the specified fluid to the entire surface of the
4) Check for oil seal damage or wear
O-ring and install the rack bushing using the special
tool (09431-11000).
 LPAC018B LPAC018E

6. Apply the specified grease to the rack teeth. 9. Apply the specified fluid and grease to the pinion
valve assembly and install the rack housing
CAUTION
assembly.
Do not plug the vent hole in the rack with grease.
Recommended fluid : Power steering fluid (PSF-3)

Recommended grease :
Multipurpose grease SAE J310a, NLGI #2 EP

LPAC018C

7. Insert the rack into the rack housing. Install the rack
bushing and rack stopper.

LPAC018F

10.Install the ball bearing using the special tool

(09222-21100).
11.Install the pinion and valve assembly to the valve
housing.

LPAC018D

8. Push the rack stopper until the circlip groove of the

rack stopper is aligned with the notched hole of the
rack housing and then install the circlip while turning
the rack stopper.
CAUTION
LPAC018G
The circlip end should not be visible through the
notched hole of the rack housing. 12.Install the oil seal using the special tool
(09432-21601).
13.Install the snap ring with snap ring pliers.
 grooves.
2. Use a new tab washer.

LPAC018H

14.With the pinion turned completely clockwise, tighten

the self-locking nut. APAC018L

CAUTION 18.Install the bushing, rack support yoke, rack support

Always replace the self-locking nut with a new spring and yoke plug in the order shown. Apply
one. semi-drying sealant to the threaded section of the
yoke plug before installation.

APAC018I

15.Apply semi-drying sealant to the threaded section of LPAC016I

the end plug and tighten to the specified torque. 19.With the rack placed at the center position, attach the
Tightening torque : yoke plug to the rack housing. Tighten the yoke plug
44 - 55 Nm (4.5 - 5.5kg-m, 32-39 lb-ft) within the range of 20-25 Nm (200-250 kg.cm,
14.5-18 lb.ft), using the special tool. Loosen the yoke
16.Stake the end plug at two points on its circumference plug for approximately 20° and tighten the locking
with a punch. nut to the standard value.
Tightening torque :
50-60 N·m (500-600 kg·cm, 36-43 lb·ft)
20.After adjusting, install the yoke plug with a lock nut.
NOTICE
When it cannot be adjusted within the specified
return angle, check the rack support plug
components or replace.
21.Tighten the feed tube to the specified torque and
install the mounting rubber with adhesive.
APAC018K

17.Install the tab washer and then the tie rod and
hammer the tab washer end at two points lightly to
the tie rod.
CAUTION
1. Align the tab washer pawIs with the rack
 APAC018N LPAC018P

22.Apply the specified grease to the bellows mounting 26.Install the tie rods.
position (fitting groove) of the tie rod. 27.Install the power steering gear box assembly to the
Recommended grease vehicle.
Multipurpose grease SAE J310a, NLGI # EP
23.Install the new attaching band to the bellows.
CAUTION
When the bellows are installed, a new band must
be used.

APAC018O

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

it.
25.Fill the dust cover inner side and lip with the specified
multipurpose grease, and place the dust cover in
position with the clip ring attached in the groove of
the tie rod end.
Recommended grease
Multipurpose grease SAE J310a, NLGI #2 EP
Power Steering Hoses
POWER STEERING HOSES
COMPONENT
 LPAC019A

REMOVAL 2) Loosen the return tube clip mounting bolt.

1. Removal of pressure hose and tube. 3) Remove the return/pressure tube clip mounting
1) Disconnect the pressure hose from the steering bolt.
oil pump. 4) Disconnect the return tube from the steering gear
box, and then disconnect the return hose and the
tube.
3. Removal of suction hose.
1) Disconnect the suction hose from the steering oil
reservoir.
2) Disconnect the suction hose.

APAC020A

2) Loosen the bolt of pressure hose mounting

clamp.
3) Remove the pressure/return tube clip mounting
bolt.
4) Disconnect the pressure tube from the steering
gear box, and then disconnect the pressure hose APAC020B
and the tube. INSTALLATION
CAUTION
• Install the hose lest they should be twisted and
come in contact with any other parts.
• After installation, bleed the air.
INSPECTION
1. Inspect the hose for cracks by twisting it by hand.
2. Check for interference between hose and the other
parts.

LPAC020A

2. Removal of return hose and tube.

1) Disconnect the return hose from the oil reservoir.

LPAC020B
Power Steering Oil Pump
COMPONETS

LPAC022A
REMOVAL INSTALLATION
1. Disconnect the pressure hose from the oil pump, 1. After installing the oil pump to the oil pump bracket.
disconnect the suction hose from the suction pipe, Tightening torque :
and drain the oil. 18 - 23 N·m (1.8 - 2.3 kg-m, 13 - 16 lb-ft)

APAC020A
APAC023C
2. Loosen the power steering tension adjusting bolt or
2. Install the belt and tighten the bolt adjusting tension
flange nut.
to the specified torque.
NOTICE
Refer to EM group in case of 2.5D Engine.

APAC023B

3. Install the suction hose.

APAC023B
CAUTION
3. Separate the belt from the power steering oil pump
Install the pressure hose to the oil pump.
pulley.
4. Install the pressure hose to the oil pump.
4. Loosen the power steering oil pump mounting bolt,
and then remove the power steering oil pump NOTICE
assembly. Install the pressure hose being careful so that it
does not twist and come in contact with other
components.

APAC023C

5. Remove the power steering oil pump mounting

APAC020A
bracket.
5. Add power steering fluid (PSF-3).
6. Air bleed the system. 7. Tap the rotor side of the shaft slightly with a plastic
7. Check the oil pump pressure. hammer to remove the shaft.

DISASSEMBLY
1. Remove the two bolts (12 mm) from oil pump body,
and then remove the suction pipe and O-ring.

APAC024F

8. Remove the oil seal from the oil pump body.

NOTICE
APAC024A When assembling, use a new oil seal.
2. Remove the four bolts (14 mm), and then remove the
rear cover assembly.
3. Remove the snap ring.
4. Remove the rotor and the vane.
5. Remove the oil pump side plate.
6. Remove the inner and outer O-ring.
NOTICE
When assembling, use an O-ring.

APAC024G

9. Remove the connector from the oil pump body, and

take out the flow control valve and the flow control
spring.
10.Remove the O-ring from the connector.
CAUTION
Do not disassemble the flow control valve.

APAC024C

APAC024H
INSPECTION 7. Check the spring for damage.
NOTICE
Replace the pump assembly if necessary.
1. Check the front and rear pump bodies for cracking or
other damage and for abnormal wear of the moving
surface of the rotor.

AP2A032C

REASSEMBLY
1. Install the flow control spring the flow control valve
and the connector in to the pump body.

AP2A032A

2. Check the moving surface of the cam ring's vanes for

abnormal wear.
3. Check the moving surface of the side plate and the
pump bodies for abnormal wear.
4. Check the moving surface of the vane cam ring for
abnormal wear.
5. Check the clearance of the rotor and vanes.

APAC024H

2. Install the oil seal in the pump body by using the

special tool.

AP2A032B

6. Check the control valve for cracking and other

damage, for clogging, and for abnormal wear of the
moving part.
APAC026B

3. After inserting the shaft assembly into the pump

body.
4. Install the outer and inner O-ring in the pump body.
5. Insert the oil pump side plate in the pump body.

AP2A031C

9. Install the O-ring and oil pump cover assembly.

LPAC026F 10.Install the suction pipe and O-ring.
6. Install the rotor to the shaft with the rotor's
identification mark facing upward.

APAC024I
BP2C030A

7. Install the cam ring so that its identification mark is

facing downward.

BP2C030B

8. Install the vanes (10 pieces) to the rotor, with the R

part of the vanes facing outward.
Electronic Power Steering System
GENERAL NOTICE
EPS performs the conventional power steering function When it is necessary to remove the EPS gear box, be
in case a fail has occurred in the system. sure to disconnect the connector to avoid damage.

EPS electronically controls the current to the solenoid of

by-pass valve by input sensor's signal to control the
hydraulic amount in cylinder chamber thereby varying the
steering effort versus the hydraulic pressure according to
vehicle speed.
ELECTRONIC POWER STEERING UNIT

LPAC030B

LPAC030A

LPAC030C

EPS SOLENOID
SOLENOID VALVE
The input current is varying from 0A to 1A according to
the vehicle speed and is controlled by EPS unit.
When the ignition switch is turned on, current is sent to
the solenoid valve to push up the plunger and
accordingly the piston contacting the plunger is pushed
up while overcoming the spring force. As the vehicle
speed increasing the current flow to the solenoid
decreased pulling down the piston bottom by the
releasing spring force.
When the piston is pushed up, it closes the oil passing
hole, therefore the power steering oil pressure is
delivered into the cylinder without any interruption. But
when the hole is opened as the piston is pulling down,
some of the oil coming from the rotary valve is drained
into reservoir via the hole inside the rotary valve.