Page 1 of 42 SPORTAGE(KM) > 2010 > G 2.0 DOHC > Steering System ‘Steering System > General Information > Specifications SPECIFICATIONS Items Specifications Rack and pinion Steering gear type Mos 1 mm (lock to loek : 3.06 Rack stroke ee Power steering pump type wp Oil pump displacement 9.6ccltev. MAX. (0.59 in?itev. 2.014) 2.7(V6) MAX) 10.Scc/tev. MAX. (0.64 intev. MAX) SERVICE STANDARD Items Specifications 0~ 30 uum (0 ~ 1.1 in) Steering wheel free play se790 x yeay" Steering angle a + 1°30’ Tuner wheel 31, Outer wheel 29.N (3.0 kg, 6.5 Ibs) or less Stationary steering effort Belt deflection {under 98N (10kg, 221b) force] New belt Used belt Oil pump relief pressure 2.0 (Id), 2.7 (V6) Total pinion preload Tie rod swing resistance Ball joint starting torque 88-110mm 12.5~ 143mm 8.6 ~ 9.1 MPa (88 ~ 93 kg/om?, 1251 ~ 1322 psi) 0.6 ~ 1.3 Nm (0.06 ~ 0.13 kgf'm, 5.2 ~ 11.3 Ib- im) 2~5 Nm (0.2 ~0.5 kef'm, 14 ~ 3.6 lb-ft) 0.5 ~2.5 Nm (0.05 ~ 0.25 kfm, 0.36 ~ 1.78 Ib-f) TIGHTENING TORQUEPage 2 of 42 Item Nm kgf-m Ib-tt Power steering column and shaft Steering cohimm and shaftmouingbot | 13~18 | 13~18 | 96 45, Power steering wheel lock nut 4o~50 | 40~50 | OBS Pinion gear and joint assembly 15~20 15~2 |igg- Ws Steering column shaft and universal joint | 15~20 | 1.5~2 108~14.8 assembly Power steering gear box Gear box mounting bolt 5 " 6o~s0 | 6-8 | 44~59 ere ead Palont audkauekleam | 4569 | 45-6 [325-434 . 1-16 | 1-16 | 74-118 Feed tube to gear box 20-30 | 2-3 | ias~217 Gear box to valve body 30.70 | 327 | 37230 ‘Yoke plug lock nut ° ; Power steering oil pump Pressure hose to oil pump 39.747 ill pump adjusting bolt 253-37 ill pump mounting bolt 2.0 (ld). 2.7 (V6) 35-50 | 35~5 | 258~37 il pump bracket mounting bolt 35~50 | 35-5 | 258-37 Power steering hose Power steering reservoir mounting bolt | 17 ~ 26 Power steering hose mounting bolt T~1L Power steering tube mounting bot T~1L LUBRICANTS Item Recommended lubricant, Quantity ALVANIA #2 OR #3 Bearing of steering shaft (KEUK DONG SHELL. Korea) | A87auzed SHOWA SUNLIGHT Ball joint of tie rod end MB-2 OF equivalent 4e ste 1 ONE-LUBER RP GREASE As ed teeing gear house (KYODOYUSHI, JAPAN) ASTequr f° LONG TIME PD2 Inner ball joint of gear box. (OPTIMOL, GERMAN) As required Contact area of gear box bellows & tie | SILICON GREASE As required rod (SPEC NO : MSS11-41) Astrea . 0.8~ 05 liter Power steering fluid PSF-3 (084-0954) Steering System > General Information > Special Service Tools SPECIAL TOOLS Tool (Number and name) Mlustration UsePage 3 of 42 09222-32100 ‘ustalling the pinion gear bearing ‘Valve stem oil seal installer 09432-21600 = Installing the pinion gear bearing ‘Bearing installer ~~ a “ © “ 09434-14200 Iustalling the gear box oil sea Counter shaft bearing installer LP < 09561-11002 Removing the steering wheel Steering wheel puller 09565-11100 Prelo ad socket Measuring the mainshaft preload. 09555-21000 Removing & installing the oil seal ‘Bar 09568-34000 Separating the tie rod end ball joint. Ball joint puller 09572-21000 Oil pressure gauge Measuring the power steering oil pressure (use with 09572-21200, 09572-22100) 09572-21200 Oil pressure gauge adapter Measuring the power steering oil pressure (use with 09572-21000, 09572-22100) 09572-22100 Oil pressure gauge adapter ‘Measuring the power steering oil presste (use with 09572-21000, 09572-21200)Page 4 of 42 09573-21000 - Installing the back-up washer and oil seal. il seal installer gauge (use with 09573-21100, 09573-21200, 09517-11000, 09555-21000) 09573-21100 Installing the back-up washer and oil sea. il seal installer (use with 09573-21000, 09573-21200, 09555-21000) 09573-21200 1, Removing the gear box oil seal and back Oil seal guide - washer (use with 09573-21000) 2. Installing the gear box oil seal and back washer (use with 09555-21000, 09573- 21000) ‘Steering System > General Information > General Information GENERAL CHECKING STEERING WHEEL FREE PLAY 1. Start the engine with the steering witeel in the straight ahead position, apply a force of SN (1.1 Ib) tothe steering ‘wheel inthe peripheral direction, 2. Measure the play at the circumference of the steering wheel. Standard value : Steering wheel fiee play : 0~ 30 mm (0~ 1.1 in) Pe RSS 3. Ifthe play exceeds the standard value, inspect the connection between the steering shaft and tie rod ends, CHECKING STEERING ANGLEPage 5 of 42 1. Place the fiout whee! on a tuning radius gauge and measure the steering angle ‘Standard value : Wheel angle Inner wheel : 36.77° = 1°30" ‘Outer wheel : 31.8° 2. Ifthe measured value is not within the standard value, adjust the linkage, CHECKING THE TIE ROD END BALL JOINT STARTING TORQUE 1, Discomnect the tie rod(A) and kuuekle(B) by using the special tool (09568-34000). 2. Shake the ball joint stud several times to check for looseness. 3, Mount the muts on the ball joint, and then measure the ball joint starting torque. Standard value : 0.5~2.5 Nm (0.05 ~ 0.25 kef-m, 0.36~1.78 Ib-ft) oA 4. Tf te starting torque exceeds the upper limit ofthe standard value, replace the tie rod end 5. Even ifthe starting torque is below the lower limit of the standard value, check the play of the ball joint and replace if nece ssary.Page 6 of 42 CHECKING STATIONARY STEERING EFFORT 1. Place the vehicle on a level surface and place the steering wheel in the straight aead position. 2. Increase the engine speed to 1000 + 100 xpm ‘After checking, reset the engine speed to the standard value (idling speed). 3. Measure the tuming force with a spring seale(A) by tuning the steering wheel(B) clockwise and counterclockwise one and a quarter tums. Standard value : Stationary steering effort 29N (3.0 kg, 6.5Ibs) of less QS Me N (L——.\ Q 0) 4. Check that there is no sudden change of force while tuming the steering wheel. 5. If te stationary steering effort is excessive, check and adjust the following points. (1) Damage or cracks on the dust cover of the lower arm ball joint and tie rod end. (2) Pinion preload of the steering gear box and starting torque of the tie rod end ball joint (3) Starting torque of the ball joint. CHECKING STEERING WHEEL RETURN 1. The force required to ttn the steering wheel and the wheel retum should be the same for both left and right in case of moderate or sharp tums 2. When the steering wheel is tumed 90° and held for a couple of secondls while the vehicle is being driven at 35kph, the steering wheel should return 70° or more. I the steering wheel is tuned very quickly, steering may be momentarily difficult. Tis is not a malfunction because the oil pump output will be somewhatcecreased.Page 7 of 42 CHECKING POWER STEERING BELT TENSION 1. Press the V belt, applying a pressure of 98N (10k, 221b) at the specified point aud measure the deflection to cconfinu that it is within the standardvalue, Standard value : ‘New belt : 8.8 ~ 1.0mm Used belt : 12.5 ~ 14.3 mm 2. Ifthe belt deflection is beyond the standard value, adjust the belt tension as follows. (1) Loosen the adjusting bolt(A) and the bolt hinged(B). Ko “ (2) Put a bar(A) or equivalent, between the bracket(B) and the oil pump(C) and adjust the tension so that the belt deflection is within the standard value. (3) Tighten the adjusting bolt(A) and the bolt hinged(B). Tightening torque : 35 ~ 30 Nm (3.5 ~ 5.0 kgf'm, 25.3 ~ 37 Ib-ft)Page 8 of 42 (4) Check the belt deflection aud adjust it again if necessary. Affer tuning the V belt in the no mal rotation direction more than once, recheck the belt deflection. CHECKING POWER STEERING FLUID LEVEL 1 Position the vehicle on a level surface. 2. Start the engine. With the vehicle kept stationary, tum the steering wheel several times continuously to raise the fluid temperature to 50 - 60°C(122 to 140°F). 3. With the engine at idle, tum the steering wheel filly clockwise and counterclockwise several times. 4. Make sure there is no foaming or cloudiness in the reservoir fd, 5. Stop the engine to check for any difference in Huid level between a stationary and a running engine. 1. Ifthe fluid level varies 5 mm (0.2 in) or more, bleed the system again. 2. I the fluid level suddenly rises after stopping the engine, further bleeding is required. 3. Incomplete bleeding will produce a chattering sound inthe pump and noise in the flow control valve, and lead to decreased durability of the pump. REPLACING POWER STEERING FLUID 1 Jack up the front wheels of the car and support them with jackstands 2. Disconnect the retum hose from the oil reservoir and plug the oil reservoir 3. Connect a hose to the disconnected retum hose, and drain the oil into a container 4, Disconnect the high-tension cables and ignition coils. While operating the starter motor intermittently, tum the steering wheel al the way to the left and then to the right several times to drain the fluid. 5. Comnect the return hose and fix it with a el ip, 6. Fill the power steering fluid reservoir with the specified fluid PSE-3 : 0.8~0.9 lit. 7. Start the engine. Check for ltd leaks from the hose, then stop the engine 8, Pout the fitid into the bottom of the oil filter in the power steering fhtid reservoir 9. Bleed the air. AIR BLEEDING 1. Fill the power steering fluid reservoir up to the "MAX" position with specified fluid. 2. Jack up the front wheels,Page 9 of 42 Disconnect the ignition coil high tension cable, and then, while operating the starter motor inteamittently (for 15 to 20 seconds), tun the steering wheel all the way to the left and then to the right five or six times. 1. When bleeding fluid, replenish with the fluid so that the level does not fall below the bottom of the filter. 2. Perform air bleeding only while cranking to avoid excessive fiuid aeration 4, Connect the high tension cable , and then start the engine (idling), 5, Tum the steering wheel tothe left and then to the right, until there are no air bubbles in the oil reservoir {NOTE | Do not hold the steering wheel tumed all the Way to either side for more than ten seconds, 6. Confirm that the uid is not milky and that the level is between "MAX" and "MIN" mau on the reservoir 7. Check that there isa little change in the fluid level when the steering wheel is tuned left and right. 1) If the fluid level varies Suun (0.2 in. or mote, bleed the system again. 2) Ifthe fluid level suddenly rises after stopping the engine, futher bleeding is required. 3) Incomplete bleeding will produce a chattering sound in the pump and noise in the flow control valve, and lead to decreased durability of the pump. OIL PUMP PRESSURE TEST 1, Disconnect the pressure hose(B) frou the pump(A). Connect the special tool between the pump and the pressure hose as illustrated 2. Bleed the air, and then start the engine aud tum the steering wheel several times, measure the fluid temperature by ‘Temperature gauge so that the fluid temperature can rise to approximately 50°C (122°F). 3. Increase the engine speed to 1,000 xp 4. Close the shut-off valve of the special tool and measure the fluid pressure to confirm that it is within the standard ‘vale range Standard value : Oil pump pressure Relief pressure 2.0(14), 2.7(V6) 8.6 ~ 9.1 MPa (88 ~ 93 kg.cm?, 1251 ~ 1322 psi) Do not keep the shut-off valve on the pressure gange closed for more than ten seconds.Page 10 of 42, 5. Remove the special tools, and tighten the pressure hose(B) against the oil pump (A) using the specified torque. Tightening torque : 55 ~ 65 Nm (5.5 ~ 6.5 kef'm, 39.7 ~ 47 lb-ft) 6. Air Dleed the system. (See page ST-10) ‘Steering System > General Information > Troubleshooting TROUBLESHOOTING Symptom. Probable cause Remedy Excessive play in steering | Loose yoke plug Retighten Loose steering gear mounting bolts Retighten Loose or worn tie rod end Retighten or replace as necessary) Steering wheel operation is not | V-belt slippage smooth (Insufficient power | Damaged V-belt Readjust assist) Low fluid level Replace Airinthe uid Replenish, Twisted or damaged hoses Bleed air Insufficient oil pump pressure Comrect the routing or replace Sticky flow control valve Repair or replace the oil pump Excessive intemal oil pump leakage Replace Excessive oil leaks from rack and pinion in| Replace the damaged parts gear box Replace the damaged parts Distorted or damaged gear box or valve body. | Replace seals Steering wheel does not retum | Ex cessive tuning resistance of tierodend | Replace properly ‘Yoke plug excessively tight Adjust Tie rod and/or ball joint cannot tum smoothly | Replace Loose mounting of gear box mounting bracket | Retighten ‘Wom steering shatt joint and/or body grommet | Correct or replace Distorted rack Replace Damaged pinion bearing Replace Twisted or damaged hoses Reposition or replacePage 11 of 42 Damaged oil pressure coutrol valve Replace Damaged oil pump input shaft bearing Replace Noise Hissing Noise in Steering Gear There is some noise with all power steering systems. Oue of the most common is a hissing sound when the steering wheel is tumed and the car is not moving. This noise will be most evident when tuming 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 noise in| Interference with hoses fiom vehicle body | Reposition the rack and pinion Loose gear box bracket Retighten, Loose tie rod end and/or ball joint Retighten, ‘Wor tie rod and/or ball joint Replace ‘Noise in the oil pump Low fluid level Replenish Air in the uid Bleed air Loose pump mounting bolts Retighten Steering System > Steering Column & Shaft > Steering Column-Shaft > Components and Components Location COMPONENTSPage 12 of 42 TORQUE : Nm (kgf-m, Ib-ft) 1. steering whoo! 7. Steering column shaft mounting bot 2. Steering column shat assembly 8. Stoorng columa she mounting nut Universal joint assombly 9. Titlever 4. Steering column shaft mounting bolt 10. Steering column lower shoud 5. Steering column upper shroud 11. Steering coum lower shroud mounting bot [6 Universal joint mounting bot 12. Mutitunetion atch Steering System > Steering Column & Shaft > Steering Column-Shaft > Repair procedures REMOVAL1, Disconnect the negative (-) tenninal(A) from the battery. 2. Take away the bolts (A) in the illistration, and then remove the driver's airbag module(B) A IN Remove the steering wheel lock mut(A), Page 13 of 42 4, Afr aligning the marks on the steering shaft and wheel(A), remove the steering wheel using the special tool (09361-11002). noe Do not hammer ou the steering wheel to remove it: it may damage the steering columnPage 14 of 42 5. Remove the steering column upper(A) and lower shrouds(B),Page 15 of 42 9, Remove the bolts connecting the steering column shaft(A) aud the universal joint(B) as shown in the illustration, Keep the neutral-range to prevent the damage of the clock spring imer cable when you handlethe steering wheel. 10. After removing the mounting bolts and nuts on the steering colunn and shaft assembly, remove the steering column and shaft assembly(A). A # DISASSEMBLY AND REASSEMBLY KEY LOCK ASSEMBLY 1 Ifit is necessary to remove the key lock assemibly(A), use a punch to make a groove on the head of the special bolt(B), and then use a screweliverto remove the key lock assembly mounting bracket(C).Page 16 of 42, 2. Disassemble the key lock assembly(A) fiom the steering colunn and shaft assembly(B). 3, Reassembly is the reverse of disassembly. UNIVERSAL JOINT ASSEMBLY 1, Remove the bolt(C) connecting the universal joint assembly(A) and the steering column and shaft assembly(B) 3. Reassembly is the reverse of disassembly. INSPECTION 1. Check the steering column shaft for damage and deformation. 2. Check connections for play, damage and smooth operation, 3. Check: the ball joint bearing for wear and damage. INSTALLATION Assembly is the reverse of removal. When installing the clock spring. refer the RT group to prevent the damage of clock spring inner cablePage 17 of 42, Steering System > Hydraulic Power Steering System > Power Steering Gear Box > Components and ‘Components Location COMPONENTS 1. Tie rod end assembly 4. Feed tubo 12. Tie rod assembly 5. Joint assembly ‘3. BellowsPage 18 of 42, 2 23 24 1. Feed tube 9. Rack suppor spring 17. Bellows clip '2. Valve body housing 10, Lock nut 18. Dust cover ‘3. Bolt 111, Power steering gear box mounting clamp 19, Bellows \4. Yoke plug 12. Rack housing 20, Bellows band '5. Oli seal 13, Rack 21, Tie rod \6. Pinion valve assembly 14, Oil seal 22. Circip '7. Oil seal 15, Tie rod end 23. Oll seal \B. Rack support yoke 16. Look nut 24. Rack stopper. Steering System > Hydraulic Power Steering System > Power Steering Gear Box > Repair procedures REMOVALPage 19 of 42 1. Disconnect the cover fixing clip(A) on the universal joint indoor driver inside, loosen the noise covers(B). ah nounting bolt and disconnect the universal joint fiom the gear box. Keep the neutral-range to prevent the damage of the clock spring imer cable when you handlethe steering wheel. 3. Lift up the vehicle 4, Remove the front tites (RH/LH). 5. Remove the engine under cover. 6. After removing the split pin, disconnect the tie rod() from the knuckle(B) by using the special tool (09568- 34000).7. Remove the stabilizer link(B) frou the strut assembly(A). 4 9. Remove the propeller shafi(A) and the front muffler assembly(B), 11. Drain power steering oil. Page 20 of 42,Page 21 of 42, 12, Remove the couneeting bolt(A) for pressure tubes. 13, Remove two engline mounting bolts(B ©) and six subframe mounting bots in order to remove the subfiame(), Tightening torque : engine mounting bolts 50 ~ 65 Nm (5 ~ 6.5 kgf-m, 37 ~ 47.8 lb-ft) DISASSEMBLY,Page 22 of 42 1, Remove the tie rod end(A) fiom the tie rod(B). 2, Affer mounting the tie 1od end(A) in a vise, eemove the dust cover(B) fiom the ball joint. ae Remove the bellows band(A) ‘a 4. Remove the bellows clip(A).Page 23 of 42, 5. Pull the bellows out towaud the tie rod. Check for rust on the rack when the bellows are replaced. 6, Remove the feed tube from the rack housing. 7. While moving the rack slowly, drain the fuid from the rack housing. 8. Unstake the tab washer(C) which fixes the tie rod(A) and rack(B) with a chisel. 9. Remove the tie rod(B) from the rack(A). Remove the tie rod(B) fiom the rack), taking eare not to twist the rack. 10, Remove the yoke plug locking nut(A), and then remove the yoke plug dpAL B 14, Page 24 of 42, Remove the lock nut(A), yoke plug(B), rack suppoxt spring(C), rack suppost yoke(D) aud bushing) fiom the gear box. FR SL) Levy Remove the valve body housing(B) by loosening the two bolts(A). A ft} Remove the rack bushing and the rack from the rack housing. Remove the O-ring(A) from the rack bushing(B).Page 25 of 42, 16, Remove the pinion vlave assembly(C) from the valve body housing(®) with a soft hammer(A). or <—"\ Bp he 17. Using the special tool, eemove the oil seal and ball bearing fiom the valve body housing. 18, Remove the oil seal and O-ring fiom the rack housing Be carefil not to damage the pinion valve cylinder inside of the rack howing 9, Using the special tool(06573-21200, 09555-21000), remove the oil seal(B) from the rack housing(A), nn Be carefull not to damage the rack cylinder inside of the rack housing. Backup washer INSPECTION AND ADJUSTMENT BEFORE DISASSEMBLY Go ‘When mounting the gear box in a vise, ensure the gear box is mounted as shown in the follwing illustration to avoid damagePage 26 of 42 TOTAL PINION PRELOAD 1. Rotate the pinion gear for approximately 4 to 6 seconds for one rotation to measure the total pinion preload. Standard value : Total pinion preload 6~ 1.3 Nm (0.06 ~ 0.13 kgm, 0.4 ~ 1 Ib-fi) Measure the pinion preload through the entire stroke of the rack, FS dea 2. Ifthe measured value is out of specifications, frst adjust the yoke plug, then recheck the total pinion preload. 3. Ifyou adjust the yoke plug but do not obtain the total pinion preload, check or replace the yoke plug components TIE ROD SWING RESISTANCE 1. Rotate the tie rod severely ten times, 2. Measure the tie rod(A) swing resistance with a spring scale(B) Standard valu Total rod swing resistance : 8~22.N(1.9-4.6 Ib) [2 ~ 5 Nm (0.2 ~ 0.5 kgf'm, 17 ~ 43 Ib-in)] 3. Ifthe measured value exceeds the standard value, replace the tie rod as sembly. Even if the measured value is below the standard value, the tie rod that swings smoothly without excessive play may be used. If the measured vahte is below 4.3 N (0.9 1b) [100 Nem (8.7 Ib-in)], replace the tie rod. BELLOWS INSPECTION 1 Inspect the bellows for damage or deterioration.Page 27 of 42, 2. Make sure the bellows are secured in the coueet position. 3. Ifthe bellows are defective, zeplave them with new ones. REASSEMBLY 1. Apply the specified fluid to the entire surface of the rack oil seal. Recommended fluid : PSE-3 2. Install the oil seal(A) tothe specified position in the rack housing. Apply the specified fluid to the entire surface of the rack bushing oil seal . Recommended fluid : PSF-3 4, Install the oil seal(B) in the rack bushing(), 5. Apply the specified fluid to the entire surface of the O-ring and install itn the rack bushingPage 28 of 42 6. Apply the specified grease to the rack teeth, Recommended grease : Multipurpose grease SAE 3310, NLGI No.2 Do not plug the vent hole(A) in the rack with grease 7 7. Inset the rack info the rack housing and install the rack bushing and rack stopper. Install the oil seal and the ball bearing in the valve body 9. After appling the specified fluid and grease to the pinion valve assembly(), install it in the rack housing assembly. aia 10, After applying the specified fluid tothe oil seal, install it in the rack housing, and fix the valve body assembly(B) and O-ring in the gear box(A).Page 29 of 42 11. Install the tab washer and the tie rod and stake the tab washer(A) end at two points over the tie rod 12 B 1. Align the tab washer pavls with the rack grooves. 2. Always use a new tab washer. O» sq Ve x Tastall the bushing(), rack support yoke(B). shown in the illustration. Apply semi-drying installation. |, rack support spring(C), lock nut(E) and yoke plug(D) in the order sealantto to the threaded section of the yoke plu g before With the rack placed in the center position, a the specified torque. tach the yoke plug to the rack housing. Tighten the yoke plug to 15 Nun (1.5 kef'm, 11 IDE). Loosen the yoke plug approximately from 30° to60° and tighten the locking nut to Tightening torque : 50 ~ 70 Nm (5 ~7 kgf'm, 37 ~ 52 Ib-ft) 14, Tighten the feed tube to the specified torque and install the mounting rubber using adhesive.Page 30 of 42 15. Apply the specified grease to the bellows mounting position (Liting groove) of the tie rod, Silicone grease J WAAAY 16. Install the new attaching band to the bellows. ‘When the bellows are installed, a new band must be used, 17. Install the bellows in position, taking care not to twist it 18. Fill the dust cover inner side and lip with the specified grease, and fix the dust cover in position with the clip ring attached in the grooveof the tie rod end. Recommended greas : A: POLY LUB GLY 801K or equivalent B: SHOWA SUNLIGHT MB? or equivalent Dust cover inner side and lip : THREE BOND 8 A “| A & a andPage 31 of 42 19. Install the tie rods so that the length of the left and right tie rods equals the standard value. Standard value : Tie rod five length : 112.2 mm, ——— 20. Check for total pinion preload. Total pinion preload : 0.6 ~ 1.3 Nun (0.06 ~ 0.13 kefim, 5.2 ~ 11.3 I-ft) INSTALLATION 1. Insiallation is the reserve of removal. 2. Add power steering fluid. 3. Air bleed the system. Steering System > Hydraulic Power Steering System > Power Steering Hoses > Components and ‘Components Location COMPONENTSPage 32 of 42 1 1. Power steering oil reservoir 6. Retum hose. '2. Suction hose 7. Pressure tube ‘3. Power steering oil pump assembly 8. Tie rod end '4, Pressure hose and tube assembly 9. Tie rod end '5. Feed tube 10. Power steering gear box assembly Steering System > Hydraulic Power Steering System > Power Steering Hoses > Repair procedures REMOVAL 1. Drain the power steering oilPage 33 of 42, 2. Remove both the pressure tube fitting(A) and the retum hose clamp(B) fiom the gearbox. after lifting the vehicle. # A (8 (FA ee hose clamp(C). Remove the pressure tube connecting bolt(A) and the pressure hose mounting bol), then remove the retum Remove the pressure tube mounting boli(A) and the return tube mounting bol(B). Tightening torque : B:7~11 Nm(0.7~ 1.1 kef'm, A: 90 ~ 100 Nun (9 ~ 10 kef'un, 65 ~ 72 lb-ft) 7.9 lb-ft)Page 34 of 42, 5. Remove the pressure tube bolt(A) and clamp(B), after lowering the vehicle, tubeB) INSTALLATION 1. Installation is the reverse of removal. 2. Add power steering fd. + While installing the tube and hose assembly, be sure to align white marks(A) on each fiting, + Install the pressure hose and tube so that they are not twisted and they do not come in contact with any other parts. + After installation, air bleed the system.Page 35 of 42 Steering System > Hydraulic Power Steering System > Power Steering Oil Pump > Components and | ‘Components Location COMPONENTS |1. Pulley & driveshaft assembly 9. Var 17. Oil pump side plate 2. Oil seal 40. Rotor 418. O-ring (Outer) 3. Bush 11. Dowel pin 19. Orting (Inner) l4. Front housing 12. Oil pump cover assembly 20. Connector '5. O-ting 13, Mounting bolt 21. O-ring . Suction pipe 14, O-ring 22. Spring z Mounting bot 15. Soop tog 3. Side plate soring 16. Cam rng 13 Steering System > Hydraulic Power Steering System > Power Steering Oil Pump > Repair procedures REMOVALPage 36 of 42, 1. Loosen the bolt fixing the wiring bracket, and then move the witing sideward Remove the pressure hose(A) fiom the oll pu ump(B), and then disconnect the suetion hose(C) fiom the suetion connector aud dain the fluid into a container. (see page ST-11) ° a vA Ss Go Loosen the tension adjusting bolt(A) on the power steering."Page 37 of 42 5. Loosen the power steering oil pump mounting bolt and the tension adjusting bolt, and then remove the steering oil tunp assembly(A). REASSEMBLY 1. Install the flow control spring, the flow control valve and the connector into the pump body.3. lusall the pump pulley(A). es v ~T 4, Assengle the inner O-ting and the outer O-tin ng and install the site plate(A), = Sy 5. Install the cam ring attending to the groove an nd the direction of the front housing. SD OP 01 purp aver sido 6. stall the rotor 7. Install vanes(A) to the rotor(B). Be sure to place vanes with a round side out Page 38 of 42,Page 39 of 42, 8, Install the O-ring and the oil pump cover assembly. 9, Install the suetion pipe(A) and O-ring. INSPECTION 1. Check the fie length of the flow control spring. Free length of the flow control spring : 36.5mm 2. Check that the flow control valve is not bent 3. Cheek the shaft for wear and damage. 4, Check the V-belt for wear and deterioration. 5. Cheek the grooves of the rotor and vanes for stratified abrasion. 6. Check the contact surface of the cam ring and vanes for stratified abrasion. 7. Check vanes for damage 8. Check that there is no striped wear in the side plate or contacting part between the shaft and the pump cover surface. DISASSEMBLY 1, Remove two bolts(A) from the oil pump body, and then remove the suction pipe(B) and O-ring(C),Page 40 of 42 2. Loosen the four bolts and remove the oil pump cover assemb ly. 3. Remove the cam ting 4, Remove the zotor and vanes. 5. Remove the oil pump side plate. 1a(B). Remove the snap ring and take out the pulley and the drive shaft assembly(), 8, Remove the oil seal(A) fiom the oil pump body.Page 41 of 42 9. Remove the connector fiom the oil pump body, and take out the flow control valve and the dow control spring. emaxeo Of) doe) INSTALLATION 1. Install the oil pump(A) to the oil pump bracket, 2. Hang the "V" belt on the oil pump and connect the suction hose() and the pressure hose(B) Install the hose being careful so that it does not twist and come in contact with other ‘components.Page 42 of 42 3. Insert a bau(C) or similar tod between the bracket(A) aud the oil pump(B) to produce tension and confium that belt deflection is within the standard value. 4, Add power steering fluid. (see page to ST-10) 5. Air bleed the system. (see page to ST-10) 6. Check the oil pump pressure. (see page to ST-11)