SECTION 6A

POWER STEERING
TABLE OF CONTENTS
General Description and Operation ..................... 6A-2 Specifications ...................................................... 6A-2 Diagnostic Information and Procedures .............. 6A-3 Component Locator ............................................ 6A-4 Power Steering System Locator ............................ 6A-4 Steering Gear Box Cross Section ......................... 6A-5 Power Steering Assembly .................................... 6A-6 General Inspection ............................................... 6A-7 Oil Pump Pressure ............................................... 6A-7 Power Steering Gear Preload Adjustment ............. 6A-8 Oil Change .......................................................... 6A-8 Oil Quantity Check and Air Bleeding .................... 6A-9 Maintenance and Repair ................................... 6A-12 On-Vehicle Service ............................................... 6A-12 Power Steering Pipe/Hose .................................. 6A-12 Power Steering Box Assembly ........................... 6A-13 Steering Gear Pump .......................................... 6A-14 Assembly Installation ........................................ 6A-14 Unit Repair .......................................................... 6A-17 Steering Gear Box ............................................. 6A-17 Special Tools and Equipment ............................ 6A-23 Special Tools Table ............................................ 6A-23

6A-2 POWER STEERING

GENERAL DESCRIPTION AND OPERATION

SPECIFICATIONS
Steering Wheel Steering Gear Box Number of spoke Outer Diameter Type Gear Ratio Steering Angle Oil pump Type MAX. Pressure Outlet Size Tilt column Angle Upper Lower Turning Radius Oil Type Capacity Inner Outer 36 17 32 40 Vane 82 ~ 92 kgf/cm 10.5L/min 124mm 4 4 5.7 m ATF DEXRON II 1L 4-Spoke Type 390 mm Rack and pinion

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POWER STEERING 6A-3

DIAGNOSTIC INFORMATION AND PROCEDURES

Phenomena Hard Steering Checks Lack of Lubrication Abnormal Wear or Binding of Steering Ball Joint Damaged or Faulty Steering Gear Improper Preload of Steering Pinion Faulty Steering Shaft Joint Steering Fluid Leaks Lack of Fluid or Air-in System Faulty Steering Oil Pump Steering Pulls to One Side Damaged or Loosened Pump Drive Belt Clogging Oil Line Damaged Wheel or Tire Faulty Suspension System Damaged Steering Linkage Damaged Wheel and Tire Faulty Brake System Faulty Suspension System Excessive Wheel Play Worn Steering Gear Worn or Damaged Steering Ball Joint Loosened Steering Gearbox Bolts Poor Return of Steering Wheel Damaged or Binding Steering Ball Joint Improper Preload of Steering Pinion Damaged Wheel or Tire Faulty Suspension System Steering Wheel Shimmy Damaged Steering Linkage Loosened Steering Gearbox Mounting Bolt Damaged or Binding Steering Ball Joint Worn or Damaged Front Wheel Bearing Damaged Wheel or Tire Faulty Suspension System Abnormal Noise From Steering System Loosened Steering Gearbox Mounting Bolt Faulty Steering Gear Steering Column Linterference Loosened Steering Linkage Damaged or Loosened Oil Pump Drive Belt Loosened Oil Pump Bracket Loosened Oil Pump Mounting Bolt Air-in System Faulty Oil Pump Lubricate Replace Replace gear assembly Adjust Replace Repair or replace Replenish or bleed Replace Adjust or replace Repair or replace Repair or replace Repair or replace Repair Repair or replace Repair or replace Repair or replace Replace gear assembly Replace Retighten Replace Replace gear assembly Repair or replace Repair or replace Replace Retighten Replace Replace Repair or replace Repair or replace Retighten Replace gear assembly Replace Retighten Adjust or replace Retighten Retighten Bleed Replace Action

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6A-4 POWER STEERING

COMPONENT LOCATOR
POWER STEERING SYSTEM LOCATOR

1
A

YAD6A020

A Mounting Position

1 Steering Component

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POWER STEERING 6A-5

STEERING GEAR BOX CROSS SECTION

10 1 2 3 4 5 6

YAD6A030

1 2 3 4 5

Tie Rod End Tie Rod Bellows Rack Housing Feed Tube

6 7 8 9 10

Mounting Bracket Tie Rod End Tie Rod End Cylinder Tube Valve Assembly

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6A-6 POWER STEERING

POWER STEERING ASSEMBLY

12

2 11 10 1 13 14 9 3

5 9 11 10 4 6 8 7

YAD6A150

1 2 3 4 5 6 7

Power Steering Pump Reservoir Assembly Power Steering Pump Cap Assembly Clip Return Line Pressure Line Power Steering Gear Power Steering Pipe Mounting Bracket Clip.

8 9 10 11 12 13 14

Hexagon Bolt Fan Screw (M5) Welded Nut Pipe Clamp Hexagon Bolt Nut Bolt

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POWER STEERING 6A-7

GENERAL INSPECTION
OIL PUMP PRESSURE
Do the pressure checking followed to check the defect of power steering pump. Notice: Before checking, check the power steering oil level and belt tension. When tightening of removing the fitting, prepare the oil container because the oil may drop down. 1. Remove the pressure line fitting of power steering pump. 2. Install the pressure check gauge between the power steering pump and power steering oil pressure line. 3. Put the transmission in neutral position. 4. Pull the lever of parking brake. 5. Open the installed pressure check gauge valve completely. 6. Start the engine and keep it to the idling. 7. Turn the steering wheel several times until the oil temperature is up to the normal operating temperature. 8. Close the pressure check gauge valve completely and then measure the oil pressure. Notice: Do not keep the valve closed for more than 10 seconds to protect the damage of pump. A 53 - 58 kgf/cm

YAD6A040

9. Open the gauge valve completely and then measure the oil pressure. A 3 - 5 kgf/cm

10. If the pressure is within specified value, the pump is normal. If not, replace the power steering pump.

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6A-8 POWER STEERING

POWER STEERING GEAR PRELOAD ADJUSTMENT

1. 2. 3. 4. Place the steering wheel in front direction. Lift the vehicle using the lifter safely. Remove the adjustment plug lock nut. Measure the torque of adjustment plug.

YAD6A050

5. If torque is excessive or too little, adjust it as specified value. Place the rack gear in center position. Tighten the adjustment plug by 100 kg.cm Turn the pinion gear in order that rack gear move to the left/right end five times. Remove the adjustment plug. Tighten the adjustment plug by 45 - 55 kg.cm Tighten the adjustment plug by 67.5 to C.C.W direction. 6. Tighten the adjustment plug lock nut.
YAD6A060

OIL CHANGE
1. Lift the vehicle slightly using the lifter. 2. Separate the oil supply hose from the power steering pump. 3. Discharge the oil in the oil tank. 4. Connect the oil supply hose with the power steering pump. 5. Separate the oil return line from the oil tank. 6. Remove the high pressure cable in the ignition coil. 7. Operating the ignition motor periodically, turn the steering wheel from lock to lock and discharge the oil through the return line. 8. Connect the return line with the oil tank. 9. Charge the oil in the oil tank as specified quantity. 10. Do bleeding procedure.

MAX MIN

YAD6A070

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POWER STEERING 6A-9

OIL QUANTITY CHECK AND AIR BLEEDING

Oil Quantity Check
MAX 5mm MIN

1. Place the vehicle on flat road and start the engine and keep it idling. 2. Turn the steering wheel from lock to lock several times until the oil temperature gets to the normal operating condition. 3. The oil level should be placed between MAX and MIN.

YAD6A080

Air Bleeding
1. Disconnect the fuel line. Using a starter motor, crank the engine and turn the steering wheel from lock to lock several times. 2. Connect the fuel feed line and start the engine at idle steed. 3. Turn the steering wheel from lock to lock until there is no more air in oil reservoir. 4. Connect the oil lever is within specification. 5. By turning the steering wheel left to right, check the oil level change.
YAD6A090

Notice: Do bleeding with engine cranking. If bleed with idling, there con be a air contact with oil. If oil is not changes more than 5mm, do bleeding again. If oil level rises suddenly when stopped engine, do bleeding again.

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6A-10 POWER STEERING Belt tension Check/Adjustment

1. Check the wear, crack and damage of belt, and if necessary, replace it. 2. Push the center position of belt (10 kg) and then check the deflection of belt.

YAD6A100

3. If the measurement value is not within the specified value, remove the bolt of power steering pump. Adjust the belt tension as moving the pump assembly.

YAD6A110

Power steering wheel Freeplay Check

15mm 15mm

1. Start the engine and place the wheels in straight ahead position. 2. Slightly move the steering wheel to the left/right and measure the steering wheel free play when the front wheel is start to move. Standard Max. 30 mm

Notice: If exceeds standard, the steering column shaft and steering linkage clearance. Replace or repair if necessary.
YAD6A120

Steering Angle Check

1. Place the front wheel on a measuring tool. 2. Rotate steering wheel to the left/right direction and measure steering angle. Standard Inner Outer 36 17 32 40

Notice: If out of standard, check or adjust toe-in.

YAD6A130

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POWER STEERING 6A-11 Steering Effort Check

1. Place a vehicle on the paved flat ground with front wheels In a straight ahead position. 2. Start the engine and run it at 1,000 rpm. 3. Using a scale, measure the steering effort in both directions. Standard Max. 3.0 kg

Notice: The difference in steering effort of left/ right should be within 0.6 kg.
YAD6A140

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6A-12 POWER STEERING

MAINTENANCE AND REPAIR ON-VEHICLE SERVICE

2

POWER STEERING PIPE/HOSE

Removal
1. Remove the supply pipe (1) and return hose (2) which is installed in power steering pump. Notice: When removing/installing the pipe and hose, prepare the oil container in order that the oil may not drop down.

1
YAD6A160

2. Remove the supply/return pipe installed in power steering gear box.

YAD6A170

3. Remove the oil pipe bracket bolt installed in front bumper and pull off the oil pipe. Notice: First, remove the pipe from the pipe clamp installed in front panel and then pull off the pipe.

YAD6A180

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POWER STEERING 6A-13

POWER STEERING GEAR BOX ASSEMBLY

1. Remove the tie rod installed in steering knuckle. Disassembly the split pin and sloted nut in tie rod end and pull off the tie rod using the special tool.

YAD6A190

2. Remove the joint blot of steering lower shaft and separate the lower shaft from the gear box.

YAD6A200

3. Remove the center bolt in gear box and left mounting bolt. Remove the supply/return pipe connection bolt.

YAD6A210

4. Remove the clamping bolt and pull off the steering gear box assembly.

YAD6A220

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6A-14 POWER STEERING

STEERING GEAR PUMP

1. Separate the drive belt from pump pulley after each pipe and hose is removed.

YAD6A230

2. Remove the bolts/nuts in pump and pull off the pump assembly from engine.

YAD6A240

ASSEMBLY INSTALLATION
1. Install the power steering pump in engine and tighten the bolt/nut as specified torque. Nut Bolt Upper Lower Torque 23 Nm (17 lb-ft) 23 Nm (17 lb-ft)

YAD6A250

2. Install the power steering gear box in frame. Tighten the mounting bolts slightly and then install the gear box clamp in left. Tighten the bolt/nut as specified torque. Notice: Because the length of bolt is same, install them after checking. Installation Notice 95 mm Bolt/Nut (Upper) 95 mm Bolt/Nut (Lower) 70 - 90 Nm (52 - 66 lb-ft) 70 - 90 Nm (52 - 66 lb-in)

YAD6A260

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POWER STEERING 6A-15

3. Completely tighten the mounting bolt/nut which is tightened slightly. Notice: First tighten the center bolt/nut and then tighten bolt/nut as specified torque. Installation Notice Center Bolt/Nut Left Bolt/Nut 70 - 90 Nm (52 - 66 lb-ft) 70 - 90 Nm (52 - 66 lb-in)

YAD6A270

4. Install the steering lower shaft to the gearbox. The joint bolt on the lower shaft should be tightened toward B (threaded) from A (non-threaded). Installation Notice

Tightening Torque

25 - 30 N m (18 - 22 lb-ft)

Notice: When installing the lower shaft to the gear box, the joint bolt (1) should be installed anto the gearbox pinion shaft splines.

YAD6A280

5. Install the tie rod end in steering knuckle. Tighten the sloted nut and then insert the new split pin. Tightening Torque 35 - 45 N m (26 - 33 lb-ft)

YAD6A290

Installation Notice 6. Install the clamp of return pipe in front end panel. Installation Notice Tightening Torque 7 - 10 N m (62 - 89 lb-in)

YAD6A300

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6A-16 POWER STEERING

7. Install the supply/return pipe in gear box housing. Installation Notice Supply Pipe 2
1

12 - 18 Nm (9 - 13 lb-ft) 12 - 18 Nm (9 - 13 lb-ft)

Return Pipe 1

YAD6A310

8. Install the supply pipe in steering gear pump.

YAD6A320

9. Insert the return hose (2) Into the reservoir tank (1) and then insert the spring clamp (3) as like the picture. Notice: After inserting the hose into the reservoir tank completely, install in order that the spring clamp is placed in the center of nipple. 10. After installing completely, do bleeding.

3 2

YAD6A330

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POWER STEERING 6A-17

UNIT REPAIR
STEERING GEAR BOX
Disassembly
1. Disassembly the tie rod end boot (a).

YAD6A340

2 1

2. Remove the cylinder tube (2) in gear box. 3. Remove the valve tube (1) in gear box.

YAD6A350

1 2 3

4. Remove the lock nut (1) and separate the plug (2) and spring (3).

YAD6A360

1 2

5. Remove the dust cover (1) and pull off the retainer ring (2).

YAD6A370

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6A-18 POWER STEERING

6. Remove the pinion dust cover (lower) (3) and remove the pinion lock nut (4). Notice: When removing the steering pinion lock nut, be sure to fix the pinion gear n order to protect the damage of pinion gear.

4 3
YAD6A380

7. Tapping the pinion lower part carefully using the plane draft and hammer, remove the steering pinion (5) from the pinion bearing.
5

Notice: Tap the draft using the hammer as lik the picture.

YAD6A390

8. Tapping the pinion bearing softly using the plane and long draft and rubber hammer, remove the bearing.
6

YAD6A400

7 8 9

9. Remove the pinion shaft seal (7), needle bearing (8), retainer ring (9). Notice: Do not overhaul the power steering gear housing and rack gear, if the damage happened, replace them with assembly.

YAD6A410

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POWER STEERING 6A-19 Rack Gear Shaft Checks

3 2 4

1. Check the rack gear damage. Set up the v-block (1) on the plane table. Put the rack gear (2, 4) on the V-block. Measure the straightness of rack gear using the dial gauge (3). Check the rack gear for the wear or damage.

YAD6A420

2. Check the steering pinion gear for the damage. Check the pinion gear (1) for the wear or damage. Check the looseness and normal operating of bearing (2).

2 1
YAD6A430

1 2

3. Check the tie rod end, rack and pinion bellows for the damage. Check the tie rod end boot (1) for the crack or wear. Check the rack and pinion boot for the crack or wear.

YAD6A440

4. Check the steering gear housing for the crack, deformation and wear.
a

YAD6A450

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6A-20 POWER STEERING

5. Check the tie rod end and ball joint for the damage. Check the tie rod end ball joint for the normal operating, Check the tie rod ball joint for the normal operating and the deflection by the self-weight of tie rod. 6. After checking, if out of specified value or damaged, replace them with the new one.

YAD6A460

7. Check the tie rod end and the rotation part of ball joint for the damage.

YAD6A470

8. Check the tie rod end and rack/pinion boot for the crack and wear. 9. Check the metal part for the damage. Check the pinion gear for the damage or wear. Check the rack gear for the damage or wear. Check the steering gear housing for the damage or wear.

YAD6A480

1 2

10. Check the bearing and oil seal for the damage. Check the pinion shaft seal for the wear or leakage. Check the needle bearing for the wear. Check the steering pinion bearing for the wear. 11. After checking, if out of specified value or damaged, replace them with the new one.

YAD6A490

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POWER STEERING 6A-21 Assembly

1. Install the steering pinion assembly gear. Install the retaining ring. Install the needle bearing. Tapping the pinion shaft seal carefully in diagonal direction using the thin draft (1), assemble them.

YAD6A500

2. Tighten the steering pinion lock nut (4) as specified torque. Notice: Because the pinion bearing is inserted into the pinion lock nut by force, be careful not to be eccentric.

4
YAD6A510

7 6

3. Tighten the steering pinion dust cover (5) as specified torque. Install the retaining ring (6). Install the plastic dust cover (7).

5
YAD6A520

4. Install the rack bearing. Install the adjustment spring. Tighten the adjustment plug as specified torque. Tighten the adjustment plug lock nut. Adjust the steering gear preload.

YAD6A480

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6A-22 POWER STEERING

5. Install the fluid pressure line in power steering gear and tighten them as specified torque. 1 Tighten the fitting to the piston side. 2 Tighten the fitting to the cylinder side.

YAD6A530

6. Assemble the tie rod end boot. Notice: Apply the grease to the tie rod end ball joint and boot.

YAD6A540

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POWER STEERING 6A-23

SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS TABLE

Tie Rod End Remover

YAD6A550

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