Steering SystemGeneral

Description.................................................... ST -2Specifications ............................................... ST -11General Diagnostics and Tests .................... ST -14Adjustment .................................................... ST -26

Steering Column and ShaftComponents Location .................................. ST -29Components ................................................. ST -30Removal ....................................................... ST -31Installation .................................................... ST -33Inspection ..................................................... ST -34

Steering LinkageComponents ................................................. ST -35Drag Link

Disassembly ............................................ ST -37Reassembly ............................................ ST -38

Tie RodDisassembly ............................................ ST -39Inspection ................................................ ST -39Reassembly ............................................ ST -40

Manual Steering SystemManual Steering Gear Box

Components ............................................ ST -41Disassembly ............................................ ST -42Reassembly ............................................ ST -43

Power Steering SystemPower Steering Gear Box

Components ............................................ ST -46Disassembly ............................................ ST -47Reassembly ............................................ ST -48Inspection ................................................ ST -48

Power Steering Oil PumpComponents ............................................ ST -50Disassembly ............................................ ST -51Inspection ................................................ ST -53Reassembly ............................................ ST -53

GeneralDescriptionThe steering system allows the driver to freely changethe vehicle's direction of travel. The steering forceapplied to the steering wheel is transmitted to theknuckle arm via the steering shaft, steering gear, pitmanarm, and the drag link so as to steer the vehicle.LHD Type

SUDSTA003L

1. Steering wheel2. Column and shaft assembly3. Steering gear box4. Drag link5. Pitman arm

6. Knuckle arm7. Tie rod8. Tie rod end9. Tie rod arm

RHD Tyep

SUDSTA004L

1. Steering wheel2. Column and shaft assembly3. Steering gear box4. Drag link5. Pitman arm

6. Knuckle arm7. Tie rod8. Tie rod end9. Tie rod arm

Steering Wheel and ShaftThe steering wheel is designed to ensure an optimumsteering effort and feel. It is connected to the steeringshaft by serration and taper boss. The steering shaft isdesigned so strong as to withstand twisting and bendingforce. It is coupled with the gear assembly with a jointassembly. The telescopic tilt steering shaft provided withtwo joint assemblies and a shaft end spline allows thedriver to select an optimum driving position.

EMTST5002A

Steering Linkage1. Drag Link Assembly

The drag link connects the pitman arm at the steeringgear end to the knuckle arm at the front wheel so asto transmit the movement of pitman arm to theknuckle arm. A coil spring is used in the ball jointsinstalled at the end portion of drag link for bufferingthe vibration of the front wheels.

SUDSTA005L

1. End plug2. Ball seat B3. Pitman arm4. Ball seat A5. Coil spring6. Drag link7. Knuckle arm

2. Tie Rod AssemblyThe tie rod assembly is connected to the both ends ofthe knuckle arms. The ball joint taper attaches thetie-rod end to the knuckle arm with a nut. Aright-handed screw and left-handed screw are usedat the right and left ends, respectively, for the tie rodto tie-rod end joints, allowing easy adjustment oftoe-in.

EMTST5004A

Steering Gear Assembly (Recirculating-ballType)1. The recirculating-ball type steering gear is a system

in which a ball nut is filled with a number of ballswhich roll along groove between the worm teethprovided on the end of the main shaft and thegrooves inside the ball nut in order to transmit theturning forces of the main shaft via the ball nut to thecross shaft. Rolling motion of the balls dramaticallyreduces the friction forces. When balls reach the end,they enter ball tubes which take them back into thefirst groove inside of the ball nut. The worm teeth andball nut are made by grinding method precisely. Ballsare confined between the external and internalthreads; i.e., the ball nut attaches to the worm via theballs. This involves a change of friction from slidinginto rolling, allowing the mechanism to withstand agreater load.

EMTST5005A

2. The ball tube has a shape, in which a pipe bent into aU shape and split into two parts, and then the dividedparts merged again. Both ends are tongued toreceive balls easily. When the balls reach the end,they are received by the tongue entering into the tubeso as to go back into the first groove inside the ballnut. The ball-nut rack is in mesh with the cross shafttilted in 6° allowing backlash adjustment.

EMTST5006A

Power Steering Gear

SUDSTA006L

1. Gear housing2. Steel ball3. Circulator4. Cross shaft5. Needle bearing6. Side cover

7. Adjusting bolt8. Adjusting plate9. Needle bearing10. Input shaft11. Ball bearing12. Valve housing

13. Angular bearing14. Torsion bar15. Rack piston16. Main shaft17. Angular bearing18. End cover

The power steering unit uses a small rotary valvemachined to close tolerances and a torsion bar thatensures smooth andlight steering reaction at low speeds.Furthermore, the torsion bar size is matched to the inputshaft control edge shape toprovide stabilized steeringaction from low to high speeds.The power steering is anintegral type. It comprises of the power transmittingsystem sending the steering force to straightdirection(ball screw unit, cross shaft), the fluid control valve (valvebody, valve housing, sleeve) and the force generatingmulticylinder (gear housing). Ball screw unit comprises ofrack piston, main shaft, input shaft, torsion bar and steelball. The ball screw has lots of ball bearings to reducefriction between torsion bar and rack piston. Steeringtorque is transmitted to cross shaft via torsion bar, main

shaft and rack piston. And the load from tire istransmitted to main shaft then the torsion bar istwisted bythe reaction force from input shaft. When the turning ofinput shaft stops, the reaction of torsion bar returnsinputshaft to approach starting point.

1. For straight-ahead position

SUDSTA007L

1. Gear housing2. Cross shaft3. Input shaft4. Left cylinder5. Main shaft6. Rack piston

7. Right cylinder8. Torsion bar9. Sleeve10. Input shaft11. Sleeve

If no steering torque is applied from the steeringwheel, the input shaft stays in neutral. In thiscondition, oil goes through the gap between the inputshaft and sleeve holes so that the oil fed underpressure of the oil pump returns to the oil tankwithoutflowing to the left and right cylinder chambers.

2. During a right turnWhen the steering wheel is turned clockwise, theload from tires acts on the main shaft so as to twistthe torsion bar. As a result, the input shaft turns toclockwise direction.As the shaft turns, the axialclearance becomes narrow to restrict the oil inflow,and then the oil pressure in the left cylinder chamberincreases. Then the oil in the right cylinder chamberis returned to the oil tank. As a result, the rack pistonreceives thrust in the right direction so as the crossshaft to turn in counter-clockwise direction. The forcethat has twisted the torsionbar during steering istransmitted to the steering wheel as a steeringreaction which gives the driver a sense of steeringresponse.

EMTST5009A

3. During a left turnThe operation is just opposite to the operationgenerated during the right turn.These descriptionsare based on the L.H.D. models

EMTST5010A

4. When hydraulic circuit failsEven the hydraulic circuit fails, the input shaft stoppercomes in direct contact with the slot in the big end ofmain shaft to transmit the steering force, allowingmanual steering for safety.

EMTST5011A

Oil Pump1. Pump

EMTST5012A

The oil discharged under pressure goes to the controlvalve that varies the flow rate. The valve spool ismoved by thepressure difference in the valve so thatthe oil returns back to the suction port of the oilpump.When the steering wheel is turned to the lockend shutting off the oil passage, the relief valve isactivated so as to return the oil back to the pumpsuction port, as with the control valve.

2. Flow control valve

EMTST5013A

While the engine is idling, the oil is fed from the pumpdischarge port via the orifice A1 to the power steeringunit.As the engine speed goes up, the delivery rate ofthe pump increases. Then, as the force P1overcomes the flow control spring set tension, the

spool valve is moving so that the excessive oilreturns to the suction port and a constant flow rate ismaintained.

3. Relief valve

EMTST5014A

As the pressure is over the maximum value, the reliefvalve is open to prevent the excessive pressure frombeing generated in the hydraulic circuit when thesteering wheel is locked or the circuit getsclogged.The internal pressure of the circuit is beingapplied to the steel ball built into the spool valvethrough the orifice A2. If a pressure over themaximum [94-99 kgf/cm²] is applied to the steel ball,it overcomes the relief spring set tension pushingthesteel ball so that the oil returns back to the pumpsuction port, thereby the internal pressure is keptunder the maximum level.

SpecificationsItem Specification

Steering wheel Type 2-spoke

O.D. (Outer Diameter) Power : Ø410 , Manual : Ø430

Power steering gear Type Integral (ball-nut type)

Gear ratio 22.6

Cross shaft operating angle Left 45°or moreRight 43°or more

Maximum operating pressure 120 kg/㎠

Set fluid flow rate 7 lit./min.

Power steering oil pump Type Vane pump

Delivery rate 10.5 cc

Relief set pressure 94~99 bar, 103~108 bar

Speed range 600~6500 rpm

Direction of rotation Clockwise (as viewed from gear side)

Fluid PSFⅢ

Service Standards

Description Nominal Value (Basi -c diameter in [ ]) Limit Correction and remarks

Steering wheel play(Straight-ahead direction, on wheel per-iphery) 0 to 25 50 Adjust with gearbox adjus-

ting screw

Cross shaft T-groove to adjusting screw clearance 0.1 or less Adjust with adjusting plate

Tie rod runout Less than 2 2 Correct or replace

Manual steering gear Cross shaft to steering gear housi-ng (bushing) clearance [32] 0.01 to 0.06 0.1 Replace steering gearhou-

sing

Cross shaft to side cover (bushing)clearance [32] 0.01 to 0.06 0.1 Replace side cover

Main shaft starting torque N·m (kgf·m) with cross shaft removed afterinstallation overall

33 to 59 (4 to 6)59 to 88 (6 to 9)

Adjust with adjusting plate

Power steering gear Main shaft O.D. 22.55 to 22.6 22.35 Replace ball screw unit

Gearbox cylinder to rack piston cl-earance

0.02 to 0.09 0.15 Replace ball screw unit

Play in cross shaft in axial directio-n with respect to adjusting bolt

0 0.1 Adjust with adjuster plate

Cross shaft O.D. [35] -0.008 to +0.008 34.96 Replace

Power steering oil pu-mp

Cam ring wear Less than 0.1 - Replace if your fingernailcatches ridge

Body cover wear, ridge - 0.05 Replace

Cover to relief valve clearance 14.010 to 14.016 0.03 Replace

Wear depth of shaft seal lip - 0.05 Replace

Rotor groove to vane clearance 0.01 0.06 Replace as cartridge ass-embly

Spring free length 36.5 33.5 Replace

V-belt tension 4.6 Adjust with oil pump

Tighten Torque Table

DescriptionTightening Torque

Nm Kgf·m Lb-ft

Steering wheel nut 39~49 4~5 28.9~36.1

Column support bolt 17~25 1.7~2.6 12.2~18.8

Steering gear and steering shaft connecting bolt and nut 53~65 5.4~6.6 39~47.7

Steering gear assembly bolt and nut 69~83 7~8.5 50.6~61.4

Pitman arm nut 125~165 13~17 94~122.9

Tie-rod end clamp nut 20~29 2~3 14.4~21.6

Tie-rod end and knuckle arm nut 69~115 7~12 50.6~86.7

Steering shaft clamp bolt tightening nut 34~54 3.5~5.5 25.3~39.7

Manual steering gear

End cover bolt 44~54 4.5~5.5 32.5~39.7

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

Adjusting screw nut 25~32 2.5~3.3 18~23.8

Oil plug tightening 15~25 1.5~2.5 10.8~18

Power steering gear

Valve house clamping nut 45~55 4.5~5.5 32.5~39.7

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

Side cover clamping nut 75~190 7.5~19 54.2~137.4

Adjusting bolt clamping lock nut 30~40 3~4 21.6~28.9

Power steering pump

Oil pump attaching bolt 18~22 1.8~2.2 13~15.9

Suction connector attaching bolt 6~10 0.6~1.0 4.3~7.2

Discharge connector 40~60 4~6 28.9~43.3

Discharge eye connector attaching bolt 16~24 1.6~2.4 11.5~17.3

Pulley clamping nut 30~40 3~4 21.6~28.9

Center bolt 48 4.8 34.7

Adjusting bolt 41 4.1 29.6

Power steering gear and pipe connecting outer (Return) 40~50 4~5 28.9~36.1

Power steering gear and pipe connecting inner (suction) 30~40 3~4 21.6~28.9

Hose connecting clip 30~40 3~4 21.6~28.9

General Diagnostics and TestsManual Steering system

EMTST5047A

EMTST5048A

EMTST5049A

EMTST5050A

EMTST5051A

Power Steering system

EMTST5052A

EMTST5053A

EMTST5054A

EMTST5055A

EMTST5056A

EMTST5057A

EMTST5058A

AdjustmentCHECKING STEERING WHEEL FREE PLAY(Manual / power)1. Start the engine with the steering wheel in the

straight ahead position, apply a force of 5 N (1.1 Ib)to the steering wheel in the peripheral direction.

2. Measure the play at the circumference of the steeringweel

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

KPSE010A

3. If the free play exceeds the standard value, inspectthe connection between the steering shaft and tie rodends.

Checking Steering Angle (Manual/power)1. Place the front wheel on a turning radius gauge and

measure the steering angle.

Standard value :Wheel angleInner wheel : 31.5°±33.5°Outer wheel : 42˚~44°

APIE101B

2. If the measured value does not meet the standardvalue, adjust the linkage.

Replacing Power Steering Fluid1. Jack up the front wheels of the car and support them

with jackstands.2. Disconnect the return hose from the oil reservoir and

plug the oil reservoir.3. Connect a hose to the disconnected return hose, and

drain the oil into a container.4. While operating the starter motor intermittently, turn

the steering wheel all the way to the left and then tothe right several times to drain the fluid.

5. Connect the return hose and fix it with a clip.6. Fill the power steering fluid reservoir with the

specified fluid.7. Start the engine.Check for fluid leaks from the hose,

then stop the engine.8. Pour the fluid into the bottom of the oil filter in the

power steering fluid reservoir.9. Bleed the air.

Air Bleeding (Power steering system)1. Fill the power steering fluid reservoir up to the "MAX"

position with specified fluid.

KMTST5013B

2. Jack up the front wheels.3. Turn the steering wheel all the way to the left and

then to the right five or six times.

NOTICEWhen bleeding fluid, replenish with the fluid so thatthe level dose not fall below the bottom of the filter.

4. Start the engine (idling).5. Turn the steering wheel to the left and then to the

right, until there are no air bubbles in the oil reservoir.6. Confirm that the fluid is not milky and that the level is

between "MAX" and "MIN" mark on the reservoir.7. Check that there is a little change in the fluid level

when the steering wheel is turned left and right.

NOTICEIf the fluid level varies 5mm (0.2 in.) or more, bleedthe system again. If the fluid level suddenly risesafter stopping the engine, further bleeding isrequired. Incomplete bleeding will produce achattering sound in the pump and noise in the flowcontrol value, and deteriorate durability of the pump.

Oil Pump Pressure Test (Power steeringsystem)1. Connect the special tool between the pump and the

pressure hose.2. Bleed the air, and then start the engine and turn the

steering wheel several times, measure the fluidtemperature by Temperature gauge so that the fluidtemperature can rise to approximately 50~60℃.

3. Discharge oil pressure measurement.Close the stopvalve of the oil pressure gauge at idling engine andmeasure the oil pressure to confirm that it is withinthe standard value.

Specified value : 10㎏/㎠ or less

4. Oil pump pressure relief pressure test.1) Increase the engine speed at 1500~1600 rpm.2) Close the stop valve of the oil pressure gauge

and measure MAX. oil pressure.

Relief oil pressure : 94~99㎏/㎠, 103~108㎏/㎠

5. Remove the oil pressure gauge with stop value andtighten the pressure hose to the specified torque.

Tightening torque : 30~40Nm (3~4kgf·m)21.7~28.9 lb-ft

6. Bleed the air from the system.

Adjustment of oil pump V-belt1. Tighten the adjusting bolt(A) until a proper tension is

achieved to V-belt of oil pump.Control the adjusting bolt(A)

EMTST5015A

2. To adjust the belt tension, a deflection(B) of beltshould be 4 ~ 6mm when pressing the belt(A) with10kgf·force.

EMTST5016A

3. After adjusting tension of belt, tighten the nut(C) withthe specified torque.

The specified torque : 22.3~40 Nm(2.72 ~ 4.08kgf·m, 19.7~29.5 lb-ft)

Steering Column And ShaftCOMPONENTS LOCATION

SUDSTA008L

1. Steering wheel2. Column support3. Dust cover

• Installation is the reverse procedure of thedisassembly

Components

SUDSTA009L

1. Lever2. Screw3. Screw4. Bolt

5. Spacer6. Lever7. Wave washer8. Spring

9. Collar10. Lever11. Column support12. Steering column

13. Cable band14. Dust "A" cover15. Dust "B" cover16. Dust "C" cover

Removal1. Disconnect the (－) battery cable2. Remove the horn pad(A) from the steering wheel.3. Remove the steering wheel nut(B)4. Mark the matchmark(C) on the steering shaft and the

wheel, and then remove the steering wheel.(LHD Type)

EMTST02B

(RHD Type)

SUDSTA501L

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

EMTST03B

(RHD Type)

SUDSTA502L

6. Disconnect the multi－function switch harnessconnector(A) and remove the multi－functionswitch(B).(LHD Type)

EMST04B

(RHD Type)

SUDSTA503L

7. Disconnect the engine stop cable(A) from thelever(B)(LHD Type)

EMTST05B

(RHD Type)

SUDSTA504L

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

9. Remove the tilt adjuster bolt(B)(LHD Type)

EMST06B

(RHD Type)

SUDSTA505L

10.Remove the return spring(A)11.Remove the steering shaft cover(B)

(LHD Type)

EMST07B

(RHD Type)

SUDSTA001L

12.Remove the gear box(A) and the steering shaftmounting bolt pin(B)

NOTICEMark a matchmark on the gear box and steeringshaft.(LHD Type)

EMST08B

(RHD Type)

SUDSTA002L

13.Remove the steering shaft.

Installation1. The installation is performed in the reverse order of

the removal.2. Align the marks on the steering wheel and column

shaft for reinstallation when installing the steeringwheel.Align the marks on the gear box and steering shaftfor reinstallation when installing the steering shaft.

Inspection1. Check the steering column shaft for damage and

deformations.2. Check the connecting parts for enough clearance,

damaged portion and proper operation.

SUDSTA010L

1. Steering shaft2. Column3. Dust seal cap4. Universial joint assembly

Steering LinkageComponents(LHD Type)

SUDSTA011L

Disassembly sequence1. Split pin2. Nut3. Tie rod assembly4. Tie rod end5. Knuckle arm6. Split pin7. Nut

8. Drag link9. Dust cap10. King pin shim11. King pin12. Knuckle13. Front axle

(RHD Type)

SUDSTA012L

Disassembly sequence1. Split pin2. Nut3. Tie rod assembly4. Tie rod end5. Knuckle arm6. Split pin7. Nut

8. Drag link9. Dust cap10. King pin shim11. King pin12. Knuckle13. Front axle

Drag LinkDisassembly

SUDSTA013L

Disassembly sequence1. Split pin2. End plug3. Spring4. Ball seat B5. Ball seat A6. Grease seat A

7. Split pin8. End plug9. Ball seat A10. Ball seat B11. Spring12. Grease seat B13. Drag link

Reassembly

EMTST5022A

To fit the end plugs in position on both the pitman armand knuckle arm ends, first fully tighten, back off a halfturn, and secure with a split pin. Face the split pin headoutward.

Tie RodDisassembly

SUDSTA014L

Disassembly sequence1. Split pin2. Slotted nut

3. Washer4. Clip

5. Dust seal6. Tie-rod end assembly

7. Large head bolt8. Tie rod

Inspection1. Measurement of Tie Rod Runout

Nominal value (mm) Less than 2

Limit (mm) 2

EMTST5024A

Reassembly

SUDSTA015L

1. Split pin2. Slotted nut3. Washer4. Dust seal5. Clip6. Tie-rod end assembly7. Large head bolt8. Tie rod

Manual Steering SystemManual Steering Gear BoxComponents

SUDSTA016L

Disassembly sequence1. Pitman arm2. Side cover3. Adjusting plate4. Adjusting screw

5. Cross shaft6. Dust cover7. End cover8. End cover shim*9. Main shaft

10. Ball bearing11. Oil seal12. Steering gear housing13. Oil seal14. Oil plug

The part marked with * must be inspected beforedisassembly.For disassembly of parts with an encircled number, seeDisassembly given later.

NOTICE• Do not disassemble the steering gear housing and

bushing in the side cover.• Do not disassemble the ball nut from the main shaft.

DisassemblyNOTICE

Measurement of Starting Torque of Main ShaftBefore disassembling the cross shaft to remove it,measure the starting torgue to be served the torgue asreference when reassemble it.

EMTST5036A

1. Draining of Gear OilRemove the oil plug to drain gear oil.

EMTST5037A

2. Removal of Pitman Arm• Remove the nut that secures the pitman arm and

remove the pitman arm.• Use pitman arm puller for the special tool.

EMTST5038A

3. Removal of Cross Shaft• With the ball nut moved to the center of the

gearbox, remove the cross shaft.

EMTST5039A

Reassembly

EMTST5040A

1. Selection of end cover shim and measurement ofstarting torque1) With the main shaft and end cover installed in the

steering gear housing, measure the end cover tosteering gear housing clearance with a thicknessgauge. The clearance is the shim thickness tobe selected.

End cover shim thickness

Thickness(mm)

0.05

0.06

0.07

0.10

0.20

0.30

0.50

EMTST5041A

2) Install the end cover shim selected and tightenthe end cover to the specified torque. Then,adjust shim to satisty with the specified startingtorque.

EMTST5042A

2. Selection of adjusting plateFit the adjusting screw into the T-groove in the crossshaft and select the adjusting plate to obtain aclearance of 0.1 mm or less.Adjusting plate thickness

Thickness (mm)

1.95

2.00

2.05

2.10

2.15

EMTST5043A

3. Installation of pitman armTo install the pitman arm, ensure that the V-groove inthe pitman arm lines up the groove that in the crossshaft.

EMTST5044A

4. Adjustment after reassembly1) Topping up with the Gear oil

With being the steering gear in the installedposition, top up with gear oil SAE #90 or theequivalent

EMTST5045A

2) Adjustment of main shaft starting torqueAfter reassembly, measure again the main shaftstarting torque to ensure that it is up tospecifications.To adjust the torque, loosen the nut "X" and turnthe adjusting screw.

EMTST5046A

Power Steering SystemPower Steering Gear BoxComponents

SUDSTA017L

Disassembly sequence1. Pitman arm2. Dust cover3. Oil seal4. Jam nut5. Side cover

6. Needle bearing7. U-packing8. Cross shaft9. Adjusting bolt10. Adjusting plate

11. Dust cover12. Valve housing assembly13. Angular contact bearing14. Bearing15. Oil seal

*16. Ball screw unit17. Lock screw18. Gearbox19. Needle bearing20. U-Packing

Inspection of the part marked with * must be made before disassembly.For disassembly of parts with an encircled number, see Disassembly given later.

NOTICE• O-rings, oil seals, seal rings, and other rubber parts

must be replaced with new ones whenever they are

disas sembled.• Make sure that the alignment mark on cross shaft

end face in perpendicular to the main shaft axis.

• Use treated oil and compressed air to remove dirtfrom metal parts.

• Keep disassembled of parts to not be damaged.

DisassemblyNOTICE

Inspection before Disassembly1. Turn input shaft clockwise and counterclockwise to

discharge oil from the cylinder. At the time, checkdischarged oil for contamination

2. Measure the starting torque of the input shaft.

EMTST5060A

1. Removal of Pitman Arm

EMTST5061A

2. Removal of Cross Shaft and Side CoverBecareful that the cross shaft serration does damageto other parts.

EMTST5062A

3. Disassembly of cross shaft from side cover

EMTST5063A

4. Removal of Valve Housing and Ball Screw Unit

EMTST5064A

Reassembly

EMTST5065A

INSPECTION1. Measurement of Input Shaft Starting Torque

Starting torgue : 29~69 N cm (3~7 kgf·cm, 2.2~5.1 lb-ft)

EMTST5066A

2. Installation of Cross Shaft Into Side CoverAfter installation, make sure that the input shaft turnsapproximately 5.5 turns. If not, it means that theneutral position is not reached. Reinsert the shaft.

EMTST5067A

3. Measurement of Overall Starting TorqueMeasure the starting torque by turning the input shaftapproximately 1/4 turn in clockwise andcounterclockwise directions. If the specified value isnot obtained, adjust with the adjusting bolt.

Starting torgue : 49~98 N cm (5~10 kgf·cm, 3.6~7.2lb-ft)

EMTST5068A

4. Installation of Oil Seal

EMTST5069A

5. Backlash Adjustment of Cross ShaftWith gears meshed in neutral position, measure thebacklash at pitman arm end. Use adjusting bolt foradjustment.

NOTICEAfter the backlash has been adjusted, move thepitman arm to make sure that the rack piston movessmoothly throughout the entire range of operatingangle.

EMTST5070A

Power Steering Oil PumpComponents

SUDSTA018L

1. Mounting bolt2. Oil pump cover assembly3. Gasket4. Lock pin5. Cam ring6. Rotor7. Vain8. Oil pump side plate9. O-ring (Outer)10. O-ring (Inter)11. Side plate spring

12. Front housing13. Connecting assembly14. Mounting bolt15. Suction pipe16. Oil seal17. Drive shaft18. Dust spacer19. Snap ring20. Pulley21. Pulley nut

Disassembly1. Remove the suction pipe and the O-ring after

removing two bolts from the oil pump body.

KPKA050B

2. Remove 4 bolts and the oil pump cover assembly.3. Remove the cam ring.4. Remove the rotor and the vain.5. Remove the oil pump side plate.

KPKA046B

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

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

KPKA055B

8. Supports the pulley with the metal plate (brass petalor aluminum) after fixing in the vice.Remove the spring washer and pulley nut.

KPKA056C

9. Pull and draw out the pulley.10.Remove the snap ring(A) of shaft by using snap ring

plier.Then remove dust spacer(B).

KPKA270B

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

KPKA058B

12.Remove the oil seal from oil pump body.

KPKA059B

13.Disconnect the connector from oil pump body andpull out the flow control value and the flow controlspring.

14.Remove the O-ring from connector.

CAUTION• Never disassemble the flow control.

KPKA060B

Inspection1. Inspect the free length of flow control spring.

Free length of flow control spring : 36.5mm

KPQE911B

2. Inspect the power of flow control valve.3. Check the shaft for wear and damage.4. Check the V-belt for wear and deterioration.5. Check the groove of rotor vain for wear.6. Inspect the contact surface of the cam ring and the

vain for wear.7. Check the vain for damage.8. Check the contact surface between the side plate(or

surface of pump cover) and shaft for stripes wear.

Reassembly1. Install the flow control spring, flow control valve and

connector.

KPKA060B

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

KPKA061B

3. Insert the shaft assembly(C) softly and install thespacer(B) and snap ring(A)

KPKA062B

KPKA270B

4. Install the steering pump gear.

KPKA056C

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

plate(A)

KMTST5032

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

EMTST5073A

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

side.

KMTST5034

10.Install the gasket and oil pump cover assembly.11.Install the suction pipe and the O-ring.

KMTST5035