Steering System - Power Hyundai Elantra I

DESCRIPTION & OPERATION

Power-assisted rack and pinion steering system consists of a vane pump, flow control valve and an oil reservoir. The belt-driven vane pump supplies fluid through hoses to the flow control valve. The flow control valve supplies fluid to the rack and pinion steering gear to steer the wheels.

STEERING PUMP PRESSURE TEST

Note. Procedure for pressure testing Excel and Scoupe is not available from manufacturer.

Elantra & Sonata

1. Disconnect pressure hose from oil pump. Install pressure tester between pump and pressure hose, using Gauge (09572-21000 ), Adapter (09572-21200 ) and Adapter (09572-33100 ). (Scheme 1)
2. Bleed air from system. Start engine and allow it to idle. Turn steering wheel several times until fluid temperature reaches 122°F (50°C). Set engine idle speed to 1000 RPM.
3. Close and open shutoff valve to measure fluid pressure. Relief pressure should be at or near specification. See «RELIEF PRESSURE SPECIFICATIONS»(/hyundai/elantra/i-1990-1995/remont/manual-power-steering/#steering-system-power) table. If relief pressure is not as specified, replace pump. Install pressure hose. Bleed system.

RELIEF PRESSURE SPECIFICATIONS

Scheme 1

CAPACITY

Fluid capacity is approximately .95 qt. (.9L).

FLUID TYPE

Fluid type is Dexron-II.

FLUID LEVEL CHECK

1. Start engine. Place vehicle on level ground. Allow engine to idle. Turn steering wheel several times to bring steering fluid to normal operating temperature.
2. Turn steering wheel left and right several times while checking fluid for foaming or bubbling. Fluid level should be between MIN and MAX marks on the dipstick attached to filler cap. Fill with Dexron-II to MAX mark.

HYDRAULIC SYSTEM BLEEDING

1. Disconnect coil high tension wire. Crank engine intermittently for 15-20 seconds, while turning steering wheel left and right. Connect coil high tension wire. Start engine and let it idle. Turn steering wheel left and right until there are no air bubbles in the oil reservoir.
2. Check fluid level and ensure fluid is not milky. Turn steering wheel left and right, and ensure fluid level does not change. If fluid level changes more than .2" (5 mm) or if noise is heard from pump and control valve, fill with fluid to the MAX mark on dipstick.
3. Repeat step 2) until air bubbles are no longer present in fluid and fluid level ceases to fluctuate more than .2" (5 mm).

POWER STEERING PUMP BELT

BELT ADJUSTMENT

PINION PRELOAD

Note. Manufacturer doesn't supply pinion load checking procedures for Sonata or Scoupe TRW-type. Pinion preload specification for TRW-type is 5-13 INCH lbs. (.6-1.5 N.m).

Elantra, Excel & Scoupe (Mando-Type)

Using INCH-lb. torque wrench and Adapter (09565-11100 ), measure preload while turning pinion gear through one rotation. If preload is not 5-11 INCH lbs. (.6-1.3 N.m), adjust rack support cover. Check preload again. Tighten rack support cover lock nut.

Sonata (Mando-Type)

Center rack. Tighten rack support cover to 15-18 ft. lbs. (20-25 N.m). Loosen rack support cover approximately 10 degrees until preload is 5-11 INCH lbs. (.6-1.3 N.m).

Removal

1. Raise and support front of vehicle. Using Puller (09568-31000 ), separate tie rod ends from steering knuckles. Remove coupling bolt from pinion shaft joint inside passenger compartment.
2. Disconnect hydraulic lines from steering gear. Drain fluid. On Sonata 4-cylinder, remove center crossmember and stabilizer bar. On Sonata V6, temporarily disconnect muffler, remove left lower control arm and remove stabilizer bar.
3. On all models, remove steering gear mounting bolts. On Elantra, carefully remove steering gear from right side. On Excel and Scoupe, slowly remove steering gear from left side of vehicle. On Sonata, move steering gear completely to the right, and remove steering gear to left of crossmember. Avoid damaging rubber boots.

Installation

To install steering gear, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS table at end of article. Fill and bleed system. Ensure steering wheel rotates smoothly and check toe-in. See appropriate WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT section

1. «WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES»(ref-53738) - 1991
2. «WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES»(/hyundai/elantra/i-1990-1995/remont/wheel-alignment/#wheel-alignment-specifications-procedures) - 1992

Disconnect pressure and return hoses from pump. Drain fluid into container. Disconnect pressure switch connector. On all models, remove oil pump mounting bolts, belt and oil pump. If necessary for repair or replacement, remove reservoir retaining bolts and reservoir.

To install, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS table at end of article. Fill and bleed system.

STEERING GEAR

Note. The power steering gear box used on some Scoupe and Sonata models produced by TRW must be replaced as a complete assembly. Manufacturer does not recommend disassembly or repair.

Disassembly

1. With rack and pinion assembly mounted in soft-jawed vise, remove tie rod ends, boot clamps and rubber boots. Remove hydraulic feed tubes. While moving the rack slowly, drain fluid from gear housing. Remove end plug, and turn pinion fully clockwise and remove self-locking nut.
2. Using a chisel, unstake tie rod tab washer. Remove tie rod assemblies. Remove rack support cover locking nut. Using Remover (09565-21100 for all models except Sonata, 09565-31300 for Sonata 4-cylinder or 09577-33100 for Sonata V6), remove rack support cover.
3. Remove rack support spring, rack support and rack support bushing. Remove 2 pinion valve body housing bolts and pinion valve body (Elantra, Excel and Scoupe). On Sonata, remove pinion dust seal and snap ring and withdraw pinion assembly. On all models, turn rack stopper clockwise to align circlip with slot in gear housing for removal.
4. When circlip comes out of housing, turn rack stopper counterclockwise to remove circlip. Remove rack stopper, rack bushing and rack from gear housing by moving it toward the pinion side. Remove "O" ring and oil seal from rack bushing.
5. On Elantra, Excel and Scoupe, use a soft hammer to remove pinion valve from valve body housing. Using Remover (09565-21000 ), remove the oil seal and ball bearing from the valve body housing. On all models, use Bearing Remover (09517-21400 ) to remove ball bearing from gear housing. Use brass drift to remove needle bearing from gear housing. Use pipe to remove back-up washer and oil seal from rear of rack housing.

Inspection

Check bearings, rack bushing and rack teeth for damage and wear. Check for bent rack. Check pinion teeth for wear or damage. Check bearings for excessive play, seizure or abnormal noise during rotation. Replace all oil seals and "O" rings.

Scheme 2

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

1. Apply Dexron-II ATF to all "O" rings. Use multipurpose grease to lubricate rack teeth, bearings and teeth on pinion valve assembly. Reassemble in reverse order of disassembly.
2. Using Driver Handle (09555-21000 ) and appropriate gauge, guide and installer, install back-up washer and oil seal in gear housing. See «POWER STEERING GEAR ASSEMBLY EQUIPMENT»(/hyundai/elantra/i-1990-1995/remont/manual-power-steering/#steering-system-power) table. (Scheme 2) Using correct bearing installer, install new bearings (needle, taper or ball) in gear housing.
3. Using correct seal installer, install rack bushing seal. Install new "O" ring onto rack bushing. Install lubricated rack into gear housing. DO NOT cover rack vent hole with grease.
4. Install rack bushing and rack stopper. Push in rack stopper until snap ring groove of rack stopper is aligned with slotted hole in rack housing. Install circlip while turning rack stopper. When installed, end of circlip should not be visible through slotted hole in rack housing. (Scheme 3) POWER STEERING GEAR ASSEMBLY EQUIPMENT Application Part No. Elantra, Excel & Scoupe Rack Oil Seal Installer Gauge 09573-21000 Rack Oil Seal Installer 09573-21100 Rack Oil Seal Installer Guide 09573-21200 Gear Housing Tapered Bearing Installer 09432-21600 Gear Housing Ball Bearing Installer 09222-21100 Rack Bushing Oil Seal Installer 09434-14200 Valve Body Oil Seal Installer 09434-14200 Rack Support Cover Socket 09565-21100 Sonata (Mando-Type) Rack Oil Seal Installer Gauge 09573-21000 Rack Oil Seal Installer 09573-33000 Rack Oil Seal Installer Guide 09573-33100 Gear Housing Needle Bearing Installer 09222-21100 Gear Housing Seal Installer 09431-11000 Rack Bushing Oil Seal Installer 09431-11000 Gear Housing Ball Bearing Installer 09222-21100 Valve Housing Oil Seal Installer 09432-21601
5. On Elantra, Excel and Scoupe, use Installer (09432-21600 ) to install oil seal and ball bearing into valve body. On Elantra, install sealing rings onto pinion valve assembly. On all models, apply multipurpose grease to pinion valve assembly gears and Dexron-II fluid to valving areas. (Scheme 4) Install pinion valve into gear housing.
6. On Elantra, Excel and Scoupe, use Seal Installer (09434-14200 ) to install seal and bearing into valve body housing. On Sonata, use Bearing Installer (09222-21100 ) and Seal Installer (09432-21601 ) to install bearing and seal into valve housing. (Scheme 5)-8. Install snap ring.
7. On Elantra, Excel and Scoupe, install new gear housing-to-gear box oil seal and install gear box to rack housing. On all models, install the tab washer and then the tie rod. Align the tab washer tabs with grooves in rack. Stake tab washer into place.
8. With the pinion shaft turned fully clockwise, tighten a new self-locking nut to specification. Tighten end plug to specification. Using a punch, stake the plug in 2 locations on its circumference.
9. Install rack support bushing, rack support and rack support spring into rack. Center rack in housing. Install rack support cover. Move rack to center position. Tighten rack support cover to 11 ft. lbs. (15 N.m). for Elantra or 15-18 ft. lbs. (20-25 N.m) for all others.
10. Loosen cover approximately 30-60 degrees on Sonata or approximately 10 degrees on all others. Install lock nut and tighten to specification. See «TORQUE SPECIFICATIONS»(/hyundai/elantra/i-1990-1995/remont/manual-power-steering/#steering-system-power) table at end of article.
11. On all models, install hydraulic feed tubes. Lubricate bellows attaching groove in tie rod with multipurpose grease. Slide new rubber bellows boot attaching band onto tie rod.
12. Carefully install bellows in position. DO NOT twist bellows. Install attaching band onto bellows. Fill tie rod end with multipurpose grease, and install new dust cover with clip ring.
13. Install tie rod ends. Adjust length of each tie rod. Measure from outer edge of clamped bellows boot to outer edge of tie rod lock nut. See «TIE ROD INSTALLED LENGTH»(/hyundai/elantra/i-1990-1995/remont/manual-power-steering/#steering-system-power) table. Check and adjust pinion preload as necessary. See «PINION PRELOAD»(/hyundai/elantra/i-1990-1995/remont/manual-power-steering/#steering-system-power__pinion-preload) under ADJUSTMENTS.

TIE ROD INSTALLED LENGTH

1. Remove suction connector and suction connector "O" ring. Remove oil pump cover, cam case and ring. Remove "O" ring from cam case. Remove vanes from rotor. Remove snap ring from shaft, and separate rotor from shaft.
2. Tap rotor side of shaft lightly with a plastic hammer. Remove shaft assembly. Remove oil seal from pump body. (Scheme 9) Remove connector from pump body, and remove flow control valve and spring. DO NOT disassemble flow control valve. Remove oil pressure switch, spring and spool.

Inspection & Reassembly

Check pulley assembly and shaft, cam ring, rotor and vanes for wear. Check pump cover and pump body for abrasion. Check flow control valve for clogging. Apply Dexron-II ATF to "O" rings and vanes. Using new seals and "O" rings, reassemble pump in reverse order of disassembly. Install vanes into rotor in right direction. (Scheme 10)

Scheme 9

Scheme 10

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES
• RELIEF PRESSURE SPECIFICATIONS
• PINION PRELOAD