Steering System: Removal & Installation Kia Rio I рестайлинг

REPLACEMENT

1. Loosen the bolt A, B and C. see scheme 19
2. Turn the adjusting bolt D to release the belt tension.
3. Remove the belt.
4. Install a new drive belt and adjust the tension and deflection. See «ADJUSTMENT»(ref-177283-S40360722532005052600000).

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1. Raise the front of the vehicle and support it with safety stands.
2. Remove wheel and tire.
3. Pull out cotter pins, and remove nuts.
4. Separate the tie rod from the knuckle arm with SST (OK670 321 019). NOTE: Replace nuts temporarily so that screw threads do not become damaged.
5. Remove the catalytic converter.
6. Disconnect the high pressure and return pipe. Then seal them with dry cloth to prevent entry of foreign materials.
7. Remove the intermediate shaft.
8. Remove the four steering gear mounting bolts and washers.
9. Slide the steering gear to the left and pull the right tie rod through the fender opening.
10. Remove the steering gear by sliding it to the right.

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1. Secure the steering gear in a vice equipped with the protective jaw caps.
2. Remove the oil pipes.
3. Place the alignment marks on the left tie rod end to aid an installation.
4. Loosen the lock nut and remove the left tie rod end.
5. Remove the boot clips.
6. Remove the boot wires.
7. Remove the boots.
8. Remove the tie rods from the rack.
9. Remove the yoke plug lock nut and yoke plug.
10. Remove the spring and support yoke.
11. Remove the pinion and control valve assembly snap ring.
12. Remove the oil seal.
13. Remove the two valve housing attaching bolts.
14. Remove the valve housing and the pinion and control valve assembly.
15. If present, remove the shim (s) from the steering gear housing.
16. Remove the O-ring.
17. Remove the lower pinion bearing from the steering gear housing.
18. Tap lightly with a rubber mallet to remove the pinion and control valve assembly from the valve housing.
19. Remove the four Teflon R seals from the pinion and control valve assembly.
20. Use the suitable tool to press the bearing out of the valve housing.
21. Use the Outer Box Torque Adapter to rotate the rack bushing until the hooked end of the retaining wire is aligned with the slot in the steering gear housing.
22. Rotate the bushing.
23. Remove the rack from the right side of the steering gear.
24. Remove the bushing from the rack.
25. Remove the O-ring.
26. Use the Rack Oil Seal Remover to remove the seal by bottoming it into the rack with a plastic hammer.
27. Use the impact Slide Hammer and the Rack Oil Seal Remover to pull the seal out of the rack.
28. Remove the mounting brackets and grommets.

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1. Install the grommets and mounting brackets. NOTE: Ensure the lip spring of the seal points toward the installation tool.
2. Use the Rack Oil Seal Replacer and install a new seal.
3. Install a new O-ring by using the Piston Seal Replacer and the Rack Piston Seal Sizer.
4. Place the Short Rack Seal Protector over the end of the rack to protect the bushing. Install the bushing on the rack.
5. Place the Rack Oil Seal Protector over the rack as shown in illustration. Install the rack, with the rack oil seal protector, into the steering gear housing. Remove the rack oil seal protector.
6. Use the Pinion Bearing Replacer to install the lower pinion bearing.
7. If the valve housing, steering gear housing, or pinion and control valve assembly have been replaced, perform the valve housing adjustment procedure. If none of these components have been replaced, install any shims that were removed.
8. Use the Seal Installation Set to install a new Teflon R pinion seals on the pinion and control valve assembly. Install the first seal (the seal closest to the bearing) by sliding the Mandrel over the valve assembly to the first seal groove. Push the seal into the groove by using the Pusher. Size the seal by sliding the large end of Sizer over the seal. Before installing the second seal, place one Spacer on the valve assembly. Install and size the seal by using the Mandrel and the Pusher. Before installing the third seal, place two Spacers, on the valve assembly. Make sure both spacers are positioned on the valve assembly as the one shown in illustration. Install and size the third seal. To install the fourth seal, turn the second spacer around so the small ends of the spacers are facing each other on the valve assembly.
9. Insert the pinion and control valve assembly into the valve housing making sure that it seats properly.
10. Install a new O-ring.
11. Position the valve housing and the pinion and control valve assembly, then install the valve housing bolts. Tighten the valve housing bolts to 15~19 lb. ft. (21~26 N.m, 2.1~2.6 kg.m).
12. Use the Pinion Seal Replacer/Torque Adapter to install the bearing.
13. Use the Pinion Seal Replacer/Torque Adapter to install the seal.
14. Install the support yoke.
15. Install the spring.
16. Apply a sealant to the yoke plug threads. Install the yoke plug and tighten it to the specified torque. Tightening torque : 14.5 lb. ft. (19.6 N.m, 2 kg.m)
17. Loosen the support yoke.
18. Tighten the yoke plug with torque wrench to 43 lb. in (4.9 N.m, 50 kg.cm) three times, then return it 67.5 degrees.
19. Measure the pinion torque with the SST and spring scale. Standard : Center of rack +/- 90° 6.9~11.3 lb. in (0.8~1.3 N.m, 8~13 kg.cm) Scale reading : 800~1,300 kg (28.2~45.9 oz)
20. If not within the specification, repeat previous steps.
21. Use the Yoke Lock Nut Wrench to install the lock nut and tighten to 29~36 lb. ft. (39~49 N.m, 4~5 kg.m).
22. Install the tie rods.
23. Align the washer with the rack groove, and then crimp the washer.
24. Install the boots.
25. Install the boot wires.
26. Install the boot clips.
27. Install the left tie rod end and lock nut.
28. Install the oil pipes.

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1. Position the steering gear in its mounting location.
2. Attach the intermediate shaft to the steering gear pinion and tighten the mounting bolt to 13~20 lb. ft. (18~26 N.m,1.8~2.7 kg.m).
3. Connect the high pressure and return pipe and then tighten the bolts. Tightening torque : 29~43 lb. ft. (39~59 N.m, 4.0~6.0kg.m)
4. Install the steering gear mounting and tighten mounting bolt and nut. Tightening torque : 27~38 lb. ft. (37~52 N.m, 3.8~5.3kg.m)
5. Install the catalytic converter to the exhaust pipe. Tightening torque : 27~38 lb. ft. (37~52 N.m, 3.8~5.3kg.m)
6. Install the tie-rod end to the steering knuckle. Tightening torque : 27~38 lb. ft. (37~52 N.m, 3.8~5.3kg.m)
7. Install the tie rod end cotter pin.
8. Install the wheel and tire. Tightening torque : 65~87 lb. ft. (88~118 N.m, 9~12kg.m)
9. Lower the vehicle.
10. Add the power steering fluid and bleed air from the system.

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1. Disconnect the electrical connector from the Power Steering Pressure (PSP) switch.
2. Disconnect the suction hose.
3. Disconnect the high pressure hose.
4. Loosen the mounting bolt. Remove the lock bolt and disconnect the drive belt.
5. Remove the mounting bolt.
6. Remove the power steering pump.

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Note. Replace the pump assembly if necessary.

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1. Check the front and rear pump bodies for cracking or other damage and for abnormal wear of the moving surface of the rotor.
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.
6. Check the control valve for cracking and other damage, for clogging, and for abnormal wear of the moving part.
7. Check the spring for damage.

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1. Install the rotor to the shaft with the rotor's identification mark facing upward.
2. Install the cam ring so that its identification mark is facing downward.
3. Install the vanes (10 pieces) to the rotor, with the R part of the vanes facing outward.

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1. Install the power steering oil pump and install the mounting bolt.
2. Connect the drive belt.
3. Connect the high pressure hose. Tightening torque : 33~40 lb. ft. (44~54 N.m, 4.5~5.5kg.m)
4. Tighten the lock bolt. Tightening torque : 27.5~38.4 lb. ft. (37.24~51.94 N.m, 3.8~5.3kg.m)
5. Connect the return hose. NOTE: Verify that the white mark on return hose aligned with the white mark on return pipe.
6. Adjust the belt deflection by turning the adjusting bolt.
7. Connect the electrical connector from the Power Steering Pressure (PSP) switch.