Suspension PDF

GENERAL SS- 2
FRONT SUSPENSION SS- 9

REAR SUSPENSION SS-24
WHEEL AND TIRES SS-30
SS-2 SUSPENSION SYSTEM
General
Specifications
Suspension system
Items Specification
Suspension type Macpherson strut
Toe-in in(mm) Vacancy 0.12±0.12(3±3)
3 passengers laden 0±0.12(0±3)
Camber angle Vacancy 0.6° ±45'
Front Wheel alignment 3 passengers laden 0° ±45'
Caster angle Vacancy Г4Г+45'
3 passengers laden 2° 5' ±45'
King pin angle Vacancy 14° 7'
3 passengers laden 14° 56'
Front strut type Cylindrical double-acting
Suspension type Torsion beam axle
Toe-in in(mm) Vacancy 0.20 + 0.24(5+6)
Wheel alignment 3 passengers laden 0.24(6)
Rear Camber angle Vacancy - 0°53'+18'
3 passengers laden - 1°00' ±18'
Rear strut type Cylindrical double-acting
*Front caster and camber are not adjustable.

Rear camber and toe-in are not adujstable.
Wheel and tire
Item Size
Wheel Size 13x5J
Off-set in(mm) 1.57±0.04(40±1)
Material Steel (alumimium)
Tire Size P155/80R13 P175/70R13
(Only General) Air pressure kgf/cm2 (psi) 2.2 (32) 2.0 (29)
Tire Size P155/80R13, P175/70R13, P175/65R14
(Only Europe) Air pressure Front 2.1
kgf/cm2 Rear ® 2.1 ® 2.3
GENERAL SS-3
Special service tools

Troubleshooting guide
Suspension system
GENERAL SS-5
Condition Possible cause Action

• Bump Steer • Worn steering gear mounting • Replace the steering gear
bushings mounting bushings
• Loose or bent steering gear • Tighten or replace the steering
mounting brackets gear mounting brackets
. Steering gear not level • Adjust steering gear mounting
• Outer or Inner Shoulder • Excessive positive or negative • Check the camber. If incorrect,
Tire wear camber and camber change option is in
right direction, adjust the
camber setting. Check the front
suspension components for
looseness or damage
• Incorrect tire pressure . Adjust the tire pressure
. Excessive toe adjustment • Check the toe and adjust to
realign if necessary
• Sawtooth Pattern or • Excessive toe-in (high inboard • Check the toe and adjust to
Excessive Tire Wear edges) or toe-out (high outboard specification
edges)
• Cupping, Dishing or • Wheel/tire imbalance or runout • Check for wheel and tire
Excessive Tire wear conditions
• Defective struts • Check struts and replace if
necessary
. Tires not rotated properly • Tires should be rotated every
12,000 km
• Steering Wheel Does Not . Damaged tires or unbalanced • Check the tires.
Return properly wheels Replace the tires if necessary.
Balance the wheels if necessary.
• Improper wheel alignment • Adjust the wheel alignment
. Steering system malfunction • Check the steering system. If
necessary
. Damaged or stuck lower control • Replace the lower control arm
arm ball joint ball joint
. Steering Wheel Pulls to • Damaged tires or unbalanced • Check the tires.
One Side wheels Replace the tires if necessary.
Balance the wheels if necessary.
• Braking system malfunction • Check the brakes If necessary.
• Steering system malfunction • Check the steering system.
(Refer to section ST)
• Improper wheel alignment • Adjust the wheel alignment
• Damaged lower control arm ball • Replace the lower control arm
joint ball joint
* Weak coil spring • Replace the coil spring
• Damaged or worn lower control • Replace the lower control arm
arm bushing bushing
. Damaged or worn stabilizer • Replace the stabilizer bushings
bushings
• Damaged or worn stabilizer . Replace the stabilizer
• Abnormal Noise From • Poor lubrication/wear of lower • Lubricate or replace the lower
Suspension System control arm ball joint control arm ball joint if necessary
• Damaged or worn stabilizer . Replace the stabilizer
• Damaged or worn torsion beam • Replace the torsion beam
• Looseness of suspension • Tighten the connection
connection
arm bushing bushing
• Strut malfunction • Replace the strut if necessary
Condition Possible cause Action

. Front/Rear Suspension • Loose/broken strut mount bolts. • Tighten/replace the strut
Noises mount bolts. Refer to Section SS.
. Loose/missing strut mounting • Tighten/replace the strut
block mounting block
. Loose/missing strut bolts to lower • Tighten/replace the strut
control arm bolts
• Dry or rough brake cable holders • Lubricate the cable and cable holders.
. Body Rolls • Weak stabilizer • Replace the stabilizer
• Damaged or worn stabilizer • Replace the stabilizer bushings
bushings
• Damaged or worn lower control • Replace the stabilizer bushings
arm bushing
arm bushing bushing
• Body Leans • Weak coil spring • Replace the coil spring
bushings
arm bushing bushing
• Poor Riding Comfort . Weak coil spring • Replace the coil spring
. Strut malfunction • Replace the strut if necessary
• General Driving Instability . Damaged tires or unbalanced • Check the tires.
wheels Replace the tires
if necessary. Balance the wheels
if necessary
• Improper wheel alignment . Adjust the wheel alignment
• Steering system malfunction • Check the steering system. If
necessary
• Damaged lower control arm ball • Replace the lower control arm
joint ball joint
• Weak coil spring . Replace the coil spring
• Damaged or worn lower control . Replace the lower control arm
arm bushing bushing
bushings
GENERAL SS-7
Wheel and tire
CONDITION POSSIBLE CAUSE ACTION PAGE

Excessive or irregular
tire wear wheel and Tire
Premature tire Incorrect tire pressure Adjust Section SS

wear
Tire squeal Incorrect tire pressure Adjust Section SS
Tire deterioration Replace
Road noise or Insufficient tire pressure Adjust Section SS
body vibration Unbalanced wheel(s) Adjust Section SS
Deformed wheel(s) or tire(s) Repair or replace Section SS
Irregular tire wear Replace Section SS
"Shake" occurs Excessive tire and wheel runout Replace
(Steering wheel Loose lug nuts Tighten Section SS
vibrates up/down) Unbalanced wheel(s) Adjust Section SS
Cracked or worn engine mount rubber Replace Section EM
Cracked or worn transaxle mount rubber Replace Section MT
AT
"Shimmy" occurs Excessive tire and wheel runout Replace
(Steering wheel Loose lug nuts Tighten Section SS
vibrates left/right) Unbalanced wheel(s) Adjust Section SS
Irregular tire wear Section SS
Insufficient tire pressure Adjust 53-5
Damaged or worn front wheel bearing Replace Section DS
Malfunction of steering system Section ST
Malfunction of suspension Section SS
Steering wheel Incorrect tire pressure Adjust Section SS

pulls to one side Excessive or irregular tire wear Section SS
Malfunction of braking system Section BR
General driving Unequal tire pressures Adjust SectionSS

instability Deformed wheel(s) or tire(s) Repair or replace
Loose lug nuts Tighten SectionSS
Uneven (one-sided) Unequal tire pressures Adjust Section SS

braking Malfunction of braking system Section BR
Heavy handling Insufficient tire pressures Adjust Section SS

Steering wheel Insufficient tire pressure Adjust Section SS

doesn't return Malfunction of steering system Section ST
properly Malfunction of suspension Section SS
FRONT SUSPENSION SS-9
Front suspension
Description
Front suspension
The front suspension system on Rio is a typical MacPherson strut layout with single pivot forged control arms.
The front suspension consists of the following :
• A transverse front tension rod that limits sway and doubles as a trailing arm on each side to maintain control arm
alignment.
• The control arms include integral ball joints which allow steering and ride travel of the wheels. The wheels are mounted
on steering knuckle forgings, clamped to the control arm ball joints and bolted to the strut lower ends.
• The upper ends of the struts are seated in towers in the engine compartment. Caster and camber are not adjustable.
• Rubber bushings at the control arm and tension rod mounting points cushion road shocks.
(1) Tension rod (4) Steering knuckle

(2) Control arm (Lower arm) (5) Stabilizer control link (Except General)
(3) Front strut (6) Stabilizer bar (Except General)
Check and adjustment Tension rod

Check the following points or replace if necessary.
1 .Looseness of the installation bolts and nuts.
Coil spring
2.Worn or deteriorated bushing.
If loading is normal and vehicle attitude is not, check for
spring damage, spring sag, or non-standard replacement
Front wheel alignment
springs.
Pre-inspection
1. Check the tire inflation and set to the recommended
pressure if necessary.
2. Inspect the front wheel bearing play and correct if
necessary.
3. Inspect the wheel and tire runout.
4. Inspect the ball joints and steering linkage for
excessive looseness.
5. Place the vehicle on level ground with no luggage or
passenger load.
6. The difference in height from the center of the wheel
to the fender brim between the left and right sides
should be within 0.39 in (10 mm)
AB3054003 H* Notice
The caster and camber is not adjustable.
The toe-in is adjustable.
Struts
Bounce test the vehicle at each front corner and at the Adjustments
rear bumper to check the strut function. Damping action Steering angle-maximum turning angle to left and to
should be positive and uniform all around. right
Inspect the struts for evidence of oil leakage. A thin film
is normal. Check the rear strut upper bushing by shake- 1. Place both front wheels on a turning radius gauge.
testing with the vehicle raised just enough to unload the 2. Turn wheels fully to left and note angles for left
struts (wheels still on the ground). Any looseness is (inner) and right (outer) wheels.
indicative of worn or deteriorated bushings, which must 3. Loosen both left and right tie rod jam nuts, then turn
be replaced. both tie rods to achieve specified angles. Tighten
jam nuts.
Lower arm 4. Repeat for a full right turn; right is now inner and left
Check the following points, repair or replace if necessary. is now outer.
1 .Loose installation bolts and nuts.
2.Deformation or cracks in the lower arm.
5. Tighten tie rod jam nuts. Adjustment

To adjust the toe-in, loosen the left and right tie rod lock
Tightening torque: nuts and turn the tie rods by the same amount.
25~37 Ib-ft (34-50 N-m, 3.5~5.1 kg-m)
Г* Caution
6. Inspect and adjust toe after adjusting steering The left and right tie rods are both right hand
angle. thread. To increase the toe-in, turn the right tie
rod toward the front of the vehicle, and turn the
left tie rod by the same amount toward the rear.
One turn of the tie rod (both sides) changes the
toe-In by about 0.24 In (6 mm).
Adjust the toe-In after adjusting the steering
angle.
AB3054018
Toe-in
Inspection
1. Raise the front of the vehicle until the wheels clear the
ground.
2. Turn the wheels by hand and mark a line in the center
of each tire tread using a scribing block.
3. Place the front wheels in the straight-ahead position Tighten the tie rod lock nuts to the specified torque.
and lower the vehicle.
4. Measure the distance between the marked lines at the Tightening torque:
front and rear of the wheels. 25-36 Ib-ft (34-50 N m, 3.5-5.1 kg-m)
Both measurements must be taken at equal distances
from the ground.
The distance between the wheels at the rear should
be greater than that at the front by 0.12±0.12 in (3±
3mm).
Front MacPherson strut and spring
Raise the front of the vehicle and support it with safety stands.
(1) Hose clip (4) MacPherson strut

(2) Bolt and nut (5) Stabilizer control link (Except General)
(3) Mounting block nut (6) Stabilizer control link nut (Except General)
Removal 4. Detach the knuckle from the strut.

Raise the front of the vehicle and support it with safety
stands.
1. Remove the clip of the strut side.
2. Remove the flexible hose and ABS sensor cable
from the strut bracket.
Disassembly
(1) Nut (6) Dust boot

(2) Plate (Sheet) (7) Coil spring
(3) Mounting block (8) MacPherson strut
(4) Spring seat (upper) (9) Bump stopper
(5) Seat rubber
1. Secure the mounting block in a vise.
Г* Caution
Use protective plates In the Jaws of the vise
2. Loosen the piston rod nut a few turns. Do not

remove it.
T
Jt Caution
Do not remove the nut
3. Use the SST or equivalent, and compress the

spring to unload the strut.
4. Remove the strut nut and lockwasher.

8. Before assembly, inspect the struts.
5. Remove the strut mounting block and plate.
Inspection 7. Secure the strut rod in the mounting block with the
Check the following points, repair or replace if lockwasher and strut rod nut.
necessary.
Tightening torque:
1. Oil leakage or abnormal noise from the
41-50 Ib-ft (55-68 N-m, 5.6-6.9 kg-m).
MacPherson strut.
2. Deterioration or damage to the mounting block.
3. Damaged or loose bearing.
Wear or damage to bump stopper and dust boot.
& AB3A54028
Assembly
1. Slide the bump stopper and dust boot onto the strut
rod and over the body.
2. Install the compressed spring, seat rubber, and
upper spring seat, positioning the spring ends
against the step in the seats.
3. Install the strut mounting block with the white
alignment spot on the same side of the strut as the
steering knuckle mounting bracket.
4. Install the plate.
5. Temporarily tighten strut rod nut by hand.

6. Release and remove the spring compressor.
3. Install the steering knuckle in the strut lower bracket 5. Position the brake line and ABS sensor cable in the
and install the two strut lower bracket nuts with cutout on the strut lower bracket and secure it with the
attaching nuts. brake line clip.
Tightening torque:
76-90.4 Ib-ft (103-123 N-m, 10.5-12.5 kg-m).
AB3054026
4. Install the stabilizer control link to the bracket mounted

to the strut (Except General).
Tightening torgue:
32-45 Ib-ft (43-60.8 N-m, 4.4-6.2 kg-m)
Lower arm and tension rod

Removal
(1) Nut (7) Nut

(2) Stopper bushing (8) Washer
(3) Rubber (9) Bushing
(4) Bolt (10) Tension rod
(5) Nut & Washer (11) Bolt
(6) Cotter pin (12) Bushing
1. Jack up the front of the vehicle and support it with 6. Lower the lower arm, prying the ball joint stud out of
safety stands. the steering knuckle, after loosening bolt and nut.
2. Remove the wheel and tire. Remove the lower arm after loosening the lower
3. Remove the tension rod attaching bolt at the frame arm attaching bolt from the frame bracket.
bracket.
AB3054037
4. Remove the tension rod bushing cotter pin and

attaching nut from the rear of the lower arm, and
remove the washer and bushing.
5. Pull the tension rod out of the lower arm and
remove the front bushing and washer.
Installation
1. Connect the SST to the ball stud, and measure the

torque with a pull scale.
Rotation torque:
7.2-25.2 Ib-ft (1.0-3.5 N m, 10-35 kg-cm)
Pull scale reading :
2.2-7.7 Ib (10-35 N, 1~3.5kg)
AB3054045
2. Raise the inner end of the lower arm into the pivot
bracket on the frame, and loosely tighten the arm
frame bracket pivot to hold it in place.
3. Position the lower arm ball joint stud in the clamp bore
of the steering knuckle and install the ball joint clamp
bolt and nut.
Tightening torque:
40-50 Ib-ft (54~68N-m, 5.5~6.9kg-m)
4. Tighten the lower arm frame bracket pivot bolt.
Tightening torque:
40-50 Ib-ft (54~68N-m, 5.5~6.9kg-m)
5. Insert the tension rod bolt into the lower arm, tighten
washer and bushing, and Install cotter pin.
6. Install bushing and rubber on the tension rod.
Tightening torque:
87-108 Ib-ft (118~147N-m, 12~15kg-m)
Stabilizer bar and control link (Except General)
(1) Stabilizer control link (5) Stabilizer mounting bracket attaching bolt
(2) Nut (6) Engine-mounting member bolt and washer
(3) Stabilizer mounting bracket (7) Engine-mounting nut
(4) Rubber bushing (8) Stabilizer bar
Removal 4. Remove the stabilizer from the stabilizer control link.

1. Support engine with SST (OK201 170 AAOA)
OK201 170 AAOA
5. Remove the control link from the control link bracket

on the strut.
2. Raise and support the vehicle with safety stand.
3. Remove wheel and tire.
6. Remove the stabilizer bar mounting bracket Inspection

attaching bolt and mounting bracket. Check the following points and replace if necessary.
1. Worn or deteriorated rubber bushing.
Stabilizer bar 2. Bent, cracked or damaged stabilizer.
Installation
1. Align the stabilizer bushing with the installation
position line painted on the stabilizer bar. Locate
the bushing adjacent to the position line on
stabilizer bar.
7. Remove the engine-mounting member bolts and

nuts from the front side of the engine-mounting
member.
8. Lower the engine-mounting member enough to pull

the stabilizer out from the engine-mounting member.
9. Remove the stabilizer bar.
4. Install the stabilizer bar mounting bracket attaching

bolt and mounting bracket and tighten the attaching
bolt.
Tightening torque:
26~42lb-ft (36~56N-m,3.7~5.8 kg-m)
АВЗА54003
5. Install the stabilizer control link onto control link

bracket on the strut.
Tightening torque:
32~45lb-ft (43~60.8N-m,4.4~6.2 kg-m)
6. Install the stabilizer bar on the stabilizer control link.
Tightening torque:
32~45lb-ft (43~60.8N-m,4.4~6.2 kg-m)
Ф Notice
Tighten the two stabilizer control link nuts to
specified torque before lowering vehicle (unload
condition).
7. Install the wheel and tire.

8. Lower the vehicle.
9. Remove the SST (201 170 AAOA) from engine.
Rear suspension
Description
The rear suspension system is the torsion beam axle type separated with spring and damper.
The rear suspension system works as follows:
. Suspension action is semi-independent, with the wheels carried on trailing arms, rigidly connected to each other by
a torsion beam.
. The beam provides positive control of trailing arm alignment, yet flexes in torsion to permit limited independent
wheel action, and is welded with the stabilizer bar at the beam to prevent it from rolling.
. For isolation of road vibration, heavy rubber bushings are installed at the torsion beam/trailing arm body brackets,
and rubber insulators cushion the spring seats in the strut towers.
(1) Torsion beam axle (4) Lateral link

(2) Rear strut (5) Trailing link
(3) Coil spring (6) Stopper
Torsion beam axle
(1) Torsion Beam (5) Stopper assembly

(2) Shock absorber (6) Lateral link
(3) Coil spring (7) Trailing bracket
(4) Rubber seat
Removal 6. Remove the flexible hose clip and remove the brake
1. Raise the rear of the vehicle and support it with pipe from bracket.
safety stands after releasing the parking brake.
2. Remove the wheel and tire assemblies. Ф Notice
3. Install the jack under the torsion beam axle. Cover the brake pipe and flexible hose to prevent
4. Loosen the rear shock absorber lower bolt. them from leaking fluid and dust contamination.
10. Release the backing plates and wheel spindle

* Notice
supports after removing the four brake backing
Be careful not to damage the parking brake cable.
plate/wheel spindle support assembly nuts from the
back of each brake assembly.
15. Remove the torsion beam axle
16. Remove the rear shock absorber upper bolt.
17. Remove the spring upper seat bolt.
11. Remove the torsion beam trailing bracket bolt.

12. Loosen the flange nut and bolt to remove the
torsion beam and trailing bracket.
18. Use the SST or equivalent to press the bushing out
of the torsion beam arms from the inboard side.
OK670 990 AAO
13. Remove the lateral link from the body.
Inspection
Check the deformation.damage or cracks, replace if
necessary.
14. Loosen the lateral link and torsion beam axle

tightening nut to remove the lateral link.
Installation 9. Tighten the flange bolt and nut of the trailing

1. Position the bushing on the outboard sides of the bracket.
torsion beam arms with the marks aligned parallel
to the arm axis and press them in with the SST or Tightening torque:
equivalent. 72-87 Ib-ft (98-118N-m,10-12kg-m)
10. Install the brake back plate and wheel support

assembly.
Tightening torque:
32-45 Ib-ft (43-61 N-m,4.4-6.2kg-m)
Notice
The arrow mark moulded on the bushing face
should be front side up.
The bushings may be lubricated with soapy water AB3054082
for easier installation. Do not use oil or grease.
11. Install the parking brake cable bracket to the torsion
2. Install the spring upper seat. beam axle.
Tightening torque: Tightening torque:

27-40 Ib-ft (36~54N-m, 3.7-5.5kg-m) 14-19 Ib-ft (19-26N-m,1.9-2.6kg-m)
3. Install the rear shock absorber upper bolt. 12. Install the flexible hose to the torsion beam axle.
13. Insert the flexible hose clip.
Tightening torque:
34-42 Ib-ft (46~57N-m, 4.7-5.8kg-m)
4. Tighten the flange nut and bolt lightly to install

trailing bracket to the torsion beam axle.
5. Install the torsion beam axle to the vehicle by using
the mission jack.
6. Install the lateral link to the body.
Tightening torque:
58-72 Ib-ft (78~98N-m, 8~10kg-m)
7. Install the lateral link to the torsion beam axle.
Tightening torque:
58-72 Ib-ft (78-98N-m, 8~10kg-m)
8. Tighten the flange bolt and nut of the torsion beam

bracket.
Tightening torque:
40-50 Ib-ft (54~68N-m,5.5~6.9kg-m)
14. Connect the brake pipe to the brake hose.
Tightening torque:
9.4~17 Ib-ft (13~23N-m, 1.3~2.3kg-m)
15. Lower the jack slightly to install the coil spring to the
torsion beam axle.
16. Tighten the rear shock absorber lower bolt.
Tightening torque:
58-72 Ib-ft (78~98N-m, 8~10kg-m)
Air leakage
Wheel and tires
verify that there is no air leakage from the air valve.
Service adjustment procedures
Inspection/Adjustment
Air pressure
Always check tire inflation pressure using an accurate
pressure gauge. Never inflate the tires to levels above
or below the recommended pressure. Tire inflation
pressures are carefully calculated to give the vehicle
satisfactory ride and steering characteristics, without
compromising the tire tread life.
BSX053002
Tire wear
To maximize tire performance, inspect the tires for
patterns of wear that may indicate improper inflation, a
need for rotation, a need for balancing or front-end
alignment, or a need for front suspension alignment. If
the tires show uneven or abnormal wear patterns.
Check the tires frequently for cuts, stone bruises,

abrasions, blisters, and objects imbedded in the tread.
Inspect them more frequently in times of rapid or
extreme temperature changes, and after driving on
rough road surfaces and road surfaces that are littered
with debris.
As an additional tire condition check, wear indicators

are imbedded in the bottom of the tread grooves.
These indicators appear as O.Sinch (12.7mm) wide
bands that show when the tread depth is reduced to
0.0625 Inch (1.6mm). When the wear indicators appear
in two or more adjacent tread grooves, at three or more
locations on the tire, or when cord or fabric is exposed,
replace the tire.
WHEEL AND TIRES SS-31
Inspection (Tire and wheel) Lug nut

Check any tire for leaks if it regularly requires the addition 1. Verify that the lug nuts are tightened to the specified
of more air. Check for leaks at the valve stem, valve core, torque.
tread, sidewall and bead. Check tires visually for cracks,
damage and foreign matter such as pieces of metal, Tightening torque:
stones, glass and nails. Check the wheel rims regularly for 65-87 ft-lb (88-118 N m, 9-12 kg-m)
damage.
Wheel and tire runout

1. Jack up the vehicle and place it on safety stands.
2. Set the probe of a dial indicator against the wheel, and
measure the runout through one full revolution.
Runout
in (mm)
Wheel 0.059(1 .5) max.
Tire 0.059(1 .5) max.
3. Replace the wheel if necessary.
r
J Caution
Adjust wheel balance after replacement of a
wheel or tire.
Removal/Installation Wheel balance adjustment

1. The wheel-to-hub contact surfaces must be clean. If a wheel becomes unbalanced or if a tire is replaced
2. Tighten the lug nuts to the specified torque. or repaired, the wheel must be rebalanced to within
specification.
Tightening torque:
65-87 ft-lb (88-118 Mm, 9-12 kg-m) Maximum unbalance (at rim edge): 20 g (0.71 oz)
STEERING
SYSTEM
GENERAL ST- 2
STEERING COLUMN AND SHAFT ST- 6
POWER STEERING GEAR AND LINKAGE ST-17
POWER STEERING OIL PUMP ST-27
ST-2 STEERING SYSTEM
General
Specifications
Steering system
GENERAL ST-3
Special service tools

Steering system
OK670 321019
Ball joint puller
Troubleshooting guide
Steering system
Manual steering
GENERAL ST-5
Steering column and shaft

Description
Manual steering
The manual rack-and-pinion steering gear is sealed against the entry of water or foreign material by rubber boots enclosing
the tie rod inboard ends at each end of the housing and by a third boot surrounding the pinion shaft and steering column
intermediate shaft. The steering gear is lubricated at assembly and must be removed and disassembled if relubrication
becomes necessary. The rack is positioned and guided in the housing by a bushing at the right end and a support yoke
holding it in engagement with the pinion at the left end. The support yoke is spring-loaded against the rack. A yoke plug and
locknut keeps the rack fully engaged with the pinion under load.
Rubber insulating mounts at each end of the housing cushion the steering gear mounting points and minimize vibration.
Looseness or deterioration of the mounts can cause noise and vibration problems.
These should be checked when investigating for such concerns.
(1) Boot (3) Steering column

(2) Steering wheel (4) Steering gear and linkage
STEERING COLUMN AND SHAFT ST-7
Power steering
The power steering system consists of:

Rack and pinion steering gear
Power steering pump
Fluid reservoir
Interconnecting hydraulic lines
The power steering system uses a hydraulic pressure which is generated by the power steering pump to reduce the effort
required to turn the steering wheel.
The power steering pump is mounted on the front of the engine. The pump has a vane-type design, and is driven by the
crankshaft through a drive belt.
The power steering fluid is drawn into the pump from the reservoir when the engine is running. The fluid is pressurized by
the rotation of the rotor and vanes, then sent to the steering gear. The fluid pressure is monitored and regulated by a Power
Steering Pressure (PSP) switch and a control valve located in the power steering pump.
(D
(1) Steering wheel (4) Oil pipe & hose

(2) Steering column (5) Oil reserve tank
(3) Steering gear and Linkage (6) Oil pump
Service adjustment procedure.

Manual steering
With the ignition OFF and the wheels in the straight ahead
position, turn the steering wheel left and right until wheel
resistance is felt. Free play should not exceed 1.18
inches (30 mm) at the wheel rim.
$ Notice
For accurate readings, always pull the scale in the
direction the point of scale attachment is moving
(tangential to the wheel rim) through the full circle.
AB3051001
4. Steering effort should be approximately 5~20 N (
Excessive free play indicates wear in the steering column 0.5-2.0 kg, 1~4.5 Ib) through a full revolution in
intermediate shaft universal joints, worn tie rod ends or
ball joints, or improper steering gear preload. either direction from the straight ahead position.
To check the steering column joints, grip or feel the lower 5. If excessive, check for binding or damage in the
joint at the floorboard and repeat the free play check. Any front suspension and the steering linkage
free play between the steering wheel and the lower joint at components. Check for excessive steering gear
the floorboard, which is clamped to the pinion shaft, is in preload.
the steering column assembly.
Check the tie rods by raising both wheels off the floor.
Check each wheel for wobble. First, check the wheels
vertically to verify that front wheel bearings are correctly
adjusted; then, check the wheels horizontally while an
assistant grips the steering column lower joint from inside
the vehicle. If horizontal wobble is present, check the tie
rod ends for free play or loose attachment to the steering
knuckles. If no free play is detected at the tie rod ends,
any horizontal wheel wobble must be the result of worn tie
rods, ball joints, or excessive gear free play between
steering gear rack and pinion. In either case the steering
gear must be removed, and adjusted, repaired or replaced
to correct the condition.
Steering wheel effort

1. Raise the road wheels clear of the floor and position
jack stands under the lower control arms, as close
to the wheels as possible without interfering with
steering travel.
2. Turn the steering wheel lock-to-lock at least five
times to free up any stickiness resulting from front
suspension components being out of their normal
riding positions, then place the wheels in the
straight ahead position.
3. Attach spring scale to the steering wheel rim and
measure the steering effort through one full turn of
the wheel.
Power steering Г* Caution

The valve on the power steering system
Power steering pressure testing analyzer must be closed briefly to read the
operating pressure. Do not leave the valve
T closed for more than 15 seconds.
J Caution
Make sure that the power steering system
5. Measure the power steering pump output pressure
analyzer valve Is OPEN to allow the system to
by closing the power steering system analyzer
function properly.
valve and increasing the engine speed to
Do not hold the steering wheel against a stop
1,000-1,500 rpm. The pressure specification is
for more than ten seconds at a time.
7,358-7,848 kPa (75-80 kg/cm2,1,067-1,138 psi).
АВ3051045
1. Disconnect the high-pressure line and attach Power • If the pressure is within specification, continue with
Steering System Analyzer or equivalent using the the remaining test procedures.
appropriate adapters. Tighten the adapters to 29-43 • If the pressure is low, repair or replace the power
Ib-ft (39-59 N-m, 4-6 kg-m). steering pump. If the pressure is too high, check
2. Insert a thermometer into the power steering fluid for a crimped pipe and repair/replace as
reservoir. necessary, or replace the power steering pump.
3. Bleed the system using the following procedure:
1) Check the fluid level in the reservoir, add fluid if 6. With the power steering system analyzer valve open,
necessary. increase the engine speed to 1,000-1,500 rpm.
2) Raise and support vehicle.
3) Turn the steering wheel fully left and fully right ten times.
4) Recheck the fluid level. If the level has dropped, Caution
add fluid to the reservior. Do not hold the steering wheel against a stop
5) Repeat Steps 3) and 4) until the fluid level for more than 15 seconds at a time.
stabilizes.
6) Key ON and let the engine run at idle.
7) Turn the steering wheel fully left and fully right ten times.
8) Verify that the fluid is not foamy. If the fluid is
foamy, air is still present in the system.
Repeat Steps 2) through 7).
$ Notice
Check the system for an air leak if foam is still
present.
4. Check the power steering fluid temperature. If the

temperature is not at 50-60°C (122~140°F), turn
the steering wheel back and forth until the specified
temperature is reached.
7. Turn the steering wheel all the way to the right or left $ Notice
and read the measured pressure. The pressure For accurate readings, always pull the scale in the
specification is 7,358-7,848 kPa (75-80 kg/cm2, direction the point of the scale attachment is moving
1,067-1,138 psl). If the pressure is not within the (tangential to the wheel rim) through the full circle.
given specification, repair or replace the steering gear.
5. If the effort is greater than the specification, check
for low fluid level, air in the system, and fluid
leakage. Check the power steering pump pressure,
steering gear pressure and tire pressure.
6. Remove the thermometer.
Power steering fluid level inspection

and adding Power steering fluid
1. Check the power steering fluid level.
If necessary, fill the fluid reservoir until the level is
between the MAX and MIN lines.
8. Remove the power steering system analyzer and

adapters. Reconnect the high-pressure line and
tighten the high-pressure line fitting to 11.5-17.3
Ib-ft (16-24 N m, 1.6-2.4 kg-m)
9. Remove the thermometer and bleed the system
as stated in Step 3.
Steering wheel effort

1. Insert a thermometer into the power steering fluid AB30521098
reservoir. 2. Run the engine until it reaches normal operating
temperature, then turn the steering wheel from lock
r* Caution to lock 10 times.
Do not hold the steering wheel against a stop 3. Turn the engine off with the wheels in the straight
for more than ten seconds at a time. ahead position.
4. Check the fluid level. If necessary, fill the fluid
2. Start the engine, then turn the steering wheel left reservoir until the level is between the MAX and
and right several times until the fluid temperature MIN lines.
reaches 50~60°C (122~140°F).
3. With the vehicle on a hard, level surface, turn the Air bleeding
steering wheel until the wheels are in the straight
1. Check the fluid level.
ahead position.
2. Raise and support the vehicle.
4. Attach Spring Scale to the steering wheel rim and
3. Turn the steering wheel fully to the left and right
measure the steering effort through one full turn of
several times with the engine not running.
the wheel. The steering wheel effort should be 39 N
4. Recheck the fluid level. If it has dropped, add a fluid.
(4 kg, 8.8 Ib) or less.
5. Repeat Steps (2) and (D until the fluid level

stabilizes.
6. Start the engine and let it idle.
7. Turn the steering wheel fully to the left and right
several times.
8. Verify that fluid is not foamy and that the fluid level
has not dropped.
9. Add a fluid if necessary and repeat Steps © and ®.
Steering wheel and column
Removal
®-
(1) Horn cap (7) Steering column

(2) Washer & nut (8) Universal joint
(3) Steering Wheel (9) Pinch bolt
(4) Column cover (10) Dust cover
(5) Combination switch (11) Intermediate shaft
(6) Ignition switch (12) Set plate
Removal 8. Remove the three lower steering column panel screws.

1. Disconnect the negative battery cable. Separate the upper and lower steering column panels.
2. Center the front wheels to the straight ahead
position.
AB3051001A
3. Remove the module mounting bolts and remove the

module.
4. Disconnect the horn switch electrical connector.
5. Make an alignment mark on the steering wheel and
the steering shaft for proper installation.
6. Remove the steering wheel nut.
AB3051011
11. Disconnect the combination switch electrical

connectors.
12. Slide the combination switch off the steering column
shaft.
AB3051009
7. Install steering suitable tool and remove the
steering wheel. Route the wire harness through the
steering wheel as the wheel is lifted off the shaft.
rj> Caution
Do not attempt to remove the steering wheel by
hitting the steering shaft with a hammer. The
steering shaft will collapse, causing the
steering wheel to bind.
13. Remove the steering upper column after loosening 17. Remove the universal joint bolt
attaching bolts. 18. Remove the two lower column bracket nuts.
AB3051013
16. Remove the bolts with a screwdriver, then remove
the ignition switch. Inspection
Check the deformation, damage and cracks of the
r
J Caution steering shaft assembly and replace it if necessary.
Secure the shaft in a vise protected with brass
pads or cloth.
Installation 7. Tighten the intermediate shaft bolt.

1. Tighten the intermediate shaft bolt.
Tightening torque:
Tightening torque: 13-19 Ib-ft (17-26N m,1.8-2.7kg-m)
13-19 Ib-ft (17-26N m, 1.8~2.7kg-m)
8. Install the Ignition switch assembly on the jacket.
Install new Ignition switch bolts, and tighten them
until the heads break off.
9. Install the ignition switch connector.
10. Install the combination switch to the steering
column shaft.
11. Install the combination switch connector.
12. Tighten the combination switch screw.
13. Install the bracket.
AB3051016
2. Install the intermediate shaft dust cover and set
plate.
Tightening torque:
4.3-6.5 Ib-ft (5.8-8.8N m, 0.6~0.9kg-m)
3. Install steering joint bolt to steering column.
Tightening torque:
13-19 Ib-ft (17-26N m, 1.8~2.7kg-m)
4. Put the steering column joint into the intermediate

shaft and tighten bolt lightly.
5. Tighten the upper column attaching bolt to the
steering column.
Tightening torque:
11-17 Ib-ft (16-22N m, 1,6-2.3kg-m)
6. To install the steering column, push the steering

column in the shaft direction. The clearance
between the lower column attaching bolt and
bracket do not have to exceed to MAX
0.02in(0.5mm)
Tightening Torque:
14-19 Ib-ft (18-26N m, 1.9-2.7 kg-m)
15. Install the steering wheel.

16. Tighten the steering wheel nut.
Tightening torque:
39-49N m (4.0~5.0kg-m,29~36 Ib-ft)
17. Install the airbag module.

18 Connect the battery 0 terminal.
Power steering gear and linkage

Steering gear
Removal
CD
(1) Steering column intermediate shaft (5) Cotter pin

(2) Steering gear mounting bolt (6) Steering knuckle
(3) Tie rod boot (7) Tie rod end
(4) Tie rod nut (8) Steering gear & Linkage
1. Raise the front of the vehicle and support it with 7. Remove the intermediate shaft.
safety stands. 8. Remove the four steering gear mounting bolts and
2. Remove wheel and tire washers.
3. Pull out cotter pins, and remove nuts.
4. Separate the tie rod from the knuckle arm with
SST(OK670 321 019).
$ Notice
Replace nuts temporarily so that screw threads do
not become damaged.
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.
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.
Power steering gear
Disassembly
(1) Tie rod end (14) Snap ring

(2) Lock nut (15) seal
(3) Boot clip (16) Bearing
(4) Boot (17) Pinion shaft assembly
(5) Boot wire (18) Bolt
(6) Inner ball joint (19) Valve housing
(7) Rack bushing (20) O-ring
(8) O-ring (21) Steering gear housing
(9) Seal (22) Mounting rubber
(10) Lock nut (23) Mounting bracket
(11) Yoke plug (24) Oil pipe
(12) Spring (25) Rack
(13) Support yoke (26) Inner guide
1. Secure the steering gear in a vice equipped with the 7. Remove the boots.
protective jaw caps. 8. Remove the tie rods from the rack.
2. Remove the oil pipe.
11. Remove the pinion and control valve assembly snap 15. If present, remove the shim(s) from the steering
ring. gear housing.
19. Remove the four Teflon® seals from the pinion and 24. Remove the bushing from the rack.
control valve assembly. 25. Remove the O-ring.
20. Use the suitable tool to press the bearing out of the 26. Use the rack oil seal remover to remove the seal by
valve housing. bottoming it into the rack with a plastic hammer.
Assembly 5. Place the rack oil seal protector over the rack as
1. Install the grommets and mounting brackets. shown. Install the rack, with the rack oil seal
protector, into the steering gear housing.
Remove the rack oil seal protector.
$ Notice
Ensure the lip spring of the seal points toward the
installation tool.
2. Use the rack oil seal replacer and install a new seal.
AB3051071
7. If the valve housing, steering gear housing, or

pinion and control valve assembly have been
replaced, perform the valve housing adjustment
procedure outlined in this section. 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 9. Insert the pinion and control valve assembly into the
® pinion seals on the pinion and control valve valve housing making sure that it seats properly.
assembly. 10. Install a new O-ring.
a) Install the first seal (the seal closest to the 11. Position the valve housing and the pinion and control
bearing) by sliding the Mandrel over the valve valve assembly, then install the valve housing bolts.
assembly to the first seal groove. Push the Tighten the valve housing bolts to 15~19 Ib-ft (21~26
seal into the groove by using the Pusher. 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.
AB3051072
b) Size the seal by sliding the large end of Sizer

over the seal.
c) Before installing the second seal, place one
Spacer, on the valve assembly as shown.
Install and size the seal by using the Mandrel
and the Pusher.
d) 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. Install and size
the third seal.
e) 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.
14. Install the support yoke. 19. Measure the pinion torque with the SST and spring
15. Install the spring. scale.
16. Apply a sealant to the yoke plug threads.
Install the yoke plug and tighten it to the specified Standard:
torque. Center of rack ± 90°
6.9-11.3 Ib-in (0.8-1.3 N m, 8-13 kg-cm)
Tightening torque: Scale reading : 800~1,300 kg (28.2~45.9 oz)
14.5 Ib-ft (19.6 N m, 2 kg-m)
Installation 4. Install the steering gear mounting and tighten

mounting bolt and nut.
1. Position the steering gear in its mounting location.
2. Attach the intermediate shaft to the steering gear Tightening torque:
pinion and tighten the mounting bolt to 13-20lb-ft 27-38 Ib-ft (37~52N-m, 3.8-5.3 kg-m)
(18-26 N-m, 1.8-2.7 kg-m)
6. Install the tie-rod end to the steering knuckle.
Tightening torque:
27-38 Ib-ft (37-52 N m, 3.8-5.3 kg-m)
7. Install the tie rod end cotter pin

8. Install the wheel and tire.
Tightening torque:
65-87 Ib-ft (88-118 Mm, 9-12 kg-m)
9. Lower the vehicle.

10. Add the power steering fluid and bleed air from the
system.
Power steering oil Pump Adjustment

1. Loosen the bolt ®, ®, and ©. Turn the adjusting
bolt © to adjust the belt to the specified tension.
Drive belt 2. Tighten the lock ©, bolt ®, and ® to the specified
Inspection torques.
Torquening torque:
1. Check the drive belts for wear.cracks and fraying: Bolt ®: 13.7~18.8 Ib-ft (18.6~25.5 N-m, 1.9-2.6 kg-m)
replace if necessary. ®: 26.7-39.8 Ib-ft (36.3-54 N-m, 3.7-5.5 kg-m)
2. Check the drive belt deflection by applying
©: 26.8-39.8 Ib-ft (36.3-54 N-m, 3.7-5.5 kg-m)
moderate pressure (22lb, 98 N,10kg) midway
between the pulleys.
Adjust if necessary.
Power steering oil pump
Removal
The following illustration shows the power steering pump and related components.
(1) Drive belt (6) Power steering oil pump

(2) Power steering pressure (PSP) (7) Oil pump bracket
switch electrical connector (8) Adjust bolt
(3) Suction hose (9) Mounting bolt
(4) High pressure hose (10) Bracket bolt
(5) Eye bolt
1. Disconnect the electrical connector from the Power 4. Loosen the mounting bolt and nut.
Steering Pressure (PSP) switch. Remove the lock bolt and disconnect the drive belt.
2. Disconnect the suction hose. 5. Remove the mounting bolt.

6. Remove the power steering pump.
Suction hose
3. Disconnect the high pressure hose.

Disassembly / Assembly
1. The following procedures show replacement of the O-rings. If a problem is found in other parts, replace the
oil pump assembly.
2. Disassemble in the order shown in the figure with referring to the Disassembly Note.
3. Inspect all parts and replace as necessary.
4. Assemble in the reverse order of disassembly with referring to the Assembly Note.
(1) Suction pipe (11) O-ring

(2) 0-ring (12) Cam ring
(3) Pressure switch assembly (13) Vane
(4) O-ring (14) Rotor
(5) Connector (15) Side plate
(6) O-ring (16) O-ring
(7) Control valve (17) O-ring
(8) Spring (18) Pin
(9) Bracket (19) Pump body (front)
(10) Pump body (rear)
Assembly note Inspection

Rotor
1. Install the rotor to the shaft with the rotor's $ Notice
identification mark facing upward. Replace the pump assembly if necessary.
Pump body
1. Check the front and rear pump bodies for
cracking or other damage and for abnormal wear
of the moving surface of the rotor.
Control valve and spring Notice

1. Check the control valve for cracking and other Verify that the white mark on return hose aligned
damage, for clogging, and for abnormal wear of with the white mark on return pipe.
the moving part.
2. Check the spring for damage.
6. Adjust the belt deflection by turning the adjusting

bolt.
7. Connect the electrical connector from the Power
Steering Pressure (PSP) switch.
AB3051082
2. Connect the drive belt.

3. Connect the high pressure hose.
Tightening torque:
33-40 Ib-ft (44-54N m, 4.5-5.5 kg-m)
4. Tighten the lock bolt.
Tightening torque:
27.5-38.4 Ib-ft (37.24-51.94 N m, 3.8-5.3 kg-m)
5. Connect the return hose.

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Suspension PDF

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GENERAL SS- 2

FRONT SUSPENSION SS- 9

*Front caster and camber are not adjustable.

Wheel and tire

Special service tools

Condition Possible cause Action

Condition Possible cause Action

Wheel and tire

CONDITION POSSIBLE CAUSE ACTION PAGE

Premature tire Incorrect tire pressure Adjust Section SS

Steering wheel Incorrect tire pressure Adjust Section SS

General driving Unequal tire pressures Adjust SectionSS

Uneven (one-sided) Unequal tire pressures Adjust Section SS

Heavy handling Insufficient tire pressures Adjust Section SS

Steering wheel Insufficient tire pressure Adjust Section SS

(1) Tension rod (4) Steering knuckle

Check and adjustment Tension rod

5. Tighten tie rod jam nuts. Adjustment

Front MacPherson strut and spring

(1) Hose clip (4) MacPherson strut

Removal 4. Detach the knuckle from the strut.

(1) Nut (6) Dust boot

1. Secure the mounting block in a vise.

2. Loosen the piston rod nut a few turns. Do not

3. Use the SST or equivalent, and compress the

4. Remove the strut nut and lockwasher.

5. Temporarily tighten strut rod nut by hand.

4. Install the stabilizer control link to the bracket mounted

Lower arm and tension rod

(1) Nut (7) Nut

4. Remove the tension rod bushing cotter pin and

1. Connect the SST to the ball stud, and measure the

4. Tighten the lower arm frame bracket pivot bolt.

Stabilizer bar and control link (Except General)

Removal 4. Remove the stabilizer from the stabilizer control link.

OK201 170 AAOA

5. Remove the control link from the control link bracket

6. Remove the stabilizer bar mounting bracket Inspection

7. Remove the engine-mounting member bolts and

8. Lower the engine-mounting member enough to pull

4. Install the stabilizer bar mounting bracket attaching

5. Install the stabilizer control link onto control link

6. Install the stabilizer bar on the stabilizer control link.

7. Install the wheel and tire.

(1) Torsion beam axle (4) Lateral link

Torsion beam axle

(1) Torsion Beam (5) Stopper assembly

10. Release the backing plates and wheel spindle

11. Remove the torsion beam trailing bracket bolt.

OK670 990 AAO

13. Remove the lateral link from the body.

14. Loosen the lateral link and torsion beam axle

Installation 9. Tighten the flange bolt and nut of the trailing

10. Install the brake back plate and wheel support

Tightening torque: Tightening torque:

4. Tighten the flange nut and bolt lightly to install

7. Install the lateral link to the torsion beam axle.

8. Tighten the flange bolt and nut of the torsion beam

14. Connect the brake pipe to the brake hose.

Check the tires frequently for cuts, stone bruises,

As an additional tire condition check, wear indicators

Inspection (Tire and wheel) Lug nut

Wheel and tire runout