2001 Kia Rio

2001 STEERING Manual & Power Rack & Pinion - Rio

2001 STEERING

Manual & Power Rack & Pinion - Rio

GENERAL
SPECIFICATION

Fig. 1: Steering System Specifications

SPECIAL SERVICE TOOLS

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Fig. 2: Steering System Special Service Tools

TROUBLESHOOTING GUIDE

MANUAL STEERING

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Fig. 3: Manual Steering Troubleshooting Guide (1 Of 2)

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Fig. 4: Manual Steering Troubleshooting Guide (2 Of 2)

POWER STEERING

Fig. 5: Power Steering Troubleshooting Guide (1 Of 2)

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Fig. 6: Power Steering Troubleshooting Guide (2 Of 2)

MANUAL STEERING SYSTEM

DESCRIPTION

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 lubrication 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
lock nut 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.

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Fig. 7: Identifying Manual Steering System Components

SERVICE ADJUSTMENT PROCEDURE

FREE PLAY INSPECTION

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.

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Fig. 8: Testing Wheel Free Play

Excessive free play indicates wear in the steering column intermediate shaft universal joints, worn tie rod ends
or ball joints, or improper steering gear preload.

To check the steering column joints, grip or feel the lower joint at the floorboard and repeat the free play check.
Any free play between the steering wheel and the lower joint at the floorboard, which is clamped to the pinion
shaft, is in 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
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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.

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Fig. 9: Measuring Steering Effort

NOTE: 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.

4. Steering effort should be approximately 5~20 N (0.5~2.0 kg, 1~4.5 lb) through a full revolution in either
direction from the straight ahead position.
5. If excessive, check for binding or damage in the front suspension and the steering linkage components.
Check for excessive steering gear preload.
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MECHANICAL POWER STEERING SYSTEM

DESCRIPTION

The power steering system consists of:

z Rack and pinion steering gear

z Power steering pump
z Fluid reservoir
z 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.

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Fig. 10: Identifying Mechanical Power Steering System Components

SERVICE ADJUSTMENT PROCEDURE

POWER STEERING PRESSURE TESTING

CAUTION: Make sure that the power steering system analyzer valve is OPEN to allow
the system to function properly. Do not hold the steering wheel against a
stop for more than ten seconds at a time.

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Fig. 11: Installing Service Tool

1. Disconnect the high-pressure line and attach Power Steering System Analyzer or equivalent using the
appropriate adapters. Tighten the adapters to 29~43 lb. ft. (39~59 N.m, 4~6kg.m).
2. Insert a thermometer into the power steering fluid reservoir.
3. Bleed the system using the following procedure :
1. Check the fluid level in the reservoir, add fluid if necessary.
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, add fluid to the reservoir.
5. Repeat Steps (3) and (4) until the fluid level 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 .

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NOTE: Check the system for an air leak if form is still present.

4. Check the power steering fluid temperature. If the temperature is not at 50~60C (122~140F), turn the
steering wheel back and forth until the specified temperature is reached.

CAUTION: The valve on the power steering system analyzer must be closed
briefly to read the operating pressure. Do not leave the valve closed
for more than 15 seconds.

5. Measure the power steering pump output pressure by closing the power steering system analyzer valve
and increasing the engine speed to 1,000~1,500 RPM. The pressure specification is 7,358~7,848 kPa
(75~80 kg/ cm2, 1,067~1,138 psi).

Fig. 12: Measuring The Power Steering Pump Output Pressure

z If the pressure is within specification, continue with the remaining test procedures.
z If the pressure is low, repair or replace the power steering pump. If the pressure is too high, check
for a crimped pipe and repair/replace as necessary, or replace the power steering pump.
6. With the power steering system analyzer valve open, increase the engine speed to 1,000~1,500 RPM.

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CAUTION: Do not hold the steering wheel against a stop for more than 15
seconds at a time.

7. Turn the steering wheel all the way to the right or left and read the measured pressure. The pressure
specification is 7,358~7,848 kPa (75~80 kg/cm2, 1,067~1,138 psi). If the pressure is not within the given
specification, repair or replace the steering gear.

Fig. 13: Measuring Locked Output Pressure

8. Remove the power steering system analyzer and adapters. Reconnect the high-pressure line and tighten
the high-pressure line fitting to 16~24 N.m (16~2.4 Kg.m, 11.5~17.3 1b. ft.).
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 reservoir.

CAUTION: Do not hold the steering wheel against a stop for more than ten
seconds at a time.

2. Start the engine, then turn the steering wheel left and right several times until the fluid temperature
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reaches 50~60C (122~140F).

3. With the vehicle on a hard, level surface, turn the steering wheel until the wheels are in the straight ahead
position.
4. Attach Spring Scale to the steering wheel rim and measure the steering effort through one full turn of the
wheel. The steering wheel effort should be 39 N (4 kg, 8.8 lbs) or less.

Fig. 14: Measuring The Steering Effort

NOTE: For accurate readings, always pull the scale in the direction the point of
the scale attachment is moving (tangential to the wheel rim) through the
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full circle.

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.

Fig. 15: Checking The Power Steering Fluid Level

2. Run the engine until it reaches normal operating temperature, then turn the steering wheel from lock to
lock 10 times.
3. Turn the engine off with the wheels in the straight ahead position.
4. Check the fluid level. If necessary, fill the fluid reservoir until the level is between the MAX and MIN
lines.
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AIR BLEEDING

1. Check the fluid level.

2. Raise and support the vehicle.
3. Turn the steering wheel fully to the left and right several times with the engine not running.
4. Recheck the fluid level. If it has dropped, add fluid as necessary.

Fig. 16: Turning The Steering Wheel Fully To The Left And Right

5. Repeat Steps 2 and 3 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.

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9. Add a fluid if necessary and repeat Steps 7 and 8.

DRIVE BELT

INSPECTION

1. Check the drive belts for wear, cracks and fraying: replace if necessary.
2. Check the drive belt deflection by applying moderate pressure (22 lb. 98 N,10 kg) midway between the
pulleys. Adjust if necessary.

Fig. 17: Identifying Drive Belt Deflection

Fig. 18: Torsion Specification

3. Check the drive belt tension with the tension gauge.

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ADJUSTMENT

1. Loosen the bolt A, B and C. Turn the adjusting bolt D to adjust the belt to the specified tension.
2. Tighten the lock C, bolt A and B to the specified torques.

Fig. 19: Illustrating Drive Belt Adjustments

Courtesy of KIA MOTORS AMERICA, INC.

REPLACEMENT

1. Loosen the bolt A, B and C.

2. Turn the adjusting bolt D to release the belt tension.
3. Remove the belt.

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4. Install a new drive belt and adjust the tension and deflection. See ADJUSTMENT .

POWER STEERING GEAR BOX

COMPONENTS

Fig. 20: Illustrating Power Steering Gear Box Components

REMOVAL

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.

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Fig. 21: Separating The Tie Rod From The Knuckle Arm

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.

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Fig. 22: Disconnecting The High Pressure And Return Pipe

7. Remove the intermediate shaft.

8. Remove the four steering gear mounting bolts and washers.

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Fig. 23: Identifying Steering Gear Mounting Bolts

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.

DISASSEMBLY

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Fig. 24: Exploded View Of Power Steering Gear Box

1. Secure the steering gear in a vice equipped with the protective jaw caps.
2. Remove the oil pipes.

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Fig. 25: Removing 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.

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Fig. 26: Removing The Boot Clips

6. Remove the boot wires.

Fig. 27: Removing The Boot Wires

7. Remove the boots.

8. Remove the tie rods from the rack.

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Fig. 28: Removing The Tie Rods From The Rack

9. Remove the yoke plug lock nut and yoke plug.

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Fig. 29: Removing Yoke Plug

Courtesy of KIA MOTORS AMERICA, INC.

10. Remove the spring and support yoke.

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Fig. 30: Removing The Spring And Support Yoke

11. Remove the pinion and control valve assembly snap ring.

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Fig. 31: Removing The Pinion And Control Valve Assembly Snap Ring

12. Remove the oil seal.

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Fig. 32: Removing The Oil Seal

13. Remove the two valve housing attaching bolts.

14. Remove the valve housing and the pinion and control valve assembly.

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Fig. 33: Removing The Valve Housing, Pinion And Control Valve Assembly

15. If present, remove the shim (s) from the steering gear housing.

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Fig. 34: Removing Shims

16. Remove the O-ring.

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Fig. 35: Removing 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.

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Fig. 36: Removing The Pinion And Control Valve Assembly

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.

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Fig. 37: Pressing 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.

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Fig. 38: Rotating The Bushing

23. Remove the rack from the right side of the steering gear.

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Fig. 39: Removing 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.

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Fig. 40: Bottoming The Oil Seal Removing Tool

27. Use the impact Slide Hammer and the Rack Oil Seal Remover to pull the seal out of the rack.

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Fig. 41: Removing Seal From The Rack

28. Remove the mounting brackets and grommets.

ASSEMBLY

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.

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Fig. 42: Installing A New Rack Seal

3. Install a new O-ring by using the Piston Seal Replacer and the Rack Piston Seal Sizer.

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Fig. 43: Installing A New O-Ring

4. Place the Short Rack Seal Protector over the end of the rack to protect the bushing. Install the bushing on
the rack.

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Fig. 44: Installing Short Rack Seal Protector

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.

Fig. 45: Installing Rack Oil Seal Protector

6. Use the Pinion Bearing Replacer to install the lower pinion bearing.

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Fig. 46: Installing 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.
a. 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.

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Fig. 47: Installing The First Seal

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. 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 in illustration. Install and size the third seal.

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Fig. 48: Installing And Sizing 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.
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.

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Fig. 49: Installing Bearing And 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)

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Fig. 50: Installing The Yoke Plug And Tightening It To The Specified Torque

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.

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Fig. 51: Tightening The Yoke Plug

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)

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Fig. 52: Measuring The Pinion Torque

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).

Fig. 53: Installing The Lock Nut

22. Install the tie rods.

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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.

Fig. 54: Installing The Oil Pipes

INSTALLATION

1. Position the steering gear in its mounting location.

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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).

Fig. 55: Installing The Intermediate Shaft

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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)

Fig. 56: Connecting The High Pressure And Return Pipe

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)

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Fig. 57: Installing The Steering Gear Mounting Bolt And Nut

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.

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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.

POWER STEERING OIL PUMP

COMPONENTS

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 2001 Kia Rio
2001 STEERING Manual & Power Rack & Pinion - Rio

Fig. 58: Identifying Power Steering Oil Pump Components

REMOVAL

1. Disconnect the electrical connector from the Power Steering Pressure (PSP) switch.

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 2001 Kia Rio
2001 STEERING Manual & Power Rack & Pinion - Rio

Fig. 59: Disconnecting Power Steering Pressure (PSP) Switch Connector

2. Disconnect the suction hose.

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 2001 Kia Rio
2001 STEERING Manual & Power Rack & Pinion - Rio

Fig. 60: Disconnecting The Suction Hose

3. Disconnect the high pressure hose.

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 2001 Kia Rio
2001 STEERING Manual & Power Rack & Pinion - Rio

Fig. 61: Disconnecting The High Pressure Hose

4. Loosen the mounting bolt. Remove the lock bolt and disconnect the drive belt.

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 2001 Kia Rio
2001 STEERING Manual & Power Rack & Pinion - Rio

Fig. 62: Removing The Lock Bolt And Disconnecting The Drive Belt

5. Remove the mounting bolt.

6. Remove the power steering pump.

INSPECTION

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 2001 Kia Rio
2001 STEERING Manual & Power Rack & Pinion - Rio

Fig. 63: Exploded View Of Power Steering Oil Pump

NOTE: Replace the pump assembly if necessary.

1. Check the front and rear pump bodies for cracking or other damage and for abnormal wear of the moving
surface of the rotor.

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 2001 Kia Rio
2001 STEERING Manual & Power Rack & Pinion - Rio

Fig. 64: Checking The Front And Rear Pump Bodies For Cracking Or Other Damage

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.

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 2001 Kia Rio
2001 STEERING Manual & Power Rack & Pinion - Rio

Fig. 65: Checking Rotor And Vanes Clearance

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.

Fig. 66: Checking The Spring For Damage

ASSEMBLY NOTE

1. Install the rotor to the shaft with the rotor's identification mark facing upward.

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 2001 Kia Rio
2001 STEERING Manual & Power Rack & Pinion - Rio

Fig. 67: Installing The Rotor To The Shaft

2. Install the cam ring so that its identification mark is facing downward.

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 2001 Kia Rio
2001 STEERING Manual & Power Rack & Pinion - Rio

Fig. 68: Installing The Cam Ring

3. Install the vanes (10 pieces) to the rotor, with the R part of the vanes facing outward.

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 2001 Kia Rio
2001 STEERING Manual & Power Rack & Pinion - Rio

Fig. 69: Installing The Vanes

INSTALLATION

1. Install the power steering oil pump and install the mounting bolt.

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 2001 Kia Rio
2001 STEERING Manual & Power Rack & Pinion - Rio

Fig. 70: Installing The Power Steering Oil Pump

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

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 2001 Kia Rio
2001 STEERING Manual & Power Rack & Pinion - Rio

return pipe.

Fig. 71: Connecting The Return Hose

6. Adjust the belt deflection by turning the adjusting bolt.

7. Connect the electrical connector from the Power Steering Pressure (PSP) switch.

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