REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Kia Rio (2000 release)

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Kia
	Rio
		Instructions
		Engines A3E, A5D
		Greasing system
		Cooling
		Fuel system
		Ignition system
		Coupling
		Transmission
		Axes and power shafts
		Suspension
		Wheels and tires
		Steering
			Technical data
			A steering without the hydraulic amplifier
			Check of a steering without the hydraulic amplifier
			A steering column without the hydraulic amplifier
			Steering with the hydraulic booster
			Checking the fluid pressure in the hydraulic system
			Check of effort steering
			Check the fluid level
			Bleeding the hydraulic system of the power steering
			Belt drive power steering pump
			Steering transfer with the steering amplifier
			Power steering pump
		Brakes
		Body
		The air conditioning system
		Electrical equipment

printable version

Steering transfer with the steering amplifier

Steering transfer with the steering amplifier

1 - an intermediate shaft of a steering column;
2 - steering gear;
3 - a protective cover;
4 - bolts;

5 - tie rod end;
6 - knuckle;
7 - the nut of tie rod;
8 - pin.

Elements of the steering transmission with power steering

1 - tie rod end;
2 - lock nut;
3 - a collar;
4 - a protective cover;
5 - wire clamp;
6 - Connector;
7 - transmission sleeve;
8 - a sealing ring;
9 - Seal rack;
10 - lock nut;
11 - a stopper;
12 - a spring;
13 - sliding emphasis;

14 - a lock ring;
15 - an oil sealing ring;
16 - the plug of the input shaft;
17 - the gear shaft;
18 - a bolt;
19 -korpus control valve;
20 - a sealing ring;
21 - Carter steering gear;
22 - Rubber Bearing;
23 - an arm;
24 - oil lines;
25 - rack;
26 - inner rail.

Withdrawal

PERFORMANCE ORDER

1. Lift the front of the car and fix on supports.
2. Remove the wheels.
3. Remove the cotter pin and loosen the nuts pins of spherical hinges of tips of steering drafts in rotary fists.
	4. A stripper OK670 321 019 squeeze the pins of spherical rod ends to the steering knuckle.
A warning To avoid damaging the screw thread on the thread of the stud nut temporary.
5. Remove the catalytic converter.
	6. Remove the return and pressure hoses.
A warning When disconnecting the hose, use a cloth or a suitable container to collect the fluid from the hydraulic power steering.
7. Remove the intermediate shaft.
	8. Remove the four screws on the steering transmission.
9. Move the steering gear to the left and remove the right tie rod through the hole in the arch of the wing.
10. Remove steering transfer on the right side of the car.

Dismantling

PERFORMANCE ORDER

1. Secure the steering gear in a vise jaws are closed brass plates.
	2. Remove the oil lines.
3. Before loosening tie rod mark the relative position of the steering rod, lock nut and rod end.
4. Loosen the lock nut and unscrew the left tie rod end from steering draft.
	5. Remove the small clamp protective cover of steering draft.
	6. Remove the wire clamp protective cover of steering draft.
7. Remove the protective cover.
	8. Separate the tie rod from the rack.
	9. Remove the lock nut locking plug and remove the plug.
	10. Remove the spring and the sliding stop.
	11. Remove the snap ring of the control valve.
	12. Remove the oil sealing ring.
13. Remove the two screws on the housing of the control valve.
	14. Remove the control valve and the control valve assembly.
	15. If necessary, remove the gasket from the crankcase steering transfer.
	16. Remove the O-ring.
17. Remove the lower bearing from the crankcase pinion steering gear.
	18. Rubber hammer beat out a gear and the control valve assembly from the housing.
19. Remove the four Teflon shims of a control valve assembly.
	20. The special tool beat out the bearing housing of the control valve.
21. The special tool, rotate the plug rack until the toe is aligned with the slot in the crankcase steering transfer.
	22. Turn the sleeve.
	23. Remove the rack from the right side of the steering gear.
24. Remove the plug from the rack.
25. Remove the O-ring.
	26. The special tool, remove the O-ring, hitting with a hammer on the rack.
	27. The inertial hammer puller and remove the seal ring of the rack.
28. Remove the brackets and sealing rings.

Check

PERFORMANCE ORDER

1. Check the steering gear parts for cracks or damage and uneven wear on the rack teeth. If necessary, replace worn parts.

2. Check the O-ring for uneven wear and damage. If necessary, replace worn parts.

3. Place the rack on the V-shaped blocks and a dial indicator, measure the deflection rail. If the deflection exceeds the limit, replace the rail.

Assembly

PERFORMANCE ORDER

1. Place the sealing rings and brackets.
A warning Set the end of the spring and the sealing rings on the tabs special tool.
	2. The special tool establish a sealing ring on the rack.
	3. The special tool establish a sealing ring on the piston.
	4. Replace end cap of the rack and install the hub cap.
	5. Replace the rack protecting oil sealing ring as shown in the figure. Set the rack with the protection of the crankcase steering transfer.
	6. A hammer and a special tool set lower bearing into the housing of the control valve.
	7. If replacement of the valve body, a control valve assembly or the steering gear housing, pick shims when installing the control valve housing. If replacement parts are not carried out, install all previously removed gaskets.
	8. The special tool establish Teflon shims in the control valve assembly. - Set the first O-ring (closest to the bearing) by moving the plunger to the first groove. - Set gasket by moving the large end of the mandrel on the O-ring. - Before installing the second spacer pad set into the housing of the control valve as shown in the figure. Place the gasket using a mandrel and follower. - Before installing the third gasket set two spacers in the case of the regulating valve. Check that the two spacers are installed as a single unit. Install the third gasket. - To set the fourth pad, turn the second spacer so that the ends of the small spacers met on the site of the control valve.
	9. Insert the control valve assembly into the housing and make sure it is properly established.
10. Install new O-ring.
11. Establish the case with the node of the control valve and fix bolts, having tightened their demanded moment. Torque: 21-26 N ??? m
12. The special tool set bearing.
	13. Special adapter gasket set.
14. Establish a sliding emphasis.
15. Install the spring.
	16. Apply a thin coat of sealant to the threads of the tube. Replace the plug and tighten it to torque. Torque: 19.6 N ??? m
17. Loosen the plug.
	18. Tighten a stopper of a sliding stop torque of 4.9 N ??? m, then loosen it at 67,5 ?�
	19. The special tool OK130 322 020 measure the time of rotation of the shaft of steering transfer. The moment of rotation at the center of the rack ?� 90 ?�: 0,8-1,3 N ??? m
20. If the time of rotation does not correspond to the required values, repeat steps 18-21.
	21. Tighten the lock nut 39-49 N ??? m.
22. Install the tie rods.
23. Align the washer with the deepening of the rack and bend it.
24. Pulling on steering drafts install protective covers of steering transfer.
25. Secure the big side cover wire by wrapping it in two turns and tighten the ends of the wire 4-4,5 times.
A warning Be careful not to damage the wire attachment case.
26. Fix the case with the smaller side clamp.
27. Screw the lock nut left steering draft and combine the labels put before a reversing of a nut. Screw the tip of the left steering draft and combine the labels put before a reversing of a tip. Tighten the tie rod lock nut.
	28. Install oil lines.

Setting

PERFORMANCE ORDER

1. Install the steering gear on the right side of the car.
	2. Connect the intermediate shaft to the steering gear shaft and secure transmission coupling bolt. Torque: 18-26 N ??? m
	3. Connect the return and pressure hoses. Torque: 39-59 N ??? m
	4. Secure the steering gear bolts and nuts. Torque: 37-52 N ??? m
5. Install the catalytic converter. Torque: 37-52 N ??? m
6. Establish pins of spherical hinges of tips of steering drafts in rotary fists. Screw nuts of fastening pins, tighten their demanded moment. Torque: 37-52 N ??? m
7. Install the cotter pins.
8. Install the wheel. Torque: 88-118 N ??? m
9. Lower the car.
10. Pour the liquid from the hydraulic system of the power steering and bleed the air.

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