Xe ô tô hyundai excel toàn tập hyundai excel - P20

Tài liệu xe ô tô hyundai excel toàn tập hyundai excel

MANUAL AND POWER Return To Main Table of Contents

G E N E R A L 2 STEERING COLUMN AND SHAFT 15 MANUAL STEERING GEAR BOX 2 3 TIE ROD 3 2 POWER STEERING GEAR BOX 3 5 POWER STEERING OIL PUMP 5 1 POWER STEERING HOSES 5 7

G E N E R A L

MANUAL STEERING

SPECIFICATIONS

Shaft and joint type

Steering gear type

Number of pinion teeth

Ball joint starting torque Ncm (Ib.in.)

Total pinion preload Ncm (Ib.in.)

0-30 (0-1.1)

35°40' ± 1°30' 29°17'

50-250 (4-22)

±180° or less from neutral position 40-110 (3.5-9.5)

±180° more from neutral position 30-130 (2.6-11.3)

Steering shaft and column support

Steering shaft and joint

Pinion gear and joint

Steering wheel and steering shaft

Gear box and cross member

Dust cover mounting bolt

Yoke plug lock nut

Tie rod ball joint and knuckle arm

Tie rod to rack

Tie rod lock nut

15-20 150-200 11-14 15-20 150-200 11-14 34-44 350-450 25-32 29-39 300-400 22-29 5-7 50-70 3.6-5.1 49-69 500-700 36-51 15-33 150-340 11-25 78-98 800-1,000 58-72 49-54 500-550 36-40

LUBRICANTS

Steering gear box

Steering column bearings

Multipurpose grease SAE J310a, NLGI grade #2 EP

Multipurpose grease SAE J310a, NLGI grade #2 EP

As required

As required

Ball joint starting torque Ncm (Ib.in.)

Oil pump pressure kPa (psi, kg/cm 2 )

Gauge hose valve closed

Gauge hose valve opened

Total pinion preload

Tie rod swing resistance

Limit

Oil pump pressure

Gauge hose valve closed

0-30 mm (0-1.1 in.)

35°40' ± 1°30' 29°17'

3.1 kg (6.8 Ibs.) or less 7-10 mm (0.28-0.4 in.) 50-250 (4-22)

4,500-5,200 (640-740,46-53)

980 (142, 10) or less 60-130 Ncm (5-11 Ib.in.)

15 N (3.3 lb) [350 Ncm (30 lb.in)]

7,800 kPa (1,110 psi, 80 kg/cm 2 )

Power Steering

Power Steering Gear Box

Gear box mounting clamp

Rack support cover locking nut

Tie rod to rack

Tie rod end lock nut

Tie rod end to knuckle

End plug

Self-locking nut

Feed tube

59-78 600-800 43-58 49-69 500-700 36-51 78-98 800-1,000 58-72 49-54 500-550 36-40 15-33 150-340 11-25 49-69 500-700 36-51 20-29 200-300 14-22 12-18 120-180 9-13 Oil Pump

Reservoir mounting bolt 8-12 80-120 6-9 Engine mounting bracket 49-69 500-700 36-51 Oil pump bracket mounting bolt 20-26 200-270 14-20 Oil pump mounting bolt 20-26 200-270 14-20 Oil pump adjust bolt 25-32 250-330 18-24 Connector to pump body 49-69 500-700 36-51 Suction connector to pump body 6-10 60-100 4.3-7.2 Pump cover to pump body 18-22 180-220 13-16 Steering Hoses

Pressure hose attaching nut

Pressure hose to gear box

Pressure hose clip

Hose clamp

Tube mounting bolt

10-15 100-150 7-11 12-18 120-180 9-13 3-6 30-60 2.2-4.3 3-5 130-50 2.2-3.6 8-12 80-120 6-9

LUBRICANTS

Recommended lubricant Quantity Steering column lower bearing

Teeth of rack and pinion

Moving parts of rack and bushings

Moving parts of pinion and needle bearing

Moving parts of rack and rack support

Lip of gear box oil seal

Tie rod side groove of bellows

Inside surface and lip of tie end dust cover

Power steering fluid

Multipurpose grease SAE J310a, NLGI grade #2 EP Multipurpose grease

SAE J310a, NLGI grade #2 EP Multipurpose grease

SAE J310a, NLGI grade #2 EP Multipurpose grease

SAE J310a, NLGI grade #2 EP Multipurpose grease

SAE J310a, NLGI grade #2 EP Multipurpose grease

SAE J310a, NLGI grade #2 EP Multipurpose grease

SAE J310a, NLGI grade #3 EP Multipurpose grease

SAE J310a, NLGI grade #2 EP Automatic transmission fluid DEXRON ® II type

Oil pressure gauge

(Power steering only)

09572-21100

Oil pressure gauge adapter

(Power steering only)

09572-21200

Oil pressure gauge adapter

(Power steering only)

ILLUSTRATlON USE

Removal of the steering wheel

Measurement of the main shaft preload

Removal and installation of pinion bearing

Removal, installation and adjustment of steering gear yoke plug

Separation of the tie rod end ball joint

Measurement of the oil pressure (Use with 09572-21100, 09572-21200)

Measurement of the oil pressure (Use with 09572-21000, 09572-21200)

Measurement of the oil pressure (Use with 09572-21000, 09572-21100)

Oil seal guide

(Power steering only)

Removal and installation of the oil seal from the gear housing

09555-21000

Bar (Power steering only)

Removal and installation of the oil seal from the gear housing

09573-21100

Oil seal installer

(Power steering only)

Installation of the oil seal from the gear housing

09573-21000

Oil seal installer guide

(Power steering only)

Installation of the oil seal from the gear housing

09432-21600

Bearing installer

(Power steering only)

Installation of the needle bearing to the gear housing and the oil seal, ball bearing to the valve body

09222-21100

Valve stem oil seal installer

(Power steering only)

Installation of the ball bearing to the gear housing

09434-14200

Countershaft bearing installer

(Power steering only)

Installation of the oil seal to the rack ing and to the valve body

bush-TROUBLESHOOTING (Manual Steering)

Excessive turning resistance of tie-rod ball joint

Excessively tightened rack support cover Rough turning of inner tie-rod and/or ball joint Bent rack

Worn steering shaft joint and/or body grommet Damaged pinion bearing

Excessive turning resistance of tie-rod ball joint Excessively tightened rack support cover Rough turning of inner tie-rod and/or ball joint Worn steering shaft joint and/or body grommet Bent rack

Damaged pinion bearing

Remedy Retighten

Retighten Retighten or relate as necessary

Replace

Adjust Lubricate or replace ball joint Replace

Replace Replace Replace Adjust Replace Correct or replace Replace

Replace

The steering wheel

does not return

properly

Noise

Probable cause Loose rack support cover Loose steering gear mounting bolts Loose or worn stud of tie-rod end V-belt slippage

Damaged V-belt Low fluid level Air in the fluid Twisted or damaged hoses Insufficient oil pump pressure Sticky flow control valve Excessive internal oil pump leakage Excessive oil leaks from rack and pinion

in gear box Bent or damaged gear box or valve body seal ring

Excessive turning resistance of tie-rod ball joint

Excessively tightened rack support cover Rough turning or inner tie-rod and/or ball joint Loose mounting of gear box to crossmember Worn steering shaft joint and/or body grommet

Bent rack Damaged pinion bearing Twisted or damaged hoses Damaged oil pressure control valve Damaged oil pump input shaft bearing Hissing Noise in Steering Gear

Remedy Retighten

Retighten Retighten or replace as necessary Check

Replace Replenish Bleed air Correct the routing or replace Repair or replace the oil pump Replace

Replace damaged parts Replace damaged parts

Replace

Replace

Adjust Replace Retighten Correct or replace

Replace Replace Reroute or replace Replace

Replace

There is some noise in all power steering systems One of the most common is a hissing sound when the steering wheel is turned and the car is not moving This noise will be most evident when turning the wheel while the brakes are applied.

There is no relationship between this noise and steering performance Do not replace the valve unless the “hissing” noise is extremely objectionable A replacement valve will also have a slight noise, and is not always a cure for the condition.

Loose tie-rod end ball joint

Reroute Retighten Retighten

Replenish Bleed air Retighten

Checking Steering Wheel Free Play

1 Check the steering wheel free play in the straight ahead position Steering wheel free play [Standard value] .

0-30 mm (0-1.1 in.)

2 If the measured value exceeds the standard value, check the looseness of the yoke plug and the connections of following parts; tie rod ball joint, steering shaft, universal joint, gear box, etc.

Checking Steering Angle

1 Place the front wheel on a turning radius gauge and measure the steering angle.

Steering angle [Standard value]

Inner wheel 35°40' ± 1°30' Outer wheel 29°17'

2 If the measured value is not within the standard value, inspect the linkage so that it might not be improperly adjusted.

Checking Tie Rod Ball Joint Starting Torque

1 Mount two nuts on the ball joint, and then measure the ball joint starting torque.

Tie rod end ball joint starting torque

[Standard value] 50-250 Ncm (4-22 in Ibs.)

2 If the starting torque exceeds the standard value, replace the tie rod end.

NOTE

Even if the starting torque is below limit of the standard value, the ball joint may be reused unless it has drag and excessive play.

POWER STEERING

Checking Steering Wheel Free Play

1 Start the engine and the steering wheel in the straight ahead

position, apply a force of 5 N (1.1 Ibs.) to the steering wheel in

the peripheral direction.

2 Measure the play at the circumference of the steering wheel.

Steering wheel free play [Standard value] .

0-30 mm (0-1.1 in.)

3 If the play exceeds the standard value, inspect the contact of the

steering shaft and tie rod ball joints.

Checking Steering Angle

1 Place the front wheel on a turning radius gauge and measure

the steering angle.

Steering angle [Standard value]

Inner wheel 35°40' ± 1°30'

Outer wheel 29°17'

2 If the measured value is not within the standard value, inspect

the linkage so that it might not be improperly adjusted.

Checking Stationary Steering Effort

1 Place the vehicle on a level surface and place the steering wheel

in the straight ahead position.

2 Set the engine speed to 1,000 rpm.

CAUTION

After checking, reset the engine speed to the standard value

(idling speed).

3 Measure the turning force with a spring scale by turning the

steering wheel clockwise and countclockwise one and a half

turns.

Stationary steering effort [Standard value]

3.5 Nm (36 kg.cm, 2.6 Ib.ft) or less

4 Check to be sure that there is no excessive force change while

turning the steering wheel.

5 If the stationary steering effort exceeds, check and adjust the

following points:

(a) Damage and cracks of dust covers of lower arm and tie rod

end ball joint.

(b) Pinion total preload of steering gear box Turning starting

torque of tie rod end ball joint.

(c) Turning starting torque of lower arm ball joint.

GENERAL Checking Steering Wheel Return

Check the steering wheel return and confirm the following

points:

1 The force required to turn the steering wheel and the wheel

return should be the same for left and right for both moderate

turns and sharp turns.

2 When the steering wheel is turned 90° and held for a couple of

seconds while the vehicle is being driven at 35° km/h (22 mph),

the steering wheel should return at least 70% when it is

released.

NOTE

If the steering wheel is turned very quickly, the steering

wheel operation may be momentarily heavy, but this is not a

malfunction (especially during idling, because the oil pump

output will be somewhat decreased).

Difference in fluid levels: within 5 mm (0.2 in.)

Checking Power Steering Fluid Level

1 Park vehicle on level place.

2 Start engine With vehicle kept stationary, turn steering wheel

several times continuously to raise fluid temperature from 50 to

60°C (122 to 140°F).

3 With engine at idle, turn steering wheel fully clockwise and

counterclockwise several times.

4 Make sure that there is no foaming or cloudiness in reservoir

fluid.

5 Stop engine to check for difference in fluid level between

sta-tionary and running engine.

NOTE

(a) If fluid level varies 5 mm (0.2 in.) or more, bleed system

again because bleeding of system is not satisfactory.

(b) If fluid level suddenly rises after stopping engine, it

shows that bleeding is not satisfactory.

(c) Incomplete bleeding will produce chattering sound in

pump and noise in flow control valve, decreasing

durabil-ity of pump, etc.

Replacing Power Steering Fluid

1 Jack up the front wheels and support with rigid racks.

2 Disconnect return hose from oil reservoir and install plug to oil

reservoir.

3 Connect vinyl hose to disconnected return hose.

4 Pull ignition cable at the ignition coil side While running engine

intermittently several times by means of starting motor, turn

steering wheel fully clockwise and couterclockwise to drain off

fluid.

5 Fill oil reservoir with specified fluid.

Automatic transmission fluid DEXRON ® ll type : As required.

While engine While engine

is running is stopped

6 Run engine

Make sure that new fluid comes out from fluid drain hose, and

turn off engine.

7 Install return hose to oil reservoir positively and secure with

clip.

8 Make sure that fluid is poured to the bottom of oil filter in oil

reservoir tank Then bleed air.

Automatic transmission fluid DEXRON ® lI type:

Total quantity : Approx 0.8 liter (49 C.I.D.)

Air Bleeding

1 Disconnect the ignition cable, and then, while operating the

starting motor intermittently (for 15 to 20 seconds), turn the

steering wheel all the way to the left and right five or six times.

CAUTION

(a) During air bleeding, replenish the fluid supply so that the

level never falls below the lower position of the filter.

(b) If air bleeding is done while the vehicle is idling, the air

will be broken up and absorbed into the fluid; be sure to

do the bleeding only while cranking.

2 Connect the ignition cable, and then start the engine (idling).

3 Turn the steering wheel to the left and right until there are no air

bubbles in the oil reservoir.

CAUTION

Do not hold the steering wheel turned all the way to either

side for longer than ten seconds.

4 Confirm that the fluid is not milky, and that the level is up to the

specified position on the level gauge.

5 Confirm that there is very little change in the fluid level when

the steering wheel is turned left and right.

CAUTION

(a) If the fluid level changes considerably, air bleeding

should be done again.

(b) If the fluid level rises suddenly when the engine is

stopped, it indicates that there is still air in the system.

(c) If there is air in the system, a jingling noise may be heard

from the pump and the control valve may also make

strange noise; air in the system will shorten the useful

life of the pump and other parts.

GENERAL Checking Power Steering Belt Tension

1 Press the V-belt by applying pressure of 100 N (22 Ibs.) at the specified point, and measure the deflection to confirm that it is within the standard value range.

V-belt deflection [Standard value]

7-10 mm (0.28-0.4 in.)

2 To adjust the belt tension, loosen the oil pump mounting bolts, move the oil pump, and then retighten the bolts.

Oil Pump Pressure Test

1 Disconnect the pressure hose from the oil pump, and then connect the special tool between the oil pump and pressure hose as illustrated.

2 Bleed the air, then start the engine and turn the steering wheel several times so that the temperature of the fluid rises to approximately 50°C (122°F).

3 Set the engine speed to 1,000 rpm.

4 Fully close and fully open the shut-off valve of the special tool and measure the fluid pressure to confirm that it is within the standard value range.

Oil pump pressure [Standard value] Gauge hose valve closed

4,500-5,200 kPa (640-740 psi, 46-53 kg/cm 2 ) Gauge hose valve opened

980 kPa (142 psi, 10 kg/cm 2 ) or less CAUTION

Be sure not to keep the shut-off valve on the pressure gauge closed for longer than ten seconds.

5 Remove the special tools, and then tighten the pressure hose to the specified torque.

Tightening torque 12-18 Nm (120-180 kg.cm, 9-13 Ib.ft)

6 Bleed the system.

STEERING COLUMN AND SHAFT

COMPONENTS

TORQUE : Nm (kg.cm, Ib.ft)

STEERING COLUMN AND SHAFT

R E M O V A L

1 Remove the horn button cover.

2 After removing the steering wheel lock nut, remove the steering

wheel dynamic damper.

3 After making alignment marks on the steering shaft and wheel,

remove the steering wheel, using a Special Tool (09561-11001).

CAUTION

Do not hammer on the steering wheel to remove it: doing so

may damage the collapsible mechanism.

4 Remove the column shroud.

5 Remove the multifunction switch and disconnect the

connec-tor.

6. Remove the bolt coupling the steering shaft with joint.

7 After removing the bolts securing the column bracket to the

frame, remove the steering shaft from the joint.

8 Remove the bolt coupling the joint with gear box.

9 Remove the dust cover mounting bolts and remove the cover

together with the joint toward the driver’s compartment.

STEERING COLUMN AND SHAFT

D I S A S S E M B L Y

1 Draw out the bearing from the dust cover.

2 Remove the boot B and the dust cover from the joint.

3 Remove the snap ring.

4 After unlocking the steering wheel, remove the steering shaft

from the column by lightly striking the shaft end with a soft

hammer.

5 To remove the steering lock, cut a slot in the mounting screw

heads and bracket with a hack saw Loosen the screws with a

flat-blade screwdriver to remove the steering wheel lock.

C A U T I O N

When the steering wheel lock is reinstalled, the bracket and

screws should be replaced with new ones.

6 To remove the column bracket A, cut a slot in the mounting bolt

head (which has no hexagonal portion) with a hacksaw Loosen

the bolt with a flat-blade screwdriver to remove the column

1 Insert the steering shaft into the column tube and secure with

the snap ring.

2 Tighten the column bracket mounting bolt until the head is

broken off at its shank.

STEERING COLUMN AND SHAFT

3 Apply grease to the inside of bearing and install the bearing

securely to the end of the column tube Be sure bearing seats

squarely in steering column.

Recommended grease

Multipurpose grease SAE J310a, NLGI grade #2 EP

4 Align the steering lock with the column boss and insert the

ignition key to verify the steering lock operation before

tighten-ing the lock to specifications.

CAUTION

Use special screws (one-way) to tighten the lock.

INSTALLATION

1 Make sure that the joint and dust cover are installed in the

correct direction as illustrated.

2 Apply grease to the bearing and dust cover, and install the

bearing into the dust cover.

Recommended grease

Multipurpose grease SAE J310a,

NLGI grade #2 EP

3 Install the joint to the gear box pinion and temporarily tighten

the dust cover.

Tighten the coupling bolt.

Pinion joint tightening torque

15-20 Nm (150-200 kg.cm, 11-14 Ib.ft)

4 After installing the steering shaft to the joint, install the shaft to

the column support Tighten the bolt coupling steering shaft

with joint.

Steering shaft column support tightening torque

9.8 Nm (100 kg.cm, 7.2 Ib.ft) Steering shaft joint tightening torque

15-20 Nm (150-200 kg.cm, 11-14 lb.ft)

5 Move the dust cover to adjust its position so that there will be no

clearance between the joint and dust cover sliding surface, and

tighten the dust cover.

STEERING COLUMN AND SHAFT

6 When the steering wheel is installed, make sure that the

align-ment marks are in alignalign-ment and that the steering wheel is in

the straight ahead position.

MANUAL STEERING GEAR BOX

D

E

Nm kg.cm Ib.ft 15-33 150-340 11-25 29-39 300-400 22-29 49-69 500-700 36-51 49-54 500-550 36-40 78-98 800-1,000 58-72

REMOVAL

1 Remove the both wheel and tire assembly.

2 Remove the bolt coupling joint with the pinion.

MANUAL STEERING GEAR BOX

3 Remove the tie rods from the knuckle arms, using Special Tool

(09568-31000).

4 Remove the rack and pinion assembly from the crossmember.

DISASSEMBLY

Before disassembly, measure and note the rack starting force

and pinion starting torque in the neutral (straight ahead)

posi-tion for reference at reassembly.

1 Clean the rack and pinion assembly and mount it in a softjawed

vise.

CAUTION

When the assembly is mounted in vise, wind a cloth around

the center pipe portion and tighten the vise being careful not

to deform the pipe.

2 Remove the tie rod assembly.

3 Remove the lock nut from the yoke plug.

4 Using Special Tool (09565-21100) remove the yoke plug.

5 Remove the yoke spring, cushion rubber and support yoke from

the gear box.

6 Remove the oil seal from the gear box.

7 Remove the snap ring from the gear box Remove the pinion

with bearing.

MANUAL STEERING GEAR BOX

8 Remove the bearing retainer snap ring from the pinion.

9 Using a Special Tool (09565-21000), remove the bearing from

the pinion.

10 Remove the bellows.

11 Using a chisel, unstake right side rack end nut.

12 Move the rack all the way toward the rack housing and hold

the toothed portion of the rack in a vise with a copper plate In

this condition, loosen the tie rod ball joint and remove the tie

rod assembly from the rack.

13 Remove the rack from the gear housing.

CAUTION

To protect the bushing from damage by the rack teeth, draw

the rack out toward the left side of the vehicle.

INSPECTIONS

MANUAL STEERING GEAR BOX REASSEMBLY AND ADJUSTMENT

1 Prior to reassembly, clean all gear box components in a suitable

solvent.

2 Press fit the bearing to the pinion with a Special Tool

(09565-21000).

3 Install the snap ring to the pinion.

4 Apply grease to rack, pinion, bushing, needle roller bearing and

other sliding surfaces.

CAUTION

Take care not to seal off the air passage in the housing

bush-ing with grease.

Recommended grease

Multipurpose grease SAEJ310a, NLGI grade #2 EP

5 After inserting the rack into the gear housing, install the pinion

gear in mesh with the rack.

CAUTION

(a) Make sure that the rack is inserted into the gear box from

the left side.

(b) Wipe away excessive grease.

6 Select and install the appropriate type of snap ring to minimize

the play in the axial direction of the pinion.

Thickness mm (in.) Identification color

Be sure to use new oil seal.

8 Install the support yoke, cushion rubber, spring and yoke plug to

the pinion gear box.

CAUTION

Apply grease to the cupped portion of the support yoke.

9 Adjust the yoke plug, with a Special Tool 09565-21000.

Tighten the yoke plug to 11 Nm (112 kg.cm, 8 ft.lbs.) and then

back off 30° to 60° Secure the yoke plug with the lock nut.

CAUTION

(a) Adjust the yoke plug with the rack in the neutral position.

(b) Apply a sealer between the lock nut and the housing.

Yoke plug lock nut tightening torque

49-69 Nm (500-700 kg.cm, 36-51 Ib.ft)