KIA CARNIVAL 2007 Workshop Manual

7.Remove the split pin and lower arm bolts and nut (A).
Tightening torque Nm (kgf- m, lb - ft):
90 ~ 120 (9.0 ~ 12.0, 65 ~ 87)
8.Disconnect the stabilizer link (B) from the strut assembly (A) by loosening nut.
Tightening torque Nm (kgf.m, lb - ft):
100 ~ 120 (10.0 ~ 12.0, 72 ~ 87)
9.Repeat on the other side.
10. Remove the front and rear roll stopper bolts and nuts (A, B).

11.Remove the sub- frame by loosening the bolts and nuts.
12.Remove the rear roll stopper (A) from the sub- frame.
13.Disconnect the pressure tube (A) and return (B) from the valve body housing.
Tightening torque Nm (kgf.m, lb - ft):
12 ~ 18 (1.2 ~ 1.8, 9 ~ 13)

14.Remove the power steering gear box (A) from the sub- frame by loosening the mounting bolts.
Tightening torque Nm (kgf.m, lb - ft):
60 ~ 80 (6.0 ~ 8.0, 43~58)
INSTALLATION
Be sure to connect between a tube and a hose as shown in the illustration.
1.Installation is the reverse of removal.
2. After installation, bleed the power steering system. (Refer to the air bleeding in ST group)
3. Adjust the wheel alignment. (Refer to SS group)
DISASSEMBLY
1.Remove the tie rod end (B) from the tie rod (A).

2.Remove the dust cover (B) from the ball joint (A).
3.Remove the bellows band (A).
4.Remove the bellows clip (A).
5.Pull the bellows out toward the tie rod.

Check for rust on the rack when the bellows are replaced.
6. Remove the feed tube(A) from the rack housing.
7.While moving the rack slowly, drain the fluid from the rack housing.
8. Unstake the tab washer (A) which fixes the tie rod (B) and rack (C) with a chisel.
9.Remove the tie rod (B) from the rack (A).
Remove the tie rod (B) from the rack (A), taking care not to twist the rack.
10. Remove the yoke plug locking nut (A).

11.Remove the yoke plug (B) with a 14mm socket (A).
12.Remove the lock nut (D), yoke plug (C), rack support spring (B) and rack support yoke (A) from the gear box.
13.When the end of the circlip comes out of the notchedhole of the housing rack cylinder, turn the rack stopper (A)
clockwise and remove the circlip.
Be careful not to damage the rack.

14.When the end of the circlip comes out of the notched hole (A) of the housing rack cylinder, turn the rack stopper
(B) counterclockwise and remove the circlip.
Be careful not to damage the rack.
15.Remove the rack bushing and rack from the rack housing.
16. Remove the O - ring(A) from the rack bushing (B).
17.Remove the oil seal (B) from the rack bushing (A).

18.Remove the valve body (A) from the valve body housing (B) with a soft hammer.
19.Using the special tool, remove the oil seal and ballbearing from the valve body housing.
20. Remove the oil seal and O - ring from the rack housing.
Be careful not to damage the pinion valve cylinderinside of the rack housing.
21. Using the special tool (09573- 33100, 09555 - 21000),remove the oil seal (A) from the rack housing.
Be careful not to damage the rack cylinder insideof the rack housing.
INSPECTION
1.Rack
(1) Check for rack tooth face damage or wear.
(2) Check for oil seal contact surface damage.
(3) Check for rack bending or twisting.

(4)Check for oil seal ring damage or wear.
(5) Check for oil seal damage or wear.
2.Pinion valve
(1) Check for pinion gear tooth face damage or wear.
(2) Check for oil seal contact surface damage.
(3) Check for seal ring damage or wear.
(4) Check for oil seal damage or wear.
3.Bearing
(1) Check for seizure or abnormal noise during abearing rotation.
(2) Check for excessive play.
(3) Check for missing needle bearing rollers.
4. Others
(1) Check for damage of the rack housing cylinder bore.
(2) Check for boot damage, cracking or aging.
REASSEMBLY
1.Apply the specified fluid to the entire surface of the rack oil seal.
Recommended fluid : PSF - 3
2. Install the backup washer and oil seal (A) to the specified position in the rack housing.

3.Apply the specified fluid to the entire surface of the rack bushing oil seal.
Recommended fluid : PSF - 3
4. Install the oil seal (A) in the rack bushing (B).
5.Apply the specified fluid to the entire surface of the O - ring and install it in the rack bushing.
6. Apply the specified grease to the rack teeth.
Recommended grease
Multipurpose grease SAE J310a NLGI No.2
Do not plug the vent hole(A) in the rack with grease.
7.Insert the rack(A) into the rack housing(B) and install the rack bushing(C).