Kia Optima DL3: Motor Driven Power Steering / Steering Gear Box

Kia Optima DL3 2019-2025 Service and Repair Manual / Steering System / Motor Driven Power Steering / Steering Gear Box

Components and components location

Components

1. Steering gear box
2. STie rod end
3. Dust cap

Repair procedures

Removal
1.

Align the steering wheel so that the front wheels to facing straight ahead.emove the front wheel and tire.

  

If the steering wheel and the front tires does not synchronize to their centers together, open circuit on the clock spring cable may occur due to change the steering wheel turning.

2.

Turn the ignition OFF and disconnect the negative (-) battery terminal.
3.

Loosen the bolt (A) and remove the universal joint (B).

Tightening torque :

49.0 - 58.8 N·m (5.0 - 6.0 kgf·m, 36.2 - 43.4 lb-ft)

  
•

Secure the steering wheel so that it does not move.
•

Lock the steering wheel in the straight ahead position to prevent the damage of the clock spring inner cable.
•

Do not reuse the bolt.
4.

Remove the front wheel and tire.

(Refer to Tires/Wheels - "Wheel")

5.

Disconnect the stabilizer link with the front strut assembly after loosening the nut (A).

Tightening torque :

98.1 - 117.7 N·m (10.0 - 12.0 kgf·m, 72.3 - 86.8 lb-ft)

  
•

When loosening the nut (A), hold the stabilizer bar link stud using hex socket or wrench.
•

Be careful not to damage the stabilizer link boots.
6.

Disconnect the tie rod end ball joint from the knuckle by using the SST (09568-2J100).

(1)

Remove the snap pin (C).
(2)

Remove the lock nut (B) and washer (A).

Tightening torque :

98.1 - 117.7 N·m (10.0 - 12.0 kgf·m, 72.3 - 86.8 lb-ft)

  

Do not reuse mounting nut.
(3)

Disconnect the tie rod end ball joint from the knuckle by using the SST (09568-2J100).

7.

Loosen the lower arm mounting nut (A).

(1)

Remove the snap pin (A).
(2)

Remove the lower arm mounting nut (B) and washer (C).

Tightening torque :

98.1 - 117.7 N·m (10.0 - 12.0 kgf·m, 72.3 - 86.8 lb-ft)

  

To loosen the nut (B), fix the bolt on the opposite side to prevent it from turning.
8.

Disconnect lower arm ball joint from the knuckle by using the SST (0K545-A9100).

(1)

After removing bolts from the front knuckle, install and tighten the sub body bolt (A)
(2)

Input the sub body (B) between the front knuckle and the sub body bolt.

(3)

Tighten the bolt (C) of the sub body to broaden the gap of the front knuckle.
(4)

Install the safe wire and main body (A) between the front strut and the lower arm.

(5)

After installing a body (A), rotate the handle (B) clockwise util the clamp is fixed on the lower arm.
(6)

Tighten the main body bolt (A) slowly and remove the lower arm from the front knuckle.
9.

Remove the engine room under cover.

G 2.0 NU MPI (Refer to Engine Mechanical System - "Engine Room Under Cover")

G 2.5 GDI THETA II (Refer to Engine Mechanical System - "Engine Room Under Cover")

10.

Separate the roll rod bracket (C) after loosening the bolts (A), (B).

Tightening torque :

(A) : 107.8 -127.4 N·m (11.0 - 13.0 kgf·m, 79.5 - 94.0 lb-ft)

(B) : 49.0 - 63.7 N·m (5.0 - 6.5 kgf·m, 36.2 - 47.0 lb-ft)

11.

Remove the heat protector (A).
12.

Remove the muffler rubber hanger (A).
13.

Remove the fasner (A).
14.

Remove the sub frame.

  

A : Front sub frame stay

B : Rear sub frame stay
(1)

Loosen the stay bolts (A) from the front sub frame stay.

Tightening torque :

44.1 - 58.8 N·m (4.5 - 6.0 kgf·m, 32.5 - 43.4 lb-ft)

[LH]

[RH]
(2)

Loosen the stay bolts (A) from the rear sub frame stay.

Tightening torque :

44.1 - 58.8 N·m (4.5 - 6.0 kgf·m, 32.5 - 43.4 lb-ft)

[LH]

[RH]
(3)

Support the sub frame securely with the jack (A).

  

If the mission jack is used to remove the subframe, it may tip forward, which may cause injury.
(4)

Loosen the mounting nut and remove the front sub frame stay (A).

Tightening torque :

176.6 -196.2 N·m (18.0 - 20.0 kgf·m, 130.1 - 144.6 lb-ft)

[LH]

[RH]
(5)

Loosen the mounting nut and remove the rear sub frame stay (A).

Tightening torque :

176.6 -196.2 N·m (18.0 - 20.0 kgf·m, 130.1 - 144.6 lb-ft)

[LH]

[RH]
(6)

Slowly lower the jack to remove the sub frame.
15.

Remove the steering gear box heat protector (A) after loosening the mounting bolts

Tightening torque :

8.0 - 12.0 N·m (0.8 - 1.2 kgf·m, 5.9 - 8.8 lb-ft)

16.

Remove the steering gear box (A) after loosening the mounting bolts

Tightening torque :

107.8 -127.4 N·m (11.0 - 13.0 kgf·m, 79.5 - 94.0 lb-ft)

Replacement
  
•

Do not disassemble the steering gear box.
•

Except the simple connecting parts, if the noise/cleanliness/functions related parts of the steering gear box replaced, its quality cannot be guaranteed.
[Interchangeable parts]

Tie rod end

1.

Loosen the tie rod end lock nut (A).

Tightening torque :

49.0 - 53.9 N·m (5.0 - 5.5 kgf·m, 36.2 - 39.8 lb-ft)

  

For easier assembly, measure the length or mark with paint on the thread before loosening the tie rod end lock nut.
2.

Remove the tie rod end (A) by loosening it in the counterclockwise.

3.

Replace the tie rod end with a new one.
4.

Check the alignment.

(Refer to Suspension System - "Alingment")

Bellows

1.

Remove the tie rod end.

(Refer to Replacement - "Tie rod end")

2.

Remove the tie rod end lock nut (A).

3.

Remove the bellows clamp (A).
4.

Remove the bellows band (A).

  
•

Be sure to replace the band with a new one.
•

After installing together with the band, assemble the bellows.
5.

Remove the bellows (A) to the arrow direction.
6.

Replace the bellows with a new one.
7.

Check the alignment.

(Refer to Suspension System - "Alingment")

Dust cap

1.

Remove the dust cap cover (A).

2.

Remove the dust cap (A).
3.

Replace the tie rod end with a new one.

  
•

Refer to the drawing below, adjust the parts to the correct position during assembly.
•

Assemble the dust cap after cleaning the pinion shaft.
4.

Check the alignment.

(Refer to Suspension System - "Alingment")

Installation
  

Install the component to the specified torque.
1.

Install in the reverse order of removal.
2.

Perform the "EPS Type Recognition" by KDS.

(Refer to MDPS System - "Diagnosis with KDS")

3.

Perform the "SAS Calibration" by KDS.

(Refer to MDPS System - "Diagnosis with KDS")

4.

Check the alignment.

(Refer to Suspension System - "Alingment")

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