NOTICE

Before using this Workshop Manual to assist you in performing

vehicle service and maintenance operations, it is recommended
that you carefully read and thoroughly understand the
information contained in Section 0A under the headings
"GENERAL REPAIR INSTRUCTIONS" and "HOW TO USE THIS
MANUAL".

All material contained in this Manual is based on the latest

product information available at the time of publication.
All rights are reserved to make changes at any time without
prior notice.

Applicable Model

N Series
NHR55 NPR55 NQR66
NHR69 NPR69 NQR70
NKR55 NPR65 NQR71
NKR69 NPR66 NPS66
NKR58 NPR70 NPS71
NKR66 NPR71
NKR77

This manual is applicable to 1994 year model and later vehicles

and later vehicles.
 HOME

SERVICE INFORMATION 00-1

SECTION 00
SERVICE INFORMATION

CONTENTS

PAGE
Troubleshooting ................................................................................................................ 00- 2
Main Data and Specifications........................................................................................... 00- 9
Service Standard ............................................................................................................... 00- 12
Servicing ............................................................................................................................ 00- 13
Fixing Torque..................................................................................................................... 00- 28
Special Tools ..................................................................................................................... 00- 46
 SERVICE INFORMATION 00-9

MAIN DATA AND SPECIFICATIONS

Front End Alignment
1994 - 1997 Model
Wishbone NHR NKR
Suspension Rigid Rigid NPR NQR NPS
Steering Angle
Inner (Deg.) 38° 46° 38° 47° 42.5° 38°
Outer (Deg.) 35° 34° 30° 36° 34° 30°
(for Taiwan, Australia and GCC)
Inner (Deg.) 38° 37.5° 37.5° 46.5° 42.5° 38°
Outer (Deg.) 35° 33° 36° 34° 34° 30°
Wheel alignment
Toe-in Bias Tire mm (in.) -2-2 3-7 (0.12-0.28) -2-2
Radial Tire mm (in.) (-0.08-0.08) 0-4 (0-0.16) (-0.08-0.08)
Camber (Deg.) 0°15'±45' 1°15'±45' 0°15'±45'
Caster (Deg.) 1°00'±1° 1°30'±1° 2°00'±1°
King Pin Inclination (Deg.) 9°45' 7°15'

∼ Model
1998∼
Wishbone NHR NKR
Suspension Rigid Rigid NPR NQR NPS
Steering Angle
Inner (Deg.) 38° 37.5° 38.5° 47.5° 38°
(7.00-15 Tire) (7.00-16 Tire)
35.5° 42.5° 42.5°
(7.00-16 Tire) (7.50-16 Tire) (7.50-16 Tire)
31.5° 36.5°
(7.50-16 Tire) (8.25-16 Tire)
Outer (Deg.) 35° 33° 29.5° 35° 30°
(7.00-15 Tire) (7.00-16 Tire)
27.9° 32.7° 32.7°
(7.00-16 Tire) (7.50-16 Tire) (7.50-16 Tire)
25.1° 30.0°
(7.50-16 Tire) (8.25-16 Tire)
(for Taiwan, Australia and GCC)
Steering Angle
Inner (Deg) 38° 37.5° 38.5° 47.5° 38°
(7.00-15 Tire) (7.00-16 Tire)
205R16, 195/85R16,
195/75R16, 195/75R16,
195/85R16, 205/85R16
185/R16
35° 35.5° 42.5° 35°
(7.00-16 Tire) (7.00-15 Tire) (7.00-16 Tire)
215/75R16, 195/85R16,
215/75R17.5, 195/75R16,
205/75R17.5 205/85R16
Outer (Deg) 29.5° 33° 29.5° 36.5° 32.7° 30°
(7.00-15 Tire) (8.25-16 Tire) (7.00-15 Tire)
205R16, 215/75R16,
195/75R16, 215/75R17.5,
195/85R16, 205/75R17.5
185/R16
27.6° 27.6° 30°
(7.00-15 Tire) (8.25-16 Tire)
Wheel alignment
Toe-in mm (in.) -2-2(-0.08-0.08)
Camber (Deg.) 0°15'±45' 1°15'±45' 0°15'±45' 0°15'±45'
Caster (Deg.) 1°00'±1° 1°30'±1° 3°±1° 2°45'±1° 2°00'±1°
King Pin Inclination (Deg.) 9°45'±30' 7°15' 12°00' 7°15'
00-10 SERVICE INFORMATION

Power Steering Unit

Right Hand Drive Left Hand Drive

Type Integral rotary valve type
Number of Ball 28 30
28 (for Taiwan, Australia and GCC)
Gear Ratio 22.6 NHR, NKR 21.9
20.9 NPR, NQR, NPS
22.6 NHR, NKR (Indep) (for Taiwan, Australia and GCC)
18.8∼20.9 NPR, NQR, NPS (Rigid)
(for Taiwan, Australia and GCC)
Ball Screw Lead mm (in.) 9.912 (0.390) NHR, NKR 10.319 (0.375)
9.922 (0.391) NPR, NQR, NPS
9.172 (0.361) NHR, NKR (Rigid)
(for Taiwan, Australia and GCC)
9.922 (0.391) NPR, NQR, NPS
(for Taiwan, Australia and GCC)
9.922 (0.391) NHR, NKR (Indep)
(for Taiwan, Australia and GCC)
Torsion Bar Spring Constant N⋅cm/deg (kg⋅cm/deg) 15.7 (16.0)
Valve Operating Angle (Deg.) ±7° ±8.3°
±7°C (for Taiwan, Australia and GCC)
2
Regulated Oil Pressure kPa (kg/cm /psi)
NHR, NKR 10,297 (105/1,493)
NPR, NQR, NPS 10,787 (110/1,564)
NHR, NKR 10,297 (105/1,439) (for Taiwan, Australia and GCC)
NPR, NQR, NPS 11,287 (115/1,635) (for Taiwan, Australia and GCC)
Regulated Oil Flow Volume
liter/min (US gal/min / UK gal/min) 8 (2.11/1.76)

Power Steering Oil Pump Unit

4B Series Engine
4J Series Engine (except Taiwan, IGM, GCC) 4H Series Engine
Type Vane Type
Theoretical Delivery
3
(cm /rev) 7.2 12.2 9.6
8.1
Regulated Oil
Flow Volume (liter/min) 8.5-6.5 8.0-6.5 8.0-6.5
Regulated Oil
2
Pressure kPa (kg/cm /psi)
NHR, NKR 10,297 (105/1,493) 10,297 (105/1,493) 10,297 (105/1,493)
NPR, NPS 10,787 (110/1,564)
NQR 11,278 (115/1,635)
Maximum Allowable
Speed (r.p.m.) 3,700 5,000 6,500
6,500
00-12 SERVICE INFORMATION

SERVICE STANDARD
ITEMS SERVICE STANDARD SERVICE LIMIT

Power Steering
Sector Shaft Outside Diameter mm (in)
RHD 39.975 (1.574) 39.925 (1.572)
LHD 38.125 (1.501) 38.043 (1.498)
RHD&LHD 39,975 (1.574) (for Taiwan, Australia and GCC)
Play between Sector Shaft
and Bearing mm (in)
RHD  0.12 (0.0047)
LHD  0.20 (0.0080)
Backlash between Sector Shaft
and Ball Nut mm (in)
RHD 0.05-0.25 (0.0020-0.0098)
LHD 0.33 (0.013) or less
RHD&LHD 0.12 (0.0047) (for Taiwan, Australia and GCC)
Steering Wheel Free Play mm (in) 10-50 (0.4-2.0)
Power Steering Fluid Pressure (at
2
idling engine speed) kPa (kg/cm /psi)
NPR66, NQR66, NPS66 10,787 (110/1,564)
except Above Models 10,297 (105/1,493)
NQR without HBB 11,278 (115/1,635) (for Taiwan, Australia and GCC)
NPR/NPS/NQR with HBB 10,787 (110/1,564) (for Taiwan, Australia and GCC)
except Above Models 10,297 (105/1,493) (for Taiwan, Australia and GCC)
Manual Steering
Sector Shaft Outside Diameter mm (in)
NHR, NKR 34.925 (1.375) 34.825 (1.371)
NPR, NQR 38.100 (1.500) 38.000 (1.496)
Play between Sector Shaft
and Needle Bearing mm (in)  0.2 (0.008)
Ball Nut Axial Play mm (in)  0.1 (0.004)
Worm Shaft Starting
Torque N⋅m (kg⋅m/lb⋅ft)
(Without Sector Shaft)
NHR, NKR 0.34-0.64 (0.035-0.065/0.25-0.47)
NPR, NQR 0.29-0.69 (0.030-0.070/0.22-0.51)
(With Sector Shaft)
NHR, NKR 0.54-1.03 (0.055-0.105/0.40-0.76)
NPR, NQR 0.98 (0.1/0.72) or less
Backlash between Sector Shaft
and Ball Nut mm (in)
NHR, NKR 0.2 (0.0079) or less
NPR, NQR 0.5 (0.0197) or less
Steering Wheel Free Play mm (in) 10-30 (0.4-1.2)
Suspension
Spring Pin Outside Diameter mm (in) 25 (0.98) 24.7 (0.019)
Clearance between Shackle Pin
and Bushing mm (in) 0.1 (0.0039) 0.5 (0.019)
 SERVICE INFORMATION 00-15

Power Steering Fluid Pressure

Preparation
1. Install the power steering fluid pressure gauge between
the pump and steering unit as figure.
Gauge: 5-8840-0162-0
2. Start and let the engine idle until oil temperature
reaches 50-60°C (122-140°F).
3. Take measurement of the pressure gauge when the
steering wheel is turned clockwise or counterclockwise
to lock.
2
Standard Pressure (at idle speed) kPa (kg/cm /psi)
NHR, NKR, NPR (except NPR66, 70, 71) 10,297 (105/1,493)
NPR66, 70, 71, NPS66, 71 10,787 (110/1,564)
NQR 11,278 (115/1,635)

for Taiwan, Australia and GCC

NQR without HBB 11,275 (115/1,635)
NPR/NPS/NQR with HBB 10,787 (110/1,563)
except Above Models 11,278 (115/1,635)

Excess pressure means pump trouble.

Less pressure means steering unit trouble.
NOTE:
This test should be done within ten seconds.

Steering Function
Check the following items.

Inspection of Wheel Alignment

The points listed in table at left must be checked prior to
inspection front wheel alignment.
00-16 SERVICE INFORMATION

Toe-In
Measurement should be taken with the vehicle on a
surface plate.
If a surface plate is not available, toe-in should be
checked with the vehicle parked on a level floor.

(Except Taiwan, Australia and GCC)

1. Set front wheels to its straight ahead position.

2. Align the toe-in gauge with center height of each wheels at
front end.
3. Apply center marks to each wheel, then take measurement
of distance A between the center marks on each wheel.
4. Move slowly the vehicle rearward until center marks get its
rear end position.
5. Take measurement of distance B between the center
marks at rear end.

The toe-in can be calculated with next formula.

Toe-in=B-A

Toe-in mm (in.)
1994 - 1997 Model
Tire Rigid Wishbone, NPS
Bias 3 – 7 (0.12 – 0.28)
-2 – 2 (-0.08 – 0.08)
Radial 0 – 4 (0 – 0.16)

1998∼ Model mm (in.)

-2–2 (-0.08 – 0.08)
00-18 SERVICE INFORMATION

Reading of the turning radius gauge directly indicates the

steering angle.
Steering Angle
1994 – 1997 Model (Deg.)
Vehicle Model Outer Inner
Wishbone Suspension 35 38
NHR (Rigid Suspension) 34 46
NKR (Rigid Suspension) 30 38
NPR (Rigid Suspension) 36 47
NQR (Rigid Suspension) 34 42.5
NPS 30 38

1998 Wishbone Suspension Model (Deg.)

Vehicle Model Outer Inner
NKR (7.00-15 Tire) 29.5 38.5
NKR (7.00-16 Tire) 27.9 35.5
NKR (7.50-16 Tire) 25.1 31.5
NKR (7.50-16 Tire)
(for Taiwan, Australia andGCC) 35 38

1998 Rigid Suspension Model (Deg.)

Vehicle Model Outer Inner
NHR 33.0 37.5
NKR (7.00-15 Tire) 29.5 38.5
NKR (7.00-16 Tire) 27.9 35.5
NKR (7.50-16 Tire) 25.1 31.5
NPR, NQR (7.00-16 Tire) 35.0 47.5
NPR, NQR (7.50-16 Tire) 32.7 42.5
NPR, NQR (8.25-16 Tire) 30.0 36.5
NPS 30.0 38.0

1999 Wishbone Suspension Model (Deg.)

Vehicle Model Outer Inner
NKR (7.00-15 Tire) 35.0 38.0

1999 Rigid Suspension Model (Deg.)

Vehicle Model Outer Inner
NHR 33.0 37.5
NKR (7.00-15 Tire) 29.5 38.5
NKR (7.00-16 Tire) 27.9 35.5
NKR (7.50-16 Tire) 25.1 31.5
NPR, NQR (7.00-16 Tire) 35.0 47.5
NPR, NQR (7.50-16 Tire) 32.7 42.5
NPR, NQR (8.25-16 Tire) 30.0 36.5
NPS 30.2 38.0
 SERVICE INFORMATION 00-23

Thickness of Shims Available (mm)

0.8, 1.6, 3.2
Conditions Where The Shims are Used
Limit
Numbers of Shims 4 or less
Thickness mm (in) 9.6 (0.378) or less
Difference of Thickness
(between Front and Rear) 4.8 (0.189) or less
mm (in)

In case the shim has already reached at the limitation in its

number or its thickness, decrease the number of shims at the
aft side to adjust the obtuse caster angle, while decrease the
number at the fore side to adjust the acute caster angle.

NOTE:
Since the number of shims needed for caster angle
adjustment varies depending on the conditions of the car,
perform the adjustment procedures which are the most
suitable for the car conditions.

4) Tighten the mounting bolts of the front shock absorber.

Shock Absorber Bolt

and Nut Torque N⋅m (kg⋅m/lb⋅ft)
Upper 40 (4.1/30)
Double nut Upper 4.0 (4.1/30)
(for Taiwan, Australia
and GCC) Lower 21 (2.1/16)
Lower 103 (10.5/76)

Measurement of Side Slippage

When inspection and adjustments of toe-in, camber,
caster and king pin inclination are completed, check for
side slippage using a side slip tester.
Roll the wheels over the side slip tester as slowly as
possible and take reading on the tester, If the amount of
side slippage is in excess of 5 mm per 1 m, recheck the
wheel alignment.
Side Slippage mm (in)
Limit
5.0 (0.197) Per 1m
 SERVICE INFORMATION 00-27

Tire Inflation Pressure

Tire pressure, in cold condition (after vehicle has set for
three hours or more, or driven less than one mile), should
be checked monthly or before any extended trip. Tire
pressure increases approx. 15% when the tires become
hot during driving. The pressure specification is shown on
the label as figure.
2
Tire Inflation Pressure kPa (kg/cm /psi)
Tire Size Inflation Pressure
6.50-15-6PR
7.00-15-6PR 319 (3.25/46)
7.50-16-6PR
5.00-12-8PR
392 (4.25/57)
5.50-13-8PR
6.00-13-8PR
6.00-14-8PR
6.00-15-8PR
7.00-15-8PR 417 (4.25/60)
7.00-16-8PR
7.50-15-8PR
7.50-16-8PR
6.00R15-8PR
6.00R15-8PR (100/98M)
7.00R15-8PR
7.00R16-8PR
441 (4.50/64)
155R13-8
155R13-8 (90/89P)
205R16C8PR
7.50R16-8PR
466 (4.75/68)
195/75R16C
6.50-15-10PR
6.50-16-10PR
7.00-15-10PR 490 (5.00/71)
7.00-16-10PR
8.25-16-12PR
7.50-15-10PR
7.50-16-10PR
7.00R15-10PR
515 (5.25/75)
7.00R15-10PR (111/109M)
7.00R16-10PR
215/75R16C
6.50R16-10PR 540 (5.50/78)
7.00-15-12PR
7.00-16-12PR
7.50R16-10PR 564 (5.75/82)
7.50R16-10PR (118/116M)
8.25-16-14PR
7.50-15-12PR
7.50-16-12PR
7.00R15-12PR
588 (6.00/85)
7.00R16-12PR
215/75R-17.5
215/75R-17.5 (126/124M)
7.50-15-14PR
7.50-16-14PR
637 (6.50/92)
7.50R16-12PR
7.50R16-12PR (121/120M)
7.00-16-14PR 711 (7.25/103)
175R14-8PR
441 (4.50/64)
185R14-8PR
185/85R16 111/109L
588 (6.00/85)
195/85R16 114/112L
8.5R17.5 121/120L 625 (6.25/90)
205/85R16 117/115L 588 (6.00/85)
205/75R17.5 124/122M 750 (7.50/109)
 SERVICE INFORMATION 00-31

Power Steering Pump (for Taiwan, Australia and GCC) N⋅⋅m (kg⋅⋅m / Ib⋅⋅ft)
 SERVICE INFORMATION 00-33

Power Steering Pump Assembly (for Taiwan, Australia and GCC) N⋅⋅m (kg⋅⋅m / Ib⋅⋅ft)
00-38 SERVICE INFORMATION

Power Linkage (Wishbone Suspension) (for Taiwan, Australia and GCC)

N⋅⋅m (kg⋅⋅m / Ib⋅⋅ft)
00-40 SERVICE INFORMATION

Setting Column (for Taiwan, Australia and GCC) N⋅⋅m (kg⋅⋅m / Ib⋅⋅ft)
00-42 SERVICE INFORMATION

Upper, Lower Link, Torsion Bar and Strut Bar

(Wishbone Suspension) N⋅⋅m (kg⋅⋅m/Ib⋅⋅ft)
HOME
3A-6 FRONT END ALIGNMENT

Reading of the turning radius gauge directly indicates the

steering angle.
Steering Angle
1994 – 1997 Model (Deg.)
Vehicle Model Outer Inner
Wishbone Suspension 35 38
NHR (Rigid Suspension) 34 46
NKR (Rigid Suspension) 30 38
NPR (Rigid Suspension) 36 47
NQR (Rigid Suspension) 34 42.5
NPS 30 38

1998 Wishbone Suspension Model (Deg.)

Vehicle Model Outer Inner
NKR (7.00-15 Tire) 29.5 38.5
NKR (7.00-16 Tire) 27.9 35.5
NKR (7.50-16 Tire) 25.1 31.5
NKR (7.50-16 Tire)
(for Taiwan, Australia and GCC) 35 38

1998 Rigid Suspension Model (Deg.)

Vehicle Model Outer Inner
NHR 33.0 37.5
NKR (7.00-15 Tire) 29.5 38.5
NKR (7.00-16 Tire) 27.9 35.5
NKR (7.50-16 Tire) 25.1 31.5
NPR, NQR (7.00-16 Tire) 35.0 47.5
NPR, NQR (7.50-16 Tire) 32.7 42.5
NPR, NQR (8.25-16 Tire) 30.0 36.5
NPS 30.0 38.0
 HOME

POWER STEERING 3B1-1

SECTION 3B1
POWER STEERING

CONTENTS

PAGE
General Description ........................................................................................................ 3B1- 2
On-Vehicle Service .......................................................................................................... 3B1- 6
Power Steering System Test...................................................................................... 3B1- 6
Power Steering System Bleeding.............................................................................. 3B1- 9
Power Steering Unit.................................................................................................... 3B1- 10
Power Steering Pump................................................................................................. 3B1- 14
Tandem Hydraulic Pump............................................................................................ 3B1- 17
Unit Repair ....................................................................................................................... 3B1- 18
Power Steering Unit (RHD Model) ............................................................................. 3B1- 18
Power Steering Unit (LHD Model).............................................................................. 3B1- 40
Power Steering Pump (4J Series Engine)................................................................. 3B1- 54
Power Steering Pump (4B Series Engine) ................................................................ 3B1- 59
Power Steering Pump (4HF1 Engine)........................................................................ 3B1- 65
Power Steering Pump (4HE Engine) ......................................................................... 3B1- 67
Tandem Hydraulic Pump............................................................................................ 3B1- 75
3B1-4 POWER STEERING

Power Steering Pump (for Taiwan, Australia and GCC)

 POWER STEERING 3B1-7

CAUTION:
Do not continue this test. It should be done within 10
seconds, because otherwise oil temperature would
rise to excess to cause trouble.
2
Standard Operating Pressure kPa (kg/cm /psi)
NHR, NKR,
NPR (except NPR66) 10,297-10,983 (105-112/1,493-1,593)
NPR66, NPS66 10,787-11,474 (110-117/1,564-1,664)

• If the pressure recorded is within specified range, the

steering system is functioning within its specifications.
• If the pressure recorded is higher than specified range,
oil pump relief valve is defective.
• If the pressure recorded is lower than specified range,
oil pump or relief valve is defective.
7. Fully open the stop valve and keep engine idled.
Turn and hold steering wheel to full left lock, and record
the highest value of fluid pressure.
Turn and hold steering wheel to full right lock, and
record the highest value of fluid pressure.

for Taiwan, Australia and GCC

NQR without HBB 11,278 (115/1,635)
NPR/NPS/NQR with HBB 10,787 (110/1,563)
except Above Models 10,297 (105/1,493)

• Fully open the stop valve and keep engine idled.

Turn and hold steering wheel to full left lock, and record
the highest value of fluid pressure.
Turn and hold steering wheel to full right lock, and
record the highest value of fluid pressure.
• If the pressure recorded is within specified range, the
steering system is functioning within its specifications.
• If the pressure recorded is higher than specified range,
oil pump relief valve is defective.
• If the pressure recorded is lower than specified range,
oil pump or relief valve is defective.
3B1-8 POWER STEERING

CAUTION:
Do not continue this test. It should be done within 5
seconds.
2
Standard Operating Pressure kPa (kg/cm /psi)
NHR, NKR,
NPR (except NPR66) 10,297-10,983 (105-112/1,493-1,593)
NPR66, NPS66 10,787-11,474 (110-117/1,564-1,664)

for Taiwan, Australia and GCC

NQR without HBB 11,278 (115/1,635)
NPR/NPS/NQR with HBB 10,787 (110/1,563)
except Above Models 10,297 (105/1,493)

• If the pressure recorded is within specified range, the

steering system is functioning within its specifications.
• If the pressure recorded is lower than specified range,
steering unit is leaking internally and must be
disassembled and repaired.
 POWER STEERING 3B1-15

4B SERIES ENGINE
(except Taiwan, Australia and GCC)
REMOVAL
• Loosen three retaining bolts for the power steering
pump and remove the bolts.

INSTALLATION
• Apply grease over the timing gear case for the engine,
and attach new O-rings and tighten them to the
specified torque.

Power Steering Pump Bolt Torque N⋅m (kg⋅m/lb⋅ft)

52 (5.2/38)

4HE ENGINE
REMOVAL
• Block the vehicle wheels and apply the parking brake.
• Battery ground cable.
1. Disconnect air intake hose at turbocharger side.
2. Raise the vehicle and remove front exhaust pipe with
exhaust brake.
• Remove bolts at manifold, silencer and support
bracket.
3. Place a container under the hydraulic pump assembly to
catch fluid when disconnecting hoses. Clean the surfaces
around fittings before removing them.

4. Remove power steering outlet flexible hose (1) and nut.

5. Remove hydraulic booster outlet pipe (2) nut.
6. Remove two clips for hydraulic booster lines on the
flywheel housing.
7. Remove clip for hydraulic booster lines on the left
sidemember.
8. Hydraulic booster inlet hose (3).
9. Power steering inlet hose (4).
10. Remove hydraulic booster pipe from the pump.
11. Remove hydraulic pump assembly with bracket and O-ring.

INSTALLATION
1. Attach new O-ring and install hydraulic pump assembly to
the engine.
3B1-16 POWER STEERING

2. Install booster outlet pipe (2) and nut.

Tighten
• Nut to 23.5 N⋅m (17 lb⋅ft).
3. Install power steering outlet flexible hose (1) and nut.
Tighten
• Nut to 23.5 N⋅m (17 lb⋅ft).
4. Connect hydraulic booster inlet hose (3).
5. Connect power steering inlet hose (4).
6. Install clips for hydraulic booster lines.
7. Connect air intake hose.
8. Install exhaust pipe with exhaust brake.
9. Fill the power steering and hydraulic booster systems with
®
DEXRON -III.
Bleed the power steering system as outlined in this section.
Bleed the hydraulic booster system. Refer to HYDRAULIC
BOOSTER SYSTEM (SEC. 5A2).

4HF1 ENGINE
REMOVAL
• Loosen three fixing bolts for power steering pump (Two
on the flywheel side and one on the cylinder body side)
and remove them.

INSTALLATION
• Attach new O-rings and tighten them to the specified
torque.

Power Steering Pump Bolt Torque N⋅m (kg⋅m/lb⋅ft)

Flywheel side 43 (4.4/32)
Cylinder Body Side 44 (4.5/33)
 POWER STEERING 3B1-67

POWER STEERING PUMP

DISASSEMBLY
4HE Engine (for Taiwan, Australia and GCC)

Disassembly Steps
1. Suction pipe 13. O-ring
2. O-ring 14. Pin
3. Nut and washer 15. Snap ring
4. Gear and key 16. Shaft assembly
5. Bolt 17. Ball bearing
6. Rear cover 18. Oil seal
7. Pin 19. Connector assembly
8. Bushing 20. O-ring
9. Cartridge assembly 21. O-ring
10. O-ring 22. Relief valve assembly
11. Side plate 23. Flow control spring
12. Oil seal 24. Body assembly
3B1-72 POWER STEERING

REASSEMBLY
4HE Engine (for Taiwan, Australia and GCC)

Reassembly Steps
1. Body assembly 13. Oil seal
2. Flow control spring 14. Cartridge assembly
3. Relief valve assembly 15. O-ring
4. O-ring 16. Pin
5. O-ring 17. Side plate
6. Connector assembly 18. Bushing
7. Oil seal 19. Rear cover
8. Ball bearing 20. Bolt
9. Shaft assembly 21. Gear and key
10. Snap ring 22. Nut and washer
11. Pin 23. O-ring
12. O-ring 24. Suction pipe
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 FRONT SUSPENSION 3C-3

Wishbone Suspension
3C-20 FRONT SUSPENSION

FRONT SUSPENSION
(WISHBONE SUSPENSION)
3C-24 FRONT SUSPENSION

Ball Joint
• Inspection the ball joint boot for damage or grease
leak.
• Move the ball joint to confirms its normal movement.
• Inspect screw / taper area of ball for flaws.
If any defects are found by the above inspections, replace
the ball joint with new one.

Upper Ball Joint Replacement

• Remove the ball joint fixing nut (Hex. 63mm).
• Remove the ball joint from the upper link using a
special tool.
Remover: 5-8840-2364-0

• Install the ball joint to the upper link using a bench

press and special tool.
Installer: 5-8840-2365-0
• Tighten nut to specified torque.
Joint Ball Nut Torque N⋅m (kg⋅m/lb⋅ft)
211 (21.5/156)
206 (21.0/152) (for Taiwan, Australia and GCC)

Upper Link Assembly

• Disassemble the upper link assembly.
• Inspect the following parts as shown in the figure for
wear, damage, bending or any other abnormal
conditions.

• Reassemble the upper link assembly.

• Apply multi-purpose with MoS2 grease to the fulcrum
pin threads.
• Fill multi-purpose with MoS2 grease to bushings.
• Install the fulcrum pin to the upper link and tighten
bushings to specified torque.
Bushing Torque N⋅m (kg⋅m/lb⋅ft)
294 (30/217)
3C-26 FRONT SUSPENSION

INSTALLATION

11. Lower Link

• Install the lower link fixing bolt from the vehicle forward
direction and set the bolt head to the bolt stopper
completely.
• Tighten the nut temporarily.
NOTE:
Tighten nuts to specified torque after following steps;
• Park the vehicle on a level ground.
• Move the front of the vehicle up and down several
times to settle the suspension.

Lower Link Nut Torque N⋅m (kg⋅m/lb⋅ft)

584 (59.5/430)
579 (59.0/427) (for Taiwan, Australia and GCC)

9. Lower Link Joint Ball

Install the lower link ball joint to specified torque.
Lower Link Ball Joint Nut Torque N⋅m (kg⋅m/lb⋅ft)
167 (17/123) (except Taiwan, Australia and GCC)

8. Shim
7. Upper Link Assembly
• Install the shims and upper link assembly.
• Tighten the fixing bolts to the specified torque.
Thickness of Shims Available (mm)
0.8, 1.6, 3.2
Upper Link Bolt Torque N⋅m (kg⋅m/lb⋅ft)
152 (15.5/112)
For adjustment of camber and caster angle, refer to "Front
End Alignment" in Section 3A.
 FRONT SUSPENSION 3C-27

10. Knuckle
• Connect the upper ball joint, lower ball joint to the
knuckle.
• Tighten the fixing nuts temporarily.
• After installation of tie rod end and strut bar assembly,
tighten fixing nuts to specified torque, with just enough
additional torque to align cotter pin holes.
Install new cotter pin.

Ball Joint Nut Torque N⋅m (kg⋅m/lb⋅ft)

206 (21.0/152)
Upper 205 (20.9/151)
for Taiwan, Australia and GCC
Lower 377 (38.4/278)

6. Shock Absorber Assembly

Shock Absorber Bolt
and Nut Torque N⋅m (kg⋅m/lb⋅ft)
Upper 40 (4.1/30)
Upper 4.0 (4.1/30)
Double nut Lower 21 (2.1/16)
(for Taiwan, IGM, GCC)
Lower 103 (10.5/76)
103 (10.5/76)
Lower for Taiwan, Australia and GCC

5. Strut Bar Assembly

• Install the strut bar assembly.
• White paint is aligned to right side strut bar. Be careful
not to install to the opposite side.
• Apply a thin coat of rubber grease to inside of the
rubber bushing.
• Tighten the rear side fixing nuts temporarily.

• Tighten the lower link side fixing bolts to specified

torque.

Strut Bar Bolt and Nut Torque N⋅m (kg⋅m/lb⋅ft)

219 (22.3/161)
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 WHEELS AND TIRES 3E-7

2
Tire Inflation Pressure kPa (kg/cm /psi)
Tire Size Inflation Pressure
6.50-15-6PR
7.00-15-6PR 319 (3.25/46)
7.50-16-6PR
5.00-12-8PR
392 (4.25/57)
5.50-13-8PR
6.00-13-8PR
6.00-14-8PR
6.00-15-8PR
7.00-15-8PR 417 (4.25/60)
7.00-16-8PR
7.50-15-8PR
7.50-16-8PR
6.00R15-8PR
6.00R15-8PR (100/98M)
7.00R15-8PR
7.00R16-8PR
441 (4.50/64)
155R13-8
155R13-8 (90/89P)
205R16C8PR
7.50R16-8PR
466 (4.75/68)
195/75R16C
6.50-15-10PR
6.50-16-10PR
7.00-15-10PR 490 (5.00/71)
7.00-16-10PR
8.25-16-12PR
7.50-15-10PR
7.50-16-10PR
7.00R15-10PR
515 (5.25/75)
7.00R15-10PR (111/109M)
7.00R16-10PR
215/75R16C
6.50R16-10PR 540 (5.50/78)
7.00-15-12PR
7.00-16-12PR
7.50R16-10PR 564 (5.75/82)
7.50R16-10PR (118/116M)
8.25-16-14PR
7.50-15-12PR
7.50-16-12PR
7.00R15-12PR
588 (6.00/85)
7.00R16-12PR
215/75R-17.5
215/75R-17.5 (126/124M)
7.50-15-14PR
7.50-16-14PR
637 (6.50/92)
7.50R16-12PR
7.50R16-12PR (121/120M)
7.00-16-14PR 711 (7.25/103)
175R14-8PR
441 (4.50/64)
185R14-8PR
185/85R16 111/109L
588 (6.00/85)
195/85R16 114/112L
8.5R17.5 121/120L 625 (6.25/90)
205/85R16 117/115L 588 (6.00/85)
205/75R17.5 124/122M 750 (7.50/109)
 LGSTG-WE-0021

You are requested to order this manual using the

manual number that is shown above.

This manual is applicable for vehicles in all countries

except the USA and Canada.

All rights reserved. This manual may not be

reproduced in whole or in part, without the permission
in writing of ISUZU MOTORS LIMITED.

Issued by
ISUZU MOTORS LIMITED
INTERNATIONAL SERVICE DEPARTMENT

Tokyo, Japan

First edition Nov, 1999 0911-01K-3

No.LGSTG-WE-0021 PRINTED IN JAPAN