Kia Mentor / Sephia Electrical System. Instruction — part 254

* STEERING UNIFORM INSPECTION GUIDELINES *Article Text (p. 46)

1996 Kia Sephia

shield cracked . . . 2 . . . Suggest replacement.
Steering coupler
shield missing . . . C . . . Require replacement.
Threads damaged . . . A ... Require repair or replacement
of part with damaged threads.
Threads stripped
(threads missing) . .. A . . Require replacement of part
with stripped threads.
U-joint binding . . . A ... Require repair or replacement
of joint.
U-joint loose . . ... A ... Require repair or replacement
of joint.
Unequal power assist . A .. Require repair or replacement.

(1) - Determine and correct source of contamination. OEM
specifications must be followed for fluid type.
(2) - If steering gear is source of inadequate assist, require
repair or replacement.

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STEERING GEARS - RACK AND PINION

If diagnosis has determined that complete disassembly is
necessary to determine the extent of the system failure, the
suggestion may be made to rebuild or replace the power steering pump.
Repair or replacement of the following components may be required, if
performed as part of a power steering pump overhaul or rebuild service
to meet a minimum rebuild standard.

STEERING GEARS - RACK AND PINION INSPECTION

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Condition Code Procedure

Attaching hardware
broken . . . . . A . . . Require replacement of
broken part.
Attaching hardware
loose . . . . .. A .. Require repair or replacement
of loose part.
Attaching hardware
missing . . . . C . . . Require replacement of
missing part.
Attaching hardware
threads damaged . . A .. Require repair or replacement
of part with damaged threads.
Attaching hardware

* STEERING UNIFORM INSPECTION GUIDELINES *Article Text (p. 47)

1996 Kia Sephia

threads stripped
(threads missing) . .. A . Require replacement of part
with stripped threads.
Balance tube blocked . A .. Require repair or replacement
of balance tube.
Balance tube missing . C .. Require replacement of balance
tube.
Balance tube restricted . A ... Require repair or replacement
of balance tube.
Bellows boot
clamp missing . . .. C ... Require replacement of clamp.
Bellows boot cracked
(not through) . . .. 2 .. Suggest replacement of bellows
boot.
Bellows boot missing . C .. Require replacement of bellows
boot.
Bellows boot
not sealing . . . A ... Require repair or replacement
of bellows boot.
Bellows boot torn . ... A .. Require replacement of bellows
boot.
Bellows boot twisted
(from toe adjustment) .. B . . . . . Require repair.
Fitting leaking . . . A .. Require repair or replacement.
Fitting missing . . . A . Require replacement of fitting.
Fitting threads
damaged . . . . A ... Require repair or replacement
of part with damaged threads.
Fitting threads stripped
(threads missing) . .. A . . Require replacement of part
with stripped threads.
Flex coupler binding . A ... Require repair or replacement
of coupler.
Flex coupler loose . .. A ... Require repair or replacement
of coupler.
Flex coupler
missing parts . . .. A ... Require repair or replacement
of coupler.
Flex coupler
soft/spongy . . . A . Require replacement of coupler.
Flex coupler torn . ... A . Require replacement of coupler.
Fluid contaminated . .. B . . (1) Require flushing and
refilling of the system.
Gasket leaking . . .. A .. Require repair or replacement.
Hard steering on cold
start-up . . . ... 1 . . ... (2) Suggest repair or

* STEERING UNIFORM INSPECTION GUIDELINES *

replacement.
Housing cracked,
affecting structural
integrity . . . .. B . . . Require replacement.
Housing leaking . . . A . . . Require replacement.
Inadequate power assist . A . . .. (3) Further inspection
required.
Lash exceeds
manufacturer's
specifications . . . B .. Require repair or replacement.
Seal leaking . . . A .. Require repair or replacement.
Splines damaged . . . A .. Require repair or replacement.
Splines stripped
(splines missing) . .. A . . . Require replacement.
Steel line blocked . .. A ... Require repair or replacement
of line.
Steel line leaking . .. A ... Require repair or replacement
of line.
Steel line missing . .. C . Require replacement of line.
Steel line restricted ... A ... Require repair or replacement
of line.
Steering coupler shield
cracked . . . . 2 . . . Suggest replacement.
Steering coupler shield
missing . . . . C . . . Require replacement.
Steering coupler shield
torn . . . . ... 2 . . . Suggest replacement.
Threads damaged . . . A ... Require repair or replacement
of part with damaged threads.
Threads stripped
(threads missing) . .. A . . Require replacement of part
with stripped threads.
U-joint binding . . . A ... Require repair or replacement
of joint.
U-joint loose . . ... A ... Require repair or replacement
of joint.
Unequal power assist . A .. Require repair or replacement.

(1) - Determine and correct source of contamination. Follow OE
specifications for fluid type.
(2) - Indicates internal wear.
(3) - If steering gear is source of inadequate assist, require
repair or replacement.

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STEERING KNUCKLES

* STEERING UNIFORM INSPECTION GUIDELINES *Article Text (p. 49)

1996 Kia Sephia

STEERING KNUCKLE INSPECTION

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Condition Code Procedure

Attaching hardware
bent . . . . ... B ... Require repair or replacement
of bent part.
Attaching hardware
broken . . . . . A ... Require replacement of broken
part.
Attaching hardware
incorrect . . . .. A . . .. Require replacement of
incorrect part.
Attaching hardware
loose . . . . .. A ... Require repair or replacement
of loose part.
Attaching hardware
missing . . . . C .. Require replacement of missing
part.
Attaching hardware
threads damaged . . A ... Require repair or replacement
of part with damaged threads.
Attaching hardware
threads stripped
(threads missing) . .. A . . Require replacement of part
with stripped threads.
Bent . . . . . B . . . Require replacement.
Broken . . . . .. A . . . Require replacement.
Pinch bolt incorrect . B ... Require replacement with bolt
that meets OE design.
Pinch bolt loose . . B . . . . . Require repair.
Pinch bolt missing . .. B . . . Require replacement.
Pinch bolt tabs
deformed (pinched
together), .032"
or more before
clamping . . . ... B . . (1) Require replacement.
Taper hole elongated . A . . (2) Require replacement.
Threads damaged . . . A .. Require repair or replacement.
Threads stripped (threads
missing) . . . ... A .. Require repair or replacement.

(1) - Steering knuckle deformation can cause pinch
bolt breakage.
(2) - Check for damaged stud.