Repair of Hyundai i30 2007, 1.6 MPI steering mechanism

The owner of a Hyundai i30 encountered a knocking noise in the steering caused by wear on the power steering drive pinion inside the steering column. STS performed a thorough diagnosis, replaced the worn EPS part, and restored the steering system, allowing the vehicle to once again drive smoothly and without knocking.

The owner of a first-generation Hyundai i30 (FD) with a 1.6 MPI 16V gasoline engine, manufactured in 2007, contacted our specialized STS auto repair shop in Warsaw. According to the customer, the main problem was a strange knocking sound coming from the steering mechanism, which occurred while driving, including on flat roads and when turning. This indicated potential problems with the steering system or suspension, so we immediately began a comprehensive diagnosis.

Diagnostics: where is the source of the knocking?

At the first stage, our specialists conducted a visual inspection and mechanical check of the main suspension and steering components. During the inspection, we noticed noticeable play in the ball joint, which is typical for cars with high mileage. However, fixing this issue alone would not have eliminated the main complaint. So, we continued our diagnostics and located the main source of the knocking in the steering column, which came as a surprise even to the car owner. After dismantling, it turned out that the cause was wear on the drive star of the electric power steering, which had lost teeth and created play and shock loads when turning the steering wheel.

How the Hyundai i30 steering column is designed

The first-generation Hyundai i30 has a design feature that significantly affects steering: its electric power steering is integrated directly into the steering column (EPS type — Electric Power Steering, column-type). Unlike traditional systems with hydraulic or rack-mounted electric power steering, in this case the entire power steering mechanism is located in the passenger compartment, in the steering column housing. This approach reduces the number of components in the engine compartment, lowers fuel consumption, and simplifies the design of the rack.

Main design elements:

• An electric motor built into the steering column housing, which uses a gear (star wheel) to rotate the shaft, amplifying the driver's effort.
• A reduction gear and connecting mechanism, which is responsible for the precise transmission of torque without backlash.
• EPS controller, which processes data from torque, speed, and steering wheel position sensors to regulate the power assistance.
• Steering column shaft, which transmits force directly to the steering rack.

Important to know: since in this generation of Hyundai i30 and similar KIA models (CEE'D ED, PRO CEE'D ED) the rack has no power assistance, all force and load compensation is provided by the EPS mechanism in the column. Because of this, any malfunction in this unit immediately leads to knocking, loss of steering precision, and potential risks while driving.

Work performed by STS specialists:

After detailed diagnostics, we dismantled the steering column and cross member, which allowed us to gain full access to the EPS mechanism. Since the knocking was localized in the steering column (the drive star of the electric power steering, which is responsible for transmitting torque from the motor-reducer to the steering shaft, was worn out), a new part was installed, fully compatible with the original unit.

In parallel with the major repair, we:

During the repair process, we had to remove the steering wheel and partially dismantle the interior trim to assess the condition of the internal components. The photo of the interior without the steering wheel clearly shows the extent of the repair work.

Result: flawless handling without any knocks

After the repair was completed, a test drive was conducted, during which the car demonstrated perfect road handling. The knocking disappeared completely, and the steering wheel became light and precise, with no play whatsoever. The driver received not just a fix for the symptoms, but a complete restoration of the functionality of the entire steering system. We always strive not only to fix the problem, but also to explain to the owner why it occurred and how to avoid it in the future.

Why choose STS:

• Replaced the worn ball joint, which also caused additional noise in the front suspension.
• Tightened the steering rack to eliminate play without replacing it.
• We did a full check of the front suspension for any potential weak spots, cracks, or metal fatigue.

  Are you experiencing similar symptoms in your car? Do you hear knocking or feel play in the steering wheel? Don't delay — contact STS in Warsaw, and we will quickly, accurately, and professionally find and fix the problem.

• Accurate diagnostics — we find the real cause of the breakdown without wasting your money on unnecessary replacements.
• Comprehensive approach — we conduct a complete analysis of the system to avoid repeat visits.
• Professional repair in 1 day — we value your time and work efficiently.
• Specialization in steering — we know all typical and atypical breakdowns.
• Responsibility for the result — after we finish, everything works as it should, and you understand exactly what was done.