POWER STEERING TO INDEX POWER STEERING SYSTEM PRECAUTIONS... OPERATION CHECK... PROBLEM SYMPTOMS TABLE... VANE PUMP ASSEMBLY COMPONENTS...

Transcription

1 TO INDEX STEERING POWER STEERING POWER STEERING SYSTEM PRECAUTIONS OPERATION CHECK PROBLEM SYMPTOMS TABLE VANE PUMP ASSEMBLY COMPONENTS REMOVAL INSTALLATION POWER STEERING LINK ASSEMBLY COMPONENTS REMOVAL DISASSEMBLY INSPECTION REASSEMBLY INSTALLATION

2 1 POWER STEERING SYSTEM STEERING STEERING POWER STEERING POWER STEERING SYSTEM PRECAUTIONS 1. HANDLING AND OPERATING PRECAUTIONS FOR SRS AIRBAG SYSTEM Some service operations affect the SRS airbag. Be sure to read the precautionary notice for the SRS airbags before servicing. (See page RS-164) OPERATION CHECK 1. CHECK STEERING MOUNT TORQUE Some service operations affect the SRS airbag. Be sure to read the precautionary notice for the SRS airbags before servicing. (a) Stop the vehicle on a level, paved road and align the front wheels straight ahead. Check the handling and operating precautions for the SRS airbag system. (c) Disconnect the negative battery terminal. (d) Remove the horn button assembly. (e) Using a torque wrench, check that there is no slack in the steering wheel set nut. Torque: 35 N*m (357 kgf*cm) (f) Connect the negative battery terminal. (g) Start the engine and idle it. (h) Turn the steering wheel 90 degrees to the right and measure steering torque while turning. Check in the opposite direction in the same manner. Reference value: Torque = 5.5 N*m (55 kgf*cm) or less (oil temperature: 80 C) (i) Align the front wheels straight ahead. (j) Disconnect the negative battery terminal. (k) Install the horn button assembly. (l) Connect the negative battery terminal. (m) Check the airbag warning light. (See page RS-1) 2. CHECK OIL PRESSURE (a) Remove No.1 engine under cover. Disconnect pressure feed tube assembly. (See page -7)

3 POWER STEERING POWER STEERING SYSTEM 2 (c) Install pressure gauge. Valve Fully Open Oil Resevoir Vane Pump Power Steering Gear Valve Fully Open Gauge IN Side Gauge OUT Side C133720J01 Power Steering Gear Oil Resevoir Vane Pump C (d) (e) (f) (1) Using the attachment, install the pressure gauge IN side to the vane pump assembly pressure port. Install the pressure gauge OUT side with the pressure gauge valve fully opened. (2) Using the attachment and a new gasket, install the pressure gauge OUT side to the pressure feed tube assembly (vane pump side). Install the pressure gauge OUT side with the pressure gauge valve fully opened. Bleed power steering fluid air. Set oil temperature for oil pressure check. (1) Start the engine. (2) With the engine running at 1,000 r/min or less, move the steering wheel from full lock on one side to full lock on the other side to raise the temperature of the fluid. Standard: 50 C Inspect vane pump generated oil pressure. (1) With the engine idling, fully close the pressure gauge valve and measure the oil pressure. Standard: 7.4 to 7.9 MPa (75 to 80 kgf/cm 2 ) Do not close the pressure gauge valve for more than 10 seconds. The fluid temperature must not exceed 85 C.

4 3 POWER STEERING POWER STEERING SYSTEM Power Steering Gear Oil Resevoir (g) Check oil temperature without load. (1) Fully open the pressure gauge valve. (2) Measure the oil pressure with the engine idling at both 1,000 r/min and 3,000 r/min and check the difference in oil pressure. If the difference is out of the specified range, replace the vane pump assembly with a new one. Standard: Within 0.5 MPa (5 kgf/cm 2 ) Do not operate the steering wheel. Vane Pump C Power Steering Gear Oil Resevoir Vane Pump (h) Check steering gear housing generated oil pressure. (1) Fully open the pressure gauge valve. (2) With the engine idling, turn the steering wheel fully left and right and measure oil pressure. Standard: 7.4 to 7.9 MPa (75 to 80 kgf/cm 2 ) Do not hold the steering wheel in the fully turned position for more than 10 seconds. Remove pressure gauge and attachment Connect pressure feed tube assembly. (See page -8) Bleed power steering fluid leakage. Check for powersteering fluid leakage. Install No.1 engine under cover. C (i) (j) (k) (l) (m) 3. CHECK STEERING WHEEL FREEPLAY (a) Start the engine and align the wheels straight ahead. Move the steering wheel gently with your fingers and check the steering wheel freeplay. Maximum freeplay: Within 30 mm 4. CHECK OIL RESERVOIR FLUID LEVEL (a) Make sure the vehicle is level. With the engine running at 1,000 r/min or less, move the steering wheel from full lock on one side to full lock on the other side to raise the temperature of the fluid. Standard: 50 C (c) Check that no bubbles or cloudy fluid come out of the mouth of the oil reservoir. (d) Measure the difference in the fluid level when the engine is running and stopped. If the difference is outside of the specified range, bleed out air. If there is no improvement after bleeding the air, check the hydraulic system for oil leakage. Standard: Within 5 mm (e) Check that the fluid level is within the range of specified values. If it is below the range of specified values, add power steering fluid up to the maximum level of the standard range. Standard: Within the HOT level range (When oil temperature is 50 C)

5 POWER STEERING POWER STEERING SYSTEM 4 When the oil temperature is low (0 to 20 C), check that the oil level is within the COLD level range. 5. BLEED POWER STEERING FLUID AIR (a) Add power steering fluid until it reaches mm above the upper level of the oil reservoir level gauge (COLD side). Idle the engine at 1,000 r/min or less for approximately 2 seconds. When the surface of the fluid drops below the upper level, add power steering fluid until it reaches the upper level mark. Repeat this procedure until the surface of the fluid settles at the upper level mark. (c) Start the engine and turn the steering wheel from lock to lock 2 to 3 times. Repeat this procedure until the oil level no longer changes. Continue to add fluid to ensure that oil reservoir does not run dry. When performing the lock to lock, hold the steering wheel at the fully turned position for 2 to 3 seconds and then turn the wheel quickly to the other side. (d) Hold the steering wheel at the lock position for 5 to 6 seconds repeatedly for 3 to 4 times at intervals of approximately 2 to 3 seconds. (e) Check that there are no fine air bubbles in the oil reservoir, and then check that the steering wheel does not stick, vibrate or malfunction in any way when it is operated. If there is no improvement after bleeding the air, check the hydraulic system for oil leakage. (f) Check the oil reservoir fluid level. PROBLEM SYMPTOMS TABLE Symptom Suspected Area See Page Front tires (improperly inflated, unevenly worn) TW-2 Front wheel alignment (incorrect) SP-4 Front suspension (lower ball joint) - Power steering motor fluid level (low) -1 Steering is heavy V-ribbed belt (slack) EM-1 Steering intermediate shaft - Steering column assembly SR-4 Power steering vane pump -7 Power steering link assembly -11 Front tires (improperly inflated, unevenly worn) TW-2 Poor steering wheel return Front wheel alignment (incorrect) SP-4 Steering column assembly SR-4 Power steering link assembly -11 Freeplay: none or excessive Steering intermediate shaft - Power steering link assembly -11

6 5 POWER STEERING POWER STEERING SYSTEM Symptom Suspected Area See Page Front wheel alignment SP-4 Front suspension (lower ball joint) - Abnormal noise or vibration in steering wheel Steering intermediate shaft - Steering column assembly SR-4 Power steering motor fluid level (low) -1 Power steering link assembly -11

7 VANE PUMP ASSEMBLY STEERING POWER STEERING COMPONENTS POWER STEERING VANE PUMP ASSEMBLY 6 T=7.5{76} AIR CLEANER HOSE NO. 1 ENGINE UNDER COVER T=5.4{55} T=20{203} VANE PUMP ASSEMBLY T=43{438} GASKET PRESSURE FEED TUBE ASSEMBLY CLIP T=54{551} OIL RESEVOIR TO PUMP HOSE TIGHTENING TORQUE [N*m{kgf*cm}] NON-REUSEABLE PART C140212J02

8 7 POWER STEERING VANE PUMP ASSEMBLY REMOVAL 1. DRAIN POWER STEERING FLUID 2. DISCONNECT NEGATIVE BATTERY TERMINAL 3. REMOVE ENGINE UNDER COVER 4. REMOVE AIR CLEANER HOSE NO. 1 (See page CO-15) 5. REMOVE FAN AND ALTERNATOR BELT (See page EM-8) 6. REMOVE OIL RESERVOIR TO PUMP HOSE (a) Slide the clip and disconnect the oil reservoir to pump hose from the vane pump assembly. 7. DISCONNECT PRESSURE FEED TUBE ASSEMBLY (a) Remove the union bolt while holding the pressure feed tube assembly using an adjustable wrench. Disconnect the pressure feed tube assembly from the vane pump assembly. C (c) Remove the gasket from the pressure feed tube assembly. 8. REMOVE VANE PUMP ASSEMBLY (a) Disconnect the connector from the oil pressure switch. Remove the 2 installation bolts from the vane pump pulley holes. C (c) Remove the bolt and vane pump assembly. C INSTALLATION 1. INSTALL VANE PUMP ASSEMBLY

9 POWER STEERING VANE PUMP ASSEMBLY 8 A B (a) Install the vane pump assembly with 2 bolts A and bolt B. Torque: 43.2 N*m (440 kgf*cm) Bolt A 20.6 N*m (210 kgf*cm) Bolt B Connect the connector to the oil pressure switch. A C CONNECT PRESSURE FEED TUBE ASSEMBLY (a) Install a new gasket and the union bolt while holding the pressure feed tube assembly using an adjustable wrench. Torque: 53.9 N*m (550 kgf*cm) 3. CONNECT OIL RESERVOIR TO PUMP HOSE (a) Connect the oil reservoir to pump hose and secure it with a clip. 4. INSTALL FAN AND ALTERNATOR V BELT 5. INSTALL FRONT TIRE RH Torque: 103 N*m (1050 kgf*cm) 6. REFILL POWER STEERING FLUID 7. BLEED AIR FROM POWER STEERING FLUID (See page -4) C CHECK FLUID LEVEL (See page -3) 9. CHECK FOR FLUID LEAKAGE 10. INSTALL ENGINE UNDER COVER

10 9 POWER STEERING POWER STEERING LINK ASSEMBLY POWER STEERING LINK ASSEMBLY STEERING STEERING COMPONENTS STEERING INTERMEDIATE ASSEMBLY T=29.4{300} STEERING SHAFT UNIVERSAL JOINT ASSEMBLY T=29.4{300} T=46.6{475} T=90.6{923} PRESSURE RETURN TUBE CLIP T=35{357} PRESSURE FEED TUBE T=46.6{475} CLIP ENGINE UNDER COVER [N*m{kgf*cm}] TIGHTENING TORQUE NON-REUSEABLE PART C139171J02

11 POWER STEERING POWER STEERING LINK ASSEMBLY 10 T=47.1{480} TIE ROD END RH STEERING RACK BOOT CLAMP STEERING RACK BOOT NO.1 STEERING RACK BOOT CLAMP NO. 1 POWER STEERING RACK END CLAW WASHER O-RING CYLINDER END STOPPER T=60{612} BUSH CYLINDER END STOPPER OIL SEAL DUST COVER POWER STEERING CONTROL VALVE ORIFICE SEAT PISTON RING POWER STEERING RACK POWER STEERING RACK HOUSING OIL SEAL RACK GUIDE SPRING RACK GUIDE SPRING CAP T=83.4{850} O-RING T=18.2{185} POWER STEERING CONTROL VALVE UPPER OIL SEAL POWER STEERING RACK GUIDE CONTROL VALVE POWER STEERING CONTROL HOUSING GASKET T=18.2{185} PRESSURE CONTROL VALVE ORIFICE SEAT STEERING RIGHT TURN PRESSURE TUBE 4 T=24.5{250} POWER STEERING CONTROL VALVE BUSH UPPER BEARING POWER STEERING CONTROL VALVE RING STEERING LEFT TURN PRESSURE TUBE CLAW WASHER T=103{1050} STEERING RACK END STEERING RACK BOOT CLAMP NO. 1 STEERING RACK BOOT NO.2 T=47.1{480} TIE ROD END LH POWER STEERING FLUID STEERING RACK BOOT CLAMP RUBBER GREASE LONG LIFE GREASE NON-REUSEABLE PART TIGHTENING TORQUE [N*m{kgf*cm}] C139172J03

12 11 POWER STEERING POWER STEERING LINK ASSEMBLY REMOVAL 1. CHECK FRONT TIRES FACING STRAIGHT AHEAD 2. REMOVE FRONT TIRE 3. REMOVE ENGINE UNDER COVER 4. REMOVE INSTRUMENT PANEL FINISH PANEL LWR (See page IP-11) 5. REMOVE INSTRUMENT PANEL UNDER COVER NO. 1 (See page IP-11) 6. DISCONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY (a) Put matchmarks on the steering intermediate shaft assembly and the steering column assembly. Remove bolt A. 7. REMOVE STEERING SHAFT UNIVERSAL JOINT ASSEMBLY (a) Put matchmarks on the intermediate shaft and the steering shaft universal joint assembly. Matchmarks Bolt A C136414J01 STEERING INTERMEDIATE ASSEMBLY (c) Remove the bolt and steering intermediate shaft assembly. Put matchmarks on the steering shaft universal joint assembly and the steering gear. Matchmarks C136672J01 (d) Remove the bolt and steering shaft universal joint assembly. 8. REMOVE TIE ROD END LH (See page DS-5) Steering Gear Assy 9. REMOVE TIE ROD END RH Perform the same procedure for the RH as for the LH. Matchmarks C136671J01

13 POWER STEERING POWER STEERING LINK ASSEMBLY DISCONNECT OIL RESERVOIR TO PUMP HOSE (a) Using a union nut wrench, disconnect the oil reservoir to pump hose from the rack and pinion type power steering gear assembly. C DISCONNECT PRESSURE FEED TUBE ASSEMBLY (a) Using a union nut wrench, disconnect the pressure feed tube assembly from the rack and pinion type power steering gear assembly. C REMOVE RACK AND PINION TYPE POWER STEERING GEAR ASSEMBLY (a) Remove the 4 bolts and rack and pinion type power steering gear assembly from the suspension cross member. Remove the rack and pinion type power steering gear assembly from the driver's seat side. DISASSEMBLY C SECURE RACK AND PINION TYPE POWER STEERING GEAR ASSEMBLY (a) Secure the power steering link assembly in a vise using the wrapped with protection tape Remove and reinstall the securing as needed. C REMOVE TIE ROD END LH (a) Put matchmarks on the tie rod end LH and the steering rack end. Loosen the lock nut, and remove the tie rod end LH and the lock nut from the steering rack end. 3. REMOVE TIE ROD END RH Perform the same procedure for the RH as for the LH. Match Mark C142403

14 13 POWER STEERING POWER STEERING LINK ASSEMBLY 4. REMOVE STEERING LEFT TURN PRESSURE TUBE (a) Using the, remove the steering left turn pressure tube from the rack and pinion type power steering gear assembly. Turning the steering wheel with the tube removed may cause residual fluid to fly out. C REMOVE STEERING RIGHT TURN PRESSURE TUBE Remove the steering right turn pressure tube using the same procedure as for the left. Turning the steering wheel with the tube removed may cause residual fluid to fly out. C REMOVE STEERING RACK BOOT CLIP (a) Remove the left and right steering rack boot clips from the left and right steering rack boots. 7. REMOVE STEERING RACK BOOT CLAMP NO. 1 (a) Using pliers, pinch steering rack boot clamp No. 1. Using a screwdriver, lift up and remove steering rack boot clamp No. 1 as shown in the illustration. 8. REMOVE STEERING RACK BOOT NO. 1 C REMOVE STEERING RACK END (a) Secure the steering rack end ball joint in the vise between aluminum plates. Do not tighten the vise too firmly. (c) Using a screwdriver and hammer, unstake the RH and LH claw washers. Avoid any impact to the power steering rack. Using a wrench, secure the steering rack. C140234

15 POWER STEERING POWER STEERING LINK ASSEMBLY 14 (d) (e) Using the, remove the left and right steering rack ends. Use the in the correct direction. Secure the steering rack securely with a wrench. Remove the left and right claw washers from the left and right steering rack ends. 10. REMOVE STEERING RACK GUIDE C (a) (c) Using the, remove the power steering rack guide spring cap. Remove the rack guide spring. Remove the power steering rack guide. 11. REMOVE CYLINDER END STOPPER (a) Using the, remove the cylinder end stopper. C Remove the O-ring from the cylinder end stopper. 12. REMOVE POWER STEERING CONTROL VALVE ASSEMBLY (a) Put matchmarks on the rack housing and the control valve housing. Remove the dust cover. (c) Remove the 2 bolts and then remove the power steering control valve from the power steering rack housing. C Matchmarks (d) Remove the power steering control valve housing gasket. C C REMOVE POWER STEERING RACK (a) Using a bolt (M14 x P1.5) and a press, remove the power steering rack and oil seal. Using a screwdriver, remove the seal ring and O-ring from the power steering rack. Do not damage the ring groove. 14. REMOVE POWER STEERING CONTROL VALVE (a) Wrap the serrated area of the power steering control valve with protective tape.

16 15 POWER STEERING POWER STEERING LINK ASSEMBLY Protective Tape (c) Using a press, remove the power steering control valve. Using a screwdriver, remove the 4 control valve rings. Do not damage the ring groove. Do not drop the power steering control valve. Do not damage the oil seal inside the control valve housing. C REMOVE POWER STEERING CONTROL VALVE UPPER BEAR- ING ( ) (a) Using the and a press, remove the oil seal and power steering control valve bearing. C REMOVE PRESSURE CONTROL VALVE ORIFICE SEAT Replace the seat only if there is significant deformation that could possibly result in fluid leakage. (a) Using a screw extractor, remove the power steering control valve spacer. Do not turn the tap any more than necessary. Do not allow any chips to get into the port. Do not damage the inside of the port. The power steering control valve spacer has an inside diameter of 5.5 mm. C REMOVE POWER STEERING CONTROL VALVE UNION SEAT Use the same procedure as for the pressure control valve orifice seat. The power steering control valve union seat has an inside diameter of 6.0 mm. 18. REMOVE POWER STEERING RACK HOUSING OIL SEAL (a) Using needle nose pliers, remove the power steering rack bush. C142405J02

17 POWER STEERING POWER STEERING LINK ASSEMBLY 16 Extension Socket C Using the, remove the oil seal. Do not damage the rack housing when pressing with a press (c) Thoroughly clean the inside and outside of the removed steering rack housing with cleaning oil to remove grease and dirt. Use a bamboo brush to clean the inside of the housing to avoid damage. After cleaning, apply air to the inside and outside of the housing to remove all of the oil cleaner. 19. CHECK POWER STEERING RACK (a) Check the tooth surface for wear and damage. Using a V-block and dial indicator, check the bend of the rack. Standard: 0.15 mm (center portion of the rack) INSPECTION C INSPECT TIE ROD END LH (a) Secure the tie rod end LH ball joint in the vise between aluminum plates. Do not tighten the vise too firmly. Install the flange nut to the stud bolt. (c) Flip the ball joint back and forth 5 times or more. (d) Set a torque wrench to the nut, turn the ball joint continuously at a rate of 3 to 5 seconds per turn, and check the turning torque. Torque: 3.5 N*m (35.7 kgf*cm) 2. INSPECT TIE ROD END RH Perform the same procedure for the RH as for the LH. 3. INSPECT POWER STEERING RACK (a) Check the tooth surface for wear and damage. ZK08184J02 Using a V-block and dial indicator, check the bend of the power steering rack. Maximum bend: 0.15 mm REASSEMBLY C INSTALL POWER STEERING RACK HOUSING OIL SEAL (a) Coat the lip of the new power steering rack housing oil seal with power steering fluid.

18 17 POWER STEERING POWER STEERING LINK ASSEMBLY Using the, install the power steering rack housing oil seal to the rack housing ( ) Make sure the oil seal is installed in the correct direction. Install the oil seal straight. STEERING RACK HOUSING OIL SEAL C Mating Marks (c) Using needle nose pliers, install a new power steering rack bush to the rack housing. C C INSTALL POWER STEERING RACK (a) Lightly stretch the O-ring using fingers as shown in the illustration and install the O-ring to the ring groove of the steering rack. Before installing, coat the O-ring with power steering fluid. Do not twist or damage the O-ring. Work the power piston ring and stretch it with your fingers to make it easier to install. (c) Install the power piston ring to the power steering rack. Before installing, coat the seal ring with power steering fluid. Do not stretch the power piston ring excessively. Stretch the full circumference of the power piston ring evenly. Do not damage the power piston ring. After installing the power piston ring, coat the ring groove with power steering fluid.

19 POWER STEERING POWER STEERING LINK ASSEMBLY 18 (d) While holding the stretched seal ring with your hand, allow the seal ring to shrink. C Width To Cover The Surface Of The Teeth Approx. 30 mm Paper Rack Cover Tube Air Passage Hole ZX09558 (e) (f) With the rack cover tube covering the tooth surface and port, cut the rack cover tube so it is approximately 30 mm longer than the power steering rack. As it is used to protect the cylinder tube oil seal, before using the rack cover tube, check that it has no burrs, cracks or other damage. Cut a piece of newspaper so it is wide enough to cover the power steering rack teeth and the same length as the rack cover tube. Make sure the newspaper is large enough that the power steering rack leaves no teeth marks on the rack cover tube when the tube is contracted. Rack Cover Tube Air Passage Hole (g) Fill the grooved sections of the power steering rack teeth with amix long life grease. Do not clog the ventilation hole of the steering rack with grease. Tuck Paper A-A Cross Section Paper Rack Rack Cover Tube (h) (i) Position the newspaper so that it covers the power steering rack teeth. Insert the rack cover tube in the direction of the crease shown in the illustration until it covers the ports. ZX06746J02 Rack Cover Tube Paper Dryer Paper Rack Cover Tube Dryer C (j) Using the rear side of the teeth, bring the dryer air outlet to the power steering rack at an angle as shown in the illustration, and move the dryer so that it pushes the air inside the rack cover tube to side B and in doing so, contracts the rack cover tube from part A to part B. If the rack cover tube is contracted by the dryer from the side of the power steering rack teeth, it will leave teeth marks on the rack cover tube, which will make it difficult to remove the rack cover tube. Using a fine head on the dryer air outlet makes it easier to contract the crease on the rack cover tube one side at a time.

20 19 POWER STEERING POWER STEERING LINK ASSEMBLY 180 Rotation Paper Paper B-B Cross Section 180 Rotation Rack Cover Tube ZX06747J02 (k) (l) (m) Turn just the rack cover tube approximately 180 degrees. Using the rear side of the power steering rack, contract the the other side of the rack cover tube. Pull out the newspaper. If the newspaper rips, pull off the rack cover tub to remove it. When installing the rack cover tube, be sure to insert the power steering rack until it fully covers the ports. Dryer Rack End Threaded Hole Rack Cover Tube Rack Cover Tube Dryer Tip C030439J02 (n) (o) (p) (q) (r) While rotating the power steering rack, thoroughly heat just the rack cover tube end C, and then twist it quickly while pushing it into the steering rack end installation hole. The rack cover tube may become difficult to remove if heat is also applied to the teeth. Make sure that there are no protrusions, edges or similar on the rack cover tube end. If there are any protrusions or edges on the end, heat the end once again and push the protrusions and or edges into the rack end installation hole using a pen or similar. Check that the surface of the rack cover tube is not scratched or otherwise damaged. Coat the rack cover tube and power steering rack power piston ring with power steering fluid. Install the power steering rack to the rack housing and remove the rack cover tube. Do not damage the power piston ring. Do not reuse the rack cover tube. As there is a risk that the power steering cylinder tube oil seal may be damaged by power steering rack overstroke, do not move the power steering rack any more than needed after the rack cover tube is removed until the control valve is installed. 3. INSTALL CYLINDER END STOPPER (a) Coat the lip of a new cylinder end stopper oil seal with power steering fluid. Install the cylinder end stopper oil seal to the rack housing. Make sure the cylinder end stopper oil seal is installed in the correct direction. Do not damage the cylinder end stopper oil seal. (c) Check that the bush located on the inner surface of the cylinder end stopper is not damaged.

21 POWER STEERING POWER STEERING LINK ASSEMBLY 20 (d) (e) Coat the bush located on the inner surface of the cylinder end stopper with long life chassis grease. Coat a new O-ring with power steering fluid and install it to the cylinder end stopper. Application of grease C Cylinder End Stopper (f) Coat the inner surface of the bush of the cylinder end stopper with power steering fluid and drive in the bush to the rack housing so that the cylinder end stopper can be tightened. C (g) Using the, tighten the cylinder end stopper. Torque: 60 N*m (612 kgf*cm) 4. CHECK POWER STEERING RACK HOUSING AIRTIGHTNESS (a) Install the on the rack housing. C Install a MIGHTY VAC to the. Then apply a vacuum of kpa (400 mm Hg) for 30 seconds and check that there is no change to the vacuum pressure in that time. If there is any air leakage, inspect the cylinder end stopper oil seal and cylinder tube oil seal and replace. C C INSTALL PRESSURE CONTROL VALVE ORIFICE SEAT (a) Using a sliding T-handle and hammer, lightly tap in a new power steering control valve spacer. Do not allow any foreign matter to get into the port. 6. INSTALL POWER STEERING CONTROL VALVE UNION SEAT Use the same procedure as for the pressure control valve orifice seat.

22 21 POWER STEERING POWER STEERING LINK ASSEMBLY Oil Seal Handle Spacer 7. INSTALL POWER STEERING CONTROL VALVE UPPER OIL SEAL (a) Apply power steering fluid to the lip of the new power steering control valve upper oil seal and power steering control valve upper bearing. Using the and a press, press in the power steering control valve upper oil seal ( ) Make sure the power steering control valve upper oil seal is installed in the correct direction. While pressing in with the press, do not apply an excessive force. Oil Seal C Spacer Handle Bearing 8. INSTALL POWER STEERING CONTROL VALVE UPPER BEAR- ING (a) Using the and a press, press in the power steering control valve upper bearing ( ) While pressing in with the press, do not apply an excessive force. C INSTALL POWER STEERING CONTROL VALVE (a) Coat 4 new power steering control valve rings with power steering fluid.

23 POWER STEERING POWER STEERING LINK ASSEMBLY 22 C Using the, stretch the 4 control valve rings. Insert the seal rings from the smaller diameter side of the. Slide the rings toward the larger diameter side of the to stretch them. Do not stretch the power steering control valve rings excessively. Stretch the full circumference of the power steering control valve rings evenly. Do not damage the power steering control valve rings. (c) While holding the 4 power steering control valve rings and allow them to shrink. C (d) (e) (f) (g) Coat the 4 rings with power steering fluid. Using the, allow the rings to shrink further. Wrap the serrated area of the control valve with protective tape. Coat the oil seal with power steering fluid. Using a press, install the power steering control valve to the power steering control valve housing. Do not damage the power steering control valve rings. Do not damage the power steering control valve upper oil seal inside the power steering control valve housing. When the power steering control valve cannot be pressed in easily, make sure that the control valve ring is not pinched and that the bearing inside the control valve housing is not tilted. C INSTALL POWER STEERING CONTROL VALVE ASSEMBLY (a) Coat the grooved sections of the pinion rack teeth with long life grease. (c) (d) Coat the needle roller bearing inside the rack housing with long life grease. Install a new power steering control valve housing gasket to the control valve housing. Align matchmarks of the control valve housing and the rack housing, and install the power steering control valve assembly. Apply Grease C057760

24 23 POWER STEERING POWER STEERING LINK ASSEMBLY Matchmarks (e) Install the power steering control valve housing to the power steering rack housing using 2 bolts. Torque: 18 N*m (185 kgf*cm) C INSTALL STEERING RACK GUIDE (a) Coat the surface that contacts the power steering rack with long life grease. Install the power steering rack guide to the rack housing. (c) Clean the threaded parts of the spring cap and the rack housing. (d) Install the rack guide spring to the rack housing. (e) Temporarily tighten the spring cap. (f) Engage the power steering rack and the control valve. Apply Grease C (g) Using the, install the spring cap. Torque: 83.4 N*m (850 kgf*cm) C INSPECT TOTAL PRELOAD (a) Temporarily install the left and right steering rack ends to the power steering rack. Make sure to install the left and right steering rack ends because moving the power steering rack at full stroke without installing the steering rack ends may damage the oil seal. Using the, move the power steering rack 1 to 2 times at full stroke to work in the power steering rack. C140245

25 POWER STEERING POWER STEERING LINK ASSEMBLY 24 (c) (d) Using the, inspect total preload. Standard: 0.8 to 1.5 N*m (8 to 14.8 kg*cm) Remove the right and left steering rack ends from the power steering rack. C INSTALL STEERING RACK END (a) Align the claws of 2 new claw washers with the RH and LH steering rack end grooves to install them to the steering rack ends. Temporarily install the left and right steering rack ends. (c) Using the and a wrench, install the steering rack end to the power steering rack. Torque: 103 N*m (1050 kgf*cm) Use the in the correct direction. When tightening, do not twist the steering rack. Secure the power steering rack securely with a spanner. C (d) (e) Secure the steering rack end ball joint in the vise between aluminum plates. Do not tighten the vise too firmly. Using a brass bar and a hammer, stake the 2 claw washers (RH and LH). Avoid any impact to the power steering rack. C INSTALL STEERING RACK BOOT NO. 2 (a) INSTALL LEFT AND RIGHT STEERING RACK BOOTS AND BOOT CLAMP Install the left and right steering rack boots and boot clamp. Using the, rotate the control valve and check that the steering rack boot expands and contracts smoothly. 15. INSTALL STEERING LEFT TURN PRESSURE TUBE (a) Using the, install the steering left turn pressure tube to the power steering gear assembly. Torque: 24.5 N*m (250 kgf*cm) C INSTALL STEERING RIGHT TURN PRESSURE TUBE (a) Use the same procedure as for the steering left turn pressure tube. Torque: 24.5 N*m (250 kgf*cm)

26 25 POWER STEERING POWER STEERING LINK ASSEMBLY Match Mark C INSTALL TIE ROD END LH (a) Install the lock nut and the tie rod end LH to the rack end until the matchmarks are aligned and install the lock nut. Torque: 47.1 N*m (480 kgf*cm) 18. INSTALL TIE ROD END RH Install the RH in the same way as the LH. INSTALLATION C INSTALL RACK AND PINION TYPE POWER STEERING GEAR ASSEMBLY (a) Using a torque wrench, install the rack and pinion type power steering gear assembly. Torque: 90.5 N*m (923 kgf*cm) 2. INSTALL STEERING SHAFT UNIVERSAL JOINT ASSEMBLY (a) Align the matchmarks and install the steering shaft universal joint assembly to the steering gear assembly. Insert the steering shaft universal joint assembly until the spline part can no longer be seen. After temporarily tightening a new bolt by hand, fully tighten the bolt. Torque: 35 N*m (357 kgf*cm) Steering Gear Assy Matchmarks (c) (d) Insert the steering intermediate shaft into the column hole cover from the cabin side. Align matchmarks and connect the steering column assembly to the steering intermediate shaft assembly. C136671J01 (e) Temporarily tighten bolt A by hand so that the steering intermediate shaft assembly slides slightly. Matchmarks Bolt A (f) Align the matchmarks and connect the steering intermediate shaft and the steering shaft universal joint assembly. Insert the steering intermediate shaft until the serrated part can no longer be seen. C136414J01

27 POWER STEERING POWER STEERING LINK ASSEMBLY 26 STEERING INTERMEDIATE ASSEMBLY (g) After temporarily tightening a new bolt by hand, fully tighten the bolt. Torque: 29.4 N*m (300 kgf*cm) Make sure the bolt does not run on the notch of the steering intermediate shaft. Matchmarks C136672J01 (h) Fully tighten bolt A. Torque: 29.4 N*m (300 kgf*cm) 3. INSTALL INSTRUMENT PANEL UNDER COVER NO. 1 (See pageip-18) Bolt A 4. INSTALL INSTRUMENT PANEL FINISH PANEL LWR (See pageip- 18) C136414J02 5. CONNECT OIL RESERVOIR TO PUMP HOSE (a) Using a torque wrench, connect the oil reservoir to pump hose to the rack and pinion type power steering gear assembly. Torque: 44.1 N*m (450 kgf*cm) 6. CONNECT PRESSURE FEED HOSE (a) Using a torque wrench, connect the pressure feed hose to the rack and pinion type power steering gear assembly. Torque: 44.1 N*m (450 kgf*cm) 7. INSTALL TIE ROD END LH (See pageds-10) 8. INSTALL TIE ROD END RH Perform the same procedure for the RH as for the LH. 9. REFILL POWER STEERING FLUID 10. BLEED AIR FROM POWER STEERING FLUID (See page-4) 11. CHECK POWER STEERING FLUID LEVEL (See page-3) 12. CHECK FOR POWER STEERING FLUID LEAKAGE 13. INSTALL ENGINE UNDER COVER 14. INSTALL FRONT TIRE Torque: 103 N*m (1050 kgf*cm) 15. PERFORM ZERO POINT CALIBRATION TO INDEX TO NEXT SECTION