). 1. REMOVE FR WIPER ARM RH

Transcription

1 5120 OVERHAUL When installing, apply power steering fluid or molybdenum disulfide lithium base grease to the parts indicated by arrows (See page 5117). 1. REMOVE FR WIPER ARM RH (See page 666) 2. REMOVE FR WIPER ARM LH (See page 666) 3. REMOVE HOOD TO COWL TOP SEAL (See page 666) 4. REMOVE COWL TOP VENTILATOR LOUVER RH (See page 666) 5. REMOVE COWL TOP VENTILATOR LOUVER LH (See page 666) 6. REMOVE WINDSHIELD WIPER MOTOR & LINK ASSY (See page 666) 7. REMOVE COWL PANEL SUBASSY (See page 5542) 8. INSPECT CENTER FRONT WHEEL 9. REMOVE STEERING COLUMN HOLE COVER PLATE (See page 508) 510ES SEPARATE STEERING SLIDING YOKE SUBASSY (a) Fix the steering wheel with the seat belt in order to prevent rotation. This operation is also useful to prevent damaging the spiral cable. F45780 Matchmarks (b) (c) Put matchmarks on the sliding yoke subassy and the intermediate shaft. Loosen the bolt, then separate the sliding yoke subassy from the intermediate shaft. F45628 B A 11. SEPARATE STEERING COLUMN HOLE COVER SUBASSY NO.1 (a) Disengage clip A and separate the hole cover subassy No.1. Be careful not to damage clip B. F REMOVE HOOD SUBASSY 13. DRAIN FLUID 14. REMOVE FRONT WHEELS 1450

2 SEPARATE TIE ROD END SUBASSY LH (See page 306) SEPARATE TIE ROD END SUBASSY RH REMOVE ENGINE UNDER COVER LH 18. REMOVE ENGINE UNDER COVER RH Clip Return Hose Pressure Feed Tube Assy F SEPARATE PRESSURE FEED TUBE ASSY (a) Remove the clip and disconnect the return hose. (b) Using, disconnect the pressure feed tube assy (c) Using, remove the return tube (d) Remove the bolt and separate the tube clamp. F SEPARATE FRONT SUSPENSION ARM SUBASSY LOWER NO.1 LH (See page 306) SEPARATE FRONT SUSPENSION ARM SUBASSY LOWER NO.1 RH

3 5122 No.1 Engine Hangers F SUSPEND ENGINE ASSEMBLY (a) Install 2 No.1 engine hangers with the bolts in the correct direction. Parts No.: No.1 engine hanger: Bolt: Torque: 40 N m (408 kgf cm, 30 ft lbf) (b) Attach the engine chain hoist to the engine hangers. CAUTION: Do not hang the engine by hooking the chain to any other parts. 23. REMOVE FRONT SUSPENSION CROSSMEMBER SUBASSY (a) Remove the 4 bolts and the 2 reinforcements. A76365 (b) (c) Remove the bolt and the 2 nuts, and separate the engine mounting insulator RR. Using a transmission jack, support the crossmember subassy. C57712 (d) Remove the 4 bolts and the crossmember subassy. C REMOVE RACK HOUSING HEAT INSULATOR (a) Remove the 2 bolts and the heat insulator. 25. REMOVE STEERING COLUMN HOLE COVER SUBASSY NO

4 5123 Matchmarks 26. REMOVE STEERING INTERMEDIATE SHAFT (a) Put matchmarks on the steering link assy and the intermediate shaft. (b) Remove the bolt and the intermediate shaft. F45585 Matchmarks 27. REMOVE (a) Put matchmarks on the steering link assy and the bracket No.2. Front F45765 (b) Remove the 4 bolts, the nuts, the bracket No.2, the grommet No.2 and the steering link assy. Torque the bolt with the nut fixed as the nut has its own stopper. Do not turn the nut. F45584 Oring 28. REMOVE STEERING RIGHT TURN PRESSURE TUBE (a) Using, remove the right turn pressure tube (b) Remove the 2 Orings from the right turn pressure tube. F REMOVE STEERING LEFT TURN PRESSURE TUBE

5 FIX (a) Using, secure the steering link assy Wrap the with vinyl tape before use. F REMOVE TIE ROD END SUBASSY LH (a) Put matchmarks on the tie rod end subassy LH and the rack end subassy. (b) Loosen the lock nut and remove the tie rod end subassy LH and the lock nut. Machmarks F REMOVE TIE ROD END SUBASSY RH 33. REMOVE STEERING RACK BOOT CLIP (a) Remove the 2 boot clips. 34. REMOVE STEERING RACK BOOT NO.2 CLAMP (a) Using a screwdriver, remove the rack boot No.2 clamp. Be careful not to damage the boot. F REMOVE STEERING RACK BOOT NO.1 CLAMP 36. REMOVE STEERING RACK BOOT NO REMOVE STEERING RACK BOOT NO

6 5125 LH: Turn Hold 38. REMOVE STEERING RACK END SUBASSY (a) Using, remove the 2 rack ends subassy Use in the direction shown in the illustration. RH: Turn Hold F45590 F45591 F REMOVE RACK GUIDE (a) Using, remove the spring cap lock nut Use in the direction shown in the illustration. F45592 Hexagon Wrench (19 mm) (b) (c) Using a hexagon wrench (19 mm), remove the rack guide spring cap. Remove the rack guide spring, the rack guide spring spacer and the rack guide. F45769 Matchmarks 40. REMOVE CONTROL VALVE (a) Put matchmarks on the control valve housing and the rack housing. (b) Remove the 2 bolts and the control valve housing with control valve. (c) Remove the gasket. F

7 REMOVE CYLINDER END STOPPER (a) Using needle nose pliers, remove the hole snap ring. (b) Pull out the cylinder end stopper. Steering Rack Rack Bush 42. REMOVE RACK (a) Using and a press, remove the steering rack with rack bush ( ) F45594 Hold 43. REMOVE RACK BUSH (a) Remove the rack bush from the steering rack. (b) Using, remove the rack bush oil seal ( ) (c) Using a screwdriver, remove the Oring from the rack bush. Oil Seal F REMOVE RACK STEERING PISTON RING (a) Using a screwdriver, remove the piston ring and the O ring. Be careful not to damage the grooves for the piston ring and the Oring. R REMOVE RACK HOUSING OIL SEAL (a) Using and a press, remove the housing oil seal ( , , ), ( ) Be careful not to damage the rack housing. F

8 5127 Dial Gauge 46. INSPECT RACK (a) Using a dial gauge, check the steering rack for runout, teeth wear and damage. Maximum runout: 0.1 mm (0.004 in.) (b) Check the rack surface of the steering rack for wear and damage. ZX9355 ZK INSPECT TIE ROD END SUBASSY LH (a) Secure the tie rod end subassy in a vise. (b) Install the nut to the stud bolt. (c) Flip the ball joint stud back and forth 5 times. (d) Using a torx wrench, turn the nut continuously at a rate of 2 to 4 seconds per turn and take the torque reading on the 5th turn. Turning torque: 0.8 to 3.4 N m (8.2 to 34.7 kgf cm, 7.1 to 30.1 in. lbf) 48. INSPECT TIE ROD END SUBASSY RH Oil Seal F INSTALL RACK HOUSING OIL SEAL (a) Coat a new oil seal lip with power steering fluid. (b) Using and a press, install the housing oil seal ( , , ), ( ) Make sure that the oil seal is installed correctly. 50. INSTALL RACK STEERING PISTON RING (a) Apply power steering fluid to a new Oring and install it to the steering rack. (b) Expand a new piston ring with your fingers. Be careful not to overly expand the piston ring. (c) Apply power steering fluid to the piston ring. C

9 5128 (d) Install the piston ring to the steering rack, and adjust with your fingers. N00401 Rack Teeth End 51. INSTALL RACK (a) Install to the steering rack If necessary, scrape the burrs off the steering rack teeth end and burnish. (b) Apply power steering fluid to the. (c) Install the steering rack to the rack housing. (d) Remove. F45771 Oil Seal F INSTALL RACK BUSH (a) Using and a press, install the rack bush oil seal to the rack bush ( , , ), ( ) Make sure that the oil seal is installed correctly. (b) Apply power steering fluid to a new Oring and install it to the rack bush. Vinyl Tape (c) Wrap vinyl tape around the steering rack end to prevent damaging the rack bush oil seal lip, and apply power steering fluid to the rack bush oil seal. (d) Install the rack bush into the rack housing. Make sure that the rack bush is installed correctly. Be careful not to damage the oil seal lip. F

10 INSTALL CYLINDER END STOPPER (a) Push into the cylinder end stopper. (b) Using needle nose pliers, install the hole snap ring. 54. AIR TIGHTNESS TEST (a) Install onto the rack housing ( ) (b) Apply vacuum of 53 kpa (400 mmhg, in.hg) for approximately 30 seconds. (c) Check that there is no change in the vacuum. If there is a change in the vacuum, check the installation of the oil seals. F INSTALL CONTROL VALVE (a) Apply grease to the needle roller bearing. (b) Install a new gasket to the rack housing. F45597 Matchmarks (c) Align the matchmarks and install the control valve housing with control valve to the rack housing with the 2 bolts. Torque: 21 N m (214 kgf cm, 15 ft lbf) F45593 F INSTALL RACK GUIDE (a) Install the rack guide, the rack guide spring spacer and the rack guide spring. Make sure that the rack guide spring spacer is installed correctly. (b) Apply sealant to 2 or 3 threads of the rack guide spring cap. Sealant: Part No , THREE BOND 1344, LOCTITE 242 or equivalent (c) Temporarily install the rack guide spring cap. 1459

11 F ADJUST TOTAL PRELOAD (a) To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the RH and LH rack ends sub assy. (b) Using a hexagon wrench (19 mm), torque the rack guide spring cap. Torque: 25 N m (250 kgf cm, 18 ft lbf) (c) Using a hexagon wrench (19 mm), return the rack guide spring cap approximately 12 degrees. (d) (e) Using, turn the control valve to the right and left once or twice Using a hexagon wrench (19 mm), loosen the rack guide spring cap until the rack guide spring stops functioning. F45604 Hexagon Wrench (19 mm) F45605 (f) Using, a torque wrench and a hexagon wrench (19 mm), tighten the rack guide spring cap until the preload is within the specification Preload (turning): 1.2 to 1.5 N m (12 to 15 kgf cm, 10.6 to 13.3 in. lbf) (g) Apply sealant to 2 or 3 threads of the spring cap lock nut. Sealant: Part No , THREE BOND 1344, LOCTITE 242 or equivalent (h) Temporarily install the spring cap lock nut. Hold Fulcrum Length F45606 (i) Hold the rack guide spring cap by using a hexagon wrench (19 mm), and using, torque the spring cap lock nut. Torque: 28 N m (286 kgf cm, 21 ft lbf) Use in the direction shown in the illustration. Use a torque wrench with a fulcrum length of 345 mm (13.58 in.). (j) (k) Recheck the total preload. Preload (turning): 1.2 to 1.5 N m (12 to 15 kgf cm, 10.6 to 13.3 in. lbf) Remove the RH and LH rack ends subassy. 1460

12 5131 LH: RH: Hold Fulcrum Length Hold 58. INSTALL STEERING RACK END SUBASSY (a) Temporarily install the 2 rack end subassy. (b) Using, torque the 2 rack end subassy Torque: 60 N m (614 kgf cm, 44 ft lbf) Use in the direction shown in the illustration. Use a torque wrench with a fulcrum length of 345 mm (13.58 in.). Using, hold the rack and install the rack end sub assy. Fulcrum Length F45608 F45607 F INSPECT STEERING RACK END HOLE (a) Ensure that the hole of the rack end subassy is not clogged with grease. If the hole is clogged, the pressure inside the boot will change after it is assembled and the steering wheel is turned. F INSTALL STEERING RACK BOOT NO.2 (a) Apply silicon grease to the inside small caliber of rack boot No.2. (b) Install the rack boot No.2 onto the groove on the rack housing. Be careful not to damage or twist the boot. C INSTALL STEERING RACK BOOT NO

13 mm (0.118 in.) or less F INSTALL STEERING RACK BOOT NO.2 CLAMP (a) Using, tighten the rack boot No.2 clamp, as shown in the illustration , Clearance: 3.0 mm (0.118 in.) or less Be careful not to damage the boot. 63. INSTALL STEERING RACK BOOT NO.1 CLAMP , INSTALL STEERING RACK BOOT CLIP (a) Using a pliers, install the 2 rack boot clips. 65. INSTALL TIE ROD END SUBASSY LH (a) Screw the lock nut and the tie rod end subassy LH on the rack end subassy until the matchmarks are aligned. Torque: 74 N m (750 kgf cm, 54 ft lbf) After adjusting toein, torque the lock nut (See page 267). Machmarks F INSTALL TIE ROD END SUBASSY RH Fulcrum Length F INSTALL STEERING RIGHT TURN PRESSURE TUBE (a) Apply power steering fluid to the 2 new Orings and install them to the right turn pressure tube. (b) Using, install the right turn pressure tube to the steering link assy Torque: 12 N m (118 kgf cm, 9 ft lbf) Use a torque wrench with a fulcrum length of 250 mm (9.84 in.). This torque value is effective when is parallel to a torque wrench. 1462

14 INSTALL STEERING LEFT TURN PRESSURE TUBE Matchmarks 69. INSTALL (a) Install the grommet No.2 to the the steering link assy. (b) Align the matchmarks and install the bracket No.2 to the steering link assy. Install the bracket with the inscribed mark facing to the front of the vehicle. Front F45765 (c) Install the steering link assy with the 4 bolts and the nuts. Torque: 74 N m (749 kgf cm, 54 ft lbf) Torque the bolt with the nut fixed as the nut has its own stopper. Do not turn the nut. F45584 Matchmarks 70. INSTALL STEERING INTERMEDIATE SHAFT (a) Align the matchmarks on the intermediate shaft with the pinion shaft. (b) Install the bolt. Torque: 28 N m (290 kgf cm, 21 ft lbf) F INSTALL STEERING COLUMN HOLE COVER SUBASSY NO.1 (a) 72. INSTALL RACK HOUSING HEAT INSULATOR (a) Install the heat insulator with the bolt as shown in the illustration. Torque: 18 N m (178 kgf cm, 13 ft lbf) (b) Install the bolt to the heat insulator. Torque: 35 N m (360 kgf cm, 26 ft lbf) F

15 INSTALL FRONT SUSPENSION CROSSMEMBER SUBASSY (a) Using a transmission jack, support the crossmember subassy. (b) Using, align the holes of the crossmember subassy F08808 B B (c) Install the crossmember subassy with the 4 bolts. Torque: Bolt A: 116 N m (1,183 kgf cm, 86 ft lbf) Bolt B: 70 N m (714 kgf cm, 52 ft lbf) A A C57743 (d) Install the crossmember subassy with the bolt and the 2 nuts. Torque: 72 N m (734 kgf cm, 53 ft lbf) C57712 (e) Install the 2 reinforcements with the 4 bolts. Torque: 47 N m (479 kgf cm, 35 ft lbf) A INSTALL FRONT SUSPENSION ARM SUBASSY LOWER NO.1 LH (See page 306) 75. INSTALL FRONT SUSPENSION ARM SUBASSY LOWER NO.1 RH 1464

16 5135 Fulcrum Length F CONNECT PRESSURE FEED TUBE ASSY (a) Using, connect the pressure feed tube assy Torque: 27 N m (273 kgf cm, 20 ft lbf) Use a torque wrench with a fulcrum length of 345 mm (13.58 in.). This torque value is effective when is parallel to a torque wrench. (b) Connect the return hose with the clip. (c) Install the tube clamp to the crossmember subassy with the bolts. Torque: 7.8 N m (80 kgf cm, 69 in. lbf) F INSTALL TIE ROD END SUBASSY LH (See page 306) 78. INSTALL TIE ROD END SUBASSY RH 79. INSTALL FRONT WHEELS Torque: 103 N m (1,050 kgf cm, 76 ft lbf) Matchmarks 80. INSTALL STEERING SLIDING YOKE SUBASSY (a) Align the matchmarks on the sliding yoke subassy and the intermediate shaft. (b) Tighten the bolt. Torque: 28 N m (290 kgf cm, 21 ft lbf) F INSPECT CENTER FRONT WHEEL 82. INSTALL STEERING COLUMN HOLE COVER SUBASSY NO ADD FLUID 84. BLEED FLUID (See page 513) 85. CHECK FULUID LEVEL IN RESERVER (See page 513) 86. INSPECT FLUID LEAK 87. INSTALL HOOD SUBASSY (See page 751) 88. ADJUST HOOD SUBASSY (See page 751) 89. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 267) 1465

17 INSTALL ENGINE UNDER COVER LH 91. INSTALL ENGINE UNDER COVER RH 92. INSTALL COWL PANEL SUBASSY (See page 5542) 93. INSTALL WINDSHIELD WIPER MOTOR & LINK ASSY (See page 666) 94. INSTALL COWL TOP VENTILATOR LOUVER LH (See page 666) 95. INSTALL COWL TOP VENTILATOR LOUVER RH (See page 666) 96. INSTALL HOOD TO COWL TOP SEAL (See page 666) 97. INSTALL FR WIPER ARM LH (See page 666) 98. INSTALL FR WIPER ARM RH (See page 666) 1466