Steering

STEERING

TROUBLESHOOTINGUse the table below to help you find the cause of the problem. The numbers indicate the priorityof the likely cause of the problem. Check each part in order. If necessary, replace these parts.

GENERAL DESCRIPTIONCare must be taken to replace parts properly because they could affect the performance of thesteering system and result in a driving hazard.

Abnormal noise

Excessive play

Hard steering

PartsName

Poor return

See page

Trouble

-STEERING GENERAL DESCRIPTIONSR-2

TROUBLESHOOTINGUse the table below to help you find the cause of the problem. The numbers indicate the priorityof the likely cause of the problem. Check each part in order. If necessary, replace these parts.

GENERAL DESCRIPTIONCare must be taken to replace parts properly because they could affect the performance of thesteering system and result in a driving hazard.

Abnormal noise

Excessive play

Hard steering

PartsName

Poor return

See page

Trouble

-STEERING TROUBLESHOOTINGSR-2

ON-VEHICLE INSPECTIONCHECK THAT STEERING WHEEL FREEPLAY IS COR-RECTWith the vehicle stopped and tires pointed straightahead, rock the steering wheel gently back and forthwith light finger pressure.Freeplay should not exceed the maximum.

Maximum freeplay:30 mm (1.18 in.)

If incorrect, repair.

-STEERING ON-VEHICLE INSPECTIONSR-3

STEERING COLUMN

PREPARATION

(09904-00050) No. 4 Claw

SST (SPECIAL SERVICE TOOLS)

For removing and installingsnap ring

RECOMMENDED TOOLS

09609-2001 1 Steering Wheel Puller

09904-00010 Expander Set

EQUIPMENTTorque wrench

-STEERING STEERING COLUMNSR-4

ASSEMBLY REMOVAL ANDINSTALLATIONRemove and install the parts, as shown.

(d) Pull the wheel pad out from the steering wheel anddisconnect the SRS connector.NOTICE: When removing the wheel pad, take care notto pull the airbag wire harness.CAUTION:

• When storing the wheel pad, keep the upper surfaceof the pad facing upward.

• Never disassemble the wheel pad.

3. REMOVE STEERING WHEEL(a) Disconnect the connector.(b) Remove the set nut.(c) Place matchmarks on the steering wheel and main

shaft.(d) Using SST, remove the steering wheel.

SST 09609-200114. REMOVE AND INSTALL COMBINATION SWITCH

w/ SRS:2. REMOVE STEERING WHEEL PAD(a) Place the front wheels facing straight ahead.(b) Remove the No.2 and No.3 covers.(c) Using a torx wrench, loosen the 3 torx screws.Torx wrench: T30 (Part No. 09042-00010 or locallymanufactured tool)HINT: Loosen the 3 screws until the groove along the

screw circumference catches on the screw case.

MAIN POINTS OF REMOVAL ANDINSTALLATION

NOTICE:

• If the SRS (Supplemental Restraint System) connec-tor is disconnected with the igniton switch at ON orACC, diagnostic trouble codes will be recorded.

• Never use SRS parts from another vehicle. Whenreplacing parts, replace with new parts.

1. DISCONNECT NEGATIVE (-) TERMINAL CABLEFROM BATTERYCAUTION: Work must be started after 90 seconds fromthe time the ignition switch is turned to the ”LOCK”position and the negative (-) terminal cable is discon-nected from the battery.(See RS section)

7. INSTALL STEERING WHEEL PAD(a) Connect the SRS connector.(b) Install the wheel pad after confirming that the circum-

ference groove of the torx screws is caught on thescrew case.

(c) Using a torx wrench, tighten the 4 screws.Torque: 8.8 N �m (90 kgf �cm. 78 in. �lbf)NOTICE:

• Make sure the wheel pad is installed to the specifiedtorque.

• If the wheel pad has been dropped, or there arecracks, dents or other defects in the case or connec-tor, replace the wheel pad with a new one.

• When installing the wheel pad, take care that thewirings do not interfere with other parts and are notpinched between other parts.

(d) Install the No.2 and No.3 covers.8. CHECK STEERING WHEEL CENTER POINT9. CONNECT NEGATIVE (-) TERMINAL CABLE TO

BATTERYw/o SRS:

1. REMOVE STEERING WHEELUsing SST, remove the steering wheel.SST 09609-20011

2. CHECK STEERING WHEEL CENTER POINT AFTERINSTALLATION STEERING COLUMN

5. CENTER SPIRAL CABLE(a) Check that the front wheels are facing straight ahead.(b) Turn the spiral cable counterclockwise by hand until it

becomes harder to turn the cable.(c) Then rotate the spiral cable clockwise about 3 turns to

align the red mark.HINT: The spiral cable will rotate about 3 turns toeither left or right of the center.

6. INSTALL STEERING WHEEL(a) Align matchmarks on the steering wheel and main

shaft, and install the steering wheel to the main shaft.(b) Install and torque the set nut.

Torque: 35 N �m (360 kgf �cm, 26 ft �lbf)

(c) Connect the connector.

STEERING COLUMN DISASSEMBLYNOTICE: When placing the column tube in a vise, do nottighten it too tight.

7. REMOVE COLUMN UPPER BRACKET(a) Using a center punch, mark the center of the 2 tap-

ered-head bolts.(b) Using a 3-4 mm (0.12-0.16 in.) drill, drill in to the 2

tapered-head 2 bolts.

STEERING COLUMNCOMPONENTS

STEERING, COLUMN INSPECTION ANDREPLACEMENT1. INSPECT KEY CYLINDER

Check that the steering lock mechanism operates pro-perly.

3. REMOVE COLUMN LOWER TUBE(a) Place matchmarks on the upper tube and lower tube.(b) Using a plastic hammer, tap out the lower tube.

(c) Using a screw extractor, remove the 2 tapered-headbolts.

(d) Remove the bracket and column upper clamp.

2. REMOVE MAIN SHAFT(a) Using snap ring pliers, remove the snap ring.(b) Tap out the main shaft.

(c) Using snap ring pliers, remove the snap ring from themain shaft.

6. IF NECESSARY, REPLACE COLUMN TUBE BUSH-ING

(a) Remove the bushing.(b) Install the bushing to the upper tube and integrate the

groove in the upper tube with the narrow projection ofthe bushing, checking that the other projections areagainst the uppper surface of the upper tube.

STEERING COLUMN ASSEMBLY

1. APPLY MOLYBDENUM DISULPHIDE LITHIUMBASE GREASE

2. INSTALL COLUMN LOWER TUBEAlign matchmarks on the upper tube and lower tubeand tap in the lower tube.

2. IF NECESSARY, REPLACE KEY CYLINDER(a) Place the ignition key at the ACC position.(b) Push down the stop pin with a thin rod, and pull out

the key cylinder.(c) Install a new key cylinder.

HINT: Make sure the ignition key is at the ACC posi-tion.

3. INSPECT COLUMN UPPER TUBE BEARINGCheck the bearing rotation condition and check forabnormal noise.If the bearing is worn or damaged, replace the uppertube.

4. IF NECESSARY. REPLACE MAIN SHAFT BUSHING(a) Using a screwdriver, remove the bushing.(b) Align the holes of the tube and the projections of the

bushing, and insert the main shaft bushing in the tube.

4. INSTALL COLUMN UPPER BRACKET(a) Install the bracket with 2 new tapered-head bolts.(b) Tighten the 2 tapered-head bolts until the bolt head

breaks off.

3. INSTALL MAIN SHAFT(a) Using snap ring pliers, install a new snap ring to the

main shaft.

(b) Install the main shaft to the column tube.(c) Using snap ring pliers, install a new snap ring.

-STEERING STEERING COLUMNSR-1 1

MANUAL STEERING GEAR HOUSING

(0961 6-10020) Steering Pinion BearingAdjusting Screw Wrench

(09617-10010) Steering Pinion BearingAdjusting Screw Lock Nut Wrench

(09616-10010) Steering Pinion BearingAdjusting Socket

(09631-00020) Handle

(09612-10061) Steering Pinion Bearing Replacer

(09617-22030) Steering Rack End Wrench

09612-24014 Steering Gear Housing OverhaulTool Set

SST (SPECIAL SERVICE TOOLS)09612-00012 Rack & Pinion Steering Rack

Housing Stand

09620-30010 Steering Gear Box Replacer Set

09617-10020 Steering Rack End Wrench

PREPARATION

09612-10131 Hexagon Wrench

-STEERING MANUAL STEERING GEAR HOUSINGSR-12

08833-00080 Adhesive 1344,THREE BOND 1344,LOCTITE 242 or equivalent

Pinion bearing adjusting screwPinion bearing adjusting screwlock nutRack guide spring cap

(09620-24030) Valve Cup Bearing Replacer

SSM (SPECIAL SERVICE MATERIALS)

09630-24013 Steering Rack Oil Seal Tool Set

EQUIPMENT

RECOMMENDED TOOLS09025-00010 Small Torque Wrench

09631-32010 Oil Seal Replacer

09628-6201 1 Ball Joint Puller

09950-20017 Universal Puller

Torque wrench

Dial indicator

Total preload

Steering rack

(MAIN POINTS OF REMOVAL ANDINSTALLATION)

1. DISCONNECT TIE ROD ENDS(a) Remove the cotter pin and nut.(b) Using SST, disconnect the tie rod end from the knuck-

le arm.SST 09628-62011

ASSEMBLY REMOVAL ANDINSTALLATIONRemove and install the parts, as shown.

3. REMOVE GEAR HOUSING(a) Remove the 2 bolts and 2 nuts.(b) Slide the gear housing to the RH side and pull it out

through the body panel.4. CHECK STEERING WHEEL CENTER POINT5. CHECK TOE-IN

(See SA section)

2. DISCONNECT SLIDING YOKE(a) Place matchmarks on the sliding yoke and pinion

shaft.(b) Loosen the upper side of sliding yoke set bolt.(c) Remove the lower side of sliding yoke set bolt.(d) Pull the sliding yoke upward from the pinion shaft.

2. REMOVE TIE ROD ENDS(a) Loosen the lock nut and place the matchmarks on the

tie rod end and rack end.(b) Remove the tie rod end and lock nut.3. REMOVE RACK BOOTS(a) Remove the clip and clamp.(b) Remove the rack boot.(c) Mark the left and right boots accordingly.

MANUAL STEERING GEAR HOUSINGDISASSEMBLY

1. SECURE GEAR HOUSING IN VISEUsing SST, secure the steering gear in a vise.SST 09612-00012

MANUAL STEERING GEAR HOUSINGCOMPONENTS

6. REMOVE RACK GUIDE SPRING CAPUsing SST, remove the cap.SST 09612-10131

7. REMOVE RACK GUIDE SPRING AND RACK GUIDE

8. REMOVE PINION BEARING ADJUSTING SCREWLOCK NUTUsing SST, remove the nut.SST 09612-10093 (09617-10010)

(b) Using SST, remove the rack end.SST 09617-10020

(c) Mark the left and right rack ends accordingly.(d) Remove the claw washer.

5. REMOVE RACK GUIDE SPRING CAP LOCK NUTUsing SST, remove the nut.SST 09612-24014 (09617-22030)

4. REMOVE RACK ENDS(a) Unstake the claw washer.

NOTICE: Avoid any impact to the rack.

MANUAL STEERING GEAR HOUSINGINSPECTION AND REPLACEMENT1. INSPECT RACK(a) Using a dial indicator, check the rack for run out and

for teeth wear or damage.Maximum runout:

0.3 mm (0.012 in.)

NOTICE: Do not use a wire brush when cleaning.

(b) Check the back surface for wear or damage.If faulty, replace it.

11. REMOVE STEERING RACKRemove the rack from the pinion side without revolv-ing it.NOTICE: If the rack is pulled from the tube side, there isa possibility of damaging the bushing with the rack teethsurface.

10. REMOVE PINION SHAFT WITH UPPER BEARINGHINT: Be careful not to damage the serrations.(a) Fully pull the steering rack from the housing side and

align the rack notched portion with the pinion.(b) Remove the pinion together with the upper bearing.

9. REMOVE PINION BEARING ADJUSTING SCREWUsing SST, remove the screw.SST 09612-24014 (09616-10020)

4. IF NECESSARY, REPLACE LOWER BEARING(a) Heat the rack housing to above 80°C (176°F).(b) Tap the rack housing with a plastic hammer or such to

remove the bearing by recoil.

5. IF NECESSARY, REPLACE RACK BUSHING(a) Using a screwdriver, loosen the 3 bushing claws and

remove the rack bushing from the housing.

(c) Heat the rack housing to above 80 C (176 F).(d) Using SST, press in a new bearing.

SST 09620-30010 (09631-00020)09630-24013 (09620-24030)HINT: Observe the correct bearing direction.

2. INSPECT UPPER AND LOWER BEARING3. IF NECESSARY, REPLACE UPPER BEARING(a) Using SST, remove the bearing.

SST 09950-20017

(b) Using SST, press in a new bearing.SST 09612-24014 (09612-10061)

MANUAL STEERING GEAR HOUSINGASSEMBLY1. INSTALL STEERING RACK(a) From the pinion side, install the rack into the rack

housing.(b) Set the rack notched side so that the pinion can be

positioned inside.

6. IF NECESSARY, REPLACE OIL SEAL(a) Using SST, remove the oil seal from the pinion bearing

adjusting screw.SST 09631-32010NOTICE: Make sure you install the oil seal facing thecorrect direction.

(b) Using SST, press in the oil seal, as shown.SST 09631-32010

(b) Ensure that the tube hole is not clogged with grease.HINT: If the tube hole is clogged, the pressure insidethe boot will change after it is assembled and thesteering wheel turned.

(c) Install a new bushing into the rack housing, makingsure to align into the 3 holes.

(c) Line up the cutout portion of the rack with the pinion.

3. INSTALL PINION BEARING ADJUSTING SCREW(a) Apply sealant to 2 or 3 threads of the screw.

Sealant:Part No.08833-00080, THREE BOND 1344, LOC-TITE 242 or equivalent

(b) Using SST, install the screw.SST 09612-24014 (09616-10020)

4. ADJUST PINION PRELOAD(a) Line up the cutout portion of the rack with the pinion.(b) Using SST and torque meter, tighten the pinion bear-

ing adjusting screw to the point where the turningtorque is 0.4 N�m (3.7 kgf�cm, 3.2 in.�lbf).SST 09612-24014 (09616-10010, 09616-10020)

(c) Using SST, loosen the pinion bearing adjusting screwto the point where turning torque is 0.2-0.3 N�m (2.3-3.3 kgf�cm, 2.0-2.9 in.�lbf).SST 09612-24014 (09616-10010, 09616-10020)Preload (turning):

0.2-0.3 N�m (2.3-3.3 kgf �cm, 2.0-2.9 in. �Ibf)

5. INSTALL PINION BEARING ADJUSTING SCREWLOCK NUT

(a) Apply sealant to 2 or 3 threads of the nut.Sealant:

Part No.08833-00080. THREE BOND 1344, LOC-TITE 242 or equivalent

(b) Using SST, install the nut.SST 09612-10093 (09617-10010)09612-24014 (09616-10020)Torque: 91 N �m (930 kgf �cm, 67 ft �lbf)

HINT: Use a torque wrench with a fulcrum length of425 mm (16.73 in.).

(c) Recheck the pinion preload.If incorrect, readjust.Preload (turning):

0.2-0.3 N�m (2.3-3.3 kgf �cm, 2.0-2.9 in. �lbf)

2. INSTALL PINION SHAFT WITH UPPER BEARINGEnsure that the pinion end is securely in the lowerbearing.

9. INSTALL RACK GUIDE SPRING CAP LOCK NUT(a) Apply sealant to 2 or 3 threads of the nut.

(b) Using SST, install the nut.SST 09612-10131,09612-24014 (09617-22030)Torque: 48 N �m (490 kgf �cm, 35 ft �lbf)

(c) Recheck the total preload. If incorrect, readjust.Preload (turning):

0.6-1.2 N�m (6-12 kgf �cm, 5.2-10.4 in. �lbf)

(b) Using SST and torque meter, while gradually loosen-ing the cap, measure and adjust the preload.SST 09612-10131,09612-24014 (09616-10010)Preload (turning):

0.6-1.2 N�m (6-12 kgf �cm, 5.2-10.4 in. �lbf)

HINT: When measuring the preload, measure in sever-al places and check that the values are within stand-ard.

6. INSTALL RACK GUIDE AND RACK GUIDE SPRING7. INSTALL RACK GUIDE SPRING CAP(a) Apply sealant to 2 or 3 threads of the cap.

Sealant:Part No.08833-00080. THREE BOND 1344, LOC-TITE 242 or equivalent

(b) Mesh the rack with the pinion.(c) Using SST, install the cap.

SST 09612-10131

8. ADJUST TOTAL PRELOAD(a) Using SST, tighten the rack guide spring cap.

SST 09612-10131Torque: 4.9 N �m (50 kgf �cm, 43 in. �lbf)

10. INSTALL RACK ENDS(a) Install a new claw washer.

HINT: Align the claw of the claw washer with the rackgroove.

(b) Using SST, install the rack end.SST 09617-10020Torque: 51 N �m (520 kgf �cm, 38 ft �lbf)

12. INSTALL TIE ROD ENDS(a) Screw the lock nut and tie rod end onto the rack end

until the matchmarks are aligned.(b) After adjusting toe-in, torque the lock nut.

(See SA section)Torque: 47 N �m (480 kgf �cm, 35 ft �lbf)

11. INSTALL RACK BOOTS(a) Install the rack boot.

HINT: Be careful not to damage or twist the boot. Theleft and right boots are different. Be careful not tointerchange them.

(b) Install the clamp and clip.HINT: Face the open ends of the clips outward/upward, as shown, to avoid damage to the boot.

(c) Using a brass bar and hammer, stake the claw washer.

POWER STEERING PRINCIPLESPower steering is a hydraulic device which utilizes engine power to reduce steering effort.Consequently, the engine is used to drive a pump to develop fluid pressure, and this pressure actson a piston within the power cylinder so that the piston assists the rack effort. The amount of thisassistance depends on the extent of pressure acting on the piston. Therefore, if more steeringforce is required, the pressure must be raised. The variation in the fluid pressure is accomplishedby a control valve which is linked to the steering main shaft.

NEUTRAL (STRAIGHT-AHEAD) POSITIONFluid from the pump is sent to the control valve. If the control valve is in the neutral position, allthe fluid will flow through the control valve into the relief port and back to the pump. At this time,hardly any pressure is created and because the pressure on the cylinder piston equal an bothsides, the piston will not move in either direction.

POWER STEERING

DESCRIPTION

-STEERING POWER STEERINGSR-24

SERVICE HINTTroubles with the power steering system are usually concerned with hard steering due to the factthat there is no assist. In such cases, before attempting to make repairs, it is necessary todetermine whether the trouble lies with the pump or with the gear housing. To do this, an on-vehicle inspection can be made by using a pressure gauge.ON-VEHICLE INSPECTIONPower steering is a hydraulic device and problems are normally due to insufficient fluid pressureacting on the piston. This could be caused by either the pump not producing the specified fluidpressure or the control valve in the gear housing not functioning properly so that the proper fluidpressure can not be obtained.If the fault lies with the pump, the same symptoms will generally occur whether the steeringwheel is turned fully to the right or left. On the other hand, if the fault lies with the control valve,there will generally be a difference between the amount of assist when the steering wheel isturned to the left and right, causing harder steering. However, if the piston seal of the powercylinder is worn, there will be a loss of fluid pressure whether the steering wheel is turned to theright or left and the symptoms will be the same for both.Before performing an on-vehicle inspection, a check must first be made to confirm that thepower steering system is completely free of any air. If there is any air in the system, the volumeof this air will change when the fluid pressure is raised, causing a fluctuation in the fluid pressureso that the power steering will not function properly. To determine if there is any air in thesystem, check to see if there is a change of fluid level in the reservoir tank when the steeringwheel is turned fully to the right or left.For example, if there is air in the system, it will be compressed to a smaller volume when the

WHEN TURNINGWhen the steering main shaft is turned in either direction, the control valve also moves, closing1 of the fluid passages. The other passage then opens wider, causing a change in fluid flowvolume and, at the same time, a differential pressure is created between both sides of the piston.Consequently, the piston moves in the direction of the lower pressure so that the fluid in thecylinder is forced back to the pump through the control valve.

VANE PUMPThe main component parts of the vane pump, such as the cam ring, rotor, vanes and flow controlvalve are high precision parts and must be handled carefully. Also, because this pump producesa very high fluid pressure, O-rings are used for sealing each part. When reassembling the pump,always use new O-rings.In the flow control valve, there is a relief valve which controls the maximum pressure of the pump.The amount of this maximum pressure is very important; if it is too low, there will be insufficientpower steering assist and if too high, it will have an adverse effect on the pressure hoses, oilseals, etc. If the maximum pressure is either too high or too low due to a faulty relief valve, do notdisassemble or adjust the relief valve, but replace the flow control valve as an assembly.The clearance between the flow control valve and pump body installation hole is very important.After manufacture, the factory measures the size of the installation hole and outer circumferenceof the flow control valve, and punches a mark accordingly. Therefore, when replacing the flowcontrol valve, be sure to do so with one having the same mark in order to insure the properclearance.

turned fully to the right or left.If there is air in the system, it will be compressed to a smaller volume when the steering wheel isturned, causing a considerable drop in the fluid level. If the system is free of air, there will be verylittle change in the level even when the fluid pressure is raised. This is because the fluid, being aliquid, does not change volume when compressed. The small change in the fluid level is due toexpansion of the hoses between the pump and gear housing when pressure rises.Also, air in the system sometimes causes abnormal noise in the pump or gear housing when thesteering wheel is fully turned in either direction.This on-vehicle inspection must be performed every time after overhauling or repairing thepump or gear housing to ensure that the power steering is working properly.

The oil seals on both sides of the power cylinder are for the prevention of leakage of the highpressure fluid which acts on the piston. Always use new oil seals when reassembling and be verycareful not to scratch or damage them.Because of the high pressure, even the slightest scratch will cause fluid leakage, resulting in aninoperative power steering system.Also, be very careful not to scratch the sliding portion of the rack which makes contact with theoil seals. When removing the rack ends from the rack, it is very easy to cause a burr when holdingthe tip of the rack with a wrench. Therefore, before assembling the rack, first check the tip forburrs and remove any with an oil stone.Teflon rings are used for the piston and control valve. These teflon rings are highly durableagainst wear, but if it is necessary to replace them, be careful not so stretch the new ones. Afterinstalling a teflon ring into its groove, snug it down into the groove before assembly of thecylinder or housing to prevent possible damage.

The functional parts of the pump which produce fluid pressure are the cam ring, rotor and vanes,and these should be checked for wear. If the clearance between each is not within standard whenreassembling, any worn parts should be replaced.In this case, the replaced cam ring and rotor should be of the same length (have the same mark),and the vanes should be replaced with those having a length corresponding to that mark,otherwise the proper thrust clearance cannot be obtained. If there is too much thrust clearance,there will be insufficient fluid pressure at low speeds. If there is too little thrust clearance, it mayresult in seizure of the vanes.

GEAR HOUSINGIf the gear housing is secured directly in a vise during overhaul, there is danger of deforming it,so always first secure it in the SST provided (rack and pinion steering rack housing stand) beforeplacing it in the vise.

IDLE-UP DEVICEThe pump produces the maximum fluid pressure when the steering wheel is turned fully to theright or left and, at this time, there is a maximum load on the pump which causes a decrease inengine idle rpm. To solve this problem, vehicles are equipped with an idle-up device which actsto raise the engine idle rpm whenever there is a heavy load on the pump.On EFI engines, when the piston of the air control valve is pushed by fluid pressure, the air valveopens and the volume of air by-passing the throttle valve is increased to regulate engine rpm.

As with the rack and pinion type steering, preload is very important. If the preload is not correct,it could result in such trouble as steering wheel play or shimmy or lack of durability, so alwaysmake sure that it is correct.

PREPARATIONSST (SPECIAL SERVICE TOOLS)

(09612-10022) Hexagon Wrench

(09612-01030) CIaw “C”

(09612-10061) Steering Pinion Bearing Replacer

09616-00010 Steering Worm Bearing AdjustingSocket

09612-00012 Rack & Pinion Steering RackHousing Stand

09613-12010 Power Steering Control ValvePuller

09617-12020 Rack Guide Cap Lock Nut Wrench

09612-65014 Steering Worm Bearing Puller

09612-2201 1 Tilt Handle Bearing Replacer

09617-10020 Steering Rack End Wrench

09278-54012 Drive Shaft Holding Tool PS pump pulley

(09631-24030) Piston Ring Tool

09631-22020 Power Steering Hose Nut14 x 17 mm Wrench Set

09631-12040 Oil Seal “A” Replacer

09631-20090 Cylinder End Stopper Nut Wrench

09633-00020 Power Steering Hose Nut Wrench

09631-12071 Steering Rack Oil Seal Test Tool

09631-10041 Steering Rack Cover ”D”

09628-6201 1 Ball Joint Puller

09950-20017 Universal Puller

09631-20081 Seal Ring Tool

09631-12020 Handle

SSM (SPECIAL SERVICE MATERIALS)08833-00080 Adhesive 1344,

THREE BOND 1344,LOCTITE 242 or equivalent

(09904-00050) No. 4 Claw

Rack housing capRack guide spring capRack guide spring cap lock nut

09025-00010 Small Torque Wrench

0.81 liters (0.86 US qts, 0.71 Imp.qts)

RECOMMENDED TOOLS

Power steering fluidTotal

09904-00010 Expander Set

EQUIPMENT

LUBRICANT

Oil pressure gauge

Power steering pump

Torque wrench

ATF DEXRON� ll

Vacuum gauge

Dial indicator

Micrometer

Total preload

Classification

Gear housing

Steering rack

CapacityItem

ON-VEHICLE INSPECTIONDRIVE BELT TENSION CHECK

Using a belt tension gauge, check the drive belt ten-sion.Belt tension gauge:

Nippondenso BTG-20 (95506-00020) orBorroughs No.BT-33-73F

Drive belt tension:New belt627-803 N (64-82 kgf, 140-180 lbf)Used belt353-529 N (36-54 kgf, 80-120 lbf)

• “New belt” refers to a belt which has been lessthan 5 minutes on a running engine.

• “Used belt” refers to a belt which has been usedon a running engine for 5 minutes or more.

• After installing the drive belt, check that it fitsproperly in the ribbed grooves.

VEHICLES WITH BELT TENSION ADJUSTING BOLTWhen belt tension adjustment is necessary, follow theprocedure below.

(a) Loosen bolts A and B.(b) Loosen lock nuts D and E.(c) Adjust adjusting bolt F so that its protrusion above

nut C is ±0 mm (0 in.).(d) Fix nut C using lock nut D.(e) Push up the P/S pump body so that there is no free

play in the belt. Turn adjusting bolt F to obtain thecorrect belt tension as specified above.

(f) Torque bolts A and B.Torque: 43 N �m (440 kgf �cm, 32 ft �lbf)

(g) Loosen adjusting bolt F by 4 or 5 turns.NOTICE: Check that there is a gap of 5 mm (0.20 in.) ormore between the tip of nut C and the P/S pump body.

(h) Fix adjusting bolt F with lock nut E.(i) Recheck the belt tension.

FLUID LEVEL CHECK1. KEEP VEHICLE LEVEL2. BOOST FLUID TEMPERATURE

With the engine idling at 1,000 RPM or less, turn thesteering wheel from lock to lock several times toboost fluid temperature.Fluid temperature:

80�C (176�F)

IDLE-UP CHECK1. WARM UP ENGINE2. TURN AIR CONDITIONER SWITCH OFF3. CHECK IDLE-UP(a) Fully turn the steering wheel.(b) Check that the engine rpm decreases when the air

control valve hose is pinched.(c) Check that the engine rpm increases when the air

control valve hose is released.

POWER STEERING FLUID REPLACEMENT1. JACK UP FRONT OF VEHICLE AND SUPPORT IT

WITH STANDS

5. CHECK FLUID LEVEL IN OIL RESERVOIRCheck the fluid level and add fluid if necessary.Fluid:

ATF DEXRON� ll

HINT: Check that the fluid level is within the HOTLEVEL of the reservoir. If the fluid is cold, check thatit is within the COLD LEVEL of the reservoir.

3. STOP ENGINE4. CHECK FOR FORMING OR EMULSIFICATION

HINT: Forming and emulsification indicate either theexistence of air in the system or that the fluid level istoo low.

2. REMOVE FLUID RETURN HOSE FROM OIL RESER-VOIR AND DRAIN FLUID INTO CONTAINER

5. START ENGINE AND RUN IT AT 1,000 RPMAfter 1 or 2 seconds, fluid will begin to discharge fromthe return hose. Stop the engine immediately at thistime.NOTICE: Take care that some fluid remains left in thereservoir.

6. REPEAT STEPS 5 AND 6 FOUR OR FIVE TIMESUNTIL THERE IS NO MORE AIR IN FLUID

7. CONNECT RETURN HOSE TO OIL RESERVOIR8. BLEED POWER STEERING SYSTEM

POWER STEERING SYSTEM BLEEDING1. CHECK FLUID LEVEL IN OIL RESERVOIR

Check the fluid level and add fluid if necessary.Fluid:

ATF DEXRON� II

HINT: Check that the fluid level is within the HOTLEVEL of the reservoir. If the fluid is cold, check thatit is within the COLD LEVEL of the reservoir.

2. START ENGINE AND TURN STEERING WHEELFROM LOCK TO LOCK 3 OR 4 TIMESWith the engine speed below 1,000 RPM, turn thesteering wheel to left or right full lock and keep itthere for 2-3 seconds, then turn the wheel to theopposite full lock and keep it there for 2-3 seconds.

4. FILL OIL RESERVOIR WITH FRESH FLUIDFluid:

ATF DEXRON� II

3. TURN STEERING WHEEL FROM LOCK TO LOCKWHILE DRAINING FLUID

3. CHECK THAT FLUID IN OIL RESERVOIR IS NOTFOAMY OR CLOUDY AND DOES NOT RISE OVERMAXIMUM WHEN ENGINE IS STOPPEDMeasure the fluid level with the engine running. Stopthe engine and measure the fluid level.Maximum rise:

5 mm (0.20 in.)

If a problem is found, repeat steps 5 to 6 on pageSR-34 . Repair the PS if the problem persists.

3. START ENGINE AND RUN IT AT IDLE4. BOOST FLUID TEMPERATURE

With the engine idling at 1,000 rpm or less, turn thesteering wheel from lock to lock several times toboost fluid temperature.Fluid temperature: 80 °C (176°F)

OIL PRESSURE CHECK1. CONNECT OIL PRESSURE GAUGE(a) Drain fluid.(b) Disconnect the pressure tube from the PS pump.

(c) Connect the gauge side of the pressure gauge to thePS pump and valve side to the pressure line.

2. BLEED POWER STEERING SYSTEM(SEE PAGE SR-34 )

5. CHECK FLUID PRESSURE READING WITH VALVECLOSEDClose the pressure gauge valve and observe the read-ing on the gauge.Minimum pressure:

5,884 kPa (60 kgf/cm 2, 853 psi)NOTICE:

• Do not keep the valve closed for more than 10seconds.

• Do not let the fluid temperature become too high.

If pressure is low, repair or replace the PS pump.6. OPEN VALVE FULLY7. CHECK AND RECORD PRESSURE READING AT

1,000 RPM8. CHECK AND RECORD PRESSURE READING AT

3,000 RPMCheck that there is 490 kPa (5 kgf/cm2, 71 psi) or lessdifference in pressure between the 1,000 RPM and3,000 RPM checks.If the difference is excessive, repair or replace theflow control valve of the PS pump.

9. CHECK PRESSURE READING WITH STEERINGWHEEL TURNED TO FULL LOCKBe sure the pressure gauge valve is fully opened andthe engine idling.Minimum pressure:

5,884 kPa (60 kgf/cm 2, 853 psi)NOTICE:

• Do not maintain lock position for more than 10seconds.

• Do not let the fluid temperature become too high.

If pressure is low, the gear housing has an internalleak and must be repaired or replaced.

10. DISCONNECT OIL PRESSURE GAUGE(a) Drain fluid.(b) Remove the oil pressure gauge.(c) Connect the pressure tube to the PS pump.

Torque: 69 N �m (700 kgf �cm, 51 ft �Ibf)

11. BLEED POWER STEERING SYSTEM(See page SR-34 )

12. MEASURE STEERING EFFORT(a) Center the steering wheel and run the engine at idle.(b) Using a torque meter, measure the steering effort in

both directions.Maximum steering effort:

7.8 N�m (80 kgf �cm, 69 in. �Ibf)

If steering effort is excessive, repair the PS unit.HINT: Be sure to consider the tire type, pressure andcontact surface before making your diagnosis.

(MAIN POINTS OF REMOVAL ANDINSTALLATION)1. ADJUST DRIVE BELT TENSION AFTER INSTALL-

ING PS PUMP(See page SR-32 )

2. BLEED POWER STEERING SYSTEM(See page SR-34 )

POWER STEERING PUMPPOWER STEERING PUMP REMOVAL ANDINSTALLATIONRemove and install the parts, as shown.

MOM-”

POWER STEERING PUMP DISASSEMBLY

1. MOUNT PUMP IN VISENOTICE: Do not tighten the noise too tight.

2. REMOVE PS PUMP PULLEY(a) Using SST, remove the pulley set nut.

SST 09278-54012(b) Remove the pulley and woodruff key.

COMPONENTS

4. REMOVE FLOW CONTROL VALVE(a) Remove the pressure port union.(b) Remove the O-ring from the union.(c) Remove the flow control valve and spring.

(b) Wind vinyl tape on the pump shaft.(c) Using a plastic hammer, the pump shaft end.

3. REMOVE SUCTION PORT UNION(a) Remove the 2 bolts and union.(b) Remove the O-ring from the union.

5. REMOVE PUMP SHAFT(a) Using 2 screwdrivers, remove the snap ring.

6. REMOVE REAR SIDE PLATE(a) Using a plastic hammer, tap the shaft end and remove

the rear plate.(b) Remove the O-ring from the rear plate.7. REMOVE VANE PUMP SHAFT, CAM RING AND

VANE PLATES(a) Remove the pump shaft with cam ring and vane plates

from the front housing.(b) Remove the cam ring and 10 vane plates from the

pump shaft.8. REMOVE STRAIGHT PIN

Remove the longer straight pin from the front hous-ing.

(b) Remove the rotor and plate from the pump shaft.(c) Remove the 2 O-rings and shorter straight pin from

the plate.

9. REMOVE ROTOR AND FRONT SIDE PLATE(a) Using snap ring pliers, remove the snap ring.

POWER STEERING PUMP INSPECTIONAND REPLACEMENT

1. MEASURE OIL CLEARANCE OF SHAFT AND BUSH-INGUsing a micrometer and calipers, measure the oil cle-arance.Standard clearance:

0.01-0.03 mm (0.0004-0.0012 in.)Maximum clearance:

0.07 mm (0.0028 in.)

If more than maximum, replace the entire power steer-ing pump.

(b) Using a feeler gauge, measure the clearance betweenthe rotor groove and vane plate.Maximum clearance:

0.03 mm (0.0012 in.)

If more than maximum, replace the vane plate and/orrotor with one having the same mark stamped on thecam ring.Inscribed mark:

1, 2, 3, 4 or None

HINT: There are 5 vane lengths with the followingrotor and cam ring marks:

2. INSPECT ROTOR AND VANE PLATES(a) Using a micrometer, measure the height, thickness

and length of the vane plates.Minimum height:

8.0 mm (0.315 in.)Minimum thickness:

1.77 mm (0.0697 in.)Minimum length:

14.97 mm (0.5894 in.)

14.996-14.998 (0.59039-0.59047)

14.994-14.996 (0.59032-0.59039)

14.990-14.992 (0.59016-0.59024)

14.988-14.990 (0.59008-0.59016)

14.992-14.994 (0.59024-0.59032)

Rotor and camring mark Vane length mm (in.)

4. INSPECT FLOW CONTROL SPRINGUsing a scale, measure the free length of the spring.Spring length:

36-38 mm (1.42-1.49 in.)

If not within specification, replace the spring.

3. INSPECT FLOW CONTROL VALVE(a) Coat the valve with power steering fluid and check

that it falls smoothly into the valve hole by its ownweight.

(b) Check the flow control valve for leakage. Close one ofthe holes and apply compressed air [392-490 kPa (4-5 kgf/cm2, 57-71 psi)] into the opposite side, andconfirm that air does not come out from the end hole.

If necessary, replace the valve with one having thesame letter as inscribed on the front housing.Inscribed mark:

A, B, C, D, E or F

5. IF NECESSARY, REPLACE OIL SEAL(a) Using a screwdriver, pry out the oil seal.

3. INSTALL FRONT PLATE AND ROTOR TO PUMPSHAFT

(a) Coat 2 new O-rings with power steering fluid, andinstall them to the from plate.

(b) Install the front plate to the pump shaft.(c) Install the rotor to the pump shaft with the inscribed

mark on the rotor facing outward.

POWER STEERING PUMP ASSEMBLY1. COAT ALL SLIDING SURFACES WITH POWER STE-

ERING FLUID BEFORE ASSEMBLY2. INSTALL LONGER STRAIGHT PIN

Using a plastic hammer, drive in the pin to the fronthousing.

(b) Coat a new oil seal lip with power steering fluid.NOTICE: Make sure you install the oil seal facing thecorrect direction.

(c) Using a socket wrench, press in the oil seal.

(d) Using snap ring pliers, install a new snap ring.

(e) Install the shorter straight pin to the front plate.

6. INSTALL REAR SIDE PLATE(a) Coat a new O-ring with power steering fluid, and

install it the side plate.(b) Match the wide hole with the longer straight pin and

install the plate.

4. INSTALL CAM RINGAlign the holes of the cam ring and straight pins, andinsert the cam ring with the inscribed mark facingoutward.

(h) Tap in the pump shaft with a plastic hammer.NOTICE: Be careful not to damage the oil seal and O-rings.

5. INSTALL VANE PLATESInstall the 10 vane plates with the round end facingoutward.

(f) Wind vinyl tape on the pump shaft.(g) Align the hole of the front plate and straight pin.

9. MEASURE PUMP SHAFT PRELOAD(a) Check that the shaft rotates smoothly without abnor-

mal noise.(b) Temporarily install the pulley nut and using a torque

meter, check the rotating toorque.Rotating torque:

0.3 N�m (2.8 kgf �cm, 2.4 in. �lbf) or less

10. INSTALL FLOW CONTROL VALVE(a) Install the spring and valve into the housing.(b) Coat a new O-ring with power steering fluid, amd

install it to the pressure port union.(c) Install the pressure port union.

(b) Install the rear housing and use a press to push downon the wave washer hard enough to compress it.NOTICE: Do not apply too much pressure.

(c) Install the snap ring.

7. INSTALL WAVE WASHERInstall the wave washer so that its protrusions fit intothe slots in the rear side plate.

8. INSTALL REAR HOUSING(a) Coat a new O-ring with power steering fluid, and

install it to the rear housing.

11. INSTALL SUCTION PORT UNION(a) Coat a new O-ring with power steering fluid, and

install it to the suction port.(b) Install the suction port union with the 2 bolts.

12. INSTALL PS PUMP PULLEY(a) Install the woodruff key to the shaft.(b) Install the pulley and nut to the shaft.

(c) Using SST, torque the set nut.SST 09278-54012Torque: 43 N �m (440 kgf �cm, 32 ft �lbf)

(MAIN POINTS OF REMOVAL ANDINSTALLATION)1. DISCONNECT TIE ROD ENDS(a) Remove the cotter pin and nut.(b) Using SST, disconnect the tie rod end from the knuck-

le arm.SST 09628-62011

GEAR HOUSINGSTEERING GEAR HOUSING REMOVALAND INSTALLATIONRemove and install the parts, as shown.

4. REMOVE GEAR HOUSING(a) Remove the 2 bolts, 2 nuts and 2 brackets.(b) Slide the gear housing to the RH side.(c) Slide the gear housing to the LH side and pull it out.5. CENTER SPIRAL CABLE

If the steering wheel has been removed, or the steer-ing wheel may have moved during the operationalways perform centering of the spiral cable.(See page SR-7 )

6. CHECK STEERING WHEEL CENTER POINT7. CHECK TOE-IN

(SEE SA SECTION)

2. DISCONNECT SLIDING YOKE(a) Place matchmarks on the sliding yoke and control

valve shaft.(b) Loosen the upper side of sliding yoke set bolt.(c) Remove the lower side of sliding yoke set bolt.(d) Pull the sliding yoke upward from the control valve

shaft.

3. DISCONNECT PRESSURE AND RETURN TUBESUsing SST, disconnect and connect the pressure andreturn tubes.SST 09631-22020Torque: 44 N �m (450 kgf �cm, 33 ft �lbf)

STEERING GEAR HOUSING DISASSEMBLY

1. SECURE GEAR HOUSING IN VISEUsing SST, secure the gear housing in a vise.SST 09612-00012

2. REMOVE TURN PRESSURE TUBESUsing SST, remove the tubes.SST 09633-00020

3. REMOVE AIR CONTROL VALVE

COMPONENTS

5. REMOVE RACK BOOTS(a) Using a screwdriver, remove the clamp.(b) Remove the clip and boot.

NOTICE: Be careful not to damage the rack boots andrack housing.

(b) Using SST, remove the rack end.SST 09617-10020HINT: Mark the left and right rack ends accordingly.

(c) Remove the claw washers.

6. REMOVE RACK ENDS AND CLAW WASHERS(a) Using a screwdriver and hammer, unstake the claw

washer.NOTICE: Avoid any impact to the rack.

7. REMOVE RACK GUIDE SPRING CAP LOCK NUTUsing SST, remove the rack guide spring cap lock nut,SST 09617-12020

4. REMOVE TIE ROD ENDS(a) Place matchmarks on the tie rod end and rack end.(b) Remove the tie rod end and lock nut.

(b) Using SST, remove the control valve with the oil sealand bearing.SST 09613-12010NOTICE: Never attempt to tap out the control valve asthis would damage it.

(c) Remove the oil seal from the control valve.

8. REMOVE RACK GUIDE SPRING CAPUsing SST, remove the rack guide spring cap.SST 09612-24014 (09612-10022)

9. REMOVE RACK GUIDE SPRING, RACK GUIDE ANDRACK GUIDE SEAT

11. REMOVE SELF-LOCKING NUTUsing SST to hold the control valve, remove the self-locking nut.SST 09616-00010

12. REMOVE CONTROL VALVE(a) Using snap ring pliers, remove the snap ring.

10. REMOVE RACK HOUSING CAP

15. REMOVE OIL SEAL AND STEERING RACK(a) Using SST, press the rack and oil seal.

SST 09612-10093 (09612-10061)(b) Pull out the steering rack with the oil seal from the

cylinder.

16. REMOVE SPACER AND OIL SEALUsing SST and a hammer, drive out the spacer and oilseal.SST 09631-12020NOTICE: Do not damage the rack housing.

13. REMOVE CONTROL VALVE UPPER BEARINGUsing SST, remove the upper bearing from the controlvalve.SST 09950-20017

14. REMOVE CYLINDER END STOPPERUsing SST, remove the stopper.SST 09631-20090

STEERING GEAR HOUSING INSPECTION ANDREPLACEMENT1. INSPECT RACK(a) Using a dial indicator, check the rack for runout, and

for tooth wear or damage.Maximum runout:

0.3 mm (0.012 in.)

(b) Check the back surface for wear or damage.If faulty, replace it.

2. MEASURE OIL CLEARANCE OF CONTROL VALVESHAFT AND BUSHINGUsing a micrometer and cylinder gauge, measure theoil clearance.Standard clearance:

0.050-0.083 mm (0.0020-0.0033 in.)Maximum clearance:

0.125 mm (0.0049 in.)

If more than maximum, replace the bushing.

3. IF NECESSARY, REPLACE BUSHING AND OIL SEAL(a) Using SST, remove the bushing.

SST 09612-65014 (09612-01030)NOTICE: As shown, from the opposite side of SST con-firm that its claw is firmly caught on the bushing.

(e) Using a socket wrench (24 mm), extension bar andhammer, carefully press in a new bushing to a depthof 73 mm (2.874 in.).NOTICE: If the bushing is pushed in too far, it will causedeformation of the housing. If it is not pushed in farenough, it will interfere with the control valve. Therefore,always use a press and install the bushing to the properdepth. Then, install the control valve and ensure that itrotates smoothly.

(b) Using a brass bar and hammer, remove the oil seal.(c) Coat a new oil seal lip with power steering fluid.(d) Using a socket wrench (24 mm), extension bar and

hammer, tap in the oil seal to the housing.NOTICE: Make sure you install the oil seal facing thecorrect direction.

4. IF NECESSARY, REPLACE STEERING RACKTEFLON RING AND O-RING

(a) Using a screwdriver, remove the teflon ring and 0-ring.NOTICE: Be careful not to damage the groove for theteflon ring.

(b) Coat a new O-ring with power steering fluid andinstall it.

5. IF NECESSARY, REPLACE CONTROL VALVETEFLON RINGS

(a) Using a screwdriver, remove the 4 teflon rings.NOTICE: Be careful not to damage the grooves for theteflon ring.

(d) Install the teflon ring to the rack.(e) Install the expanded teflon ring to the steering rack

and snug it down with your fingers.

(b) Expand 4 new teflon rings with your fingers.NOTICE: Be careful not to over-expand the teflon ring.

(c) Expand a new teflon ring with your fingers.NOTICE: Be careful not to over-expant the teflon ring.

STEERING GEAR HOUSING ASSEMBLY1. INSTALL OIL SEAL AND SPACER(a) Coat a new oil seal lip with power steering fluid.(b) Install the oil seal and spacer to SST, and drive in them

with a plastic hammer.SST 09631-12020, 09631-12040NOTICE:

• Make sure you install the oil seal facing the correctdirection.

• Take care that the oil seal does not get reversed asyou install it.

2. INSTALL STEERING RACK(a) Install SST to the rack.

HINT: If necessary, scrape the burrs off the rack teethend and burnish.SST 09631-10041

(e) Carefully slide the tapered end of the SST over theteflon rings to seat the rings.SST 09631-20081NOTICE: Be careful not to damage the teflon rings.

(c) Install the 4 teflon rings to the control valve.(d) Coat the 4 teflon rings with power steering fluid and

snug them down with your fingers.

3. INSTALL OIL SEAL(a) Install SST to the rack.

SST 09631-10041(b) Coat SST and a new oil seal with power steering fluid.(c) Install the oil seal by pushing it into the rack housing,

without tilting.(d) Remove SST.

NOTICE:

• Make sure you install the oil seal facing the correctdirection.

• Take care that the oil seal does not get reversed asyou install it.

4. INSTALL CYLINDER END STOPPER(a) Using SST, torque the stopper.

SST 09631-20090Torque: 59 N �m (600 kgf �cm. 43 ft �lbf)

(b) Coat SST with power steering fluid.(c) Insert the rack into the cylinder.(d) Remove SST.

(b) Using a punch and hammer, stake the stopper andcylinder end.

5. AIR TIGHTNESS TEST(a) Install SST to the union of the cylinder housing.

SST 09631-12071NOTICE: Do not install union seats.

(b) Apply 53.3 kPa (400 mmHg, 15.75 in.Hg) of vacuumfor about 30 seconds.

(c) Check that there is no change in the vacuum.If there is change in the vacuum, check the installationof the oil seals.

(d) Coat a new oil seal lip with power steering fluid.(e) Using SST and hammer, install the oil seal until it

contacts the bearing.SST 09612-22011NOTICE: Make sure you install the oil seal facing thecorrect direction.

7. INSTALL SELF-LOCKING NUTUsing SST to hold the control valve, install a new self-locking nut.SST 09616-00010Torque: 59 N �m (600 kgf �cm, 43 ft �Ibf )

6. INSTALL CONTROL VALVE(a) Coat the teflon rings with power steering fluid.(b) Push the control valve into the housing.(c) Using SST, press in a new upper bearing.

SST 09612-22011

(f) Using snap ring pliers, install a new snap ring.

10. ADJUST TOTAL PRELOAD(a) Apply sealant to 2 or 3 threads of the spring cap.

Sealant:Part No.08833-00080, THREE BOND 1344,LOCTITE 242 or equivalent

(b) Using SST, install and torque the spring cap.SST 09612-24014 (09612-10022)Torque: 25 N �m (250 kgf �cm, 18 ft �lbf )

(c) Using SST, return the rack guide spring cap 12°.SST 09612-24014 (09612-10022)

(d) Using SST, turn the control valve shaft right and left 1or 2 times.SST 09616-00010

(e) Loosen the spring cap until the rack guide spring isnot functioning.

8. INSTALL RACK HOUSING CAP(a) Apply sealant to 2 or 3 threads of the cap.

(b) Install the rack housing cap.Torque: 59 N �m (600 kgf �cm, 43 ft �lbf)

(f) Using SST and torque meter, tighten the rack guidespring cap until the preload is within specification.SST 09612-24014 (09612-10022),09616-00010Preload (turning):

0.9-1.5 N�m (9-15 kgf �cm, 7.8-13.0 in. �lbf)

(c) Using a center punch and hammer, stake the housingcap at 2 places.

9. INSTALL RACK GUIDE SEAT, RACK GUIDE SPRINGAND RACK GUIDE

11. INSTALL RACK GUIDE SPRING CAP LOCK NUT(a) Apply sealant to 2 or 3 threads of the lock nut.

Sealant:Part No.08833-00080. THREE BOND 1344,LOCTITE 242 or equivalent

(b) Using SST, install and torque the lock nut.SST 09612-24014 (09612-10022),09617-12020Torque: 37 N �m (380 kgf �cm, 27 ft �lbf)

(c) Recheck the total preload.Preload (turning):

0.9-1.5 N�m (9-15 kgf �cm, 7.8-13.0 in. �lbf)

12. INSTALL RACK ENDS(a) Install a new claw washer.(b) Using SST, install the rack end.

SST 09617-10020Torque: 51 N �m (520 kgf �cm, 38 ft �lbf)

13. INSTALL RACK BOOTS(a) Ensure that the tube hole is not clogged with grease.

HINT: If the tube hole is clogged, the pressure insidethe boot will change after it is assembled and thesteering wheel turned.

(b) Install the boot.NOTICE: Be careful not to damage or twist the boots.

(c) Using a brass bar and hammer, stake the claw washer.

15. INSTALL AIR CONTROL VALVETorque: 29 N �m (300 kgf �cm, 22 ft �lbf)

16. INSTALL TURN PRESSURE TUBES(a) Install new union seat.(b) Using SST, install the tube.

SST 09633-00020Torque: 20 N �m (200 kgf �cm, 14 ft �lbf)

14. INSTALL TIE ROD ENDS(a) Screw the lock nut and tie rod end onto the rack end

until the matchmarks are aligned.(b) After adjusting toe-in, torque the lock nut.

(See SA section)Torque: 47 N �m (480 kgf �cm, 35 ft �lbf)

(c) Install new clamp.(d) Install the clip with the end facing outward.

SERVICE SPECIFICATIONSSERVICE DATA

Oil pressure at idle speed with valve closed (Minimum)

Control valve shaft bushing oil clearance (Maximum)

Vane plate to rotor groove clearance (Maximum)

0.1-0.2 N�m (1.5-2.5 kgf�cm, 1.3-2.2 in.�lbf)

Control valve shaft bushing oil clearance (STD)

0.9-1.5 N�m (9-15 kgf�cm, 7.8-13.0 in.�lbf)

0.6-1.2 N�n (6-12 kgf�cm, 5.2-10.4 in.�lbf)

14.994-14.996 mm (0.59032-0.59039 in.)

14.996-14.998 mm (0.59039-0.59047 in.)

14.990-14.992 mm (0.59016-0.59024 in.)

14.988-14.990 mm (0.59008-0.59016 in.)

14.992-14.994 mm (0.59024-0.59032 in.)

Rotor shaft bushing oil clearance (Maximum)

Flow control valve spring length (Minimum)

628-794 N (64-81 kgf, 140-180 lbf)

0.050-0.083 mm (0.0020-0.0033 in.)

Steering effort at idle speed (Maximum)

363-529 N (37-54 kgf, 80-120 lbf)

Rotor shaft bushing oil clearance (STD)

Flow control valve spring length (STD)

0.01-0.03 mm (0.0004-0.0012 in.)

Steering wheel freeplay (Maximum)

Pump rotating torque (Maximum)

5,883 kPa (80 kgf/cm2, 853 psi)

Vane plate thickness (Minimum)

Steering rack runout (Maximum)

0.3 N�m (2.8 kgf�cm, 2.4 in.�lbf)

7.8 N�m (80 kgf�cm, 69 in.�lbf)

Drive belt tension (Used belt)

Vane plate height (Minimum)

PS ON-VEHICLE INSPECTION

Vane plate length (Minimum)

Drive belt tension (New belt)

Total preload (Turning)

(Rotor and cam ring mark)

Pinion preload (Turning)

Maximum rise of oil level

Total preload (Turning)

14.97 mm (0.5894 in.)

0.125 mm (0.0049 in.)

0.07 mm (0.0028 in.)

0.03 mm (0.0012 in.)

1.77 mm (0.0697 in.)

0.3 mm (0.012 in.)

8.0 mm (0.315 in.)

PS GEAR HOUSING

Vane plate length

30 mm (1.18 in.)

36 mm (1.42 in.)

38 mm (1.49 in.)

5 mm (0.20 in.)

PS PUMP

-STEERING SERVICE SPECIFICATIONSSR-61

TORQUE SPECIFICATIONS

Pressure and return tube clamp x Gear housing

Transaxle case x Control cable bracket (M/T)

Pinion bearing adjusting screw lock nut

Pressure and return tube x Gear housing

Engine rear mount bracket x Transaxle

Steering main shaft x Universal joint

Pressure port union x Pump housing

Control valve shaft x Universal joint

Suction port union x Pump housing

Pressure tube x Pressure port union

POWER STEERING GEAR HOUSING

Engine rear mount bracket x Body

Exhaust pipe x Exhaust manifold

Rack guide spring cap lock nut

Air control valve x Gear housing

Rack guide spring cap lock nut

Tie rod end x Steering knuckle

Turn pressure tube union nut

Control valve self-locking nut

Pinion shaft x Universal joint

Gear housing bracket x Body

Drive pulley x Rotor shaft

Column hole cover x Body

PS pump installation bolt

Column hole cover x Body

Exhaust pipe x Converter

POWER STEERING PUMP

Column bracket x Body

Cylinder end stopper

Tie rod end lock nut

STEERING COLUMN

Tie rod end lock nut

Rack housing cap

Rack x Rack end

Steering wheel

Part tightened

43 in.�lbf

kgf�cm

43 in.�lbf

ft.�Ibf

-STEERING SERVICE SPECIFICATIONSSR-62

Steering

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