POWER STEERING SR03–1

POWER STEERING
SR03

SR03-001

POWER STEERING SYSTEM .................. SR03-2

TROUBLESHOOTING..................................... SR03-2
AIR BLEEDING................................................ SR03-4
HYDRAULIC TEST .......................................... SR03-5
HYDRAULIC TEST (STEERING BOOSTER).. SR03-8

POWER STEERING GEAR UNIT ........... SR03-11

DATA AND SPECIFICATIONS...................... SR03-11
DESCRIPTION .............................................. SR03-12
OPERATION.................................................. SR03-13
SPECIAL TOOL ............................................. SR03-15
COMPONENT LOCATOR ............................. SR03-17

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OVERHAUL ................................................... SR03-21
INSPECTION AND REPAIR .......................... SR03-34

POWER STEERING BOOSTER UNIT.... SR03-36

DATA AND SPECIFICATIONS...................... SR03-36
DESCRIPTION .............................................. SR03-36
SPECIAL TOOL ............................................. SR03-37
COMPONENT LOCATOR ............................. SR03-38
OVERHAUL ................................................... SR03-39
INSPECTION AND REPAIR .......................... SR03-42

POWER STEERING PUMP..................... SR03-43

DATA AND SPECIFICATIONS...................... SR03-43
DESCRIPTION .............................................. SR03-43
OPERATION.................................................. SR03-44
COMPONENT LOCATOR ............................. SR03-45
OVERHAUL ................................................... SR03-46
INSPECTION AND REPAIR .......................... SR03-51

OIL RESERVOIR ..................................... SR03-52

DESCRIPTION .............................................. SR03-52
COMPONENT LOCATOR ............................. SR03-54
OVERHAUL ................................................... SR03-56
INSPECTION AND REPAIR .......................... SR03-56
SR03–2 POWER STEERING

POWER STEERING SYSTEM

TROUBLESHOOTING
EN07Z0703F300001

Symptom Possible cause Remedy/Prevention

Fluid leakage Pump Replace pump.
Fluid leakage (Gear box, steering Oil seal, O-rings other than those for Repair oil seal or O-ring.
booster) the seal lock nut and drain plug
Seal lock nut, drain plug Replace lock nut or plug.
Fluid leakage Line joints Replace leaky parts.
Hard steering (Excessive steering Steering gear is faulty Hydraulic test. Replace piston sub-
effort) (One side is hard) assembly.
Hard steering (Excessive steering Steering gear pump faulty Hydraulic test.
effort) (Both sides are hard) Measure pump discharge pressure.
Replace pump.
Incorrect preload of the sector shaft Measure system hydraulic pressure.
bearing Replace piston sub-assembly.
Adjust sector shaft preload.
Hard steering (Excessive steering Incorrect preload of the sector shaft Adjust sector shaft preload.

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effort) (Hard, when starting to steer) bearing
NOTICE
Basic inspection items
• Fluid level, Fluid cleanliness
• Air in fluid
• Tire pressure
• Front alignment
• Steering linkage
• Universal joint
Abnormal noise (Pump) Air sucked in at input pipe Repair and bleed air or replace pump.
NOTICE
Basic inspection items
• Fluid level, fluid cleanliness
• Air mixed in fluid
• Pump piping
• Steering linkage
Abnormal noise Gear box Replace piston sub-assembly.
POWER STEERING SR03–3

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SHTS07Z070300001
SR03–4 POWER STEERING

AIR BLEEDING
EN07Z0703H200001

1. FILL THE OIL RESERVOIR WITH POWER STEERING FLUID.

NOTICE
• Use only specified fluid.
• Do not overfill the oil reservoir.
• Replace old fluid with new fluid after overhauling power
steering gear unit or power steering pump.
• Specified fluid....Refer to recommended lubricant list.

2. JACK UP THE FRONT AXLE AND SUPPORT THE FRAME

WITH STANDS.
NOTICE
Block the rear wheels.

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SHTS07Z070300002

3. TURN THE STEERING WHEEL FULLY IN BOTH DIRECTIONS

SEVERAL TIMES.

4. CHECK THE FLUID LEVEL IN THE OIL RESERVOIR.

(1) Add the fluid, if necessary.

SHTS07Z070300003

5. START THE ENGINE AND TURN THE STEERING WHEEL

FULLY IN BOTH DIRECTIONS SEVERAL TIMES WITH
ENGINE IDLING.
NOTICE
The fluid in the oil reservoir should be continuously replenished
while air bleeding so that the oil reservoir never become empty.

6. RETURN THE STEERING WHEEL TO STRAIGHT AHEAD.

SHTS07Z070300004
 POWER STEERING SR03–5

7. RECHECK THE FLUID LEVEL WHEN THE ENGINE IS

STOPPED.
(1) If necessary, add or decrease the power steering fluid to match
the between "MAX" and "MIN".

SHTS07Z070300005

HYDRAULIC TEST
EN07Z0703H300001

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SHTS07Z070300006

HYDRAULIC TEST

1. JACK UP THE FRONT AXLE AND SUPPORT THE FRAME

WITH STANDS.
NOTICE
Block the rear wheels.

SHTS07Z070300002
SR03–6 POWER STEERING

2. SET THE STOP VALVE AND OIL PRESSURE GAUGE AS

SHOWN IN THE FIGURE.
NOTICE
After setting the stop valve and oil pressure gauge, perform the air
bleeding in the system according to "AIR BLEEDING".

SHTS07Z070300007

3. CHECK THE FLOW CONTROL VALVE OPERATION.

(1) Start the engine and idle then close the stop valve until the fluid
pressure is at 5.0 MPa {51 kgf/cm2, 725 lbf/in.2}.
(2) Run the engine up to 1,500 r/min, then reduce the engine speed
suddenly.
NOTICE
This operation should be repeated more than 5 times.
(3) Good, if the set pressure of 5.0 MPa {51 kgf/cm2, 725 lbf/in.2} is
recovered immediately.

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If the set pressure is not recovered immediately, stop the engine
and replace the flow control valve assembly.
SHTS07Z070300008
(4) Open the stop valve fully.

4. CHECK THE RELIEF VALVE OPERATION.

(1) Run the engine up to 2,000 r/min.
(2) Close the stop valve until the fluid pressure is at 14.7 MPa {150
kgf/cm2, 2,132 lbf/in.2}.
NOTICE
Be careful not to exceed 14.7 MPa {150 kgf/cm2, 2,132 lbf/in.2}

(3) Good, if the fluid pressure is maintained at 14.0-14.7 MPa {143-

150 kgf/cm2, 2,030-2,132 lbf/in.2}.
(4) If pressure is higher, stop the engine and replace the flow control
valve assembly.
SHTS07Z070300009

5. MEASURE THE SYSTEM HYDRAULIC PRESSURE.

(1) Make sure that the stop valve is fully open.
(2) Start the engine and idle and then turn the steering wheel to a full
stop.
(3) Apply a force of approx. 147.1 N {15 kgf, 33 lbf} to the steering
wheel and measure the hydraulic pressure.
(4) Repeat the measurement by fully turning the steering wheel in the
opposite direction.
Hydraulic pressure:
14.0-14.7 MPa {143-150 kgf/cm2, 2,030-2,132 lbf/in.2}
(5) If the above pressure is not attained, measure the discharge pres-
SHTS07Z070300010 sure or stop the engine and repair the power steering gear unit.
 POWER STEERING SR03–7

6. MEASURE THE DISCHARGE PRESSURE.

(1) Make sure that the stop valve is fully open.
(2) Start the engine and idle and measure the discharge pressure
with the stop valve fully close.
Discharge Pressure:
14.0-14.7 MPa {143-150 kgf/cm2, 2,030-2,132 lbf/in.2}
NOTICE
Do not allow the stop valve to remain closed for more than 15 sec-
onds.
(3) Open the stop valve fully.

SHTS07Z070300009

7. REMOVE THE STOP VALVE AND OIL PRESSURE GAUGE.

(1) Stop the engine and remove the stop valve and oil pressure
gauge.
NOTICE
After removing stop valve and oil pressure gauge, perform the air
bleeding in according to "AIR BLEEDING".

8. INSPECT THE STEERING SYSTEM FOR OPERATION ABIL-

ITY.

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(1) Place the front wheels on turn tables then start the engine and
idle.
SHTS07Z070300011 (2) Check to see that the steering wheel turned smoothly without any
jolts or abnormal resistance, when it is turned fully in both direc-
tions.
(3) Measure the steering wheel turning force.
Turning force: Less than 40 N {4.1 kgf, 8.9 lbf}

SHTS07Z070300012
SR03–8 POWER STEERING

HYDRAULIC TEST
(STEERING BOOSTER)
EN07Z0703H300002

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SHTS07Z070300013

HYDRAULIC TEST

1. JACK UP THE FRONT AXLE AND SUPPORT THE FRAME

WITH STANDS.
NOTICE
Block the rear wheels.

SHTS07Z070300002

2. SET THE STOP VALVE AND OIL PRESSURE GAUGE AS

SHOWN IN THE FIGURE.
NOTICE
After setting the stop valve and oil pressure gauge, perform the air
bleeding in the system according to "AIR BLEEDING".

SHTS07Z070300014
 POWER STEERING SR03–9

3. CHECK THE FLOW CONTROL VALVE OPERATION.

(1) Start the engine and idle then close the stop valve until the fluid
pressure is at 5.0 MPa {51 kgf/cm2, 725 lbf/in.2}
(2) Run the engine up to 1,500 r/min, then reduce the engine speed
suddenly.
NOTICE
This operation should be repeated more than 5 times.
(3) Good, if the set pressure of 5.0 MPa {51 kgf/cm2, 725 lbf/in.2} is
recovered immediately.
If the set pressure is not recovered immediately, stop the engine
and replace the flow control valve assembly.
SHTS07Z070300008
(4) Open the stop valve fully.

4. CHECK THE RELIEF VALVE OPERATION.

(1) Run the engine up to 2,000 r/min.
(2) Close the stop valve fully.
(3) Good, if the fluid pressure is maintained at 14.0-14.7 MPa {143-
150 kgf/cm2, 2,030-2,132 lbf/in.2}.
(4) If pressure is higher, stop the engine and replace the flow control
valve assembly.
NOTICE
Be careful not to exceed 14.7 MPa {150 kgf/cm2, 2,132 lbf/in.2}

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SHTS07Z070300009

5. MEASURE THE SYSTEM HYDRAULIC PRESSURE.

(1) Make sure that the stop valve is fully open.
(2) Run the engine up to 2,000 r/min.
(3) Repeat the measurement by fully turning the steering wheel in the
opposite direction.
Hydraulic pressure:
14.0-14.7 MPa {143-150 kgf/cm2, 2,030-2,132 lbf/in.2}
(4) If the above pressure is not attained, measure the discharge pres-
sure or stop the engine and repair the steering booster unit.

SHTS07Z070300010

6. MEASURE THE DISCHARGE PRESSURE.

(1) Make sure that the stop valve is fully open.
(2) Start the engine and idle and measure the discharge pressure
with the stop valve fully close.
Discharge Pressure:
14.0-14.7 MPa {143-150 kgf/cm2, 2,030-2,132 lbf/in.2}
NOTICE
Do not allow the stop valve to remain closed for more than 15 sec-
onds.
(3) Open the stop valve fully.

SHTS07Z070300009
SR03–10 POWER STEERING

7. REMOVE THE STOP VALVE AND OIL PRESSURE GAUGE.

(1) Stop the engine and remove the stop valve and oil pressure
gauge.
NOTICE
After removing stop valve and oil pressure gauge, perform the air
bleeding in according to "AIR BLEEDING".

8. INSPECT THE STEERING SYSTEM FOR OPERATION ABIL-

ITY.
(1) Place the front wheels on turn tables then start the engine and
idle.
SHTS07Z070300011 (2) Check to see that the steering wheel turned smoothly without any
jolts or abnormal resistance, when it is turned fully in both direc-
tions.
(3) Measure the steering wheel turning force.
Turning force: Less than 24.5 N {2.5 kgf, 5.5 lbf}

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SHTS07Z070300012
 POWER STEERING SR03–11

POWER STEERING GEAR UNIT

DATA AND SPECIFICATIONS
EN07Z0703I200001

FR, FS, SH, SS, ZS Integral type power steering

Type MODEL
FY Integral type power steering with steering booster

FR, FS, SH, SS, ZS 21.4-23.8

Gear ratio MODEL
FY 22.4

FR, FS, SH, SS, ZS 110 mm {4.331 in.}

Cylinder inside diameter MODEL
FY 100 mm {3.937 in.}

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SR03–12 POWER STEERING

DESCRIPTION
EN07Z0703C100001

4 3 2 1

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6 7 8 9 10
SHTS07Z070300015

1 Valve housing assembly 6 Dust cover

2 Worm valve assembly 7 Needle roller bearing
3 Steel ball 8 Oil seal
4 Ball nut assembly 9 Adjusting screw
5 Sector shaft 10 Adjusting screw lock nut
 POWER STEERING SR03–13

OPERATION
EN07Z0703C100002

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SHTS07Z070300016

1 Oil reservoir 6 Spool valve

2 Oil pump 7 Sleeve
3 Flow control valve assembly 8 Ball nut
4 Relief valve 9 Torsion bar
5 Stud shaft 10 Worm shaft
SR03–14 POWER STEERING

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SHTS07Z070300017

1 Oil reservoir 6 Spool valve

2 Oil pump 7 Sleeve
3 Flow control valve assembly 8 Ball nut
4 Relief valve 9 Torsion bar
5 Stud shaft 10 Worm shaft
 POWER STEERING SR03–15

SPECIAL TOOL
EN07Z0703K100001

Prior to starting a power steering gear unit overhaul, it is necessary to have the following special tools.

Tool and accessory set: 09030-4180

Illustration Part number Tool name Remarks

TOOL ASSEMBLY

09657-1870
• For 85 mm {3.346 in.}
• For 90-110 mm
{3.544-4.330 in.}
(Used together with tool assem-
bly)

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09659-1400 ATTACHMENT ASSEMBLY

09603-1560 WRENCH ASSEMBLY

INSERTER ASSEMBLY

A:
For 40 mm {1.575 in.}
09657-1860
For 45 mm {1.772 in.}
For 48 mm {1.890 in.}
For 53 mm {2.087 in.}
For 58 mm {2.283 in.}
(Used together with inserter
assembly)
A

09659-1410 PRESS FITTER

09699-1360 NEEDLE

09657-1840 INSERTER
SR03–16 POWER STEERING

Illustration Part number Tool name Remarks

09694-1020 CAULKING TOOL

09657-1850 INSERTER

09712-1130 BAR

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 POWER STEERING SR03–17

COMPONENT LOCATOR
EN07Z0703D100001

RIGHT-HAND DRIVE VEHICLE

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SHTS07Z070300028

1 Dust cover 17 Valve housing

2 Stab shaft 18 Power piston (Ball nut)
3 Pin 19 Ball tube
4 Plug 20 Tube clip
5 O-ring 21 Plug
6 Oil seal 22 Dust cover
7 Ball bearing 23 Oil seal
8 Washer 24 Steering body
9 Rotor 25 Back up ring
10 Needle roller bearing 26 Y-packing
11 Side race 27 Needle roller bearing
12 Ball bearing 28 Sector shaft
13 Ball bearing cage 29 Adjusting screw
14 Torsion bar 30 Retainer
15 Worm shaft 31 Side cover
16 Seal ring

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}

A 226-245 {2,305-2,498, 167-180} D 118-127 {1,203-1,295, 87-93}
B 4.4-5.4 {45-55, 3.3-4.0} E 74-83 {755-846, 55-61}
C 294-392 {2,998-3,997, 217-289} F 112-127 {1,142-1,295, 83-93}
SR03–18 POWER STEERING

LEFT-HAND DRIVE VEHICLE

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SHTS07Z070300029

1 Dust cover 17 Valve housing

2 Stab shaft 18 Power piston (Ball nut)
3 Pin 19 Ball tube
4 Plug 20 Tube clip
5 O-ring 21 Plug
6 Oil seal 22 Dust cover
7 Ball bearing 23 Oil seal
8 Washer 24 Steering body
9 Rotor 25 Back up ring
10 Needle roller bearing 26 Y-packing
11 Side race 27 Needle roller bearing
12 Ball bearing 28 Sector shaft
13 Ball bearing cage 29 Adjusting screw
14 Torsion bar 30 Retainer
15 Worm shaft 31 Side cover
16 Seal ring

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}

A 226-245 {2,305-2,498, 167-180} D 118-127 {1,203-1,295, 87-93}
B 4.4-5.4 {45-55, 3.3-4.0} E 74-83 {755-846, 55-61}
C 294-392 {2,998-3,997, 217-289} F 112-127 {1,142-1,295, 83-93}
 POWER STEERING SR03–19

MODEL: FY (LEFT-HAND DRIVE VEHICLE)

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SHTS07Z070300030
SR03–20 POWER STEERING

1 Dust cover 20 Tube clip

2 Stab shaft 21 Plug
3 Pin 22 Dust cover
4 Plug 23 Oil seal
5 O-ring 24 Steering body
6 Oil seal 25 Back up ring
7 Ball bearing 26 Y-packing
8 Washer 27 Needle roller bearing
9 Rotor 28 Sector shaft
10 Needle roller bearing 29 Adjusting screw
11 Side race 30 Retainer
12 Ball bearing 31 Side cover
13 Ball bearing cage 32 Power steering control valve body
14 Torsion bar 33 Spring
15 Worm shaft 34 Spool valve
16 Seal ring 35 Plug
17 Valve housing 36 Valve assembly
18 Power piston (Ball nut) 37 Connector

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19 Ball tube

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}

A 226-245 {2,305-2,498, 167-180} F 112-127 {1,142-1,295, 83-93}
B 4.4-5.4 {45-55, 3.3-4.0} G 24.5-34.3 {250-350, 18-25}
C 294-392 {2,998-3,997, 217-289} H 29.4-39.2 {300-400, 22-29}
D 118-127 {1,203-1,295, 87-93} J 49.0-53.9 {500-550, 36-40}
E 74-83 {755-846, 55-61} K 8.8-12.7 {90-130, 6.5-9.4}
 POWER STEERING SR03–21

OVERHAUL
EN07Z0703H200002

NOTICE
OBSERVE THE FOLLOWING INSTRUCTIONS BEFORE DISASSEM-
BLY AND ASSEMBLY.
1. All functional parts should be clean. Blow dirty parts off with
dry compressed air, then clean them with volatile metal
cleanser. Never use brushes or cloth.
2. Handle rubber parts, seals, etc., in clean condition. Any worn
part should be replaced immediately.
Volatile metal cleanser may attack rubber parts, so they
should never be used. Always use fluid.
3. For disassembling and assembling, only use the specified
fluid.
4. Standard tools can generally be used for assembling and dis-
assembling, although special tools may be required. When
using special tools, read the instruction carefully, and never
use standard tools in place of special tools.

IMPORTANT POINTS - DISASSEMBLY

1. BEFORE DISASSEMBLY, SECURE THE POWER STEERING IN

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THE VISE, AND THEN CENTER THE POWER PISTON.

SHTS07Z070300031

2. REMOVE THE SIDE COVER ASSEMBLY AND SECTOR

SHAFT.
(1) Loosen and remove the nut fixing the adjusting screw to the side
cover.
BOLT
(2) Remove the eight bolts and washers fitting the side cover to the
steering body.

NUT

SHTS07Z070300032

(3) Confirm that the power piston is located in the center, and then
gently tap the output end of the sector shaft with a plastic (or
wooden) hammer to remove the sector shaft assembly and the
side cover together from the steering body.
NOTICE
Never use a steel hammer when removing the sector shaft (as the
PLASTIC HAMMER threads will be damaged).

SHTS07Z070300033
SR03–22 POWER STEERING

(4) Turn the adjusting screw clockwise using a screwdriver to raise

and separate the side cover assembly from the sector shaft
SCREWDRIVER assembly.
ADJUSTING SCREW
SIDE COVER NOTICE
• Do not secure the sector shaft directly in the vise.
• Always use a cloth etc. to protect the sector shaft.

SECTOR SHAFT

SHTS07Z070300034

(5) Remove the O-ring from the groove around the outside of the side
BACK-UP RING cover using the special tool. Then remove the Y-packing from
behind the needle roller bearing and the back-up ring using the
Y-PACKING special tool.
NOTICE
O-RING
It is not necessary to remove the needle bearing unless it is dam-
aged.
SIDE COVER SST: Needle (09699-1360)

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SHTS07Z070300035

3. REMOVE THE VALVE HOUSING AND BALL NUT ASSEMBLY.

(1) Remove the dust cover from the valve housing.
WRENCH ASSEMBLY
(2) Loosen the plug and seal assembly in the valve housing section
using the special tool. At this time, only back off the plug and seal
assembly 180°. Do not remove it.
NOTICE
If the plug and seal assembly is removed, the steel balls (bearing)
in the valve housing may spring out.
SST: Wrench Assembly (09603-1560)

SHTS07Z070300036

(3) Remove the bolts to remove the worm shaft assembly and valve
housing assembly from the steering body.
NOTICE
• Do not damage the internal surface of the steering body
when removing the worm shaft assembly and valve housing
assembly.
• Do not let the steel balls spring out.
• Never damage the power piton.
BOLT

SHTS07Z070300037
 POWER STEERING SR03–23

4. REMOVE THE ADJUSTING SCREW AND SECTOR SHAFT.

(1) Uncaulk the retainer at two caulked positions.
NOTICE
RETAINER
• Do not disassemble the sector shaft assembly unless it is
damaged.
SECTOR
SHAFT • Do not secure the sector shaft directly in the vise. Always
use a cloth etc. to protect the sector shaft.

SHTS07Z070300038

(2) Remove the retainer using the special tool. Remove the adjusting
RETAINER screw at the same time.
BAR SST: Bar (09712-1130)

ADJUSTING SCREW

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SHTS07Z070300039

5. REMOVE THE WORM SHAFT ASSEMBLY, VALVE HOUSING

STUB SHAFT AND POWER PISTON ASSEMBLY.
(1) Place the assembly on the work bench with the power piston side
VALVE
down. Turn the stub shaft while holding the valve housing, and
HOUSING remove the worm shaft from the power piston.
(2) Let the steel balls assembled in the power piston and ball race of
the worm shaft drop into the power piston.
WORM SHAFT POWER PISTON
NOTICE
Do not tilt the piston as it contains the steel balls. Do not lose the
steel balls.

SHTS07Z070300040

(3) Secure the special tool in the vise.

SST: Attachment Assembly (09659-1400)

WRENCH (4) Remove the O-rings fitted on the contact surfaces of the steering
ATTACHMENT ASSEMBLY body of the valve housing.
ASSEMBLY (5) Attach the valve housing to the attachment assembly, and remove
the previously loosened plug and seal assembly.
SST: Wrench Assembly (09603-1560)

SHTS07Z070300041
SR03–24 POWER STEERING

(6) Remove the ball bearing and oil seal from the plug and seal
BEARING assembly.

OIL SEAL

PLUG AND
SEAL ASSEMBLY

SHTS07Z070300042

6. REMOVE THE WORM SHAFT ASSEMBLY AND VALVE HOUS-

VALVE HOUSING ING.
(1) Prepare a plastic box, etc. Hold the valve housing over the box
BEARING CAGE
and remove the worm shaft assembly by pushing it from the
STEEL BALLS power piston side as shown in figure. The side race, steel balls,
SIDE RACE
and bearing cage will come apart and fall into the box.
NOTICE
• Do not lose any steel balls.
• If only one side race and/or steel ball is lost, the worm shaft

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and valve housing assembly must be replaced.
Number of the steel balls: 18 pieces.
SHTS07Z070300043

(2) Remove the rotor from the worm shaft assembly, and then remove
the seal ring from the rotor using the special tool.
SEAL RING SST: Needle (09699-1360)

ROTOR

SHTS07Z070300044

(3) Remove the three seal rings and three O-rings from the valve
SEAL RING (3) housing using the special tool.
SST: Needle (09699-1360)
O-RING (3)

VALVE HOUSING

SHTS07Z070300045
 POWER STEERING SR03–25

7. REMOVE THE POWER PISTON.

BALL TUBE SCREW (1) Place the piston's steel balls in a separate container.
WASHER (2) Loosen the screw of the tube clip securing the ball tube using a
PISTON wrench. Remove the ball tube from the power piston by pinching it
CLIP with your fingers and shaking it.
NOTICE
• Never insert a screwdriver etc., between the ball tube and the
piston to pry them apart.
• Check for any steel balls remaining in the ball tube.
Number of the steel balls: 32 pieces.
SHTS07Z070300046

(3) Remove the seal ring and O-ring from the power piston using the
PISTON
special tool.
SEAL RING SST: Needle (09699-1360)
O-RING

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SHTS07Z070300047

8. REMOVE THE STEERING BODY.

OIL SEAL (1) Remove the oil seal, back-up ring, and Y-packing from the section
BACK-UP RING of the steering body contacting the sector shaft.
Y-PACKING
NOTICE
STEERING BODY
Do not remove the needle roller bearing and taper plug unless
they are damaged.

SHTS07Z070300048

IMPORTANT POINTS - ASSEMBLY

RETAINER 1. INSTALL THE SECTOR SHAFT.
(1) Secure the sector shaft in the vise while protecting the geared
BAR
base of the shaft with a rag.
ADJUSTING
SCREW
(2) Fill the assembly with grease through the adjusting screw hole.
Then, insert the adjusting screw, and fix the retainer using the
special tool.
SST: Bar (09712-1130)

SHTS07Z070300049
SR03–26 POWER STEERING

NOTICE
How to tighten the retainer; After fully tightening, back off the
CAULKING TOOL
retainer 180° and then, after retightening it to 39 N⋅m {400 kgf⋅cm,
29 lbf⋅ft}, back it off 20°. Ensure the adjusting screw rotates
smoothly.

(3) After tightening the retainer, securely caulk it at two positions

using the special tool.
SST: Caulking Tool (09694-1020)

SHTS07Z070300050

2. INSTALL THE SIDE COVER.

O-RING (1) Insert the Y-packing and back-up ring in the bottom of the needle
BACK-UP RING
roller bearing press fitted inside the side cover.
NOTICE
Y-PACKING • The back-up ring can be assembled easily if inserted by
pinching it with the fingers as shown in figure.
SIDE COVER • After filling the groove with grease, assemble the Y-packing
so that the lip faces to the needle roller bearing side.

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SHTS07Z070300051

(2) Form the back-up ring using the special tool.

SST: Inserter Assembly (09657-1860)

NOTICE
INSERTER ASSEMBLY There are five kinds of inserters as below, and install the back-up
ring using the inserter for the diameter 48 mm {1.890 in.}.
INSERTER

SIDE COVER
Unit: mm {in.}
INSERTER DIAMETER
40 {1.575}
45 {1.772}
SHTS07Z070300052
48 {1.890}
53 {2.087}
58 {2.283}

3. INSTALL THE VALVE HOUSING.

O-RING (1) Insert an O-ring and a seal ring into each of the three narrower
grooves of the five grooves in the valve housing.
(2) Then, form the seal ring using the special tool.
INSERTER
SST: Inserter (09657-1850)

SEAL RING

SHTS07Z070300053
 POWER STEERING SR03–27

4. INSTALL THE PLUG AND SEAL ASSEMBLY.

HAND PRESS
(1) Press fit the oil seal into the inside of the plug and seal assembly
using the special tool.
OIL SEAL NOTICE
PRESSFITTER Always use a hand press when press fitting the oil seal.
PLUG SST: Press Fitter (09659-1410)

SHTS07Z070300054

(2) Apply grease to the oil seal and then install the ball bearing.

OIL SEAL
GREASE

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SHTS07Z070300055

5. INSTALL THE WORM SHAFT AND THE VALVE HOUSING.

(1) Form the seal ring using the special tool after assembling the seal
INSERTER ring in the outer groove of the rotor.
SST: Inserter (09657-1850)

SEAL RING

ROTOR

SHTS07Z070300056

(2) Insert the rotor between the stub shaft and the worm shaft. At this
ROTOR time, assemble it so that the straight pin in the bottom fits in the
rotor notch.
ROTOR NOTCH

WORM SHAFT STRAIGHT PIN

SHTS07Z070300057
SR03–28 POWER STEERING

(3) Fit the guide into the special tool and insert the previously assem-
bled worm shaft assembly into the guide with the input side down.
SST: Tool Assembly (09657-1870)
WORM SHAFT
BEARING CAGE NOTICE
GUIDE
There are two kinds of guide as below, and install worm shaft
STEEL BALL
assembly using the guide for power piston diameter 90-110 mm
TOOL {3.544-4.330 in.}.
ASSEMBLY
Unit: mm {in.}
POWER PISTON DIAMETER

SHTS07Z070300058
85 {3.346}
90-110 {3.544-4.330}

(4) Install the race of bearing side (one side), the bearing cage and
the steel balls, and allow the tool assembly to slide down and set
the balls in position.
(5) Remove the guide and fit the other side race.
SIDE RACE

SIDE RACE

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BEARING CAGE
STEEL BALL

SHTS07Z070300059

(6) Assemble the valve housing to the worm shaft assembly and pre-
viously assembled bearing sub-assembly by inserting it from the
worm shaft side.
NOTICE
VALVE HOUSHING
• When fitting the valve housing, do not damage the seal ring
in the valve housing.
• Inserter (09657-1850) can be used to form the seal rings of
the valve housing part.

SHTS07Z070300060

(7) Secure the special tool in the vise.

PLUG AND
SECTION ON SST: Attachment Assembly (09659-1400)
SEAL ASSEMBLY
WITH LIQUID
GASKET IS (8) Fit the previously assembled worm shaft assembly and valve
O-RING APPLIED housing onto the attachment assembly, place the O-ring in the
(SEE NOTE)
inner groove of the valve housing, and screw the plug and seal
assembly into the valve housing.
NOTICE
• Apply liquid gasket (equivalent to ThreeBond 1102) to the
ATTACHMENT
ASSEMBLY screw section of the plug and seal assembly.
• The O-ring must not be fitted in the thread escape groove of
SHTS07Z070300061 the valve housing.
• When assembling the plug and seal assembly, do not let the
stub shaft serration damage the oil seal.
 POWER STEERING SR03–29

(9) Tighten the plug and seal assembly using the special tool.
LOOSEN THE PLUG SST: Wrench Assembly (09603-1560)
AND SEAL ASSEMBLY
BY 180 FOR STUB SHAFT
SUBSEQUENT WORK NOTICE
Check that the stub shaft rotates smoothly and uniformly while
holding the valve housing.
(10) Loosen the plug and seal assembly by approx 180°.

SHTS07Z070300062

(11) Install O-rings in the groove around the outside of the valve hous-
ing, and in the oil port recess.
NOTICE
Do not twist the O-rings.
O-RING

O-RING

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SHTS07Z070300063

6. INSTALL THE POWER PISTON.

(1) Fit the O-ring and seal ring in the groove around the outside of the
power piston and form the seal ring using the special tool.
O-RING NOTICE
INSERTER SEAL RING Do not twist the O-ring or stretch the seal ring.
SST: Inserter (09657-1840)
PISTON

SHTS07Z070300064

(2) Place the power piston on the bench.

(3) Fill the ball tube with grease, lay 10-11 steel balls in the tube, and
BALL TUBE place the other side of the ball tube on top.
NOTICE
Never fix the piston in a vise.

STEEL BALL

SHTS07Z070300065
SR03–30 POWER STEERING

(4) Insert the worm shaft and valve housing assembly in the center
PUNCH STEEL BALL hole of the power piston, align the power piston and worm shaft
STUB SHAFT ball races, and drop the remaining steel balls one by one through
PISTON the piston's ball tube hole.
NOTICE
• Drop the steel balls while turning the stub shaft to facilitate
assembly.
• Steel balls sometimes come out of the hole on the other side
of the ball tube after a certain number are inserted. Plug the
hole with a punch to prevent the steel balls from coming out.
• When installing the steel balls, the worm shaft and valve
SHTS07Z070300066 housing assembly must not be drawn out to its extreme posi-
tion, as the steel balls may drop outside the ball race.

(5) After inserting the steel balls in the power piston, insert the ball
BALL TUBE tube into the power piston and fix it using the clip, washer, and
screw.
NOTICE
Always push in the ball tube by hand. Never force or strike it. If
forced or struck, the ball tube may be deformed, the edge may be
nipped, or otherwise damaged, causing malfunctions.
(6) Tighten the screw to the specified torque.

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CLIP

SHTS07Z070300067

(7) Measure the axial play between the power piston and the worm
B (AXIAL PLAY) shaft assembly.

2 mm (0.079 in.) A (point of application) 20 mm {0.787 in.}

F (force) 5 kg
B (axial play) 0.5 mm {0.0197 in.} or less

A
NEUTRAL POSITION F
SHTS07Z070300068

7. INSTALL THE STEERING BODY.

(1) Fit the Y-packing and back-up ring in the groove in front of the
Y-PACKING BACK-UP RING needle roller bearing (in the hole for the steering body output
shaft).
NOTICE
• Back-up ring installation is facilitated by pinching the ring
with the fingers as shown in figure.
• After filling the groove with grease, assemble the Y-packing
so that the lip faces to the needle roller bearing.

STEERING BODY
SHTS07Z070300069
 POWER STEERING SR03–31

(2) Form the back-up ring using the special tool.

SST: Inserter Assembly (09657-1860)

INSERTER ASSEMBLY
NOTICE
INSERTER There are five kinds of inserters as below, and install the back-up
ring using the inserter for the diameter 58 mm {2.283 in.}.
Unit: mm {in.}
INSERTER DIAMETER
40 {1.575}
45 {1.772}
SHTS07Z070300070
48 {1.890}
53 {2.087}
58 {2.283}

(3) Press fit the oil seal into the steering body using the special tool.
SST: Inserter Assembly (09657-1860)
INSERTER ASSEMBLY

(4) Fill the oil seal with grease.

OIL SEAL

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SHTS07Z070300071

8. INSTALL THE VALVE HOUSING AND BALL NUT ASSEMBLY.

STEERING BODY
(1) Secure the steering body in the vise.
PISTON (2) Fit the worm shaft and valve housing assembly by inserting it into
the steering body with the power piston gear placed on the side of
the sector shaft. Hold the power piton lightly by hand so that it
dose not rotate.
NOTICE
• When inserting the worm shaft and valve housing assembly,
do not damage the piston seal ring.
• Be careful that the O-ring dose not fall out.

SHTS07Z070300072

(3) Align the steering body and valve housing oil passage holes and
tighten the bolt to the specified torque.
NOTICE
Insert a bar into the bolt hole to align the body and housing oil
passage holes. Prevent housing rotation to prevent the O-ring
from being cut or dislodged.

SHTS07Z070300073
SR03–32 POWER STEERING

(4) Tighten the plug and seal assembly (which was previously loos-
ened through 180°) to the specified torque using the wrench
assembly.
WRENCH ASSEMBLY SST: Wrench Assembly (09603-1560)

NOTICE
After applying a thin and uniform coat of liquid gasket to 3-5 whole
threads of the screw part of the plug and seal assembly and tight-
ening it with the indicated torque, apply turning stopper punches
every 180°.

Liquid gasket: Equivalent to ThreeBond 1102

SHTS07Z070300074

(5) Attach the dust cover to the valve housing.

DUST COVER

NUT

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SHTS07Z070300075

9. INSTALL THE SIDE COVER ASSEMBLY AND SECTOR

SHAFT.
SCREWDRIVER ADJUSTING SCREW (1) Assemble the side cover assembly to the sector shaft assembly
by aligning the screw hole in the center of the side cover with the
SIDE COVER
adjusting screw and turning the adjusting screw.
Install the O-ring around the outside of the side cover.

SECTOR SHAFT

SHTS07Z070300076

(2) Insert the sector shaft into the steering body so that its gear and
the power piston gear engage in the center.
NOTICE
When inserting the sector shaft, do not let the sector shaft serra-
tion damage the lip of the Y-packing. Damage may affect oil tight-
ness.

SHTS07Z070300077
 POWER STEERING SR03–33

(3) Assemble the side cover to the steering body using the bolts.
STEERING BODY Tighten them to the specified torque.

SIDE COVER

SHTS07Z070300078

10. MEASURE THE SECTOR SHAFT BACKLASH.

(1) Align the marks on the sector shaft with pitman arm.
(2) Install the pitman arm and tighten the nut finger tight.

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SHTS07Z070300079

(3) Use a dial gauge to check to see that the sector shaft backlash in
neutral position.

L Backlash
0.05-0.25 mm
270 mm {10.63 in.}
{0.002-0.009 in.}

(4) If measurement is not within specification, readjust the backlash

with adjusting screw.

SHTS07Z070300080

11. INSPECT THE WORM VALVE ASSEMBLY ROTATION CONDI-

TION.
(1) Check to see that the worm valve assembly rotate smoothly with-
out any shocks, abnormal resistance, noise and drag, when the
worm valve assembly rotates full lock in both direction.

12. TIGHTEN THE PITMAN ARM LOCK NUT.

SHTS07Z070300081
SR03–34 POWER STEERING

INSPECTION AND REPAIR

EN07Z0703H300003

METALLIC PARTS

Inspection item Location Remedy

Steering body • The internal surface of the cyl- Repair or replace the steering body if there is evi-
inder dence of abrasion or stepped wear. Check visu-
ally and by touch for any flaws that may affect
smooth piston stroke.

• Side cover assembly surface Repair or replace the steering body if there is evi-
dence of any flaws, rust or gouging that may
affect oil tightness (check visually and by touch).

• Y-packing groove in the sector Repair or replace the steering body if there is evi-
shaft hole dence of any flaws, rust or gouging that may
affect oil tightness (check visually and by touch).

Sector shaft • Gear Replace the gear if it is severely flawed or worn.

Chipped gears must also be replaced. (Check
visually and by touch)

• Gear shaft and serrations Check for cracks using magnetic-particle test
equipment and a color penetration test. Replace
any cracked parts.

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• Needle roller bearing contact Check for wear, flaws or gouging (visually and by
surface touch). Repair or replace if necessary.

• Y-packing contact surface Repair or replace if any flaws, rust or gouging

affecting oil tightness are found (check visually
and by touch).

• Adjusting screw Measure the axial clearance of the adjusting

screw with a dial gauge.
0.01-0.1 mm is acceptable, but if excessive, the
screw must be disassembled for inspection. Also
check whether the adjusting screw rotates
smoothly. If not, the screw must be disassembled
and inspected.

Power piston • Cylinder contact surface Any wear or abrasion that affects smooth piston
stroke must be corrected, or the power piston
must be replaced.

• Rack gear Replace the rack gear if severely flawed, worn or

chipped.

• Steel ball race surface Any wear or flaw that disturbs smooth rotation
and movement of steel balls must be corrected,
or the race must be replaced. (Visual inspection)

• Seal ring and O-ring Replace the seal ring or O-ring if any flaws or
tears affecting oil tightness are found.

Ball tube • Steel ball rotation surface Replace the ball tube if any wear, flaws or goug-
ing that affect smooth ball rotation are found on
the inside at the tube.

• Tang (end) Replace the ball tube if any warping, bending,

flaws or pits that affect smooth ball rotation are
found on the tang.
 POWER STEERING SR03–35

Inspection item Location Remedy

Worm shaft • Steel ball race surface Repair or replace the race if any wear, flaws or
(stub shaft) pits that affect smooth ball rotation are found.

• Seal ring Any wear, flaw, or gouge affecting oil tightness

must be corrected or the seal ring must be
replaced.

• Y-packing contact surface Any wear, flaw, rust, or gouge which may affect
oil tightness must be corrected or the packing
must be replaced.

• Thrust bearing (steel ball) con- Check the bearing for wear, flaws or pits if shaft
tact surface rotation is stiff or uneven. Repair or replace if
found.

Thrust bearing • Bearing race and steel ball Check the bearing for wear, flaws or pits if shaft
(steel ball) rotation is stiff or uneven. Repair or replace if
and bearing cage found.

• Bearing cage Replace the cage if any flaws or damage affecting

smooth rotation are found.

Rotor • External surface Repair or replace the rotor if any wear, flaws or
gouging affecting smooth rotation are found.

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• Chamber Replace the chamber if any flaws, breaks, or
chips affecting steering characteristics are
found.

• Seal ring groove Replace the seal ring if any flaws or tears affect-
ing oil tightness are found.

Side cover • Steering body contact surface Repair or replace the side cover if any flaws,
gouging or rust affecting oil tightness are found.

• Y-packing groove Repair or replace the side cover if any flaws,

gouging or rust affecting oil tightness are found.

• O-ring groove Repair or replace the side cover if any flaws,

gouging or rust affecting oil tightness are found.

Plug and seal • Thrust bearing side race con- Repair or replace the plug and seal assembly if
assembly tact surface any flaws, rust or gouging affecting uniform tight-
ening are found.

• Y-packing press fitted section Replace the plug and seal assembly if any flaws,
rust or gouging affecting oil tightness are found.

• O-ring contact surface Replace the plug and assembly if any flaws, rust
or gouging affecting oil tightness are found.

Bearings Check that the bearing rotates smoothly. Replace

the bearing if rotation is stiff or uneven.
SR03–36 POWER STEERING

POWER STEERING BOOSTER UNIT

DATA AND SPECIFICATIONS
EN07Z0703I200002

Bore 50 mm {1.968 in.}

Stroke 280 mm {11.024 in.}

Piston rod diameter 22 mm {0.866 in.}

DESCRIPTION
EN07Z0703C100003

SHTS07Z070300082 cardiagn.com
1 Ball joint socket 5 Guide assembly
2 Piston 6 Boot
3 Cylinder 7 Dust seal
4 Rod
 POWER STEERING SR03–37

SPECIAL TOOL
EN07Z0703K100002

Prior to starting a power steering booster unit overhaul, it is necessary to have these special tools.

Illustration Part number Tool name Remarks

09603-1540 GUIDE REMOVER

09657-1780 DUST SEAL INSTALLING JIG

09657-1770 ROD CAP

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09434-1120 ROD END STAKING JIG

09657-1760 PISTON INSTALLING JIG

SR03–38 POWER STEERING

COMPONENT LOCATOR
EN07Z0703D100002

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SHTS07Z070300088

1 Cylinder 7 Dust seal

2 Nut 8 Back up ring
3 Piston 9 Guide assembly
4 Slipper seal 10 Dust seal
5 O-ring 11 Ring retainer
6 Rod

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}

A 98 {1,000, 72}
 POWER STEERING SR03–39

OVERHAUL
EN07Z0703H200003

IMPORTANT POINTS - DISASSEMBLY

1. INSTALL THE POWER CYLINDER IN VICE.

(1) When disassembling the power cylinder, hold in a vice using wood
block to prevent damage.

2. REMOVE THE BALL JOINT SOCKET.

SHTS07Z070300089

3. LOOSEN THE GUIDE ASSEMBLY.

(1) Raise staked portion of the guide and using the special tool,
loosen the guide assembly.
Do not remove the guide assembly from the rod side but remove
integral with the rod from the cylinder.
SST: Guide Remover (09603-1540A)

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SHTS07Z070300090

4. REMOVE THE PISTON.

(1) Loosen the nut and remove the piston and guide assembly. Do
not reuse the nut. Be sure to replace it with a new one. Correct the
piston side threaded portion of the rod by dies.

SHTS07Z070300091

5. REMOVE THE RETAINER RING AND DUST SEAL.

(1) Remove the retainer ring, dust seal, etc. from the guide assembly,
using care not to damage grooves and rod sliding surface.

SHTS07Z070300092
SR03–40 POWER STEERING

6. REMOVE THE BALL JOINT SOCKET.

(1) Loosen the lock bolt of ball joint socket, then turn the ball joint
socket to counterclockwise and remove it.

SHTS07Z070300093

IMPORTANT POINTS - ASSEMBLY

1. ASSEMBLE THE GUIDE ASSEMBLY.

(1) Install the dust seal.
When inserting the dust seal, bend it to heart shape.

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SHTS07Z070300094

(2) Install the dust seal.

Install the dust seal using the special tool.
SST: Dust Seal Installing Jig (09657-1780A)

SHTS07Z070300095

2. INSTALL THE GUIDE ASSEMBLY.

(1) Using the special tool, at the piston rod end, insert the guide
assembly.
SST: Rod Cap (09657-1770A)

SHTS07Z070300096
 POWER STEERING SR03–41

3. INSTALL THE PISTON.

(1) Install the piston, and then tighten the nut.
(2) Staking the rod end (three places) using the special tool.
SST: Rod End Staking Jig (09434-1120A)

SHTS07Z070300097

4. INSTALL THE PISTON AND ROD.

(1) Apply hydraulic oil to inside of cylinder.
(2) Install the piston and rod using the special tool.
SST: Piston Installing Jig (09657-1760A)

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SHTS07Z070300098

5. STAKING THE GUIDE ASSEMBLY.

(1) Tighten the guide assembly using the special tool.
SST: Guide Remover (09603-1540A)

(2) Secure the guide assembly on the cylinder by staking the tube
end on the outer circumference groove of the guide assembly.

SHTS07Z070300099

6. INSTALL THE BALL JOINT SOCKET.

SHTS07Z070300100
SR03–42 POWER STEERING

INSPECTION AND REPAIR

EN07Z0703H300004

Unit: mm {in.}

Inspection item Standard Limit Remedy Inspection procedure

Clearance between piston and 0.064 - 0.137 0.18 Replace the Measure
cylinder {0.0025-0.0054} {0.0071} piston and/or
cylinder.

Cylinder: — — Replace, Visual check

Scratches on inner surface. if necessary.

Clearance between rod and 0.024-0.112 0.12 Replace the rod Measure
guide assembly {0.0009-0.0044} {0.0047} and/or guide.

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Rod: — — Replace, Visual check
Bent and/or damaged. if necessary.

Boots: — — Replace, Visual check

Damaged. if necessary.
 POWER STEERING SR03–43

POWER STEERING PUMP

DATA AND SPECIFICATIONS
EN07Z0703I200003

Type Vane type

Speed range 707-5,200 r/min

Relief pressure 14.0-14.7 MPa {143-150 kgf/cm2, 2,030-2,132 lbf/in.2}

Front single axle model 18.5-21.5 L/min. {4.89-5.67 U.S.gal, 4.07-4.72 lmp.gal} at 2,000 r/min.
Flow rate
Front tandem axle model 26-29 L/min. {6.87-7.66 U.S.gal, 5.72-6.38 lmp.gal} at 2,000 r/min.

DESCRIPTION
EN07Z0703C100004

cardiagn.com
SHTS07Z070300106

1 Flow control valve assembly 9 Ball bearing

2 Relief valve 10 Pump shaft
3 Spring 11 Pump body
4 Rotor 12 Pump cover
5 Cam ring 13 Dowel
6 Vane 14 Front plate
7 Suction connector 15 Rear plate
8 Oil seal
SR03–44 POWER STEERING

OPERATION
EN07Z0703C100005

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SHTS07Z070300107

1 Reservoir 5 Flow control valve assembly

2 Vane 6 Relief valve
3 Cam ring A To power steering gear unit
4 Rotor B From power steering gear unit
 POWER STEERING SR03–45

COMPONENT LOCATOR
EN07Z0703D100003

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SHTS07Z070300108

1 Plug 7 Bearing 13 Vane

2 O-ring 8 Oil seal 14 Rotor
3 Drive gear 9 Pump body 15 Cam ring
4 Retainer ring 10 Spring 16 Dowel
5 Suction connector 11 Flow control valve 17 Rear plate
6 Pump shaft 12 Front plate 18 Pump cover

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}

A 108-127 {1,100-1,295, 80-93} B 29-39 {295-397, 22-28}
SR03–46 POWER STEERING

OVERHAUL
EN07Z0703H200004

IMPORTANT POINTS - DISASSEMBLY

1. REMOVE THE FLOW CONTROL VALVE ASSEMBLY.

(1) Remove the plug, spring and flow control valve assembly.
NOTICE
Be careful not to drop, scratch or nick the flow control valve
assembly.

SHTS07Z070300109

2. REMOVE THE BODY COVER.

(1) Remove the retainer ring.
(2) Remove the body cover and spring.

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SHTS07Z070300110

3. REMOVE THE VANE PUMP CORE.

(1) As shown in the figure, face the vane pump core side downward
and remove the rear plate and vane pump core. The vane pump
core consists of the cam ring, rotor and vane. Since dimensional
checks of these parts have been completed, handle the vane
pump core carefully. Remove the front plate.

SHTS07Z070300111

4. REMOVE THE PUMP SHAFT ASSEMBLY.

(1) Remove the retainer ring from the pump body, and push and
remove the spline edge surface of the pump shaft by hand or by
using a plastic hammer. Be careful not to damage the oil seal lip.
This process completes disassembly. Carry out inspection.

SHTS07Z070300112
 POWER STEERING SR03–47

REPLACEMENT

1. REPLACE THE BALL BEARING, IF NECESSARY.

(1) Use a pair of snap ring pliers to remove the retainer ring.

SHTS07Z070300113

(2) Use a press, press out the ball bearing.

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SHTS07Z070300114

(3) Use a press to press in the ball bearing.

SHTS07Z070300115

(4) Use snap ring pliers to install the retainer ring.

SHTS07Z070300116

2. REPLACE THE OIL SEAL, IF NECESSARY.

(1) Use a screw driver to remove the oil seal.
NOTICE
Do not scrape or damage the inside of pump body.

SHTS07Z070300117
SR03–48 POWER STEERING

(2) Insert the oil seal as shown in the figure.

NOTICE
To prevent oil leakage from oil seal due to lip wear, apply lithium
base grease to A and B.
(3) Using a press, press in the oil seal into the pump body.

SHTS07Z070300118

IMPORTANT POINTS - ASSEMBLY

NOTICE
• Before assembling, clean all the parts and lubricate them
with fluid.
• When assembling the power steering pump, be sure to use
new O-rings.

1. INSTALL THE FLOW CONTROL VALVE ASSEMBLY.

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(1) Apply fluid to the valve and check to see that it falls smoothly into
the valve hole by its own weight.
I II If a problem is detected, replace the flow control valve assembly.
NOTICE
• There are three different valve diameters, therefore be careful
that the mark on both valve and the pump body are always
matched.
• Rank indication of flow control valve is not found on the
valve built-in the power steering pump assembly. On flow
control valve of spare parts, the rank is indicated.
SHTS07Z070300119
• On the body of “A”rank, the rank is not indicated.
I: Letter on the valve, II : Letter of the body

I A B C
March mark
II — B C

(2) Install the spring and the flow control valve assembly, and tighten
the plug.
NOTICE
Apply lithium base grease to an O-ring.

SHTS07Z070300120
 POWER STEERING SR03–49

2. INSTALL THE PUMP SHAFT.

(1) Using a press, press in the pump shaft with bearing into the pump
body.
(2) Install the retainer ring.
NOTICE
When installing the retainer ring, face the chamfer side toward ball
bearing.

SHTS07Z070300121

3. INSTALL THE FRONT PLATE.

(1) As shown in the figure, insert the front plate into the pump body
and the dowel into the standard hole and the long one of front
plate
A A: Front plate
B: Pump body
NOTICE
When inserting the front plate, the face with a stamped “RR“ indi-
B cation should be turned to the rear side and also the long hole be
faced against the suction pipe side for the installation.

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SHTS07Z070300122

4. INSTALL THE CAM RING.

(1) Insert the cam ring into the pump body through the standard hole
and elliptic one with the dowel, as shown in the figure.
NOTICE
At this moment, the stamped side should be faced against ball
bearing side and also the long hole turned against suction pipe
side.

SHTS07Z070300123

5. INSTALL THE ROTOR AND VANE.

(1) Insert the rotor with the cut spline "A" side facing toward the ball
bearing.
(2) Insert the vanes with the rounded part facing outward.

SHTS07Z070300124
SR03–50 POWER STEERING

6. INSTALL THE REAR PLATE, SPRING, O-RING AND PUMP

COVER.
(1) Put the rear plate on the cam ring through the standard hole and
elliptic one with the dowel.
NOTICE
At this moment, the stamped side should be faced against ball
bearing side and also the long hole turned against suction pipe
side.
(2) Put the spring on the rear plate and insert the O-ring into the
groove of the pump body.

SHTS07Z070300125

(3) Using a press, press in the pump cover and then install the
retainer ring securely.
NOTICE
• Be careful to see that the O-ring is not pinched by the rear
cover.
• With the pump cover pressed in completely fit the retainer
ring to pump body.

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SHTS07Z070300126

7. INSPECT PUMP SHAFT ROTATING CONDITION.

(1) Check to see that the pump shaft rotates smoothly without abnor-
mal noise.

SHTS07Z070300127
 POWER STEERING SR03–51

INSPECTION AND REPAIR

EN07Z0703H300005

Inspection item Standard Limit Remedy Inspection procedure

Shaft: — — Replace, Visual check

Damage if necessary.

Side plate: — — Replace, Visual check

Abrasion and flaw if necessary.

Flow control valve assembly: — — Replace, Visual check

Wear and damage if necessary.

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Ball bearing: — — Replace, Visual check
Scratched and damage if necessary.

Cam ring inner surface: — — Replace, Visual check

Rotor surface: if necessary.
Vane surface:
Wear, scratches and scoring

Oil seal: — — Replace, Visual check

Wear and damage if necessary.

Bushing: — — Replace the Visual check

Scratched and damage pump body,
if necessary.
SR03–52 POWER STEERING

OIL RESERVOIR
DESCRIPTION
EN07Z0703C100006

EXCEPT FY LEFT-HAND DRIVE MODEL

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SHTS07Z070300135

1 Oil reservoir cap 3 Oil strainer

2 Oil seal 4 Oil filter
 POWER STEERING SR03–53

EXCEPT FY LEFT-HAND DRIVE MODEL

cardiagn.com
SHTS07Z070300136

1 Oil reservoir cap 3 Oil strainer

2 Oil seal 4 Oil filter
SR03–54 POWER STEERING

COMPONENT LOCATOR
EN07Z0703D100004

EXCEPT FY LEFT-HAND DRIVE MODEL

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SHTS07Z070300137

1 Oil reservoir cap 4 Oil filter

2 Oil seal 5 Oil reservoir
3 Oil strainer
 POWER STEERING SR03–55

FOR FY LEFT-HAND DRIVE MODEL

cardiagn.com
SHTS07Z070300138

1 Oil reservoir cap 4 Oil filter

2 Oil seal 5 Oil reservoir
3 Oil strainer
SR03–56 POWER STEERING

OVERHAUL
EN07Z0703H200005

IMPORTANT POINT - ASSEMBLY

NOTICE
• Use only compressed air to clean the oil filter.
• The oil filter is made of synthetic resin, so never wash it with
hot water, solvent or detergent.
• Before assembling, clean all the parts.

INSPECTION AND REPAIR

EN07Z0703H300006

Inspection item Standard Limit Remedy Inspection procedure

Oil strainer: — — Clean or replace, Visual check

Clogged and damage if necessary.

Oil reservoir: — — Replace,

Damage if necessary.

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