STEERING SYSTEM GI

SECTION ST MA

EM

LC

EC

CONTENTS FE

PRECAUTIONS ...............................................................2 TILT MECHANISM ...................................................15

CL
Supplemental Restraint System (SRS) ″AIR POWER STEERING GEAR AND LINKAGE ................16
BAG″ and ″SEAT BELT PRE-TENSIONER″...............2 Components...............................................................16 MT
Precautions for Steering System.................................2 Removal and Installation ...........................................17
PREPARATION ...............................................................3 Disassembly...............................................................18
Special Service Tools ..................................................3 Inspection...................................................................19 AT
Commercial Service Tool.............................................4 BOOT .....................................................................19
NOISE, VIBRATION AND HARSHNESS (NVH) RACK .....................................................................19
TROUBLESHOOTING .....................................................5 GEAR SUB-ASSEMBLY ...........................................19 AX
GEAR HOUSING CYLINDER ....................................19
NVH Troubleshooting Chart.........................................5
TIE-ROD OUTER AND INNER SOCKETS..................20
ON-VEHICLE SERVICE ..................................................6 SU
Assembly ...................................................................20
Checking Steering Wheel Play....................................6
Adjustment .................................................................23
Checking Neutral Position on Steering Wheel ............6
POWER STEERING OIL PUMP (QG ENGINE) ...........25
PRE-CHECKING ........................................................6
Components...............................................................25
BR
CHECKING ...............................................................6
Front Wheel Turning Angle..........................................6 Pre-disassembly Inspection.......................................25
Checking Gear Housing Movement ............................6 Disassembly...............................................................26
Checking and Adjusting Drive Belts ............................7 Inspection...................................................................27
Checking Steering Gear and Linkage .........................7 Assembly ...................................................................27
STEERING GEAR ......................................................7 POWER STEERING OIL PUMP (YD ENGINE) ............29 RS
STEERING LINKAGE .................................................7 Components...............................................................29
Checking Fluid Level ...................................................7 Pre-disassembly Inspection.......................................29
Removal and Installation ...........................................30
BT
Checking Fluid Leakage ..............................................7
Bleeding Hydraulic System..........................................8 Disassembly...............................................................30
Checking Steering Wheel Turning Force ....................8 Inspection...................................................................31 HA
Checking Hydraulic System.........................................9 Assembly ...................................................................32
STEERING WHEEL AND STEERING COLUMN .........11 SERVICE DATA AND SPECIFICATIONS (SDS) .........33
Components...............................................................11 General Specifications...............................................33 SC
Removal and Installation ...........................................11 Steering Wheel ..........................................................33
STEERING WHEEL .................................................11 Steering Column ........................................................33
STEERING COLUMN ...............................................12 Steering Gear and Linkage .......................................34 EL
Disassembly and Assembly.......................................14 Power Steering ..........................................................35
Inspection...................................................................15
IDX
 PRECAUTIONS
Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

Supplemental Restraint System (SRS) “AIR

BAG” and “SEAT BELT PRE-TENSIONER” NJST0001
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with
a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of
collision. The SRS system composition which is available to NISSAN MODEL N16 is as follows (The compo-
sition varies according to the destination and optional equipment.):
I For a frontal collision
The Supplemental Restraint System consists of driver air bag module (located in the center of the steer-
ing wheel), front passenger air bag module (located on the instrument panel on passenger side), front seat
belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.
I For a side collision
The Supplemental Restraint System consists of front side air bag module (located in the outer side of front
seat), side air bag (satellite) sensor, diagnosis sensor unit (one of components of air bags for a frontal
collision), wiring harness, warning lamp (one of components of air bags for a frontal collision).
Information necessary to service the system safely is included in the RS section of this Service Manual.
WARNING:
I To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance should be per-
formed by an authorized NISSAN dealer.
I Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the RS section.
I Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. Spiral cable and wiring harnesses covered with yellow insulation tape either just
before the harness connectors or for the complete harness are related to the SRS.
Precautions for Steering System NJST0003
I Before disassembly, thoroughly clean the outside of the unit.
I Disassembly should be done in a clean work area. It is important to prevent the internal parts from
becoming contaminated by dirt or other foreign matter.
I Place disassembled parts in order, on a parts rack, for easier and proper assembly.
I Use nylon cloths or paper towels to clean the parts; common shop rags can leave lint that might
interfere with their operation.
I Before inspection or reassembly, carefully clean all parts with a general purpose, non-flammable
solvent.
I Before assembly, apply a coat of recommended power steering fluid* to hydraulic parts. Vaseline
may be applied to O-rings and seals. Do not use any grease.
I Replace all gaskets, seals and O-rings. Avoid damaging O-rings, seals and gaskets during instal-
lation. Perform functional tests whenever designated.
*: DEXRONTMIII or equivalent. Refer to MA-21, “Fluids and Lubricants”.

ST-2
 PREPARATION
Special Service Tools

Special Service Tools NJST0004

Tool number
Description GI
Tool name

KV48100700 Measuring pinion rotating torque

Torque adapter MA

EM
NT169

KV48102500 Measuring oil pressure

Pressure gauge adapter
LC

EC

FE
NT542

ST27180001 Removing steering wheel CL

Steering wheel puller

MT

AT
NT544

HT72520000 Removing ball joint AX

Ball joint remover a: 33 mm (1.30 in)
b: 50 mm (1.97 in)
r: R11.5 mm (0.453 in)
SU

NT546 BR
KV48103500 Measuring oil pressure
Pressure gauge

RS
NT547

KV48104400 Reforming teflon ring BT

Rack seal ring reformer a: 50 mm (1.97 in) dia.
b: 36 mm (1.42 in) dia.
c: 100 mm (3.94 in) HA

SC
NT550

ST3127S000 Measuring turning torque EL

1 GG91030000
Torque wrench
2 HT62940000 IDX
Socket adapter
3 HT62900000
Socket adapter
NT541

ST-3
 PREPARATION
Commercial Service Tool

Commercial Service Tool NJST0005

Tool number Description

Oil pump attachment Disassembling and assembling oil pump

Unit: mm (in)

NT774

KV48105210 Removing and Installing power steering oil pump

Sprocket holder

NT809

ST-4
 Symptom

×: Applicable
Reference page

Possible cause and

SUSPECTED PARTS

STEERING
Noise

Shake

Judder
Shimmy
Vibration
×
Fluid level ST-7

×
Air in hydraulic system ST-8

×
Tie-rod ball joint swinging force ST-20

×
Tie-rod ball joint rotating torque ST-20

×
Tie-rod ball joint end play ST-20

×
Steering gear fluid leakage ST-7

×
Steering wheel play ST-6

ST-5
×
Steering gear rack sliding force ST-8

×
Drive belt looseness Refer to EM-18.

×
×
×
Improper steering wheel —

×
×
×
Improper installation or looseness or tilt lock lever ST-11

×
×
×
× Mounting rubber deterioration ST-6
× Steering column deformation or damage ST-15
NVH Troubleshooting Chart

Improper installation or looseness of steering column ST-14

×
×

Steering linkage looseness ST-16

×
×
×

DRIVE SHAFT AX-3

×
×
×
×
×

AXLE AX-3
×
×
×
×
×

SUSPENSION SU-4
×
×
×
×
×

TIRES SU-4
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

×
×
×
×

ROAD WHEEL SU-4

×
×
×
×

BRAKES BR-6
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
NJST0006S01
NJST0006

NVH Troubleshooting Chart

GI

AT

EL
FE

BT
CL
LC

AX

RS

SC
SU
EC

HA
BR
MT
EM
MA

IDX
 ON-VEHICLE SERVICE
Checking Steering Wheel Play

Checking Steering Wheel Play NJST0007

I With wheels in a straight-ahead position, check steering wheel
play.
Steering wheel play:
35 mm (1.38 in) or less
I If it is not within specification, check the following for loose or
worn components.
Steering gear assembly
Steering column
SST489B
Front suspension and axle

Checking Neutral Position on Steering Wheel NJST0008

PRE-CHECKING NJST0008S01
I Make sure that wheel alignment is correct.
Wheel alignment:
Refer to SU-15, SDS.
I Verify that the steering gear is centered before removing the
steering wheel.
CHECKING NJST0008S02
1. Check that the steering wheel is in the neutral position when
SST490BA driving straight ahead.
2. If it is not in the neutral position, remove the steering wheel and
reinstall it correctly.
3. If the neutral position is between two teeth, loosen tie-rod lock
nuts. Turn the tie-rods by the same amount in opposite direc-
tions on both left and right sides.

Front Wheel Turning Angle NJST0009

1. Rotate steering wheel all the way right and left; measure turn-
ing angle.
Turning angle of full turns:
Refer to SU-15, SDS.
2. If it is not within specification, check rack stroke.
Rack stroke “S”:
Refer to SDS, ST-34.

SMA127

Checking Gear Housing Movement NJST0010

1. Check the movement of steering gear housing during station-
ary steering on a dry paved surface.
I Apply a force of 49 N (5 kg, 11 lb) to steering wheel to check
the gear housing movement.
Turn off ignition key while checking.
Movement of gear housing:
±2 mm (±0.08 in) or less
2. If movement exceeds the limit, replace mount insulator after
confirming proper installation of gear housing clamps.
SST663B

ST-6
 ON-VEHICLE SERVICE
Checking and Adjusting Drive Belts

Checking and Adjusting Drive Belts NJST0011

Refer to EM-18, “Checking Drive Belts”.
GI

MA

EM

LC
Checking Steering Gear and Linkage NJST0037
STEERING GEAR NJST0037S01
EC
I Check gear housing and boots for looseness, damage or
grease leakage.
I Check connection with steering column for looseness. FE
STEERING LINKAGE NJST0037S02
I Check ball joint, dust cover and other component parts for CL
looseness, wear, damage or grease leakage.

SMA851B
MT
Checking Fluid Level NJST0012
Check fluid level, referring to the scale on reservoir tank. AT
Use “HOT” range for fluid temperatures of 50 to 80°C (122 to
176°F).
Use “COLD” range for fluid temperatures of 0 to 30°C (32 to 86°F). AX
CAUTION:
I Do not overfill. SU
I Recommended fluid is DEXRONTMIII or equivalent. Refer
to MA-21, “Fluids and Lubricants”.
BR
SST850C

Checking Fluid Leakage NJST0013

Check the lines for improper attachment and for leaks, cracks,
damage, loose connections, chafing and deterioration.
1. Run engine between idle speed and 1,000 rpm. RS
Make sure temperature of fluid in oil tank rises to 60 to 80°C
(140 to 176°F).
2. Turn steering wheel right-to-left several times.
BT
3. Hold steering wheel at each “lock” position for five seconds
and carefully check for fluid leakage. HA
SST874C
CAUTION:
Do not hold the steering wheel in a locked position for more
than 15 seconds. SC
4. If fluid leakage at connectors is noticed, loosen flare nut and
then retighten.
Do not overtighten connector as this can damage O-ring,
EL
washer and connector.
5. If fluid leakage from power steering pump is noticed, check IDX
power steering pump. Refer to ST-25.
6. Check rack boots for accumulation of power steering fluid.

ST-7
 ON-VEHICLE SERVICE
Bleeding Hydraulic System

Bleeding Hydraulic System NJST0014

1. Raise front end of vehicle until wheels are clear of the ground.
2. Add fluid into oil tank to specified level. Then quickly turn steer-
ing wheel fully to right and left and lightly touch steering stop-
pers.
Repeat steering wheel operation until fluid level no longer
decreases.
3. Start engine.
Repeat step 2. above.
I Incomplete air bleeding will cause the following to occur. When
this happens, bleed air again.
a) Air bubbles in reservoir tank
b) Clicking noise in oil pump
c) Excessive buzzing in oil pump
Fluid noise may occur in the valve or oil pump. This is common
when the vehicle is stationary or while turning the steering wheel
slowly. This does not affect the performance or durability of the
system.

Checking Steering Wheel Turning Force NJST0015

1. Park vehicle on a level, dry surface and set parking brake.
2. Start engine.
3. Bring power steering fluid up to adequate operating tempera-
ture. [Make sure temperature of fluid is approximately 60 to
80°C (140 to 176°F).]
Tires need to be inflated to normal pressure.
4. Check steering wheel turning force when steering wheel has
been turned 360° from the neutral position.
SST491B
Steering wheel turning force:
39 N (4 kg, 9 lb) or less
5. If steering wheel turning force is out of specification, check
rack sliding force.
a. Disconnect steering column lower joint and knuckle arms from
the gear.
b. Start and run engine at idle to make sure steering fluid has
reached normal operating temperature.
c. Pull tie-rod slowly to move it from neutral position to ±11.5 mm
(±0.453 in) at speed of 3.5 mm (0.138 in)/s. Check that rack
sliding force is within specification.
Average rack sliding force:
SST090B
Sedan
152 - 240 N (15.5 - 24.5 kg, 34 - 54 lb)
Hatchback
132 - 308 N (13.5 - 31.4 kg, 30 - 69 lb)
Maximum force deviation:
Sedan
98 N (10 kg, 22 lb)
Hatchback
176 N (17.9 kg, 39 lb)
d. Check sliding force outside the above range at rack speed of
40 mm (1.75 in)/s.

ST-8
 ON-VEHICLE SERVICE
Checking Steering Wheel Turning Force (Cont’d)
Rack sliding force (Sedan only):
Not more than 294 N (30 kg, 66 lb)
Maximum force deviation: GI
147 N (15 kg, 33 lb)
6. If rack sliding force is not within specification, overhaul steer- MA
ing gear assembly.
7. If rack sliding force is OK, inspect steering column. Refer to
ST-14. EM

LC
Checking Hydraulic System NJST0016
Before starting, check belt tension, driving pulley and tire pressure. EC
1. Set Tool. Open shut-off valve. Then bleed air. Refer to “Bleed-
ing Hydraulic System”, ST-8.
2. Run engine at idle speed or 1,000 rpm. FE
Make sure temperature of fluid in tank rises to 60 to 80°C (140
to 176°F).
CL
WARNING:
Warm up engine with shut-off valve fully opened. If engine is
started with shut-off valve closed, fluid pressure in oil pump MT
SST834-I
increases to maximum. This will raise oil temperature abnor-
mally.
3. Check pressure with steering wheel fully turned to left and right AT
positions with engine idling at 1,000 rpm.
CAUTION:
Do not hold the steering wheel in a locked position for more AX
than 15 seconds.
Oil pump maximum standard pressure: SU
QG13, 15 engine (Sedan)
7,600 - 8,200 kPa (76.0 - 82.0 bar, 77.5 - 83.6
kg/cm2, 1,102 - 1,189 psi) BR
QG16, 18 engine (Sedan)
8,600 - 9,200 kPa (86.0 - 92.0 bar, 87.7 - 93.8
kg/cm2, 1,247 - 1,334 psi)
QG15, 18 engine (Hatchback)
8,600 - 9,200 kPa (86.0 - 92.0 bar, 88.7 - 93.8 RS
kg/cm2, 1,247 - 1,334 psi)
YD22 engine
8,800 - 9,400 kPa (88.0 - 94.0 bar, 88.7 - 95.8 BT
kg/cm2, 1,261 - 1,362 psi)
I If pressure reaches maximum operating pressure, system is
OK. HA
I If pressure increases above maximum operating pressure,
check power steering pump flow control valve. Refer to ST-25. SC
4. If power steering pressure is below the maximum operating
pressure, slowly close shut-off valve and check pressure
again. EL
CAUTION:
Do not close shut-off valve for more than 15 seconds.
I If pressure increases to maximum operating pressure, gear is IDX
damaged. Refer to “Removal and Installation”, ST-17.
I If pressure remains below maximum operating pressure, pump
is damaged. Refer to “Disassembly”, ST-26.
5. After checking hydraulic system, remove Tool and add fluid as

ST-9
 ON-VEHICLE SERVICE
Checking Hydraulic System (Cont’d)
necessary. Then completely bleed air out of system. Refer to
ST-8.

ST-10
 STEERING WHEEL AND STEERING COLUMN
Components

Components NJST0017

GI

MA

EM

LC

EC

FE

CL

MT

AT

JST875C
AX

1. Air bag module 5. Combination switch 8. Hole cover SU

2. Steering wheel 6. Steering column assembly 9. Lower joint
3. Spiral cable 7. Clip 10. Lower cover
4. Column cover BR

CAUTION:
I The rotation of the spiral cable (SRS “Air bag” component
part) is limited. If the steering gear must be removed, set
the front wheels in the straight-ahead direction. Do not RS
rotate the steering column while the steering gear is
removed.
I Remove the steering wheel before removing the steering BT
lower joint to avoid damaging the SRS spiral cable.

HA

Removal and Installation NJST0018

SC
STEERING WHEEL NJST0018S01
I Remove air bag module and spiral cable. EL
Refer to RS-29, “Removal — Air Bag Module and Spiral Cable”.

IDX

SBF812E

ST-11
 STEERING WHEEL AND STEERING COLUMN
Removal and Installation (Cont’d)
I Align spiral cable correctly when installing steering wheel.
a) Set the front wheels in the straight-ahead position.
b) Make sure that the spiral cable is in the neutral position.
The neutral position is detected by turning left 2.5 revolutions
from the right end position. Align the two marks ( ).
CAUTION:
The spiral cable may snap due to steering operation if the
cable is installed in an improper position.
Also, with the steering linkage disconnected, the cable may
snap by turning the steering wheel beyond the limited number
of turns. (The spiral cable can be turned up to 2.5 turns from
the neutral position to both the right and left.)

SRS266

I Remove steering wheel with Tool.

SST777C

STEERING COLUMN NJST0018S02

I Remove key interlock cable (A/T models).

SST329C

I When installing steering column, fingertighten all lower bracket

and clamp retaining bolts; then tighten them securely. Do not
apply undue stress to steering column.
I When attaching coupling joint, be sure tightening bolt faces
cutout portion.

SST800A

ST-12
STEERING WHEEL AND STEERING COLUMN
Removal and Installation (Cont’d)
I Align slit of lower joint with projection on dust cover. Insert joint
until surface A contacts surface B.
CAUTION: GI
After installation, turn steering wheel to make sure it moves
smoothly. Ensure the number of turns are the same from the
straight forward position to left and right locks. Be sure that MA
the steering wheel is in a neutral position when driving
straight ahead.
EM

SST491C LC

EC

FE

CL

MT

AT

AX

SU

BR

RS

BT

HA

SC

EL

IDX

ST-13
 STEERING WHEEL AND STEERING COLUMN
Disassembly and Assembly

Disassembly and Assembly =NJST0019

SST920C

1. Combination switch 6. Lower seal cover 11. Spring

2. Lock nut 7. Hole cover 12. Adjust bolt
3. Jacket tube assembly 8. Tilt lever 13. Adjust bolt stopper
4. Column shaft assembly 9. Tilt lever stopper 14. Nut
5. Clip 10. Steering column mounting bracket 15. Steering column lower cover

I When disassembling and assembling, unlock steering lock

with key.
I Remove combination switch.
I Install lock nut on steering column shaft and tighten the nut.

SST490C

ST-14
STEERING WHEEL AND STEERING COLUMN
Disassembly and Assembly (Cont’d)
I Steering lock
a) Break self-shear type screws with a drill or other appropriate
tool. GI

MA

EM

SST741A LC
b) Install new self-shear type screws and then cut off self-shear
type screw heads.
EC

FE

CL

SST742A
MT
Inspection NJST0020
I When steering wheel does not turn smoothly, check the steer- AT
ing column as follows and replace damaged parts.
a) Check column bearings for damage or unevenness. Lubricate
with recommended multi-purpose grease or replace steering
AX
column as an assembly, if necessary.
b) Check jacket tube for deformation or breakage. Replace if SU
necessary.
I When the vehicle comes into a light collision, check length “L”.
Steering column length “L”: BR
SST855C
Refer to SDS, ST-33.
If out of the specifications, replace steering column as an assem-
bly.

RS

BT

HA

TILT MECHANISM NJST0020S01

SC
I After installing steering column, check tilt mechanism opera-
tion.
EL

IDX

SST582B

ST-15
 POWER STEERING GEAR AND LINKAGE
Components

Components NJST0021

SST877CA

1. Rear cover cap 11. Retainer 20. Boot band

2. Gear sub-assembly 12. Gear housing 21. Dust boot
3. O-ring 13. Center bushing 22. Boot band
4. Shim 14. Rack oil seal 23. Spacer ring
5. Lock nut 15. Rack assembly 24. Lock plate
6. Adjusting screw 16. Rack seal ring 25. Tie-rod inner socket
7. Spring 17. O-ring 26. Tie-rod outer socket
8. Diaphragm spring 18. Rack oil seal 27. Cotter pin
9. Washer 19. End cover assembly 28. Gear housing tube
10. Spring seat

ST-16
 POWER STEERING GEAR AND LINKAGE
Removal and Installation

Removal and Installation NJST0022

GI

MA

EM

LC

EC

FE

CL

MT

AT

SST878CA
AX

1. Lower joint 4. Upper gear housing mounting 6. Lower gear housing mounting SU
2. Washer bracket bracket
3. Gear and linkage assembly 5. Rack mounting insulator 7. Cotter pin
BR
CAUTION:
I The rotation of the spiral cable (SRS “Air bag” component
part) is limited. If the steering gear must be removed, set
the front wheels in the straight-ahead direction. Do not
rotate the steering column while the steering gear is RS
removed.
I Remove the steering wheel before removing the steering BT
lower joint to avoid damaging the SRS spiral cable.
I Detach tie-rod outer sockets from knuckle arms with Tool.
1. Remove stabilizer fixing bolts. Refer to SU-12, “Removal and HA
SFA455BA
Installation”.
2. Disconnect lower joint.
3. Remove gear housing mounting bracket fixing bolts. SC
4. Remove steering gear assembly.
EL

IDX

ST-17
 POWER STEERING GEAR AND LINKAGE
Removal and Installation (Cont’d)
I Install pipe connector.
I Observe specified tightening torque when tightening high-pres-
sure and low-pressure pipe connectors. Excessive tightening
will damage threads of connector or O-ring.
Connector tightening torque:
1 Low-pressure side
27 - 39 N·m (2.8 - 4.0 kg-m, 20 - 29 ft-lb)
2 High-pressure side
15 - 25 N·m (1.5 - 2.5 kg-m, 11 - 18 ft-lb)
I The O-ring in low-pressure pipe connector is larger than that
SST879C
in high-pressure connector. Take care to install the proper
O-ring.

I Initially, tighten nut on tie-rod outer socket and knuckle arm to

29 to 39 N·m (3 to 4 kg-m, 22 to 29 ft-lb). Then tighten further
to align nut groove with first pin hole so that cotter pin can be
installed.
CAUTION:
Tightening torque must not exceed 49 N·m (5 kg-m, 36 ft-lb).
NOTE:
Only the dust boot, tie-rod inner socket and tie-rod outer socket can
be disassembled on models for Europe.

SST824A

I Before removing lower joint from gear, set gear in neutral

(wheels in straight-ahead position). After removing lower joint,
put matching mark on pinion shaft and pinion housing to record
neutral position.
I To install, set left and right dust boots to equal deflection.
Attach lower joint by aligning matching marks of pinion shaft
and pinion housing.
I Tighten gear housing mounting bracket bolts.

SST819A

Disassembly NJST0023
1. Prior to disassembling, measure pinion rotating torque. Record
the pinion rotating torque as a reference.
I Before measuring, disconnect gear housing tube and
drain fluid.
I Use soft jaws when holding steering gear housing. Handle
gear housing carefully, as it is made of aluminum. Do not
grip cylinder in a vise.
2. Remove gear sub-assembly, O-ring and shim.
Gear sub-assembly cannot be disassembled. If it is faulty,
SST862CB
replace with a new one.
ST-18
POWER STEERING GEAR AND LINKAGE
Disassembly (Cont’d)
3. Remove tie-rod outer sockets and boots.
4. Loosen tie-rod inner socket by prying up staked portion, and
remove socket and spacer. GI
5. Remove retainer.
6. Use a 2 to 2.5 mm (0.079 to 0.098 in) diameter drill to com-
pletely remove staked portion of gear housing end. MA

EM

SST051C LC
7. Remove end cover assembly with a suitable tool.
8. Draw out rack assembly.
EC
9. Remove rack seal ring.
I Using a heat gun, heat rack seal to approximately 40°C
(104°F). FE
I Remove rack seal ring.
Be careful not to damage rack.
CL

SST052C
MT
10. Remove center bushing and rack oil seal using tape wrapped
socket and extension bar. AT
Do not scratch inner surfaces of pinion housing.

AX

SU

BR
SST472A

Inspection NJST0024
Thoroughly clean all parts in cleaning solvent or DEXRONTMIII or
equivalent. Blow dry with compressed air, if available.
BOOT RS
NJST0024S01
I Check condition of boot. If cracked excessively, replace it.
I Check boots for accumulation of power steering fluid. BT
RACK NJST0024S02
Thoroughly examine rack gear. If damaged, cracked or worn, HA
replace it.
GEAR SUB-ASSEMBLY
I
NJST0024S03
Check pinion gear. If it is worn or damaged, replace as a gear
SC
sub-assembly.
I Manually spin bearing. If torque variations or free play are EL
noted, replace as a gear sub-assembly.
GEAR HOUSING CYLINDER NJST0024S04 IDX
Check gear housing cylinder bore for scratches or other damage.
Replace if necessary.

ST-19
 POWER STEERING GEAR AND LINKAGE
Inspection (Cont’d)
TIE-ROD OUTER AND INNER SOCKETS NJST0024S05
I Check ball joints for swinging force.
Tie-rod outer and inner ball joints swinging force “A”:
Refer to SDS, ST-34.
I Check ball joint for rotating torque.
Tie-rod outer ball joint rotating torque “B”:
Refer to SDS, ST-34.
I Check ball joints for axial end play.
Tie-rod outer and inner ball joints axial end play “C”:
SST468C Refer to SDS, ST-34.
I Check condition of dust cover. If cracked excessively, replace
outer tie-rod.

Assembly NJST0025
1. Using a heat gun, heat new teflon rack seal ring to approxi-
mately 40°C (104°F). Then place it onto rack.

SST083B

2. Using Tool, compress rack seal ring securely onto rack.

Always insert Tool from the rack gear side.

SST885BA

3. Insert new rack oil seal.

I Place plastic film into rack oil seal to prevent damage by
rack teeth.
I Do not forget to remove plastic film after rack oil seal is
positioned properly.
I Make sure lips of rack oil seal face each other.

SST201A

ST-20
POWER STEERING GEAR AND LINKAGE
Assembly (Cont’d)
4. Install center bushing and rack oil seal with rack assembly.

GI

MA

EM

SST863C LC
5. Insert rack oil seal and end cover assembly to rack. Then
tighten end cover assembly.
EC

FE

CL

SST321B
MT
6. Fasten end cover assembly to gear housing by staking.
AT

AX

SU

BR
SST073B

7. Set rack gear in neutral position.

Rack stroke “S”:
Refer to SDS, ST-34.
RS

BT

HA
SST086BA

8. Install adjustment shims and O-rings to gear sub-assembly. SC

I Install the same number of adjustment shims as before,
regardless of whether or not gear sub-assembly is replaced.
I Discard old O-rings; replace with new ones. EL
9. Tighten gear subassembly securing bolts to specified tighten-
ing torque.
IDX

SST880C

ST-21
 POWER STEERING GEAR AND LINKAGE
Assembly (Cont’d)
10. Ensure that the rack is centered. Install rear cover cap so that
its protrusion is positioned as shown in figure.

SST865C

11. Install diaphragm spring into gear housing.

I Always install retainer, spring washer and diaphragm spring in
that order.
I Make sure convex end (painted white) of diaphragm spring
faces outward when installing.
12. Install spring seat retainer spring and adjusting screw tempo-
rarily.

SST087B

13. Install lock plate to rack.

a. Temporarily install spacer ring to rack.
Discard old spacer ring; replace with a new one.
b. Install lock plate to inner socket.
Discard old lock plate; replace with a new one.
c. Apply a coat of locking sealant to inner socket threads. Screw
inner socket into rack and tighten to specified torque.
d. Clinch lock plate at rack groove location (at two points).
e. Install spacer ring to lock plate as shown in the Figure at left.
SST866C Be careful not to damage spacer ring during installation
14. Tighten outer socket lock nut.
Tie-rod length “L”:
Refer to SDS, ST-34.

SST867C

15. Measure rack stroke.

Rack stroke “S”:
Refer to SDS, ST-34.

SST086BA

ST-22
POWER STEERING GEAR AND LINKAGE
Assembly (Cont’d)
16. Before installing boot, coat the contact surfaces between boot
and tie-rod with grease.
GI

MA

EM

SST967A LC
17. Install boot bands.
I Securely install boot band to boot groove and clinch the root
section of the trapezoidal area.
EC
I Make sure that there is a clearance of 3.5 mm (0.138 in) or less
at the clinched section of the boot band. Refer to the Figure at FE
left.

CL

SST868C
MT
I After installing gear in vehicle, make sure that the clinched
section of boot band is positioned toward the rear of vehicle (to AT
prevent interference with adjacent parts).

AX

SU

BR
SST869C

Adjustment NJST0026
Adjust pinion rotating torque as follows:
1. Set rack to the neutral position without fluid in the gear.
2. Coat the adjusting screw with locking sealant and screw it in. RS
3. Lightly tighten lock nut.
4. Tighten adjusting screw to a torque of 4.9 to 5.9 N·m (50 to 60 BT
kg-cm, 43 to 52 in-lb).
5. Loosen adjusting screw, then retighten it to 0.2 N·m (2 kg-cm,
1.7 in-lb). HA
SST719C

6. Move rack over its entire stroke several times. SC

7. Measure pinion rotating torque within the range of 180° from
neutral position.
Stop the gear at the point of maximum torque. EL
8. Loosen adjusting screw, then retighten it to 4.9 N·m (50 kg-cm,
43 in-lb).
9. Loosen adjusting screw by 50° to 70°. IDX

SST862CB

ST-23
 POWER STEERING GEAR AND LINKAGE
Adjustment (Cont’d)
10. Prevent adjusting screw from turning, and tighten lock nut to
specified torque.

SST713C

11. Check rack sliding force on vehicle as follows:

a. Install steering gear onto vehicle, but do not connect tie-rod to
knuckle arm.
b. Connect all piping and fill with steering fluid.
c. Start engine and bleed air completely.
d. Disconnect steering column lower joint from the gear.
e. Keep engine at idle and make sure steering fluid has reached
normal operating temperature.
f. Pull tie-rod slowly to move it from neutral position to ±11.5 mm
(±0.453 in) at speed of 3.5 mm (0.138 in)/s. Check that rack
SST090B sliding force is within specification.
Average rack sliding force:
Sedan
152 - 240 N (15.5 - 24.5 kg, 34.2 - 54.0 lb)
Hatchback
132 - 308 N (13.5 - 31.4 kg, 30 - 69 lb)
Maximum force deviation:
Sedan
98 N (10 kg, 22 lb)
Hatchback
176 N (17.9 kg, 39 lb)
g. Check sliding force outside above range at rack speed of 40
mm (1.57 in)/s.
Maximum rack sliding force (Sedan only):
294 N (30 kg, 66 lb)
Maximum force deviation (Sedan only):
147 N (15 kg, 33 lb)
I If rack sliding force is not within specification, readjust by
repeating adjustment procedure from the beginning.
I If rack sliding force is still out of specification after
readjustment, gear assembly needs to be replaced.

ST-24
 POWER STEERING OIL PUMP (QG ENGINE)
Components

Components NJST0027

GI

MA

EM

LC

EC

FE

CL

MT

AT

AX

SU
SST881CA
BR
1. Pulley 8. Flow control A valve 15. Rotor snap ring
2. Bracket 9. Dowel pin 16. Rear side plate
3. Drive shaft seal 10. Flow control B valve assy 17. Side plate inner seal
4. Inlet connector 11. Front side plate 18. Side plate outer seal
5. Inlet connector seal 12. Cartridge 19. Body seal
6. Front housing 13. Rotor 20. Rear body RS
7. Flow control valve spring 14. Vane

BT

HA

Pre-disassembly Inspection NJST0028

SC
Disassemble the power steering oil pump only if the following items
are found.
I Oil leak from any point shown in the figure
EL
I Deformed or damaged pulley
I Poor performance IDX

SST984A

ST-25
 POWER STEERING OIL PUMP (QG ENGINE)
Disassembly

Disassembly NJST0029
CAUTION:
I The power steering pump cannot be disassembled on
Hatchback with QG engine. If it is faulty, replae with a new
assembly.
I Parts which can be disassembled are strictly limited.
Never disassemble parts other than those specified.
I Disassemble in as clean a place as possible.
I Clean your hands before disassembly.
I Do not use rags; use nylon cloths or paper towels.
I Follow the procedures and cautions in the Service
Manual.
I When disassembling and reassembling, do not let foreign
matter enter or contact the parts.

I Remove snap ring, then draw drive shaft out.

Be careful not to drop drive shaft.

SST010B

I Remove oil seal.

Be careful not to damage front housing.

SST034A

I Remove connector and flow control valve with spring.

Be careful not to drop flow control valve.
Do not disassemble flow control valve.

SST036A

ST-26
POWER STEERING OIL PUMP (QG ENGINE)
Inspection

Inspection NJST0030
I If pulley is cracked or deformed, replace it.
I If an oil leak is found around pulley shaft oil seal, replace the GI
seal.
I If serration on pulley or pulley shaft is deformed or worn, MA
replace it.

EM

LC
Assembly NJST0031
Assemble oil pump, noting the following instructions. EC
I Make sure O-rings and oil seal are properly installed.
I Always install new O-rings and oil seal.
I Be careful of oil seal direction. FE
I Cam ring, rotor and vanes must be replaced as a set if neces-
sary. CL
I Coat each part with DEXRONTMIII or equivalent when assem-
bling.
SST038A
MT
I Pay attention to the direction of rotor.
AT

AX

SU

BR
SST289A

I When assembling vanes to rotor, rounded surfaces of vanes

must face cam ring side.

RS

BT

HA
SST843A

SC

EL

IDX

ST-27
 POWER STEERING OIL PUMP (QG ENGINE)
Assembly (Cont’d)
I Insert pin 2 into pin groove 1 of front housing and front side
plate. Then install cam ring 3 as shown at left.
Cam ring:
D1 is less than D2.

SST472C

ST-28
 POWER STEERING OIL PUMP (YD ENGINE)
Components

Components NJST0038

GI

MA

EM

LC

EC

FE

CL

MT

AT

AX

SU
SST882CA
BR
1. Rear bracket 9. O-ring (Outer) 17. Outlet connector
2. Rear body 10. O-ring (Inner) 18. Connector seal
3. Dowel pin 11. Front body 19. Flow control valve
4. Side plate seal 12. Drive shaft rear oil seal 20. Flow control valve spring
5. Cam ring 13. Drive shaft front oil seal 21. Inlet connector
6. Vane 14. Drive shaft 22. O-ring RS
7. Rotor 15. Snap ring 23. Washer
8. Side plate 16. O-ring
BT

HA

Pre-disassembly Inspection NJST0039

SC
Disassemble the power steering oil pump only if the following items
are found.
I Oil leak from any point shown in the figure
EL
I Poor performance
IDX

SST883C

ST-29
 POWER STEERING OIL PUMP (YD ENGINE)
Removal and Installation

Removal and Installation NJST0040

1. Remove chain case cover.

SST884C

2. Revolving crank pulley, set tool.

3. Fix tool with chain cover fixing bolts.
4. Using suitable tool, remove sprocket fixing nut and washer.
Do not remove Tool while power steering oil pump is
removed.

SST885C

5. Remove power steering pump fixing bolts, then remove it.

SST886C

I Apply Gasket to the installation surface of the engine chain

case cover as shown in the figure before installing the chain
case cover to the engine.
I Bleed air after installation.
Refer to ST-8.

SST890C

Disassembly NJST0041
CAUTION:
I Parts which can be disassembled are strictly limited.
Never disassemble parts other than those specified.
I Disassemble in as clean a place as possible.
I Clean your hands before disassembly.
I Do not use rags; use nylon cloths or paper towels.
I Follow the procedure and cautions in the Service Manual.
I When disassembling and reassembling, do not let foreign
matter enter or contact the parts.

ST-30
POWER STEERING OIL PUMP (YD ENGINE)
Disassembly (Cont’d)
I Remove rear bracket and rear body.
I Remove side plate seal, cam ring vane, rotor side and plate.
GI

MA

EM

SST887C LC
I Remove inlet connector and outlet connector with spring.
Be careful not to drop the flow control valve.
Do not disassemble the flow control valve. EC

FE

CL

SST036A
MT
I Remove oil seal
AT

AX

SU

BR
SST888C

I Remove snap ring, then draw drive shaft.

Be careful not to drop drive shaft.

RS

BT

HA
SST889C

Inspection NJST0042
SC
I If pulley is cracked or deformed, replace it.
I If an oil leak is found around pulley shaft oil seal, replace the
seal.
EL
I If serration on pulley or pulley shaft is deformed or worn,
replace it. IDX

ST-31
 POWER STEERING OIL PUMP (YD ENGINE)
Assembly

Assembly NJST0043
Assemble oil pump, noting the following instructions.
I Make sure O-rings and oil seal are properly installed.
I Always install new O-rings and oil seal.
I Be careful of oil seal direction.
I Cam ring, rotor and vanes must be replaced as a set if neces-
sary.
I Coat each part with DEXRONTMIII or equivalent when assem-
bling.
SST038A

I Pay attention to the direction of rotor.

SST289A

I When assembling vanes to rotor, rounded surfaces of vanes

must face cam ring side.

SST843A

I Insert pin 2 into pin groove 1 of front housing and front side
plate. Then install cam ring 3 as shown at left.
Cam ring:
D1 is less than D2.

SST472C

ST-32
 SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications

General Specifications NJST0032

Applied model Sedan Hatchback GI

Steering model Power steering

Steering gear type PR24AD PR25T MA

Steering overall gear ratio 16.6 16.8

Turns of steering wheel (Lock to lock) 2.9 EM

Steering column type Collapsible, tilt

Steering Wheel LC
NJST0033

Steering wheel axial play mm (in) 0 (0)

EC
Steering wheel play mm (in) 35 (1.38) or less

Movement of gear housing mm (in) ±2 (±0.08) or less

FE
Steering Column NJST0034

Sedan
CL
Applied model Except for Taiwan, Thailand, Malay- For Taiwan, Thailand, Malaysia and Hatchback
sia and the Philippines the Philippines MT
Steering column length “L” mm
542 - 544 (21.34 - 21.42) 545 - 547 (21.46 - 21.54)
(in)
AT

AX

SU

BR

SST855C

RS

BT

HA

SC

EL

IDX

ST-33
 SERVICE DATA AND SPECIFICATIONS (SDS)
Steering Gear and Linkage

Steering Gear and Linkage NJST0035

Sedan Hatchback
Applied model
QG engine YD engine QG engine YD engine

Steering gear type PR24AD PR25T

Swinging force at cotter pin hole:

6.9 - 65.7 (0.66 - 6.59, 1.5 - 14.8)
“A” N (kg, lb)
Tie-rod outer ball
Rotating torque: “B” N·m (kg-cm,
joint 0.29 - 2.94 (3.0 - 30.0, 2.6 - 26.0)
in-lb)

Axial end play: “C” mm (in) 0.4 (0.016) or less

Tie-rod inner ball Swinging force*: “A” N (kg, lb) 5.9 - 46.1 (0.58 - 4.65, 1.3 - 10.4)
joint
Axial end play: “C” mm (in) 0.2 (0.004) or less

Tie-rod standard length “L” mm (in) 160.0 (6.299) 164.0 (6.457) 132 (5.20) 136 (5.35)

*: Measuring point [: 172 mm (6.77 in)]

SST867C

Initial tightening torque N·m (kg-

3.9 - 5.9 (40 - 60, 35 - 52) —
cm, in-lb)

Retightening torque after

Retainer adjustment 0.2 (2, 1.7) —
loosening N·m (kg-cm, in-lb)
Adjusting screw
Tightening torque after gear has
3.9 - 5.9 (40 - 60, 35 - 52) —
settled N·m (kg-cm, in-lb)

Returning angle degree 50° - 70° —

Rack stroke “S” mm (in) 65.0 (2.559)

SST086BA

ST-34
 SERVICE DATA AND SPECIFICATIONS (SDS)
Power Steering

Power Steering NJST0036

Applied model Sedan Hatchback GI

Steering gear type PR24AD PR25T

Range within ±11.5 mm (±0.453 in) Average force

152 - 240 (15.5 - 24.5, 34.2 132 - 308 (13.5 - 31.4, 30 - MA
from the neutral position at rack - 54.0) 69)
Rack sliding
force N (kg, lb) speed of 3.5 mm (0.138 in)/s
Maximum force deviation 98 (10, 22) 176 (17.9, 39)
Under normal oper- EM
ating oil pressure Maximum sliding force 294 (30, 66) —
Except for the above range
Maximum force deviation 147 (15, 33) —
LC
Steering wheel turning force
39 (4, 9) or less
(Measured at one full turn from the neutral position) N (kg, lb)

Fluid capacity (Approximate)  (Imp qt) 1.0 (7/8) EC

7,600 - 8,200 (76.0 - 82.0, 8,600 - 9,200 (876.9 -
QG13, 15 engines
77.5 - 83.6, 1,102 - 1,189) 917.7, 1,934 - 2,024)
Oil pump maximum pressure kPa (bar, kg/cm2, psi)
FE
QG16, 18 engines 8,600 - 9,200 (86.0 - 92.0, 87.7 - 93.8, 1,247 - 1,334)

YD22 engine 8,800 - 9,400 (88.0 - 94.0, 88.7 - 95.8, 1,261 - 1,362)
CL

MT

AT

AX

SU

BR

RS

BT

HA

SC

EL

IDX

ST-35
NOTES