SR-1

STEERING
Page
PRECAUTION SR-2
TROUBLESHOOTING SR-2
ON-VEHICLE INSPECTION SR-3
STEERING COLUMN SR-4
Non-Tilt Steering Column SR-6
Tilt Steering Column SR-9
MANUAL GEAR HOUSING SR-20
POWER STEERING SR-29
Description SR-29
On-Vehicle Inspection SR-33
Power Steering Pump SR-38
Gear Housing SR-62
STEERING LINKAGE (HEAVY DUTY) SR-72
STEERING LINKAGE (LIGHT DUTY) SR-76

SR


SR-2 S T E ERING - Precaution, Troubleshooting

PRECAUTION

Care must be taken to replace parts properly because

they may affect the performance of the steering system
and result in a driving hazard .

TROUBLESHOOTING

Possible cause Remedy Page

Problem
Tires improperly inflated Inflate tires to proper pressure A-15
Hard steering
Insufficient lubricant Lubricate suspension and
steering linkage

Excessive caster Check front wheel alignment SA-3

Steering system joints worn Replace steering system joints SR-72, 76

Steering column binding Inppect steering column SR-4

Steering gear out of adjustment or broken Adjust or repair steering gear SR-20, 62

Power steering belt loose Adjust belt SR-33

Fluid level in reservoir low Check reservoir SR-34

11 Power steering unit faulty Check power steering unit SR-38, 62

1 A-15
Poor return Tires improperly inflated Inflate tires to proper pressure

Insufficient lubricant Lubricate suspension

Wheel alignment incorrect Check front wheel alignment SA-3

Steering column binding Inspect steering column SR-4

Steering gear out of adjustment or broken Adjust or repair steering gear SR-20, 62

Excessive play Front wheel bearing worn Replace front wheel bearing SA-29

Main shaft yoke or intermediate shaft Replace main shaft or interme- SR-4
yoke worn diate shaft

Steering system joints worn Replace steering system joints SR-72, 76

Steering gear out of adjustment or broken Adjust or repair steering gear SR-20, 62

Steering linkage loose Tighten steering linkage SR-72, 7

Abnormal noise
Steering system joints worn Replace steering system joints SR-72, 7

Steering gear out of adjustment or broken Adjust or repair steering gear SR-20, 6


STEERING - On-Vehicle Inspection SR-3

ON-VEHICLE INSPECTION
STEERING WHEEL FREEPLAY
1. CHECK THAT STEERING WHEEL FREEPLAY IS COR-
RECT
With the vehicle stopped and pointed straight ahead,
rock the steering wheel gently back and forth with light
finger pressure . Freeplay should not exceed the maxi-
mum limit .
Maximum play : 40 mm (1 .58 in .)
If incorrect, adjust or repair as required .

2. POINT WHEELS STRAIGHT AHEAD

3. ADJUST STEERING GEAR HOUSING

(a) Loosen the lock nut .
(b) Turn the adjusting screw clockwise to decrease
wheel freeplay and counterclockwise to increase it .
HINT : Turn the adjusting screw in small increments and
check the wheel freeplay between each adjustment .

4. CHECK THAT STEERING DOES NOT BIND

Turn the steering wheel half way around in both direc-
tions .
Check that the freeplay is correct and steering is smooth
and without rough spots .

5. HOLD ADJUSTING SCREW AND TIGHTEN LOCK NUT

OIL LEVEL
CHECK STEERING GEAR HOUSING OIL LEVEL
Oil level : 12 - 20 mm (0 .47 - 0 .79 in .)
If low, fill with gear oil and check for leakage .


SR-4 STEERING - S teering Column

STEERING COLUMN
REMOVAL AND INSTALLATION OF STEERING
COLUMN
Remove and install the parts as shown .

Steering Wheel

Air Duct

kg-cm (ft-lb, N •m ) Specified torque

• Non-reusable part SR4

(MAIN POINT OF REMOVAL)

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

STEERING - Steering Column SR-5

2. DISCONNECT UNIVERSAL JOINT

(a) Place matchmarks on the intermediate shaft and the
universal joint .
(b) Disconnect the universal joint from the intermediate
shaft .


STEERING - Steering Column (Tilt Steering Column) SR-9

Tilt Steering Column

COMPONENTS

• Tapered-head Bolt
Column Tube Support

S nap Ring Damper Seal

Clamp
Bearing Block

+0-Ring

Column Hole
Cover
a
nap Ring S nap Ring
185 (13, 18)

•S nap Ring
Thrust Stopper
S nap Ring
Dust Seat
250 (18, 25)

Breakaway Bracket Tilt Pawl

kg-cm (ft-Ib, N •m ) Specified torque

• Non-reusable part
SR4165
* Precoated part S R 1008
SR-10 STEERING - Steering Column (Tilt Steering Column)

DISASSEMBLY OF STEERING COLUMN

(See page SR-9)
1. REMOVE TENSION SPRINGS AND CORDS
(a) Fully tilt the main shaft upward .
(b) Release the cord from the hook .
(c) Using a screwdriver, pry out the cord tip and remove
the spring and cord .

2. DISCONNECT INTERMEDIATE SHAFT FROM MAIN

SHAFT
(a) Place matchmarks on the intermediate shaft and uni •
versaljoint .
(b) Remove the bolt .

(c) Remove the snap ring .

(d) Pull out the intermediate shaft from the main shaft.

3. REMOVE COLUMN TUBE FROM BREAKAWAY

BRACKET
Remove the four bolts with a clamp . t

4. REMOVE IGNITION KEY CYLINDER

(a) Place the ignition key at the "ACC" position .
(b) Push down the stop key with a thin rod, and pull
the key cylinder .


STEERING - Steering Column (Tilt Steering Column) SR- 1 1

5. REMOVE UPPER BRACKET WITH MAIN SHAFT

FROM BREAKAWAY BRACKET
(a) Remove the support reinforcement with two bolts .
q(1
(b) Loosen the broken bolt by tapping the chisel .
(c) Remove the three bolts .
(d) Disconnect the upper bracket from the breakaway
bracket .
SO 6. REMOVE IGNITION SWITCH
SR0956

7 . REMOVE MAIN SHAFT FROM UPPER BRACKET

SST (a) Using SST, compress the main shaft and upper
bracket .

wuuuu-NUO" SST 09950-20017

I NOTICE : Do not tighten the SST too tightly .
VE (b) Using snap ring pliers, remove the snap ring .
(c) Loosen SST and remove the main shaft, spring and
collar from the upper bracket .
SR1034

8. DISASSEMBLE TILT STEERING SUPPORT AND

BREAKAWAY BRACKET
(a) Remove the tension spring .

SR0957

(b) Remove the two nuts and bolt .

(c) Remove the tilt lever retainer and collar .

-400
SR0958

(d) Remove the release pin .



SR-12 STEERING - Steering Column (Tilt Steering Column )

(e) Remove the tilt steering pawl .

(f) Remove the tilt pawl set bolt .

(g) Remove the nut and support stopper bolt with

clamp .
(h) Remove the tilt lever set nut .

(i) Temporarily install the nut flat with the end of

bolt and tap it with a hammer .
(j) Remove the nut . c
(k) Remove the collar and shim .
(I) Remove the another set bolt, nut and collar .


STEERING - Steering Column (Tilt Steering Column) SR-13

INSPECTION AND REPLACEMENT OF STEERING

COLUMN
1. IF NECESSARY, REPLACE BEARING IN UPPER
BRACKET
(a) Using SST and a hammer, remove the bearing .
SST 09620-30010 (09623-30010)

(b) Pack MP grease into the bearing .

(c) Using SST and a hammer, drive the bearing into the
bracket .
SST 09620-30010 (09624-30010, 09631-00020)
j

2. IF NECESSARY, REPLACE LOWER BEARING

(a) Using SST and a press, remove the lower bearing from
the main shaft .
SST 09527-20011
(b) Pack MP grease into the bearing .

(c) Using SST and a press, assemble the lower bearing

and main shaft .
SST 09236-00101 (09237-00010) and 09612-22011

3. IF NECESSARY, REPLACE INTERMEDIATE SHAFT

BEARING
(a) Using snap ring pliers, remove the snap ring .
(b) Pull out the bearing from the intermediate shaft .


SR-14 STEERING - Steering Column (Tilt Steering Column)

(c) Install the bearing .

(d) Using snap ring pliers, install the snap ring .

SH0959

4. IF NECESSARY, REPLACE SPIDER BEARING

(a) Using needle-nose pliers, remove the four snap rings .

(b) Using a 12-mm and 22-mm socket wrench and vise

press out the yoke side outer race .
(c) Clamp the outer race in a vise and tap off the yok
with a hammer .
HINT : Remove the other bearing races in the sam
procedure .
(d) Apply molybdenum disulphide lithium base greaset
the spider and bearings .
HINT : Be careful not to apply too much grease .

(e) Using a 12-mm socket wrench and vise, press t

bearing outer race .

(f) Using a 10-mm and 12-mm socket wrench, adj

both bearings so that the snap ring grooves are
maximum and equal widths .


STEERING - Steering Column (Tilt Steering Column) SR-15

(g) Select two snap rings of the same thickness, which

will allow 0 - 0 .05 mm (0 - 0 .0020 in .) of axial play .
HINT : Do not reuse the snap rings .

Snap ring thickness

Mark Thickness mm (in .)

None 1 .175 - 1 .225 (0 .0463 - 0 .0482)

Brown 1 .225 - 1 .275 (0 .0482 - 0 .0502)
SR0133
Blue 1 .275 - 1 .325 (0 .0502 - 0 .0522)

(h) Using needle-nose pliers, install the snap rings .

HINT : Install the bearing outer races in the yoke side
using the same procedure .

(i) Using a hammer, tap the shaft and yoke until the
clearance between the bearing outer race and snap
ring is zero .
(j) Check the spider bearing .
• Check that the spider bearing moves smoothly .
• Check the spider bearing axial play .
Bearing axial play : 0 .05 mm (0 .0020 in .) or less


SR-16 STEERING - Steering Column (Tilt Steering Column)

ASSEMBLY OF STEERING COLUMN

(See page SR-6)
1. COAT ALL RUBBING PARTS WITH MP GREASE

2. ASSEMBLE PAWL SET BOLT

Torque : 185 kg-cm (13 ft-lb, 18 N .m)

3. ASSEMBLE TILT LEVER TO SUPPORT

(a) Select a collar No . 1 which will eliminate play .

17 .989 - 17 .996 (0 .7082 - 0.7085)

17 .996 - 18 .003 (0 .7085 - 0 .7088)
18 .003 - 18 .010 (0 .7088 - 0 .7091)
18 .010 - 18 .017 (0.7091 - 0.7093)
18 .017 - 18 .024 (0 .7093 - 0 .7096)

I (b) Install tilt lever and collar No . 1 to the support .

(c) Select a collar No . 2 which will eliminate all play .

17 .982 - 18 .000 (0 .7080 - 0 .7087)

18 .000 - 18 .018 (0 .7087 - 0 .7094)

(d) Install collar No . 2 to the support .

(e) Drive in the serration bolt to the support .

(f) Install the tilt pawl .



STEERING - Steering Column (Tilt Steering Column) SR-17

(g) Install the tension spring and the release pin .

(h) Assemble the collar and tilt lever retainer .

Torque : 185 kg-cm (13 ft-Ib, 18 N .m)

4. INSTALL SHIM, BOLT AND NUT

(a) Select a shim which fits snugly when pressed in by
hand .

Mark Thickness mm (in .)

None 0.197 - 0 .203 (0.0078 - 0 .0080)
5 0 .495 - 0 .505 (0.0195 - 0 .0199)
8 0 .795 - 0.805 (0.0313 - 0 .0317)
14 1 .395 - 1 .405 (0.0549 - 0 .0553)
18 1 .795 - 1 .805 (0.0707 - 0 .0711)

(b) Install the shim, bolt, washer and a lock nut .

Torque : 185 kg-cm (13 ft-Ib, 18 N .m)

5. INSTALL TILT STEERING SUPPORT STOPPER

BOLT
(a) Install the stopper bolt, bracket, washer and nut .

(b) Tighten the nut by holding the bracket as shown .

Torque : 100 kg-cm (7 ft-lb, 10 N .m)


SR-18 STEERING - Steering Column (Tilt Steering Column)

6. ASSEMBLE MAIN SHAFT AND UPPER BRACKET

SST (a) Assemble the collar, spring and main shaft, and insert
.jr,
~ ∎rlunu(MM(IW1lplQ/fo r
105 (b)
them into the bracket .
Using SST and snap ring pliers, install the snap ring
W~q by compressing the main shaft and upper bearing .
NOWEft SST 09950-20017
NOTICE : Do not tighten the SST more than necessary .
6
SR1034

7. ASSEMBLE UPPER BRACKET AND SUPPORT

(a) Apply sealant to one or two threads of the bolt end .
Sealant : Part No . 08833-00070, Three bond 1324
equivalent
HINT : This adhesive will not harden while exposed t
air . It will act as a sealer or binding agent only when a
plied to threads, etc . and the air is cut off.
(b) Install the two bolts ; one with a wiring clamp .
Torque : 75 kg-cm (65 in .-Ib, 7 .4 N .m)

(c) Install the break down bolt and tighten until th

bolt head breaks off .
(d) Install the support reinforcement .

8. INSTALL BREAKAWAY BRACKET TO COLUMN

TUBE
Torque : 185 kg-cm (13 kg-cm, 18 N .m)

9. INSTALL COLUMN HOLE COVER TO COLUMN

TUBE
Install the following parts on the column .
• Hole cover plate
• New 0-ring
• Column hole cover
10 . CONNECT MAIN SHAFT AND INTERMEDIATE
SHAFT
(a) Align the marks on the joint yoke and intermediate
shaft and tighten the bolt .
Torque : 250 kg-cm (18 ft-lb, 25 N .m)
HINT : Be careful not to push out the damper seal while
installing the intermediate shaft .

(b) Install the snap ring .

11 . INSTALL TWO SPRINGS AND TWO CORDS

(a) Connect the tension spring and cord, and hook the
spring to the hanger .
(b) Pry the spring end and hook the cord end to the
support .
(c) Hook the cord to the cord guides .

12 . CHECK OPERATION OF TILT STEERING LEVER

AND SUPPORT
(a) Check that there is no axial or horizontal play at the
end of the main shaft .
(b) Check that the main shaft locks securely in all six
positions .

13 . INSTALL IGNITION SWITCH

(a) Turn the ignition key plate to the "ACC" position
and install the key cylinder into the upper bracket .
(b) Install the ignition switch .
SR-34 STEERING - Power Steering (On-Vehicle Inspection)

FLUID LEVEL CHECK

1. KEEP VEHICLE LEVEL

2. BOOST FLUID TEMPERATURE

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

3. CHECK FOR FOAMING OR EMULSIFICATION

HINT : Foaming and emulsification indicate either th
existence of air in the system or that the fluid level is to
low .

4. CHECK FLUID LEVEL IN RESERVOIR

Check the fluid level and add fluid if necessary .
Fluid : ATF DEXRON ® II
HINT : Check that the fluid level is within the H
LEVEL of the dipstick . If the fluid is cold, check that it
within the COLD LEVEL of the dipstick .

REPLACEMENT OF POWER STEERING FLUID

1. JACK UP FRONT OF VEHICLE AND SUPPORT IT WI
l1 STANDS
i
AIMN

SR0357

2. REMOVE FLUID RETURN HOSE FROM RESERVOIR T

AND DRAIN FLUID INTO CONTAINER


STEERING - Power Steering (On-Vehicle Inspection) SR-35

3. TURN STEERING WHEEL FROM LOCK TO LOCK WHILE

DRAINING FLUID

rpm

SR1096

4. FILL RESERVOIR TANK WITH FRESH FLUID

Fluid : ATF DEXRONe II

ti 10

W
'~e'i -
B1306

5. START ENGINE AND RUN IT AT 1,000 RPM

After 1 or 2 seconds, fluid will begin to discharge from
the return hose . Stop the engine immediately at this time .
NOTICE : Take care that some fluid remains left in the
reservoir tank .

6. REPEAT STEPS 4 AND 5 FOUR OR FIVE TIMES UNTIL

THERE IS NO MORE AIR IN FLUID

7. CONNECT RETURN HOSE TO RESERVOIR TANK

8. BLEED POWER STEERING SYSTEM

BLEEDING OF POWER STEERING SYSTEM

1. CHECK FLUID LEVEL IN RESERVOIR TANK
Check the fluid level and add fluid if necessary .
Fluid : ATF DEXRONe II
HINT : Check that the fluid level is within the HOT
LEVEL of the dipstick . If the fluid is cold, check that it is
within the COLD LEVEL of the dipstick .

2. START ENGINE AND TURN STEERING WHEEL FROM

LOCK TO LOCK THREE OR FOUR TIMES
With the engine speed below 1,000 rpm, turn the steer-
ing wheel to left or right full lock and keep it there for 2 -
3 seconds, then turn the wheel to the reverse full lock
and keep it there for 2 - 3 seconds .


SR-36 STEERING - Power Steering (On-Vehicle Inspection)

3. CHECK THAT FLUID IN RESERVOIR IS NOT FOAMY OR

CLOUDY AND DOES NOT RISE OVER MAXIMUM WHEN
ENGINE IS STOPPED
Measure the fluid level with the engine running . Stop the
engine and measure the fluid level .
Maximum rise : 5 mm (0 .20 in .)
If a problem is found, repeat steps 4 and 5 on page SR1
35 .
Repair the PS if the problem persists .

OIL PRESSURE CHECK

1. CONNECT PRESSURE GAUGE
(a) Using SST, disconnect the pressure line joint .
SST 09631-22020

(b) Connect the gauge side of the pressure gauge to t

PS pump side and the valve side to the pressure I'
side .
(c) Bleed the system . Start the engine and turn t
steering wheel from lock to lock two or three time
(d) Check that the fluid level is correct .

2. CHECK THAT FLUID TEMPERATURE IS AT LEAST 80

(176°F)

3. START ENGINE AND RUN IT AT IDLE

4. CHECK FLUID PRESSURE READING WITH VA

CLOSED
Close the pressure gauge valve and observe the rea
on the gauge .
Minimum pressure : FJ Series
80 kg/cm 2 (1,138 psi, 7,845
HZJ and PZJ Series
85 kg/cm 2 (1,209 psi, 8,336
LJ and RJ Series
75 kg/cm 2 (1,067 psi, 7,355
NOTICE :
• Do not keep the valve closed for more than 10
onds .
• Do not let the fluid temperature become too high
If pressure is low, repair or replace the PS pump .


STEERING - Power Steering (On-Vehicle Inspection) SR-37

5. OPEN VALVE FULLY

6. CHECK AND RECORD PRESSURE READING AT 1,000

RPM

7. CHECK AND RECORD PRESSURE READING AT 3,000

RPM
Check that there is 5 kg/cm 2 (71 psi, 490 kPa) or less dif-
ference in pressure between the 1,000 rpm and 3,000
rpm checks .
If the difference is excessive, repair or replace the flow
control valve of the PS pump .

8 . CHECK PRESSURE READING WITH STEERING WHEEL

TURNED TO FULL LOCK
Be sure the pressure gauge valve is fully opened and the
engine idling .
Minimum pressure : FJ Series
80 kg/cm 2 (1,138 psi, 7,845 kPa)
HZJ and PZJ Series
85 kg/cm 2 (1,209 psi, 8,336 kPa)
LJ and RJ Series
75 kg/cm 2 (1,067 psi, 7,355 kPa)
NOTICE :
• Do not maintain lock position for more than 10 sec-
onds .
• Do not let the fluid temperature become too high .
If pressure is low, the gear housing has an internal leak
and must be repaired or replaced .

9. MEASURE STEERING EFFORT

(a) Center the steering wheel and run the engine at idle .
(b) Using a spring scale, measure the steering effort in
both directions .
Maximum steering effort : 4 kg (8 .8 lb, 39 N)
If steering effort is excessive, repair the power steering
unit .
HINT : Be sure to consider tire type, pressure and con-
tact surface before making your diagnosis .


SR-38 STEERING - Power Steering (Power Steering Pump)

Power Steering Pump

REMOVAL AND INSTALLATION OF POWER
STEERING PUMP
Remove and install the parts as shown .

FJ Series r
i
1
Return Hose

1I(ll((~
~

450 (33, 44)

-370(27,36)

450 (33, 44)

SR3'

HZJ and PZJ Series

80 (69 in .-lb, 7 .8)

kg-cm (ft-lb, N •m )


STEERING - Power Steering (Power Steering Pump) SR-39

J and RJ Series

Union Bolt

Low

kg-cm (ft-lb, N •m ) Specified torque

• Non-reusable part SR4145

(MAIN POINT OF REMOVAL AND

INSTALLATION)
1. (FJ Series)
DISCONNECT AND CONNECT PRESSURE TUBE
Using SST, disconnect and connect the pressure tube
from/to the PS pump .
SST 09631-22020
Torque : 370 kg-cm (27 ft-lb, 36 N •m )
HINT : Use a torque wrench with a fulcrum length of
300mm (11 .81 in .) .

2. (Ex . HZJ and PZJ Series)

LOOSEN PULLEY NUT
Push on the drive belt with your hand to hold the pulley in
place and loosen the pulley nut .

3. (Ex . HZJ and PZJ Series)

ADJUST DRIVE BELT TENSION AFTER INSTALLING PS
PUMP
(See page SR-33)


SR-54 STEERING - Power Steering ( Power St e ering Pump)

COMPONENTS (LJ and RJ series)

Pressure Port Union,

700 (51, 69)

r0*4

Straight Pin

M1lllllllh

470 (34, 46)

Ikg-cm (ft-lb, N •m ) : Specified torque

• Non-reusable part SR4

DISASSEMBLY OF POWER STEERING PUMP

1. CLAMP PS PUMP IN VISE
NOTICE : Do not tighten the vise too tight .


STEERING - Power Steering (Power Steering Pump) SR-55

2. REMOVE SUCTION PORT UNION

(a) Remove the bolt and union .
(b) Remove the 0-ring from the union .

3. REMOVE FOUR FRONT HOUSING BOLTS

4. REMOVE FRONT HOUSING

(a) Place matchmarks on the front and rear housing .
(b) Using a plastic hammer, tap off the front housing .
NOTICE : Be careful that the vane plates, rotor and cam
ring do not fall out .

5. REMOVE CAM RING, ROTOR AND VANE PLATES

NOTICE : Be careful not to scratch the cam ring, rotor or
vane plates .

6. REMOVE ROTOR SHAFT

(a) Clamp the front housing in a vise .
NOTICE : Do not tighten the vise too tight .
(b) Using a chisel and hammer, pry off the oil seal .
(c) Using snap ring pliers, remove the snap ring .
SR-56 STEERING - Power Steering (Power Steering Pump)

(d) Using a plastic hammer, lightly tap the rotor shaft

out of the front housing .

7. REMOVE REAR PLATE AND SPRING

Using a plastic hammer, tap the bottom end of the rear
housing, and remove the rear plate and spring .

8. REMOVE PRESSURE PORT UNION

(a) Remove the pressure port union .
(b) Remove the 0-rings from the union and housing .

(c) Remove the flow control valve and spring .

NOTICE : Use care not to drop, scratch or nick t
valve .

9. REMOVE FLOW CONTROL SPRING SEAT

(a) Temporarily install a bolt to the spring seat .
(b) Push the bolt and remove the snap ring with s
ring pliers .


STEERING - Power Steering (Power Steering Pump) SR-57

(c) Pull out the bolt and remove the spring seat .
(d) Remove the O-ring from the spring seat .

SR2998

INSPECTION OF POWER STEERING PUMP

1. INSPECT BUSHING AND MEASURE BUSHING OIL
∎
Oft CLEARANCE
o,n-\ (a) Check the bushing for wear or damage . The bushing
cannot be replaced separately .
If wear or damage is found, replace entire housing .
(b) Check the oil clearance between the bushing and ro-
tor shaft .
SR0206 SR0207 Maximum oil clearance : 0 .07 mm (0 .0028 in .)

2. IF NECESSARY, REPLACE ROTOR SHAFT BEARING

J (a) Using snap ring pliers, remove the snap ring .
(b) Using a press, press out the bearing .
(c) Using a press, press in a new bearing .
(d) Using snap ring pliers, install the snap ring .

SR0208 SR0209

3. INSPECT ROTOR AND CAM RING

Measure the cam ring thickness . Check that the differ-
ence between the rotor and cam ring measurement is
less than maximum .
Maximum difference : 0 .06 mm (0 .0024 in .)
If the difference is excessive, replace the cam ring with
one having the same letter as on the rotor .

SR0362 SR0210
4. INSPECT AND MEASURE VANE PLATES
(a) Check the vane plates for wear or scratches .
/ i Length
(b) Measure the length, height and thickness of the
vane plates .
Minimum length : 14 .97 mm (0 .5894 in .)
Minimum height : 7 .8 mm (0 .307 in .)
Minimum thickness : 1 .7 mm (0 .067 in .)
(c) Measure the clearance between the vane plate and
rotor groove .
Height
Z5090 Z5089 Maximum clearance : 0 .06 mm (0 .0024 in .)


SR-58 STEERING - Power Steering (Power Steering Pump)

HINT : There are five vane lengths with the following ro-
tor and cam ring numbers :

Rotor and cam

Vane length mm (in .)
ring number
None 14 .996 - 14 .998 (0 .5904 - 0 .5905)
1 14 .994 - 14 .996 (0 .5903 - 0 .5904)
2 14 .992 - 14 .994 (0 .5902 - 0 .5903)
3 14 .990 - 14 .992 (0 .59016 - 0 .59024)
4 14 .988 - 14 .990 (0 .5901 - 0 .5902)

5. INSPECT FLOW CONTROL VALVE

(a) Check the flow control valve for wear or damage .
(b) Apply fluid to the valve and check that if falls
smoothly into the valve hole by its own weight .
(c) Check the flow control valve for leakage . Close one
of the holes and apply compressed air [4 or 5
kg/cm 2 (57 or 71 psi, 392 or 490 kPa)] into the op-
posite side, and confirm that air does not come out
from the end hole .
If necessary, replace the valve with one having the same
letter as inscribed on the rear housing .

6. INSPECT FLOW CONTROL VALVE SPRING

Check that the spring is within specification .
Spring length : 47 - 50 mm (1 .85 - 1 .97 in .)
10, If the spring is not within specification, replace it .
L 19 I

SR0044


STEERING - Power Steering (Power Steering Pump) SR-59

ASSEMBLY OF POWER STEERING PUMP

(See page SR-54)

1. INSTALL FLOW CONTROL SPRING SEAT

(a) Install a new 0-ring to the spring seat .

(b) Insert the spring seat to the housing .

(c) Using snap ring pliers, install the snap ring .

2. INSTALL FLOW CONTROL VALVE AND SPRING

(a) Install new 0-ring to the housing .
(b) Insert the spring and valve to the housing .
HINT : Be sure the letter inscribed on the flow control
valve matches the letter stamped on the rear of the pump
body .
Inscribed mark : A, B, C, D, E or F

3. INSTALL PRESSURE PORT UNION

(a) Install a new 0-ring to the pressure port union .
(b) Install and torque the union .
Torque : 700 kg-cm (51 ft-lb, 69 N •m )

4. INSTALL ROTOR SHAFT TO FRONT HOUSING

Install the rotor shaft into the front housing by tapping it
in with a plastic hammer .

5. INSTALL SNAP RING

Using snap ring pliers, install the snap ring to the front
housing .
SR-60 STEERING - Power Steering (Power Steering Pump)

6. INSTALL OIL SEAL

(a) Apply a light coat of MP grease to the oil seal lip .
(b) Using SST and hammer, install the oil seal .
SST 09608-30012 (09608-04030)

7. INSTALL NEW O-RING

8. INSTALL CAM RING

Align the fluid passages of the cam ring and front hous-
ing, and install the cam ring .

9. INSTALL ROTOR
Install the rotor with the chamfered end facing towar
the front .
HINT : Be sure the letters inscribed on the cam ring an
rotor match .
Inscribed mark : 1, 2, 3, 4, or None

10 . INSTALL VANE PLATES

Install the vane plates with the round end facing ou
ward .

11 . INSTALL REAR PLATE AND SPRING

(a) Align the fluid passages of the rear plate and ca
ring, and install the rear plate .

STEERING - Power Steering (Power Steering Pump) SR-61

(b) Place the spring on the rear plate .

12 . INSTALL REAR HOUSING

(a) Align the matchmarks on the front and rear housing
and assemble them .
(b) Tighten the front and rear housing mount bolts by
hand .

13 . TIGHTEN FOUR HOUSING BOLTS

(a) Clamp the rear housing in a vise .
NOTICE : Do not tighten the vise too tight .
(b) Tighten the four housing bolts evenly in 3 or 4
passes .
Torque : 470 kg-cm (34 ft-lb, 46 N •m )

14 . INSTALL SUCTION PORT UNION

Insert and tighten the union .
Torque : 130 kg-cm (9 ft-lb, 13 N •m )

15 . CHECK ROTOR SHAFT ROTATION CONDITION

(a) Check that the rotor shaft rotates smoothly without
abnormal noise .
(b) Provisionally install the pulley nut and check the ro-
tation torque .
Rotation torque : 2 .8 kg-cm (2 .4 in .-Ib, 0 .3 N •m ) or less

SR3039
 STEERING - Power Steering (Gear Housing)

Gear Housing
REMOVAL AND INSTALLATION OF GEAR
HOUSING
Remove and install the parts as shown .

Pressure and Return Line

450(33,44)
360 (26, 35)

Gear Housing

Joint Protector

1,450 (105,142)

to

Pitman Arm with Relay Rod

(Heavy Duty)

(Light Duty) 1,800 (130, 177)

kg-cm (ft-lb, N •m ) : Specified torque SR41

(MAIN POINTS OF REMOVAL AND

INSTALLATION)
1. DISCONNECT PITMAN ARM
(a) Loosen the pitman arm nut .
(b) Using SST, disconnect the pitman arm from the
for shaft .
SST 09628-62011
(c) Remove the nut, the spring washer and the arm


STEERING - Power Steering (Gear Housing) SR-63

(d) When connecting the pitman arm, align alignment

marks on the pitman arm and the sector shaft, and
install the spring washer and nut .
Torque : 1,800 kg-cm (130 ft-lb, 177 N •m )

2. DISCONNECT UNIVERSAL JOINT FROM GEAR

HOUSING
(a) Place matchmarks on the universal joint and the
worm shaft .
(b) Loosen the universal joint upper bolt .
(c) Remove the universal joint lower bolt .
(d) Slide the joint backward to disconnect the joint from
the worm shaft .


SR-64 STEERING - Power Steering (Gear Housing)

COMPONENTS

470 (34, 46)

k 470 (34, 46) J

• Washer t

End Cover

• O-Ring

470 (34, 46)

• O-Ring V
• Teflon Ring
Spacer
Snap Ring
• Oil Seal

kg-cm (ft-lb, N-m) Specified torque

• Non-reusable part


STEERING - Power Steering (Gear Housing) SR-65

DISASSEMBLY OF GEAR HOUSING

(See page SR-64)

1. MOUNT HOUSING ON STAND

Mount the gear housing on SST and clamp SST in a vise .
SST 09630-00012 (09631-00140)

2. REMOVE END COVER

(a) Remove the adjusting screw lock nut .
(b) Remove the four bolts .
(c) Screw in the adjusting screw until the cover comes
off .

3. REMOVE CROSS SHAFT

Using a plastic hammer, tap on the cross shaft end and
pull out the shaft .

4. REMOVE PLUNGER GUIDE NUT

(a) Using SST, remove the plunger guide nut .
SST 09043-38100
(b) Remove the spring, plunger and plunger guide .
(c) Remove the 0-ring .

5. REMOVE WORM GEAR VALVE BODY ASSEMBLY

(a) Remove the four cap bolts from the housing .
(b) Using SST, turn the shaft clockwise to disconnect
the worm gear valve body assembly from gear hous-
ing .
SST 09616-00010
SR-66 STEERING - Power Steering (Gear Housing)

(c) Hold the power piston nut with your thumb so it

cannot move, then withdraw the valve body and
power piston assembly .
NOTICE : Ensure that the power piston nut does not
come off the worm shaft .
(d) Remove the 0-ring .

STEERING - Power Steering (Gear Housing) SR-67

INSPECTION AND REPLACEMENT OF GEAR

HOUSING
1. CHECK BALL CLEARANCE
(a) Mount the valve body in a vise .
(b) Using a dial indicator, check the ball clearance .
Move the worm gear up and down .
Maximum ball clearance : 0 .15 mm (0 .0059 in . )
If clearance is excessive, the power control valve assem-
bly must be replaced .

2. INSPECT CROSS SHAFT ADJUSTING SCREW THRUST

CLEARANCE
(a) Clamp the cross shaft in a vise .
(b) Using a dial indicator, measure the thrust clearance .
Thrust clearance : 0 .03 - 0 .05 mm
(0 .0012 - 0 .0020 in .)
If thrust clearance is not correct, adjust the thrust clear-
ance .

3. IF NECESSARY, ADJUST THRUST CLEARANCE

(a) Using a chisel and hammer, remove the lock nut
stake .

(b) Using SST, remove the lock nut .

SST 09630-00012 (09631-00050)
(c) Adjust the adjusting screw for correct thrust clear-
ance and tighten a new lock nut .
(d) Stake the lock nut .

4. IF NECESSARY, REPLACE NEEDLE ROLLER BEARING

(a) Using a screwdriver, pry out the oil seal .
(b) Using snap ring pliers, remove the snap ring .
(c) Remove the metal spacer, teflon ring and 0-ring .


SR-68 STEERING - Power Steering (Gear Housing)

(d) Using SST, press out the upper bearing .

SST 09630-00012 (09631-00020, 09631-00070)
(e) Using SST, press out the lower bearing .
SST 09630-00012 (09631-00020, 09631-00090)

(f) Using SST, press in a new lower bearing .

SST 09630-00012 (09631-00020, 09631-00090)
HINT : Install the lower bearing so that it is positionec
23 .1 mm (0 .909 in .) away from the housing inner en(
surface .

(g) Using SST, press in a new upper bearing .

SST 09630-00012 (09631-00020, 09631-00090)
HINT : The bearing's top end should be installed so th
it aligns with the housing end surface .
(h) Install a new 0-ring and metal spacer .

(i) Using snap ring pliers, install the snap ring .

G

(j) Form a new teflon ring into a heart shapeand in

it with hand .
(k) Using SST, form the teflon ring .
NOTICE : The teflon ring must be squeezed befor
serting the sector shaft or damage will result .
SST 09630-00012 (09631-00120)
I


STEERING - Power Steering (Gear Housing) SR-69

(I) Using SST, drive a new oil seal into the gear hous-
ing
SST 09630-00012 (09631-00020, 09631-00090)

5. IF NECESSARY, REPLACE CONTROL VALVE TEFLON

RING
(a) Using a screwdriver, remove the teflon ring and 0-
ring .
NOTICE : Be careful not to damage the control valve .
(b) Install a new 0-ring .
(c) Expand a new teflon ring with your fingers .
NOTICE : Be careful not to over-expand the teflon ring .
(d) Install a new teflon ring .

(e) Coat the teflon ring with power steering fluid and
snug it down with piston ring compressor for 5 - 7
minutes .

6. IF NECESSARY, REPLACE UNION SEAT

(a) Using a screw extractor, remove the union seat .

(b) Using a plastic hammer and extension bar, tap in a

new union seat .
SR-70 STEERING - Power Steering (Gear Housing)

ASSEMBLY OF GEAR HOUSING

(See page SR-64)

1. INSTALL WORM GEAR VALVE BODY ASSEMBLY

(a) Install the three 0-rings to the gear housing and
valve body .
(b) Mount the gear housing on SST and clamp SST in
vise .
SST 09630-00012 (09631-00140)
(c) Insert the worm gear valve body assembly to the
gear housing as shown .
(d) Install and torque the four bolts .
Torque : 470 kg-cm (34 ft-lb, 46 N •m )
NOTICE : Be careful not to damage the teflon ring .

(e) Using SST, check the worm gear preload .

SST 09616-00010
Preload : (at starting)
3 - 5 .5 kg-cm (2 .6 - 4 .8 in .-lb, 0 .3 - 0 .5 N •m )
HINT : Hold the power piston nut to prevent it from turn
ing .
If preload is not correct, replace the worm gear assemb

2. INSTALL PLUNGER GUIDE NUT

(a) Install the plunger, plunger guide and spring .
(b) Install a new 0-ring to the plunger guide nut and
stall the plunger guide nut with SST .
SST 09043-38100
Torque : 205 kg-cm (15 ft-lb, 20 N •m )

3. INSTALL CROSS SHAFT AND END COVER

(a) Install a new 0-ring on the end cover .
(b) Using a screwdriver, assemble the cross shaft to
end cover .
HINT : Fully loosen the adjusting screw .


STEERING - Power Steering (Gear Housing) SR-71

(c) Set the worm gear at the center of the gear housing .
(d) Insert and push the cross shaft into the gear housing
so that the center teeth mesh together .

(e) Install the four cap bolts . Torque the bolts in a diag-
onal pattern .
Torque : 470 kg-cm (34 ft-lb, 46 N •m )

4. DETERMINE CENTER POSITION OF GEAR HOUSING

(a) Using SST, turn the worm shaft so full lock in both
directions and determine the exact center .
SST 09616-00010
(b) Place matchmarks on the worm shaft and housing
to show neutral position .

5. ADJUST CROSS SHAFT ADJUSTING SCREW

(a) Install SST with a torque meter on the worm shaft .
SST 09616-00010
(b) Turn the adjusting screw while measuring the pre-
loaduntilit is correct .
Total preload : (at starting)
7 .5 - 11 kg-cm (6 .5 - 9 .6 in .-Ib, 0 .74 - 9 .6 N •m )

6. INSTALL NEW WASHER

7. INSTALL AND TIGHTEN LOCK NUT

Torque the lock nut while holding the adjusting screw .
Torque : 470 kg-cm (34 ft-lb, 46 N •m )

8. CHECK TOTAL PRELOAD



SR-76 STEERING - Steering Linkage (Light Duty)

STEERING LINKAGE (LIGHT DUTY)

REMOVAL AND INSTALLATION OF STEERING
LINKAGE
Remove and install the parts as shown .

Steering Damper

925 (67, 91)

I
450 (33, 44)

750(54,74)

(l .

kg-cm (ft-lb, N • m) Specified torque

• Non-reusable part SR415

HINT :
• When connecting the ball stud to the arm or rod,
move the grease on the joint surfaces .
• After torquing the ball stud nut to specified torque, a
vance the nut just enough to insert the cotter pin .
• After installing any of the steering linkage corn
nents, check the front wheel alignment and side sl
(See page SA-3)


STEERING - Steering Linkage (Light Duty) SR-77

(MAIN POINTS OF REMOVAL AND

INSTALLATION)
1. DISCONNECT AND CONNECT PITMAN ARM FROM/TO
SECTOR SHAFT
(a) Loosen the pitman arm nut .
(b) Using SST, disconnect pitman arm from sector
shaft .
SST 09628-62011

(c) When connecting, align alignment marks on the pit-

Alignment Marks man arm and the sector shaft, and install the spring
washer and nut .

SR2922

2. DISCONNECT PITMAN ARM FROM RELAY ROD

(a) Remove the cotter pin and nut .
HINT : Before removing the arm, temporarily install the
pitman arm nut .
(b) Using SST, disconnect the pitman arm from relay
rod .
SST 0961 1-22012

3. DISCONNECT RELAY ROD FROM KNUCKLE ARM

(a) Remove the cotter pin and nut .
(b) Using SST, disconnect the relay rod from knuckle
arm .
SST 09611-12010

4. DISCONNECT STEERING DAMPER FROM TIE ROD

(a) Remove the nut .
(b) Using SST, disconnect steering damper from tie rod .
SST 09611-12010
STEERING - Steering Linkage (Light Duty)

5. DISCONNECT STEERING DAMPER FROM HINGE

(a) Clamp the hinge in a vise .
(b)Using SST, disconnect the damper from hinge .
SST 0961 1-22012

6. DISCONNECT TIE ROD FROM KNUCKLE ARM

(a) Remove the cotter pin and nut .
(b) Using SST, disconnect the tie rod from knuckle arm .
SST 0961 1-22012

7. IF NECESSARY, ADJUST TIE ROD LENGTH

(a) Loosen the tie rod end clamp .
(b) Turn the tie rod ends equal amounts into the tie rod
tube . Tie rods should be approximately 1,207 mm
(47 .51 in .) .

(c) Temporarily tighten the tie rod end clamp .

8. IF NECESSARY, ADJUST RELAY ROD LENGTH

(a) Loosen the relay rod end clamp .
(b) Turn the relay rod ends equal amounts into the rel
rod tube . Relay rods should be approximately 1,20
mm (47 .51 in .) .
(c) Temporarily tighten the relay rod end clamp .