Steering System GENERAL MECHANICAL POWER STEERING SYSTEM ‘SPECIFICATIONS... sre POWER STEERING GEAR BOX LUBRICANTS. ve STB ‘COMPONENTS sT-18 SPECIAL TOOL! ST -4 REMOVAL -sornsnon senna ST #20 TROUBLESHOOTING st-7 INSPECTION snennenrnan ST 22. GENERAL “STB DISASSEMBLY... ST -23 INSPECTION .sovcsorsnsnsnsninanninannnes ST-27 STEERING COLUMN AND SHAFT REASSEMBLY era, ‘STEERING COLUMN / SHAFT INSTALLATION ve STS COMPONENTS sone ST-13 POWER STEERING HOSES. REMOVAL. sT-14 COMPONENTS som ST 82 INSPECTION ..-. ert REMOVAL 7 ST-33 DISASSEMBLY won non sone STAB INSTALLATION vrcsonsnsnsssnnnsansnnssnane ST “35: INSTALLATION vocsnsnonnsnsnnsnsnnnen STAT POWER STEERING Oll PUMP ‘COMPONENTS : sT-37 REMOVAL... ST 38 DISASSEMBLY vosscssnsnnsnsngsennnns ST ~39 INSPECTION wren ST 44 REASSEMBLY wrcscscncnonnennnnsnene ST-A4 INSTALLATION ST -43ST STEERING SYSTEM GENERAL SPECIFICATIONS | esos: tems. Specifications ‘Shaft and joint type Steering gear type Rack stroke Power steering pump type il pump displacement 2.0(I4), 2.0(D-ENG) 2.7(V8) Cross joint, tit column with pop-up weight Rack and pinion 4140 « 1 mm (lock to lock : 3.06 turns) Vane type 9.6ocirev, MAX. (0.59 in*/rev. MAX.) 10.5cc/rev. MAX. (0.64 ins/rev. MAX.) SERVICE STANDARD Items Specifications Steering wheel free play Steering angle Inner wheel Outer wheel Difference between LH and RH Stationary steering effort Bolt deflection [under 98N (10kg, 221b) force] New bett Use batt Oil pump reliot pressure 2.0 (14), 2.7 (V8) 2.0 (D-ENG) Total pinion preload Tie rod swing resistance 0-30mm (0-1.1 in.) 38°1" = 1°30" 32°5" 2° oF less 29N (3.0kg, 6.5Ibs) or less 8.8-11.0mm 12.5~14.3mm, 8.6-9.1 MPa (88-93 kg/cm?, 1251~1322 psi) 9.1~9.6 MPa (93~98 kg/cm?, 1322~1393 ps!) 0.6-1.3 Nm (6-19 kg.om, §.2-11.9 Ib.in.) 2-5 Nm (20-50 kg.cm, 1.4~3.6 Ib.) TIGHTENING TORQUE tem Nm kgrem Ibet Power steering column and shaft Steering column and shaft mounting bolt 13 ~18 130 ~ 180 96 ~ 13.8 Power steering wheel lock nut 40 ~ 50 400 ~ 500 28.9 ~ 37 Pinion gear and joint assembly 15 ~ 20 150 ~ 200 10.8 ~ 148 Steering column shaft and universal joint assembly 15 ~ 20 150 ~ 200 108 ~ 14.8 Dust cover mounting bolt 4-6 40 ~ 60 30-40 Power steering gear box Gear box mounting bolt 60 - 80 600 ~ 800 44 - 59 Tie rod end ball joint and knuckle arm mounting nut 45 ~ 60 ‘450 ~ 600 92.5 ~ 43.4 Feed tube to gear box 10 ~ 16 100 ~ 160 74 ~ 11.8 Gear box to valve body 20 ~ 30 200 ~ 300 14.8 ~ 21.7 ‘Yoke plug lock nut 50 ~ 70 500 ~ 700 37 ~ 50GENERAL ST tem Nm kgem Ib-ft Power steering oil pump Pressure hose to oil pump 65 ~ 75 650 ~ 750 479 ~ 54.2 il pump adjusting bott 35 ~ 50 ‘350 ~ 500 25.3 - 37 il pump mounting bolt 2.0 (D-ENG) 17 ~ 26 170 ~ 260 12.3 ~ 18.8 2.0 (Ia), 2.7 (V6) 35 ~ 50 350 ~ 500 25.8 ~ 37 Oil pump bracket mounting bolt 35 ~ 50 350 ~ 500 25.8 ~ 37 Power steering hose Power steering reservoir mounting bolt 17 ~ 26 170 ~ 260 12.3 ~ 188 Power steering hose mounting bolt 4-6 40 ~ 60 3.0 ~ 4.0 Power steering tube mounting bolt 4-6 40 ~ 60 3.0 ~ 4.0 LUBRICANTS | cuezooe Tem Recommended abieant Guentiy Hom coat ing of stoning wheal GeTORLarS hs rauted Bearing of eaing sat AANA HOR AD fs vequited Balint of od on SHOWA SUNLIGHT | As reed Sienng gear housing ONELUBER RP GREASE pa vein Ine alin of gsr bor LONG THE PE as vouiod Cant ara gerboxbalons ated | SLCON GREASE fs recute Foner tenn i bars eee hesT-4 SPECIAL TOOLS | xci010s STEERING SYSTEM Tool (Number and name) lustration Use 09222-82100 Valve stom oil seal installer Installing the pinion gear bearing (09432-21600 Bearing installer Installing the pinion gear bearing (09434-14200 Counter shaft bearing installer Installing the gear box oil seal. (09861-11002 Removing the steering wheel. Steering wheel puller (09565-11100 Measuring the mainshalt preload. Preload socket O&O (08555-21000 Bar Removing & installing the oil seal.GENERAL Tool (Number and name) Illustration Use Oil pressure gauge (09568-34000 ‘Separating the tie rod end ball joint Ball joint puller i (09572-21000 Measuring the power steering oll pressure (use with 09572-21200, 09572-22100) (09572-21200 ll pressure gauge adapter ‘Measuring the power steering oil pressure (use with 09572-21000, 09572-22100) (09572-22100 Oil pressure gauge adapter ‘Measuring the power steering oll pressure (use with 09572-21000, 09572-21200) (09573-21000 Oil seal installer gauge Installing the back-up washer and oil seal {use with 09573-21100, 09573-21200, 09517-11000, 09555-21000)st STEERING SYSTEM ‘Tool (Number and name) llustration Use (09573-21100 Oil seal installer Installing the back-up washer and oil seal. (use with 09573-21000, 09573-21200, 09555-21000) (09573-21200 1, Removing the gear box oil seal and back Oil seal guide washer (use with 08573-21000) < 2. Installing the gear box oil seal and back washer (use with 09555-21000, 09573-21000)GENERAL sT-7 a TROUBLESHOOTING rs: Symptom Probable cause Remedy (see page) Excessive play in steering Loose yoke plug Loose steering gear mounting botts, Loose or worn tie rod end Retighten Retighten Retighten or replace as necessary (Gee page ST-8) Steering wheel operation is not smooth (Insuticient power assis!) V-belt slippage Damaged V-belt Low fluid level Air in the fluid Twisted or damaged hoses Insufficient oil pump pressure Sticky flow control valve Excessive internal oil pump leakage Excessive oil leaks from rack and pinion in gear box Readjust (See page ST-10) Replace (See page ST-10) Replenish (See page ST-11) Bleed air (See page ST-11) Correct the routing of replace Repair or replace the oil pump (See page ST-12) Replace Replace the damaged parts, Replace the damaged parts Distorted or damaged gear box or valve Replace body seals Steering wheel does not Excessive turning resistance of tierod end Replace return properly Yoke plug excessively tight Adjust Tie rod and/or ball joint cannot turn smoothly | Replace (See page ST-8) Loose mounting of gear box mounting bracket | Retighten Worn steering shatt joint and/or body grommet | Correct or repface Distorted rack Replace Damaged pinion bearing Replace Twisted or damaged hoses Reposition or replace Damaged oil pressure control valve Replace Damaged oil pump input shaft bearing Replace Noise Hissing Noise in Steering Gear There Is some noise with all power steering systems. Oe of the most common Is a hissing sound when the steering wheel is tur This noise will be most evident when turning the wheel while the brakes are being applied. There is no relationship between this noise and steering performance. Do not replace the valve unless the "hissing" noise becomes extreme. A replaced valve will also make a slight noise, andis not always a solution for the condition ‘ned and the car is not moving. Rating or chucking noise in the rack and pinion Interference with hoses from vehicle body Loose gear box bracket Loose tie rod end and/or ball joint Worn tie rod andior ball joint Reposition RRetighten Retighten Replace (See page ST-8) Noise in the oil pump Low fluid level Air in the fluid Loose pump mounting bolts Replenish (See page ST-11) Bleed air (See page ST-11) RetightensT-8 STEERING SYSTEM GENERAL CHECKING STEERING WHEEL FREE PLAY 1. Startthe engine with the steering wheel in the straight ahead position, apply a force of 5 N (1.1 Ib) to the steering wheel in the peripheral direction, 2, Measure the play at the circumference of the steering wheel. Standard val Steering whee! tree play : 0-30 mm (0~1.1 in) 3. If the play exceeds the standard value, inspect the connection between the steering shaft and tie rod ends, CHECKING STEERING ANGLE Place the front wheel on a turning radius gauge and measure the steering angle, Standard value ‘Wheel angle Inner wheel : 38°" = 1°30" Outer wheel : 32°5' 2, Ifthe measured value is not within the standard value, adjust the linkage. CHECKING THE TIE ROD END BALL JOINT STARTING TORQUE : 1. Disconnect the tie rod(A) and knuckte(B) by using the special tool (09568-34000). 2. Shake the ball joint stud several times to check for looseness.GENERAL 3, Mount the nuts on the ball joint, and then measure the ball joint starting torque. ‘Standard value 5 Nm (5-25 kg-om, 0.36~1.78 Ibs) 4. Ifthe starting torque exceeds the upper limit of the standard value, replace the tie rod end. 5. Even if the starting torque is below the lower limit of the standard value, check the play of the ball joint and replace if necessary. CHECKING STATIONARY STEERING EFFORT 1. Place the vehicle on a level surface and place the ‘steering wheel in the straight ahead position, 2. Increase the engine speed to 1000 = 100 rpm. Alter checking, reset the engine speed to the standard value (ialing speed). Measure the turning force with a spring scale(A) by turning the steering wheel(B) clockwise and counter- ‘clockwise one and a quarter turns. Standard value Stationary steering effort : 29 N (3.0 kg, 6.5ibs) or loss 4. Check that there is no sudden change of force while turning the steering wheel. 5. Ifthe stationary steering effortis excessive, check and adjust the following points. 1) Damage or cracks on the dust cover of the lower arm ball joint and tie rod end. 2) Pinion preload of the steering gear box and start- ing torque of the tie rod end ball joint. 3) Starting torque of the ball joint. CHECKING STEERING WHEEL RETURN Check the steering wheel return and confirm the following points : 1. The force required to turn the steering wheel and the wheel retum should be the same for both left and right in case of moderate or sharp turns. 2. When the steering wheel is turned 90° and held for a ‘couple of seconds while the vehicle is being driven at 35kph, the steering wheel should return 70° or more. If the steering wheel is turned very quickly, steering may be momentanly difficult. This is not a maifunc- tion because the oil pump output will be somewhat- decreased.ST-10 CHECKING POWER STEERING BELT TENSION 1. Press the V belt, applying a pressure of SBN (10kg, 221) at the specified point and measure the deflection to confirm that itis within the standardvalue. Standard value New belt : 8.8 ~ 11.0 mm Used belt : 12.5 ~ 14.3 mm 2. If the belt deflection is beyond the standard value, adjust the belt tension as follows. 1) Loosen the bolt adjusting(A) the power steering "V"belt tension. STEERING SYSTEM 2) Put a bar(A) or equivalent, between the bracket(B) and the oil pump(C) and adjust the tension so that the belt deflection is within the standard value. 3) Tighten the bolt adjusting the power steering "V"belt tension, 4) Check the belt deflection and adjust it again if necessary. & caution After turning the V belt in the normal rotation di- rection more than once, recheck the belt deflec- tion.GENERAL ST -11 em CHECKING POWER STEERING FLUID LEVEL 1. Position the vehicle on a level surface. 2. Start the engine. With the vehicle kept stationary, turn the steering wheel several times continuously to raise the fluid temperature to 60 - 60°C(122 to 140°F), 3. With the engine at idle, turn the steering wheel fully clockwise and counterclockwise several times. 4, Make sure there is no foaming or cloudiness in the reservoir fluid. 5. Stop the engine to check for any difference in fluid level between a stationary and a running engine. nore 1. If the fluid level varios § mm (0.2 in.) or more, bleed the system again. 2, Ifthe fuid level suddenly rises after stopping the engine, further bleeding is required. 3. Incomplete bleeding will produce a chattering ‘sound in the pump and noise in the flow control valve, and lead to decreased durabilityof the pump. REPLACING POWER STEERING FLUID 1. Jack up the front wheels of the car and support them with jackstands. 2, Disconnect the return hose from the oil reservoir and plug the oil reservoir. 3. Connect a hose to the disconnected return hose, and rain the oll into a container. 4, Disconnect the high-tension cables and ignition coils. ‘While operating the starter motor intermittently, turn the steering wheel all the way to the left and then to the right several times to drain the fluid. Connect the return hose and fix it with a clip. Fill he power steering fluid reservoir with the specified fluid, PSF-3 : 0.75~0.8 lit. 7. Start the engine. Check for fluid leaks from the hose, then stop the en- gine, 8. Pour the fluid into the bottom of the oil fiter in the power steering fluid reservoir, 9. Bleed the air. AIR BLEEDING Fill he power steering fluid reservoir up to the "MAX" position with specified fluid. » Jack up the front wheels. » Disconnect the ignition coil high tension cable, and then, while operating the starter motor intermittentty (for 16 to 20 seconds), turn the steering whee! all the way to the left and then to the right five or six times. NOTE When bleeding fiuid, replenish with the fluid so that the level does not fall below the bottom of the filter. 2. Ifair bleeding is done while the vehicle is idling, the air will be broken up and absorbed into the fluid. Be sure to do the bleeding only while crank- ing. - Connect the high tension cable, and then start the ‘engine (idling). 5. Turnthe steering wheelto the left and then to the right, Until there are no air bubbles in the oil reservoir. Do not hold the steering wheel tured all the way to either side for more than ten seconds. 6. Confirm that the fluid is not milky and that the level is between "MAX" and *MIN’ mark on the reservoir. 7. Check that there is a litle change in the fluid level when the steering whee! is turned left and right.ST -12 NOTE If the fluid level varies 5mm (0.2 in.) or more, bleed the system again. 2. Ifthe fuid level suddenly rises after stopping the engine, further bleeding is required. 3. Incomplete bleeding will produce a chattering sound in the pump and noise in the flow controt valve, and lead to decreased durabilty of the pump. OIL PUMP PRESSURE TEST 1. Disconnect the pressure hose(B) from the pump(A).. Connect the special toot between the pump and the Pressure hose as illustrated. 2. Bleed the air, and thon start the engine and turn the steering wheel several times, measure the fluid tem- perature by Temperature gauge so that the fluid tem- erature can rise to approximately 50°C (122°F).. 3. Increase the engine speed to 1,000 rpm. 4, Close the shut-off valve of the special tool and mea- sure the fluid pressure to confirm that itis within the standard value range. Standard value il pump pressure Relief pressure 2.0(I4), 2.7(V6) : 8.6-9.1 MPa (88-93 kg.cm?, 1251-1322 psi) 2.0(D-ENG) = 9.1-9.6 MPa (93-98 kg.cm?, 1322-1393 psi) STEERING SYSTEM & caution Do not keep the shut-off valve on the pressure gauge closed for more than ten seconds. Remove the special tools, and tighten the pressure hose(B) against the oil pump (A) using the specified torque. Tightening torque 65-75 Nm (650-750 kg.cm, 47.9~54.2 Ib.ft) Ol prossure gauge . (09872-21000) Air bleed the system. (see page ST-11)STEERING COLUMN AND SHAFT ST-13 STEERING COLUMN AND SHAFT STEERING COLUMN / SHAFT COMPONENTS | ccorcs0 Steering wheel Universal joint assembly Steering column shaft assombly - Universal joint assembly Steering column shaft Steoring column upper shroud assembly Steering column shaft mounting bolt 18-18 (130-180, 9.6~13.3) Universal joint mounting bott 15-20 (160-200, 10.8-14.8) Multifunction ‘switch Steering column shaft mounting bolt 13-18 (130-180, 9.6-13.3) Titlover Steering column shaft mounting nut Steering column lower shoud leering ‘Steering column lower shroud ‘mounting bolt 4-6 (40-60, 3-4) TORQUE : Nm (kg-cm, lb-ft)ST-14 STEERING SYSTEM REMOVAL crocea 3. Remove the steering whee! lock nut(A). 4. Disconnect the negative () terminal(A) from the bat- tery. 4, After aligning the marks on the steering shaft and on wheel(A), remove the steering wheel using the spe- cial toot (09561-11002). . 2. Take away the bolts (A) in the illustration, and then : remove the drivers airbag module(B). Qnore Do not hammer on the steering wheel to remove it: it ‘may damage the steering colurnn. TBASTEERING COLUMN AND SHAFT ST-15 6. Remove the steering column upper(A) and lower 7. Remove the connectors of the muttifunction switch(A). shrouds(B). 6. Disconnect two tightening bolt(A) and remove the 8 Alter removing three bolts(A) in the illustration, re- lower crash pad(B). move the multitunetion switch agsembly(B).ST-16 Remove the bolts connecting the steering column shaft(A) and the universal joint(B) as shown in the illustration, 10. After removing the mounting bolts and nuts on the steering column and shaft assembly, remove the steering column and shaft assembly(A). 2. Disassemble the key lock assembly(A) from the st STEERING SYSTEM DISASSEMBLY AND REASSEMBLY case KEY LOCK ASSEMBLY It itis necessary to remove the key lock assembiy(A), Use @ punch to make a groove on the head of the special bolt(B), and then use a screwdriverto remove the key lock assembly mounting bracket(C). jr ing column and shaft assembly(B). INSPECTION | crsraso 1. Check the steering column shaft for damage and de- formation. 2. Check connections for play, damage and smooth op- eration. 3. Check the ball joint bearing for wear and damage. 3. Reassombly is the reverse of disassembly.STEERING COLUMN AND SHAFT. UNIVERSAL JOINT ASSEMBLY INSTALLATION | exoteoe: 4. Remove the bolt(A) connecting the universal joint as- Assembly is the reverse of removal. ‘sembly(B) and the steering column and shatt assem- biy(C). 2, Remove the universal joint assembly(A) from the steering column and shaft assembiy(B).. 3, Reassembly is the reverse of disassembly.ST-18 MECHANICAL POWER STEERING SYSTEM POWER STEERING GEAR BOX STEERING SYSTEM COMPONENTS | couceser Tie rod end assembly Valve body assembly ‘Tie rod assembly [VIEW A] [view B} [VIEW c} Tie od end cascombly Sloted nut spit pinMECHANICAL POWER STEERING SYSTEM ST-19 Feed tube Valve body housing Power stoering gear box ‘mounting clamp 3 pe Yoke plug Boren 5 fh | | ~ ~ Tie rod end = Lock nut ~- ae @ ~ Bellows clip. Wey . Dust cover Bellows Bellows band Tie rod ) t | | Circlip Oilseal Rack stopperST -20 STEERING SYSTEM REMOVAL erase 5. After removing the split pin, disconnect the tie rod(A) from the knuckle(B) by using the special tool (09568- 1. Disconnect the cover fixing clip(A) on the universial 34000). joint indoor driver isde, loosen the noise covers(B). 6. Drain the power steering fluid. (see. page ST-11) 2. Loosen the iniversial joint and the gear box mounting : bolt and disconnect the universial joint from the gear. 7. Remove the engine under cover(A).. box. 3. Lift up the vehicle. 4, Remove the front tres (RH/LH).MECHANICAL POWER STEERING SYSTEM ST -21 8. Remove the front mutfler assembly(A). 10. Remove the bracket(A) holding the end tubes of the pressure tube and the return tuba. 11. Remove the mounting clamp of power steering gear box, and also remove the clamp holding the pressure tube and the return tube. 9. Disconnect the end tube of the pressure hose(A) and the end hose of the return hose(B) from the gear box.ST -22 STEERING SYSTEM 42, Remove the mounting bol(A) from the powersteering INSPECTION AND ADJUSTMENT BEFORE eee DISASSEMBLY | cronscis Fix a brass plate or aluminum plate for protection to the jaws of a vise and mount the gear box(A) in a vise(B). Q caution When mounting the gear box in a vise, let the in- stallation section of Ite fixed to the Jaws. If other ‘section Is fixed the gear box may be damaged. 13. Pull the power steering gear box assembly(A) toward, the right side of the vehicle. (G) nore When removing the gear box, pull it out carefully and slowly so as not to cause damage to the Bellows(B) TOTAL PINION PRELOAD 4. Rotate the pinion gear for approximately 4 to 6 ‘seconds for one rotation to measure the total pinion preload. Standard value Total pinion preload = 0.6-1.3 Nm (6-13 kg.cm, 0.4~1.0 Ib.) ‘Measure the pinion preload through the entire stroke of the rack.MECHANICAL POWER STEERING SYSTEM 2. If the measured value is out of specifications, first adjust the yoke plug, then recheck the total pinion preload. 3. Ifyou adjust the yoke plug but do not oblain the total pinion preload, check or replace the yoke plug com- ponents TIE ROD SWING RESISTANCE 1. Rotate the tio rod severely ten times. 2. Measure the tie rod(A) swing resistance with a spring scale(B). Standard value Total rod swing resistance : 8-22 N (1.9~4.6 Ib) [2~5 Nm (20-50 kg.om, 17-43 Ib.in)] ST -23 3. If the measured value exceeds the standard value, replace the tie rod assembly. Q caution Even if the measured value is below the standard value, the tie rod that swings smoothly without ex- cessive play may be used. If the measured value Is below 4.3 N (0.91b) [100 Nem (8.7 lb.in.)}, replace the tle rod. BELLOWS INSPECTION 4. Inspect the bellows for damage or deterioration. 2. Make sure the bellows are secured in the correct po- sition. 3. If the bellows are defective, replace them with new ones. DISASSEMBLY 1. Remove the tie rod end(A) from the tie rod(B).s STEERING SYSTEM 2. Alter mounting the tie rod end(A) ina vise, remove the 4. Remove the bellows clip(A). dust cover(B) from the ball joint. 5. Pull the bellows out toward the tie rod. Remove the bellows band(A). Check for rust on the rack when the bellows are re- placed. 6. Remove the feed tube from the rack housing. 7. While moving the rack slowly, drain the fluid from the rack housing. Unstake the tab washer(A) which fixes the tie rod(B) and rack(C) with a chisel.MECHANICAL POWER STEERING SYSTEM ST-25 9. Remove the tie rod(A) from the rack(B). 11. Remove the lock nut(A), yoke plug(B), rack support ‘spring(C), rack support yoke(D) and bushing(E) from Ay caution the gear box. Remove the tie rod{A) from the rack(B), taking care not to twist the rack. 12, Remove the valve body housing(A) by loosening the rortgon two bolts(B).. ‘ 10. Remove the yoke plug locking nut(A), and then re- move the yoke plug.ST -26 18. Remove the rack bushing and the rack from the rack housing. 14, Remove the O-ring(A) from the rack bushing(B). 7. 18. 48. Remove the oll seal(A) from the rack bushing(®). 19. 16. STEERING SYSTEM Remove the pinion viave assembly(A) from the valve body housing(B) with a soft hammer(C).. Using the special tool, remove the oil seal and ball bearing from the valve body housing, Remove the oil seal and O-ring from the rack housing, & cauTION Be careful not to damage the pinion valve cylinder Inside of the rack housing. Using the special tool(08573-21200, 09555-21000), remove the oll seal(A) from the rack housing. QS cauTion Be careful not to damage the rack cylinder inside of the rack housing. 09573-21200MECHANICAL POWER STEERING SYSTEM INSPECTION 1. Rack + Check for rack tooth face damage or wear = Check for oil seal contact surface damage = Check for rack bending or twisting = Check for oil seal ring damage or wear = Check for oil seal damage or wear 2. Pinion valve = Check for pinion gear tooth face damage or wear = Check for ol seal contact surface damage = Check for seal ring damage or wear = Check for oil seal damage or wear ST 3. Bearing = Check for seizure or abnormal noise during rotat- ing a bearing = Check for excessive play = Check for missing needle bearing rollers 4, Others = Check for damage of the rack housing cylinder bore = Check for boot damage, cracking or aging REASSEMBLY | ecossoss 1. Apply the specified fluid to the entire surface of the rack oil seal. Recommended fluid : PSF-3 2. Install the oil seal(A) to the specified position in the rack housing. cosrs2ion j X pee oor A'| 09885-21000 creation 3. Apply the specified fluid to the entire surface of the rack bushing oil seal. Recommended fluid : PSF-3‘ST -28 STEERING SYSTEM 4, Install the oil seal(A) in the rack bushing(B).. 8, Install the oil seal and the ball bearing in the valve body, 9. Alter appling the specified fluid and grease to the pin- jon valve assembly(A), install it in the rack housing assembly. 5. Apply the specitiod fluid to the entire surface of the O-ring and install it in the rack bushing. 6. Apply the specified grease to the rack teeth. : epaezsce Recommended grease 10. Alter applying the specified fluid to the oil seal, install Muttipurpose grease SAE J310, NLGI No.2 itn the rack housing, and fix the valve body assem- bly(A) and O-ring in the gear box(B). (Dnore Do not plug the vent hole(A) in the rack with grease. 7. Insert the rack into the rack housing and install the rack bushing and rack stopper.MECHANICAL POWER STEERING SYSTEM 11. Install the tab washer and the tie rod and stake the tab washer(A) end at two points over the tie rod. (GW anore 1. Align the tab washer pawis withthe rack grooves. 2, Always use a new tab washer. 12. Install the bushing(A), rack support yoke(B), rack sup- Port spring(C), lock nut(E) and yoke plug(D) in the ‘order shown in the illustration. Apply semi-drying ssealantio to the threaded section of the yoke plug be- fore installation. ST-29 4. With the rack placed in the center position, attach the yoke plug to the rack housing. Tighten the yoke plug to 15 Nm (150 kg.om, 11 Ib.ft). Loosen the yoke plug approximately from 30° to60* and tighten the locking nut to the specified torque. Tightening torque 50-70 Nm (500-700 kg.cm, 37~52 bt) (09565-21100 14, Tighten the feed tube to the specified torque and in- stall the mounting rubber using adhesive. 15. Apply the specified grease to the bellows mounting Position (fting groove) of the tie rod. Recommended grease : Slicone grease (N=ST -30 16, Install the new attaching band to the bellows. (@ nore When the bellows are installed, a new band must be used. 17. Install the bellows in position, taking care not to twist it. 18. Fill the dust cover inner side and lip with the specified grease, and fix the dust cover in position with the clip ring attached in the grooveof the tie rod end, Recommended greas A: POLY LUB GLY 801K or equivalent B : SHOWA SUNLIGHT MB2 or equivalent Dust cover inner side and lip : THREE BOND STEERING SYSTEM 419, Install the tie rods so that the length of the left and right tie rods equals the standard value. Standard value Tie rod free length : 112.2mm. Locking nut 20. Check for total pinion preload.MECHANICAL POWER STEERING SYSTEM INSTALLATION | cessrsas 1. Push in the power steering gear box assembly(A) on. the right side of the vehicle. 2. Install the dust cover mounting plate. 3. Connect the dust cover to its mounting plate with a now strap. 4, Connect the steering gear box assembly to the unk versal joint assembly(A) by using the bolt(B). all fini 5. Installation is the reverse of removal. 6. Ator installation, air bleed the system. (see page ST-11) ST -31ST -32 STEERING SYSTEM POWER STEERING HOSES COMPONENTS | excerie Power steering oil reservoir pl Suction hose Te rod ond Power steering gear box assemblyMECHANICAL POWER STEERING SYSTEM ST-33 REMOVAL escies 4. Disconnect the pressure tube fiting(A) atthe gear box side. (when removing the pressure tube) 1. Support the specified point of the vehicle with a lit. 5. Remove the return hose(A) in the gear box. (when 2. Drain the power steering fluid. (see page ST-11) removing return hose) . 3. Lift up the vehicle and remove the mounting clamp which is holding both the pressure tube and the return tube(A).ST-34 STEERING SYSTEM 6. Lower the vehicle. 9. Disconnect the pressure hose connector from the oil pump. (when removing the pressure hose) 7. Remove the clamp of the return tube and hose. (when oe Femoving return tube and hose) 10, Disconnect the pressure hose assembly. (when re- : moving the pressure hose) . 8. Remove the return tube and hose. (when removing ‘ return hose) 11. Remove the color tube mounting clip bolt. (when re- moving the color tube) 12. Disconnect the remove the color tube from the power steering oll reservoir tank side hose. (when working (on the color tube)MECHANICAL POWER STEERING SYSTEM ST-35 INSTALLATION | ex:soacs 5. Raise the vehicle with a lift. 1. Support the specitied portion ofthe vehicle witha lift. 6. Fix the return hose(A) and pressure tube(B) fitting to the power steering gear box. 2, Insert the color tube from the front pump upper part . to the lower part and install mounting bolts. (when : installing the color tube) 3. Connect the color tube to the power steering oil reser- \oir tank side hose, return tube and hose side and fix it with clips. (when instaling the color tube) 4, Place the pressure hose and tube assembly in posi- tion and connect it to the oil pump. (when installing the pressure hose and tube)ST -36, STEERING SYSTEM 7. Fix the power steering pressure tube and return tube mounting clamp(A) with a bolt. 8. Lower the vehicle. 9. Add power steering fluid(PSF-3). (see page ST-11) 10. Air bleed the system. (see page ST-11)MECHANICAL POWER STEERING SYSTEM ST-37 POWER STEERING OIL PUMP COMPONENTS | excraace Mounting bolt Oting Cam ring Bush —— — eg sae pte O+ing——>O ving J (Outer) S) oving (inner) Spring —=6 | Cam ring ll pump ‘cover assembly Pulley & driveshaft assembly ate ie Sa Neuntng bot - sveton poe a BushST -38 STEERING SYSTEM REMOVAL excroxcr 3. Loosen the tension adjusting bolt(A) on the power steering “V" belt. 1. Loosen the bott fixing the wiring bracket, and then move the wiring sideward. erorzon 4. Remove the *V" belt(A) from the power steering oll pump pulley. * 2. Remove the pressure hose(A) from the oil pump(B),, and then disconneet the suction hose(C) from the suc- tion connector and drain the fluid into a container. (see page ST-11, Replacing power steering fluid) SS ST Sh9 | | © | I 7 — YMECHANICAL POWER STEERING SYSTEM ST-39 5. Loosen the power steering oil pump mounting bot DISASSEMBLY csszxcc and the tension adjusting bolt, and then remove the steering oil pump assembly(A). 1. Remove two two bolts(A) from the oil pump body, and then remove the suction pipe(B) and O-ring(C). x / 2, Loosen the four bolts and remove the oil pump cover 6. Remove the power steering oil pump mounting assembly 7 bracket(A). ‘ 3. Remove the cam ring. 4, Remove the rotor and vanes. 5, Remove the oil pump side plate.‘ST -40 STEERING SYSTEM 6. Remove the inner O-ring(A) and outer O-ring(B). 8. Remove the oil seal(A) from the oll pump body. 7. Remove the snap ring and take out the pulley andthe 9. Remove the connector from the oil pump body, and drive shaft assembiy(A). take out the flow control valve and the flow control spring.MECHANICAL POWER STEERING SYSTEM INSPECTION Check the free length of the flow control spring. Free length of the flow control spring : 36.5mm_ ST -44 REASSEMBLY | croriser 1. Install the flow control spring, the flow control valve and the connector into the pump body. Check that the flow control valve is not bent. Check the shatt for wear and damage. Check the V-belt for wear and deterioration, oR ee RN Check the grooves of the rotor and vanes for stratified abrasion. 6. Check the contact surface of the cam ring and vanes. for stratified abrasion. 7. Check vanes for damage. & Check that there is no striped wear in the side plate or contacting part between the shaft and the pump cover surface. 2. Install the oil seal in the pump body by using the spe- cial tool(09222-32100).ST -42 STEERING SYSTEM 3, Install the pump pulley(A). 5. Install the cam ring attending to the groove and the direction of the front housing. &) ‘gr Front housing side 42 Oil pump cover side 4, Assengle the inner O-ring and the outer O-ring and install the site plate(A). wroreicn 6. Install the rotor, 7. Install vanes(A) to the rotor(B).“AL POWER STEERING SYSTEM. MECHAI 8. Install the O-ring and the oil pump cover assembly. 8. Install the suction pipe(A) and O-ring. INSTALLATION 1. Install the oil pump(A) to the oil pump bracket. 2. Hang the "V" belt on the oil pump and connect the suction hose(A) and the pressure hose(B). (@Qaore Install the hose being careful so that it does not twist and come in contact with other components, ST -43 3. Insert a stick(C) or similar thing between the bracket(A) and the oil pump(B) to produce tension and confirm that velt deflection is within the standard value. 4. Add power steering fluid. (see page to ST-11) 5. Air bleed the system. (see page to ST-11) 6. Check the oil pump pressure. (see page to ST-12)