GENERAL ‘SPECIFICATIONS TIGHTENING TORQUE LUBRICANTS SPECIAL TOOLS. TROUBLESHOOTING SERVICE ADJUSTMENT PROCEDURE... ‘STEERING COLUMN AND SHAFT ‘STEERING COLUMN / SHAFT COMPONENTS. REMOVAL INSPECTION. INSTALLATION DISASSEMBLY AND REASSEMBLY. ST-2 ST-3 ST-3 sT4 ST STB ST-13 ST-14 ST-16 sT-16 ST-16 Steering System MECHANICAL POWER STEERING SYSTEM POWER STEERING GEAR BOX COMPONENTS, REMOVAL. INSPECTION AND ADJUSTMENT BEFORE DISASSEMBLY... DISASSEMBLY INSPECTION REASSEMBLY INSTALLATION POWER STEERING HOSES COMPONENTS, REPLACEMENT POWER STEERING OIL PUMP. COMPONENTS, REMOVAL. DISASSEMBLY INSPECTION REASSEMBLY INSTALLATION ST-18 ST-19 .ST-22 ST-23 ST-26 ST-27 ST-30 sT-31 ST-32 ST-34 ST-35 ST-36 ST-38 ST-39 ST-41sT2 STEERING SYSTEM GENERAL SPECIFICATIONS | e002 ems: Specifications Steering column & joint type Collapsible, cross Steering gear type Rack & pinion ‘Type Vane Max. pressure 70 kgtiom® Power steering pump Discharge 9.6 cclrev Max. pressure 80 kato? Discharge 7.2 eclrev SERVICE STANDARD Toms. Specifications Steering wheel free play 30 mm (1.18 in) Inner 38° 58°21 ° 30 Manual Outer 32° 38 Steering angle Inner 39° 67'1 * 30° Power Outer 32° 54" Drive belt deflection 7 = 10mm (0.27 ~ 0.39 in) Power steering pump pressure 40 kgtlem™| Tie rod swing resistance 1.5~5.0 Nm (0.15 = 0.5 kgfm , 1.1 ~36 Ib) Tie rod ball joint starting toque 0.5 ~ 2.5 Nm (0.05 ~ 0.25 kgfm 0.36 ~ 1.81 lb)GENERAL sT3 TIGHTENING TORQUE | «1xoc0 ems, Nm Kgtm Lot Steering wheel lock nut 40 ~ 50 40-60 29 ~ 36 Steering column mounting bolts and nut 13 = 18 13-18 94 = 13.0 Bal comecing stare 13-18 13-18 e4~130 Bolt connecting universal joint to steering gear 13-18 13-18 94 = 13.0 ‘Steering column mounting bolts and nut 13 = 18 13-18 o4~ 130 Tie rod end castle nut 24 ~ 34 2434 17 ~ 26 Front lower arm bal joint assembly bolts 100 ~ 120 10.0 = 120 72 ~ 86 Stabilizer link to strut assembly nut 35 ~ 45 35-45 25 ~ 33 Rear roll stopper to sub-frame bolts 50 ~ 60 5.0 ~ 6.0 36 ~ 43 Pressure tube to valve body housing nut 12-18 12-18 9-13 Pressure tube to oll pump eye bolt 55 ~ 65 55-65 40 ~ 47 Return tube to valve body housing aut 12-18 12-18 9-13 Power steering gear box to sub-frame bots 60 ~ 80 60-80 43 ~ 58 LUBRICANTS Htoms. Recommended lubricant Quantity ‘SHOWA SUNLIGHT Ball joint of tie rod end MB? OR souvatent 49 Contact area of gear box bellows &: tie rod_| SILICON GREASE As required 08 liter Power steering fluid PSFAIl (0.84 ats.)sT4 STEERING SYSTEM SPECIAL TOOLS som ‘Tool (Number and name) illustration Use 09222-32100 Valve stem 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 Steering wheel puller Removing the steering wheel, 09565-17100 Proload socket ‘Measuring the pinion shaft preload,GENERAL Ball joint puller Tool (Number and name) lustration Use (09555-21000 Removing & installing the oil seal of Bar the rack housing OP a a a (09568-4A000 ‘Separating the te rod end ball joint. (09572-21000 Oil pressure gauge FP A < | 2 Measuring the power steering oil pressure (use with 09572-21200, 09572-22100) (09572-21200 il pressure gauge adapter Measuring the power steering oil pressure {use with 09572-21000, 09572-22100) (09572-22100 Gil pressure gauge adapter Measuring the power steering oil pressure {use with 09572-21000, 09572-21200)sT-6 STEERING SYSTEM Tool (Number and name) Illustration Use (09873-21000 Oil seal installer gauge Installing the oll eal of the rack housing (09673-21100 Oil seal installer Installing the oll seal of the rack housing 09873-21200 Oil seal guide Removing & installing the oll seal of the rack housingGENERAL st7 TROUBLESHOOTING | ssn ‘Symptom Excessive play in steering Probable cause Remedy Loose yoke plug Retighten Loose steering gear mounting bolts Retighten Loose or worn tie rod end Retighten or replace as necessary ‘Steering wheel operation is not ‘smooth (Insufficient power assist) V-belt slippage Readjust Damaged V-belt Replace Tow fluid level Replenish ‘Air in the fluid Bleed air Twisted or damaged hoses Correct the routing or replace Insufficient oll pump pressure Repair or replace the oil pump Sticky flow control valve Replace Excessive internal oil pump leakage Replace the damaged parts Excessive oil leaks from rack and pinion in gear box Replace the damaged parts, Distorted or damaged gear box or valve body seals Replace Steering wheel does not Excessive turning resistance oftierod end _| Replace return properly Yoko plug excessively tight ‘Adjust Tie rod andor balljoint cannot turn smoothly | Replace Loose mounting of gear box mounting bracket | Retighten Worn steering shaft joint and/or body grommet Correct or replace Distorted rack Replace Damaged pinion bearing Replace Twisted or damaged hoses Reposition or replace Damaged oll pressure control valve Replace Damaged oll pump input shaft bearing Replace Noise Hissing Noise in Steering G There is some noise with all power steering systems, One of the most common turned and the car is nat moving. 1e wheal 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, and is not always a solution for the condition. is a hissing sound when the steering wheel ist This noise will be most evident when turning th Ratting or chucking noise in | Interference with hoses from vehicle body __| Reposition the rack and pinion Loose gear box bracket Retighten| Loose tie rod end and/or ball joint Retighten Worn tie rod andlor ball joint Replace Noise in the oll pump Low fluid tevel Replenish Air in the fluid Bleed air Loose pump mounting bolts Retighten|sT-8 STEERING SYSTEM [Dore A sight “rincing nose" may be heard immedetey Siero engine 6 sated i oxtemely col weather tontltons (below - 20°). Tis due fo power seer inofld chrecoraies textrome cold condone and isnot an indeation ofa maturation SERVICE ADJUSTMENT PROCEDURE CHECKING STEERING WHEEL FREE PLAY 1. Startthe engine withthe 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 value Steering whee! free play : 0 ~ 30 mm (0 ~ 1.18 in) 3. If the play exceeds the standard value, inspect the connection between the steering shaft and tie rod ends. CHECKING STEERING ANGLE 4. Place the front wheel on a turning radius gauge and measure the steering angle. ‘Standard value Steering angle : See page ST-2 2. Ifthe measured value is not within the standard value, agjust the linkage. CHECKING THE TIE ROD END BALL JOINT STARTING TORQUE 4. Disconnect the tie rod(A) and knuckle(B) by using the ‘special tool (09568-44000). 109568-<4000 2. Shake the ball joint stud several times to check for looseness.GENERAL sT-9 3. Mount the nuts on the ball joint, and then measurethe CHECKING STATIONARY STEERING EFFORT ball joint starting torque. 4, Place the vehicle on a level surface and place the ‘Standard value steering wheel in the straight ahead position 0.5 ~ 2.5 Nm (0.05 ~ 0.25 kgm, 0.36 ~ 1.80 lb-ft) 2. Increase the engine speed to 1000 + 100 rpm. (wore / After checking, reset the engine speed tothe standard value (iding speed). 3, Measure the turing force with a spring scale(A) by turning the steering wheel(B) clockwise and counter- clockwise one and a quarter tums. ZZ antl S >) / SSS 34.N (3.5 kg, 7.7 Ibs) or less 4. Ifthe starting torque exceeds the upper limit of the standard value, replace the tie rod end. 5. Even ifthe starting torque is below the lower limit of ir the standard value, check the play of the ball joint and replace if necessary. 4, Check that there is no sudden change of force while turning the steering wheel. 5. Ifthe stationary steering effort is excessive, check and adjust the following points, 41) 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sT-10 CHECKING STEERING WHEEL RETURN 1. The force required to turn and return the steering wheel should be the same for both left and right in case of moderate or sharp turns. 2. When the steering wheel is tuned 90° and held for a couple of seconds while the vehicle is being driven at ‘35kph, the steering wheel should return to within 20° from the neutral position when itis released. [Gwore 1 he steering wheel is tured very aulhy, steering may be momentanly difeut. This isnot a malune- tan because th ol pump output wil be somewhat decreased. CHECKING POWER STEERING BELT TENSION 1. Press the V belt, applying a pressure of 98N (10kg, 22Ib) at the specified point and measure the deflection to confirm that itis within the standard value. Standard value V belt deflection : 7 ~ 10 mm (0.27 ~ 0.39 in) STEERING SYSTEM 2. If the belt deflection is beyond the standard value, adjust the belt tension as follows. 1) Loosen the boit(A) adjusting the power steering V belt tension. 2) Puta bar or equivalent, between the bracket and the oil pump 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. CHECKING POWER STEERING FLUID LEVEL 41. Position the vehicle on a surface level 2. Startthe engine. With the vehicle kept stationary, turn the stearing wheel several times continuously to raise the fluid temperature to 50 - 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 fuid level between a stationary and a running engine. [hnore 1. If the fluid level varies 15 mm (5.9 in) or more, blood the system again. 2. Ifthe fluid level suddenly rises after stopping the ‘engine, further bleeding is required.GENERAL 3. Incomplete bleeding will produce a chattering sound in the pump and noise in the flow control valve, and lead to decreased durability of the pump. tt CSS a REPLACING POWER STEERING FLUID 1. Jack up the frant 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 drain the oll into a container. 4. Disconnect the high tension cables and ignition coils. While operating the starter motor intermittently, ‘tum the steering whee! all the way tothe left and then ‘to the right several times to drain the fluid 5. Connect the return hose and fxit with a clip. 6. Fillthe power steering fuid reservoir with the specified fluid. PSFAIIr: 08 Ii (0.84 gis) 7. Start the engine. Check for uid 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 intermittently (for 15 to 20 seconds), turn the steering wheel al the way to the left and then to the right five or six times, (Dijwore 1. When bleeding fluid, replenish with the fluid so that the level does not fall below the bottom of the filter 2. If air bleeding is done white 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). ‘Turn the steering wheel tothe left and then to the right, until there are no air bubbles in the oil reservoir (Gnore Do not hol the stooring whoo! tuned al the way to either si for more than fon socands. Confirm that the fluid is not milky and that the level is between "MAX" and *MIN" mark on the reservoir. Check that there is a little change in the fluid level when the steering wheel is turned left and right. (hnore 1. If the fluid level varies 15mm (5.9 in) or moro, bleed the air in the system again. 2. If tho fluid level suddenly rises after stopping the engine, further bleeding is required.sT-12 3. Incomplete bleeding will produce a chattering sound in the pump and noise in the flow control valve, and lead to decreased durability of the pump, i STEERING SYSTEM 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 6.6 ~ 7.3 MPa (68 ~ 75 kglem’, 967 ~ 1066 psi) >—T OIL PUMP PRESSURE TEST 1. Disconnect the pressure hose from the pump. Con- rect the special tool between the pump and the pres- sure hose as illustrated, 2. Bleed the air, and then start the engine and turn the steering wheel several times, measure the fluid tem- perature by Temperature gauge so that the fuid tem- perature can rise to approximately 50°C (122'F) 3. Increase the engine speed to 1,000 rpm. 2 caution Do not keep the shut-off valve on the pressure gauge closed for more than ten seconds. ol pressure gauge (09572-21000), Tenpatire shutovave one tons) oieume \ rot rgsce Aor (os572.21200 tesrazz100) Oi pressure ‘gauge adapser (oosr2-22%00) 5. Remove the special tools, and tighten the pressure hose against the oll pump using the specified torque. Tightening torque 55 ~ 65 Nm (5.5 ~ 6.5 kfm, 40 ~ 47 Ib-t) 6. Bleed the air in the system.STEERING COLUMN AND SHAFT ST -13 STEERING COLUMN AND SHAFT COMPONENTS | esceross ae 45 (3.5 ~ 4.5, 25.3 ~ 32.5) 13-18 (1.3 ~1.8,9.4~13.0) 6 13-18 (1.3~1.8, 9.4~13.0) Yt 8~11 (0.8 ~ 1.1, 5.78 ~ 7.95) TORQUE : Nm (kgf-m, Ib-ft) 1. Steering wheel 6. Stoering column shaft mounting nut 2. Steering column 7.Titlever 3. Universal joint assembly 8. Steering column upper shroud 4, Universal joint mounting bolt 9 Multifunction switch 5, Steering column shaft mounting bolt 10. Steering column lower shroudsT-14 REMOVAL exsaxe 1. Disconnect the negative terminal (A) from the battery. 2. Loosen the bolts (A) in the illustration, and then re- move the horn pad (B). STEERING SYSTEM 3. Disconnect the connector (A) and remove the steering wheel lock nut (B).. ning torque Nm (kgfm, tb 0 (4 29 ~ 36) 4. Alter making the marks on the steering wheel and shaft for reinstallation, remove the steering wheel us- ing a SST (09561-11002), Do not hammer on the steering wheel to remove it; it may damage the steering column. \ 09561-11002STEERING COLUMN AND SHAFT ST -15 5. Loosen the screws (A), and then remove the steering 8. Disconnect the connectors and remove the mutifunc- column upper and lower shrouds. tion switch (A). Loosen the screws and bolts, and then remove the 9. Remove the bolt (A) connecting steering gear to uni- lower crash pad (A). versal joint. 7, 10. Remove the steering column after loosening the steering column mounting bolts and nut Tightening torque Nm (kgm, 13 ~ 18 (1.3 ~ 1.8, 94 ~ 13.0)sT-16 INSPECTION 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. INSTALLATION 4. Instalaion isthe reverse of removal {\ cauion Align the marks on the steering whee! and shaft for reinstallation when installing the steering wheel. STEERING SYSTEM DISASSEMBLY AND REASSEMBLY KEY LOCK ASSEMBLY 41. Ifitis necessary to remove the key lock assembly (A), Use @ punch to make a groove on the head of the special bolt (8), and then use a screwdriver to remove the key lock assembly mounting bracket (C). 2. Disassemble the key lock assembly (A) from the steering column and shaft assembly (B). 3. Reassembly is reverse of disassembly.STEERING COLUMN AND SHAFT ST -17 UNIVERSAL JOINT ASSEMBLY 1. Remove the bolt (A) connecting the universal joint as- sembly (B) and the steering column and shaft assem- bly (C). 2. Remove the universal joint assembly (A) from the steering column and shaft assembly (B). 3. Reassembly is reverse of disassembly.sT-18 STEERING SYSTEM MECHANICAL POWER STEERING SYSTEM POWER STEERING GEAR BOX COMPONENTS exae0 50-55 ° ‘1 Se _ sores 882-408) Qs 40 ~ 50 (4~5, 28.9 ~36.2) 14 | 45-55 (45~5.5, 925~39.7) 100 ~ 120 (10~ 12, 72.3~ 86.8) TORQUE : Nm (kgfm, Ib-f) 4. Protector rubber 8. Needle bearing 15, Feed tube 22. Bellows band 2. Dusteap 8. Rack support yoke 18. Rack housing 23. Tie rod 3. Snap ring 410. Rack suppor spring 17. Mounting bracket 24. Bellows 4. Input shaft seal 411, Lock nut 18. Mounting isolator 25. Bellows clip 5. Input shaft bearing 42. Yoke plug 18. Rack 28. Lock nut 6. Pinion valve assembly 13. Pinion locking nut 20. Oilsea! 27. Tie rod end 7. Pinion seal 14, Pinion plug 21. Rack stopperMECHANICAL POWER STEERING SYSTEM ST-19 REMOVAL ses 3. Remove the bot (A) connecting steering gear to uni- versal joint. 41. Drain the power steering fui by disconnecting the return hose (A). Tightening torque Nm (kgf, 1b): 13 ~ 18 (1.3 4 ~ 13.0) 2. Disconnect the pressure tube (8) from the power fence steering oll pump (A) by loosening eye bolt. 4, Remove the both front wheel & tite assemblies. Tightening torque Nm (kgfm, lb-ft) 5. Loosen the driveshaft castle nut, and then remove the ~47) tie rod end (A) from the knuckle (B) by using a SST 09568-44000. Tightening torque Nm (kgm, Ib-ft): 24 ~ 34 (24 ~ 3.4, 17 ~ 26) (09568-44000ST -20 STEERING SYSTEM 6. Remove lower arm ball joint assembly bolts (A). 9. Remove the dust cover by loosening the bolts (A). Tightening traue Nem (gh, I 100 ~ 120 (10 ~ 12, 73 tector. 7. Disconnect the stabilizer ink (B) from the strut assem- bly (A). Tightening torque Nm (kgf'm, Ib-ft 35 ~ 45 (3.5 ~ 4.5, 25 ~ 33) 11, Remove the muffler mounting rubber (A) 8 Repeat on the other side.MECHANICAL POWER STEERING SYSTEM ST -21 12, Remove the front and rear roll stopper bolt (A, 8). 14, Remove the rear roll stopper by loosening the bol. Tightening torque Nm (kgfm, Ib-ft): Tightening torque Nm (kgfm, Ib-ft): 50 ~ 65 (5.0 ~ 6.0, 36 ~ 47) 50 ~ 60 (6.0 ~ 6.0, 36 ~ 43) 15, Disconnect the pressure hose and return tube & hose assembly from the valve body housing. 13, Remove the sub-frame by loosening the bolts and nuts (A).ST -22 16. Remove the power steering gear box (A) by loosening the mounting bolt (B). Tightening torque Nm (kgf'm, Ib-ft): 60 ~ 80 (6.0 ~ 8.0, 43 ~ 58) STEERING SYSTEM INSPECTION AND ADJUSTMENT BEFORE DISASSEMBLY | exe 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). AS caution When mounting the gear box in a vise, let the in- stallation section of it be fixed to the jaws. Ifother ‘section is fixed the gear box may be damaged. TOTAL PINION PRELOAD 1. Rotate the pinion gear for approximately 4 to 6sec- fonds for one rotation to measure the total pinion preload Standard value Total pinion preload : 0.6 ~ 1.3 Nm (0.0 13 kgm, 0.4 ~ 1.0 lb-ft) (pore Measure the pinion preload through the entire stroke of the rack. 9565-11100 —MECHANICAL POWER STEERING SYSTEM ST -23 2. Ifthe measured value is out of specifications, frst ad- DISASSEMBLY cxxcox: just the yoke plug (A), then recheck the total pinion preload 1. Remove the tie rod end (B) from the tie rod (A). 3. If you adjust the yoke plug but do not obtain the total pinion preload, check or replace the yoke plug com- ponents. TIE ROD SWING RESISTANCE 1. Rotate the tie rod severely ten times, 2. Measure the tie rod (A) swing resistance with a spring scale (8). ‘Standard value Total rod swing resistance : 1.5 ~ 5 Nem (0.15 ~ 0.5 kgfm, 1.1 ~ 3.6 lb-h) 3. If the measured value exceeds the standard value, replace the tie rod assembly. \ caution . Even ifthe measured value is below the standlard- value, the te rod that swings smoothly without ex- essive play may be used. If the measured value is below 0.044 Nm (0.44kgrcm, 0.03 lb-) replace the tie rod. BELLOWS INSPECTION 3. Remove the bellows clip (A). 1. Inspect the bellows for damage or deterioration, 2. Make sure the bellows are secured in the correct po- sttion 3. If the bellows are defective, replace them with newST -24 4. Pullthe bellows out toward the te rod [Gwore Check for rust on the rack when the bellows are re- placed. 5. Remove the feed tube (A) from the rack housing, 6. While moving the rack slowly, drain the fluid from the rack housing 7. Remove the tie rod (B) from the rack (A). A caution Remove the tle rod (B) from the rack (A), taking care not to twist the rack. STEERING SYSTEM 8. Remove the yoke plug locking nut (A). 9. Remove the yoke plug (A) with a 14 mm socket. 10. Remove the lock nut (D), yoke plug (C), rack support ‘spring (B)and rack support yoke (A) from the gear box. ertMECHANICAL POWER STEERING SYSTEM 11. When the end of the circlip comes out of the notched hole (B) ofthe housing rack cylinder (C), turn the rack stopper (A) clockwise and remove the circip. {\ caurion Bo careful not to damage the rack. 12, Remove the rack bushing and rack from the rack housing 13. Remove the O-ring (A) from the rack bushing (8). ST-25 14. Remove the oil seal (B) from the rack bushing (A). 15, Remove the valve body from the valve body housing with a soft hammer. 46. Using the special tool, remove the oil seal and ball bearing from the valve body housing, 17. Remove the oil seal and O-ring from the rack housing, Acaution {carat to darnage the pion vate cytinder frais ofthe rock hash 418. Using the special tool (09573-21200, 09555-21000), remove the oil seal (A) from the rack housing. §\ cauTION Be careful not to damage the rack cylinder inside of the rack housing. (09573-21200 Backup washer (09555.21000ST-26 STEERING SYSTEM INSPECTION | tessa 3. Bearing 1. Rack 1) Check for seizure or abnormal noise during a bearing rotation 1) Check for rack tooth face damage or weer 2) Check for excessive play 2) Check for ol seal contact surface damage 3) Check for missing needle bearing rollers 3) Check for rack bending or twisting 4. Others 4) Check for oll seal ring damage or wear 1) Check for damage of the rack housing cylinder 5) Check for oll seal damage or wear bore VENT HOLE 2) Check for boot damage, cracking or aging 3 Ven hole 2. Pinion valve 1) Check for pinion gear tooth face damage or wear 2) Check for ol seal contact surface damage 3) Check for seal ring damage or wear 4) Check for oll seal damage or wearMECHANICAL POWER STEERING SYSTEM REASSEMBLY 1. Apply the specified fluid to the entire surface of the rack il seal Recommended fluid :PSF-II 2. Install the backup washer and oil seal (A) tothe spec- ified position in the rack housing, casreaoen oasroaran _ f 2] —_ \ =r oasro.s00 3. Apply the specified fluid to the entire surtace of the rack bushing oil seal Recommended fluid :PSF-Ii ST-27 4. Install the oil seal (A) in the rack bushing (B). ‘00424-14200 5. Apply the specified fluid to the entire surface of the (O-ring and install itn the rack bushing, 6. Apply the specified grease to the rack teeth. Recommended grease = Multipurpose grease SAE J310a NLGI No.2 (Ghnore Do not plug the vont hole (A) inthe rack wih groaseST -28 7. Insert the rack (A) into the rack housing (B) and install the rack bushing (C). a A 8. Using a special tool, install the oil seal and the ball bearing in the valve body housing, 8. After applying the specified fluid and grease to the pinion valve assembly (A), installitin the rack housing assembly. STEERING SYSTEM 10. Install the rack support yoke (A), rack support spring (6), yoke plug (C) and lock nut (D) in the order shown, in the ilustration. Apply semi-drying sealant to the threaded section of the yoke plug before installation, 11, Install the locking nut with a specified torque, after ad- justing the rack support york as following instruction. 41). Place the rack in the center position, 2) Tighten the york plug with a specified torque. Specified torque Nm(kgt-mb-ft) Manual 9 ~ 11(0.9 ~ 1.1,6.5 ~ 7.9), Power 20(2,14.5) 3) Reciprocate the rack slowly 5 times. 4) Place the rack in the center position again, and then loosen the york plug, 5) Tighten the york with a specified torque, and turn ata certain degree in reverse. Specified torque Nm(kgfmb-ft) Manual 4.5 ~ 6.5(0.45 ~ 0.65,3.25 ~ 4.70), Power 5 ~ 6(0.5 ~ 0.6,3.62 ~ 4.34) Reverse angle : 25 + 5 (Manual), 35 (Power)MECHANICAL POWER STEERING SYSTEM 6) Tighten the yoke lock nut without moving yoke plug. Specified torque Nm(kaf'm,lb-ft): Manual 40 ~ 50(4 ~ 5,28.9 ~ 36.2), Power 50 ~ 60(6 ~ 6,36.2 ~ 43.4) 12, Tighten the feed tube (A) to the specified torque and install the mounting rubber using adhesive. Tightening torque 25 ~ 30 Nm (2.5 ~ 3 kgfm, 18.0 ~ 21.7 Ib-A) ST -29 13. Apply the specified grease to the bellows mounting position (fiting groove) of the tie rod. Recommended grease ‘Silicone grease 14, instal the new allaching band tothe belows. (Gore When the bellows are installed, a new band must be used. 15. Install the bellows in position, taking care not to twist it 16. Install temporarily the tie rod (A) to the tie rod end (B).ST -30 17. Check for total pinion preload. Total ponion preload : 0.6 ~ 1.3 Nm (6 ~ 13 kgfom, 0.4 ~ 1.0 lb-ft) STEERING SYSTEM INSTALLATION | srceate (wore Be sure to connect between @ lube and a hose as shown lathe Mutation 41. Installation is the reverse of removal. 2. Alter instalation, bleed the power steering system. (See page ST-11) 3. Adjust the wheel alignment, (Refer to SS group)MECHANICAL POWER STEERING SYSTEM ST -31 POWER STEERING HOSES COMPONENTS | csinsce 1, Power steering oll reservoir 4, Retum hose 2. Power steering pump 5. Power steering gear box 3. Pressure hose 6. Cooler tubeST -32 STEERING SYSTEM REPLACEMENT | een 3. Disconnect the pressure tube (A) from the valve body housing. PRESSURE HOSE AND TUBE 1. Drain the power steering fluid by disconnecting the return hose (A). 2. Disconnect the pressure tube (B) from the power 4 Remove the brackets of the pressure tube and hose steering ol pump (A) by loosening eye bolt from the sub-rame. Tightening torque Nm (kgfm, Ib-ft): 55 ~ 85 (4.5 ~ 5.5, 40 ~ 47) 5. Installation is the reverse of removal.MECHANICAL POWER STEERING SYSTEM ST -33 RETUREN HOSE AND TUBE 4, Remove the brackets of the return tube and hose from the sub-rame. WK ‘ 1. Drain the power steering fluid by disconnecting the return hose (A). texcow 5: Installation is the reverse of removal 2. Disconnect the return hose (B) from the power steer- ing fli reservoir (A). 3. Disconnect the return tube (A) from the valve body housing.ST -34 POWER STEERING OIL PUMP COMPONENTS | escescce STEERING SYSTEM TORQUE : Nm (kgfm, tb-ft) 1, Pump cover assembly 6. Side plate spring 2. Gasket 7. Suction pipe 3. Cam ring 8. O-ring (Outer) 4, Rotor & vane 9. O-ring (Inner) 5. Side plate 10. pump body 11. Pump body 42, Flow control spring 48. Connector 14, Eye bolt 16. Pump pulleyMECHANICAL POWER STEERING SYSTEM REMOVAL 1. Disconnect the pressure tube (A) from the oll pump (6) by loosening the eye bolt. Tightening torque Nm (kgm, Ib-f) 55 ~ 65 (5.5 ~ 65, 7) 2. Disconnect the suction hose (C) from the suction pipe © 3. Loosen the tension adjusting bolt (A), and then re- move the oil pump drive belt. Tightening torque Nm (kgf'm, Ib-ft): 25 ~ 33 (2.5 ~ 3.3, 18 ~ 24) ST -35 4. Loosen the power steering pump mounting bolt and rut (A), and then remove the power steering pump assembly from the pump bracket. Tightening torque Nm (kgfm, tb-ft): 20 ~ 27 (2.0 ~ 2.7, 14 ~ 20) ‘Be careful not to spill uid from the power steering oil pump.ST -36 STEERING SYSTEM DISASSEMBLY sere 1. Remove two bolts from the oll pump body (A), and then remave the suction pipe (B) and O-ring, 2. Loosen the four bolts and remove the oll pump cover assembly (A) and the gasket. 4. Remove the cam ring.MECHANICAL POWER STEERING SYSTEM 5. Remove the oil pump side plate (B) and the side plate spring (A). [Gore Wen assembling, use a new gasket and Oxieg 7. 8 ST -37 ‘Mount the pump in a vise and remove the pulley (A) ‘nut and the spring washer. ‘After removing the snap ring (A) of the shaft with snap ‘ing pliers, remove the dust spacer.ST -38 8. Tap the rotor side of the shaft slightly with a plastic hammer (A) to remove the shaft (8). 10, Remove he ol seal fom the ol pump bod, [Gore When assamblng, use @ ow of soa 14, Remove the connector from the oil pump body, and take out the flow control valve (A) and the flow control spring (8). 12, Remove the O-ring from the connector. AS caution Do not disassemble the flow control valve. INSPECTION STEERING SYSTEM Check that the flow control valve is not bent. Check the shaft for wear and damage. Check the V belt for wear and deterioration Check the grooves of the rotor and vanes for stratified abrasion. Check the contact surface of the cam ring and vanes for stratified abrasion, Check vanes for damage. Check that there is no striped wear inthe side plate or contacting part between the shaft and the pump cover, surface,MECHANICAL POWER STEERING SYSTEM ST -39 REASSEMBLY tac 3. After inserting the shaft assembly nto the pump body, install the dust spacer and snap ring (A). 1. Install the flow control spring (B), the flow control valve (A) and the connector into the pump body. 4, Install the pump pulley(A).. Tightening torque 55 ~ 69 Nm (5.5 ~ 6.9 kgfim, 39.8 ~ 49.9 lb-ft) 2. Install the ol seal in the pump body by using the spe- cial tool (09222-32100), 5. Install the inner O-ring and outer O-ring (A).sT~40 6. 7 Insert the spring (A) and the oil pump side plate (B) in the pump body. ‘After inserting the lock pin into the groove of the front housing, install the camring (A) attending to the direc- tion, STEERING SYSTEM 8. Install the rotor and the vanes. Rotor ages 9. Install the gasket and oil pump cover assembly (A).MECHANICAL POWER STEERING SYSTEM 410. Install the O-ring (A) and the suction pipe mounting bolt Tightening torque 13.6 ~ 18.4 Nm (1.36 ~ 1.84 kgfm, 9.84 ~ 13.3 Ib-f) st INSTALLATION 1. Installation is the reverse of removal &\ caution The pressure tube does not twist and come in contact with other components. 2. Adjust the drive belt tension. (See page ST-9) 3. Add power steering fluid 4, Bleed the power steering system. (See page ST-11) 5. Check the oil pump pressure. (See page ST-12)