POWER STEERING SYSTEM

G STEERING

POWER STEERING SYSTEM

SECTION PS B

E
CONTENTS
PRECAUTIONS .......................................................... 2 Removal and Installation ........................................ 14 F
Precautions for Supplemental Restraint System COMPONENT ..................................................... 14
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN- REMOVAL ........................................................... 14
SIONER” .................................................................. 2 INSTALLATION ................................................... 15 PS
Precautions for Steering System .............................. 2 INSPECTION AFTER INSTALLATION ................ 15
PREPARATION ........................................................... 3 Disassembly and Assembly .................................... 16
Special Service Tools [SST] ..................................... 3 COMPONENT ..................................................... 16
H
Commercial Service Tools ........................................ 4 DISASSEMBLY ................................................... 17
NOISE, VIBRATION, AND HARSHNESS (NVH) INSPECTION AFTER DISASSEMBLY ................ 18
TROUBLESHOOTING ................................................ 5 ASSEMBLY ......................................................... 20
NVH Troubleshooting Chart ..................................... 5 POWER STEERING OIL PUMP ............................... 25 I
POWER STEERING FLUID ........................................ 6 On-Vehicle Inspection and Service ......................... 25
Checking Fluid Level ................................................ 6 CHECKING RELIEF OIL PRESSURE ................ 25
Checking Fluid Leakage ........................................... 6 Removal and Installation ........................................ 25 J
Air Bleeding Hydraulic System ................................. 6 REMOVAL ........................................................... 25
STEERING WHEEL .................................................... 8 INSTALLATION ................................................... 26
On-Vehicle Inspection and Service .......................... 8 Disassembly and Assembly .................................... 26
K
CHECKING CONDITION OF INSTALLATION ..... 8 COMPONENT ..................................................... 26
CHECKING STEERING WHEEL PLAY ................ 8 INSPECTION BEFORE DISASSEMBLY ............. 26
CHECKING NEUTRAL POSITION STEERING DISASSEMBLY ................................................... 27
WHEEL ................................................................. 8 INSPECTION AFTER DISASSEMBLY ................ 27 L
CHECKING STEERING WHEEL TURNING ASSEMBLY ......................................................... 28
FORCE .................................................................. 8 HYDRAULIC LINE .................................................... 30
CHECKING FRONT WHEEL TURNING ANGLE..... 9 Component (RHD Models) ..................................... 30 M
Removal and Installation ........................................ 10 Component (LHD Models) ...................................... 32
REMOVAL ........................................................... 10 Removal and Installation ........................................ 33
INSTALLATION ................................................... 10 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 34
STEERING COLUMN ................................................11 Steering Wheel ....................................................... 34
Removal and Installation .........................................11 Steering Angle ........................................................ 34
COMPONENT ......................................................11 Steering Column ..................................................... 34
REMOVAL ............................................................11 Steering Outer Socket and Inner Socket ................ 34
INSPECTION AFTER REMOVAL ....................... 12 Steering Gear ......................................................... 35
INSTALLATION ................................................... 12 Oil Pump ................................................................. 35
INSPECTION AFTER INSTALLATION ............... 13 Steering Fluid .......................................................... 35
POWER STEERING GEAR AND LINKAGE ............ 14

PS-1
 PRECAUTIONS

PRECAUTIONS PFP:00001

Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER” EGS001M0

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.
● Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
Precautions for Steering System EGS001L9

● In case of removing steering gear assembly, make the final tightening with grounded and unloaded vehi-
cle condition, and then check wheel alignment.
● Observe the following precautions when disassembling.
– Before disassembly, thoroughly clean the outside of the unit.
– Disassembly should be done in a clean work area. It is important to prevent the internal parts from becom-
ing contaminated by dirt or other foreign matter.
– For easier and proper assembly, place disassembled parts in order on a parts rack.
– Use nylon cloth or paper towels to clean the parts; common shop rags can leave lint that might interfere
with their operation.
– Do not reuse non-reusable parts.
– Before assembling, apply the specified grease to the directed parts.

PS-2
 PREPARATION

PREPARATION PFP:00002
A
Special Service Tools [SST] EGS001LA

Tool number Description

Tool name B

C
ST27180001
Removing steering wheel
Steering wheel puller

D
S-NT544

ST3127 S000
Preload gauge E
1. GG9103000
Torque wrench
Inspecting of rotating torque for ball joint
2. HT62940000
Socket adapter F
3. HT62900000
Socket adapter S-NT541

PS
KV489Q0030
Rear cover wrench
Removing and installing rear cover
a: 19 mm (0.75 in) H
b: 34.9 mm (1.374 in)

SGIA0516E

KV489Q0020
Teflon ring correcting tool
a: 50 mm (1.97 in) dia. Installing rack Teflon ring J
b: 36 mm (1.42 in) dia.
c: 100 mm (3.94 in) dia.
S-NT550 K

L
KV48103400
Inspecting rotating torque
Preload adapter

M
ZZA0824D

KV48103500
Measuring oil pump relief pressure
Pressure gauge

S-NT547

KV48102500
Measuring oil pump relief pressure
Pressure gauge adapter

S-NT542

PS-3
 PREPARATION

Commercial Service Tools EGS001LB

Tool name Description

● Removing wheel nuts

Power tool
● Removing undercover

PBIC0190E

PS-4
 Symptom

×: Applicable
Reference page

Steering
Noise
Shake

Shimmy
Shudder
Vibration
Possible cause and SUSPECTED PARTS
NVH Troubleshooting Chart

×
Fluid level PS-6

×
Air in hydraulic system PS-6

×
Outer socket ball joint swinging force PS-18

×
Outer socket ball joint rotating torque PS-18

×
Outer socket ball joint end play PS-18

×
Steering fluid leakage PS-6

PS-5
×
Steering wheel play PS-8

×
Steering gear rack sliding force PS-8

×
Drive belt looseness EM-12

×
×
×
Improper steering wheel PS-8

×
×
×
Improper installation or looseness of tilt lock lever —

×
×
×
×
Mounting rubber deterioration PS-18

×
Steering column deformation or damage PS-12

×
Improper installation or looseness of steering column PS-11

×
×
Steering linkage looseness PS-16

×
×
×
PROPELLER SHAFT NVH in PR section

×
DIFFERENTIAL NVH in RFD section
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING

×
×
×
×
×
AXLE and SUSPENSION NVH in FAX, RAX, FSU, RSU section

×
×
×
×
× TYRES NVH in WT section
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING

×
×
×
×
ROAD WHEEL NVH in WT section
Use chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

×
×
×

DRIVE SHAFT NVH in BR section

×
×
×
×

BRAKES NVH in BR section

EGS001LC
PFP:00003

L
F

K
E
B
A

H
D
C

PS

M
 POWER STEERING FLUID

POWER STEERING FLUID PFP:KLF20

Checking Fluid Level EGS001LD

● Check fluid level with engine stopped.

● Make sure that fluid level is between MIN and MAX.
● Fluid levels at HOT and COLD are different. Do not confuse
them.
HOT : Fluid temperature 50 - 80 °C (122 - 176°F)
COLD : Fluid temperature 0 - 30 °C (32 - 86°F)
CAUTION:
● The fluid level should not exceed the MAX line. Excessive
fluid will cause fluid leakage from the cap.
● Do not reuse drained power steering fluid.
SGIA0232J
● Recommended fluid is Type DEXRONTM III or equivalent.
Checking Fluid Leakage EGS001LE

Check hydraulic connections for fluid leakage, cracks, damage,

looseness, or wear.
1. Run engine until the fluid temperature reaches 50 to 80°C (122
to 176°F) in reservoir tank, and keep engine speed idle.
2. Turn steering wheel several times from full left stop to full right
stop.
3. Hold steering wheel at each lock position for five seconds and
carefully, check for fluid leakage.
CAUTION:
Do not hold the steering wheel in a locked position for more SGIA0506E
than 10 seconds. (There is the possibility that oil pump may
be damaged.)
4. If fluid leakage at connections is noticed, then loosen flare nut and then retighten. Do not over-tighten con-
nector as this can damage O-ring, washer and connector.
5. If fluid leakage from oil pump is noticed, check oil pump. Refer to PS-25, "POWER STEERING OIL
PUMP" .
6. Check steering gear boots for accumulation of fluid, indicating from steering gear.
Air Bleeding Hydraulic System EGS001LF

If air bleeding is not complete, the following symptoms can be observed.

● Bubbles are created in reservoir tank.
● Clicking noise can be heard from oil pump.
● Excessive buzzing in the oil pump
NOTE:
Fluid noise may occur in the steering gear or oil pump. This does not affect performance or durability of
the system.
1. Turn steering wheel several times from full left to full right stop with engine off.
CAUTION:
Turn steering wheel while filling reservoir tank with fluid so as not to lower fluid level below the
MIN line.
2. Start engine and hold steering wheel at each lock position for 3 seconds at idle to check for fluid leakage.
3. Repeat step 2 above several times at approximately 3 second intervals.
CAUTION:
Do not hold the steering wheel in a locked position for more than 10 seconds. (There is the possi-
bility that oil pump may be damaged.)
4. Check fluid for bubbles and while contamination.

PS-6
 POWER STEERING FLUID

5. Stop engine if bubbles and white contamination do not drain out. Perform step 2 and 3 above after waiting
until bubbles and white contamination drain out. A
6. Stop the engine, and then check fluid level.

PS

PS-7
 STEERING WHEEL

STEERING WHEEL PFP:48430

On-Vehicle Inspection and Service EGS001LG

CHECKING CONDITION OF INSTALLATION

● Check installation conditions of steering gear assembly, front suspension assembly, axle and steering col-
umn assembly.
● Check if movement exists when steering wheel is moved up and down, to the left and right and to the axial
direction.
Steering wheel axial end play : 0 mm (0 in)

● Check steering gear assembly mounting bolts and nuts for looseness. Refer to PS-14, "COMPONENT" .
CHECKING STEERING WHEEL PLAY
● Turn steering wheel so that front wheels come to the straight-ahead position. Start engine and lightly turn
steering wheel to the left and right until front wheels start to move. Measure steering wheel movement on
the outer circumference.
Steering wheel play : 0 - 35 mm (0 - 1.38 in)
● When the measurement value is outside the standard value, check backlash for each joint of steering col-
umn assembly and installation condition of steering gear assembly.
CHECKING NEUTRAL POSITION STEERING WHEEL
● Make sure that steering gear assembly, steering column assembly and steering wheel are installed in the
correct position.
● Perform neutral position inspection after wheel alignment. Refer to FSU-7, "Front Wheel Alignment" .
● Set vehicle to the straight-ahead position and confirm steering wheel is in the neutral position.
● Loosen outer socket lock nut and turn inner socket to left and right equally to make fine adjustment if
steering wheel is not in the neutral position.
CHECKING STEERING WHEEL TURNING FORCE
1. Park vehicle on a level and dry surface, set parking brake.
2. Start engine.
3. Bring power steering fluid up to adequate operating temperature. [Make sure temperature of fluid is
approximately 50 to 80°C (122 to 176°F).]
4. Check steering wheel turning force when steering wheel has
been turned 360° from neutral position.
Steering wheel turn- : Less than 39 N (4.0 kg-m, 8.8 lb)
ing force
NOTE:
Multiply the distance (L) from the hook of spring scale to the
center of steering wheel by the measurement value with a spring
scale.
5. If steering wheel turning force is out of the specification, check
rack sliding force and relief hydraulic pressure of oil pump. SGIA1136E
Regarding relief hydraulic pressure of oil pump, refer to PS-25,
"CHECKING RELIEF OIL PRESSURE" .
a. Disconnect lower joint and steering knuckle from steering gear assembly. Refer to PS-11, "COMPO-
NENT" , FAX-5, "Removal and Installation" .
b. Start and run engine at idle to make sure steering fluid has reached normal operating temperature.

PS-8
 STEERING WHEEL

c. While pulling outer socket slowly in ± 11.5 mm (± 0.453 in) range

from neutral position, make sure rack sliding force is within A
specification.
Rack sliding force: 210 - 270 N
(21.4 - 27.5 kg, 47.2 - 60.6 lb) B

d. If rack sliding force is not within specification, overhaul steering

gear assembly.
C

SST090B

D
CHECKING FRONT WHEEL TURNING ANGLE
● Check front wheel turning angle after toe-in inspection. Place
front wheels on turning radius gauges and rear wheels on
stands. Check the maximum inner and outer wheel turning E
angles for LH and RH road wheels.

PS

FAA0016D

H
● With the engine at idle, turn steering wheel from full left stop to
full right stop and measure the turning angles.

2WD 33° 31′ - 35° 31′ I

(33.5° - 36.5°)
Inner wheel (Angle: A)
4WD 33° 48′ - 35° 48′
(33.8° - 35.8°) J
2WD 29° 23′ - 31° 23′
(29.4° - 31.4°)
Outer wheel (Angle: B) K
4WD 29° 40′ - 31° 40′ SGIA0055E

(29.7° - 31.7°)

● Measure rack stroke if angles are outside the specified value. L

Rack stroke “L” : 84 mm (3.31 in)

● Disassemble steering gear assembly to check the cause that M
rack stroke is outside of the standard.
● Steering angles are not adjustable. Check steering gear assem-
bly, steering column assembly and front suspension compo-
nents for wear or damage if any of the turning angles are
different from the specified value. Replace any of them, if any
non-standard condition exists.
SGIA0629J

PS-9
 STEERING WHEEL

Removal and Installation EGS001LH

REMOVAL
NOTE:
When reconnecting spiral cable, fix cable with a tape so that fixing case and rotating part keep aligned. This
will omit neutral position alignment procedure during spiral installation.
1. Set vehicle to the straight-ahead position.
2. Remove driver air bag module. Refer to SRS-36, "DRIVER AIR BAG MODULE" .
3. Remove steering wheel lock nut after steering is locked.
4. Remove steering wheel with the steering wheel puller [SST:
ST27180001] (A).

SGIA1323E

INSTALLATION
Reverse the removal procedure for installation attentive to the following operation.
NOTE:
Make sure that the spiral cable is in the neutral position. The neutral
position is detected by turning left 2.6 revolutions from the right end
position and ending with the locating pin at the top.
CAUTION:
Do not run spiral cable idle needlessly. And do not turn it more
than necessary (or it leads to disconnection of the cable).

PHIA0275E

PS-10
 STEERING COLUMN

STEERING COLUMN PFP:48810

A
Removal and Installation EGS001LI

COMPONENT
B

PS

SGIA1221E
K
1. Steering wheel 2. Combination switch & spiral cable 3. Steering column assembly
4. Upper joint 5. Collar 6. Hole cover seal
L
7. Clamp 8. Hole cover mounting plate 9. Hole cover
10. Upper shaft 11. Boot clamp 12. Lower shaft
13. Boot 14. Clips (plastic) 15. Spring
M
Refer to GI-10, "Components" for the symbols in the figure.

CAUTION:
● Do not give axial impact to steering column assembly during removal and installation.
● Do not move steering gear assembly when removing steering column assembly.
REMOVAL
1. Set vehicle to the straight ahead-position.
2. Remove driver air bag module. Refer to SRS-36, "DRIVER AIR BAG MODULE" .
3. Remove steering wheel. Refer to PS-10, "Removal and Installation" .
4. Remove steering column cover (upper and lower). Refer to IP-10, "INSTRUMENT PANEL ASSEMBLY" .
5. Remove combination switch & spiral cable. Refer to SRS-38, "SPIRAL CABLE" .
6. Remove lower instrument panel LH. Refer to IP-10, "INSTRUMENT PANEL ASSEMBLY" .
7. Disconnect each switch connectors installed to steering column assembly, and then disconnect harness
from steering column assembly.
8. Remove fixing bolt of upper joint (steering column assembly side), and then remove upper joint from
steering column assembly.

PS-11
 STEERING COLUMN

9. Remove steering column assembly mounting nuts, and then remove steering column assembly from vehi-
cle.
10. Remove fixing bolt and nut of upper joint (lower side), and then remove upper joint and collar from upper
shaft.
11. Loosen clamp, and then remove hole cover seal from hole cover.
12. Remove mounting nuts of hole cover, and then remove clamp, hole cover mounting plate and hole cover
from dash panel.
13. Raise vehicle.
14. Remove fixing bolt of lower shaft (lower side), and then remove lower shaft and upper shaft from vehicle.
INSPECTION AFTER REMOVAL
● Check component parts for damage or other malfunctions. Replace if there are.
● Measure the length “L” as shown in the figure if vehicle has been
involved in a minor collision. Replace steering column assembly
if outside the standard.
Steering column length “L” : 423.1 mm (16.66 in)
● Measure steering column assembly rotating torque using pre-
load gauge [SST: ST3127S000]. Replace steering column
assembly if outside the standard.
Rotating torque : 0 - 0.2 N·m (0 - 0.02 kg-m, 0 - 1 in-lb)
SGIA1222E

INSTALLATION
● Installation is the reverse order of removal. For tightening torque, refer to PS-11, "COMPONENT" .
● When installing lower shaft to steering gear assembly, follow the procedure listed below.
– Set rack of steering gear in the neutral position.
NOTE:
To get the neutral position of rack, turn pinion assembly and measure the distance of inner socket, and
then measure the intermediate position of the distance.
– Align rear cover cap projection (A) with the marking position (B)
of gear housing assembly.
– Install slit part of lower shaft (C) aligning with the projection (A)
of rear cover cap (1). Make sure that the slit part of lower shaft
(C) is aligned with both the projection (A) of rear cover cap (1)
and the marking position (B) of gear housing assembly.

SGIA1140E

PS-12
 STEERING COLUMN

INSPECTION AFTER INSTALLATION

● Check tilt mechanism operating range “A” as shown in the fig- A
ure.
Operating range “A” : 73.8 mm (2.906 in)
B
● Make sure that steering wheel operates smoothly by turning
several times from full left stop to full right stop.
C

WGIA0083E
D

PS

PS-13
 POWER STEERING GEAR AND LINKAGE

POWER STEERING GEAR AND LINKAGE PFP:49001

Removal and Installation EGS001LJ

COMPONENT

SGIA1315E

1. Cotter pin 2. Steering gear assembly 3. Rack mounting bracket

4. Rack mounting insulator 5. Washer 6. RHD models
Refer to GI-10, "Components" for the symbols in the figure.

CAUTION:
Spiral cable may be cut if steering wheel turns while separating steering column assembly and steer-
ing gear assembly. Be sure to secure steering wheel using string to avoid turning.
REMOVAL
1. Set vehicle to the straight-ahead position.
2. Remove tyres from vehicle with a power tool.
3. Remove undercover from vehicle with a power tool.
4. Remove lower side fixing bolt of lower shaft.
5. Remove cotter pin (1), and then loosen the nut.
6. Remove steering outer socket (2) from steering knuckle (3) so
as not to damage ball joint boot (4) using the ball joint remover
(suitable tool).
CAUTION:
Temporarily tighten the nut to prevent damage to threads
and to prevent the ball joint remover (suitable tool) from
suddenly coming off.

SGIA1183E

PS-14
 POWER STEERING GEAR AND LINKAGE

7. Remove high and low pressure piping of hydraulic piping, and

then drain power steering fluid. Refer to PS-6, "POWER A
STEERING FLUID" .
8. Remove steering hydraulic piping bracket from front suspension
member. Refer to PS-30, "HYDRAULIC LINE" . B
9. Remove mounting bolts and nuts of steering gear assembly, and
then remove steering gear assembly, rack mounting bracket,
rack mounting insulator and washer from vehicle.
C

LGIA0032E

D
INSTALLATION
● Installation is the reverse order of removal. For tightening torque, refer to PS-14, "COMPONENT" .
● When installing lower shaft to steering gear assembly, follow the procedure listed below. E
– Set rack of steering gear in the neutral position.
NOTE:
To get the neutral position of rack, turn pinion assembly and measure the distance of inner socket, and F
then measure the intermediate position of the distance.
– Align rear cover cap projection (A) with the marking position (B)
of gear housing assembly.
PS
– Install slit part of lower shaft (C) aligning with the projection (A)
of rear cover cap (1). Make sure that the slit part of lower shaft
(C) is aligned with both the projection (A) of rear cover cap (1)
and the marking position (B) of gear housing assembly. H
● After installation, bleed air from the steering hydraulic system.
Refer to PS-6, "Air Bleeding Hydraulic System" .
● Perform final tightening of nuts and bolts on each part under I
unladen conditions with tyres on level ground when removing
steering gear assembly. Check wheel alignment. Refer to FSU- SGIA1140E

7, "Front Wheel Alignment" . J

INSPECTION AFTER INSTALLATION
Make sure that steering wheel operates smoothly by turning several times from full left stop to full right stop.
K

PS-15
 POWER STEERING GEAR AND LINKAGE

Disassembly and Assembly EGS001LK

COMPONENT

SGIA1349E

1. Outer socket 2. Boot clamp 3. Boot

4. Inner socket 5. Boot clamp 6. Gear housing assembly
7. Cylinder tubes 8. Rear cover cap 9. Rear cover
10. O-ring A 11. Pinion assembly 12. Rack oil seal
13. Rack assembly 14. Rack Teflon ring 15. O-ring B
16. End cover assembly
Refer to GI-10, "Components" and the followings for the symbols in the figure.
: Apply Type DEXRONTM III or equivalent.
: Apply Genuine Thread Locking Sealant, Three Bound TB1111 or equivalent.

: Apply multi-purpose grease.

CAUTION:
● Disassemble and assemble steering gear assembly by securing the mounting area in a vise using
copper plates.
● Clean steering gear assembly with kerosene before disassembling. Be careful to avoid splashing
or applying any kerosene over connector of discharge port or return port.

PS-16
 POWER STEERING GEAR AND LINKAGE

DISASSEMBLY
1. Remove cylinder tubes from gear housing assembly. A
2. Remove rear cover cap from gear-sub assembly.
3. Using a rear cover wrench [SST: KV489Q0030] (A) to remove
rear cover from pinion assembly. B

SGIA1331E
E
4. Remove O-ring A using a flat-bladed screwdriver, and pull out
rear cover.
F

PS

H
SGIA0508E

5. Measure adjusting screw height “H”, and loosen adjusting I

screw.
CAUTION:
● Do not loosen adjusting screw 2 turns or more.
J
● Replace steering gear assembly if adjusting screw is
loosened 2 turns or more and it is removed.
6. Remove pinion assembly from gear housing assembly. K
7. Loosen outer socket lock nut, and remove outer socket.
8. Remove boot clamp, and then remove boot from inner socket.
CAUTION: SGIA0624E L
Do not damage inner socket and gear housing assembly
when removing boot. Inner socket and gear housing assembly must be replaced if inner socket
and gear housing assembly are damaged because it may cause foreign material interfusion. M
9. Remove inner socket from gear housing assembly.
10. Drill out the clinching part of gear housing assembly (end cover
assembly side) outer rim with a 3 mm (0.12 in) drill bit. [Drill for
approximately 1.5 mm (0.059 in) depth.]

STC0013D

PS-17
 POWER STEERING GEAR AND LINKAGE

11. Remove end cover assembly with a 45 mm (1.77 in) open head
(suitable tool).
CAUTION:
Do not damage rack assembly surface when removing.
Rack assembly must be replaced if damaged because it
may cause fluid leakage.
12. Pull rack assembly together with rack oil seal (outer side) out
from gear housing assembly.
CAUTION:
Do not damage cylinder inner wall when removing rack
assembly. Gear housing assembly must be replaced if dam- SST081B

aged because it may cause fluid leakage.

13. Heat rack Teflon ring to approximately 40°C (104°F) with a
dryer, and remove rack Teflon ring and O-ring B from rack
assembly.
CAUTION:
Do not damage rack assembly. Rack assembly must be
replaced if damaged because it may cause fluid leakage.

SGIA0151E

14. Push rack oil seal inside with a 29 mm (1.14 in) socket and an
extension bar to push out rack oil seal (inner side) from gear
housing assembly.
CAUTION:
Do not damage gear housing assembly and cylinder inner
wall. Gear housing assembly must be replaced if damaged
because it may cause fluid leakage.

SGIA0179E

INSPECTION AFTER DISASSEMBLY

Boot
Check boot for cracks, and replace it if a malfunction is detected.
Rack Assembly
Check rack for damage or wear, and replace it if a malfunction is detected.
Pinion Assembly
● Check pinion assembly for damage or wear, and replace it if a malfunction is detected.
● Rotate pinion and check for torque variation or rattle, and replace it if a malfunction is detected.
Gear Housing Assembly
Check gear housing assembly for damage and scratches (inner wall). Replace if there are.
Outer Socket and Inner Socket
1. Ball joint swinging torque

PS-18
 POWER STEERING GEAR AND LINKAGE

● Hook a spring balance at the point shown in the figure and

pull the spring balance. Make sure that the spring balance A
reads the specified value when ball stud and inner socket
start to move. Replace outer socket and steering gear assem-
bly if they are outside the standard.
B

SGIA0896E

Items Outer socket Inner socket

Measuring point at *mark E
Measuring point of spring balance Stud cotter pin mounting hole
shown in the figure
0.3 - 2.9 N·m 1.0 - 7.8 N·m
Swinging torque F
(0.03 - 0.29 kg-m, 3.0 - 25 in-lb) (0.11 - 0.79 kg-m, 9.0 - 69 in-lb)
4.84 - 46.7 N 12.1 - 93.7 N
Spring balance measurement
(0.5 - 4.8 kg, 1.1 - 10.6 lb) (1.2 - 9.6 kg, 2.6 - 21.2 lb) PS
2. Ball joint rotating torque
● Make sure that the reading is within the following specified
range using the preload gauge [SST]. Replace outer socket if H
the reading is outside the specified value.

Outer socket 0.3 - 2.9 N·m

rotating torque (0.03 - 0.29 kg-m, 3.0 - 25 in-lb I

SGIA0083E

K
3. Ball joint axial end play
● Apply an axial load of 490 N (50 kg, 111 lb) to ball stud using a
dial gauge. Measure amount of stud movement, and then L
make sure that the value is within the following specified
range. Replace outer socket and inner socket if the measured
value is outside the standard.
M
Outer socket 0.5 mm (0.020 in) or less
Inner socket 0.2 mm (0.008 in) or less

SGIA0057E

PS-19
 POWER STEERING GEAR AND LINKAGE

ASSEMBLY
1. Apply recommended fluid to O-ring B. Put an O-ring B into a rack Teflon ring.
2. Heat rack Teflon ring to approximately 40° C (104°F) with a
dryer. Assemble it to mounting groove of rack assembly.

SGIA0153E

3. Install the Teflon ring correcting tool [SST: KV489Q0020] (A)

from tooth side of rack to fit rack Teflon ring (1) on rack. Com-
press the ring with tool.

SGIA1324E

4. Apply recommended grease to rack oil seal. And install rack oil
seal in the following procedure. Then assemble rack assembly
to gear housing assembly.
CAUTION:
● Install rack oil seal in a direction so that the lip of inner oil
seal and the lip of outer oil seal face each other.
● Do not damage retainer sliding surface by rack assembly.
Replace gear housing assembly if damaged.
● Do not damage gear housing assembly inner wall by rack
assembly. Gear housing assembly must be replaced if
damaged because it may cause fluid leakage. SGIA0205E

a. Wrap an OHP sheet [approximately 70 mm (2.76 in) × 100 mm

(3.94 in)]. Around rack assembly teeth to avoid damaging rack
oil seal (inner). Install rack oil seal over sheet. Then, pull oil seal
along with OHP sheet until they pass rack assembly teeth, and
remove OHP sheet.

SGIA0155E

PS-20
 POWER STEERING GEAR AND LINKAGE

b. Insert rack oil seal (inner) into rack assembly piston (rack Teflon
ring). A
c. Push retainer to adjusting screw side by hand, and move the
rack assembly inside the gear housing assembly so that the
rack oil seal (inner) can be pressed against the gear housing B
assembly.

SGIA0671E

D
d. Wrap an OHP sheet [approximately 70 mm (2.76 in) × 100 mm
(3.94 in)]. Around the edge to avoid damaging rack oil seal
(outer). Install rack oil seal over sheet. Then, pull oil seal along
E
with OHP sheet until they pass rack edge, and remove OHP
sheet.
e. Install end cover assembly to rack edge, and move rack oil seal
(outer) until it contacts with gear housing assembly. F

PS
SGIA0157E

5. Tighten end cover assembly to specified torque using a 45 mm H

(1.77 in) open head (suitable tool).
CAUTION:
Do not damage rack assembly. Replace it if damaged
because it may cause fluid leakage. I

SST081B
K
6. Crimp gear housing assembly at one point using a punch as
shown in the figure so as to prevent end cover assembly from
getting loose after tightening end cover assembly. L
7. Install pinion assembly to gear housing assembly.
CAUTION:
In order to protect rack oil seal from any damage, insert pin- M
ion assembly out straightly.
8. Apply recommended fluid to O-ring A. Install O-ring A to rear
cover.
SGIA0871E

9. Using a rear cover wrench [SST: KV489Q0030] (A), install rear

cover to gear housing assembly.

SGIA1331E

PS-21
 POWER STEERING GEAR AND LINKAGE

10. Decide on the neutral position for the rack.

Rack stroke : 84 mm (3.31 in)
11. Install rear cover cap to gear sub-assembly.
CAUTION:
Make sure that the projection of rear cover cap is aligned
with the marking position of gear housing assembly.

SGIA0877E

12. Apply recommended thread locking sealant to the thread (2

turns thread), and then screw in the adjusting screw until it
reaches height “H” from gear housing assembly measured
before disassembling.
13. Move rack assembly 10 strokes throughout the full stroke so that
the parts can fit with each other.

SGIA0624E

14. Measure pinion rotating torque within ±180° of neutral position

of the rack assembly using the preload gauge [SST] and preload
adapter [SST]. Stop the gear at the point where highest torque is
read.
15. Loosen adjusting screw and retighten to 5.4 N·m (0.55 kg-m, 48
in-lb), and then loosen by 20 to 40°.

STC0036D

16. Measure pinion rotating torque using the preload adapter [SST]
and preload gauge [SST] to make sure that the measured value
is within the standard. Readjust if the value is outside the stan-
dard. Replace steering gear assembly if the value is outside the
standard after readjusting or adjusting screw rotating torque is 5
N·m (0.51 kg-m, 44 in-lb) or less.

Pinion rotating torque standard

Around neutral position 0.8 - 2.0 N·m
(within±100°) Average A (0.09 - 0.20 kg-m, 7.0 - 17 in-lb)
SGIA0936E
Maximum variation B 2.3 N·m (0.23 kg-m, 20 in-lb)
17. Apply recommended thread locking sealant to inner socket and turn pinion fully to left with inner socket
installed to gear housing assembly.

PS-22
 POWER STEERING GEAR AND LINKAGE

18. Set dial gauge as shown in the figure. Measure vertical move-
ment of rack assembly when pinion is turned clockwise with A
torque of 19.6 N·m (2.0 kg-m, 14 ft-lb). Readjust adjusting screw
angle if the measured value is outside the standard. Replace
steering gear assembly if the measured value is still outside the
B
standard or adjusting screw rotating torque is 5 N·m (0.51 kg-m,
44 in-lb) or less.

SGIA1147E

D
Rack axial direction 5 mm (0.20 in) from housing end surface
Measuring point
Rack radial direction Axial direction of the adjusting screw
Vertical movement 0.265 mm (0.0104 in) E
19. Install large end of boot to gear housing assembly.
20. Install small end of boot to inner socket boot mounting groove.
F

PS

SGIA1325E

21. Install boot clamps to boots, as shown in the figure. I

AST139

PS-23
 POWER STEERING GEAR AND LINKAGE

22. Crimp the large-diameter boot clamp using suitable tool.

23. Install cylinder tubes to gear housing assembly.

RAC1133D

24. Adjust inner socket to standard length “L”, and then tighten lock
nut to the specified torque. Refer to PS-16, "COMPONENT" .
Check length of inner socket “L” again after tightening lock nut.
Make sure that the length is the standard.
Inner socket length “L” : 79 mm (3.11 in)
CAUTION:
Adjust toe-in after this procedure. Length achieved after
toe-in adjustment is not necessary the above value.

SGIA0167E

PS-24
 POWER STEERING OIL PUMP

POWER STEERING OIL PUMP PFP:49110

A
On-Vehicle Inspection and Service EGS001LL

CHECKING RELIEF OIL PRESSURE

CAUTION: B
Make sure that belt tension is normal before starting the following procedure.
1. Connect the hydraulic pressure gauge [SST] between oil pump
discharge connector and high-pressure hose. Bleed air from the
hydraulic circuit while opening valve fully. Refer to PS-6, "Air C
Bleeding Hydraulic System" .
2. Start engine. Run engine until oil temperature reaches 50 to
80°C (122 to 176°F). D
CAUTION:
● Leave the valve of the hydraulic pressure gauge [SST]
fully open while starting and running engine. If engine is E
started with the valve closed, the hydraulic pressure in
oil pump goes up to the relief pressure along with
unusual increase of oil temperature.
F
● Be sure to keep hose clear or belts and other parts when
engine is started.
3. Fully close the hydraulic pressure gauge [SST] valve with PS
engine at idle and measure the relief oil pressure.
Relief oil pressure:
8,500 - 9,300 kpa (86.7 - 94.9 kg/cm2 , 1,233 - 1,349 psi) H

CAUTION:
Never keep valve closed for 10 seconds or longer.
I
4. Open the valve slowly after measuring. Repair oil pump is the SGIA1225E

relief oil pressure is outside the standard. Refer to PS-26, "Dis-

assembly and Assembly" .
5. After inspection, disconnect the hydraulic pressure gauge [SST] from hydraulic circuit, then add fluid and J
bleed air. Refer to PS-6, "Air Bleeding Hydraulic System" .
Removal and Installation EGS001LM
K
REMOVAL
1. Drain power steering fluid from reservoir tank.
2. Remove radiator shroud. Refer to CO-11, "Components" . L
3. Loosen drive belt. Refer to EM-12, "DRIVE BELTS" .
4. Remove drive belt from oil pump pulley.
5. Disconnect the pressure sensor electrical connector. M
6. Remove piping of high pressure and low pressure (drain fluid from their pipings). Refer to PS-30,
"HYDRAULIC LINE" .
7. Remove oil pump mounting bolts, and then remove power steering pump. Refer to PS-30, "HYDRAULIC
LINE" .

PS-25
 POWER STEERING OIL PUMP

INSTALLATION
Installation is the reverse order of removal. For tightening torque, refer to PS-30, "HYDRAULIC LINE" .
● Perform the following procedure after installing.
– Adjust belt tension. Refer to EM-12, "DRIVE BELTS" .
– Bleed air. Refer to PS-6, "Air Bleeding Hydraulic System" .
Disassembly and Assembly EGS001LN

COMPONENT

SGIA1318E

1. Pulley 2. Front bracket 3. Snap ring

4. Oil seal 5. Drive shaft 6. Body assembly
7. Suction pipe 8. O-ring A 9. Spring
10. Flow control valve 11. Copper washer 12. Joint
13. O-ring B 14. Side plate 15. Rotor
16. Cartridge 17. Vane 18. Cam ring
19. Dowel pin 20. Gasket 21. Rear cover
22. Rear bracket
Referr to GI-10, "Components" and the followings for the symbols in the figure.
: Apply Type DEXRONTM III or equivalent.
: Apply multi-purpose grease.

INSPECTION BEFORE DISASSEMBLY

Disassemble oil pump only when the following malfunctions occur.
● If oil leakage is found on oil pump.
● Oil pump pulley is damaged or deformed.
● Performance of oil pump is low.

PS-26
 POWER STEERING OIL PUMP

DISASSEMBLY
NOTE: A
Secure oil pump in a vise if necessary.
CAUTION:
Use copper plates when securing in a vise. B
1. Remove rear bracket mounting bolts, and then remove rear bracket from rear cover.
2. Remove rear cover mounting bolts, and then remove rear cover from body assembly.
3. Remove gasket from body assembly. C
4. Remove dowel pin, cartridge and side plate from body assembly.
5. Remove pulley mounting nut and washer, then remove pulley from drive shaft.
D
6. Remove snap ring from drive shaft and press out it.
CAUTION:
When removing snap ring, be careful not to damage drive
E
shaft.

PS
SST010B

7. Remove oil seal from body assembly using flat-bladed screw

driver. H
8. Remove O-ring B from body assembly.

SST034A
K
9. Remove eye bolt, and then remove joint and copper washer,
then pull out flow control valve and spring from body assembly.
10. Remove fixing bolts of suction pipe, and then remove suction L
pipe from body assembly.
11. Remove O-ring A from body assembly.
12. Remove mounting bolts of front bracket, and then remove front M
bracket from body assembly.

SGIA0524E

INSPECTION AFTER DISASSEMBLY

Body Assembly and Rear Cover Inspection
Check body assembly and rear cover for internal damage. Replace rear cover if it is damaged. Replace oil
pump assembly if body assembly is damaged.
Cartridge Assembly Inspection
Check cam ring, rotor and vane for damage. Replace cartridge assembly if there are.
Side Plate Inspection
Check side plate for damage. Replace side plate if there are.

PS-27
 POWER STEERING OIL PUMP

Flow Control Valve Inspection

Check flow control valve and spring for damage. Replace if there are.
ASSEMBLY
NOTE:
Secure oil pump in a vise if necessary.
CAUTION:
Use copper plates when securing in a vise.
1. Apply recommended grease to oil seal lips (1). Apply recom-
mended fluid to around oil seal, and then install oil seal to body
assembly.
2. Apply recommended fluid to drive shaft, and press drive shaft
into body assembly, then install snap ring.
3. Apply recommended fluid to O-ring B, and install O-ring B into
body assembly.

SGIA1150E

4. Install side plate to body assembly.

SGIA0422E

5. Install dowel pin (3) into dowel pin hole (A), and install cam ring
(2) pointing it's D1 side toward the body assembly (1) side as
shown in the figure.
● When installing cam ring, turn carved face with a letter E (B)
of it to rear cover.
CAUTION:
Do not confuse the assembling direction of cam ring. If
cam ring is installed facing the incorrect direction, it may
cause oil pump operation malfunction.
6. Install rotor to body assembly.

SGIA1166E

PS-28
 POWER STEERING OIL PUMP

● When installing rotor, turn mark face on rotor to body assem-

bly. A

SGIA0874E

D
7. Install vane to rotor so that arc of vane faces cam ring side.
8. Check if drive shaft turns smoothly.
9. Install gasket to body assembly. E

PS
SGIA0613E

10. Install rear cover to body assembly, and then tighten mounting H
bolts to the specified torque.
11. Install rear bracket to body assembly, and tighten the mounting
bolts to the specified torque.
I
12. Install front bracket to body assembly, and tighten the mounting
bolts to the specified torque.
13. Install pulley and washer to drive shaft, and then tighten lock nut
at the specified torque. J
14. Install spring, flow control valve, copper washer, joint and eye-
bolt to body assembly. Then tighten eye-bolt to the specified SGIA0425E
torque. K
15. Apply recommended fluid to O-ring A, and then install O-ring A to body assembly.
16. Install suction pipe to body assembly.
L

PS-29
 HYDRAULIC LINE

HYDRAULIC LINE PFP:49721

Component (RHD Models) EGS001LO

CAUTION:
Securely insert harness connector to pressure sensor.

SGIA1319E

1. Reservoir tank 2. Reservoir tank bracket 3. Suction hose

4. High pressure hose 5. Oil pump assembly 6. Steering gear assembly

PS-30
 HYDRAULIC LINE

7. Eye-bolt 8. Pressure sensor 9. Copper washer

10. Eye-joint (assembled to 11. O-ring 12. Low pressure piping A
high pressure side hose)
13. High pressure piping
Refer to GI-9, "HOW TO USE THIS MANUAL" and the followings for the symbols in the figure. B
: Apply Type DEXRONTM III or equivalent.

PS

PS-31
 HYDRAULIC LINE

Component (LHD Models) EGS001LP

CAUTION:
Securely insert harness connector to pressure sensor.

SGIA1320E

1. Reservoir tank 2. Reservoir tank bracket 3. Suction hose

4. High pressure hose 5. Oil pump assembly 6. Steering gear assembly
7. Eye-bolt 8. Pressure sensor 9. Copper washer

PS-32
 HYDRAULIC LINE

10. Eye-joint (assembled to 11. O-ring 12. Low pressure piping

high pressure side hose) A
13. High pressure piping
Refer to GI-9, "HOW TO USE THIS MANUAL" and the followings for the symbols in the figure.
: Apply Type DEXRONTM III or equivalent. B

Removal and Installation EGS001LQ

● Insert hose securely until it contacts tube spool. C

CAUTION:
Do not apply fluid.
D

SGIA0514E
F

● Install eye-bolt with eye-joint (assembled to high-pressure hose)

protrusion facing with pump side cutout, and then tighten it to PS
the specified torque after tightening by hand.

SGIA0515E

PS-33
 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

Steering Wheel EGS001LR

Steering wheel axial end play 0 mm (0 in)

Steering wheel play 0 - 35 mm (0 - 1.38 in)

Steering Angle EGS001LS

Inner wheel 2WD 33° 31′ - 35° 31′ (33.5° - 36.5°)

Degree minute (Decimal degree) 4WD 33° 48′ - 35° 48′ (33.8° - 35.8°)

Outer wheel 2WD 29° 23′ - 31° 23′ (29.4° - 31.4°)

Degree minute (Decimal degree) 4WD 29° 40′ - 31° 40′ (29.7° - 31.7°)

Steering Column EGS001LT

Steering column length “L” 423.1 mm (16.66 in)

SGIA1222E

Steering Outer Socket and Inner Socket EGS001LU

Steering gear type PR32AM

Swinging torque 0.3 - 2.9 N·m (0.03 - 0.29 kg-m, 3.0 - 25 in-lb)
Measurement on spring balance
4.84 - 46.7 N (0.5 - 4.8 kg, 1.1 - 10.6 lb)
Outer socket Measuring point: cotter pin hole of stud
Rotating torque 0.3 - 2.9 N·m (0.03 - 0.29 kg-m, 3.0 - 25 in-lb)
Axial end play 0.5 mm (0.020 in) or less
Swinging torque 1.0 - 7.8 N·m (0.11 - 0.79 kg-m, 9.0 - 69 in-lb)
● Measurement on spring balance
Inner socket 12.1 - 93.7 N (1.2 - 9.6 kg, 2.6 - 21.2 lb)
● Measuring point at *mark shown in the figure
Axial end play 0.2 mm (0.008 in) or less
Inner socket length “L” 79 mm (3.11 in)

SGIA0950E

PS-34
 SERVICE DATA AND SPECIFICATIONS (SDS)

Steering Gear EGS001LV

A
Steering gear model PR32AM
Rack neutral position, dimension “L” (rack stroke) 84 mm (3.31 in)
B

SGIA0877E
E

Oil Pump EGS001LW

F
Oil pump relief hydraulic pressure 8,500 - 9,300 kpa (86.7 - 94.9 kg/cm2 , 1,233 - 1,349 psi)

Steering Fluid EGS001LX

PS
Fluid capacity Approx. 1.0 (1 - 1/8 US qt, 7/8 Imp qt)

PS-35
SERVICE DATA AND SPECIFICATIONS (SDS)

PS-36