Installation
INSTALLATION - POWER STEERING GEARNOTE: When the original or a replacement steering gear is being installed in vehicle, be sure the tie rod attachment at the steering gear is in the center of steering gear travel.
1. Install the steering gear in the vehicle using the reverse sequence of the removal steps.
NOTE: If the vehicle is equipped with a 2.7 Liter engine, position the left front tire so it is facing straight forward.
2. Install the right tie rod through the tie rod hole in the inner fender.
3. Install the outer tie rod on the steering arm of the right strut. Install the tie rod to steering arm attaching nut. Tighten the attaching nut to a torque of 37 Nm (27 ft. lbs.).
4. Install the right side tire/wheel.
5. Install and tighten wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.).
6. Lower the vehicle until the front tires are just clear of the floor.
7. Install the intermediate steering shaft on the steering gear.
8. Using roll pin Installer, Special Tool 6831A, install the roll pin in the flex joint of the intermediate shaft. Roll pin is installed in coupler using the following procedure:
a. Remove knurled nut from small end of tool.
b. Insert small end of removal tool through center of roll pin and then install and hand tighten knurled nut.
c. Position sleeve of removal tool on flex joint as shown.
d. While holding threaded shaft of tool from turning, tighten nut pulling roll pin into flex joint.
e. Center roll pin in flex joint. Do not over-install roll pin.
9. Slide steering gear and intermediate shaft back into dash panel sealing boot. Align the steering gear mounting holes with its mounting holes in crossmember.
10. Loosely install the bolts mounting the left side of the steering gear to the crossmember.
CAUTION: Tightening the steering gear to crossmember mounting bolts to the proper torque is very important.
11. Install the bolts mounting the right side mounting bracket for the steering gear to the crossmember. Tighten the mounting bolts to a torque of 58 Nm (43 ft. lbs.).
12. Tighten the bolts mounting the left side of the steering gear to the crossmember to a torque of 58 Nm (43 ft. lbs.).
13. If previously loosened, tighten the bolts mounting the steering gear mounting bracket to the right side of the steering gear to a torque of 37 Nm (27 ft. lbs.).
CAUTION: Before installing tie rods on steering gear be sure the tie rod spacer block inside the steering gear bellows (boot) is correctly aligned with the bolt holes in the rack of the steering gear and the steering gear bellows.
14. Attach power steering fluid pressure, and return lines into proper ports of the steering gear. Tighten both power steering hose tube nuts to a torque of 47 Nm (35 ft. lbs.).
15. If equipped with speed proportional steering, connect the wiring harness connector to the solenoid control valve electrical connector.
16. Align center take off on steering gear with the tie rod assemblies. Install tie rod attaching bolts and washers into steering gear assembly. Be sure washers are installed between tie rods and steering gear. Tighten the tie rod to steering gear bolts to a torque of 100 Nm (74 ft. lbs.).
CAUTION: After tie rod attaching bolts are torqued, bend the retaining plate tabs against heads of the attaching bolts.
17. Install the vacuum hose for the power brake booster on intake manifold vacuum port. Install hose clamp on vacuum hose.
18. Install the master cylinder on the power brake vacuum booster. Install the two nuts attaching the master cylinder to the booster. Tighten the master cylinder mounting nuts to a torque of 28 Nm (250 inch lbs.).
19. Connect wire connector to the brake fluid level switch on the side of the master cylinder fluid reservoir.
20. Install the in-line resonator and inlet hose on the throttle body and air inlet hose coming from the lid of the air cleaner housing.
21. Install the cowl reinforcement on the vehicle. Install the eight bolts attaching the reinforcement to the strut towers. Install the bolt attaching the wiper module to the reinforcement.
22. Install the covers over the wiper module and the cowl. Install and securely tighten the attaching screws.
23. Install the wiper arms on the pivots. Install and securely tighten the wiper arm to pivot attaching nuts. Install the caps on the wiper arms covering the pivot nuts.
24. Install the intermediate shaft onto the steering column shaft. Install steering column coupler pinch bolt and tighten to a torque of 28 Nm (21 ft. lbs.). Install the pinch bolt nut retaining pin in pinch bolt.
25. Remove the holding clamp from the steering wheel.
26. Install the battery ground cable onto the ground stud on the shock tower.
27. Perform Power Steering Pump Initial Operation procedure to properly refill and bleed power steering system.
28. Lower vehicle.
29. Adjust front toe.