Repair Procedures

REMOVAL

1. Remove the both front wheels.
2. Drain the power steering fluid by disconnecting the return hose (A).




3. Disconnect the pressure tube (A) from the power steering pump by loosening the eye bolt.








4. Disconnect the stabilizer link (A) with the strut assembly by loosening the nut.




5. Remove the split pin and castle nut and then disconnect the tie-rod end (A) with the knuckle using a SST (09568-34000).




6. Separate the knuckle with the lower arm by loosening the mounting bolts (A).




7. Loosen the bolt (A) and then disconnect the universal joint assembly (B) with the pinion of the steering gear.





CAUTION:
Keep the neutral-range to prevent the damage of the clock spring inner cable when you handle the steering wheel.

8. Remove the muffler rubber hanger (A).




9. Remove the front and rear roll stopper through bolts & nuts (A, B).








10. Remove the sub-frame (A) and stay by loosening mounting bolts.




11. Loosen the return hose mounting bracket bolt (A).




12. Remove the rear roll stopper (A) from the sub-frame by loosening the mounting bolts.




13. Remove the heat protector (A).




14. Remove the pressure (A) and return tube (B) from the steering gear box.




15. Remove the steering gear box from the sub-frame by loosening the mounting bolts.






DISASSEMBLY

1. Remove the feed tubes (A) from the steering gear box.




2. Loosen the lock nut (A) and then unscrew the toe-rod end (B) and lock nut from the tie-rod.




3. Remove the bellows clip (A) and band (B) and then pull the bellows (C) away from the end of the tie-rod.




4. Unscrew the tie-rod (B) from the rack bar (A).




5. Remove the lock nut (A) and yoke plug (B) and then pull out the yoke spring (C) and support yoke (D).




6. Remove the dust packing (A) and cap (B).




7. Remove the snap ring (A) from the pinion housing.




8. Remove the pinion plug (A) and lock nut (B).




9. Pull the pinion assembly (A) out of the pinion housing.




10. Remove the oil seal (A) and bearing (B) from the valve assembly.




11. Unscrew the rack bush (A) from the rack housing.




12. Pull the rack bar (A) out of the rack housing.






REASSEMBLY

1. Apply the grease to rack gear teeth and then insert the rack bar (A) into the rack housing.




2. Apply the sealant to the thread of rack bush (A) and then install it to rack housing.

Tightening torque Nm (kgf.m, lb-ft):
100 - 120 (10.0 - 12.0, 72 - 87)




3. Apply the power steering fluid to the bearing (A) and then install it to the valve assembly.




4. Insert the pinion assembly (A) into the pinion housing. Tap the top of the pinion assembly with a plastic hammer to seat the pinion assembly thoroughly.




5. Install a new oil seal to valve assembly.




6. Tighten the pinion lock nut (B).

Tightening torque Nm (kgf.m, lb-ft):
40 - 50 (4.0 - 5.0, 29 - 36)

7. Apply the sealant the thread of pinion plug (A) and then install it.

Tightening torque Nm (kgf.m, lb-ft):
45 - 55 (4.5 - 5.5, 33 - 40)




8. Install the snap ring (A) to the pinion housing.




9. Install the dust packing (A) and cap (B).




10. Insert the support yoke (D) and yoke spring (C) into the rack housing.
11. Apply the sealant to the thread of yoke plug (B) and then install it to the rack housing.
12. Torque the yoke plug to approx 20Nm (2kgf.m, 14lb-ft) and then loosen it.
13. Torque the yoke plug to 5 - 6Nm (0.5 - 0.6, 3.6 - 4.3lb-ft) again, and then loosen it by approx 35°.
14. Tighten the lock nut (A) while holding the yoke plug.

Tightening torque Nm (kgf.m, lb-ft):
50 - 60 (5.0 - 6.0, 36 - 43)




15. Apply the sealant to the thread (A) of tie-rod ball joint and then install it to the rack bar.

Tightening torque Nm (kgf.m, lb-ft):
120 - 140 (12.0 - 14.0, 87 - 101)




16. Assemble new bellows band (A) to the bellows.




17. Apply the grease to the portion (D) of the tie-rod.
18. Apply the sealant to the bellows mating surface of the rack housing.
19. Assemble the bellows (C) to rack housing and then tighten the bellows clip (A) and band (B).




20. Assemble the lock nut (A) and tie rod end (B) to tie rod.




21. Install the feed tubes (A) to steering gear box.






INSTALLATION

1. Install the steering gear box (A) to the sub frame by tightening the mounting bolts.

Tightening torque Nm (kgf.m, lb-ft):
60 - 80 (6.0 - 8.0, 43 - 58)




2. Install the pressure tube (A) and return tube (B) to the steering gear box and then tighten the flare nut.

Tightening torque Nm (kgf.m, lb-ft):
12 - 18 (1.2 - 1.8, 9 - 13)




3. Install the heat protector (A).




4. Install the rear roll stopper (A) to the sub-frame by tightening the mounting bolts.

Tightening torque Nm (kgf.m, lb-ft):
50 - 65 (5.0 - 6.5, 36 - 47)




5. Install the return hose mounting bracket (A) to rear roll stopper.




6. Install the sub-frame (A) and stay by tightening the mounting bolts.

Tightening torque Nm (kgf.m, lb-ft):
Sub-frame mounting bolt:
160 - 180 (16.0 - 18.0, 116 - 130)
Sub-frame stay mounting bolt:
45 - 55 (4.5 - 5.5, 33 - 40)




7. Install the front and rear roll stopper through bolts and nut (A, B).

Tightening torque Nm (kgf.m, lb-ft):
50 - 65 (5.0 - 6.5, 36 - 47)








8. Connect the return hose (A).




9. Install the muffler rubber hanger (A).




10. Connect the lower arm with the knuckle by tightening the bolts (A).

Tightening torque Nm (kgf.m, lb-ft):
100 - 120 (10.0 - 12.0, 72 - 87)




11. Connect the tie rod end with the knuckle and then install the castle nut and split pin.

Tightening torque Nm (kgf.m, lb-ft):
24 - 34 (2.4 - 3.4, 17 - 25)

12. Connect the stabilizer link (A) with the front strut assembly and than tighten the nut.

Tightening torque Nm (kgf.m, lb-ft):
100 - 120 (10.0 - 12.0, 72 - 87)




13. Connect the universal joint assembly (B) with the pinion of the steering gear box and then tighten the bolt (A).

Tightening torque Nm (kgf.m, lb-ft):
30 - 35 (3.0 - 3.5, 22 - 25)




14. Connect the pressure tube to power steering pump by tightening the eye bolt.

Tightening torque Nm (kgf.m, lb-ft):
55 - 65 (5.5 - 6.5, 40 - 47)

15. Add power steering fluid to reservoir.
16. Bleed the power steering system.
17. Check and adjust front wheel alignment.

INSPECTION

1. Rack bar
A. Check the rack gear for damage.
B. Check the rack bar for bend and deformation.
2. Pinion assembly
A. Check the pinion gear for damage.
B. Check the surface contacting the oil seal for damage.
C. Check the oil seal for damage.
3. Check the inside of rack housing for damage.
4. Check the bellows for being torn.