Part 2
OVERHAUL46. INSTALL POWER STEERING CONTROL VALVE
a. Expand 4 new valve rings with your fingers.
NOTICE: Be careful not to overexpand the valve ring.
b. Coat the 4 valve rings with power steering fluid.
c. Install the 4 valve rings to the control valve, and settle them down with your fingers.
d. Carefully slide the tapered end of SST over the valve rings until they fit to the control valve.
SST 09631-20081
NOTICE: Be careful not to damage the valve rings.
e. To prevent upper oil seal lip damage, wind vinyl tape around the serrated part of the control valve.
f. Coat the upper oil seal lip with power steering fluid.
g. Install the control valve to the control valve housing.
NOTICE: Be careful not to damage the control valve ring and upper oil seal lip.
h. Coat a new oil seal lip with power steering fluid.
i. Using SST and a press, install the oil seal.
SST 09612-22011
NOTICE: Make sure that the oil seal is installed facing in the correct direction.
j. Apply grease to the needle bearing.
k. Install a new gasket to the valve housing.
l. Wind vinyl tape around the serration part of the control valve.
m. Install the valve housing to the rack housing with the 2 bolts.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)
n. Using SST, stop the control valve shaft rotation and install a new lock nut.
Torque: 24.5 Nm (250 kgf-cm, 18 ft. lbs.)
SST 09616-00011
o. Apply sealant to 2 or 3 threads of the rack housing cap.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
p. Using a socket wrench (27 mm), install the rack housing cap.
Torque: 58.5 Nm (597 kgf-cm, 43 ft. lbs.)
q. Using a punch and a hammer, stake the rack housing cap and rack housing.
47. INSTALL RACK GUIDE
a. Apply molybdenum disulfide lithium base grease to the rack guide.
b. Install the rack guide.
c. Install the compression spring.
d. Apply sealant to 2 or 3 threads of the rack guide spring cap.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
e. Temporarily install the rack guide spring cap.
48. ADJUST TOTAL PRELOAD
a. To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the RH and LH rack ends.
b. Using SST, torque the rack guide spring cap.
SST 09631-10021
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
c. Using SST, loosen the rack guide spring cap.
SST 09631-10021
d. Using SST, turn the control valve shaft to the right and left 1 or 2 times.
SST 09616-00011
e. Using SST, loosen the rack guide spring cap until the rack guide spring is not functioning.
SST 09631-10021
f. Using SST and a torque wrench, tighten the rack guide spring cap until the preload is within specification.
SST 09616-00011, 09631-10021
Preload (turning): 1.2 - 1.5 Nm (12.2 - 15.3 kgf-cm, 10.6 - 13.3 inch lbs.)
g. Apply sealant to 2 or 3 threads of the rack guide spring cap nut.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
h. Temporarily install the rack guide spring cap nut.
i. Using SST, hold the rack guide spring cap and using another SST, torque the rack guide spring cap nut.
SST 09616-00011, 09922-10010
Torque: 48 Nm (489 kgf-cm, 35 ft. lbs.)
NOTICE: Use SST 09922-10010 in the direction shown in the illustration.
HINT: Use a torque wrench with a fulcrum length of 345 mm (13.58 inch).
j. Precheck the total preload.
Preload (turning): 1.2 - 1.5 Nm (12.2 - 15.3 kgf-cm, 10.6 - 13.3 inch lbs.)
k. Remove the RH and LH rack ends.
l. Apply MP grease into the control valve, as shown in the illustration.
m. Wind vinyl tape around the serration part of the control valve.
n. Install the dust cover to the control valve housing.
49. INSTALL STEERING RACK END SUB-ASSY
a. Install a new 2 claw washers, and temporarily install the 2 rack ends.
HINT: Align the claws of the claw washer with the steering rack grooves.
b. Using 2 SSTs, install the 2 rack ends.
SST 09922-10010
Torque: 58.5 Nm (597 kgf-cm, 43 ft. lbs.)
NOTICE: Use SST 09922-10010 in the direction shown in the illustration.
HINT:
^ Using SST, hold the rack and install the rack end.
^ Use a torque wrench with a fulcrum length of 345 mm (13.58 inch).
c. Using a brass bar and a hammer, stake the claw washer.
NOTICE: Avoid any impact to the steering rack.
50. INSPECT POWER STEERING RACK
a. Ensure that the steering rack end hole is not clogged with grease.
HINT: If the hole is clogged, the pressure inside the boot will change after it is assembled and steering wheel is turned.
51. INSTALL STEERING RACK BOOT NO. 2
a. Install the steering rack boot No. 2.
52. INSTALL STEERING RACK BOOT NO. 1
HINT: Remove the steering rack boot No. 1 by the same procedures with steering rack boot No. 2.
53. INSTALL STEERING RACK BOOT NO. 2 CLAMP
a. Using SST, tighten the steering rack boot No. 2 clamp, as shown in the illustration.
SST 09521-24010
Clearance: 3.0 mm (0.118 inch) or less
NOTICE: Be careful not to damage the boot.
54. INSTALL STEERING RACK BOOT NO. 1 CLAMP
SST 09521-24010
NOTICE: Be careful not to damage the boot.
HINT: Install the steering rack boot No. 1 clamp by the same procedures with steering rack boot No. 2 clamp.
55. INSTALL STEERING RACK BOOT CLIP
a. Using pliers, install the 2 rack boot clips.
56. INSTALL TIE ROD ASSY LH
a. Screw the lock nut and tie rod assy LH onto the rack end until the matchmarks are aligned.
HINT: After adjusting toe-in, torque the lock nut.
57. INSTALL TIE ROD ASSY RH
HINT: Install the RH side by the same procedures with LH side.
58. INSTALL STEERING LEFT TURN PRESSURE TUBE
a. Coat 2 new O-rings with power steering fluid and install them to the left turn pressure tube.
b. Using SST, install the left turn pressure tube to the steering gear assy.
SST 09023-38200
Torque: 11.5 Nm (117 kgf-cm, 8 ft. lbs.)
HINT:
^ Use a torque wrench with a fulcrum length of 345 mm (9.84 inch).
^ This torque value is effective in the case that SST is parallel to a torque wrench.
59. INSTALL STEERING RIGHT TURN PRESSURE TUBE
a. Coat 2 new O-rings with power steering fluid and install them to the right turn pressure tube.
b. Using SST, install the right turn pressure tube to the steering gear assy.
SST 09023-38200
Torque: 11.5 Nm (117 kgf-cm, 8 ft. lbs.)
HINT:
^ Use a torque wrench with a fulcrum length of 345 mm (11.81 inch).
^ This torque value is effective in the case that SST is parallel to a torque wrench.
60. INSTALL POWER STEERING RACK HOUSING HEAT INSULATOR
a. Install the power steering rack housing heat insulator.
HINT: Install nut when installing the return clamp.
61. INSTALL RACK & PINION POWER STEERING GEAR ASSY
a. Install the power steering gear assy with the 2 bolts and nuts.
Torque: 70 Nm (714 kgf-cm, 52 ft. lbs.)
b. Connect the pressure feed tube assy clamp with the bolt.
Torque: 9.8 Nm (100 kgf-cm, 87 inch lbs.)
62. CONNECT PRESSURE FEED TUBE ASSY
a. Using SST, connect the pressure feed tube assy to the steering gear.
SST 09023-12700
Torque: 22.5 Nm (229 kgf-cm, 17 ft. lbs.)
HINT:
^ Use a torque wrench with a fulcrum length of 300 mm (11.81 inch).
^ This torque value is effective in the case that SST is parallel to a torque wrench.
b. Using SST, connect the return tube assy to the steering gear.
SST 09023-12700
Torque: 22.5 Nm (229 kgf-cm, 17 ft. lbs.)
HINT:
^ Use a torque wrench with a fulcrum length of 300 mm (11.81 inch).
^ This torque value is effective in the case that SST is parallel to a torque wrench.
c. Install the return tube clamp with the nut.
Torque: 9.8 Nm (100 kgf-cm, 87 inch lbs.)
63. INSTALL FRONT STABILIZER BRACKET NO. 1 LH
a. Install the front stabilizer bracket No. 1 LH with the 2 bolts.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
64. INSTALL FRONT STABILIZER BRACKET NO. 1 RH
HINT: Remove the RH side by the same procedures with LH side.
65. CONNECT FRONT STABILIZER LINK ASSY LH
a. Connect the stabilizer link assy LH to the stabilizer bar with the nut.
Torque: 74 Nm (755 kgf-cm, 55 ft. lbs.)
HINT: If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud.
66. CONNECT FRONT STABILIZER LINK ASSY RH
HINT: Connect the RH side by the same procedures with LH side.
67. CONNECT STEERING INTERMEDIATE SHAFT SUB-ASSY
a. Align the matchmarks on the intermediate shaft sub-assy and steering gear assy.
b. Install the bolt.
Torque: 35.3 Nm (360 kgf-cm, 26 ft. lbs.)
c. Tighten the bolt.
Torque: 35.3 Nm (360 kgf-cm, 26 ft. lbs.)
d. Install the steering column hole cover No. 2 to the steering hole cover No. 1.
e. Connect the clamp to the steering column hole cover No. 1 and tighten the bolt.
68. CONNECT TIE ROD ASSY LH
a. Connect the tie rod assy LH with the nut.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
b. Install a new cotter pin.
NOTICE: If the holes for a new cotter pin are not aligned, tighten the nut further up 60°.
69. CONNECT TIE ROD ASSY RH
HINT: Install the RH side by the same procedures with LH side.
70. INSTALL FRONT WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
71. BLEED POWER STEERING FLUID
72. CHECK POWER STEERING FLUID LEAKAGE
73. INSTALL SPIRAL CABLE SUB-ASSY
74. CENTER SPIRAL CABLE
75. INSTALL STEERING WHEEL ASSY
76. INSTALL HORN BUTTON ASSY
77. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
78. INSPECT STEERING WHEEL CENTER POINT
79. INSPECT SRS WARNING LIGHT