Part 2
OVERHAULHINT:
COMPONENTS: See Diagrams; Exploded Views.
41. INSTALL POWER STEERING RACK
a) Coat a new oil seal lip with power steering fluid.
b) Using SST, press in the power steering cylinder tube oil seal.
SST 09950-60010 (09951-00330, 09951-00490, 09952-06010), 09950-07310 (09951-07360)
NOTICE:
^ Make sure that the oil seal is installed facing in the correct direction.
^ Take care that the oil seal does not get reversed as you install it.
c) Install SST to the power steering rack sub-assy.
SST 09631-20102
NOTICE: If necessary, scrape the burrs off the steering rack teeth end and burnish.
d) Coat the SST with fluid.
e) Install the power steering rack sub-assy into the power steering rack housing sub-assy.
NOTICE: Be careful not to damage the oil seal lip.
f) Remove the SST.
SST 09631-20102
g) Install SST to the power steering rack sub-assy opposite end.
SST 09631-20102
h) Coat SST with power steering fluid.
i) Coat a new power steering rack housing oil seal lip with power steering fluid.
j) Install the power steering rack housing oil seal by pushing it onto the SST without tilting.
NOTICE: Make sure that the oil seal is installed facing in the correct direction.
k) Remove the SST.
SST 09631-20102
l) Using SST and a hammer, drive in the power steering cylinder housing spacer.
SST 09950-60010 (09951-00280, 09951-00420, 09952-06010), 09950-70010 (09951-07200)
42. INSTALL CYLINDER END STOPPER
a) Coat a new O-ring with power steering fluid, and install it to the cylinder end stopper.
b) Using a wooden block and a hammer, drive in the cylinder end stopper until it is tightly installed.
NOTICE: Be careful not to damage the O-ring.
c) Using SST, torque the cylinder end stopper.
SST 09631-20120
Torque: 59 Nm (600 kgf-cm, 43 ft. lbs.)
43. AIR TIGHTNESS TEST
a) Install the SST to the unions of the power steering rack housing.
SST 09631-12071
b) Apply 53 kPa (400 mmHg, 15.75 inch Hg) of vacuum for about 30 seconds.
c) Check that there is no change in the vacuum.
If there is change in the vacuum, check the installation of the oil seals.
44. INSTALL POWER STEERING CONTROL VALVE LOWER OIL SEAL
a) Coat a new power steering control valve lower oil seal lip with power steering fluid.
b) Using SST, press in the power steering control valve lower oil seal.
SST 09950-60010 (09951-00280, 09951-00360, 09952-06010), 09950-70010 (09951-7100)
NOTICE: Make sure that the oil seal is installed facing in the correct direction.
45. INSTALL POWER STEERING CONTROL VALVE UPPER OIL SEAL
a) Coat a new power steering control valve upper oil seal lip with power steering fluid.
b) Using SST, press in the power steering control valve upper oil seal.
SST 09950-60010 (09951-00180, 09951-00330, 09952-06010), 09950-70010 (09951-07150)
c) Coat a bearing with molybdenum disulfide lithium base grease.
d) Using SST, press in the bearing.
SST 09950-60010 (09951-00180, 09951-00330, 09952-06010), 09950-70010 (09951-07150)
46. INSTALL POWER STEERING CONTROL VALVE
a) Coat the power steering control valve rings with power steering fluid
b) Install the power steering control valve rings to the power steering control valve sub-assy, and settle them down with your fingers.
c) Carefully slide the tapered end of SST over the power steering control valve rings until the power steering control valve ring fits to the power steering rack.
SST 09631-20081
NOTICE: Be careful not to damage the power steering control valve rings.
d) Coat the power steering control valve rings with power steering fluid.
e) To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft.
f) Push the power steering control valve assembly into the control valve housing.
NOTICE: Be careful not to damage the power steering control valve rings and oil seal lip.
g) Coat a new O-ring with power steering fluid, and install it to the bearing guide nut.
h) Using SST, torque the bearing guide nut.
SST 09631-20060
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
NOTICE: Be careful not to damage the oil seal lip.
i) Using a punch, stake the bearing guide nut.
j) Coat a new O-ring with power steering fluid, and install it to the control valve housing.
k) Align the matchmarks on the control valve housing and power steering rack housing, and install the control valve housing with the control valve assembly to the power steering rack housing.
l) Install the 2 bolts.
Torque: 18 Nm (180 kgf-cm, 13 ft. lbs.)
m) Install steering gear dust cover.
47. INSTALL RACK GUIDE
a) Install the rack guide seat to the steering gear rack guide.
b) Install the rack guide subassembly, conical spring washer and steering rack guide spring.
c) Apply sealant to 2 or 3 threads of the steering rack guide spring cap.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
d) Temporarily install the rack guide spring cap.
48. ADJUST TOTAL PRELOAD
a) To prevent the power steering rack teeth from damaging the oil seal lip, temporarily install the RH and LH steering rack end sub-assy.
b) Torque the steering rack guide spring cap.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
c) Return the steering rack guide spring cap 17°.
d) Using SST, turn the control valve shaft right and left 1 or 2 times.
SST 09616-00011
e) Loosen the steering rack guide spring cap until the steering rack guide spring is not functioning.
f) Using SST and a torque wrench, tighten the steering rack guide spring cap until the preload is within specification.
SST 09616-00011
Preload (turning): 0.5 - 1.7 Nm (4.7 - 17.2 kgf-cm, 4.1 - 14.9 inch lbs.)
g) Apply sealant to 2 or 3 threads of the steering rack guide spring cap nut.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
h) Holding the steering rack guide spring cap rotating, and using SST, torque the steering rack guide spring nut.
SST 09922-10010
Torque: 51 Nm (520 kgf-cm, 38 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).
i) Recheck the total preload.
Preload (turning): 0.5 - 1.7 Nm (4.7 - 17.2 kgf-cm, 4.1 - 14.9 inch lbs.)
j) Remove the RH and LH steering rack end sub-assys.
49. INSTALL STEERING RACK END CLAW WASHER [45503B/98-53]
a) Install a new claw washer, and temporarily tighten the rack end.
HINT: Align the claws of the steering rack end claw washer with the steering rack grooves.
b) Employ the same manner described to the other side.
50. INSTALL STEERING RACK END SUB-ASSY [45503/98-53]
a) Using a spanner, hold the power steering rack steadily, and using SST, torque the steering rack end sub-assy.
SST 09922-10010
Torque: 76 Nm (770 kgf-cm, 56 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).
b) Using a brass bar and a hammer, stake the steering rack end claw washer.
NOTICE: Avoid any impact to the rack.
c) Employ the same manner described to the other side.
51. INSTALL STEERING RACK BOOT NO. 1 [45535/98-53]
a) Ensure that the steering rack hole is not clogged with grease.
HINT: If the tube hole is clogged, the pressure inside the boot will change after it is assembled and the steering wheel is turned.
b) Install the steering rack boot No. 1.
52. INSTALL STEERING RACK BOOT NO. 2 [45536/98-53]
HINT: Employ the same manner described to the steering rack boot No. 1.
53. INSTALL STEERING RACK BOOT NO. 1 CLAMP [45535D/98-53]
a) Install a new steering rack boot No. 1 clamp.
NOTICE: Be careful not to damage or twist the rack boot.
b) Using pliers tighten a new clamp, as shown in the illustration.
54. INSTALL STEERING RACK BOOT NO. 2 CLAMP [45536A/98-53]
HINT: Employ the same manner described to the rack boot No. 1 clamp.
55. INSTALL STEERING RACK BOOT CLIP [45535B/98-53]
a) Using pliers, install 2 steering rack boot clips.
NOTICE: Be careful not to damage or twist the rack boot.
56. INSTALL TIE ROD ASSY LH [45470/98-53]
a) Screw the lock nut and tie rod assy LH onto the steering rack end sub-assy until the match-marks are aligned.
b) After adjusting toe-in, torque the nut.
Torque: 56 Nm (570 kgf-cm, 41 ft. lbs.)
57. INSTALL TIE ROD ASSY RH [45460/98-53]
HINT: Employ the same manner described to the tie rod assy LH.
58. INSTALL RACK & PINION POWER STEERING GEAR ASSY [44250/98-53]
a) Install 2 new steering turn pressure tube union seats to the rack housing.
b) Using SST, install the steering left turn pressure tube and steering right turn pressure tube.
SST 09023-38200
Torque: 23 Nm (240 kgf-cm, 17 ft. lbs.)
HINT:
^ Use a torque wrench with a fulcrum length of 300 mm (11.81 inch).
^ This torque valve is effective in case that SST is parallel to a torque wrench.
c) Install the grommet and steering rack housing bracket No. 2 to the rack and pinion power steering gear assy.
d) Install the rack and pinion power steering gear assy with the 4 gear assy set bolts.
Torque: 65 Nm (660 kgf-cm, 48 ft. lbs.)
e) Connect the connector.
f) Connect the 2 tube clamps with the bolt.
Torque: 5.0 Nm (55 kgf-cm, 48 inch lbs.)
59. CONNECT STEERING SLIDING YOKE SUB�ASSY [45209/98-49]
60. CONNECT PRESSURE FEED TUBE ASSY [44410/98-51]
a) Pressure feed tube:
Contect the pressure feed tube and a new gasket with the union bolt.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
b) Return tube:
Contect the return tube and 2 new gaskets with the union bolt.
Torque: 49 Nm (250 kgf-cm, 36 ft. lbs.)
61. CONNECT TIE ROD ASSY LH [45470/98-53]
a) Connect the tie rod assy to the lower ball joint and install the clip and nut.
Torque: 87 Nm (890 kgf-cm, 64 ft. lbs.)
b) Install the 2 nuts and caliper.
Torque: 118 Nm (1200 kgf-cm, 87 ft. lbs.)
62. CONNECT TIE ROD ASSY RH [45460/98-53]
HINT: Employ the same manner described to the other side.
63. INSPECT CENTER FRONT WHEEL
HINT: Do it with the front of the vehicle jacked up.
64. INSTALL FRONT SUSPENSION MEMBER BRACE SUB-ASSY RH [51403A/98-65]
a) Install the front suspension member brace sub-assy and 4 bolts.
Torque: 58 Nm (590 kgf-cm, 43 ft. lbs.)
65. INSTALL FRONT SUSPENSION MEMBER BRACE REAR LH [52258A/98-65]
a) Install the front suspension member brace rear LH, bolt and nut.
Torque: 58 Nm (590 kgf-cm, 43 ft. lbs.)
66. INSTALL FRONT SUSPENSION MEMBER BRACE REAR RH [52257/98-65]
a) Install the front suspension member brace rear RH, bolt and nut.
Torque: 58 Nm (590 kgf-cm, 43 ft. lbs.)
67. INSTALL ENGINE UNDER COVER NO. 2 [51442E/98-65]
68. CENTER SPIRAL CABLE
69. TEMPORARY TIGHTEN STEERING WHEEL ASSY [45100/98-52]
a) Align the matchmarks on the wheel and steering column main shaft.
b) Temporarily tighten the steering wheel set nut.
c) Connect the connector.
70. BLEED POWER STEERING SYSTEM
71. INSPECT STEERING WHEEL CENTER POINT
72. FULLY TIGHTEN STEERING WHEEL SET NUT [45201P/98-52]
Torque: 50 Nm (510 kgf-cm, 37 ft. lbs.)
73. INSTALL HORN BUTTON ASSY [45130/98-52]
74. INSTALL STEERING WHEEL COVER LOWER NO. 2 [45186/98-52]
75. INSTALL STEERING PAD SWITCH MODULATOR [84245A/98-52])
76. INSTALL SWITCH & VOLUME CASE [86174A/98-52]
77. INSTALL FRONT WHEEL
a) Install the front wheel with the 5 nuts.
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
b) Install the ornament with the 10 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
78. INSPECT TIRE
79. INSPECT TOE-IN
80. ADJUST TOE-IN
81. INSPECT WHEEL ANGLE
82. DRIVING TEST