Part 2
Part 1 Of 3:
Part 2 Of 3:
Part 3 Of 3:
RACK & PINION POWER STEERING GEAR ASSEMBLY
OVERHAUL
45. INSTALL POWER STEERING CONTROL VALVE UPPER OIL SEAL
a. Coat a control valve upper bearing and a new power steering control valve upper oil seal with power steering fluid.
b. Using SST and a press, install the power steering control valve upper oil seal.
SST 09950-70010 (09951-07150), 09950-60010 (09951-00180, 09952-06010, 09951-00320)
c. Using SST and a press, install the control valve upper bearing.
SST 09950-70010 (09951-07150), 09950-60010 (09951-00180, 09952-06010, 09951-00340)
46. INSTALL POWER STEERING CONTROL VALVE
a. Expand 4 new control valve rings with your fingers.
NOTICE: Be careful not to over expand the control valve ring.
b. Coat the 4 control valve rings with power steering fluid.
c. Install the 4 control valve rings to the control valve, and settle them down with your fingers.
d. Carefully slide the tapered end of SST over the control valve rings until they fit to the control valve.
SST 09631-20081
NOTICE: Be careful not to damage the control valve rings.
e. To prevent power steering control valve upper oil seal lip damage, wind vinyl tape around the serrated part of the control valve.
f. Coat the power steering control valve 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 power steering control valve 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 control valve housing.
l. Wind vinyl tape around the serration part of the control valve.
m. Install the control 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 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 steering rack ends sub-assembly.
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 to the right and left 1 or 2 times.
SST 09616-00011
e. Using SST, loosen the rack guide spring cap until the compression 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, tighten 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 steering rack ends sub-assembly.
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-ASSEMBLY
a. Install a new 2 claw washers, and temporarily install the 2 steering rack ends sub-assembly.
HINT: Align the claws of the claw washer with the power steering rack grooves.
b. Using 2 SSTs, install the 2 steering rack ends sub-assembly.
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 power steering rack and install the steering rack end sub-assembly.
^ 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 power steering rack.
50. INSPECT STEERING RACK END SUB-ASSEMBLY
a. Ensure that the steering rack end sub-assembly 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 steering rack boot NO. 2.
54. INSTALL STEERING RACK BOOT NO. 1 CLAMP
SST 09521-24010
NOTICE: Be careful not to damage the steering rack boot NO. 1.
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 steering rack boot clips.
56. INSTALL TIE ROD ASSEMBLY LH
a. Screw the lock nut and tie rod assembly LH onto the steering rack end sub-assembly until the matchmarks are aligned.
HINT: After adjusting toe-in, torque the lock nut.
57. INSTALL TIE ROD ASSEMBLY 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 steering left turn pressure tube.
b. Using SST, install the steering left turn pressure tube to the rack & pinion power steering gear assembly.
SST 09023-38201
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 steering right turn pressure tube.
b. Using SST, install the steering right turn pressure tube to the rack & pinion power steering gear assembly.
SST 09023-38201
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 ASSEMBLY
a. Install the rack & pinion power steering gear assembly with the 2 bolts and 2 nuts.
Torque: 70 Nm (714 kgf-cm, 52 ft. lbs.)
b. Connect the tube clamp with the bolt.
Torque: 9.8 Nm (100 kgf-cm, 87 inch lbs.)
62. CONNECT PRESSURE FEED TUBE ASSEMBLY
a. Using SST, connect the pressure feed tube assembly to the rack & pinion power steering gear assembly.
SST 09023-12701
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 assembly to the rack & pinion power steering gear assembly.
SST 09023-12701
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 assembly 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 ASSEMBLY LH
a. Connect the front stabilizer link assembly LH to the shock absorber assembly front LH 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 ASSEMBLY RH
HINT: Connect the RH side by the same procedures with LH side.
67. CONNECT STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY
a. Align the matchmarks on the steering intermediate shaft sub-assembly and rack & pinion power steering gear assembly.
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 ASSEMBLY LH
a. Connect the tie rod assembly 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 ASSEMBLY 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-ASSEMBLY
74. CENTER SPIRAL CABLE
75. INSTALL STEERING WHEEL ASSEMBLY
76. INSTALL HORN BUTTON ASSEMBLY
77. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
78. INSPECT STEERING WHEEL CENTER POINT
79. INSPECT SRS WARNING LIGHT