Part 2

45. INSTALL POWER STEERING RACK
a. Coat a new O-ring with power steering fluid and install it to the steering rack.
b. Expand the new oil seal with your fingers.

NOTICE: Be careful not to overly expand the oil seal.

c. Coat the oil seal with power steering fluid.





d. Install the oil seal to the steering rack, and adjust with your fingers.





e. Apply molybdenum disulfide lithium base grease to the rack teeth ends.

HINT: If necessary, scrape the burrs off the rack teeth ends and burnish.

f. Affix SST to the steering rack.
SST 09631-20102
g. Coat SST with power steering fluid.
h. Install the steering rack to the rack housing.
i. Remove SST.





46. INSTALL CYLINDER END STOPPER
a. Wrap vinyl tape around the RH side of the power steering rack and apply power steering fluid.
b. Apply power steering fluid to the lip of a new cylinder end stopper oil seal.
c. Install the cylinder end stopper oil seal to the RH side of the rack housing.

NOTICE:
- Ensure that the cylinder end stopper oil seal is installed in the correct direction as shown in the illustration.
- Do not damage the cylinder end stopper oil seal.

d. Remove the vinyl tape from the power steering rack.
e. Apply power steering fluid to a new cylinder end stopper O-ring.
f. Install the cylinder end stopper O-ring to the cylinder end stopper.





g. Install a new cylinder end stopper bush to the cylinder end stopper.
h. Apply molybdenum disulfide lithium base grease to the entire inner side of the cylinder end stopper bush.





i. Using SST, install the cylinder end stopper to the rack housing.
SST 09631-20120
Torque: 122 Nm (1,244 kgf-cm, 90 ft. lbs.)





47. AIR TIGHTNESS TEST
a. Install SST to the rack housing.
SST 09631-12071 (09633-00010)
b. Apply a vacuum of 53 kPa (398 mmHg, 15.65 inch Hg) for approximately 30 seconds.
c. Check that there is no change in the vacuum pressure.
If there is a change in the vacuum pressure, check the installation of the oil seals.





48. INSTALL POWER STEERING CONTROL VALVE UPPER OIL SEAL
a. Coat the control valve upper bearing with molybdenum disulfide lithium base grease, and a new control valve upper oil seal lip with power steering fluid.
b. Using SST and a press, install the control valve upper oil seal.
SST 09950-70010 (09951-07150), 09950-60010 (09952-06010, 09951-00180, 09951-00300)

NOTICE: Make sure that the oil seal is installed in the correct direction as shown in the illustration.





c. Using SST and a press, install the control valve upper bearing.
SST 09950-70010 (09951-07150), 09950-60010 (09952-06010, 09951-00180, 09951-00320)





49. INSTALL POWER STEERING CONTROL VALVE
a. Expand 4 new valve spacers with your fingers.

NOTICE: Be careful not to overly expand the valve spacers.

b. Coat the 4 valve spacers with power steering fluid.





c. Install the 4 valve spacers to the control valve, and adjust with your fingers.





d. Coat the control valve with power steering fluid.
e. Install the control valve into the valve housing.

NOTICE: Be careful not to damage the valve spacers and oil seal lip.

HINT: Wrap vinyl tape around the end of the steering rack in order to prevent damaging the oil seal.





f. Install the control valve housing with the control valve and a new gasket to the rack housing with the 2 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)





50. INSTALL RACK GUIDE
a. Apply molybdenum disulfide lithium base grease to the compression spring and the contact surface of the rack guide and the power steering rack.
b. Install the rack guide and the compression spring.
c. 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
d. Using a straight hexagon wrench (24 mm), temporarily install the rack guide spring cap.





51. INSPECT TOTAL PRELOAD
a. Using a straight hexagon wrench (24 mm), loosen and retighten the rack guide spring cap.
b. Temporarily install the steering rack ends to the power steering rack.

NOTICE: Do not fully turn the power steering rack without the steering rack end as it may damage the oil seal in the rack housing and the cylinder end stopper bush.

c. Using SST, fully turn the power steering rack right and left 10 times to settle.
SST 09616-00011





d. Loosen the rack guide spring cap in small amounts until the preload while turning the control valve using SST falls within the specified range.
SST 09616-00011
Preload (turning): 0.9 to 1.6 Nm (9.2 to 16.3 kgf-cm, 8.0 to 14.2 inch lbs.)

NOTICE: Retighten and loosen the rack guide spring cap if the preload falls below the specified range.

e. Remove the steering rack ends from the power steering rack.





52. INSTALL STEERING RACK END SUB-ASSEMBLY
a. Install 2 new claw washers, and temporarily install the rack ends.

HINT: Align the claws of the claw washers with the steering rack grooves.

b. Apply MP grease to the rack end ball joint.
c. Using 2 SST, install the rack end sub-assembly (LH side).
SST 09922-10010
Torque: 73 Nm (744 kgf-cm, 54 ft. lbs.)

NOTICE:
- Use SST 09922-10010 in the direction shown in the illustration.
- Use a torque wrench with a fulcrum length of 345 mm (13.58 inch).

HINT: Using SST, hold the rack and install the rack end sub-assembly.

d. Using SST and a wrench (22 mm), tighten the rack end sub-assembly (RH side).
SST 09922-10010
Torque: 73 Nm (744 kgf-cm, 54 ft. lbs.)

NOTICE:
- Use SST 09922-10010 in the direction shown in the illustration.
- Use a torque wrench with a fulcrum length of 345 mm (13.58 inch).

HINT: Using SST, hold the rack and install the rack end sub-assembly.





e. Using a brass bar and a hammer, stake the 2 claw washers.

NOTICE: Avoid any impact to the steering rack.





f. Ensure that the steering rack hole is not clogged with grease.

HINT: If the hole is clogged, the pressure inside the boot will change after it is assembled and the steering wheel is turned.





53. INSTALL STEERING RACK BOOT NO.2
a. Apply silicon grease to the inside of the small opening of the rack boot No.2.





b. Temporarily install a new steering rack boot No.2 clamp to the large opening of the steering rack boot No.2 at the position shown by arrow (A).

NOTICE:
- Use a new steering rack boot No.2 clamp.
- Do not expand the steering rack boot No.2 clamp more than necessary to perform installation.
- Do not deform the steering rack boot No.2 clamp.
- Tightening force of the steering rack boot No.2 clamp becomes uneven if it is installed after being expanded as shown in the illustration. As a result, rust is caused by water entering from the clearance between the boot and rack housing, causing a malfunction.
- Use only the supply parts which are applicable to the vehicle to secure the boot.

HINT: After disengaging the claw of a new steering rack boot No.2 clamp, temporarily install it from the end without expanding the clamp diameter as much as possible.

c. Install the rack boot No.2 to the groove on the rack housing.

NOTICE:
- Be careful not to damage or twist the boot.
- Do not damage the steering rack boot No.2.
- Ensure that the steering rack boot clamp is installed before installing the steering rack boot No.2 to the rack housing.

54. INSTALL STEERING RACK BOOT NO.1

HINT: Perform the same procedure as for the rack boot No.2.





55. INSTALL STEERING RACK BOOT NO.2 CLAMP
a. Using pliers and a screwdriver, install a new rack boot No.2 clamp.

NOTICE:
- Be careful not to damage or twist the rack boot.
- Do not twist the steering rack boot.

56. INSTALL STEERING RACK BOOT NO.1 CLAMP

HINT: Perform the same procedure as for the No.2 clamp.





57. INSTALL STEERING RACK BOOT CLIP
a. Using pliers, install the 2 boot clips.
b. Using SST, turn the control valve, and check that the rack boots expand and contract smoothly.
SST 09616-00011





58. INSTALL TIE ROD END SUB-ASSEMBLY LH
a. Screw the lock nut and the tie rod end sub-assembly to the rack end until the matchmarks are aligned.

HINT: After adjusting toe-in, torque the lock nut.

59. INSTALL TIE ROD END SUB-ASSEMBLY RH

HINT: Perform the same procedure as for the LH.





60. INSTALL POWER STEERING LINK ASSEMBLY
a. Using SST, install the left turn pressure tube to the steering link assembly.
SST 09023-38201
Torque: 22 Nm (224 kgf-cm, 16 ft. lbs.)

NOTICE: Use a torque wrench with a fulcrum length of 300 mm (11.81 inch).

HINT: This torque value is effective when SST is parallel to the torque wrench.

b. Using SST, install the right turn pressure tube to the steering link assembly.
SST 09023-38201
Torque: 22 Nm (224 kgf-cm, 16 ft. lbs.)

NOTICE: Use a torque wrench with a fulcrum length of 300 mm (11.81 inch).

HINT: This torque value is effective when SST is parallel to the torque wrench.





c. Install the power steering link assembly with the 4 bolts and 4 nuts.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)

NOTICE: Because the nut has its own stopper, do not turn the nut. Torque the bolt with the nut fixed.





61. INSTALL STEERING INTERMEDIATE SHAFT
a. Align the matchmarks on the intermediate shaft and the pinion shaft.
b. Install the bolt.
Torque: 35 Nm (357 kgf-cm, 26 ft. lbs.)
62. INSTALL STEERING COLUMN HOLE COVER SUB-ASSEMBLY NO.1





63. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
a. Using a transmission jack, support the crossmember sub-assembly w/ power steering link assembly.
b. Install the crossmember sub-assembly with the 2 nuts.
Torque: 133 Nm (1,356 kgf-cm, 98 ft. lbs.)





c. Install the crossmember bracket LH with the 4 bolts.
Torque:
Bolt A: 133 Nm (1,356 kgf-cm, 98 ft. lbs.)
Bolt B: 80 Nm (816 kgf-cm, 59 ft. lbs.)





d. Install the crossmember bracket RH with the 4 bolts.
Torque:
Bolt A: 133 Nm (1,356 kgf-cm, 98 ft. lbs.)
Bolt B: 80 Nm (816 kgf-cm, 59 ft. lbs.)





e. Install the engine mounting insulator RR to the crossmember sub-assembly with the bolt and the 3 nuts.
Torque: 65 Nm (663 kgf-cm, 48 ft. lbs.)





f. Install the center member with the 4 bolts.
Torque:
Bolt A: 45 Nm (459 kgf-cm, 33 ft. lbs.)
Bolt B: 72 Nm (734 kgf-cm, 53 ft. lbs.)





64. INSTALL NO.1 HOOK
a. Install the No.1 hook with the 2 bolts.
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
65. CONNECT FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH
66. CONNECT FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH

HINT: Perform the same procedure as for the LH.

67. CONNECT FRONT STABILIZER LINK ASSEMBLY LH
68. CONNECT FRONT STABILIZER LINK ASSEMBLY RH

HINT: Perform the same procedure as for the LH.





69. CONNECT PRESSURE FEED TUBE ASSEMBLY
a. Using SST, connect the pressure feed tube assembly.
SST 09023-12701
Torque: 41 Nm (414 kgf-cm, 30 ft. lbs.)

NOTICE: Use a torque wrench with a fulcrum length of 345 mm (13.58 inch).

HINT: This torque value is effective when SST is parallel to the torque wrench.





b. Install the tube clamp with the bolt to the power steering link assembly.
Torque: 7.8 Nm (80 kgf-cm, 69 inch lbs.)
70. CONNECT TIE ROD END SUB-ASSEMBLY LH
71. CONNECT TIE ROD END SUB-ASSEMBLY RH

HINT: Perform the same procedure as for the LH.

72. INSTALL EXHAUST PIPE ASSEMBLY CENTER
73. INSTALL FLOOR PANEL BRACE FRONT
74. INSTALL FRONT WHEELS
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
75. CONNECT STEERING COLUMN HOLE COVER SUB-ASSEMBLY NO.1





76. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY NO.2
a. Align the matchmarks on the intermediate shaft assembly No.2 and the intermediate shaft.
b. Install the bolt.
Torque: 35 Nm (357 kgf-cm, 26 ft. lbs.)
77. INSTALL COLUMN HOLE COVER SILENCER SHEET
78. INSTALL ENGINE COVER SUB-ASSEMBLY NO.1
79. ADD POWER STEERING FLUID
80. BLEED POWER STEERING FLUID
81. CHECK POWER STEERING FLUID LEVEL IN RESERVOIR
82. CHECK FOR FLUID LEAKS
83. INSTALL HOOD SUB-ASSEMBLY
84. ADJUST HOOD SUB-ASSEMBLY
85. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
86. INSTALL ENGINE UNDER COVER LH
87. INSTALL ENGINE UNDER COVER RH