Reassembly

POWER STEERING: STEERING LINKAGE: REASSEMBLY

REASSEMBLY
NOTE: When installing, coat the parts indicated by arrows with power steering fluid, molybdenum disulfide lithium base grease, MP grease or silicon grease Components.

1. INSTALL POWER STEERING CYLINDER TUBE OIL SEAL

(a) Apply power steering fluid to the lip of a new power steering cylinder tube oil seal.
(b) Install the power steering cylinder tube oil seal to the rack housing at a slant.
NOTICE:
- Ensure the power steering cylinder tube oil seal is installed in the correct direction as shown in the illustration.
- Install the power steering cylinder tube oil seal at an angle of approximately 15° so that the lowermost part comes to the point, indicated by the arrow in the illustration, to prevent damage to the side of the oil seal when it passes the 2 ports.

(c) Using SST, insert the power steering cylinder tube oil seal by pushing the SST in by hand until the oil seal passes the 2 ports.
NOTE: Do not turn the SST when inserting the oil seal.

(d) Install SST (09631-00200) to SST (09951-07360) upside down.

(e) Using SST, level the power steering cylinder tube oil seal by pushing the SST in by hand. Using SST and a press, install the oil seal.
SST: 09950-70010
09951-07360
SST: 09631-00200
2. 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.
NOTE: 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
Coat SST with power steering fluid.
(g) Install the steering rack to the rack housing.
(h) Remove SST.
3. 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-lbf)

4. 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 in.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.
5. 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, press in the control valve upper oil seal.
SST: 09950-70010
09951-07150
SST: 09950-60010
09952-06010
09951-00180
09951-00300
NOTE: Make sure that the oil seal is installed in the correct direction as shown in the illustration.

(c) Using SST and a press, press in the control valve upper bearing.
SST: 09950-70010
09951-07150
SST: 09950-60010
09952-06010
09951-00180
09951-00320
6. INSTALL POWER STEERING CONTROL VALVE

(a) Expand 4 new valve spacers with your fingers.
NOTE: Be careful not to overly expand the valve spacers.

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

(d) Coat the control valve with power steering fluid.
(e) Install the control valve into the valve housing.
NOTE: 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-lbf)

7. 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 24 mm straight hexagon wrench, temporarily install the rack guide spring cap.
8. INSPECT TOTAL PRELOAD

(a) Using a 24 mm straight hexagon wrench, loosen and retighten the rack guide spring cap.
(b) Temporarily install the steering rack ends to the power steering rack.
NOTE: 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) While turning the control valve using SST, loosen the rack guide spring cap in small amounts until the preload falls within the specified range.
SST: 09616-00011
Standard preload (turning):
0.9 to 1.6 N*m (9.2 to 16.3 kgf*cm, 8.0 to 14.2 in.*lbf)
NOTE: Retighten and loosen the rack guide spring cap if preload falls below the specified range.

(e) Remove the steering rack ends from the power steering rack.
9. 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-lbf)
HINT:
- Use SST 09922-10010 in the direction shown in the illustration.
- Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).
- Using SST, hold the rack and install the rack end sub-assembly.

(d) Using SST and a 22 mm wrench, tighten the rack end sub-assembly (RH side).
SST: 09922-10010
Torque: 73 Nm (744 kgf-cm, 54 ft-lbf)
HINT:
- Use SST 09922-10010 in the direction shown in the illustration.
- Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).
- Using SST, hold the rack and install the rack end sub-assembly.

(e) Using a brass bar and hammer, stake the 2 claw washers.
NOTE: 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.

10. INSTALL NO. 2 STEERING RACK BOOT

(a) Apply silicon grease to the inside of the small opening of the No. 2 rack boot.

(b) Temporarily install a new steering rack boot clamp to the large opening of the steering rack boot at the position shown by arrow (A).

NOTICE:
- Use a new steering rack boot clamp.
- Do not expand the steering rack boot clamp more than necessary to perform installation.
- Do not deform the steering rack boot clamp.
- Tightening force of the steering rack boot 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 clamp, temporarily install it from the end without expanding the clamp diameter as much as possible.

(c) Install the rack boot to the groove on the rack housing.
NOTICE:
- Be careful not to damage or twist the boot.
- Do not damage the steering rack boot.
- Ensure that the steering rack boot clamp is installed before installing the steering rack boot to the rack housing.

11. INSTALL NO. 1 STEERING RACK BOOT
HINT: Perform the same procedure as for the No. 2 rack boot.

12. INSTALL NO. 2 STEERING RACK BOOT CLAMP
(a) Using pliers and a screwdriver, install a new rack boot clamp.
NOTICE:
- Be careful not to damage or twist the rack boot.
- Do not twist the steering rack boot.

13. INSTALL NO. 1 STEERING RACK BOOT CLAMP
HINT: Perform the same procedure as for the clamp.

14. 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

15. INSTALL TIE ROD END SUB-ASSEMBLY LH
(a) Screw the lock nut and the tie rod end to the rack end until the matchmarks are aligned.
HINT: After adjusting toe-in, torque the lock nut.

16. REMOVE TIE ROD END SUB-ASSEMBLY RH
HINT: Perform the same procedure as for the LH.