Part 2
POWER STEERING LINK ASSY
OVERHAUL
51. INSTALL POWER STEERING RACK
a. Install SST to the steering rack.
SST 09631-10041
HINT: If necessary, scrape the burrs off the steering rack teeth end and burnish.
b. Apply power steering fluid to the SST.
c. Install the steering rack to the rack housing.
d. Remove SST.
52. INSTALL POWER STEERING RACK BUSH
a. Using SST and a press, install the rack bush oil seal to the rack bush.
SST 09950-60010 (09951-00210, 09951-00340, 09952-06010), 09950-70010 (09951-07100)
NOTICE: Make sure that the oil seal is installed correctly.
b. Apply power steering fluid to a new O-ring and install it to the rack bush.
c. Wrap vinyl tape around the steering rack end to prevent damaging the rack bush oil seal lip, and apply power steering fluid to the rack bush oil seal.
d. Install the rack bush into the rack housing.
NOTICE:
^ Make sure that the rack bush is installed correctly.
^ Be careful not to damage the oil seal lip.
53. INSTALL CYLINDER END STOPPER
a. Push into the cylinder end stopper.
b. Using needle nose pliers, install the hole snap ring.
54. AIR TIGHTNESS TEST
a. Install SST onto the rack housing.
SST 09631-12071 (09633-00010)
b. Apply vacuum of 53 kPa (400 mm Hg, 15.75 inch Hg) for approximately 30 seconds.
c. Check that there is no change in the vacuum.
If there is a change in the vacuum, check the installation of the oil seals.
55. INSTALL POWER STEERING CONTROL VALVE
a. Apply grease to the needle roller bearing.
b. Install a new gasket to the rack housing.
c. Align the matchmarks and install the control valve housing with control valve to the rack housing with the 2 bolts.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)
56. INSTALL RACK GUIDE
a. Install the rack guide, the rack guide spring spacer and the rack guide spring.
NOTICE: Make sure that the rack guide spring spacer is installed correctly.
b. 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
c. Temporarily install the rack guide spring cap.
57. ADJUST TOTAL PRELOAD
a. To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the RH and LH rack ends sub-assy.
b. Using a hexagon wrench (19 mm), torque the rack guide spring cap.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
c. Using a hexagon wrench (19 mm), return the rack guide spring cap approximately 12 degrees.
d. Using SST, turn the control valve to the right and left once or twice.
SST 09616-00011
e. Using a hexagon wrench (19 mm), loosen the rack guide spring cap until the rack guide spring stops functioning.
f. Using SST, a torque wrench and a hexagon wrench (19 mm), tighten the rack guide spring cap until the preload is within the specification.
SST 09616-00011
Preload (turning): 1.2 to 1.5 Nm (12 to 15 kgf-cm, 10.6 to 13.3 inch lbs.)
g. Apply sealant to 2 or 3 threads of the spring cap lock nut.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
h. Temporarily install the spring cap lock nut.
i. Hold the rack guide spring cap by using a hexagon wrench (19 mm), and using SST, torque the spring cap lock nut.
Torque: 28 Nm (286 kgf-cm, 21 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. Recheck the total preload.
Preload (turning): 1.2 to 1.5 Nm (12 to 15 kgf-cm, 10.6 to 13.3 inch lbs.)
k. Remove the RH and LH rack ends sub-assy.
58. INSTALL STEERING RACK END SUB-ASSY
a. Temporarily install the 2 rack end sub-assy.
b. Using SST, torque the 2 rack end sub-assy.
SST 09922-10010
Torque: 60 Nm (614 kgf-cm, 44 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).
^ Using SST, hold the rack and install the rack end sub-assy.
59. INSPECT STEERING RACK END HOLE
a. Ensure that the hole of the rack end sub-assy 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.
60. INSTALL STEERING RACK BOOT NO.2
a. Apply silicon grease to the inside small caliber of rack boot No.2.
b. Install the rack boot No.2 onto the groove on the rack housing.
NOTICE: Be careful not to damage or twist the boot.
61. INSTALL STEERING RACK BOOT NO.1
HINT: Perform the same procedure on the other side.
62. INSTALL STEERING RACK BOOT NO.2 CLAMP
a. Using SST, tighten the rack boot No.2 clamp, as shown in the illustration.
SST 09240-00020, 09521-24010
Clearance: 3.0 mm (0.118 inch) or less
NOTICE: Be careful not to damage the boot.
63. INSTALL STEERING RACK BOOT NO.1 CLAMP
SST 09240-00020, 09521-24010
HINT: Perform the same procedure on the other side.
64. INSTALL STEERING RACK BOOT CLIP
a. Using a pliers, install the 2 rack boot clips.
65. INSTALL TIE ROD END SUB-ASSY LH
a. Screw the lock nut and the tie rod end sub-assy LH on the rack end sub-assy until the matchmarks are aligned.
Torque: 74 Nm (750 kgf-cm, 54 ft. lbs.)
HINT: After adjusting toe-in, torque the lock nut.
66. INSTALL TIE ROD END SUB-ASSY RH
HINT: Perform the same procedure on the other side.
67. INSTALL STEERING RIGHT TURN PRESSURE TUBE
a. Apply power steering fluid to the 2 new O-rings and install them to the right turn pressure tube.
b. Using SST, install the right turn pressure tube to the steering link assy.
SST 09023-38200
Torque: 12 Nm (118 kgf-cm, 9 ft. lbs.)
HINT:
^ Use a torque wrench with a fulcrum length of 250 mm (9.84 inch).
^ This torque value is effective when SST is parallel to a torque wrench.
68. INSTALL STEERING LEFT TURN PRESSURE TUBE
SST 09023-38200
HINT: Perform the same procedure on the other side.
69. INSTALL POWER STEERING LINK ASSY
a. Install the grommet No.2 to the steering link assy.
b. Align the matchmarks and install the bracket No.2 to the steering link assy.
NOTICE: Install the bracket with the inscribed mark facing to the front of the vehicle.
c. Install the steering link assy with the 4 bolts and the nuts.
Torque: 74 Nm (749 kgf-cm, 54 ft. lbs.)
NOTICE:
^ Torque the bolt with the nut fixed as the nut has its own stopper.
^ Do not turn the nut.
70. INSTALL STEERING INTERMEDIATE SHAFT
a. Align the matchmarks on the intermediate shaft with the pinion shaft.
b. Install the bolt.
Torque: 28 Nm (290 kgf-cm, 21 ft. lbs.)
71. INSTALL STEERING COLUMN HOLE COVER SUB-ASSY NO.1
72. INSTALL POWER STEERING RACK HOUSING HEAT INSULATOR
a. Install the heat insulator with the bolt as shown in the illustration.
Torque: 18 Nm (178 kgf-cm, 13 ft. lbs.)
b. Install the bolt to the heat insulator.
Torque: 35 Nm (360 kgf-cm, 26 ft. lbs.)
73. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSY
a. Using a transmission jack, support the crossmember sub-assy.
b. Using SST, align the holes of the crossmember sub assy.
SST 09670-00010
HINT: Perform the same procedure on the other side.
c. Install the crossmember sub-assy with the 4 bolts.
Torque:
Bolt A: 116 Nm (1,183 kgf-cm, 86 ft. lbs.)
Bolt B: 70 Nm (714 kgf-cm, 52 ft. lbs.)
d. Install the crossmember sub-assy with the bolt and the 2 nuts.
Torque: 72 Nm (734 kgf-cm, 53 ft. lbs.)
e. Install the 2 reinforcements with the 4 bolts.
Torque: 47 Nm (479 kgf-cm, 35 ft. lbs.)
74. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH
75. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH
HINT: Perform the same procedure on the other side.
76. CONNECT PRESSURE FEED TUBE ASSY
a. Using SST, connect the pressure feed tube assy.
SST 09023-12700
Torque: 27 Nm (273 kgf-cm, 20 ft. lbs.)
HINT:
^ Use a torque wrench with a fulcrum length of 345 mm (13.58 inch).
^ This torque value is effective when SST is parallel to a torque wrench.
b. Connect the return hose with the clip.
c. Install the tube clamp to the crossmember sub-assy with the bolts.
Torque: 7.8 Nm (80 kgf-cm, 69 inch lbs.)
77. INSTALL TIE ROD END SUB-ASSY LH
78. INSTALL TIE ROD END SUB-ASSY RH
HINT: Perform the same procedure on the other side.
79. INSTALL FRONT WHEELS
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.l
80. INSTALL STEERING SLIDING YOKE SUB-ASSY
a. Align the matchmarks on the sliding yoke sub-assy and the intermediate shaft.
b. Tighten the bolt.
Torque: 28 Nm (290 kgf-cm, 21 ft. lbs.)
81. INSPECT CENTER FRONT WHEEL
82. INSTALL STEERING COLUMN HOLE COVER SUB-ASSY NO.1
83. ADD POWER STEERING FLUID
84. BLEED POWER STEERING FLUID
85. CHECK POWER STEERING FLUID LEVEL IN RESERVER
86. INSPECT FLUID LEAK
87. INSTALL HOOD SUB-ASSY
88. ADJUST HOOD SUB-ASSY
89. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
90. INSTALL ENGINE UNDER COVER LH
91. INSTALL ENGINE UNDER COVER RH
92. INSTALL COWL PANEL SUB-ASSY
93. INSTALL WINDSHIELD WIPER MOTOR & LINK ASSY
94. INSTALL COWL TOP VENTILATOR LOUVER LH
95. INSTALL COWL TOP VENTILATOR LOUVER RH
96. INSTALL HOOD TO COWL TOP SEAL
97. INSTALL FR WIPER ARM LH
98. INSTALL FR WIPER ARM RH