Steering

SR-1
STEERING
SR-2
STEERING - GENERAL DESCRIPTION
GENERAL DESCRIPTION
Care must be taken to replace parts properly because they could affect the performance of the
steering system and result in a driving hazard.
TROUBLESHOOTING
Use the table below to help you find the cause of the problem. The numbers indicate the priority
of the likely cause of the problem. Check each part in order. If necessary, replace these parts.
SR-32
SR-32
Suspension arm ball joints (Worn) SA-37
SA-10
SA-3
SA-5
See page
Front wheel alignment (Incorrect)
Steering system joints (Worn)
Front wheel bearing (Worn)

Steering column (Binding)
Tires (Improperly inflated)
Parts
Steering gear housing

Name
Sliding yoke (Worn)

Drive belt (Loose)
Fluid level (Low)
Trouble
Hard steering
Poor return
Excessive play
Abnormal noise
SR-2
STEERING - TROUBLESHOOTING
GENERAL DESCRIPTION
Care must be taken to replace parts properly because they could affect the performance of the
steering system and result in a driving hazard.
TROUBLESHOOTING
Use the table below to help you find the cause of the problem. The numbers indicate the priority
of the likely cause of the problem. Check each part in order. If necessary, replace these parts.
SR-32
SR-32
Suspension arm ball joints (Worn) SA-37
SA-10
SA-3
SA-5
See page
Front wheel alignment (Incorrect)
Steering system joints (Worn)
Front wheel bearing (Worn)

Steering column (Binding)
Tires (Improperly inflated)
Parts
Steering gear housing

Name
Sliding yoke (Worn)

Drive belt (Loose)
Fluid level (Low)
Trouble
Hard steering
Poor return
Excessive play
Abnormal noise
SR-3
STEERING - ON-VEHICLE INSPECTION
ON-VEHICLE INSPECTION
CHECK THAT STEERING WHEEL FREEPLAY IS COR-
RECT
With the vehicle stopped and tires pointed straight
ahead, rock the steering wheel gently back and forth
with light finger pressure.
Freeplay should not exceed the maximum.
Maximum freeplay:
30 mm (1.18 in.)
If incorrect, repair.
SR-4
STEERING - STEERING COLUMN
STEERING COLUMN
PREPARATION
SST (SPECIAL SERVICE TOOLS)

09609-2001 1 Steering Wheel Puller
RECOMMENDED TOOLS
09904-00010 Expander Set For removing and installing
snap ring
(09904-00050) No. 4 Claw
EQUIPMENT
Torque wrench
SR-5
ASSEMBLY REMOVAL AND

INSTALLATION
Remove and install the parts, as shown.
SR-6
MAIN POINTS OF REMOVAL AND

INSTALLATION
NOTICE:
• If the SRS (Supplemental Restraint System) connec-
tor is disconnected with the igniton switch at ON or
ACC, diagnostic trouble codes will be recorded.
• Never use SRS parts from another vehicle. When
replacing parts, replace with new parts.
1. DISCONNECT NEGATIVE (-) TERMINAL CABLE

FROM BATTERY
CAUTION: Work must be started after 90 seconds from
the time the ignition switch is turned to the ”LOCK”
position and the negative (-) terminal cable is discon-
nected from the battery.
(See RS section)
w/ SRS:
2. REMOVE STEERING WHEEL PAD
(a) Place the front wheels facing straight ahead.
(b) Remove the No.2 and No.3 covers.
(c) Using a torx wrench, loosen the 3 torx screws.
Torx wrench: T30 (Part No. 09042-00010 or locally
manufactured tool)
HINT: Loosen the 3 screws until the groove along the
screw circumference catches on the screw case.
(d) Pull the wheel pad out from the steering wheel and
disconnect the SRS connector.
NOTICE: When removing the wheel pad, take care not
to pull the airbag wire harness.
CAUTION:
• When storing the wheel pad, keep the upper surface
of the pad facing upward.
• Never disassemble the wheel pad.
3. REMOVE STEERING WHEEL
(a) Disconnect the connector.
(b) Remove the set nut.
(c) Place matchmarks on the steering wheel and main
shaft.
(d) Using SST, remove the steering wheel.
SST 09609-20011
4. REMOVE AND INSTALL COMBINATION SWITCH
SR-7
5. CENTER SPIRAL CABLE

(a) Check that the front wheels are facing straight ahead.
(b) Turn the spiral cable counterclockwise by hand until it
becomes harder to turn the cable.
(c) Then rotate the spiral cable clockwise about 3 turns to
align the red mark.
HINT: The spiral cable will rotate about 3 turns to
either left or right of the center.
6. INSTALL STEERING WHEEL

(a) Align matchmarks on the steering wheel and main
shaft, and install the steering wheel to the main shaft.
(b) Install and torque the set nut.
Torque: 35 Nm (360 kgfcm, 26 ftlbf)
(c) Connect the connector.
7. INSTALL STEERING WHEEL PAD

(a) Connect the SRS connector.
(b) Install the wheel pad after confirming that the circum-
ference groove of the torx screws is caught on the
screw case.
(c) Using a torx wrench, tighten the 4 screws.
Torque: 8.8 Nm (90 kgfcm. 78 in.lbf)
NOTICE:
• Make sure the wheel pad is installed to the specified
torque.
• If the wheel pad has been dropped, or there are
cracks, dents or other defects in the case or connec-
tor, replace the wheel pad with a new one.
• When installing the wheel pad, take care that the
wirings do not interfere with other parts and are not
pinched between other parts.
(d) Install the No.2 and No.3 covers.
8. CHECK STEERING WHEEL CENTER POINT
9. CONNECT NEGATIVE (-) TERMINAL CABLE TO
BATTERY
w/o SRS:
1. REMOVE STEERING WHEEL
Using SST, remove the steering wheel.
SST 09609-20011
2. CHECK STEERING WHEEL CENTER POINT AFTER
INSTALLATION STEERING COLUMN
SR-8
STEERING COLUMN
COMPONENTS
STEERING COLUMN DISASSEMBLY

NOTICE: When placing the column tube in a vise, do not
tighten it too tight.
7. REMOVE COLUMN UPPER BRACKET
(a) Using a center punch, mark the center of the 2 tap-
ered-head bolts.
(b) Using a 3-4 mm (0.12-0.16 in.) drill, drill in to the 2
tapered-head 2 bolts.
SR-9
(c) Using a screw extractor, remove the 2 tapered-head

bolts.
(d) Remove the bracket and column upper clamp.
2. REMOVE MAIN SHAFT

(a) Using snap ring pliers, remove the snap ring.
(b) Tap out the main shaft.
(c) Using snap ring pliers, remove the snap ring from the
main shaft.
3. REMOVE COLUMN LOWER TUBE

(a) Place matchmarks on the upper tube and lower tube.
(b) Using a plastic hammer, tap out the lower tube.
STEERING, COLUMN INSPECTION AND

REPLACEMENT
1. INSPECT KEY CYLINDER
Check that the steering lock mechanism operates pro-
perly.
SR-10
2. IF NECESSARY, REPLACE KEY CYLINDER

(a) Place the ignition key at the ACC position.
(b) Push down the stop pin with a thin rod, and pull out
the key cylinder.
(c) Install a new key cylinder.
HINT: Make sure the ignition key is at the ACC posi-
tion.
3. INSPECT COLUMN UPPER TUBE BEARING

Check the bearing rotation condition and check for
abnormal noise.
If the bearing is worn or damaged, replace the upper
tube.
4. IF NECESSARY. REPLACE MAIN SHAFT BUSHING

(a) Using a screwdriver, remove the bushing.
(b) Align the holes of the tube and the projections of the
bushing, and insert the main shaft bushing in the tube.
6. IF NECESSARY, REPLACE COLUMN TUBE BUSH-

ING
(a) Remove the bushing.
(b) Install the bushing to the upper tube and integrate the
groove in the upper tube with the narrow projection of
the bushing, checking that the other projections are
against the uppper surface of the upper tube.
STEERING COLUMN ASSEMBLY

1. APPLY MOLYBDENUM DISULPHIDE LITHIUM
BASE GREASE
2. INSTALL COLUMN LOWER TUBE
Align matchmarks on the upper tube and lower tube
and tap in the lower tube.
SR-1 1
3. INSTALL MAIN SHAFT

(a) Using snap ring pliers, install a new snap ring to the
main shaft.
(b) Install the main shaft to the column tube.

(c) Using snap ring pliers, install a new snap ring.
4. INSTALL COLUMN UPPER BRACKET

(a) Install the bracket with 2 new tapered-head bolts.
(b) Tighten the 2 tapered-head bolts until the bolt head
breaks off.
SR-12
STEERING - MANUAL STEERING GEAR HOUSING
MANUAL STEERING GEAR HOUSING
PREPARATION
09612-00012 Rack & Pinion Steering Rack
Housing Stand
09612-10093 Steering Gear Housing Overhaul

Tool Set
(09617-10010) Steering Pinion Bearing

Adjusting Screw Lock Nut Wrench
09612-10131 Hexagon Wrench

Tool Set
(09612-10061) Steering Pinion Bearing Replacer
(09616-10010) Steering Pinion Bearing

Adjusting Socket
(0961 6-10020) Steering Pinion Bearing

Adjusting Screw Wrench
(09617-22030) Steering Rack End Wrench
09617-10020 Steering Rack End Wrench
09620-30010 Steering Gear Box Replacer Set
(09631-00020) Handle
SR-13
09628-6201 1 Ball Joint Puller
09630-24013 Steering Rack Oil Seal Tool Set
(09620-24030) Valve Cup Bearing Replacer
09631-32010 Oil Seal Replacer
09950-20017 Universal Puller
RECOMMENDED TOOLS
09025-00010 Small Torque Wrench Total preload
EQUIPMENT
Dial indicator Steering rack
Torque wrench
SSM (SPECIAL SERVICE MATERIALS)

08833-00080 Adhesive 1344, Pinion bearing adjusting screw
THREE BOND 1344, Pinion bearing adjusting screw
LOCTITE 242 or equivalent lock nut
Rack guide spring cap
SR-14
ASSEMBLY REMOVAL AND

INSTALLATION
(MAIN POINTS OF REMOVAL AND

INSTALLATION)
1. DISCONNECT TIE ROD ENDS
(a) Remove the cotter pin and nut.
(b) Using SST, disconnect the tie rod end from the knuck-
le arm.
SST 09628-62011
SR-15
2. DISCONNECT SLIDING YOKE

(a) Place matchmarks on the sliding yoke and pinion
shaft.
(b) Loosen the upper side of sliding yoke set bolt.
(c) Remove the lower side of sliding yoke set bolt.
(d) Pull the sliding yoke upward from the pinion shaft.
3. REMOVE GEAR HOUSING

(a) Remove the 2 bolts and 2 nuts.
(b) Slide the gear housing to the RH side and pull it out
through the body panel.
5. CHECK TOE-IN
(See SA section)
SR-16

COMPONENTS

DISASSEMBLY
1. SECURE GEAR HOUSING IN VISE
Using SST, secure the steering gear in a vise.
SST 09612-00012
2. REMOVE TIE ROD ENDS

(a) Loosen the lock nut and place the matchmarks on the
tie rod end and rack end.
(b) Remove the tie rod end and lock nut.
3. REMOVE RACK BOOTS
(a) Remove the clip and clamp.
(b) Remove the rack boot.
(c) Mark the left and right boots accordingly.
SR-17
4. REMOVE RACK ENDS

(a) Unstake the claw washer.
NOTICE: Avoid any impact to the rack.
(b) Using SST, remove the rack end.

SST 09617-10020
(c) Mark the left and right rack ends accordingly.
(d) Remove the claw washer.
5. REMOVE RACK GUIDE SPRING CAP LOCK NUT

Using SST, remove the nut.
SST 09612-24014 (09617-22030)
6. REMOVE RACK GUIDE SPRING CAP

Using SST, remove the cap.
SST 09612-10131
7. REMOVE RACK GUIDE SPRING AND RACK GUIDE
8. REMOVE PINION BEARING ADJUSTING SCREW

LOCK NUT
Using SST, remove the nut.
SST 09612-10093 (09617-10010)
SR-18
9. REMOVE PINION BEARING ADJUSTING SCREW

Using SST, remove the screw.
SST 09612-24014 (09616-10020)
10. REMOVE PINION SHAFT WITH UPPER BEARING

HINT: Be careful not to damage the serrations.
(a) Fully pull the steering rack from the housing side and
align the rack notched portion with the pinion.
(b) Remove the pinion together with the upper bearing.
11. REMOVE STEERING RACK

Remove the rack from the pinion side without revolv-
ing it.
NOTICE: If the rack is pulled from the tube side, there is
a possibility of damaging the bushing with the rack teeth
surface.

INSPECTION AND REPLACEMENT
1. INSPECT RACK
(a) Using a dial indicator, check the rack for run out and
for teeth wear or damage.
Maximum runout:
0.3 mm (0.012 in.)
NOTICE: Do not use a wire brush when cleaning.

(b) Check the back surface for wear or damage.
If faulty, replace it.
SR-19
2. INSPECT UPPER AND LOWER BEARING

3. IF NECESSARY, REPLACE UPPER BEARING
(a) Using SST, remove the bearing.
SST 09950-20017
(b) Using SST, press in a new bearing.

SST 09612-24014 (09612-10061)
4. IF NECESSARY, REPLACE LOWER BEARING

(a) Heat the rack housing to above 80°C (176°F).
(b) Tap the rack housing with a plastic hammer or such to
remove the bearing by recoil.
(c) Heat the rack housing to above 80 C (176 F).

(d) Using SST, press in a new bearing.
SST 09620-30010 (09631-00020)
09630-24013 (09620-24030)
HINT: Observe the correct bearing direction.
5. IF NECESSARY, REPLACE RACK BUSHING

(a) Using a screwdriver, loosen the 3 bushing claws and
remove the rack bushing from the housing.
SR-20
(b) Ensure that the tube 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 turned.
(c) Install a new bushing into the rack housing, making

sure to align into the 3 holes.
6. IF NECESSARY, REPLACE OIL SEAL

(a) Using SST, remove the oil seal from the pinion bearing
adjusting screw.
SST 09631-32010
NOTICE: Make sure you install the oil seal facing the
correct direction.
(b) Using SST, press in the oil seal, as shown.
SST 09631-32010

ASSEMBLY
1. INSTALL STEERING RACK
(a) From the pinion side, install the rack into the rack
housing.
(b) Set the rack notched side so that the pinion can be
positioned inside.
(c) Line up the cutout portion of the rack with the pinion.
SR-21
2. INSTALL PINION SHAFT WITH UPPER BEARING

Ensure that the pinion end is securely in the lower
bearing.
3. INSTALL PINION BEARING ADJUSTING SCREW

(a) Apply sealant to 2 or 3 threads of the screw.
Sealant:
Part No.08833-00080, THREE BOND 1344, LOC-
TITE 242 or equivalent
(b) Using SST, install the screw.
SST 09612-24014 (09616-10020)
4. ADJUST PINION PRELOAD
(a) Line up the cutout portion of the rack with the pinion.
(b) Using SST and torque meter, tighten the pinion bear-
ing adjusting screw to the point where the turning
torque is 0.4 Nm (3.7 kgfcm, 3.2 in.lbf).
SST 09612-24014 (09616-10010, 09616-10020)
(c) Using SST, loosen the pinion bearing adjusting screw
to the point where turning torque is 0.2-0.3 Nm (2.3
-3.3 kgfcm, 2.0-2.9 in.lbf).
SST 09612-24014 (09616-10010, 09616-10020)
Preload (turning):
0.2-0.3 Nm (2.3-3.3 kgfcm, 2.0-2.9 in.Ibf)
5. INSTALL PINION BEARING ADJUSTING SCREW
LOCK NUT
(a) Apply sealant to 2 or 3 threads of the nut.
Sealant:
Part No.08833-00080. THREE BOND 1344, LOC-
(b) Using SST, install the nut.
SST 09612-10093 (09617-10010)
09612-24014 (09616-10020)
HINT: Use a torque wrench with a fulcrum length of
425 mm (16.73 in.).
(c) Recheck the pinion preload.
If incorrect, readjust.
Preload (turning):
0.2-0.3 Nm (2.3-3.3 kgfcm, 2.0-2.9 in.lbf)
SR-22
6. INSTALL RACK GUIDE AND RACK GUIDE SPRING

7. INSTALL RACK GUIDE SPRING CAP
(a) Apply sealant to 2 or 3 threads of the cap.
Sealant:
Part No.08833-00080. THREE BOND 1344, LOC-
(b) Mesh the rack with the pinion.
(c) Using SST, install the cap.
SST 09612-10131
8. ADJUST TOTAL PRELOAD

(a) Using SST, tighten the rack guide spring cap.
SST 09612-10131
Torque: 4.9 Nm (50 kgfcm, 43 in.lbf)
(b) Using SST and torque meter, while gradually loosen-

ing the cap, measure and adjust the preload.
SST 09612-10131,
09612-24014 (09616-10010)
Preload (turning):
0.6-1.2 Nm (6-12 kgfcm, 5.2-10.4 in.lbf)
HINT: When measuring the preload, measure in sever-
al places and check that the values are within stand-
ard.
9. INSTALL RACK GUIDE SPRING CAP LOCK NUT

(a) Apply sealant to 2 or 3 threads of the nut.
Sealant:
(b) Using SST, install the nut.
SST 09612-10131,
09612-24014 (09617-22030)
340 mm (13.39 in.).
(c) Recheck the total preload. If incorrect, readjust.
Preload (turning):
0.6-1.2 Nm (6-12 kgfcm, 5.2-10.4 in.lbf)
SR-23
10. INSTALL RACK ENDS

(a) Install a new claw washer.
HINT: Align the claw of the claw washer with the rack
groove.
(b) Using SST, install the rack end.
SST 09617-10020
340 mm (13.39 in.).
(c) Using a brass bar and hammer, stake the claw washer.
11. INSTALL RACK BOOTS

(a) Install the rack boot.
HINT: Be careful not to damage or twist the boot. The
left and right boots are different. Be careful not to
interchange them.
(b) Install the clamp and clip.

HINT: Face the open ends of the clips outward/
upward, as shown, to avoid damage to the boot.
12. INSTALL TIE ROD ENDS

(a) Screw the lock nut and tie rod end onto the rack end
until the matchmarks are aligned.
(b) After adjusting toe-in, torque the lock nut.
(See SA section)
SR-24
STEERING - POWER STEERING
POWER STEERING
DESCRIPTION
POWER STEERING PRINCIPLES

Power steering is a hydraulic device which utilizes engine power to reduce steering effort.
Consequently, the engine is used to drive a pump to develop fluid pressure, and this pressure acts
on a piston within the power cylinder so that the piston assists the rack effort. The amount of this
assistance depends on the extent of pressure acting on the piston. Therefore, if more steering
force is required, the pressure must be raised. The variation in the fluid pressure is accomplished
by a control valve which is linked to the steering main shaft.
NEUTRAL (STRAIGHT-AHEAD) POSITION

Fluid from the pump is sent to the control valve. If the control valve is in the neutral position, all
the fluid will flow through the control valve into the relief port and back to the pump. At this time,
hardly any pressure is created and because the pressure on the cylinder piston equal an both
sides, the piston will not move in either direction.
SR-25
WHEN TURNING
When the steering main shaft is turned in either direction, the control valve also moves, closing
1 of the fluid passages. The other passage then opens wider, causing a change in fluid flow
volume and, at the same time, a differential pressure is created between both sides of the piston.
Consequently, the piston moves in the direction of the lower pressure so that the fluid in the
cylinder is forced back to the pump through the control valve.
SERVICE HINT
Troubles with the power steering system are usually concerned with hard steering due to the fact
that there is no assist. In such cases, before attempting to make repairs, it is necessary to
determine whether the trouble lies with the pump or with the gear housing. To do this, an on-
vehicle inspection can be made by using a pressure gauge.
Power steering is a hydraulic device and problems are normally due to insufficient fluid pressure
acting on the piston. This could be caused by either the pump not producing the specified fluid
pressure or the control valve in the gear housing not functioning properly so that the proper fluid
pressure can not be obtained.
If the fault lies with the pump, the same symptoms will generally occur whether the steering
wheel is turned fully to the right or left. On the other hand, if the fault lies with the control valve,
there will generally be a difference between the amount of assist when the steering wheel is
turned to the left and right, causing harder steering. However, if the piston seal of the power
cylinder is worn, there will be a loss of fluid pressure whether the steering wheel is turned to the
right or left and the symptoms will be the same for both.
Before performing an on-vehicle inspection, a check must first be made to confirm that the
power steering system is completely free of any air. If there is any air in the system, the volume
of this air will change when the fluid pressure is raised, causing a fluctuation in the fluid pressure
so that the power steering will not function properly. To determine if there is any air in the
system, check to see if there is a change of fluid level in the reservoir tank when the steering
wheel is turned fully to the right or left.
For example, if there is air in the system, it will be compressed to a smaller volume when the
SR-26
turned fully to the right or left.

If there is air in the system, it will be compressed to a smaller volume when the steering wheel is
turned, causing a considerable drop in the fluid level. If the system is free of air, there will be very
little change in the level even when the fluid pressure is raised. This is because the fluid, being a
liquid, does not change volume when compressed. The small change in the fluid level is due to
expansion of the hoses between the pump and gear housing when pressure rises.
Also, air in the system sometimes causes abnormal noise in the pump or gear housing when the
steering wheel is fully turned in either direction.
This on-vehicle inspection must be performed every time after overhauling or repairing the
pump or gear housing to ensure that the power steering is working properly.
VANE PUMP
The main component parts of the vane pump, such as the cam ring, rotor, vanes and flow control
valve are high precision parts and must be handled carefully. Also, because this pump produces
a very high fluid pressure, O-rings are used for sealing each part. When reassembling the pump,
always use new O-rings.
In the flow control valve, there is a relief valve which controls the maximum pressure of the pump.
The amount of this maximum pressure is very important; if it is too low, there will be insufficient
power steering assist and if too high, it will have an adverse effect on the pressure hoses, oil
seals, etc. If the maximum pressure is either too high or too low due to a faulty relief valve, do not
disassemble or adjust the relief valve, but replace the flow control valve as an assembly.
The clearance between the flow control valve and pump body installation hole is very important.
After manufacture, the factory measures the size of the installation hole and outer circumference
of the flow control valve, and punches a mark accordingly. Therefore, when replacing the flow
control valve, be sure to do so with one having the same mark in order to insure the proper
clearance.
SR-27
The functional parts of the pump which produce fluid pressure are the cam ring, rotor and vanes,
and these should be checked for wear. If the clearance between each is not within standard when
reassembling, any worn parts should be replaced.
In this case, the replaced cam ring and rotor should be of the same length (have the same mark),
and the vanes should be replaced with those having a length corresponding to that mark,
otherwise the proper thrust clearance cannot be obtained. If there is too much thrust clearance,
there will be insufficient fluid pressure at low speeds. If there is too little thrust clearance, it may
result in seizure of the vanes.
GEAR HOUSING
If the gear housing is secured directly in a vise during overhaul, there is danger of deforming it,
so always first secure it in the SST provided (rack and pinion steering rack housing stand) before
placing it in the vise.
The oil seals on both sides of the power cylinder are for the prevention of leakage of the high
pressure fluid which acts on the piston. Always use new oil seals when reassembling and be very
careful not to scratch or damage them.
Because of the high pressure, even the slightest scratch will cause fluid leakage, resulting in an
inoperative power steering system.
Also, be very careful not to scratch the sliding portion of the rack which makes contact with the
oil seals. When removing the rack ends from the rack, it is very easy to cause a burr when holding
the tip of the rack with a wrench. Therefore, before assembling the rack, first check the tip for
burrs and remove any with an oil stone.
Teflon rings are used for the piston and control valve. These teflon rings are highly durable
against wear, but if it is necessary to replace them, be careful not so stretch the new ones. After
installing a teflon ring into its groove, snug it down into the groove before assembly of the
cylinder or housing to prevent possible damage.
SR-28
As with the rack and pinion type steering, preload is very important. If the preload is not correct,
it could result in such trouble as steering wheel play or shimmy or lack of durability, so always
make sure that it is correct.
IDLE-UP DEVICE
The pump produces the maximum fluid pressure when the steering wheel is turned fully to the
right or left and, at this time, there is a maximum load on the pump which causes a decrease in
engine idle rpm. To solve this problem, vehicles are equipped with an idle-up device which acts
to raise the engine idle rpm whenever there is a heavy load on the pump.
On EFI engines, when the piston of the air control valve is pushed by fluid pressure, the air valve
opens and the volume of air by-passing the throttle valve is increased to regulate engine rpm.
SR-29
PREPARATION
09278-54012 Drive Shaft Holding Tool PS pump pulley
09612-00012 Rack & Pinion Steering Rack

Housing Stand

Tool Set
(09612-10061) Steering Pinion Bearing Replacer
09612-2201 1 Tilt Handle Bearing Replacer

Tool Set
(09612-10022) Hexagon Wrench
09612-65014 Steering Worm Bearing Puller
(09612-01030) CIaw “C”
09613-12010 Power Steering Control Valve

Puller
09616-00010 Steering Worm Bearing Adjusting

Socket
09617-10020 Steering Rack End Wrench
09617-12020 Rack Guide Cap Lock Nut Wrench

SR-30
09628-6201 1 Ball Joint Puller
(09631-24030) Piston Ring Tool
09631-10041 Steering Rack Cover ”D”
09631-12020 Handle
09631-12040 Oil Seal “A” Replacer
09631-12071 Steering Rack Oil Seal Test Tool
09631-20081 Seal Ring Tool
09631-20090 Cylinder End Stopper Nut Wrench
09631-22020 Power Steering Hose Nut

14 x 17 mm Wrench Set
09633-00020 Power Steering Hose Nut Wrench
09950-20017 Universal Puller

SR-31
RECOMMENDED TOOLS
09025-00010 Small Torque Wrench Total preload
09904-00010 Expander Set
(09904-00050) No. 4 Claw
EQUIPMENT
Dial indicator Steering rack
Micrometer Power steering pump
Oil pressure gauge
Torque wrench
Vacuum gauge Gear housing
LUBRICANT
Item Capacity Classification
Power steering fluid 0.81 liters (0.86 US qts, 0.71 Imp.qts) ATF DEXRON ll
Total
SSM (SPECIAL SERVICE MATERIALS)

08833-00080 Adhesive 1344, Rack housing cap
THREE BOND 1344, Rack guide spring cap
LOCTITE 242 or equivalent Rack guide spring cap lock nut
SR-32
DRIVE BELT TENSION CHECK
Using a belt tension gauge, check the drive belt ten-
sion.
Belt tension gauge:
Nippondenso BTG-20 (95506-00020) or
Borroughs No.BT-33-73F
Drive belt tension:
New belt
627-803 N (64-82 kgf, 140-180 lbf)
Used belt
353-529 N (36-54 kgf, 80-120 lbf)
HINT:
• “New belt” refers to a belt which has been less
than 5 minutes on a running engine.
• “Used belt” refers to a belt which has been used
on a running engine for 5 minutes or more.
• After installing the drive belt, check that it fits
properly in the ribbed grooves.
VEHICLES WITH BELT TENSION ADJUSTING BOLT
When belt tension adjustment is necessary, follow the
procedure below.
(a) Loosen bolts A and B.
(b) Loosen lock nuts D and E.
(c) Adjust adjusting bolt F so that its protrusion above
nut C is ±0 mm (0 in.).
(d) Fix nut C using lock nut D.
(e) Push up the P/S pump body so that there is no free
play in the belt. Turn adjusting bolt F to obtain the
correct belt tension as specified above.
(f) Torque bolts A and B.
(g) Loosen adjusting bolt F by 4 or 5 turns.
NOTICE: Check that there is a gap of 5 mm (0.20 in.) or
more between the tip of nut C and the P/S pump body.
(h) Fix adjusting bolt F with lock nut E.
(i) Recheck the belt tension.
FLUID LEVEL CHECK

1. KEEP VEHICLE LEVEL
2. BOOST FLUID TEMPERATURE
With the engine idling at 1,000 RPM or less, turn the
steering wheel from lock to lock several times to
boost fluid temperature.
Fluid temperature:
80C (176F)
SR-33
3. STOP ENGINE
4. CHECK FOR FORMING OR EMULSIFICATION
HINT: Forming and emulsification indicate either the
existence of air in the system or that the fluid level is
too low.
5. CHECK FLUID LEVEL IN OIL RESERVOIR

Check the fluid level and add fluid if necessary.
Fluid:
ATF DEXRON ll
HINT: Check that the fluid level is within the HOT
LEVEL of the reservoir. If the fluid is cold, check that
it is within the COLD LEVEL of the reservoir.
IDLE-UP CHECK
1. WARM UP ENGINE
2. TURN AIR CONDITIONER SWITCH OFF
3. CHECK IDLE-UP
(a) Fully turn the steering wheel.
(b) Check that the engine rpm decreases when the air
control valve hose is pinched.
(c) Check that the engine rpm increases when the air
control valve hose is released.
POWER STEERING FLUID REPLACEMENT
1. JACK UP FRONT OF VEHICLE AND SUPPORT IT
WITH STANDS
2. REMOVE FLUID RETURN HOSE FROM OIL RESER-

VOIR AND DRAIN FLUID INTO CONTAINER
SR-34
3. TURN STEERING WHEEL FROM LOCK TO LOCK

WHILE DRAINING FLUID
4. FILL OIL RESERVOIR WITH FRESH FLUID

Fluid:
ATF DEXRON II
5. START ENGINE AND RUN IT AT 1,000 RPM

After 1 or 2 seconds, fluid will begin to discharge from
the return hose. Stop the engine immediately at this
time.
NOTICE: Take care that some fluid remains left in the
reservoir.
6. REPEAT STEPS 5 AND 6 FOUR OR FIVE TIMES
UNTIL THERE IS NO MORE AIR IN FLUID
7. CONNECT RETURN HOSE TO OIL RESERVOIR
8. BLEED POWER STEERING SYSTEM
POWER STEERING SYSTEM BLEEDING
1. CHECK FLUID LEVEL IN OIL RESERVOIR
Check the fluid level and add fluid if necessary.
Fluid:
ATF DEXRON II
HINT: Check that the fluid level is within the HOT
LEVEL of the reservoir. If the fluid is cold, check that
it is within the COLD LEVEL of the reservoir.
2. START ENGINE AND TURN STEERING WHEEL

FROM LOCK TO LOCK 3 OR 4 TIMES
With the engine speed below 1,000 RPM, turn the
steering wheel to left or right full lock and keep it
there for 2-3 seconds, then turn the wheel to the
opposite full lock and keep it there for 2-3 seconds.
SR-35
3. CHECK THAT FLUID IN OIL RESERVOIR IS NOT

FOAMY OR CLOUDY AND DOES NOT RISE OVER
MAXIMUM WHEN ENGINE IS STOPPED
Measure the fluid level with the engine running. Stop
the engine and measure the fluid level.
Maximum rise:
5 mm (0.20 in.)
If a problem is found, repeat steps 5 to 6 on page
SR-34 . Repair the PS if the problem persists.
OIL PRESSURE CHECK

1. CONNECT OIL PRESSURE GAUGE
(a) Drain fluid.
(b) Disconnect the pressure tube from the PS pump.
(c) Connect the gauge side of the pressure gauge to the

PS pump and valve side to the pressure line.
(SEE PAGE SR-34 )
3. START ENGINE AND RUN IT AT IDLE

4. BOOST FLUID TEMPERATURE
With the engine idling at 1,000 rpm or less, turn the
steering wheel from lock to lock several times to
boost fluid temperature.
Fluid temperature: 80°C (176°F)
SR-36
5. CHECK FLUID PRESSURE READING WITH VALVE

CLOSED
Close the pressure gauge valve and observe the read-
ing on the gauge.
Minimum pressure:
5,884 kPa (60 kgf/cm2, 853 psi)
NOTICE:
• Do not keep the valve closed for more than 10
seconds.
• Do not let the fluid temperature become too high.
If pressure is low, repair or replace the PS pump.
6. OPEN VALVE FULLY
7. CHECK AND RECORD PRESSURE READING AT
1,000 RPM
8. CHECK AND RECORD PRESSURE READING AT
3,000 RPM
Check that there is 490 kPa (5 kgf/cm2, 71 psi) or less
difference in pressure between the 1,000 RPM and
3,000 RPM checks.
If the difference is excessive, repair or replace the
flow control valve of the PS pump.
9. CHECK PRESSURE READING WITH STEERING
WHEEL TURNED TO FULL LOCK
Be sure the pressure gauge valve is fully opened and
the engine idling.
Minimum pressure:
5,884 kPa (60 kgf/cm2, 853 psi)
NOTICE:
• Do not maintain lock position for more than 10
seconds.
• Do not let the fluid temperature become too high.
If pressure is low, the gear housing has an internal
leak and must be repaired or replaced.
10. DISCONNECT OIL PRESSURE GAUGE
(a) Drain fluid.
(b) Remove the oil pressure gauge.
(c) Connect the pressure tube to the PS pump.
Torque: 69 Nm (700 kgfcm, 51 ftIbf)
(See page SR-34 )
12. MEASURE STEERING EFFORT
(a) Center the steering wheel and run the engine at idle.
(b) Using a torque meter, measure the steering effort in
both directions.
Maximum steering effort:
7.8 Nm (80 kgfcm, 69 in.Ibf)
If steering effort is excessive, repair the PS unit.
HINT: Be sure to consider the tire type, pressure and
contact surface before making your diagnosis.
SR-37
POWER STEERING PUMP

POWER STEERING PUMP REMOVAL AND
INSTALLATION

INSTALLATION)
1. ADJUST DRIVE BELT TENSION AFTER INSTALL-
ING PS PUMP
(See page SR-32 )
(See page SR-34 )
SR-38
COMPONENTS
MOM-”
POWER STEERING PUMP DISASSEMBLY

1. MOUNT PUMP IN VISE
NOTICE: Do not tighten the noise too tight.
2. REMOVE PS PUMP PULLEY
(a) Using SST, remove the pulley set nut.
SST 09278-54012
(b) Remove the pulley and woodruff key.
SR-39
3. REMOVE SUCTION PORT UNION

(a) Remove the 2 bolts and union.
(b) Remove the O-ring from the union.
4. REMOVE FLOW CONTROL VALVE

(a) Remove the pressure port union.
(b) Remove the O-ring from the union.
(c) Remove the flow control valve and spring.
5. REMOVE PUMP SHAFT

(a) Using 2 screwdrivers, remove the snap ring.
(b) Wind vinyl tape on the pump shaft.

(c) Using a plastic hammer, the pump shaft end.
SR-40
6. REMOVE REAR SIDE PLATE

(a) Using a plastic hammer, tap the shaft end and remove
the rear plate.
(b) Remove the O-ring from the rear plate.
7. REMOVE VANE PUMP SHAFT, CAM RING AND
VANE PLATES
(a) Remove the pump shaft with cam ring and vane plates
from the front housing.
(b) Remove the cam ring and 10 vane plates from the
pump shaft.
8. REMOVE STRAIGHT PIN
Remove the longer straight pin from the front hous-
ing.
9. REMOVE ROTOR AND FRONT SIDE PLATE

(b) Remove the rotor and plate from the pump shaft.
(c) Remove the 2 O-rings and shorter straight pin from
the plate.
SR-41
POWER STEERING PUMP INSPECTION

AND REPLACEMENT
1. MEASURE OIL CLEARANCE OF SHAFT AND BUSH-
ING
Using a micrometer and calipers, measure the oil cle-
arance.
Standard clearance:
0.01-0.03 mm (0.0004-0.0012 in.)
Maximum clearance:
0.07 mm (0.0028 in.)
If more than maximum, replace the entire power steer-
ing pump.
2. INSPECT ROTOR AND VANE PLATES

(a) Using a micrometer, measure the height, thickness
and length of the vane plates.
Minimum height:
8.0 mm (0.315 in.)
Minimum thickness:
1.77 mm (0.0697 in.)
Minimum length:
14.97 mm (0.5894 in.)
(b) Using a feeler gauge, measure the clearance between

the rotor groove and vane plate.
Maximum clearance:
0.03 mm (0.0012 in.)
If more than maximum, replace the vane plate and/or
rotor with one having the same mark stamped on the
cam ring.
Inscribed mark:
1, 2, 3, 4 or None
HINT: There are 5 vane lengths with the following
rotor and cam ring marks:
Rotor and cam
Vane length mm (in.)
ring mark
None 14.996-14.998 (0.59039-0.59047)
14.994-14.996 (0.59032-0.59039)
14.992-14.994 (0.59024-0.59032)
14.990-14.992 (0.59016-0.59024)
14.988-14.990 (0.59008-0.59016)
SR-42
3. INSPECT FLOW CONTROL VALVE

(a) Coat the valve with power steering fluid and check
that it falls smoothly into the valve hole by its own
weight.
(b) Check the flow control valve for leakage. Close one of
the holes and apply compressed air [392-490 kPa (4
-5 kgf/cm2, 57-71 psi)] into the opposite side, and
confirm that air does not come out from the end hole.
If necessary, replace the valve with one having the

same letter as inscribed on the front housing.
Inscribed mark:
A, B, C, D, E or F
4. INSPECT FLOW CONTROL SPRING

Using a scale, measure the free length of the spring.
Spring length:
36-38 mm (1.42-1.49 in.)
If not within specification, replace the spring.
5. IF NECESSARY, REPLACE OIL SEAL

(a) Using a screwdriver, pry out the oil seal.
SR-43
(b) Coat a new oil seal lip with power steering fluid.
correct direction.
(c) Using a socket wrench, press in the oil seal.
POWER STEERING PUMP ASSEMBLY

1. COAT ALL SLIDING SURFACES WITH POWER STE-
ERING FLUID BEFORE ASSEMBLY
2. INSTALL LONGER STRAIGHT PIN
Using a plastic hammer, drive in the pin to the front
housing.
3. INSTALL FRONT PLATE AND ROTOR TO PUMP

SHAFT
(a) Coat 2 new O-rings with power steering fluid, and
install them to the from plate.
(b) Install the front plate to the pump shaft.
(c) Install the rotor to the pump shaft with the inscribed
mark on the rotor facing outward.
(d) Using snap ring pliers, install a new snap ring.
(e) Install the shorter straight pin to the front plate.

SR-44
(f) Wind vinyl tape on the pump shaft.

(g) Align the hole of the front plate and straight pin.
(h) Tap in the pump shaft with a plastic hammer.

NOTICE: Be careful not to damage the oil seal and O-rings.
4. INSTALL CAM RING

Align the holes of the cam ring and straight pins, and
insert the cam ring with the inscribed mark facing
outward.
5. INSTALL VANE PLATES

Install the 10 vane plates with the round end facing
outward.
6. INSTALL REAR SIDE PLATE

(a) Coat a new O-ring with power steering fluid, and
install it the side plate.
(b) Match the wide hole with the longer straight pin and
install the plate.
SR-45
7. INSTALL WAVE WASHER

Install the wave washer so that its protrusions fit into
the slots in the rear side plate.
8. INSTALL REAR HOUSING

install it to the rear housing.
(b) Install the rear housing and use a press to push down
on the wave washer hard enough to compress it.
NOTICE: Do not apply too much pressure.
(c) Install the snap ring.
9. MEASURE PUMP SHAFT PRELOAD

(a) Check that the shaft rotates smoothly without abnor-
mal noise.
(b) Temporarily install the pulley nut and using a torque
meter, check the rotating toorque.
Rotating torque:
0.3 Nm (2.8 kgfcm, 2.4 in.lbf) or less
10. INSTALL FLOW CONTROL VALVE

(a) Install the spring and valve into the housing.
(b) Coat a new O-ring with power steering fluid, amd
install it to the pressure port union.
(c) Install the pressure port union.
SR-46
11. INSTALL SUCTION PORT UNION

install it to the suction port.
(b) Install the suction port union with the 2 bolts.
12. INSTALL PS PUMP PULLEY

(a) Install the woodruff key to the shaft.
(b) Install the pulley and nut to the shaft.
(c) Using SST, torque the set nut.

SST 09278-54012
SR-47
GEAR HOUSING
STEERING GEAR HOUSING REMOVAL
AND INSTALLATION

INSTALLATION)
1. DISCONNECT TIE ROD ENDS
(a) Remove the cotter pin and nut.
(b) Using SST, disconnect the tie rod end from the knuck-
le arm.
SST 09628-62011
SR-48
2. DISCONNECT SLIDING YOKE

(a) Place matchmarks on the sliding yoke and control
valve shaft.
(b) Loosen the upper side of sliding yoke set bolt.
(c) Remove the lower side of sliding yoke set bolt.
(d) Pull the sliding yoke upward from the control valve
shaft.
3. DISCONNECT PRESSURE AND RETURN TUBES

Using SST, disconnect and connect the pressure and
return tubes.
SST 09631-22020
4. REMOVE GEAR HOUSING

(a) Remove the 2 bolts, 2 nuts and 2 brackets.
(b) Slide the gear housing to the RH side.
(c) Slide the gear housing to the LH side and pull it out.
5. CENTER SPIRAL CABLE
If the steering wheel has been removed, or the steer-
ing wheel may have moved during the operation
always perform centering of the spiral cable.
(See page SR-7 )
7. CHECK TOE-IN
(SEE SA SECTION)
SR-49
COMPONENTS
STEERING GEAR HOUSING DISASSEMBLY

1. SECURE GEAR HOUSING IN VISE
Using SST, secure the gear housing in a vise.
SST 09612-00012
2. REMOVE TURN PRESSURE TUBES

Using SST, remove the tubes.
SST 09633-00020
3. REMOVE AIR CONTROL VALVE
SR-50
4. REMOVE TIE ROD ENDS

(a) Place matchmarks on the tie rod end and rack end.
(b) Remove the tie rod end and lock nut.
5. REMOVE RACK BOOTS

(a) Using a screwdriver, remove the clamp.
(b) Remove the clip and boot.
NOTICE: Be careful not to damage the rack boots and
rack housing.
6. REMOVE RACK ENDS AND CLAW WASHERS

(a) Using a screwdriver and hammer, unstake the claw
washer.
NOTICE: Avoid any impact to the rack.
(b) Using SST, remove the rack end.

SST 09617-10020
HINT: Mark the left and right rack ends accordingly.
(c) Remove the claw washers.
7. REMOVE RACK GUIDE SPRING CAP LOCK NUT

Using SST, remove the rack guide spring cap lock nut,
SST 09617-12020
SR-51
8. REMOVE RACK GUIDE SPRING CAP

Using SST, remove the rack guide spring cap.
SST 09612-24014 (09612-10022)
9. REMOVE RACK GUIDE SPRING, RACK GUIDE AND
RACK GUIDE SEAT
10. REMOVE RACK HOUSING CAP
11. REMOVE SELF-LOCKING NUT

Using SST to hold the control valve, remove the self-
locking nut.
SST 09616-00010
12. REMOVE CONTROL VALVE

(b) Using SST, remove the control valve with the oil seal
and bearing.
SST 09613-12010
NOTICE: Never attempt to tap out the control valve as
this would damage it.
(c) Remove the oil seal from the control valve.
SR-52
13. REMOVE CONTROL VALVE UPPER BEARING

Using SST, remove the upper bearing from the control
valve.
SST 09950-20017
14. REMOVE CYLINDER END STOPPER

Using SST, remove the stopper.
SST 09631-20090
15. REMOVE OIL SEAL AND STEERING RACK

(a) Using SST, press the rack and oil seal.
SST 09612-10093 (09612-10061)
(b) Pull out the steering rack with the oil seal from the
cylinder.
16. REMOVE SPACER AND OIL SEAL

Using SST and a hammer, drive out the spacer and oil
seal.
SST 09631-12020
NOTICE: Do not damage the rack housing.
SR-53
STEERING GEAR HOUSING INSPECTION AND

REPLACEMENT
1. INSPECT RACK
(a) Using a dial indicator, check the rack for runout, and
for tooth wear or damage.
Maximum runout:
0.3 mm (0.012 in.)
(b) Check the back surface for wear or damage.
If faulty, replace it.
2. MEASURE OIL CLEARANCE OF CONTROL VALVE

SHAFT AND BUSHING
Using a micrometer and cylinder gauge, measure the
oil clearance.
Standard clearance:
0.050-0.083 mm (0.0020-0.0033 in.)
Maximum clearance:
0.125 mm (0.0049 in.)
If more than maximum, replace the bushing.
3. IF NECESSARY, REPLACE BUSHING AND OIL SEAL

(a) Using SST, remove the bushing.
SST 09612-65014 (09612-01030)
NOTICE: As shown, from the opposite side of SST con-
firm that its claw is firmly caught on the bushing.
(b) Using a brass bar and hammer, remove the oil seal.
(c) Coat a new oil seal lip with power steering fluid.
(d) Using a socket wrench (24 mm), extension bar and
hammer, tap in the oil seal to the housing.
correct direction.
(e) Using a socket wrench (24 mm), extension bar and

hammer, carefully press in a new bushing to a depth
of 73 mm (2.874 in.).
NOTICE: If the bushing is pushed in too far, it will cause
deformation of the housing. If it is not pushed in far
enough, it will interfere with the control valve. Therefore,
always use a press and install the bushing to the proper
depth. Then, install the control valve and ensure that it
rotates smoothly.
SR-54
4. IF NECESSARY, REPLACE STEERING RACK

TEFLON RING AND O-RING
(a) Using a screwdriver, remove the teflon ring and 0-
ring.
NOTICE: Be careful not to damage the groove for the
teflon ring.
(b) Coat a new O-ring with power steering fluid and
install it.
(c) Expand a new teflon ring with your fingers.

NOTICE: Be careful not to over-expant the teflon ring.
(d) Install the teflon ring to the rack.

(e) Install the expanded teflon ring to the steering rack
and snug it down with your fingers.
5. IF NECESSARY, REPLACE CONTROL VALVE

TEFLON RINGS
(a) Using a screwdriver, remove the 4 teflon rings.
NOTICE: Be careful not to damage the grooves for the
teflon ring.
(b) Expand 4 new teflon rings with your fingers.

NOTICE: Be careful not to over-expand the teflon ring.
SR-55
(c) Install the 4 teflon rings to the control valve.

(d) Coat the 4 teflon rings with power steering fluid and
snug them down with your fingers.
(e) Carefully slide the tapered end of the SST over the
teflon rings to seat the rings.
SST 09631-20081
NOTICE: Be careful not to damage the teflon rings.
STEERING GEAR HOUSING ASSEMBLY

1. INSTALL OIL SEAL AND SPACER
(a) Coat a new oil seal lip with power steering fluid.
(b) Install the oil seal and spacer to SST, and drive in them
with a plastic hammer.
SST 09631-12020, 09631-12040
NOTICE:
• Make sure you install the oil seal facing the correct
direction.
• Take care that the oil seal does not get reversed as
you install it.
2. INSTALL STEERING RACK

(a) Install SST to the rack.
HINT: If necessary, scrape the burrs off the rack teeth
end and burnish.
SST 09631-10041
SR-56
(b) Coat SST with power steering fluid.

(c) Insert the rack into the cylinder.
(d) Remove SST.
3. INSTALL OIL SEAL

(a) Install SST to the rack.
SST 09631-10041
(b) Coat SST and a new oil seal with power steering fluid.
(c) Install the oil seal by pushing it into the rack housing,
without tilting.
(d) Remove SST.
NOTICE:
• Make sure you install the oil seal facing the correct
direction.
• Take care that the oil seal does not get reversed as
you install it.
4. INSTALL CYLINDER END STOPPER

(a) Using SST, torque the stopper.
SST 09631-20090
Torque: 59 Nm (600 kgfcm. 43 ftlbf)
(b) Using a punch and hammer, stake the stopper and

cylinder end.
SR-57
5. AIR TIGHTNESS TEST

(a) Install SST to the union of the cylinder housing.
SST 09631-12071
NOTICE: Do not install union seats.
(b) Apply 53.3 kPa (400 mmHg, 15.75 in.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.
6. INSTALL CONTROL VALVE

(a) Coat the teflon rings with power steering fluid.
(b) Push the control valve into the housing.
(c) Using SST, press in a new upper bearing.
SST 09612-22011
(d) Coat a new oil seal lip with power steering fluid.
(e) Using SST and hammer, install the oil seal until it
contacts the bearing.
SST 09612-22011
correct direction.
(f) Using snap ring pliers, install a new snap ring.
7. INSTALL SELF-LOCKING NUT

Using SST to hold the control valve, install a new self
-locking nut.
SST 09616-00010
Torque: 59 Nm (600 kgfcm, 43 ftIbf)
SR-58
8. INSTALL RACK HOUSING CAP

(a) Apply sealant to 2 or 3 threads of the cap.
Sealant:
(b) Install the rack housing cap.
(c) Using a center punch and hammer, stake the housing

cap at 2 places.
9. INSTALL RACK GUIDE SEAT, RACK GUIDE SPRING
AND RACK GUIDE
10. ADJUST TOTAL PRELOAD

(a) Apply sealant to 2 or 3 threads of the spring cap.
Sealant:
Part No.08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using SST, install and torque the spring cap.
SST 09612-24014 (09612-10022)
(c) Using SST, return the rack guide spring cap 12°.
SST 09612-24014 (09612-10022)
(d) Using SST, turn the control valve shaft right and left 1
or 2 times.
SST 09616-00010
(e) Loosen the spring cap until the rack guide spring is
not functioning.
(f) Using SST and torque meter, tighten the rack guide
spring cap until the preload is within specification.
SST 09612-24014 (09612-10022),
09616-00010
Preload (turning):
0.9-1.5 Nm (9-15 kgfcm, 7.8-13.0 in.lbf)
SR-59
11. INSTALL RACK GUIDE SPRING CAP LOCK NUT

(a) Apply sealant to 2 or 3 threads of the lock nut.
Sealant:
Part No.08833-00080. THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using SST, install and torque the lock nut.
SST 09612-24014 (09612-10022),
09617-12020
300 mm (11.81 in.).
(c) Recheck the total preload.
Preload (turning):
0.9-1.5 Nm (9-15 kgfcm, 7.8-13.0 in.lbf)
12. INSTALL RACK ENDS

(a) Install a new claw washer.
(b) Using SST, install the rack end.
SST 09617-10020
340 mm (13.39 in.).
(c) Using a brass bar and hammer, stake the claw washer.
13. INSTALL RACK BOOTS

(a) Ensure that the tube 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 turned.
(b) Install the boot.
NOTICE: Be careful not to damage or twist the boots.
SR-60
(c) Install new clamp.

(d) Install the clip with the end facing outward.
14. INSTALL TIE ROD ENDS

(a) Screw the lock nut and tie rod end onto the rack end
until the matchmarks are aligned.
(b) After adjusting toe-in, torque the lock nut.
(See SA section)
15. INSTALL AIR CONTROL VALVE

16. INSTALL TURN PRESSURE TUBES
(a) Install new union seat.
(b) Using SST, install the tube.
SST 09633-00020
300 mm (11.81 in.).
SR-61
STEERING - SERVICE SPECIFICATIONS
SERVICE SPECIFICATIONS
SERVICE DATA
Steering wheel freeplay (Maximum) 30 mm (1.18 in.)
Steering rack runout (Maximum) 0.3 mm (0.012 in.)
Pinion preload (Turning) 0.1-0.2 Nm (1.5-2.5 kgfcm, 1.3-2.2 in.lbf)
Total preload (Turning) 0.6-1.2 Nn (6-12 kgfcm, 5.2-10.4 in.lbf)
PS ON-VEHICLE INSPECTION
Drive belt tension (New belt) 628-794 N (64-81 kgf, 140-180 lbf)
Drive belt tension (Used belt) 363-529 N (37-54 kgf, 80-120 lbf)
Maximum rise of oil level 5 mm (0.20 in.)
Oil pressure at idle speed with valve closed (Minimum) 5,883 kPa (80 kgf/cm2, 853 psi)
Steering effort at idle speed (Maximum) 7.8 Nm (80 kgfcm, 69 in.lbf)
PS PUMP
Rotor shaft bushing oil clearance (STD) 0.01-0.03 mm (0.0004-0.0012 in.)
Rotor shaft bushing oil clearance (Maximum) 0.07 mm (0.0028 in.)
Vane plate to rotor groove clearance (Maximum) 0.03 mm (0.0012 in.)
Vane plate length (Minimum) 14.97 mm (0.5894 in.)
Vane plate height (Minimum) 8.0 mm (0.315 in.)
Vane plate thickness (Minimum) 1.77 mm (0.0697 in.)
Vane plate length
(Rotor and cam ring mark)
None 14.996-14.998 mm (0.59039-0.59047 in.)
14.994-14.996 mm (0.59032-0.59039 in.)
14.992-14.994 mm (0.59024-0.59032 in.)
14.990-14.992 mm (0.59016-0.59024 in.)
14.988-14.990 mm (0.59008-0.59016 in.)
Flow control valve spring length (STD) 38 mm (1.49 in.)
Flow control valve spring length (Minimum) 36 mm (1.42 in.)
Pump rotating torque (Maximum) 0.3 Nm (2.8 kgfcm, 2.4 in.lbf)
PS GEAR HOUSING
Steering rack runout (Maximum) 0.3 mm (0.012 in.)
Control valve shaft bushing oil clearance (STD) 0.050-0.083 mm (0.0020-0.0033 in.)
Control valve shaft bushing oil clearance (Maximum) 0.125 mm (0.0049 in.)
Total preload (Turning) 0.9-1.5 Nm (9-15 kgfcm, 7.8-13.0 in.lbf)
SR-62
STEERING - SERVICE SPECIFICATIONS
TORQUE SPECIFICATIONS
Part tightened Nm kgfcm ft.Ibf
STEERING COLUMN
Steering main shaft x Universal joint 290
Column bracket x Body 260
Steering wheel 350
Pinion bearing adjusting screw lock nut 930
Rack guide spring cap lock nut 490
Rack x Rack end 520
Tie rod end lock nut 480
Gear housing bracket x Body 590
Pinion shaft x Universal joint 290
Column hole cover x Body 4.9 43 in.lbf
Tie rod end x Steering knuckle 500
POWER STEERING PUMP
Pressure port union x Pump housing 700
Suction port union x Pump housing 130
Pressure tube x Pressure port union 550
Drive pulley x Rotor shaft 440
PS pump installation bolt 440
POWER STEERING GEAR HOUSING
Cylinder end stopper 600
Control valve self-locking nut 600
Rack housing cap 600
Rack guide spring cap lock nut 380
Rack x Rack end 520
Tie rod end lock nut 480
Turn pressure tube union nut 200
Air control valve x Gear housing 300
Gear housing bracket x Body 590
Engine rear mount bracket x Body 800
Engine rear mount bracket x Transaxle 490
Exhaust pipe x Exhaust manifold 630
Exhaust pipe x Converter 440
Column hole cover x Body 4.9 43 in.lbf
Control valve shaft x Universal joint 290
Pressure and return tube x Gear housing 450
Pressure and return tube clamp x Gear housing 130
Tie rod end x Steering knuckle 500
Transaxle case x Control cable bracket (M/T) 115

Steering

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Steering

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SR-1

Suspension arm ball joints (Worn) SA-37

Front wheel alignment (Incorrect)

Steering system joints (Worn)

Front wheel bearing (Worn)

Steering gear housing

Sliding yoke (Worn)

Suspension arm ball joints (Worn) SA-37

Front wheel alignment (Incorrect)

Steering system joints (Worn)

Front wheel bearing (Worn)

Steering gear housing

Sliding yoke (Worn)

SST (SPECIAL SERVICE TOOLS)

(09904-00050) No. 4 Claw

ASSEMBLY REMOVAL AND

MAIN POINTS OF REMOVAL AND

1. DISCONNECT NEGATIVE (-) TERMINAL CABLE

5. CENTER SPIRAL CABLE

6. INSTALL STEERING WHEEL

7. INSTALL STEERING WHEEL PAD

STEERING COLUMN DISASSEMBLY

(c) Using a screw extractor, remove the 2 tapered-head

2. REMOVE MAIN SHAFT

3. REMOVE COLUMN LOWER TUBE

STEERING, COLUMN INSPECTION AND

2. IF NECESSARY, REPLACE KEY CYLINDER

3. INSPECT COLUMN UPPER TUBE BEARING

4. IF NECESSARY. REPLACE MAIN SHAFT BUSHING

6. IF NECESSARY, REPLACE COLUMN TUBE BUSH-

STEERING COLUMN ASSEMBLY

3. INSTALL MAIN SHAFT

(b) Install the main shaft to the column tube.

4. INSTALL COLUMN UPPER BRACKET

MANUAL STEERING GEAR HOUSING

09612-10093 Steering Gear Housing Overhaul

(09617-10010) Steering Pinion Bearing

09612-10131 Hexagon Wrench

09612-24014 Steering Gear Housing Overhaul

(09612-10061) Steering Pinion Bearing Replacer

(09616-10010) Steering Pinion Bearing

(0961 6-10020) Steering Pinion Bearing

(09617-22030) Steering Rack End Wrench

09617-10020 Steering Rack End Wrench

09620-30010 Steering Gear Box Replacer Set

09628-6201 1 Ball Joint Puller

09630-24013 Steering Rack Oil Seal Tool Set

(09620-24030) Valve Cup Bearing Replacer

09631-32010 Oil Seal Replacer

09950-20017 Universal Puller

Dial indicator Steering rack

SSM (SPECIAL SERVICE MATERIALS)

ASSEMBLY REMOVAL AND

(MAIN POINTS OF REMOVAL AND

2. DISCONNECT SLIDING YOKE

3. REMOVE GEAR HOUSING

MANUAL STEERING GEAR HOUSING

MANUAL STEERING GEAR HOUSING

2. REMOVE TIE ROD ENDS

4. REMOVE RACK ENDS

(b) Using SST, remove the rack end.

5. REMOVE RACK GUIDE SPRING CAP LOCK NUT

6. REMOVE RACK GUIDE SPRING CAP