Part 2

POWER STEERING LINK (Continued)

8. INSTALL POWER STEERING CONTROL VALVE UPPER OIL SEAL
(a) Coat a new power steering control valve upper oil seal lip with power steering fluid.
(b) Using SST and a press, press in the power steering control valve upper oil seal.
SST 09950-70010 (09951-07150), 09950-60010 (09951-00180, 09952-06010, 09951-00320)

NOTICE: Make sure that the power steering control valve upper oil seal is installed in the correct direction as shown in the illustration.

9. INSTALL POWER STEERING CONTROL VALVE UPPER BEARING
(a) Coat the power steering control valve upper bearing with molybdenum disulfide lithium base grease.





(b) Using SST and a press, press in the power steering control valve upper bearing.
SST 09950-70010 (09951-07150), 09950-60010 (09951-00180, 09951-00340)

NOTICE: Make sure that the power steering control valve upper bearing is installed in the correct direction as shown in the illustration.





10. INSTALL POWER STEERING CONTROL VALVE SPACER
(a) Expand 4 new power steering control valve spacers with your fingers.

NOTICE: Be careful not to expand the power steering control valve spacers excessively.

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





(c) Install the 4 power steering control valve spacers to the control valve, and adjust them with your fingers.

11. INSTALL POWER STEERING CONTROL VALVE SUBASSEMBLY
(a) Coat the power steering control valve subassembly with power steering fluid.





(b) Install the power steering control valve subassembly into the control valve housing subassembly.

NOTICE: Be careful not to damage the power steering control valve spacers and power steering control valve upper oil seal lip.

HINT: Wrap protective tape around the spline of the power steering control valve subassembly in order to prevent damage to the oil seal.

12. INSTALL POWER STEERING CONTROL VALVE LOWER OIL SEAL
(a) Coat a new power steering control valve lower oil seal lip with power steering fluid.





(b) Using SST and a press, install the power steering control valve lower oil seal to the control valve assembly.
SST 09612-22011

NOTICE:
^ Make sure that the power steering control valve lower oil seal is installed in the correct direction as shown in the illustration.
^ Do not damage the power steering control valve lower oil seal.





13. INSTALL POWER STEERING CONTROL VALVE ASSEMBLY
(a) Install the power steering control valve assembly and a new gasket to the power steering rack housing with the 2 bolts.
Torque: 21 Nm (214 kgf-cm, 16 ft. lbs.)





(b) Using SST, hold the control valve shaft and install a new nut.
SST 09616-00011
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
(c) Apply sealant to 2 or 3 threads of the rack housing cap.
Sealant: TOYOTA genuine adhesive 1344, THREE BOND 1344 or equivalent





(d) Using a socket wrench (27 mm (1.06 inch)), install the rack housing cap.
Torque: 54 Nm (546 kgf-cm, 40 ft. lbs.)





(e) Using a punch and a hammer, stake the rack housing cap and the power steering rack housing.





14. INSTALL RACK GUIDE
(a) Coat a new O-ring with molybdenum disulfide lithium base grease and install it to the rack guide spring cap.

NOTICE: Make sure that no foreign matter, such as aluminum dust, is on the power steering rack housing and rack guide spring cap.

(b) Apply molybdenum disulfide lithium base grease to the rack guide base and rack guide.





(c) Install the rack guide base to the rack guide.
(d) Apply molybdenum disulfide lithium base grease to the compression spring and the contact surface of the rack guide subassembly and the power steering rack.





(e) Install the compression spring and rack guide subassembly to the power steering rack housing.





(f) Using a straight hexagon wrench (24 mm (0.94 inch)), install the rack guide spring cap to the power steering rack housing.
Torque: 50 to 70 Nm (514 to 714 kgf-cm, 37 to 52 ft. lbs.)





(g) Using SST, turn the control valve and measure the turning torque.
Torque: 6.0 Nm (61 kgf-cm, 54 inch lbs.) or more





(h) Put matchmarks on the power steering rack housing and the rack guide spring cap.





(i) Put matchmarks 30° counterclockwise from matchmarks on the power steering rack housing.

(j) Using a straight hexagon wrench (24 mm (0.94 inch)), loosen the rack guide spring cap until matchmarks and matchmarks on the rack guide spring cap are aligned. Measure the rotating torque required when loosening the rack guide spring cap.
Torque: 10 Nm (102 kgf-cm, 7.4 ft. lbs.) or more

(k) If the rotating torque required when loosening is below the specified value, perform the following procedure to achieve the specified value.
(1) Using a straight hexagon wrench (24 mm (0.94 inch)), re-tighten the rack guide spring cap.
Torque: 50 to 70 Nm (510 to 714 kgf-cm, 37 to 52 ft. lbs.)

(2) Using a punch and hammer, stake the power steering rack housing and rack guide spring cap at 3 equally spaced positions.

HINT: Tap the power steering rack housing and rack guide spring cap strongly and repeatedly to stake them securely.

(3) Using a straight hexagon wrench (24 mm (0.94 inch)), loosen the rack guide spring cap until matchmarks and matchmarks on the rack guide spring cap are aligned. Measure the rotating torque required when loosening the rack guide spring cap.
Torque: 10 Nm (102 kgf-cm, 7.4 ft. lbs.) or more

15. INSPECT TOTAL PRELOAD

16. INSTALL DUST COVER
(a) Apply MP grease around the control valve shaft as shown in the illustration.

(b) Wrap vinyl tape around the spline of the control valve.
(c) Install the dust cover to the control valve assembly.
17. INSTALL STEERING RACK END SUBASSEMBLY
(a) Install 2 new claw washers.

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

(b) Using SST, install the steering rack end subassembly (LH side).
SST 09922-10010
Torque:
Without SST 84 Nm (852 kgf-cm, 62 ft. lbs.)
With SST 60 Nm (613 kgf-cm, 44 ft. lbs.)

NOTICE:
^ Use SST 09922-10010 as shown in the illustration.
^ Use a torque wrench with a fulcrum length of 345 mm (13.58 inch)
^ This torque value is effective when SST is parallel to the torque wrench.

HINT: Using SST, hold the steering rack and install the steering rack end subassembly (LH side).

(c) Using SST, install the steering rack end subassembly (RH side).
SST 09922-10010
Torque:
Without SST 84 Nm (852 kgf-cm, 62 ft. lbs.)
With SST 60 Nm (613 kgf-cm, 44 ft. lbs.)

NOTICE:
^ Use SST 09922-10010 as shown in the illustration.
^ Use a torque wrench with a fulcrum length of 345 mm (13.58 inch)
^ This torque value is effective when SST is parallel to the torque wrench.

HINT: Using SST, hold the steering rack end subassembly (LH side) and install the steering rack end subassembly (RH side).

(d) Using a brass bar and a hammer, stake the 2 claw washers.

NOTICE: Avoid any impact to the steering rack.

(e) Ensure that the holes of the rack ends are 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.

18. INSTALL NO. 2 STEERING RACK BOOT
(a) Apply silicon grease to the inside of the small opening of the No. 2 steering rack boot.
(b) Install the No. 2 steering rack boot to the groove on the rack housing.

NOTICE: Be careful not to damage or twist the No. 2 steering rack boot.

19. INSTALL NO. 1 STEERING RACK BOOT

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

20. INSTALL NO. 2 STEERING RACK BOOT CLAMP
(a) Using SST, tighten the 2 No. 2 steering rack boot clamps as shown in the illustration.
SST 09521-24010
Clearance: 2.0 mm (0.079 inch) or less

NOTICE: Be careful not to damage the No. 2 steering rack boot.

21. INSTALL STEERING RACK BOOT CLIP
(a) Using pliers, install the 2 steering rack boot clips.

NOTICE: Make sure that each clip claw is positioned within the area shown in the illustration.

(b) Using SST, turn the pinion and check that the rack boots expand and contract smoothly.
SST 09616-00011

22. INSTALL TIE ROD ASSEMBLY LH
(a) Install the lock nut and the tie rod assembly LH to the steering rack end subassembly until the matchmarks are aligned.

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

23. INSTALL TIE ROD ASSEMBLY RH

HINT: Perform the same procedure as for the LH side.

24. 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 right turn pressure tube to the power steering link assembly.
SST 09023-38201
Torque:
Without SST 13 Nm (128 kgf-cm, 9 ft. lbs.)
With SST 11 Nm (114 kgf-cm, 8 ft. lbs.)

NOTICE:
^ Use a torque wrench with a fulcrum length of 250 mm (9.84 inch).
^ This torque value is effective when SST is parallel to the torque wrench.

25. 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 left turn pressure tube to the power steering link assembly.
SST 09023-38201
Torque:
Without SST 13 Nm (128 kgf-cm, 9 ft. lbs.)
With SST 11 Nm (114 kgf-cm, 8 ft. lbs.)

NOTICE:
^ Use a torque wrench with a fulcrum length of 250 mm (9.84 inch).
^ This torque value is effective when SST is parallel to the torque wrench.

INSTALLATION

1. INSTALL POWER STEERING RACK HOUSING HEAT INSULATOR (for 2GR-FE)
(a) Install the power steering rack housing heat insulator to the power steering link assembly.

2. INSTALL POWER STEERING LINK ASSEMBLY
(a) Install the power steering link assembly with the 2 bolts and 2 nuts.
Torque: 70 Nm (714 kgf-cm, 52 ft. lbs.)

3. CONNECT PRESSURE FEED TUBE ASSEMBLY
(a) Temporarily connect the pressure feed tube assembly to the power steering link assembly.

(b) Install the pressure feed tube assembly clamp with the 2 bolts.
Torque: 9.8 Nm (100 kgf-cm, 87 inch lbs.)

(c) Using SST, tighten the pressure feed tube assembly (pressure feed tube side).
SST 09023-12701
Torque:
Without SST 25 Nm (250 kgf-cm, 18 ft. lbs.)
With SST 22 Nm (227 kgf-cm, 16 ft. lbs.)

NOTICE:
^ Use a torque wrench with a fulcrum length of 300 mm (11.81 inch).
^ This torque value is effective when SST is parallel to the torque wrench.

(d) Using SST, tighten the pressure feed tube assembly (return tube side).
SST 09023-12701
Torque:
Without SST 25 Nm (250 kgf-cm, 18 ft. lbs.)
With SST 22 Nm (227 kgf-cm, 16 ft. lbs.)

NOTICE:
^ Use a torque wrench with a fulcrum length of 300 mm (11.81 inch).
^ This torque value is effective when SST is parallel to a torque wrench.

4. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

HINT: Refer to the instructions for installation of the engine assembly.

5. CONNECT TIE ROD ASSEMBLY LH
(a) Connect the tie rod assembly LH to the steering knuckle with the nut.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
(b) Install a new cotter pin.

NOTICE: Further tighten the nut up to 60° if the holes for the cotter pin are not aligned.

6. CONNECT TIE ROD ASSEMBLY RH

HINT: Perform the same procedure on the other side.

7. CONNECT STEERING SLIDING YOKE
(a) Align the matchmarks on the steering sliding yoke and the steering link assembly.

(b) Install the bolt.
Torque: 35 Nm (360 kgf-cm, 26 ft. lbs.)

8. INSTALL FRONT WHEELS
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)

9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
10. BLEED POWER STEERING FLUID
11. CHECK POWER STEERING FLUID LEVEL
12. CHECK FOR POWER STEERING FLUID LEAKAGE
13. CHECK FOR EXHAUST GAS LEAKS
14. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
15. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT