Part 1

RACK AND PINION POWER STEERING GEAR

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

REMOVAL
1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
2. REMOVE FRONT WHEELS
3. REMOVE ENGINE UNDER COVER LH
4. REMOVE ENGINE UNDER COVER RH
5. REMOVE EXHAUST PIPE ASSEMBLY FRONT

6. DISCONNECT TIE ROD END SUB-ASSEMBLY LH
(a) Remove the cotter pin and nut.
(b) Using SST, disconnect tie rod end sub-assembly LH from the steering knuckle.
SST 09628-62011
7. DISCONNECT TIE ROD END SUB-ASSEMBLY RH
SST 09628-62011

HINT: Remove the RH side by the same procedures as the LH side.

8. REMOVE COLUMN HOLE COVER SILENCER SHEET
(a) Remove the 2 clips and the column hole cover silencer sheet.

9. DISCONNECT STEERING INTERMEDIATE SHAFT
(a) Fix the steering wheel with the seat belt in order to prevent rotation.

HINT: This operation is useful to prevent damage to the spiral cable.

(b) Put matchmarks on the intermediate shaft assembly No. 2 and the intermediate shaft.
(c) Loosen bolt A, remove bolt B, and separate the intermediate shaft assembly No. 2 from the intermediate shaft.
10. SEPARATE STEERING COLUMN HOLE COVER SUB-ASSEMBLY NO. 1

11. DISCONNECT PRESSURE FEED TUBE ASSEMBLY
(a) Remove the bolt and separate the tube clamp from the power steering gear assembly.

(b) Using SST, disconnect the pressure feed tube assembly.
SST 09023-12701
12. REMOVE FRONT STABILIZER LINK ASSEMBLY LH
(a) Remove the nut and disconnect the front stabilizer link assembly LH from the stabilizer bar.
13. REMOVE FRONT STABILIZER LINK ASSEMBLY RH

HINT: Remove the RH side by the same procedures as the LH side.

14. DISCONNECT FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 LH
(a) Remove the bolt and 2 nuts and disconnect the front suspension arm sub-assembly lower No. 1 LH from the lower ball joint.
15. DISCONNECT FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 RH

HINT: Remove the RH side by the same procedures as the LH side.

16. REMOVE HOOD SUB-ASSEMBLY
17. REMOVE CYLINDER HEAD COVER NO. 2

18. SUSPEND ENGINE ASSEMBLY
(a) Install the 2 engine hangers with the bolts in the correct direction.
Parts No.:
No. 1 engine hanger: 12281-22021
No. 2 engine hanger: 12281-15040
Bolt: 91512-B1016
Torque: 38 Nm (390 kgf-cm, 28 ft. lbs.)

(b) Attach the engine chain hoist to the engine hangers.

CAUTION: Do not attempt to hang the engine by hooking the chain to any other parts.

19. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
(a) Remove the 4 bolts and separate the center member.

(b) Remove the bolt and 3 nuts, disconnect the engine mounting insulator RR from the crossmember.
(c) Using a transmission jack, support the crossmember.
(d) Remove the 4 bolts and front suspension crossmember sub-assembly with the steering gear assembly.
20. REMOVE STEERING COLUMN HOLE COVER SUB-ASSEMBLY NO. 1

21. REMOVE STEERING INTERMEDIATE SHAFT
(a) Place matchmarks on the intermediate shaft with control valve.
(b) Remove the bolt and steering intermediate shaft.
22. REMOVE RACK & PINION POWER STEERING GEAR ASSEMBLY
(a) Remove the 4 bolts and rack & pinion power steering gear assembly from the crossmember.

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

DISASSEMBLY

NOTICE: When using a vise, do not overtighten.

1. FIX RACK & PINION POWER STEERING GEAR ASSEMBLY
(a) Using SST, secure the rack & pinion power steering gear assembly in a vise.
SST 09612-00012

2. REMOVE STEERING LEFT TURN PRESSURE TUBE
(a) Using SST, remove the left turn pressure tube.
SST 09023-38201
(b) Remove the 2 O-rings from the left turn pressure tube.
3. REMOVE STEERING RIGHT TURN PRESSURE TUBE
(a) Using SST, remove the right turn pressure tube.
SST 09023-38201
(b) Remove the 2 O-rings from the right turn pressure tube.

4. REMOVE TIE ROD END SUB-ASSEMBLY LH
(a) Place matchmarks on the tie rod end with rack end.
(b) Loosen the lock nut, and remove the tie rod end and lock nut.
5. REMOVE TIE ROD END SUB-ASSEMBLY RH

HINT: Remove the RH side by the same procedures as the LH side.

6. REMOVE STEERING RACK BOOT NO. 2 CLAMP
(a) Using a screwdriver, remove the rack boot No. 2 clamp (LH side).

NOTICE: Be careful not to damage the boot.

(b) Remove the RH side by using the same procedure as for the LH side.
7. REMOVE STEERING RACK BOOT CLIP
(a) Remove the 2 boot clips.
8. REMOVE STEERING RACK BOOT NO. 1
9. REMOVE STEERING RACK BOOT NO. 2

10. REMOVE STEERING RACK END SUB-ASSEMBLY
(a) Using a wrench, hold the steering rack steadily and using SST, remove the rack end.
SST 09922-10010

NOTICE: Use SST in the direction shown in the illustration.

HINT: Mark the RH and LH rack ends.

(b) Use the same manner described above to the other side.

11. REMOVE RACK GUIDE
(a) Using SST, remove the rack guide spring cap nut.
SST 09922-10010

NOTICE: Use SST in the direction shown in the illustration.

(b) Using a hexagon wrench (19 mm), remove the rack guide spring cap.
(c) Remove the conical spring, rack guide spring and rack guide.

12. REMOVE POWER STEERING CONTROL VALVE
(a) Remove the rack housing cap.
(b) Using SST, hold the control valve shaft and remove the self-locking nut.
SST 09616-00011

(e) To prevent oil seal lip damage, wind vinyl tape around the serrated part of the control valve.
(f) Using a plastic hammer, remove the control valve with oil seal from the control valve housing.
(g) Remove the oil seal from the control valve.

(h) Using a screwdriver, remove the 4 control valve spacers.

NOTICE: Be careful not to damage the grooves for the control valve.

13. REMOVE POWER STEERING CONTROL VALVE UPPER OIL SEAL
(a) Using SST and a press, remove the control valve upper bearing and upper oil seal from the control valve housing.
SST 09950-70010 (09951-07150), 09950-60010 (09951-00260)
14. REMOVE CYLINDER END STOPPER
(a) Using snap ring pliers, remove the snap ring.
(b) Pull out the cylinder end stopper.

15. REMOVE POWER STEERING RACK
(a) Using SST and a press, remove the steering rack with the bushing.
SST 09612-24014 (09613-22011)

NOTICE: Take care not to drop the steering rack.

(b) Using a screwdriver, remove the power piston oil seal and O-ring from the power steering rack.

16. REMOVE POWER STEERING RACK BUSH
(a) Remove the power steering rack bush from the power steering rack.
(b) Remove the O-ring from the power steering rack bush.
(c) Using SST, remove the rack bush oil seal.
SST 09612-24014 (09613-22011)

17. REMOVE POWER STEERING CYLINDER TUBE OIL SEAL
(a) Using SST and a press, remove the power steering cylinder tube oil seal.
SST 09950-60010 (09951-00260), 09950-70010 (09951-07360)

18. REMOVE POWER STEERING CONTROL VALVE LOWER BEARING
(a) Using SST and a press, remove the power steering control valve lower bearing.
SST 09950-70010 (09951-07100)

(b) Using SST and a press, remove the power steering control valve center bearing.
SST 09950-70010 (09951-07100)

INSPECTION

1. INSPECT TIE ROD END SUB-ASSEMBLY LH
(a) Secure the tie rod end LH in a vise.
(b) Install the nut to the stud bolt.
(c) Flip the ball joint stud back and forth 5 times.
(d) Using a torque wrench, turn the nut continuously at a rate of 2 to 4 seconds per 1 turn and take the torque reading of the 5th turn.
Torque: Turning torque 0.49 to 3.43 Nm (5.0 to 35 kgf-cm, 4.34 to 30.38 inch lbs.)
2. INSPECT TIE ROD END SUB-ASSEMBLY RH

HINT: Inspect the RH side by the same procedures as the LH side.

3. INSPECT POWER STEERING RACK
(a) Using a screwdriver, remove the O-ring from the power steering rack bush sub-assembly.
(b) Using a dial indicator, check the steering rack for runout and for teeth wear and damage.
Maximum runout: 0.1 mm (0.004 inch)
(c) Check the back surface for wear and damage.