Part 2

RACK AND PINION POWER STEERING GEAR(continued)

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

REASSEMBLY

NOTICE: When installing, coat the parts indicated by arrows with power steering fluid or molybdenum disulfide lithium base grease.





1. INSTALL POWER STEERING CONTROL VALVE LOWER BEARING
(a) Coat a new bearing with molybdenum disulfide lithium base grease.
(b) Using SST and a press, install in the control valve center bearing.
SST 09950-60010 (09951-00220, 09951-00280, 09952-06010), 09950-70010 (09951-07100)





(c) Coat a new bearing with molybdenum disulfide lithium base grease.
(d) Using SST and a press, install the control valve lower bearing.
SST 09950-60010 (09951-00220, 09951-00280, 09952-06010), 09950-70010 (09951-07100)





2. INSTALL POWER STEERING CYLINDER TUBE OIL SEAL
(a) Coat a new power steering cylinder tube oil seal lip with power steering fluid.
(b) Using SST and a press, install the power steering cylinder tube oil seal.
SST 09950-60010 (09951-00240, 09951-00400, 09952-06010), 09950-70010 (09951-07360)

NOTICE:
^ Make sure that the power steering cylinder tube oil seal is installed facing in the correct direction.
^ Take care so that the power steering cylinder tube oil seal will not be reversed with you install it.





3. INSTALL POWER STEERING RACK
(a) Coat a new power piston O-ring with power steering fluid and install it to the steering rack.
(b) Coat a new power piston oil seal with power steering fluid.
(c) Expand the power piston oil seal with your fingers.

NOTICE: Be careful not to expand the power piston oil seal excessively.





(d) Install the power piston oil seal to the steering rack, and settle it down with your fingers.
SST 09631-16020





(e) Install SST to the steering rack.
SST 09631-16020

HINT: If necessary, scrape the burrs off the steering rack teeth end and burnish.

(f) Coat the SST with power steering fluid.
(g) Install the steering rack into the rack housing.
(h) Remove the SST.
SST 09631-16020





4. INSTALL POWER STEERING RACK BUSH
(a) Using SST and a press, install the rack bush oil seal to the power steering rack bush.
SST 09950-60010 (09951-00400), 09950-70010 (09951-07100)

NOTICE: Make sure that the rack bush oil seal is installed facing in the correct direction.

(b) Coat a new O-ring with power steering fluid and install it to the power steering rack bush.





(c) To prevent rack bush oil seal lip damage, wind vinyl tape around the steering rack end, and apply power steering fluid.
(d) Install the rack bush to the steering rack.





5. INSTALL CYLINDER END STOPPER
(a) Using SST and a hammer, drive in the cylinder end stopper.
SST 09612-22011
(b) Using snap ring pliers, install a new snap ring to the rack housing.





6. INSTALL RACK & PINION POWER STEERING GEAR ASSEMBLY
(a) Install SST to the rack housing.
SST 09631-12071 (09633-00010)
(b) Apply vacuum of 53 kPa (400 mmHg, 15.75 inch Hg) for about 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.





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

NOTICE: Make sure that the oil seal is installed facing in the correct direction.





(c) Using SST and a press, install the upper bearing.
SST 09950-60010 (09951-00190, 09951-00360, 09952-06010), 09950-70010 (09951-07150)





8. INSTALL POWER STEERING CONTROL VALVE
(a) Expand 4 new control valve rings with your fingers.

NOTICE: Be careful not to over expand the valve ring.

(b) Coat the 4 control valve rings with power steering fluid.
(c) Install the 4 control valve rings to the control valve, and settle them down with your fingers.





(d) Carefully slide the tapered end of SST over the control valve rings until they fit to the control valve.
SST 09631-20081

NOTICE: Be careful not to damage the control valve rings.





(e) To prevent oil seal lip damage, wind vinyl tape around the serrated part of the control valve.
(f) Install the control valve to the valve housing.

NOTICE: Be careful not to damage the control valve rings and oil seal lip.

HINT: Wrap vinyl tape around the end of the control valve in order to prevent damaging the oil seal.





(g) Coat a new oil seal lip with power steering fluid.
(h) Using SST and a press, install the oil seal.
SST 09612-22011, 09616-00011, 09631-20081

NOTICE: Make sure that the oil seal is installed facing in the correct direction.





(i) Apply grease to the needle bearing.
(j) Install a new gasket to the valve housing.
(k) Wind vinyl tape around the serration part of the control valve.
(l) Install the valve housing to the rack housing with the 2 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)





(m) Using SST, stop the control valve shaft rotation and install the self-locking nut.
SST 09616-00011
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
(n) Apply sealant to 2 or 3 threads of the rack housing cap.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
(o) Install the rack housing cap.
Torque: 59 Nm (602 kgf-cm, 44 ft. lbs.)





(p) Using a punch and a hummer, stake the rack housing cap and rack housing.
9. INSTALL RACK GUIDE
(a) Apply molybdenum disulfide lithium base grease to the contact surface of the power steering rack and of the rack guide.
(b) Install the rack guide and compression spring to the rack housing.
(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) Temporarily install the rack guide spring cap.





10. INSPECT TOTAL PRELOAD
(a) To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the RH and LH rack ends.
(b) Torque the rack guide spring cap.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
(c) Back off the rack guide spring cap 12°.





(d) Using SST, turn the control valve shaft right and left 1 or 2 times.
SST 09616-00011
(e) Loosen the rack guide spring cap until the rack guide spring is not functioning.





(f) Using SST and torque wrench, tighten the rack guide spring cap until the preload is within the specification.
SST 09616-00011
Torque: Preload (turning) 1.0 to 1.8 Nm (10 to 18 kgf-cm, 8.9 to 15.9 inch lbs.)
(g) Apply sealant to 2 or 3 threads of the rack guide spring cap lock nut.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
(h) Temporarily install the lock nut.





(i) Using a hexagon wrench (19 mm), hold the rack guide spring cap and using SST, torque the nut.
SST 09922-10010
Torque: 42 Nm (428 kgf-cm, 31 ft. lbs.)

NOTICE: Use SST 09922-0010 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.
Torque: Preload (turning) 1.0 to 1.8 Nm (10 to 18 kgf-cm, 8.6 to 15.7 inch lbs.)
(k) Remove the RH and LH rack ends.





11. INSTALL STEERING RACK END SUB-ASSEMBLY
(a) Using a wrench, hold the steering rack steadily and using SST, install the 2 rack ends.
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:
^ Using SST, hold the rack and install the rack end sub-assembly.
^ Use a torque wrench with a fulcrum length of 380 mm (14.96 inch).





(b) 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 steering wheel is turned.





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

NOTICE: Be careful not to damage or twist the boot.

13. INSTALL STEERING RACK BOOT NO. 1

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





14. INSTALL STEERING RACK BOOT NO. 2 CLAMP
(a) Install a new rack boot No. 2 clamp (LH side).
(b) Using SST, stake the rack boot No. 2 clamp (LH side) as shown in the illustration.
SST 09521-24010
(c) Install the RH side by using the same procedure as for the LH side.





15. 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





16. INSTALL TIE ROD END SUB-ASSEMBLY LH
(a) Screw the lock nut and tie rod end sub-assembly LH onto the rack end until the matchmarks are aligned.

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

17. INSTALL TIE ROD END SUB-ASSEMBLY RH

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





18. INSTALL STEERING RIGHT TURN PRESSURE TUBE
(a) Coat 2 new O-rings with power steering fluid and install them to the right turn pressure tube.
(b) Using SST, install the right turn pressure tube to the steering gear assembly.
SST 09023-38201
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)

HINT:
^ Use a torque wrench with a fulcrum length of 345 mm (13.58 inch).
^ This torque value is effective in the case that SST is parallel to a torque wrench.

19. INSTALL STEERING LEFT TURN PRESSURE TUBE
(a) Coat 2 new O-rings with power steering fluid and install them to the left turn pressure tube.
(b) Using SST, install the left turn pressure tube to the steering gear assembly.
SST 09023-38201
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)

HINT:
^ Use a toque wrench with a fulcrum length of 345 mm (13.58 inch).
^ This torque value is effective in the case that SST is parallel to a torque wrench.

INSTALLATION
1. INSTALL RACK & PINION POWER STEERING GEAR ASSEMBLY
(a) Install the power steering gear assembly with the 4 bolts and nuts.
Torque: 58 Nm (591 kgf-cm, 43 ft. lbs.)

NOTICE:
^ The 4 bush must be securely installed to the power steering gear assembly.
^ When tightening the installation bolt for power steering gear, the bush should not bitten in.





2. INSTALL STEERING INTERMEDIATE SHAFT
(a) Align the matchmarks on the steering intermediate shaft with steering pinion shaft.
(b) Install the bolt.
Torque: 35 Nm (360 kgf-cm, 26 ft. lbs.)
3. INSTALL STEERING COLUMN HOLE COVER SUB-ASSEMBLY NO. 1





4. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
(a) Using SST, align the holes of the front suspension member RH and body, and temporarily tighten the bolt in order of A, B.
SST 09670-00010





(b) Using SST, align the holes of the front suspension member LH and body, and temporarily tighten the bolt in order of A, B.
SST 09670-00010
(c) Using SST, align the holes of the front suspension member RH and body, and torque the bolt A and B.
SST 09670-00010
Torque:
Bolt A 157 Nm (1,600 kgf-cm, 116 ft. lbs.)
Bolt B 113 Nm (1,152 kgf-cm, 83 ft. lbs.)
(d) Using SST, align the holes of the front suspension member LH and body, and torque the bolt A and B.
SST 09670-00010
Torque:
Bolt A 157 Nm (1,600 kgf-cm, 116 ft. lbs.)
Bolt B 113 Nm (1,152 kgf-cm, 83 ft. lbs.)





(e) Connect the engine mounting insulator RR to the crossmember with the bolt and 3 nuts.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)





(f) Install the center member to the frame with the 2 bolts.
Torque: NUMMI/TMMC Made 60 Nm (612 kgf-cm, 44 ft. lbs.)
Torque: TMC Made 39 Nm (398 kgf-cm, 29 ft. lbs.)





(1) The shapes of bolts A are as shown in the illustration.
(g) Connect the engine mounting insulator FR to the center member with the 2 bolts.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)





5. CONNECT FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 LH
(a) Connect the front suspension lower arm No. 1 to the lower ball joint with the bolt and 2 nuts.
Torque: 89 Nm (908 kgf-cm, 66 ft. lbs.)
6. CONNECT FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 RH

HINT: Use the same manner described above to the other side.

7. CONNECT FRONT STABILIZER LINK ASSEMBLY LH
(a) Connect the front stabilizer link assembly LH with the nut.
Torque: 74 Nm (750 kgf-cm, 55 ft. lbs.)
8. CONNECT FRONT STABILIZER LINK ASSEMBLY RH

HINT: Use the same manner described above to the other side.





9. CONNECT PRESSURE FEED TUBE ASSEMBLY
(a) Using SST,connect the pressure feed tube assembly.
SST 09023-12701
Torque: 23 Nm (229 kgf-cm, 17 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 the torque wrench.





(b) Install the tube clamp with the bolt to the power steering gear assembly.
Torque: 7.8 Nm (80 kgf-cm, 69 inch lbs.)





10. CONNECT STEERING INTERMEDIATE SHAFT
(a) Align the matchmarks on the intermediate shaft assembly No. 2 and the intermediate shaft.
(b) Install bolt B and tighten bolt A.
Torque: 35 Nm (360 kgf-cm, 26 ft. lbs.)
11. CONNECT TIE ROD END SUB-ASSEMBLY LH
(a) Connect the tie rod end sub-assembly LH with the nut.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
(b) Install a new cotter pin.

NOTICE: If the holes for a new cotter pin are not aligned, tighten the nut further up to 60°.

12. CONNECT TIE ROD END SUB-ASSEMBLY RH

HINT: Use the same manner described above to the other side.

13. INSTALL EXHAUST PIPE ASSEMBLY FRONT
14. INSTALL ENGINE UNDER COVER LH
15. INSTALL ENGINE UNDER COVER RH
16. INSTALL FRONT WHEELS
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
17. INSPECT CENTER FRONT WHEEL
18. INSTALL COLUMN HOLE COVER SILENCER SHEET
(a) Install the column hole cover silencer sheet with the 2 nuts.
19. ADD POWER STEERING FLUID
20. BLEED POWER STEERING FLUID
21. INSPECT FOR POWER STEERING FLUID LEAK
22. INSTALL CYLINDER HEAD COVER NO. 2
(a) Install the cylinder head cover No. 2 with 2 nuts and 2 clips.
Torque: 7.0 Nm (71 kgf-cm, 62 ft. lbs.)
23. INSTALL HOOD SUB-ASSEMBLY
24. INSPECT HOOD SUB-ASSEMBLY
25. ADJUST HOOD SUB-ASSEMBLY
26. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT