Page 1673 of 2543

POWER STEERING GEAR ASSEMBLY
NOTICE: When using a vise, do not overtighten it.
1. COAT WITH POWER STEERING FLUID OR
MOLYBDENUM DISULPHIDE LITHIUM BASE GREASE
(See page SR±34 and SA±35)
2. INSTALL SPACER AND OIL SEAL
(a) Coat a new oil seal lip with power steering fluid.
(b) Using SST and a hammer, softly tap in the oil seal.
SST 09631±12020, 09631±22070
NOTICE:
wMake sure you install the oil seal facing the correct
direction.
wTake care that the oil seal does not get reversed as you
install it.
3. INSTALL STEERING RACK
(a) Install SST to the rack.
HINT: If necessary, scrape the burrs off the rack teeth end
and burnish.
SST 09631±20102
(b) Coat SST with power steering fluid.
(c) Install the rack into the cylinder.
(d) Remove SST.
4. INSTALL OIL SEAL
(a) To prevent oil seal lip damage, wind vinyl tape on the steering
rack, and apply power steering fluid.
(b) Coat a new oil seal lip with power steering fluid.
(c) Install the oil seal by pushing it into the rack housing without
tilting.
NOTICE: Make sure you install the oil seal facing the cor-
rect direction.
5. INSTALL 2 SPACERS AND CYLINDER END STOPPER
(a) Using SST, drive in the stopper.
SST 09620±30010 (09627±30010, 09631±00020)
(b) Using snap ring pliers, install a new snap ring to the rack
housing. SR±42
± STEERINGPOWER STEERING GEAR
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6. AIR TIGHTNESS TEST
(a) Install SST to the unions of the rack 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.
7. INSTALL CONTROL VALVE ASSEMBLY
(a) Coat the teflon rings, with power steering fluid.
(b) Push the valve assembly into the rack housing.
8. INSTALL CONTROL VALVE HOUSING
(a) Coat a new O±ring with power steering fluid, and install it to
the housing.
(b) To prevent oil seal lip damage, wind vinyl tape on the serrated
part of the control valve shaft.
(c) Using a hexagon wrench (6 mm), torque the 2 bolts.
Torque: 18 NVm (185 kgfVcm, 13 ftVlbf)
9. INSTALL SPACER, BEARING AND SELFLOCKING NUT
Using SST to stop the control valve shaft rotating, torque a
new nut.
SST 09616±00010
Torque: 39 NVm (400 kgfVcm, 29 ftVlbf)
10. INSTALL RACK HOUSING CAP
(a) Apply sealant to 2 or 3 threads of the cap.
Sealant:
Part No. 08833±00080, THREE BOND 1344, LOCTITE
242 or equivalent
(b) Torque the cap.
Torque: 69 NVm (700 kgfVcm, 50 ftVlbf)
11. INSTALL RACK GUIDE SEAT, RACK GUIDE, RACK
GUIDE SPRING AND RACK GUIDE SPRING CAP
(a) Install the seat to the guide.
(b) Apply sealant to 2 or 3 threads of the cap.
Sealant:
Part No. 08833±00080, THREE BOND 1344, LOCTITE
242 or equivalent
(c) Temporarily install the cap.
± STEERINGPOWER STEERING GEARSR±43
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12. ADJUST TOTAL PRELOAD
(a) Using a hexagon wrench (24 mm), torque the rack guide
spring cap.
Torque: 25 NVm (250 kgfVcm, 18 ftVlbf)
(b) Using a hexagon wrench (24 mm), return the cap 125
(c) Using SST, turn the control valve shaft right and left 1 or 2
times.
SST 09616±00010
(d) Using a hexagon wrench (24 mm), loosen the cap until the
rack guide spring is not functioning.
(e) Using SST, a torque wrench and hexagon wrench (24 mm),
tighten the cap until the preload is within specification.
SST 09616±00010
Preload (turning):
1.0±1.9 NVm (10±20 kgfVcm, 8.7±17.4 in.Vlbf)
13. INSTALL RACK GUIDE SPRING CAP LOCK NUT
(a) Apply sealant to 2 or 3 threads of the nut.
Sealant:
Part No. 08833±00080, THREE BOND 1344, LOCTITE
242 or equivalent
(b) Using SST and hexagon wrench (24 mm), torque the nut.
SST 09922±10010
Torque: 56 NVm (567 kgfVcm, 41 ftVlbf)
NOTICE: Use SST 09922±10010 in the direction shown in
the illustration.
HINT: Use a torque wrench with a fulcrum length of 340 mm
(13.39 in.)
(c) Recheck the total preload.
Preload (turning):
1.0±1.9 NVm (10±20 kgfVcm, 8.7±17.4 in.Vlbf)
14. INSTALL DUST COVER
15. INSTALL RH AND LH CLAW WASHERS AND RACK ENDS
(a) Install a new washer, and temporarily install the rack end.
HINT: Align the claws of the washer with the rack grooves.
(b) Using a spanner (22 mm) to hold the steering rack, and using
SST, torque the rack end.
SST 09922±10010
Torque: 90 NVm (914 kgfVcm, 66 ftVlbf)
NOTICE: Use SST 09922±10010 in the direction shown in
the illustration.
HINT: Use a torque wrench with a fulcrum length of 380 mm
(14.96 in.) SR±44
± STEERINGPOWER STEERING GEAR
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(c) Using a brass bar and hammer, stake the washer.
NOTICE: Avoid any impact to the rack.
16. INS TALL RH AND LH RACK BO O TS , CLAMP S AND
CLIPS
(a) 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 the steering wheel turned.
(b) Install the boot.
NOTICE: Be careful not to damage or twist the boot.
(c) Install the clamp and clip to the boot.
HINT: When the rack guide spring cap is towards you, install
the clip and clamp in the positions shown in the illustration.
17. 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 nut.
Torque: 56 NVm (570 kgfVcm, 41 ftVlbf)
18. INSTALL TURN PRESSURE TUBES
(a) Install 2 new union seats.
(b) Using SST, install the 2 tubes.
SST 09633±00020
Torque: 24 NVm (243 kgfVcm, 17 ftVlbf)
HINT: Use a torque wrench with a fulcrum length of 300 mm
(11.81 in.)
(c) Torque the 2 union bolts over 4 new gaskets.
Torque: 34 NVm (350 kgfVcm, 25 ftVlbf)
POWER STEERING GEAR
INSTALLATION
1. INSTALL POWER STEERING GEAR ASSEMBLY
(a) Temporarily install the 2 bolts and nuts.
(b) After installing the rack housing bracket and grommet, torque
the 2 bolts and nuts.
Torque: 75 NVm (770 kgfVcm, 55 ftVlbf)
± STEERINGPOWER STEERING GEARSR±45
Page 1677 of 2543
2. INSTALL RACK HOUSING BRACKET AND GROMMET
Torque the 2 bolts and nuts.
Torque: 75 NVm (770 kgfVcm, 55 ftVlbf)
3. CONNECT PPS SOLENOID CONNECTOR
4. CONNECT PRESSURE FEED TUBE
Torque the union bolt over a new gasket.
Torque: 49 NVm (500 kgfVcm, 36 ftVlbf)
5. CONNECT RETURN TUBE
Torque the union bolt over 2 new gaskets.
Torque: 49 NVm (500 kgfVcm, 36 ftVlbf)
6. CONNECT RH AND LH TIE ROD ENDS
(See page SA±17)
7. CONNECT INTERMEDIATE SHAFT
(See page SR±21)
8. INSTALL FR SUSPENSION MEMBER PROTECTOR
Torque the 4 bolts.
9. INSTALL ENGINE UNDER COVER
Install the 10 screws.
10. BLEED POWER STEERING SYSTEM
(See page SR±9)
11. CHECK FRONT WHEEL ALIGNMENT
(See page SA±4) SR±46
± STEERINGPOWER STEERING GEAR
Page 1678 of 2543
ELECTRONIC CONTROL SYSTEM
TROUBLESHOOTING FLOW±CHART
Trouble Symptom
wHard steering at idle or low±speed driving.
wSteering too sensitive during high±speed driving.
Preliminary Check
wCheck tire pressure.
wCheck lubrication of suspension and steering linkage.
wCheck front wheel alignment.
wCheck steering system joint and suspension arm ball joint.
wCheck for bent steering column.
wCheck that all connectors are secure.
wCheck PS pump fluid pressure. (See page SR±37)
Turn ignition switch on.
Is ECU±IG fuse normal?
Disconnect the ECU connector.
Fuse faulty.
Replace fuse.
Is operation normal?Short circuit in wire
harness between fuse
and ECU terminal +B.
Check 1.
Check that there is battery voltage (10 Ð 14V) between the
ECU terminal +B and body ground.
Open circuit in wire harness between the fuse and ECU terminal +B.
± STEERINGELECTRONIC CONTROL SYSTEMSR±47
Page 1679 of 2543
Check 2.
Check that there is continuity between the ECU terminal GND and
body ground.
Open circuit in wire harness between the ECU terminal
GND and body ground.
Body ground faulty.
Check 3.
(a) Jack up one of the rear wheels.
(b) Connect a voltmeter between the ECU connector terminals
SPD and GND.
(c) Spin the rear wheel and check that the meter needle deflects
0 V " 5 V or more " 0 V.
Check 4.
Check that there is no continuity between terminals SOL (+) or
SOL (±) and GND.
Open or short circuit in wire harness between the ECU
terminal SPD and speed sensor.
Speed sensor faulty (See BE section.)
Short circuit in wire harness between the terminals
SOL (+) and SOL (±).
Solenoid valve faulty. SR±48
± STEERINGELECTRONIC CONTROL SYSTEM
Page 1680 of 2543
Check 5.
Measure the resistance between terminal SOL (+) and SOL (±).
Standard resistance: 6 Ð 11
Open circuit in wire harness between the terminals SOL (+)
and SOL (±).
Solenoid valve faulty.
Check 6.
Inspect ECU.Replace ECU.
PPS SOLENOID VALVE INSPECTION
1. DISCONNECT PPS SOLENOID CONNECTOR
(See page SR±33)
2. MEASURE RESISTANCE
Measure the resistance between SOL and SOL .
Resistance:
6±11
3. CHECK PPS SOLENOID OPERATION
(a) Connect the battery positive terminal to the solenoid terminal
SOL .
(b) Connect the battery negative terminal to the solenoid
terminal SOL .
(c) Check that the solenoid makes a 'clicks' sound.
If faulty, replace the pressure control valve with the solenoid
valve.
NOTICE:
wDo not apply voltage for more than 30 seconds to avoid
burning out the solenoid.
wIf repeating this step, wait until the solenoid cools down
enough that it can be touched by hand.
4. CONNECT PPS SOLENOID CONNECTOR
± STEERINGELECTRONIC CONTROL SYSTEMSR±49