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POWER STEERING GEAR AND LINKAGE
PS-19
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e. When installing outer rack oil seal, cover end of rack with an
OHP sheet [70 mm (2.76 in) × 100 mm (3.94 in)]. It will avoid
damaging rack oil seal. Then place oil seal over sheet. Pull rack
oil seal along with OHP sheet until they pass rack end. Install
rack oil seal in place using end cover assembly.
f. Attach rack oil seal. Both inner lip and outer lip should face each
other.
5. Using a 36-mm open head, tighten end cover assembly to spec-
ified torque.
CAUTION:
Do not damage rack surface. If it damaged, it may cause oil
leak. Replace rack assembly.
6. After tightening end cover, crimp cylinder at one point as shown
in figure using a punch. This will prevent end cover from getting
loose.
7. Assemble an O-ring to the gear housing.
8. Install gear sub assembly to gear housing.
SGIA0097E
SGIA0058E
: 59 - 74 N·m (6.0 - 7.5 kg-m, 43 - 54 ft-lb)
SST081B
SST073B
SGIA0203E
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PS-20
POWER STEERING GEAR AND LINKAGE
9. Install mounting bolts to rear housing. Tighten them to specified
torque.
10.
11. Attach lock plate.
CAUTION:
The lock plate is not reusable. Never reuse lock plate.
a. Position spacer ring to rack.
b. Set lock plate to tie rod and inner socket.
c. Apply thread lock adhesive (Three Bond 1324 or equivalent) to
thread of inner socket. Screw inner socket into rack and tighten
to specified torque.
d. Crimp lock plate at two points on rack slit.
e. Install spacer ring to lock plate as shown in the figure.
CAUTION:
When installing spacer ring, avoid scratching it.
12. Decide neutral position of rack gear.
13. Coat the adjusting screw with locking sealant and screw it in.
14. Screw lock nut. Do not tighten lock nut.
15. Tighten adjusting screw to following specified torque.
16. Rotate throughout whole range of pinion so that parts fit with
each other.
17. Install rear cover cap.
18. Install cylinder tube.: 15.7 - 20.5 N·m (1.6 - 2.0 kg·m, 12 - 15 ft-lb)
SGIA0022J
Rack stroke (L) : 66.5 mm (2.618 in)
SST866C
STC0034D
: 4.9 - 5.9 N·m (0.5 - 0.6 kg-m, 44 - 52 in-lb)
: 20 - 26 N·m (2.0 - 2.7 kg-m,14 - 20 ft-lb)
SST742C
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POWER STEERING GEAR AND LINKAGE
PS-21
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19. Use preload gauge. Measure pinion rotation torque within ±180°
of neutral position of the gear. Stop the gear at the point where
highest torque is read.
20. Loosen adjusting screw and retighten to 4.9 - 5.9 N·m (0.50 -
0.60 kg-m, 44 - 52 in-lb), and then loosen by 60 - 80°(140-
176°F).
21. With adjusting screw held in place, tighten lock nut to 40 - 58
N·m (4.0 - 6.0 kg-m, 29 - 43 ft-lb).
22. Using a preload gauge, measure rotational torque of pinion gear.
Check that reading is within range specified. If reading is outside
specification, readjust rack. If reading is still outside specifica-
tion, replace power steering gear.
23. With tie rod gear installed to gear assembly, turn pinion gear
fully to left.
24. Set dial gauge as shown in figure. Measure vertical movement
of rack when pinion is turned counterclockwise with torque of 4.9
N·m (0.5 kg-m, 43 in-lb). Check reading is within range speci-
fied. If reading is outside of specification, readjust rack. If read-
ing is still outside of specification, replace power steering gear.
STC0036D
SGIA0098E
Rotational torque of pinion gear : Around neutral position [within ±11.5 mm (0.453 in)]
Average A : 1.67 - 2.25 N·m (0.17 - 0.22 kg-m, 1.3 - 1.6 ft-lb)
Maximum variation B : 0.98 N·m (0.10 kg-m, 1 ft-lb)
Other than above
Average A : 2.94 N·m (0.30 kg-m, 2 ft-lb)
Maximum variation B : 1.47 N·m (0.15 kg-m, 1 ft-lb)
Specification : 0.08 mm (0.0031 in) or less
SGIA0465E
Measuring point in shown in figure at right.Rack axle direction 5 mm (0.197 in) from housing vertical surface
Rack radial direction Direction of adjusting screw
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PS-22
POWER STEERING GEAR AND LINKAGE
25. Position boot band on large-diameter side before installing it.
26. Install small-diameter side of boot to inner socket boot mounting
groove.
27. Install boot band to small-diameter side of boot.
28. Install boot clamp.
a. Tighten large-diameter side of RH/LH boot with boot clamp
(stainless wire).
b. Wrap clamp around boot groove for two turns. Insert screwdriv-
ers in loops on both ends of wire. Twist 4 to 4.5 turns while pull-
ing them with force of approx. 98 N (10 kg, 22.1 lb).
c. Twist boot clamp as shown. Pay attention to relationship
between winding and twisting directions.
d. Twisted point should face front of vehicle with gear installed on
vehicle (to prevent interference with other parts).
e. After twisting wire 4 to 4.5 turns, bend cut end of wire. Cut end of
wire should not touch boot. Be sure wire end is at least 5 mm
(0.20 in) away from clearance for tube.
SGIA0374E
Wire length ( ): 370 mm (14.57 in)
SST097B
SST440A
SGIA0025E
STC0124D
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POWER STEERING GEAR AND LINKAGE
PS-23
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29. Connect lock nut and outer socket to inner socket. Temporarily
tighten lock nut until length of tie rod is within specification.
CAUTION:
Perform toe-in adjustment after this procedure. Length
achieved after toe-in adjustment is not necessarily value given
here.Tie rod length (L) : 169.67 mm (6.68 in)
STC0125D
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PS-24
POWER STEERING OIL PUMP
POWER STEERING OIL PUMP
PFP:49110
On-Vehicle Inspection and ServiceEGS000AF
OIL PUMP PULLEY HYDRAULIC PRESSURE INSPECTION
Before starting following procedure, check tension of belt.
1. Raise vehicle. Connect oil pressure gauge between oil pump
discharge connector and high pressure hose. Then bleed the
hydraulic circuit.
2. Start engine. Run engine until oil temperature reaches 50°C -
80°C (122 - 176°F)
CAUTION:
●Leave valve of hydraulic pressure gauge fully open while
starting and running engine. If engine is started with
valve closed, hydraulic pressure in oil pump goes up.
This will relief pressure along with abnormal increase of
oil temperature.
●Care must be taken to keep hose clear of belt and other parts when engine is started.
3. Fully close hydraulic pressure gauge valve with engine at idle. Measure relief pressure.
4. After measurement, open valve slowly.
CAUTION:
Never keep valve closed for 15 seconds or longer.
●If relief pressure is outside specification, disassemble and service oil pump. Refer to PS-25, "Disas-
sembly and Assembly(QR20DE and QR25DE engine models)" .
5. After inspection, remove oil pressure gauge from hydraulic circuit. Add fluid. Be sure to bleed the system
completely. Refer to PS-5, "
Bleeding Hydraulic System"
Removal and Installation (QR20DE and QR25DE engine models)EGS000AG
REMOVAL
1. Loosen adjusting screw and oil pump mounting bolt. Then, remove belt.
2. Remove union bolt and hose for oil pump.
3. Remove oil pump bracket attaching bolt.
4. Remove oil pump from vehicle.
INSTALLATION
Paying attention to following items, install in the reverse order of removal.
●After installation, adjust belt tension. Refer to EM-12, "DRIVE BELTS" .
●After installation, be sure to bleed system. Refer to PS-5, "Bleeding Hydraulic System" . Relief pressure specification:
8,140 - 8,728 kPa (81.4 - 87.3 bar, 83 - 89 kg/cm
2 , 1,180 - 1,266 psi)
SST834-H
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POWER STEERING OIL PUMP
PS-25
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Disassembly and Assembly(QR20DE and QR25DE engine models)EGS000AH
INSPECTION BEFORE DISASSEMBLY
Disassemble the power steering oil pump only if the following items
are found.
●Oil leak from any point shown in the figure
●Deformed or damaged pulley
●Poor performance
DISASSEMBLY
1. Fix power steering pump in a vise.
CAUTION:
When fixing pump in a vise, use aluminum plates to protect steering pump mounting surface.
2. Remove rear bracket mounting bolts. Remove rear bracket from rear body.
3. Remove three front bracket attaching bolts and remove front bracket from casing.
4. Remove four rear body attaching bolts and remove rear body from casing.
5. Remove body seal from casing.
6. Remove side plate (rear) from cartridge. Remove side plate inner and outer seals from side plate (rear).
1. Pulley 2. Front bracket 3. Drive shaft seal
4. Casing 5. Inlet connector seal 6. Inlet connector
7. Flow control valve spring 8. Flow control A valve 9. Dowel pin
10. Flow control B valve assembly 11. Side plate (front) 12. Cartridge
13. Rotor 14. Vane 15. Rotor snap ring
16. Side plate (rear) 17. Side plate inner seal 18. Side plate outer seal
19. Body seal 20. Rear body 21. Rear bracket
SGIA0012E
SST984A
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PS-26
POWER STEERING OIL PUMP
7. Remove rotor snap ring using a snap ring pliers and remove pul-
ley from casing.
CAUTION:
When removing rotor snap ring, be careful not to damage
pulley shaft.
8. Remove following parts from casing: cartridge, rotor, vane, side
plate (front), flow control valve A, flow control valve spring, and
flow control valve B assembly
CAUTION:
Do not drop flow control A valve and flow control B valve
assembly to floor. If dropped, they may be deformed.
9. Remove inlet connector attaching bolt and remove inlet connector from casing.
10. Remove inlet connector seal from inlet connector.
11. Using a screwdriver or equivalent tool, remove drive shaft seal from casing.
CAUTION:
Be careful not to damage casing surface with screwdriver.
INSPECTION AFTER DISASSEMBLY
Inspecting Casing and Rear Body
●Check casing and rear body for internal damage. If rear body is damaged, replace rear body. If casing is
damaged, replace power steering pump assembly.
Cartridge Inspection
●Check cartridge for damage. If damaged, cartridge, rotor, and vane must be replaced as a set.
Inspecting Side Plate
●Check side plates (front and rear) for damage. If damaged, side plates (front and rear) must be replaced
as a set.
ASSEMBLY
1. Apply multi-purpose grease to lip of drive shaft seal. Using a
drift, install drive shaft seal to casing.
CAUTION:
Drive shaft seal is not reusable. Never reuse drive shaft
seal.
2. If removed dowel pin cannot be inserted to casing by hand, tap
it with hammer.
3. Connect flow control valve A, flow control valve spring and flow
control valve B assembly as shown.
SGIA0059E
SST038A
SGIA0061E