Page 2777 of 3066

POWER STEERING GEAR AND LINKAGE
PS-17
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lHook spring scale at the position indicated in the figure. Con-
firm the reading at the moment the ball stud begins moving is
within specifications. If the value is outside the standard,
replace outer and inner sockets.
2. Sliding torque
lUsing a preload gauge, check reading is within range speci-
fied below. If the value is outside the standard, replace outer
and inner sockets.
3. Axial endplay
lApply load of 490 N (50 kg,110.6 lb) to ball stud axially. Mea-
sure amount of movement that stud makes by using a dial
gauge. Check reading is within range specified below. If not,
replace outer and inner sockets.
ASSEMBLY
lAlways replace O-rings, oil seals, and copper washers with new
ones.
1. Install an O-ring.
CAUTION:
Do not reuse rack Teflon ring and O-ring.
2. Heat rack Teflon ring to approximately 40°C with dryer. Assem-
ble it to rack.Outer socket Inner socket
Oscillating torque
[N·m (kg·m, in-lb)]0.30 - 2.94 N·m
[0.03 - 0.30 kg·m,3-
26 in·lb]1.0 - 7.8 N·m
[0.10 - 0.80 kg·m,9-
69 in·lb]
Measurement on
spring balance [N
(kg, lb)]4.84 - 47.4 N
[0.49 - 4.84
kg,1.08-10.7 lb]5.2 - 41 N
[0.53 - 4.1 kg,1.17-
9.07 lb]
SST338B
Outer socket PR24AD
Sliding torque0.30 - 2.94 N·m (0.03 - 0.30 kg·m,3-26
in·lb)
SGIA0083E
Outer socket : 0.5 mm (0.02 in) or less
Inner socket : 0.2 mm (0.008 in) or less
SGIA0057E
SST083B
Page 2778 of 3066

PS-18
POWER STEERING GEAR AND LINKAGE
3. To fit Teflon ring on rack, install Teflon ring correcting tool from
tooth side. Compress the rim of ring with the tool.
4. Insert new rack oil seal.
CAUTION:
Rack oil seal is not reusable. Never reuse rack oil.
a. To avoid damaging inner rack oil seal, wrap an OHP sheet
{approx. 70 mm (2.76 in)´100 mm (3.94 in)} around rack tooth.
Place oil seal over sheet. Then, pull oil seal along with OHP
sheet until they pass toothed section of rack.
b. Insert rack assembly into gear housing assembly.
CAUTION:
When inserting rack assembly, do not damage cylinder
inner wall. If it damaged, it may cause oil leak. Replace gear
housing assembly.
c. Install center busing and rack oil seal separately.
d. Press rack piston in to move inner rack oil seal to proper posi-
tion.
CAUTION:
Move it until it contacts center bushing.
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.
SST885BA
SGIA0097E
SST830A
SGIA0097E
Page 2779 of 3066
POWER STEERING GEAR AND LINKAGE
PS-19
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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. The number of shims to be installed should be the same as that
of shims before removal. It is regardless of with or without
replacement of piston assembly or gear subassembly.
8. Assemble an O-ring to the gear housing.
9. Install gear sub assembly to gear housing.
10. Install mounting bolts to rear housing. Tighten them to specified
torque.
11 .
SGIA0058E
: 59 - 74 N·m (6.0 - 7.5 kg·m, 43 - 54 ft·lb)
SST081B
SST073B
SGIA0021E
: 16 - 21 N·m (1.6 - 2.1 kg·m,12-15 ft·lb)
SGIA0022J
Page 2780 of 3066

PS-20
POWER STEERING GEAR AND LINKAGE
12. 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.
13. Decide neutral position of rack gear.
14. Coat the adjusting screw with locking sealant and screw it in.
15. Screw lock nut. Do not tighten lock nut.
16. Tighten adjusting screw to following specified torque.
17. Rotate throughout whole range of pinion so that parts fit with
each other.
18. Install rear cover cap.
19. Install cylinder tube.
20. 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.
21. 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).
22. With adjusting screw held in place, tighten lock nut to 40 - 58
N·m (4.0 - 6.0 k·gm,29 - 43 ft-lb).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)
:20-26N·m(2.0-2.7kg·m,14-20ft·lb)
SST742C
STC0036D
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POWER STEERING GEAR AND LINKAGE
PS-21
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23. 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.
24. With tie rod gear installed to gear assembly, turn pinion gear
fully to left.
25. 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,43in·lb). Check reading is within range specified.
If reading is outside of specification, readjust rack. If reading is
still outside of specification, replace power steering gear.
26. Position boot band on large-diameter side before installing it.
27. Apply multi-purpose grease to both large- and small- diameter
sides.
28. Install small-diameter side of boot to inner socket boot mounting
groove.
29. Install boot band to small-diameter side of boot.
30. Install boot band.
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).Rotational torque
of pinion gear: Around neutral position
{within±11.5 mm (0.453 in)}
Average A : 167 - 225 N·m (17 - 23
kg·m,123-166 ft·lb)
Maximum varia-
tion B: 98 N·m (10 kg·m,72 ft·lb)
Other than above
Average A : 294 N·m (30 kg·m,217 ft·lb)
Maximum varia-
tion B: 147 N·m (15 kg·m,108 ft·lb)
SGIA0098E
Specification : 0.08 mm (0.0031 in) or less
SGIA0099E
Measuring point in shown in figure at right.Rack axle direction 5 mm from housing vertical surface
Rack radial direction Direction of adjusting screw
SGIA0024E
Wire length (L) : 370 mm (14.57 in)
SST097B
Page 2782 of 3066
PS-22
POWER STEERING GEAR AND LINKAGE
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.
31. 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.
SST440A
SGIA0025E
STC0124D
Tie rod length (L) : 169.67 mm (6.68 in)
STC0125D
Page 2783 of 3066

POWER STEERING OIL PUMP
PS-23
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POWER STEERING OIL PUMPPFP: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-
60°C (122 - 140°F)
CAUTION:
lLeave 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.
lCare 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.
lIf relief pressure is outside specification, disassemble and service oil pump. Refer toPS-24, "Disas-
sembly and Assembly(QR20DE engine model)".
5. After inspection, remove oil pressure gauge from hydraulic circuit. Add fluid. Be sure to bleed the system
completely. Refer toPS-5, "
Bleeding Hydraulic System"
Removal and Installation (QR20DE engine model)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.
lAfter installation, adjust belt tension. Refer to “Accessory belt” in ”B1 Engine Body”.
lAfter installation, be sure to bleed system. Refer toPS-5, "Bleeding Hydraulic System". Relief pressure specification:
: 8.3 + 0.4 - 0.2 MPa (85 + 4 - 2 kg/cm
2)
SST834-H
Page 2784 of 3066

PS-24
POWER STEERING OIL PUMP
Disassembly and Assembly(QR20DE engine model)
EGS000AH
INSPECTION BEFORE DISASSEMBLY
Disassemble the power steering oil pump only if the following items
are found.
lOil leak from any point shown in the figure
lDeformed or damaged pulley
lPoor 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).
SGIA0012E
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
SST984A