Page 2626 of 3000
BR–34BRAKE – REAR DISC BRAKE
BR
6. INSTALL PISTON SEAL
(a) Apply lithium soap base glycol grease to a new
piston seal.
(b) Install the piston seal to the disc brake cylinder
assembly rear LH.
7. INSTALL REAR DISC BRAKE PISTON
(a) Apply lithium soap base glycol grease to the rear
disc brake piston and new cylinder boot.
(b) Install the cylinder boot to the rear disc brake piston.
(c) Install the rear disc brake piston to the disc brake
cylinder assembly rear LH.
NOTICE:
Do not install the piston forcibly in the disc
brake cylinder.
8. INSTALL CYLINDER BOOT
(a) Install a new cylinder boot to the rear disc brake
cylinder sub-assembly.
NOTICE:
Install the boot securely to the grooves of the
cylinder and piston.
(b) Using a screwdriver, install the set ring.
NOTICE:
Do not damage the cylinder boot.
9. INSTALL REAR DISC BRAKE BUSH DUST BOOT
(a) Install the 2 rear disc brake bush dust boot to the
disc brake cylinder mounting LH.
10. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN
(a) Apply the lithium soap base glycol grease to the
sealing surface of the 2 rear disc brake cylinder
slide pins.
G024295
G024294
Page 2631 of 3000
BR–34BRAKE – REAR DISC BRAKE
BR
6. INSTALL PISTON SEAL
(a) Apply lithium soap base glycol grease to a new
piston seal.
(b) Install the piston seal to the disc brake cylinder
assembly rear LH.
7. INSTALL REAR DISC BRAKE PISTON
(a) Apply lithium soap base glycol grease to the rear
disc brake piston and new cylinder boot.
(b) Install the cylinder boot to the rear disc brake piston.
(c) Install the rear disc brake piston to the disc brake
cylinder assembly rear LH.
NOTICE:
Do not install the piston forcibly in the disc
brake cylinder.
8. INSTALL CYLINDER BOOT
(a) Install a new cylinder boot to the rear disc brake
cylinder sub-assembly.
NOTICE:
Install the boot securely to the grooves of the
cylinder and piston.
(b) Using a screwdriver, install the set ring.
NOTICE:
Do not damage the cylinder boot.
9. INSTALL REAR DISC BRAKE BUSH DUST BOOT
(a) Install the 2 rear disc brake bush dust boot to the
disc brake cylinder mounting LH.
10. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN
(a) Apply the lithium soap base glycol grease to the
sealing surface of the 2 rear disc brake cylinder
slide pins.
G024295
G024294
Page 2675 of 3000
STEERING COLUMN – STEERING COLUMN ASSEMBLYSR–11
SR
9. INSTALL STEERING INTERMEDIATE SHAFT
ASSEMBLY
(a) Align the matchmarks on the steering intermediate
shaft assembly and main shaft.
(b) Temporarily install the steering intermediate shaft
assembly with the bolt.
Torque: 36 N*m (370 kgf*cm, 27 ft.*lbf)
INSTALLATION
1. INSTALL STEERING COLUMN ASSEMBLY
(a) Install the steering column assembly with the 3
bolts.
Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
(b) Connect the connectors.
(c) Connect the wire harness clamps to the steering
column tube.
2. CONNECT STEERING INTERMEDIATE SHAFT
ASSEMBLY
(a) Align the matchmarks on the intermediate shaft
assembly and steering gear assembly.
(b) Install the steering intermediate shaft assembly with
the bolt.
Torque: 36 N*m (370 kgf*cm, 27 ft.*lbf)
(c) Install the dust cover to the hole cover. Check that
the 3 clips of the dust cover are securely fitted into
the groove on the hole cover.
3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
4. INSTALL SPIRAL CABLE SUB-ASSEMBLY (See page
RS-434)
5. INSTALL STEERING COLUMN COVER
6. CENTER SPIRAL CABLE (See page RS-435)
F045002E02
F045001
D029986E02
D030704E02
Page 2684 of 3000
STEERING COLUMN – STEERING COLUMN ASSEMBLYSR–11
SR
9. INSTALL STEERING INTERMEDIATE SHAFT
ASSEMBLY
(a) Align the matchmarks on the steering intermediate
shaft assembly and main shaft.
(b) Temporarily install the steering intermediate shaft
assembly with the bolt.
Torque: 36 N*m (370 kgf*cm, 27 ft.*lbf)
INSTALLATION
1. INSTALL STEERING COLUMN ASSEMBLY
(a) Install the steering column assembly with the 3
bolts.
Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
(b) Connect the connectors.
(c) Connect the wire harness clamps to the steering
column tube.
2. CONNECT STEERING INTERMEDIATE SHAFT
ASSEMBLY
(a) Align the matchmarks on the intermediate shaft
assembly and steering gear assembly.
(b) Install the steering intermediate shaft assembly with
the bolt.
Torque: 36 N*m (370 kgf*cm, 27 ft.*lbf)
(c) Install the dust cover to the hole cover. Check that
the 3 clips of the dust cover are securely fitted into
the groove on the hole cover.
3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
4. INSTALL SPIRAL CABLE SUB-ASSEMBLY (See page
RS-434)
5. INSTALL STEERING COLUMN COVER
6. CENTER SPIRAL CABLE (See page RS-435)
F045002E02
F045001
D029986E02
D030704E02
Page 2688 of 3000
POWER STEERING – VANE PUMPPS–17
PS
(c) Install the vane pump plates with the round end
facing outward.
NOTICE:
Make sure that the vane pump plates are
installed facing in the correct direction.
6. INSTALL VANE PUMP SHAFT SNAP RING
(a) Using a screwdriver and a snap ring expander,
install a new vane pump shaft snap ring onto the
vane pump shaft with pulley.
NOTICE:
Make sure that the vane pump shaft snap ring is
securely installed in the vane pump shaft
groove.
7. INSTALL VANE PUMP REAR HOUSING
(a) Coat a new O-ring with power steering fluid and
install it onto the vane pump rear housing.
(b) Align the straight pin of the vane pump rear housing
with the notches of the vane pump cam ring, vane
pump front side plate, and vane pump front housing.
C141370E01
D030336E01
C107040
C136780E01
Page 2691 of 3000
PS–20POWER STEERING – VANE PUMP
PS
(b) Temporarily connect the pressure feed tube
assembly to the vane pump assembly with the union
bolt.
(c) Fully tighten the union bolt.
Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf)
NOTICE:
Make sure that the stopper of the pressure feed
tube assembly contacts the vane pump
assembly securely as shown in the illustration.
4. CONNECT NO. 1 FLUID RESERVOIR TO PUMP HOSE
(a) Connect the No. 1 fluid reservoir to pump hose to
the vane pump assembly with the clip.
NOTICE:
• Connect the No. 1 fluid reservoir to pump
hose with the paint mark facing toward the
rear of the vehicle.
• Push the No. 1 fluid reservoir to pump hose
as far as it goes as shown in the illustration.
• Install the clip at the position specified in the
illustration.
5. INSTALL FAN AND GENERATOR V BELT (See page
EM-7)
6. ADD POWER STEERING FLUID
7. BLEED POWER STEERING SYSTEM (See page PS-6)
8. CHECK POWER STEERING FLUID LEVEL (See page
PS-2)
9. INSPECT FOR POWER STEERING FLUID LEAK
10. INSTALL FRONT FENDER APRON SEAL RH (See
page EM-62)
11. INSTALL FRONT WHEEL RH
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
C161548
C133183E02
Page 2694 of 3000
PS–26POWER STEERING – RACK AND PINION POWER STEERING GEAR
PS
(d) Remove the nut and separate the tube clamp.
11. REMOVE RACK & PINION POWER STEERING GEAR
ASSEMBLY
(a) Remove the 2 bolts, nuts and the power steering
gear assembly.
NOTICE:
Do not damage the 2 pressure tubes.
DISASSEMBLY
1. REMOVE RETURN TUBE NO.2
(a) Using SST, remove the return tube No. 2.
SST 09023-12701
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
SST 09023-38201
HINT:
Perform the same procedure on the other side.
4. FIX RACK & PINION POWER STEERING GEAR
ASSEMBLY
(a) Using SST, secure the power steering gear
assembly.
SST 09612-00012
HINT:
Tape the SST before use.
D029975
D029979
D030600E01
D029981E01
D030616E01
Page 2696 of 3000
PS–28POWER STEERING – RACK AND PINION POWER STEERING GEAR
PS
(b) Using 2 SST, remove the 2 steering rack end sub-
assembly and 2 claw washers.
SST 09922-10010
NOTICE:
• Use SST 09922-10010 in the direction shown
in the illustration.
• Securely hold the power steering rack end
with a SST.
13. REMOVE RACK GUIDE
(a) Using SST, remove the rack guide spring cap nut.
SST 09922-10010
NOTICE:
Use SST 09922-10010in the direction shown in
the illustration.
(b) Using SST, remove the rack guide spring cap.
SST 09631-10021
(c) Remove the compression spring and the rack guide.
14. REMOVE POWER STEERING CONTROL VALVE
(a) Using a socket wrench (27 mm), remove the rack
housing cap.
F041526E01
F041500E01
F041501E01
F041502E01
