ST-30
< PERIODIC MAINTENANCE >
POWER STEERING FLUID
PERIODIC MAINTENANCE
POWER STEERING FLUID
InspectionINFOID:0000000006225597
FLUID LEVEL
1. Check fluid level with engine stopped.
2. Ensure that fluid level is between MIN and MAX.
3. Fluid levels at HOT and COLD are different. Do not confuse
them.
CAUTION:
The fluid level should not exceed the MAX line. Excessive flui d causes fluid leakage from the
cap.
Never reuse drained power steering fluid.
Always use the specified fluid. Refer to MA-10, "
Fluids and Lubricants".
FLUID LEAKAGE
Check hydraulic connections for fluid leakage, cracks, damage,
looseness, or wear.
1. Run engine until the fluid temperature reaches 50 to 80 °C (122
to 176 °F) in reservoir tank, and keep engine speed idle.
2. Turn steering wheel several times from full left stop to full right stop.
3. Hold steering wheel at each lock position for five seconds and carefully, check for fluid leakage.
CAUTION:
Never hold the steering wheel in a locked position for more
than 10 seconds. (There is the possibility that power steer-
ing oil pump assembly may be damaged.)
4. If fluid leakage at connections is noticed, then loos en flare nut and then retighten. Do not overtighten con-
nector as this can damage O-ring, washer and connector.
5. If fluid leakage from oil pump is noticed, check oil pump. Refer to ST-52, "
Inspection".
6. Check steering gear boots for accumulation of fluid indicating from steering gear.
AIR BLEEDING HYDRAULIC SYSTEM
If air bleeding is not complete, the following symptoms can be observed.
Bubbles are created in reservoir tank.
Clicking noise can be heard from oil pump.
Excessive buzzing in the oil pump. NOTE:
Fluid noise may occur in the steering gear or oil pump. This does not affect performance or durability of the
system.
1. Turn steering wheel several times from full left stop to full right stop with engine off. CAUTION:
Fill reservoir tank with a sufficien t amount of fluid so that fluid level is not below the MIN line while
turning steering wheel.
2. Start engine and hold steering wheel at each lock position for 3 seconds at idle to check for fluid leakage.
HOT : Fluid temperature 50 – 80
°C (122 – 176 °F)
COLD : Fluid temperature 0 – 30 °C (32 – 86 °F)
Recommended fluid : Refer to MA-10, "
Fluids
and Lubricants".
Fluid capacity : Refer to ST-57, "
General
Specifications".
SGIA0232J
SGIA0506E
Revision: 2010 May2011 QX56
POWER STEERING FLUIDST-31
< PERIODIC MAINTENANCE >
C
DE
F
H I
J
K L
M A
B
ST
N
O P
3. Repeat step 2 above several times at approximately 3 seconds intervals. CAUTION:
Never hold the steering wheel in a locked positio n for more than 10 seconds. (There is the possi-
bility that oil pump may be damaged.)
4. Check fluid for bubbles and while contamination.
5. Stop engine if bubbles and white contamination do not drain out. Perform step 2 and 3 above after waiting
until bubbles and white contamination drain out.
6. Stop the engine, and then check fluid level.
Revision: 2010 May2011 QX56
ST-44
< REMOVAL AND INSTALLATION >
STEERING GEAR AND LINKAGE
3. Measure adjusting screw height (H), and loosen adjusting screwlock nut (1) and adjusting screw (2).
CAUTION:
Never loosen adjusting screw 2 turns or more.
Replace steering gear assembly if adjusting screw is
loosened 2 turns or more and it is removed.
4. Remove gear-sub assembly from gear housing assembly.
5. Remove O-ring from gear housing assembly.
6. Loosen outer socket lock nut, and remove outer socket.
7. Remove boot clamps, and then remove boot from inner socket. CAUTION:
Never damage inner socket and gear housing assembly when removing boot. Inner socket and
gear housing assembly must be replaced if inne r socket and gear housing assembly are damaged
because it may cause foreign material interfusion.
8. Remove inner socket from gear housing assembly.
ASSEMBLY
1. Apply recommended fluid to O-ring, and then install O-ring to gear housing assembly. CAUTION:
Never reuse O-ring.
2. Install gear-sub assembly to gear housing assembly. CAUTION:
In order to protect oil seal from any da mage, insert gear-sub assembly straightly.
3. Install inner socket to gear housing assembly with the following procedure.
a. Apply thread locking sealant into the thread of inner socket. Use Genuine High Strength Thread Locking Sealant or equivalent. Refer to GI-22, "
Recommended
Chemical Products and Sealants".
4. Screw inner socket into rack part and tighten at the specified torque.
5. Decide on the neutral position of the rack stroke (L).
6. Install rear cover cap to gear sub-assembly. CAUTION:
Make sure that the projection of rear cover cap is aligned
with the marking position of gear housing assembly.
7. Install adjusting screw with the following procedure.
a. Apply recommended sealant into the thread of adjusting screw (2) (2 turns thread), and then screw in the adjusting screw until it
reaches height (H) from gear housing assembly (3) measured
before disassembling.
Use Genuine Liquid Gasket Gasket, Three Bond 1111B or
equivalent.
b. Tighten the adjusting screw lock nut (1) to the specified torque.
8. Move rack assembly 10 strokes throughout the full stroke so that the parts can fit with each other.
9. Adjust pinion rotating torque with the following procedure.
3 : Gear housing assembly
JPGIA0065ZZ
L : Refer to ST-58, "Rack Stroke".
SGIA0877E
JPGIA0065ZZ
Revision: 2010 May2011 QX56
ST-48
< REMOVAL AND INSTALLATION >
POWER STEERING OIL PUMP
POWER STEERING OIL PUMP
Exploded ViewINFOID:0000000006225611
REMOVAL
DISASSEMBLY
1. Power steering oil pump 2. Bracket: Vehicle front
Refer to GI-4, "
Components" for symbols in the figure.
JPGIA0031GB
Revision: 2010 May2011 QX56
POWER STEERING OIL PUMPST-49
< REMOVAL AND INSTALLATION >
C
DE
F
H I
J
K L
M A
B
ST
N
O P
Removal and InstallationINFOID:0000000006225612
REMOVAL
1. Drain power steering fluid from reservoir tank. CAUTION:
Never reuse drained power steering fluid.
Always use the specified fluid. Refer to MA-10, "
Fluids and Lubricants".
2. Remove the reservoir tank. Refer to CO-13, "
Removal and Installation".
3. Remove the battery and battery tray from vehicle. Refer to PG-164, "
Removal and Installation".
4. Loosen drive belt. Refer to EM-20, "
Removal and Installation".
5. Remove drive belt from oil pump pulley.
6. Remove copper washers and eye bolt (drain fluid from their pipings).
7. Remove suction hose (drain fluid from their pipings).
8. Remove oil pump mounting bolts, and then remove oil pump.
INSTALLATION
1. Pulley 2. Snap ring 3. Drive shaft assembly
4. Oil seal 5. Body assembly 6. Suction pipe
7. O-ring 8. Side plate 9. Vane
10. Rotor 11. Cam ring 12. Cartridge
13. Dowel pin 14. Gasket 15. Rear cover
16. Flow control valve spring 17. Flow control valve 18. Connector bolt
19. Bracket
: Replace the parts as a set.
A. Oil seal lip
: Apply power steering fluid.: Apply multi-purpose grease.
Refer to GI-4, "
Components" for symbols not described on the above.
JPGIA0032GB
Revision: 2010 May2011 QX56
ST-50
< REMOVAL AND INSTALLATION >
POWER STEERING OIL PUMP
Note the following, and install in the reverse order of removal.
When installing suction hoses (1), refer to the figure.CAUTION:
Never apply fluid to the hose (1) and tube (2).
Insert hose securely until it contacts spool (A) of tube.
Leave clearance (L) when installing clamp (3).
When installing eye bolt (1) and copper washer (2) to oil pump (3), refer to the figure.
CAUTION:
Never reuse copper washer.
Apply power steering fluid to around copper washers, then
install eye bolt.
Install eye bolt with eye join t (assembled to high pressure
hose) (B) protrusion (A) facing with pump side cutout, and
then tighten it to the specifi ed torque after tightening by
hand. Refer to ST-54, "
Exploded View".
Securely insert harness connector to pressure sensor.
About the installation of drive belt. Refer to EM-20,
"TensionAdjustment".
Check fluid level, fluid leakage and air bleeding hydr aulic system after the installation. Refer to ST-30,
"Inspection".
Disassembly and AssemblyINFOID:0000000006225613
DISASSEMBLY
CAUTION:
Fix oil pump with a vise if necessary.
Use copper plates when fixing with a vise.
1. Perform inspection before disassembly. Refer to ST-52, "
Inspection".
2. Remove rear cover mounting bolts, and then remove rear cover from body assembly.
3. Remove gasket from body assembly.
4. Remove dowel pin, cartridge and side plate from body assembly.
5. Remove pulley mounting nut and washer, then remove pulley from drive shaft.
6. Remove snap ring from drive shaft and press out it. CAUTION:
When removing snap ring, be careful not to damage drive
shaft.
7. Remove oil seal from body assembly using a suitable tool.
8. Remove O-ring from body assembly.
9. Remove mounting bolts of suction pipe, and then remove suc- tion pipe and bracket from body assembly.
10. Remove connector bolt, and then remove O-ring, flow control
valve and spring from body assembly
11. Perform inspection after disassembly. Refer to ST-52, "
Inspec-
tion".
ASSEMBLY
CAUTION:
Fix oil pump with a vise if necessary.
Use copper plates when fixing with a vise.L : 3 – 8 mm (0.12 – 0.31 in)
JSGIA0118ZZ
JSGIA0452ZZ
SST010B
Revision: 2010 May2011 QX56
POWER STEERING OIL PUMPST-51
< REMOVAL AND INSTALLATION >
C
DE
F
H I
J
K L
M A
B
ST
N
O P
1. Apply recommended grease to oil seal lips (1). Apply recom- mended fluid to around oil seal. Install oil seal to body assembly,
using a drift.
CAUTION:
Never reuse oil seal.
2. Apply recommended fluid to drive shaft, and press drive shaft into body assembly, then install snap ring.
CAUTION:
Never reuse snap ring.
3. Apply recommended fluid to O-ring, and then install O-ring into body assembly.
CAUTION:
Never reuse O-ring.
4. Install side plate to body assembly.
5. Install dowel pin (1) into dowel pin hole (A), and then install cam ring (2) pointing it's D
1 side toward the body assembly (3) side
as shown in the figure.
When installing cam ring, turn carved face with a letter E (B) of
it to rear cover.
CAUTION:
Do not confuse the assembling direction of cam ring. If
cam ring is installed facing th e incorrect direction, it may
cause oil pump operation malfunction.
SGIA1150E
SGIA0422E
JSGIA0110ZZ
Revision: 2010 May2011 QX56
ST-52
< REMOVAL AND INSTALLATION >
POWER STEERING OIL PUMP
6. Install rotor to body assembly.CAUTION:
When installing rotor, turn mark face on rotor to body
assembly.
7. Install vane to rotor so that arc of vane faces cam ring side.
8. Check if drive shaft assembly turns smoothly.
9. Install gasket to body assembly. CAUTION:
Never reuse gasket.
10. Install rear cover to body assembly, and then tighten mounting bolts to the specified torque.
11. Install pulley and washer to drive shaft, and then tighten lock nut at the specified torque.
12. Apply recommended fluid to O-ring. Install flow control valve spring, flow control valve and O-ring to body assembly, and then
tighten connector bolt to the specified torque.
CAUTION:
Never reuse O-ring.
13. Apply recommended fluid to O-ring, and then install O-ring to body assembly. CAUTION:
Never reuse O-ring.
14. Install suction pipe and bracket to body assembly.
15. Perform inspection after assembly. Refer to ST-52, "
Inspection".
InspectionINFOID:0000000006225614
INSPECTION BEFORE DISASSEMBLY
Disassemble oil pump only when the following malfunctions occur.
If oil leakage is found on oil pump.
Oil pump pulley is damaged or deformed.
Performance of oil pump is low.
INSPECTION AFTER DISASSEMBLY
Body Assembly and Rear Cover Inspection
Check body assembly and rear cover for internal damage. Replace oil pump assembly if necessary.
Cartridge Assembly Inspection
Check cam ring, rotor and vane for damage. Replace oil pump assembly if necessary.
Side Plate Inspection
Check side plate for damage. Replace oil pump assembly if necessary.
Flow Control Valve Inspection
Check flow control valve and spring for damage. Replace oil pump assembly if necessary.
INSPECTION AFTER ASSEMBLY
Relief Oil Pressure
CAUTION:
Make sure that belt tension is normal before starting the following procedure.
SGIA0989E
SST843A
Revision: 2010 May2011 QX56