GROUP-l 9

NG
POWER
CONTENTS

SPECIFICATIONS .. .. .... .. .. .. ...... .. ...... .... .... ........... 2 CHECKING POWER STEERING BELT TEN:
SION .............. .. ...... ... ..... .. ................................ 11
GENERAL SPECIFICATIONS . .. .. .. .. ............... 2
SERVICE SPECIFICATIONS . .... .. .. ................. 2 CHECKING FLUID LEVEL .... ...... .................. 11
TORQUE SPECIFICATIONS ... .... .. ... ... ........... BLEEDING ...................................................... 11
3
OIL PUMP PRESSURE TEST .......................... 12
LUBRICANTS .. .... .... .... .... .. .. ... ... .. ........ .... .. ..... 4
CHECKING BALL JOINT END PLAY ........... 13
SPECIAL TOOLS .,...........................................,.. 5 CHECKING STEERING’ ANGLE ..........i.. ....... 13
TROUBLESHOOTING ..................... .... .. .. .. .. ....... 6 COMPONENT SERVICE .................................... 14
SERVICE ADJUSTMENT PROCEDURES . .. .. ..... 10 STEERING COLUMN AND SHAFT ............... 14
CHECKING STEERING WHEEL FREE POWER STEERING. GEAR BOX ..............-a..... 18
PLAY .... ........ ..... ..... .f. ... ..... ... ... ...... ..... .. .. .. .... ... 10 POWER STEERING OIL PUMP ...................... 25
CHECKING STATIONARY STEERING STEERING HOSES ......................................... 31
EFFORT ...... .. .......... .. .. .. .. .. .. .. .. .... .... .. ...... .. .. .. . 10 STEERING LINKAGE .................................... 31
CHECKING STEERING WHEEL
RETURN TO CENTER .................................. . 10

19-1
m SPkCIFICATIONS

GENERAL SPECIFICATIONS

Steering wheel diameter mm (in.) 403 (15.9)

Steering shaft type / Collapsible type
Gear box
Steering gear type Ball and nut, torsion bar type
Steering gear ratio 16.4
Oil pump
Oil pump type Vane type
Displacement 10.5 cc/rev. (0.64 in.3/rev.)

SERVICE SPECIFICATIONS

Standard values
Steering angle
Inner wheel 33°00’-;o

Outer wheel 29’00’

Steering wheel free play mm (in.) 25 (1.0) or less
Stationary steering effort N (lbs.) 37 (8.2) or less
V belt deflection mm (in.) 9-12 (.35-.47)
Mainshaft starting torque Ncm (m.lbs.) 25-65 (2-6)
Distance between top of balls and 13 (.5)
rack piston surface mm,(in.)
Cross-shaft end’play mm (in.) o-0.05 (O-.002)
Mainshaft total starting torque Ncm (in.lbs.) 50-90 (4-8)
Oil pump pressure kRa (psi)’ ’
7,500-8,200 (1,067-l ,166)
Gauge hose valve closed
Gauge hose valve opened 980 (142) or less
Tie rod ends ball joint center distance mm (in.) 297.5 (11.7)
Idler arm turning torque Ncm (inlbs.) 300-900 (26-78)
Spring scale reading N (lbs.) 25-75 (5.5-16.5)
Repair limits
Steering wheel free play mm (in.) 50 (2.0)
Steering gear backlash mm (in.) 0.5 (.02)
Service limits
Steering shaft runout mm (in.) 0.5 (.02)
Steering shaft length mm (in.) 750 f 5 (29.5 + .2)
Backlash between rack piston ball groove and balls mm (in.) 0.2 (.008)
Free length of flow control spring mm (in.) 36.5 (1.44)
Clearance between oil pump drive shaft and bushing mm (in.) 0.09 (.004)
Ball joint end play mm (in.) 1.5 (.06)
Joint assembly end play mm (in.) 0.2 (.008)

19-2
 SPECIFICAIWNS m
TORQUE SPECIFICATIONS Nm (ft.lbs.)

Steering column and shaft

Steering wheel lock nut 3 5-45 (26-33)
Column tube calmp 8-l 1 (6-8)
Dash panel cover 3-5 (2-4)
Joint assembly 30-35 (22-26)
Column bracket 8-12 (6-9)
Special bolt for column bracket 8- 11 (6-8)
Power steering gear box
Side cover 45-55 (33-40)
Adjusting bolt lock nut 30-45 (22-33)
Breather plug 3-4 (2-3)
Pitman arm installation 130-150 (94-108)
Gear box installation 55-65 (40-47)
Ball guides installation 3.5-4.5 (2.5-3.3)
Valve housing 45-55 (33-40)
Lock nut* 180-230 (130-166)’
Oil pump
Suction plate 6-10 (4-7)
Connector 50-70 (36-5 1)
Reservoir to reservoir bracket 6-10 (47)
Reservoir bracket to oil pump body 18-22 (13-16)
Oil pump bracket to oil pump body
Front 25-33 (1824)
Rear 14-21 (1@15)
Oil pump bracket to engine
Left 27-41 (2030)
Right 14-21 (1015)
Oil pump brace bolt 25-33 (18-24)
Pump bracket stay 14-21 (10-15)
Oil pump cover 18-22 (13-16)
Steering hoses
Pressure hose 30-40 (22-29)
Return hose 40-50 (29-36)
Clamp bolts 8-12 (6-9)
Breather stays 8 12 (6-9)
Steering linkage
Tie rod ends 45 (33)
Tie rod sockets and relay rod 45 (33)
Relay rod to pitman arm 45 (33)
Relay rod to idler arm 45 (33)
Idler arm and bracket 40-60 (29-43)
Tie rod end studs 65-80 (47-58)
Idler arm bracket and frame 55-65 (40-47)

NOTE
*If the special tool is used to measure the torque, the measurement should be 13 5-175 Nm (98-127 ft.lbs.).

19-3
 SPECIFICATIONS

LUBRICANTS .’

Specified lubricants Quantity

Power steering fluid Automatic transmission fluid 900 cc (54.9 in.?)

ATF DEXRON or DEXRON II type
Dash panel cover grommet Multipurpose grease SAE 53 1Oa, As required
NLGI grade #2
Cross-shaft oil seal lip Multipurpose grease SAE 53 1Oa, As required
NLGI grade #2EP
Side cover needle bearing Multipurpose grease SAE J3 lOa, As required
NLGI grade #2EP
U-packing of side cover Multipurpose grease SAE 53 lOa, As required
NLGI grade #2EP
Ball joint dust covers Multipurpose grease SAE 53 lOa, As required
NLGI grade #2EP
Idler arm support and bushings ‘i
Multipurpose grease SAE 53 lOa, As required.
NLGI grade #2EP

..

. 19-4
 SPECIAL POOLS m

Tool (Number and name) Use Tool (Number and name) Use

MB990635 “*” Disconnection of the MB990228 Measurement of

Steering linkage’ puller relay rod Preload socket mainshaft starting torque

MB990809 “*” Removal of the pitman MB990826 “D” Removal and installation
Pitman arm puller arm Torx wrench of the tilt bracket

MB990852 Removal and installa- MB990662 Measurement of oil

Housing locking nut special tion of the housing lock Oil pressure gauge pump pressure
nut

MB990853 “*” Removal and installa- MB990854 Installation of the snap

Top cover remover tion of the top cover Snap ring installer MA4

MB990925 Installation of the oil

Bearing and oil seal installer set seal and the ball bearing
(Refer to GROUP 3.)

“*“, “D” see page 2 for instructions.

19-5
Da TROUEILESHOOTING

Symptom Probable cause Remedy

Steering wheel return malfunction Steering components damaged Replace

Incorrect tire pressure Adjust the tire pressure
Steering components binding Repair or replace

Steering operation is “heavy” Incorrect tire pressure Adjust the tire pressure

Loose’belt Adjust the belt tension

Damaged belt Replace the belt

Low fluid level ’ .Replenish fluid

Air in fluid line Bleed the system

Restricted hose(s) Correct the hose routing or

replace the hose(s)

Fluid leakage i I Locate and correct

3
Incorrect wheel alignment Adjust the wheel alignment
(especially caster)
Binding linkage ball joint Check the ball joint turning
torque, and replace the ball
joint if necessary
Malfunction of gear box Check, and replace the gear box if
necessary
Malfunction of oil pump Check the oil pump pressure, and
repair oil pump(Refer to p. 19-12.)
Steering wheel pulls to one side ( Pxcessive steering wheel play Adjust the steering wheel play
I
Insufficient tire inflation pressure Adjust the tire pressure
(Refer to GROUP 22)
Unevenly worn or deformed tire(s) Rotate the wheels or replace
the tire(s) (Refer to GROUP 22)
Dragging brakes, Adjust (Refer to GROUP 5)
Deteriorated or broken front spring Replace
Distorted knuckle arm
Incorrect wheel alignment Adjust the wheel alignment
(Refer to GROUP 2)
Damaged wheel b,earing Replace
Ret&&en or replace
(Refer to GROUP 2)
Retighten
Worn or damaged. ball joints Replace
Deteriorated or .broken lower arm bushing
Incorrect installation or internal damage Correct or replace
of gear box

19-6
 TROUBLESHOOTING
E!a

i
Symptom Probable cause ’ Remedy
Steering wheel pulls to one side Malfunction of shock absorber Replace
(continued)
Uneven wheel base Adjust the body alignment
(between right side and left side) (Refer to GROUP 13)
Steering wheel vibrates Insufficient tire inflation pressure Adjust the tire pressure
(Refer to GROUP 22)

Unevenly worn or deformed tire(s) Rotate the wheelsor replacethe

tire(s) (Refer to GROUP 22)

Loosehub nut Retighten (Refer to GROUP 2)

Excessiverunout, or unbalanceof tire Adjust the wheel balance,or

and wheel replacewheel(s) and/or tire(s)
(Refer to GROUP 22)

Poor wheel alignment Adjust the wheel alignment

(Refer to GROUP 2)

Damagedwheel bearing Replace

Distorted or looselower arm Retighten or replace

(Refer to GROUP 2) ’
Bent or damagedlinkage Repair or replace

Looselinkagejoints 1 Retighten

Worn or damagedball joints Replace

Malfunction of front suspension Check and adjust; replacethe

parts if necessary
(Refer to GROUP 2)

Incorrect installation or internal damage Correct or replace

of gearbox

Malfunction of shock absorber Replace

Loosejoint assembly Retighten

Road shock is felt in steering wheel Insufficient steeringwheel play Adjust the steeringwheel play

Insufficient tire inflation pressure Adjust the tire pressure “’ .’

(Refer to GROUP 22)

Unevenly worn or deformed tire(s) Rotate the wheelsor replace

the tire(s)

Malfunction of shock absorber Replace

Poor recovery of steering wheel to Insufficient tire inflation pressure Adjust the tire pressure
straight ahead position i\ (Refer to GROUP 22)

Excessivemainshaft preload Adjust the preload

Stuck or damagedball joint Replace
Improper wheel alignment angles Adjust the wheel alignment
(Refer to GROUP 2)
I

19-7
 TROUE3LESHOOTIE(G

Symptom . ; Probable cause Remedy

Poor recovery of steermg wheel to Seizure of steerirtg shaft bearing Lubricate or replace
straight ahead position (continued) Seizure of steering column bearing

Rattling noise Loose installatiori. of oil pump or gear box Retighten the oil pump or
I gear box

Steering linkage looseness or play Retighten or replace the steering

linkage
Loose oil pump pulley nut Retighten the oil pump pulley nut

Interference around column or between Correct, or replace the pressure

pressure hose and/ other parts hose and the parts around the
column

Abnormal noise inside gear box or oil pump Replace the gear box or oil pump

Shrill noise Air sucked into oeil pump Check the oil level and hose clips;
bleed the system or replace the
oil pump
Oil pump seizure Replace the oil pump

Check the oil level and hose clips;

r Damage to the gear box port section

Malfunction of return hose
Replace the gear box
Replace the hose
Whistling noise Malfunction of gear box port section Replace the gear box
Droning noise Loose mounting bolt on oil pump or oil pump Retighten the pump bracket
bracket or pump mounting bolt

: I-Poor condition’of oil pump body* Replace the oil pump

Squeaking noise Malfunction of.steering stopper contact Check and adjust the steering
stopper
Interference of wheel with vehicle body Adjust the steering angle

I----
Interference of steering shaft and joint assembly Reposition the interfering parts
with other parts
Malfunction of gear box Replace the gear box
Vibration**
k;ear box

NOTE
* A slight beatin noise is produced by the oil pump; this is not a malfunction. (This noise occurs particularly during stationary
steering effort. e
** A slight vibration may be felt during stationary steering, effort due to the condition of the road surface.
To check whether the vibration is a problem or not, test drive the vehicle on a dry concrete or asphalt surface.
Moreover,-a very slight amount of vibration is not a mallfunction.

19-8
 TROUBLESHOOTING m

,
Symptom Probable cause Remedy
Oil leakage from hose connections Improperly tightened flare nut Check, and repair or replace
Incorrectly inserted hose
Improperly clamped hose
Oil leakage from hose assembly Damaged or clogged hose Replace
Hose connector malfunction
Oil leakage from oil reservoir Leaking reservoir Replace
Improperly welded pipe
Overflow 1 Bleed the system or adjust the oil
level
Oil leakage from oil pump Malfunction of oil pump housing Replace the oil pump
Malfunction of O-ring and/or oil seal Replace the O-ring and oil seal
Oil leakage from gear box Malfunction of gear box housing Replace the gear box
(including leakage from air hole)
Malfunction of O-ring and/or oil seal Replace the O-ring and oil seal

19-9
m SERVICE ADJUSTMENT

:
PROCEDURES

CHECKING STEERING WYEEL FREE PLAY

1. With the engine ‘turned. off and the steering’ wheel in
the straight-ahead posi&n, apply a force of 5 N (1.1 lbs.)
to the steerjng wheel in the peripheral direction.
2. Measure the play at the circumference of the steering
wheel. (60D578)

Steering wheel free play .[Repair limit.] . . . . Y. . . .

50 mm (Zl.0 in.)

60057 8

3. If the measured value exceeds the repair limit, screw in

the, cross-shaft adjusting bolt until the steering wheel free
play meets specifications. (S 13 127) .
Caution ‘. 4
If the adjusting bolt is oveitightened, moiz steering effort
will be required and returri of the wheel will & adversely
affected.
‘-
Mainshaft starting torque . . . . . . . . . . . . . . . .’ . . . .
25-65 Ncm (2-6 ‘in. lbs.)

4. If steering wheel free play cannot be adjusted to meet

specifications, check the mainshaft or steering linkage
ball joint for wear.
CHECKING STATIONARY. STEERING EFFORT
1. Position the vehicle on, a level surface with the steering
wheel in the straight-ahead position.
2. Run the engine at 1,000 rpm.
3. Measure the turning force with a spring scale by turning
the steering wheel clockwise and counterclockwise one
and a half turns. (13WOO6)
Stationary steering effort . . . . . . . . . . 37 N (8.2 lbs.)

4. If the stationary steering effort exceeds the standard

value, check for belt looseness, damage, insufficient oil, 13WOO6
air mixed into oil, collapsed or twisted hoses, etc., and
repair as necessary.
CHECKING STEERING WHEEL RETURN TO CElNTER
1. To check for the return of steering wheel to center,
during a test drive, check the following points.
2. Make both gentle and sharp turns and check tlo get a feel
that there is no appreciable difference either in steering
effort or return to center between right and left turns.
NOTE
When the steering wheel is turned abruptly, monientary hard
steering might result, but this does not indicate ,a problem,
since it is caused by low oil pump delivery during idling,

19-10
 SERVICE ADJUSTMENT PROCEDURES

CHECKING POWER STEERING BELT TENSION:.

1. Check the belt for looseness by applying pressure of
100 N (22 lbs.) to the center of the belt. (Y13613)
V belt deflection . . . . . . . . . . 9-12 mm (.35-.47 in.)

2. If the measured value exceeds the standard value, adjust

the belt tension.

CHECKING FLUID LEVEL

1. Start the engine on a level surface, and turn the steering
wheel several times fully to the right and left while the
engine is idling, and then check the fluid for contami-
nation.
NOTE
Replace the fluid if it has bubbles or is somewhat white in
color.
2. Fill the reservoir to the MAX level with the specified
automatic transmission fluid. (13Y622, 13S6 17)
Specified fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic transmission fluid ATF DEXRON
or DEXRON II type

BLEEDING
Check the stationary steering effort. If it is not within the
range of the standard value, it is possible that there is air in
the system. Bleed the system.
1. Make certain the reservoir is full.
2. Jack up the front wheels.
3. Disconnect and ground the coil high tension cable.
4. Crank the engine with the starter motor while turning the
steering wheel completely to the right and left.
Repeat several times.
5. Lower the front wheels.
6. Connect one end of a clear vinyl hose to the breather
plug on the gear box, and place the other end in a con-
tainer. Start the engine and run at idle speed.

19-11
m SERVICE ADJUSTMENT

7. Loosen the breather plug and then turn the steering

PROCEDURES

wheel completely to the right and left continuously until

air bubbles no longer appear in the fluid comj& out of
the tube. (Y 13620)
NOTE
Do not allow the power steering reservoir to run dry.
8. After bleeding, tighten the breather plug and remove the
tube.
9. Check the fluid level, and refill if necessary.
NOTE
When turning the steering wheel completely to the: right and
left, check that the fluid level fluctuation is less than 4 mm
(. 16 in.) at a constant’temperature.
OIL PUMP PRESSURE TESF
1. Disconnect the pressure hose from the oil .pump and Thermometer
connect the special tool as illustrated. (C 13692)
NOTE
Use the adapter to connect the special tool to the pump.
2. ,Bleed the power steering system.
3. Start the engine and operate it until the fluid telmperature
reaches about 55°C (131°F).
4. Run the engine at 1,000 rpm.
5. Completely close the shut-off valve of the special tool
and read the gauge pressure.
Cl 3692
Caution
Do not close the shutoff valve of the special tobl. for more
than 3 seconds.
If the hydraulic pressure is not within the range of the
standard value, replace the oil pump.
Oil pump pressure
Valve closed . . . . . . . . . . . . . . . 7,500~8,200 kPa
( 1,067- 1,166 psi)
Valve opened . . . . . . . . 980 kPa (142 psi) or less

6. Completely open the shut-off valve of the special tool

and read the gauge pressure. If the hydraulic’ pressure is
not within the range of the standard value, dheck for a
clogged or collapsed oil line, or for a clogged’oil passage
inside the gear box.
7. With the shut-off valve’ of the special tool completely
open, and turn the steering wheel completely to the right
or left, then measure the maximum oil pressure in this
condition. If the maximum oil pressure is not within the
range of the standard value, (valve closed) the v,alve of the
gear box is faulty, and the gear box must be replaced.

19-12
 SERVICE ADJUSTMENT PROCEDURES
m

CHECKING BALL JOINT END PLAY

Grip the ball joint with pliers and, compressing the stud
fully, measure the deflection.

Ball joint end play [Service limit] . .. . . . .. . . . . .

1.5 mm (.06 in.)

CHECKING STEERING ANGLE

1. Place the front wheel on a turning radius gauge and meas-
ure the steering angle.

Steering angle
Inner wheel . . . . . . . . . . . . . . . . . . . . 33” 00’ _$J

Outer wheel . . . . . . . . . . . . . . . . . . . . . . . . 29’00’

13FOO6

2. Adjust the ‘steering angle of each wheel by turning the

stop bolt of the knuckle arm.
Caution
Be sure that the toe-in is properly adjusted before adjusting
the steering angle.

19-13
 COMPONENT SERVICE,- STEERING COLUMN AND SHAFT

COMPONENTS

1. Snap ring
2. Steering shaft
3. Steering wheel
4. Center pad
5. Boot
6. Joint assembly
7. Dash panel cover
8. Column tube, lower
9. Column bushing
10. Column support
11. Column tube, upper
12. Column bracket
13. Column tube clamp

Nm ft.lbs.

A 35-45 26-33
B 30-35 22-26
c 3-5 2-4
D 8-12 6-9
E 8-l 1 68
F 8-11 6-8

REMOVAL
1. Remove the center pad.
2. Remove the steering wheel. (13W506)
3. Remove the instrument cluster.
4. Remove the column cover and then remove tlhe column
switch assembly.
5. Remove the heater duct. (Refer to GROUP 24.)
6. Ldosen the dash panel cover.

7. Disconnect the joint assembly from the steering gear box.

I 13W5021

19-14
 COMPONENT SERVICE- STEERING COLUMN AND SHAFT
m

8. Remove the Torx bolt and the clamping bolts of the

column support, and remove the steering column assembly.

DISASSEMBLY
1. Disconnect the joint assembly from the steering shaft.

I 13woo3

2. Undo the column tube clamp, and then separate the

upper column tube from the lower column tube.
(13W529)
3. Unlock the steering lock and remove the steering shaft’
from the lower column tube.
4. Remove the dash panel cover from the lower column
tube.

5. If it is necessary to remove the steering lock, cut a groove

on the head of each special bolt with a metal saw, and
remove the steering lock with a screwdriver.
 COMPONENT SERVICE- STEERING COLUMN AND SHAFT

6. If it is necessary to remove the column bracket of the

upper tube, cut a groove on the head of each special bolt
with a metal saw, and remove the column bracket with a
screwdriver.

INSPECTION
1. Check tilt bracket for cracks or damage.
2. Check column bushing for damage.
3. Check dash panel cover for damage.
4. Check steering shaft bearing for wear.
5. Check steering shaft for length, damage and deformation.

Steering shaft runout .[Service limit].......,..

0.5 mm (.02 in.)
Steering shaft length[ Service limit] . . . . . . . : ,.. .
1 745 (29.33 in.)

6. Check joint assembly for end play. (138606)

Joint assembly end play [Service limit] . . . . . . . .
0.2 mm (:008 in.)

REASSEMBLY
1. When mounting the column bracket onto the column,
tighten the special bolts until the heads twist off.

19-16
 COMPONENT SERVICE-STEERING COLUMN AND SHAFT m

2. Attach the column bushing to the upper and lower

column tubes, and then tighten the column tube clamp
bolts to the specified torque. (13W528)

Column tube clamp bolts tightening torque . . . . . .

8-l 1 Nm (6-8 ft.lbs.)

3. When installing the steering lock onto the column, install

it loosely in alignment with the column boss and check
that it works properly, and then tighten the special bolts
until the heads twist off. (13W505)

4. Apply the specified multipurpose grease to the dash panel

cover grommet. (133620)

Recommended multipurpose grease . . . . . . . . . , . .

SAE 53 lOa, NLGI grade #2

INSTALLATION
1. Loosely connect the joint assembly to the steering shaft
and to the steering gear box.
Caution
Install the boot with the bellows toward the steering column.
Also, be sure that the boots are not damaged by the bolts
when the joint assembly is installed.
2. Install the column assembly to pedal support.
3. Tighten the joint assembly bolt.
4. Attach the dash panel cover and apply sealant around the
bolt holes. (133694)
Caution
Do not loosen the column tube clamp bolts. If the clamp
bolts should be loosened, retighten them securely while pull-
ing the steering shaft out fully toward the interior side.
5. Position the front wheels in the’ straight-ahead position
and install the steering wheel.
6. Tighten the steering wheel lock nut to the specified
torque.

-Steering wheel lock nut tightening torque . . . . . . .

35-45 Nm (26-33 ft.lbs.)

NOTE
Check to be sure that when the steering wheel is turned
clockwise or counterclockwise and returned, the turn signal is
automatically released.
 m COMPONENT SERVICE-POWER STEERING GEAR BOX

COMPONENTS

1. Breather plug cap

2. Breather plug
3. Side cover
4. O-ring
5. U-packing
6. Adjusting plate
7. Adjusting bolt
8. Cross-shaft
9. Gear bdx housing
10. Oil seal
11. Pitman arm
12. Nut ’

13. Seal ring

14. Rack piston
15. Valve housing
16. Needle thrust bearing
17. Mainshaft
18. Ball bearing
19. Oil seal ’
20. Top cover
21. Valve housing lock nut
22. Dust cover

Nm ft.lbs.

45-55 33-40
30-45 22-33
3.040 2-3
13cL150 94-108
55-65 40-47
3.5-4.5 2.5-3.3
45-55 33-40
180-230 130-166

13W521

REMOVAL
1. Remove the clamp bolt which connects the joint assem-
bly to the gear box mainshaft.
2. Disconnect the pressure hose and return hose from the
gear box. (14W5 14)
I

19-18
 COMPONENT SERVICE- POWER STEERING GEAR BOX rn’

3. Disconnect the pitman arm from the relay rod with the
special tool shown in the illustration.

4. Remove the gear box assembly.

5. Remove the pitman arm from,the gear box assembly with
the special tool shown in the illustration. (138729)

SEALS REPLACEMENT
Side Cover and Gear Box Housing
1. Place the mainshaft and cross-shaft in the straight-ahead
position.
2. Remove the breather plug, and drain off the steering gear
Oil.
3. Remove the side cover attaching bolts. (Y 1367 1)
4. Remove the lock nut of the adjusting bolt, and screw in
the adjusting bolt so that the side cover rises slightly.

5. Tap the bottom of the cross-shaft with a plastic hammer

to remove the cross-shaft and the side cover. (Y 13019)
6. Remove the side cover from the cross-shaft by turning
the adjusting bolt.
Caution
Do not lose the needle bearing rollers.
m COMPONENT SERVICE- POWER STEERING GEAR BOX

7. Remove the needle rollers from the side cover. (13Y896)

8. Remove the O-ring and U-packing from the side cover.
\ U-packing

i 3ya9t

9. Remove the oil seal and U-packing from the gear box
housing.

U-packing

Oil seal

10. Apply specified multipurpose grease to the seal surface of

the U-packing and fit it into the side cover. (13’11896)
11. Apply specified automatic transmission fluid to the
O-ring, and attach it to the side cover.
12. Install the needle rollers into the side cover.
13. Apply specified multipurpose grease to the needle rollers.

13Y896
..

14. Apply specified multipurpose grease to the seal surface of

the U-packing, and fit it into the gear box housirig.
15. Apply specified automatic transmission fluid to the oil
seal lip, and press it into the gear box housing with the
special tools. (13WOO5) .
>.‘
-.
‘r:

19-20
*‘I.*
 COMPONENT SERVICE- POWER STEERING GEAR BOX m

16. Attach the side cover to the cross-shaft and temporarily

tighten the adjusting bolt lock nut.
17. Install the cross-shaft assembly (with the side cover) to
the gear box. (C 13 187)
Caution
1. Do not rotate the side cover during installation.
2. Take care not to damage the cross-shaft oil seal.

18. While turning the adjusting bolt, measure the mainshaft

total starting torque by using the special tool. (Y 1363 1)

Mainshaft total starting torque . . . . . . . . . . . . . . . .

50-90 Ncm (4-8 in.lbs.)

NOTE
Position the mainshaft in the center position during mea-
surement.
19. Tighten the adjusting bolt lock nut to the specified
torque.

Lock nut tightening torque . . . . . . . . . . . . . . . . . .

30-45 Nm (22-33 ft.lbs.)

Valve Housing and Top Cover

1. Remove the cross-shaft assembly. (Refer to p. 19-I 9.)
2. Remove the valve housing lock nut with the special tool
as illustrated. (13YO33)
3. Remove the valve housing bolts and remove the valve
housing and rack piston while holding the rack piston by
hand to avoid rotation,
Caution
Do not hold housing with rack piston facing downward,
otherwise the rack piston will fall off, scattering the steel
balls.

4. Remove the O-ring and seal ring from the rack piston and
remove O-rings from the valve housing.
I O-rings

13Y931

19-21
m COMPONENT SERVICE-POWER STEERING GEAR BOX

5. Remove the top cover from the.valve housing with the

special tool.

6.. Remove the ball bearing and the oil seal with a punch.

13S623

Y 13024

7. Apply specified multipurpose grease to the new oil seal,

then press the oil seal and ball bearing inl:o the top
cover with special tools.

MB990926

Y 1360E

8. Install the thinner thrust plate, needle thrust bearing and

thicker thrust plate into the top cover in the order shown
in the illustration. (C 13 18 1)
9. Attach the top cover to the valve housing.
Caution
Be careful that the thrust plates and the needle, thrust bear-
ing do not come off the ‘top cover.

Cl3181

19-22
 COMPONENT SERVICE-POWER STEERING GEAR BOX m

10. Apply specified automatic transmission fluid to the new

O-rings and new seal ring, then install them onto the rack I O-rings

piston and valve housing.

ig and

11. In order to fit in the assembly parts, use the special tool
and a spring scale, and tighten the top cover until the
force becomes 62-83 N (14-19 Ibs.). Then turn the top
cover lock nut until the force becomes 0 N (0 lbs.).
Caution
After tightening the top cover lock nut, rotate the mainshaft
to confirm that there is no binding or abnormal noise.

12. Measure the mainshaft starting torque with the special

tools as illustrated. (13Y85 7)
13. Tighten the top cover until’ the mainshaft starting torque
is 20-30 Ncm (1.8-2.7 in.lbs.) greater than the measured
value.
NOTE
Tighten the top cover gradually while measuring the starting
torque.

14. Tighten the valve housing lock nut to the specified torque
with the special tool as illustrated.
Lock nut tightening torque . . . . . . . . . . . . . . . . . .
180-230 Nm (130-66 ft.lbs.)
With special tool attached
135-175 Nm (98-127 ftlbs.)

Caution
Be sure that the top cover does not turn with the lock nut.

19-23
m COMPONENT SERVICE- POWER STEERING GEAR BOX

15. Measure the mainshaft starting torque by using. the

special tools as illustrated. If the measured (main&aft
starting torque does not comply with the standard value,
remove the valve housing lock nut and adjust the-tight-
ening of the top cover.
MB990228

Mainshaft starting torque . . . . . . . . . . . . . . . . . . . .

25-65 Ncm (2-6 in.lbs.)

16. Install valve housing assembly and cross-shaft assembly

to the gear box housing.
17. Adjust the mainshaft total starting torque and, tighten the
adjusting bolt lock nut. (Refer to p. 19-21.)

INSPECTION Mating-
marks
1. Install the pitman arm to the gear box with .the mating
marks aligned.

/ Y1365L

2. Measure the steering geaFbacklash at the pitman arm top

end with a dial indicator.

Steering gear backlash [Repair limit] . . . . . . . . . . .

0.5 mm CO2 in.)

19-24
 COMPONENT SERVICE- POWER STEERING GEAR BOX/
POWER STEERING OIL PUMP

INSTALLATION
1. Connect the pressure hose and the return hose to the gear
box. (Y 13620)
2. Pour specified automatic transmission fluid into the
reservoir, and then bleed the system. (Refer to p. 19-11,
12.)
3. Start the engine, run it for approximately five minutes at
2,000 rpm, and then check each seal for oil leakage.
Caution
If the gear box has been disassembled, be sure to check the
oil pressure. (Refer to p. 19-i2.)

POWER STEERING OIL PUMP

COMPONENTS

1. Drive belt
2. hction plate
3. Suction tutie
4. Pulley assembly
5. Connector
6: 0-rino
7. Flow control valve
8. Flow control spring
9. Cam ring
10. Rotor
11. Collar
12. Reservoir bracket
13. Reservoir cap
14. Oil filter
15. Reservoir
16. Pump cover
17. Snap ring
18. Vanes
19. Oil pump bracket
20. Oil pump body

Nm ft.lbs.

A 610 4-7
B 50-70 36-51
C 18-22 13-16
D 25-33 18-24
E 14-21 10-15
F 27-41 20-30

19-25
m COMPONENT SERVkPOWER STEERING OIL PUMP

REMOVAL
1. Remove the reservoir cap and disconnect the return hose
from the reservoir to drain the fluid. (13W533)
2. Jack up the front of the vehicle and support it with floor
stands.
3. Disconnect the coil high tension cable and crank the
engine over serveral times to drain the fluid from the
power steering system.

4. Loosen the brace bolts and lock bolt, and then remove
the drive belt. (13W534)
5. Disconnect the pressure hose form the oil pump.

6. Remove the oil pump ,and reservoir from th.e bracket.

(13W535)

DISASSEMBLY
1. Remove .the oil pump cover.

19-26
 COMPONENT SERVICE- POWER STEERING OIL PUMP

2. Remove the cam ring.

3. Remove the O-rings from the cam ring.
4. Remove the vanes from the rotor.

5. Remove the snap ring of the shaft with snap ring pliers I\ \ I

and separate the rotor from the shaft.

6. Tap the rotor side of the shaft lightly with a plastic

hammer, and take out the pulley assembly.

7. Remove the suction connector from the oil pump body. I -

8. Remove the O-ring from suction connector.
 COMPONENT SERVICE- POWER STEERING OIL PUMP

9. Remove the oil seal from the oil pump body.

10. Remove the connector from the oil pump body, and take
out the flow control valve and flow control spring.
(13K564)
11. Remove the O-ring from the connector. (Y 1366 1)
Caution
Do not disassemble the flow contol valve.

INSPECTION
1. Check flow control spring for spring free lengthi.
(13C210)
2. Check flor control valve for clogging.
3. Check pulley assembly for wear or damage.
4. Check V-belt for cracks and deterioration.
5. Check groove of rotor and vane for “stepped” wear.
6. Check contact surface of cam ring and vanes for “step-
ped” wear.
7. Check vanes for damage.
8. Check contact surface of pump body, and pump cover
with rotor for streak-like abrasion.
I 13C210

REASSEMBLY
1. Drive the oil seal into the pump body with the special
tools.

19-28
 COMPONENT SERVICE- POWER STEERING OIL PUMP
m

2. Gently move the pulley assembly up and down, and

measure the clearance between it and the bushing as
illustrated.

3. Install the rotor to the pulley assembly. When the rotor is

to be installed, face the countersunk portion to the
pump cover side. (C13214)

4. Apply automatic transmission fluid to the O-rings.

Recommended fluid........................
Automatic transmission fluid
ATF DEXRON or DEXRON II type

5. Install the O-rings to the cam ring.

Cl3214

6. Install the snap ring with the special tool as illustrated.

7. Install the cam ring to the pump body. (13C216)

8. Install the cam ring hole shown in the illustration so that
it aligns with the dowel protruding from the oil pump
body. (13Y939)
Pump body side

19-29
 COMPONENT SERVICE- POWER STEERING OIL PUMP

9. Apply automatic transmission fluid to the vanes and

install the vanes on the rotor, paying close attention
to the installation direction. (C 132 17) Direct round edge to the cam ring

Recommended fluid . . . . . . . . . . . . . . . . . . . . . . . .
Automatic transmissi0.n fluid
, ’ ATF DEXRON or DEXRON II type
,-
ring

Vane

13K662 Cl3217

10. Install the pump cover. (13Y94 1)

11. Apply automatic transmission fluid to the ‘O-ring and
install O-ring to the suction connector.
12. Install the suction connector.

INSTALLATION
1. Mount the oil pump onto the oil pump bracket.
2. Install the drive belt, and adjust the deflection. (Refer to
p. 19-11.)
3. Connect the pressure hose. and return hose to the oil
pump. .
NOTE
Install the hoses so that they are not twisted armso that they
do not come in contact with any other parts.
4. Fill with automatic transmission fluid.
(Refer to p. 19-11;)
5. Bleed the system. (Refer to p. 19-l 1.)
6. Check the oil pump pressure. (Refer to p. 19-,12.)
7. Torque all parts to specifications during assemlbly.

19-30
COMPONENTS

1. Pressure hose
2. Return hose
3. Breather hose
4. Breather pipe

Nm ft.lbs.

A 30-40 22-29
B 40-50 29-36
C B-l 2 6-9

STEERING LINKAGE
COMPONENTS

1. Idler arm support

2. Idler arm assembly
3. Idler arm bushing
4. Tie rod end dust cover
5. Tie rod assembly, right
6. Relay rod
7. Tie rod assembly, left

Nm ft.lbs.

A 55-65 40-47
B 45 33
C 40-60 29-43
D 65-80 47-58

13W518

REMOVAL
Tie Rods and Relay Rod
1. Loosen the nut on the ball joint and remove the linkage
by using the special tool as illustrated. (138668)
2. Disassemble the tie rod.
NOTE
The outer tie rod end is left threaded and the inner tie rod
end is right threaded.
 I.
COMPONENT”SERVICE- STEERING LlNK/iGi

Idler Arm Assembly

1. Detach the relay rod from the idler arm by using the
special tool. (13W501)
2. Remove the idler arm assembly, (13W501)
3. Disassemble the idler arm assembly.

Ball Joint Dust Cover

Remove the dust cover and O-ring from the ball joint.

INSPECTION
1. Check idler arm support for damage or deformation.
2. Check idler arm, for damage or deformation.
3. Check idler arm bushings for wear or deterioration.
4. Check dust covers and O-rings for damage or deteriora-
tion.
5. Check tie rods for damage or deformation.
6. Check relay rod for bends or damage.

INSTALLATION
Ball Joint Dust Cover
1. Before installing the dust cover, apply the: ‘specified
multipurpose grease to the cover lip and the interior.

Recommeded multipurpose grease . . . . . , . . . . , . .

SAE J3 lOa, NLGI grade. #2EP

2.’ Apply packing sealant to the-tie rod mounting surface.

‘.

19-32
 COMPONENT SERVICE- STEERING LINKAGE m

Tie Rod
1. Apply the specified multipurpose grease to the threaded
portion of the tie rods, and then adjust the tie rod
so that the distance between the stud bolts of the tie rod
agrees with the standard value. (Y 13569)

Tie rod ends ball joint center distance A . , . , . . . .

326.5 mm (12.85 in.)

Caution
Tie rod end tightness, left to right, should be uniform.
2. Connect the tie rod to the steering arm and to the relay I Y 13569
rod. Torque to specification and insert cotter pins.
3. Adjust toe-in. (Refer to GROUP 2.)

Idler Arm Assembly

1. Apply a thin coat of the specified multipurpose grease to
the arm support and bushings. ( 13WOO1)
Recommended multipurpose grease . . . . . . . . . . . .
SAE J3 1Oa, NLGI grade #2EP
2. Insert the bushings into the idler arm.
3. Insert the support into the idler arm.
NOTE
The washer should be installed with the knurled surface
facing the bushing.
4. Measure the turning torque of the idler arm with a spring
scale. (S13115)
Idler arm turning torque . . . . , . . . . . . . . . . . . . . . .
300-900 Ncm (26-78 inlbs.)
Turning force (when measured with a spring scale)
25-75 N (5.5-16.5 lbs.)