Part 2

RACK & PINION POWER STEERING GEAR ASSY
OVERHAUL





40. AIR TIGHTNESS TEST
a. Install SST to the rack housing.
SST 09631-12071 (09633-00010)
b. Apply a vacuum of 53 kPa (398 mm Hg, 15.65 inch Hg) for approximately 30 seconds.
c. Check that there is no change in the vacuum pressure.
If there is a change in the vacuum pressure, check the installation of the oil seals.





41. INSTALL POWER STEERING CONTROL VALVE UPPER OIL SEAL
a. Coat the control valve upper bearing with grease.
b. Coat a new control valve upper oil seal lip with power steering fluid.
c. Using SST and a press, install a new control valve upper oil seal.
SST 09950-70010 (09951-07150), 09950-60010 (09951-00180, 09952-06010, 09951-00320)

NOTICE: Make sure that the oil seal is installed in the correct direction.





d. Using SST and a press, install the control valve upper bearing.
SST 09950-70010 (09951-07150), 09950-60010 (09951-00180, 09952-06010, 09951-00340)





42. INSTALL POWER STEERING CONTROL VALVE
a. Expand 4 new valve spacers with your fingers.

NOTICE: Be careful not to overly expand the valve spacers.

b. Coat the 4 valve spacers with power steering fluid.
c. Install the 4 valve spacers to the control valve, and adjust with your fingers.





d. Carefully slide the tapered end of SST over the valve spacers until they fit to the control valve.
SST 09631-20081

NOTICE: Be careful not to damage the valve spacers.





e. Install the control valve into the valve housing.

NOTICE: Be careful not to damage the valve spacers and the oil seal lip.

HINT: Wrap vinyl tape around the serrated part of the control valve in order to prevent damaging the oil seal.





f. Coat a new oil seal lip with power steering fluid.
g. Using SST and a press, install the oil seal.
SST 09612-22011

NOTICE: Make sure that the oil seal is installed in the correct direction.

h. Apply grease to the needle roller bearing of the rack housing and the serrated part of the control valve.
i. Install a new gasket to the control valve housing.





j. Install the control valve housing together with the control valve to the rack housing with the 2 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)





k. Using SST, hold the control valve from rotating and install a new lock nut.
SST 09616-00011
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
l. Apply sealant to 2 or 3 threads of the rack housing cap.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent





m. Using a socket wrench (27 mm), install the rack housing cap.
Torque: 59 Nm (597 kgf-cm, 43 ft. lbs.)





n. Using a punch and a hammer, stake the rack housing cap and the rack housing.
43. INSTALL RACK GUIDE
a. Apply grease to the contact surface of the rack guide.
b. Install the rack guide and the compression spring.
c. Apply sealant to 2 or 3 threads of the rack guide spring cap.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
d. Temporarily install the rack guide spring cap.





44. ADJUST TOTAL PRELOAD
a. Temporarily install the RH and the LH rack end sub-assy, in order to prevent the oil seal from being damaged by the rack teeth.
b. Using SST, torque the rack guide spring cap.
SST 09631-10021
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)





c. Using SST, loosen the rack guide spring cap.
SST 09631-10021





d. Using SST, turn the control valve to right and left 1 or 2 times.
SST 09616-00011
e. Using SST, loosen the rack guide spring cap until the compression spring stops functioning.
SST 09631-10021





f. Using SST and a torque wrench, tighten the rack guide spring cap until the preload falls within specifications.
SST 09616-00011, 09631-10021
Preload (turning): 1.2 to 1.5 Nm (12.2 to 15.3 kgf-cm, 10.6 to 13.3 inch lbs.)
g. Apply sealant to 2 or 3 threads of the rack guide spring cap lock nut.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
h. Temporarily install the rack guide spring cap lock nut.





i. Using SST, hold the rack guide spring cap and using another SST, torque the spring cap lock nut.
SST 09616-00011, 09922-10010
Torque: 51 Nm (520 kgf-cm, 38 ft. lbs.)

NOTICE:
^ Use SST 09922-10010 following the direction shown in the illustration.
^ Use a torque wrench with a fulcrum length of 345 mm (13.58 inch).

j. Recheck the total preload.
Preload (turning): 1.2 to 1.5 Nm (12.2 to 15.3 kgf-cm, 10.6 to 13.3 inch lbs.)
k. Remove the RH and the LH rack end sub-assy.





l. Apply MP grease around the control valve shaft, as shown in the illustration.





m. Wrap vinyl tape around the spline of the control valve.
n. Install the dust cover to the control valve housing.





45. INSTALL STEERING RACK END SUB-ASSY
a. Install 2 new claw washers, and temporarily install the LH and the RH steering rack end sub-assy.

HINT: Align the claws of the claw washer with the steering rack grooves.

b. Using SST, install the 2 steering rack ends sub-assy.
SST 09922-10010
Torque: 60 Nm (615 kgf-cm, 45 ft. lbs.)

NOTICE:
^ Use SST 09922-10010 following the direction shown in the illustration.
^ Use a torque wrench with a fulcrum length of 345 mm (13.58 inch).

HINT: Using SST, hold the rack and install the steering rack end sub-assy.





c. Using a brass bar and a hammer, stake the 2 claw washers.

NOTICE: Avoid any impact to the steering rack.





46. INSPECT POWER STEERING RACK
a. Ensure that the holes of the steering rack ends are not clogged with grease.

HINT: If the hole is clogged, the pressure inside the boot will change after it is assembled and the steering wheel is turned.





47. INSTALL STEERING RACK BOOT NO.2
a. Apply silicon grease to the inside of the small opening of the rack boot No.2.
b. Install the rack boot No.2 to the groove on the rack housing.

NOTICE: Be careful not to damage or twist the boot.

48. INSTALL STEERING RACK BOOT NO.1

HINT: Perform the same procedure as for the rack boot No.2.





49. INSTALL STEERING RACK BOOT NO.2 CLAMP
a. Using SST, tighten the rack boot No.2 clamp, as shown in the illustration.
SST 09521-24010
Clearance: 3.0 mm (0.118 inch) or less

NOTICE: Be careful not to damage the boot.

50. INSTALL STEERING RACK BOOT NO.1 CLAMP
SST 09521-24010

HINT: Perform the same procedure as for the No.2 clamp.

51. INSTALL STEERING RACK BOOT CLIP
a. Using pliers, install the 2 boot clips.





52. INSTALL TIE ROD ASSY LH
a. Screw the lock nut and the tie rod assy LH on the rack end until the matchmarks are aligned.

HINT: After adjusting toe-in, torque the lock nut.

53. INSTALL TIE ROD ASSY RH

HINT: Perform the same procedure as for the LH.





54. INSTALL STEERING LEFT TURN PRESSURE TUBE
a. Coat 2 new O-rings with power steering fluid and install them to the left turn pressure tube.
b. Using SST, install the left turn pressure tube to the power steering gear assy.
SST 09023-38200
Torque: 11 Nm (113 kgf-cm, 8 ft. lbs.)

NOTICE: Use a torque wrench with a fulcrum length of 250 mm (9.84 inch).

HINT: This torque value is effective when SST is parallel to the torque wrench.

55. INSTALL STEERING RIGHT TURN PRESSURE TUBE SST 09023-38200

HINT: Perform the same procedure as for the left turn pressure tube.





56. INSTALL RACK & PINION POWER STEERING GEAR ASSY
a. Install the power steering gear assy with the 2 bolts and nuts.
Torque: 70 Nm (714 kgf-cm, 52 ft. lbs.)
57. INSTALL POWER STEERING RACK HOUSING HEAT INSULATOR (3MZ-FE ENGINE TYPE)





58. CONNECT PRESSURE FEED TUBE ASSY
a. Using SST, connect the pressure feed tube assy to the power steering gear assy.
SST 09023-12700
Torque: 22 Nm (227 kgf-cm, 16 ft. lbs.)

NOTICE: Use a torque wrench with a fulcrum length of 300 mm (11.81 inch).

HINT: This torque value is effective when SST is parallel to the torque wrench.





b. Using SST, connect the return tube assy to the power steering gear assy.
SST 09023-12700
Torque: 22 Nm (227 kgf-cm, 16 ft. lbs.)

NOTICE: Use a torque wrench with a fulcrum length of 300 mm (11.81 inch).

HINT: This torque value is effective when SST is parallel to the torque wrench.





c. 2AZ-FE: Install the tube clamp with the nut.
Torque: 9.8 Nm (100 kgf-cm, 87 inch lbs.)
d. 3MZ-FE: Install the tube clamp and the heat insulator with the nut.
Torque: 9.8 Nm (100 kgf-cm, 87 inch lbs.)





e. Install the tube clamp with the bolt.
Torque: 9.8 Nm (100 kgf-cm, 87 inch lbs.)





59. INSTALL FRONT STABILIZER BRACKET NO.1 LH
a. Install the stabilizer bar bush No.1 to the stabilizer bar.
b. Install the front stabilizer bracket No.1 LH with the 2 bolts.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
60. INSTALL FRONT STABILIZER BRACKET NO.1 RH

HINT: Perform the same procedure as for the LH.

61. INSTALL FRONT STABILIZER LINK ASSY LH
62. INSTALL FRONT STABILIZER LINK ASSY RH

HINT: Perform the same procedure as for the LH.

63. INSTALL TIE ROD ASSY LH
64. INSTALL TIE ROD ASSY RH

HINT: Perform the same procedure as for the LH.

65. INSTALL FRONT WHEEL
Torque: 103 Nm (1.050 kgf-cm, 76 ft. lbs.)





66. INSTALL STEERING INTERMEDIATE SHAFT ASSY
a. Align the matchmarks on the intermediate shaft assy and the power steering gear assy.
b. Install the bolt.
Torque: 35 Nm (360 kgf-cm, 26 ft. lbs.)





c. Tighten bolt B.
Torque: 35 Nm (360 kgf-cm, 26 ft. lbs.)
d. Install the hole cover No.2 to the hole cover No.1.
e. Install the clamp to the hole cover No.1 and tighten bolt A.
67. BLEED POWER STEERING FLUID
68. CHECK FOR FLUID LEAKS
69. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
70. INSPECT STEERING WHEEL CENTER POINT
71. PERFORM STEERING ANGLE SENSOR ZERO POINT CALIBRATION