Removal
Note: Wash off dirt and oil from the valve body, lines and reducer using solvent and a brush. Dry with compressed air.
1. Drain the power steering fluid.
2. Raise the front of the vehicle and secure it to safety stands in appropriate locations,
3. Remove the front wheels.
4. Vehicles with SRS: Before disconnecting the steering crosspiece, remove the steering wheel.
5. Remove the steering column cover.
6. Remove the lower steering cross member bolt and disconnect the steering cross member by sliding it towards the column.
7. Remove the cotter pin from the lock nut and remove the nut.
8. Install the 10mm hex nut on the ball joint. Make sure the 10mm hex nut matches the end of the steering pin, otherwise, the threaded part of the steering pin may be damaged by the special tool.
Note: Remove the steering knuckle using a 28mm puller (07MAC SL00200).
9. Disconnect the steering rod and the joint using a special tool.
Caution: Avoid damaging the steering knuckle boot.
10. Remove the left tie rod end (for right hand drive cars - right), then turn the steering rack to the right (for right hand drive vehicles left hand drive).
11. Disconnect the exhaust pipe A or TWC.
12. Disconnect the gearbox shift rod.
13. Loosen the 14mm nipple and disconnect the supply line.
14. Loosen the adjustable clamp and disconnect the return hose.
15. Loosen the 16mm fitting and remove the return hose from the valve body.
Caution: After disconnecting the hose and line, cover the openings of the hose and line with tape or a substitute to prevent foreign material from entering the valve body.
Note: Do not loosen lines A and B between the valve body and the cylinder.
Note: LHO shown, RHD is symmetrical.
16. Remove the stiffener.
Note: Some of the stiffener connecting bolts are used as steering gear mounting bolts. When these bolts are removed, the steering gear will tilt to the side.
17. Remove the mounting brackets.
18. Pull the rack and pinion mechanism down to release the drive pinion shaft from the bulkhead and remove the pinion shaft retaining sleeve.
19. Slide the rack and pinion mechanism to the right to release the left end of the steering rack and tilt the left side down to remove from the vehicle.
Caution: Be careful not to bend or damage the feed line and cylinder line when removing the steering gear.
Steering rack parts
Note:
- Wash the disassembled parts in the solution and dry them with compressed air. Do not immerse the rubber seals in the solution.
- Always replace O-rings and rubber seals with new ones before assembly.
- Apply power steering fluid or grease () to the parts indicated in the assembly diagram.
- Do not allow dust or other foreign material to enter the power steering system.
- Use appropriate special tools where necessary.
Installation
Caution: Be careful not to bend or damage the feed line and cylinder lines when installing the mechanism.
1. Before installing the mechanism, move the steering rack to the right (for RHD: left).
2. Install the mount protector onto the steering gear.
3. Install the pinion shaft cover and install the pinion shaft through the partition.
Note: Align the slot on the pinion drive shaft with the protrusion on the valve body.
4. Install the mounting brackets with two mechanism mounting bolts on the protector.
5. Secure the steering gear subframe with two gear mounting bolts and connecting bolts.
Caution: Make sure the air duct is not caught or pinched by the steering gear subframe.
Note: Install the bolts loosely first, then tighten them firmly for security.
6. Install the return hose joint by tightening the 16mm union nut.
7. Securely fasten the return hose and tighten the bolt clamp from the engine compartment
8. Connect the supply line and tighten the 14mm union nut.
Note: Make sure that the fluid lines, rear crossbar and other parts are not intertwined.
Note: LHD type shown, RHD type is symmetrical.
9. Center the steering rack while it is moving.
10. Before connecting the steering crosspiece, do the following.
For SRS:
Center the cable reel by rotating it clockwise first (about two turns) until the arrow reaches the "straight" position.
Without SRS (regular steering wheel)
Set the steering wheel in a strictly straight position by turning the wheel from lock to lock.
11. Slide the lower end of the steering crosspiece onto the pinion shaft (aligning the bolt hole and shaft groove on the same line), and tighten the bottom bolt.
Note:
- Connect the steering shaft and pinion shaft with the rack and SRS cable reel centered.
- Make sure the lower steering column bolt fits into the groove on the pinion shaft.
- If the steering wheel and rack are not centered after assembly, reconnect the lower end of the crosspiece.
12. Secure the steering cross housing with the clamp and brackets.
13. Vehicles with SRS: Install the steering wheel and airbag.
14. Attach the tie rod ends to the steering knuckles, tighten the lock nut to the specified torque and install new cotter pins.
Note: Before connecting the tie rod ends, check the threaded portion of the steering pin for contamination with grease, remove it if necessary.
Caution: Tighten the locknut to the lower torque required, then tighten it to align the groove with the pin hole. Do not try to align it in one line by loosening the nut.
15. Install the exhaust pipe or TWC.
16. Connect the gear shift rod.
17. Set the wheels straight.
18. Fill the system with power steering fluid and bleed air from the system.
19. After installation, perform the following checks.
- Start the engine, let it idle, and turn the steering wheel from lock to lock for a while to warm up the fluid.
- Check the steering gear housing for leaks.
- Adjusts the front finger.
- Check the steering wheel spoke angle. Adjust by turning the right and left steering rods if necessary.
Note: Turn the right and left steering rods equally.
Replacing the ball joint boot
1. Remove the boot retaining ring and boot.
Caution: Do not contaminate the boot installation area with grease.
2. Apply grease to the inner surface and edges of the boot.
3. Wipe off the grease from the ball joint sliding surface, then apply fresh grease to the bottom.
Attention:
- Maintains lubrication at the boot installation site and the conical surface of the ball pin.
- Keep the inside surface of the boot free of dust, dirt and other foreign objects.
4. Install the boot carefully into the boot recess, then squeeze the air out of the boot.
5. Install the special tool with the pressure bolt at the end of the tool aligned with the groove on the boot. Slide the locking ring from the tool into place.
Caution: After installing the boot, check the conical surface for grease contamination and wipe it off if necessary.