Steering system
Steering system
Common steps
Engine speed sensitive power steering
Check of power steering fluid ......................................................................................................................... N-1
Check of steering wheel and steering column ................................................................................................. N-2
Removal/installation of steering wheel and steering column .......................................................................... N-4
Disassembly Instructions of Steering Lock Bolt and Bracket ......................................................................... N-5
Removal/installation of steering and connecting rod ...................................................................................... N-6
Disassembly instructions of steering and joint ................................................................................................ N-7
Check of Steering and joint ........................................................................................................................... N-10
Removal/installation of power steering oil pump ......................................................................................... N-14
Disassembly/assembly power steering oil pump ........................................................................................... N-15
Decomposition description of power steering oil pump components ........................................................... N-16
Power steering
N-1
Common steps
Removal/installation of wheels and tires
● The description of this chapter doesn’t include
the installation steps of wheels and tires. After
the wheels removed, the tightening torque of
reinstallation will be: 88-127N.m
{9.0-13.0kgf.m, 65-94ft.lbf}
Removal/installation of power steering
components
● If the power steering fluid line used to have
been disconnected during the operation, M-III
or same type of ATF liquid (e.g. Dexron II )
shall be added after the operation completed.
Exhaust the air from the power line and check
for any leakages.
Disconnection/connection of joints
● Prior to carry out any operations requesting the
hand contact with a plug, the negative cable of
battery shall be disconnected. The cable can be
reconnected only after the work completed.
Engine speed sensitive power steering
Air exhaust
1. Check the oil level of power steering (Refer to
Check of Power Steering OIL; Check of Liquid
Level)
2. Jack up by use of a jack the front end of
vehicle and hold it with the safety bracket.
3. Turn back and forth several times the steering
wheel to the maximum with the engine flamed
out.
4. Recheck the oil level of power steering. If the
level decreases, add the power steering oil.
5. Repeat the steps 3 and 4 until the level
stabilized at the defined value.
6. Lay down the vehicle.
7. Start the engine and run it idle.
8. Turn back and forth several times the steering
wheel to the maximum.
9. Confirm that neither the power steering oil
foams, nor the level decreases.
10. When necessary, add the power steering oil and
repeat the steps 8 and 9.
Check of power steering fluid
Check of liquid level
1. Check the power steering fluid liquid level.
● If necessary, add the power steering fluid to the
specified level.
Type of power steering fluid
Power steering oil- ATF M-Ⅲ or Dexron
Check the leakage of power steering fluid
Caution:
● If keeping the steering wheel on the max.
steering position for more than 5s, the
temperature of power steering fluid may rise
very high and have adverse effect on the power
steering pump.
1. Start the engine and runs it idle.
2. Turn back and forth several times the steering
wheel to the maximum, enabling the power
steering fluid to reach everywhere.
Attention:
● Leakage may occur at the positions indicated
by the arrow in Fig.
2. Check whether there are any leakages.
Check of power steering fluid pressure
1. Fit up the special tool as shown in Fig.
2. Remove the HP tube from the oil pump and
connect the special tool.
Tightening torque:
30-44N·m {3.0-4.5kgf.m,22-32ft1·lbf}
Steering system
N-2
3. Exhaust the air from the system.
4. Fully open the pressure gauge valve.
5. Start the engine and back and forth several
times the steering wheel to the maximum
wheel, increasing the temperature of steering
liquid up to 50°-60°C{122-140°F}.
Caution:
● If the valve is closed more than 5s, the
temperature of power steering fluid will raise
very high and result in adverse effect on the
power steering pump.
6. Completely close the pressure gauge valve.
7. Increase the engine speed up to 1000-1500rpm
and measure the pressure of power steering
liquid.
● If the hydraulic pressure is not within the
specified range, repair or replace the
components of power steering pump.
Hydraulic pressure of power steering oil pump:
9.85-10.35Mpa
Caution
● If the steering wheel holds its maximum
steering position for more than 5s, the
temperature of power steering liquid will
increase very slow and have adverse effect on
the oil pump of power steering oil pump.
8. Fully open the pressure gauge valve and
increase the engine speed up to 1, 000-
1,500rpm;
9. Turn back and forth several times the steering
wheel to the maximum the steering wheel and
measure the hydraulic pressure produced in the
steering casing.
● If the pressure is not within the specified range,
repair or replace the steering components.
Pressure of steering liquid: 9.85-10.35Mpa
10. Remove the special tool
11. Install and screw in the HP tube and have the
tightening torque stay within the defined scope.
Tightening torque: 30-44N.m {3.0-4.5kgf.m ,
22-32ft1·lbf}
12. Exhaust the air from the system.
Check of steering wheel and steering
column
Check of steering wheel “run-out”
1. Stop the wheels in a position facing the front,
and slightly turn around the steering wheel to
confirm whether the amplitude of run-out is in
the specified range.
● if the amplitude of run-out is not within the
specified range, it is possible that the steering
knuckle is worn or the clearance of steering
gear excessive, the correction has to be made
as necessary.
Oscillation amplitude: 0-30mm {0-1.18in}
Check of steering wheel looseness
1. Swing the steering wheel in the direction as
shown in Fig..Check the swings of bearing
sleeve of steering column and steering shaft
hinge, the looseness of steering wheel and
steering column etc.,
Thermometer
Pressure gauge
Valve switch
Valve iron
Thermometer
Pressure gauge
Valve switch
Steering system
N-3
Check of steering wheel force
1. Check the following items
● Tire size and tire pressure.
● Steering liquid level.
● Drive belt tightness.
2. Stop the wheels on a solid and level roadway
and orient the wheels to the front.
3. Start the engine and increase the temperature of
power steering liquid up to 50°-
60°C {122-140°F}
Warning
● Remove the safety airbag module and install
properly after the check.
(Refer to the Safety Airbag System.
Removal/Installation of Airbag Module of
Driver-Sided Safety)
4. Remove the safety airbag module (Refer to the
Safety Airbag System).
5. Use a torque wrench to measure the steering
force F.
● If it is not within the specified range, pay
attention to the following items:
－ Whether there is air in the system?
－ Whether there are any leakages in the hose or
joints?
－ Whether the performances of power steering
oil pump and gear are in sound condition?
Steering force: 7.8N·m {80kgf }.cm , 69in.lbf
[maximum value]
Attention
● In order to judge whether the steering effect is
satisfactory, under the equivalent conditions
use the same method to check the steering of
another vehicle in same model and compare the
result of inspection.
● The steering will have different effect under the
following cases.
- Road conditions. Whether the roadway is wet
of dried, whether it is the asphalt pavement or
cement road.
- Tire conditions. E.g. the tire patterns, wears,
and tire pressure etc.,
Steering system
N-4
Removal/installation of steering wheel and steering column
Warning
● Improper handling of safety airbag module will induce sudden opening of safety airbag and result in
personnel injury, thus if it is necessary to process the safety airbag, please read first the “Warning of the
Safety Airbag”(Refer to the Safety Airbag System; Warning of Maintenance )
1. Remove as per the order shown in the following figure.
2. Assemble in the reversing order of disassembly.
1
Safety airbag: Refer to the Safety Airbag
System; Removal/Installation of Driver-Sided
Safety Airbag;
2
Lock nut
3
Steering wheel: Refer to the Disassembly
Instructions; Refer to the Installation
instructions
4
Steering column cover
5
Clock spring
6
Combination switch
7
Lower cover flap
8
Steering column: Refer to the Installation
instructions
9
Steering column gland
10
Steering column mounting seat
11
Dust cover
12
Steering coupling
13
Full-lock fixing bolts and brackets
14
Full -lock component
Steering system
N-5
Disassembly instructions of steering wheel
Caution
● When removing the steering wheel, do not
use the hammer to hit the steering shaft, for
this will result in steering column.
1. Park your vehicle while orienting the wheels to
the front.
2. Use a suitable puller to remove the steering
wheel.
Disassembly Instructions of Steering
Lock Bolt and Bracket
1. Use a hammer and chisel to cut a slot on the
lock bolt.
2. Use a straight screwdriver to remove the bolt.
3. Decompose the steering lock component.
Disassembly instructions of full-lock
component
Caution
● When replacing the full-lock component, the
anti-theft bolt has to be changed either.
1. Turn the ignition key in the “`ACC” position.
2. Pull out the full-lock component.
Installation instructions of steering lock bolt and
bracket the
1. Install the steering lock component on the
steering shaft.
2. Confirm that the locking operation is correct.
3. Fit up the steering lock bolt.
4. Tighten the bolt until the bolt head comes off.
Installation instructions of steering shaft
Caution
Do not use the shaft to knock the steering shaft.
1. Tighten the bolt A.
2. Tighten the bolt B from the right side.
3. Screw in the bolt D after the bolt C has been
tightened.
Installation instructions of steering wheel
1. Adjust the clock spring (Refer to the
Adjustment of Clock Spring of Safety Airbag
System)
2. Orient the wheels to the front and install the
steering wheel.
Check of steering column
Carry out the check as below. Replace the
components of steering shaft as necessary.
1. Whether the steering column bearing is
damaged.
2. Length of steering shaft: 834-836 mm
{32.8-32.9in}
2. Tilting operation
● Confirm that the adjusting rod is able to move
from the non-lock position steadily to the lock
position.
Steering system
N-6
● Confirm that the steering shaft is loosened
when the adjusting rod is locked.
Removal/installation of steering and
connecting rod
Caution
● Carry out the following operations, if the wheel
speed sensor in the ABS system is not going to
be removed first. When the wrong harness is
pulled, it will result in the break-circuit of
harness. Thus, prior to carry out the following
operation, remove the wheel speed sensor (at
the side of axle) and place it at a suitable place,
the wrong drawing of harness may be avoided.
1. Remove in the order as shown in the Table.
2. Install in the reversing order of removal.
3. After installation, check the toe-in of wheels
(Refer to the Positioning Parameters of Wheels,
Positioning Parameters of Front Wheels).
1
Bolt (intermediate shaft ): Refer to the Disassembly Instructions /
Refer to the Installation instructions
2 Cotter pin
3 Flange nut
4
Steering tie rod end ball:
Refer to the Disassembly Instructions;
Refer to the Disassembly Instructions
5 Hollow bolt
6 Oil return tube
7 Steering fixing bolt
8 oil pipe
9
Steering pinion and torsion rod:
Refer to the Disassembly Instructions
Locking
Adjusting rod
Unlocking
Steering system
N-7
Disassembly Instructions of steering tie rod
end ball
1. Remove the end rod nut.
2. Use a special tool to remove the steering
knuckle from the ended column.
Disassembly Instructions of bolt
(intermediate shaft)
● Make the alignment mark on the gear shaft and
steering casing body for correct installation.
Disassembly instructions of steering
and joint
● Pull out the steering and joint from the right
side.
Installation instructions of bolt
(intermediate shaft)
● After the mark aligned, install the intermediate
shaft and bolt.
Mark
Steering system
N-8
Decomposition of steering pinion and torsion rod
● Decompose as per the order shown in the Table.
1 Oil pipes 1 and 2
2 Inlet pipe
3 Outside tie rod assembly
4 Tie rod lock nut
5 Small clip
6 Dust cover
7 Clamp
8 Inside tie rod assembly
9
Lock nut(adjusting cap): Refer to
decomposition description
10
Adjusting cap
11
Spring
12
Briquetting plug
13
Lock bolt
14
Pinion shaft and valve chamber components
·Refer to the Decomposition Description
15
Pinion shaft components
·Refer to the Decomposition Description
16
Spring snap ring
17
Control valve
18
Seal ring
19
Pinion shaft
20
Valve body components
21
Oil seal:
Refer to the Decomposition Description
22
Upper bearing:
Refer to the Decomposition Description
23
Valve casing
24
“O” ring
25
Snap ring
26
Rack block
27
“O” ring
28
Rack bushing assembly
29
Piston
30
Oil seal
31
Gear rack
32
Rubber cushion block :
Refer to the Decomposition Description
33
Bracket
34
Steering casing
35
Steering tie rod ball dust cover
·Refer to the Decomposition Description
Steering system
N-9
Precautions to the decomposition of
steering tie rod
1. Take out the dust cover
2. Remove the steering tie rod
Precautions to the decomposition of lock
nut (adjusting cap)
● Use a special tool to remove the lock nut
Pinion shaft and valve chamber
components
1. Remove the connection gear shaft and the bolts
of valve chamber (2).
2. As shown in Fig., seize the gear shaft and pull
out the gear shaft and valve chamber
components.
Precautions to the decomposition of pinion
shaft components
● If difficult to pull out the pinion shaft, remove
it by use of compression way;
1. By use of the method as shown in Fig. push out
the pinion shaft from the valve chamber.
Decomposition description of snap spring
● Carefully remove the snap spring, avoiding
damage on the pinion shaft components.
Decomposition description of upper
bearing and oil seal
1. Fit up the special tool as shown in Fig.
2. Use the special tool to extrude the oil seal and
Upper bearing. Do not press the edge of valve
chamber.
Snap ring
Guide shaft collar
Steering system
N-10
Decomposition description of inner guide
sleeve and oil seal
1. Install the special tool onto the valve side;
2. Install the special tool in the gear chamber.
3. Extrude the oil seal and inner guide sleeve.
Disassembly Instructions of rubber
cushion block
● Use a special tool and a presser to extrude the
rubber pad from the steering casing body.
Decomposition description of steering tie
rod ball dust cover
1. Place the end of tie rod on a jig and clamp it.
2. Clamp the end of tie rod as per the angle shown
in Fig. and use a chisel to align with the dust
cover.
3. Hit with a hammer, the chisel to remove the
dust cover.
Check of Steering and joint
Check of gear rack
1. Check the gear rack for any fracture, damage
and broken teeth.
● If yes, replace the gear rack.
2. Measure the radial run-out of gear rack. If it is
not within the specified range, replace the gear
rack.
Range of radial run-out
Near the point A: 0.15mm{0.006in}
Near the point B: 0.20mm{0.008in}
Check of steering tie rod ball
1. Check whether the end ball of tie rod is
damaged and the dust cover broken. Replace
when necessary.
2. Check whether the end ball is loosened.
Replace the tie rod end ball when necessary.
3. Turn the end ball 5 times.
4. Use a special tool and spring balance to
measure the rotation torque of end ball.
● If it is not within the specified range, replace
the tie rod end ball.
Steering system
N-11
Rotation torque:
0.4-2.7N·m {3.5-26.0kgf.Cm, 3.1-22.5in.lbf}
Reading on the spring balance
3.4-25.5N {0.35-2.60kgf, 0.8-5.71bf}
Check of steering tie rod
1. Check whether the tie rod is bent or damaged.
Replace it when necessary.
2. Check whether the ball nodes are loosened and
replace them when necessary.
3. Swing around the tie rod for 5 times.
4. Use a spring balance to measure the swing
torque.
● If the torque is not within the specified range,
replace the tie rod.
Swing torque:
0.1-4.0N·m(1-39kgf.cm, 0.9-30.8in.lbf}
Reading of spring balance:
0.6-24.5N{0.06-2.50kgf, 0.13-5.501bf}
Steering system
N-12
Installation of steering and joint
1. Install in the order shown in the Table.
1
Dust cover of steering tie rod ball
·Refer to the Installation Instructions
2
Rubber cushion block:
Refer to the Installation Instructions
3 Steering casing
4 Bracket
5 Gear rack
6 Oil seal: Refer to the Installation Instructions
7 Piston
8 Rack bushings assembly
9 “O” ring
10 Rack block
11 Snap ring
12 “O” ring
13 Valve casing
14 Oil seal
15
Upper bearing: Refer to the Installation
instructions
16 Pinion shaft
17
Seal ring: Refer to the Installation
instructions
18 Control valve
19 Spring snap ring
20 Lock bolt
21 Briquetting plug
22 Spring
23
adjusting cap:
Refer to the Installation Instructions
24
Lock nut(adjusting cap): Refer to the
Installation Instructions
25 Inside tie rod assembly
26 Dust cover
27 Clamp
28 Small clip
29 Tie rod lock nut
30 Outside tie rod assembly
31 Intake oil pipe
32 Oil pipes 1 and 2
Steering system
N-13
Installation instructions of steering tie rod
ball dust cover
1. Wipe out greasy dirt on the ball joint;
2. Add a few grease in the new dust cover.
3. Use a special tool and a presser to fit up the
dust cover onto the tie rod end ball.
4. Wipe out all exposed grease.
Installation instructions of rubber cushion
block
1. Smear soapsuds on the rubber part of rubber
pad.
2. Use a special tool and a presser to press the
rubber spacer block until then end of rubber
comes out of the casing.
3. Turn over the casing, press the rubber spacer
block until it comes out of another end.
4. The rubber spacer block shall be aligned with
the steel tube.
Installation instructions of upper bearing
1. Smear suitable amount of grease on the new
upper bearing.
2. Use a special tool to press in the bearing.
Installation instructions of seal ring
1. Use a special tool to fit up a new seal ring on
the valve body of gear shaft.
2. After installation, use a special tool to put the
seal ring in place.
3. Fit up the snap ring
Installation instructions of adjusting cap
1. Place the gear rack in the middle place.
2. Tighten the adjusting cap, enabling its
tightening torque to reach to 19.6N.m
{2.0kgf.m,14.5ft.1bf} for three times, and then
use a special tool to turn the end cap for 23°.
3. Smear a layer of sealant on the threads of lock
nut.
4. Connect the lock nut
5. Use a special tool and a spring balance to
measure the torque of adjusting rod.
● If non-conform to the standard, repeat the steps
2-5.
Steering system
N-14
Standard
Position of gear rack when it is in the center (in
the middle of steering wheel)
1.0-1.4N.m {10-14kgf.cm, 8.7-12.1 in.lbf}
[Reading of spring balance]
9.9-13.7N {1.0-1.4kgf, 2.2-3.Olbf}
6. Use a special tool to fit up the lock nut
Tightening torque:
40-49N·m {4.0-5.0kgf.m, 29-36ft.lbf}
Check of air tightness
1. Connect the special tool with gear chamber of
booster cylinder
2. Use the vacuum pump to apply the vacuum of
53.3kpa{400mmHg,15.7inHg) in the cylinder
and maintain the vacuum at least for 30s.
● If unable to maintain this vacuum degree,
replace the oil seal.
Removal/installation of power
steering oil pump
1. Remove in the order as shown in the Table.
2. Install in the reversing order of removal.
3. Adjust the drive belt (Refer to the Adjustment
of Drive Belt and Drive Belt).
1 Engine harness joint
2 Punch bolt
3 Seal spacer
4 HP oil pipe
5 Oil suction hose
6 Adjusting nut and bolt
7 Adjusting bolt
8 Drive belt
9 Tightening bolt
10 Tightening bolt
11 Steering oil pump assembly
Steering system
N-15
Disassembly/assembly power steering oil pump
Attention
The following operations can be carried out only when the “O” ring and oil seal are to be replaced. If
necessary to check other items, the component of pump body shall be replaced.
1. Disassemble in the order as shown in the Table.
2. The assembly is in the reversing order of disassembly.
1
Components of power steering oil pump:
Refer to the Decomposition Description
2 Bolt
3 Oil suction pipe
4 “O" ring
5 Components of pressure switch
6
Rear pump body:
Refer to the Assembly Description
7 “O” ring
8 Side disc
9
Internal camshaft:
Refer to the Assembly Description
10
Snap ring
11
Rotor
12
Blade:
Refer to the Assembly Description
13
Front pump body
14
Shaft group body
15
Oil seal: Refer to Assembly Description
Steering system
N-16
Decomposition description of power
steering oil pump components
Caution
● When clamping with a vice, a special tool shall
be used to prevent damage on the oil pump.
Installation instructions of oil seal
Caution: The pump body shall be properly
positioned.
1. Use a special tool and a hammer to fit up the
oil seal.
Installation instructions of blades
1. Place the blades in the rotor, the round edge of
blade shall get in touch with the inner edge of
internal cam rim.
Installation instructions of internal cam
ring
1. Face the mark upward and contain the internal
cam ring into the front pump body.
Installation instructions of rear pump body
1. After the rear pump body installed, turn
manually the shaft to see whether it rotate
smoothly.
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