SECTION 9 - STEERING

MAIN DATA AND SPECIFICATIONS

TORQUE SPECIFICATIONS

STANDARD BOLTS

FLARE NUTS

SPECIAL PARTS FIXING NUTS AND BOLTS

SERVICING

POWER STEERING FLUID

DRAINING

REFILLING

STEERING WHEEL PLAY

INSPECTION

ADJUSTMENT

AIR BLEEDING

MEASUREMENT OF FLUID PRESSURE

STEERING MECHANISM

GENERAL DESCRIPTION

STEERING COLUMN

REMOVAL AND INSTALLATION

STEERING UNIT

GENERAL DESCRIPTION

MANUAL STEERING UNIT

POWER STEERING UNIT

POWER S TEERING HYDRAULIC LINE

REMOVAL AND INSTALLATION

MANUAL STEERING UNIT

DISASSEMBLY

INSPECTION AND REPAIR

REASSEMBLY

POWER STEERING UNIT

REPAIR KIT

DISASSEMBLY

INSPECTION AND REPAIR

REASSEMBLY

Techline

STEERING LINKAGE

GENERAL DESCRIPTION

REMOVAL AND INSTALLATION

DISASSEMBLY

INSPECTION AND REPAIR

REASSEMBLY

POWER STEERING OIL PUMP

GENERAL DESCRIPTION

REPAIR KIT (C22, C20 SERIES ENGINE MODEL)

REPAIR KIT (4J SERIES ENGINE MODEL)

REMOVAL AND INSTALLATION (C22, C20 SERIES ENGINE MODEL)

REMOVAL AND INSTALLATION (4J SERIES ENGINE MODEL)

REMOVAL AND INSTALLATION (6VD1 ENGINE MODEL)

DISASSEMBLY (C22, C20 SERIES ENGINE MODEL)

INSPECTION AND REPAIR (C22, C20 SERIES ENGINE MODEL)

REASSEMBLY (C22, C20 SERIES ENGINE MODEL)

DISASSEMBLY AND REASSEMBLY (4J SERIES ENGINE MODEL)

DISASSEMBLY AND REASSEMBLY (6VD1 ENGINE MODEL)

TROUBLESHOOTING

SPECIAL SERVICE TOOL (C22, C20 SERIES ENGINE MODEL)

MAIN DATA AND SPECIFICATIONS

Manual steering Power steering

Unit type Recirculating ball Integral, ball screw

Gear ratio 20.5 - 23.5 15.8:1

Sector shaft operating angle degree 95 94

Starting torque N⋅m (kgf⋅m/lb.ft) 0.064 - 1.07

(0.065 - 0.11/0.47 - 0.79) 0.59 - 0.88

(0.06 - 0.09/0.43 - 0.65)

Maxi mum oil pressure kg/cm2 (psi/kPa) - 95

(1350 / 9300),

105 (1493/10297)

Oil pump type - Vane

Steering wheel - Diameter mm (in.) 382 (15.04)

Steering wheel - Free play mm (in.) 10 - 30 (0.394 - 1.181) 10 - 30 (0.394 - 1.181)

Oil Gear oil GL-5 grade Besco ATF

(DEXRON II or III)

* : 4J Series Engine Model

TORQUE SPECIFICATIONS

STANDARD BOLTS

The torque values given in the following table should be applied where a particular torque is not specified.

N⋅m (kgf⋅m / lb⋅ft)

4.8/4T 7T 8.8 9.8/9T

Refined Non-Refined

M6×1.0 6 (0.6 / 52 lb⋅in) 7 (0.7 / 61 lb⋅in) 8 (0.8 / 69 lb⋅in) -

M8×1.25 13 (1.3 113) 17 (1.7 / 12) 20 (2.0 /14) 24 (2.4 / 17)

M10×1.25 27 (2.8 / 20) 37 (3.8 / 27) 42 (4.3 / 31) 50 (5.1 / 37)

M12×1.25 61 (6.3 / 45) 76 (7.8 / 56) 87 (8.9 /64) 95 (9.7 / 70)

M14×1.5 96 (9.8 / 71) 116 (11.8 / 85) 133 (13.6 / 98) 142 (14.5 / 105)

M16×1.5 130 (13.3 / 96) 170 (17.3 / 125) 193 (19.7 / 143) 200 (20.4 / 148)

M18×1.5 188 (19.2 / 139) 244 (24.9 / 180 ) 278 (28.3 / 205) 287 (29.3 / 212)

M20×1.5 258 (26.3 / 190 337 (34.4 / 249) 385 (39.3 / 284) 396 (40.4 / 292)

M22×1.5 332 (33.9 / 245) 453 (46.3 / 335) 517 (52.7 / 381) 530 (54.1 / 391)

M24×2.0 449 (45.8 / 331) 570 (58.2 / 421) 651 (66.3 / 480) 692 (70.6 / 511)

*M10×1.5 26 (2.7 / 20) 36 (3.7 / 27) 41 (4.2 / 30) 48 (4.9 / 35)

*M12×1.75 57 (5.8 / 42) 71 (7.2 / 52) 80 (8.2 / 59) 89 (9.1 / 66)

*M14×2.0 89 (9.1 / 66) 110 (11.2 / 81) 125 (12.7 / 92) 133 (13.6 / 98)

*M16×2.0 124 (12.7 / 92) 162 (16.5 / 119) 185 (18.9 / 137) 191 (19.5 / 141)

M6×1.0 7 (0.7 /61 lb⋅in) 8 (0.8 / 69 lb⋅in) 9 (0.9 / 78 lb⋅in)

M8×1.25 15 (1.5 / 11) 19 (1.9 / 14) 22 (2.2 / 16) 26 (2.7 / 20)

M10×1.25 31 (3.2 / 23) 41 (4.2 / 30) 47 (4.8 / 35) 56 (5.7 / 41)

M12×1.25 69 (0.7 / 51) 85 (8.7 / 63) 97 (9.9 / 72) 106 (10.8 / 78)

M14×1.5 104 (10.6 / 77) 126 (12.8 / 93) 144 (14.6 / 106) 154 (5.7 / 114)

M16×1.5 145 (14.8 / 127) 188 (.2 / 139) 214 (21.8 / 158) 221 (22.5 / 163)

M18×1.5 -- - -

M20×1.5 -- - -

M22×1.5 -- - -

M24×2.0 -- - -

*M10×1.5 30 (3.1 / 22) 40 (4.1 / 30) 46 (4.7 / 34) 54 (5.5 / 40)

*M12×1.75 64 (6.5 / 47) 78 (8.0 / 58) 89 (9.1 / 66) 99 (10.1 / 73)

*M14×2.0 97 (9.9 / 72) 119 (12.1 / 88) 135 (13.8 / 99.7) 144 (14.7 / 107)

*M16×2.0 137 (14.0 / 101) 178 (18.2 / 132) 203 (20.7 / 150) 210 (21.5 / 155)

The asterisk * indicates that the bolts are used for female-threaded parts that are made of soft materials such as

casting, etc.

FLARE NUTS N⋅m (kgf⋅m / lb⋅ft)

Pipe diameter mm (in) Torque Pipe diameter mm (in) Torque

4.76 (0.187) 16 (1.6 / 12) 10.00 (0.394) 54 (5.5 / 40)

6.35 (0.250) 26 (2.7 / 20) 12.00 (0.472) 88 (9.0 / 65)

8.00 (0.315) 44 (4.5 / 33) 15.00 (0.591) 106 (10.8 / 78)

Strength

Class

Bolt

Identification

Bolt

Diameter ×

××

Pitch (m m)

Standard

Hex.

Head Bolt

Flange

Bolt

SPECIAL PARTS FI XING NUTS AND BOLTS

STEERING COLUM N N⋅m (kgf⋅m/Ib⋅ft)

STEERING UNIT N⋅m (kgf⋅m/Ib⋅ft)

POWER STEERING UNIT N⋅m (kgf⋅m/lb⋅ft)

POWER STEERING HYDRAULIC LINE N⋅m (kgf⋅m/Ib⋅ft)

N⋅m (kgf⋅m/Ib⋅ft)

STEERING LINKAGE N⋅m (kgf⋅m/Ib⋅ft)

SERVICING

C22, C20 Series Engine Model POWER STEERING FLUID

DRAINING

1. Jack up the front wheels until they are clear of the ground.

2. Disconnect the fluid pipes between the steering unit and the

fluid reservoir, and the fluid hose between the pump and the

fluid reservoir.

3. When draining is completed, remove remaining fluid within

hydraulic system by turning the steering wheel to stop in

both directions several times.

Full level

Min. level

REFILLING

1. Connect the fluid lines securely and fill the fluid reservoi

with specified automatic transmission fluid.

2. W hen the f luid reservoir is f illed to the specified level, allo

2 or 3 minutes. While refilling, keep fluid reservoi

replenished as necessary to prevent air from entering the

hydraulic system.

3. Lower the front wheels to the ground. Start and let the

engine idle for a few minutes.

Recheck the fluid level and replenish if necessary.

STEERING WHEEL PLAY

INSPECTION

1. Check the am ount of the steering wheel play by turning the

wheel in both directions until the tires begin to move with

the front wheels properly in the straight-ahead position.

Note:

If the vehicle is equipped with a power steering unit, the

wheel free play should be checked with the engine

running.

Free Play mm(in)

(Manual/Power Steering)

10 - 30 (0.4 - 1.2)

2. Also check the steering wheel for play and looseness in

mount by moving it back and forth and sideways. While

driving check for hard-steering, steering shimmy and

tendency of steering to pull to one side.

ADJUSTMENT

1. Align the front wheels properly in the straight ahead

position.

2. Loosen the lock nut on the adjusting screw of the steering

unit.

3. Turn the adjust screw clockwise to decrease free play o

counter-clockwise to increase.

4. After check of specified free play, tighten the lock nut to

specified torque.

Lock Nut Torque N⋅m (kgf⋅m/Ib⋅ft)

Manual Steering 24.5±4.9 (2.5±0.5/18.1±3.6)

Power Steering 41.2±5.9 (4.2±0.6/30.4±4.3)

AIR BLEEDING

Fill fluid reservoir with specified automatic transmission fluid

(DEXRON) and turn the steering wheel to lock in both

directions repeatedly, so that level of fluid in the reservoir to the

specified level and start the engine.

Perform the following check with the engine running at idle.

Bleeding is considered to be completed if the following

conditions apply;

(1) Turn the steering wheel to lock in both directions 3 or 4

times.

A buzz is not produced in the hydraulic line.

(2)Stop the engine with steering wheel in a straight ahead

position.

Level of fluid in reservoir does no increase.

Note:

Do not hold the steering wheel in position of loc k for more

than 5 seconds, or temperature of fluid increases sharply.

MEASUREM ENT OF FLUID PRESSURE

Measurement of fluid pressure in the power steering sy stem is performed to determine whether or not the oil pump and

power steering unit are functioning normally.

C22. C20 Series Engine Model

1. Installation of Tester

•Power Steering Tester : 5-8840-0135-0

(J-29877-A)

Adapter; Power Steering Tester :

5-8840-0136-0

(J-33996)

1Oil Pressure Gauge with Shut off Valve

2Shut off Valve

3Adapter (to steering unit)

4Adapter (to oil pump)

•Installation Procedure;

Disconnect the hose on the outlet side of the pump.

Connect the gauge hose closest to the power steering

gauge shut off valve to the hose on the vehicle.

Connect the gauge hose f urthest from the shut of f valve

to the outlet side of the power steering pump.

2. Bleeding

•Open stop valve fully.

•Refer to air bleeding procedure.

3. Measurement of Fluid Pressure

•Open stop valve fully.

•Increase engine speed to 1500 rpm.

•Measure the fluid pressure when the steering wheel is

turned to lock in both directions.

Fluid Pressure kg/cm2(psi/kPa)

95 - 100

(1351 - 1422/9316 - 9806) (C22, C20 Series Engine Model)

100 - 105

(1422 - 1493/9806 - 10297) (4J Series Engine Model)

DIAGNOSIS:

(1)W hen pr essure is higher than Specif ied pres sure, the valve

within the oil pump is defective.

(2)When the pressure is lower than Specified pressure.

•Return steering wheel to straight-ahead position.

•Close stop valve completely.

•Hold engine running at 1500 rpm, and take reading o

the pressure gauge.

Fluid Pressure kg/cm2(psi/kPa

)

Possible trouble

95 - 100

(1351 -1422/9316 - 9806)

(C22, C20 Series Engine Model)

100 - 105

(1422 - 1493/9806 - 10297)

(4J Series Engine Model)

Lower than 95 (1351/9316)

(C22, C20 Series Engine Model)

Lower than 100 (1422/9806)

(4J Series Engine Model)

Oil pump

Steering unit

STEERING MECHANISM

GENERAL DESCRI PTION

STEERING MECHANISM

Techline

The steering mechanism comprises a steering wheel, steering column, steering shaft, steering unit, and steering

linkage.

The steering shaft is equipped with slid joints to prevent vehicle vibration from transferring to the steering wheel.

STEERING COLUM N

REMOVAL AND INSTALLATION

REMOVAL STEPS

▲1., 1a. Horn shroud

2., 2a. Nut

▲3., 3a.Steering wheel

4. Steering cowl

5. Combination switch

6. Snap ring

7. Bushing

▲8. Steering lock and bearing

▲9. Steering column assembly

INSTALLATION STEPS

▲9. Steering column assembly

▲8. Steering lock and bearing

7. Bushing

6. Snap ring

5. Combination switch

4. Steering cowl

▲3., 3a. Steering wheel

▲2., 2a. Nut

▲1., 1a. Horn shroud

IMPORTANT OPERATIONS - REMOVAL

1. SRS AIRBAG

REFER TO SECTION 12M1 SRS - AIRBAG FOR REMOVAL

INSTRUCTIONS

1a. Horn Cover

(1)Remove the arrowed screw at the rear side of the steering

wheel.

(2)Pull up the pad along the direction shown in the left figure

and remove from the steering wheel.

Setting mark

3., 3a. Steering Wheel

(1)Apply a setting mark acros s the s teer ing wheel and s haf t s o

parts can be reassembled in their original position.

5-8521-0016-0

(2)Steering Wheel Puller : 5-8521-0016-0

(J-29752)

Note :

Never apply blow to the setting wheel in direction of the

shaft by using a hammer or other impact tools in an

attempt to remove the steering wheel, the setting shaft is

designed as an energy absorbing unit.

8. Steering Lock and Bearing

Remove the steering lock assembly using the inner hex

wrench.

Turn the ignition/starter key to OFF position.

Note :

With the steering in lock position, the steering lock

assembly cannot be removed.

9. Steering Column Assembly

Apply a setting mark across the universal joint and steering

shaft to reassemble of the parts in their original position.

Note :

A Setting mark can be easily punched if the shaft is

withdrawn a little by loosening the steering shaft universal

joint.

IMPORTANT OPERATIONS - INSTALLATION

9. Steering Column Assembly

Steering Column Torque N⋅m (kgf⋅m/Ib⋅ft)

16.7 +2.9

−0 (1.7 +0.3

−0/12.3 +2.1

−0)

Align the setting marks made when removing.

8. Steering Lock and Bearing

Turn the ignition/starter key to OFF position.

With the steering in lock position, the steering lock assembly

cannot be installed.

Install the steering lock assembly using the inner hex wrench.

Setting mark

3., 3a. Steering Wheel

(1)Align the setting marks made when removing.

(2)Apply grease to contact ring.

Note :

Never apply blow to the setting wheel in direction of the

shaft by using a hammer or other impact tools in an

attempt to install the steering wheel, the setting shaft is

designed as an energy absorbing unit.

2., 2a. Nut

Steering Wheel Nut Torque N⋅m (kgf⋅m/Ib⋅ft

)

34.3±4.9 (3.5±0.5/25.3±3.6)

1. Horn shroud

(1)Remove the bracket from the nail at the lower side of pad

assembly with a screw driver.

(2)Install the bracket (removed at procedure 1) onto the

steering wheel sub assembly with a screw.

(3)Connect the harnesses, then, hang the nail of the pad

assembly onto the plate of the steering wheel sub

assem bly, and install the pad caref ully so that the nail is not

separated from the bracket. (See the lowest figure.)

STEERING UNIT

GENERAL DESCRI PITION

MANUAL STEERI NG UNIT

The steering gear is mainly comprised of the sector gear and the worm nut assembly.

There are many recirculating balls installed to the ball groove (way) between the worm nut and the steering worm shaft.

The steering gear's high mechanical efficiency provides very light steering.

Racks machined into the worm nut side face engage the fan shaped sector gear to transfer the steering wheel applied

torque to the pitman arm.

POWER STEERING UNIT

Power steering is designed to reduce the steering wheel turning effort by utilizing hydraulic pressure to bolster the

normal torque developed by the steering wheel box.

The power steering unit incorporates a power piston and sector shaft as an integral part of the steering gear. A control

valve is built into the steering housing.

Because the tire rolling resistance is constantly applied to the worm shaft, the torsion bar twists with the Steering

Wheel. As the torsion bar twists, the relative torque displacement between the worm shaft and the rotor changes. An

equivalent oil pressure is applied to the piston to bolster the normal torque.

POWER STEERING HYDRAULIC LINE

The function of each major component is described below:

Power Steering Unit

Refer to the previous page.

Oil Pump

The oil pump uses the power of the engine to send hydraulic fluid to the power steering unit.

An oil pressure relief valve and an oil flow relief valve are installed to the oil pump.

The oil pressure relief valve prevents any excessive oil pressure from reaching the hydraulic circuit.

The oil flow control valve controls the hydraulic fluid volume within the hydraulic system. It prevents too much fluid from

entering the system. This, in turn, prevents harmful heat build-up.

Oil Reservoir and Piping

The oil reservoir stores and filters the hydraulic fluid.

REMOVAL AND INSTALLATION

REMOVAL STEPS

1. Nut

▲2. Pitman arm

3. Bolt

4. Unit assembly

▲5. Coupling assembly

INSTALLATION STEPS

▲5. Coupling assembly

4. Unit assembly

▲3. Bolt

▲2. Pitman arm

▲1. Nut

IMPO RTANT OPERATIONS - REMOVAL

2. Pitman Arm

Pitman Arm Remover : 5-8840-2017-0

5. Coupling Assembly

Make a setting mark across the coupling flange and worm

shaft to ensure reassembly of the parts in the original position.

IMPORTANT OPERATIONS - INSTALLATION

5. Coupling Assembly

Align the Setting mark made at removal

3. Bolt

Steering Unit Bolt N⋅m (kgf⋅m/Ib⋅ft)

44.1 +9.8

−4.9 (4.5 +1

−0.5 /32.5 +7.2

−3.6 )

2. Pitman Arm

Align the notched tooth

1. Nut

Pitman Arm Nut Torque N⋅m (kgf⋅m/Ib⋅ft)

215.6±19.6 (22.0±2.0/159.0±14.5)

MANUAL STEERI NG UNIT

DISASSEM BLY

DISASSEM BLY STEPS

1. Lock nut

▲2. Side cover

3. Gasket

4. Adjusting screw

5. Adjusting shim

6. Needle bearing

▲7. Sector shaft

▲8. Lock nut

▲9. End cover

10. Oil seal

11. O-ring

▲12. Ball nut and worm shaft

13. Bearing

14. Bearing

15. Oil seal

16. Gear box

IMPORTANT OPERATIONS

2. Side Cover

(1)Turn the adjusting screw counter-clockwise slightly, then

remove the side cover fixing bolt.

(2)Turn the adjusting scr ew clock wise with the side cover held

from turning.

7. Sector Shaft

Hold the sector shaft in straight-ahead position when removing

it from the gear box. Do not drive the sector shaft off the gear

box with a hammer or other impact tools.

8. Lock Nut

Lock Nut Wrench : 5-8840-2006-0

(J-29753)

9. End Cover

(1)End Cover Remover : 5-8840-2007-0

(J-7624)

(2)When removing, take care so as not to damage the oil seal.

Taping the splines will provide some protection.

12.Ball-Nut and Worm Shaft

Always keep ball-nut assembly in a horizontal position. Do not

hold it vertically, or ball-nut will slide out.

INSPECTION AND REPAIR

Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are found through

inspection.

• Bearing

• Oil seal, bushing

• Ball-nut and worm shaft

• Sector shaft

• Gear box

VISUAL CHECK

Inspect the following parts for wear, damage or other abnormal

conditions.

BALL-NUT ROTATIO N

Hold the worm shaft vertically and check that the ball-nut

lowers with a smooth turning motion. If the lowering of the ball-

nut by its own weight is not smooth, check the worm shaft for

bending and the ball-groove for burrs, dents, and foreign

matter.

Note :

When testing the ball-nut assembly, do not let it travel all

the way to the end of worm shaft, or damage to the ball

tubes will result.

Sector Shaft Outside Diameter mm(in)

Standard Limit

A 28.6 (1.13) 28.3 (1.12)

B 31.8 (1.25) 31.5 (1.24)

REASSEMBLY

REASSEMBLY STEPS

1. Gear box

2. Oil seal

3. Bearing

4. Bearing

5. Ball nut and worm shaft

6. Oil seal

7. O-ring

▲8. End cover

▲9. Lock nut

▲10. Sector shaft

11. Needle bearing

▲12. Adjust shim

13. Adjust screw

▲14. Gasket

▲15. Side cover

▲16. Lock nut

IMPORTANT OPERATIONS

8. End Cover

(1)When installing, take care so as not to cause damage to

the oil seal.

Taping the splines will provide some protection.

(2)Adjust the bearing preload by using socket.

Bearing Preload N⋅m (kgf⋅m/Ib⋅ft)

0.29 - 0.59 (0.03 - 0.06/0.22 - 0.43)

9. Lock Nut

Lock Nut Torque N⋅m (kgf⋅m/Ib⋅ft)

176.5±19.5 (18.0±2.0/130.2±14.4)

Lock Nut Wrench : 5-8840-2006-0

(J-29753)

End Cover Installer : 5-8840-2007-0

(J-7624)

Note:

After tightening, check the bearing preload.

10.Sector Shaft

Align the center tooth of the ball-nut with that of the sector

shaft.

12.Adjust Shim

Adjust the clearance and check that the adjusting screw turns

freely.

Clearance mm (in)

0.1 (0.004)

Adjusting shims available mm (in)

1.524 (0.0600)

1.554 (0.0612)

1.585 (0.0624)

1.615 (0.0636)

1.646 (0.0648)

14.Gasket

15.Side Cover

Apply liquid gasket to the joining surface of each parts.

16.Lock Nut

Adjust the backlash between the sector gear and ball-nut.

(1)Install the pitman arm.

(2)Check that the sector shaft moves smoothly in the correct

working angle range, then semi-tighten the lock nut.

(3)Measure preload of worm gear.

Preload N⋅m (kgf⋅m/Ib⋅ft)

less than 1.079 (0.11/0.795)

Note:

Obtain the specified backlash by turning the adjust screw.

The backlash should be measured at the drop arm end.

Backlash mm (in

)

0.2 (0.008)

POWER STEERING UNIT

REPAIR KI T

1. Nut : adjust screw

2. Gasket : cover

3. Gasket : sector shaft

4. Seal : sector shaft

5. Gasket : housing

6. Ring : retaining

7. Ring : seal

8. Seal: oil

9. Gasket : housing

10. Gasket : housing

11. Seal ring : housing

DISASSEM BLY

DISASSEM BLY STEPS

1. Retaining ring

2. Seal ring

▲3. Oil seal

▲4. Lock nut

▲5. Top cover assembly

6. O-ring

7. Needle bearing

▲8. Sector shaft

▲9. Ball nut and valve housing assembly

10. Gasket

11. Seal ring

12. Gasket

13. Needle bearing

14. Sector shaft seal

15. Sector shaft gasket

16. Gear box

IMPORTANT OPERATIONS

Avoid clamping the steering gear assembly in a vise by the

power cylinder housing.

3. Oil Seal

(1)Clean the faces of the extended stub shaft.

(2)Plug the hose fitting on the inlet side.

(3)Rem ove the oil seal by blowing com pres sed air through the

hole in the outlet side.

4. Lock Nut

Remove the adjusting screw lock nut and turn the adjusting

screw counter-clockwise to remove the preload between the

sector gear and the rack piston, then remove the top cover

bolts.

5. Top Cover

Hold the top cover stationary, turn the adjusting screw

clockwise to raise and free the cover, then remove the cover.

8. Sector Shaft

Bring the stub shaft into straight-ahead position.

Do not force the sector shaft off the gear box with a hammer or

other impact tools.

9. Ball Screw and Valve Housing Assembly

It is strongly advisable to keep the ball nut and valve housing

assembly always in a horizontal position, or the rack piston will

fall off onto the end of the worm, causing the rack piston to slip

out of the worm shaft and the balls to fall out.

INSPECTION AND REPAIR

Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are found through

inspection.

• Bearing

• Oil seal, Dust seal, Dust cover

• O-Ring, seal ring

• Ball nut and valve housing

• Sector shaft

• Gear box

VISUAL CHECK

Inspect the following parts for wear, damage or other abnormal

conditions.

BALL-NUT ROTATIO N

Hold the ball nut and valve housing assembly vertically and see

if the ball-nut lowers by turning smoothly. If the lowering of the

ball-nut by its own weight is not smooth, check the worm shaft

for bending and the ball-groove for burrs, dents and foreign

matter.

Note :

When testing the ball nut and valve housing assembly, do

not let it travel all the way to the end of worm shaft, or

damage to the ball tubes will result.

SECTOR SHAFT OUTSIDE DIAMETER mm (in)

Standard Limit

32.0 (1.260) 31.97 (1.258)

REASSEMBLY

REASSEMBLY STEPS

1. Gear box

▲2. Gasket

▲3. Seal

4. Needle bearing

▲5. Gasket

▲6. Seal ring

▲7. Gasket

▲8. Ball nut and valve housing assembly

▲9. Oil seal

▲10. Seal ring

▲11. Retaining ring

▲12. Sector shaft

13. Needle bearing

14. O-ring

▲15. Top cover assembly

▲16. Lock nut

IMPORTANT OPERATIONS

2. Seal Ring

3. Dust Seal

Note the setting direction.

Apply a thin coat of grease to lip of each part.

5. O-Ring

6. Seal Ring

7. O-Ring

Apply a thin coat of grease.

8. Ball Nut and Valve Housing Assembly

(1) It is strongly advisable to keep the ball screw and valve

housing assembly always in a horizontal position and avoid

holding it vertically, or the rack piston will fall off onto the

end of the worm, causing the rack piston to slip out of the

worm shaft and balls to fall out.

(2)Be careful so as not to the drop the O-ring fitted to oil

passage in the valve housing.

(3) Tighten the valve housing retaining bolts to the specified

torque.

Valve Housing Bolt Torque N⋅m (kgf⋅m/Ib⋅ft

)

47±7 (4.8±0.8/34.7±5.8)

9. Oil Seal

Oil Seal Installer : 5-8522-0026-0

(J-26508)

10.Back Up Ring

11.Retaining Ring

Turn the face with rounded edge (outer circumference) to the

oil seal.

12.Sector Shaft

(1)Tape the sector shaft serrations to protect the seal ring

from damage.

(2)Align the center tooth of ball nut with that of the sector shaft.

15.Top Cover Assembly

Top Cover Bolt Torque N⋅m (kgf⋅m/Ib⋅ft)

47±7 (4.8±0.7/34.7 ±5.2)

16.Lock Nut

Adjust the backlash between the worm gear and the ball nut.

(1) With the worm gear rotating, set it to the straight ahead

position.

(2)Set the worm shaft preload to below 0.98 N⋅m (10 kgf⋅cm/

8.7 lb⋅in) with the sector shaft adjusting screw.

(3)Measure the worm shaft backlash with the worm gea

turned 450° both to the right and to the left.

The worm gear preload in these positions should be 0.3 ±

0.1 N⋅m (3 ± 1 kgf⋅cm / 2.6 ± 0.9 lb⋅in) lower than in the

straight ahead position.

(4)Lock the sector shaft adjusting screw with the lock nut.

Lock Nut Torque N⋅m (kgf⋅m/Ib⋅ft)

41±6 (4.2±0.6/30.2±4.4)

STEERING LINKAGE

GENERAL DESCRI PTION

Techline

REMOVAL AND INSTALLATION

0 Except Europe and Thailand for 4J series and 6VD1 engine model

REMOVAL STEPS

1. Nut

2. Bolt

3. Steering damper

4. Nut

▲5. Nut ; pitman arm

▲6. Nut ; relay lever

▲7. Intermediate rod

INSTALLATION STEPS

7. Intermediate rod

▲6. Nut ; relay lever

▲5. Nut ; pitman arm

4. Nut

3. Steering damper

2. Bolt

▲1. Nut

5-8840-2017-0

IMPO RTANT OPERATIONS - REMOVAL

5., 6. Pitman Arm Nut and Relay Lever Nut

Remove relay lever or pitman arm to shafts nut and lock

washer. Remove the relay lever or pitman arm from the shaft

using remover.

Remover : 5-8840-2017-0

5-8840-2121-0

7. Outer Track Rod

Remove split pin from the ball stud connecting outer track rod

end. Remove the castellated nuts and disconnect the parts

using remover.

Tie Rod Remover : 5-8840-2121-0

IMPORTANT OPERATIONS - INSTALLATION

6. Nut ; Relay Lever

Relay Lever Nut Torque N⋅m (kgf⋅m/Ib⋅ft)

117.7±9.8 (12.0±1.0/86.8±7.2)

5. Nut ; Pitman Arm

Pitman Arm Nut Torque N⋅m (kgf⋅m/Ib⋅ft)

215.8±19.6 (22.0±2.0/159.2±14.5)

1. Nut

Steering Damper Torque N⋅m (kgf⋅m/Ib⋅ft)

39.2 +9.8

−4.9 (4.0 +1

−0.5 /28.9 +7.2

−3.6 )

DISASSEMBLY

DISASSEM BLY STEPS

1. Nut

2. Pitman arm

3. Nut

4. Relay lever

▲5. End assembly (outer)

6. Nut

▲7. End assembly (inner)

8. Pin assembly

9. Center track rod assembly

IMPORTANT OPERATIONS

5. End Assembly (Outer)

Apply the setting mark to reassemble the parts in their original

position.

7. End Assembly (Inner)

Apply the setting mark to reassemble the parts in their original

position.

INSPECTION AND REPAIR

Make all necessary adjustments, repairs, and part replacements if wear, damage, or other problems are discovered

during inspection.

• Pitman arm, relay lever

• End assembly, pin assembly

• Center track rod assembly

• Boot

VISUAL CHECK

Inspect the following parts for wear, damage or other abnormal

conditions.

BALL JOI NTS (CENTER TRACK ROD ASSEMBLY

AND OUTER TRACK ROD TRACK ROD ASSEMBLY)

Inspect the following.

If one or more of the abnormal conditions listed in parenthesis

is discovered during inspection, the entire track rod

assembly(s) must be replaced.

1. Ball joint boot (Tearing and grease leakage)

2. Ball joint (Rough movement)

The ball joint must move smoothly with no snagging.

3. Ball joint screws (Excessive damage)

4. Ball joint tapered surfaces (Excessive wear and damage)

REASSEMBLY

REASSEMBLY STEPS

1. Center track rod assembly

2. Pin assembly

▲3. End assembly (inner)

▲4. Nut

▲5. End assembly (outer)

6. Relay lever

▲7. Nut

8. Pitman arm

▲9. Nut

IMPORTANT OPERATIONS

3. End Asseembly (Inner)

Align the setting marks applied at the disassembly.

End Assembly Torque N⋅m (kgf⋅m/Ib⋅ft)

117.7±19.6 (12.0±2.0/86.8±14.5)

After tightening, stake the two portions securely.

5. End Assembly (Outer)

Align the setting marks applied during disassembly.

7. Nut

Relay Lever Nut Torque N⋅m (kgf⋅m/Ib⋅ft)

58.8+29.4

−9.8 (6.0+3

−1/43.4+21.7

−7.2 )

9. Nut

Pitman Arm Nut Torque N⋅m (kgf⋅m/lb⋅ft)

98.0+29.4

−9.8 (10+3

−1/72.3+21.7

−7.2 )

Note :

When change the track rod, adjust the track rod length.

mm (in)

4×2 (except Sporty) 306.9±1.5 (12.08±0.059)

4×4 and 4×2 Sporty 262±1.5 (10.31±0.059)

ADJUSTMENT

Adjust the toe-in angle.

POWER STEERING OIL PUMP

GENERAL DESCRI PTION

C22, C20 Series Engine Model

4J Series Engine Model

REPAIR KI T (C22, C20 SERIES ENGINE MO DEL)

LEGEND

1. Bolt

2. Suction Pipe

3. O-ring

4. Connector

5. O-ring

6. Valve

7. Retaining Ring

8. Filter

9. Spring

10. Pressure Switch

11. Retaining Ring

12. Shaft assembly

13. Bearing

14. Shaft

15. Retaining Ring

16. Oil Seal

17. Bolt

18. Rear Housing Assembly and Pump

Cartridge

19. Gasket

20. O-ring

21. O-ring

22. Front Housing

23. Pressure Plate

24. Rotor and Vane

25. Cam

26. Pin

27. Rear Housing

REPAIR KI T

3. O-ring

5. O-ring

13. Bearing

16. Oil Seal

19. Gasket

20. O-ring

21. O-ring

REPAIR KI T (4J SERI ES ENGINE MODEL)

1. O-ring

2. O-ring

3. O-ring

4. Oil seal

5. O-ring

6. O-ring

7. O-ring

8. Bearing

9. Gasket

REMOVAL AND INSTALLATION (C22, C20 SERIES ENGINE MODEL)

REMOVAL STEPS

1. Belt : oil pump

2. Hose : rubber, suction

3. Hose : flexible

4. Bolts

5. Pump assembly : oil

6. Pulley : oil pump

INSTALLATION STEPS

To install follow the removal procedure in

reverse order

REMOVAL AND INSTALLATION (4J SERIES ENGINE MODEL)

REMOVAL STEPS

1. Hose, suction

2. Hose, flexible

3. Adjust nut

4. Bolt

5. Adjust bolt

6. Belt

7. Bracket

8. Pulley

9. Bolt

10. Bracket

11. Pump assembly

INSTALLATION STEPS

11. Pump assembly

10. Bracket

9. Bolt

8. Pulley

7. Bracket

6. Belt

5. Adjust bolt

4. Bolt

3. Adjust nut

2. Hose, flexible

1. Hose, suction

REMOVAL

Preparation:

•Place a drain pan below the pump.

1. Hose, Suction

2. Hose, Flexible

3. Adjust Nut

4. Bolt

5. Adjust Bolt

6. Belt

7. Bracket

8. Pulley

9. Bolt

10. Bracket

11. Pump A ssembly

INSTALLATION

11. Pump A ssembly

10. Bracket

9. Bolt

Bolt Torque N⋅m (kgf⋅m / lb⋅ft)

37 (3.8 / 27)

8. Pulley

Pulley Nut Torque N⋅m (kgf⋅m / lb⋅ft

)

78.4±9.8 (8.0±1.0/ 57.8±7.2)

7. Bracket

6. Belt

5. Adjust Bolt

4. Bolt

After adjusting drive belt tension, tighten bolt to specified

torque.

Bracket Bolt Torque N⋅m (kgf⋅m / lb⋅ft)

37 (3.8 / 27)

3. Adjust Nut

After adjusting drive belt tension, tighten bolt to specified

torque.

Adjust Nut Torque N⋅m (kgf⋅m / lb⋅ft

)

37 (3.8 / 27)

2. Hose Flexible

Hose, Nut Torque N⋅m (kgf⋅m / lb⋅ft)

19.6±3.9 (2.0±0.4/14.5±2.9)

1. Hose, Suction

Fill and bleed the system. Refer to "Bleeding the Power

Steering System" in this section.

REMOVAL AND INSTALLATION (6VD1 ENGINE MODEL)

REMOVAL STEPS

1. Hose, suction

2. Hose, flexible

3. Belt

4. Pulley

5. Bolt

6. Pump assembly

INSTALLATION STEPS

6. Pump assembly

5. Bolt

4. Pulley

3. Belt

2. Hose, flexible

1. Hose, suction

REMOVAL

Preparation:

•Place a drain pan below the pump.

1. Hose, Suction

2. Hose, Flexible

3. Belt

4. Pulley

5. Bolt

6. Pump A ssembly

INSTALLATION

6. Pump A ssembly

5. Bolt

Bolt Torque N⋅m (kgf⋅m / lb⋅ft)

46 (4.7 / 34)

4. Pulley

Pulley Nut Torque N⋅m (kgf⋅m / lb⋅ft

)

78.4±9.8 (8±1/ 57.8±7.2)

3. Belt

2. Hose, Flexible

Hose, Bolt Torque N⋅m (kgf⋅m / lb⋅ft

)

53.9±4.9 (5.5±0.5 / 39.8±3.6)

1. Hose, Suction

Fill and bleed the system. Refer to "Bleeding the Power

Steering System" in this section.

DISASSEM BLY ( C22, C20 SERIES ENGINE MODEL)

DISASSEM BLY STEPS

1. Bolt

2. Suction Pipe

3. O-ring

4. Connector

5. O-ring

6. Valve

7. Retaining ring

8. Filter

9. Spring

10. Pressure switch

▲11. Retaining ring

▲12. Shaft assembly

▲13. Bearing

14. Shaft

15. Retaining ring

▲16. Oil seal

17. Bolt

18. Rear housing assembly and pump

cartridge

19. Gasket

20. O-ring

21. O-ring

22. Front housing

23. Pressure plate

24. Rotor and vane

25. Cam

26. Pin

27. Rear housing

IMPORTANT OPERATIONS

11.Snap Ring

Use a pair of snap ring pliers to remove the snap ring.

12.Shaft

Use a bench press to slowly force the shaft from the rear cover

side.

Note :

Take care not to damage the end of the shaft when

removing the shaft.

13.Bearing

Use the bench press and bearing remover.

Bearing Remover : 5-8840-2206-0

Note :

Take care not to damage the shaft when removing the

shaft.

16.Oil Seal

Use a suitable bar.

INSPECTION AND REPAIR (C22, C20 SERIES ENGINE MODEL)

Make all necessary adjustments, repairs, and part replacements if wear, damage, or other problems are discovered

during inspection.

ROTOR

Check that the groove in the vane is free from excessive wear

and that the vane slides smoothly.

When part replacement becomes necessary, the pump

cartridge should preferably be replaced as a sub assembly.

VANE

Sliding faces of the vane should be free from wear.

(particularly the curved face at the tip in contact with the cam

should be free from wear and distortion.)

When part replacement becomes necessary, the pump

cartridge should preferably be replaced as a sub assembly.

CAM

The inner face of the cam should have a trace of uniform

contact without a sign of step wear.

When part replacement becomes necessary, the pump

cartridge should preferably be replaced as a sub assembly.

PRESSURE PLATE AND THRUST PLATE

The sliding faces of the parts must be free from step wear

(more than 0.01 mm) which can be felt by the finger nail.

The parts with minor scores may be reused after lapping the

face.

SHAFT

Oil seal sliding faces must be free from a step wear which can

be felt by the finger nail.

REASSEMBLY ( C22, C20 SERIES ENGINE MODEL)

REASSEMBLY STEPS

1. Rear housing

2. Pin

3. Cam

4. Rotor and vane

▲5. Pressure plate

6. Front housing

7. O-ring

8. O-ring

9. Gasket

10. Rear housing assembly and pump

cartridge

▲11. Bolt

▲12. Oil seal

13. Retaining ring

14. Shaft

15. Bearing

▲16. Shaft assembly

▲17. Retaining ring

18. Pressure switch

19. Spring

20. Filter

21. Retaining ring

22. Valve

23. O-ring

▲24. Connector

25. O-ring

26. Pipe, suction

27. Bolt

5. Pressure Plate

When installing the pressure plate, align the projection of

pressure plate with the grove of oil pump body.

ROTOR

Place the rotor so that specified mark ■ turns down.

Note :

When part replacement becomes necessary, the pump

cartridge should be replaced as a sub assembly.

CAM

When installing the cam, align the projection of cam with the

grove of oil pump body.

Install the cam with the pin "A" side turn down.

VANE

The round end of the vane should be matched to the inner

surface of the cam ring.

11.Cover and Bolt

Torque N⋅m (kgf⋅m/lb⋅ft)

53.9±4.9 (5.5±0.5 / 39.8±3.6)

IMPORTANT OPERATIONS

12.Oil Seal

Apply compressed air to the inside of the oil pump body.

Use the bench press and oil seal installer.

Oil Seal Installer : 5-8840-2205-0

16.Shaft and Bearing

Install the bearing to the shaft with a bench press and bearing

installer.

Bearing installer : 5-8840-2206-0

Use a bench press and bearing installer to slowly force the

shaft from front side of the oil pump body.

Bearing Installer : 5-8840-2206-0

17.Snap Ring

Use a pair of snap ring pliers to install the snap ring.

24.Connector

Torque N⋅m(kgf⋅m/lb⋅ft

)

53.9±4.9 (5.5±0.5 / 39.8±3.6)

DISASSEM BLY AND REASSEMBLY (4J SERIES ENGINE MODEL)

DISASSEM BLY STEPS

1. Bolt

2. Pipe, suction

3. O-ring

4. O-ring

5. O-ring

6. Connector

7. O-ring

8. Valve

9. Retaining ring

10. Filter

11. Spring

12. Retaining ring

13. Shaft assembly

14. Bearing

15. Shaft

16. Retaining ring

17. Oil seal

18. Bolt

19. Rear housing assembly and pump

cartridge

20. Gasket

21. O-ring

22. O-ring

23. Front housing

24. Pressure plate

25. Rotor and vane

26. Cam

27. Pin

28. Rear housing

REASSEMBLY STEPS

28. Rear housing

27. Pin

26. Cam

25. Rotor and vane

24. Pressure plate

23. Front housing

22. O-ring

21. O-ring

20. Gasket

19. Rear housing assembly and pump

cartridge

18. Bolt

17. Oil seal

16. Retaining ring

15. Shaft

14. Bearing

13. Shaft assembly

12. Retaining ring

11. Spring

10. Filter

9. Retaining ring

8. Valve

7. O-ring

6. Connector

5. O-ring

4. O-ring

3. O-ring

2. Pipe

1. Bolt

DISASSEMBLY

Preparation:

Clean oil pump with solvent (its plug discharge and suction port

to prevent the entry of solvent). Be careful not to expose the oil

seal of shaft assembly to solvent.

1. Bolt

2. Pipe, Suction

3. O-ring

4. O-ring

5. O-ring

6. Connector

7. O-ring

8. Valve

9. Retaining Ring

10. Filter

11. Spring

12. Retaining Ring

13. Shaft Assembly

14. Bearing

15. Shaft

16. Retaining Ring

17. Oil Seal

CAUTION:

When removing the oil seal, be careful not to damage the

housing.

18. Bolt

19. Rear Housing Assembly and Pump Cartridge

20. Gasket

21. O-ring

22. O-ring

23. Front Housing

24. Pressure Plate

25. Rotor and Vane

26. Cam

27. Pin

28. Rear Housing

REASSEMBLY

28. Rear Housing

27. Pin

26. Cam

25. Rotor and Vane

Install the rotor with its punch mark facing the front

housing.

Install the vane with curved face in contact with the inner

wall of the cam.

24. Pressure Plate

CAUTION:

When install pressure plate, be careful not to damage its

inner surface. Damaged pressure plate may cause poor

pump performance, pump seizure or oil leakage.

23. Front Housing

22. O-ring

Be sure to discard used parts, and always used new parts

for installation.

21. O-ring

Be sure to discard used parts, and always used new parts

for installation.

20. Gasket

Be sure to discard used parts, and always used new parts

for installation.

19. Rear Housing Assembly and Pump Cartridge

18. Bolt

Rear Housing Bolt Torque N⋅m (kgf⋅m / lb⋅ft)

54 (5.5 / 40)

17. Oil Seal

Be sure to discard used parts, and always used new parts

for installation.

CAUTION:

When installing the oil seal, be careful not to damage the

oil seal contacting surface of the housing.

16. Retaining Ring

15. Shaft

14. Bearing

13. Shaft Assembly

12. Retaining Ring

11. Spring

10. Filter

9. Retaining Ring

8. Valve

7. O-ring

Be sure to discard used parts, and always used new parts

for installation.

6. Connector

Connector Torque N⋅m (kgf⋅m / lb⋅ft)

54 (5.5 / 40)

5. O-ring

Be sure to discard used parts, and always used new parts

for installation.

4. O-ring

Be sure to discard used parts, and always used new parts

for installation.

3. O-ring

Be sure to discard used parts, and always used new parts

for installation.

2. Pipe, Suction

1. Bolt

Suction Pipe Bolt Torque N⋅m (kgf⋅m / lb⋅ft)

21 (2.1 / 15)

DISASSEM BLY AND REASSEMBLY (6VD1 ENGINE MODEL)

DISASSEM BLY STEPS

1. Bolt

2. Pipe, suction

3. O-ring

4. Connector

5. O-ring

6. Valve

7. Retaining ring

8. Filter

9. Spring

10. Pressure switch

11. Retaining ring

12. Shaft assembly

13. Bearing

14. Shaft

15. Retaining ring

16. Oil seal

17. Bolt

18. Rear housing assembly and pump

cartridge

19. Gasket

20. O-ring

21. O-ring

22. Front housing

23. Pressure plate

24. Rotor and vane

25. Cam

26. Pin

27. Rear housing

REASSEMBLY STEPS

27. Rear housing

26. Pin

25. Cam

24. Rotor and vane

23. Pressure plate

22. Front housing

21. O-ring

20. O-ring

19. Gasket

18. Rear housing assembly and pump

cartridge

17. Bolt

16. Oil seal

15. Retaining ring

14. Shaft

13. Bearing

12. Shaft assembly

11. Retaining ring

10. Pressure switch

9. Spring

8. Filter

7. Retaining ring

6. Valve

5. O-ring

4. Connector

3. O-ring

2. Pipe, suction

1. Bolt

DISASSEMBLY

Preparation:

Clean oil pump with solvent (its plug discharge and suction port

to prevent the entry of solvent). Be careful not to expose the oil

seal of shaft assembly to solvent.

1. Bolt

2. Pipe, Suction

3. O-ring

4. Connector

5. O-ring

6. Valve

7. Retaining Ring

8. Filter

9. Spring

10. Pressure Switch

11. Retaining Ring

12. Shaft Assembly

13. Bearing

14. Shaft

15. Retaining Ring

16. Oil Seal

CAUTION:

When removing the oil seal, be careful not to damage the

housing.

17. Bolt

18. Rear Housing Assembly and Pump Cartridge

19. Gasket

20. O-ring

21. O-ring

22. Front Housing

23. Pressure Plate

24. Rotor and Vane

25. Cam

26. Pin

27. Rear Housing

INSPECTION AND REPAIR

Make all necessary adjustments, repairs, and part

replacements if wear, damage, or other problems are

discovered during inspection.

ROTOR

Check that the groove in the vane is free from excessive wear

and that the vane slides smoothly

When part replacement becomes necessary, the pump

cartridge should be replaced as a subassembly.

VANE

Sliding faces of the vane should be free from wear.

(Particularly the curved face at the tip in contact with the cam

should be free from wear and distortion.)

When part replacement becomes necessary, the pump

cartridge should be replaced as a subassembly.

CAM

The inner face of the cam should have a trace of uniform

contact without a sign of step wear.

When part replacement becomes necessary, the pump

cartridge should be replaced as a subassembly.

SIDE PLATE

The sliding faces of parts must be free from step wear (more

than 0.01 mm), which can be felt by the finger nail.

The parts with minor scores may be reused after lapping the

face.

VALVE

The sliding face of the valve must be free from burrs and

damage.

The parts with minor scores may be reused after smoothing

with emery cloth (#800 or finer).

SHAFT

Oil seal sliding faces must be free from a step wear which can

be felt by the finger nail.

Needle bearing fitting face must be free from disintegration and

wear.

O-RING, OIL SEAL RETAINING RING

Be sure to discard used parts, and always use new parts for

installation. Prior to installation, lubricate all seals and rings

with power steering fluid.

REASSEMBLY

27. Rear Housing

26. Pin

25. Cam

24. Rotor and Vane

1. Install the rotor with its punch mark facing the front

housing.

2. Install the vanes with curved face in contact with the

inner wall of the cam.

23. Pressure plate

CAUTION:

When install pressure plate, be careful not to damage its

inner surface. Damaged pressure plate may cause poor

pump performance, pump seizure or oil leakage.

22. Front Housing

21. O-ring

Be sure to discard used parts, and always used new parts

for installation.

20. O-ring

Be sure to discard used parts, and always used new parts

for installation.

19. Gasket

Be sure to discard used parts, and always used new parts

for installation.

18. Rear Housing Assembly and Pump Cartridge

17. Bolt

Rear Housing Bolt Torque N⋅m (kgf⋅m / lb⋅ft)

17.6 (1.8 / 12.8)

16. Oil Seal

Be sure to discard used parts, and always used new parts

for installation.

CAUTION:

When installing the oil seal, be careful not to damage the

oil seal contacting surface of the housing.

15. Retaining Ring

14. Shaft

13. Bearing

12. Shaft Assembly

11. Retaining Ring

10. Pressure Switch

Pressu re Switch Torque N⋅m (kgf⋅m / lb⋅ft)

20 (2.0 / 14)

9. Spring

8. Filter

7. Retaining ring

6. Valve

5. O-ring

Be sure to discard used parts, and always used new parts

for installation.

4. Connector

Connector Torque N⋅m (kgf⋅m / lb⋅ft

)

74 (7.5 / 54)

3. O-ring

Be sure to discard used parts, and always used new parts

for installation.

2. Pipe, Suction

1. Bolt

Suction Pipe Bolt Torque N⋅m ( kgf⋅m / lb⋅ft

)

16 (1.6 / 12)

TROUBLESHOOTING

INSPECTION PRO CEDURES FOR STEERING SYSTEM

COMPONENT AND TEST PROCEDURE

HANDLE Check for

play and

slack

1. Place the steering wheel in the straight forward position. Gently move the

wheel to the right and to the left. About ten millimeters of play in either

direction should be present before the front tires begin to move.

If the vehicle is equipped with power steering, the engine should be running

when these tests are made.

2. Grasp the steering wheel firmly with both hands. Exert force in an up and

down direction on the steering column. There should be no play.

3. Move the steering wheel to the right and to the left. Check to see the

steering shaft.

Make sure that there is no slack in those areas where parts are joined

together.

Check the

operating

condition of

the system

1. Make the following checks while actually driving the vehicle.

a. Check the position of the steering wheel when the vehicle is traveling

straight ahead.

b. Make sure that the vehicle does not have a tendency to steer to the right

or the left.

c. There should be no excessive vibration present at the steering wheel.

d. Turn the vehicle as sharply as possible to both the right and the left.

When the steering wheel is turned fully in either direction, check for

abnormal noise.

Neither should the wheel feel overly heavy when it is fully turned to either

the left or the right. Loosen your grip on the steering wheel. It should

return to its center position.

GEAR BOX Check for

oil leakage 1. Check all parts of the steering unit (the oil seals of the front cover, side

cover, sector shaft, etc.) to make sure that there is no oil leakage.

Check for

looseness

in the

assembly

1. With the wheels of the vehicle on the ground (the vehicle should not be

jacked up), have an assistant or helper turn the steering wheel to the right

and to the left. As he does this, you should carefully check all areas where

the steering unit is attached to the frame for looseness and other possible

problems.

Check for

bearing

backlash

1. Check the condition of the connections between the steering shaft and the

bearings. Move the steering shaft in the direction of the axle and make sure

that there is no backlash present.

2. Rotate the steering shaft. There should be no abnormal noise. It should

rotate smoothly and there should be no feeling of roughness.

Check to make sure that there is no abnormal or excessive bearing wear.

Check for

gear

backlash

1. The front wheels should be facing straight ahead. Have an assistant or

helper grasp the drop arm so as to immobilize it. Now try to turn the steering

wheel. Backlash should not exceed one millimeter.

Inspect the

sector shaft

for c racks

1. Remove the steering unit from the vehicle and break it down into its

component parts. Carefully inspect the sector shaft for cracks or other

damage.

COMPONENT AND TEST PROCEDURE

RODS AND

ARMS Check for

play,

backlash,

and

damage

1. With the wheels of the vehicle on the ground (the vehicle should not be

jacked up), have an assistant or helper turn the steering wheel to the right

and to the left. As he does this, you should carefully check the connecting

points of all the parts for play, slack, or damage.

a. Specifically check the pitman arm, the intermediate rod, the tie rods, the

tie rod ends, the knuckle arms and the relay lever.

2. Carefully check all of the pins for cracks and other damage.

3. Make sure that the rod end boots and related areas are not cracked or

otherwise damaged.

Check the

coupling

parts for

abrasion

and other

abnormal

conditions

1. The ball joints and the rubber bushings should be free from abrasion or any

other damage.

2. Pay careful attention to the coupling areas. Make sure that everything is

properly connected.

Check for

cracks in

the knuckle

arms and

also for

poor

knuckle

attachment

1. Make sure that both the knuckle arms and the tie rod arms are free from

cracks.

The fit between the knuckles and the tapers should be secure.

Look for any abnormal coloring which may indicate trouble.

KNUCKLES Check for

loose and

damaged

joints

1. Jack up the front axle and the front crosspiece. By hand, rotate the two front

tires in either direction. Check that the king pins and the ball joints are free

of play or slack.

If play or slack is present, have an assistant or helper, hold down the brake

pedal. Using a dial gauge, once again check the wheels for play and

vibration. It is possible that the problem lies not with the steering system but

with the wheel bearings.

Check the

gap

between

the steering

knuckles

and the

front axle

1. Use a thickness gauge or other appropriate tool to measure the width of the

gap between the steering knuckles and the front axle. Measure in the

direction of the king pin.

After measurement, thrust washers may be inserted to alter the gap.

1. HARD STEERING W ITH POOR STEERING WHEEL RETURN

Checkpoint Trouble Cause Countermeasure

Steering shaft bearings

Steering linkage

Front wheel alignment

Oil level in the reservoir

(Power steering only)

Replace the bearings

Repair or replace the joint ball

and/or the ball seat

Correct the front wheel

alignment

Replenish the oil

Bearings sticking or rusted

Joint ball sticking or rusted

Front wheels out of alignment

Insufficient oil

Steering wheel play Adjust the play

Correct the Tyre inflation

pressure

Insufficient play

Low Tyre inflation pressure

Continued on the next page

Tyre inflation pressure

Checkpoint Trouble Cause Countermeasure

Steering unit internal parts

Worm shaft bearing preload

Hydraulic system (Power

steering only)

Replace the damaged parts

Adjust the preload

Air bleeding

Part damage

Preload too heavy

Air in the hydraulic system

Control valve lock nut

(Power steering only) Retighten the lock nut to the

specified torque

Repair or replace

Control valve lock nut

overtightened

Joints and sleeve yoke

sticking or rusted

Joints and sleeve yoke

Continued from the previous page

2. STEERING VIBRATION AND SHIMMY

Checkpoint Trouble Cause Countermeasure

Steering link joint ball play

Front wheel alignment

Steering wheel play

Wheel pins

Replace the joint ball and the

ball seat

Correct the front wheel

alignment

Adjust the play

Retighten or replace the wheel

pin(s)

Joint ball excessively worn

Front wheels out of alignment

Excessive play

Broken or loose wheel pin(s)

Tyres and disc wheels Correct the Tyre balance

Replace the disc wheel

Retighten the wheel nuts to

the specified torque

Unbalanced Tyres

Deformed disc wheel(s)

Wheel nuts unevenly torqued

Continued on the next page

Wheel nuts

Checkpoint Trouble Cause Countermeasure

Steering unit internal parts

Sector shaft needle bearing

Wheel bearings

Replace the damaged parts

Replace the needle bearing

Replace the bearings

Part damage

Needle bearing excessively

worn

Play in bearings excessive or

bearings disintegrated

Adjust screw and sector shaft

clearance Adjust the clearance

Replace the shock absorbers

Excessive clearance

Faulty shock absorbers

Shock absorbers

Continued from the previous page

3. STEERING PULLS TO ONE SIDE OR THE OTHER

Checkpoint Trouble Cause Countermeasure

Brakes

Front wheel alignment

Shock absorbers

Tyres and disc wheels

Refer to Section 5A"BRAKE

VACUUM ASSISTED

HYDRAULIC TYPE"

Correct the front wheel

alignment

Replace the shock absorbers

Correct the Tyre balance

Replace the disc wheel

One wheel dragging

Front wheels out of alignment

Faulty shock absorbers

Unbalanced Tyres

Deformed disc wheel(s)

Wheel bearings Correct or replace

Inflate all the Tyres to the

specified pressure

Incorrect preload or damage

Tyres unevenly inflated

Tyre inflation pressure

Steering shaft end play Adjust the end playExcessive end play

4. STEERING WANDER (EXCESSIVE PLAY OR LOOSENESS)

Checkpoint Trouble Cause Countermeasure

Steering shaft universal joint

Steering wheel and shaft

Front wheel alignment (Toe-

in)

Oil level in the reservoir

(Power steering only)

Tighten the bolts to the

specified torque

Tighten the lock nut to the

specified torque

Correct the front wheel

alignment

(Adjust the toe-in)

Replenish the oil

Universal joint bolts loose

Steering wheel lock nut loose

Front wheels out of alignment

(Toe-in out of adjustment)

Insufficient oil

Manual or power steering unit Tighten the steering unit bolts

to the specified torque

Replace the tires and check

the wheel alignment

Steering unit mounting loose

Tires badly worn

Rounded tire edges

Tires

Continued on the next page

Steering linkage joint ball nut Tighten the nut to the

specified torque

Joint ball nut loose

Checkpoint Trouble Cause Countermeasure

Worm shaft bearing preload

Front wheel bearings

Adjust the preload

Replace the bearings or adjust

the preload

Preload improperly adjusted

Bearings excessively worn or

preload incorrectly adjusted

Hydraulic system (Power

steering only) Air bleeding

Tighten the nut to the

specified torque

Air in the hydraulic system

Pitman arm nut loose

Pitman arm and sector shaft

Continued from the previous page

5. MO MENTARY INCREASE IN STEERING EFFORT WHEN THE STEERING WHEEL IS TURNED

QUICKLY TO ONE SIDE OR THE OTHER (POWER STEERING ONLY)

Checkpoint Trouble Cause Countermeasure

Oil pump

(Power steering only) Repair or replace the oil pumpOil pump internal leakage

Replenish the oilInsufficient oil

Oil level in the reservoir

(Power steering only)

6. STEERING WHEEL SURGE OR JERK WHEN PARKING THE VEHICLE (POWER STEERING ONLY)

Checkpoint Trouble Cause Countermeasure

Oil pump pressure Adjust the pressure and/or

replace the relief valve

Pressure too low

Replenish the oilInsufficient oil

Oil level in the reservoir

(Power steering only)

7. EXCESSIVE RO AD SHOCK

Checkpoint Trouble Cause Countermeasure

Camber angle (4×2)

Suspension

Adjust the camber angle

Repair or replace the

applicable parts

Camber angle incorrectly

adjusted

Loose suspension

Shock absorbers Replace the shock absorbers

Inflate all the tires to the

specified pressure

Faulty shock absorbers

Tires overinflated

Tire inflation pressure

Hub bearing preload Adjust the preloadPreload out of adjustment

8. ABNO RMAL NOI SE

(1) RATTLING OR CLICKING NOISE IN THE STEERING GEAR

Checkpoint Trouble Cause Countermeasure

Steering linkage

Hydraulic pressure hose

(Power steering only)

Repair or replace the steering

linkage parts

Reposition the hose

Steering linkage loose or worn

Hose touching another part of

the vehicle

Pitman arm Tighten the pitman arm nut to

the specified torque

Tighten the steering unit bolts

to the specified torque

Pitman arm loose

Steering unit mounting bolts

loose

Manual or power steering unit

9. OIL PUMP NOISY

Checkpoint Trouble Cause Countermeasure

Oil pump NG

Pressure of air in hydraulic

circuit

Overhaul or replace

Bleed circuit

Defective

Air in circuit

Suction tube and filter for

restrictions Clean or replace

Replenish

Restrictions in tubing or filter

Insufficient

Oil level

Steering gear box Overhaul or replaceDefective

SPECIAL SERVICE TOOL (C22, C20 SERIES ENGINE MO DEL)

ITEM NO. ILLUSTRATION PART NO. PART NAME

STL-19 5-8840-0135-0

(J-29877-A) Power steering tester

STL-21 5-8840-0136-0

(J-33996) Power steering tester

adapter

STL-1 5-8521-0016-0

(J-29752) Steering wheel puller

STL-13 5-8840-2017-0

(J-35707) Pitman arm remover

STL-2 5-8840-2006-0

(J-29753) Input cover lock nut

wrench

STL-5 5-8840-2007-0

(J-7624) End cover remover

STL-8 5-8522-0026-0

(J-26508) Extension housing oil

seal installer

STL-12 5-8840-2121-0

(J-21677-2) Tie-rod remover

STL-10 5-8840-2206-0 Power steering pump

bearing remover and

installer

STL-9 5-8840-2205-0 Power steering pump

oil seal installer