S T E E R IN G S T E M SYS E C T TIO N I----.. . -'CONTENTSPRECAUTIONS ......... ...... ............ ........ .................. ................... .............................. .............. ... ST- 2 PREPARATION ........ ...... ....... ........ . ..................... ......................... ............. .............. ..... ............ ST- 3 ON-VEHICLE INSPECTION ........... .................. ....... .... .. ................................. ....... ...... .... ........ ST- 5 STEERING WHEEL AND STEERING COLUMN .......... ........ .............................. .... ..... ......... .... ST- 9 MANUAL STEERING GEAR AND LINK AGE (Model R24S and R24N) ... ........................... .... ST-15 POWER STEERING GEAR AND LINKAGE (Mod el PR24SC) ......................... ....... ............. ... ST-22 POWER STEERING OIL PUMP ................ ...... ............. ......................... . ... ....... ................... ST-34 SERVICE DATA AND SPEC!F!CATIONS ( S.O.S.) ....... ......................... ................ ................. ST-37PRECAUTIONSThe power steering gear and oil pump should be disassem bled only when repairing an "oil leak". they should not be disassembled to repair any other steering defect, steering noise, etc. Before disassembly, thoroughly clean the outside of the unit. Disassembly should be done in a clean work area. It is important to prevent the internal parts from becoming contaminated by dirt or other foreign matter. When disassembling parts, be sure to place them in order in a parts rack so they can be put back in the unit in their proper positions. Use a nylon cloth or paper towel for wiping parts c lea n. Common shop rags can leave lint that might interfere with the operation. All parts should be carefully cleaned with a general pur pose, non-flammable so lvent before inspectio n or reassem bly. Before assem bly, apply a coat of recommended A.T.F.' to hydraulic parts. Vase!\ne may be applied to 0-rings and seals. Do not use any grease. Gaskets, seals and 0-rings should be replace d. Care should be taken to avoid damaging 0-rings, sea!s and gaskets when assembling. It is also very important to perform functional tests whenever it is designated. Automatic transmission fluid *EJXPREPARATIONSPECIAL SERVICE TOOLSTool number Unit application Manual steering KV48102000 End cover socket wrench Removing and instal l1 ng Power steeringrear cover and end coverXXKV48100700 Torque adapterMeasuring pinion torquerotat ingXKV48 101100 Torque adapter- - +- - - - - - - - - - - -- - - - - - - -- Measuring torque- - ----- --- --pinion rotating ----- - - --+--- -- --XST27180001 Steering wheei pu ller------ ------- ---- - - --- - ----Removing steering wheeland installingXX---, ---------------I-IT72520000 Ball JOint remover-- Remo ving ball J Oint- -- +- - - ,- ---- j------ -----vII'AST27091000 Pressure gaugeMeasur ing oil pressureKV48102500 pressure Pressure gauge adapterMeasuring o il IIi- I1XiReforming te flon r ingXKV48104400 Rack seal ring reiormerv"ST-3Un i1'Tl'Tl( in ) vPREPARATIONTool number Tool name Descripl:onUnit application Manual steering Power steeringST3127SOOO r,' GG91030000Torque wrenchMeasuring torqueturning' HT62940000Socket adapterT O--X,. HT6290DOOOSocket adapterXCOMMERCIAL SERVICE TOOLSUn:t applicati or. Tool nam e Oesuipiion Manual steering Rear oil seal dnft Installing rear oiI seal Power steer ingX' 28m ( 1.l0inidi m a Installing seal pi nto n oil-- ----- - - - ----- --P:n:on oil seal dr:t:X--- - --. -- --,- -------Oi! pump attachment(For011(For oil pump)pump)SST481A- - - - -- -- -- -- -- - - - -------- ------ - - - - - - - - - - - - - - - - - - --- - - ----- - - - - - -'ON-VEHICLE INSPECTION Checking Steering Wheel Play1. With wheels in a straight-aheadposition, check steering wheel play. Steering wheel play: 35 mm (1.38 in) or less lf it is not within specification. check steering gear assem bly when front suspension and axle, steering gear assem bly and steering column are mounted correctly.2.--- - -- - -- , -IChecking Neutral Position on Steering WheelN G.O.K.Pre-checking Make sure that wheel alignment is correct. Wheel alignme nt: Refer to section FA for S.O.S. Verify that the steenng gear is centered before remov 1 ng the steering wheeL"Checkingi. 2.SST9-JGAJ3.Check that the steering wheel is in the neutra l position when dri ving straight ahead. If it is not in the neutral position, remove the steering whe el and reinstal l it correctly. If the neutrai position is between two serrated teeth, loosen tie-rod lock nut and move tie-rod in the opposite direction by the same amount on both left and rig ht sides to compen sate for error in the neutral posit ion.Front Wheel Turning AngleRotate steering wheel all the way right and left: measure turning angle. Turning angle of full turns: Refer to section FA for S.O.S. i f i t is not within specification, check rack stroke. Rack stroke "L": Refer to S.O.S.2.L- --Checking Gear Housing Movement-----1.2.Check the movement of steering gear housing during stationary steering on a dry paved surface. Apply a force of 49 N (5 kg, 11 lb} to steering wheel to check the gear housing movement. Turn off ignition key while checking. Movement of gear housin g: 2 mm ( 0.08 in) or less If movement exceeds the limit, replace mount insulator after confirming proper installat ion of gear housing c! amps.ST-5ON-VEHICLE INSPECTION Checking and Adjusting Drive BeltsRefer to section MA for Drive Belt Inspection.-- - ---- ---1- -'i-- !Checking Fluid LevelCheck fluid level. Fiuid level should be check ed using "HOT" range on dipstick at fluid temperat ures of 50 to 80cC (122 t o 176F) or using "COLD" range on dips tick at fiuid tem peratures of 0 to 3o c (32 to 86 F).i I.-d-1- - - - - - . ..l - :.'"'--: -;:;":;:::/] ,:' ------- ------ ---- ----------------- - - 8 0Bl 'ISS T 2.CAUTION: Do not overfill. Recommended fluid 8 Fluid "DEXRON " type.isAutomaticTrans mi ssionChecking Fluid Leakage-rSST631 6,Check the lines for improper attachment and for lea ks, c racks, damag e, loose connection s, chafing or deter iorat ion. 1. Run engine betw een idle speed and 1 , 000 rpm. Make sure temper ature of fluid in oil tank rises to 60 to 80,C (140to 176. F).2. 3. Turn steering whee l r ight-to -left severai times. Hoid stee ring wheel at each "lock'' posit ion for five secon ds and care fully check f or f luid leakage.CAUTION: Do not hold the stee ring wheel in a locked position for more than 15 seconds.4. If fluid leaka ge at connect ors i s noticed , loos en flare nut and then retighten.Do not overtighten connect or as this can damage 0-rin g, washer and connecto r.Bleeding Hydraulic SystemRaise front end of vehicle until wheels are clear of the groun d. 2. Add flu id into oil tank to specified leve l. Mea nwhile quick ly tur n stee ring wheel fully to right and left and lightly touch steering stopper s. Repeat steering whee! operation unt il fluid lev el no longer decrease s. 3. Start engine. Repeat step 2 above. 1.ST-6-II-ON-VEHICLE INSPECTION Bleeding Hydraulic System (Confd ) Incomplete air bleeding will cause the following to occur. When this happens. bleed air again. a. Generation of air bubbles in reservoir tank b. Generation of clicking noise in oil pump c. Excessive buzzmg rn oil pump While the vehicle is stationary or while moving the steering wheel slowly, fluid noise may occur in the valve or oil pump. This noise is inherent in this steering system, and it will not affect performance or durability of the system.-lChecking Steering Wheel Turning Force1. 2. 3. Park vehicle on a lev el, dry surface and set parking brak e. Start engine. Bnng power steer r ng fluid up to adequate opera t ing tem perature. [Make sure temperature of fluid is approximately 60 to 80C (140 to 176"F).] Tires need to be inflated to normal pressur e. 4. Check steerrng wheel turning force when steering has been turned 360 from the neutral position. Steering wheel turning force: 39 N (4 kg, 9 lb) or less 'Vheel . < -._ -j' .-:_/- - - ---- -\\i,ISST901A!5.if steering wheel turning force is out of specifications.a. b. c.SST0906i,'Average value _ (Max . varus+ Min. valual/ B. . .0-2d... ..: a:j"s '-_ j_Ma: dmum value6.Min im. umcheck rack siiding force to detect condition of steering gear assembly. Disconnect steering column lower joint and knuckle arms from the gear. Start and run engine at idle to make sure steer ng fluid has reached norma! operating temperatur e. While pulling tie-rod slowly in the 1\.5 mm (0.453 in} range from the neutral posit ion, make sure rack sliding force is within specification. Average rack sliding force: Less than 226 N (23 kg, 51 lb) Check sliding force outside above range. Maximum rack sliding force: Not more than 39 N (4 kg, 9 lb) beyond above value If rack sliding force is not within specifica tio n, overhaul steering gear assembl y.vafuel 11.5 Rack stroke (-0.453 ) Neutral (0.4351 SST717A position Un it: mm {inf-1 1.5IST-7ONVEHICLE INSPECTION Checking Hydraulic SystemBefore startin g, check belt tension. dr iving pulley and tire pressure. 1. Set Tool. Open shut-off val ve. Then bleed air . (See "B le eding Hydraulic Syste m".) 2. Run engin e.High pressu r e hose- - - - - ----, IIST2 70 91 0 00Make sure temperature of fluid in tank rises to 60 to to 176.F).WARNING:aoc (140Warm up engine with shut-off valve fully opened. If engine is started with shut-off valve close d, oil pressure in oil pump will increase to relief pressur e, result ing in an abnormal rise in oil temperatur e.'--L. .. .Low-. . .pres .Hl! : Direc tion ot oil flow3.hoseCheck pressure with steer ing wheel fully turned to left and right positions with engine idlin g at 1,000 rpm.CAUTION:Ij__- S S T 8 3 41Do not hold the steering wheel in a locked posi tion for more than 15 sec onds. Oil pump maximum stand ard pressur e: Except CD17 engine 7,649 - 8,238 kPa (76.5- 82.4 bar, 78 - 84 kg/cm 2 , 1,109 - 1,194 psi) CD17 engine 6,669 - 7,257 kPa (66.7 - 72.6 bar, 68 - 74 kg/cm 2 , 967 - 1,052 psi)4. If oi [ press ure is below the stan dard pressu re, slo w ly c lose shut- oH valve and c heck pressure. e When pressure rea ches standar d pressur e, gear is dam aged. iib When pressur e r emains be1o w stand ard pressure, pump is damage d. CAUTIO N:De not close shut-off val ve for more than 15 second s.5. 6. If oil pres sure is higher t han s tandard pressur e. c heck oil pump flow con trol valve. After checking hydra ulic system, r emo ve Tool and add fiuid as necessa ry, then comp letel y bleed air out of system.STEERING WHEEL AND STEERING COLUMNNm (kg-m, ft-lb)SST664BAG) Co lumn cover@ Steering column assembly@ Combination switch@ Stee ring wheelHorn padRemovalSTEERING WHEEL1. Remove horn pad. - Two spoke type Horn pad is installed using pawls (plastic) and ciamps. To remove horn pad, pry pawls by hand and push clamps with a standard screwdriver inserted between pad and steering wheel.ST-9STEERING WHEEL AND STEERING COLUMN Removal (Confd )- Three spoke type Horn pad is installed using three clamps. To remove horn pad, insert a standard screwdriver into hole on back of lower spoke and pry clamps up.- Four spoke type Insert a crosshead screwdriver into hole on lower side of spoke and remove clamps. lift ho rn pad off by hana.'------------------SST6678j2.Remove steering wheel w ith Too l.installationSTEERING WHEELWhen installing steering whee l, app ly multi-purpose grease to ent ire surface of turn signa! cancel pin (both portions) a11d also !o horn contact slip ring.SST112BST-10''...STEERING WHEEL AND STEERING COLUMN Installation (Cont'd) STEERING COLUMN When installing steering colum n, fingertighten all lower bracket and clamp retaini ng bolt s; then tighten them se curel y. Do not apply undue stress to steering column. When attaching coupling join t, be sure tightenin g boll faces cutout portion_ CAUTION:Ii sure it moves smoothly and that the number of turns from thestraight forward position to left and right locks are equal. Be sure that the steering wheel is in a neutral position when driv i ng straight ahea d.After installingsteering column, turn steeringwheel to makeL_owe r _o_i" i ----- srsooA I L . _ST-11STEERING WHEEL AND STEERING COLUMN Disassembly and Assembly@:\--ri\\\'\(]. 1',/ /_ /. / /IC D Snapassemblyring@ Boot:];: Jacket tube ass embly ;: Com b:nation switch - --ST821_r:j---S -'1; 0- ring@ Column shaftWhen disassem bling and assem bling, unlock steer ing lock with key.ST-12-STEERING WHEEL AND STEERING COLUMN Disassembly and Assembly (Cont'd ) Remove combination switch.'Ii-!ISST6698l' 'i [ Upper shaftIISST67081'Ensure that rounded surface of snap ring faces toward bearing when snap ring is installed. Install snap ring on upper shaft with a suitable tool. a.Steering !ock Break self-shear type screws with a drill or other appropri ate tool.b.Install self-shear type screws and then cut off self-shear type screw heads.Se If-shear screwSST742AITilt mechanisme After insta!J ing steering column, check til t mechanism op eration.i15 " ' "II I i!I IST-13'Jnit : mm lin)SST582B!STEERING WHEEL AND STEERING COLUMNInspectiona. b.ISST125BIWhen steering wheel can not be rotated smoothly, check the steering column for the following matters and replace damaged parts. Check column bearings for damage or unevenness. Lubri cate with recommended multi-purpose grease or replace steering column as an assembly, if necessary. Check jacket tube for deformation or breakag e. Replace if necessary. When the vehicle is involved in a light collision, check column length "L". If it is not within specifications, replace steering column as an assembly.Column length "L": 536.2-537.8 mm (21.11- 21.17 in)ST-14MANUAL STEERING GEAR AND LINKAGE (Model R24S and R24N), !Removal and Installation!!M NmC D Lower 0G) Hole coverjoint steering gear assembly(kg-m. ft-lb)SST6716 : : D Manual\1;Steering gear mounting clamp Cotter pin( ) Rack mounting insu!a t oreDetach tie-r od ball studs from knuck!e arms with Tool.ST-15., .,." Pinion bearing- . Gear housrng assembl y @: Spacer MANUAL STEERING GEAR AND LINKAGE (Model R24S and R24N) Removal and Installation (Cont'd) Initially, tighten nut on tie-rod outer socket and knuck le arm to 29 to 39 Nm (3 to 4 kg-m, 22 to 29 ft-lb ). Tighten nut further to align nut groove w i th the first pin hole so cotter pin can be installed.CAUTION: Tightening torque must not exceed 49 Nm (5 kg-m, 36 fHb ).Disassembly,- 1,[::?J1 : Nm (kg-rn, fl-ib)---- --- -- -----------@- Plain- ------- - - --:- --- ---- - - -SST672B ;-- ...- -(i Gurae chip washer ij Rear co ver lock nut ; Dust seal(4' ,'j---Tie-rod inn er socket_ _ : ::ST-32.> .POWER STEERING GEAR AND LINKAGE (Model PR24SC )Adjustment(Cont'd )11. Measure pinion rotating tor que.Within 1oo from the neutral positio n: Average rotating torque 0.8 - 1.3 Nm (8- 13 kg-e m, 6.9 - 11.3 inlb) Maximum torque deviation 0.4 Nm (4 kg-e m, 3.5 in-lb) Except tor above measuring rang e: Maximum rotating torque 1.9 Nm (19 kg-em, 16 in-l b) Maximum force deviation 0.6 Nm (6 kg-em, 5.2 in-lb)If pinion rotating torque is not within specifications, readj ust it starting from procedure 4. If pinion rotating torque is still out of specifications after readjustmen t, repl ac e steering gear asse mbly.iSST090B 1I12. Check rack sl iding force on vehicle as follows: a. Inst a ll ste ering gear onto vehicl e, but do not connect t ierod to knuc kle arm. b. Connect all piping and fi!l with steering fluid. c. Start engine and ble ed air com pletel y. d. Disconne ct stee ring column lower joint from the gear. e. Keep engine at idle and make sure steer ing fluid has reached normal operating temper ature. f. While pulling tie-rod slowly in the 11.5 mm ( 0.453 in) range from the neutral posit ion, make sure r ack sliding force is wit hin specificatio n. ' '" {M ." "+ " " ' Mi., I 0.II f02" '"'1'Average rack sliding force: Less than 226 N (23 kg, 51 lb)g. Check sliding force outside above rang e.i IMax imum valuat more thanNlb) beyond above"!:'-IMinimum value [kg, Maximum rack sliding forc e: No 39 (4 9 value"..l-11.5l 11.5 Rack strokeUni t: mm ti n)I1 1 rack sliding force is not w ithin speci f ication. readjus t b ' y r epeating adjustment proced ure from the beginning. If r ack sli ding force is still out of speci fication after read justment, gear assembly needs to be replace d.(-0.453 i N tal {0 51 e . 34 SS T7\ 7A pOSi t iOn1ST-33- 1- ----._ /.'-V .POWER STEERING OIL PUMP . Disassembly and Assembly54 - 68 (5.5 6.9, 40 - 50) . -'i.Puiley Snap r ing Dr i ve shaft.,-,i(i.v/Oil seal 0- ring Spring Control val vei;: @ I Front housmgWas her Joint Connector bolt!3Vane Pin@ R oto r's': S uction pipe@ Sp nng@ Cam ring @ Gask et(:"; t .5 " '" 5i. '..:.J0-ri ng 0-r in;J Fr ont s ide plate.g.Rear housing(i'2 .1, .@ Moun ting bracketc\ -Pre-disassembly Inspection"'1IDi sassemble the powe r steering oil pump onl y i f the follow ing i tems ar e found. O il leak from any poin : shown in t he figure. Deformed or damaged pui ley .lLJ_'iST-34POWER STEERING OIL PUMP DisassemblyCAUTION: Parts which can be disassembled are strictly limited. Never disassemble parts other than those specified. Disassemble in as clean a place as possible. Clean your hands before disassembly. Do not use rags; use nylon cloths or paper towels. Follow the procedures and cautions in the Service Manual. When disassembling and reassembling, do not let foreign matter enter or contact the parts. Remove snap ring, then draw drive shaft outBe careful not to drop drive shaft.iI IISST0 1OBtRemove oil seal.Be careful not to damage front housing.SST034 AFront housingRemove connector.Be careful not to drop control valv e.SST036AInspectioninspec t each component part for wear, deformatio n, scr atche s, and cracks. If damage is found, replace the part.ST-35POWER STEERING OIL PUMP AssemblyAssemble oil pump, noting the following instructio ns. Make sure 0-rings and oil seal are properly installed. Always install new 0-rings and oil seal. Be careful of oil seal direc t ion. Cam ring, rotor and vanes must be rep laced as a set if necessary. Coat each part with A.T.F. when assembling.SST038JRear housing sideFront housing sidePu nchmark-!Pay attention to the direction of roto r.- -- - .- - , - -- - - --Faces ins i de,--Vane I \\When assembling vanes to roLO r, r ounded vanes must face cam ring s ide.surf aces ofI- - - SST54-insert pin @ into pin gr oove G ) of front hou s ing anci f ront side plate. Then instal l cam r ing @ as shown at left.IIl_ASST497ST-364SERVICE DATA AND SPECIFICATIONS (S.O.S.) General SpecificationsApplied model Steering model Manual steenng Except Europe Power steering Manual steenng Europe Power steer1ng- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - + - - - - - -- - - - - - - - - - - - - - - - - - - --Steering gear type R24S R24N PR24SC PR24SC - - - - - - - - - - - - - --- - - - - - - - - - . - - - - - - - - - - - - - - - - - - ----------- , - - - - - - - - - - - - --1 2WD 4WDTurns of steering whee lI I3.75'1 3.33'3I. '!R O H!LHD4.on 2 .s n. .Ii. ... 741 2.s323.75'1_3.17'22.a332 21 3 2.97"1 (Except SR20DE} 2.72'1 (GA16DS) 2.69'1 (SR20DET )(lock to lock)f!- -- - - -- --------+-4 21"3! I3 17"2, 3.33'3. 13 07'3------'------------_1___----'-------------_j Collapsi ble. tilt2_.9_3_'_1_(S_R_2_0_D_E_J_lSteer1ng column type'1 Models equipped W!lh 14-Jnch \ires . 2 D1esel engine models equipped w1th 13-inch t1res '3: Gasol1ne engine models equipped wit h 13-inch tiresInspection and AdjustmentGENERALSteering wheel ax1al playSTEERING GEAR AND LINKAGEmm(m) 0 (0)Steering gear type Side rod outer ball jomt Swinging force at cotter p1n hole N (kg, lb} Rotating torque Nm (kg-e m. in-lb) A x ial end play limitR24S, R24NPR24SCSteering wheel play i1mit- - - - - - - - - - - - +- - - - - - - - - 35 (i 38)m rn (in)Maximum movement of gear housing mm (1n) 0.08)6.9- 64.7(0.7 - 6.6, 1.5 - 14.6) 2 ( :i:0.3- 2.9(3 - 30, 2.6 - 26.0)mm {in)Less than 0.5 (0.020}STEERING COLUMNSteenng column lengtn L" mm (in) .. 536.2- -537 8 (.2111 - 21 17)S1de rod inner bali joint Swing1ng forc e' N (kg, ib) 14.7 - 21.6(1.5- 2.2, 3.3- 4.9)0 (0)Axial end play limit mm (in) Side r od standard leng th "L " mm (in)184 (7.24)LSST125BSST3048': Meas uring pointST-37IISERVICE DATA AND SPECIFICATIONS (S.O.S.) Inspection and Adjustment (Cont'd)STEERING GEAR AND LINKAGE (Cont'd)2WD 4WD-E600 ' 1POWER STEERINGSteering gear type Rack sl iding force N (kg, lbJ Und er normal operat ing oil pressureiRack stroke"l"65.5 (2.579) '1I IIJPR24SCmm (in)70.0(2.756)'2,73.5 (2.894 )"3 "1: Models equipped with 14-inch tires62.5 "3"2 Diesel engine models equipped with 13-inch tires" 3 Gaso line engine mod els equipp ed w tth 13-inch tiresRange within ";1.5m rn-- --( 0.453 in) from the neutraliLess than 226 (23, 51 )pos ition Except above r ange-----+------------iSteen ng wheel turning force (Mea sured at one full turn fr om the neutral pos ition)/Not mo re than 39 (4, 9) beyond a bo ve va luei1-- - --N (kg. l b!I39 (4, 9) o r lessF!t;;cicapacit y ;Appro ximat e j-r. -1 (7/8jSteer t ng gear typeReta iner adjustment--- .-- - i - - - -rR 24SR "2 4 NSS T0866 .PR24SC-+-- - -- ----Except CD17 engt e 7 649 - 8.238(76 5 82. 4, 78- 84, Oil pump maxim um pressure kPa (bar, kg.'crn' .I1. t09 - 1,194 ) CD17 engineAdjusting screw Nm (kg-em. in-lb) Init ial tightening torque Reti ghtening torque at ter looseningI4.9 (50, 43)0.2 (2, 1.7)psil6.669 - 7.257(66.7 - 72.6, 68 - 74,- - --+ ---- - - +' -I- -967 - 1,052)2.9 (30. 26)0.2 ( 2. 1 7)I Tigh teni ng torque afte-;--' - - - --gear has settled Returntng angl e degr ee Pinton gear preload without gear oo! N m (kg-e m. inlb) Witht n 100< !rom the neutral posi t t on P..verage rotat ing torque Maximum tor que devi ation Except above range Maximum rotating torque Maximum torque devi ation1.5 (15, 13) 0.7 - 1.2 (7 12, 2.9 (30. 26)4.9 (50, 43)4 '050' - 70'so 6.1 10.4)0.3 (3. 2 6)08 - 1.3 (8 - 13, 6 9 11.3) -0.4 (4, 3.5)1.9 (19, 16)05 (5, 43 )0.6 (6. 5.2)ST-38