Download: STEERING SYSTEM SECTIONST

STEERING SYSTEM SECTIONST CONTENTS

PRECAUTIONS ...2 TILT MECHANISM ...15 Supplemental Restraint System (SRS) ″AIR POWER STEERING GEAR AND LINKAGE ...16 BAG″ and ″SEAT BELT PRE-TENSIONER″...2 Components...16 Precautions for Steering System...2 Removal and Installation ...17 PREPARATION ...3 Disassembly...18 Special Service Tools ...3 Inspection...19 Commercial Service Tool...4 BOOT ...19 NOISE, VIBRATION AND HARSHNESS (NVH) RACK ...19 TROUBLESHOOTING ...5 GEAR SUB-ASSEMBLY ...19 NVH Troubleshooting Chart...5 GEAR HOUSING CYLINDER...19 ON-VEHICLE SERVICE TIE-ROD OUTER AND INNER SOCKETS ...20 ...6 Assembly ...20 Checking Steering Wheel Play...6 Adjustment ...23 Checking Neutral Position on Steering Wheel ...6 PRE-CHECKING...6 POWER STEERING OIL PUMP (QG ENGINE) ...25 CHECKING ...6 Components...25 Front Wheel Turning Angle...6 Pre-disassembly Inspection...25 Checking Gear Housing Movement ...6 Disassembly...26 Checking and Adjusting Drive Belts ...7 Inspection...27 Checking Steering Gear and Linkage ...7 Assembly ...27 STEERING GEAR...7 POWER STEERING OIL PUMP (YD ENGINE) ...29 STEERING LINKAGE...7 Components...29 Checking Fluid Level ...7 Pre-disassembly Inspection...29 Checking Fluid Leakage...7 Removal and Installation ...30 Bleeding Hydraulic System...8 Disassembly...30 Checking Steering Wheel Turning Force ...8 Inspection...31 Checking Hydraulic System...9 Assembly ...32 STEERING WHEEL AND STEERING COLUMN ...11 SERVICE DATA AND SPECIFICATIONS (SDS) ...33 Components...11 General Specifications...33 Removal and Installation ...11 Steering Wheel ...33 STEERING WHEEL ...11 Steering Column...33 STEERING COLUMN...12 Steering Gear and Linkage ...34 Disassembly and Assembly...14 Power Steering ...35 Inspection...15,

PRECAUTIONS

Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

NJST0044 The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. The SRS system composition which is available to NISSAN MODEL N16 is as follows (The compo- sition varies according to the destination and optional equipment.): + For a frontal collision The Supplemental Restraint System consists of driver air bag module (located in the center of the steer- ing wheel), front passenger air bag module (located on the instrument panel on passenger side), front seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. + For a side collision The Supplemental Restraint System consists of front side air bag module (located in the outer side of front seat), side air bag (satellite) sensor, diagnosis sensor unit (one of components of air bags for a frontal collision), wiring harness, warning lamp (one of components of air bags for a frontal collision). Information necessary to service the system safely is included in the RS section of this Service Manual. WARNING: + To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance should be per- formed by an authorized NISSAN dealer. + Improper maintenance, including incorrect removal and installation of the SRS, can lead to per- sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the RS section. + Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses (except “SEAT BELT PRE-TENSIONER” connector) can be identified by yellow harness connector.

Precautions for Steering System

NJST0003 + 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. + Place disassembled parts in order, on a parts rack, for easier and proper assembly. + Use nylon cloths or paper towels to clean the parts; common shop rags can leave lint that might interfere with their operation. + Before inspection or reassembly, carefully clean all parts with a general purpose, non-flammable solvent. + Before assembly, apply a coat of recommended power steering fluid* to hydraulic parts. Vaseline may be applied to O-rings and seals. Do not use any grease. + Replace all gaskets, seals and O-rings. Avoid damaging O-rings, seals and gaskets during instal- lation. Perform functional tests whenever designated. *: DEXRONTMIII or equivalent. Refer to MA-16, “Fluids and Lubricants”.

ST-2

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PREPARATION

Special Service Tools

Special Service Tools

NJST0004 Tool number Description Tool name KV48100700 Measuring pinion rotating torque Torque adapter NT169 KV48102500 Measuring oil pressure Pressure gauge adapter NT542 ST27180001 Removing steering wheel Steering wheel puller NT544 HT72520000 Removing ball joint Ball joint remover a: 33 mm (1.30 in) b: 50 mm (1.97 in) r: R11.5 mm (0.453 in) NT546 KV48103500 Measuring oil pressure Pressure gauge NT547 KV48104400 Reforming teflon ring Rack seal ring reformer a: 50 mm (1.97 in) dia. b: 36 mm (1.42 in) dia. c: 100 mm (3.94 in) NT550 ST3127S000 Measuring turning torque 1 GG91030000 Torque wrench 2 HT62940000 Socket adapter 3 HT62900000 Socket adapter NT541

ST-3

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PREPARATION

Commercial Service Tool

Commercial Service Tool

NJST0005 Tool number Description Oil pump attachment Disassembling and assembling oil pump Unit: mm (in) NT774 KV48105210 Removing and Installing power steering oil pump Sprocket holder NT809

ST-4

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NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NVH Troubleshooting Chart

NVH Troubleshooting Chart

NJST0006S01

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

Reference page Possible cause and SUSPECTED PARTS Noise × × × × × × × × × × × × × × × Shake × × × × × × × × × Symptom STEERING Vibration × × × × × × × × × Shimmy × × × × × × × × × Judder × × × × × × × ×: Applicable

ST-5

Fluid level ST-7 Air in hydraulic system ST-8 Tie-rod ball joint swinging force ST-20 Tie-rod ball joint rotating torque ST-20 Tie-rod ball joint end play ST-20 Steering gear fluid leakage ST-7 Steering wheel play ST-6 Steering gear rack sliding force ST-8 Drive belt looseness Refer to EM-16. Improper steering wheel — Improper installation or looseness or tilt lock lever ST-11 Mounting rubber deterioration ST-6 Steering column deformation or damage ST-15 Improper installation or looseness of steering column ST-14 Steering linkage looseness ST-16 DRIVE SHAFT AX-3 AXLE AX-3 SUSPENSION SU-4 TIRES SU-4 ROAD WHEEL SU-4 BRAKES BR-7,

ON-VEHICLE SERVICE

Checking Steering Wheel Play

Checking Steering Wheel Play

NJST0007 + With wheels in a straight-ahead position, check steering wheel play. Steering wheel play: 35 mm (1.38 in) or less + If it is not within specification, check the following for loose or worn components. Steering gear assembly Steering column Front suspension and axle SST489B

Checking Neutral Position on Steering Wheel

NJST0008 PRE-CHECKING NJST0008S01 + Make sure that wheel alignment is correct. Wheel alignment: Refer to SU-14, SDS. + Verify that the steering gear is centered before removing the steering wheel.

CHECKING

NJST0008S02 1. Check that the steering wheel is in the neutral position when SST490BA driving straight ahead. 2. If it is not in the neutral position, remove the steering wheel and reinstall it correctly. 3. If the neutral position is between two teeth, loosen tie-rod lock nuts. Turn the tie-rods by the same amount in opposite direc- tions on both left and right sides.

Front Wheel Turning Angle

NJST0009 1. Rotate steering wheel all the way right and left; measure turn- ing angle. Turning angle of full turns: Refer to SU-14, SDS. 2. If it is not within specification, check rack stroke. Rack stroke “S”: Refer to SDS, ST-34. SMA127

Checking Gear Housing Movement

NJST0010 1. Check the movement of steering gear housing during station- ary 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 housing: ±2 mm (±0.08 in) or less 2. If movement exceeds the limit, replace mount insulator after confirming proper installation of gear housing clamps. SST663B

ST-6

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ON-VEHICLE SERVICE

Checking and Adjusting Drive Belts

Checking and Adjusting Drive Belts

NJST0011 Refer to EM-16, “Checking Drive Belts”.

Checking Steering Gear and Linkage

NJST0037 STEERING GEAR NJST0037S01 + Check gear housing and boots for looseness, damage or grease leakage. + Check connection with steering column for looseness. STEERING LINKAGE NJST0037S02 + Check ball joint, dust cover and other component parts for looseness, wear, damage or grease leakage. SMA851B

Checking Fluid Level

NJST0012 Check fluid level, referring to the scale on reservoir tank. Use “HOT” range for fluid temperatures of 50 to 80°C (122 to 176°F). Use “COLD” range for fluid temperatures of 0 to 30°C (32 to 86°F). CAUTION: + Do not overfill. + Recommended fluid is DEXRONTMIII or equivalent. Refer to MA-16, “Fluids and Lubricants”. YST003

Checking Fluid Leakage

NJST0013 Check the lines for improper attachment and for leaks, cracks, damage, loose connections, chafing and deterioration. 1. Run engine between idle speed and 1,000 rpm. Make sure temperature of fluid in oil tank rises to 60 to 80°C (140 to 176°F). 2. Turn steering wheel right-to-left several times. 3. Hold steering wheel at each “lock” position for five seconds and carefully check for fluid leakage. CAUTION: YST006 Do not hold the steering wheel in a locked position for more than 15 seconds. 4. If fluid leakage at connectors is noticed, loosen flare nut and then retighten. Do not overtighten connector as this can damage O-ring, washer and connector. 5. If fluid leakage from power steering pump is noticed, check power steering pump. Refer to ST-25. 6. Check rack boots for accumulation of power steering fluid. YST007

ST-7

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ON-VEHICLE SERVICE

Bleeding Hydraulic System

Bleeding Hydraulic System

NJST0014 1. Raise front end of vehicle until wheels are clear of the ground. 2. Add fluid into oil tank to specified level. Then quickly turn steer- ing wheel fully to right and left and lightly touch steering stop- pers. Repeat steering wheel operation until fluid level no longer decreases. 3. Start engine. Repeat step 2. above. + Incomplete air bleeding will cause the following to occur. When this happens, bleed air again. a) Air bubbles in reservoir tank b) Clicking noise in oil pump c) Excessive buzzing in oil pump Fluid noise may occur in the valve or oil pump. This is common when the vehicle is stationary or while turning the steering wheel slowly. This does not affect the performance or durability of the system.

Checking Steering Wheel Turning Force

NJST0015 1. Park vehicle on a level, dry surface and set parking brake. 2. Start engine. 3. Bring power steering fluid up to adequate operating tempera- ture. [Make sure temperature of fluid is approximately 60 to 80°C (140 to 176°F).] Tires need to be inflated to normal pressure. 4. Check steering wheel turning force when steering wheel has been turned 360° from the neutral position. Steering wheel turning force: SST491B 39 N (4 kg, 9 lb) or less 5. If steering wheel turning force is out of specification, check rack sliding force. a. Disconnect steering column lower joint and knuckle arms from the gear. b. Start and run engine at idle to make sure steering fluid has reached normal operating temperature. c. Pull tie-rod slowly to move it from neutral position to ±11.5 mm (±0.453 in) at speed of 3.5 mm (0.138 in)/s. Check that rack sliding force is within specification. Average rack sliding force: SST090B Sedan 152 - 240 N (15.5 - 24.5 kg, 34 - 54 lb) Hatchback 132 - 308 N (13.5 - 31.4 kg, 30 - 69 lb) Maximum force deviation: Sedan 98 N (10 kg, 22 lb) Hatchback 176 N (17.9 kg, 39 lb) d. Check sliding force outside the above range at rack speed of 40 mm (1.75 in)/s.

ST-8

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ON-VEHICLE SERVICE

Checking Steering Wheel Turning Force (Cont’d) Rack sliding force (Sedan only): Not more than 294 N (30 kg, 66 lb) Maximum force deviation: 147 N (15 kg, 33 lb) 6. If rack sliding force is not within specification, overhaul steer- ing gear assembly. 7. If rack sliding force is OK, inspect steering column. Refer to ST-14.

Checking Hydraulic System

NJST0016 Before starting, check belt tension, driving pulley and tire pressure. 1. Set Tool. Open shut-off valve. Then bleed air. Refer to “Bleed- ing Hydraulic System”, ST-8. 2. Run engine at idle speed or 1,000 rpm. Make sure temperature of fluid in tank rises to 60 to 80°C (140 to 176°F). WARNING: Warm up engine with shut-off valve fully opened. If engine is started with shut-off valve closed, fluid pressure in oil pump SST834-I increases to maximum. This will raise oil temperature abnor- mally. 3. Check pressure with steering wheel fully turned to left and right positions with engine idling at 1,000 rpm. CAUTION: Do not hold the steering wheel in a locked position for more than 15 seconds. Oil pump maximum standard pressure: QG15 engine (Sedan) 7,600 - 8,200 kPa (76.0 - 82.0 bar, 77.5 - 83.6 kg/cm2, 1,102 - 1,189 psi) QG 18 engine (Sedan) 8,600 - 9,200 kPa (86.0 - 92.0 bar, 87.7 - 93.8 kg/cm2, 1,247 - 1,334 psi) QG15, 18 engine (Hatchback) 8,600 - 9,200 kPa (86.0 - 92.0 bar, 88.7 - 93.8 kg/cm2, 1,247 - 1,334 psi) YD22 engine 8,800 - 9,400 kPa (88.0 - 94.0 bar, 88.7 - 95.8 kg/cm2, 1,261 - 1,362 psi) + If pressure reaches maximum operating pressure, system is OK. + If pressure increases above maximum operating pressure, check power steering pump flow control valve. Refer to ST-25. 4. If power steering pressure is below the maximum operating pressure, slowly close shut-off valve and check pressure again. CAUTION: Do not close shut-off valve for more than 15 seconds. + If pressure increases to maximum operating pressure, gear is damaged. Refer to “Removal and Installation”, ST-17. + If pressure remains below maximum operating pressure, pump is damaged. Refer to “Disassembly”, ST-26. 5. After checking hydraulic system, remove Tool and add fluid as

ST-9

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ON-VEHICLE SERVICE

Checking Hydraulic System (Cont’d) necessary. Then completely bleed air out of system. Refer to ST-8.

ST-10

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STEERING WHEEL AND STEERING COLUMN

Components

Components

NJST0017 JST875C 1. Air bag module 5. Combination switch 8. Hole cover 2. Steering wheel 6. Steering column assembly 9. Lower joint 3. Spiral cable 7. Clip 10. Lower cover 4. Column cover CAUTION: + The rotation of the spiral cable (SRS “Air bag” component part) is limited. If the steering gear must be removed, set the front wheels in the straight-ahead direction. Do not rotate the steering column while the steering gear is removed. + Remove the steering wheel before removing the steering lower joint to avoid damaging the SRS spiral cable.

Removal and Installation

NJST0018

STEERING WHEEL

NJST0018S01 + Remove air bag module and spiral cable. Refer to RS-29, “Removal — Air Bag Module and Spiral Cable”. SBF812E

ST-11

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STEERING WHEEL AND STEERING COLUMN

Removal and Installation (Cont’d) + Align spiral cable correctly when installing steering wheel. a) Set the front wheels in the straight-ahead position. b) Make sure that the spiral cable is in the neutral position. The neutral position is detected by turning left 2.5 revolutions from the right end position. Align the two marks ( ). CAUTION: The spiral cable may snap due to steering operation if the cable is installed in an improper position. Also, with the steering linkage disconnected, the cable may snap by turning the steering wheel beyond the limited number of turns. (The spiral cable can be turned up to 2.5 turns from the neutral position to both the right and left.) SRS266 + Remove steering wheel with Tool. SST777C STEERING COLUMN NJST0018S02 + Remove key interlock cable (A/T models). SST329C + When installing steering column, fingertighten all lower bracket and clamp retaining bolts; then tighten them securely. Do not apply undue stress to steering column. + When attaching coupling joint, be sure tightening bolt faces cutout portion. SST800A

ST-12

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STEERING WHEEL AND STEERING COLUMN

Removal and Installation (Cont’d) + Align slit of lower joint with projection on dust cover. Insert joint until surface A contacts surface B. CAUTION: After installation, turn steering wheel to make sure it moves smoothly. Ensure the number of turns are the same from the straight forward position to left and right locks. Be sure that the steering wheel is in a neutral position when driving straight ahead. SST491C

ST-13

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STEERING WHEEL AND STEERING COLUMN

Disassembly and Assembly

Disassembly and Assembly

=NJST0019 SST920C 1. Combination switch 6. Lower seal cover 11. Spring 2. Lock nut 7. Hole cover 12. Adjust bolt 3. Jacket tube assembly 8. Tilt lever 13. Adjust bolt stopper 4. Column shaft assembly 9. Tilt lever stopper 14. Nut 5. Clip 10. Steering column mounting bracket 15. Steering column lower cover + When disassembling and assembling, unlock steering lock with key. + Remove combination switch. + Install lock nut on steering column shaft and tighten the nut. SST490C

ST-14

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STEERING WHEEL AND STEERING COLUMN

Disassembly and Assembly (Cont’d) + Steering lock a) Break self-shear type screws with a drill or other appropriate tool. SST741A b) Install new self-shear type screws and then cut off self-shear type screw heads. SST742A

Inspection

NJST0020 + When steering wheel does not turn smoothly, check the steer- ing column as follows and replace damaged parts. a) Check column bearings for damage or unevenness. Lubricate with recommended multi-purpose grease or replace steering column as an assembly, if necessary. b) Check jacket tube for deformation or breakage. Replace if necessary. + When the vehicle comes into a light collision, check length “L”. Steering column length “L”: SST855C Refer to SDS, ST-33. If out of the specifications, replace steering column as an assem- bly. TILT MECHANISM NJST0020S01 + After installing steering column, check tilt mechanism opera- tion. SST582B

ST-15

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POWER STEERING GEAR AND LINKAGE

Components

Components

NJST0021 SST997C 1. Rear cover cap 10. Gear housing 19. Dust boot 2. Gear sub-assembly 11. Center bushing 20. Boot band 3. O-ring 12. Rack oil seal 21. Spacer ring 4. Shim 13. Rack assembly 22. Lock plate 5. Lock nut 14. Rack seal ring 23. Tie-rod inner socket 6. Adjusting screw 15. O-ring 24. Tie-rod outer socket 7. Spring 16. Rack oil seal 25. Cotter pin 8. Spring seat 17. End cover assembly 26. Gear cylinder tube 9. Retainer 18. Boot band

ST-16

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POWER STEERING GEAR AND LINKAGE

Removal and Installation

Removal and Installation

NJST0022 SST878CA 1. Lower joint 4. Upper gear housing mounting 6. Lower gear housing mounting 2. Washer bracket bracket 3. Gear and linkage assembly 5. Rack mounting insulator 7. Cotter pin CAUTION: + The rotation of the spiral cable (SRS “Air bag” component part) is limited. If the steering gear must be removed, set the front wheels in the straight-ahead direction. Do not rotate the steering column while the steering gear is removed. + Remove the steering wheel before removing the steering lower joint to avoid damaging the SRS spiral cable. + Detach tie-rod outer sockets from knuckle arms with Tool. 1. Remove stabilizer fixing bolts. Refer to SU-11, “Removal and SFA455BA Installation”. 2. Disconnect lower joint. 3. Remove gear housing mounting bracket fixing bolts. 4. Remove steering gear assembly.

ST-17

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POWER STEERING GEAR AND LINKAGE

Removal and Installation (Cont’d) + Install pipe connector. + Observe specified tightening torque when tightening high-pres- sure and low-pressure pipe connectors. Excessive tightening will damage threads of connector or O-ring. Connector tightening torque: 1 Low-pressure side 27 - 39 N·m (2.8 - 4.0 kg-m, 20 - 29 ft-lb) 2 High-pressure side 15 - 25 N·m (1.5 - 2.5 kg-m, 11 - 18 ft-lb) + The O-ring in low-pressure pipe connector is larger than that SST879C in high-pressure connector. Take care to install the proper O-ring. + Initially, tighten nut on tie-rod outer socket and knuckle arm to 29 to 39 N·m (3 to 4 kg-m, 22 to 29 ft-lb). Then tighten further to align nut groove with first pin hole so that cotter pin can be installed. CAUTION: Tightening torque must not exceed 49 N·m (5 kg-m, 36 ft-lb). NOTE: Only the dust boot, tie-rod inner socket and tie-rod outer socket can be disassembled on models for Europe. SST824A + Before removing lower joint from gear, set gear in neutral (wheels in straight-ahead position). After removing lower joint, put matching mark on pinion shaft and pinion housing to record neutral position. + To install, set left and right dust boots to equal deflection. Attach lower joint by aligning matching marks of pinion shaft and pinion housing. + Tighten gear housing mounting bracket bolts. SST819A

Disassembly

NJST0023 1. Prior to disassembling, measure pinion rotating torque. Record the pinion rotating torque as a reference. + Before measuring, disconnect gear housing tube and drain fluid. + Use soft jaws when holding steering gear housing. Handle gear housing carefully, as it is made of aluminum. Do not grip cylinder in a vise. 2. Remove gear sub-assembly, O-ring and shim. Gear sub-assembly cannot be disassembled. If it is faulty, SST862CB replace with a new one.

ST-18

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POWER STEERING GEAR AND LINKAGE

Disassembly (Cont’d) 3. Remove tie-rod outer sockets and boots. 4. Loosen tie-rod inner socket by prying up staked portion, and remove socket and spacer. 5. Remove retainer. 6. Usea2to 2.5 mm (0.079 to 0.098 in) diameter drill to com- pletely remove staked portion of gear housing end. SST051C 7. Remove end cover assembly with a suitable tool. 8. Draw out rack assembly. 9. Remove rack seal ring. + Using a heat gun, heat rack seal to approximately 40°C (104°F). + Remove rack seal ring. Be careful not to damage rack. SST052C 10. Remove center bushing and rack oil seal using tape wrapped socket and extension bar. Do not scratch inner surfaces of pinion housing. SST472A

Inspection

NJST0024 Thoroughly clean all parts in cleaning solvent or DEXRONTMIII or equivalent. Blow dry with compressed air, if available.

BOOT

NJST0024S01 + Check condition of boot. If cracked excessively, replace it. + Check boots for accumulation of power steering fluid.

RACK

NJST0024S02 Thoroughly examine rack gear. If damaged, cracked or worn, replace it. GEAR SUB-ASSEMBLY NJST0024S03 + Check pinion gear. If it is worn or damaged, replace as a gear sub-assembly. + Manually spin bearing. If torque variations or free play are noted, replace as a gear sub-assembly. GEAR HOUSING CYLINDER NJST0024S04 Check gear housing cylinder bore for scratches or other damage. Replace if necessary.

ST-19

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POWER STEERING GEAR AND LINKAGE

Inspection (Cont’d) TIE-ROD OUTER AND INNER SOCKETS NJST0024S05 + Check ball joints for swinging force. Tie-rod outer and inner ball joints swinging force “A”: Refer to SDS, ST-34. + Check ball joint for rotating torque. Tie-rod outer ball joint rotating torque “B”: Refer to SDS, ST-34. + Check ball joints for axial end play. Tie-rod outer and inner ball joints axial end play “C”: SST468C Refer to SDS, ST-34. + Check condition of dust cover. If cracked excessively, replace outer tie-rod.

Assembly

NJST0025 1. Using a heat gun, heat new teflon rack seal ring to approxi- mately 40°C (104°F). Then place it onto rack. SST083B 2. Using Tool, compress rack seal ring securely onto rack. Always insert Tool from the rack gear side. SST885BA 3. Insert new rack oil seal. + Place plastic film into rack oil seal to prevent damage by rack teeth. + Do not forget to remove plastic film after rack oil seal is positioned properly. + Make sure lips of rack oil seal face each other. SST201A

ST-20

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POWER STEERING GEAR AND LINKAGE

Assembly (Cont’d) 4. Install center bushing and rack oil seal with rack assembly. SST863C 5. Insert rack oil seal and end cover assembly to rack. Then tighten end cover assembly. SST321B 6. Fasten end cover assembly to gear housing by staking. SST073B 7. Set rack gear in neutral position. Rack stroke “S”: Refer to SDS, ST-34. SST086BA 8. Install adjustment shims and O-rings to gear sub-assembly. + Install the same number of adjustment shims as before, regardless of whether or not gear sub-assembly is replaced. + Discard old O-rings; replace with new ones. 9. Tighten gear subassembly securing bolts to specified tighten- ing torque. SST880C

ST-21

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POWER STEERING GEAR AND LINKAGE

Assembly (Cont’d) 10. Ensure that the rack is centered. Install rear cover cap so that its protrusion is positioned as shown in figure. SST865C 11. Install diaphragm spring into gear housing. + Always install retainer, spring washer and diaphragm spring in that order. + Make sure convex end (painted white) of diaphragm spring faces outward when installing. 12. Install spring seat retainer spring and adjusting screw tempo- rarily. SST087B 13. Install lock plate to rack. a. Temporarily install spacer ring to rack. Discard old spacer ring; replace with a new one. b. Install lock plate to inner socket. Discard old lock plate; replace with a new one. c. Apply a coat of locking sealant to inner socket threads. Screw inner socket into rack and tighten to specified torque. d. Clinch lock plate at rack groove location (at two points). e. Install spacer ring to lock plate as shown in the Figure at left. SST866C Be careful not to damage spacer ring during installation 14. Tighten outer socket lock nut. Tie-rod length “L”: Refer to SDS, ST-34. SST867C 15. Measure rack stroke. Rack stroke “S”: Refer to SDS, ST-34. SST086BA

ST-22

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POWER STEERING GEAR AND LINKAGE

Assembly (Cont’d) 16. Before installing boot, coat the contact surfaces between boot and tie-rod with grease. SST967A 17. Install boot bands. + Securely install boot band to boot groove and clinch the root section of the trapezoidal area. + Make sure that there is a clearance of 3.5 mm (0.138 in) or less at the clinched section of the boot band. Refer to the Figure at left. SST868C + After installing gear in vehicle, make sure that the clinched section of boot band is positioned toward the rear of vehicle (to prevent interference with adjacent parts). SST869C

Adjustment

NJST0026 Adjust pinion rotating torque as follows: 1. Set rack to the neutral position without fluid in the gear. 2. Coat the adjusting screw with locking sealant and screw it in. 3. Lightly tighten lock nut. 4. Tighten adjusting screw to a torque of 4.9 to 5.9 N·m (50 to 60 kg-cm, 43 to 52 in-lb). 5. Loosen adjusting screw, then retighten it to 0.2 N·m (2 kg-cm, 1.7 in-lb). SST719C 6. Move rack over its entire stroke several times. 7. Measure pinion rotating torque within the range of 180° from neutral position. Stop the gear at the point of maximum torque. 8. Loosen adjusting screw, then retighten it to 4.9 N·m (50 kg-cm, 43 in-lb). 9. Loosen adjusting screw by 50° to 70°. SST862CB

ST-23

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POWER STEERING GEAR AND LINKAGE

Adjustment (Cont’d) 10. Prevent adjusting screw from turning, and tighten lock nut to specified torque. SST713C 11. Check rack sliding force on vehicle as follows: a. Install steering gear onto vehicle, but do not connect tie-rod to knuckle arm. b. Connect all piping and fill with steering fluid. c. Start engine and bleed air completely. d. Disconnect steering column lower joint from the gear. e. Keep engine at idle and make sure steering fluid has reached normal operating temperature. f. Pull tie-rod slowly to move it from neutral position to ±11.5 mm (±0.453 in) at speed of 3.5 mm (0.138 in)/s. Check that rack SST090B sliding force is within specification. Average rack sliding force: Sedan 152 - 240 N (15.5 - 24.5 kg, 34.2 - 54.0 lb) Hatchback 132 - 308 N (13.5 - 31.4 kg, 30 - 69 lb) Maximum force deviation: Sedan 98 N (10 kg, 22 lb) Hatchback 176 N (17.9 kg, 39 lb) g. Check sliding force outside above range at rack speed of 40 mm (1.57 in)/s. Maximum rack sliding force (Sedan only): 294 N (30 kg, 66 lb) Maximum force deviation (Sedan only): 147 N (15 kg, 33 lb) + If rack sliding force is not within specification, readjust by repeating adjustment procedure from the beginning. + If rack sliding force is still out of specification after readjustment, gear assembly needs to be replaced.

ST-24

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POWER STEERING OIL PUMP (QG ENGINE)

Components

Components

NJST0027 SST881CA 1. Pulley 8. Flow control A valve 15. Rotor snap ring 2. Bracket 9. Dowel pin 16. Rear side plate 3. Drive shaft seal 10. Flow control B valve assy 17. Side plate inner seal 4. Inlet connector 11. Front side plate 18. Side plate outer seal 5. Inlet connector seal 12. Cartridge 19. Body seal 6. Front housing 13. Rotor 20. Rear body 7. Flow control valve spring 14. Vane

Pre-disassembly Inspection

NJST0028 Disassemble the power steering oil pump only if the following items are found. + Oil leak from any point shown in the figure + Deformed or damaged pulley + Poor performance SST984A

ST-25

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POWER STEERING OIL PUMP (QG ENGINE)

Disassembly

Disassembly

NJST0029 CAUTION: + The power steering pump cannot be disassembled on Hatchback with QG engine. If it is faulty, replae with a new assembly. + 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 out. Be careful not to drop drive shaft. SST010B + Remove oil seal. Be careful not to damage front housing. SST034A + Remove connector and flow control valve with spring. Be careful not to drop flow control valve. Do not disassemble flow control valve. SST036A

ST-26

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POWER STEERING OIL PUMP (QG ENGINE)

Inspection

Inspection

NJST0030 + If pulley is cracked or deformed, replace it. + If an oil leak is found around pulley shaft oil seal, replace the seal. + If serration on pulley or pulley shaft is deformed or worn, replace it.

Assembly

NJST0031 Assemble oil pump, noting the following instructions. + Make sure O-rings and oil seal are properly installed. + Always install new O-rings and oil seal. + Be careful of oil seal direction. + Cam ring, rotor and vanes must be replaced as a set if neces- sary. + Coat each part with DEXRONTMIII or equivalent when assem- bling. SST038A + Pay attention to the direction of rotor. SST289A + When assembling vanes to rotor, rounded surfaces of vanes must face cam ring side. SST843A

ST-27

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POWER STEERING OIL PUMP (QG ENGINE)

Assembly (Cont’d) + Insert pin 2 into pin groove 1 of front housing and front side plate. Then install cam ring 3 as shown at left. Cam ring: D1 is less than D2. SST472C

ST-28

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POWER STEERING OIL PUMP (YD ENGINE)

Components

Components

NJST0038 SST882CA 1. Rear bracket 9. O-ring (Outer) 17. Outlet connector 2. Rear body 10. O-ring (Inner) 18. Connector seal 3. Dowel pin 11. Front body 19. Flow control valve 4. Side plate seal 12. Drive shaft rear oil seal 20. Flow control valve spring 5. Cam ring 13. Drive shaft front oil seal 21. Inlet connector 6. Vane 14. Drive shaft 22. O-ring 7. Rotor 15. Snap ring 23. Washer 8. Side plate 16. O-ring

Pre-disassembly Inspection

NJST0039 Disassemble the power steering oil pump only if the following items are found. + Oil leak from any point shown in the figure + Poor performance SST883C

ST-29

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POWER STEERING OIL PUMP (YD ENGINE)

Removal and Installation

Removal and Installation

NJST0040 1. Remove chain case cover. SST884C 2. Revolving crank pulley, set tool. 3. Fix tool with chain cover fixing bolts. 4. Using suitable tool, remove sprocket fixing nut and washer. Do not remove Tool while power steering oil pump is removed. SST885C 5. Remove power steering pump fixing bolts, then remove it. SST886C + Apply Gasket to the installation surface of the engine chain case cover as shown in the figure before installing the chain case cover to the engine. + Bleed air after installation. Refer to ST-8. SST890C

Disassembly

NJST0041 CAUTION: + 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 procedure and cautions in the Service Manual. + When disassembling and reassembling, do not let foreign matter enter or contact the parts.

ST-30

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POWER STEERING OIL PUMP (YD ENGINE)

Disassembly (Cont’d) + Remove rear bracket and rear body. + Remove side plate seal, cam ring vane, rotor side and plate. SST887C + Remove inlet connector and outlet connector with spring. Be careful not to drop the flow control valve. Do not disassemble the flow control valve. SST036A + Remove oil seal SST888C + Remove snap ring, then draw drive shaft. Be careful not to drop drive shaft. SST889C

Inspection

NJST0042 + If pulley is cracked or deformed, replace it. + If an oil leak is found around pulley shaft oil seal, replace the seal. + If serration on pulley or pulley shaft is deformed or worn, replace it.

ST-31

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POWER STEERING OIL PUMP (YD ENGINE)

Assembly

Assembly

NJST0043 Assemble oil pump, noting the following instructions. + Make sure O-rings and oil seal are properly installed. + Always install new O-rings and oil seal. + Be careful of oil seal direction. + Cam ring, rotor and vanes must be replaced as a set if neces- sary. + Coat each part with DEXRONTMIII or equivalent when assem- bling. SST038A + Pay attention to the direction of rotor. SST289A + When assembling vanes to rotor, rounded surfaces of vanes must face cam ring side. SST843A + Insert pin 2 into pin groove 1 of front housing and front side plate. Then install cam ring 3 as shown at left. Cam ring: D1 is less than D2. SST472C

ST-32

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SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications

General Specifications

NJST0032 Applied model Sedan Hatchback Steering model Power steering Steering gear type PR24AD PR25T Steering overall gear ratio 17.1 16.8 Turns of steering wheel (Lock to lock) 2.9 Steering column type Collapsible, tilt

Steering Wheel

NJST0033 Steering wheel axial play mm (in) 0 (0) Steering wheel play mm (in) 35 (1.38) or less Movement of gear housing mm (in) ±2 (±0.08) or less

Steering Column

NJST0034 Applied model Sedan Hatchback Steering column length “L” mm (in) 545 - 547 (21.46 - 21.54) SST855C

ST-33

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SERVICE DATA AND SPECIFICATIONS (SDS)

Steering Gear and Linkage

Steering Gear and Linkage

NJST0035 Sedan Hatchback Applied model QG engine YD engine QG engine YD engine Steering gear type PR24AD PR25T Swinging force at cotter pin hole: 64.6 - 65.0 (6.59 - 6.63, 14.52 - 14.61) “A” N (kg, lb) Tie-rod outer ball Rotating torque: “B” N·m (kg-cm, joint 0.29 - 2.94 (3.0 - 30.0, 2.6 - 26.0) in-lb) Axial end play: “C” mm (in) 0 (0) Tie-rod inner ball Swinging force*: “A” N (kg, lb) 1.61 - 12.9 (0.164 - 1.32, 0.36 - 2.90) joint Axial end play: “C” mm (in) 0 (0) Tie-rod standard length “L” mm (in) 160.0 (6.299) 164.0 (6.457) 132 (5.20) 136 (5.35) *: Measuring point [!: 62 mm (2.44 in)] SST488C Initial tightening torque N·m (kg- 3.9 - 5.9 (40 - 60, 35 - 52) — cm, in-lb) Retightening torque after Retainer adjustment 0.2 (2, 1.7) —loosening N·m (kg-cm, in-lb) Adjusting screw Tightening torque after gear has 3.9 - 5.9 (40 - 60, 35 - 52) — settled N·m (kg-cm, in-lb) Returning angle degree 50° - 70° — Rack stroke “S” mm (in) 65.0 (2.559) SST086BA

ST-34

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SERVICE DATA AND SPECIFICATIONS (SDS)

Power Steering

Power Steering

NJST0036 Applied model Sedan Hatchback Steering gear type PR24AD PR25T Range within ±11.5 mm (±0.453 in) 152 - 240 132 - 308Average force from the neutral position at rack (15.5 - 24.5, 34.2 - 54.0) (13.5 - 31.4, 30 - 69)Rack sliding force N (kg, lb) speed of 3.5 mm (0.138 in)/s Maximum force deviation 98 (10, 22) 176 (17.9, 39) Under normal oper- ating oil pressure Maximum sliding force 294 (30, 66) — Except for the above range Maximum force deviation 147 (15, 33) — Steering wheel turning force 39 (4, 9) or less (Measured at one full turn from the neutral position) N (kg, lb) Fluid capacity (Approximate) ! (Imp qt) 1.0 (7/8) 7,600 - 8,200 8,600 - 9,200 QG15 engines (76.0 - 84.0, 77.5 - 85.68, (86.0 - 92.0, 87.72 - 93.84, 1,102 - 1,218) 1,247 - 1,334) Oil pump maximum pressure kPa (bar, kg/cm2, psi) QG18 engines 8,800 - 9,400 (88.0 - 94.0, 88.7 - 95.8, 1,261 - 1,362) YD22 engine

ST-35

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SERVICE DATA AND SPECIFICATIONS (SDS)

Power Steering (Cont’d)

ST-36

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