Steering Control System: Overhaul Lexus ES XV30

OVERHAUL

Note. When using a vise, do not over tighten. When installing, coat the parts indicated by the arrows with power steering fluid. See VANE PUMP ASSEMBLY .

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1. Remove front wheel RH.
2. Drain power steering fluid.
3. Remove front fender liner RH.
4. Remove front fender apron seal RH.
5. Disconnect oil reservoir to pump hose No. 1. Remove the clip and disconnect the oil reservoir to pump hose No. 1. NOTE: Take care not to spill fluid on the V belt.
6. Remove power steering oil pressure switch. Disconnect the connector. Remove the oil power steering pressure switch from the union bolt. NOTE: Be careful not to drop the oil power steering pressure switch. If the oil power steering pressure switch is dropped or strongly damaged, replace it with a new one.
7. Disconnect pressure feed hose. Using a 22 mm spanner to hold the pressure port union, remove the union bolt and gasket.
8. Remove vane pump V belt. Loosen the 2 bolts and remove the vane pump V belt.
9. Remove vane pump assembly. Remove the 2 bolts and vane pump assembly.
10. Remove vane pump pulley (type a vane pump). Using SST, stop the vane pump pulley rotation and loosen the nut. SST 09960-10010 (09962-01000, 09963-01000) Remove the nut and vane pump pulley from the vane pump shaft.
11. Remove power steering suction port union. Remove the bolt and power steering suction port union. Remove the O-ring from the power steering suction port union.
12. Remove pressure port union. Remove the pressure port union. Remove the O-ring from the pressure port union.
13. Remove flow control valve.
14. Remove flow control valve compression spring.
15. Remove vane pump bracket rear (type a vane pump). Remove the 2 bolts and pump bracket rear from the vane pump assembly.
16. Remove vane pump bracket rear (type "B" vane pump). Remove the 2 bolts, 2 nuts and pump bracket rear from the vane pump assembly.
17. Remove vane pump housing rear. Remove the 4 bolts and vane pump housing rear from the vane pump housing front. Remove the gasket. Remove the 2 O-rings from the vane pump housing rear.
18. Remove vane pump side plate rear. Remove the wave washer from the side plate rear. Remove the side plate rear.
19. Remove vane pump cam ring.
20. Remove vane pump rotor. Remove the 10 vane pump plates from the vane pump rotor. Using a screwdriver, remove the vane pump shaft snap ring from the vane pump shaft. Remove the vane pump rotor.
21. Remove vane pump shaft (type "A" vane pump).
22. Remove w/pulley shaft sub-assembly (type "B" vane pump).
23. Remove pump bracket front. Remove the bolt and pump bracket front from the pump housing front.
24. Remove vane pump housing oil seal. Using SST and a hammer, tap out the vane pump housing oil seal from the vane pump housing front. SST 09631-10030 NOTE: Be careful not to damage the bushing of the vane pump housing front.
25. Inspect oil clearance. Using a micrometer and a caliper gauge, measure the oil clearance. Standard Clearance: 0.027-0.054 mm (0.0011-0.0021 in.) Maximum Clearance: 0.07 mm (0.0028 in.) If it is more than the maximum, replace the vane pump assembly.
26. Inspect vane pump rotor and vane plates. Using a micrometer, measure the height, thickness and length of the vane pump plates. Minimum Height: 8.6 mm (0.339 in.) Minimum Thickness: 1.397 mm (0.0550 in.) Minimum Length: 14.991 mm (0.5902 in.) Using a feeler gauge, measure the clearance between the vane pump rotor groove and vane pump plate. Maximum Clearance: 0.03 mm (0.0012 in.) If it is more than the maximum, replace the vane pump assembly.
27. Inspect flow control valve. Coat the flow control valve with power steering fluid and check that it falls smoothly into the flow control valve hole by its own weight. Check the flow control valve for leakage. Close one of the holes and apply compressed air of 392-490 kPa (4-5 kgf/cm 2 , 57-71 psi) into the opposite side hole, and confirm that air does not come out from the end holes. If necessary, replace the vane pump assembly.
28. Inspect flow control valve compression spring. Using vernier calipers, measure the free length of the flow control valve compression spring. Minimum Free Length: 32.24 mm (1.269 in.) If it is not within the specification, replace the vane pump assembly.
29. Inspect pressure port union. If the union seat in the pressure port union is remarkably damaged and it may cause fluid leakage, replace the vane pump assembly.
30. Install vane pump housing oil seal. Coat a new vane pump housing oil seal lip with power steering fluid. Using SST and a press, install a new vane pump housing oil seal. SST 09950-60010 (09951-00330), 09950-70010 (09951-07100) NOTE: Make sure that the vane pump housing oil seal is installed facing the correct direction.
31. Install pump bracket front. Install the pump bracket front with the bolt. Torque: Type "A" Vane Pump: 43 N.m (438 kgf.cm, 32 ft.lbf) Type "B" Vane Pump: 44 N.m (449 kgf.cm, 32 ft.lbf)
32. Install vane pump shaft (type "A" vane pump). Coat inside bushing surface of the pump housing front with power steering fluid. Gradually insert the vane pump shaft from the pulley side. NOTE: Do not damage the vane pump housing oil seal lip in the vane pump housing front.
33. Install w/pulley shaft sub-assembly (type "B" vane pump). Coat inside bushing surface of the pump housing front with power steering fluid. Gradually insert the vane pump shaft from the pulley side. NOTE: Do not damage the vane pump housing oil seal lip in the vane pump housing front.
34. Install vane pump rotor Install the vane pump rotor. Using a snap ring expander, install a new vane pump shaft snap ring to the vane pump shaft.
35. Install vane pump cam ring. Align the holes of the vane pump cam ring with 2 straight pins, and install the vane pump cam ring with inscribed mark facing outward. Coat 10 vane pump plates with power steering fluid. Install the vane pump plates with the round end facing outward. Install a new gasket.
36. Install vane pump side plate rear. Coat a new O-ring with power steering fluid and install it to the side plate rear. Align the groove of the cam ring with that of the side plate, install the side plate rear. Install the wave washer so that its protrusions fit into the slots in the side plate rear.
37. Install vane pump housing rear. Coat a new O-ring with power steering fluid and install it to the vane pump housing rear. Install the pump housing rear with the 4 bolts. Torque: 24 N.m (245 kgf.cm, 18 ft.lbf)
38. Measure power steering vane pump rotation torque (type "A" vane pump). Check that the vane pump rotates smoothly without abnormal noise. Temporarily install the pulley set nut. Using a torque wrench, check the vane pump rotating torque. Rotating Torque: 0.27 N.m (2.8 kgf.cm, 2.4 in.lbf) or less
39. Measure power steering vane pump rotation torque (type "B" vane pump). Check that the vane pump rotates smoothly without abnormal noise. Temporarily install the service bolt. Recommended Service Bolt: Thread Diameter: 10 mm (0.39 in.) Thread Pitch: 1.25 mm (0.0492 in.) Bolt Length: 50 mm (1.97 in.) Using a torque wrench, check the vane pump rotating torque. Rotating Torque: 0.27 N.m (2.8 kgf.cm, 2.4 in.lbf) or less
40. Install vane pump bracket rear (type "A" vane pump). Install the pump bracket rear with the 2 bolts. Torque: 43 N.m (438 kgf.cm, 32 ft.lbf)
41. Install vane pump bracket rear (type "B" vane pump). Install the pump bracket rear with the 2 bolts and 2 nuts. Torque: 44 N.m (449 kgf.cm, 32 ft.lbf)
42. Install flow control valve compression spring. Coat the flow control valve compression spring with power steering fluid and install it.
43. Install flow control valve. Coat the flow control valve with power steering fluid. Install the flow control valve.
44. Install pressure port union. Coat a new O-ring with power steering fluid and install it to the pressure port union. Install the pressure port union. Torque: 83 N.m (846 kgf.cm, 61 ft.lbf)
45. Install power steering suction port union. Coat a new O-ring with power steering fluid and install it to the power steering suction port union. Install the power steering suction port union with the bolt. Torque: 13 N.m (133 kgf.cm, 10 ft.lbf)
46. Install vane pump pulley (type "A" vane pump). Install the vane pump pulley to the vane pump shaft. Using SST, stop the vane pump pulley rotation and install the nut. SST 09960-10010 (09962-01000, 09963-01000) Torque: 44 N.m (449 kgf.cm, 32 ft.lbf)
47. Install vane pump assembly. Temporarily install the vane pump assembly with the 2 ("A" and "B") bolts.
48. Install vane pump V belt. Install the vane pump V belt and adjust the V belt tension. See «SERPENTINE BELT ROUTING & ALIGNMENT»(ref-139175-S41326166082002042600000) . Torque the bolt "A". Torque: 43 N.m (438 kgf.cm, 32 ft.lbf) Torque the bolt "B". Torque: 43 N.m (438 kgf.cm. 32 ft.lbf)
49. Connect pressure feed hose. Using a 22 mm spanner to hold the pressure port union, connect the pressure feed tube assembly with the union bolt and a new gasket. Torque: 51.5 N.m (525 kgf.cm, 38 ft.lbf) NOTE: Make sure the stopper of the pressure feed tube touches the front bracket as shown in the illustration, then install the union bolt.
50. Install power steering oil pressure switch. Install the power steering oil pressure switch to the union bolt. Torque: 21 N.m (214 kgf.cm, 15 ft.lbf) NOTE: Be careful not to allow oil from being attached to the connector. Connect the connector.
51. Connect oil reservoir to pump hose No. 1. Connect the oil reservoir to pump hose No. 1. Install the clip.
52. Install front fender apron seal RH.
53. Install front fender liner RH.
54. Install front wheel RH. Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf)
55. Bleed power steering fluid.
56. Inspect fluid leak.

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Note. When installing, coat the parts indicated by the arrow with power steering fluid or molybdenum disulfide lithium base grease. See COMPONENTS .

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1. Precaution. See «POWER STEERING SYSTEM»(ref-175163-S15736903502005041800000).
2. Disconnect battery negative terminal.
3. Remove horn button assembly. See «OVERHAUL»(ref-175190-S42342846022005041800000).
4. Remove steering wheel assembly. See «OVERHAUL»(ref-175190-S42342846022005041800000). SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
5. Remove front wheel.
6. Remove spiral cable sub-assembly. See «OVERHAUL»(ref-175190-S42342846022005041800000).
7. Disconnect tie rod assembly LH. Remove the cotter pin and nut. Using SST, remove the tie rod assembly LH from the steering knuckle. SST 09628-62011
8. Disconnect tie rod assembly RH. SST 09628-62011 NOTE: Remove the RH side by the same procedures with LH side.
9. Disconnect steering intermediate shaft sub-assembly. Loosen the bolt and remove the clamp from the steering column hole cover No. 1. Disconnect the steering column hole cover No. 2 from the steering column hole cover No. 1. Loosen the bolt. Place matchmarks on the steering intermediate shaft sub-assembly and steering gear assembly. Remove the bolt and separate the steering intermediate shaft sub-assembly.
10. Disconnect front stabilizer link assembly LH. Remove the nut and disconnect the front stabilizer link assembly from the absorber. NOTE: If the ball joint turns together with the nut, use a 6 mm hexagon wrench to hold the stud.
11. Disconnect front stabilizer link assembly RH. NOTE: Remove the RH side by the same procedures with LH side.
12. Remove front stabilizer bracket No. 1 LH. Remove the 2 bolts and disconnect the front stabilizer bracket No. 1 LH.
13. Remove front stabilizer bracket No. 1 RH. NOTE: Remove the RH side by the same procedures with LH side.
14. Disconnect pressure feed tube assembly. Using SST, disconnect the return tube assembly from the steering gear assembly. SST 09023-12700 Using SST, disconnect the pressure feed tube assembly from the steering gear assembly. SST 09023-12700 Remove the nut and disconnect the return feed tube clamp.
15. Remove rack & pinion power steering gear assembly. Remove the bolt and disconnect the tube clamp. Remove the 2 bolts, nuts and steering gear assembly.
16. Remove power steering rack housing heat insulator. Remove the power steering rack housing heat insulator.
17. Remove steering left turn pressure tube. Using SST, remove the left turn pressure tube. SST 09023-38200 Remove the 2 O-rings from the left turn pressure tube.
18. Remove steering right turn pressure tube. Using SST, secure the steering gear assembly. SST 09023-38200 Remove the 2 O-rings from the right turn pressure tube.
19. Fix rack & pinion power steering gear assembly. Using SST, secure the steering gear assembly. SST 09612-00012 NOTE: Tape the SST before use.
20. Remove tie rod assembly LH. Place matchmarks on the tie rod assembly LH and rack end. Loosen the lock nut, and remove the tie rod assembly LH and lock nut.
21. Remove tie rod assembly RH. NOTE: Remove the RH side by the same procedures with LH side.
22. Inspect tie rod assembly LH. Secure the tie rod LH in a vise. Install the nut to the stud bolt. Flip the ball joint stud back and forth 5 times. Using a torx wrench, turn the nut continuously at a rate of 2-4 seconds per one turn and take the torque reading of the 5th turn. Turning torque: 0.83-3.43 N.m (8.5-35.0 kgfcm, 7.3-30.4 in.lbf)
23. Inspect tie rod assembly RH. NOTE: Remove the RH side by the same procedures with LH side.
24. Remove steering rack boot clip. Remove the 2 steering rack boot clips.
25. Remove steering rack boot No. 2 clamp. Using pliers, remove the steering rack boot No. 2 clamp. NOTE: Be careful not to damage the steering rack boot.
26. Remove steering rack boot No. 1 clamp. NOTE: Remove the steering rack boot No. 1 clamp by the same procedures with the steering rack boot No. 2 clamp. NOTE: Be careful not to damage the steering rack boot.
27. Remove steering rack boot No. 2. Remove the steering rack boot No. 2.
28. Remove steering rack boot No. 1. NOTE: Remove the steering rack boot No. 1 by the same procedures with the steering rack boot No. 2.
29. Remove steering rack end sub-assembly. Using a screwdriver and a hammer, unstake the claw washer. NOTE: Avoid any impact to the power steering rack. Using 2 SSTs, remove the 2 rack ends and 2 claw washers. SST 09922-10010 NOTE: Use SST 09922-10010 in the direction shown in the illustration. Securely hold the power steering rack end with a SST.
30. Remove rack guide. Using SST, remove the rack guide spring cap nut. SST 09922-10010 NOTE: Use SST 09922-10010 in the direction shown in the illustration. Using SST, remove the rack guide spring cap. SST 09631-10021 Remove the compression spring and rack guide.
31. Remove power steering control valve. Using a 27 mm socket wrench, remove the rack housing cap. Using SST, hold the control valve shaft and remove the nut. SST 09616-00011 Wind vinyl tape around the serrated part of the control valve. Remove the dust cover from the control valve housing. Remove the 2 bolts and control valve. Remove the gasket. To prevent oil seal lip damage, wind vinyl tape around the serrated part of the control valve. Using a plastic hammer, remove the control valve with oil seal from the control valve housing. Remove the oil seal from the control valve. Using a screwdriver, remove the 4 control valve rings. NOTE: Be careful not to damage the grooves for the control valve ring.
32. Remove power steering control valve upper oil seal. Using SST and a press, remove the control valve upper bearing and upper oil seal from the control valve housing. SST 09950-70010 (09951-07150), 09950-60010 (09951-00250)
33. Remove cylinder end stopper. Using a screwdriver and a hammer, turn the cylinder end stopper clockwise until the wire end is visible through the service hole. Using a screwdriver and a hammer, turn the cylinder end stopper counterclockwise, and remove the wire and cylinder end stopper.
34. Remove power steering rack.
35. Remove power steering rack bush. Remove the power steering rack bush from the power steering rack. Using SST, remove the rack bush oil seal. SST 09527-21011, 09612-24014 (09613-22011) Using a screwdriver, remove the O-ring from the power steering rack bush.
36. Inspect power steering rack. Using a dial indicator, check the steering rack for runout and for teeth wear and damage. Maximum Runout: 0.3 mm (0.0118 in.) Check the back surface for wear and damage.
37. Remove power steering cylinder tube oil seal. Using SST and a press, remove the power steering cylinder oil seal. SST 09950-70010 (09951-07360), 09950-60010 (09951-00290)
38. Remove rack steering piston ring. Using a screwdriver, remove the rack steering piston ring and O-ring. NOTE: Be careful not to damage the grooves for rack steering piston ring.
39. Install rack steering piston ring. Coat a new O-ring with power steering fluid and install it to the steering rack. Expand a new rack steering piston ring with your fingers. NOTE: Be careful not to over expand the rack steering piston ring. Coat a new rack steering ring with power steering fluid. Install the rack steering piston ring to the power steering rack, and settle it down with your fingers.
40. Install power steering cylinder tube oil seal. Coat a new power steering cylinder tube oil seal lip with power steering fluid. SST 09950-60010 (09951-00420, 09951-00250, 09952-06010), 09950-70010 (09951-07360) Using SST and a press, install the power steering cylinder tube oil seal. NOTE: Make sure that the power steering cylinder tube oil seal is installed facing in the correct direction. Take care so that the power steering cylinder tube oil seal will not be reversed as you install it.
41. Install power steering rack. Install SST to the power steering rack. SST 09631-33010 NOTE: If necessary, scrape the burrs off the power steering rack teeth end and burnish. Coat the SST with power steering fluid. Install the power steering rack into the rack housing. Remove the SST.
42. Install power steering rack bush. Using SST and a press, install the rack bush oil seal to the power steering rack bush. SST 09950-60010 (09951-00400), 09950-70010 (09951-07100) NOTE: Make sure that the rack bush oil seal is installed facing in the correct direction. Coat a new O-ring with power steering fluid and install it to the power steering rack bush. To prevent rack bush oil seal lip damage, wind vinyl tape around the steering rack end, and apply power steering fluid. Install the rack bush to the steering rack.
43. Install cylinder end stopper. Align the installation hole for the wire of the cylinder end stopper with the slot of the rack housing. Install a new wire into the cylinder end stopper. Using a screwdriver, turn the cylinder end stopper clockwise by 450 +/- 50 degrees.
44. Air tightness test. Install SST to the rack housing. SST 09631-12071 (09633-00010) Apply vacuum of 53 kPa (400 mmHg, 15.75 in.Hg) for about 30 seconds. Check that there is no change in the vacuum. If there is a change in the vacuum, check the installation of the oil seals.
45. Install power steering control valve upper oil seal. Coat a control valve upper bearing and a new upper oil seal with power steering fluid. Using SST and a press, install the upper oil seal. SST 09950-70010 (09951-07150), 09950-60010 (09951-00180, 09952-06010, 09951-00320) Using SST and a press, install the control valve upper bearing. SST 09950-70010 (09951-07150), 09950-60010 (09951-00180, 09952-06010, 09951-00340)
46. Install power steering control valve. Expand 4 new valve rings with your fingers. NOTE: Be careful not to over expand the valve ring. Coat the 4 valve rings with power steering fluid. Install the 4 valve rings to the control valve, and settle them down with your fingers. Carefully slide the tapered end of SST over the valve rings until they fit to the control valve. SST 09631-20081 NOTE: Be careful not to damage the valve rings. To prevent upper oil seal lip damage, wind vinyl tape around the serrated part of the control valve. Coat the upper oil seal lip with power steering fluid. Install the control valve to the control valve housing. NOTE: Be careful not to damage the control valve ring and upper oil seal lip. Coat a new oil seal lip with power steering fluid. Using SST and a press, install the oil seal. SST 09612-22011 NOTE: Make sure that the oil seal is installed facing in the correct direction. Apply grease to the needle bearing. Install a new gasket to the valve housing. Wind vinyl tape around the serrated part of the control valve. Install the valve housing to the rack housing with the 2 bolts. Torque: 21 N.m (214 kgf.cm, 15 ft.lbf) Using SST, stop the control valve shaft rotation and install a new lock nut. Torque: 24.5 N.m (250 kgf.cm, 18 ft.lbf) SST 09616-00011 Apply sealant to 2 or 3 threads of the rack housing cap. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Using a 27 mm socket wrench, install the rack housing cap. Torque: 58.5 N.m (597 kgf.cm, 43 ft.lbf) Using a punch and a hammer, stake the rack housing cap and rack housing.
47. Install rack guide. Apply molybdenum disulfide lithium base grease to the rack guide. Install the rack guide. Install the compression spring. Apply sealant to 2 or 3 threads of the rack guide spring cap. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent. Temporarily install the rack guide spring cap.
48. Adjust total preload. To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the RH and LH rack ends. Using SST, torque the rack guide spring cap. SST 09631-10021 Torque: 25 N.m (255 kgf.cm, 18 ft.lbf) Using SST, loosen the rack guide spring cap. SST 09631-10021 Using SST, turn the control valve shaft to the right and left 1 or 2 times. SST 09616-00011 Using SST, loosen the rack guide spring cap until the rack guide spring is not functioning. SST 09631-10021 Using SST and a torque wrench, tighten the rack guide spring cap until the preload is within specification. SST 09616-00011, 09631-10021 Preload (turning): 1.2-1.5 N.m (12.2-15.3 kgf.cm, 10.6-13.3 in.lbf) Apply sealant to 2 or 3 threads of the rack guide spring cap nut. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Temporarily install the rack guide spring cap nut. Using SST, hold the rack guide spring cap and using another SST, torque the rack guide spring cap nut. SST 09616-00011, 09922-10010 Torque: 48 N.m (489 kgf.cm, 35 ft.lbf) NOTE: Use SST 09922-10010 in the direction shown in the illustration. Use a torque wrench with a fulcrum length of 345 mm (13.58 in.). Precheck the total preload. Preload (turning): 1.2-1.5 N.m (12.2-15.3 kgf.cm, 10.6-13.3 in.lbf) Remove the RH and LH rack ends. Apply MP grease into the control valve, as shown in the illustration. (Scheme 94) Wind vinyl tape around the serrated part of the control valve. Install the dust cover to the control valve housing.
49. Install steering rack end sub-assembly. Install a new 2 claw washers, and temporarily install the 2 rack ends. NOTE: Align the claws of the claw washer with the steering rack grooves. Using 2 SSTs, install the 2 rack ends. SST 09922-10010 Torque: 58.5 N.m (597 kgf.cm, 43 ft.lbf) NOTE: Use SST 09922-10010 in the direction shown in the illustration. NOTE: Using SST, hold the rack and install the rack end. Use a torque wrench with a fulcrum length of 345 mm (13.58 in.). Using a brass bar and a hammer, stake the claw washer. NOTE: Avoid any impact to the steering rack.
50. Inspect power steering rack. Ensure that the steering rack end hole is not clogged with grease. NOTE: If the hole is clogged, the pressure inside the boot will change after it is assembled and steering wheel is turned.
51. Install steering rack boot No. 2. Install the steering rack boot No. 2.
52. Install steering rack boot No. 1. NOTE: Remove the steering rack boot No. 1 by the same procedures with steering rack boot No. 2
53. Install steering rack boot No. 2 clamp. Using SST, tighten the steering rack boot No. 2 clamp, as shown in the illustration. SST 09521-24010 Clearance: 3.0 mm (0.118 in.) or less NOTE: Be careful not to damage the boot.
54. Install steering rack boot No. 1 clamp. SST 09521-24010 NOTE: Be careful not to damage the boot. NOTE: Install the steering rack boot No. 1 clamp by the same procedures with steering rack boot No. 2 clamps.
55. Install steering rack boot clip. Using pliers, install the 2 rack boot clips.
56. Install tie rod assembly LH. Screw the lock nut and tie rod assembly LH onto the rack end until the matchmarks are aligned. NOTE: After adjusting toe-in, torque the lock nut.
57. Install tie rod assembly RH. NOTE: Install the RH side by the same procedures with LH side
58. Install steering left turn pressure tube. Coat 2 new O-rings with power steering fluid and install them to the left turn pressure tube. Using SST, install the left turn pressure tube to the steering gear assembly. SST 09023-38200 Torque: 11.5 N.m (117 kgf.cm, 8 ft.lbf) NOTE: Use a torque wrench with a fulcrum length of 345 mm (9.84 in.). This torque value is effective in the case that SST is parallel to a torque wrench.
59. Install steering right turn pressure tube. Coat 2 new O-rings with power steering fluid and install them to the right turn pressure tube. Using SST, install the right turn pressure tube to the steering gear assembly. SST 09023-38200 Torque: 11.5 N.m (117 kgf.cm, 8 ft.lbf) NOTE: Use a torque wrench with a fulcrum length of 345 mm (11.81 in.). This torque value is effective in the case that SST is parallel to a torque wrench.
60. Install power steering rack housing heat insulator. Install the power steering rack housing heat insulator. NOTE: Install nut when installing the return clamp
61. Install rack & pinion power steering gear assembly. Install the power steering gear assembly with the 2 bolts and nuts. Torque: 70 N.m (714 kgf.cm, 52 ft.lbf) Connect the pressure feed tube assembly clamp with the bolt. Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)
62. Connect pressure feed tube assembly. Using SST, connect the pressure feed tube assembly to the steering gear. SST 09023-12700 Torque: 22.5 N.m (229 kgf.cm, 17 ft.lbf) NOTE: Use a torque wrench with a fulcrum length of 300 mm (11.81 in.). This torque value is effective in the case that SST is parallel to a torque wrench. Using SST, connect the return tube assembly to the steering gear. SST 09023-12700 Torque: 22.5 N.m (229 kgf.cm, 17 ft.lbf) NOTE: Use a torque wrench with a fulcrum length of 300 mm (11.81 in.). This torque value is effective in the case that SST is parallel to a torque wrench. Install the return tube clamp with the nut. Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)
63. Install front stabilizer bracket No. 1 LH. Install the front stabilizer bracket No. 1 LH with the 2 bolts. Torque: 19 N.m (194 kgf.cm, 14 ft.lbf)
64. Install front stabilizer bracket No. 1 RH. NOTE: Remove the RH side by the same procedures with LH side.
65. Connect front stabilizer link assembly LH. Connect the stabilizer link assembly LH to the stabilizer bar with the nut. Torque: 74 N.m (755 kgf.cm, 55 ft.lbf) NOTE: If the ball joint turns together with the nut, use a 6 mm hexagon wrench to hold the stud.
66. Connect front stabilizer link assembly RH. NOTE: Connect the RH side by the same procedures with LH side.
67. Connect steering intermediate shaft sub-assembly. Align the matchmarks on the intermediate shaft sub-assembly and steering gear assembly. Install the bolt. Torque: 35.3 N.m (360 kgf.cm, 26 ft.lbf) Tighten the bolt. Torque: 35.3 N.m (360 kgf.cm, 26 ft.lbf) Install the steering column hole cover No. 2 to the steering hole cover No. 1. Connect the clamp to the steering column hole cover No. 1 and tighten the bolt.
68. Connect tie rod assembly LH. Connect the tie rod assembly LH with the nut. Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) Install a new cotter pin. NOTE: If the holes for a new cotter pin are not aligned, tighten the nut further up 60 degrees.
69. Connect tie rod assembly RH. NOTE: Install the RH side by the same procedures with LH side.
70. Install front wheel. Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf)
71. Bleed power steering fluid.
72. Check power steering fluid leakage.
73. Install spiral cable sub-assembly. See «OVERHAUL»(ref-175190-S42342846022005041800000).
74. Center spiral cable. See «OVERHAUL»(ref-175190-S42342846022005041800000).
75. Install steering wheel assembly. See «OVERHAUL»(ref-175190-S42342846022005041800000).
76. Install horn button assembly. See «OVERHAUL»(ref-175190-S42342846022005041800000).
77. Inspect and adjust front wheel alignment. See «WHEEL ALIGNMENT»(ref-156462-S24951027832003071700000).
78. Inspect steering wheel center point.
79. Inspect SRS warning light. See «DIAGNOSTICS»(ref-150793-S31442541522002112100000).