Power Steering - Except Lancer Evolution Mitsubishi Lancer Evolution X

GENERAL INFORMATION

1. The steering wheel has three spokes. All vehicles are equipped with SRS (Supplemental Restraint System).
2. The steering column has a shock absorbing mechanism and a tilt steering mechanism.
3. The steering system uses a vane oil pump with a fluid flow control system, so that steering effort varies with engine speed.

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GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

SERVICE SPECIFICATIONS

SERVICE SPECIFICATIONS

LUBRICANTS

LUBRICANTS

SEALANT

SEALANT SPECIFICATIONS

INTRODUCTION TO POWER STEERING DIAGNOSIS

Hydraulic power steering is used for all vehicles. Faults in the power steering can include excessive play of the steering wheel, difficult steering wheel operation, noise, vibration, and oil leaks, etc. Possible causes of these faults can include defects in the gear box, oil pump or steering linkage.

POWER STEERING DIAGNOSIS TROUBLESHOOTING STRATEGY

Use these steps to plan your diagnostic strategy. If you follow them carefully, you will be sure that you have exhausted most of the possible ways to find a power steering fault.

1. Gather information from the customer.
2. Verify that the condition described by the customer exists.
3. Find the malfunction by following the SYMPTOM CHART.
4. Verify malfunction is eliminated.

SYMPTOM CHART

SYMPTOM CHART

DIAGNOSIS

1. STEP 1. Check for looseness at the steering shaft coupling section and at the steering wheel linkage. Q: Is there any looseness? YES: Repair or replace the part. Then go to Step 3 . NO: Go to Step 2.
2. STEP 2. Check the steering wheel free play. With the engine running (hydraulic operation), set the front wheels straight ahead. Measure the play on the steering wheel circumference before the wheels start to move when slightly moving the steering wheel in both directions. Limit: 30 mm (1.2 inch) or less If the free play exceeds the limit value, set the steering wheel straight ahead with the engine stopped. Load approximately 5 N (1.1 pound) towards the steering circumference and check the play. Standard value (steering wheel free play with engine stopped): 16.5 mm (0.65 inch) or less Q: Does the play exceed the standard value? YES: Remove the steering gear box (Refer to «POWER STEERING GEAR BOX AND LINKAGE»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution) ) and check the total pinion torque (Refer to «POWER STEERING GEAR BOX AND LINKAGE»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution) ). Then go to Step 3. NO: Go to Step 3.
3. STEP 3. Check the steering wheel play. Verify that the steering wheel play is not excessive. Q: Is the steering wheel play excessive? YES: Repeat from Step 1 . NO: The procedure is complete.

Scheme 3

1. STEP 1. Check the power steering oil pump drive belt tension. Refer to «DRIVE BELT TENSION CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-20l-non-turbo-except-lancer-evolution) <2.0L Non-Turbo>, «DRIVE BELT TENSION CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-20l-turbo-except-lancer-evolution) < 2.0L Turbo Engine >, «DRIVE BELT TENSION CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-24l-except-lancer-evolution) < 2.4L Engine >. Q: Is the power steering oil pump drive belt tension within the standard value? YES: Go to Step 2. NO: Adjust the tension (Refer to «DRIVE BELT TENSION CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-20l-non-turbo-except-lancer-evolution) <2.0L Non-Turbo>, «DRIVE BELT TENSION CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-20l-turbo-except-lancer-evolution) < 2.0L Turbo Engine >, «DRIVE BELT TENSION CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-24l-except-lancer-evolution) < 2.4L Engine >). Then go to Step 10 .
2. STEP 2. Check the drive belt for damage. Q: Is the drive belt damaged? YES: Replace the drive belt (Refer to «DRIVE BELT TENSION CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-20l-non-turbo-except-lancer-evolution) <2.0L Non-Turbo>, «DRIVE BELT TENSION CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-20l-turbo-except-lancer-evolution) < 2.0L Turbo Engine >, «DRIVE BELT TENSION CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-24l-except-lancer-evolution) < 2.4L Engine >). Then go to Step 10 . NO: Go to Step 3.
3. STEP 3. Check the fluid level. Park the vehicle on a flat, level surface, and then start the engine. Turn the steering wheel several times to raise the temperature of the fluid to approximately 50 - 60°C (122 - 140°F). With the engine running, turn the wheel all the way to the left and right several times. Check the fluid in the oil reservoir for foaming or milkiness. Check the difference of the fluid level when the engine is stopped, and while it is running. If the change of the fluid level is 5 mm (0.2 inch) or more, bleed the air from the system (Refer to «POWER STEERING SYSTEM AIR BLEEDING»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution__power-steering-system-air-bleeding) ). Q: Is the fluid foamy? YES: Go to Step 4. NO: Go to Step 10 .
4. STEP 4. Check for entry of air. Q: Has air entered? YES: Bleed the air (Refer to «POWER STEERING SYSTEM AIR BLEEDING»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution__power-steering-system-air-bleeding) ). Then go to Step 10 . NO: Go to Step 5.
5. STEP 5. Check each hose for crushing or twisting. Q: Is any hose crushed or twisted? YES: Repair or replace the hose (Refer to «POWER STEERING HOSES»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution) ). Then go to Step 10 . NO: Go to Step 6.
6. STEP 6. Check for oil leaks. Q: Are there oil leaks? YES: Repair it. Then go to Step 10 . NO: Go to Step 7.
7. STEP 7. Check the wheel alignment (camber and caster). Refer to «FRONT WHEEL ALIGNMENT CHECK AND ADJUSTMENT»(/mitsubishi/lancer-evolution/x-2007-2016/remont/suspension-front/#front-suspension-wheel-alignment-except-lancer-evolution__front-wheel-alignment-check-and-adjustment) . Q: Is the alignment incorrect? YES: Adjust it (Refer to «FRONT WHEEL ALIGNMENT CHECK AND ADJUSTMENT»(/mitsubishi/lancer-evolution/x-2007-2016/remont/suspension-front/#front-suspension-wheel-alignment-except-lancer-evolution__front-wheel-alignment-check-and-adjustment) ). Then go to Step 10 . NO: Go to Step 8.
8. STEP 8. Check the gear box rack piston seal for damage. Q: Is there damage? YES: Replace it (Refer to «DISASSEMBLY AND ASSEMBLY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution) ). Then go to Step 10 . NO: Go to Step 9.
9. STEP 9. Check for excessive tie rod end ball joint breakaway torque. Refer to «TIE ROD END BALL JOINT ROTATION TORQUE CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution__tie-rod-end-ball-joint-rotation) . Q: Is there fault? YES: Replace the part (Refer to «DISASSEMBLY AND ASSEMBLY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution) ). Then go to Step 10. NO: Go to Step 10.
10. STEP 10. Check the steering wheel operation. Verify that the steering wheel operation is not difficult. Q: Is the steering wheel operation difficult? YES: Repeat from Step 1 . NO: The procedure is complete.

1. STEP 1. Check for proper oil pump and steering gear installation. Q: Is the oil pump and the steering gear installation correct? YES: Go to Step 2. NO: Repair it (Refer to «POWER STEERING OIL PUMP ASSEMBLY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution) , «POWER STEERING GEAR BOX AND LINKAGE»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution) ). Then go to Step 4 .
2. STEP 2. Check for interference of other parts with the steering column and the power steering hoses. Q: Is there interference? YES: Correct the interference. Then go to Step 4 . NO: Go to Step 3.
3. STEP 3. Check for noise from inside the oil pump or the steering gear. Q: Is there noise? YES: Replace the part (Refer to «REMOVAL AND INSTALLATION»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution) and «DISASSEMBLY AND ASSEMBLY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution) ). Then go to Step 4. NO: Go to Step 4.
4. STEP 4. Check for rattling noise. Confirm that no noise is generated. Q: Is there noise? YES: Repeat from Step 1 . NO: The procedure is complete.

1. STEP 1. Check for entry of air. Q: Is the power steering fluid foamy? YES: Bleed the air (Refer to «POWER STEERING SYSTEM AIR BLEEDING»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution__power-steering-system-air-bleeding) ). Then go to Step 3 . NO: Go to Step 2.
2. STEP 2. Check for seizure in the oil pump. Q: Is there seizure? YES: Replace the part (Refer to «REMOVAL AND INSTALLATION»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution) ). Then go to Step 3. NO: Go to Step 3.
3. STEP 3. Retest the system. Confirm that no noise is generated. Q: Is there noise? YES: Repeat from Step 1 . NO: The procedure is complete.

1. STEP 1. Check the drive belt tension. Refer to «DRIVE BELT TENSION CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-20l-non-turbo-except-lancer-evolution) <2.0L Non-Turbo>, «DRIVE BELT TENSION CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-20l-turbo-except-lancer-evolution) < 2.0L Turbo Engine >, «DRIVE BELT TENSION CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-24l-except-lancer-evolution) < 2.4L Engine >. Q: Is the drive belt tension incorrect? YES: Adjust the belt tension (Refer to «DRIVE BELT TENSION CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-20l-non-turbo-except-lancer-evolution) <2.0L Non-Turbo>, «DRIVE BELT TENSION CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-20l-turbo-except-lancer-evolution) < 2.0L Turbo Engine >, «DRIVE BELT TENSION CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/mechanical/#engine-mechanical-24l-except-lancer-evolution) < 2.4L Engine >). Then go to Step 3 . NO: Go to Step 2.
2. STEP 2. Check for seizure in the oil pump. Q: Is there seizure? YES: Replace the part (Refer to «REMOVAL AND INSTALLATION»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution) ). Then go to Step 3. NO: Go to Step 3.
3. STEP 3. Retest the system. Confirm that no noise is generated. Q: Is there noise? YES: Repeat from Step 1 . NO: The procedure is complete.

1. STEP 1. Check for entry of air. Q: Is the power steering fluid foamy? YES: Bleed the air (Refer to «POWER STEERING SYSTEM AIR BLEEDING»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution__power-steering-system-air-bleeding) ). Then go to Step 4 . NO: Go to Step 2.
2. STEP 2. Check each hose for crushing or twisting. Q: Is any hose crushed or twisted? YES: Replace the hose (Refer to «POWER STEERING HOSES»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution) ). Then go to Step 4 . NO: Go to Step 3.
3. STEP 3. Check the steering gear for damage. Q: Is there damage? YES: Replace the part (Refer to «DISASSEMBLY AND ASSEMBLY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution) ). Then go to Step 4. NO: Go to Step 4.
4. STEP 4. Retest the system. Confirm that no noise is generated. Q: Is there noise? YES: Repeat from Step 1 . NO: The procedure is complete.

1. STEP 1. Check the oil pump or oil pump bracket installation. Q: Is the oil pump or the oil pump bracket installation correct? YES: Go to Step 2. NO: Repair it (Refer to «POWER STEERING OIL PUMP ASSEMBLY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution) and «POWER STEERING GEAR BOX AND LINKAGE»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution) ). Then go to Step 3 .
2. STEP 2. Check the oil pump for damage. NOTE: If a slight "beat noise" is produced by the oil pump when the steering wheel is turned fully and held in that position, this is not a malfunction. Q: Is there damage? YES: Replace the oil pump (Refer to «REMOVAL AND INSTALLATION»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution) ). Then go to Step 3. NO: Go to Step 3.
3. STEP 3. Retest the system. Confirm that no noise is generated. Q: Is there noise? YES: Repeat from Step 1 . NO: The procedure is complete.

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Scheme 5

1. STEP 1. Check for interference of the wheel and the vehicle body. If interfering, adjust the steering angle. Place the front wheel on a turning radius gauge and measure the steering angle. STEERING ANGLE STANDARD VALUE SPECIFICATIONS Inner wheel 40°50' ± 1°30' (Difference between right and left wheels must be 2°00' or less) Outer wheel (reference value) 33°50' If the steering angle is not within the standard value, adjust the toe-in. Standard value: 1 ± 2 mm (0.04 ± 0.08 inch) Adjust the toe-in by undoing the clip and jam nut, and turning the left and right tie rod turnbuckles by the same amount (in opposite directions). NOTE: The toe will move out as the left turnbuckle is turned toward the front of the vehicle and the right turnbuckle is turned toward the rear of the vehicle. Q: Is the steering angle normal? YES: Go to Step 2. NO: Adjust the steering angle (Refer to «STEERING ANGLE CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution__steering-angle-check) ). Then go to Step 3 .
2. STEP 2. Check the steering gear for damage. Q: Is there damage? YES: Repair or replace the part (Refer to «DISASSEMBLY AND ASSEMBLY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution) ). Then go to Step 3. NO: Go to Step 3.
3. STEP 3. Retest the system. Confirm that no noise is generated. Q: Is there noise? YES: Repeat from Step 1 . NO: The procedure is complete.

INSPECTION PROCEDURE 9: Vibration

Note. A slight vibration may be felt when the stationary steering effort is made due to the condition of the road surface. To check whether the vibration actually exists or not, test-drive the vehicle on a dry concrete or asphalt surface. A very slight amount of vibration is not a malfunction.

1. STEP 1. Check for entry of air. Q: Is the power steering fluid foamy? YES: Bleed the air (Refer to «POWER STEERING SYSTEM AIR BLEEDING»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution__power-steering-system-air-bleeding) ). Then go to Step 3 . NO: Go to Step 2.
2. STEP 2. Check the steering gear for damage. Q: Is there damage? YES: Replace the part (Refer to «DISASSEMBLY AND ASSEMBLY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution) ). Then go to Step 3. NO: Go to Step 3.
3. STEP 3. Retest the system. Confirm that no vibration is generated. Q: Is there vibration? YES: Repeat from Step 1 . NO: The procedure is complete.

1. STEP 1. Check for loosening of the return tube flare nut. Q: Is the flare nut loose? YES: Tighten it to standard value (Refer to «POWER STEERING HOSES»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution) ). Then go to Step 3 . NO: Go to Step 2.
2. STEP 2. Check the hose connection and the clamp installation. Q: Are they correct? YES: Go to Step 3. NO: Repair or replace the part (Refer to «POWER STEERING HOSES»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution) ). Then go to Step 3.
3. STEP 3. Retest the system. Check that no oil is leaking. Q: Is there oil leakage? YES: Repeat from Step 1 . NO: The procedure is complete.

1. STEP 1. Check the hose for damage or clogging. Q: Is the hose damaged or clogged? YES: Replace it (Refer to «POWER STEERING HOSES»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution) ). Then go to Step 2. NO: Go to Step 2.
2. STEP 2. Retest the system. Check that no oil is leaking. Q: Is there oil leakage? YES: Repeat from Step 1 . NO: The procedure is complete.

1. STEP 1. Check the oil reservoir for damage. Q: Is there damage? YES: Replace the oil reservoir (Refer to «POWER STEERING HOSES»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution) ). Then go to Step 3 . NO: Go to Step 2.
2. STEP 2. Check for overflowing. Q: Is there oil overflowing from the reservoir? YES: Adjust fluid level. Then go to Step 3. NO: Go to Step 3.
3. STEP 3. Retest the system. Q: Is there oil leakage? YES: Repeat from to Step 1 . NO: The procedure is complete.

1. STEP 1. Check the oil pump body for damage. Q: Is there damage? YES: Replace the part (Refer to «REMOVAL AND INSTALLATION»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution) ). Then go to Step 3 . NO: Go to Step 2.
2. STEP 2. Check the O-ring or oil seal for damage. Q: Is there damage? YES: Replace the part (Refer to «REMOVAL AND INSTALLATION»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution) ). Then go to Step 3. NO: Go to Step 3.
3. STEP 3. Retest the system. Check that no oil is leaking. Q: Is there oil leakage? YES: Repeat from Step 1 . NO: The procedure is complete.

1. STEP 1. Check the steering gear housing for damage. Q: Is there damage? YES: Replace the part (Refer to «DISASSEMBLY AND ASSEMBLY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution) ). Then go to Step 3 . NO: Go to Step 2.
2. STEP 2. Check the oil-ring or oil seal for damage. Q: Is there damage? YES: Replace the part (Refer to «DISASSEMBLY AND ASSEMBLY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution) ). Then go to Step 3. NO: Go to Step 3.
3. STEP 3. Retest the system. Check that no oil is leaking. Q: Is there oil leakage? YES: Repeat from Step 1 . NO: The procedure is complete.

SPECIAL TOOLS

SPECIAL TOOLS Tool Tool number and name Supersession Application MB991955 MB991824 MB991827 MB991910 MB991911 MB991825 MB991826 M.U.T.-III Sub Assembly Vehicle communication interface (V.C.I.) M.U.T.-III USB cable M.U.T.-III main harness A (Vehicles with CAN communication system) M.U.T.-III main harness B (Vehicles without CAN communication system) M.U.T.-III main harness C (for Daimler models only) M.U.T.-III trigger Harness MB991824-KIT NOTE: G: MB991826 M.U.T.-III Trigger Harness is not necessary when pushing V.C.I. ENTER key. CAUTION: For vehicles with CAN communication, use M.U.T.-III main harness A to send simulated vehicle speed. If you connect M.U.T.-III main harness B instead, the CAN communication does not function correctly. Power steering system air bleeding (Calibration by using the scan tool) MB991897 or MB992011 Ball joint remover MB991113-01, MB990635-01 or General service tool Knuckle and tie rod end ball joint disconnection NOTE: Steering linkage puller (MB990635 or MB991113) is also available to disconnect knuckle and tie rod end ball joint. MB990326 Preload socket General service tool Tie rod end ball joint breakaway torque check MB991548 Power steering oil pressure gauge adapter (Pump side) MB991548-01 Oil pump pressure test MB991549 Power steering oil pressure gauge adapter (Hose side) MB991549-01 MB990662 Power steering oil pressure gauge MB990662-01 MB990784 Ornament remover General service tool Cover removal MB990803 Steering wheel puller General service tool Steering wheel removal MB990228 or MB991006 Preload socket MB990228-01 Steering gear total pinion torque check MB990925 Bearing and oil seal installer set MB990925-01 or general service tool Oil seal and bearing installation MB990927, MB990938, MB990939 (For details, refer to SPECIAL TOOLS ). MB991203 Oil seal and bearing installer Tool not available Oil seal and bearing installation MB992209 Bellows band crimping tool MB992209 Bellows band installation MB992249 Variable spanner Tie-rod removal and installation

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STEERING WHEEL FREE PLAY CHECK

1. With the engine running (hydraulic pressure applied), position the front wheel in the straight ahead position.
2. Measure the side to side steering wheel play until the front wheels actually start moving while turning the steering wheel slightly in the left and right directions. Limit: 30 mm (1.2 inch) or less
3. If the steering wheel free play exceeds the limit value, check the steering shaft joint or steering linkage for looseness, and replace or repair the faulty components if necessary.
4. If the steering wheel free play still exceeds the limit value after Step 3 is performed, position the steering wheel in the straight ahead position, and then apply the force (approximately 5 N) in the circumferential direction. Standard value (steering wheel free play with the engine stopped): 16.5 mm (0.65 inch) or less
5. If the steering wheel free play is outside the standard value after Step 4 is performed, remove the steering gear and linkage (Refer to «POWER STEERING GEAR BOX AND LINKAGE»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution) ), and check and adjust the pinion total rotation torque (Refer to «PINION TOTAL ROTATION TORQUE CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution__pinion-total-rotation-torque-check) ).

STEERING ANGLE CHECK

Scheme 16

1. Check that the wheel alignment is normal (Refer to «FRONT WHEEL ALIGNMENT CHECK AND ADJUSTMENT»(/mitsubishi/lancer-evolution/x-2007-2016/remont/suspension-front/#front-suspension-wheel-alignment-except-lancer-evolution__front-wheel-alignment-check-and-adjustment) ).
2. Place the front wheel on a turning radius gauge and measure the steering angle. STEERING ANGLE STANDARD VALUE SPECIFICATIONS Inner wheel 40°50' ± 1°30' (Difference between right and left wheels must be 2°00' or less) Outer wheel (reference value) 33°50'
3. If not within the standard value, adjust the tie-rods (right and left), and repeat Steps 1 and 2 .
4. If the measured value exceeds the standard range by performing Step 3 , replace the steering gear and linkage assembly (Refer to «POWER STEERING GEAR BOX AND LINKAGE»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution) ).

TIE-ROD LOOSENESS CHECK

When an abnormal noise is generated by the steering system, check the tie-rod for looseness. For the tie-rod looseness check, using a push-pull gauge and a spring scale, carry out the items below.

1. Install a dial gauge.
2. Check the points to load for a push-pull gauge and a spring scale.
3. Operate to stabilize the load and fluctuation with a push-pull gauge and a spring scale.
4. Carry out the dial gauge measurement and calculation with a push-pull gauge and a spring scale.

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1. Before the looseness check, check the items below. Check that the Mitsubishi genuine wheel with specified size is mounted. Also check that the wheel bearing is not loose. (Refer to «WHEEL BEARING CHECK FOR LOOSENESS IN THE AXIAL DIRECTION»(/mitsubishi/lancer-evolution/x-2007-2016/remont/axle-shafts/#front-axle-except-lancer-evolution__wheel-bearing-end-play-check) .) Raise the vehicle at the jack up point on the side sill of the inspection side, and lift the tire for approximately 30 mm (1.2 in). At this time, check that the tire of the opposite side is grounded.
2. Install a dial-gauge respectively to the "Position a (front side position)" and "Position b (rear side position)" on the wheel rim, 25 mm (1.0 in) below from the wheel center. (Install the dial gauges to the smooth position that is around the edge of the tire.)
3. The push-pull gauge shall be set to the smooth position that is 25 mm (1.0 in) above from the wheel center and the edge of the tire on the wheel rim. Then the position on the vehicle front side shall be the "Position A" and the vehicle rear side shall be the "Position B".
4. To stabilize the relationship between the load and fluctuation, push with the specified load by wheel size in the order of "Position A", "Position B", and "Position A" using the push-pull gauge. Note that the pushed load on each position shall be extracted. LOAD SPECIFICATIONS WITH RESPECT TO WHEEL Wheel size Specified load 16 inches 120 N 18 inches 100 N
5. Using the push-pull gauge, carry out the procedure below to read the value on the dial gauge and calculate the looseness. NOTE: The +/- sign acquired with the calculation result shall be used as it is. While pushing the "Position B" with the specified load by wheel size, read the values on the dial gauges at the "Position a" and "Position b". The values of the dial gauges at this time shall respectively be "aB" and "bB". LOAD SPECIFICATIONS WITH RESPECT TO WHEEL Wheel size Specified load 16 inches 120 N 18 inches 100 N Remove the load in the "Position B". Then while pushing the "Position A" with the specified load by wheel size, read the values on the dial gauge in the "Position a" and "Position b". The values on the dial gauges at this time shall respectively be "aA" and "bA". LOAD SPECIFICATIONS WITH RESPECT TO WHEEL Wheel size Specified load 16 inches 120 N 18 inches 100 N Make calculation taking the value differences of the dial gauge positions a and b which were read while pushing the "Position A" and "Position B" as each fluctuation. Fluctuation of the dial gauge position a: aA - aB Fluctuation of the dial gauge position b: bA - bB Calculate each fluctuation difference of the dial gauge positions a and b acquired above for looseness. Perform the procedure above twice. Fluctuation of the dial gauge position a - Fluctuation of the dial gauge position b Calculate the average of the looseness calculated twice.
6. If the average exceeds the standard value, check the ball joint rotation torque. (Refer to «TIE ROD END BALL JOINT ROTATION TORQUE CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution__tie-rod-end-ball-joint-rotation) .) Standard value: Within ± 2.0 mm (0.08 in) NOTE: Measure the tie-rod looseness on the right side and left side respectively.

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

Scheme 29

1. Carry out the confirmation before the looseness check with the same manner as the check using a push-pull gauge.
2. At the position that is 25 mm (1.0 in) above from the wheel center, bind the tire and the wheel rim with a cord for both the front and rear sides, and fix them with a tape not to loose vertically.
3. Set the spring scale to the cord bound as above. At this time, the point to pull shall be in the dimension between the "Position C" and "Position D" by wheel size, and the position on the vehicle front side shall be the "Position C" and the vehicle rear side shall be the "Position D". POSITION C AND D DIMENSIONS Wheel size C - D dimension 16 inches 480 - 495 mm (18.9 - 19.5 in) 18 inches 525 mm (20.7 in)
4. To stabilize the relationship between the load and fluctuation, pull with the specified load by wheel size in the order of "Position C", "Position D", and "Position C" using the spring scale. Note that the pulled load on each position shall be extracted. LOAD SPECIFICATIONS WITH RESPECT TO WHEEL Wheel size Specified load 16 inches 120 N 18 inches 80 N
5. Using the spring scale, carry out the procedure below to read the value on the dial gauge and calculate the looseness. NOTE: The +/- sign acquired with the calculation result shall be used as it is. While pulling the "Position D" with the specified load by wheel size, read the values on the dial gauges in the "Position a" and "Position b". The values on the dial gauges at this time shall respectively be "aD" and "bD". LOAD SPECIFICATIONS WITH RESPECT TO WHEEL Wheel size Specified load 16 inches 120 N 18 inches 80 N Remove the load at the "Position D". Then while pulling the "Position C" with the specified load by wheel size, read the values on the dial gauge in the "Position a" and "Position b". The values on the dial gauges at this time shall respectively be "aC" and "bC". LOAD SPECIFICATIONS WITH RESPECT TO WHEEL Wheel size Specified load 16 inches 120 N 18 inches 80 N Make calculation taking the value differences of the dial gauge positions a and b which were read while pulling the "Position C" and "Position D" as each fluctuation. Fluctuation of the dial gauge position a: aC - aD Fluctuation of the dial gauge position b: bC - bD Calculate each fluctuation difference of the dial gauge positions a and b acquired above for looseness. Perform the procedure above twice. Fluctuation of the dial gauge position a - Fluctuation of the dial gauge position b Calculate the average of the looseness calculated twice.
6. If the average exceeds the standard value, check the ball joint rotation torque. (Refer to «TIE ROD END BALL JOINT ROTATION TORQUE CHECK»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution__tie-rod-end-ball-joint-rotation) .) Standard value: Within ± 2.0 mm (0.08 in) NOTE: Measure the tie-rod looseness on the right side and left side respectively.

BALL JOINT DUST COVER CHECK

1. Using your fingers, press the dust cover to check for cracks or damage.
2. If there are any cracks in the dust cover or it is damaged, replace the tie-rod end (Refer to «DISASSEMBLY AND ASSEMBLY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution) ). NOTE: If the dust cover has a crack or damage, the ball joint could be damaged.

TIE ROD END BALL JOINT ROTATION TORQUE CHECK

Required Special Tools

1. MB990326: Preload Socket
2. MB991897 or MB992011: Ball Joint Remover

Scheme 30

Scheme 31

Scheme 32

1. Install special tool MB991897 or MB992011 as shown in the figure.
2. Turn the bolt and knob to make the special tool jaws parallel, then hand-tighten the bolt. After tightening, check that the jaws are still parallel. NOTE: To adjust the special tool jaws to be parallel, set the orientation of the knob as shown in the figure.
3. Unscrew the bolt to disconnect the ball joint.
4. Move the ball joint stud several times and install the nut on the stud. Using the special tool MB990326, measure the ball joint rotation torque. Standard value: 2.9 N.m (26 in-lb) or less
5. If the rotation torque exceeds the standard value, replace the tie rod end (Refer to «DISASSEMBLY AND ASSEMBLY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution) ).
6. If any looseness or scraping feeling is experienced in the ball joint, even when the measurement is within the range of the standard value, the ball joint should be judged to be faulty. In this case, replace the tie-rod end (Refer to «DISASSEMBLY AND ASSEMBLY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution) ).

Scheme 33

1. Park the vehicle on a level paved road, position the steering wheel in the straight ahead position.
2. Start the engine, and maintain the engine speed at 1,000 ± 100 r/min.
3. Position the spring scale on the circumference of the steering wheel, and measure the steering force at the time when the steering wheel is turned to right or left side (within the range of one and a half turns) from the center position. STEERING FORCE STANDARD VALUE SPECIFICATIONS Steering force 29 (6.5 lb) N or less Fluctuation band 5.9 (1.33 lb) N or less
4. If not within the standard value, check and adjust the suspected components.

STEERING WHEEL RETURN TO CENTER CHECK

Conduct a road test

Scheme 34

1. Make both gradual and sudden turns and check the steering wheel return.
2. At a vehicle speed of approximately 22 mph (35 km/h), turn the steering wheel 90 degrees, hold a few seconds, then release. If the steering wheel then returns 70 degrees or more, the return can be judged satisfactory. NOTE: There will be a momentary feeling or "heaviness" when the wheel is turned quickly, but this is not abnormal (Oil pump discharge amount is especially apt to be insufficient during idling).

DRIVE BELT TENSION CHECK

Refer to DRIVE BELT TENSION CHECK <2.0L Non-Turbo>, DRIVE BELT TENSION CHECK < 2.0L Turbo Engine >, Refer to DRIVE BELT TENSION CHECK < 2.4L Engine >.

Scheme 35

1. Park the vehicle on a flat, level surface.
2. Start the engine, and then turn the steering wheel several times to raise the temperature of the fluid to approximately 50 - 60°C (122 - 140°F).
3. With the engine running, turn the wheel all the way to the left and right several times.
4. Check the fluid in the oil reservoir for foaming or milkiness. Check the difference of the fluid level when the engine is stopped, and while it is running. If the change of the fluid level is 5 mm (0.2 inch) or more, air bleeding should be done (Refer to «POWER STEERING SYSTEM AIR BLEEDING»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution__power-steering-system-air-bleeding) ).

Scheme 36

Scheme 37

1. Raise and support the front wheels.
2. Disconnect the return hose connection, and then connect a vinyl hose to the return hose, and drain the fluid into a container.
3. Disconnect the crank angle sensor connector.
4. While operating the starter motor intermittently, turn the steering wheel all the way to the left and right several times to drain all of the fluid.
5. Connect the return hose securely, and then secure with the clip.
6. Fill the oil reservoir with GENUINE MITSUBISHI POWER STEERING FLUID to the lower position of the filler, and then bleed the air (Refer to «POWER STEERING SYSTEM AIR BLEEDING»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution__power-steering-system-air-bleeding) ).

Scheme 38

1. Raise and support the front wheels.
2. Disconnect the return hose connection, and then connect a vinyl hose to the return hose, and drain the fluid into a container.
3. Disconnect the all of the injector connectors.
4. While operating the starter motor intermittently, turn the steering wheel all the way to the left and right several times to drain all of the fluid.
5. Connect the return hose securely, and then secure with the clip.
6. Fill the oil reservoir with GENUINE MITSUBISHI POWER STEERING FLUID to the lower position of the filler, and then bleed the air (Refer to «POWER STEERING SYSTEM AIR BLEEDING»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution__power-steering-system-air-bleeding) ).

POWER STEERING SYSTEM AIR BLEEDING

Perform air bleeding procedure as necessary after replacing the steering gear or the steering fluid lines.

< 2.0L Engine >

Required Special Tools

1. MB991955: M.U.T.-III Sub Assembly

Scheme 39

1. Raise and support the front wheels.
2. Disconnect the crank angle sensor connector. CAUTION: Perform air bleeding only while cranking the engine. If air bleeding is performed while the engine is running, air could enter the fluid. During air bleeding, refill the steering fluid supply so that the level never falls below the lower mark on the dipstick.
3. Turn the steering wheel all the way to the left and right five or six times while using the starter motor to crank the engine intermittently several times (for 15 to 20 seconds).
4. Connect the crank angle sensor connector.
5. Start the engine (idling).
6. Turn the steering wheel to the left and right until there are no air bubbles in the oil reservoir.
7. Confirm that the fluid is not milky, and that the level is between the high and low dipstick marks.
8. Confirm that there is very little change in the fluid level when the steering wheel is turned left and right. CAUTION: If the fluid level rises suddenly after the engine is stopped, the air has not been completely bled. If air bleeding is not complete, there will be abnormal noises from the pump and the flow-control valve, and this condition could cause reduce the life of the power steering components.
9. Confirm that the change in the fluid level is no more than 5 mm (0.2 inch) when the engine is stopped and when it is running.
10. If the change of the fluid level is 5 mm (0.2 inch) or more, the air has not been completely bled from the system. The air bleeding procedure must be repeated.
11. Use the M.U.T-III, check if the DTC is set. If it is set, erase it.

< 2.4L Engine >

Required Special Tools

1. MB991955: M.U.T.-III Sub Assembly

1. Raise and support the front wheels.
2. Disconnect the all of the injector connectors. CAUTION: Perform air bleeding only while cranking the engine. If air bleeding is performed while the engine is running, air could enter the fluid. During air bleeding, refill the steering fluid supply so that the level never falls below the lower mark on the dipstick.
3. Turn the steering wheel all the way to the left and right five or six times while using the starter motor to crank the engine intermittently several times (for 15 to 20 seconds).
4. Connect the all of the injector connectors.
5. Start the engine (idling).
6. Turn the steering wheel to the left and right until there are no air bubbles in the oil reservoir.
7. Confirm that the fluid is not milky, and that the level is between the high and low dipstick marks.
8. Confirm that there is very little change in the fluid level when the steering wheel is turned left and right. CAUTION: If the fluid level rises suddenly after the engine is stopped, the air has not been completely bled. If air bleeding is not complete, there will be abnormal noises from the pump and the flow-control valve, and this condition could cause reduce the life of the power steering components.
9. Confirm that the change in the fluid level is no more than 5 mm (0.2 inch) when the engine is stopped and when it is running.
10. If the change of the fluid level is 5 mm (0.2 inch) or more, the air has not been completely bled from the system. The air bleeding procedure must be repeated.
11. Use M.U.T-III if the DTC is set or not. If the DTC is set, erase it.

OIL PUMP PRESSURE TEST

Required Special Tools

1. MB990662: Power Steering Oil Pressure Gauge
2. MB991548: Oil Pressure Gauge Adapter A (Pump Side)
3. MB991549: Oil Pressure Gauge Adapter B (Hose Side)

Scheme 40

1. Disconnect the pressure hose from the oil pump, and then connect the special tools MB991548, MB990662 and MB991549.
2. Bleed air, then turn the steering wheel several times while the vehicle is not moving so that the temperature of the fluid rises to approximately 50 - 60°C (122 - 140°F).
3. Start the engine and idle it at 1,000 ± 100 r/min. CAUTION: The pressure gauge shut-off valve must not remain closed for more than 10 seconds.
4. Fully close the shut-off valve of the pressure gauge and measure the oil pump relief pressure to confirm that it is within the standard value range. Open it again immediately after checking the pressure. Standard value 8.1 - 8.8 MPa (1,175 - 1,276 psi) < 2.0L Engine > 8.8 - 9.5 MPa (1,276 - 1,378 psi) < 2.4L Engine >
5. If it is not within the standard value, replace the oil pump.
6. Check whether or not the hydraulic pressure is the standard value when no-load conditions are created by fully opening the shut-off valve of the pressure gauge. Standard value 1.0 MPa (145 psi) < 2.0L Engine > 0.2 - 0.7 MPa (29 - 102 psi) < 2.4L Engine >
7. If it is not within the standard value, the probable cause is a malfunction of the oil line or steering gear, so check these parts and repair as necessary.
8. Turn the steering wheel all the way to the left or right; then check whether or not the retention hydraulic pressure is the standard value. Standard value 8.1 - 8.8 MPa (1,175 - 1,276 psi) < 2.0L Engine > 8.8 - 9.5 MPa (1,276 - 1,378 psi) < 2.4L Engine >
9. If not the standard value, overhaul the steering gear. Remeasure fluid pressure.
10. Remove the special tools MB991548, MB990662 and MB991549, and then tighten the pressure hose to the specified torque. Tightening torque: 57 ± 7 N.m (42 ± 5 ft-lb)
11. Bleed the system (Refer to «POWER STEERING SYSTEM AIR BLEEDING»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution__power-steering-system-air-bleeding) ).

POWER STEERING PRESSURE SWITCH CHECK

Required Special Tools

1. MB990662: Power Steering Oil Pressure Gauge
2. MB991548: Oil Pressure Gauge Adapter A (Pump Side)
3. MB991549: Oil Pressure Gauge Adapter B (Hose Side)

Scheme 41

1. Disconnect the pressure hose from the oil pump, and then connect the special tools MB991548, MB990662 and MB991549.
2. Bleed air, and then turn the steering wheel several times while the vehicle is not moving so that the temperature of the fluid rises to approximately 50 - 60°C (122 - 140°F).
3. Start the engine and idle it at 1,000 ± 100 r/min.
4. Disconnect the connector for the oil pressure switch, and place an ohmmeter at the switch.
5. Gradually close the shut-off valve of the pressure gauge and increase the hydraulic pressure, then check whether or not the hydraulic pressure that activates the switch is the standard value. Standard value 2.5 - 3.0 MPa (363 - 435 psi) < 2.0L Engine > 1.5 - 2.0 MPa (218 - 290 psi) < 2.4L Engine >
6. Gradually open the shut-off valve and reduce the hydraulic pressure; then check whether or not the hydraulic pressure that deactivates the switch is the standard value. Standard value 1.5 - 3.0 MPa (218 - 435 psi) < 2.0L Engine > 0.5 - 2.0 MPa (73 - 290 psi) < 2.4L Engine >
7. Remove special tools MB991548, MB990662 and MB991549, connect the pressure hose to the oil pump, and then tighten the eye bolt to the specified torque. Tightening torque: 57 ± 7 N.m (42 ± 5 ft-lb)
8. Bleed the system. (Refer to «POWER STEERING SYSTEM AIR BLEEDING»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution__power-steering-system-air-bleeding) ).

STEERING COLUMN SHAFT ASSEMBLY SHOCK ABSORBING MECHANISM CHECK

If a collision accident occurs or severe impact is applied on the steering wheel, the collision energy absorbing mechanism may have operated. Once the mechanism has operated, it will be inoperative even if it has suffered no apparent damage. Determine if the steering column shaft can be reused by the following procedure. If the collision energy absorbing mechanism has already operated, replace the steering shaft assembly (Refer to STEERING COLUMN SHAFT ASSEMBLY ). If any excessive radial free play on the steering wheel is found with the tilt lever in the lock position, always inspect the steering shaft assembly.

Scheme 42

1. Remove the lower and upper column covers. CAUTION: After inspection, do not release the tilt lever until the steering shaft assembly has been installed.
2. Ensure that the tilt lever is in the lock position.
3. Loosen the two upper steering column mounting bolts by two turns.
4. Hold the one-way capsules as shown in figure, and then try to rock them. If there is a slack in either of the capsules, replace the steering column shaft assembly (Refer to «STEERING COLUMN SHAFT ASSEMBLY»(/mitsubishi/lancer-evolution/x-2007-2016/remont/manual-power-steering/#power-steering-except-lancer-evolution) ). Reference: The mounting base is fixed to the column bracket with the rivet. Before the collision energy absorbing mechanism operates, the column bracket is secured to the mounting base. After operation, the rivet will break off causing a slack. CAUTION: Be careful that nothing is pinched between the mounting base and the body. After inspection, do not release the tilt lever until the steering shaft assembly has been installed.
5. After inspection, if there is no fault, tighten the two steering column upper side mounting bolts (2 bolts) to the specified torque. Tightening torque: 12 ± 3 N.m (106 ± 27 in-lb)

REMOVAL AND INSTALLATION

Scheme 43

Scheme 44

Scheme 45

Required Special Tools

1. MB990784: Ornament Remover
2. MB990803: Steering wheel puller

<< A >> COVER REMOVAL

Insert the special tool MB990784 at the indicated position to remove the cover.

Note. The special tool MB990784 can be inserted through the notch behind the area shown in figure.

Scheme 46

<< B >> DRIVER'S AIR BAG MODULE CONNECTOR DISCONNECTION

Slide the outer housing of the driver's air bag module connector in the arrow direction shown in figure and disconnect the connector.

Scheme 47

<< C >> DRIVER'S AIR BAG MODULE REMOVAL

Scheme 48

1. Position the steering wheel in a straight ahead position. CAUTION: Use the special tool to remove the steering wheel since the steering column collision absorbing mechanism may be damaged.
2. Use special tool MB990803 to remove the steering wheel.

>> A << STEERING WHEEL ASSEMBLY INSTALLATION

After centering the clock spring install the steering wheel assembly. (Refer to REMOVAL AND INSTALLATION Except RALLIART, or REMOVAL AND INSTALLATION RALLIART).

>> B << DRIVER'S AIR BAG MODULE CONNECTOR CONNECTION/STEERING SWITCH CONNECTOR CONNECTION/HORN CONNECTOR CONNECTION

Connect the connector securely and route the harnesses not to lie off the cover hole.

Scheme 49

<< A >> KNOB CAP REMOVAL

Remove the knob cap while pressing the two projections.

Scheme 50

1. Remove the clip (for securing the floor carpet), and turn back the floor carpet.
2. Remove the clip (for securing the steering shaft cover), and then remove the steering shaft cover.

Scheme 51

1. Remove the steering column bolt connecting the steering gear to the steering column assembly.
2. Disconnect the steering gear from the steering column assembly while sliding the shaft A to the shaft B with the clip claw as shown in the figure is pinched.
3. Remove the steering column mounting bolt.

Scheme 52

1. Ensure that the tilt lever is in the lock position.
2. Temporarily tighten the mounting bolts in the order of a, b, and c, and then tighten them in the order of c, b, and a to the specified torque. Tightening torque a: 28 ± 7 N.m (21 ± 5 ft-lb) Tightening torque b, c: 12 ± 3 N.m (106 ± 27 in-lb)

Scheme 53

1. While sliding shaft A from shaft B with the clip claw as shown in the figure being pinched, connect the steering column shaft assembly and the steering gear and linkage.
2. Insert the steering column bolt from the no tapped bolt hole, and tighten it to the specified torque. Tightening torque : 20 ± 5 N.m (15 ± 4 ft-lb)

Scheme 54

Scheme 55

1. Use a drill to make a hole just deeply enough for the tap to stand on the steering lock bolt.
2. Remove the steering lock bolt using the screw extractor (Recommended tool: MB992678), or equivalent.

Scheme 56

1. When installing the steering lock assembly to the steering column shaft assembly, temporarily assemble the steering lock assembly while aligning it with the boss on the column.
2. Make sure that the steering lock operates normally, and then tighten the steering lock bolt until its head is broken off.

Scheme 57

Required Special Tool

1. MB991897 or MB992011: Ball Joint Remover

<< A >> JAM NUT (TIE-ROD END AND KNUCKLE CONNECTION) REMOVAL

1. Install special tool MB991897 or MB992011 as shown in the figure.
2. Turn the bolt and knob to make the special tool jaws parallel, then hand-tighten the bolt. After tightening, check that the jaws are still parallel. NOTE: To adjust the special tool jaws to be parallel, set the orientation of the knob as shown in the figure.
3. Unscrew the bolt to disconnect the ball joint.

Scheme 58

1. Jack up and support the crossmember, and remove it.
2. Check the hoses and harnesses for roughness, and then remove the front suspension crossmember with the rear roll stopper and the steering gear and linkage installed.

>> A << JOINT COVER GROMMET INSTALLATION

Install the joint cover grommet to the steering gear and linkage by aligning L mark and the protrusion part of gearbox as shown in the figure.

Scheme 59

PINION TOTAL ROTATION TORQUE CHECK

Required Special Tools

1. MB991006: Preload Socket

Scheme 60

1. Using the special tool preload socket (MB991006) to rotate the pinion at a rate of one turn per 4 to 6 seconds, and then measure the pinion total rotation torque. Standard value: Total rotation torque: 1.0 - 2.0 N.m (8.9 - 17.7 in-lb) Torque fluctuation: 0.4 N.m (3.5 in-lb) or less NOTE: During measurement, remove the bellows from the gear housing. Rotate the pinion by 180° in left and right directions from the neutral position, and measure the pinion total rotation torque.
2. If the measurement value is outside the standard value, replace the gear housing.

Scheme 61

Required Special Tool

1. MB992209: Boot band clipping tool
2. MB992249: Variable spanner

Scheme 62

Scheme 63

Scheme 64

1. Move the bellows and pull the rack bar toward arrow direction shown in illustration. CAUTION: Do not tighten the vise strongly in order not to damage the rack bar.
2. Wrap rack bar with cloth in order not to damage, and fix the rack bar with a vise.
3. Use special tool variable spanner (MB992249) to remove the tie-rod.

>> A << TIE-ROD INSTALLATION

1. Wrap rack bar with cloth in order not to damage, and fix the rack bar with a vise.
2. Use special tool variable spanner (MB992249) to tighten the tie-rod to the specified torque. Tightening torque: 89 ± 9 N.m

>> B << BAND INSTALLATION

Scheme 65

Scheme 66

1. Using the special tool (MB992209), crimp the bellows band.
2. Check that the crimping width of the band (A) is within the range of the standard value. Standard value (A): 2.4 - 2.8 mm (0.09 - 0.11 in)

>> C << TIE-ROD END/JAM NUT INSTALLATION

Screw in the tie-rod to the length shown in the figure, and hand-tighten the jam nut.

Note. Install the steering gear and linkage to the body, adjust the toe-in, and then tighten the jam nut to the specified torque.

Scheme 67

Scheme 68

>> A << SUCTION HOSE CONNECTION

Align the suction hose marking within the area shown in the figure and connect the suction hose.

Scheme 69

Scheme 70

INSPECTION

1. Check the drive belt for cracks.
2. Check the pulley for uneven rotation.

Scheme 71

Required Special Tool

1. MB990938: Installer bar (MB990925: Including in the bearing and oil seal installer set)
2. MB991203: Oil seal and bearing installer

>> A << O-RING INSTALLATION

O-RING DIMENSIONS

Scheme 72

>> B << OIL SEAL INSTALLATION

Use the following special tools to install the oil seal.

Scheme 73

1. Installer bar (MB990938) [Including in the bearing and oil seal installer set (MB990925)]
2. Oil seal and bearing installer (MB991203)

>> C << CAM RING INSTALLATION

Scheme 74

1. Check the pulley and shaft for wear or damage.
2. Check the rotor and vane groove for "stepped" wear.
3. Check the contact surface of cam ring and vanes for "stepped" wear.
4. Check the vanes for damage.

Scheme 75

Scheme 76

Scheme 77

Scheme 78

Scheme 79

1. Align the marking as shown in the figure and connect the return hose.
2. Align the return hose marking within the area shown in the figure and connect the return hose.
3. Using clip and hose clamp align the return hose marking within the area shown in the figure and connect the return hose.

>> B << PRESSURE HOSE ASSEMBLY INSTALLATION

Align the pressure hose plate as shown in the figure and connect pressure hose assembly.

Scheme 80

Scheme 81

Scheme 82

1. Align the oil reservoir side suction hose marking within the area shown in the figure and connect the suction hose.
2. Align the oil pump side suction hose marking within the area shown in the figure and connect the suction hose.

See also:
• DRIVE BELT TENSION CHECK
• DRIVE BELT TENSION CHECK
• DRIVE BELT TENSION CHECK
• FRONT WHEEL ALIGNMENT CHECK AND ADJUSTMENT
• SPECIAL TOOLS
• STEERING WHEEL SENSOR CALIBRATION
• WHEEL BEARING CHECK FOR LOOSENESS IN THE AXIAL DIRECTION
• SERVICE PRECAUTIONS
• INSPECTION PROCEDURE 1: EXCESSIVE PLAY OF STEERING WHEEL
• INSPECTION PROCEDURE 9: VIBRATION
• POWER STEERING SYSTEM AIR BLEEDING
• TIE ROD END BALL JOINT ROTATION TORQUE CHECK
• STEERING ANGLE CHECK
• PINION TOTAL ROTATION TORQUE CHECK