Steering: Other Subaru Forester SF рестайлинг

Service Data

Steering System Service Data

Precaution

AIRBAG system wiring harness is routed near the steering wheel, steering shaft and column.

Scheme 56

Scheme 57

Scheme 58

Scheme 59

1. Disconnect battery minus terminal.
2. Lift-up vehicle.
3. Remove AIRBAG module. For 2000 models, see «AIR BAG RESTRAINT SYSTEMS»(ref-97335). For 2001 models, see «AIR BAG RESTRAINT SYSTEMS»(ref-150189). WARNING: Always refer to Supplemental Restraint System" before performing AIRBAG module service (if so equipped). For 2000 models, see «AIR BAG RESTRAINT SYSTEMS»(ref-97335). For 2001 models, see «AIR BAG RESTRAINT SYSTEMS»(ref-150189).
4. Remove steering wheel nut, then draw out steering wheel from shaft using steering puller. (Scheme 56): Removing Steering Wheel Nut
5. Remove universal joint bolts and then remove universal joint. CAUTION: Scribe alignment marks on universal joint so that it can be reassembled at the original serration. (Scheme 57): Removing Universal Joint Bolts
6. Remove trim panel under instrument panel.
7. Remove knee bolster. (Scheme 58): Removing Knee Bolster
8. Disconnect connectors for ignition switch and combination switch wiring harness under instrument panel.
9. Remove the two bolts under instrument panel securing steering column. (Scheme 59): Removing Bolts Securing Steering Column
10. Pull out steering shaft assembly from hole on toe board.

Service Limit

Make a measurement as follows. If it exceeds the specified service limit, adjust or replace.

Note. When making a measurement, vise gearbox by using ST. Never vise gearbox by inserting aluminum plates, etc. between vise and gearbox.

ST 926200000 STAND

Sliding resistance of rack shaft

Service limit: 304.0 N (31.0 kg, 68.4 lb) or less.

Measuring Sliding Resistance Of Rack Shaft (1 Of 2). Scheme 60

Measuring Sliding Resistance Of Rack Shaft (2 Of 2). Scheme 61

Rack Shaft Play In Radial Direction

Right-turn steering

Service limit: 0.15 mm (0.0059 in) or less.

Note. On condition refers to directions in see scheme 29.

On condition

1. L: 5 mm (0.20 in)
2. P: 98 N (10 kg, 22 lb)

Left-turn steering

Service limit

1. Direction (In white arrow direction in see scheme 30 ) 0.3 mm (0.012 in) or less
2. Direction (In solid arrow direction in see scheme 30 ) 0.15 mm (0.0059 in) or less

Input Shaft Play

In radial direction

Service limit - 0.18 mm (0.0071 in) or less.

On condition

1. P: 98 N (10 kg, 22 lb)

Checking Input Shaft Play In Radial Direction. Scheme 62

In axial direction

Service limit- 0.1 mm (0.004 in) or less.

On condition

1. P: 20-49 N (2-5 kg, 4-11 lb)

Checking Input Shaft Play In Axial Direction. Scheme 63

Turning Resistance Of Gearbox

Using ST, measure gearbox turning resistance.

ST 926230000 SPANNER

Service limit

1. Straight-ahead position within 30 mm (1.18 in) from rack center Less than 11.18 N (1.14 kg, 2.51 lb)
2. Maximum allowable resistance 12.7 N (1.3 kg, 2.9 lb)

Checking Turning Resistance Of Gearbox. Scheme 64

Oil Leaking Points

1. If leak point is other than a, b, c, or d, perform 5th step in "OIL LEAK CHECK PROCEDURE AND REPLACEMENT PARTS" before dismounting gearbox from vehicle. See 5 . If gearbox is dismounted without confirming where the leak is, it must be mounted again to locate the leak point.
2. Even if the location of the leak can be easily found by observing the leaking condition, it is necessary to thoroughly remove the oil from the suspected portion and turn the steering wheel from lock to lock about 30 to 40 times with engine running, then make comparison of the suspected portion between immediately after and several hours after this operation.
3. Before starting oil leak repair work, be sure to clean the gearbox, hoses, pipes, and surrounding parts. After completing repair work, clean these areas again.

Valve Housing Oil Seal

Specified steering grease: VALIANT GREASE M2 (Part No. 003608001)

Scheme 65

Scheme 66

Scheme 67

Scheme 68

1. Using ST and a press, remove dust seal, oil seal and special bearing from valve housing. ST 34099FA120 SEAL INSTALLER & REMOVER CAUTION: Do not apply a force to end surface of valve housing. Do not reuse oil seal after removal. (Scheme 65): Removing Dust Seal, Oil Seal & Special Bearing From Valve Housing
2. Apply a coat of specified power steering fluid to inner wall of valve housing. (Scheme 66): Identifying Area To Apply Coat Of Specified Power Steering Fluid
3. Attach ST2 to ST1, and press oil seal into place using a press. ST1 34099FA120 SEAL INSTALLER & REMOVER ST2 34099FA130 SEAL INSTALLER Face oil seal in the direction shown in figure when installing. To avoid scratching oil seal, apply a coat of grease to contact surface of installer and oil seal. To facilitate installation, attach oil seal to installer and position in valve housing before pressing into place. (Scheme 67): Pressing Oil Seal Into Place Using (ST1 & ST2) Using ST and press, install special bearing in valve housing. ST 34099FA120 SEAL INSTALLER & REMOVER NOTE: To facilitate installation, attach ball bearing to remover and position in valve housing before pressing it into place. (Scheme 68): Installing Special Bearing In Valve Housing

Scheme 69

Scheme 70

Scheme 71

Scheme 72

1. Remove snap ring using snap ring pliers. CAUTION: Do not reuse removed snap ring. Be careful not to scratch pinion and valve assembly. (Scheme 69): Removing Snap Ring
2. Press out bearing together with backing washer using pipe of I.D. 38.5 to 39.5 mm (1.516 to 1.555 in) and press. CAUTION: Do not reuse removed bearing. (Scheme 70): Identifying Bearing & Backing Washer
3. Remove oil seal. CAUTION: Do not reuse removed oil seal.
4. Put vinyl tape around pinion shaft splines to protect oil seal from damage.
5. Fit pinion and valve assembly into valve housing. NOTE: Apply specified power steering fluid to outer diameter surface of input shaft and outer surface of valve body seal ring, and pay special attention not to damage seal when inserting pinion and valve assembly.
6. Secure valve assembly to ST1 and ST2.
7. Put ST3 over pinion, and insert oil seal, then force-fit oil seal into housing using ST4. ST1 926370000 INSTALLER A ST2 34099FA100 STAND BASE ST3 926360000 INSTALLER A ST4 927620000 INSTALLER B (Scheme 71): Installing Pinion & Valve Assembly Into Valve Housing NOTE: Apply specified power steering fluid to oil seal and ST3, being careful not to damage oil seal lip. Push oil seal until ST3 contacts housing end face.
8. Remove ST3, and fit backing washer.
9. Force-fit ball bearing using ST3. ST1 926370000 INSTALLER A ST2 34099FA100 STAND BASE ST3 927640000 INSTALLER B (Scheme 72): Installing Backing Washer NOTE: Be careful not to tilt ball bearing during installation.
10. Install snap ring using snap ring pliers. NOTE: Rotate snap ring to check for proper installation.

Scheme 73

Scheme 74

1. Insert ST from pinion housing side and remove oil seal using a press. ST 34199AE050 OIL SEAL REMOVER (Scheme 73): Removing Oil Seal NOTE: Discard removed oil seal.
2. Force-fit oil seal using ST. ST 34099FA110 INSTALLER CAUTION: Be careful not to damage or scratch cylinder inner wall. NOTE: Apply specified power steering fluid to oil seal. Pay special attention not to install oil seal in wrong direction. Push oil seal until the stepped portion of A contacts end face of B. (Scheme 74): Installing Oil Seal

Check

Check all disassembled parts for wear, damage or other abnormalities. Repair or replace faulty parts as required.

Inspection Chart. Scheme 75

Scheme 76

Scheme 77

Scheme 78

Scheme 79

Scheme 80

1. Connect pipes C and D to steering gearbox. Tightening torque: Joint nut: 15+/-5 N.m (1.5+/-0.5 kg-m, 10.8+/-3.6 ft-lb) CAUTION: Visually check that hose between tank and pipe D is free from bending or twisting. (Scheme 76): Identifying Bolt A & Pipes "C" & "D" At Oil Tank
2. Connect pipe D to oil tank.
3. Connect pipe C to oil pump. CAUTION: Use a new gasket. Tightening torque: 39+/-5 N.m (4.0+/-0.5 kg-m, 28.9+/-3.6 ft-lb)
4. Tighten bolt A. Tightening torque: 13+/-3 N.m (1.3+/-0.3 kg-m, 9.4+/-2.2 ft-lb)
5. Temporarily connect pipes C and D to pipes (on the gearbox side). (Scheme 77): Identifying Pipes "C" & "D" At Gearbox
6. Temporarily install clamp E on pipes C and D. CAUTION: Ensure that the letter "8" side of clamp E is on the pipe C side as shown in the figure. (Scheme 78): Identifying Clamp "E"
7. Tighten clamp E firmly. Tightening torque: 7.4+/-2.0 N.m (0.75+/-0.20 kg-m, 5.4+/-1.4 ft-lb)
8. Tighten joint nut. Tightening torque: 15+/-5 N.m (1.5+/-0.5 kg-m, 10.8+/-3.6 ft-lb)
9. Connect pipes A and B to the four pipe joints of gearbox. Connect upper pipe B first, and lower pipe A second. Tightening torque: 13+/-3 N.m (1.3+/-0.3 kg-m, 9.4+/-2.2 ft-lb) (Scheme 79): Connecting Pipes "A" & "B" To Four Pipe Joints Of Gearbox
10. Install jack-up plate.
11. Connect battery minus terminal.
12. Feed the specified fluid and discharge air. NOTE: Never start the engine before feeding the fluid; otherwise vane pump might be seized up. (Scheme 80): Identifying Hose Routing "A" & "B"
13. Finally check clearance between pipes and/or hoses, as shown above. If clearance between cruise control pump and power steering hose is less than 10 mm (0.39 in), proceed as follows: Move clamped section (A) (refer to figure above.) down to a point where pipe is close to crossmember. Pipe-to-crossmember clearance: 10 mm (0.39 in), Min. Check that clearance between cruise control pump and power steering hose is at least 10 mm (0.39 in). If it is not, bend section (B) down until a clearance of at least 10 mm (0.39 in) is obtained.

Scheme 81

Scheme 82

Scheme 83

Scheme 84

Scheme 85

1. Remove ground cable from battery.
2. Drain the working fluid about 0.3 l (0.3 US qt, 0.3 lmp qt) from oil tank.
3. Remove pulley belt cover bracket.
4. Loosen oil pump pulley nut, then remove bolts which secure generator. (Scheme 81): Loosening Oil Pump Pulley Nut
5. Loosen pulley belt(s).
6. Remove the nut and detach oil pump pulley.
7. Disconnect pipe C from oil pump. Disconnect pipe D from oil tank. CAUTION: Do not allow fluid from the hose end to come into contact with pulley belt. To prevent foreign matter from entering the hose and pipe, cover the open ends of them with a clean cloth. Except when only oil tank needs to be inspected, detach oil tank and oil pump as a unit. Then separate one from the other on a work bench to prevent oil from spilling on any part of the engine. (Scheme 82): Identifying Bolt A, Pipe "C" & Pipe "D" At Oil Tank
8. Remove the three bolts from the front side of oil pump and detach the pump. (Scheme 83): Identifying Oil Pump Mounting Bolts
9. Remove the three bolts from the lower side of bracket and detach the bracket. CAUTION: The bracket does not need to be removed unless it is damaged.
10. Place oil pump in a vise, and remove upper shell and baffle from lower shell. CAUTION: Do not clamp oil pump too hard; otherwise oil pump may be dented. (Scheme 84): Removing Upper Shell From Lower Shell
11. Remove lower shell from oil pump. (Scheme 85): Removing Lower Shell From Oil Pump

Scheme 86

1. In accordance with the following table, check all removed parts for wear and damage, and make repair or replacement if necessary. (Scheme 86): Checking Parts For Wear & Damage Chart

Make a measurement as follows. If it exceeds the specified service limit, replace the parts with new ones.

Scheme 87

Scheme 88

Scheme 89

Scheme 90

1. Play of pulley shaft On condition: P: 9.8 N (1.0 kg, 2.2 lb) Service limit: Radial play (Direction <---->): 0.4 mm (0.016 in) or less (Scheme 87): Checking Play Of Pulley Shaft (Radial Play) Axial play (Direction <---->): 0.9 mm (0.035 in) or less (Scheme 88): Checking Play Of Pulley Shaft (Axial Play)
2. Ditch deflection of pulley Service limit: 1.0 mm (0.039 in) or less NOTE: Read the value for one surface of V ditch, and then the value for another off the dial. (Scheme 89): Measuring Ditch Deflection Of Pulley
3. Resistance to rotation of pulley Service limit: Maximum load; 9.22 N (0.94 kg, 2.07 lb) or less. NOTE: A rather higher value may be indicated when pulley starts turning. Measure the load during rotation and make a judgment. (Scheme 90): Measuring Resistance To Rotation Of Pulley

Scheme 91

Scheme 92

Scheme 93

Scheme 94

1. Install bracket on engine. Tightening torque: 22+/-2 N.m (2.2+/-0.2 kg-m, 15.9+/-1.4 ft-lb)
2. Install oil pump on oil tank as follows outside the vehicle: NOTE: Prior to installation, make sure that all oil is removed from oil pump, oil tank and pipe. Place oil pump in a vise and install stay to oil pump. CAUTION: Do not place oil pump directly in vise; use soft pads and hold oil pump lightly to protect it. Tightening torque: 15.7+/-2.4 N.m (1.60+/-0.24 kg-m, 11.6+/-1.7 ft-lb) Install lower shell to oil pump. Tightening torque: 18 +5/0 N.m (1.8 +0.5/0 kg-m, 13.0 +3.6/0 ft-lb) CAUTION: Be sure to use a new seal washer. (Scheme 91): Identifying Lower Shell & Seal Install upper shell and baffle to lower shell. Tightening torque: 13+/-3 N.m (1.3+/-0.3 kg-m, 9.4+/-2.2 ft-lb) (Scheme 92): Installing Upper Shell & Baffle To Lower Shell
3. Install oil pump, previously assembled to oil tank, on bracket. Tightening torque: 18 +5/0 N.m (1.8 +0.5/0 kg-m, 13.0 +3.6/0 ft-lb) (Scheme 93): Installing Oil Pump Onto Bracket
4. Place oil pump pulley and tighten pulley nut temporarily.
5. Install pulley belt to oil pump.
6. Tighten oil pump pulley nut to the specified torque. Tightening torque: 52+/-10 N.m (5.3+/-1.0 kg-m, 38+/-7 ft-lb)
7. Check pulley belt tension. See «DRIVE BELT ROUTING & ADJUSTMENT»(ref-149713).
8. Tighten bolt belt tension. Tightening torque: 8+/-2 N.m (0.8+/-0.2 kg-m, 5.8+/-1.4 ft-lb)
9. Interconnect pipes C and D. Tightening torque: Eye bolt: 39+/-5 N.m (4.0+/-0.5 kg-m, 28.9+/-3.6 ft-lb) CAUTION: If a hose is twisted at this step, the hose may come into contact with some other parts. (Scheme 94): Identifying Interconnect Pipes "C & D"
10. Install pulley belt cover bracket.
11. Connect minus terminal of battery.
12. Feed the specified power steering fluid and discharge air. See «POWER STEERING FLUID»(ref-176750-S17103790642005051100000). CAUTION: Never start the engine before feeding the fluid; otherwise vane pump might be seized up.

Scheme 95

1. Feed the specified fluid with its level being about 4 cm (1.6 in) lower than the mouth of tank.
2. Continue to turn steering wheel slowly from lock to lock until bubbles stop appearing in the tank while keeping the fluid at that level.
3. In case air is absorbed to deliver bubbles into piping because the fluid level is lower, leave it about half an hour and then do the previous step all over again.
4. Start, and idle the engine.
5. Continue to turn steering wheel slowly from lock to lock again until bubbles stop appearing in the tank while keeping the fluid at that level. It is normal that bubbles stop appearing after three times turning of steering wheel.
6. In case bubbles do not stop appearing in the tank, leave it about half an hour and then do the step 5) all over again.
7. Stop the engine, and take out safety stands after jacking up vehicle again. Then lower the vehicle, and idle the engine.
8. Continue to turn steering wheel from lock to lock until bubbles stop appearing and change of the fluid level is within 3 mm (0.12 in).
9. In case the following happens, leave it about half an hour and then do the previous step. The fluid level changes over 3 mm (0.12 in). Bubbles remain on the upper surface of the fluid. Grinding noise is generated from oil pump.
10. Check the fluid leakage at flare nuts after turning steering wheel from lock to lock with engine running. CAUTION: Before checking, wipe off any fluid on flare nuts, eye bolt and piping. In case the fluid leaks from flare nut, it is caused by dust (or the like) and/or damage between flare and tapered seat in piping. So remove the flare nut, tighten again it to the specified torque after cleaning flare and tapered seat. If flare or tapered seat is damaged, replace it with a new one.
11. Inspect fluid level on a flat and level surface with engine "OFF" by the indicator of filler cap. If the level is at lower point or below, add fluid to keep the level in the specified range of the indicator. If at upper point or above, drain fluid by using a syringe or the like. Fluid capacity: 0.7 l (0.7 US qt, 0.6 lmp qt) Check at temperature 21°C (70°F) on reservoir surface of oil pump, read the fluid level on the "COLD" side. Check at temperature 60°C (140°F) on reservoir surface of oil pump, read the fluid level on the "HOT" side. (Scheme 95): Inspecting Fluid Level Using Indicator Of Filler Cap

Measurement Of Hydraulic Pressure

Note. Keep engine idling during the measurement.

Scheme 96

Scheme 97

Scheme 98

1. 1B1: MEASURE REGULAR PRESSURE. Install STs to power steering pump. Drain the power steering fluid about 0.35 l (0.4 US qt, 0.3 lmp qt) from oil tank. remove the two bolts securing power steering pipes to engine. Install ST1, 2 and 3 between power steering pump and pipes using gasket (Part No. 34621AC020) and bolt (Part No. 34620AC010). ST1 925711000 PRESSURE GAUGE ST2 34099AC020 ADAPTER HOSE B ST3 34099AC010 ADAPTER HOSE A (Scheme 96): Installing Pressure Gauge Power Steering Pump Replenish power steering fluid up to specified level. Open valve, and start the engine. Measure regular pressure. CHECK: Is pressure 981 kPa (10 kg/cm 2, 142 psi) or less? YES: Go to step 1B2. NO: Trouble may be due to crushed pipe or hose, leakage from fluid line, foreign particles in fluid line, etc. Replace faulty parts with new ones.
2. 1B2: MEASURE RELIEF PRESSURE. Using STs, measure relief pressure. ST1 925711000 PRESSURE GAUGE ST2 34099AC020 ADAPTER HOSE B ST3 34099AC010 ADAPTER HOSE A (Scheme 97): Measuring Relief Pressure Close valve. CHECK: Is pressure 7,159-7,748 kPa (73-79 kg/cm 2, 1,038-1,123 psi)? YES: Go to step 1B3. NO: Trouble may be due to malfunctioning relief valve, fluid leaking into oil pump interior, abnormal wear of pump vanes, etc. Replace with new oil pump.
3. 1B3: MEASURE WORKING PRESSURE. Using STs, measure working pressure. ST1 925711000 PRESSURE GAUGE ST2 34099AC020 ADAPTER HOSE B ST3 34099AC010 ADAPTER HOSE A (Scheme 98): Measure Working Pressure Open valve. Measure working pressure of control valve by turning wheel from stop to stop. CHECK: Is pressure 7,159-7,748 kPa (73-79 kg/cm 2, 1,038-1,123 psi)? YES: Measure steering force, see «MEASUREMENT OF STEERING EFFORT»(ref-176750-S34683536762005051100000). NO: Control valve is inoperative. Replace control valve itself or control valve and pinion as a single unit with new ones.

Scheme 99

Scheme 100

Scheme 101

Scheme 102

Scheme 103

Scheme 104

Scheme 105

Scheme 106

Scheme 107

1. Measurement of steering effort is as shown in the figures. (Scheme 99): Measuring Of Steering Effort Right (Scheme 100): Measuring Of Steering Effort Left
2. Measurement of folding torque of universal joint is as shown in the figures. Service limit: Maximum load; 5.49 N (0.56 kg, 1.23 lb) or less. (Scheme 101): Measuring Folding Torque Of Universal Joint (Long Yoke As Shown; 1 Of 2) Service limit: Maximum load; 5.49 N (0.56 kg, 1.23 lb) or less. (Scheme 102): Measuring Folding Torque Of Universal Joint (Long Yoke As Shown; 2 Of 2) Service limit: Maximum load; 8.43 N (0.86 kg, 1.90 lb) or less. (Scheme 103): Measuring Folding Torque Of Universal Joint (Short Yoke As Shown; 1 Of 2) Service limit: Maximum load; 8.43 N (0.86 kg, 1.90 lb) or less. (Scheme 104): Measuring Folding Torque Of Universal Joint (Short Yoke As Shown; 2 Of 2)
3. Using ST, measure resistances of gearbox. ST 926230000 SPANNER Rotating resistance: Straight-ahead position within 30 mm (1.18 in) from rack center; Less than 11.18 N (1.14 kg, 2.51 lb) Maximum allowable torque; 15.7 N (1.6 kg, 3.5 lb) (Scheme 105): Measuring Rotating resistance Of Gearbox Sliding resistance: Right-turn steering; 304 N (31 kg, 68 lb) or less. (Scheme 106): Measuring Sliding Resistance Of Gearbox (Right-Turn) Left-turn steering; 304 N (31 kg, 68 lb) or less. (Scheme 107): Measuring Sliding Resistance Of Gearbox (Left-Turn)

Clearance Table

Components Clearance Table. Scheme 108

Components Clearance Locations. Scheme 109

Breakage Of Hoses

Trouble Shooting Hose Condition Chart. Scheme 110