Power Steering Pump. REMOVAL AND INSTALLATION OF POWER STEERING PUMP Remove and install the parts as shown. (MAIN POINTS OF REMOVAL AND INSTALLATION)
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1 SR44 STEERING Power Steering Pump REMOVAL AND INSTALLATION OF POWER STEERING PUMP Remove and install the parts as shown. (MAIN POINTS OF REMOVAL AND INSTALLATION) 1. ADJUST DRIVE BELT TENSION AFTER INSTALLING PS PUMP (See page SR38) 2. BLEED POWER STEERING SYSTEM (See page SR40)
2 STEERING SR45 REMOVAL AND INSTALLATION OF POWER STEERING PUMP (CONT D) Remove and install the parts as shown. (MAIN POINTS OF REMOVAL AND INSTALLATION) 1. DISCONNECT AND CONNECT PRESSURE LINE Using SST, disconnect and connect the pressure line. SST Torque: 36 Nm (370 kgfcm, 27 ftlbf) HINT: When connecting, use a torque wrench with a fulcrum length of 300 mm (11.81 in.).
3 SR46 STEERING 2. (4WD) DISCONNECT TIE ROD END RH (a) Remove the cotter pin and nut. (b) Using SST, disconnect the tie rod end RH. SST (4WD) REMOVE PS PUMP WITH PRESSURE TUBE (a) Using SST to hold the pulley, loosen the pulley set SST (b) Slide the pump pulley, and loosen the through bolt. (c) Remove the PS pump from the tie rod end hole. 4. REMOVE PRESSURE TUBE (a) Mount the PS pump in the vise. NOTICE: Do not tighten the vise too tight. (b) Remove the union bolt and pressure tube.
4 STEERING SR47 5. INSTALL PRESSURE TUBE (a) Install the pressure tube with the union bolt and a new gasket. (b) Make sure the stopper is touching the pump hous ing as shown, then torque the union bolt. Torque: 51 Nm (525 kgfcm, 38 ftlbf) 6. ADJUST DRIVE BELT TENSION AFTER INSTALLING PS PUMP 7. BLEED POWER STEERING SYSTEM
5 SR48 STEERING COMPONENTS (4AFE ENGINE)
6 STEERING SR49 DISASSEMBLY OF POWER STEERING PUMP 1. MOUNT POWER STEERING PUMP IN VISE NOTICE: Do not tighten the vise too tight. 2. REMOVE DRIVE PULLEY (a) Using SST to hold the pulley, remove the pulley set nut. SST (b) Remove the pulley and woodruff key. 3. REMOVE RESERVOIR TANK AND BRACKET (a) Remove the three bolts and bracket. (b) Remove the bolt and reservoir tank. (c) Remove the 0ring from the reservoir tank. 4. REMOVE AIR CONTROL VALVE Remove the air control valve. HINT: Replace the union seat with a new one only when it is damaged. 5. REMOVE PRESSURE FEED TUBE, PRESSURE PORT UNION, FLOW CONTROL VALVE AND SPRING (a) Remove the union bolt, gaskets and pressure feed tube.
7 SR50 STEERING (b) Remove the pressure port union. (c) Remove the Oring from the union. (d) Remove the flow control valve and spring. 6. REMOVE REAR HOUSING (a) Using two screwdrivers, remove the snap ring. (b) Using a plastic hammer, tap out the rear housing and wave washer. (c) Remove the Oring from the rear housing. 7. REMOVE REAR SIDE PLATE (a) Using a plastic hammer, tap the shaft end and re move the rear plate. (b) Remove the 0ring from the rear plate.
8 STEERING SR51 8. REMOVE VANE PUMP SHAFT, CAM RING AND VANE PLATES (a) Remove the pump shaft with cam ring, vane plates from the front housing. (b) Remove the cam ring and ten vane plates from the pump shaft. (c) Remove the longer straight pin from the front hous ing. 9. REMOVE ROTOR AND FRONT SIDE PLATE (a) Using a screwdriver, remove the snap ring. (b) Remove the rotor and front plate from the pump shaft. (c) Remove the two 0rings from the front plate. (d) Using a pin punch and hammer, drive out the straight pin.
9 SR52 STEERING INSPECTION OF POWER STEERING PUMP 1. MEASURE OIL CLEARANCE OF SHAFT AND BUSHING Using a micrometer and calipers, measure the oil clear ance. Standard clearance: mm ( i n.) Maximum clearance: 0.07 mm ( in.) If more than maximum, replace the entire power steering pump. 2. INSPECT ROTOR AND VANE PLATES (a) Using a micrometer, measure the height, thickness and length of the vane plates. Minimum height: 8.00 mm ( in.) Minimum thickness: 1.77 mm ( in.) Minimum length: mm ( in.) (b) Using a feeler gauge, measure the clearance be tween the rotor groove and vane plate. Maximum clearance: 0.03 mm ( in.) If more than maximum, replace the vane plate and/or rotor with one having the same mark stamped on the cam ring. Inscribed mark: 1,2,3,4 or None HINT: There are five vane lengths with the following rotor and cam ring marks: Rotor and carp ring mark None Vane length mm tiny ( ) ( ) ( ) ( ) ( ) 3. INSPECT FLOW CONTROL VALVE (a) Coat the valve with power steering fluid and check that it falls smoothly into the valve hole by its own weight.
10 STEERING SR53 (b) Check the flow control valve for leakage. Close one of the holes and apply compressed air [ kpa 14 5 kgfcm 2, psi)] into the opposite side, and confirm that air does not come out from the end hole. If necessary, replace the valve with one having the same letter as inscribed on the front housing. Inscribed mark: A,B,C,D,E or F 4. INSPECT FLOW CONTROL SPRING Using a scale, measure the free length of the spring. Spring length: mm ( in.) If not within specification, replace the spring. 5. IF NECESSARY, REPLACE OIL SEAL (a) Using a screwdriver, pry out the oil seal. (b) Using a socket wrench and hammer, drive in a new oil seal.
11 SR54 STEERING ASSEMBLY OF POWER STEERING PUMP (See page SR48) 1. COAT ALL SLIDING SURFACES WITH POWER STEERING FLUID BEFORE ASSEMBLY 2. INSTALL FRONT SIDE PLATE AND ROTOR TO PUMP SHAFT (a) Install the shorter straight pin to the front plate. (b) Install two new Orings to the front plate. (c) Install the front plate to the pump shaft. (d) Install the rotor to the shaft with the inscribed mark on the rotor facing toward the rear. (e) Install the snap ring. 3. INSTALL PS PUMP SHAFT TO FRONT HOUSING (a) Coat the oil seal lip with MP grease. (b) Install the longer straight pin to the front housing. (c) Align the hole of the front plate and straight pin and tap in the pump shaft with a plastic hammer. NOTICE: Be careful not to damage the oil seal and Orings.
12 STEERING SR55 4. INSTALL CAM RING Match the wide hole of the cam ring with the longer straight pin, and install the cam ring. HINT: Install the cam ring with the inscribed mark fac ing the rear. 5. INSTALL VANE PLATES Install the vane plates with the round end facing out ward. 6. INSTALL REAR SIDE PLATE (a) Install a new Oring to the side plate. (b) Match the wide hole with the longer straight pin and install the plate. 7. INSTALL WAVE WASHER Install the wave washer so that its protrusions fit into the slots in the rear side plate. 8. INSTALL REAR HOUSING (a) Install a new 0ring to the rear housing. (b) Install the rear housing and use a press to push down on the wave washer hard enough to compress it. NOTICE: Do not apply too much pressure. (e) Install the snap ring.
13 SR56 STEERING 9. MEASURE PUMP SHAFT PRELOAD (a) Check that the shaft rotates smoothly without ab normal noise. (b) Temporarily install the pulley nut and check the ro tating torque. Rotating torque: 0.3 Nm (2.8 kgfcm, 2.4in lbf) or less 10. INSTALL SPRING, FLOW CONTROL VALVE, PRESSURE PORT UNION AND PRESSURE FEED TUBE (a) Install the spring and the valve into the housing. (b) Install a new 0ring in the groove of the pressure port union. (c) Install and torque the pressure port union. Torque: 69 Nm (700 kgfcm, 51 ftlbf) (d) Install the pressure feed tube, new gaskets and union bolt. Torque: 69 Nm (700 kgfcm, 51 ftlbf) 11. INSTALL AIR CONTROL VALVE Install and tighten the valve. Torque: 36 Nm (370 kgfcm, 27 ftlbf)
14 STEERING SR INSTALL RESERVOIR TANK AND BRACKET (a) Install a new 0ring to the reservoir tank. (b) Install the reservoir tank and bracket and torque the bolts. Torque: 72 mm head bolt 13 Nm (130 kgfcm, 9 inlbf) 14 mm head bolt 41 Nm (420 kgfcm, 30 ftlbf) 13. INSTALL DRIVE PULLEY (a) install the woodruff key to the shaft. (b) Install the pulley and nut to the shaft. (c) Using SST to hold the pulley, torque the nut. SST Torque: 43 Nm (440 kgfcm, 32 ftlbf)
15 SR58 STEERING COMPONENTS (5SFE, 3SGTE ENGINE) DISASSEMBLY OF POWER STEERING PUMP 1. MOUNT POWER STEERING PUMP IN VISE NOTICE: Do not tighten the vise too tight. 2. (5SFE Engine) REMOVE PS PUMP PULLEY (a) Using SST, remove the pulley set nut. SST (b) Remove the pulley and woodruff key. 3. REMOVE AIR CONTROL VALVE Remove the air control valve. HINT: Replace the union seat with a new one only when it is damaged.
16 STEERING SR59 4. REMOVE SUCTION PORT UNION (a) Remove the bolt and union. (b) Remove the Oring from the union. 5. REMOVE PRESSURE PORT UNION, FLOW CONTROL VALVE AND SPRING (a) Remove the pressure port union. (b) Remove the 0ring from the union. (c) Remove the flow control valve and spring. 6. REMOVE REAR HOUSING (a) Using two screwdrivers, remove the snap ring. (b) Using a plastic hammer, tap out the rear housing and wave washer. (c) Remove the Oring from the rear housing.
17 SR60 STEERING 7. REMOVE REAR SIDE PLATE (a) Using a plastic hammer, tap the shaft end and re move the rear plate. (b) Remove the 0ring from the rear plate. 8. REMOVE VANE PUMP SHAFT, CAM RING AND VANE PLATES (a) Remove the pump shaft with cam ring and vane plates from the front housing. (b) Remove the cam ring and ten vane plates from the pump shaft. (c) Remove the longer straight pin from the front hous ing. 9. REMOVE ROTOR AND FRONT SIDE PLATE (a) Using a screwdriver, remove the snap ring. (b) Remove the rotor and front plate from the pump shaft. (c) Remove the two 0rings from the front plate. (d) Using a pin punch and hammer, driver out the straight pin.
18 STEERING SR61 INSPECTION OF POWER STEERING PUMP 1. MEASURE OIL CLEARANCE OF SHAFT AND BUSHING Using a micrometer and calipers, measure the oil clear ance. Standard clearance: mm ( in.) Maximum clearance: 0.07 mm ( in.) If more than maximum, replace the entire power steering pump. 2. INSPECT ROTOR AND VANE PLATES (a) Using a micrometer, measure the height, thickness and length of the vane plates. Minimum height: 8.0 mm (0.315 in.) Minimum thickness: 1.77 mm ( in.) Minimum length: mm ( in.) (b) Using a feeler gauge, measure the clearance be tween the rotor groove and vane plate. Maximum clearance: 0.03 mm ( in.) If more than maximum, replace the vane plate and/or rotor with one having the same mark stamped on the cam ring. Inscribed mark: 1,2,3,4 or None HINT: There are five vane lengths with the following rotor and cam ring marks: Rotor and cam ring mark Vane length mm (in.) None ( ) ( ) ( ) ( ) ( ) 3. INSPECT FLOW CONTROL VALVE (a) Coat the valve with power steering fluid and check that it falls smoothly into the valve hole by its own weight.
19 SR62 STEERING (b) Check the flow control valve for leakage. Close one of the holes and apply compressed air [ kpa (4 5 kgf/cm2, psi)] into the opposite side, and confirm that air does not come out from the end hole. If necessary, replace the valve with one having the same letter as inscribed on the front housing. Inscribed mark: A, B, C, D, E or F 4. INSPECT FLOW CONTROL SPRING Using a scale, measure the free length of the spring. Spring length: mm ( in.) If not within specification, replace the spring. 5. IF NECESSARY, REPLACE OIL SEAL (a) Using a screwdriver, pry out the oil seal. (b) Using a socket wrench and hammer, drive in a new oil seal.
20 STEERING SR63 ASSEMBLY OF POWER STEERING PUMP (See page SR58) 1. COAT ALL SLIDING SURFACES WITH POWER STEER ING FLUID BEFORE ASSEMBLY 2. INSTALL FRONT SIDE PLATE AND ROTOR TO PUMP SHAFT (a) Using a plastic hammer, drive in the shorter straight pin to the front plate. (b) Install two new 0rings to the front plate. (c) Install the front plate to the pump shaft. (d) Install the rotor to the shaft with the inscribed mark on the rotor facing toward the rear. (e) Install the snap ring. 3. INSTALL PS PUMP SHAFT TO FRONT HOUSING (a) Coat the oil seal lip with MP grease. (b) Install the longer straight pin to the front housing. (c) Align the hole of the front plate and straight pin and tap in the pump shaft with a plastic hammer. NOTICE: Be careful not to damage the oil seal and Orings.
21 SR64 STEERING 4. INSTALL CAM RING Match the wide hole of the cam ring with the longer straight pin, and install the cam ring. HINT: Install the cam ring with the inscribed mark fac ing the rear. 5. INSTALL VANE PLATES Install the vane plates with the round end facing out ward. 6. INSTALL REAR SIDE PLATE (a) Install a new Oring to the side plate. (b) Match the wide hole with the longer straight pin and install the plate. 7. INSTALL WAVE WASHER Install the wave washer so that its protrusions fit into the slots in the rear side plate. 8. INSTALL REAR HOUSING (a) Install a new 0ring to the rear housing. (b) Install the rear housing and use a press to push down on the wave washer hard enough to compress it. NOTICE: Do not apply too much pressure. (c) Install the snap ring.
22 STEERING SR65 9. MEASURE PUMP SHAFT PRELOAD (a) Check that the shaft rotates smoothly without ab normal noise. (b) Temporarily install the pulley nut and check the ro tating torque. Rotating torque: 0.3 Nm (2.8 kgfcm, 2.4 in.lbf) or less 10. INSTALL SPRING, FLOW CONTROL VALVE AND PRESSURE PORT UNION (a) Install the spring and the valve into the housing. (b) Install a new 0ring in the groove of the pressure port union. (c) Install and torque the pressure port union. Torque: 69 Nm (700 kgfcm, 51 ftlbf) 11. INSTALL SUCTION PORT UNION (a) Install a new Oring to the suction port union. (b) Install the suction port union into the housing. (c) Install and torque the bolt. Torque: 13 Nm (130 kgfcm, 9 ftlbf) 12. INSTALL AIR CONTROL VALVE Install and tighten the valve. Torque: 36 Nm (370 kgfcm, 27 ftlbf)
23 SR66 STEERING 13. (5SFE Engine) INSTALL PS PUMP PULLEY (a) Install the woodruff key to the shaft. (b) Install the pulley and nut to the shaft. (c) Using SST, torque the nut. SST Torque: 43 Nm (440 kgfcm, 32 ftlbf)
24 STEERING Power Steering (Gear Housing) SR67 Gear Housing REMOVAL AND INSTALLATION OF STEERING GEAR HOUSING (2WD) Remove and install the parts as shown.
25 SR68 STEERING Power Steering (Gear Housing) REMOVAL AND INSTALLATION OF STEERING GEAR HOUSING (4WD) Remove and install the parts as shown.
26 STEERING Power Steering (Gear Housing) SR69 MAIN POINTS OF REMOVAL AND INSTALLATION) (USA) NOTICE: When disconnecting the universal joint dur ing removal of the gear housing, remove the steering wheel and perform centering of the spiral cable. (See page AB15) If the operation is performed without removing the steering wheel, use the procedure below to make sure the steering wheel is firmly fixed in position and can not turn. 1. DISCONNECT UNIVERSAL JOINT (a) Position the front wheels facing straight ahead. (b) Using the seat belt of the driver s seat, fix the steer ing wheel so that it does not turn. (c) Place matchmarks on the universal joint and control valve shaft. (d) Loosen the bolt on the upper side of the universal joint, remove the bolt on the lower side and disconnect the universal joint. 2. DISCONNECT TIE ROD ENDS (a) Remove the cotter pin and nut. (b) Using SST, disconnect the tie rod end from the knuckle arm. SST DISCONNECT AND CONNECT PRESSURE AND RETURN LINE Using SST, disconnect and connect the pressure and return line. SST Torque: 44 Nm (450 kgfcm, 33 ftibf)
27 SR70 STEERING Power Steering (Gear Housing) 4. (4WD) REMOVE PROPELLER SHAFT (a) Place matchmarks to the propeller shaft flange and intermediate shaft flange. (b) Remove the four bolts and nuts. (c) Pull out the propeller shaft and install SST. SST (4WD) DISCONNECT STABILIZER BAR RH (a) Remove the stabilizer bar bracket RH. (b) Disconnect the stabilizer bar from the link. 6. (2WD) REMOVE GEAR HOUSING (a) Slide the gear housing to the RH side of the vehicle. (b) Pull the gear housing out through the LH lower side of vehicle body. NOTICE: Do not damage the turn pressure tubes. 7. (4WD) REMOVE GEAR HOUSING (a) Remove the two bolts, two nuts and the two brackets. (b) Remove the PS tube clamp bolt. (c) Move the gear housing to the right side. (d) Remove the gear housing through the RH hole.
28 STEERING Power Steering (Gear Housing) SR71 8. CONNECT UNIVERSAL JOINT (a) Set the gear housing so that it matches the dimen sions shown below, with the gear housing at the center point. HINT: The dimension of the tie rod end is a reference value, so always adjust the toein before tightening the lock nut. (b) Align matchmarks on the universal joint and control valve shaft and connect them. 9. CENTER SPIRAL CABLE If the steering wheel has been removed, or the steering wheel may have moved during the operation, always perform centering of the spiral cable. (See page AB16) 10. CHECK STEERING WHEEL CENTER POINT 11. CHECK TOEIN (See page SA4)
29 SR72 STEERING Power Steering (Gear Housing) (CANADA) 1. DISCONNECT UNIVERSAL JOINT (a) Place matchmarks on the universal joint and control valve shaft. (b) Loosen the bolt on the upper side of the universal joint. remove the bolt on the lower side and discon nect the universal joint. 2. DISCONNECT TIE ROD ENDS (a) Remove the cotter pin and nut. (b) Using SST, disconnect the tie rod end from the knuckle arm. SST DISCONNECT AND CONNECT PRESSURE AND RETURN LINE Using SST, disconnect and connect the pressure and return line. SST Torque: 44 Nm (450 kgfcm, 33 ftibf) 4. (4WD) REMOVE PROPELLER SHAFT (a) Place matchmarks to the propeller shaft flange and intermediate shaft flange. (b) Remove the four bolts and nuts. (c) Pull out the propeller shaft and install SST. SST
30 STEERING Power Steering (Gear Housing) SR73 5. (4WD) DISCONNECT STABILIZER BAR RH (a) Remove the stabilizer bar bracket RH. (b) Disconnect the stabilizer bar from the link. 6. (2WD) REMOVE GEAR HOUSING (a) Slide the gear housing to the RH side of the vehicle. (b) Pull the gear housing out through the LH lower side of vehicle body. NOTICE: Do not damage the turn pressure tubes. 7. (4WD) REMOVE GEAR HOUSING (a) Remove the two bolts, two nuts and the two brackets. (b) Remove the PS tube clamp bolt. (c) Move the gear housing to the right side. (d) Remove the gear housing through the RH hole. 8. CHECK STEERING WHEEL CENTER POINT 9. CHECK TOEIN (See page SA4)
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