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Power Steering Gear: Installation

  1. INSTALL PS GEAR ASSEMBLY 

    Torque the 2 new gear assembly set bolts, nuts and washers.

    Torque: 100 N.m (1,020 kgf.cm, 74 ft.lbf) 

    NOTE: Slide the gear assembly to the right side, slide the gear assembly to the left side and position it.
    Fig 1: Installing PS Gear Assembly
    G03322536Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL RH AND LH TIE ROD ENDS AND LOCK NUTS 
    1. Screw the lock nut and tie rod end onto the rack end until the matchmarks are aligned.
    2. After adjusting toe-in, torque the nut (See FRONT WHEEL ALIGNMENT ).

      Torque: 55 N.m (560 kgf.cm, 41 ft.lbf) 

  3. CONNECT TUBE CLAMP 

    Torque the bolt.

    Torque: 18 N.m (184 kgf.cm, 13 ft.lbf) 

  4. INSTALL GROMMET AND BRACKET 

    Torque 2 new bolts.

    Torque: 100 N.m (1,020 kgf.cm, 74 ft.lbf) 

  5. CONNECT RETURN TUBE 

    Using SST, connect the tube.

    Fig 2: Connecting Return Tube
    G03322537Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    SST 09023-38400

    Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) 

    NOTE:
    • Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).
    • This torque value is effective in case that SST is parallel to a torque wrench.
  6. CONNECT PRESSURE FEED TUBE 

    Torque the union bolt with a new gasket.

    Fig 3: Connecting Pressure Feed Tube
    G03322538Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: Make sure the stopper of the pressure feed tube touches the PS gear assembly as shown in the illustration, then torque the bolt.

    Torque: 42 N.m (430 kgf.cm, 31 ft.lbf) 

  7. CONNECT NO. 2 INTERMEDIATE SHAFT ASSEMBLY (See  INSTALLATION  ) 
  8. INSTALL ENGINE OIL FILTER ASSEMBLY 
    1. Install a new O-ring.
    2. Torque the 2 bolts and nut with the bracket.

      Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 

    3. Connect the 2 clips and hoses.
  9. CONNECT RH AND LH TIE ROD ENDS (See  ASSEMBLY 
  10. INSTALL NO. 2 ENGINE UNDER COVER 

    Tighten the 6 bolts.

  11. INSTALL NO. 1 ENGINE UNDER COVER 

    Tighten the 7 bolts.

  12. POSITION FRONT WHEELS FACING STRAIGHT AHEAD 
    NOTE: Do it with the front of the vehicle jacked up.
  13. CENTER SPIRAL CABLE (See  INSTALLATION  ) 
  14. INSTALL STEERING WHEEL 
    1. Align the matchmarks on the wheel and steering column main shaft.
    2. Temporarily tighten the wheel set nut.
    3. Connect the connector.
  15. BLEED POWER STEERING SYSTEM (See  BLEEDING  ) 
  16. CHECK STEERING WHEEL CENTER POINT 
  17. TORQUE STEERING WHEEL SET NUT 

    Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) 

  18. INSTALL STEERING WHEEL PAD (See  INSTALLATION  ) 
  19. CHECK FRONT WHEEL ALIGNMENT (See  FRONT WHEEL ALIGNMENT 
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