Pipe Assembly (Power Steering System): Installation

Connect pipes C and D to steering gearbox.
Tightening torque:
1. 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.

Fig 1: Identifying Bolt A & Pipes "C" & "D" At Oil Tank
Connect pipe D to oil tank.
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)
Tighten bolt A.
Tightening torque: 13+/-3 N.m (1.3+/-0.3 kg-m, 9.4+/-2.2 ft-lb)
Temporarily connect pipes C and D to pipes (on the gearbox side).

Fig 2: Identifying Pipes "C" & "D" At Gearbox
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.

Fig 3: Identifying Clamp "E"
Tighten clamp E firmly.
Tightening torque: 7.4+/-2.0 N.m (0.75+/-0.20 kg-m, 5.4+/-1.4 ft-lb)
Tighten joint nut.
Tightening torque: 15+/-5 N.m (1.5+/-0.5 kg-m, 10.8+/-3.6 ft-lb)
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)

Fig 4: Connecting Pipes "A" & "B" To Four Pipe Joints Of Gearbox
Install jack-up plate.
Connect battery minus terminal.
Feed the specified fluid and discharge air.
NOTE: Never start the engine before feeding the fluid; otherwise vane pump might be seized up.

Fig 5: Identifying Hose Routing "A" & "B"
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:
1. 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.
2. 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.