STEERING SYSTEM GI

SECTION ST MA

EM

LC

EC

CONTENTS FE

PRECAUTIONS ...............................................................2 TILT MECHANISM ...................................................15

CL
Supplemental Restraint System (SRS) ″AIR POWER STEERING GEAR AND LINKAGE ................16
BAG″ and ″SEAT BELT PRE-TENSIONER″...............2 Components...............................................................16 MT
Precautions for Steering System.................................2 Removal and Installation ...........................................17
PREPARATION ...............................................................3 Disassembly...............................................................18
Special Service Tools ..................................................3 Inspection...................................................................20 AT
Commercial Service Tool.............................................4 BOOT .....................................................................20
NOISE, VIBRATION AND HARSHNESS (NVH) RACK .....................................................................20
TROUBLESHOOTING .....................................................5 GEAR SUB-ASSEMBLY ...........................................20 AX
GEAR HOUSING CYLINDER ....................................20
NVH Troubleshooting Chart.........................................5
TIE-ROD OUTER AND INNER SOCKETS..................20
ON-VEHICLE SERVICE ..................................................6 SU
Assembly ...................................................................21
Checking Steering Wheel Play....................................6
POWER STEERING OIL PUMP (QG ENGINE) ...........28
Checking Neutral Position on Steering Wheel ............6
Components...............................................................28
PRE-CHECKING ........................................................6
Pre-disassembly Inspection.......................................28
BR
CHECKING ...............................................................6
Front Wheel Turning Angle..........................................6 Disassembly...............................................................29
Checking Gear Housing Movement ............................6 Inspection...................................................................30
Checking and Adjusting Drive Belts ............................7 Assembly ...................................................................30
Checking Steering Gear and Linkage .........................7 POWER STEERING OIL PUMP (YD ENGINE) ............32
STEERING GEAR ......................................................7 Components...............................................................32 RS
STEERING LINKAGE .................................................7 Pre-disassembly Inspection.......................................32
Checking Fluid Level ...................................................7 Removal and Installation ...........................................33
Disassembly...............................................................33
BT
Checking Fluid Leakage ..............................................7
Air Bleeding Hydraulic System ....................................8 Inspection...................................................................34
Checking Steering Wheel Turning Force ....................8 Assembly ...................................................................35 HA
Checking Hydraulic System.........................................9 HYDRAULIC LINE .........................................................36
STEERING WHEEL AND STEERING COLUMN .........11 Removal and Installation ...........................................36
Components...............................................................11 SERVICE DATA AND SPECIFICATIONS (SDS) .........37 SC
Removal and Installation ...........................................11 General Specifications...............................................37
STEERING WHEEL .................................................11 Steering Wheel ..........................................................37
STEERING COLUMN ...............................................12 Steering Column ........................................................37 EL
LOWER JOINT AND STEERING GEAR .....................13 Steering Gear and Linkage .......................................38
Disassembly and Assembly.......................................14 Power Steering ..........................................................39
Inspection...................................................................15
IDX
 PRECAUTIONS
Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

Supplemental Restraint System (SRS) “AIR

BAG” and “SEAT BELT PRE-TENSIONER” NJST0001
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with
a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of
collision. The SRS system composition which is available to NISSAN MODEL N16 is as follows (The compo-
sition varies according to the destination and optional equipment.):
I For a frontal collision
The Supplemental Restraint System consists of driver air bag module (located in the center of the steer-
ing wheel), front passenger air bag module (located on the instrument panel on passenger side), front seat
belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.
I For a side collision
The Supplemental Restraint System consists of front side air bag module (located in the outer side of front
seat), side air bag (satellite) sensor, diagnosis sensor unit (one of components of air bags for a frontal
collision), wiring harness, warning lamp (one of components of air bags for a frontal collision).
Information necessary to service the system safely is included in the RS section of this Service Manual.
WARNING:
I To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance should be per-
formed by an authorized NISSAN dealer.
I Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the RS section.
I Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow harness connector.
Precautions for Steering System NJST0003
I Before disassembly, thoroughly clean the outside of the unit.
I Disassembly should be done in a clean work area. It is important to prevent the internal parts from
becoming contaminated by dirt or other foreign matter.
I Place disassembled parts in order, on a parts rack, for easier and proper assembly.
I Use nylon cloths or paper towels to clean the parts; common shop rags can leave lint that might
interfere with their operation.
I Before inspection or reassembly, carefully clean all parts with a general purpose, non-flammable
solvent.
I Before assembly, apply a coat of recommended power steering fluid* to hydraulic parts. Vaseline
may be applied to O-rings and seals. Do not use any grease.
I Replace all gaskets, seals and O-rings. Avoid damaging O-rings, seals and gaskets during instal-
lation. Perform functional tests whenever designated.
*: DEXRONTMIII or equivalent. Refer to MA-21, “Fluids and Lubricants”.

ST-2
 PREPARATION
Special Service Tools

Special Service Tools NJST0004

Tool number
Description GI
Tool name

KV48100700 Measuring pinion rotating torque

Torque adapter MA

EM
NT169

KV48102500 Measuring oil pressure

Pressure gauge adapter
LC

EC

FE
NT542

ST27180001 Removing steering wheel CL

Steering wheel puller

MT

AT
NT544

HT72520000 Removing ball joint AX

Ball joint remover a: 33 mm (1.30 in)
b: 50 mm (1.97 in)
r: R11.5 mm (0.453 in)
SU

NT546 BR
KV48103500 Measuring oil pressure
Pressure gauge

RS
NT547

KV48104400 Reforming Teflon ring BT

Rack Teflon ring reformer a: 50 mm (1.97 in) dia.
b: 36 mm (1.42 in) dia.
c: 100 mm (3.94 in) HA

SC
NT550

ST3127S000 Measuring turning torque EL

1 GG91030000
Torque wrench
2 HT62940000 IDX
Socket adapter
3 HT62900000
Socket adapter
NT541

ST-3
 PREPARATION
Commercial Service Tool

Commercial Service Tool NJST0005

Tool number Description

Oil pump attachment Disassembling and assembling oil pump

Unit: mm (in)

NT774

KV48105210 Removing and Installing power steering oil pump

Sprocket holder

NT809

ST-4
 ×: Applicable

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
Symptom

suspected parts
Possible cause and

Reference page

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

Judder

Shimmy

Vibration

Shake

Noise
Fluid level ST-7

×
Air in hydraulic system ST-8

×
Tie-rod ball joint swinging force ST-20

×
Tie-rod ball joint rotating torque ST-20

NVH Troubleshooting Chart

Tie-rod ball joint end play ST-20

×
Steering gear fluid leakage ST-7

×
Steering wheel play ST-6
ST-5

×
Steering gear rack sliding force ST-8

×
Drive belt looseness Refer to EM-22.

×
Improper steering wheel —
×

×
Improper installation or looseness of tilt lock lever ST-11
×

×
Mounting insulator deterioration ST-17
×

×
Steering column deformation or damage ST-15
×

Improper installation or looseness of steering column ST-14

×

Steering linkage looseness ST-16

×

NVH Troubleshooting Chart

Drive shaft AX-3
×

Axle AX-3
×

Suspension SU-4
×

Tires SU-4
×

Road wheel SU-4

×

NJST0006S01

NJST0006
Brakes BR-6
×

×
IDX

EL

SC

HA

BT

RS

BR

SU

AX

AT

MT

CL

FE

EC

LC

EM

MA

GI
 ON-VEHICLE SERVICE
Checking Steering Wheel Play

Checking Steering Wheel Play NJST0007

I With wheels in a straight-ahead position, check steering wheel
play.
Steering wheel play:
35 mm (1.38 in) or less
I If it is not within specification, check the following for loose or
worn components.
Steering gear assembly
Steering column
SST489B
Front suspension and axle

Checking Neutral Position on Steering Wheel NJST0008

PRE-CHECKING NJST0008S01
I Make sure that wheel alignment is correct.
Wheel alignment:
Refer to SU-15, SDS.
I Verify that the steering gear is centered before removing the
steering wheel.
CHECKING NJST0008S02
1. Check that the steering wheel is in the neutral position when
SST490BA driving straight ahead.
2. If it is not in the neutral position, remove the steering wheel and
reinstall it correctly.
3. If the neutral position is between two teeth, loosen tie-rod lock
nuts. Turn the tie-rods by the same amount in opposite direc-
tions on both left and right sides.

Front Wheel Turning Angle NJST0009

1. Rotate steering wheel all the way right and left; measure turn-
ing angle.
Turning angle of full turns:
Refer to SU-15, SDS.
2. If it is not within specification, check rack stroke.
Rack stroke “S”:
Refer to SDS, ST-38.

SMA127

Checking Gear Housing Movement NJST0010

1. Check the movement of steering gear housing during station-
ary steering on a dry paved surface.
I Apply a force of 49 N (5 kg, 11 lb) to steering wheel to check
the gear housing movement.
Turn off ignition key while checking.
Movement of gear housing:
±2 mm (±0.08 in) or less
2. If movement exceeds the limit, replace mount insulator after
confirming proper installation of gear housing clamps.
SST663B

ST-6
 ON-VEHICLE SERVICE
Checking and Adjusting Drive Belts

Checking and Adjusting Drive Belts NJST0011

Refer to EM-22, “Checking Drive Belts”.
GI

MA

EM

LC
Checking Steering Gear and Linkage NJST0037
STEERING GEAR NJST0037S01
EC
I Check gear housing and boots for looseness, damage or
grease leakage.
I Check connection with steering column for looseness. FE
STEERING LINKAGE NJST0037S02
I Check ball joint, dust cover and other component parts for CL
looseness, wear, damage or grease leakage.

SMA851B
MT
Checking Fluid Level NJST0012
Check fluid level, referring to the scale on reservoir tank. AT
Use “HOT” range for fluid temperatures of 50 to 80°C (122 to
176°F).
Use “COLD” range for fluid temperatures of 0 to 30°C (32 to 86°F). AX
CAUTION:
I Do not overfill. SU
I Recommended fluid is DEXRONTMIII or equivalent. Refer
to MA-21, “Fluids and Lubricants”.
BR
SST850C

Checking Fluid Leakage NJST0013

Check the lines for improper attachment and for leaks, cracks,
damage, loose connections, chafing and deterioration.
1. Run engine between idle speed and 1,000 rpm. RS
Make sure temperature of fluid in oil tank rises to 60 to 80°C
(140 to 176°F).
2. Turn steering wheel right-to-left several times.
BT
3. Hold steering wheel at each “lock” position for five seconds
and carefully check for fluid leakage. HA
SST874C
CAUTION:
Do not hold the steering wheel in a locked position for more
than 15 seconds. SC
4. If fluid leakage at connectors is noticed, loosen flare nut and
then retighten.
Do not overtighten connector as this can damage O-ring,
EL
washer and connector.
5. If fluid leakage from power steering pump is noticed, check IDX
power steering pump. Refer to ST-28 or ST-32.
6. Check rack boots for accumulation of power steering fluid.

ST-7
 ON-VEHICLE SERVICE
Air Bleeding Hydraulic System

Air Bleeding Hydraulic System NJST0014

1. Raise front end of vehicle until wheels are clear of the ground.
2. Add fluid into reservoir tank to specified level. Then quickly turn
steering wheel fully to right and left and lightly touch steering
stoppers.
Repeat steering wheel operation until fluid level no longer
decreases.
3. Start engine.
Repeat step 2. above.
I Incomplete air bleeding will cause the following to occur. When
this happens, bleed air again.
a) Air bubbles in reservoir tank
b) Clicking noise in oil pump
c) Excessive buzzing in oil pump
Fluid noise may occur in the valve or oil pump. This is common
when the vehicle is stationary or while turning the steering wheel
slowly. This does not affect the performance or durability of the
system.

Checking Steering Wheel Turning Force NJST0015

1. Park vehicle on a level, dry surface and set parking brake.
2. Start engine.
3. Bring power steering fluid up to adequate operating tempera-
ture. [Make sure temperature of fluid is approximately 60 to
80°C (140 to 176°F).]
Tires need to be inflated to normal pressure.
4. Check steering wheel turning force when steering wheel has
been turned 360° from the neutral position.
SST491B
Steering wheel turning force:
39 N (4 kg, 9 lb) or less
5. If steering wheel turning force is out of specification, check
rack sliding force.
a. Disconnect steering column lower joint and knuckle arms from
the gear.
b. Start and run engine at idle to make sure steering fluid has
reached normal operating temperature.
c. Pull tie-rod slowly to move it from neutral position to ±11.5 mm
(±0.453 in) at speed of 3.5 mm (0.138 in)/s. Check that rack
sliding force is within specification.
Average rack sliding force:
SST090B
Sedan
152 - 240 N (15.5 - 24.5 kg, 34 - 54 lb)
Hatchback
132 - 308 N (13.5 - 31.4 kg, 30 - 69 lb)
Maximum force deviation:
Sedan
98 N (10 kg, 22 lb)
Hatchback
176 N (17.9 kg, 39 lb)
d. Check sliding force outside the above range at rack speed of
40 mm (1.75 in)/s.

ST-8
 ON-VEHICLE SERVICE
Checking Steering Wheel Turning Force (Cont’d)
Rack sliding force (Sedan only):
Not more than 294 N (30 kg, 66 lb)
Maximum force deviation: GI
147 N (15 kg, 33 lb)
6. If rack sliding force is not within specification, overhaul steer- MA
ing gear assembly.
7. If rack sliding force is OK, inspect steering column. Refer to
ST-14. EM

LC
Checking Hydraulic System NJST0016
Before starting, check belt tension, driving pulley and tire pressure. EC
1. Set Tool. Open shut-off valve. Then bleed air. Refer to “Air
Bleeding Hydraulic System”, ST-8.
2. Run engine at idle speed or 1,000 rpm. FE
Make sure temperature of fluid in tank rises to 60 to 80°C (140
to 176°F).
CL
WARNING:
Warm up engine with shut-off valve fully opened. If engine is
started with shut-off valve closed, fluid pressure in oil pump MT
SST834-I
increases to maximum. This will raise oil temperature abnor-
mally.
3. Check pressure with steering wheel fully turned to left and right AT
positions with engine idling at 1,000 rpm.
CAUTION:
Do not close shut-off valve in pressure gauge for more than AX
15 seconds.
Oil pump maximum standard pressure: SU
QG13, 15 engine (Sedan)
7,500 - 8,300 kPa (75.0 - 83.0 bar, 76.5 - 84.7
kg/cm2, 1,088 - 1,204 psi) BR
QG16, 18 engine (Sedan)
8,500 - 9,300 kPa (85.0 - 93.0 bar, 86.7 - 94.9
kg/cm2, 1,233 - 1,349 psi)
QG15, 18 engine (Hatchback)
8,600 - 9,200 kPa (86.0 - 92.0 bar, 88.7 - 93.8 RS
kg/cm2, 1,247 - 1,334 psi)
YD22 engine
8,500 - 9,300 kPa (85.0 - 93.0 bar, 86.7 - 94.9 BT
kg/cm2, 1,233 - 1,349 psi)
I If pressure reaches maximum operating pressure, system is
OK. HA
I If pressure increases above maximum operating pressure,
check power steering pump flow control valve. Refer to ST-28 SC
or ST-32.
4. If power steering pressure is below the maximum operating
pressure, slowly close shut-off valve and check pressure EL
again.
CAUTION:
Do not close shut-off valve for more than 15 seconds. IDX
I If pressure increases to maximum operating pressure, gear is
damaged. Refer to “Removal and Installation”, ST-17.
I If pressure remains below maximum operating pressure, pump
is damaged. Refer to “Disassembly”, ST-29 or ST-32.

ST-9
 ON-VEHICLE SERVICE
Checking Hydraulic System (Cont’d)
5. After checking hydraulic system, remove Tool and add fluid as
necessary. Then completely bleed air out of system. Refer to
“Air Bleeding Hydraulic System”, ST-8.

ST-10
 STEERING WHEEL AND STEERING COLUMN
Components

Components NJST0017

GI

MA

EM

LC

EC

FE

CL

MT

AT

SST999C
AX

1. Air bag module 5. Combination switch 8. Lower joint SU

2. Steering wheel 6. Steering column assembly 9. Lower cover
3. Spiral cable 7. Hole cover 10. Fastener
4. Column cover BR

CAUTION:
I The rotation of the spiral cable (SRS “Air bag” component
part) is limited. If the steering gear must be removed, set
the front wheels in the straight-ahead direction. Do not RS
rotate the steering column while the steering gear is
removed.
I Remove the steering wheel before removing the steering BT
lower joint to avoid damaging the SRS spiral cable.

HA

Removal and Installation NJST0018

SC
STEERING WHEEL NJST0018S01
I Remove air bag module and spiral cable. EL
Refer to RS-30, “Removal — Air Bag Module and Spiral Cable”.

IDX

SBF812E

ST-11
 STEERING WHEEL AND STEERING COLUMN
Removal and Installation (Cont’d)
I Align spiral cable correctly when installing steering wheel.
a) Set the front wheels in the straight-ahead position.
b) Make sure that the spiral cable is in the neutral position.
The neutral position is detected by turning left 2.5 revolutions
from the right end position. Align the two marks ( ).
CAUTION:
The spiral cable may snap due to steering operation if the
cable is installed in an improper position.
Also, with the steering linkage disconnected, the cable may
snap by turning the steering wheel beyond the limited number
of turns. (The spiral cable can be turned up to 2.5 turns from
the neutral position to both the right and left.)

SRS266

I Remove steering wheel with Tool.

SST777C

STEERING COLUMN NJST0018S02

I Remove key interlock cable (A/T models).

SST329C

I When installing steering column, tighten by hand all lower

bracket and clamp retaining bolts; then tighten them securely.
Do not apply undue stress to steering column.

ST-12
STEERING WHEEL AND STEERING COLUMN
Removal and Installation (Cont’d)
LOWER JOINT AND STEERING GEAR NJST0018S03
I Align slit of lower portion of lower joint so that it engages with
guide tip on rear cover cap with steering gear. GI
I Install pinch bolt for lower portion of lower joint. Check steer-
ing gear is in straight-ahead position. Also check rear cover is
in position as shown in the figure. Then install lower joint to MA
steering gear.
CAUTION: EM
After installation, turn steering wheel to make sure it moves
smoothly. Ensure the number of turns are the same from the
straight forward position to left and right locks. Be sure that LC
the steering wheel is in a neutral position when driving
straight ahead.
EC

FE

CL

SST988C
MT

AT

AX

SU

BR

RS

BT

HA

SC

EL

IDX

ST-13
 STEERING WHEEL AND STEERING COLUMN
Disassembly and Assembly

Disassembly and Assembly =NJST0019

SST920CB

1. Combination switch 6. Lower seal cover 11. Spring

2. Lock nut 7. Hole cover 12. Adjust bolt
3. Jacket tube assembly 8. Tilt lever 13. Adjust bolt stopper
4. Column shaft assembly 9. Tilt lever stopper 14. Nut
5. Clip 10. Steering column mounting bracket 15. Steering column lower cover

I When disassembling and assembling with steering column,

unlock steering lock with key.
I Remove combination switch.
I Install lock nut on steering column shaft and tighten the nut.

SST490C

ST-14
STEERING WHEEL AND STEERING COLUMN
Disassembly and Assembly (Cont’d)
I Steering lock
a) Break self-shear type screws with a drill or other appropriate
tool. GI

MA

EM

SST741A LC
b) Install new self-shear type screws and then cut off self-shear
type screw heads.
EC

FE

CL

SST742A
MT
Inspection NJST0020
I When steering wheel does not turn smoothly, check the steer- AT
ing column as follows and replace damaged parts.
a) Check column bearings for damage or unevenness. Lubricate
with recommended multi-purpose grease or replace steering
AX
column as an assembly, if necessary.
b) Check jacket tube for deformation or breakage. Replace if SU
necessary.
I When the vehicle comes into a light collision, check length “L”.
Steering column length “L”: BR
SST855C
Refer to SDS, ST-37.
If out of the specifications, replace steering column as an assem-
bly.

RS

BT

HA

TILT MECHANISM NJST0020S01

SC
I After installing steering column, check tilt mechanism opera-
tion.
EL

IDX

SST582B

ST-15
 POWER STEERING GEAR AND LINKAGE
Components

Components NJST0021

SST989C

1. Rear cover cap 9. Rack assembly 16. Boot band

2. Gear sub-assembly 10. Rack Teflon ring 17. Spacer ring
3. O-ring 11. O-ring 18. Lock plate
4. Adjusting screw 12. Rack oil seal 19. Tie-rod inner socket
5. Spring 13. End cover assembly 20. Tie-rod outer socket
6. Retainer 14. Boot clamp 21. Cotter pin
7. Gear housing 15. Dust boot 22. Gear housing tubes
8. Rack oil seal

ST-16
 POWER STEERING GEAR AND LINKAGE
Removal and Installation

Removal and Installation NJST0022

GI

MA

EM

LC

EC

FE

CL

MT

AT

SST990C
AX

1. Lower joint 4. Upper gear housing mounting 6. Lower gear housing mounting SU
2. Washer bracket bracket
3. Gear and linkage assembly 5. Rack mounting insulator 7. Cotter pin
BR
CAUTION:
I The rotation of the spiral cable (SRS “Air bag” component
part) is limited. If the steering gear must be removed, set
the front wheels in the straight-ahead direction. Do not
rotate the steering column while the steering gear is RS
removed.
I Remove the steering wheel before removing the steering BT
lower joint to avoid damaging the SRS spiral cable.
I Detach tie-rod outer sockets from knuckle arms with Tool.
1. Remove stabilizer fixing bolts. Refer to SU-12, “Removal and HA
SFA455BA
Installation”.
2. Disconnect lower joint.
3. Remove gear housing mounting bracket fixing bolts. SC
4. Remove steering gear assembly.
EL

IDX

ST-17
 POWER STEERING GEAR AND LINKAGE
Removal and Installation (Cont’d)
I Install pipe connector.
I Observe specified tightening torque when tightening high-pres-
sure and low-pressure pipe connectors. Excessive tightening
will damage threads of connector or O-ring.
Connector tightening torque:
1 Low-pressure side
27.5 - 39.2 N·m (2.8 - 3.9 kg-m, 21 - 28 ft-lb)
2 High-pressure side
14.8 - 24.5 N·m (1.5 - 2.4 kg-m, 11 - 18 ft-lb)
I The O-ring in low-pressure pipe connector is larger than that
SST879C
in high-pressure connector. Take care to install the proper
O-ring.

I Initially, tighten nut on tie-rod outer socket and knuckle arm to

29.5 to 39.2 N·m (3.0 to 3.9 kg-m, 22 to 28 ft-lb). Then tighten
further to align nut groove with first pin hole so that cotter pin
can be installed.
CAUTION:
Tightening torque must not exceed 49 N·m (5 kg-m, 36 ft-lb).
NOTE:
Only the dust boot, tie-rod inner socket and tie-rod outer socket can
be disassembled on models for Europe.

SST824A

I Before removing lower joint from gear, set gear in neutral

(wheels in straight-ahead position). After removing lower joint,
put matching mark on pinion shaft and pinion housing to record
neutral position.
I To install, set left and right dust boots to equal deflection.
Attach lower joint by aligning matching marks of pinion shaft
and pinion housing.
I Tighten gear housing mounting bracket bolts.

SST819A

Disassembly NJST0023
I Secure power steering gear in a vise, using copper plates or
something similar to prevent it from being damaged. Do not
grip cylinder in a vise.
I Before disassembly, clean the power steering gear with kero-
sene. Be careful not to bring any kerosene into contact with the
discharge and return port connectors.

SGIA0149E

ST-18
POWER STEERING GEAR AND LINKAGE
Disassembly (Cont’d)
1. Remove cylinder tubes from gear housing assembly.
2. Remove rear cover cap from gear-sub assembly.
GI

MA

EM

LC
3. Measure projection height with adjusting screw from gear
housing, then loosen adjusting screw.
CAUTION:
EC
I Do not remove adjusting screw from gear housing.
I Change gear housing when adjusting screw is removed or FE
it is turned more than two times.
4. Remove bolt of gear-sub assembly and remove gear-sub
assembly from gear housing assembly, holding rack against CL
retainer side.
CAUTION:
SGIA0150E Do not overhaul because gear sub-assembly is non overhaul MT
part. Or something is wrong with gear sub-assembly, change
it with new one.
AT

AX

SU

BR
5. Remove tie-rod outer sockets and boots.
6. Loosen tie-rod inner socket by prying up caulking portion, and
remove socket and spacer.
7. Remove retainer. RS
8. Use a 2 to 2.5 mm (0.079 to 0.098 in) diameter drill to com-
pletely remove caulking portion of gear housing end.
BT

HA
SST051C

9. Remove end cover assembly with a suitable tool. SC

10. Draw out rack assembly.
11. Remove rack Teflon ring.
I Using a dryer, heat rack Teflon ring to approximately 40°C EL
(104°F).
I Remove rack Teflon ring. IDX
Be careful not to damage rack.

SST991C

ST-19
 POWER STEERING GEAR AND LINKAGE
Disassembly (Cont’d)
12. Remove center bushing and rack oil seal using tape wrapped
socket and extension bar.
Do not scratch inner surfaces of pinion housing.

SGIA0179E

Inspection NJST0024
Thoroughly clean all parts in cleaning solvent or DEXRONTMIII or
equivalent. Blow dry with compressed air, if available.
BOOT NJST0024S01
I Check condition of boot. If cracked excessively, replace it with
new one.
I Check boots for accumulation of power steering fluid.
RACK NJST0024S02
Thoroughly examine rack gear. If damaged, cracked or worn,
replace it.
GEAR SUB-ASSEMBLY NJST0024S03
I Check pinion gear. If it is worn or damaged, replace as a gear
sub-assembly.
I Manually spin bearing. If torque variations or free play are
noted, replace as a gear sub-assembly.
GEAR HOUSING CYLINDER NJST0024S04
Check gear housing cylinder bore for scratches or other damage.
Replace if necessary.

TIE-ROD OUTER AND INNER SOCKETS NJST0024S05

I Check ball joints for swinging force.
Tie-rod outer and inner ball joints swinging force “A”:
Refer to SDS, ST-38.
I Check ball joint for rotating torque.
Tie-rod outer ball joint rotating torque “B”:
Refer to SDS, ST-38.
I Check ball joints for axial end play.
Tie-rod outer and inner ball joints axial end play “C”:
SST468C Refer to SDS, ST-38.
I Check condition of dust cover. If cracked excessively, replace
outer tie-rod.

ST-20
POWER STEERING GEAR AND LINKAGE
Assembly

Assembly NJST0025
1. Using a dryer, heat new rack Teflon ring to approximately 40°C
(104°F). Then place it onto rack. GI
CAUTION:
Do not reuse rack Teflon ring. MA

EM

SGIA0153E LC
2. Using Tool, compress rack Teflon ring securely onto rack.
Always insert Tool from the rack teeth side. EC

FE

CL

SST992C
MT
3. Insert new rack oil seal.
I Place plastic film into rack oil seal to prevent damage by AT
rack teeth.
I Do not forget to remove plastic film after rack oil seal is
positioned properly. AX
I Make sure lips of rack oil seal face each other.
SU

BR
SST993C

4. Install center bushing and rack oil seal (gear sub-assembly

side) with rack assembly.

RS

BT

HA
SST994C

5. Insert rack oil seal and end cover assembly to rack. Then SC
tighten end cover assembly.
Tightening torque:
Refer to “Components”, ST-16. EL
CAUTION:
When inserting rack assembly, do not damage cylinder inner
wall. If it damaged, it may cause oil leak. Replace gear hous-
IDX
ing assembly.

SST321B

ST-21
 POWER STEERING GEAR AND LINKAGE
Assembly (Cont’d)
6. Using a 42 mm (1.65 in) open head, tighten end cover assem-
bly to specified torque.
Tightening torque:
59 - 74 N·m (6.0 - 7.5 kg-m, 43 - 54 ft-lb)
CAUTION:
Do not damage rack surface. If it damaged, it may cause oil
leak. Replace rack assembly.

SST081B

7. After tightening end cover, caulk cylinder at one point as shown

in the figure using a punch. This will prevent end cover from
coming loose.

SGIA0158E

8. Set rack gear in neutral position.

Rack stroke “S”:
Refer to SDS, ST-38.

SST086BA

9. Install adjustment shims and O-rings to gear sub-assembly.

I Install the same number of adjustment shims as before,
regardless of whether or not gear sub-assembly is replaced.
I Replace old O-ring with new one.
10. Tighten gear subassembly securing bolts to specified tighten-
ing torque. Refer to “Components”, ST-16.

SST995C

ST-22
POWER STEERING GEAR AND LINKAGE
Assembly (Cont’d)
11. Ensure that the rack is centered. Install rear cover cap so that
its projection is positioned as shown in the figure.
GI

MA

EM

SST004D LC

EC

FE

CL

SST996C
MT
12. Install retainer and spring into gear housing.
13. Install adjusting screw temporarily. AT

AX

SU

BR
SST003D

14. Install lock plate to rack.

a. Temporarily install spacer ring to rack.
Replace old spacer ring with new one.
b. Install lock plate to inner socket. RS
c. Apply a coat of locking sealant to inner socket threads. Screw
inner socket into rack and tighten to specified torque.
Tightening torque: BT
Refer to “Components”, ST-16.
d. Caulk lock plate at rack groove location (at two points). HA
SGIA0177E
e. Install spacer ring to lock plate as shown in the figure.
Be careful not to damage spacer ring during installation
SC

EL

IDX

ST-23
 POWER STEERING GEAR AND LINKAGE
Assembly (Cont’d)
15. Decide neutral position of rack gear.
Rack stroke “L”:
Refer to SDS, ST-37.

SST086BA

16. Install rear cover cap in the gear sub-assembly, holding rela-
tion between projection part (Tip) of rear cover on the gear
sub-assembly and the line that is in parallel with rack center
line as shown in the figure.

SST004D

SST996C

17. Apply thread locking adhesive (Three Bond TB1111B) to the

thread of adjusting screw, and screw it to the projection height
from the gear housing. The projection height is the same as it
was measured in the overhaul in advance.

SGIA0150E

18. Rotate ten times throughout whole range of pinion so that parts
fit with each other.

SST002D

ST-24
POWER STEERING GEAR AND LINKAGE
Assembly (Cont’d)
19. Measure pinion rotation torque with preload gauge (SST), then
confirm whether its reading is within the specific range. If the
reading is not within the specific range, readjust screw angle GI
with adjusting screw. Change gear assembly with new one, if
the reading is still not within the specific range or the rotation
torque of adjusting screw is less than 5 N·m (0.5 kg-m, 43 in-lb) MA
Pinion rotation torque:
Around neutral position (within ±100°)
Average “A” EM
0.8 - 2.0 N·m (0.09 - 0.20 kg-m, 8 - 17 in-lb)
SGIA0160E Other than above (more than ±100°) LC
Maximum variation “B”
2.3 N·m (0.23 kg-m, 20 in-lb)
EC

FE

CL

MT
20. Turn gear sub-assembly fully to the end of the left.
21. Set dial gauge as shown in figure. Measure vertical movement AT
of rack when pinion is turned counterclockwise with torque of
19.6 N·m (2.0 kg-m, 14 ft-lb). Check reading is within range
specified. If reading is outside of specification, readjust screw AX
angle with the adjusting screw. If reading is still outside of
specification, or if the rotation torque of adjusting screw is less
than 5 N·m (0.51 kg-m, 44 in-lb), replace power steering gear. SU
Measuring point:
Rack radial direction
BR
SST001D Direction of adjusting screw
Specification:
Rack radial direction
Less than 0.25 mm (0.0098 in)
CAUTION: RS
I If adjusting screw is readjusted, recheck the rotation
torque with the pinion.
I Be careful, incomplete caulking around adjusting screw BT
can cause looseness.

HA

22. Position boot clamp on large-diameter side before installing it. SC

23. Apply multi-purpose grease to both large and small diameter
sides.
24. Install small-diameter side of boot to inner socket boot mount- EL
ing groove.
25. Install boot clamp to small-diameter side of boot.
IDX

SGIA0162E

ST-25
 POWER STEERING GEAR AND LINKAGE
Assembly (Cont’d)
26. Tighten boot clamp.
a. Tighten large-diameter side of RH/LH boot with boot clamp
(stainless wire).
Wire length “L”: 390 mm (15.354 in)
b. After wrapping clamp around boot groove for two turns, insert
screwdriver in loop on both ends of wire. Twist 4 to 4.5 turns
while pulling with a force of approx. 98 N (10 kg, 22 lb).

SGIA0163E

c. Twist boot clamp as shown in the figure, pay attention to rela-

tionship between winding and twisting directions.

SGIA0164E

d. Confirm the twisted point with clamp opposite to the adjusting

screw is within 90° as shown in the figure.

SGIA0165E

e. After twisting wire 4 to 4.5 turns, bend cut end of wire. Cut end
of wire should not touch boot. Be sure wire end is at least 5
mm (0.20 in) away from clearance for tube.

SGIA0166E

27. Install cylinder-tube to the gear housing assembly.

28. Install lock nut and outer socket to inner socket, then tighten
temporarily lock nut until length of tie rod is specification.
Tightening torque of lock nut:
Refer to “Components”, ST-16.
Tie rod length “L”:
Refer to SDS, ST-38.
CAUTION:
Perform toe-in adjustment after this procedure. Length
achieved after toe-in adjustment is not necessarily value given
SGIA0167E here.
ST-26
POWER STEERING GEAR AND LINKAGE
Assembly (Cont’d)
29. After power steering is installed in the vehicle, confirm the sid-
ing torque is within specifications:
Rack sliding force [at the neutral point: ±11.5mm GI
(±0.453 in) with the engine at idle]:
Area mean
152 - 240 N (15.5 - 24.5 kg, 34.2 - 54.0 lb) MA
Fluctuating range
Less than 98 N (10 kg, 22 lb) EM
Whole range (with the engine stopped):
Peak value
SST002D
Less than 294 N (30.0 kg, 66 lb) LC
Fluctuating range
Less than 147 N (15.0 kg, 33 lb) EC

FE

CL

MT

AT

AX

SU

BR

RS

BT

HA

SC

EL

IDX

ST-27
 POWER STEERING OIL PUMP (QG ENGINE)
Components

Components NJST0027

SST881CA

1. Pulley 8. Flow control A valve 15. Rotor snap ring

2. Bracket 9. Dowel pin 16. Rear side plate
3. Drive shaft seal 10. Flow control B valve assy 17. Side plate inner seal
4. Inlet connector 11. Front side plate 18. Side plate outer seal
5. Inlet connector seal 12. Cartridge 19. Body seal
6. Front housing 13. Rotor 20. Rear body
7. Flow control valve spring 14. Vane

Pre-disassembly Inspection NJST0028

Disassemble the power steering oil pump only if the following items
are found.
I Oil leak from any point shown in the figure
I Deformed or damaged pulley
I Poor performance

SST984A

ST-28
POWER STEERING OIL PUMP (QG ENGINE)
Disassembly

Disassembly NJST0029
CAUTION:
I The power steering pump cannot be disassembled on GI
Hatchback with QG engine. If it is faulty, replae with a new
assembly.
I Parts which can be disassembled are strictly limited.
MA
Never disassemble parts other than those specified.
I Disassemble in as clean a place as possible. EM
I Clean your hands before disassembly.
I Do not use rags; use nylon cloths or paper towels.
I Follow the procedures and cautions in the Service LC
Manual.
I When disassembling and reassembling, do not let foreign EC
matter enter or contact the parts.

FE

CL

MT
I Remove snap ring, then draw drive shaft out.
Be careful not to drop drive shaft. AT

AX

SU

BR
SST010B

I Remove oil seal.

Be careful not to damage front housing.

RS

BT

HA
SST034A

I Remove connector and flow control valve with spring. SC

Be careful not to drop flow control valve.
Do not disassemble flow control valve.
EL

IDX

SST036A

ST-29
 POWER STEERING OIL PUMP (QG ENGINE)
Inspection

Inspection NJST0030
I If pulley is cracked or deformed, replace it.
I If an oil leak is found around pulley shaft oil seal, replace the
seal.
I If serration on pulley or pulley shaft is deformed or worn,
replace it.

Assembly NJST0031
Assemble oil pump, noting the following instructions.
I Make sure O-rings and oil seal are properly installed.
I Always install new O-rings and oil seal.
I Be careful of oil seal direction.
I Cam ring, rotor and vanes must be replaced as a set if neces-
sary.
I Coat each part with DEXRONTM III or equivalent when assem-
bling.
SST038A

I Pay attention to the direction of rotor.

SST289A

I When assembling vanes to rotor, rounded surfaces of vanes

must face cam ring side.

SST843A

ST-30
POWER STEERING OIL PUMP (QG ENGINE)
Assembly (Cont’d)
I Insert pin 2 into pin groove 1 of front housing and front side
plate. Then install cam ring 3 as shown at left.
Cam ring: GI
D1 is less than D2.
MA

EM

LC

EC

FE

CL

SST472C
MT

AT

AX

SU

BR

RS

BT

HA

SC

EL

IDX

ST-31
 POWER STEERING OIL PUMP (YD ENGINE)
Components

Components NJST0038

SST005D

1. Rear body 9. O-ring (Inner) 16. Outlet connector

2. Dowel pin 10. Front body 17. Connector seal
3. Side plate seal 11. Drive shaft rear oil seal 18. Flow control valve
4. Cam ring 12. Drive shaft front oil seal 19. Flow control valve spring
5. Vane 13. Drive shaft 20. Inlet connector
6. Rotor 14. Snap ring 21. O-ring
7. Side plate 15. O-ring 22. Washer
8. O-ring (Outer)

Pre-disassembly Inspection NJST0039

Disassemble the power steering oil pump only if the following items
are found.
I Oil leak from any point shown in the figure
I Poor performance

SST883C

ST-32
POWER STEERING OIL PUMP (YD ENGINE)
Removal and Installation

Removal and Installation NJST0040

1. Remove chain case cover.
GI

MA

EM

SST884C LC
2. Revolving crank pulley, set tool.
3. Fix tool with chain cover fixing bolts.
EC
4. Using suitable tool, remove sprocket fixing nut and washer.
Do not remove Tool while power steering oil pump is
removed. FE

CL

SST885C
MT
5. Remove power steering pump fixing bolts, then remove it.
AT

AX

SU

BR
SST886C

I Apply Gasket to the installation surface of the engine chain

case cover as shown in the figure before installing the chain
case cover to the engine.
I Bleed air after installation.
Refer to “Air Bleeding Hydraulic System”, ST-8.
RS

BT

HA
SST890C

Disassembly NJST0041
SC
CAUTION:
I Parts which can be disassembled are strictly limited.
Never disassemble parts other than those specified. EL
I Disassemble in as clean a place as possible.
I Clean your hands before disassembly. IDX
I Do not use rags; use nylon cloths or paper towels.
I Follow the procedure and cautions in the Service Manual.
I When disassembling and reassembling, do not let foreign
matter enter or contact the parts.

ST-33
 POWER STEERING OIL PUMP (YD ENGINE)
Disassembly (Cont’d)
I Remove rear bracket and rear body.
I Remove side plate seal, cam ring vane, rotor side and plate.

SST887C

I Remove inlet connector and outlet connector with spring.

Be careful not to drop the flow control valve.
Do not disassemble the flow control valve.

SST036A

I Remove oil seal

SST888C

I Remove snap ring, then draw drive shaft.

Be careful not to drop drive shaft.

SST889C

Inspection NJST0042
I If pulley is cracked or deformed, replace it.
I If an oil leak is found around pulley shaft oil seal, replace the
seal.
I If serration on pulley or pulley shaft is deformed or worn,
replace it.

ST-34
POWER STEERING OIL PUMP (YD ENGINE)
Assembly

Assembly NJST0043
Assemble oil pump, noting the following instructions.
I Make sure O-rings and oil seal are properly installed. GI
I Always install new O-rings and oil seal.
I Be careful of oil seal direction. MA
I Cam ring, rotor and vanes must be replaced as a set if neces-
sary.
I Coat each part with DEXRONTM III or equivalent when assem- EM
bling.
SST038A LC
I Pay attention to the direction of rotor.
EC

FE

CL

SST289A
MT
I When assembling vanes to rotor, rounded surfaces of vanes
must face cam ring side. AT

AX

SU

BR
SST843A

I Insert pin 2 into pin groove 1 of front housing and front side
plate. Then install cam ring 3 as shown at left.
Cam ring:
D1 is less than D2. RS

BT

HA

SC

EL

IDX

SST472C

ST-35
 HYDRAULIC LINE
Removal and Installation

Removal and Installation NJST0044

SST998C

ST-36
 SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications

General Specifications NJST0032

Applied model Sedan Hatchback GI

Steering model Power steering

Steering gear type PR24AD PR25T MA

Steering overall gear ratio 17.1 16.8

*1 *2 *3 EM
Turns of steering wheel (Lock to lock) 2.9
3.2 2.9 3.1

Steering column type Collapsible, tilt LC

*1: Australia, General areas, South Africa (QG16), Indonesia, Malaysia (185/65R14), the Middle East, the Philippines and Taiwan (185/
65R14).
*2: General areas (YD22), South Africa (QG18) and Taiwan (195/60R15) EC
*3: Malaysia (195/60R15)

Steering Wheel NJST0033

FE
Steering wheel axial play mm (in) 0 (0)

Steering wheel play mm (in) 35 (1.38) or less

CL
Movement of gear housing mm (in) ±2 (±0.08) or less
MT
Steering Column NJST0034

Sedan AT
Applied model Taiwan, Thailand, Malaysia, the Hatchback
Taiwan, Thailand, Malaysia, Indone-
Philippines, the Middle East,
Australia, South Africa and Europe
sia and the Philippines AX
Steering column length “L” mm
542 - 544 (21.34 - 21.42) 546 (21.50)
(in)
SU

BR

RS

SST855C BT

HA

SC

EL

IDX

ST-37
 SERVICE DATA AND SPECIFICATIONS (SDS)
Steering Gear and Linkage

Steering Gear and Linkage NJST0035

General
*1 *2 *3
areas
Hatchback
Applied model
Sedan

QG engine YD engine QG engine YD engine

Steering gear type PR24AD PR25T

Swinging force at cot-

ter pin hole: “A” N 6.9 - 65.7 (0.66 - 6.59, 1.5 - 14.8)
(kg, lb)
Tie-rod
Rotating torque:
outer ball
“B” N·m (kg-cm, 0.29 - 2.94 (3.0 - 30.0, 2.6 - 26.0)
joint
in-lb)

Axial end play:

0.4 (0.016) or less
“C” mm (in)

Swinging force*:
Tie-rod 5.9 - 46.1 (0.58 - 4.65, 1.3 - 10.4)
“A” N (kg, lb)
inner ball
joint Axial end play:
0.4 (0.016) or less
“C” mm (in)

Tie-rod standard length “L” mm

156.0 (6.142) 161.0 (6.339) 166.0 (6.535) 164.0 (6.457) 132 (5.20) 136 (5.35)
(in)

*: Measuring point [: 172 mm (6.77 in)]

*1: Indonesia, Malaysia, Thailand, the Philippines and Taiwan
*2: South Africa (QG18), General areas (RHD) and the Middle East
*3: Australia, General areas (LHD) and South Africa (QG16)

SST867C

ST-38
 SERVICE DATA AND SPECIFICATIONS (SDS)
Steering Gear and Linkage (Cont’d)

*1 *2 *3
Applied model —
Sedan GI
Initial tightening
torque N·m (kg-cm, 3.9 - 5.9 (40 - 60, 35 - 52) —
in-lb) MA
Retightening torque
after loosening N·m 0.2 (2, 1.7) —
Retainer
adjustment (kg-cm, in-lb) EM
Adjusting Tightening torque
screw after gear has
settled N·m (kg-cm,
3.9 - 5.9 (40 - 60, 35 - 52) — LC
in-lb)

Returning angle
gree
de-
50° - 70° — EC
Rack stroke “S” mm (in) 65.0 (2.559) 67.5 (2.657) 70.0 (2.756) —

*1: General areas (YD22), South Africa (QG18) and Taiwan (195/60R15)
FE
*2: Malaysia (195/60R15)
*3: Australia, General areas, South Africa (QG16), Indonesia, Malaysia (185/65R14), the Middle East, the Philippines and Taiwan (185/65R14)
CL

MT

AT

AX

SST086BA
SU

Power Steering NJST0036 BR

Applied model Sedan Hatchback

Steering gear type PR24AD PR25T

Range within ±11.5 mm (±0.453 in) 152 - 240 (15.5 - 24.5, 34.2 132 - 308 (13.5 - 31.4, 30 -
Average force
from the neutral position at rack - 54.0) 69)
Rack sliding
force N (kg, lb) speed of 3.5 mm (0.138 in)/s
Maximum force deviation 98 (10, 22) 176 (17.9, 39)
RS
Under normal oper-
ating oil pressure Maximum sliding force 294 (30, 66) —
Except for the above range BT
Maximum force deviation 147 (15, 33) —

Steering wheel turning force

39 (4, 9) or less
(Measured at one full turn from the neutral position) N (kg, lb) HA
Fluid capacity (Approximate)  (Imp qt) 1.0 (7/8)

QG13, 15 engines
7,500 - 8,300 (75.0 - 83.0, 8,600 - 9,200 (876.9 - SC
76.5 - 84.7, 1,088 - 1,204) 917.7, 1,934 - 2,024)
Oil pump maximum pressure kPa (bar, kg/cm2, psi)
QG16, 18 engines 8,500 - 9,300 (85.0 - 93.0, 86.7 - 94.9, 1,088 - 1,349)
EL
YD22 engine 8,500 - 9,300 (85.0 - 93.0, 86.7 - 94.9, 1,088 - 1,349)

IDX

ST-39
NOTES