STEERING
MANUAL AND POWER
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GENERAL
...................................... 2
STEERING COLUMN AND SHAFT
.................... 15
MANUAL STEERING GEAR BOX
......................
23
TIE ROD
........................................
32
POWER STEERING GEAR BOX
........................
35
POWER STEERING OIL PUMP
......................
51
POWER STEERING HOSES
........................
57
GENERAL
MANUAL STEERING
SPECIFICATIONS
Shaft and joint type
Steering gear type
Number of pinion teeth
Rack stroke
Collapsible, cross joints (two joints used)
Rack and pinion

5
138 mm (5.43 in.)
SERVICE STANDARD
Standard Value
Steering wheel free play mm (in.)
Steering angle
Inner wheel
Outer wheel
Ball joint starting torque Ncm (Ib.in.)
Total pinion preload Ncm (Ib.in.)
0-30 (0-1.1)
35°40' ± 1°30'
29°17'
50-250 (4-22)
±180° or less from neutral position
40-110 (3.5-9.5)
±180° more from neutral position
30-130 (2.6-11.3)
TIGHTENING TORQUE
Nm
kg.cm
lb.ft
Steering shaft and column support
Steering shaft and joint
Pinion gear and joint
Steering wheel and steering shaft
Gear box and cross member
Dust cover mounting bolt
Yoke plug lock nut
Tie rod ball joint and knuckle arm

Tie rod to rack
Tie rod lock nut
9.8
100
7.2
15-20
150-200
11-14
15-20
150-200
11-14
34-44
350-450
25-32
29-39
300-400
22-29
5-7
50-70
3.6-5.1
49-69 500-700
36-51
15-33
150-340
11-25
78-98
800-1,000
58-72
49-54 500-550
36-40

LUBRICANTS
Steering gear box
Steering column bearings
Multipurpose grease SAE J310a, NLGI
grade #2 EP
Multipurpose grease SAE J310a, NLGI
grade #2 EP
As required
As required
56-2
GENERAL
POWER STEERING
SPECIFICATIONS
Power steering
Gear box
Steering gear type
Rack stroke
Oil pump
Oil pump type
Displacement
Rack and pinion
136 mm (5.3 in.)
Vane type
9.6 em
3
/rev. (0.59 ins/rev.)
SERVICE STANDARD
Power Steering
Standard Value
Steering wheel free play

Steering angle
Inner wheel
Outer wheel
Stationary steering effort
Belt deflection
Ball joint starting torque Ncm (Ib.in.)
Oil pump pressure kPa (psi, kg/cm
2
)
Gauge hose valve closed
Gauge hose valve opened
Total pinion preload
Tie rod swing resistance
Limit
Oil pump pressure
Gauge hose valve closed
0-30 mm (0-1.1 in.)
35°40' ± 1°30'
29°17'
3.1 kg (6.8 Ibs.) or less
7-10 mm (0.28-0.4 in.)
50-250 (4-22)
4,500-5,200 (640-740,46-53)
980 (142, 10) or less
60-130 Ncm (5-11 Ib.in.)
15 N (3.3 lb)
[350 Ncm (30 lb.in)]
7,800 kPa (1,110 psi, 80 kg/cm
2
)

56-3
GENERAL
TIGHTENING TORQUE
Nm
kg.cm
Ib.ft
Power Steering
Power Steering Gear Box
Gear box mounting clamp
Rack support cover locking nut
Tie rod to rack
Tie rod end lock nut
Tie rod end to knuckle
End plug
Self-locking nut
Feed tube
59-78 600-800 43-58
49-69 500-700
36-51
78-98
800-1,000 58-72
49-54 500-550 36-40
15-33 150-340
11-25
49-69 500-700
36-51
20-29 200-300 14-22
12-18 120-180
9-13
Oil Pump

Reservoir mounting bolt
8-12
80-120
6-9
Engine mounting bracket
49-69 500-700
36-51
Oil pump bracket mounting bolt
20-26 200-270
14-20
Oil pump mounting bolt
20-26 200-270
14-20
Oil pump adjust bolt
25-32 250-330
18-24
Connector to pump body
49-69 500-700 36-51
Suction connector to pump body
6-10
60-100 4.3-7.2
Pump cover to pump body
18-22
180-220 13-16
Steering Hoses
Pressure hose attaching nut
Pressure hose to gear box
Pressure hose clip
Hose clamp
Tube mounting bolt

10-15 100-150
7-11
12-18
120-180 9-13
3-6
30-60
2.2-4.3
3-5
130-50
2.2-3.6
8-12
80-120 6-9
LUBRICANTS
Recommended lubricant
Quantity
Steering column lower bearing
Teeth of rack and pinion
Moving parts of rack and bushings
Moving parts of pinion and needle bearing
Moving parts of rack and rack support
Lip of gear box oil seal
Tie rod side groove of bellows
Inside surface and lip of tie end dust cover
Power steering fluid
Multipurpose grease
SAE J310a, NLGI grade #2 EP
Multipurpose grease
SAE J310a, NLGI grade #2 EP
Multipurpose grease
SAE J310a, NLGI grade #2 EP

Multipurpose grease
SAE J310a, NLGI grade #2 EP
Multipurpose grease
SAE J310a, NLGI grade #2 EP
Multipurpose grease
SAE J310a, NLGI grade #2 EP
Multipurpose grease
SAE J310a, NLGI grade #3 EP
Multipurpose grease
SAE J310a, NLGI grade #2 EP
Automatic transmission fluid
DEXRON
®
II type
As required
As required
As required
As required
As required
As required
As required
As required
0.8 liter (4 C.I.D.)
56-4
GENERAL
SPECIAL TOOLS
TOOL
[Number and name)
09561-11001
Steering wheel puller

09565-11100 (ST-1303)
Preload socket
09565-21000
Pinion bearing remover and
installer
09565-21100
Yoke plug torque wrench
socket
09568-31000
Tie rod end puller
09572-21000
Oil pressure gauge
(Power steering only)
09572-21100
Oil pressure gauge adapter
(Power steering only)
09572-21200
Oil pressure gauge adapter
(Power steering only)
ILLUSTRATlON
USE
Removal of the steering wheel
Measurement of the main shaft preload
Removal and installation of pinion bearing
Removal, installation and adjustment of
steering gear yoke plug
Separation of the tie rod end ball joint
Measurement of the oil pressure (Use with
09572-21100, 09572-21200)
Measurement of the oil pressure (Use with

09572-21000, 09572-21200)
Measurement of the oil pressure (Use with
09572-21000, 09572-21100)
56-5
GENERAL
TOOL
(Number and name)
09517-21400
Drift (Rower steering only)
ILLUSTRATION
USE
Removal of the ball bearing, needle bearing
from the gear housing
09573-21200
Oil seal guide
(Power steering only)
Removal and installation of the oil seal from
the gear housing
09555-21000
Bar (Power steering only)
Removal and installation of the oil seal from
the gear housing
09573-21100
Oil seal installer
(Power steering only)
Installation of the oil seal from the gear
housing
09573-21000
Oil seal installer guide
(Power steering only)

Installation of the oil seal from the gear
housing
09432-21600
Bearing installer
(Power steering only)
Installation of the needle bearing to the gear
housing and the oil seal, ball bearing to the
valve body
09222-21100
Valve stem oil seal installer
(Power steering only)
Installation of the ball bearing to the gear
housing
09434-14200
Countershaft bearing installer
(Power steering only)
Installation of the oil seal to the rack bush-
ing and to the valve body
56-6
GENERAL
TROUBLESHOOTING (Manual Steering)
Symptom
Excessive play of steering
wheel
Steering wheel operation
is hard
Steering wheel does not
return properly
Probable cause
Loose rack support cover

Loose steering gear mounting bolts
Loose or worn stud of tie-rod end
Excessive turning resistance of tie-rod
ball joint
Excessively tightened rack support cover
Rough turning of inner tie-rod and/or ball joint
Bent rack
Worn steering shaft joint and/or body grommet
Damaged pinion bearing
Excessive turning resistance of tie-rod ball joint
Excessively tightened rack support cover
Rough turning of inner tie-rod and/or ball joint
Worn steering shaft joint and/or body grommet
Bent rack
Damaged pinion bearing
Remedy
Retighten
Retighten
Retighten or relate as
necessary
Replace
Adjust
Lubricate or replace ball joint
Replace
Replace
Replace
Replace
Adjust
Replace
Correct or replace

Replace
Replace
56-7
GENERAL
TROUBLESHOOTING (Power Steering)
Symptom
Excessive play of
steering wheel
Steering wheel
operation is heavy
(Insufficient power
assist)
The steering wheel
does not return
properly
Noise
Probable cause
Loose rack support cover
Loose steering gear mounting bolts
Loose or worn stud of tie-rod end
V-belt slippage
Damaged V-belt
Low fluid level
Air in the fluid
Twisted or damaged hoses
Insufficient oil pump pressure
Sticky flow control valve
Excessive internal oil pump leakage
Excessive oil leaks from rack and pinion
in gear box

Bent or damaged gear box or valve
body seal ring
Excessive turning resistance of tie-rod
ball joint
Excessively tightened rack support cover
Rough turning or inner tie-rod and/or ball joint
Loose mounting of gear box to crossmember
Worn steering shaft joint and/or body
grommet
Bent rack
Damaged pinion bearing
Twisted or damaged hoses
Damaged oil pressure control valve
Damaged oil pump input shaft bearing
Hissing Noise in Steering Gear
Remedy
Retighten
Retighten
Retighten or replace as necessary
Check
Replace
Replenish
Bleed air
Correct the routing or replace
Repair or replace the oil pump
Replace
Replace damaged parts
Replace damaged parts
Replace
Replace

Adjust
Replace
Retighten
Correct or replace
Replace
Replace
Reroute or replace
Replace
Replace
There is some noise in all power steering systems. One of the most common is a hissing
sound when the steering wheel is turned and the car is not moving. This noise will be
most evident when turning the wheel while the brakes are applied.
There is no relationship between this noise and steering performance. Do not replace the
valve unless the “hissing” noise is extremely objectionable. A replacement valve will also
have a slight noise, and is not always a cure for the condition.
56-8
GENERAL
Symptom
Rattling or chucking
noise in rack and
pinion
Probable cause
Interference with hoses from vehicle body
Loose gear box bracket
Loose tie-rod end ball joint
Reroute
Retighten
Retighten
Remedy
Worn tie-rod end ball joint

Replace
Groaning noise in
oil pump
Low fluid level
Air in the fluid
Loose pump mounting bolts
Replenish
Bleed air
Retighten
56-9
GENERAL
SERVICE ADJUSTMENT PROCEDURE
Checking Steering Wheel Free Play
1.
Check the steering wheel free play in the straight ahead position.
Steering wheel free play [Standard value]. . . . . . . . . . . . . . . . . .
0-30 mm (0-1.1 in.)
2. If the measured value exceeds the standard value, check the
looseness of the yoke plug and the connections of following
parts; tie rod ball joint, steering shaft, universal joint, gear box,
etc.
Checking Steering Angle
1. Place the front wheel on a turning radius gauge and measure
the steering angle.
Steering angle [Standard value]
Inner wheel
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35°40' ± 1°30'
Outer wheel
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29°17'
2. If the measured value is not within the standard value, inspect
the linkage so that it might not be improperly adjusted.
Checking Tie Rod Ball Joint Starting Torque
1.
Mount two nuts on the ball joint, and then measure the ball joint
starting torque.
Tie rod end ball joint starting torque
[Standard value]. . . . . . . . . . . . . . . . . 50-250 Ncm (4-22 in. Ibs.)
2.
If the starting torque exceeds the standard value, replace the tie
rod end.
NOTE
Even if the starting torque is below limit of the standard
value, the ball joint may be reused unless it has drag and
excessive play.
56-10
GENERAL
POWER STEERING
Checking Steering Wheel Free Play
1. Start the engine and the steering wheel in the straight ahead
position, apply a force of 5 N (1.1 Ibs.) to the steering wheel in
the peripheral direction.
2. Measure the play at the circumference of the steering wheel.
Steering wheel free play [Standard value]. . . . . . . . . . . . . . . . .
0-30 mm (0-1.1 in.)
3. If the play exceeds the standard value, inspect the contact of the
steering shaft and tie rod ball joints.
Checking Steering Angle
1. Place the front wheel on a turning radius gauge and measure

the steering angle.
Steering angle [Standard value]
Inner wheel
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35°40' ± 1°30'
Outer wheel
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29°17'
2. If the measured value is not within the standard value, inspect
the linkage so that it might not be improperly adjusted.
Checking Stationary Steering Effort
1.
Place the vehicle on a level surface and place the steering wheel
in the straight ahead position.
2. Set the engine speed to 1,000 rpm.
CAUTION
After checking, reset the engine speed to the standard value
(idling speed).
3. Measure the turning force with a spring scale by turning the
steering wheel clockwise and countclockwise one and a half
turns.
Stationary steering effort [Standard value] . . . . . . . . . . . . . . . . . .
3.5 Nm (36 kg.cm, 2.6 Ib.ft) or less
4. Check to be sure that there is no excessive force change while
turning the steering wheel.
5. If the stationary steering effort exceeds, check and adjust the
following points:
(a) Damage and cracks of dust covers of lower arm and tie rod
end ball joint.
(b) Pinion total preload of steering gear box. Turning starting

torque of tie rod end ball joint.
(c) Turning starting torque of lower arm ball joint.
56-11
GENERAL
Checking Steering Wheel Return
Check the steering wheel return and confirm the following
points:
1. The force required to turn the steering wheel and the wheel
return should be the same for left and right for both moderate
turns and sharp turns.
2. When the steering wheel is turned 90° and held for a couple of
seconds while the vehicle is being driven at 35° km/h (22 mph),
the steering wheel should return at least 70% when it is
released.
NOTE
If the steering wheel is turned very quickly, the steering
wheel operation may be momentarily heavy, but this is not a
malfunction (especially during idling, because the oil pump
output will be somewhat decreased).
Difference in fluid levels:
within 5 mm (0.2 in.)
Checking Power Steering Fluid Level
1. Park vehicle on level place.
2. Start engine. With vehicle kept stationary, turn steering wheel
several times continuously to raise fluid temperature from 50 to
60°C (122 to 140°F).
3. With engine at idle, turn steering wheel fully clockwise and
counterclockwise several times.
4. Make sure that there is no foaming or cloudiness in reservoir
fluid.

5. Stop engine to check for difference in fluid level between sta-
tionary and running engine.
NOTE
(a) If fluid level varies 5 mm (0.2 in.) or more, bleed system
again because bleeding of system is not satisfactory.
(b) If fluid level suddenly rises after stopping engine, it
shows that bleeding is not satisfactory.
(c) Incomplete bleeding will produce chattering sound in
pump and noise in flow control valve, decreasing durabil-
ity of pump, etc.
Replacing Power Steering Fluid
1. Jack up the front wheels and support with rigid racks.
2. Disconnect return hose from oil reservoir and install plug to oil
reservoir.
3. Connect vinyl hose to disconnected return hose.
4.
Pull ignition cable at the ignition coil side. While running engine
intermittently several times by means of starting motor, turn
steering wheel fully clockwise and couterclockwise to drain off
fluid.
5. Fill oil reservoir with specified fluid.
Automatic transmission fluid DEXRON
®
ll type : As required.
While engine
While engine
is running
is stopped
56-12
GENERAL

6. Run engine
Make sure that new fluid comes out from fluid drain hose, and
turn off engine.
7. Install return hose to oil reservoir positively and secure with
clip.
8. Make sure that fluid is poured to the bottom of oil filter in oil
reservoir tank. Then bleed air.
Automatic transmission fluid DEXRON
®
lI type:
Total quantity : Approx. 0.8 liter (49 C.I.D.)
Air Bleeding
1. Disconnect the ignition cable, and then, while operating the
starting motor intermittently (for 15 to 20 seconds), turn the
steering wheel all the way to the left and right five or six times.
CAUTION
(a)
During air bleeding, replenish the fluid supply so that the
level never falls below the lower position of the filter.
(b) If air bleeding is done while the vehicle is idling, the air
will be broken up and absorbed into the fluid; be sure to
do the bleeding only while cranking.
2. Connect the ignition cable, and then start the engine (idling).
3.
Turn the steering wheel to the left and right until there are no air
bubbles in the oil reservoir.
CAUTION
Do not hold the steering wheel turned all the way to either
side for longer than ten seconds.
4. Confirm that the fluid is not milky, and that the level is up to the

specified position on the level gauge.
5. Confirm that there is very little change in the fluid level when
the steering wheel is turned left and right.
CAUTION
(a) If the fluid level changes considerably, air bleeding
should be done again.
(b) If the fluid level rises suddenly when the engine is
stopped, it indicates that there is still air in the system.
(c)
If there is air in the system, a jingling noise may be heard
from the pump and the control valve may also make
strange noise; air in the system will shorten the useful
life of the pump and other parts.
56-13
GENERAL
Checking Power Steering Belt Tension
1. Press the V-belt by applying pressure of 100 N (22 Ibs.) at the
specified point, and measure the deflection to confirm that it is
within the standard value range.
V-belt deflection [Standard value] . . . . . . . . . . . . . . . . . . . . . . . . . .
7-10 mm (0.28-0.4 in.)
2. To adjust the belt tension, loosen the oil pump mounting bolts,
move the oil pump, and then retighten the bolts.
Oil Pump Pressure Test
1. Disconnect the pressure hose from the oil pump, and then
connect the special tool between the oil pump and pressure
hose as illustrated.
2. Bleed the air, then start the engine and turn the steering
wheel several times so that the temperature of the fluid rises to
approximately 50°C (122°F).

3. Set the engine speed to 1,000 rpm.
4. Fully close and fully open the shut-off valve of the special tool
and measure the fluid pressure to confirm that it is within the
standard value range.
Oil pump pressure [Standard value] . . . . . . . . . . . . . . . . . . . . . . . .
Gauge hose valve closed
4,500-5,200 kPa (640-740 psi, 46-53 kg/cm
2
)
Gauge hose valve opened
980 kPa (142 psi, 10 kg/cm
2
) or less
CAUTION
Be sure not to keep the shut-off valve on the pressure gauge
closed for longer than ten seconds.
5.
Remove the special tools, and then tighten the pressure hose to
the specified torque.
Tightening torque . . .
12-18 Nm (120-180 kg.cm, 9-13 Ib.ft)
6. Bleed the system.
56-14
STEERING COLUMN AND SHAFT
STEERING COLUMN AND SHAFT
COMPONENTS
TORQUE : Nm (kg.cm, Ib.ft)
56-15
STEERING COLUMN AND SHAFT
REMOVAL

1. Remove the horn button cover.
2.
After removing the steering wheel lock nut, remove the steering
wheel dynamic damper.
3.
After making alignment marks on the steering shaft and wheel,
remove the steering wheel, using a Special Tool (09561-11001).
CAUTION
Do not hammer on the steering wheel to remove it: doing so
may damage the collapsible mechanism.
4. Remove the column shroud.
5. Remove the multifunction switch and disconnect the connec-
tor.
56-16
STEERING COLUMN AND SHAFT
6.
Remove the bolt coupling the steering shaft with joint.
7. After removing the bolts securing the column bracket to the
frame, remove the steering shaft from the joint.
8.
Remove the bolt coupling the joint with gear box.
9.
Remove the dust cover mounting bolts and remove the cover
together with the joint toward the driver’s compartment.
56-17
STEERING COLUMN AND SHAFT
DISASSEMBLY
1. Draw out the bearing from the dust cover.
2. Remove the boot B and the dust cover from the joint.
3. Remove the snap ring.

4. After unlocking the steering wheel, remove the steering shaft
from the column by lightly striking the shaft end with a soft
hammer.
5. To remove the steering lock, cut a slot in the mounting screw
heads and bracket with a hack saw. Loosen the screws with a
flat-blade screwdriver to remove the steering wheel lock.
CAUTION
When the steering wheel lock is reinstalled, the bracket and
screws should be replaced with new ones.
56-18
STEERING COLUMN AND SHAFT
6. To remove the column bracket A, cut a slot in the mounting bolt
head (which has no hexagonal portion) with a hacksaw. Loosen
the bolt with a flat-blade screwdriver to remove the column
bracket.
CAUTION
Replace the mounting bolt with a new one on reassembly.
INSPECTION
REASSEMBLY
1. Insert the steering shaft into the column tube and secure with
the snap ring.
2. Tighten the column bracket mounting bolt until the head is
broken off at its shank.
56-19
STEERING COLUMN AND SHAFT
3. Apply grease to the inside of bearing and install the bearing
securely to the end of the column tube. Be sure bearing seats
squarely in steering column.
Recommended grease
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Multipurpose grease SAE J310a, NLGI grade #2 EP
4. Align the steering lock with the column boss and insert the
ignition key to verify the steering lock operation before tighten-
ing the lock to specifications.
CAUTION
Use special screws (one-way) to tighten the lock.
INSTALLATION
1. Make sure that the joint and dust cover are installed in the
correct direction as illustrated.
CAUTION
Apply grease to the grooved portion of the dust cover.
Recommended grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Multipurpose grease SAE J310a, NLGI grade #2 EP
56-20
STEERING COLUMN AND SHAFT
2. Apply grease to the bearing and dust cover, and install the
bearing into the dust cover.
Recommended grease . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Multipurpose grease SAE J310a,
NLGI grade #2 EP
3. Install the joint to the gear box pinion and temporarily tighten
the dust cover.
Tighten the coupling bolt.
Pinion joint tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . .
15-20 Nm (150-200 kg.cm, 11-14 Ib.ft)
4. After installing the steering shaft to the joint, install the shaft to
the column support. Tighten the bolt coupling steering shaft
with joint.
Steering shaft column support tightening torque . . . . . . . . . . . .

9.8 Nm (100 kg.cm, 7.2 Ib.ft)
Steering shaft joint tightening torque.. . . . . . . . . . . . . . . . . . . . . .
15-20 Nm (150-200 kg.cm, 11-14 lb.ft)
5.
Move the dust cover to adjust its position so that there will be no
clearance between the joint and dust cover sliding surface, and
tighten the dust cover.
56-21
STEERING COLUMN AND SHAFT
6. When the steering wheel is installed, make sure that the align-
ment marks are in alignment and that the steering wheel is in
the straight ahead position.
56-22
MANUAL STEERING GEAR BOX
MANUAL STEERING GEAR BOX
COMPONENTS
1.
Oil seal
2.
Snap ring
3.
Snap ring
4. Bearing
5. Pinion
6.
Rack
7.
Mounting bracket
8.
Mounting rubber

9. Rack support yoke
10.
Cushion rubber
11. Yoke spring
12.
Yoke plug
13. Lock nut
14. Gear box
15.
Tie rod
16. Bellows band
17. Bellows
18. Clip
19. Tie rod end
20.
Bushing
A
B
C
D
E
Nm
kg.cm
Ib.ft
15-33
150-340
11-25
29-39
300-400
22-29

49-69
500-700
36-51
49-54
500-550
36-40
78-98
800-1,000
58-72
REMOVAL
1. Remove the both wheel and tire assembly.
2. Remove the bolt coupling joint with the pinion.
56-23
MANUAL STEERING GEAR BOX
3. Remove the tie rods from the knuckle arms, using Special Tool
(09568-31000).
4. Remove the rack and pinion assembly from the crossmember.
DISASSEMBLY
Before disassembly, measure and note the rack starting force
and pinion starting torque in the neutral (straight ahead) posi-
tion for reference at reassembly.
1. Clean the rack and pinion assembly and mount it in a softjawed
vise.
CAUTION
When the assembly is mounted in vise, wind a cloth around
the center pipe portion and tighten the vise being careful not
to deform the pipe.
2. Remove the tie rod assembly.
3. Remove the lock nut from the yoke plug.
56-24

MANUAL STEERING GEAR BOX
4. Using Special Tool (09565-21100) remove the yoke plug.
5. Remove the yoke spring, cushion rubber and support yoke from
the gear box.
6. Remove the oil seal from the gear box.
7. Remove the snap ring from the gear box. Remove the pinion
with bearing.
56-25