To Remove/Replace Steering Rack Assembly; To Re-Fit/Replace Steering Rack Assembly; Pas Pump Test Procedure - Lotus Evora Service Notes

Lotus Service Notes

To Remove/Replace Steering Rack Assembly

The steering rack may be removed from the front subframe after first removing the front anti-roll bar with
its mounting brackets.
1. Remove both front wheels, and the front undertray.
2. Release the anti-roll bar from the drop link at each side.
3. At each side, remove the six screws securing the extruded alloy mounting plate to which the ARB clamp
is fixed. Captive threaded inserts are used in the subframe. Withdraw the anti-roll bar assembly from the
car.
4. Remove the nut securing each track rod end to the steering arm, and use a ball joint splitter to separate
the joint.
5. Match mark the pinion shaft against the u/j yoke to aid steering wheel alignment on re-assembly, and
remove the pinch bolt.
6. Slacken the banjo bolts securing the feed and return pipes to the pinion housing, and collect the draining
oil. Removal of the bolts may not be possible at this stage.
7. At each end of the rack housing, remove the two bolts securing the unit to the mounting brackets. With-
draw the pinion shaft from the lower u/j and remove the two banjo bolts as the assembly is withdrawn from
below.

To Re-fit/Replace Steering Rack Assembly

Refit in the reverse order to removal, with the following notes:
- Engage the pinion shaft with the column u/j (match marks aligned) as the housing is positioned. Fit and
tighten the u/j pinch bolt to 25 Nm.
- Before securing the rack housing, refit the feed and return pipes to the pinion housing using new or an-
nealed washers. Torque tighten M14 (return) to 18 - 25 Nm; M16 (feed) to 25 - 30 Nm.
- Torque tighten housing fixing bolts (4 off) to 45 Nm.
- Torque tighten track rod end ball pin nuts to 45 Nm.
- Torque tighten the anti-roll bar clamp mounting plate to subframe bolts (8 off) to 24 Nm.
- Torque tighten the anti-roll bar to drop link fixings to 38 Nm.
- Refill the power steering reservoir and bleed the system as detailed in sub-section HI.3
- Check and adjust the front wheel alignment as detailed in sub-section CK.2.
Note: If the rack mounting plinths are removed from the front subframe, note that there are shim plates fitted
between the plinths and the subframe top surface in order to control the height of the rack and the bump steer
characteristic. Shim plates are available in thicknesses of 5, 2 and 1mm, with the standard setting being two
2mm shim plates at each position. Torque tighten the plinth to subframe fixing bolts to 45 Nm.
HI.7 - PAS PUMP & TESTING PROCEDURE
The vane type, constant displacement hydraulic pump is mounted on the right hand front of the cylinder
block, and is driven by the automatically tensioned multi-rib auxiliary belt from the crankshaft pulley. To check
for correct functionality, the steering effort may be checked with the engine running and the car stationary:

PAS Pump Test Procedure

Tools required
PAS Pressure Test Gauge Kit - use a universal kit, or Toyota part number 09640-10010
1. Remove the rear clamshell (see Sub-Section BV.6).
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Section HI