Subaru 2001 FORESTER Service Manual
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Subaru 2001 FORESTER Service Manual

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2001 FORESTER SERVICE MANUAL

CHASSIS SECTION

This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair of
SUBARU vehicles.
This manual includes the procedures for
maintenance, disassembling, reassem-
bling, inspection and adjustment of com-
ponents and diagnostics for guidance of
experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping their
vehicle in optimum condition. When
replacement of parts during repair work is
needed, be sure to use SUBARU genu-
ine parts.
All information, illustration and specifica-
tions contained in this manual are based
on the latest product information avail-
able at the time of publication approval.
FUJI HEAVY INDUSTRIES LTD.

QUICK REFERENCE INDEX

G8050GE5

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Summary of Contents for Subaru 2001 FORESTER

  • Page 1 When replacement of parts during repair work is needed, be sure to use SUBARU genu- ine parts. All information, illustration and specifica- tions contained in this manual are based on the latest product information avail- able at the time of publication approval.

  • Page 2: Table Of Contents

    POWER ASSISTED SYSTEM (POWER STEERING) Page General Description..................2 Steering Wheel..................27 Universal Joint...................28 Tilt Steering Column..................30 Steering Gearbox [LHD Model]..............33 Steering Gearbox [RHD Model] ..............53 Pipe Assembly...................78 Oil Pump....................93 Reservoir Tank ..................100 Power Steering Fluid................101 General Diagnostic Table ................103...

  • Page 3: General Description

    GENERAL DESCRIPTION Power Assisted System (Power Steering) 1. General Description S601001 A: SPECIFICATIONS S601001E49 Model Steering wheel Free play mm (in) 17 (0.67) Inner tire & wheel 34.4°±1.5° Turning angle Outer tire & wheel 30.2°±1.5° Clearance between steering Steering shaft mm (in) 3.0 (0.118) wheel and column cover...
  • Page 4 GENERAL DESCRIPTION Power Assisted System (Power Steering) Model Non-turbo Turbo Minimum turning radius m (ft) 5.4 (17.7) Steering angle (Inside-Outside) 34.4°±1.5° — 30.2°±1.5° With AIRBAG: 385 (15.16) Whole system Steering wheel diameter mm (in) Without AIRBAG: 385 (15.16) LHD: 19.0 (3.4) Overall gear ratio (Turns, lock to lock) RHD: 16.7 (3.0) Type...
  • Page 5 GENERAL DESCRIPTION Power Assisted System (Power Steering) ¼ Non-turbo model S4M0172A ¼ Turbo model S4M0565A PS-4...
  • Page 6 GENERAL DESCRIPTION Power Assisted System (Power Steering) B: COMPONENT S601001A05 1. STEERING WHEEL AND COLUMN S601001A0501 ¼ With Airbag Model S4M0304B (1) Bushing (6) Steering wheel Tightening torque: N·m (kgf-m, ft-lb) (2) Steering shaft (7) Airbag module 1.2 (0.12, 0.9) (3) Knee protector 3.4 (0.35, 2.5) (4) Steering roll connector...
  • Page 7 GENERAL DESCRIPTION Power Assisted System (Power Steering) ¼ Without Airbag Model S4M0311A (1) Bushing (6) Steering wheel Tightening torque: N·m (kgf-m, ft-lb) (2) Steering shaft (7) Pad ASSY 1.2 (0.12, 0.9) (3) Knee protector 3.4 (0.35, 2.5) (4) Combination switch 25 (2.5, 18.1) (5) Column cover 44 (4.5, 32.5)
  • Page 8 GENERAL DESCRIPTION Power Assisted System (Power Steering) MEMO: PS-7...
  • Page 9 GENERAL DESCRIPTION Power Assisted System (Power Steering) 2. POWER ASSISTED SYSTEM FOR NON-TURBO MODEL S601001A0504 ¼ LHD Model S4M0175E PS-8...
  • Page 10 GENERAL DESCRIPTION Power Assisted System (Power Steering) (1) Eye bolt (27) Oil seal (53) Steering body (2) Pipe C (28) Special bearing (54) Oil seal (3) Gasket (29) Seal ring (55) Piston ring (4) Clip (30) Pinion and valve ASSY (56) Rack (5) Pipe D (31) Oil seal...
  • Page 11 GENERAL DESCRIPTION Power Assisted System (Power Steering) ¼ RHD Model S4M0232C PS-10...
  • Page 12 GENERAL DESCRIPTION Power Assisted System (Power Steering) (1) Eye bolt (29) O-ring (57) Lock nut (2) Pipe C (30) Oil seal (58) Adjusting screw (3) Gasket (31) Spacer (59) Spring (4) Clip (32) Pinion (60) Sleeve (5) Pipe D (33) Shim (61) Seat pad (6) Clamp E (34) Adapter...
  • Page 13 GENERAL DESCRIPTION Power Assisted System (Power Steering) 3. POWER ASSISTED SYSTEM FOR TURBO MODEL S601001A0505 ¼ LHD Model S4M0566A PS-12...
  • Page 14 GENERAL DESCRIPTION Power Assisted System (Power Steering) (1) Eye bolt (28) Oil seal (55) Rack stopper (2) Pipe C (29) Back-up washer (56) Circlip (3) Gasket (30) Ball bearing (57) Suction hose (4) Clip (31) Snap ring (58) Tank hose (5) Pipe D (32) Lock nut (6) Clamp E...
  • Page 15 GENERAL DESCRIPTION Power Assisted System (Power Steering) ¼ RHD Model S4M0567A PS-14...
  • Page 16 GENERAL DESCRIPTION Power Assisted System (Power Steering) (1) Eye bolt (28) Pinion (55) Spring (2) Pipe C (29) Shim (56) Sleeve (3) Gasket (30) Adapter (57) Seat pad (4) Clip (31) Clamp (58) Suction hose (5) Pipe D (32) Castle nut (59) Tank hose (6) Clamp E (33) Cotter pin...
  • Page 17 ¼ Be careful not to burn your hands, because each part on the vehicle is hot after running. ¼ Use SUBARU genuine steering fluid, grease etc. or the equivalent. Do not mix steering fluid, grease etc. with that of another grade or from other manufacturers.

  • Page 18: Special Tools

    GENERAL DESCRIPTION Power Assisted System (Power Steering) D: PREPARATION TOOL S601001A17 1. SPECIAL TOOLS S601001A1701 ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ¼ Used for removing and installing tie-rod. 925700000 WRENCH ¼ Apply this tool to rack. B4M2411 925711000 PRESSURE GAUGE Used for measuring oil pump pressure. B4M2412 926200000 STAND...
  • Page 19 GENERAL DESCRIPTION Power Assisted System (Power Steering) ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 34099AC020 ADAPTER HOSE B Used with PRESSURE GAUGE (925711000). B4M2415 ¼ For the lock nut when adjusting backlash of 926230000 SPANNER gearbox. ¼ Measurement of rotating resistance of gear- box assembly.
  • Page 20 GENERAL DESCRIPTION Power Assisted System (Power Steering) ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ¼ Used for assembling rack assembly. 926390001 COVER & ¼ For LHD model REMOVER ASSY B4M2422 ¼ When oil leaks from pinion side of gearbox 926420000 PLUG assembly, remove pipe B from valve housing, attach this tool and check oil leaking points.
  • Page 21 GENERAL DESCRIPTION Power Assisted System (Power Steering) ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ¼ Used for assembling power steering gearbox. 34099FA100 STAND BASE ¼ For LHD model B4M2427 ¼ Used as a guide to install oil seal. 926360000 INSTALLER A ¼ Used with INSTALLER B (927620000). ¼...
  • Page 22 GENERAL DESCRIPTION Power Assisted System (Power Steering) ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ¼ Used for installing valve housing oil seal. 34099FA130 INSTALLER SEAL ¼ Used with INSTALLER AND REMOVER SEAL (34099FA120). ¼ For LHD model B4M2431 ¼ Used for installing holder ASSY into rack 926250000 GUIDE hous-ing.
  • Page 23 GENERAL DESCRIPTION Power Assisted System (Power Steering) ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ¼ Used for installing oil seal to pinion. 926450000 COVER ¼ For RHD model B4M2491 ¼ Used for installing oil seal into rack ASSY. 927490000 INSTALLER A, B, C ¼...
  • Page 24 GENERAL DESCRIPTION Power Assisted System (Power Steering) ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ¼ Used for installing seal ring to rack pinion. 927600000 FORMER ¼ For RHD model B4M2495 ¼ Used for installing pinion bearing. 927520000 INSTALLER D ¼ For RHD model B4M2496 ¼...
  • Page 25 GENERAL DESCRIPTION Power Assisted System (Power Steering) ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ¼ Used for installing rack and seal into housing 34099FA010 GUIDE assembly. ¼ For RHD model B4M2500 ¼ Used for installing valve assembly into valve 34099FA020 GUIDE housing assembly. ¼...
  • Page 26 GENERAL DESCRIPTION Power Assisted System (Power Steering) ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ¼ Used for installing bearing into valve housing. 34099FA050 SPACER ¼ For RHD model B4M2504 ¼ Used for caulking. 34099FA060 PUNCH ¼ For RHD model B4M2505 ¼ Used for supporting housing assembly. 34099FA070 BASE ¼...
  • Page 27 GENERAL DESCRIPTION Power Assisted System (Power Steering) ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS ¼ Used for installing seal ring to rack pinion. 926050000 FORMER ¼ For RHD model B4M2508 2. GENERAL PURPOSE TOOLS S601001A1702 TOOL NAME REMARKS Spring scale Used for measuring tightening torque. Snap ring pliers Used for removing and installing snap ring.

  • Page 28: Steering Wheel

    STEERING WHEEL Power Assisted System (Power Steering) 2. Steering Wheel NOTE: S601274 Align matching marks on steering wheel and steer- A: REMOVAL ing column. S601274A18 Tightening torque: 1) Disconnect ground terminal from battery. 44 N·m (4.5 kgf-m, 32.5 ft-lb) 2) Set tires to straight-ahead position. 3) Remove airbag module.

  • Page 29: Universal Joint

    UNIVERSAL JOINT Power Assisted System (Power Steering) 3. Universal Joint B: INSTALLATION S601273A11 S601273 1) Install universal joint. A: REMOVAL S601273A18 (1) Align bolts hole on the long yoke side of 1) Set the vehicle on the lift. universal joint with the cutout at the serrated 2) Remove the steering wheel.

  • Page 30: Universal Joint

    UNIVERSAL JOINT Power Assisted System (Power Steering) C: INSPECTION S601273A10 Clean the disassembled parts with a cloth, and check for wear, damage, or any other faults. If necessary, repair or replace faulty parts. Corrective action Inspection ¼ Free play ¼ Swinging torque Yawing torque Looseness Replace if faulty.

  • Page 31: Tilt Steering Column

    TILT STEERING COLUMN Power Assisted System (Power Steering) 4. Tilt Steering Column S601544 A: REMOVAL S601544A18 S4M0136B (1) Tilt steering column Tightening torque: N·m (kgf-m, ft-lb) (2) Universal joint 24 (2.4, 17.4) 25 (2.5, 18.1) PS-30...
  • Page 32 TILT STEERING COLUMN Power Assisted System (Power Steering) 1) Set the vehicle on the lift. B: INSTALLATION S601544A11 2) Disconnect battery minus terminal. 1) Insert end of steering shaft into toe board grom- 3) Remove airbag module. <Ref. to AB-12 met.
  • Page 33 TILT STEERING COLUMN Power Assisted System (Power Steering) 11) Install horn pad to steering wheel. (without air- bag model) C: DISASSEMBLY S601544A06 Remove the two screws securing upper steering column covers, and the two screws securing com- bination switch, then remove related parts. D: ASSEMBLY S601544A02 1) Insert combination switch to upper column...

  • Page 34: Steering Gearbox [Lhd Model]

    STEERING GEARBOX [LHD MODEL] Power Assisted System (Power Steering) 5. Steering Gearbox [LHD 7) Remove one pipe joint at the center of gearbox, and connect vinyl hose to pipe and joint. Discharge Model] S601272 fluid by turning steering wheel fully clockwise and counterclockwise.
  • Page 35 STEERING GEARBOX [LHD MODEL] Power Assisted System (Power Steering) 4) Connect tie-rod end and knuckle arm, and tighten with castle nut. Fit cotter pin into the nut and bend the pin to lock. Castle nut tightening torque: Tighten to 27.0 N·m (2.75 kgf-m, 19.9 ft-lb), and tighten further within 60°...
  • Page 36 STEERING GEARBOX [LHD MODEL] Power Assisted System (Power Steering) 15) After adjusting toe-in and steering angle, 4) Remove small clip from boot using pliers, and tighten lock nut on tie-rod end. move boot to tie-rod end side. Tightening torque: 83 N·m (8.5 kgf-m, 61.5 ft-lb) CAUTION: When adjusting toe-in, hold boot as shown to prevent it from being rotated or twisted.
  • Page 37 STEERING GEARBOX [LHD MODEL] Power Assisted System (Power Steering) 7) Using ST, loosen lock nut. 11) Remove two bolts securing valve assembly. ST 926230000 SPANNER S4M0154 S4M0147B 12) Carefully draw out input shaft and remove valve assembly. Lock nut 8) Tighten adjusting screw until it no longer tight- ens.
  • Page 38 STEERING GEARBOX [LHD MODEL] Power Assisted System (Power Steering) 14) Pull rack assembly from cylinder side, and NOTE: draw out rack bushing and rack stopper together Discard removed oil seal. with rack assembly. 2. CONTROL VALVE ASSEMBLY S601272A0602 CAUTION: NOTE: Be careful not to contact rack to inner wall of Parts requiring replacement are described in the cylinder when drawing out.
  • Page 39 STEERING GEARBOX [LHD MODEL] Power Assisted System (Power Steering) 3) Remove two bolts securing valve assembly. 6) Using a press remove pinion and valve assem- bly from valve housing. S4M0154 S4M0157B 4) Carefully draw out input shaft and remove valve assembly.
  • Page 40 1. RACK HOUSING ASSEMBLY S601272A0201 ¼ Do not reuse removed snap ring. CAUTION: ¼ Be careful not to scratch pinion and valve Use only SUBARU genuine grease for gearbox. assembly. Grease: VALIANT GREASE M2 [Part No. 003608001, net 0.5 kg (1.1 lb)] 1) Clean all parts and tools before reassembling.
  • Page 41 STEERING GEARBOX [LHD MODEL] Power Assisted System (Power Steering) ¼ Pay special attention not to install oil seal in 8) Fit ST over toothed portion of rack assembly, wrong direction. and check for binding or unsmooth insertion. If any ¼ Push oil seal until the stepped portion of A con- deformation is noted on flats at the end of rack, tacts end face of B.
  • Page 42 STEERING GEARBOX [LHD MODEL] Power Assisted System (Power Steering) 11) Fit ST1 and ST2 over the end of rack, and 15) Apply genuine grease to pinion gear and bear- install rack bushing. ing of valve assembly. ST1 926400000 GUIDE ST2 927660000 GUIDE CAUTION: ¼...
  • Page 43 STEERING GEARBOX [LHD MODEL] Power Assisted System (Power Steering) Tightening torque: (4) Tighten adjusting screw by two threads. 78 N·m (8.0 kgf-m, 58 ft-lb) G4M0121 S4M0150B (5) Apply liquid packing to at least 1/3 of entire perimeter of adjusting screw thread. Tie-rod Liquid packing: 19) Bend lock washer using a chisel.
  • Page 44 STEERING GEARBOX [LHD MODEL] Power Assisted System (Power Steering) 22) Install boot to housing. 24) Fix boot end with clip (small). NOTE: CAUTION: ¼ Before installing boot, be sure to apply grease to After installing, check boot end is positioned the groove of tie-rod.
  • Page 45 STEERING GEARBOX [LHD MODEL] Power Assisted System (Power Steering) 26) Inspect gearbox as follows: ST1 34099FA120 SEAL INSTALLER & “A” Holding tie-rod end, repeat lock to lock two or REMOVER three times as quickly as possible. ST2 34099FA130 SEAL INSTALLER “B”...
  • Page 46 STEERING GEARBOX [LHD MODEL] Power Assisted System (Power Steering) 5) Put vinyl tape around pinion shaft splines to 10) Force-fit ball bearing using ST3. protect oil seal from damage. ST1 926370000 INSTALLER A 6) Fit pinion and valve assembly into valve hous- ST2 34099FA100 STAND BASE ing.
  • Page 47 STEERING GEARBOX [LHD MODEL] Power Assisted System (Power Steering) 15) Install gasket on valve assembly. Insert valve 20) Rack and pinion backlash adjustment assembly into place while facing rack teeth toward (1) Loosen adjusting screw. pinion. (2) Rotate input shaft so that rack is in the straight ahead direction.
  • Page 48 STEERING GEARBOX [LHD MODEL] Power Assisted System (Power Steering) (7) Install lock nut. While holding adjusting screw with a wrench, tighten lock nut using ST. ST 926230000 SPANNER Tightening torque (Lock nut): 39 N·m (4.0 kgf-m, 29 ft-lb) NOTE: ¼ Hold adjusting screw with a wrench to prevent it from turning while tightening lock nut.
  • Page 49 STEERING GEARBOX [LHD MODEL] Power Assisted System (Power Steering) E: INSPECTION S601272A10 1. BASIC INSPECTION S601272A1001 1) Clean all disassembled parts, and check for wear, damage, or any other faults, then repair or replace as necessary. 2) When disassembling, check inside of gearbox for water. If any water is found, carefully check boot for damage, input shaft dust seal, adjusting screw and boot clips for poor sealing.
  • Page 50 STEERING GEARBOX [LHD MODEL] Power Assisted System (Power Steering) 2. SERVICE LIMIT 3. RACK SHAFT PLAY IN RADIAL S601272A1002 DIRECTION Make a measurement as follows. If it exceeds the S601272A1003 specified service limit, adjust or replace. Right-turn steering: NOTE: Service limit When making a measurement, vise gearbox by 0.19 mm (0.0075 in) or less using ST.
  • Page 51 STEERING GEARBOX [LHD MODEL] Power Assisted System (Power Steering) 4. INPUT SHAFT PLAY 5. TURNING RESISTANCE OF GEARBOX S601272A1004 S601272A1005 In radial direction: Using ST, measure gearbox turning resistance. Service limit ST 926230000 SPANNER 0.18 mm (0.0071 in) or less Service limit: On condition Straight-ahead position within 30 mm (1.18...
  • Page 52 STEERING GEARBOX [LHD MODEL] Power Assisted System (Power Steering) 6. OIL LEAKING S601272A1006 S4M0153A (1) Power cylinder (3) Rack piston (5) Input shaft (2) Cylinder (4) Rack axle (6) Valve housing NOTE: (1) Inspect leakage from “e”. If gearbox is dismounted without confirming where The cylinder seal is damaged.
  • Page 53 STEERING GEARBOX [LHD MODEL] Power Assisted System (Power Steering) F: ADJUSTMENT S601272A01 1) Adjust front toe. Standard of front toe: IN 3 — OUT 3 mm (IN 0.12 — OUT 0.12 G4M0133 2) Adjust steering angle of wheels. Standard of steering angle: Inner wheel: 37.4°±1.5°...

  • Page 54: Steering Gearbox [Rhd Model]

    STEERING GEARBOX [RHD MODEL] Power Assisted System (Power Steering) 6. Steering Gearbox [RHD 7) Disconnect one pipe joint A from center of gear- box assembly, and connect a vinyl hose to it. While Model] turning steering wheel to the left and right, drain S601276 fluid through the hose.
  • Page 55 STEERING GEARBOX [RHD MODEL] Power Assisted System (Power Steering) 11) Check for fluid leaks. <Ref. to PS-76, OIL B: INSTALLATION S601276A11 LEAKING, INSPECTION, Steering Gearbox [RHD 1) Insert gearbox into crossmember, being careful Model].> not to damage gearbox boot. 12) Install jack-up plate. 2) Tighten gearbox to crossmember bracket via WARNING: clamp with bolt to the specified torque.
  • Page 56 STEERING GEARBOX [RHD MODEL] Power Assisted System (Power Steering) 2) Secure gearbox removed from vehicle in vise 5) Extend rack approximately 40 mm (1.57 in) out. using ST. Unlock lock wire at lock washer on each side of ST 926200000 STAND tie-rod end using a standard screwdriver.
  • Page 57 STEERING GEARBOX [RHD MODEL] Power Assisted System (Power Steering) 7) Tighten adjusting screw until it no longer tight- 10) Disconnect pipes A and B from steering body ens. and control valve housing. CAUTION: Replace pipes and/or flare nuts if damaged. S4M0392A Adjusting screw S4M0394A...
  • Page 58 STEERING GEARBOX [RHD MODEL] Power Assisted System (Power Steering) 13) Remove valve housing, pinion and valve as a 15) Install ST on valve side of rack and press unit. outer side oil seal out. 34099FA030 INSTALLER & REMOVER CAUTION: ¼ Block pipe connection of steering body to prevent fluid from flowing out.
  • Page 59 STEERING GEARBOX [RHD MODEL] Power Assisted System (Power Steering) 16) Insert ST from valve side and press back-up 17) Using ST1 and ST2, repair cylinder’s clinched ring and oil seal out. sections. ST1 34099FA080 PUNCH CAUTION: ST2 34099FA070 BASE Discard back-up ring and oil seal after removal and replace with new ones.
  • Page 60 STEERING GEARBOX [RHD MODEL] Power Assisted System (Power Steering) 4) Using ST, remove lock wire from inner end of boot, and remove boot. ST 927590000 WRENCH S4M0423A Sharp-edged, long rod Seal ring O-ring S4M0390A Wire 2. CONTROL VALVE ASSEMBLY S601276A0602 1) Disconnect four pipes from gearbox.
  • Page 61 STEERING GEARBOX [RHD MODEL] Power Assisted System (Power Steering) 8) Slide dust cover out. 11) After removing dust cover, extract pinion and valve from valve housing. CAUTION: ¼ Be careful not to scratch housing or input CAUTION: ¼ If pinion and valve is difficult to remove, use shaft during dust cover removal.
  • Page 62 D: ASSEMBLY S601276A02 pinion and valve, and remove valve sleeve. CAUTION: CAUTION: Use only SUBARU genuine grease for gearbox. Be careful not to scratch pinion and valve when Specified grease for gearbox: removing snap ring. VALIANT GREASE M2 (Part No.
  • Page 63 STEERING GEARBOX [RHD MODEL] Power Assisted System (Power Steering) 5) Apply a coat of grease to inner surface of ST 7) Using ST·B and ST·C, attach oil seal to ST·A. and insert rack piston into it. Leave ST at least 10 Insert ST·A into rack from gear side.
  • Page 64 STEERING GEARBOX [RHD MODEL] Power Assisted System (Power Steering) 9) Install ST on rack and equally apply a thin coat 11) Slowly press inner side oil seal until distance of grease to rack and ST, then install oil seal. between ST and end of rack is 65 mm (2.56 in). ST 926250000 GUIDE ST 34099FA010 GUIDE (Oil seal) CAUTION:...
  • Page 65 STEERING GEARBOX [RHD MODEL] Power Assisted System (Power Steering) 13) Install holder from cylinder side of steering 15) Using ST, clinch steering body cylinder at a body. point less than 3 mm (0.12 in) from holder. Tightening torque: CAUTION: 64 N·m (6.5 kgf-m, 47.0 ft-lb) Be careful not to deform holder.
  • Page 66 STEERING GEARBOX [RHD MODEL] Power Assisted System (Power Steering) with two bolts to 25 N·m (2.5 kgf-m, 18.1 ft-lb). 23) Apply a coat of grease to sliding surface of Then, measure clearance between steering body seat pad, sleeve and seating surface of spring, and and valve housing using a thickness gauge.
  • Page 67 STEERING GEARBOX [RHD MODEL] Power Assisted System (Power Steering) 25) Using a chisel and hammer, bend lock wash- (5) Tighten adjusting plug to 5 N·m (0.5 kgf-m, ers (at two places). 3.6 ft-lb) and loosen, then tighten to 5 N·m (0.5 kgf-m, 3.6 ft-lb) and loosen, and finally tighten to CAUTION: 5 N·m (0.5 kgf-m, 3.6 ft-lb) and loosen 30°.
  • Page 68 STEERING GEARBOX [RHD MODEL] Power Assisted System (Power Steering) 28) Attach lock wire to boot large end, and twist it 31) Install pipes A and B. while pulling it upward (with a force of approxi- Tightening torque: mately 39 N (4 kgf, 9 lb). Valve housing side ST 927590000 WRENCH 20 N·m (2.0 kgf-m, 14.5 ft-lb)
  • Page 69 STEERING GEARBOX [RHD MODEL] Power Assisted System (Power Steering) 4) Install ST to input shaft, and apply a coat of 9) Apply a coat of grease to the inner wall of the grease to the cover surface. Install O-ring and seal ST.
  • Page 70 STEERING GEARBOX [RHD MODEL] Power Assisted System (Power Steering) 11) Apply a coat of grease to inner wall of valve 13) Attach ST2 to ST1, and press ball bearing into housing, oil seal and outer perimeter of dust seal. place using a press. NOTE: ¼...
  • Page 71 STEERING GEARBOX [RHD MODEL] Power Assisted System (Power Steering) 16) While supporting pinion and valve, push end 20) Position a shim in graded portion of steering of pinion until bearing contacts brazed end of valve body pinion housing, and apply an even coat of housing.
  • Page 72 STEERING GEARBOX [RHD MODEL] Power Assisted System (Power Steering) ¼ Also turn plug to ensure that its entire contact 25) Alternately and slowly tighten socket bolts. area is coated with liquid packing. NOTE: Replace faulty parts before installing valve. (5) Tighten adjusting plug to 5 N·m (0.5 kgf-m, Otherwise, valve may not be installed properly.
  • Page 73 STEERING GEARBOX [RHD MODEL] Power Assisted System (Power Steering) 29) Attach lock wire to boot large end, and twist it while pulling it upward (with a force of approxi- mately 39 N (4 kgf, 9 lb). ST 927590000 WRENCH CAUTION: Ensure that lock wire is not loose.
  • Page 74 STEERING GEARBOX [RHD MODEL] Power Assisted System (Power Steering) E: INSPECTION S601276A10 1. BASIC INSPECTION S601276A1001 1) Clean all disassembled parts, and check for wear, damage, or any other faults, then repair or replace as necessary. 2) When disassembling, check inside of gearbox for water. If any water is found, carefully check boot for damage, input shaft dust seal, adjusting screw and boot clips for poor sealing.
  • Page 75 STEERING GEARBOX [RHD MODEL] Power Assisted System (Power Steering) 2. SERVICE LIMIT 3. RACK SHAFT PLAY IN RADIAL S601276A1002 DIRECTION Make a measurement as follows. If it exceeds the S601276A1003 specified service limit, adjust or replace. Right-turn steering: NOTE: Service limit When making a measurement, vise gearbox by Less than 0.4 mm (0.016 in) using ST.
  • Page 76 STEERING GEARBOX [RHD MODEL] Power Assisted System (Power Steering) 4. INPUT SHAFT PLAY 5. TURNING RESISTANCE OF GEARBOX S601276A1004 S601276A1005 In radial direction: Using ST, measure gearbox turning resistance. Service limit ST 926230000 SPANNER 0.18 mm (0.0071 in) or less Service limit: On condition Straight-ahead position within 30 mm (1.18...
  • Page 77 STEERING GEARBOX [RHD MODEL] Power Assisted System (Power Steering) 6. OIL LEAKING S601276A1006 S4M0408A (1) Power cylinder (4) Rack shaft (7) From pump (2) Cylinder (5) Gearbox (8) To tank (3) Rack piston (6) Pinion shaft NOTE: 6) If leak is other than a, b, c, or d, and if oil is If gearbox is dismounted without confirming where leaking from the gearbox, move the right and left the leak is, it must be mounted again to locate the...
  • Page 78 STEERING GEARBOX [RHD MODEL] Power Assisted System (Power Steering) CAUTION: 4) If steering wheel spokes are not horizontal with ¼ If leakage from “f” is noted again: vehicle set in the straight ahead position after this adjustment, correct it by turning the right and left The oil seal of pinion and valve assembly is tie-rods in the same direction by the same amount.

  • Page 79: Pipe Assembly

    PIPE ASSEMBLY Power Assisted System (Power Steering) 7. Pipe Assembly RHD model S601277 A: REMOVAL S601277A18 1. NON-TURBO MODEL S601277A1803 1) Set the vehicle on the lift. 2) Disconnect battery minus terminal. 3) Lift vehicle and remove jack-up plate. B4M0671F Pipe A Pipe B 5) Remove clamp E from pipes.
  • Page 80 PIPE ASSEMBLY Power Assisted System (Power Steering) RHD model S4M0235B Steering gearbox 7) Lower the vehicle. 8) Remove intake duct and cleaner case. <Ref. IN(SOHC)-8, INSTALLATION, Air Intake Duct.> and <Ref. IN(SOHC)-7, Air Cleaner Case.> 9) Remove bolt A. 10) Disconnect pipe C from oil pump. Disconnect pipe D from return hose.
  • Page 81 PIPE ASSEMBLY Power Assisted System (Power Steering) 3) Lift vehicle and remove jack-up plate. RHD model B4M0671F S4M0380A Pipe A Jack-up plate Pipe B 4) Remove one pipe joint at the center of gearbox, 5) Remove clamp E from pipes. and connect vinyl hose to pipe and joint.
  • Page 82 PIPE ASSEMBLY Power Assisted System (Power Steering) RHD model (2) RHD model Using ST, remove flare nuts from control valve of gearbox assembly, and then disconnect pipe. ST 34099AC050 GEARBOX SPANNER CAUTION: ¼ When disconnecting pipes, wrenches to prevent deformities. ¼...
  • Page 83 PIPE ASSEMBLY Power Assisted System (Power Steering) (4) Disconnect pipe C from oil pump. Discon- B: INSTALLATION S601277A11 nect pipe D from return hose. 1. NON-TURBO MODEL S601277A1103 CAUTION: 1) Tighten bolt A. ¼ Do not allow fluid from the hose end to come into contact with pulley belt.
  • Page 84 PIPE ASSEMBLY Power Assisted System (Power Steering) 2) Temporarily connect pipes C and D. (LHD 4) Temporarily install clamp E on pipes C and D, model) and tighten clamp E firmly. CAUTION: Ensure that the letter “8” on each clamp are diagonally opposite each other as shown in fig- ure.
  • Page 85 PIPE ASSEMBLY Power Assisted System (Power Steering) (2) RHD model 7) Install jack-up plate. Connect pipes A and B to four pipe joints of gear- 8) Connect battery ground terminal. box. Connect upper pipe A first, and lower pipe B 9) Feed the specified fluid.
  • Page 86 PIPE ASSEMBLY Power Assisted System (Power Steering) RHD model B4M1205B Clearance between blow-by hose and pipe: 3 — 5 mm (0.12 — 0.20 in) No interference is allowed between hoses Clearance between side frame and hose: 15 mm (0.59 in) or more Clearance between crossmember and pipe: 5 —...
  • Page 87 PIPE ASSEMBLY Power Assisted System (Power Steering) 2. TURBO MODEL 2) Install coolant filler tank. (Turbo model) S601277A1104 Tightening torque: 1) Tighten bolt A. T1: 19 N·m (1.9 kgf-m, 13.7 ft-lb) CAUTION: T2: 21 N·m (2.1 kgf-m, 15.2 ft-lb) Visually check that hose between tank and pipe D is free from bending or twisting.
  • Page 88 PIPE ASSEMBLY Power Assisted System (Power Steering) 3) Temporarily connect pipes C and D. (LHD 5) Temporarily install clamp E on pipes C and D, model) and tighten clamp E firmly. CAUTION: Ensure that the letter “8” on each clamp are diagonally opposite each other as shown in fig- ure.
  • Page 89 PIPE ASSEMBLY Power Assisted System (Power Steering) (2) RHD model 8) Install jack-up plate. Connect pipes A and B to four pipe joints of gear- 9) Connect battery ground terminal. box. Connect upper pipe A first, and lower pipe B 10) Feed the specified fluid.
  • Page 90 PIPE ASSEMBLY Power Assisted System (Power Steering) RHD model B4M1205B Clearance between blow-by hose and pipe: 3 — 5 mm (0.12 — 0.20 in) No interference is allowed between hoses Clearance between side frame and hose: 15 mm (0.59 in) or more Clearance between crossmember and pipe: 5 —...
  • Page 91 PIPE ASSEMBLY Power Assisted System (Power Steering) C: INSPECTION S601277A10 Check all disassembled parts for wear, damage or other abnormalities. Repair or replace faulty parts as required. Part name Inspection Remedy ¼ O-ring fitting surface for damage Replace with Pipe ¼...
  • Page 92 PIPE ASSEMBLY Power Assisted System (Power Steering) CAUTION: It is likely that although one judges fluid leakage, there is actually no leakage. This is because the fluid spilt during the last maintenance was not completely wiped off. Be sure to wipe off spilt fluid thoroughly after maintenance.
  • Page 93 PIPE ASSEMBLY Power Assisted System (Power Steering) Turbo model S4M0565B Fluid leaking area Possible cause Corrective action Insufficient tightening of flare nut, catching Loosen and retighten, if ineffective, dirt or the like, damage to flare or flare nut replace. or eye bolt Leakage from connecting portions of pipes and hoses, numbered with (1) Poor insertion of hose, poor clamping...

  • Page 94: Oil Pump

    OIL PUMP Power Assisted System (Power Steering) 8. Oil Pump 8) Remove three bolts from the front side of oil S601070 pump and detach the pump. A: REMOVAL S601070A18 1. NON-TURBO MODEL S601070A1804 1) Remove ground cable from battery. 2) Drain the working fluid about 0.3 (0.3 US qt, 0.3 Imp qt) from oil tank.
  • Page 95 OIL PUMP Power Assisted System (Power Steering) 2. TURBO MODEL S601070A1805 1) Remove ground terminal from battery. 2) Remove intake duct. <Ref. to IN(DOHC TURBO)-8, REMOVAL, Air Intake Duct.> 3) Remove pulley belt cover. 4) Loosen lock bolt and slider bolt and remove power steering pump drive V-belt.
  • Page 96 OIL PUMP Power Assisted System (Power Steering) B: INSTALLATION S601070A11 1. NON-TURBO MODEL S601070A1104 1) Install bracket on engine. Tightening torque: 22 N·m (2.2 kgf-m, 15.9 ft-lb) 2) Install oil pump on oil tank as follows outside the vehicle: NOTE: H4M1078B Prior to installation, make sure that all oil is removed from oil pump, oil tank and pipe.
  • Page 97 OIL PUMP Power Assisted System (Power Steering) 2) Tighten bolt which install power steering pump bracket. Tightening torque: 22 N·m (2.2 kgf-m, 15.9 ft-lb) B4M1670B Bush 21 mm 14 mm B2M3151 Bolt 3) Interconnect pipes C and suction hose. (2) Tighten bolt which installs oil pump to Tightening torque: bracket.

  • Page 98: Basic Inspection

    OIL PUMP Power Assisted System (Power Steering) C: INSPECTION S601070A10 1. BASIC INSPECTION S601070A1002 ¼ In accordance with the following table, check all removed parts for wear and damage, and make repair or replacement if necessary. Parts Inspection Corrective action (1) Crack, damage or oil leakage Replace oil pump with a new one.
  • Page 99 OIL PUMP Power Assisted System (Power Steering) 2. SERVICE LIMIT NOTE: S601070A1001 Read the value for one surface of V ditch, and then Make a measurement as follows. If it exceeds the the value for another off the dial. specified service limit, replace the parts with new ones.
  • Page 100 OIL PUMP Power Assisted System (Power Steering) NOTE: Service limit: Non-turbo model: Keep engine idling during the measurement. 7,159 — 7,748 kPa (73 — 79 kg/cm , 1,038 1) MEASURE REGULAR PRESSURE. — 1,123 psi) (1) Remove two bolts securing power steering Turbo model: pipes to engine.

  • Page 101: Reservoir Tank

    RESERVOIR TANK Power Assisted System (Power Steering) 9. Reservoir Tank 2. TURBO MODEL S601075A1105 S601075 1) Install reservoir tank to bracket. A: REMOVAL S601075A18 2) Connect return hose and suction hose to reser- voir tank. 1. NON-TURBO MODEL S601075A1804 Refer to “Oil Pump” section for details of reservoir tank removal order.

  • Page 102: Power Steering Fluid

    POWER STEERING FLUID Power Assisted System (Power Steering) 10. Power Steering Fluid C: REMOVAL S601275A18 S601275 1) Set the vehicle on the lift. A: SPECIFICATION S601275A22 2) Disconnect battery minus terminal. 3) Remove air intake duct. Recommended power steering fluid Manufacturer 4) Drain fluid from the reservoir tank.
  • Page 103 POWER STEERING FLUID Power Assisted System (Power Steering) RHD model 8) Stop the engine, and take out safety stands after jacking up vehicle again. Then lower the vehicle, and idle the engine. 9) Continue to turn steering wheel from lock to lock until bubbles stop appearing and change of the fluid level is within 3 mm (0.12 in).

  • Page 104: General Diagnostic Table

    GENERAL DIAGNOSTIC TABLE Power Assisted System (Power Steering) 11. General Diagnostic Table S601257 A: INSPECTION S601257A10 Trouble Possible cause Corrective action 1. Pulley belt ¼ Unequal length of pulley belts ¼ Adhesion of oil and grease ¼ Loose or damage of pulley belt Adjust or replace.
  • Page 105 GENERAL DIAGNOSTIC TABLE Power Assisted System (Power Steering) 1. NOISE AND VIBRATION S601257A1001 CAUTION: Don’t keep the relief valve operated over 5 sec- onds at any time or inner parts of the oil pump may be damaged due to rapid increase of fluid temperature.
  • Page 106 GENERAL DIAGNOSTIC TABLE Power Assisted System (Power Steering) Trouble Possible cause Corrective action Relief valve emits operating sound when steering wheel is completely turned in either direction. (Don’t keep this Normal Hiss noise (continuous) condition over 5 seconds.) While engine is running. Relief valve emits operating sound when steering wheel Defective is not turned.
  • Page 107 GENERAL DIAGNOSTIC TABLE Power Assisted System (Power Steering) 2. MEASUREMENT OF STEERING EFFORT S601257A1002 Step Check CHECK STEERING EFFORT. Is the steering effort 29.4 N Go to step 2. Adjustment back- 1) Stop the vehicle on a concrete road. (3.0 kgf, 6.6 lb) or less? lash.

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