Steering Gearbox Installation
|1.||Center the steering rack within its stroke.|
|2.||Install the pinion shaft grommet (A) aligning the projection (B) with the cutout in the top of the torque sensor.|
Turn out the lip (C) of the grommet to facilitate installation. Return the lip of the grommet after the operation of step 5.
|3.||Install the steering gearbox (A) on the front suspension subframe (B) with the stiffeners (C) and bracket (D).|
NOTE: For equipped models, install the steering gearbox mounting bracket (E) with the stiffener and the washer (F) before installing the steering gearbox if it removed.
|4.||Set the front suspension subframe (A) mounted with the steering gearbox on the transmission jack and support it.|
|5.||Carefully raise the front suspension subframe with the jack, and pass the pinion shaft into the cabin.|
|6.||Install the front suspension subframe with new 14 mm flange bolts, and tighten to the specified torque.|
|7.||Connect the transmission rear mount bracket (A) and rear mount (B) on the front suspension subframe with the support bolt.|
|8.||Connect the motor 2P connector (A), EPS wire harness 6P connector (B) and steering gearbox 1P connector (C).|
NOTE: Insert the connectors securely until the connector tabs lock (click). Loose connection or leaving the connectors not connected will cause poor assist performance.
|9.||Install the heated oxygen sensor (HO2S) cord clip (A) on the gearbox housing.|
|10.||Connect the stabilizer links (A) to the stabilizer bar (B). Tighten the new self-locking nuts while holding the joint pin (C) with a hex wrench (D).|
NOTE: Tighten all mounting hardware to the specified torque values.
|11.||Wipe off any grease contamination from the ball joint tapered section and threads. Then reconnect the tie-rod end (A) to the knuckle arms. Install the 10 mm nut (B) and tighten it.|
|12.||Install a new cotter pin (C), and bend it as shown (D) or (E).|
|13.||Wipe off any grease contamination from the lower arm ball joint tapered section and threads.|
Then reconnect the lower arm (A) to the knuckle. Install the 12 mm castle nut (B) and tighten it.
|14.||Install the new lock pin (D).|
NOTE: Insert the lock pin from the inside to the outside of the vehicle.
|15.||Install the front splash shield (A), and rear left and right splash shields (B).|
|16.||Move the steering column to the uppermost position, and pull up the tilt lever firmly.|
|17.||Install the steering joint (A), and reconnect the steering shaft (B) and pinion shaft (C). Make sure the steering joint is connected as follows:|
|18.||Install the steering joint cover.|
|19.||Center the cable reel by first rotating it clockwise until it stops. Then rotate it counterclockwise (about two turns) until the arrow mark on the label points straight up. Install the steering wheel.|
|20.||Install the front wheels.|
|21.||Holding the tyres raised off the ground (lifted up), check for the following symptoms by turning the steering wheel fully to the right and left several times.|
|22.||Lower the vehicle on the ground, and connect the negative cable to the battery.|
|23.||Check and adjust the front wheel alignment.|
|24.||Start the engine, and let it idle, and perform the following checks.|