Power steering--Power steering gear assembly

29. Assemble steering No.2 dust-proof cover.

(a) Insure steering gear hole is not plugged by lubricating

grease.

Hint: if hole is plugged, the pressure in dust-proof

cover when steering wheel turns after combin-

ing will change.

(b) Assemble dust-proof cover, fixed clamp and new iron wire.

Note: do no t hurt or bend dust-proof cover.

(c) After coiling dust-proof cover with iron wire for two circles,

turn it for several circles to fix it.

(d) Liking that shown in figure, bend iron wire to rotating di-

rection to prevent it from hurting dust-proof cover.

Hint: assemble the other side with same method.

30. Assemble No.1 dust-proof cover of steering gear.

31. Assemble left ball head of transversal lever  .

(a) Screw locking cap and transversal lever ball head in gear

terminal lever until aligning the mark.

(b) After adjusting front wiring harness, tighten the screw cap

(referring to page 80).

Torque: 74 ± 5 N

x

m

Hint: assemble the other side with same method.

32. Assemble right ball head of transversal lever  .

33. Assemble power steering gear assembly [64000133].

(a) Assemble power steering gear assembly on beam with

four bolts.

Torque: 58 N

x

m

 209 

Align  the mark

Power steering--Power steering gear assembly

34. Assemble steering middle shaft.

(a) Align the mark of steering middle shaft and steering small

gear shaft.

(b) Assemble the bolt.

Torque: 35 N

xxxxx

m

35. Assemble exterior dustproof cover of steering

column.

36. Assemble auxiliary bracket assembly (64000087).

(a) Use special tool to align the right side of auxiliary bracket

with the hole of body, then lock the A bolt and B bolt

temporarily.

(b) Use special tool to align the left side of auxiliary bracket

with the hole of body, then lock the A bolt and B bolt

temporarily.

(c) Use special tool to align the left side of auxiliary bracket

with the hole of body, then lock the A bolt and B bolt.

Torque:

A bolt: 157 ± 10 N

xxxxx

m

B bolt: 113 ± 10 N

xxxxx

m

(d) Use special tool to align the right side of auxiliary bracket

with the hole of body, then lock the A bolt and B bolt.

Torque:

A bolt: 157 ± 10 N

xxxxx

m

B bolt: 113 ± 10 N

xxxxx

m

(e) After connecting with engine with one bolt and three screw

caps, hang it to auxiliary bracket.

Torque: 52 N.m ± 5 N

xxxxx

m

(f) Assemble carling to body with two bolts.

Torque: 39 ± 3 N

xxxxx

m

(g) Assemble the front suspension of engine to carling with

two screw caps.

Torque: 52 ± 5 N

xxxxx

m

Align  the mark

Special
tool

Special tool

 210 

Power steering--Power steering gear assembly

37. Connect the bolts and nuts of left/right control arm

and control arm ball head.

Torque: 142 ± 10 N

xxxxx

m

Hint: connect the other side with same method.

Connect left lower control arm to steering knuckle with

bolt and two nuts.

38. Connect linking lever assembly of left/right front

stabilizer bar [64000097].

Use socket head wrench (5mm) to fix bolt, then connect sta-

bilizer linking lever with screw cap.

Torque: 74 ± 5 N

xxxxx

m

Hint: connect the other side with same method.

39. Connect the in-out oil pipe assembly of power steer-

ing gear [64000131].

(a) Connect the in-out oil pipe fixed clamp of power steering

gear with bolt.

Torque: 7.8 N

xxxxx

m

(b) Use special tool to connect the in-out oil pipe assembly of

power steering gear.

Torque: 41 N

xxxxx

m

Hint:

z

Use the torque wrench whose lever length is

345mm.

z

Special tool should be parallel with torque wrench,

only this could make practical torque value.

Hint: connect the other side with same method.

40. Connect the ball head at the left side of  transversal

lever.

(a) Connect the ball head at the left side of transversal lever

with screw cap.

Torque: 49 ± 5 N

xxxxx

m

(b) Assemble new cotter pin.

Note: if cotter pin hole could not be aligned , tighten

the screw cap for 60 again.

Hint: connect the other side with same method.

 211 

Length of lever

Power steering--Power steering gear assembly

41. Connect the ball head at the right side of transver

sal lever .

42. Assemble right bottom defending board of engine

[68000004].

43. Assemble left bottom defending board of engine

[68000003].

44. Assemble front wheel

Torque: 103 ± 10 N

xxxxx

m

45. Connect steering slide shaft assembly.

(a) Align the mark between steering middle shaft and sliding

shaft.

(b) Assemble B bolt.

Torque: 35 ± 3 N

xxxxx

m

(c) Tighten the A bolt.

Torque: 35 ± 3 N

xxxxx

m

46. Assemble inner dustproof cover of steering column [64000123].

Assemble inner dustproof cover of steering column with two screw caps.

47. Make front wheel face the front

Hint: lift up front wheel shaft.

48. Assemble helix cable assembly (equipping with SRS).

49. Assemble steering wheel assembly [67010001].

(a) Align the mark between steering wheel and main shaft of steering column.

(b) Lock the fixed screw cap of steering wheel temporarily.

50. Add power steering oil (referring to page 200).

51. Exhaust the air in power steering system (referring to page 200).

52. Check the central point of steering wheel.

(a) Check the central point of steering wheel.

(b) Lock the fixed screw cap of steering wheel.

Torque: 50 ± N

xxxxx

m

53. Assemble safety airbag assembly at the side of driver (equipping with SRS) [67010011].

54. Check whether there is oil leakage.

55. Check the engine cover assembly.

56. Adjust the engine cover assembly.

57. Check and adjust the front wheel alignment (referring to page 87).

 212