Nissan PULSAR N13 Series / ASTRA LD Series. Instruction — part 37

Steering — Part 2

149

Dismantled view of the steering column and tilt bracket assembly.

(b) Using a suitable drill, carefully remove the

heads of the steering lock bracket shear type retaining
bolt heads. Remove the steering lock bracket from the
column.

(c) Install the steering lock to the column

using
new shear bolts. Ensure that the steering lock is
operating correctly and tighten the shear bolts until
the heads snap off.

(d) Install the ignition switch and tighten

the
retaining screw securely.

TO CHECK AND INSPECT

(1) Thoroughly clean and dry the components

using a suitable solvent.

(2) Inspect the steering shaft for bends, damage

and wear. Pay particular attention to the steering shaft
universal coupling joint and the internal and external
splines. Renew as necessary.

(3) Inspect the steering column upper bearing

for ease of operation and if necessary, renew the
column assembly.

TO ASSEMBLE

Assembly is a reversal of the dismantling proce-

dure with attention to the following points:

(1) Install the steering shaft to the column.

Ensure that the steering shaft is correctly located in
the upper bearing and install the wave washer and the
plain washer. Install the snap ring using a ring
spanner
which has minimum clearance over the steering shaft.

(2) Install the rubber boot and floor bracket

to
the steering column aligning the marks made during
removal. If no marks were made, align the cutouts of
the rubber boots with the protrusions on the steering
column and the floor bracket.

(3) Before installing the tilt bracket assembly to

the column, measure the steering column length as
shown on the illustration.

If the length is not as specified, the steering

column and the steering shaft must be renewed as an
assembly.

(4) Install the tilt bracket, lever, through bolt,

washers and adjusting nut to the t i l t bracket.

(5) Before installing the column assembly to the

vehicle adjust the column tilt lever as follows:

(a) Position the tilt lever in its locked position,

the end of the lever should contact the flanged portion
of the tilt bracket.

(b) Tighten the adjusting bolt to 11 Nm.
(c) Unlock the tilt lever fully and ensure that the

column moves smoothly up and down the tilt bracket.

(d) Return the t i l t lever to the locked position

and ensure that the column is locked securely. Adjust
the tilt bracket through bolt if necessary.

(6) Install the universal coupling joint to the

lower steering shaft and tighten the pinch bolt se-
curely.

(7) Install the steering column assembly to

the
vehicle as previously described.

4. STEERING GEAR ASSEMBLY

Special Equipment Required:

To Renew Tie Rod Ball Housings — Large Still-
sons.

TO REMOVE AND INSTAL

(1) Working in the engine compartment and

with the wheels in the straight ahead position, suitably

150

Steering — Part 2

View of the steering gear and associated components removed from the vehicle.

mark the universal coupling joint in relation to the
steering gear pinion as an aid to installation.

(2) Remove the bolt retaining the universal

coupling joint to the steering gear pinion.

(3) Raise the front of the vehicle, support it on

chassis stands at the jacking points and remove the
front wheels. Refer to the Wheel and Tires section.

(4) Remove the split pins and castellated nuts

from the tie rod end studs and disconnect the tie rod
ends from the steering arms.

NOTE: Disconnect each tie rod end by
placing a suitable dolly or hammer against
one side of the steering arm eye and striking
the opposite side with a hammer.

(5) Remove the bolts from the steering gear

mounting brackets.

(6) Separate the steering gear pinion from the

universal coupling joint and maneuver the steering
gear from the vehicle.

Installation is a reversal of the removal procedure

with attention to the following points:

(1) Ensure that the steering gear mounting

bracket rubbers are in good condition. Renew if
necessary.

(2) Renew the split pins on the tie rod castel-

lated nuts.

(3) Check and if necessary adjust the front wheel

toe in. Refer to the Front Suspension section for the
correct procedure.

TO OVERHAUL

To overhaul the steering gear a range of special

tools is required. If the steering gear has a fault
which requires the removal of the rack or pinion it
is recommended that the necessary repairs be car-
ried out by an authorized dealer.

TO RENEW TIE ROD BALL HOUSINGS

(1) Remove the steering gear from the vehicle as

previously described.

(2) Note or mark the installed position of the

mounting rubbers as an aid to assembly and remove
the rubbers from the steering gear.

(3) Thoroughly clean the exterior of the steering

gear in a suitable cleaning solvent.

(4) Secure the steering gear in a soft jawed vice

and centralize the rack in the steering gear.

(5) Loosen both the tie rod end locknuts and

unscrew the tie rod ends from the tie rods, noting the
number of turns required to do so. Remove the
locknuts from the tie rods.

(6) Remove the tie rod rubber boot retaining

clamps, detach the boots from the steering gear
housing and slide them from the tie rods. Take care to
position a container to catch the oil contained in the
steering gear assembly.

(7) Where the tie rod ball housing is retained by

staking, drill the staking away from the rack and tie
rod using a 4.0 mm drill. Do not drill into the rack
more than is necessary to drill out the staking.

Where the tie rod ball housing is retained by a

lock pin, drill out the lock pin from the ball housing
and tie rod using a 4.0 mm drill. Do not exceed a
drilling depth of 10.0 mm.

Using a 4.0 mm drill to remove the staking from the tie

rod ball housing.

Steering — Part 2

151

(8) Slide the rack out of the housing slightly so

that an adjustable spanner can be used to hold the
rack.

(9) Using a Stillsons wrench, unscrew the ball

housings in turn using care not to allow the rack to
rotate. Keep all the tie rod parts in order.

(10) Inspect the rack boots for cracks and deteri-

oration and renew as necessary.

(11) Inspect the tie rod ends for wear and damage

and renew as necessary.

Dismantled view of the tie rod ball housing and the tie

rod end assemblies removed from the steering gear.

Assembly is a reversal of the dismantling proce-

dure with attention to the following points:

(1) Using large Stillsons and a large adjustable

spanner, install the tie rod and ball housing
assemblies
to the rack. Tighten the ball housings to the specified
torque.

NOTE: To avoid damage to the rack or
pinion the adjustable spanner must be
firmly tightened over the rack teeth and the
rack must not be allowed to rotate when
installing the ball housings.

(2) Measure a point 9 mm in from the rear face

of the ball housing of the rack and at 90 deg to the
rack teeth. Centre punch this point.

(3) At this point drill a 4 mm hole, 10 mm deep

through the rack and into the ball housing thread.

(4) Place a locking pin above the hole and drive

it into position.

(5) Lubricate the rack, rack teeth and ti e rod

boot groove with suitable EPL 1 grease.

(6) Install the rack boots and secure with the

clamps. Renew the clamps if necessary.

(7) Install the tie rod end locknuts and then the

tie rod ends, ensuring that they are screwed on the
same number of turns as was necessary to remove
them.

(8) Tighten the locknuts to the specified torque.
(9) Install the mounting rubbers and brackets

to
the steering gear as noted on removal.

(10) Install the steering gear assembly to

the
vehicle as previously described.

(11) Check and if necessary adjust the front wheel

toe in as described in the Front Suspension section
under the appropriate heading.

TO RENEW TIE ROD END

(1) Raise the front of the vehicle and support it

on chassis stands.

(2) Remove the relevant front wheel.
(3) Loosen the tie rod end locknut and remove

the tie rod end castellated nut. Disconnect the tie rod
from the steering arm by placing a suitable dolly or
hammer against one side of the steering arm eye and
striking the opposite side with a hammer.

(4) Unscrew the tie rod end from the tie rod,

noting the number of turns necessary to remove it.

(5) Screw the new tie rod end onto the tie rod

the same number of turns noted during removal.

(6) Connect the tie rod to the steering arm and

install the castellated nut. Tighten the nut to the
specified torque and secure it with a new split pin.

(7) Install the front wheel and lower the vehicle

to the ground.

(8) Check and if necessary, adjust the front

wheel toe in as described in the Front Suspension
section. Ensure that the rubber boots are not distorted
or twisted on the tie rod when the adjustment is
completed.

TO RENEW RUBBER BOOT

(1) Raise the front of the vehicle and support it

on chassis stands.

(2) Remove the relevant tie rod end as previ-

ously described.

(3) Release the clamps securing the boot to the

tie rod and steering gear housing.

(4) Unscrew and remove the locknut from the

tie rod.

(5) Remove the rubber boot together with the

outer retaining clamp from the tie rod.

(6) Sparingly lubricate the tie rod boot groove

with EPL 1 grease, install the new boot to the tie
rod
and push it onto the steering gear rack housing. Install
and secure the inner and outer retaining clamps.

(7) Install the tie rod end locknut and screw

the
tie rod end onto the tie rod the same number of turns
noted during removal.

(8) Connect the tie rod to the steering arm and

install the castellated nut. Tighten the nut to the
specified torque and secure it with a new split pin.

(9) Install the wheel and lower the vehicle to the

ground.

(10) Check and if necessary, adjust the front

wheel toe in as described in the Front Suspension
section. Ensure that the rubber boots are not distorted
or twisted when the adjustment is completed.

152

PART 3. POWER STEERING

SPECIFICATIONS

Steering gear type . . . . Rack and pinion with

integral power cylinder

Steering column type . . . . . Energy absorbing

collapsible and lilt adjustable

Steering wheel free play . . . . . . . . . 35 mm

Number of turns lock to lock:

TRW . . . . . . . . . . . . . . . ...2.82

PR24SA . . . . . . . . . . . . . . ... 2.7

Linkage. . . . . . . . . .Direct from rack ends

to tie rods and steering knuckles

Power steering pump

maximum pressure . . . . . . . . . 6 865 kPa

Lubricant . . . . . . . . . . . . . ..Dexron II

TORQUE WRENCH SETTINGS

Steering gear to bulkhead mounting bolts... 108 Nm

Tie rod to steering knuckle nut . . . . . .. 98 Nm

Tie rod to tie rod end locknut . . . . . ... 98 Nm

Tie rod ball housing to rack. . . . . . . 88 Nm

Power steering pump pulley nut . . . . . . 68 Nm

1. DESCRIPTION

The vehicles covered by this instruction are equipped

with either a TRW power steering system or a
Japanese PR24SA power steering system.

Both types are similar in construction and appear-

ance.

The power steering is a rack and pinion type

which is mounted on the lower section of the engine
compartment bulkhead by rubber mountings and
brackets.

Hydraulic pressure is supplied to the power

steering gear by a pump driven by a drive belt from
the engine.

The power steering pump has a separate fluid

reservoir located on the right side of the bulkhead.

No lubrication of the steering gear or steering

pump is required in service and in the event of the
loss of power assistance, the steering will continue to
operate but will require a greatly increased effort.
However, as the steering gear and pump are lubricated
by the power steering fluid, the cause of the loss of
power steering or fluid loss must be determined and
repaired promptly to prevent damage to the steering
pump and to a lesser extent, the steering gear.

The tie rod ends and rubber boots can be renewed

without removing the steering gear from the vehicle.
To renew the integral tie rod and tie rod ball housings,
the steering gear must be removed.

As specialist knowledge and equipment are re-

quired to overhaul the power steering gear and the

hydraulic pump, it is recommended that these op-
erations be carried out by an authorized dealer.
However, procedures for the removal and installa-
tion of the steering gear and pump are fully de-
scribed in this section.

The steering column is of the energy absorbing

type and is designed to collapse in the event of a
severe front end collision. The energy absorbing com-
ponents are the column tubes, steering shaft and tilt
bracket breakaway capsules. All these components
should be handled with extreme care if service opera-
tions are to be carried out on the steering column
assembly.

2. IN CAR ADJUSTMENTS, CHECKS AND

MINOR REPAIRS

If the power steering system becomes partially or

fully inoperative it is most important that the follow-
ing preliminary inspection and testing procedure be
performed prior to undertaking any trouble shooting
or repair operations.

PUMP DRIVE BELT

Inspect the pump drive belt for breakage, glazing

or wear. If any of these characteristics are evident,
renew the belt using only a genuine replacement.

If the belt is loose but still serviceable, adjust it

using the procedure outlined in the Engine Tune-up
section.

NOTE: In most cases a loose drive belt can
be heard squealing when a load is placed on
the pump as the steering wheel is turned or
as the engine speed is increased.

Checking the power steering pump drive belt for

deterioration.