Almera Tino V10 (2003 year). Manual — part 239

SST491C

I

Align slit of lower joint with projection on dust cover. Insert joint
until surface A contacts surface B.

CAUTION:

After installation, turn steering wheel to make sure it moves
smoothly. Ensure the number of turns are the same from the
straight forward position to left and right locks. Be sure that
the steering wheel is in a neutral position when driving
straight ahead.

STEERING WHEEL AND STEERING COLUMN

Removal and Installation (Cont’d)

ST-12

Disassembly and Assembly

=NLST0019

NST048

1.

Combination switch

2.

Column shaft assembly

3.

Clip

4.

Lower seal cover

5.

Hole cover

YST032

I

Steering lock

a)

Break self-shear type screws with a drill or other appropriate
tool.

YST033

b)

Install new self-shear type screws and then cut off self-shear
type screw heads.

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STEERING WHEEL AND STEERING COLUMN

Disassembly and Assembly

ST-13

SST855C

Inspection

NLST0020

I

When steering wheel does not turn smoothly, check the steer-
ing column as follows and replace damaged parts.

a)

Check column bearings for damage or unevenness. Lubricate
with recommended multi-purpose grease or replace steering
column as an assembly, if necessary.

b)

Check jacket tube for deformation or breakage. Replace if
necessary.

I

When the vehicle comes into a light collision, check length “L”.

Steering column length “L”:

Refer to SDS, ST-26.

If out of the specifications, replace steering column as an assem-
bly.

NST049

TILT MECHANISM

NLST0020S01

I

After installing steering column, check tilt mechanism opera-
tion.

STEERING WHEEL AND STEERING COLUMN

Inspection

ST-14

Components

NLST0021

NST054

1.

Gear assembly

2.

Tie-rod outer socket

3.

Lock plate

4.

Dust boot

5.

Boot band

6.

Boot band

7.

Spacer ring

8.

Tie-rod inner socket

9.

Cotter pin

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POWER STEERING GEAR AND LINKAGE

Components

ST-15

Removal and Installation

NLST0022

NST050

1.

Lower joint

2.

Washer

3.

Gear and linkage assembly

4.

Upper gear housing mounting
bracket

5.

Rack mounting insulator

6.

Lower gear housing mounting
bracket

7.

Cotter pin

SFA455BA

CAUTION:

I

The rotation of the spiral cable (SRS “Air bag” component
part) is limited. If the steering gear must be removed, set
the front wheels in the straight-ahead direction. Do not
rotate the steering column while the steering gear is
removed.

I

Remove the steering wheel before removing the steering
lower joint to avoid damaging the SRS spiral cable.

I

Detach tie-rod outer sockets from knuckle arms with Tool.

1.

Remove stabilizer fixing bolts. Refer to SU-12, “Removal and
Installation”.

2.

Disconnect lower joint.

3.

Remove gear housing mounting bracket fixing bolts.

4.

Remove steering gear assembly.

POWER STEERING GEAR AND LINKAGE

Removal and Installation

ST-16

SST879C

I

Install pipe connector.

I

Observe specified tightening torque when tightening high-pres-
sure and low-pressure pipe connectors. Excessive tightening
will damage threads of connector or O-ring.

Connector tightening torque:

1 Low-pressure side

27 - 39 N·m (2.8 - 4.0 kg-m, 20 - 29 ft-lb)

2 High-pressure side

15 - 25 N·m (1.5 - 2.5 kg-m, 11 - 18 ft-lb)

I

The O-ring in low-pressure pipe connector is larger than that
in high-pressure connector. Take care to install the proper
O-ring.

SST824A

I

Initially, tighten nut on tie-rod outer socket and knuckle arm to
29 to 39 N·m (3 to 4 kg-m, 22 to 29 ft-lb). Then tighten further
to align nut groove with first pin hole so that cotter pin can be
installed.

CAUTION:

Tightening torque must not exceed 49 N·m (5 kg-m, 36 ft-lb).
NOTE:
Only the dust boot, tie-rod inner socket and tie-rod outer socket can
be disassembled on models for Europe.

SST819A

I

Before removing lower joint from gear, set gear in neutral
(wheels in straight-ahead position). After removing lower joint,
put matching mark on pinion shaft and pinion housing to record
neutral position.

I

To install, set left and right dust boots to equal deflection.
Attach lower joint by aligning matching marks of pinion shaft
and pinion housing.

I

Tighten gear housing mounting bracket bolts.

Inspection

NLST0024

Thoroughly clean all parts in cleaning solvent or DEXRON

TM

III or

equivalent. Blow dry with compressed air, if available.

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POWER STEERING GEAR AND LINKAGE

Removal and Installation (Cont’d)

ST-17

SST090B

STEERING GEAR

NLST0024S06

1.

Check rack sliding force on vehicle as follows:

a.

Install steering gear onto vehicle, but do not connect tie-rod to
knuckle arm.

b.

Connect all piping and fill with steering fluid.

c.

Start engine and bleed air completely.

d.

Disconnect steering column lower joint from the gear.

e.

Keep engine at idle and make sure steering fluid has reached
normal operating temperature.

f.

Pull tie-rod slowly to move it from neutral position to

±

11.5 mm

(

±

0.453 in) at speed of 3.5 mm (0.138 in)/s. Check that rack

sliding force is within specification.

Average rack sliding force:

197 - 255 N (20.1 - 26.0 kg, 44.3 - 57.3 lb)

BOOT

NLST0024S01

I

Check condition of boot. If cracked excessively, replace it.

I

Check boots for accumulation of power steering fluid.

SST468C

TIE-ROD OUTER AND INNER SOCKETS

NLST0024S05

I

Check ball joints for swinging force.

Tie-rod outer and inner ball joints swinging force “A”:

Refer to SDS, ST-27.

I

Check ball joint for rotating torque.

Tie-rod outer ball joint rotating torque “B”:

Refer to SDS, ST-27.

I

Check ball joints for axial end play.

Tie-rod outer and inner ball joints axial end play “C”:

Refer to SDS, ST-27.

I

Check condition of dust cover. If cracked excessively, replace
outer tie-rod.

SST866C

Assembly

NLST0025

1.

Install lock plate to rack.

a.

Temporarily install spacer ring to rack.

Discard old spacer ring; replace with a new one.
b.

Install lock plate to inner socket.

Discard old lock plate; replace with a new one.
c.

Apply a coat of locking sealant to inner socket threads. Screw
inner socket into rack and tighten to specified torque.

d.

Clinch lock plate at rack groove location (at two points).

e.

Install spacer ring to lock plate as shown in the Figure at left.

POWER STEERING GEAR AND LINKAGE

Inspection (Cont’d)

ST-18

Be careful not to damage spacer ring during installation

SST867C

2.

Tighten outer socket lock nut.

Tie-rod length “L”:

Refer to SDS, ST-27.

SST086BA

3.

Measure rack stroke.

Rack stroke “S”:

Refer to SDS, ST-27.

SST967A

4.

Before installing boot, coat the contact surfaces between boot
and tie-rod with grease.

SST868C

5.

Install boot bands.

I

Securely install boot band to boot groove and clinch the root
section of the trapezoidal area.

I

Make sure that there is a clearance of 3.5 mm (0.138 in) or less
at the clinched section of the boot band. Refer to the Figure at
left.

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POWER STEERING GEAR AND LINKAGE

Assembly (Cont’d)

ST-19

SST090B

Adjustment

NLST0026

1.

Check rack sliding force on vehicle as follows:

a.

Install steering gear onto vehicle, but do not connect tie-rod to
knuckle arm.

b.

Connect all piping and fill with steering fluid.

c.

Start engine and bleed air completely.

d.

Disconnect steering column lower joint from the gear.

e.

Keep engine at idle and make sure steering fluid has reached
normal operating temperature.

f.

Pull tie-rod slowly to move it from neutral position to

±

11.5 mm

(

±

0.453 in) at speed of 3.5 mm (0.138 in)/s. Check that rack

sliding force is within specification.

Average rack sliding force:

197 - 255 N (20.1 - 26.0 kg, 44.3 - 57.3 lb)

POWER STEERING GEAR AND LINKAGE

Adjustment

ST-20

Components

NLST0027

NST051

NST053

Inspection

NLST0028

Disassemble the power steering oil pump only if the following items
are found.

I

Oil leak from any point shown in the figure

I

Deformed or damaged pulley

I

Poor performance

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POWER STEERING OIL PUMP (QG ENGINE)

Components

ST-21

Components

NLST0038

SST882CA

1.

Rear bracket

2.

Rear body

3.

Dowel pin

4.

Side plate seal

5.

Cam ring

6.

Vane

7.

Rotor

8.

Side plate

9.

O-ring (Outer)

10. O-ring (Inner)
11. Front body
12. Drive shaft rear oil seal
13. Drive shaft front oil seal
14. Drive shaft
15. Snap ring
16. O-ring

17. Outlet connector
18. Connector seal
19. Flow control valve
20. Flow control valve spring
21. Inlet connector
22. O-ring
23. Washer

SST883C

Pre-disassembly Inspection

NLST0039

Disassemble the power steering oil pump only if the following items
are found.

I

Oil leak from any point shown in the figure

I

Poor performance

POWER STEERING OIL PUMP (YD ENGINE)

Components

ST-22

SST884C

Removal and Installation

NLST0040

1.

Remove chain case cover.

SST885C

2.

Revolving crank pulley, set tool.

3.

Fix tool with chain cover fixing bolts.

4.

Using suitable tool, remove sprocket fixing nut and washer.
Do not remove Tool while power steering oil pump is
removed.

SST886C

5.

Remove power steering pump fixing bolts, then remove it.

SST890C

I

Apply Gasket to the installation surface of the engine chain
case cover as shown in the figure before installing the chain
case cover to the engine.

I

Bleed air after installation.
Refer to ST-8.

Disassembly

NLST0041

CAUTION:

I

Parts which can be disassembled are strictly limited.
Never disassemble parts other than those specified.

I

Disassemble in as clean a place as possible.

I

Clean your hands before disassembly.

I

Do not use rags; use nylon cloths or paper towels.

I

Follow the procedure and cautions in the Service Manual.

I

When disassembling and reassembling, do not let foreign
matter enter or contact the parts.

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POWER STEERING OIL PUMP (YD ENGINE)

Removal and Installation

ST-23

SST887C

I

Remove rear bracket and rear body.

I

Remove side plate seal, cam ring vane, rotor side and plate.

SST036A

I

Remove inlet connector and outlet connector with spring.
Be careful not to drop the flow control valve.
Do not disassemble the flow control valve.

SST888C

I

Remove oil seal

SST889C

I

Remove snap ring, then draw drive shaft.
Be careful not to drop drive shaft.

Inspection

NLST0042

I

If pulley is cracked or deformed, replace it.

I

If an oil leak is found around pulley shaft oil seal, replace the
seal.

I

If serration on pulley or pulley shaft is deformed or worn,
replace it.

POWER STEERING OIL PUMP (YD ENGINE)

Disassembly (Cont’d)

ST-24

SST038A

Assembly

NLST0043

Assemble oil pump, noting the following instructions.

I

Make sure O-rings and oil seal are properly installed.

I

Always install new O-rings and oil seal.

I

Be careful of oil seal direction.

I

Cam ring, rotor and vanes must be replaced as a set if neces-
sary.

I

Coat each part with DEXRON

TM

III or equivalent when assem-

bling.

SST289A

I

Pay attention to the direction of rotor.

SST843A

I

When assembling vanes to rotor, rounded surfaces of vanes
must face cam ring side.

SST472C

I

Insert pin 2 into pin groove 1 of front housing and front side
plate. Then install cam ring 3 as shown at left.

Cam ring:

D

1

is less than D

2

.

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POWER STEERING OIL PUMP (YD ENGINE)

Assembly

ST-25

General Specifications

NLST0032

Applied model

Steering model

Power steering

Steering gear type

PR25T

Steering overall gear ratio

18.07

Turns of steering wheel (Lock to lock)

3.26

Steering column type

Collapsible, tilt

Steering Wheel

NLST0033

Steering wheel axial play

mm (in)

0 (0)

Steering wheel play

mm (in)

35 (1.38) or less

Movement of gear housing

mm (in)

±

2 (

±

0.08) or less

Steering Column

NLST0034

Steering column length “L”

mm (in)

531.8 - 533.8 (20.94 - 21.02)

SST855C

SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications

ST-26

Steering Gear and Linkage

NLST0035

Steering gear type

PR25T

Tie-rod outer ball
joint

Swinging force at cotter pin hole:
“A”

N (kg, lb)

6.5 - 64.6 (0.66 - 6.59, 1.5 - 14.6)

Rotating torque: “B”

N·m (kg-cm,

in-lb)

0.29 - 2.94 (3.0 - 30.0, 2.6 - 26.0)

Axial end play: “C”

mm (in)

0.4 (0.016) or less

Tie-rod inner ball
joint

Swinging force*: “A”

N (kg, lb)

5.7 - 45.6 (0.58 - 4.65, 1.3 - 10.3)

Axial end play: “C”

mm (in)

0.2 (0.008) or less

Tie-rod standard length “L”

mm (in)

185 (7.28)

*: Measuring point [



: 172 mm (6.77 in)]

SST867C

Rack stroke “S”

mm (in)

70 (2.76)

SST086BA

Power Steering

NLST0036

Steering gear type

PR25T

Rack sliding
force

N (kg, lb)

Under normal operat-
ing oil pressure

Range within

±

11.5 mm (

±

0.453 in)

from the neutral position at rack
speed of 3.5 mm (0.138 in)/s

Average force

197 - 255 (20.1 - 26.0, 44.3 - 57.3)

Steering wheel turning force
(Measured at one full turn from the neutral position)

N (kg, lb)

26 - 32 (2.7 - 3.2, 5.8 - 7.2)

Fluid capacity (Approximate)



(Imp qt)

1.0 (7/8)

Oil pump maximum pressure

kPa (bar, kg/cm

2

, psi)

QG

8,100 - 8,700 (81 - 87, 82.6 - 88.7, 1,175 - 1,262)

YD

8,520 - 9,320 (85.2 - 93.2, 86.9 - 95.1, 1,235 - 1,351)

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SERVICE DATA AND SPECIFICATIONS (SDS)

Steering Gear and Linkage

ST-27