Lexus ES300 (1997 year). Manual — part 559

W03098

Rack Guide
Spring Cap

SST

W03099

12

°

W03100

SST

W03101

SST

SST

Rack Guide

Spring Cap

SR–44

–

STEERING

POWER STEERING GEAR

1340

1997 LEXUS ES300 (RM511U)

15.

ADJUST TOTAL PRELOAD

(a)

To prevent the steering rack teeth from damaging the oil
seal lip, temporarily install the RH and LH rack ends.

(b)

Using SST, torque the rack guide spring cap.
SST

09631–10021

Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)

(c)

Using SST, return the cap 12

°

.

SST

09631–10021

(d)

Using SST, turn the control valve shaft right and left 1 or
2 times.
SST

09616–00010

(e)

Using SST, loosen the cap until the rack guide spring is
not functioning.
SST

09631–10021

(f)

Using SST and a torque wrench, tighten the cap until the
preload is within specification.
SST

09616–00010, 09631–10021

Preload (turning):
0.8 – 1.4 N·m (8 – 14 kgf·cm, 6.9 – 12.2 in.·lbf)

W03102

Rack Guide

Spring Cap

Lock Nut

Fulcrum

Length

SST

SST

R11667

Claw

R15545

Fulcrum Length

SST

R11668

Brass Bar

–

STEERING

POWER STEERING GEAR

SR–45

1341

1997 LEXUS ES300 (RM511U)

16.

INSTALL RACK GUIDE SPRING CAP LOCK NUT

(a)

Apply sealant to 2 or 3 threads of the nut.
Sealant:
Part No.08833–00080, THREE BOND 1344,
LOCTITE 242 or equivalent

(b)

Using SST to hold the rack guide spring cap, and using
SST, torque the nut.
SST

09631–10021, 09922–10010

Torque: 50 N·m (513 kgf·cm, 37 ft·lbf)

NOTICE:
Use SST 09922–10010 in the direction shown in the illustra-
tion.
HINT:
Use a torque wrench with a fulcrum length of 345 mm (13.58
in.).
(c)

Recheck the total preload.
Preload (turning):
0.8 – 1.4 N·m (8 – 14 kgf·cm, 6.9 – 12.2 in.·lbf)

(d)

Remove the RH and LH rack ends.

17.

INSTALL RH AND LH CLAW WASHERS AND RACK
ENDS

(a)

Install a new claw washer, and temporarily install the rack
end.

HINT:
Align the claws of the washer with the steering rack grooves.

(b)

Using a spanner (24 mm) to hold the steering rack steady,
and using SST, torque the rack end.
SST

09922–10010

Torque: 60 N·m (615 kgf·cm, 45 ft·lbf)

NOTICE:
Use SST 09922–10010 in the direction shown in the illustra-
tion.
HINT:
Use a torque wrench with a fulcrum length of 345 mm (13.58
in.).
(c)

Using a brass bar and hammer, stake the washer.

NOTICE:
Avoid any impact to the rack.

R11669

W04223

SST

2 mm
(0.79 in.)
or less

W04231

Fulcrum

SST

Length

SR–46

–

STEERING

POWER STEERING GEAR

1342

1997 LEXUS ES300 (RM511U)

18.

INSTALL RH AND LH RACK BOOTS, CLAMPS AND
CLIPS

(a)

Ensure that the steering rack hole is not clogged with
grease.

HINT:
If the hole is clogged, the pressure inside the boot will change
after it is assembled and the steering wheel is turned.

(b)

Install the boot.

NOTICE:
Be careful not to damage or twist the boot.
(c)

Using SST, tighten the clamp as shown in the illustration.
SST

09521–24010

19.

INSTALL RH AND LH TIE ROD ENDS AND LOCK NUTS

(a)

Screw the lock nut and tie rod end onto the rack end until
the matchmarks are aligned.

(b)

After adjusting toe–in, torque the nut.
(See page

SA–4

)

Torque: 74 N·m (750 kgf·cm, 54 ft·lbf)

20.

INSTALL 2 TURN PRESSURE TUBES

(a)

Coat 2 new O–rings with power steering fluid and install
them to the tube.

(b)

Using SST, install the tube.
SST

09633–00020

Torque: 10 N·m (102 kgf·cm, 7 ft·lbf)

HINT:

Use a torque wrench with a fulcrum length of 250 mm
(9.84 in.).

This torque value is effective in case that SST is parallel
to a torque wrench.

SR069–01

W04224

SST

Length

Fulcrum

–

STEERING

POWER STEERING GEAR

SR–47

1343

1997 LEXUS ES300 (RM511U)

INSTALLATION

1.

INSTALL PS GEAR ASSEMBLY

(a)

Install the gear assembly from the LH of the vehicle.

NOTICE:
Do not damage the turn pressure tubes.
(b)

Torque the 2 gear assembly set bolts and nuts.
Torque: 181 N·m (1,850 kgf·cm, 134 ft·lbf)

HINT:
Lift up the stabilizer bar and install the bolts.
2.

INSTALL NO.1 FUEL TUBE PROTECTOR

Install the 2 bolts and nut.
3.

CONNECT STABILIZER BAR

Torque the 4 bolts.

Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)

4.

CONNECT PRESSURE FEED AND RETURN TUBES

Using SST, connect the tube.

SST

09631–22020

Torque: 32 N·m (326 kgf·cm, 24 ft·lbf)

HINT:

Use a torque wrench with a fulcrum length of 300 mm
(11.81 in.).

This torque value is effective in case that SST is parallel
to a torque wrench.

5.

CONNECT CLAMP PLATE

Torque the nut.

Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)

6.

CONNECT INTERMEDIATE SHAFT ASSEMBLY
(See page

SR–16

)

7.

CONNECT RH AND LH TIE ROD ENDS
(See page

SA–9

)

8.

POSITION FRONT WHEELS FACING STRAIGHT
AHEAD

HINT:
Do it with the front of the vehicle jacked up.
9.

CENTER SPIRAL CABLE
(See page

SR–16

)

10.

INSTALL STEERING WHEEL

(a)

Install the wheel at straight–ahead position.

(b)

Temporarily tighten the wheel set nut.

(c)

Connect the connector.

11.

BLEED POWER STEERING SYSTEM
(See page

SR–4

)

12.

CHECK STEERING WHEEL CENTER POINT