TOYOTA SIENNA 2007 Service Repair Manual

POWER STEERING – RACK AND PINION POWER STEERING GEARPS–33
PS
4. INSTALL POWER STEERING RACK BUSH
(a) Using SST and a press, install the rack bush oil seal
onto the rack bush.
SST 09950-60010 (09951-00400), 09950-70010
(09951-07100)
NOTICE:
Make sure that the rack bush oil seal is installed
facing in the correct direction.
(b) Coat a new O-ring with power steering fluid and
install it onto the rack bush.
(c) To prevent rack bush oil seal lip damage, wind vinyl
tape around the rack end, and apply power steering
fluid.
(d) Install the rack bush onto the power steering rack.
5. INSTALL CYLINDER END STOPPER
(a) Align the installation hole for the wire of the cylinder
end stopper with the slot of the rack housing.
(b) Install a new wire into the cylinder end stopper.
(c) Using a screwdriver, turn the cylinder end stopper
counterclockwise by 450 +- 50
.
6. AIR TIGHTNESS TEST
(a) Install SST onto the rack housing.
SST 09631-12071 (09633-00010)
(b) Apply vacuum of 53 kPa (400 mmHg, 15.75 in.Hg)
for about 30 seconds.
(c) Check that there is no change in the vacuum.
If there is a change in the vacuum, check the
installation of the oil seals.
7. INSTALL POWER STEERING CONTROL VALVE
UPPER OIL SEAL
(a) Coat a control valve upper bearing and a new
control valve upper oil seal with power steering fluid.
(b) Using SST and a press, install the control valve
upper oil seal.
SST 09950-70010 (09951-07150), 09950-60010
(09951-00180, 09952-06010, 09951-00320)
F040543E06
F005730E07
F040546E07
F045546E01
F040912E08

PS–34POWER STEERING – RACK AND PINION POWER STEERING GEAR
PS
(c) Using SST and a press, install the control valve
upper bearing.
SST 09950-70010 (09951-07150), 09950-60010
(09951-00180, 09952-06010, 09951-00340)
8. INSTALL POWER STEERING CONTROL VALVE
(a) Expand 4 new control valve rings with your fingers.
NOTICE:
Be careful not to over expand the control valve
rings.
(b) Coat the 4 control valve rings with power steering
fluid.
(c) Install the 4 control valve rings onto the control
valve, and settle them down with your fingers.
(d) Carefully slide the tapered end of SST over the
control valve rings until they fit to the control valve.
SST 09631-20081
NOTICE:
Be careful not to damage the control valve rings.
(e) To prevent control valve upper oil seal lip damage,
wind vinyl tape around the serrated part of the
control valve.
(f) Coat the control valve upper oil seal lip with power
steering fluid.
(g) Install the control valve onto the control valve
housing.
NOTICE:
Be careful not to damage the control valve ring
and control valve upper oil seal lip.
(h) Coat a new oil seal lip with power steering fluid.
(i) Using SST and a press, install the oil seal.
SST 09612-22011
NOTICE:
Make sure that the oil seal is installed facing in
the correct direction.
(j) Apply grease to the needle roller bearing.
(k) Install a new gasket onto the control valve housing.
(l) Wind vinyl tape around the serrated part of the
control valve.
F040913E09
C003629
R011573E06
F041508E01
F041509E01

POWER STEERING – RACK AND PINION POWER STEERING GEARPS–35
PS
(m) Install the control valve w/ control valve housing
onto the rack housing with the 2 bolts.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
(n) Using SST, hold the control valve rotation and install
a new lock nut.
SST 09616-00011
Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf)
(o) Apply sealant to 2 or 3 threads of the rack housing
cap.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond
1344, or equivalent
(p) Using a socket wrench (27 mm), install the rack
housing cap.
Torque: 59 N*m (597 kgf*cm, 43 ft.*lbf)
(q) Using a punch and a hammer, stake the rack
housing cap and rack housing.
9. INSTALL RACK GUIDE
(a) Install the rack guide.
(b) Install the compression spring.
(c) Apply sealant to 2 or 3 threads of the rack guide
spring cap.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond
1344, or equivalent
(d) Temporarily install the rack guide spring cap.
F045545
F041513E01
F041502E02
F041608

PS–36POWER STEERING – RACK AND PINION POWER STEERING GEAR
PS
10. INSTALL TOTAL PRELOAD
(a) To prevent the steering rack teeth from damaging
the oil seal lip, temporarily install the RH and LH
steering rack ends sub-assembly.
(b) Using SST, torque the rack guide spring cap.
SST 09631-10021
Torque: 25 N*m (254 kgf*cm, 18 ft.*lbf)
(c) Using SST, loosen the rack guide spring cap.
SST 09631-10021
(d) Using SST, turn the control valve to the right and left
1 or 2 times.
SST 09616-00011
(e) Using SST, loosen the rack guide spring cap until
the compression spring is not functioning.
SST 09631-10021
(f) Using SST and a torque wrench, tighten the rack
guide spring cap until the preload is within
specification.
SST 09631-10021, 09616-00011
Torque: Preload (turning)
1.2 to 1.5 N*m (12.2 to 15.3 kgf*cm, 10.6
to 13.3 in.*lbf)
(g) Apply sealant to 2 or 3 threads of the rack guide
spring cap nut.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond
1344, or equivalent
(h) Temporarily install the rack guide spring cap nut.
F041514E01
F041515E01
F041516E01
F041517E01

POWER STEERING – RACK AND PINION POWER STEERING GEARPS–37
PS
(i) Using SST, hold the rack guide spring cap and using
another SST, torque the rack guide spring cap nut.
SST 09616-00011, 09922-10010
Torque: 48 N*m (489 kgf*cm, 35 ft.*lbf)
NOTICE:
Use SST 09922-10010 in the direction shown in
the illustration.
HINT:
Use a torque wrench with a fulcrum length of 345
mm (13.58 in.).
(j) Precheck the total preload.
Torque: Preload (turning)
1.2 to 1.5 N*m (12.2 to 15.3 kgf*cm, 10.6
to 13.3 in.*lbf)
(k) Remove the RH and LH steering rack ends sub-
assembly.
(l) Apply MP grease to the control valve, as shown in
the illustration.
(m) Wind vinyl tape around the serrated part of the
control valve.
(n) Install the dust cover onto the control valve housing.
F041518E01
F040555E08
F040538E10

PS–38POWER STEERING – RACK AND PINION POWER STEERING GEAR
PS
11. INSTALL STEERING RACK END SUB-ASSEMBLY
(a) Install 2 new claw washers, and temporarily install
the 2 steering rack end sub-assembly.
HINT:
Align the claws of the claw washer with the power
steering rack grooves.
(b) Using 2 SST, install the 2 rack end sub-assembly.
SST 09922-10010
Torque: 58.5 N*m (597 kgf*cm, 43 ft.*lbf)
NOTICE:
Use SST 09922-10010 in the direction shown in
the illustration.
HINT:
• Using SST, hold the power steering rack and
install the rack end sub-assembly.
• Use a torque wrench with a fulcrum length of 345
mm (13.58 in.).
(c) Using a brass bar and a hammer, stake the 2 claw
washers.
NOTICE:
Avoid any impact to the power steering rack.
12. INSPECT STEERING RACK END SUB-ASSEMBLY
(a) Ensure that the rack end sub-assembly hole is not
clogged with grease.
HINT:
If the hole is clogged, the pressure inside the boot
will change after it is assembled and steering wheel
is turned.
13. INSTALL STEERING RACK BOOT NO.2
14. INSTALL STEERING RACK BOOT NO.1
15. INSTALL STEERING RACK BOOT NO.2 CLAMP
(a) Using SST, tighten the rack boot No.2 clamp, as
shown in the illustration.
SST 09521-24010
Clearance:
3.0 mm (0.118 in.) or less
NOTICE:
Be careful not to damage the rack boot No. 2.
16. INSTALL STEERING RACK BOOT NO.1 CLAMP
SST 09521-24010
F041576E01
C035928
C063521
F040556E07

POWER STEERING – RACK AND PINION POWER STEERING GEARPS–39
PS
HINT:
Perform the same procedure on the other side.
17. INSTALL STEERING RACK BOOT CLIP
(a) Using pliers, install the 2 rack boot clips.
18. INSTALL TIE ROD ASSEMBLY LH
(a) Screw the lock nut and tie rod assembly onto the
rack end sub-assembly until the matchmarks are
aligned.
HINT:
After adjusting toe-in, torque the lock nut.
19. INSTALL TIE ROD ASSEMBLY RH
HINT:
Perform the same procedure on the other side.
20. INSTALL STEERING LEFT TURN PRESSURE TUBE
(a) Coat 2 new O-rings with power steering fluid and
install them onto the left turn pressure tube.
(b) Using SST, install the left turn pressure tube onto
the power steering gear assembly.
SST 09023-38201
Torque: 11.5 N*m (117 kgf*cm, 8 ft.*lbf)
HINT:
• Use a torque wrench with a fulcrum length of 345
mm (13.58 in.).
• This torque value is effective when SST is
parallel to the torque wrench.
21. INSTALL STEERING RIGHT TURN PRESSURE TUBE
SST 09023-38201
HINT:
Perform the same procedure on the other side.
22. INSTALL RETURN TUBE NO.2
(a) Using SST, install the return tube No. 2.
SST 09023-12701
Torque: 22.5 N*m (229 kgf*cm, 17 ft.*lbf)
HINT:
Use a torque wrench with a fulcrum length of 345
mm (13.58 in.).
INSTALLATION
1. INSTALL RACK & PINION POWER STEERING GEAR
ASSEMBLY
(a) Install the power steering gear assembly with the 2
bolts and nuts.
Torque: 70 N*m (714 kgf*cm, 52 ft.*lbf)
D029981E02
D030601E01
D029979

PS–40POWER STEERING – RACK AND PINION POWER STEERING GEAR
PS
2. CONNECT PRESSURE FEED TUBE ASSEMBLY
(a) Connect the pressure feed tube assembly to the
power steering gear assembly.
(b) Install the clip.
(c) Using SST, connect the return tube assembly to the
power steering gear assembly.
SST 09023-12701
Torque: 22.5 N*m (229 kgf*cm, 17 ft.*lbf)
HINT:
• Use a torque wrench with a fulcrum length of 300
mm (11.81 in.).
• This torque value is effective when SST is
parallel to the torque wrench.
(d) Install the tube clamp with the bolt.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
(e) Install the tube clamp with the nut.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
D029970
D029977E01
D029974
D029975

POWER STEERING – RACK AND PINION POWER STEERING GEARPS–41
PS
3. INSTALL FRONT STABILIZER BRACKET NO.1 LH
(a) Install the stabilizer bracket No. 1 with the 2 bolts.
Torque: 17 N*m (173 kgf*cm, 12 ft.*lbf)
4. INSTALL FRONT STABILIZER BRACKET NO.1 RH
HINT:
Perform the same procedure on the other side.
5. INSTALL FRONT STABILIZER LINK ASSEMBLY LH
6. INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT:
Perform the same procedure on the other side.
7. INSTALL STEERING INTERMEDIATE SHAFT
ASSEMBLY
(a) Align matchmarks on the intermediate shaft
assembly and power steering gear assembly.
(b) Install the bolt.
Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)
(c) Install the dust cover.
HINT:
Ensure that the springs are installed tightly.
8. INSTALL TIE ROD ASSEMBLY LH
9. INSTALL TIE ROD ASSEMBLY RH
HINT:
Perform the same procedure on the other side.
10. INSTALL FRONT WHEEL
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
11. INSPECT CENTER FRONT WHEEL
12. INSPECT STEERING WHEEL CENTER POINT
13. ADD POWER STEERING FLUID
14. BLEED POWER STEERING FLUID
HINT:
(See page PS-6)
15. INSPECT FOR POWER STEERING FLUID LEAK
D030615E04
D029986E04
D030704E04

PS–42POWER STEERING – RACK AND PINION POWER STEERING GEAR
PS
16. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
HINT:
(See page SP-4)