TOYOTA SIENNA 2007 Service Repair Manual

PS–30POWER STEERING – RACK AND PINION POWER STEERING GEAR
PS
15. REMOVE POWER STEERING CONTROL VALVE
UPPER OIL SEAL
(a) Using SST and a press, remove the control valve
upper bearing and control valve upper oil seal from
the control valve housing.
SST 09950-70010 (09951-07150), 09950-60010
(09951-00250)
16. REMOVE CYLINDER END STOPPER
(a) Using a screwdriver and a hammer, turn the cylinder
end stopper clockwise until the wire end is visible
through the service hole.
(b) Using a screwdriver and a hammer, turn the cylinder
end stopper counterclockwise, and remove the wire
and cylinder end stopper.
17. REMOVE POWER STEERING RACK
18. REMOVE POWER STEERING RACK BUSH
(a) Remove the rack bush from the power steering
rack.
(b) Using SST, remove the rack bush oil seal.
SST 09527-21011, 09612-24014 (09613-22011)
(c) Using a screwdriver, remove the O-ring from the
rack bush.
19. REMOVE POWER STEERING CYLINDER TUBE OIL
SEAL
(a) Using SST and a press, remove the cylinder tube oil
seal.
SST 09950-70010 (09951-07360), 09950-60010
(09951-00290)
F040911E07
C083179E06
F040542E06
F040544E06

POWER STEERING – RACK AND PINION POWER STEERING GEARPS–31
PS
20. REMOVE RACK STEERING PISTON RING
(a) Using a screwdriver, remove the rack steering
piston ring and O-ring.
NOTICE:
Be careful not to damage the grooves for rack
steering piston ring.
INSPECTION
1. INSPECT POWER STEERING RACK
(a) Using a dial indicator, check the power steering rack
for runout and for teeth wear and damage.
Maximum runout:
0.3 mm (0.012 in.)
If necessary, replace the rack & pinion power
steering gear assembly.
(b) Check the back surface for wear and damage.
If necessary, replace the rack & pinion power
steering gear assembly.
2. INSPECT TIE ROD ASSEMBLY LH
(a) Secure the tie rod assembly in a vise.
(b) Install the nut to the stud bolt.
(c) Flip the ball joint stud back and forth 5 times.
(d) Using a torque wrench, turn the nut continuously at
a rate of 3 to 5 seconds per turn and take the torque
reading on the 5th turn.
Torque: Turning torque
0.83 to 3.43 N*m (8.5 to 35.0 kgf*cm, 7.3
to 30.4 in.*lbf)
3. INSPECT TIE ROD ASSEMBLY RH
HINT:
Perform the same procedure on the other side.
REASSEMBLY
1. INSTALL RACK STEERING PISTON RING
(a) Coat a new O-ring with power steering fluid and
install it onto the power steering rack.
(b) Expand a new rack steering piston ring with your
fingers.
NOTICE:
Be careful not to over expand the rack steering
piston ring.
(c) Coat a new rack steering piston ring with power
steering fluid.
R010955
ZX09355
ZK08184
C003629

PS–32POWER STEERING – RACK AND PINION POWER STEERING GEAR
PS
(d) Install the rack steering piston ring onto the power
steering rack, and settle it down with your fingers.
2. INSTALL POWER STEERING CYLINDER TUBE OIL
SEAL
(a) Coat a new cylinder tube oil seal lip with power
steering fluid.
(b) Using SST and a press, install the cylinder tube oil
seal.
SST 09950-60010 (09951-00420, 09951-00250,
09952-06010), 09950-70010 (09951-07360)
NOTICE:
• Make sure that the cylinder tube oil seal is
installed facing in the correct direction.
• Take care so that the cylinder tube oil seal
will not be reversed as you install it.
3. INSTALL POWER STEERING RACK
(a) Install SST onto the power steering rack.
SST 09631-33010
HINT:
If necessary, scrape the burrs off the power steering
rack teeth end and burnish.
(b) Coat the SST with power steering fluid.
(c) Install the power steering rack into the rack housing.
(d) Remove the SST.
N000401
F040545E06
W002101E12

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