Steering Gear: Installation

WARNING: This page is about a different car, the 2008 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL NO. 2 TIE ROD END SUB-ASSEMBLY
1. Screw the lock nut and No. 2 tie rod end sub-assembly on the rack end until the matchmarks are aligned and temporarily tighten the lock nut.
  HINT:
  
  Fully tighten the lock nut after adjusting toe-in.
  
  Fig 1: Identifying Matchmarks On No. 2 Tie Rod End Sub-Assembly And Rack End
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 TIE ROD END SUB-ASSEMBLY
HINT:

Use the same procedures described for the No. 2 tie rod end sub-assembly.
INSTALL STEERING GEAR ASSEMBLY
1. Install the steering gear onto the front suspension crossmember with the 2 bolts and 2 nuts.
  Torque: 138 N*m (1407 kgf*cm, 102 ft.*lbf)
  
  NOTE: Keep the nut from rotating while turning the bolt.
  
  Fig 2: Installing Steering Gear Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INTERMEDIATE SHAFT
1. Align the matchmarks and install the intermediate shaft onto the steering gear.
  Torque: 35 N*m (360 kgf*cm, 26 ft.*lbf)
  
  Fig 3: Identifying Matchmarks On Intermediate Shaft Of Steering Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY
1. Install the column hole cover onto the steering gear with a new clamp.
INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
1. Install the engine with transaxle (see INSTALLATION ).
INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY
1. Attach clip B onto the body and install the No. 1 hole cover onto the body with clip A.
  NOTE: Make sure that the lip of the No. 1 hole cover is not damaged.
  
  Fig 4: Identifying Clip A And B
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT STEERING SLIDING YOKE SUB-ASSEMBLY
1. Align the matchmarks and install the sliding yoke onto the intermediate shaft.
  Torque: 35 N*m (360 kgf*cm, 26 ft.*lbf)
  
  Fig 5: Identifying Matchmarks On Sliding Yoke Of Steering Intermediate Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL COLUMN HOLE COVER SILENCER SHEET
1. Install the column hole cover silencer sheet with the 2 clips.
2. Install the floor carpet.
  
  Fig 6: Locating Floor Carpet Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT NO. 2 TIE ROD END SUB-ASSEMBLY
1. Connect the No. 2 tie rod end sub-assembly onto the steering knuckle with the castle nut.
  Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
  
  NOTE: If the holes for the clip are not aligned, tighten the nut up to 60° further.
  
  Fig 7: Connecting Tie Rod End Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install a new cotter pin.
CONNECT NO. 1 TIE ROD END SUB-ASSEMBLY
HINT:

Use the same procedure for the No. 1 tie rod end sub-assembly as for the No. 2 tie rod end sub-assembly.
INSTALL FRONT WHEELS
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
POSITION FRONT WHEELS FACING STRAIGHT AHEAD
INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
1. Inspect and adjust the wheel alignment (see ADJUSTMENT ).