Nova/Chevy II L4-1600cc 4ALC Nummi (1988)
8.
Remove cylinder end stopper snap ring, then withdraw rack assembly, cylinder and stopper as an assembly.
9.
Remove inner rack seal and spacer using tool No. J-35434, then the pistons and O-ring seals from rack.
10.
Using tool No. J-35420, remove inner bushing from valve housing, then the inner valve housing seal using a suitable brass drift.
Inspection & Assembly
1.
Install inner bushings using tool Nos. J-35695 and J-8092. Bushing must be installed to a depth of 2.736 inch. If bushing is installed too far, it
will deform. If bushing is not installed deep enough, it will interfere with the control valve pinion.
2.
Apply a suitable lubricant to valve and inner bushing, then ensure proper operation of valve and remove.
3.
Remove piston and O-ring from rack, then apply a suitable lubricant. Install new O-ring, then expand new piston ring to ensure tight fit in piston
groove.
4.
Install inner cylinder seal and spacer as follows:
a. Clean rack teeth, then wrap vinyl tape around rack teeth.
b. Apply a suitable lubricant to cylinder bore and inner seal, then install inner cylinder seal and thin spacer onto rack. Seal must be installed
with lip end onto rack first followed by thin spacer.
c. Insert rack into cylinder, then tap end of rack with a suitable mallet to seat inner seal and spacer.
5.
Apply a suitable lubricant to seal and end stopper, then install outer cylinder seal spacer and end stopper, using tool No. J-35425 as follows:
a. Install seal with lip end into cylinder, followed by thick spacer.
b. Install stopper until bottomed using tool J-35425.
c. Stopper should be in far enough to expose snap ring groove.
d. Install snap ring.
6.
Test inner and outer seals using vacuum gauge tool No. J-35465. Apply 15-3/4 inch Hg for approximately 30 seconds. If vacuum does not hold,
reinstall inner seals.
7.
Install pinion control valve into housing, then the upper pinion bearing using tool No. J-35425.
8.
Apply a suitable lubricant to seal, then install seal and snap ring.
9.
Install dust cover.
10.
Install spacer, lower bearing and new self locking nut onto pinion valve shaft, then torque lower nut to 43 ft. lbs., using tool No. J-35428 and a
suitable torque wrench.
11.
Apply a suitable sealant to threads of lower cap, then install cap and torque to 51 ft. lbs. Stake cap to housing.
12.
Install rack guide seat, guide and spring, then apply a suitable sealant to guide cap. Install cap.
13.
Install inner tie rods with claw washers, then torque to 61 ft. lbs. Stake locking washers, ensuring air bleed holes in rack are open.
14.
Install rack boots and clips, ensuring clips are installed with loop facing away from boot. Apply a suitable lubricant to inside of boot at small end.
15.
Install tie rods and align mating marks. Ensure distance between inner tie rod and outer tie rod ends are 1.890 inch (48 mm). Torque locking nut to
35 ft. lbs.
16.
Install right and left pressure tubes, then torque to 18 ft. lbs.
17.
Adjust total preload as follows:
a. Using tool no. J-35423 and a suitable torque wrench, torque rack guide cap to 18 ft. lbs.
b. Back cap off 12 degrees, then move rack back and forth one or 2 times.
c. Check value of preload using a suitable torque wrench. Preload should be 7-11 inch lbs.
d. Install locking nut after adjusting preload to specifications, then torque locknut to 33 ft. lbs.
e. Ensure final preload is 7-11 inch lbs. and readjust as necessary.
18.
Apply a suitable sealer to pressure switch threads, then torque to 10 ft. lbs.
