Steering Coupling - Lower: Installation

Push the column end of the steering column lower coupling partway up through the hole in the dash panel, then match the flat on the on the inside of the lower coupling to the flat on the power steering gear pinion shaft and slide the coupling onto the shaft.
Align the roll pin hole in the coupling to the notch in the gear pinion shaft and instal the roll pin through the coupling until it is centered. See Figure.
Center the power steering gear rack in its travel.
Using the transmission jack, raise the front suspension crossmember and power steering gear until the crossmember contacts its mounting spot against the body and frame rails of the vehicle. As the crossmember is raised, carefully guide the steering column lower coupling up through its hole in the dash panel.
Start the two crossmember mounting bolts through the lower control arm rear isolator bushings into the tapping plates mounted in the body. Next, install the two front and the two rear mounting bolts attaching front suspension crossmember to frame rails of vehicle. Lightly tighten all six mounting bolts to approximately 2 N.m (20 in. lbs.) to hold the front suspension crossmember in position at this time.
NOTE: When installing the front suspension crossmember back in the vehicle, it is very important that the crossmember be attached to the body in exactly the same spot as when it was removed. Otherwise, the vehicle's wheel alignment settings (caster and camber) will be lost.
Using a soft face hammer, tap the front suspension crossmember back-and-forth or side-to-side until it is aligned with the previously scribed positioning marks on the body of the vehicle. See Figure. Once the front suspension crossmember is correctly positioned, tighten the two crossmember mounting bolts through the lower control arm rear isolator bushings to a torque of 250 N.m (185 ft. lbs.), then tighten the four remaining crossmember mounting bolts to a torque of 153 N.m (113 ft. lbs.).
Fasten the engine torque strut to the right forward corner of the front suspension crossmember using its mounting bolt. See Figure. Follow the procedure described in 1.6L SOHC or 2.4L DOHC to properly align and tighten the torque strut and it's mounting bolts.
Install the washer on the end of the stud extending from the torque strut bolt. See Figure.
Install the pencil strut to the right front corner of the crossmember and body of the vehicle. See Figure. Tighten the pencil strut nuts to a torque of 52 N.m (38 ft. lbs.).
Install the drive-belt splash shield and fasteners. See Figure.
Install the screws fastening the front fascia to the reinforcement. See Figure.
Install the right front tire and wheel assembly. Tighten the mounting nuts to a torque of 135 N.m (100 ft. lbs.).
Reconnect the wiring harness connector from the power steering fluid pressure switch. See Figure. Be sure the locking tab on the wiring harness connector is securely latched.
Lower the vehicle.
Install the dash-to-lower coupling seal in place over the lower coupling's plastic collar.
NOTE: Verify that grease is present on the lip of the dash-to-coupling seal where it contacts the coupling's plastic collar.
Inside the passenger compartment, reconnect the steering column lower coupling to the steering column upper coupling. See Figure. Install the coupling pinch bolt and tighten the pinch bolt nut to a torque of 28 N.m (250 in. lbs.). Install the pinch bolt retainer pin.
Remove the steering wheel holder.
While looking under the instrument panel at the lower coupling, rotate the steering wheel back-and-forth to verify that the lower coupling does not squeak against the dash-to-coupling seal.
Install the knee blocker.
Install the silencer pad below the knee blocker panel below the steering column.