Toyota Corolla (2004+). Manual - part 34

 

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Toyota Corolla (2004+). Manual - part 34

 

 

50-5
STEERING COLUMN
- STEERING
(7)
Convert the measured distance to steering angle.
Measured distance 1 mm (0.04 in.) = Steering angle
approximately 1 deg.
HINT:
Make a note of the steering angle.
(b) Adjust steering angle.
NOTICE:
The adjustment method for steering angle varies depend-
ing on the models. Check whether it is type A or B.
(1)
Draw a line on the RH and LH tie rod and rack ends
where it can easily be seen.
(2)
Using a paper gauge, measure the distance from
RH and LH tie rod ends to the rack end screws.
HINT:
F
Measure the RH side and LH side.
Marked Line
F
Make a note of the measured values.
R00429
(3)
Remove the RH and LH boot clips from the rack
boots.
(4)
Loosen the RH and LH lock nuts.
(5)
Turn the RH and LH rack end by the same amount
(but in different directions) according to the steering
angle.
1 turn 360 deg. of rack end (1.5 mm (0.059 in.) horizon-
tal movement) - 12 deg. of steering angle.
F16018
(6)
Tighten the RH and LH lock nuts by the specified
torque.
Torque: 74 N·m (750 kgf·cm, 54 ftlbf)
NOTICE:
Make sure that the difference in length between RH and LH
tie rod ends and rack end screws are within 1.5 mm (0.059
in.).
(7)
Install the RH and LH boot clips.
50-6
STEERING COLUMN
- STEERING COLUMN ASSY
STEERING COLUMN ASSY
5003U-01
COMPONENTS
Horn Button Assy
Torx Screw
50 (510, 37)
8.8 (90, 78 in.lbf)
Steering Wheel Assy
Windshield Wiper Switch Assy
Torx Screw
8.8 (90, 78 in.lbf)
Column Upper Cover
Headlamp Dimmer Switch Assy
Spiral Cable Sub-assy
A/T:
Floor Shift Parking
Lock Cable Assy
Steering Column
Assy
Column Lower Cover
35 (360, 26)
21 (210, 15)
35 (360, 26)
Column Hole Cover Silencer Sheet
Nm(kgfcm, ftlbf)
: Specified torque
F42414
50-7
STEERING COLUMN
- STEERING COLUMN ASSY
Ignition Switch Lock Cylinder Assy
F Tapered-head Bolt
Un-lock Warning
Switch Assy
Steering Column Clamp Upper
Steering Column Upper
Bracket Assy
Ignition or Starter
Switch Assy
Steering Column Assy
F Non-reusable part
F42415
50-8
STEERING COLUMN
- STEERING COLUMN ASSY
5003V-02
OVERHAUL
1.
PRECAUTION
2.
DISCONNECT BATTERY NEGATIVE TERMINAL
3.
INSPECT PLACE FRONT WHEELS FACING STRAIGHT AHEAD
Torx Screw
Screw Case
4.
REMOVE HORN BUTTON ASSY
NOTICE:
If the airbag connector is disconnected with the ignition
switch being at ON, DTCs will be recorded.
(a) Using a torx socket wrench, loosen the 2 torx screws until
the groove along the screw circumference catches on the
screw case.
F42416
(b) Pull out the horn button assy from the steering wheel.
(c)
Using a screwdriver, release the lock part of each airbag
connector and disconnect the 2 airbag connectors.
NOTICE:
When removing the horn button assy, take care not to pull
the airbag wire harness.
Airbag Connector
F42417
CAUTION:
F
When storing the horn button assy, keep the upper
surface of the pad facing upward.
F
Never disassemble the horn button assy.
F42418
50-9
STEERING COLUMN
- STEERING COLUMN ASSY
5.
REMOVE STEERING WHEEL ASSY
Matchmarks
(a) Disconnect the connector.
(b) Remove the steering wheel assy set nut.
(c)
Place matchmarks on the steering wheel assy and main
shaft assy.
(d) Using SST, remove the steering wheel assy.
SST
09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05021)
SST
F42419
6.
REMOVE STEERING COLUMN COVER
(a) Remove the 3 screws and steering column cover.
7.
DISCONNECT FLOOR SHIFT PARKING LOCK CABLE
ACC
ASSY (A/T TRANSAXLE)
(a) With the key in ACC, push the claw and pull out the floor
shift parking lock cable.
F42420
8.
REMOVE SPIRAL CABLE SUB-ASSY
9.
REMOVE HEADLAMP DIMMER SWITCH ASSY
(a) Disconnect the connector and remove the headlamp dimmer switch assy.
10. REMOVE WINDSHIELD WIPER SWITCH ASSY
(a) Disconnect the connector and remove the windshield wiper switch assy.
11. REMOVE COLUMN HOLE COVER SILENCER SHEET
12. DISCONNECT STEERING INTERMEDIATE SHAFT
(a) Place matchmarks on the sliding yoke and steering inter-
mediate shaft.
(b) Loosen the bolt A and remove the bolt B, then disconnect
A
the steering intermediate shaft.
B
Matchmarks
F42421
50-10
STEERING COLUMN
- STEERING COLUMN ASSY
13. REMOVE STEERING COLUMN ASSY
(a) Disconnect the connectors and wire harness clamps from
the steering column assy.
(b) Remove the 3 bolts and steering column assy.
F42425
14. REMOVE STEERING COLUMN UPPER W/SWITCH
BRACKET ASSY
(a) Using a centering punch, mark the center of the 2 ta-
pered-head bolts.
(b) Using a 3 - 4 mm (0.12 - 0.16 in.) drill, drill into the 2 bolts.
(c)
Using a screw extractor, remove the 2 bolts and steering
column upper w/switch bracket assy.
C92363
15. REMOVE STEERING COLUMN CLAMP UPPER
16. REMOVE IGNITION SWITCH LOCK CYLINDER ASSY
(a) Place the ignition switch lock cylinder assy at the ACC
position.
(b) Push down the stop pin with a screwdriver, and pull out
the cylinder assy.
C90811
50-11
STEERING COLUMN
- STEERING COLUMN ASSY
17. REMOVE UN-LOCK WARNING SWITCH ASSY
(a) Disconnect the un-lock warning switch assy connector
from the ignition or starter switch assy.
(b) Remove the un-lock warning switch assy.
C90812
18. REMOVE IGNITION OR STARTER SWITCH ASSY
(a) Remove the 2 screws and ignition or starter switch assy from the steering column bracket assy.
19. INSTALL IGNITION OR STARTER SWITCH ASSY
(a) Install the ignition or starter switch assy to the steering column bracket assy with the 2 screws.
20. INSTALL UN-LOCK WARNING SWITCH ASSY
(a) Install the un-lock warning switch assy.
(b) Connect the un-lock warning switch assy connector to
the ignition or starter switch assy.
C90812
21. INSTALL IGNITION SWITCH LOCK CYLINDER ASSY
(a) Make sure that the ignition switch lock cylinder assy is at the ACC position.
(b) Install the ignition switch lock cylinder assy.
22. INSPECT STEERING LOCK OPERATION
(a) Check that the steering lock mechanism is activated when removing the key.
(b) Check that the steering lock mechanism is deactivated when inserting the key and turning it to ACC
position.
23. INSTALL STEERING COLUMN UPPER W/SWITCH
BRACKET ASSY
(a) Temporarily install the steering column upper w/switch
bracket assy and steering column upper clamp with 2 new
tapered-head bolts.
(b) Tighten the 2 tapered-head bolts until the bolt heads
break off.
C93841
50-12
STEERING COLUMN
- STEERING COLUMN ASSY
24. INSTALL STEERING COLUMN ASSY
(a) Install the steering column assy with the 3 bolts.
Torque: 21 N·m (210 kgf·cm, 15 ftlbf)
(b) Connect the connectors and wire harness clamps.
F42425
25. CONNECT STEERING INTERMEDIATE SHAFT
(a) Align the matchmarks on the sliding yoke and steering in-
termediate shaft.
(b) Install the bolt B and torque the bolt A.
A
Torque: 35 N·m (360 kgf·cm, 26 ftlbf)
B
Matchmarks
F42421
26. INSTALL COLUMN HOLE COVER SILENCER SHEET
27. INSTALL WINDSHIELD WIPER SWITCH ASSY
(a) Install the windshield wiper switch assy and connect the connector.
28. INSTALL HEADLAMP DIMMER SWITCH ASSY
(a) Install the headlamp dimmer switch assy and connect the connector.
29. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
30. INSTALL SPIRAL CABLE SUB-ASSY
31. CONNECT FLOOR SHIFT PARKING LOCK CABLE
ACC
ASSY (A/T TRANSAXLE)
(a) With the key in ACC, push into the floor shift parking lock
cable and install it.
F42422
50-13
STEERING COLUMN
- STEERING COLUMN ASSY
32. CONNECT CHECK KEY INTERLOCK OPERATION
33. INSTALL COVER SET STEERING COLUMN
(a) Install the steering column cover with the 3 screws.
34. CENTER SPIRAL CABLE
(a) Check that the ignition switch is at OFF.
(b) Check that the battery negative terminal is disconnected.
NOTICE:
Do not start the operation for 90 seconds after removing
the terminal.
(c)
Turn the cable counterclockwise by hand until it becomes
harder to turn.
H41415
(d) Then rotate the cable clockwise about 2.5 turns to align
the marks.
HINT:
The cable will rotate about 2.5 turns to either right or left of the
center.
H41416
35. INSTALL STEERING WHEEL ASSY
(a) Align the matchmark with the one on the steering wheel assy and steering main shaft assy.
(b) Install the steering wheel assy with the set nut.
Torque: 50 N·m (510 kgf·cm, 37 ftlbf)
(c)
Connect the connector.
36. INSPECT HORN BUTTON ASSY (See page 60-8)
37. INSTALL HORN BUTTON ASSY
NOTICE:
F
Never use the airbag parts removed from another ve-
hicle. When replacing parts, replace with new ones.
F
Make sure that the horn button assy is installed to the
specified torque.
F
If the horn button assy has been dropped, or there are
cracks, dents or other defects in the case or connec-
tor, replace the horn button assy with a new one.
F
When installing the horn button assy, take care so
that the wirings do not interfere with other parts and
that they are not pinched between other parts.
50-14
STEERING COLUMN
- STEERING COLUMN ASSY
(a) Connect the 2 airbag connectors.
(b) Install the horn button assy after confirming that the cir-
cumference groove of the torx screws is caught on the
screw case.
(c)
Using a torx socket wrench, torque the 2 torx screws.
Torx Screw
Screw Case
Torque: 8.8 N·m (90 kgf·cm, 78 in.lbf)
F42424
38. STEERING WHEEL CENTER POINT
39. INSPECT SRS WARNING LIGHT (See page 05-424)
50-2
STEERING COLUMN
- STEERING
5002P-02
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in the order shown. If necessary, repair or replace these parts.
Symptom
Suspect Area
See page
1. Tires (Improperly inflated)
28-1
2. Power steering fluid level (Low)
51-3
3. Front wheel alignment (Incorrect)
26-5
4. Steering system joints (Worn)
-
Hard steering
5. Suspension arm ball joints (Worn)
26-17
6. Steering column (Binding)
-
7. Power steering vane pump
51-8
8. Power steering gear
51-18
1. Tires (Improperly inflated)
28-1
2. Front wheel alignment (Incorrect)
26-5
Poor return
3. Steering column (Binding)
-
4. Power steering gear
51-18
1. Steering system joints (Worn)
-
2. Suspension arm ball joints (Worn)
26-17
Excessive play
3. Intermediate shaft, Sliding yoke (Worn)
-
4. Front wheel bearing (Worn)
30-17
5. Power steering gear
51-18
1. Power steering fluid level (Low)
51-3
2. Steering system joints (Worn)
-
Abnormal noise
3. Power steering vane pump
51-8
4. Power steering gear
51-18
51-3
POWER STEERING
- POWER STEERING SYSTEM
5105M-02
ON-VEHICLE INSPECTION
1.
INSPECT DRIVE BELT
(a) Visually check the belt for excessive wear, frayed cords,
etc.
If any defect is found, replace the drive belt.
HINT:
Cracks on the rib side of a belt are considered acceptable. If the
missing chunks from the ribs are found on the belt, it should be
replaced.
F40449
2.
BLEED POWER STEERING SYSTEM
(a) Check the fluid level.
(b) Jack up the front of the vehicle and support it with the
stands.
(c)
Turn the steering wheel.
(1)
With the engine stopped, turn the wheel slowly from
lock to lock several times.
(d) Lower the vehicle.
(e) Start the engine.
(1)
Run the engine at idle for a few minutes.
(f)
Turn the steering wheel.
(1)
With the engine idling, turn the wheel to left or right
full lock position and keep it there for 2 - 3 seconds,
then turn the wheel to the opposite full lock position
and keep it there for 2 - 3 seconds.
(2)
Repeat (1) several times.
(g) Stop the engine.
(h) Check for foaming or emulsification.
Normal
Abnormal
Especially, if the system has to be bled twice because of foam-
ing or emulsification, check for fluid leaks in the system.
(i)
Check the fluid level.
F40897
3.
CHECK FLUID LEVEL
(a) Keep the vehicle level.
(b) With the engine stopped, check the fluid level in the oil
reservoir.
If necessary, add fluid.
Fluid: ATF DEXRON ® II or III
HINT:
Check that the fluid level is within the HOT LEVEL range on the
F40898
reservoir tank. If the fluid is cold, check that it is within the COLD
LEVEL range.
51-4
POWER STEERING
- POWER STEERING SYSTEM
(c)
Start the engine and run it at idle.
(d) Turn the steering wheel from lock to lock several times to
raise fluid temperature.
Fluid temperature: 75 - 80
°C (167 - 176°F)
(e) Check for foaming or emulsification.
Normal
Abnormal
If foaming or emulsification is identified, bleed the power steer-
ing system.
F40897
(f)
With the engine idling, measure the fluid level in the oil
5 mm (0.20 in.)
reservoir.
or less
(g) Stop the engine.
(h) Wait a few minutes and measure the fluid level in the oil
reservoir again.
Maximum fluid level rise: 5 mm (0.20 in.)
If a problem is found, bleed the power steering system.
(i)
Check the fluid level.
Engine Idling
Engine Stopped
R11786
4.
CHECK STEERING FLUID PRESSURE
(a) Disconnect the pressure feed tube from the PS gear (See
page 51-18).
(b) Connect SST, as shown in the illustration.
SST
09640-10010 (09641-01010, 09641-01020,
09641-01030)
NOTICE:
Check that the valve of the SST is in the open position.
(c)
Bleed the power steering system.
(d) Start the engine and run it at idle.
(e) Turn the steering wheel from lock to lock several times to
raise fluid temperature.
Fluid temperature: 75 - 80
°C (167 - 176 °F)
51-5
POWER STEERING
- POWER STEERING SYSTEM
Attachment
Pressure
SST
Feed Tube
Attachment
IN
OUT
F42426
(f)
With the engine idling, close the valve of the SST and ob-
serve the reading on the SST.
Oil
Reservoir
Fluid pressure:
7,300 - 7,800 kPa (75 - 80 kgf/cm 2, 1,067 - 1,138 psi)
PS Gear
NOTICE:
Closed
F
Do not keep the valve closed for more than 10 se-
PS Vane
conds.
Pump
F
Do not let the fluid temperature become too high.
SST
Z15498
(g) With the engine idling, open the valve fully.
Oil
(h) Measure the fluid pressure at engine speeds of 1,000 rpm
Reservoir
and 3,000 rpm.
Fluid pressure difference:
PS Gear
490 kPa (5 kgf/cm 2, 71 psi) or less
Open
NOTICE:
Do not turn the steering wheel.
PS Vane
Pump
SST
Z15499
(i)
With the engine idling and valve fully opened, turn the
steering wheel to full lock position.
Oil
Reservoir
Fluid pressure:
Lock Position
7,300 - 7,800 kPa (75 - 80 kgf/cm 2, 1,067 - 1,138 psi)
NOTICE:
PS Gear
Open
F
Do not maintain lock position for more than 10 se-
PS Vane
conds.
Pump
F
Do not let the fluid temperature become too high.
SST
Z15500
51-6
POWER STEERING
- POWER STEERING SYSTEM
(j)
Disconnect the SST.
SST
09640-10010 (09641-01010, 09641-01020,
09641-01030)
(k)
Connect the pressure feed tube to the PS gear
(See page 51-18).
(l)
Bleed the power steering system.
5.
CHECK STEERING EFFORT
(a) Center the steering wheel assy.
(b) Remove the horn button assy (See page 50-8).
(c)
Start the engine and run it at idle.
(d) Measure the steering effort in both directions.
Steering effort (Reference):
6 N·m (60 kgf·cm, 53 in.·lbf) or less
HINT:
F42428
Take the tire type, pressure and contact surface into consider-
ation before making your diagnosis.
(e) Install the steering wheel assy set nut.
Torque: 50 N·m (510 kgf·cm, 37 ft·lbf)
(f)
Install the horn button assy (See page 50-8).

 

 

 

 

 

 

 

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