Toyota Corolla (2004+). Manual - part 35

 

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Toyota Corolla (2004+). Manual - part 35

 

 

51-1
POWER STEERING
- POWER STEERING SYSTEM
POWER STEERING SYSTEM
5107U-01
PRECAUTION
1.
HANDLING PRECAUTIONS ON SRS AIRBAG SYSTEM
(a) The vehicle is equipped with SRS (Supplemental Restraint System) such as the driver airbag and front
passenger airbag. Failure to carry out service operation in correct sequence could cause the SRS to
unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing (includ-
ing removal or installation of parts, inspection or replacement), be sure to read the precautionary notice
for the supplemental restraint system (See page 60-1).
51-15
POWER STEERING
- RACK & PINION POWER STEERING GEAR ASSY
RACK & PINION POWER STEERING GEAR ASSY
5107X-01
COMPONENTS
Pressure Feed
7.8 (80, 69 in.lbf)
and Return Tube
Engine Hood
25 (255, 18)
Column Hole Cover
*23 (235, 17)
Sub-assembly
Extension
13 (130, 9)
Shaft
Engine Rear Mount Insulator
35 (360, 26)
_ Cotter Pin
64 (650, 47)
49 (500, 36)
_ Cotter Pin
Engine Rear
58 (590, 43)
Mount Bracket
49 (500, 36)
87 (890, 64)
157 (1,600, 116)
PS Gear Assembly
64 (650, 47)
74 (750, 54)
74 (750, 54)
89 (910, 66)
157 (1,600, 116)
157 (1,600, 116)
52 (530, 38)
52 (530, 38)
89 (910, 66)
157 (1,600, 116)
39 (400, 29)
LH Engine Under Cover
RH Engine Under Cover
Nm (kgfcm, ftlbf)
: Specified torque
_ Non-reusable part
* For use with SST
F42430
51-16
POWER STEERING
- RACK & PINION POWER STEERING GEAR ASSY
Tie Rod End
Lock Nut
74 (750, 54)
Clip
Rack Boot
_ Clamp
Rack End
83 (850,61)
*62 (630, 46)
_ Oil Seal
_ Snap Ring
_ O-Ring
Cylinder End Stopper
Bushing
_ Teflon Ring
_ O-Ring
Steering Rack
_ Oil Seal
Rack Housing
Rack End
83 (850, 61)
*62 (630, 46)
_ Clamp
Rack Boot Clip
Nm (kgfcm, ftlbf)
: Specified torque
Lock Nut
_ Non-reusable part
74 (750, 54)
Molybdenum disulfide lithium base grease
Power steering fluid
* For use with SST
Tie Rod End
F42481
51-17
POWER STEERING
- RACK & PINION POWER STEERING GEAR ASSY
18 (185, 13)
13 (130, 9)
*12 (120, 9)
Turn Pressure Tube
13 (130, 9)
Control Valve
*12 (120, 9)
Housing
18 (185, 13)
_ O-Ring
_ O-Ring
_ O-Ring
_ Gasket
_ Oil Seal
_ O-Ring
_ Bearing
Turn Pressure Tube
F Rack Guide Spring
Cap Lock Nut
Control
59 (600, 43)
Valve Assembly
*43 (440, 32)
F Rack Guide
_ Teflon Ring
Spring Cap
_ Oil Seal
Rack Guide Spring
_ Bearing
Rack Guide
Sub-Assembly
Rack Housing
_ Bearing
Self-locking Nut
25 (250, 18)
F Rack Housing Cap
59 (600, 43)
Nm (kgfcm, ftlbf)
: Specified torque
_ Non-reusable part
F Precoated part
Molybdenum disulfide lithium base grease
Power steering fluid
* For use with SST
F42432
51-18
POWER STEERING
- RACK & PINION POWER STEERING GEAR ASSY
5107Y-02
OVERHAUL
NOTICE:
When installing, coat the parts indicated by the arrow with power steering fluid or molybdenum disul-
fide lithium base grease(See page
51-15).
1.
PRECAUTION(See page 60-1)
2.
DISCONNECT BATTERY NEGATIVE TERMINAL
3.
INSPECT CENTER FRONT WHEEL
4.
REMOVE HORN BUTTON ASSY(See page 50-8)
5.
REMOVE STEERING WHEEL ASSY(See page 50-8)
SST
09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
6.
REMOVE FRONT WHEELS
7.
REMOVE ENGINE UNDER COVER LH
8.
REMOVE ENGINE UNDER COVER RH
9.
DISCONNECT TIE ROD END SUB-ASSY LH
(a) Remove the cotter pin and nut.
(b) Using SST, disconnect tie rod end sub-assy LH from the
steering knuckle.
SST
09628-62011
SST
F41955
10. DISCONNECT TIE ROD END SUB-ASSY RH
SST
09628-62011
HINT:
Remove the RH side by the same procedures as of the LH side.
11. REMOVE COLUMN HOLE COVER SILENCER SHEET
12. DISCONNECT STEERING INTERMEDIATE SHAFT(See page 50-8)
13. DISCONNECT PRESSURE FEED TUBE ASSY
(a) Using SST, disconnect the pressure feed tube assy.
SST
SST
09023-38400
F42433
51-19
POWER STEERING
- RACK & PINION POWER STEERING GEAR ASSY
14. DISCONNECT RETURN TUBE SUB-ASSY
(a) Using SST, disconnect the return tube sub-assy.
SST
09023-38400
(b) Remove the bolt and disconnect the tube clamp.
F42436
15. DISCONNECT FRONT STABILIZER LINK ASSY LH
(a) Remove the nut and disconnect the front stabilizer link assy LH.
16. DISCONNECT FRONT STABILIZER LINK ASSY RH
HINT:
Remove the RH side by the same procedures as the LH side.
17. DISCONNECT FRONT SUSPENSION ARM
SUB-ASSY LOWER NO.1 LH
(a) Remove the bolt and 2 nuts and disconnect the front sus-
pension arm sub-assy lower No.1 LH from the lower ball
joint.
C88538
18. DISCONNECT FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH
HINT:
Remove the RH side by the same procedures as the LH side.
19. REMOVE HOOD SUB-ASSY
20. REMOVE CYLINDER HEAD COVER NO.2
51-20
POWER STEERING
- RACK & PINION POWER STEERING GEAR ASSY
21. SUSPEND ENGINE ASSEMBLY
(a) Install the 2 engine hangers with the bolts in the correct
direction.
Parts No.:
No.1 engine hanger: 12281 - 22021
No.2 engine hanger: 12281 - 15040
Bolt: 91512 - B1016
Torque:
F42894
38 Nm (390 kgfcm, 28 ftlbf)
(b) Attach the engine chain hoist to the engine hangers.
CAUTION:
Do not attempt to hang the engine by hooking the chain to
any other parts.
22. REMOVE FRONT SUSPENSION CROSSMEMBER
SUB-ASSY
(a) Remove the 2 bolts and disconnect the center member
from the engine mounting insulator FR.
(b) Remove the 2 bolts and disconnect the center member
from the frame.
C80317
(c)
Remove the bolt and 3 nuts, disconnect the engine
mounting insulator RR from the crossmember.
(d) Using a transmission jack, support the crossmember.
(e) Remove the 4 bolts and front suspension crossmember
sub-assy with the steering gear assy.
C80318
23. REMOVE STEERING COLUMN HOLE COVER SUB-ASSY NO.1
24. REMOVE STEERING INTERMEDIATE SHAFT
(a) Place matchmarks on the intermediate shaft with control
Matchmarks
valve.
(b) Remove the bolt and steering intermediate shaft.
F42435
51-21
POWER STEERING
- RACK & PINION POWER STEERING GEAR ASSY
25. REMOVE RACK & PINION POWER STEERING GEAR ASSY
(a) Remove the 4 bolts and rack & pinion power steering gear assy from the crossmember.
26. FIX RACK & PINION POWER STEERING GEAR ASSY
(a) Using SST, secure the rack & pinion power steering gear
assy in a vise.
SST
SST
09612-00012
F42437
27. REMOVE STEERING LEFT TURN PRESSURE TUBE
(a) Using SST, remove the left turn pressure tube.
SST
09023-38200
(b) Remove the 2 O-rings from the left turn pressure tube.
SST
28. REMOVE STEERING RIGHT TURN PRESSURE TUBE
(a) Using SST, remove the right turn pressure tube.
SST
09023-38200
(b) Remove the 2 O-rings from the right turn pressure tube.
F42438
29. REMOVE TIE ROD END SUB-ASSY LH
(a) Place matchmarks on the tie rod end with rack end.
(b) Loosen the lock nut, and remove the tie rod end and lock
nut.
Matchmarks
F40050
30. REMOVE TIE ROD END SUB-ASSY RH
HINT:
Remove the RH side by the same procedures as the LH side.
31. INSPECT TIE ROD END SUB-ASSY LH
(a) Secure the tie rod end LH 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 torx wrench, turn the nut continuously at a rate of
2 - 4 seconds per 1 turn and take the torque reading of
the 5th turn.
Turning torque:
ZK8184
0.49 - 3.43 Nm (5.0 - 35 kgfcm, 4.34 - 30.38 in.lbf)
51-22
POWER STEERING
- RACK & PINION POWER STEERING GEAR ASSY
32. INSPECT TIE ROD END SUB-ASSY RH
HINT:
Inspect the RH side by the same procedures as the LH side.
33. REMOVE STEERING RACK BOOT NO.1
(a) Remove the steering rack boot clip.
(b) Using a screwdriver, remove the clamp and steering rack
boot No.1.
F42439
34. REMOVE STEERING RACK BOOT NO.2
HINT:
Remove the steering rack boot No.2 by same procedures as the No.1.
35. REMOVE STEERING RACK END SUB-ASSY
(a) Using a spanner, hold the steering rack steadily and using
SST, remove the rack end.
SST
09922-10010
SST
NOTICE:
Use SST 09922-10010 in the direction shown in the illustra-
tion.
HINT:
F42440
Mark the RH and LH rack ends.
(b) Use the same manner described above to the other side.
36. REMOVE RACK GUIDE
(a) Using SST, remove the rack guide spring cap nut.
SST
09922-10010
NOTICE:
Use SST 09922-10010 in the direction shown in the illustra-
tion.
SST
(b) Using a hexagon wrench (19 mm), remove the rack guide
spring cap.
F42441
(c)
Remove the conical spring, rack guide spring and rack
guide.
37. REMOVE POWER STEERING CONTROL VALVE
(a) Remove the rack housing cap.
51-23
POWER STEERING
- RACK & PINION POWER STEERING GEAR ASSY
(b) Using SST, hold the control valve shaft and remove the
self-locking nut.
SST
SST
09616-00011
F42442
(c)
Remove the 2 bolts and power steering control valve.
(d) Remove the gasket.
F42443
(e) To prevent oil seal lip damage, wind vinyl tape around the
Vinyl Tape
serrated part of the control valve.
(f)
Using a plastic hammer, remove the control valve with oil
seal from the control valve housing.
(g) Remove the oil seal from the control valve.
F40540
(h) Using a screwdriver, remove the 4 control valve rings.
Control Valve Ring
NOTICE:
Be careful not to damage the grooves for the control valve
ring.
R11572
38. REMOVE POWER STEERING CONTROL VALVE
UPPER OIL SEAL
(a) Using SST and a press, remove the control valve upper
SST
bearing and upper oil seal from the control valve housing.
SST
09950-60010 (09951-00260), 09950-70010
(09951-07150)
39. REMOVE CYLINDER END STOPPER
(a) Using snap ring pliers, remove the snap ring.
F40911
(b) Pull out the cylinder end stopper.
51-24
POWER STEERING
- RACK & PINION POWER STEERING GEAR ASSY
40. REMOVE POWER STEERING RACK
SST
(a) Using SST and a press, remove the steering rack with the
Rack
bushing.
SST
09612-24014 (09612-10061)
NOTICE:
Take care not to drop the steering rack.
(b) Remove the O-ring from the bushing.
F42444
41. REMOVE POWER STEERING RACK BUSH
SST
SUB-ASSY
(a) Remove the power steering rack bush from the power
steering rack.
(b) Using SST, remove the rack bush oil seal.
SST
09612-24014 (09613-22011)
F40542
42. REMOVE POWER STEERING CYLINDER TUBE OIL
SEAL
(a) Using SST and a press, remove the power steering cylin-
SST
der tube oil seal.
SST
09950-60010 (09951-00260), 09950-70010
(09951-07360)
Oil Seal
F42445
43. REMOVE POWER STEERING CONTROL VALVE
SST
LOWER BEARING
(a) Using SST and a press, remove the power steering con-
trol valve lower bearing.
SST
09950-70010 (09951-07100)
F42464
(b) Using SST and a press, remove the power steering con-
SST
trol valve center bearing.
SST
09950-70010 (09951-07100)
F42465
51-25
POWER STEERING
- RACK & PINION POWER STEERING GEAR ASSY
44.
INSPECT POWER STEERING RACK
(a)
Using a screwdriver, remove the O-ring from the power
steering rack bush sub-assy.
(b)
Using a dial indicator, check the steering rack for run out
and for teeth wear and damage.
Maximum run out: 0.1 mm (0.004 in.)
(c)
Check the back surface for wear and damage.
ZX9355
45.
INSTALL POWER STEERING CONTROL VALVE
LOWER BEARING
SST
(a)
Coat a new bearing with molybdenum disulfide lithium
base grease.
(b)
Using SST and a press, install the control valve center
bearing.
SST
09950-60010 (09951-00220, 09951-00280,
SST
09952-06010), 09950-70010 (09951-07100)
F42466
(c)
Coat a new bearing with molybdenum disulfide lithium
SST
base grease.
(d)
Using SST and a press, install the control valve lower
bearing.
SST
09950-60010 (09951-00280), 09950-70010
(09951-07100)
F42467
46. INSTALL POWER STEERING CYLINDER TUBE OIL
SST
SEAL
(a) Coat a new power steering cylinder tube oil seal lip with
power steering fluid.
(b) Using SST and a press, install the power steering cylinder
tube oil seal.
SST
09950-60010 (09951-00240, 09951-00400,
09952-06010), 09950-70010 (09951-07360)
Oil Seal
SST
F42446
NOTICE:
F
Make sure that the power steering cylinder tube oil
seal is installed facing in the correct direction.
F
Take care so that the power steering cylinder tube oil
seal will not be reversed when you install it.
51-26
POWER STEERING
- RACK & PINION POWER STEERING GEAR ASSY
47. INSTALL POWER STEERING RACK
(a) Coat a new power piston O-ring with power steering fluid
and install it to the steering rack.
(b) Coat a new power piston oil seal with power steering fluid.
(c)
Expand the power piston oil seal with your fingers.
NOTICE:
Be careful not to expand the power piston oil seal exces-
sively.
C03629
(d) Install the power piston oil seal to the steering rack, and
settle it down with your fingers.
SST
09631-16020
N00401
(e) Install SST to the steering rack.
SST
09631-16020
HINT:
If necessary, scrape the burrs off the steering rack teeth end
and burnish.
(f)
Coat the SST with power steering fluid.
(g) Install the steering rack into the rack housing.
Rack Teeth End
(h) Remove the SST.
SST
09631-16020
SST
W02101
48. INSTALL POWER STEERING RACK BUSH
SUB-ASSY
(a) Using SST and a press, install the rack bush oil seal to the
SST
power steering rack bush.
SST
09950-60010 (09951-00400), 09950-70010
(09951-07100)
NOTICE:
Make sure that the rack bush oil seal is installed facing in
F40543
the correct direction.
51-27
POWER STEERING
- RACK & PINION POWER STEERING GEAR ASSY
(b) Coat a new O-ring with power steering fluid and install it
to the power steering rack bush.
(c)
To prevent rack bush oil seal lip damage, wind vinyl tape
around the steering rack end, and apply power steering
fluid.
(d) Install the rack bush to the steering rack.
Vinyl Tape
F05730
49. INSTALL CYLINDER END STOPPER
(a) Using SST and a hammer, drive in the cylinder end stop-
per.
SST
09612-22011
(b) Using snap ring pliers, install a new snap ring to the rack
SST
housing.
F42447
50. INSPECT RACK & PINION POWER STEERING GEAR
SST
ASSY
(a) Install SST to 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
F42448
oil seals.
51. INSTALL POWER STEERING CONTROL VALVE
SST
UPPER OIL SEAL
(a) Coat an upper bearing and a new upper oil seal with pow-
er steering fluid.
(b) Using SST and a press, install the upper oil seal.
SST
09950-60010 (09951-00180, 09951-00320,
09952-06010), 09950-70010 (09951-07100)
NOTICE:
F41137
Make sure that the oil seal is installed facing in the correct
direction.
51-28
POWER STEERING
- RACK & PINION POWER STEERING GEAR ASSY
(c)
Using SST and a press, install the upper bearing.
SST
SST
09950-60010 (09951-00190, 09951-00360,
09952-06010), 09950-70010 (09951-07100)
F41138
52. INSTALL POWER STEERING CONTROL VALVE
(a) Expand 4 new control valve rings with your fingers.
NOTICE:
Be careful not to over expand the valve ring.
(b) Coat the 4 control valve rings with power steering fluid.
(c)
Install the 4 control valve rings to the control valve, and
settle them down with your fingers.
C03629
(d) Carefully slide the tapered end of SST over the control
SST
valve rings until they fit to the control valve.
SST
09631-20081
NOTICE:
Be careful not to damage the control valve rings.
Control Valve Ring
R11573
(e) To prevent oil seal lip damage, wind vinyl tape around the
serrated part of the control valve.
(f)
Install the control valve to the valve housing.
NOTICE:
Vinyl Tape
Be careful not to damage the control valve rings and oil
seal lip.
F42449
(g) Coat a new oil seal lip with power steering fluid.
(h) Using SST and a press, install the oil seal.
SST
SST
09612-22011
NOTICE:
Make sure that the oil seal is installed facing in the correct
direction.
Oil Seal
F42450

 

 

 

 

 

 

 

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