Toyota Corolla (2004+). Manual

51-29

POWER STEERING

- RACK & PINION POWER STEERING GEAR ASSY

(i)

Apply grease to the needle bearing.

(j)

Install a new gasket to the valve housing.

(k)

Wind vinyl tape around the serration part of the control

valve.

(l)

Install the valve housing to the rack housing with the 2

bolts.

Torque: 18 N m (185 kgf cm, 13 ft lbf)

F42443

(m)

Using SST, stop the control valve shaft rotation and install

SST

a self-locking nut.

SST

09616-00011

Fulcrum

Torque: 25 N m (250 kgf cm,18 ft lbf)

Length

(n)

Apply sealant to 2 or 3 threads of the rack housing cap.

Sealant:

Part No. 08833-00080, THREE BOND 1344, LOCTITE

242 or equivalent

F42451

(o)

Install the rack housing cap.

Torque: 59 N m (600kgf cm, 43 ft lbf)

(p)

Using a punch and a hummer, stake the rack housing cap

and rack housing.

F42452

53. INSTALL RACK GUIDE

(a) Apply molybdenum disulfide lithium base grease to the contact surface of the power steering rack and

of the rack guide.

(b) Install the rack guide and compression spring to the rack housing.

(c)

Apply sealant to 2 or 3 threads of the rack guide spring cap.

Sealant:

Part No. 0.8833-00080, THREE bOND 1344, LOCTITE 242 or equivalent

(d) Temporarily install the rack guide spring cap.

54. INSPECT TOTAL PRELOAD

(a) To prevent the steering rack teeth from damaging the oil

seal lip, temporarily install the RH and LH rack ends.

(b) Torque the rack guide spring cap.

Torque: 25 N m (250 kgf cm, 18 ft lbf)

(c)

Back off the rack guide spring cap 12_.

12_

F42453

51-30

POWER STEERING

- RACK & PINION POWER STEERING GEAR ASSY

(d) Using SST, turn the control valve shaft right and left 1 or

2 times.

SST

09616-00011

(e) Loosen the rack guide spring cap until the rack guide

spring is not functioning.

F42454

(f)

Using SST and torque wrench, tighten the rack guide

spring cap until the preload is within the specification.

SST

09616-00011

Preload (turning):

1.0 - 1.8 Nm (20 - 18 kgf cm, 8.6 - 15.7 ft lbf)

(g) Apply sealant to 2 or 3 threads of the rack guide spring

cap lock nut.

Sealant:

F42455

Part No. 08833-00080, THREE BOND 1344, LOCTITE

242 or equivalent

(h) Temporarily install the lock nut.

(i)

Using a hexagon wrench (19 mm), hold the rack guide

spring cap and using SST, torque the nut.

SST

09922-10010

Torque: 43 N m (440 kgf cm, 32 ft lbf)

NOTICE:

Use SST 09922-10010 in the direction shown in the illustra-

tion.

Fulcrum

HINT:

Length

F42456

Use a torque wrench with a fulcrum length of 345 mm (13.58

in.).

(j)

Recheck the total preload.

Preload (turning):

1.0 - 1.8 Nm (10 - 18 kgf cm, 8.6 - 15.7 ft lbf)

(k)

Remove the RH and LH rack ends.

51-31

POWER STEERING

- RACK & PINION POWER STEERING GEAR ASSY

55. INSTALL STEERING RACK END SUB-ASSY

(a) Using a spanner, hold the steering rack steadily and using

SST

SST, install the 2 rack ends.

SST

09922-10010

Torque: 62 N m (630 kgf cm, 46 ft lbf)

Fulcrum

NOTICE:

Length

Use SST 09922-10010 in the direction shown in the illustra-

tion.

F42457

HINT:

Using SST, hold the rack and install the rack and sub-

assy.

Use a torque wrench with a fulcrum length of 380 mm

(14.96 in.).

(b) Ensure that the steering rack hole is not clogged with

grease.

HINT:

If the hole is clogged, the pressure inside the boot will change

after it is assembled and steering wheel is turned.

F42458

56. INSTALL STEERING RACK BOOT NO.2

(a) Install the steering rack boot No.2.

(b) Using SST, tighten the steering rack boot No.2 clamp, as

shown in the illustration.

SST

09521-24010

Clearance: 3.0 mm (0.118 in.) or less

3 mm

NOTICE:

(0.118 in.)

Be careful not to damage the boot.

SST

or less

F42459

(c)

Using a pliers, install the rack boot clip.

57. INSTALL STEERING RACK BOOT NO.1

HINT:

Install the rack boot No.1 by the same procedures as the rack boot No.2.

58. INSTALL TIE ROD END SUB-ASSY LH

(a) Screw the lock nut and tie rod end sub-assy LH onto the

Matchmarks

rack end until the matchmarks are aligned.

HINT:

After adjusting toe-in, torque the lock nut (See page 26-5).

Torque: 74 N m (750 kgf cm, 54 ft lbf)

F41467

51-32

POWER STEERING

- RACK & PINION POWER STEERING GEAR ASSY

59. INSTALL TIE ROD END SUB-ASSY RH

HINT:

Install the RH side by the same procedures as the LH side.

60. INSTALL STEERING RIGHT TURN PRESSURE TUBE

Fulcrum

(a) Coat 2 new O-rings with power steering fluid and install

Length

them to the right turn pressure tube.

(b) Using SST, install the right turn pressure tube to the steer-

ing gear assy.

SST

09023-38200

Torque:12 N m (120 kgf cm, 8 ft lbf)

O-Ring SST

HINT:

F42460

Use a torque wrench with a fulcrum length of 345 mm

(13.58 in.).

This torque value is effective in the case that SST is paral-

lel to a torque wrench.

61. INSTALL STEERING LEFT TURN PRESSURE TUBE

(a) Coat 2 new O-rings with power steering fluid and install them to the left turn pressure tube.

(b) Using SST, install the left turn pressure tube to the steering gear assy.

SST

09023-38200

Torque 12 N m (120 kgf cm, 8 ft lbf)

HINT:

Use a toque wrench with a fulcrum length of 345 mm (13.58 in.).

This torque value is effective in the case that SST is parallel to a torque wrench.

62. INSTALL RACK & PINION POWER STEERING GEAR ASSY

(a) Install the power steering gear assy with the 4 bolts and nuts.

Torque 58 N m (590 kgf cm, 43 ft lbf)

NOTICE:

The 4 bush must be securely installed to the power steering gear assy.

When tightening the installation bolt for power steering gear, the bush should not bitten in.

63. INSTALL STEERING INTERMEDIATE SHAFT

(a) Align the matchmarks on the steering intermediate shaft

Matchmarks

with steering pinion shaft.

(b) Install the bolt.

Torque: 35 N m (360 kgf cm, 26 ft lbf)

F42435

64. INSTALL STEERING COLUMN HOLE COVER SUB-ASSY NO.1

51-33

POWER STEERING

- RACK & PINION POWER STEERING GEAR ASSY

65.

INSTALL FRONT SUSPENSION CROSSMEMBER

SUB-ASSY

(a)

Using SST, align the holes of the front suspension mem-

ber RH and body, and temporarily tighten the bolt in order

of A, B.

SST

09670-00010

SST

F40256

(b)

Using SST, align the holes of the front suspension mem-

ber LH and body, and temporarily tighten the bolt in order

of A, B.

SST

09670-00010

(c)

Using SST, align the holes of the front suspension mem-

ber RH and body, and torque the bolt A and B.

SST

09670-00010

Torque:

F40257

Bolt A: 157 N m (1,600 kgf cm, 116 ft lbf)

Bolt B: 157 N m (1,600 kgf cm, 116 ft lbf)

(d)

Using SST, align the holes of the front suspension mem-

ber LH and body, and torque the bolt A and B.

SST

09670-00010

Torque:

Bolt A: 157 N m (1,600 kgf cm, 116 ft lbf)

Bolt B: 157 N m (1,600 kgf cm, 116 ft lbf)

(e) Connect the engine mounting insulator RR to the cross-

member with the bolt and 3 nuts.

Torque: 52 N m (530 kgf cm, 38 ft lbf)

C80318

(f)

Install the center member to the frame with the 2 bolts.

Torque: 39 N m (400 kgf cm, 29 ft lbf)

(g) Connect the engine mounting insulator FR to the center

member with the 2 bolts.

Torque: 52 N m (530 kgf cm, 38 ft lbf)

C85673

51-34

POWER STEERING

- RACK & PINION POWER STEERING GEAR ASSY

66. CONNECT FRONT SUSPENSION ARM SUB-ASSY

LOWER NO.1 LH

(a) Connect the front suspension lower arm No.1 to the lower

ball joint with the bolt and 2 nuts.

Torque: 89 N m (910 kgf cm, 66 ft lbf)

C88538

67. CONNECT FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH

HINT:

Use the same manner described above to the other side.

68. CONNECT FRONT STABILIZER LINK ASSY LH

(a) Connect the front stabilizer link assy LH with the nut.

Torque: 74 N m (755 kgf cm, 55 ft lbf)

69. CONNECT FRONT STABILIZER LINK ASSY RH

HINT:

Use the same manner described above to the other side.

70. CONNECT RETURN TUBE SUB-ASSY

SST

(a) Using SST, connect the return tube sub-assy.

SST

09023-38400

Torque: 23 N m (235 kgf cm, 17 ft lbf)

HINT:

Use a torque wrench with a fulcrum length of 345 mm

(13.58 in.).

This torque value is effective in case that SST is parallel

Fulcrum

Length

F42461

to a torque wrench.

71. CONNECT PRESSURE FEED TUBE ASSY

(a) Using SST, connect the pressure feed tube assy.

SST

09023-38400

Torque: 23 N m (235 kgf cm, 17 ft lbf)

HINT:

Use a torque wrench with a fulcrum length of 345 mm

(13.58 in.).

This torque value is effective in case that SST is parallel

to a torque wrench.

(b) Connect the tube clamp with the bolt.

Torque: 7.8 N m (80 kgf cm, 69 ft lbf)

F42436

51-35

POWER STEERING

RACK & PINION POWER STEERING GEAR ASSY

72. CONNECT STEERING INTERMEDIATE SHAFT(See page 50-8)

73. CONNECT TIE ROD END SUB-ASSY LH

(a) Connect the tie rod end sub-assy LH with the nut.

Torque: 49 N m (500 kgf cm, 36 ft lbf)

(b) Install a new cotter pin.

NOTICE:

If the holes for a new cotter pin are not aligned, tighten the nut further up to 60

74. CONNECT TIE ROD END SUB-ASSY RH

HINT:

Use the same manner described above to the other side.

75. INSTALL ENGINE UNDER COVER LH

76. INSTALL ENGINE UNDER COVER RH

77. INSTALL FRONT WHEELS

Torque: 103 N m (1,050 kgf cm, 76 ft lbf)

78. INSPECT CENTER FRONT WHEEL

79. INSTALL COLUMN HOLE COVER SILENCER SHEET

(a) Install the column hole cover silencer sheet with the 2 nuts.

80. ADD POWER STEERING FLUID

81. BLEED POWER STEERING FLUID(See page 51-3)

82. INSPECT FLUID LEAK

83. INSTALL CYLINDER HEAD COVER NO.2

(a) Install the cylinder head cover No.2 with 2 nuts and 2 clips.

Torque: 7.0 N m (71 kgf cm, 62 ft lbf)

84. INSTALL HOOD SUB-ASSY

85. INSPECT HOOD SUB-ASSY

86. ADJUST HOOD SUB-ASSY(See page 75-1)

87. CENTER SPIRAL CABLE(See page 50-8)

88. INSTALL STEERING WHEEL ASSY(See page 50-8)

89. INSTALL HORN BUTTON ASSY(See page 50-8)

90. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT(See page

26-5)

91. INSPECT SRS WARNING LIGHT(See page 05-424)

51-2

POWER STEERING

- POWER STEERING SYSTEM

5105L-02

PROBLEM SYMPTOMS TABLE

HINT:

Use the table below to help you find the cause of the problem. The numbers indicate the probability of the

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. Drive belt (Loose)

14-4

4. Front wheel alignment (Incorrect)

26-5

Hard steering

5. Steering system joints (Worn)

6. Suspension arm ball joints (Worn)

26-17

7. Steering column (Binding)

8. Power steering vane pump

51-8

9. 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

51-7

POWER STEERING

- VANE PUMP ASSY

VANE PUMP ASSY

5107V-01

COMPONENTS

Pressure Port Union

69 (700, 51)

FO-Ring

Flow Control Valve

Oil Pressure Switch

Spring

21 (210, 15)

FO-Ring

Suction Port Union

12 (120, 9)

37 (380, 27)

Vane Pump Bracket Rear

Front Housing

FOil Seal

22 (220, 16)

Rear Housing

Vane Pump Shaft with

Vane Pump Pulley

FSnap Ring

Vane Pump Rotor

Side Plate

F O-Ring

FO-Ring

 10

22 (220, 16)

Vane Plate

Cam Ring

Nm (kgfcm, ftlbf)

: Specified torque

FNon-reusable part

Power steering fluid

F42473

51-8

POWER STEERING

- VANE PUMP ASSY

5107W-01

OVERHAUL

NOTICE:

When using a vise, do not over tighten.

When installing, coat the parts indicated by the arrows with power steering fluid

(See page 51-7).

REMOVE FRONT WHEEL RH

DRAIN POWER STEERING FLUID

REMOVE ENGINE UNDER COVER RH

REMOVE FAN AND GENERATOR V BELT

DISCONNECT OIL RESERVOIR TO PUMP HOSE NO.1

(a) Remove the clip and disconnect the oil reservoir to pump hose No.1.

DISCONNECT PRESSURE FEED TUBE ASSY

SST

(a) Using SST, disconnect the pressure feed tube assy.

SST

09023-38400

(b) Remove the bolt and disconnect the pressure feed tube

clamp.

F42474

REMOVE VANE PUMP ASSY

(a) Disconnect the oil pressure switch connector.

(b) Remove the 2 bolts, nuts and vane pump assy.

C80321

REMOVE VANE PUMP BRACKET REAR

(a) Remove the bolt and vane pump bracket rear.

FIX VANE PUMP ASSY

(a) Using SST, hold the vane pump assy in a vise.

SST

09630-00014 (09631-00132)

SST

F42477

51-9

POWER STEERING

- VANE PUMP ASSY

10. REMOVE POWER STEERING SUCTION PORT UNION

(a) Remove the bolt and power steering suction port union.

(b) Remove the O-ring from the power steering suction port union.

11. REMOVE FLOW CONTROL VALVE

(a) Remove the pressure port union.

(b) Remove the O-ring from the pressure port union.

(c)

Remove the flow control valve and flow control valve compression spring.

12. REMOVE POWER STEERING OIL PRESSURE SWITCH

NOTICE:

Be careful so that oil pressure switch is not dropped or strongly damaged, however if it is damaged

replace it with a new one.

13. REMOVE VANE PUMP HOUSING REAR

(a) Remove the 4 bolts and vane pump housing rear from the vane pump housing front.

(b) Remove the O-ring from the vane pump housing front.

14. REMOVE W/PULLEY SHAFT SUB-ASSY

(a) Using a screwdriver, remove the snap ring from the w/ pulley shaft sub-assy.

(b) Remove the w/ pulley shaft sub-assy.

15. REMOVE VANE PUMP ROTOR

(a) Remove the 10 vane plates.

(b) Remove the vane pump rotor.

16. REMOVE VANE PUMP CAM RING

17. REMOVE VANE PUMP SIDE PLATE FRONT

(a) Remove the side plate from the pump housing front.

(b) Remove the O-ring from the side plate front.

C65368

(c)

Remove the O-ring from the pump housing front.

C65369

51-10

POWER STEERING

- VANE PUMP ASSY

18. REMOVE VANE PUMP HOUSING OIL SEAL

(a) Using SST and a hammer, remove the vane pump hous-

SST

ing oil seal.

SST

09631-10030

NOTICE:

Be careful not to damage the pump housing.

F42143

19. INSPECT OIL CLEARANCE

(a) Using a micrometer and a caliper gauge, measure the oil

Bushing

seal clearance.

Standard clearance:

0.021 - 0.043 mm (0.0008 - 0.0017 in.)

Maximum clearance: 0.07 mm (0.0028 in.)

If it is more than the maximum, replace the vane pump assy.

Front Housing

Vane Pump Shaft

F09875

20. INSPECT VANE PUMP ROTOR AND VANE PLATES

Thickness

(a) Using a micrometer, measure the height, thickness and

length of the vane plates.

Height

Minimum height: 7.6 mm (0.299 in.)

Minimum thickness: 1.405 mm (0.0553 in.)

Minimum length: 11.993 mm (0.4722 in.)

Length

N00372

(b) Using a feeler gauge, measure the clearance between a

side face of the vane pump rotor groove and vane plate.

Maximum clearance: 0.03 mm (0.0012 in.)

If it is more than the maximum, replace the vane pump assy.

Feeler Gauge

R10282

21. INSPECT FLOW CONTROL VALVE

(a) Coat the flow control valve with power steering fluid and

check that it falls smoothly into the flow control valve hole

by its own weight.

F41493

51-11

POWER STEERING

- VANE PUMP ASSY

(b) Check the flow control valve for leakage. Close one of the

holes and apply compressed air of 392 - 490 kPa (4 - 5

Compressed Air

kgfcm2, 57 - 71 psi) into the opposite side hole, and con-

firm that air does not come out from the end holes.

If necessary, replace the vane pump assy.

F41491

F41622

22. INSPECT FLOW CONTROL VALVE COMPRESSION

SPRING

(a) Using vernier calipers, measure the free length of the

spring.

Minimum free length: 36.9 mm (1.453 in.)

If it is not within the specification, replace the vane pump assy.

Vernier Calipers

R08702

23. INSPECT PRESSURE PORT UNION

(a) If the union seat in the pressure port union is remarkably damaged and it may cause fluid leakage,

replace the vane pump assy.

24. INSTALL VANE PUMP HOUSING OIL SEAL

(a) Coat a new vane pump housing oil seal lip with power

SST

steering fluid.

(b) Using SST and a press, install a new vane pump housing

oil seal.

SST

09950-60010 (09951-00280), 09950-70010

(09951-07100)

NOTICE:

Oil Seal

F08480

Make sure that the vane pump housing oil seal is installed

facing in the correct direction.

25. INSTALL W/PULLEY SHAFT SUB-ASSY

Power Steering Fluid

(a) Coat inside bushing surface of the vane pump housing

front with power steering fluid.

(b) Gradually insert the vane pump shaft.

NOTICE:

Do not damage the vane pump housing oil seal lip in the

vane pump housing front.

F40339

51-12

POWER STEERING

- VANE PUMP ASSY

26. INSTALL VANE PUMP SIDE PLATE FRONT

(a) Coat a new O-ring with power steering fluid and install

it to the vane pump housing front.

C65369

(b) Coat a new O-ring with power steering fluid and install it

to the side plate front.

C65368

(c)

Align the dent of the vane pump side plate front with that

of the vane pump housing front, and install the vane pump

side plate front.

NOTICE:

Make sure that the side plate front is installed facing in the

correct direction.

F08482

27. INSTALL VANE PUMP CAM RING

Inscribed Mark

(a) Align the dent of the cam ring with that of the side plate

front, and install the cam ring with the inscribed mark fac-

ing outward.

F08483

28. INSTALL VANE PUMP ROTOR

Inscribed Mark

(a) Install the vane pump rotor with the inscribed mark facing

Round End

outward.

(b) Coat 10 vane plates with power steering fluid.

(c)

Install the vane plates with the round end facing outward.

F08484

51-13

POWER STEERING

- VANE PUMP ASSY

(d) Using a snap ring expander, install a new snap ring to the

w/ pulley shaft sub-assy.

F40343

29. INSTALL VANE PUMP HOUSING REAR

(a) Coat a new O-ring with power steering fluid and install it to the pump housing rear.

(b) Align the straight pin of the vane pump housing rear with the dents of the vane pump cam ring, vane

pump side plate front and vane pump housing front, and install the vane pump housing rear with the

4 bolts.

Torque: 22 N m (220 kgf cm, 16 ft lbf)

30. INSPECT PRELOAD

(a) Check that the pump rotates smoothly without abnormal

noise.

(b) Temporarily install the service bolt.

Recommended service bolt:

Thread diameter: 10 mm (0.3937 in.)

Thread pitch: 1.25 mm (0.0492 in.)

Bolt length: 50 mm (1.9685 in.)

C53369

(c)

Using a torque wrench, check the pump rotating torque.

Rotating torque:

0.27 Nm (2.8 kgf cm, 2.4 ft lbf) or less

31. INSTALL POWER STEERING OIL PRESSURE SWITCH

(a) Coat a new O-ring with power steering fluid and install it to the power steering oil pressure switch.

(b) Install the power steering oil pressure switch to the vane pump assy.

Torque: 21 N m (210 kgf cm, 15 ft lbf)

32. INSTALL FLOW CONTROL VALVE

(a) Coat the flow control valve compression spring and flow

control valve with power steering fluid.

(b) Install the flow control valve compression spring and flow

control valve.

(c)

Coat a new O-ring with power steering fluid and install it

to the pressure port union.

(d) Install the pressure port union.

F42475

Torque: 69 N m (700 kgf cm, 51 ft lbf)

Toyota Corolla (2004+). Manual - part 36