Steering.pdf

F06726

2UZ-FE engine:

Vacuum Hose

SR01X-04

SR-8-STEERING AIR CONTROL VALVE

4334Author�: Date�:

AIR CONTROL VALVEINSPECTION1. TURN AIR CONDITIONING SWITCH OFF2. CHECK IDLE-UP(a) Start the engine and run it at idle.(b) Fully turn the steering wheel.(c) Check that the engine rotations decrease when the vacu-

um hose of the air control valve is pinched.(d) Check that the engine rotations increase when the hose

is released.

P06717

SR1KF-01

P06723

CORRECT WRONG WRONG

-STEERING DRIVE BELTSR-3


DRIVE BELTINSPECTIONINSPECT 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. Re-place the belt if there are any missing ribs.

HINT:� After installing a belt, check that it fits properly in the

ribbed grooves.� Check with your hand to confirm that the belt has not

slipped out of the groove on the bottom of the pulley.

SR01V-11

R07281

Normal Abnormal

SR-4-STEERING POWER STEERING FLUID


POWER STEERING FLUIDBLEEDING1. CHECK FLUID LEVEL (See page SR-5 )2. JACK UP FRONT OF VEHICLE AND SUPPORT IT

WITH STANDS3. TURN STEERING WHEELWith the engine stopped, turn the wheel slowly from lock to lockseveral times.4. LOWER VEHICLE5. START ENGINERun the engine at idle for a few minutes.6. TURN STEERING WHEEL(a) With the engine idling, turn the wheel left or right to the full

lock position and keep it there for 2 to 3 seconds, then turnthe wheel to the opposite full lock position and keep itthere for 2 to 3 seconds.

(b) Repeat (a) several times.7. STOP ENGINE

8. CHECK FOR FOAMING OR EMULSIFICATIONIf the system has to be bled twice specifically because of foam-ing or emulsification, check for fluid leaks in the system.9. CHECK FLUID LEVEL (See page SR-5 )

R11740

HOTCOLD

SR01W-12

R07281

Normal Abnormal

R10552

5 mm (0.20 in.)or less

Engine Idling Engine Stopped

-STEERING POWER STEERING FLUIDSR-5


INSPECTION1. CHECK FLUID LEVEL(a) Keep the vehicle level.(b) With the engine stopped, check the fluid level in the reser-

voir.If necessary, add fluid.

Fluid: ATF DEXRON ® II or IIIHINT:When the fluid is hot, check that the fluid level is within the HOTrange.If the fluid is cold, check that it is within the COLD range.(c) Start the engine and run at idle.(d) Turn the steering wheel from lock to lock several times to

raise fluid temperature.Fluid temperature: 80 °C (176°F)

(e) Check for foaming or emulsification.If foaming or emulsification is identified, bleed air from the pow-er steering system (See page SR-4 ).

(f) With the engine idling, measure the fluid level in the reser-voir.

(g) Stop the engine.(h) Wait a few minutes and remeasure the fluid level in the

reservoir.Maximum fluid level rise: 5 mm (0.20 in.)

If the fluid level rise exceeds the maximum, bleed air from thepower steering system (See page SR-4 ).(i) Check the fluid level.

F17911

SST

IN OUT

1GR-FE engine: 2UZ-FE engine:

Attachment

Pressure Feed Tube

IN OUT

Attachment

Pressure Feed Tube

SST

Attachment

SR-6-STEERING POWER STEERING FLUID


2. CHECK STEERING FLUID PRESSURE(a) 2UZ-FE engine:

Remove the air cleaner assembly with the air cleanerhose (See page SR-61 ).

(b) Disconnect the pressure feed tube from the PS vanepump.(1GR-FE engine: See page SR-47 .)(2UZ-FE engine: See page SR-61 .)

(c) Connect SST, as shown in the illustration below.SST 09640- 10010 (09641- 01010, 09641- 01030,

09641-01060)NOTICE:Check that the valve of the SST is in the open position.

(d) Bleed air from the power steering system (See pageSR-4 ).

(e) Start the engine and run at idle.(f) Turn the steering wheel from lock to lock several times to

raise fluid temperature.Fluid temperature: 80 °C (176 °F)

Z15498

OilReservoir

PS VanePump

PS Gear

SST

Closed

Z15499

OilReservoir

PS VanePump

PS Gear

SST

Open

Z15500

OilReservoir

PS VanePump

PS Gear

SST

Open

Lock Position

-STEERING POWER STEERING FLUIDSR-7


(g) With the engine idling, close the valve of the SST and ob-serve the reading on the SST.Minimum fluid pressure:8,336 kPa (85 kgf/cm 2, 1,209 psi)

NOTICE:� Do not keep the valve closed for more than 10 se-

conds.� Do not allow the fluid temperature to become too

high.

(h) With the engine idling, fully open the valve.(i) Measure the fluid pressure at engine speeds of 1,000 rpm

and 3,000 rpm.Difference in fluid pressure:490 kPa (5 kgf/cm 2, 71 psi) or less

NOTICE:Do not turn the steering wheel.

(j) With the engine idling and the valve fully opened, turn thesteering wheel left or right to the full lock position.Minimum fluid pressure:8,336 kPa (85 kgf/cm 2, 1,209 psi)

NOTICE:� Do not keep the steering wheel in the full lock position

for more than 10 seconds.� Do not allow the fluid temperature to become too

high.(k) Disconnect the SST.

SST 09640- 10010 (09641- 01010, 09641- 01030,09641-01060)

(l) Connect the pressure feed tube.(1GR-FE engine: See page SR-57 .)(2UZ-FE engine: See page SR-69 .)

(m) 2UZ-FE engine:Install the air cleaner assembly with the air cleaner hose(See page SR-69 ).

(n) Bleed air from the power steering system (See pageSR-4 ).

SR02N-09

F17905

Bracket

Grommet

PS Gear Assembly

Pressure Feed Tube

: Specified torque�Non-reusable part* For use with SST

N·m (kgf·cm, ft·lbf)

29 (290, 21)

Clamp Plate

Return Tube25 (250, 18)*22 (227, 16)

25 (250, 18)*22 (227, 16)

�Cotter Pin

91 (930, 67)

165 (1,700, 123) 35 (360, 26)

No. 2 Intermediate Shaft Assembly

�

91 (930, 67)

165 (1,700, 123)

20 (200, 15)

130 (1,350, 96)

SR-70-STEERING POWER STEERING GEAR


POWER STEERING GEARCOMPONENTS

F06761

Rack Housing

� Claw Washer

Rack End

Lock Nut

Tie Rod End

Rack Boot

� Clamp

Clip

Steering Rack

� Teflon Ring

� Oil Seal

Bushing

� O-Ring

� Oil Seal

� Wire

�

�

N·m (kgf·cm, ft·lbf) : Specified touque

Power steering fluid

For use with SST

Non-reusable partMolybdenum disulfide lithium base grease

�

*

� O-Ring

55 (560, 41)

103 (1,050, 76)*76 (770, 56)

55 (560, 41)

103 (1,050, 76)*76 (770, 56)

Cylinder End Stopper

-STEERING POWER STEERING GEARSR-71


�Rack Housing Cap59 (600, 43)

F06760

Turn Pressure Tube

Dust Cover

Turn Pressure Tube

� O-Ring

Control ValveHousing

� Oil Seal

� Bearing

� Teflon Ring

Rack GuideSpring CapLock Nut

Rack Guide Spring

Rack Guide

� Self-locking Nut

� Bearing

N·m (kgf·cm, ft·lbf) : Specified torqueNon-reusable partPrecoated partMolybdenum disulfide lithium base greasePower steering fluidFor use with SST

Rack Housing

� Bearing

� Gasket

Control Valve Assembly

�

�

�

�

*

� Oil seal

15 (150, 11)*13 (135, 10)

18 (185, 13)

�

69 (700, 51)*51 (520, 38)

Rack GuideSpring Cap

�

30 (300, 22)

18 (185, 13)

15 (150, 11)*13 (135, 10)

15 (150, 11)*13 (135, 10)

15 (150, 11)*13 (135, 10)



SR0V9-06

F13620

SST

F06746

SST

Bolt

SST

Bolt

F06747

Matchmarks

F06748



DISASSEMBLYNOTICE:When using a vise, do not overtighten it.1. REMOVE 2 TURN PRESSURE TUBES(a) Using SST, remove the 2 turn pressure tubes.

SST 09023-38401(b) Remove the 4 O-rings from the tubes.

2. SECURE PS GEAR ASSEMBLY IN VISEUsing SST, 2 bolts and nuts, secure the gear assembly in a vise,as shown in the illustration.

SST 09612-00012Reference:Bolt: 90105-10346Nut: 90170-10198

HINT:Use 2 of the same type of SST.

3. REMOVE RH AND LH TIE ROD ENDS AND LOCKNUTS

(a) Put matchmarks on the tie rod end, lock nut and rack end.(b) Loosen the lock nut, remove the tie rod end and lock nut.(c) Perform the same procedure on the other side.

4. REMOVE RH AND LH CLIPS, RACK BOOTS ANDCLAMPS

(a) Using a screwdriver, loosen the 2 clamps.(b) Remove the 2 clips and boots.HINT:Mark the RH and LH boots.NOTICE:Be careful not to damage the boot.

F03699

F06749

SST

F06751

SST



5. REMOVE RH AND LH RACK ENDS AND CLAW WASH-ERS

(a) Using a screwdriver and hammer, unstake the washer.NOTICE:Avoid any impact on the steering rack.

(b) Using a spanner to hold the steering rack steadily, and us-ing SST, remove the rack end.SST 09922-10010

HINT:Mark the RH and LH rack ends.NOTICE:Use SST 09922-10010 in the direction shown in the illustra-tion.(c) Remove the washer from the rack end.(d) Perform the same procedure on the other side.

6. REMOVE RACK GUIDE SPRING CAP LOCK NUTUsing SST, remove the lock nut.

SST 09922-10010NOTICE:Use SST 09922-10010 in the direction shown in the illustra-tion.7. REMOVE RACK GUIDE SPRING CAP, RACK GUIDE

SPRING AND RACK GUIDE(a) Using a hexagon wrench, remove the rack guide spring

cap.(b) Remove the rack guide spring and rack guide.

F06753

SST

F06754

SST

F06755

Matchmarks

F06756

Vinyl Tape

Shop Rag



8. REMOVE RACK HOUSING CAPUsing SST, remove the rack housing cap.

SST 09816-30010

9. REMOVE SELF-SOCKING NUTUsing SST to stop the control valve shaft rotating, remove thenut.

SST 09616-0001 110. REMOVE DUST COVER

11. REMOVE CONTROL VALVE HOUSING WITH CON-TROL VALVE ASSEMBLY

(a) Put matchmarks on the control valve housing and rackhousing.

(b) Remove the 2 bolts and control valve housing with controlvalve assembly.

(c) Remove the gasket from the rack housing.

12. REMOVE CONTROL VALVE ASSEMBLY(a) To prevent oil seal lip damage, wind vinyl tape on the ser-

rated part of the valve shaft.(b) Press out the valve assembly with the oil seal.NOTICE:� Place a shop rag between the valve housing and the

blocks.� Be careful not to drop the valve assembly.� Be careful not to damage the oil seal lip.

13. REMOVE OIL SEALRemove the oil seal from the control valve assembly.

R11651

SST

WireCylinder EndStopper

F08343

SST

F08340Oil Seal

SST



14. REMOVE CYLINDER END STOPPER(a) Using SST, turn the stopper clockwise until the wire end

is visible through the service hole.SST 09631-16010

(b) Using SST, turn the stopper counterclockwise, and re-move the wire.SST 09631-16010

15. REMOVE STEERING RACK AND BUSHING(a) Using SST, press out the steering rack with the bushingNOTICE:Take care not to drop the rack.

SST 09950-70010 (09951-07200)(b) Remove the bushing from the rack.(c) Remove the O-ring from the bushing.

16. REMOVE OIL SEALUsing SST, press out the oil seal.

SST 09950-60010 (09951-00360),09950-70010 (09951-07360)

R10072

Dial Indicator

SR0VA-01



INSPECTIONINSPECT STEERING RACK(a) Using a dial indicator, check the rack for runout, teeth

wear and damage.Maximum runout: 0.09 mm (0.0035 in.)

(b) Check the back surface for wear and damage.

SR02S-09

F06730

b

c

a

b

dd

F13617

FulcrumLength

SST



INSTALLATION1. INSTALL GROMMET AND BRACKET2. INSTALL PS GEAR ASSEMBLY(a) Install the PS gear assembly with the gear assembly set

bolt.Torque: 165 N·m (1,700 kgf·cm, 123 ft·lbf)

(b) Install the gear assembly set bolt, washer and nut.Torque: 130 N·m (1,350 kgf·cm, 96 ft·lbf)

(c) Install the stud bolt to the bracket.Torque: 20 N·m (200 kgf·cm, 15 ft·lbf)

(d) Install the bolt and nut to the bracket.Torque: 165 N·m (1,700 kgf·cm, 123 ft·lbf)

3. CONNECT PRESSURE FEED AND RETURN TUBESUsing SST, connect the tubes.

SST 09023-12701Torque: 22 N·m (227 kgf·cm, 16 ft·lbf)

HINT:� Use a torque wrench with a fulcrum length of 300 mm

(11.81 in.).� This torque value is effective in case that SST is parallel

to a torque wrench.4. CONNECT CLAMP PLATEConnect the clamp plate and install the bolt.

Torque: 29 N·m (290 kgf·cm, 21 ft·lbf)5. CONNECT NO. 2 INTERMEDIATE SHAFT ASSEMBLY

(See page SR-28 , SR-42 )6. CONNECT RH AND LH TIE ROD ENDS (See page

SA-84 )7. POSITION FRONT WHEEL FACING STRAIGHT

AHEADHINT:Do it with the front of the vehicle jacked up.8. CENTER SPIRAL CABLE

(See page SR-28 , SR-42 )9. INSTALL STEERING WHEEL(a) Align the matchmark on the wheel and steering column

main shaft.(b) Temporarily tighten the wheel set nut.(c) Connect the connector.10. BLEED POWER STEERING SYSTEM (See page

SR-4 )



11. CHECK STEERING WHEEL CENTER POINT12. TORQUE STEERING WHEEL SET NUT

Torque: 50 N·m (510 kgf·cm, 37 ft·lbf)13. INSTALL STEERING WHEEL PAD

(See page SR-28 , SR-42 )14. CHECK FRONT WHEEL ALIGNMENT

(See page SA-5 )15. CONNECT CABLE TO NEGATIVE BATTERY TERMI-

NAL16. PERFORM YAW RATE AND DECELERATION SENSOR

ZERO POINT CALIBRATION (See page DI-1494 )

SR02R-10

F08341

SST

Oil Seal SST

W02101

SST

Rack Teeth End

R11574

Vinyl Tape



REASSEMBLYNOTICE:When using a vise, do not overtighten it.1. COAT PARTS INDICATED BY ARROWS WITH POWER

STEERING FLUID OR MOLYBDENUM DISULFIDELITHIUM BASE GREASE (See pages SR-70 )

2. INSTALL OIL SEAL(a) Coat a new oil seal lip with power steering fluid.(b) Using SST, press in the oil seal.

SST 09950-60010 (09951-00330, 09951-00490,09952-06010), 09950-70010 (09951-07360)

NOTICE:� Make sure to install the oil seal in the correct direc-

tion.� Take care that the oil seal does not get reversed as

you install it.3. INSTALL STEERING RACK(a) Install SST to the rack.

SST 09631-20051HINT:If necessary, scrape the burrs off the rack teeth end and bur-nish.(b) Coat the SST with power steering fluid.(c) Install the steering rack into the rack housing.NOTICE:Be careful not to damage the oil seal lip.(d) Remove the SST.

SST 09631-20051

4. INSTALL BUSHING(a) Coat a new O-ring with power steering fluid and install it

to the bushing.(b) To prevent oil seal lip damage, wind vinyl tape on the

steering rack end, and apply power steering fluid.(c) Install the bushing.NOTICE:� Make sure to install the bushing in the correct direc-

tion.� Be careful not to damage the oil seal lip.

R11656

SST Wire

Cylinder EndStopper

F06757

SST

F06758

Vinyl Tape

F08339Oil Seal

SST



5. INSTALL CYLINDER END STOPPER(a) Align the installation hole for the wire of the stopper with

the slot of the rack housing.(b) Install a new wire into the stopper.(c) Using SST, turn the stopper clockwise 400° to 500°.

SST 09631-16010

6. AIR TIGHTNESS TEST(a) Install SST to the rack housing.

SST 09631-12071(b) Apply 53 kPa (400 mmHg, 15.75 in.Hg) of vacuum for

about 30 seconds.(c) Check that there is no change in the vacuum.If there is change in the vacuum, check the installation of the oilseals.

7. INSTALL CONTROL VALVE ASSEMBLY(a) To prevent oil seal lip damage, wind vinyl tape on the ser-

rated part of the valve shaft.(b) Coat the teflon rings with power steering fluid.(c) Install the valve assembly into the valve housing.NOTICE:Be careful not to damage the teflon rings and oil seal.

8. INSTALL OIL SEAL(a) Coat a new oil seal lip with power steering fluid.(b) Using SST, press in the oil seal.

SST 09612-2201 1NOTICE:Make sure to install the oil seal in the correct direction.9. INSTALL CONTROL VALVE HOUSING WITH CON-

TROL VALVE ASSEMBLY(a) Place a new gasket on the rack housing.(b) Align the matchmark on the control valve housing with

control valve assembly and rack housing.(c) Install the 2 bolts.

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

F06754

SST

F06753

SST

F06759

Punch

F08342

12°



10. INSTALL SELF-LOCKING NUTUsing SST to stop the control valve shaft rotating, install a newnut.

SST 09616-0001 1Torque: 30 N·m (300 kgf·cm, 22 ft·lbf)

11. INSTALL DUST COVER

12. INSTALL RACK HOUSING CAP(a) Apply sealant to 2 or 3 threads of the rack housing cap.

Sealant:Part No.08833-00080, THREE BOND 1344,LOCTITE 242 or equivalent

(b) Using SST, install the rack housing cap.SST 09816-30010Torque: 59 N·m (600 kgf·cm, 43 ft·lbf)

(c) Using a punch and hammer, stake the 2 parts of the cap.13. INSTALL RACK GUIDE, RACK GUIDE SPRING AND

RACK GUIDE SPRING CAP(a) Install the rack guide and rack guide spring.(b) Apply sealant to 2 or 3 threads of the rack guide spring

cap.Sealant:Part No.08833-00080, THREE BOND 1344,LOCTITE 242 or equivalent

(c) Temporarily install the rack guide spring cap.

14. ADJUST TOTAL PRELOAD(a) To prevent the steering rack teeth from damaging the oil

seal lip, temporarily install the RH and LH rack ends.(b) Using a hexagon wrench, install the rack guide spring

cap.Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)

(c) Using a hexagon wrench, return the rack guide spring cap12°.

F08330

SST

F08329

SST

F06752

SST

Rack GuideSpring Cap Lock Nut

FulcrumLength

R07337

Claw



(d) Using SST, turn the control valve shaft right and left 1 or2 times.SST 09616-0001 1

(e) Using a hexagon wrench, loosen the rack guide springcap until the rack guide spring is not functioning.

(f) Using SST, torque wrench and hexagon wrench, tightenthe rack guide spring cap until the preload is within specifi-cation.SST 09616-0001 1Preload (turning):1.0 to 1.45 N·m (10 to 14.5 kgf·cm, 8.7 to 12.6 in.·lbf)

15. INSTALL RACK GUIDE SPRING CAP LOCK NUT(a) Apply sealant to 2 or 3 threads of the lock nut.

Sealant:Part No.08833-00080, THREE BOND 1344,LOCTITE 242 or equivalent

(b) Temporarily install the lock nut.(c) Using a hexagon wrench to hold the rack guide spring

cap, and using SST, tighten the lock nut.SST 09922-10010Torque: 51 N·m (520 kgf·cm, 38 ft·lbf)

NOTICE:Use SST 09922-10010 in the direction shown in the illustra-tion.HINT:Use a torque wrench with a fulcrum length of 345 mm (13.58in.).(d) Recheck the total preload.

Preload (turning):1.0 to 1.45 N·m (10 to 14.5 kgf·cm, 8.7 to 12.6 in.·lbf)

(e) Remove the RH and LH rack ends.16. INSTALL RH AND LH CLAW WASHERS AND RACK

ENDS(a) Install a new claw washer, and temporarily install the rack

end.HINT:Align the claws of the claw washer with the steering rackgrooves.

F06750

Fulcrum Length

SST

R06400

Brass Bar

W01261

W04223

3 mm(0.12 in.)or less

SST



(b) Using a spanner to hold the steering rack steady, and us-ing SST, tighten the rack end.SST 09922-10010Torque: 76 N·m (770 kgf·cm, 56 ft·lbf)

NOTICE:Use SST 09922-10010 in the direction shown in the illustra-tion.HINT:Use a torque wrench with a fulcrum length of 345 mm (13.58in.).(c) Using a brass bar and hammer, stake the washer.NOTICE:Avoid any impact on the rack.(d) Perform the same procedure on the other side.

17. INSTALL RH AND LH RACK BOOTS, CLAMPS ANDCLIPS

(a) Ensure that the steering rack hole is not clogged withgrease.

HINT:If the hole is clogged, the pressure inside the boot will changeafter it is assembled and the steering wheel is turned.(b) Set a new clamp to the groove of the rack boot.

(c) Install the boot.NOTICE:Be careful not to damage or twist the boot.(d) Using SST, tighten the clamp as shown in the illustration.

SST 09521-24010(e) Install the clip to the rack boot.(f) Perform the same procedure on the other side.18. INSTALL RH AND LH TIE ROD ENDS AND LOCK NUTS(a) Screw the lock nut and tie rod end onto the rack end until

the matchmarks are aligned.(b) After adjusting toe-in, tighten the nut

(See page SA-5 ).Torque: 55 N·m (560 kgf·cm, 41 ft·lbf)

F13621

FulcrumLength

SST



19. INSTALL 2 TURN PRESSURE TUBES(a) Coat 4 new O-rings with power steering fluid and install

them to the turn pressure tubes.(b) Using SST, install the 2 turn pressure tubes.

SST 09023-34201Torque: 13 N·m (135 kgf·cm, 10 ft·lbf)

HINT:� Use a torque wrench with a fulcrum length of 250 mm

(9.84 in.).� This torque value is effective in case that SST is parallel

to a torque wrench.

SR02O-10

F13616SST



REMOVALNOTICE:Remove the steering wheel assembly before the steeringgear removal, because there is possibility of breaking ofthe spiral cable.1. DISCONNECT CABLE FROM NEGATIVE BATTERY

TERMINALWait for 90 seconds after disconnecting the cable to prevent theairbag working.2. PLACE FRONT WHEELS FACING STRAIGHT AHEAD3. REMOVE STEERING WHEEL PAD

(See page SR-18 , SR-33 )4. REMOVE STEERING WHEEL

(See page SR-18 , SR-33 )5. DISCONNECT RH AND LH TIE ROD ENDS

(See page SA-84 )6. DISCONNECT NO. 2 INTERMEDIATE SHAFT AS-

SEMBLY (See page SR-18 , SR-33 )7. DISCONNECT CLAMP PLATERemove the bolt and disconnect the clamp plate.

8. DISCONNECT PRESSURE FEED AND RETURNTUBES

Using SST, disconnect the tube.SST 09023-12701

9. REMOVE PS GEAR ASSEMBLY(a) Remove the bolt, nut and stud bolt from the bracket.(b) Remove the 2 set bolts, nut, washer and PS gear assem-

bly.10. REMOVE BRACKET AND GROMMET

SR0VB-05

F08332

SST

OilSeal

Bearing

F08333

SST

SSTBearing

F08335

SST

Bearing

F08334Bearing

SST

F08336

SST

Bearing



REPLACEMENTNOTICE:When using a vise, do not overtighten it.1. IF NECESSARY, REPLACE OIL SEAL AND BEARING(a) Using SST, press out the oil seal and bearing from the

control valve housing.SST 09950-60010 (09951-00250),

09950-70010 (09951-07150)

(b) Coat a new oil seal lip with power steering fluid.(c) Using SST, press in the oil seal.

SST 09950-60010 (09951-00180, 09951-00320,09952-06010), 09950-70010 (09951-07150)

NOTICE:Make sure to install the oil seal in the correct direction.

(d) Coat a new bearing with molybdenum disulfide lithiumbase grease.

(e) Using SST, press in the bearing.SST 09950-60010 (09951-00340),

09950-70010 (09951-07150)

2. IF NECESSARY, REPLACE 2 BEARINGS(a) Using SST, press out the bearing.

SST 09950-60010 (09951-00260),09950-70010 (09951-07150)

(b) Using SST, press out the bearing from the rack housing.SST 09950-60010 (09951-00260),

09950-70010 (09951-07200)

F08337

Bearing

SST

F08338

Bearing

SST

F01798

BushingSST

SST

Oil Seal

F01799

Press

Oil Seal

SST

SST

R10955



(c) Coat a new bearing with molybdenum disulfide lithiumbase grease.

(d) Using SST, press in the bearing.SST 09950-60010 (09951-00310),

09950-70010 (09951-07150)

(e) Coat a new bearing with molybdenum disulfide lithiumbase grease.

(f) Using SST, press in the bearing.SST 09950-60010 (09951-00320),

09950-70010 (09951-07150)

3. IF NECESSARY, REPLACE OIL SEAL(a) Using SST, remove the oil seal from the bushing.

SST 09527-2001 1, 09612-24014 (09613-22011)NOTICE:Be careful not to damage the bushing.


SST 09950-60010 (09951-00300, 09951-00460,09952-06010)


4. IF NECESSARY, REPLACE TEFLON RING AND O-RING

(a) Using a screwdriver, remove the teflon ring and O-ringfrom the steering rack.

NOTICE:Be careful not to damage the groove for the teflon ring.(b) Coat a new O-ring with power steering fluid and install it

to steering rack.

R06172

N00401

R11572

Teflon Ring

R11573

Teflon Ring

SST



(c) Expand a new teflon ring with your fingers.NOTICE:Be careful not to over-expand the teflon ring.

(d) Coat the teflon ring with power steering fluid.(e) Install the teflon ring to the steering rack, and settle it

down with your fingers.

5. IF NECESSARY, REPLACE TEFLON RINGS(a) Using a screwdriver, remove the 4 teflon rings from the

control valve assembly.NOTICE:Be careful not to damage the grooves for the teflon ring.(b) Expand 4 new teflon rings with your fingers.NOTICE:Be careful not to overexpand the teflon ring.(c) Coat the teflon rings with power steering fluid.(d) Install the teflon rings to the control valve assembly, and

settle them down with your fingers.

(e) Carefully slide the tapered end of SST over the teflonrings until they fit to the control valve assembly.SST 09631-20081

NOTICE:Be careful not to damage the teflon rings.

SR1KS-01

F17902

Gasket

Pressure Feed Tube

Union Bolt

Suction HoseVane Pump Assembly

�

46.5 (474, 34)

N·m (kgf·cm, ft·lbf) : Specified torque

Non-reusable part�

Drive Belt

21 (210, 15)

Oil Pressure Switch

-STEERING POWER STEERING VANE PUMP (1GR-FE)SR-45


POWER STEERING VANE PUMP (1GR-FE)COMPONENTS

F17906

Pressure Port Union

Flow Control Valve

O-Ring

Spring

Oil Pressure Switch

Suction Port Union

Vane Pump Shaft withVane Pump Pulley

Oil SealFront Housing

Rear Housing

Vane Pump Rotor

Side Plate

Cam Ring

Vane Plate

�

�

O-Ring�

Snap Ring�

O-Ring�

O-Ring�

N·m (kgf·cm, ft·lbf) : Specified torque� Non-reusable part


22 (220, 16)

12 (120, 9)

21 (210, 15)

X10

69 (700, 51)

22 (220, 16)

SR-46-STEERING POWER STEERING VANE PUMP (1GR-FE)


SR1KU-01

F19807

SST

F19949

F19950



DISASSEMBLYNOTICE:When using a vise, do not overtighten it.1. FIX VANE PUMP ASSEMBLY(a) Using SST, hold the vane pump assembly in a vise.

SST 09630-00014 (09631-00132)HINT:Detach SST depending on the situation.2. REMOVE SUCTION PORT UNION(a) Remove the bolt and suction port union.(b) Remove the O-ring from the suction port union.3. REMOVE PRESSURE PORT UNION, FLOW CONTROL

VALVE AND SPRING(a) Remove the pressure port union, flow control valve and

spring.(b) Remove the O-ring from the pressure port union.4. REMOVE OIL PRESSURE SWITCHNOTICE:If the oil pressure switch is dropped or damaged, replaceit with a new one.

5. REMOVE REAR HOUSING(a) Remove the 4 bolts and rear housing.(b) Remove the O-ring from the rear housing.

6. REMOVE VANE PUMP SHAFT WITH VANE PUMPPULLEY

(a) Using 2 screwdrivers, remove the snap ring from the vanepump shaft with vane pump pulley.

(b) Remove the vane pump shaft with vane pump pulley.NOTICE:Be careful not to drop or damage the vane pump shaft withvane pump pulley. If it is damaged, replace the vane pumpassembly.

F19951

O-Ring

Side Plate

F19952



7. REMOVE 10 VANE PLATES AND VANE PUMP ROTOR(a) Remove the 10 vane plates.NOTICE:Take care not to drop the vane plate.(b) Remove the vane pump rotor.8. REMOVE CAM RING

9. REMOVE SIDE PLATE(a) Remove the side plate from the front housing.(b) Remove the O-ring from the side plate.

(c) Remove the O-ring from the front housing.

SR1KV-01

F09875

Bushing

Vane Pump Shaft Front Housing

N00372

Thickness

Height

Length

R10282

Feeler Gauge

F08476

F08804

Compressed Air



INSPECTION1. MEASURE OIL CLEARANCE BETWEEN VANE PUMP

SHAFT AND BUSHINGUsing a micrometer and a caliper gauge, measure the oil clear-ance.

Maximum clearance: 0.07 mm (0.0028 in.)If it is more than the maximum, replace the vane pump assem-bly.

2. INSPECT VANE PUMP ROTOR AND VANE PLATES(a) Using a micrometer, measure the thickness of the 10

vane plates.Standard thickness:1.405 to 1.411 mm (0.05531 to 0.05555 in.)

(b) Using a feeler gauge, measure the clearance between aside face of the vane pump rotor groove and the vaneplate.Maximum clearance: 0.03 mm (0.0012 in.)

If it is more than the maximum, replace the vane pump assem-bly.

3. INSPECT FLOW CONTROL VALVE(a) Coat the flow control valve with power steering fluid and

check that it falls smoothly into the valve hole of the fronthousing under its own weight.

If it lacks smoothness, replace the vane pump assembly.

(b) Check the flow control valve for leakage. Close one of theholes and apply compressed air of 392 to 490 kPa (4 to5 kgf/cm2, 57 to 71 psi) into the opposite side hole, andconfirm that air does not come out from the end hole.

If air leaks, replace the vane pump assembly.

R08702

Vernier Calipers



4. INSPECT SPRINGUsing 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 as-sembly.5. INSPECT PRESSURE PORT UNIONIf the union seat in the pressure port union is severely dam-aged, it may cause fluid leakage. In that case, replace the vanepump assembly.

SR1KY-01

F17910

F17909

F17908Pressure Feed Tube

F17903

Pressure Feed TubeStopper

F17907

Suction Hose



INSTALLATION1. INSTALL VANE PUMP ASSEMBLY(a) Install the vane pump assembly with the 2 bolts.


(b) Connect the oil pressure switch connector.NOTICE:Be careful that the oil does not come into contact with theconnector.

2. CONNECT PRESSURE FEED TUBE(a) Install a new gasket to the pressure feed tube.(b) Install the pressure feed tube with the union bolt.

HINT:Make sure that the stopper of the pressure feed tube contactsthe pump housing as shown in the illustration.(c) Tighten the union bolt.

Torque: 46.5 N·m (474 kgf·cm, 34 ft·lbf)

3. CONNECT SUCTION HOSEConnect the suction hose with the clip.

F19813

Belt Tensioner

Turn

HolesBar

F19812

Vane Pump Assembly Water Pump Generator

Idler No. 2

Idler No. 1A/C Compressor

Idler No. 2

Tensioner

Crankshaft



4. INSTALL DRIVE BELT(a) While turning the belt tensioner counterclockwise, align

the holes, and then insert a bar of 6 mm (0.24 in.) into theholes to fix the belt tensioner.

(b) Install the drive belt.(c) While turning the belt tensioner counterclockwise, re-

move the bar.

(d) If it is hard to install the drive belt, perform the followingprocedure:(1) Wrap the drive belt around all the pulleys and idlers,

except for the vane pump assembly, as shown inthe illustration.

(2) While releasing belt tension by turning the belt ten-sioner counterclockwise, wrap the drive belt aroundthe vane pump assembly.

5. ADD POWER STEERING FLUID6. BLEED POWER STEERING FLUID7. INSPECT FLUID LEAK8. INSTALL ENGINE UNDER COVER

SR1KX-01

F19808

Bushing

F17912

Vinyl Tape

F19952

F19951

O-Ring

Side Plate




STEERING FLUID (See page SR-45 )

2. INSTALL VANE PUMP SHAFT WITH VANE PUMPPULLEY

(a) Coat the inside surface of the bushing in the front housingwith power steering fluid.

(b) Gradually insert the vane pump shaft.NOTICE:Do not damage the oil seal lip in the front housing.

HINT:Wrap the shaft surface with vinyl tape before inserting.

3. INSTALL SIDE PLATE(a) Coat a new O-ring with power steering fluid, and install

it to the front housing.

(b) Coat a new O-ring with power steering fluid, and installit to the side plate.

F19953

Side Plate

Front Housing

F19954

Front Housing

Cam Ring

Inscribed Mark

F19955

F19956

Round End

Outward

Inward

F19811

Snap Ring



(c) Align the dent of the side plate with the dent of the fronthousing, and install the side plate.

NOTICE:Make sure that the side plate is installed in the correctdirection.

4. INSTALL CAM RINGAlign the dent of the cam ring with the dent of the side plate, andinstall the cam ring with the inscribed mark facing outward.NOTICE:Make sure that the cam ring is installed in the correct direc-tion.

5. INSTALL VANE PUMP ROTOR(a) Install the vane pump rotor.HINT:Vane pump rotor has no specific direction.

(b) Coat 10 vane plates with power steering fluid.(c) Install the 10 vane plates with the round end facing out-

ward.

(d) Using a screwdriver and a snap ring expander, install anew snap ring to the vane pump shaft.

F19957

Front Housing

Cam RingRear Housing

F19809

Service Bolt



6. INSTALL REAR HOUSING(a) Coat a new O-ring with power steering fluid, and install

it to the rear housing.(b) Align the straight pin of the rear housing with the dents of

the cam ring, side plate and front housing, and install therear housing with the 4 bolts.Torque: 22 N·m (220 kgf·cm, 16 ft·lbf)

7. 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 (0.39 in.)Thread pitch: 1.25 mm (0.0492 in.)Bolt length: 50 mm (1.97 in.)

(c) Using a torque wrench, check the pump rotating torque.Rotating torque:0.27 N·m (2.8 kgf·cm, 2.4 in.·lbf) or less

If the rotating torque is not as specified above, check the instal-lation of the vane pump housing oil seal.8. INSTALL OIL PRESSURE SWITCH

Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)9. INSTALL SPRING, FLOW CONTROL VALVE AND

PRESSURE PORT UNION(a) Coat the spring and flow control valve with power steering

fluid.(b) Install the spring.(c) Install the flow control valve in the correct direction

(See page SR-45 ).(d) Coat a new O-ring with power steering fluid, and install

it to the pressure port union.(e) Install the pressure port union.

Torque: 69 N·m (700 kgf·cm, 51 ft·lbf)10. INSTALL SUCTION PORT UNION(a) Coat a new O-ring with power steering fluid, and install

it to the suction port union.(b) Install the suction port union with the bolt.


SR1KT-01

F19814Belt Tensioner

F17907

Suction Hose

F17908Pressure Feed Tube

F17909



REMOVAL1. REMOVE ENGINE UNDER COVER

2. REMOVE DRIVE BELTWhile releasing the belt tension by turning the belt tensionercounterclockwise, remove the drive belt.

3. DISCONNECT SUCTION HOSERemove the clip and disconnect the suction hose.

4. DISCONNECT PRESSURE FEED TUBE(a) Remove the bolt and disconnect the pressure feed tube.(b) Remove the gasket.

5. REMOVE VANE PUMP ASSEMBLY(a) Disconnect the oil pressure switch connector.

F17910



(b) Remove the 2 bolts and vane pump assembly.

SR1KW-01

F08479

Vinyl Tape

F08480

SST

Oil Seal



REPLACEMENTNOTICE:When using a vise, do not overtighten it.IF NECESSARY, REPLACE OIL SEAL(a) Using a screwdriver with vinyl tape wound around its tip,

remove the oil seal.NOTICE:Be careful not to damage the bushing of the front housing.


SST 09950-60010 (09951-00280),09950-70010 (09951-07100)

NOTICE:Make sure that the oil seal is installed in the correct direc-tion.

SR0MD-14

F06723

Air Cleaner Assemblywith Air Cleaner Hose

MAF Meter Connector

Clamp

Return Hose


� Gasket

46.5 (475, 34)Clip

Vacuum Hose

Clip

Drive Belt

PS Vane PumpAssembly

44 (450, 33)

Pressure Feed Tube

22 (220, 16)

-STEERING POWER STEERING VANE PUMP (2UZ-FE)SR-59


POWER STEERING VANE PUMP (2UZ-FE)COMPONENTS

F06720

Pressure Port Union83 (850, 61)

� O-Ring

Flow Control Valve

Spring

� O-Ring

Suction Port Union

13 (130, 9)

Vane Pump Shaftwith Vane Pump Pulley

� Oil Seal Front Housing

� Gasket

24 (240, 17)

Rear Housing

� O-Ring

Wave Washer

Side Plate

Cam Ring

� Straight Pin

Vane PumpRotor

�

� Snap Ring

x10

Vane Plate



SR-60-STEERING POWER STEERING VANE PUMP (2UZ-FE)


SR0V7-04

F06739



DISASSEMBLYNOTICE:When using a vise, do not overtighten it.1. MEASURE PS VANE PUMP ROTATING TORQUE(a) Check that the pump rotates smoothly without abnormal

noise.(b) Temporarily install the bolt.(c) Using a torque wrench, check the pump rotating torque.

Rotating torque:0.28 N·m (2.8 kgf·cm, 2.4 in.·lbf) or less

2. REMOVE SUCTION PORT UNION(a) Remove the bolt and suction port union.(b) Remove the O-ring from the union.3. REMOVE PRESSURE PORT UNION, FLOW CONTROL

VALVE AND SPRING(a) Remove the pressure port union, the flow control valve

and spring.(b) Remove the O-ring from the pressure port union.4. REMOVE REAR HOUSING(a) Remove the 4 bolts and rear housing.HINT:If the wave washer and side plate are stuck to the rear housing,lightly tap the rear housing with a plastic hammer, and removethe wave washer and side plate.(b) Remove the 2 O-rings from the rear housing.5. REMOVE WAVE WASHER6. REMOVE SIDE PLATE7. REMOVE GASKET8. REMOVE CAM RING, 10 VANE PLATES AND VANE

PUMP ROTOR(a) Using a screwdriver, remove the snap ring from the vane

pump shaft.(b) Remove the cam ring, 10 vane plates and vane pump ro-

tor.NOTICE:Be careful not to drop the plates.9. REMOVE VANE PUMP SHAFT WITH VANE PUMP

PULLEY10. REMOVE STRAIGHT PINSRemove the 2 pins from the front housing.

SR0RF-05

F06719

Vane Pump Shaft

Front HousingBushing

N00372

Height

Thickness

Length

R10282

Feeler Gauge



INSPECTION1. CHECK OIL CLEARANCE BETWEEN VANE PUMP

SHAFT AND BUSHINGUsing a micrometer and caliper gauge, measure the oil clear-ance.

Standard clearance:0.03 to 0.05 mm (0.0012 to 0.0020 in.)Maximum clearance: 0.07 mm (0.0028 in.)

If it is more than the maximum, replace the shaft and front hous-ing.

2. INSPECT VANE PUMP ROTOR AND VANE PLATES(a) Using a micrometer, measure the height, thickness and

length of the 10 plates.Minimum height: 8.6 mm (0.339 in.)Minimum thickness: 1.397 mm (0.0550 in.)Minimum length: 14.991 mm (0.5902 in.)

(b) Using a feeler gauge, measure the clearance betweenthe rotor groove and plate.Maximum clearance: 0.033 mm (0.0013 in.)

R13897Inscribed Mark

W04759

F04865

Compressed Air

F04866Inscribed Mark



If it is more than the maximum, replace the plate and/or rotorwith the one having the same mark stamped on the cam ring.

Inscribed mark: 1, 2, 3, 4 or NoneHINT:There are 5 vane plate lengths with the following rotor and camring marks:

Rotor and cam

ring mark

Vane plate part

number

Vane plate length

mm (in.)

None 44345-0401014.999-15.001

(0.59051-0.59059)

1 44345-0402014.997-14.999

(0.59043-0.59051)

2 44345-0403014.995-14.997

(0.59035-0.59043)

3 44345-0404014.993-14.995

(0.59027-0.59035)

4 44345-0405014.991-14.993

(0.59020-0.59027)

3. INSPECT FLOW CONTROL VALVE(a) Coat the valve with power steering fluid and check that it

falls smoothly into the valve hole under its own weight.

(b) Check the flow control valve for leakage.Close one of the holes and apply compressed air 392 to490 kPa (4 to 5 kgf/cm2, 57 to 71 psi) into the oppositeside, and confirm that air does not come out from the endholes.

If necessary, replace the valve with the one having the same let-ter inscribed on the front housing.

Inscribed mark: A, B, C, D, E or F

R08702

Vernier Calipers



4. INSPECT SPRINGUsing vernier calipers, measure the free length of the spring.

Minimum free length: 33.2 mm (1.307 in.)If it is not within the specification, replace the spring.

SR0MI-14

F06724Stopper

EM6656



INSTALLATION1. INSTALL PS VANE PUMP ASSEMBLY(a) Install the PS vane pump assembly with the stud bolt.

Torque: 22 N·m (220 kgf·cm, 16 ft·lbf)(b) Install the 2 bolt and nut.


2. INSTALL PRESSURE FEED TUBE(a) Connect the pressure feed tube.(b) Install a new gasket and the union bolt on the pressure

feed tube.HINT:Make sure that the stopper of the pressure feed tube contactsthe PS vane pump body as shown in the illustration, then tight-en the union bolt.

Torque: 46.5 N·m (475 kgf·cm, 34 ft·lbf)3. CONNECT RETURN HOSEConnect the return hose with the clip.4. CONNECT 2 VACUUM HOSESConnect the 2 vacuum hoses and install the 2 clips.

5. INSTALL DRIVE BELTLoosen the drive belt tension by turning the drive belt tensionercounterclockwise, and install the belt.6. INSTALL AIR CLEANER ASSEMBLY WITH AIR

CLEANER HOSE(a) Install the air cleaner assembly with air cleaner hose and

the 3 bolts.(b) Install the clamp.(c) Connect the hoses.(d) Connect the MAF meter connector.7. BLEED POWER STEERING SYSTEM

(See page SR-4 )

SR0V8-05

F04809

Inscribed Mark

F04810

Round End

F01507




STEERING FLUID (See page SR-59 )2. INSTALL VANE PUMP SHAFT WITH VANE PUMP

PULLEY3. INSTALL STRAIGHT PINSUsing a plastic hammer, tap in 2 new pins into the front housing.NOTICE:Be careful not to damage the pins.

4. INSTALL CAM RINGInstall the cam ring with the inscribed mark facing outward.HINT:Align the hole of the cam ring with the one of the straight pins.5. INSTALL VANE PUMP ROTOR(a) Install the vane pump rotor with the inscribed mark facing

outward.(b) Install a new snap ring to the vane pump shaft.

6. INSTALL VANE PLATES AND GASKET(a) Install the 10 plates with the round end facing outward.(b) Install a new gasket on the front housing.NOTICE:Be careful of the direction of the gasket.7. INSTALL SIDE PLATEAlign the hole of the plate with the hole of the 2 straight pins.

8. INSTALL WAVE WASHERInstall the washer so that the protrusions fit into the slots in theside plate.9. INSTALL REAR HOUSING(a) Coat 2 new O-rings with power steering fluid and install

them to the rear housing.(b) Install the rear housing with the 4 bolts.




10. INSTALL SPRING, FLOW CONTROL VALVE ANDPRESSURE PORT UNION

(a) Install the spring on the front housing.(b) Install the flow control valve in the correct direction

(See page SR-59 ).(c) Coat a new O-ring with power steering fluid and install it

on the pressure port union.(d) Install the pressure port union.

Torque: 83 N·m (850 kgf·cm, 61 ft·lbf)11. INSTALL SUCTION PORT UNION(a) Coat a new O-ring with power steering fluid and install it

on the suction port union.(b) Install the suction port union with the bolt.

Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)12. MEASURE PS VANE PUMP ROTATING TORQUE

(See page SR-62 )

SR0ME-08

EM6656



REMOVAL1. REMOVE AIR CLEANER ASSEMBLY WITH AIR

CLEANER HOSE(a) Disconnect the MAF meter connector.(b) Disconnect the hoses.(c) Remove the clamp.(d) Remove the 3 bolts and air cleaner assembly with air

cleaner hose connected.

2. REMOVE DRIVE BELTLoosen the drive belt tension by turning the drive belt tensionercounterclockwise, and remove the drive belt.3. DISCONNECT 2 VACUUM HOSESRemove the 2 clips and disconnect the 2 vacuum hoses.4. DISCONNECT RETURN HOSERemove the clip and disconnect the return hose.5. DISCONNECT PRESSURE FEED TUBERemove the union bolt and gasket, disconnect the pressurefeed tube.6. REMOVE PS VANE PUMP ASSEMBLYRemove the 2 bolts, nut, stud bolt and PS vane pump assembly.

SR0RG-09

F01511

Vinyl Tape

F06727

Press

SST

Oil Seal

SST



REPLACEMENTNOTICE:When using a vise, do not overtighten it.IF NECESSARY, REPLACE OIL SEAL(a) Using a screwdriver with vinyl tape wound around its tip,

remove the oil seal.NOTICE:Be careful not to damage the front housing.


SST 09950-60010 (09951-00330),09950-70010 (09951-07100)


SR1KM-01

F19883

Steering Wheel Pad

Steering Wheel

Column LowerCover

CombinationSwitch

Steering Column Assembly

Torx® Screw

Transmission ControlCable Assembly

Lower LH Finish Panel

Column HoleCover No. 2

No. 2 UniversalJoint Assembly

No. 2 Heater to Register Dust

Torx® Screw

35 (360, 26)

35 (360, 26)

8.0 (82, 71 in.·lbf)

26 (260, 19)

26 (260, 19)

8.8 (90, 78 in.·lbf)

50 (510, 37)

8.8 (90, 78 in.·lbf)

Hood LockRelease Lever

8.0 (82, 71 in.·lbf)

No. 2 lntermediate Shaft Assembly

Brake PedalReturn Spring

Column Upper Cover


Steering Wheel LowerNo. 3 Cover

Steering Wheel LowerNo. 2 Cover

35 (360, 26)

Sliding Yoke

-STEERING STEERING COLUMN (Double Cab)SR-31


STEERING COLUMN (Double Cab)COMPONENTS

F19959

�Non-reusable partMolybdenum disulfide lithium base grease

: Specified torqueN·m (kgf·cm, ft·lbf)

Column Upper Bracket

Key CylinderKey UnlockWarning Switch

Ignition Switch

10.5 (110, 8)�

Column TubeAssembly

2.2 (23, 19 in.·lbf)�

Spring Guide

�

Tilt Spring

Main Shaft Assembly

Steering Column Housing

Tilt Lever

Release Lever SpringTurn Signal Bracket

�

CompressionSpring

SpringRetainer

Upper Bearing Inner Race SeatInner Race

� 12 (120, 9)

Pivot Pin

Spring

Park Lock Cable Assembly

Shaft Bearing

Main Shaft Stopper

Pivot Pin

Shift LeverHousing

18 (180, 13)�

�

�

Shift Lever

No. 2 Steering Column Ring�

Tilt Lever Lock Shaft9.0 (90, 78 in.·lbf)

�

�

�

7.5 (75, 65 in.·lbf)

2.9 (29, 25 in.·lbf)

Key CylinderLamp Assembly

Tilt No. 1 Stopper

SR-32-STEERING STEERING COLUMN (Double Cab)


SR1KO-01

F13611

Screw Extractor

F06733



DISASSEMBLYNOTICE:When using a vise, do not overtighten it.1. REMOVE KEY CYLINDER LAMP ASSEMBLY

2. REMOVE COLUMN UPPER BRACKET(a) Using a centering punch, mark the center of the 2 ta-

pered-head bolts.(b) Using a 3 to 4 mm (0.12 to 0.16 in.) drill, drill a hole into

the 2 bolts.(c) Using a screw extractor, remove the 2 bolts and column

upper bracket.3. REMOVE SHIFT LEVERUsing a torx® socket wrench, remove the torx® screw and shiftlever.4. REMOVE PARK LOCK CABLE ASSEMBLY

(See page AT-21 )

5. REMOVE SHIFT LEVER HOUSINGUsing a torx® socket wrench, remove the 3 torx® screws andshift lever housing.6. REMOVE RELEASE LEVER SPRING7. REMOVE TURN SIGNAL BRACKETUsing a torx® socket wrench, remove the 2 torx® screws andturn signal bracket.

F06734

Plate Washer A

Plate Washer B

SST

Screw

R12472

SSTRetaining Ring



8. REMOVE STEERING COLUMN HOUSING WITH MAINSHAFT ASSEMBLY

(a) Set SST, 2 plate washers (18 and 36 mm outer diameter)and a screw (4.0 mm diameter, 0.7 mm pitch, 15.0 mmlength), as shown in the illustration. Then remove the 2pivot pins.SST 09910-00015 (09911-0001 1, 09912-00010)ReferencePlate washer A (18 mm): 90562-04012Plate washer B (36 mm): 90201-10201Screw: 90154-40015

(b) Remove the column housing with the shaft assembly fromthe column tube assembly.

NOTICE:Do not bend the universal joint of the main shaft assemblymore than 15 °.(c) Remove the tilt spring and spring guide.9. REMOVE 2 TILT NO. 1 STOPPERS10. REMOVE MAIN SHAFT STOPPER

11. REMOVE MAIN SHAFT ASSEMBLY(a) Install SST to the main shaft assembly, as shown in the

illustration.SST 09612-07010

(b) Using SST, compress the compression spring.SST 09612-07010

NOTICE:Do not bend the universal joint of the shaft assembly morethan 15 °.HINT:Hold the shaft assembly with your hand to prevent rotation.(c) Using a screwdriver, remove the No. 2 steering column

ring.(d) Remove the spring retainer, compression spring, upper

bearing inner race seat and inner race.12. REMOVE TILT LEVERRemove the tilt lever lock shaft and shift lever.

SR1KP-01

F13613

F13618

R11908

F13614

SST

Shaft Bearing



INSPECTION1. INSPECT STEERING LOCK OPERATIONCheck that the steering lock mechanism operates properly.

2. IF NECESSARY, REPLACE KEY CYLINDER(a) Turn the ignition key to the ACC position.(b) Push down the stop pin with a screwdriver, and pull out

the cylinder.(c) Install a new cylinder.HINT:Make sure that the key is in the ACC position.3. INSPECT IGNITION SWITCH (See page BE-37 )4. IF NECESSARY, REPLACE IGNITION SWITCH(a) Remove the 2 screws and ignition switch.(b) Install a new ignition switch with the 2 screws.5. INSPECT KEY UNLOCK WARNING SWITCH

(See page BE-37 )6. IF NECESSARY, REPLACE KEY UNLOCK WARNING

SWITCH(a) Slide out the key unlock warning switch.(b) Install a new key unlock warning switch.

7. INSPECT BEARING(a) Check that the bearing rotates smoothly without abnor-

mal noise.If it does not rotate smoothly or abnormal noise occurs, replacethe column housing.(b) Coat the bearing with molybdenum disulfide lithium base

grease.

8. IF NECESSARY, REPLACE SHAFT BEARING(a) Using SST and a press, press out the shaft bearing.

SST 09950-60010 (09951-00400),09950-70010 (09951-07360)

F13615

SST

Shaft Bearing



(b) Coat a new shaft bearing with molybdenum disulfide lithi-um base grease.

(c) Using SST and a press, press in the shaft bearing.SST 09950-60010 (09951-00460),

09950-70010 (09951-07150)

SR1KR-01

F17897Matchmarks

F17913

Matchmarks



INSTALLATIONNOTICE:When replacing the steering angle sensor, drive the vehiclestraight ahead at a speed of 6.5 mph (10.5 km/h) or more.Accordingly, zero point calibration of the steering anglesensor is performed.HINT:If the steering angle sensor zero point calibration is not per-formed, its value will be fixed. Check after driving the vehiclestraight ahead at a speed of 6.5 mph (10.5 km/h) or more (Seepage DI-1568 ).

1. INSTALL NO. 2 INTERMEDIATE SHAFT ASSEMBLY(a) Align the matchmark on the No. 2 intermediate shaft as-

sembly with the one on the control valve shaft.(b) Install the bolt.


2. CONNECT NO. 2 UNIVERSAL JOINT ASSEMBLY(a) Insert the column hole cover No. 2.(b) Align the matchmarks on the column assembly and No.

2 universal joint assembly.(c) Install the bolt.

Torque: 35 N·m (360 kgf·cm, 26 ft·lbf)3. INSTALL STEERING COLUMN ASSEMBLY WITH NO.

2 UNIVERSAL JOINT ASSEMBLY(a) Install the column assembly with the No. 2 universal joint

assembly.(b) Install the 4 steering column set nuts.

Torque: 26 N·m (260 kgf·cm, 19 ft·lbf)(c) Connect the connectors.4. CONNECT TRANSMISSION CONTROL CABLE AS-

SEMBLYConnect the cable assembly to the shift lever assembly.

F13260

F17896

A

B

Matchmarks

F19948

Mark



5. INSTALL COLUMN HOLE COVER NO. 2Install the column hole cover No. 2 to the body with the 3 bolts.


6. INSTALL SLIDING YOKE(a) Align the matchmark on the sliding yoke with the one on

the No. 2 intermediate shaft assembly.(b) Install the ”B” bolt.

Torque: 35 N·m (360 kgf·cm, 26 ft·lbf)(c) Install the ”A” bolt.

Torque: 35 N·m (360 kgf·cm, 26 ft·lbf)7. INSTALL BRAKE PEDAL RETURN SPRING8. INSTALL NO. 2 HEATER TO REGISTER DUCT9. INSTALL LOWER LH FINISH PANEL(a) Install the lower LH finish panel with the 4 bolts.(b) Connect the hood lock release lever with the 2 screws.10. INSTALL SPIRAL CABLE (See page BE-40 )11. INSTALL COMBINATION SWITCH WITH SPIRAL

CABLE(a) Install the combination switch with the 3 screws.(b) Connect the airbag connector.(c) Connect the 4 connectors.12. INSTALL UPPER AND LOWER COLUMN COVERSInstall the upper and lower column covers with the 3 screws.13. CENTER SPIRAL CABLE(a) Check that the front wheels are facing straight ahead.(b) Turn the cable counterclockwise by hand until it feels firm.(c) Then rotate the cable clockwise about 2.5 turns to align

the marks.HINT:The cable will rotate about 2.5 turns to both the left and rightfrom the center.14. INSTALL STEERING WHEEL(a) Align the matchmarks on the wheel and main shaft.(b) Install the wheel set nut.

Torque: 50 N·m (510 kgf·cm, 37 ft·lbf)(c) Connect the connector.

F19882

Torx® Screw Screw Case



15. INSTALL STEERING WHEEL PADNOTICE:� Never use airbag parts from another vehicle. When

replacing parts, replace with new ones.� Make sure the wheel pad is installed with the speci-

fied torque.� If the wheel pad has been dropped, or there are

cracks, dents or other defects on the case or connec-tor, replace the wheel pad with a new one.

� When installing the wheel pad, take care that the wir-ings do not interfere with other parts and are notpinched between other parts.

� When installing torx ® screws, take care not to scratchother parts (ex. cruise control switch, lower cover)with a torx ® socket wrench.

(a) Connect the airbag connectors and horn terminal.(b) Install the wheel pad after confirming that the circumfer-

ence groove of the torx® screw is caught on the screwcase.

(c) Using a torx® socket wrench, tighten the 2 screws whileholding down the upper surface of the wheel pad properlyto prevent the wheel pad from floating up.Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)

(d) Install the steering wheel lower No. 2 cover.(e) Install the steering wheel lower No. 3 cover.16. CHECK STEERING WHEEL CENTER POINT17. CONNECT CABLE TO NEGATIVE BATTERY TERMI-

NAL

SR1KQ-01

R12807

Washer

Retaining Ring

SST

F06735



REASSEMBLYNOTICE:When using a vise, do not overtighten it.1. COAT PARTS INDICATED BY ARROWS WITH MOLYB-

DENUM DISULFIDE LITHIUM BASE GREASE (Seepage SR-31 )

2. INSTALL TILT LEVERInstall the tilt lever with a new tilt lever lock shaft.

Torque: 9.0 N·m (90 kgf·cm, 78 in.·lbf)

3. INSTALL MAIN SHAFT ASSEMBLY(a) Install the inner race, upper bearing inner race seat, com-

pression spring and spring retainer.(b) Install a new No. 2 steering column ring to the main shaft

assembly.(c) Install the washer of SST on the main shaft assembly.

SST 09612-07010(d) Set SST on the main shaft assembly, as shown in the il-

lustration.SST 09612-07010

(e) Using SST, push down the retaining ring until it fits into theshaft groove and install the main shaft assembly.

NOTICE:Do not bend the universal joint of the shaft assembly morethan 15 °.HINT:Hold the main shaft assembly with your hand to prevent rota-tion.4. INSTALL MAIN SHAFT STOPPER5. INSTALL 2 NEW TILT NO. 1 STOPPERS

6. INSTALL STEERING COLUMN HOUSING WITH MAINSHAFT ASSEMBLY

(a) Install the steering column housing with the main shaft as-sembly into the column tube assembly.

(b) Install the tilt spring and spring guide.(c) Hold the steering column housing and steering column

housing support in a vise.(d) Temporarily install 2 new pivot pins.

F06736

F06737

F13612



(e) Using a punch and a hammer, tap in the pivot pin.(f) Using a pin punch and a hammer, stake at 3 places evenly

around the hole as shown in the illustration.

7. INSTALL TURN SIGNAL BRACKETUsing a torx® socket wrench, install the turn signal bracket with2 new torx® screws.

Torque: 7.5 N·m (75 kgf·cm, 65 in.·lbf)HINT:Make sure that the protrusion on the steering column housingis fitted into the hole of the turn signal bracket.8. INSTALL RELEASE LEVER SPRING9. INSTALL SHIFT LEVER HOUSINGUsing a torx® socket wrench, install the shift lever housing with3 new torx® screws.

Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)10. INSTALL PARK LOCK CABLE ASSEMBLY (See page

AT-22 )11. INSTALL SHIFT LEVERUsing a torx® socket wrench, install the shift lever with a newtorx® screw.


12. INSTALL COLUMN UPPER BRACKET(a) Install the column upper bracket with 2 new tapered-

head bolts.HINT:Insert the bracket pin into the column tube hole.(b) Tighten the tapered-head bolts until the bolt heads break

off.13. INSTALL KEY CYLINDER LAMP ASSEMBLY

SR1KN-01

F19881

Screw CaseTorx® Screw

F17904

Correct Wrong

Airbag Connectors

F14451

Matchmarks

SST



REMOVAL1. DISCONNECT CABLE FROM NEGATIVE BATTERY

TERMINALWait for 90 seconds after disconnecting the cable to prevent theairbag working.2. REMOVE STEERING WHEEL PADNOTICE:If the airbag connector is disconnected with the ignitionswitch in the ON or ACC position, DTCs will be recorded.

(a) Place the front wheels facing straight ahead.(b) Remove the steering wheel lower No. 2 cover.(c) Remove the steering wheel lower No. 3 cover.(d) Using a torx® socket wrench, loosen the 2 torx® screws.HINT:Loosen each screw until the groove along the screw circumfer-ence is caught on the screw case.

(e) Pull out the wheel pad from the steering wheel and dis-connect the airbag connectors and horn terminal.

CAUTION:� When storing the wheel pad, keep the upper surface

of the pad facing upward.� Never disassemble the wheel pad.

NOTICE:When removing the wheel pad, take care not to pull the air-bag wire harness.

3. REMOVE STEERING WHEEL(a) Remove the steering wheel set nut.(b) Put matchmarks on the steering wheel and main shaft as-

sembly.(c) Using SST, remove the wheel.

SST 09950- 50013 (09951- 05010, 09952- 05010,09953-05020, 09954-05021)

(d) Disconnect the connector.

F17896

A

B

Matchmarks

F13260

F06703



4. REMOVE UPPER AND LOWER COLUMN COVERSRemove the 3 screws, upper and lower column covers.5. REMOVE COMBINATION SWITCH WITH SPIRAL

CABLE(a) Disconnect the 4 connectors.(b) Disconnect the airbag connector.(c) Remove the 3 screws and combination switch.6. REMOVE SPIRAL CABLE (See page BE-40 )NOTICE:Do not disassemble the cable or apply oil to it.7. REMOVE LOWER LH FINISH PANEL(a) Remove the 2 screws and disconnect the hood lock re-

lease lever from the panel.(b) Remove the 4 panel set bolts and lower LH finish panel.8. REMOVE NO. 2 HEATER TO REGISTER DUCT9. REMOVE BRAKE PEDAL RETURN SPRING

10. REMOVE SLIDING YOKE(a) Put matchmarks on the sliding yoke and No. 2 intermedi-

ate shaft assembly.(b) Remove the ”A” bolt.(c) Remove the ”B” bolt.(d) Slide the sliding yoke and remove it.

11. REMOVE COLUMN HOLE COVER NO. 2Remove the 3 bolts and column hole cover No. 2.

12. DISCONNECT TRANSMISSION CONTROL CABLEASSEMBLY

Disconnect the cable assembly from the column shift lever as-sembly.

F17913

Matchmarks

F17897Matchmarks



13. REMOVE STEERING COLUMN ASSEMBLY WITH NO.2 UNIVERSAL JOINT ASSEMBLY

(a) Disconnect the connectors.(b) Remove the 4 steering column set nuts.(c) Pull out the steering column assembly with the No. 2 uni-

versal joint assembly.

14. DISCONNECT NO. 2 UNIVERSAL JOINT ASSEMBLY(a) Put matchmarks on the steering column assembly and

No. 2 universal joint assembly.(b) Remove the bolt and No. 2 universal joint assembly.

15. REMOVE NO. 2 INTERMEDIATE SHAFT ASSEMBLY(a) Put matchmarks on the No. 2 intermediate shaft assem-

bly and control valve shaft.(b) Remove the bolt and No. 2 intermediate shaft assembly.

SR1KG-02

F17898


Steering Wheel Lower No. 2 Cover

Steering Wheel

Column Upper Cover

Combination Switch

50 (510, 37)


8.8 (90, 78 in.·lbf)

Torx® Screw8.8 (90, 78 in.·lbf)

Non-tilt steering column (M/T)

Column Lower Cover

Steering Column Assembly



Hood Lock ReleaseLever


No. 2 IntermediateShaft Assembly

No. 2 Heater to Register Duct


26 (260, 19)8.0 (82, 71 in.·lbf)

35 (360, 26)

35 (360, 26)

Steering Wheel Pad

Sliding Yoke

35 (360, 26)

Torx® Screw

SR-12-STEERING STEERING COLUMN (Standard Cab, Access Cab)


STEERING COLUMN (Standard Cab, Access Cab)COMPONENTS

F17899



Steering Wheel

Column Upper Cover

Combination Switch

50 (510, 37)


8.8 (90, 78 in.·lbf)

8.8 (90, 78 in.·lbf)

Non-tilt steering column (A/T)

Column Lower CoverSteering Column Assembly







26 (260, 19)8.0 (82, 71 in.·lbf)

35 (360, 26)

35 (360, 26)

Steering Wheel Pad



Sliding Yoke

35 (360, 26)

Torx® Screw

Torx® Screw

-STEERING STEERING COLUMN (Standard Cab, Access Cab)SR-13


F17900



Steering Wheel

Column Upper Cover

Combination Switch

50 (510, 37)


8.8 (90, 78 in.·lbf)

8.8 (90, 78 in.·lbf)

Tilt steering column (M/T)

Column Lower Cover Steering Column Assembly




Sliding Yoke



26 (260, 19)8.0 (82, 71 in.·lbf)

35 (360, 26)

35 (360, 26)

Steering Wheel Pad


35 (360, 26)


Torx® Screw

Torx® Screw



F17901



Steering Wheel

Column Upper Cover

Combination Switch

50 (510, 37)


8.8 (90, 78 in.·lbf)

Torx® Screw8.8 (90, 78 in.·lbf)

Tilt steering column (A/T)

Column Lower CoverSteering Column Assembly







26 (260, 19)8.0 (82, 71 in.·lbf)

35 (360, 26)

35 (360, 26)

Steering Wheel Pad



Sliding Yoke

35 (360, 26)

Torx® Screw



F14448

�


Compression Spring

A/T

Shift Lever

18 (180, 13)

Upper No. 2Steering Cover

� 12 (120, 9)Shift LeverHousing


Key Cylinder

Key UnlockWarning Switch

IgnitionSwitch

� Retaining Ring

Spring Retainer

7.5 (75, 65 in.·lbf)

Turn Signal Bracket

� 19 (195, 14)

�

�

�

Main Shaft Stopper

Main Shaft Assembly

Column Upper Tube

Shaft Bearing

A/T2.2 (23, 19 in.·lbf) Spring

2.9 (29, 25 in.·lbf)


10.5 (110, 8)

Non-tilt steering column

Column Tube Assembly



�

�

�

Column Upper Clamp

� Tapered-head Bolt

Clip



F14449

�

A/TShift Lever

� 12 (120, 9)Shift LeverHousing

�

CompressionSpring

� Retaining Ring

SpringRetainer

�

Main Shaft Assembly

Tilt Lever

Steering Column Housing



Key Cylinder

Key UnlockWarning Switch

IgnitionSwitch

Main ShaftStopper

Shaft Bearing

A/T

Spring2.2 (23, 19 in.·lbf)

Upper BearingInner Race Seat

7.5 (75, 65 in.·lbf)

Turn Signal BracketRelease Lever Spring

InnerRace

� Tilt No. 1 Stopper

Steering ColumnHousing Support

�

�

Tilt Spring

Spring Guide

�

Tilt steering column

19 (195, 14)

Pivot Pin

Column TubeAssembly



Column Upper Clamp

� Tapered-head Bolt

2.9 (29, 25 in.·lbf)

�


18 (180, 13)

Upper No. 2Steering Cover

Clip

10.5 (110, 8)�



SR1KI-02

F06732

ScrewExtractor

F06733



DISASSEMBLYNOTICE:When using a vise, do not overtighten it.1. REMOVE KEY CYLINDER LAMP ASSEMBLYRemove the clip and key cylinder lamp assembly.

2. REMOVE COLUMN UPPER BRACKET AND COLUMNUPPER CLAMP

(a) Using a centering punch, mark the center of the 2 ta-pered-head bolts.

(b) Using a 3 to 4 mm (0.12 to 0.16 in.) drill, drill a hole intothe 2 bolts.

(c) Using a screw extractor, remove the 2 bolts, column up-per bracket and column upper clamp.

3. A/T:REMOVE SHIFT LEVER

Remove the screw and shift lever.4. A/T:

REMOVE UPPER NO. 2 STEERING COVER

5. A/T:REMOVE PARK LOCK CABLE ASSEMBLY(See page AT-21 )

6. A/T:REMOVE SHIFT LEVER HOUSING

Remove the 3 torx® screws and shift lever housing.7. Tilt steering column:

REMOVE RELEASE LEVER SPRING8. REMOVE TURN SIGNAL BRACKETRemove the 2 torx® screws and turn signal bracket.9. Non-tilt steering column:

REMOVE COLUMN UPPER TUBE WITH MAIN SHAFTASSEMBLY

(a) Remove the 4 torx® bolts.(b) Remove the column upper tube with the main shaft as-

sembly from the column tube assembly.

F06734

Plate Washer A

Plate Washer B

SST

Screw

R12472

SSTRetaining Ring



10. Tilt steering column:REMOVE STEERING COLUMN HOUSING WITH MAINSHAFT ASSEMBLY

(a) Set SST, 2 plate washers (18 and 36 mm outer diameter)and a screw (4.0 mm diameter, 0.7 mm pitch, 15.0 mmlength), as shown in the illustration. Then remove the 2pivot pins.SST 09910-00015 (09911-0001 1, 09912-00010)ReferencePlate washer A (18 mm): 90562-04012Plate washer B (36 mm): 90201-10201Screw: 90154-40015

(b) Remove the column housing with the shaft assembly fromthe column tube assembly.

NOTICE:Do not bend the universal joint of the main shaft assemblymore than 15 °.(c) Remove the tilt spring and spring guide.11. Tilt steering column:

REMOVE STEERING COLUMN HOUSING SUPPORT(a) Remove the 4 torx® bolts.(b) Remove the 2 tilt No.1 stoppers and steering column

housing support.12. REMOVE MAIN SHAFT STOPPER

13. REMOVE MAIN SHAFT ASSEMBLY(a) Install SST to the main shaft assembly, as shown in the

illustration.SST 09612-07010

(b) Using SST, compress the compression spring.NOTICE:Do not bend the universal joint of the shaft assembly morethan 15 °.HINT:Hold the shaft assembly with your hand to prevent rotation.(c) Using a screwdriver, remove the retaining ring.(d) Non-tilt steering column:

Remove the spring retainer and compression spring.(e) Tilt steering column:

Remove the spring retainer, compression spring, upperbearing inner race seat and inner race.

SR1KJ-02

F02583

F02584

R11908

F14452

SST

Shaft Bearing



INSPECTION1. INSPECT STEERING LOCK OPERATIONCheck that the steering lock mechanism operates properly.

2. IF NECESSARY, REPLACE KEY CYLINDER(a) Place the ignition key in the ACC position.(b) Push down the stop pin with a screwdriver, and pull out

the cylinder.(c) Install a new cylinder.HINT:Make sure the key is in the ACC position.3. INSPECT IGNITION SWITCH (See page BE-37 )4. IF NECESSARY, REPLACE IGNITION SWITCH(a) Remove the 2 screws and ignition switch.(b) Install a new ignition switch with the 2 screws.5. INSPECT KEY UNLOCK WARNING SWITCH

(See page BE-37 )6. IF NECESSARY, REPLACE KEY UNLOCK WARNING

SWITCH(a) Slide out the key unlock warning switch.(b) Install a new key unlock warning switch.

7. A/T:INSPECT BEARING

(a) Check that the bearing rotates smoothly without abnor-mal noise.

If it does not rotate smoothly or abnormal noise occurs, replacethe column housing.(b) Coat the bearing with molybdenum disulfide lithium base

grease.

8. IF NECESSARY, REPLACE SHAFT BEARING(a) Using SST and a press, press out the shaft bearing.

SST 09950-60010 (09951-00430),09950-70010 (09951-07360)

F14453

SST

Shaft Bearing



(b) Coat a new shaft bearing with molybdenum disulfide lithi-um base grease.

(c) Using SST and a press, press in the shaft bearing.SST 09950-60010 (09951-00460),

09950-70010 (09951-07150)

SR1KL-02

F17897Matchmarks

F17913

Matchmarks



INSTALLATIONNOTICE:When replacing the steering angle sensor, drive the vehiclestraight ahead at a speed of 6.5 mph (10.5 km/h) or more.Accordingly, zero point calibration of the steering anglesensor is performed.HINT:If the steering angle sensor zero point calibration is not per-formed, its value will be fixed. Check after driving the vehiclestraight ahead at a speed of 6.5 mph (10.5 km/h) or more (Seepage DI-1568 ).

1. INSTALL NO. 2 INTERMEDIATE SHAFT ASSEMBLY(a) Align the matchmark on the No. 2 intermediate shaft as-

sembly with the one on the control valve shaft.(b) Install the bolt.


2. CONNECT NO. 2 UNIVERSAL JOINT ASSEMBLY(a) Insert the column hole cover No. 2.(b) Align the matchmarks on the column assembly and No.

2 universal joint assembly.(c) Install the bolt.

Torque: 35 N·m (360 kgf·cm, 26 ft·lbf)3. INSTALL STEERING COLUMN ASSEMBLY WITH NO.

2 UNIVERSAL JOINT ASSEMBLY(a) Install the column assembly with the No. 2 universal joint

assembly.(b) Install the 4 steering column set nuts.

Torque: 26 N·m (260 kgf·cm, 19 ft·lbf)(c) Connect the connectors.4. A/T:

CONNECT TRANSMISSION CONTROL CABLE AS-SEMBLY

Connect the cable assembly to the shift lever assembly.

F13260

F17896

A

B

Matchmarks

F19948

Mark



5. INSTALL COLUMN HOLE COVER NO. 2Install the column hole cover No. 2 to the body with the 3 bolts.


6. INSTALL SLIDING YOKE(a) Align the matchmark on the sliding yoke with the one on

the No. 2 intermediate shaft assembly.(b) Install the ”B” bolt.

Torque: 35 N·m (360 kgf·cm, 26 ft·lbf)(c) Install the ”A” bolt.

Torque: 35 N·m (360 kgf·cm, 26 ft·lbf)7. INSTALL BRAKE PEDAL RETURN SPRING8. INSTALL NO. 2 HEATER TO REGISTER DUCT9. INSTALL LOWER LH FINISH PANEL(a) Install the lower LH finish panel with the 4 bolts.(b) Connect the hood lock release lever with the 2 screws.10. INSTALL SPIRAL CABLE (See page BE-40 )11. INSTALL COMBINATION SWITCH WITH SPIRAL

CABLE(a) Install the combination switch with the 3 screws.(b) Connect the airbag connector.(c) M/T:

Connect the 3 connectors.(d) A/T:

Connect the 4 connectors.12. INSTALL UPPER AND LOWER COLUMN COVERSInstall the upper and lower column covers with the 3 screws.

13. CENTER SPIRAL CABLE(a) Check that the front wheels are facing straight ahead.(b) Turn the cable counterclockwise by hand until it feels firm.(c) Then rotate the cable clockwise about 2.5 turns to align

the marks.HINT:The cable will rotate about 2.5 turns to both the left and rightfrom the center.

F19882

Torx® Screw Screw Case



14. INSTALL STEERING WHEEL(a) Align the matchmarks on the wheel and main shaft.(b) Install the wheel set nut.

Torque: 50 N·m (510 kgf·cm, 37 ft·lbf)(c) Connect the connector.15. INSTALL STEERING WHEEL PADNOTICE:� Never use airbag parts from another vehicle. When

replacing parts, replace with new ones.� Make sure the wheel pad is installed with the speci-

fied torque.� If the wheel pad has been dropped, or there are

cracks, dents or other defects on the case or connec-tor, replace the wheel pad with a new one.

� When installing the wheel pad, take care that the wir-ings do not interfere with other parts and are notpinched between other parts.

� When installing torx ® screws, take care not to scratchother parts (ex. cruise control switch, lower cover)with a torx ® socket wrench.

(a) Connect the airbag connectors and horn terminal.(b) Install the wheel pad after confirming that the circumfer-

ence groove of the torx® screw is caught on the screwcase.

(c) Using a torx® socket wrench, tighten the 2 screws whileholding down the upper surface of the wheel pad properlyto prevent the wheel pad from floating up.Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)

(d) Install the steering wheel lower No. 2 cover.(e) Install the steering wheel lower No. 3 cover.16. CHECK STEERING WHEEL CENTER POINT17. CONNECT CABLE TO NEGATIVE BATTERY TERMI-

NAL

SR1KK-02

R12807

Washer

Retaining Ring

SST



REASSEMBLYNOTICE:When using a vise, do not overtighten it.1. COAT PARTS INDICATED BY ARROWS WITH MOLYB-

DENUM DISULFIDE LITHIUM BASE GREASE (Seepage SR-12 )

2. INSTALL MAIN SHAFT ASSEMBLY(a) Non-tilt steering column:

Install the compression spring and spring retainer.(b) Tilt steering column:

Install the inner race, upper bearing inner race seat, com-pression spring and spring retainer.

(c) Install a new retaining ring to the main shaft assembly.(d) Install the washer of SST to the main shaft assembly.(e) Set SST on the main shaft assembly, as shown in the il-

lustration.SST 09612-07010

(f) Using SST, push down the retaining ring until it fits into theshaft groove and install the main shaft assembly.

NOTICE:Do not bend the universal joint of the shaft assembly morethan 15 °.HINT:Hold the main shaft assembly with your hand to prevent rota-tion.3. INSTALL MAIN SHAFT STOPPER4. Tilt steering column:

INSTALL STEERING COLUMN HOUSING SUPPORT(a) Install 2 new tilt No.1 stoppers and the steering column

housing support.(b) Install 4 new torx® bolts.

Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)5. Non-tilt steering column:

INSTALL COLUMN UPPER TUBE WITH MAIN SHAFTASSEMBLY

(a) Install the column upper tube with the main shaft assem-bly to the column tube assembly.

(b) Install 4 new torx® bolts.Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)

F06735

F06736

F06737



6. Tilt steering column:INSTALL STEERING COLUMN HOUSING WITH MAINSHAFT ASSEMBLY

(a) Install the steering column housing with the main shaft as-sembly into the column tube assembly.

(b) Install the tilt spring and spring guide.(c) Hold the steering column housing and steering column

housing support in a vise.(d) Temporarily install 2 new pivot pins.

(e) Using a punch and a hammer, tap in the pivot pin.(f) Using a pin punch and hammer, stake at 3 places evenly

around the hole as shown in the illustration.

7. INSTALL TURN SIGNAL BRACKETInstall the turn signal bracket with 2 new torx® screws.

Torque: 7.5 N·m (75 kgf·cm, 65 in.·lbf)HINT:Make sure that the protrusion on the steering column housingis fitted into the hole of the turn signal bracket.8. Tilt steering column:

INSTALL RELEASE LEVER SPRING9. A/T:

INSTALL PARK LOCK CABLE ASSEMBLY (See pageAT-22 )

10. A/T:INSTALL SHIFT LEVER HOUSING

Install the shift lever housing with 3 new torx® screws.Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

11. A/T:INSTALL UPPER NO. 2 STEERING COVER

12. A/T:INSTALL SHIFT LEVER

Install the shift lever with a new torx® screw.Torque: 18 N·m (180 kgf·cm, 13 ft·lbf)

F06731



13. INSTALL COLUMN UPPER BRACKET AND COLUMNUPPER CLAMP

(a) Install the column upper bracket and column upper clampwith 2 new tapered-head bolts.

HINT:Insert the bracket pin into the column tube hole.(b) Tighten the tapered-head bolts until the bolt heads break

off.14. INSTALL KEY CYLINDER LAMP ASSEMBLYInstall the key cylinder lamp assembly with the clip.

SR1KH-01

F19881

Screw CaseTorx® Screw

F17904

Correct Wrong

Airbag Connectors

F14451

Matchmarks

SST



REMOVAL1. DISCONNECT CABLE FROM NEGATIVE BATTERY

TERMINALWait for 90 seconds after disconnecting the cable to prevent theairbag working.2. REMOVE STEERING WHEEL PADNOTICE:If the airbag connector is disconnected with the ignitionswitch in the ON or ACC position, DTCs will be recorded.

(a) Place the front wheels facing straight ahead.(b) Remove the steering wheel lower No. 2 cover.(c) Remove the steering wheel lower No. 3 cover.(d) Using a torx® socket wrench, loosen the 2 torx® screws.HINT:Loosen each screw until the groove along the screw circumfer-ence is caught on the screw case.

(e) Pull out the wheel pad from the steering wheel and dis-connect the airbag connectors and horn terminal.

CAUTION:� When storing the wheel pad, keep the upper surface

of the pad facing upward.� Never disassemble the wheel pad.

NOTICE:When removing the wheel pad, take care not to pull on theairbag wire harness.

3. REMOVE STEERING WHEEL(a) Remove the steering wheel set nut.(b) Put matchmarks on the steering wheel and main shaft as-

sembly.(c) Using SST, remove the wheel.

SST 09950- 50013 (09951- 05010, 09952- 05010,09953-05020, 09954-05021)

(d) Disconnect the connector.

F17896

A

B

Matchmarks

F13260

F06703



4. REMOVE UPPER AND LOWER COLUMN COVERSRemove the 3 screws, upper and lower column covers.5. REMOVE COMBINATION SWITCH WITH SPIRAL

CABLE(a) M/T:

Disconnect the 3 connectors.(b) A/T:

Disconnect the 4 connectors.(c) Disconnect the airbag connector.(d) Remove the 3 screws and combination switch.6. REMOVE SPIRAL CABLE (See page BE-40 )NOTICE:Do not disassemble the cable or apply oil to it.7. REMOVE LOWER LH FINISH PANEL(a) Remove the 2 screws and disconnect the hood lock re-

lease lever from the panel.(b) Remove the 4 panel set bolts and lower LH finish panel.8. REMOVE NO. 2 HEATER TO REGISTER DUCT9. REMOVE BRAKE PEDAL RETURN SPRING

10. REMOVE SLIDING YOKE(a) Put matchmarks on the sliding yoke and No. 2 intermedi-

ate shaft assembly.(b) Remove the ”A” bolt.(c) Remove the ”B” bolt.(d) Slide the sliding yoke and remove it.

11. REMOVE COLUMN HOLE COVER NO. 2Remove the 3 bolts and column hole cover No. 2.

12. A/T:DISCONNECT TRANSMISSION CONTROL CABLEASSEMBLY

Disconnect the cable assembly from the column shift lever as-sembly.

F17913

Matchmarks

F17897Matchmarks



13. REMOVE STEERING COLUMN ASSEMBLY WITH NO.2 UNIVERSAL JOINT ASSEMBLY

(a) Disconnect the connectors.(b) Remove the 4 steering column set nuts.(c) Pull out the steering column assembly with the No. 2 uni-

versal joint assembly.

14. DISCONNECT NO. 2 UNIVERSAL JOINT ASSEMBLY(a) Put matchmarks on the steering column assembly and

No. 2 universal joint assembly.(b) Remove the bolt and No. 2 universal joint assembly.

15. REMOVE NO. 2 INTERMEDIATE SHAFT ASSEMBLY(a) Put matchmarks on the No. 2 intermediate shaft assem-

bly and control valve shaft.(b) Remove the bolt and No. 2 intermediate shaft assembly.

SR01S-07

-STEERING STEERING SYSTEMSR-1


STEERING SYSTEMPRECAUTION� Care must be taken to replace parts properly because they could affect the performance of the

steering system and result in a driving hazard.� The TOYOTA TUNDRA is equipped with an SRS (Supplemental Restraint System) such as the

driver airbag and front passenger airbag. Failure to carry out service operation in the correctsequence could cause the SRS to unexpectedly deploy during servicing, possibly leading toa serious accident. Before servicing (including removal or installation of parts, inspection orreplacement), be sure to read the precautionary notices in the RS section.

� When replacing the steering angle sensor, drive the vehicle straight ahead at a speed of 6.5 mph(10.5 km/h) or more. Accordingly, zero point calibration of the steering angle sensor is per-formed.

� After performing ”Front wheel alignment adjustment”, clearing and reading the yaw rate & de-celeration sensor zero point calibration data is necessary (See page DI-1494 ).

R07653

SR01Y-13

F14454

-STEERING STEERING WHEELSR-9


STEERING WHEELINSPECTION1. CHECK STEERING WHEEL FREE PLAY(a) Stop the vehicle and face the tires straight ahead.(b) Gently rock the steering wheel up and down with a finger,

and check the steering wheel free play.Maximum free play: 30 mm (1.18 in.)

2. CHECK STEERING EFFORT(a) Center the steering wheel.(b) Remove the steering wheel pad

(See page SR-18 , SR-33 ).(c) Start the engine and run at idle.(d) Measure the steering effort in both directions.

Steering effort (Reference):4.9 N·m (50 kgf·cm, 43 in.·lbf)

HINT:Check tire type, pressure and contact surface before makingyour diagnosis.(e) Tighten the steering wheel set nut.

Torque: 50 N·m (510 kgf·cm, 37 ft·lbf)(f) Install the steering wheel pad

(See page SR-28 , SR-42 ).

SR1HN-03

F16015

Steering Wheel

Masking Tape

Steering ColumnUpper Cover

F16016


Marked Line

SteeringWheel

MaskingTape

SR-10-STEERING STEERING WHEEL


REPAIR PROCEDURESHINT:This is the repair procedure for steering off center.

1. INSPECT STEERING WHEEL OFF CENTER(a) Apply masking tape on the top center of the steering

wheel and steering column upper cover.

(b) Drive the vehicle in a straight line for 100 meters at aconstant speed of 35 mph (56 km/h), and hold the steer-ing wheel to maintain the course.

(c) Draw a line on the masking tape as shown in the illustra-tion.

F16017


New MarkedLineSteering Wheel

F16018

-STEERING STEERING WHEELSR-1 1


(d) Turn the steering wheel to its straight position.HINT:Refer to the upper surface of the steering wheel, steering spokeand SRS airbag line for the straight position.(e) Draw a new line on the masking tape of the steering wheel

as shown in the illustration.(f) Measure the distance between the 2 lines on the masking

tape of the steering wheel.(g) Convert the measured distance to steering angle.

Measured distance 1 mm (0.04 in.) = Steering angleapproximately 1 deg.

HINT:Make a note of the steering angle.2. ADJUST STEERING ANGLE(a) Lift up the vehicle.NOTICE:The adjustment method for steering angle is different de-pending on the models. Check whether it is type A or B.(b) Draw a line on the RH and LH tie rod and rack ends where

it can easily be seen.(c) Using a paper gauge, measure the distance from RH and

LH tie rod ends to the rack end screws.HINT:� Measure the RH side and LH side.� Make a note of the measured values.

(d) Remove the RH and LH boot clips from the rack boots.(e) Loosen the RH and LH lock nuts.(f) 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

(g) Tighten the RH and LH lock nuts by the specified torque.Torque: 55 N·m (560 kgf·cm, 41 ft·lbf)

NOTICE:Make sure that the difference in length between RH and LHtie rod ends and rack end screws are within 1.5 mm (0.059in.).(h) Install the RH and LH boot clips.

SR01T-09

SR-2-STEERING TROUBLESHOOTING


TROUBLESHOOTINGPROBLEM SYMPTOMS TABLEUse the table below to help you find the cause of the problem. The numbers indicate the priority of the likelycause of the problem. Check each part in the order shown. If necessary, repair or replace these parts.

Symptom Suspect Area See page

Hard steering

1. Tires (Improperly inflated)

2. Power steering fluid level (Low)

3. Drive belt (Loose)

4. Front wheel alignment (Incorrect)

5. Steering system joints (Worn)

6. Suspension arm ball joints (Worn)

7. Steering column (Binding)

8. Power steering vane pump

9. Power steering gear

SA-3

SR-5

SR-3

SA-5

-

SA-84

-

SR-45

SR-59

SR-70

Poor return

1. Tires (Improperly inflated)

2. Front wheel alignment (Incorrect)

3. Steering column (Binding)


SA-3

SA-5

-

SR-70

Excessive play


2. Suspension arm ball joints (Worn)

3. Intermediate shaft, Sliding yoke (Worn)

4. Front wheel bearing (Worn)


-

SA-84

-

SA-19

SR-70

Abnormal noise

1. Power steering fluid level (Low)


3. Power steering vane pump


SR-5

-

SR-45

SR-59

SR-70

Steering.pdf

Documents

pressure feed

lower column

power steering

ps gear assembly

facing straight

column tube

vane pump

flow control