ST-16
< ON-VEHICLE REPAIR >
LOWER SHAFT
LOWER SHAFT
Exploded ViewINFOID:0000000003806319
Removal and InstallationINFOID:0000000003806320
REMOVAL
1. Set the vehicle to the straight-ahead position.
2. Fix the steering wheel.
3. Remove upper joint fixing bolt and nut (lower shaft side).
4. Separate the lower shaft from the steering gear assembly by
sliding the slide shaft (A: sliding range).
CAUTION:
Spiral cable may be cut if steering wheel turns while sepa-
rating steering column assembly and steering column
assembly. Be sure to secure steering wheel using string to
avoid turning.
5. Remove the accelerator pedal assembly. Refer to ACC-3,
"Exploded View".
6. Remove the side brake pedal bracket and wire clamp stay.
7. Remove the hole cover mounting nuts.
8. Remove the hole cover seal, clamp and hole cover.
9. Remove lower shaft joint fixing bolt (steering gear side).
10. Remove the lower shaft.
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
Spiral cable may be cut if steering wheel turns while separating steering column assembly and steer-
ing gear assembly. Be sure to secure steering wheel using string to avoid turning.
1. Steering column assembly 2. Hole cover seal 3. Clamp
4. Hole cover 5. Lower shaft
Refer to GI-4, "
Components" for symbols in the figure.
JSGIA0392GB
JSGIA0393ZZ
LOWER SHAFT
ST-17
< ON-VEHICLE REPAIR >
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After lower shaft (steering gear side) fitted, make sure there is not
gap (A) between the yoke (1), lower shaft (2), joint fixing bolt (3).
When installing lower joint to steering gear assembly, follow the procedure listed below.
- Set rack of steering gear in the neutral position.
NOTE:
To get the neutral position of rack, turn gear-sub assembly and measure the distance of inner socket, and
then measure the intermediate position of the distance.
- Align rear cover cap projection (A) with the marking position of
gear housing assembly (B).
- Install slit part of lower joint (C) aligning with the rear cover cap
projection (A). Make sure that the slit part of lower joint (C) is
aligned with rear cover cap projection (A) and the marking position
of gear housing assembly (B).
Adjust neutral position of steering angle sensor. Refer to BRC-66,
"ADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL
POSITION : Special Repair Requirement".
Check the following after installation:
- Check if steering wheel turns smoothly when it is turned several times fully to the end of the left and right.
- Check the steering wheel play, neutral position steering wheel, steering wheel turning force, and front wheel
turning angle. Refer to ST-9, "
Inspection".
InspectionINFOID:0000000003806321
Check the length (A) (extended position) of the lower shaft.
Check each part of lower shaft for damage or other malfunctions.
Replace if there are.
JSGIA0180ZZ
: Bolt
JSGIA0313ZZ
Standard
A : Refer to ST-38, "
Lower
Shaft Sliding Range".
JSGIA0405ZZ
STEERING GEAR AND LINKAGE
ST-19
< ON-VEHICLE REPAIR >
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Removal and InstallationINFOID:0000000003806323
REMOVAL
1. Set the vehicle to the straight-ahead position.
2. Remove front tires.
3. Remove splash guards (RH and LH). Refer to EXT-22, "
FENDER PROTECTOR : Exploded View".
4. Remove engine under cover. Refer to EXT-28, "
Exploded View".
5. Remove heat insulator from front floor.
6. Remove cotter pin (1), and then loosen the nuts.
7. Remove steering outer socket (2) from steering knuckle (3) so
as not to damage ball joint boot (4) using suitable ball joint
remover.
CAUTION:
Temporarily tighten the nut to prevent damage to threads
and to prevent the ball joint remover from suddenly coming
off.
8. Remove high pressure piping and low pressure hose of hydrau-
lic piping, and then drain power steering fluid.
9. Remove steering hydraulic piping bracket from front steering
gear assembly.
10. Remove power steering solenoid valve harness connector and harness clip.
11. Separate the lower shaft from the steering gear assembly by sliding the slide shaft.
CAUTION:
Spiral cable may be cut if steering wheel turns while separating steering column assembly and
steering gear assembly. Be sure to secure steering wheel using string to avoid turning.
12. Remove the front stabilizer assembly. Refer to FSU-16, "
Exploded View".
13. Remove the mounting bolts and nuts of steering gear assembly.
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
Spiral cable may be cut if steering wheel turns while separating steering column assembly and steer-
ing gear assembly. Be sure to secure steering wheel using string to avoid turning.
10. Boot clamp 11. Boot 12. Inner socket
13. Boot clamp (stainless wire) 14. Spacer 15. Cylinder tube
16. Gear housing assembly 17. Rack oil seal 18. Rack assembly
19. Rack Teflon ring 20. O-ring 21. End cover assembly
: Apply power steering fluid.
: A p p l y G e n u i n e L i q u i d G a s k e t , T h r e e B o n d 1111 B o r e q u i v a l e n t .
: Apply Genuine High Strength Thread Locking Sealant, Loctite 271 or equivalent.
: Apply multi-purpose grease.
Refer to GI-4, "
Components" for symbols not described on the above.
JSGIA0320ZZ
: Bolt
JSGIA0321ZZ
ST-20
< ON-VEHICLE REPAIR >
STEERING GEAR AND LINKAGE
When installing low pressure hose (1), refer to the figure.
CAUTION:
Never apply fluid to the hose (1) and tube (2).
Insert hose securely until it contacts spool (A) of tube.
Leave clearance (L) when installing clamp (3).
When installing lower joint to steering gear assembly, follow the procedure listed below.
- Set rack of steering gear in the neutral position.
NOTE:
To get the neutral position of rack, turn gear-sub assembly and measure the distance of inner socket, and
then measure the intermediate position of the distance.
- Align rear cover cap projection (A) with the marking position of
gear housing assembly (B).
- Install slit part of lower joint (C) aligning with the rear cover cap
projection (A). Make sure that the slit part of lower joint (C) is
aligned with rear cover cap projection (A) and the marking position
of gear housing assembly (B).
After installation, bleed air from the steering hydraulic system.
Refer to ST-32, "
Inspection".
Perform final tightening of nuts and bolts on each part under
unladen conditions with tires on level ground when removing steer-
ing gear assembly. Check wheel alignment. Refer to FSU-7, "
Wheel Alignment Inspection".
Adjust neutral position of steering angle sensor after checking wheel alignment. Refer to BRC-66, "
ADJUST-
MENT OF STEERING ANGLE SENSOR NEUTRAL POSITION : Special Repair Requirement" (VDC mod-
els).
Disassembly and AssemblyINFOID:0000000003806324
DISASSEMBLY
1. Remove low pressure piping.
CAUTION:
Disassemble and assemble steering gear assembly by fixing the mounting area with a vise using
copper plates.
Clean steering gear assembly with kerosene before disassembling. Be careful to avoid splash-
ing or applying any kerosene over connector of discharge port or return port.
2. Remove cylinder tubes from gear housing assembly.
3. Remove rear cover cap from gear-sub assembly.
4. Measure adjusting screw height “H”, and loosen adjusting
screw.
CAUTION:
Never loosen adjusting screw 2 turns or more.
Replace steering gear assembly if adjusting screw is
loosened 2 turns or more and it is removed.
5. Remove gear-sub assembly from gear housing assembly.
6. Remove O-ring from gear housing assembly.
7. Loosen outer socket lock nut, and remove outer socket.
8. Remove boot clamps, and then remove boot from inner socket.
CAUTION:Standard
L : 3 – 8 mm (0.12 – 0.31 in)
JSGIA0118ZZ
: Bolt
J S G I A 0 111 Z Z
SGIA0624E
ST-26
< ON-VEHICLE REPAIR >
STEERING GEAR AND LINKAGE
e. Bent cut end of the wire toward rack axial as shown in the figure
after twisting the wire 4 to 4.5 turns so that cut end does not con-
tact with boot.
19. Install cylinder tubes to gear housing assembly.
20. Install low pressure piping.
21. Adjust inner socket to standard length (L), and then tighten lock
nut to the specified torque. Check length again after tightening
lock nut.
CAUTION:
Adjust toe-in after this procedure. The length achieved after
toe-in adjustment is not necessary the above value.
InspectionINFOID:0000000003806325
INSPECTION AFTER INSTALLATION
Check if steering wheel turns smoothly when it is turned several times fully to the end of the left and right.
Check the steering wheel play, neutral position steering wheel, steering wheel turning force, and front wheel
turning angle. Refer to ST-9, "
Inspection".
Check the fluid level, fluid leakage, and air bleeding hydraulic system. Refer to ST-7, "
Inspection".
INSPECTION AFTER DISASSEMBLY
Boot
Check boot for cracks, and replace it if a malfunction is detected.
Rack Assembly
Check rack for damage or wear, and replace it if a malfunction is detected.
Gear-Sub Assembly
Check gear-sub assembly for damage or wear, and replace it if a malfunction is detected.
Rotate gear-sub assembly and check for torque variation or rattle, and replace it if a malfunction is detected.
Gear Housing Assembly
Check gear housing assembly for damage and scratches (inner wall). Replace if there are.
Outer Socket and Inner Socket
Check the following items and replace the component if it does not meet the standard.
BALL JOINT SWINGING TORQUE
STC0124D
Standard
L : Refer to ST-38, "
Inner
Socket Length".
SGIA0167E
SERVICE DATA AND SPECIFICATIONS (SDS)
ST-37
< SERVICE DATA AND SPECIFICATIONS (SDS)
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SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
General SpecificationsINFOID:0000000003806332
Steering Wheel Axial End Play and PlayINFOID:0000000003806333
Unit: mm (in)
Steering Wheel Turning ForceINFOID:0000000003806334
Unit: N·m (kg-m, in-lb)
Steering AngleINFOID:0000000003806335
Unit: Degree minute (Decimal degree)
Steering Column LengthINFOID:0000000003826226
Unit: mm (in)
Steering Column Mounting DimensionsINFOID:0000000003826227
Unit: mm (in)
Steering Column Operating RangeINFOID:0000000003806336
Steering gear modelPR26AF
Fluid capacity (Approx.)
(lmp qt)1.0 (7/8)
Item Standard
Steering wheel axial end play 0 (0)
Steering wheel play on the outer circumference 0 – 35 (0 – 1.38)
Item Standard
Steering wheel turning force 7.45 (0.76, 66)
ItemStandard
Tire size: 205/65R16 Tire size: 215/55R17
Inner wheelMinimum 38°00′ (38.0°)34°00′ (34.0°)
Nominal 41°00′ (41.0°)37°00′ (37.0°)
Maximum 42°30′ (42.5°)38°30′ (38.5°)
Outer wheel Nominal 33°00′ (31.0°)31°00′ (31.0°)
Item Standard
Column length484 – 486 (19.06 – 19.13)
Item Standard
Mounting dimension 19.5 (0.768) or less
Item Standard
Tilt operating range 37 mm (1.46 in)
Rotating torque 0.49 N·m (0.05 kg-m, 4 in-lb)
STC-1
STEERING
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CONTENTS
STEERING CONTROL SYSTEM
BASIC INSPECTION ....... .............................2
DIAGNOSIS AND REPAIR WORK FLOW .... .....2
Work Flow ........................................................... ......2
FUNCTION DIAGNOSIS ...............................3
EPS SYSTEM ... .............................................. .....3
System Diagram .................................................. ......3
System Description ...................................................3
Component Parts Location ........................................5
Component Description .............................................5
COMPONENT DIAGNOSIS ..........................6
POWER SUPPLY AND GROUND CIRCUIT .. .....6
Description .......................................................... ......6
Diagnosis Procedure .................................................6
POWER STEERING SOLENOID VALVE ...........7
Description .......................................................... ......7
Diagnosis Procedure .................................................7
Component Inspection ..............................................8
ENGINE SPEED SIGNAL CIRCUIT ............... .....9
Description .......................................................... ......9
Diagnosis Procedure .................................................9
VEHICLE SPEED SIGNAL CIRCUIT .................11
Description .......................................................... ....11
Diagnosis Procedure ...............................................11
ECU DIAGNOSIS .........................................13
POWER STEERING CONTROL UNIT ..............13
Reference Value .................................................. ....13
Wiring Diagram - ELECTRONICALLY CON-
TROLLED POWER STEERING SYSTEM - ............
14
Fail-Safe .............................................................. ....15
SYMPTOM DIAGNOSIS ..............................17
UNBALANCE STEERING WHEEL TURNING
FORCE (TORQUE VARIATION) .......................
17
Description ........................................................... ....17
Diagnosis Procedure ...............................................17
PRECAUTION ..............................................18
PRECAUTIONS .................................................18
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ............................................................. ....
18
Precaution Necessary for Steering Wheel Rota-
tion after Battery Disconnect ...................................
18
ON-VEHICLE REPAIR .................................19
POWER STEERING CONTROL UNIT ..............19
Exploded View ..................................................... ....19
Removal and Installation .........................................19
STC-4
< FUNCTION DIAGNOSIS >
EPS SYSTEM
The valve driving voltage to control the power steering solenoid
valve varies according to the vehicle speed.
OPERATION PRINCIPLE
During Parking (When Turning The Steering Wheel To The Right.)
1. Power steering solenoid valve is closed while a vehicle is stopped.
2. Pinion “1R”, “2R” and “3R” are closed depending on steering torque of steering wheel.
3. Oil pressure “P” in the gear housing assembly is the sum of oil pressures occurred in “2R” and “3R”. This
results in a light steering force because of high pressure.
During High-speed Operation
1. Power steering solenoid valve is opened during high-speed operation.
2. Pinion “1R”, “2R” and “3R” are closed depending on steering torque of steering wheel.
3. Oil pressure “2R” does not occur because the power steering solenoid valve is on full throttle.
4. Oil pressure “P” in the gear housing assembly includes only oil pressure occurred in “3R” and results in a
heavy steering force.
JSGIA0374GB
JSGIA0020GB
JSGIA0021GB