STEERING SYSTEM SECTION ST CONTENTS STEERING ST-1 SYMPTOM DIAGNOSIS... 2 PRECAUTION... 3 DISASSEMBLY AND ASSEMBLY...14 PREPARATION...

Transcription

1 RG ST RG SY TTS SYT GSS... 2 S, VRT RSSS (V) TRUSTG... 2 V Troubleshooting hart...2 RUT... 3 RUTS... 3 recaution for Supplemental Restraint System (SRS) "R G" and "ST T R-T- SR"...3 recautions or igh-voltage System...3 ecessary for Steering Wheel Rotation after attery isconnect...3 General recautions...4 Service otice or recautions...4 RRT... 5 RRT... 5 Special Service Tool...5 ommercial Service Tool...5 -V T... 6 RG W... 6 nspection...6 -V RR... 8 RG W... 8 Removal and nstallation... 8 RG U... 9 xploded View... 9 Removal and nstallation... 9 RG GR G...12 xploded View...12 Removal and nstallation...12 SSSY SSY...14 RG U...14 isassembly and ssembly...14 RG GR G...15 xploded View...15 isassembly...15 nspection...15 ssembly...16 SRV T STS (SS)...17 SRV T STS (SS)...17 Steering Wheel...17 Steering ngle...17 Steering olumn...17 Steering Gear

2 S, VRT RSSS (V) TRUSTG < SYT GSS > SYT GSS S, VRT RSSS (V) TRUSTG V Troubleshooting hart Use chart below to help you find the cause of the symptom. f necessary, repair or replace these parts. : Reference page X-2, "V Troubleshooting hart" SU-2, "V Troubleshooting hart" WT-29, "V Troubleshooting hart" WT-29, "V Troubleshooting hart" X-2, "V Troubleshooting hart" R-3, "V Troubleshooting hart" ossible cause and SUST RTS uter socket ball joint swinging force uter socket ball joint rotating torque uter socket ball joint end play Steering wheel play Steering gear rack sliding force mproper steering wheel mproper installation or looseness of tilt lock lever ounting rubber deterioration Steering column deformation or damage mproper installation or looseness of steering column Steering linkage looseness W U X SUSS TRS R W RV ST RS Symptom : pplicable Steering oise Shake Vibration Shimmy Shudder -2

3 < RUT > RUT RUTS RUTS recaution for Supplemental Restraint System (SRS) "R G" and "ST T R-TSR" : The Supplemental Restraint System such as R G and ST T R-TSR, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. nformation necessary to service the system safely is included in the SR and S section of this Service anual. WRG: To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized SS/T dealer. mproper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. or removal of Spiral able and ir ag odule, see the SR section. o not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service anual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. recautions or igh-voltage System : Refer to G-24, "recautions or igh-voltage System". ecessary for Steering Wheel Rotation after attery isconnect : T: efore removing and installing any control units, first turn the push-button ignition switch to the position, then disconnect both battery cables. fter finishing work, confirm that all control unit connectors are connected properly, then re-connect both battery cables. lways use SUT- to perform self-diagnosis as a part of each function inspection after finishing work. f a T is detected, perform trouble diagnosis according to self-diagnosis results. This vehicle is equipped with a push-button ignition switch and a steering lock unit. f the battery is disconnected or discharged, the steering wheel will lock and cannot be turned. f turning the steering wheel is required with the battery disconnected or discharged, follow the procedure below before starting the repair operation. RT RUR 1. onnect both battery cables. T: Supply power using jumper cables if battery is discharged. 2. arry the ntelligent ey or insert it to the key slot and turn the push-button ignition switch to position. (t this time, the steering lock will be released.) 3. isconnect both battery cables. The steering lock will remain released with both battery cables disconnected and the steering wheel can be turned. 4. erform the necessary repair operation. 5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn the push-button ignition switch from position to position, then to position. (The steering wheel will lock when the push-button ignition switch is turned to position.) 6. erform self-diagnosis check of all control units using SUT-. -3

4 < RUT > General recautions Service otice or recautions RUTS : : n case of removing steering gear assembly, make the final tightening with grounded and unloaded vehicle condition, and then check wheel alignment. bserve the following precautions when disassembling. - efore disassembly, thoroughly clean the outside of the unit. - isassembly should be done in a clean work area. t is important to prevent the internal parts from becoming contaminated by dirt or other foreign matter. - or easier and proper assembly, place disassembled parts in order on a parts rack. - Use nylon cloth or paper towels to clean the parts; common shop rags can leave lint that might interfere with their operation. - o not reuse non-reusable parts. - efore assembling, apply the specified grease to the directed parts. erform S motor angle sensor intialization and torque sensor calibration when replacing steering gear assembly. Refer to -5, "S TR G SSR TZT TRQU SSR RT : Special Repair Requirement". -4

5 < RRT > RRT RRT Special Service Tool RRT The actual shapes of ent-oore tools may differ from those of special service tools illustrated here. : Tool number (ent-oore o.) Tool name escription ( ) Steering wheel puller Removing steering wheel S-T S000 (See ) reload gauge 1. GG ( ) Torque wrench 2. T ( ) Socket adapter 3. T ( ) Socket adapter S-T541 nspecting of rotating torque for ball joint (-44372) Spring gauge easuring steering wheel turning force or rack sliding force T ( ) all joint remover 024 Removing ball joint T146 ommercial Service Tool : Tool number Tool name ower tool escription Removing wheel nuts Removing undercover

6 < -V T > RG W -V T RG W nspection : T T heck installation conditions of steering gear assembly, front suspension assembly, axle and steering column assembly. heck if movement exists when steering wheel is moved up and down, to the left and right and to the axial direction. Steering wheel axial end play : 0 mm (0 in) heck steering gear assembly mounting bolts and nut for looseness. Refer to -12, "xploded View". RG W Y Turn steering wheel so that front wheels come to the straight-ahead position. Start engine and lightly turn steering wheel to the left and right until front wheels start to move. easure steering wheel movement on the outer circumference. Steering wheel play : 0-35 mm ( in) When the measurement value is outside the standard value, check backlash for each joint of steering column assembly and installation condition of steering gear assembly. UTR RG W ake sure that steering gear assembly, steering column assembly and steering wheel are installed in the correct position. erform neutral position inspection after wheel alignment. Refer to R-9, "RR ZR T RG G SSR : Special Repair Requirement". Set vehicle to the straight-ahead position and confirm steering wheel is in the neutral position. oosen outer socket lock nut and turn inner socket to left and right equally to make fine adjustments if steering wheel is not in the neutral position. RG W TURG R 1. ark vehicle on a level, dry surface and set parking brake. 2. Start engine. 3. Tires need to be inflated to normal pressure. 4. heck steering wheel turning force when steering wheel has been turned 360 from the neutral position. Steering wheel turning force : 39 (4 kg-f, 9 lb-f) or less 5. f steering wheel turning force is out of specification, check rack sliding force. Refer to -15, "nspection". 6. f rack sliding force is not within specifications, adjust rack sliding force. Refer to -15, "nspection". 7. f rack sliding force is, inspect steering column. Refer to - 9, "Removal and nstallation". WG0035 RT W TURG G -6

7 < -V T > RG W heck front wheel turning angle after toe-in inspection. lace front wheels on turning radius gauges and rear wheels on stands. heck the maximum inner and outer wheel turning angles for and R road wheels. With the engine at idle, turn steering wheel from full left stop to full right stop and measure the turning angles SG0055 Unit: egee minute (ecimal egree) inimum (35.5 ) nner wheel (ngle: ) ominal (38.5 ) aximum (39.5 ) uter wheel (ngle: ) ominal (31.5 ) easure rack stroke if angles are outside the specified value. Rack stroke 69 mm (2.72 in) SG0171G -7

8 < -V RR > -V RR RG W Removal and nstallation RG W : RV T: When reconnecting spiral cable, fix cable with a tape so that fixing case and rotating part keep aligned. This will omit neutral position alignment procedure during spiral cable installation. 1. Set front wheels to straight-ahead position. 2. Remove driver air bag module. Refer to SRS-4, "Removal and nstallation". 3. Remove steering wheel lock nut after steering is locked. 4. Remove steering wheel using Tool (). Tool number : ( ) WG0004G T nstallation is in the reverse order of removal. 1. djust the spiral cable locating pin (2) to the steering wheel locating pin hole (1). 2. Set the spiral cable neutral position. Slowly turn the spiral cable clockwise to the end position. ext, turn it counterclockwise (about 2 turns) then stop turning at the point when the alignment arrows () are directly across from each other. Rotate the spiral cable slightly so the locating pin (2) is positioned at the top. T: service part is installed in the neutral position with a stopper clip in place and should not be adjusted after the stopper clip is removed. 3. lign the locating hole (1) at the top of the steering wheel with the locating pin of spiral cable during installation. UT: The spiral cable may snap by steering operation if the cable is installed in an improper position. o not turn the spiral cable quickly or beyond the limit number of turns. (This can cause the cable to snap.) fter the work is completed, make sure no system malfunction is detected by air bag warning lamp. 0014ZZ n case a malfunction is detected by the air bag warning lamp, reset with the self-diagnosis function and delete the memory with SUT. f a malfunction is still detected after the above operation, perform self-diagnosis to repair malfunctions. Refer to SR-7, "river ir ag odule". -8

9 < -V RR > RG U xploded View RG U : WG0014G 1. Steering wheel 2. ombination switch & spiral cable 3. Steering column assembly 4. ole cover seal 5. erbie clip 6. ole cover 7. ower shaft assembly Removal and nstallation RV Steering olumn, ole over Seal, ole over, ower Shaft ssembly 1. ull the service plug to disconnect high voltage battery. 2. Set wheels to the straight ahead-position. 3. Remove lower side bolt of lower shaft assembly. : SG Remove upper side bolt of lower shaft, then remove lower shaft assembly from steering gear assembly. -9

10 < -V RR > RG U 5. oosen herbie clip, then remove hole cover seal from hole cover. 6. Remove hole cover nuts, then remove hole cover from dash panel. 7. Remove driver air bag module. Refer to SRS-4, "Removal and nstallation". 8. Remove spiral cable. Refer to SRS-6, "Removal and nstallation". 9. Remove steering wheel. Refer to -8, "Removal and nstallation". 10. Remove steering column cover and instrument driver lower panel and knee protector. Refer to -11, "Removal and nstallation". 11. isconnect harness from steering column. 12. Remove steering column nuts, then remove steering column assembly. ST TR RV ole over Seal, ole over, ower Shaft ssembly heck each part of hole cover seal, hole cover and steering column, lower shaft and lower joint for damage or other malfunctions. Replace if necessary. Steering olumn ssembly heck each part of steering column assembly for damage or other malfunctions. Replace if necessary. easure the length as shown if vehicle has been involved in a minor collision. Replace steering column assembly if outside the specifications. SG1177 Steering column length Telescopic maximum Telescopic minimum mm ( in) mm ( in) easure steering column rotating torque using preload gauge. Replace steering column assembly if outside the standard. Rotating torque : m ( kg-m, 0-1 in-lb) heck tilt and telescopic mechanism operating range 1, 2 as shown. Tilt operating range 1 Telescopic operating range 2 : 41 mm (1.61 in) : 40 mm (1.57 in) SG1179 T Steering olumn, ole over Seal, ole over, ower Shaft ssembly nstallation is the reverse order of removal. or tightening specifications, refer to -9, "xploded View". When installing lower shaft assembly to steering gear assembly, follow the procedure listed below. - Set rack of steering gear in the neutral position. T: 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. -10

11 < -V RR > RG U - nstall slit part () of lower shaft assembly joint aligning with the marking position () of steering gear assembly input shaft. ake sure that the slit part of lower joint () is aligned with the marking position () of gear housing assembly input shaft. - erform final tightening of nuts and bolts on each part under unladen conditions with tires on level ground when removing steering gear assembly. heck wheel alignment. Refer to SU-6, "nspection and djustment". SG0172ZZ -11

12 < -V RR > RG GR G xploded View RG GR G : WG0011G 1. otter pin 2. Steering gear assembly : ront Removal and nstallation : RV 1. ull the service plug to disconnect high voltage battery. 2. Remove tires using power tool. 3. Remove undercover using power tool. 4. Remove stabilizer bar connecting rods from struts and reposition stabilizer bar. 5. Remove front exhaust tube. Refer to X-5, "Removal and nstallation". 6. Remove lower side bolt of lower joint. SG Remove cotter pin (1), and then loosen the nut. 8. Remove steering outer socket (2) from steering knuckle (3) so as not to damage ball joint boot (4) using the Tool. Tool number : T ( ) UT: Temporarily tighten the nut to prevent damage to threads and to prevent the Tool from suddenly coming off. SG

13 < -V RR > RG GR G 9. isconnect S torque sensor harness connector (1), S motor angle sensor harness connector (2) and S motor power line connector (3) from the steering gear (4). T: or S motor power line connector (3), perform the following; 1. ull lock plate (5) up until it stops. 2. Turn the lock lever (6) until it stops. 3. ull S motor power line connector (3) to disconnect it. G0018ZZ 10. Remove ground bracket and harness bracket on steering gear. 11. Remove bolts and nuts of steering gear assembly, and then remove steering gear assembly from vehicle. ST TR RV heck for damage to steering gear. f any exist, replace steering gear as an assembly. T nstallation is the reverse order of removal. or tightening specifications, refer to -12, "xploded View". UT: fter connecting the S motor power line connector, make sure the connector is locked. When installing lower joint to steering gear assembly, follow the procedure listed below. - Set rack of steering gear in the neutral position. T: 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. - nstall slit part () of lower shaft assembly joint aligning with the marking position () of steering gear assembly input shaft. ake sure that the slit part of lower joint () is aligned with the marking position () of gear housing assembly input shaft. erform final tightening of nuts and bolts on each part under unladen conditions with tires on level ground when removing steering gear assembly. heck wheel alignment. Refer to SU-6, "nspection and djustment". SG0172ZZ ST TR T ake sure that steering wheel operates smoothly by turning several times from full left stop to full right stop. -13

14 < SSSY SSY > RG U SSSY SSY RG U isassembly and ssembly : The steering column assembly is not serviceable and must be replaced as an assembly. -14

15 < SSSY SSY > RG GR G xploded View RG GR G : uter socket 2. ock nut 3. nner socket 4. Small boot clamp 5. oot 6. arge boot clamp 7. Gear assembly ront Refer to G section for symbol marks except in the above. Refer to G-4, "omponents". isassembly Remove outer socket locknut and outer socket. T: nly outer socket can be disassembled. o not disassemble steering gear assembly. nspection ST TR SSSY oot heck boot for cracks. Replace if there are. uter Socket and nner Socket 1. all joint swinging torque ook a spring balance at the point shown in the figure and pull the spring balance. ake sure that the spring balance reads the specified value when ball stud and inner socket start to move. Replace outer socket and steering gear assembly if they are outside the standard. WG0015G : : SG

16 RG GR G < SSSY SSY > tems uter socket nner socket easuring point of spring balance easuring point at * mark Stud cotter pin mounting hole shown in the figure Swinging torque m ( kg-m, in-lb) m ( kg-m, in-lb) Spring balance measurement ( kg, lb) ( kg, lb) 2. all joint rotating torque ake sure that the reading is within the following specified range using Tool. Replace outer socket if the reading is outside the specified value. Tool number : 31227S000 ( ) uter socket rotating torque m ( kg-m, in-lb) SG all joint axial end play pply an axial load of 490 (50 kg-f, 111 lb-f) to ball stud using a dial gauge. easure amount of stud movement, and then make sure that the value is within the following specified range. Replace outer socket and inner socket if the measured value is outside the standard. uter socket nner socket 0.5 mm (0.020 in) or less 0.2 mm (0.008 in) or less ssembly SG0057 : ssembly is in the reverse order of disassembly. djust inner socket to standard length, and then tighten lock nut to the specified torque. Refer to -15, "xploded View". heck length of inner socket again after tightening lock nut. ake sure that the length is the standard. nner socket length 43.9 mm (1.728 in) UT: djust toe-in after this procedure. ength achieved after toein adjustment should not be more than 47.8 mm (1.882 in) max. SG

17 SRV T STS (SS) < SRV T STS (SS) SRV T STS (SS) SRV T STS (SS) Steering Wheel : Steering wheel axial end play Steering wheel play Steering ngle 0 mm (0 in) 0-35 mm ( in) : Unit: egee minute (ecimal egree) Steering olumn RG U GT SG0055 inimum (35.5 ) nner wheel (ngle: ) ominal (38.5 ) aximum (39.5 ) uter wheel (ngle: ) ominal 31 (31.5 ) : SG1177 Steering column length Telescopic maximum Telescopic minimum mm ( in) mm ( in) TT S RTG RG -17

18 SRV T STS (SS) < SRV T STS (SS) Unit: mm (in) SG1179 Tilt operating range " 1 " 41 (1.61) Telescopic operating range " 2 " 40 (1.57) Steering Gear : RG UTR ST R ST Steering gear type R26 Swinging torque m ( kg-m, in-lb) easurement on spring balance uter socket easuring point: cotter pin hole of stud ( kg, lb) Rotating torque m ( kg-m, in-lb) xial end play 0.5 mm (0.020 in) or less Swinging torque m ( kg-m, in-lb) nner socket easurement on spring balance easuring point at* mark shown ( kg, lb) xial end play 0.2 mm (0.008 in) or less nner socket length ominal 43.9 mm (1.728 in) aximum 47.8 mm (1.882 in) R R SG

19 SRV T STS (SS) < SRV T STS (SS) Steering gear model Rack neutral position, dimension (rack stroke) R26 69 mm (2.72 in) SG0171G -19