POWER STEERING SYSTEM

G STEERING

B
SECTION
POWER STEERING SYSTEM C

E
CONTENTS
PRECAUTIONS .......................................................... 2 ING COLUMN ASSEMBLY ................................... 8 F
SRS Air Bag and Seat Belt Pre-Tensioner Precau- INSTALLATION OF STEERING COLUMN
tions .......................................................................... 2 ASSEMBLY ........................................................... 8
CAUTION: ................................................................ 2 CHECK AFTER STEERING COLUMN ASSEM- PS
PREPARATION ........................................................... 3 BLY INSTALLATION .............................................. 8
Special Service Tools ............................................... 3 POWER STEERING GEAR AND LINKAGE .............. 9
NOISE, VIBRATION, AND HARSHNESS (NVH) Removal and Installation .......................................... 9
H
TROUBLESHOOTING ................................................ 4 REMOVAL ............................................................. 9
NVH Trouble Shooting Chart .................................... 4 INSTALLATION ..................................................... 9
STEERING WHEEL .................................................... 5 Disassembly and Assembly .................................... 10
On Board Inspection and Service ............................ 5 COMPONENT PARTS LOCATION (R24T TYPE)... 10 I
PLAY INSPECTION .............................................. 5 DISASSEMBLY ................................................... 10
NEUTRAL POSITION INSPECTION .................... 5 INSPECTION AFTER DISASSEMBLY ................ 10
STEERING TORQUE INSPECTION .................... 5 ASSEMBLY ......................................................... 11 J
STEERING ANGLE INSPECTION ........................ 5 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 13
Removal and Installation .......................................... 6 Wheel ..................................................................... 13
STEERING COLUMN ................................................. 7 Steering Angle ........................................................ 13
K
Removal and Installation .......................................... 7 Steering Column ..................................................... 13
REMOVAL OF STEERING COLUMN ASSEM- Steering Linkage ..................................................... 13
BLY ........................................................................ 7 Tightening Torque ................................................... 13
INSPECTION AFTER REMOVAL OF STEER- L

PS-1
 PRECAUTIONS

PRECAUTIONS PFP:00001

SRS Air Bag and Seat Belt Pre-Tensioner Precautions EGS000J0

WARNING:
● Before removal and installation of SRS air bag and pre-tensioner seat belt system components
and related harnesses, turn the ignition switch OFF, disconnect both battery cables, and wait at
least 3 minutes. (This is to discharge electricity stored in the auxiliary power supply circuit within
air bag sensor unit.)
● Do not use pneumatic or electric tools to remove or install components.
● Do not solder SRS air bag and seat belt pre-tensioner system harnesses when making repairs.
Make sure harness is not pinched and there is no contact with other components.
● When checking the SRS air bag and pre-tensioner seat belt circuit as a set or as a unit, do not use
an electric tester such as a circuit tester (to prevent accidental triggering caused by the weak elec-
tric current of a tester).
● Do not insert a slotted screwdriver or similar tool into the connectors on air bag module or pre-
tensioner seat belt (to prevent accidental triggering caused by static).
● The harness for pre-tensioner seat belt system can be identified by a yellow tape at the neck of the
connector to distinguish it from other harnesses.
● For safe service operations, refer to SB section and SRS section.
CAUTION: EGS000J1

● Always follow the warnings and the cautions below in disassembly procedures:
– Work in a clean, dust-free place. No dustproof device is necessary.
– Clean the outside of the unit before disassembly.
– Clean the parts to be disassembled. Care must be taken not to allow any dirt or other foreign materials to
enter or come in contact with the parts.
– Assemble the disassembled parts properly, following the order shown in the manual. If work has been
suspended in the middle of assembly, place a clean cover over the parts to prevent them from being con-
taminated.
– Use paper towels when removing dirt and other foreign materials. Cloth shop towels can leave lint on the
cleaned parts that might affect the operation of the parts.
– Clean disassembled parts with kerosene (except rubber parts), and then dry them thoroughly with an air
blower or paper towels.

PS-2
 PREPARATION

PREPARATION PFP:00002
A
Special Service Tools EGS000J2

Description Application
B

● Checking steering torque

Preload gauge C
ST3127S000 ● Pinion gear rotating torque measurement
for steering gear

ZZA0806D D

PS

PS-3
 Symptom

×: Applicable
Reference page

STEERING
Possible cause and SUSPECTED PARTS

Noise
Shake

Judder
NVH Trouble Shooting Chart

Shimmy
Vibration
×
Tie-rod ball joint tensile force PS-9

Tie-rod ball joint sliding torque PS-9

×
×
Tie-rod ball joint end play PS-9

PS-4
Steering wheel play PS-5

×
×
×
Improper steering wheel –

Improper installation or looseness or tilt lock lever PS-7

×
×
×
Mounting rubber deterioration –

×
×
×
×
×
Steering column deformation or damage PS-7

Improper installation or looseness of steering column PS-7

×
×
Steering linkage looseness PS-9

×
×
×
×
×
AXLE AND SUSPENSION NVH in FAX, RAX, FSU, RSU section
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING

TIRES NVH in WT section

×
×
×
×
× ROAD WHEEL NVH in WT section

×
×
×
×
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING

×
×
×

DRIVE SHAFT NVH in FAX section

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

×
×
×
×

BRAKES NVH in BR section

PFP:00003

EGS000J3
 STEERING WHEEL

STEERING WHEEL PFP:48430

A
On Board Inspection and Service EGS000J4

PLAY INSPECTION
1. Turn steering wheel to the straight-ahead position. Start engine and lightly turn steering wheel clockwise
B
and counterclockwise until the front wheels start moving. Measure the travel to the starting point on the
circumference of steering wheel. If play is outside the specified range, check steering gear assembly, front
suspension, axles, and steering column for proper installation.
C
Steering wheel play inspection standard : 0 - 35 mm (0 - 1.38 in)
2. Check steering wheel for vertical, horizontal, or axial play.
D
Steering wheel axial end play : 0 mm (0 in)
● Lift vehicle and check steering gear nuts and bolts for looseness.
Tightening torque : 85 - 103 N·m (8.7 - 10.5 kg-m, 63 - 75 ft-lb) E

NEUTRAL POSITION INSPECTION

● After wheel alignment inspection, perform neutral position inspection. Refer to FSU-6, "Wheel Alignment" F
.
● Set vehicle to the straight-ahead position and confirm steering wheel is in the neutral position.
● If it is not in the neutral position, loosen lock nut on tie-rod. Then adjust until the amount of left and right PS
becomes equal.
STEERING TORQUE INSPECTION
1. Stop vehicle on a dry flat paved road and apply parking brake. H
2. Remove air bag module. Refer to SRS-36, "DRIVER AIR BAG MODULE" .
3. Start engine and use a preload gauge (SST) to check steering
wheel torque. I

Steering torque : 1.8 - 5.6 N·m (0.18 - 0.57 kg-m,

16 - 49 in-lb) or less J
4. When torque is outside the standard, check steering column and
steering gear. If any non-standard condition is detected, replace
if necessary. K

STA0005D
L
STEERING ANGLE INSPECTION
● After toe-in inspection, check the steering angle. Place the front
wheels on turning radius gauges and the rear wheels on stands M
so that the vehicle can be level. Check the maximum inner and
outer wheel steering angles for LH and RH road wheels.

FAA0016D

PS-5
 STEERING WHEEL

● With the engine at idle, turn steering wheel from stop to stop and
measure the steering angles.
Inner wheel : 44° +1°
-3°
Outer wheel : 36° +1°
-3°
● Steering angles are not adjustable. If any of the steering angles
is different from the specified value, check steering gear, column
and front suspension components for wear or damage. If any SGIA0055E
non-standard condition exists, replace if necessary.
Removal and Installation EGS000J5

Refer to SRS-36, "DRIVER AIR BAG MODULE" and SRS-38, "SPIRAL CABLE" .

PS-6
 STEERING COLUMN

STEERING COLUMN PFP:48810

A
Removal and Installation EGS000J6

PS
MGIA0012E

1. Steering wheel 2. Steering column assembly (with EPS 3. Intermediate shaft

control unit, motor, reduction gear,
sensor) H
4. Torx bolt (E10)

CAUTION: I
● Care must be taken not to give axial impact to the steering column assembly during removal and
installation.
● When steering wheel is turned repeatedly with the vehicle stopped, care must be taken because
J
motor and control unit may get too hot.
● Steering column assembly is heavy (approximately 10 kg). Care must be taken when removing col-
umn from vehicle.
K
● Steering column assembly cannot be disassembled. If any non-standard condition exists, replace
column assembly as a unit.
REMOVAL OF STEERING COLUMN ASSEMBLY L
1. Remove driver air bag module. Refer to SRS-36, "DRIVER AIR BAG MODULE" .
2. Remove steering wheel and spiral cable. Refer to SRS-38, "SPIRAL CABLE" .
3. Remove column cover and instrument panel & pad. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . M
4. Remove front wiper and washer switch and light and turn signal lamp switch. Refer to SRS-38, "Removal
and Installation" in “Light and Turn Signal Switch”, and SRS-38, "Removal and Installation" .
5. Disconnect all the clamps and harness connectors from steering column assembly.
6. Remove intermediate shaft mounting bolt on steering gear, and disconnect the shaft from steering gear.
7. Remove nut on steering column assembly, and make sure steering column moves freely.
8. Remove harness connector of electric power steering.
9. Remove steering column assembly from vehicle.
10. Remove intermediate shaft mounting bolt (torx bolt E10), and disconnect the shaft from steering column.
CAUTION:
Be sure not to rotate column shaft by 360° or more. (Doing this causes error in steering angle
value memorized in electric power steering.)

PS-7
 STEERING COLUMN

INSPECTION AFTER REMOVAL OF STEERING COLUMN ASSEMBLY

● Check each part of column assembly and intermediate shaft for damage or other malfunctions. If any non-
standard condition exists, replace if necessary.
● If vehicle has been involved in a minor collision, measure length
L as shown. If outside the standard, replace steering column
assembly.
Length L : 429±2 mm (16.9±0.1 in)
● Using preload gauge, measure steering column rotating torque.
If outside the standard, replace steering column assembly.
Rotating torque : 0 - 2.1 N·m (0 - 0.21 kg-m, 0 - 18 in-lb)

SGIA0182J

INSTALLATION OF STEERING COLUMN ASSEMBLY

Note the following, and install in the reverse order of removal. Tighten bolts and nuts to the specified torque.
● Connect intermediate shaft to steering column, and tighten torx bolt (E10) to the specified torque. Connect
pinion shaft to yoke of intermediate shaft, and tighten bolt to the specified torque.
CAUTION:
● When tightening bolts, tighten them by hand first, and
make sure there is no feeling of sticking or galling before
final tightening.
● Insert bolts in the proper direction. (Do not insert them
from the other side.)
● When connecting intermediate shaft and steering col-
umn, make sure the bolt is securely fit into the groove of
steering column before final tightening.
● Tighten bolts at connecting pinion shaft and intermediate
shaft side. Make sure there is no space between pinion
shaft and yoke, and between pinion shaft and cam nut. MGIA0013E

CHECK AFTER STEERING COLUMN ASSEMBLY INSTALLATION

● Using CONSULT-II, check steering angle. Refer to STC-4, "Steering Angle Adjustment (WORK SUP-
PORT)" .
● Rotating steering wheel, check for decentered condition, binding, noise or excessive steering effort.

PS-8
 POWER STEERING GEAR AND LINKAGE

POWER STEERING GEAR AND LINKAGE PFP:49001

A
Removal and Installation EGS000J7

PS
MGIA0014E

1. Steering gear assembly 2. Suspension member

REMOVAL H
1. Lift vehicle and remove tires.
2. Activate key lock of steering column.
3. Remove intermediate shaft mounting bolt on steering gear, and disconnect the shaft. I
4. Remove tie-rod from steering knuckle. If tie-rod could not be
removed easily, use ball joint remover (commercial service tool).
J
CAUTION:
To avoid damage to threads and sudden disconnection of
ball joint remover (commercial service tool), temporarily
tighten lock nut. K
5. Remove the exhaust front tube. Refer to EX-3, "EXHAUST SYS-
TEM" .
L

SGIA0184J

M
6. Remove steering gear mounting nuts and bolts, and remove the
steering gear through the right side of vehicle.
(Remove from left side for LHD models and right side for RHD
models.)

SGIA0185J

INSTALLATION
Note the following, and install in the reverse order of removal. Tighten bolts and nuts to the specified torque.
● Refer to PS-7, "Removal and Installation" .

PS-9
 POWER STEERING GEAR AND LINKAGE

Disassembly and Assembly EGS000J8

COMPONENT PARTS LOCATION (R24T TYPE)

MGIA0015E

1. Outer socket 2. Bulkhead sealing 3. Seal ring

4. Strap 5. Dust boot 6. Spring clip
7. Lock nut 8. Steering gear assembly

DISASSEMBLY
1. Disengage the tab of bulkhead seal, and remove it from steering
gear.
2. Loosen lock nut of tie-rod outer socket, and remove it from
steering gear.
3. Remove spring clip and strap (cutting off), and remove dust boot
and seal ring.
CAUTION:
When removing dust boot, be careful not to damage inner
socket and gear housing assembly.
SGIA0187J

INSPECTION AFTER DISASSEMBLY

Rack
Check rack gear, and, if any damage or wear, replace steering gear assembly.
Bulkhead Sealing
In case of broken tab, or torn sealing in bulkhead seal, replace the damaged part.

PS-10
 POWER STEERING GEAR AND LINKAGE

Tie-Rod Ball Joint

1. Tensile force A
● Hook a spring balance onto the point shown in the figure and
pull the balance. Make sure the balance reads the specified
value when ball stud and the inner socket start to move. If it is B
outside the standard, replace both outer socket and steering
gear assembly.

Outer socket Inner socket C

Measuring point
Edge of stud bolt Measuring point
of spring balance
D
0.3 - 2.9 0.5 - 5.0
Tensile force MGIA0016E
(0.03 - 0.29, 3 - (0.05 - 0.51,
N·m (kg-m, in-lb)
25) 5 - 44) E
Spring balance 5 - 54 4 - 43
measurement (0.51 - 5.5, (0.41 - 4.4,
N (kg, lb) 1.1 - 12.1) 0.9 - 9.7) F
2. Axial end play
● Apply 490 N (50 kg, 110 lb) of load to the ball stud axially and
use a dial gauge to measure the amount of movement the PS
stud makes. Make sure the reading is within the range speci-
fied. If outside the standard, replace outer socket and steering
assembly. H

Outer socket No Free Play

Inner socket No Free Play I
3. Using preload gauge (SST), measure rotating torque of pinion
gear. If the measurement is outside of the specified range,
SGIA0057E
replace steering gear. J
Rotating torque of pinion
gear
Around neutral position : 1.3 N·m (0.13 kg-m, K
(Within ±100°) Average A 11 in-lb)
Other than the above: Maxi- : 1.6 N·m (0.16 kg-m,
mum value C 14 in-lb) L

M
MGIA0017E

ASSEMBLY
Note the following, and assemble in the reverse order of disassembly
● Apply multi-purpose grease to the sliding part of rack.
● Securely fix dust boot and seal ring with strap. Caulk the strap,
and cut the excess of strap off.
● Engage the tab of bulkhead seal to steering gear.

MGIA0018E

PS-11
 POWER STEERING GEAR AND LINKAGE

● Install lock nut and the outer socket to the inner socket and
tighten lock nut until the length of the tie-rod is within the stan-
dard (length before toe-in adjustment.)
Length of tie-rod : 62.6 mm (2.46 in)
(L)
CAUTION:
Perform toe-in adjustment after this procedure. Length
achieved after toe-in adjustment is not necessarily the
value given here.
SGIA0195J

PS-12
 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

A
Wheel EGS000J9

Steering wheel axial end play 0 mm (0 in)

Steering wheel free play 0 - 35 mm (0 - 138 in) B

Steering Angle EGS000JA

44° +1° C
Inner wheel
-3°
36° +1°
Outer wheel D
-3°

Steering Column EGS000JB

E
Steering column length L 429±2 mm (16.9±0.1 in)

PS

SGIA0207J

Steering Linkage EGS000JC

H

Steering gear type R24T

Tensile force 0.3 - 2.9 N·m (0.03 - 0.29 kg-m, 3 - 25 in-lb) I
Tie-rod ball joint outer Spring balance measurement
5 - 54 N (0.51 - 5.5 kg, 1.1 - 12.1 lb)
socket (Upper edge of stud bolt)
Axial end play No Free Play J
Tensile force 0.5 - 5.0 N·m (0.05 - 0.51 kg-m, 5 - 44 in-lb)
Tie-rod ball joint inner Spring Balance measurement (measured
4 - 43 N (0.41 - 4.4 kg, 0.9 - 9.7 lb)
socket at * mark) K
Axial end play No Free Play
Tie-rod length L 62.6mm (2.46 in)
L

STC1006D

Tightening Torque EGS000JD

Unit: N·m (kg-m, ft-lb)

Steering wheel bolt 29.4 - 39.2 (3.0 - 4.0, 22 - 28)
Steering column to intermediate shaft to Steering gear 27 - 32 (2.8 - 3.3, 21 - 23)
Steering gear to Suspension member 85 - 103 (8.7 - 10.5, 63 - 75)
Outer socket to Steering knuckle 29.5 - 39. 2 (23.0 - 4.0, 22 - 28)
Tie-rod outer socket lock nut 48 - 58 (4.9 - 5.9, 36 - 42)

PS-13
SERVICE DATA AND SPECIFICATIONS (SDS)

PS-14