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Steering Wheel and Column: Removal & Installation Suzuki Aerio I

Ignition Switch/steering Lock 29 illustrations ~1345 words

Steering Wheel Removal and Installation

CAUTIONRemoval of the steering wheel allows the contact coil to turn freely but do not turn the contact coil (on the combination switch) more than allowable number of turns (about two and a quarter turns from the center position clockwise or counterclockwise respectively), or coil will break. Do not remove steering wheel lower cover from steering wheel to prevent its mounting screws from loosing. If it is removed from steering wheel, be sure to replace it with a new one. Never disassemble audio control switch. Disassembly will spoil its original functions.

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Scheme 6: Removal
Scheme 6: Removal

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  1. Remove driver air bag (inflator) module from steering wheel. Refer to «AIR BAG SYSTEM -- AERIO»(ref-251097) .
  2. Disconnect connector (1) from audio control switch (2) and cruise control lever (3), if vehicle equipped.
  3. Remove steering shaft nut.
  4. Make alignment marks (1) on steering wheel and shaft for a guide during reinstallation. CAUTION: Do not hammer the end of the shaft. Hammering it will loosen the plastic shear pins which maintain the column length and impair the collapsible design of the column.
  5. Remove steering wheel (1) with special tool. Special Tool (A): 09944-36011

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Scheme 10: Installation
Scheme 10: Installation

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  1. Install new steering wheel lower cover to steering wheel as follows if necessary. Install steering wheel lower cover (1) to steering wheel (2), and tighten steering wheel lower cover screws (3) as specified torque. Tightening torque Steering wheel lower cover screw a: 0.85 N.m (0.085 kg-m, 0.6 lb-ft) Install audio control switch (1) to steering wheel (2).
  2. Check that vehicle's front tires are at straight-ahead position and contact coil is centered. Refer to «CENTERING CONTACT COIL»(ref-251090-S12327578782007032000000) . CAUTION: These two conditions are prerequisite for installation of steering wheel. If steering wheel has been installed without these conditions, contact coil will break when steering wheel is turned.
  3. When installing new steering wheel, place match mark at the same position of new steering wheel as that of removed steering wheel.
  4. Install steering wheel (1) to steering shaft with 3 lugs (2) on contact coil fitted in three grooves (3) in the back of steering wheel and also aligning marks (4) on steering wheel and steering shaft.
  5. Tighten steering shaft nut (1) to specified torque. Tightening torque Steering shaft nut a: 33 N.m (3.3 kg-m, 24.0 lb-ft) NOTE: After installing the steering wheel, turn the steering wheel about 1 full rotation so that the cancel cam pin fits into the pin hole in the steering wheel and then check the turn signal lever for proper function.
  6. Connect audio control switch connector to audio control switch, if necessary.
  7. Install driver air bag (inflator) module to steering wheel. Refer to «AIR BAG SYSTEM -- AERIO»(ref-251097) .

Contact Coil and Combination Switch Assembly Removal and Installation

CAUTIONDo not turn contact coil (on combination switch) more than allowable number of turns (about two and a quarter turns from the center position clockwise or counterclockwise respectively), or coil will break.

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Scheme 14: Removal
Scheme 14: Removal

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  1. Remove steering wheel from steering column referring to «STEERING WHEEL REMOVAL AND INSTALLATION»(ref-251090-S22565319772007032000000) .
  2. Remove steering column hole cover (1).
  3. Remove steering column cover screws (1).
  4. Separate upper cover (2) and lower cover (3), then remove them.
  5. Remove contact coil and combination switch assembly screws (1) and disconnect connectors (2) from combination switch (3).
  6. Disconnect horn connector and air bag connector (1) from instrument panel harness.
  7. Remove contact coil and combination switch assembly from steering column.

Installation

Reference: CONTACT COIL AND COMBINATION SWITCH ASSEMBLY INSPECTION

Reference: CENTERING CONTACT COIL

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Scheme 18: Installation
Scheme 18: Installation

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  1. Check to make sure that vehicle's front tires are set at straight-ahead position and then ignition switch is at "LOCK" position.
  2. Install contact coil and combination switch assembly (3) and then connect all connectors disconnected in Removal. NOTE: New contact coil and combination switch assembly is supplied with contact coil set and held at its center position with a lock pin (1) and seal (2). Remove this lock pin after installing contact coil and combination switch assembly to steering column.
  3. Install steering column upper cover (2) and lower cover (3), and then tighten steering column cover screws (1). CAUTION: When installing lower cover (3) and upper cover (2), be careful so that contact coil and combination switch lead wire is not caught between covers.
  4. Install steering column hole cover (1).
  5. Install steering wheel to steering column. Refer to «STEERING WHEEL REMOVAL AND INSTALLATION»(ref-251090-S22565319772007032000000) .

Steering Column Assembly Removal and Installation

Reference: STEERING WHEEL AND COLUMN CONSTRUCTION

CAUTIONOnce the steering column is removed from the vehicle, the column is extremely susceptible to damage. Dropping the column assembly on its end could collapse the steering shaft or loosen the plastic shear pins which maintain column length. Leaning on the column assembly could cause it to bend or deform. Any of the damage could impair the column's collapsible design.

Removal

WARNINGNever rest a steering column assembly on the steering wheel with the air bag (inflator) module face down and column vertical. Otherwise, personal injury may result.

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  1. Disconnect negative cable at battery.
  2. Disable air bag system. Refer to «DISABLING AIR BAG SYSTEM: ADVANCED AIR BAG OR DISABLING AIR BAG SYSTEM: EXCEPT ADVANCED AIR BAG»(ref-251090-S04121659082007032000000) .
  3. Remove steering wheel referring to «STEERING WHEEL REMOVAL AND INSTALLATION»(ref-251090-S22565319772007032000000) .
  4. If it is necessary to remove contact coil and/or combination switch assembly, remove them, referring to «CONTACT COIL AND COMBINATION SWITCH ASSEMBLY REMOVAL AND INSTALLATION»(ref-251090-S02383570152007032000000) .
  5. Remove steering column hole cover (1).
  6. Remove steering column cover screws (1).
  7. Separate upper column cover (2) and lower column cover (3), then remove these covers.
  8. Disconnect connectors (1) from combination switch assembly (2).
  9. Disconnect ignition switch connectors (1) from ignition switch (2).
  10. For A/T vehicle, disconnect shift (key) interlock cable (1) from ignition switch with ignition switch turned at "ACC" position. After disconnecting, turn ignition switch to "LOCK" position.
  11. Disconnect horn connector (black) and air bag connector (yellow) (1) from instrument panel harness.
  12. Remove steering joint cover.
  13. Make alignment marks (1) on pinion shaft (2) and joint of steering lower shaft (3) for a guide during reinstallation.
  14. Loosen joint bolt (steering column side) (4) and remove joint bolt (pinion shaft side) (5) and disconnect steering lower shaft (3) from pinion shaft (2).
  15. Remove steering column mounting nuts ("A", "B").
  16. Remove steering column assembly from vehicle. CAUTION: Don't separate steering column assembly into steering column and shaft. If column or shaft is defective, replace as an assembly.
  17. If it is necessary to remove steering lock assembly (ignition switch), remove it referring to «STEERING LOCK ASSEMBLY (IGNITION SWITCH) REMOVAL AND INSTALLATION»(ref-251090-S21310072202007032000000) .

Reference: STEERING COLUMN ASSEMBLY INSPECTION

CAUTIONAfter tightening steering column mounting nuts, shaft joint bolts should be tightened. Wrong tightening order could cause a damage to shaft joint.

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  1. Be sure that front wheels and steering wheel are in straight forward state. If steering lock assembly (ignition switch) is removed, install it referring to «STEERING LOCK ASSEMBLY (IGNITION SWITCH) REMOVAL AND INSTALLATION»(ref-251090-S21310072202007032000000) .
  2. When installing new steering column assembly, place match mark at the same position of new steering column assembly as that of removed steering column assembly.
  3. Tighten mounting nuts to specified torque in the order "A"-"B" indicated in figure. Tightening torque Steering column mounting nut a: 14 N.m (1.4 kg-m, 10.5 lb-ft)
  4. Insert lower shaft (2) into pinion shaft (3) with matching marks (4) made before removal.
  5. Tighten joint bolts (1) in order "C"-"D" indicated in figure to specified torque. Tightening torque Steering shaft joint bolt b: 25 N.m (2.5 kg-m, 18.5 lb-ft)
  6. Install steering joint cover.
  7. For A/T vehicle, connect shift (key) interlock cable (1) to ignition switch with ignition switch turned at "ACC" position. And then turn ignition switch "LOCK" position.
  8. If contact coil and combination switch assembly is removed, install it. Refer to «CONTACT COIL AND COMBINATION SWITCH ASSEMBLY REMOVAL AND INSTALLATION»(ref-251090-S02383570152007032000000) .
  9. Connect the following connectors disconnected in "Removal". Ignition switch Combination switch Horn
  10. Install upper and lower column covers (2, 3) to steering column assembly by screws (1).
  11. Install steering wheel referring to «STEERING WHEEL REMOVAL AND INSTALLATION»(ref-251090-S22565319772007032000000) .
  12. Install steering column hole cover (1).
  13. Enable air bag system. Refer to «ENABLING AIR BAG SYSTEM»(ref-251090-S30209664302007032000000) .
  14. Connect negative cable at battery.

Steering Lower Shaft Removal and Installation

Reference: STEERING WHEEL AND COLUMN CONSTRUCTION

CAUTIONNever turn steering wheel while steering lower shaft is removed. Should it have been turned and contact coil (on combination switch) have got out of its centered position, it needs to be centered again. Also, turning steering wheel more than about two and a quarter turns will break contact coil.

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Scheme 33: Removal
Scheme 33: Removal
  1. Turn steering wheel so that vehicle's front tires are at straight-ahead position.
  2. Turn ignition switch to "LOCK" position and remove key.
  3. Remove steering joint cover (5).
  4. Make alignment marks (4) on lower shaft (1) and shaft joint of steering column (2) and lower shaft (1) and pinion shaft (3) for a guide during reinstallation.
  5. Remove lower shaft joint bolts (6).
  6. Remove steering lower shaft (1).

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Scheme 34: Installation
Scheme 34: Installation
  1. Be sure that front wheels and steering wheel are in straight forward state.
  2. Align flat part "A" of steering lower shaft (1) with bolt hole "B" of shaft joint (2) of column as shown. Then insert lower shaft into shaft joint of steering column with matching marks (4).
  3. Insert lower shaft (1) into pinion shaft (3) with matching marks (4).
  4. Tighten joint bolt (pinion shaft side) (6) to specified torque first and then joint bolt (steering column side) (5) to specified torque. Tightening torque Steering shaft joint bolt a: 25 N.m (2.5 kg-m, 18.5 lb-ft)
  5. Install steering joint cover (7).

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