Steering System: Overhaul Toyota Corolla IX

DISASSEMBLY

Note. When using a vise, do not overtighten it.

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1. w/ Key cylinder lamp : Remove the clip and key cylinder lamp assembly.
2. Remove column upper bracket and column upper clamp : Using a centering punch, mark the center of the 2 tapered-head bolts. Using a 3 - 4 mm (0.12 - 0.16 in.) drill, drill into the 2 bolts. Using a screw extractor, remove the 2 bolts, column upper bracket and column upper clamp.

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1. Inspect steering lock operation : Check that the steering lock mechanism operates properly.
2. If necessary, replace key cylinder : Place the ignition key at the ACC position. Push down the stop pin with a screwdriver, and pull out the cylinder. Install a new key cylinder. HINT: Make sure the key is at the ACC position.
3. Inspect ignition switch .
4. Inspect key unlock warning switch .
5. If necessary, replace ignition switch with key unlock warning switch : Remove the 2 screws and slide the ignition switch with key unlock warning switch out of the column upper bracket. Slide a new ignition switch with key unlock warning switch in the column upper bracket and install the 2 screws.
6. A/T: inspect : KEY INTERLOCK SOLENOID
7. A/T: if necessary, replace key interlock solenoid : Remove the 2 screws and key interlock solenoid. Install a new key interlock solenoid with the 2 screws.

REASSEMBLY

Note. When using a vise, do not overtighten it.

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1. Install column upper bracket and column upper clamp : Install the column upper bracket and column upper clamp with the 2 new tapered-head bolts. Tighten the new tapered-head bolts until the bolt heads break off.
2. W/key cylinder lamp: Install the key cylinder lamp assembly with the clip.

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1. Temporarily install the sliding yoke and bolt A .
2. Install steering column assembly : Install the steering column assembly with the 2 set bolts and nuts. Torque: 26 N.m (260 kgf.cm, 19 ft.lbf) Connect the connectors.
3. Connect sliding yoke : Align the matchmarks on the sliding yoke and control valve shaft. Install the bolt B. Torque: 35 N.m (360 kgf.cm, 26 ft.lbf) . Torque the bolt A. Torque: 35 N.m (360 kgf.cm, 26 ft.lbf) .
4. Install the column hole cover with the 5 bolts . Torque: 4.9 N.m (50 kgf.cm, 43 in..lbf)
5. Install the No. 2 heater to register duct with the clip .
6. Install spiral cable .
7. Install combination switch with spiral cable : Install the combination switch with spiral cable with the 3 screws. Connect the airbag connector. Connect the 3 connectors.
8. Install column upper and lower covers Install the column upper cover with the screw. Install the column lower cover with the 3 screws.
9. Install the lower LH instrument panel insert with the 2 bolts .
10. Install lower LH instrument finish panel : Connect the hood lock control cable. Install the lower LH instrument finish panel with the 2 bolts.
11. Install front door scuff plate and cowl side trim .
12. Center spiral cable : Check that the front wheels are facing straight ahead. Turn the spiral cable counterclockwise by hand until it becomes harder to turn. NOTE: The cable will rotate about 2.5 turns to either left or right of the center. Then rotate the spiral cable clockwise about 2.5 turns to align the marks.
13. Install steering wheel : Align the matchmarks on the steering wheel and main shaft assembly. Install the steering wheel set nut. Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) . Connect the connector.
14. Install steering wheel pad : Connect the airbag connector. Install the wheel pad after confirming that the circumference groove of the torx screws is caught on the screw case. Using a torx socket wrench, install the 2 screws. Torque: 8.8 N.m (90 kgf.cm, 78 in..lbf) . Install the 2 steering wheel lower No. 2 covers.
15. Check steering wheel center point .

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1. Remove the 4 bolts, 2 screws and RH engine under cover.
2. Loosen the drive belt tension by turning the drive belt tensioner arm clockwise, and remove the drive belt.
3. Remove the clip and disconnect the suction hose.
4. Remove oil pressure switch : Disconnect the connector. CAUTION: Be careful not to drop the pressure switch. Remove the oil pressure switch, as shown in the illustration. If the oil pressure switch is dropped or strongly damaged, replace it with a new one.
5. Remove the union bolt and gasket, and disconnect the pressure feed tube.
6. Remove vane pump pulley : Using SST, stop the pulley rotating and loosen the nut. Remove the nut and vane pump pulley from the vane pump shaft. SST 09960-10010 (09962-01000, 09963-01000).
7. Remove the 2 pump assembly set bolts, nuts and the PS vane pump assembly.

Note. When using a vise, do not overtighten it.

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1. Measure PS vane pump rotating torque : Check that the vane pump rotates smoothly without abnormal noise. Temporarily install the vane pump pulley set nut. Using a torque wrench, check the vane pump rotating torque. Rotating torque: 0.3 N.m (2.8 kgf.cm, 2.4 in..lbf) or less .
2. Remove suction port union : Remove the bolt from the bracket of the suction port union. Remove the 2 suction port union set bolts and suction port union. Remove the O-ring from the suction port union.
3. Remove the union bolt, 2 gaskets and pressure feed No. 1 tube.
4. Remove pressure port union : Remove the pressure port union. Remove the O-ring from the pressure port union.
5. Remove flow control valve and spring .
6. Remove rear housing, wave washer and side plate : Remove the 4 bolts and rear housing. Remove the O-ring from the rear housing. Remove the wave washer and side plate. Remove the O-ring from the side plate.
7. Remove cam ring, 10 vane plates and vane pump rotor .
8. Remove gasket .
9. Using pliers, remove the 2 straight pins from the front housing.
10. Remove vane pump shaft with bearing : Using snap ring pliers, remove the snap ring from the front housing. Wind vinyl tape on the serrated part of the vane pump shaft. Press out the vane pump shaft with the bearing. NOTE: Be careful not to damage the oil seal lip.

Note. When using a vise, do not overtighten it.

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1. Coat parts indicated by arrows with power steering fluid . See «COMPONENTS»(ref-170954-S26528982862005012400000) under POWER STEERING VANE PUMP.
2. Install vane pump shaft with bearing : Wind vinyl tape on the serrated part of the vane pump shaft. CAUTION: Be careful not to damage the oil seal. Using SST, press in the vane pump shaft with the bearing. SST 09608-04031. Using snap ring pliers, install a new snap ring to the front housing.
3. Using a plastic hammer, tap in 2 new straight pins to the front housing.
4. Install the cam ring with the inscribed mark facing outward.
5. Install the vane pump rotor with the inscribed mark facing outward.
6. Install 10 vane plates and gasket : Install the 10 vane plates with the round end facing outward. CAUTION: Be careful of the direction of the gasket. Install a new gasket on the front housing.
7. Install side plate : Coat a new O-ring with power steering fluid and install it to the side plate. Align the holes of the side plate and 2 straight pins, and install the side plate.
8. Install the wave washer so that its protrusions fit into the slots in the side plate.
9. Install rear housing : Coat a new O-ring with power steering fluid and install it to the rear housing. Install the rear housing with the 4 bolts. Torque: 24 N.m (240 kgf.cm, 17 ft.lbf) .
10. Install spring and flow control valve : Install the spring. Install the flow control valve facing in the correct direction. See «COMPONENTS»(ref-170954-S26528982862005012400000) under POWER STEERING VANE PUMP.
11. Install pressure port union : Coat a new O-ring with power steering fluid and install it to the pressure port union. Install the pressure port union. Torque: 83 N.m (850 kgf.cm, 61 ft.lbf) .
12. Install new gasket on each side of the pressure feed No. 1 tube. Install the pressure feed No. 1 tube with the union bolt. Torque: 69 N.m (700 kgf.cm, 51 ft.lbf) .
13. Install suction port union : Coat a new O-ring with power steering fluid and install it to the suction port union. Install the suction port union with the 2 union set bolts. Torque: 13 N.m (130 kgf.cm, 10 ft.lbf) . Install the bolt to the bracket of the suction port union. Torque: 43 N.m (440 kgf.cm, 32 ft.lbf) .
14. Measure PS vane pump rotating torque. See step 1 in DISASSEMBLY under POWER STEERING VANE PUMP.

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1. Install the PS vane pump assembly with the 2 pump assembly set bolts and nuts . Torque: 37 N.m (370 kgf.cm, 27 ft.lbf)
2. Install vane pump pulley : Install the vane pump pulley and nut to the vane pump shaft. Using SST, stop the vane pump pulley rotating and torque the nut. Torque: 43 N.m (440 kgf.cm, 32 ft.lbf) . SST 09960-10010 (09962-01000, 09963-01000).
3. Install a new gasket, and connect the pressure feed tube with the union bolt . Torque: 54 N.m (550 kgf.cm, 40 ft.lbf) .
4. Install the oil pressure switch . Torque: 21 N.m (210 kgf.cm, 15 ft.lbf) Connect the connector.
5. Connect the suction hose with the clip .
6. Loosen the drive belt tension by turning the drive belt tensioner arm clockwise, and install the drive belt .
7. Install the RH engine under cover with the 4 bolts and 2 screws .
8. Bleed power steering system . See «REPLACEMENT»(ref-170954-S17588757932005012400000) .

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Note. When using a vise, do not overtighten it.

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1. SECURE PS GEAR ASSEMBLY IN VISE Using SST, secure the PS gear assembly in a vise. SST 09612-00012.
2. Remove 2 turn pressure tubes : Using SST, remove the 2 turn pressure tubes. SST 09023-38200. Remove the 4 O-rings from the 2 turn pressure tubes.
3. Remove RH and LH tie rod ends and lock nuts : Place matchmarks on the tie rod end and rack end. Loosen the lock nut, and remove the tie rod end and lock nut. Employ the same manner described above to the other side.
4. Remove RH And LH Clips, Rack Boots And Clamps CAUTION: Be careful not to damage the boot. Using pliers, loosen the clamp. NOTE: Mark the RH and LH rack boots. Remove the clip and boot. Employ the same manner described above to the other side.
5. Remove RH And LH Rack Ends And Claw Washers CAUTION: Avoid any impact on the steering rack. Using a chisel and hammer, unstake the washer. NOTE: Use SST 09922-10010 in the direction shown in the illustration. Mark the RH and LH rack ends. Using SST, remove the rack end and claw washer. SST 09922-10010. Employ the same manner described above to the other side.
6. Using SST, remove the rack guide spring cap lock nut . SST 09922-10010.
7. Remove rack guide spring cap, rack guide spring, conical spring washer, rack guide subassembly : Using a hexagon wrench (19 mm), remove the rack guide spring cap. Remove the rack guide spring, conical spring washer, rack guide subassembly.
8. Remove rack housing cap .
9. Using SST, stop the control valve shaft rotating and remove the self-locking nut . SST 09616-00011.
10. Remove control valve housing with control valve assembly : Place matchmarks on the control valve housing and rack housing. Remove the 2 bolts and control valve housing with the control valve assembly. Remove the gasket from the control valve housing.
11. Remove control valve assembly and oil seal : To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft. CAUTION: Be careful not to damage the oil seal lip. Using a plastic hammer, tap out the control valve assembly with the oil seal from the control valve housing. Remove the oil seal from the control valve assembly.
12. Remove cylinder end stopper : Using SST, turn the cylinder end stopper clockwise until the wire end is visible through the service hole. SST 09631-10021 Using SST, turn the cylinder end stopper counterclockwise, and remove the wire. SST 09631-10021.
13. Remove steering rack with bushing : CAUTION: Take care not to drop the steering rack. Using SST, press out the steering rack with the bushing. SST 09612-24014 (09612-10061). Remove the O-ring from the bushing.
14. Using SST, press out the oil seal . SST 09950-60010 (09951-00260), 09950-70010 (09951-07360).

Note. When using a vise, do not overtighten it.

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1. Coat parts indicated by arrows with power steering fluid or molybdenum disulfide lithium base grease .
2. Install oil seal : Coat a new oil seal lip with power steering fluid. CAUTION: Make sure to install the oil seal facing in the correct direction. Using SST, press in the oil seal. SST 09950-60010 (09951-00240, 09951-00400, 09952-06010), 09950-70010 (09951-07360). Take care that the oil seal does not get reversed as you install it.
3. Install Steering Rack NOTE: If necessary, scrape the burrs off the steering rack teeth end and burnish. Install SST to the steering rack. SST 09631-16020 Coat SST with power steering fluid. Install the rack into the rack housing. Remove the SST.
4. Install Bushing Coat a new O-ring with power steering fluid and install it to the bushing. To prevent oil seal lip damage, wind vinyl tape on the steering rack end, and apply power steering fluid. CAUTION: Make sure to install the bushing facing in the correct direction. Be careful not to damage the oil seal lip. Install the bushing into the rack housing.
5. Install cylinder end stopper : Align the installation hole for the wire of the cylinder end stopper with the slot of the rack housing. Install a new wire into the cylinder end stopper. Using SST, turn the cylinder end stopper clockwise 150 ° 50°. SST 09631-10021.
6. Air Tightness Test Install SST to the rack housing. SST 09631-12071. Apply 53 kPa (400 mmHg, 15.75 in.Hg) of vacuum for about 30 seconds. Check that there is no change in the vacuum. If there is change in the vacuum, check the installation of the oil seals.
7. Install control valve assembly : To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft. Coat the teflon rings with power steering fluid. CAUTION: Be careful not to damage the teflon rings and oil seal. Install the control valve assembly into the control valve housing.
8. Install Oil Seal Coat a new oil seal lip with power steering fluid. CAUTION: Make sure to install the oil seal facing in the correct direction. Using SST, press in the oil seal. SST 09612-22011.
9. Install control valve housing with control valve assembly : Place a new gasket on the rack housing. Align the matchmarks on the control valve housing and rack housing. Install the 2 bolts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) .
10. Install Self-Locking Nut Using SST, stop the control valve shaft rotating and Install a new self-locking nut. Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) . SST 09616-00011.
11. Install Rack Housing Cap Apply sealant to 2 or 3 threads of the rack housing cap. Sealant : Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent. Install the rack housing cap. Torque: 59 N.m (600 kgf.cm, 43 ft.lbf) Using a punch and hammer, stake the 2 parts of the rack housing cap.
12. Install Rack Guide Subassembly, Conical Spring Washer, Rack Guide Spring And Rack Guide Spring Cap Install the rack guide subassembly, conical spring washer and rack guide spring. 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. Temporarily install the rack guide spring cap.
13. Adjust Total Preload To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the RH and LH rack ends. Using a hexagon wrench (19 mm), install the rack guide spring cap. Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) Using a hexagon wrench (19 mm), return the cap 12°. Using SST, turn the control valve shaft right and left 1 or 2 times. SST 09616-00011 Using a hexagon wrench (19 mm), loosen the rack guide spring cap until the rack guide spring is not functioning. Using SST, a torque wrench and hexagon wrench (19 mm), tighten the rack guide spring cap until the preload is within the specification. SST 09616-00011. Preload (turning): 0.8 - 1.4 N.m (8 - 14 kgf.cm, 6.9 - 12.2 in..lbf)
14. Install Rack Guide Spring Cap Lock Nut Apply sealant to 2 or 3 threads of the rack guide spring cap lock nut. Sealant: Part No. 08833-00080, Three Bond 1344, Loctite 242 or equivalent Temporarily install the lock nut. Using a hexagon wrench (19 mm), hold the rack guide spring cap and using SST, torque the nut. Torque: 43 N.m (439 kgf.cm, 32 ft.lbf) SST 09922-10010. NOTE: Use SST 09922-10010 in the direction shown in the illustration. HINT: Use a torque wrench with a fulcrum length of 345 mm (13.58 in.). Recheck the total preload. Preload (turning) : 0.8 - 1.4 N.m (8 - 14 kgf.cm, 6.9 - 12.2 in..lbf). Remove the RH and LH rack ends.
15. Install RH And LH claw washers and rack ends NOTE: Align the claws of the washer with the steering rack grooves. Install a new claw washer, and temporarily install the rack end. NOTE: Use SST 09922-10010 in the direction shown in the illustration. Use a torque wrench with a fulcrum length of 380 mm (14.96 in.). Using SST, torque the rack end. Torque: 62 N.m (633 kgf.cm, 46 ft.lbf) . SST 09922-10010. CAUTION: Avoid any impact on the steering rack. Using a brass bar and a hammer, stake the washer. Employ the same manner described above to the other side.
16. Install RH and LH rack boots, clamps and clips : NOTE: If the hole is clogged, the pressure inside the boot will change after it is assembled and the steering wheel is turned. Make sure that the steering rack hole is not clogged with grease. CAUTION: Be careful not to damage or twist the boots. Install the boot clip and a new clamp. Using SST, tighten the clamp as shown in the illustration. SST 09521-24010. Employ the same manner described above to the other side.
17. Install RH and LH tie rod ends and lock nuts : Screw the lock nut and tie rod end onto the rack end until the matchmarks are aligned. After adjusting toe-in, See «SPECIFICATIONS & PROCEDURES»(ref-157296) in ALIGNMENT under STEERING. Torque the nut. Torque: 56 N.m (570 kgf.cm, 41 ft.lbf)
18. Install 2 turn pressure tubes : Coat 4 new O-rings with power steering fluid and install them to the 2 turn pressure tubes. NOTE: 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. Using SST, install the 2 tubes. Torque: 11 N.m (112 kgf.cm, 8 ft.lbf) . SST 09023-38200.

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1. Slide the PS gear assembly to the RH of the vehicle, slide the PS gear assembly to the LH side and position it.
2. Install 2 grommets and brackets Install the grommet and bracket with the bolt and nut. Torque: 71 N.m (720 kgf.cm, 52 ft.lbf) . Employ the same manner described above to the other side. Install the bolt A. Torque: 5.4 N.m (55 kgf.cm, 48 in..lbf) .
3. Using SST, connect the pressure feed tube . Torque: 30 N.m (306 kgf.cm, 22 ft.lbf) . SST 09023-12700.
4. Connect the return hose with the clip .
5. Install the 2 tube clamps with the 2 bolts . Torque: 5.4 N.m (55 kgf.cm, 48 in..lbf) .
6. Install Rack Boot Heat Insulator Install the rack boot heat insulator with the bolt and nut. Torque: 5.4 N.m (55 kgf.cm, 48 in..lbf) .
7. Install Engine Rear Mount Bracket A131L A/T: Install the engine rear mount bracket with the 2 bolts and drive shaft heat insulator set nut. Torque: Bolt: 77 N.m (790 kgf.cm, 57 ft.lbf) Nut: 17 N.m (168 kgf.cm, 12 ft.lbf) M/T, A245E A/T: Install the engine rear mount bracket with the 3 bolts and drive shaft heat insulator set nut. Torque: Bolt: 77 N.m (790 kgf.cm, 57 ft.lbf) Nut: 17 N.m (168 kgf.cm, 12 ft.lbf)
8. Install the engine rear mount insulator to the engine rear mount bracket with the bolt . Torque: 87 N.m (890 kgf.cm, 64 ft.lbf) .
9. Install front sub-frame and lower suspension arm : Install the front sub-frame and lower suspension arm with the 14 bolts and 3 nuts. Torque: Bolt A: 60 N.m (620 kgf.cm, 45 ft.lbf) Bolt B: 64 N.m (650 kgf.cm, 47 ft.lbf) Bolt C: 225 N.m (2,305 kgf.cm, 167 ft.lbf) Bolt D: 147 N.m (1,500 kgf.cm, 109 ft.lbf) Bolt E: 175 N.m (1,790 kgf.cm, 129 ft.lbf) Nut: 57 N.m (580 kgf.cm, 42 ft.lbf) Remove the engine support fixture.
10. Install the brace with the 2 nuts . Torque: 69 N.m (700 kgf.cm, 51 ft.lbf) .
11. Connect lower ball joint to lower suspension arm .
12. Connect sliding yoke . See 3 in INSTALLATION under STEERING COLUMN.
13. Install Column Hole Cover Install the column hole cover with the 5 bolts. Torque: 4.9 N.m (50 kgf.cm, 43 in..lbf) .
14. Connect RH and LH tie rod ends . See «FRONT AXLE HUB & WHEEL BEARING»(ref-164703-S36077080852004081300000) .
15. Install the RH and LH engine under covers with the 8 bolts and 4 screws .
16. Place front wheels facing straight ahead .
17. Center Spiral Cable .
18. Install steering wheel : Align the matchmarks on the steering wheel and steering column main shaft. Temporarily tighten the steering wheel set nut. Connect the connector.
19. Bleed power steering system. . See «REPLACEMENT»(ref-170954-S17588757932005012400000) .
20. Check steering wheel center point .
21. Torque Steering wheel set nut. Torque: 34 N.m (350 kgf.cm, 25 ft.lbf) .
22. Install steering wheel pad. See step 2 f in INSPECTION under STEERING WHEEL.
23. Check front wheel alignment . See «SPECIFICATIONS & PROCEDURES»(ref-157296) in WHEEL ALIGNMENT article..