DISASSEMBLY
Note. When using a vise, do not overtighten it.
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- REMOVE TRANSPONDER KEY AMPLIFIER WITH COIL Widen the claw hung on the upper bracket by approx. 1.0 mm (0.039 in.) using a screwdriver. Pull the transponder key amplifier toward the rear of the vehicle with the claw open. NOTE: Take care not to use excessive force to prevent the case from being damaged.
- REMOVE COLUMN UPPER BRACKET AND COLUMN UPPER CLAMP Using a centering punch, mark the center of the 2 tapered-head bolts. Using a 3-4mm (0.12-0.16 in.) drill, drill into the 2 bolts. Using a screw extractor, remove the 2 bolts, column upper clamp and column upper bracket.
- REMOVE TILT STEERING SUPPORT Remove the bolt and tilt steering support.
- REMOVE BRACKET SPACER AND NO. 1 SUPPORT COLLARS Using an extension bar and a hammer, tap out the bracket spacer. Using a screwdriver, remove the 2 No. 1 support collars.
- REMOVE TILT LEVER AND BREAK AWAY BRACKET Remove the tilt spring. Remove the No. 2 tilt lever lock bolt and No. 1 support reinforce. HINT: This bolt is left-handed one. Remove the adjusting nut, tilt lever, stopper, tilt lever lock bolt and break away bracket. HINT: This nut is left-handed one. Remove the No. 2 support collar from the break away bracket.
- REMOVE MAIN SHAFT ASSEMBLY AND MAIN SHAFT BUSHING Using a snap ring expander, remove the snap ring on the upper side. Pull out the main shaft assembly and main shaft bushing. Using a snap ring expander, remove the snap ring on the lower side.
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- INSPECT STEERING LOCK OPERATION Check that the steering lock mechanism operates properly.
- 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 cylinder. HINT: Make sure the key is at the ACC position.
- INSPECT IGNITION SWITCH (See INSPECTION ).
- IF NECESSARY, REPLACE IGNITION SWITCH Remove the 2 screws and ignition switch from the column upper bracket. Install a new ignition switch with the 2 screws.
- INSPECT KEY UNLOCK WARNING SWITCH (See INSPECTION ).
- IF NECESSARY, REPLACE KEY UNLOCK WARNING SWITCH Slide the key unlock warning switch out of the column upper bracket. Slide a new key unlock warning switch in the column upper bracket.
- INSPECT BEARING Check the bearing rotation condition and check for abnormal noise. If the bearing is worn or damaged, replace the column tube.
REASSEMBLY
Note. When using a vise, do not overtighten it.
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- COAT PARTS INDICATED BY ARROWS WITH MOLYBDENUM DISULFIDE LITHIUM BASE GREASE (See «COMPONENTS»(ref-192703-S04584547732005092700000) ).
- INSTALL MAIN SHAFT ASSEMBLY Using a snap ring expander, install a new snap ring on the lower side. Install the main shaft assembly. Using a snap ring expander, install a new snap ring on the upper side.
- INSTALL MAIN SHAFT BUSHING Coat a new bushing with molybdenum disulfide lithium base grease. Using SST and a hammer, tap in the main shaft bushing. SST 09608-04031
- INSTALL BREAK AWAY BRACKET AND TILT LEVER Install the No. 2 support collar to the break away bracket. Install the break away bracket, tilt lever lock bolt, stopper and tilt lever. HINT: Align the holes in the column tube with the projections of the tilt lever lock bolt and stopper. Install the adjusting nut by rotating it counterclockwise in the specified torque so that the locking load (load applied to when a knob is operated) of the tilt lever will be 38 - 82 N (3.9 - 8.4 kgf, 8.5 - 18.4 lbf). Torque: 9 N.m - 14 N.m (90 kgf.cm - 145 kgf.cm, 80 in.lbf - 10 ft.lbf) Install the No. 1 support reinforce with the No. 2 tilt lever lock bolt by turning it counterclockwise. Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) HINT: Align the No. 1 support reinforce with the nut to eliminate looseness by turning the No. 1 support reinforce counterclockwise a little, then torque the No. 2 tilt lever lock bolt. Install the tilt spring.
- INSTALL NO. 1 SUPPORT COLLARS AND BRACKET SPACER Install 2 new No. 1 support collars. NOTE: Install the white support collar to the RH side, black support collar to the LH side. Using an extension bar and a hammer, drive in the bracket spacer.
- INSTALL TILT STEERING SUPPORT Install the tilt steering support with the bolt. Torque: 15 N.m (155 kgf.cm, 11 ft.lbf) NOTE: Make sure that the tilt steering support is installed facing in the correct direction.
- INSTALL COLUMN UPPER BRACKET AND COLUMN UPPER CLAMP Install the column upper bracket and column upper clamp with 2 new tapered-head bolts. Tighten the 2 tapered-head bolts until the bolt heads break off.
- INSTALL TRANSPONDER KEY AMPLIFIER WITH COIL Align the transponder key amplifier with the installation position of the upper bracket with the amplifier inclined. Push the transponder key amplifier up and connect it to the upper bracket. NOTE: Take care not to push the amplifier up with excessive force to prevent it from being damaged.
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- INSTALL SLIDING YOKE AND NO. 2 COLUMN HOLE COVER TO NO. 2 INTERMEDIATE SHAFT Install the No. 2 column hole cover and intermediate shaft dust cover Temporarily install the sliding yoke with the bolt.
- INSTALL NO. 2 INTERMEDIATE SHAFT ASSEMBLY Align the matchmarks on the sliding yoke and main shaft assembly. Install the No. 2 intermediate shaft assembly with the bolt. Torque: 35 N.m (360 kgf.cm, 26 ft.lbf)
- PLACE COLUMN UPPER COVER TO STEERING COLUMN ASSEMBLY
- INSTALL STEERING COLUMN ASSEMBLY Install the steering column assembly with the 2 bolts and nuts. Torque: 21 N.m (210 kgf.cm, 15 ft.lbf) Connect the 3 connectors and 2 wire harness clamps.
- CONNECT NO. 2 INTERMEDIATE SHAFT ASSEMBLY Align the matchmarks on the No. 2 intermediate shaft assembly 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) Connect the No. 2 column hole cover and tighten the clamp.
- INSTALL LIGHT CONTROL SWITCH AND HEADLIGHT DIMMER SWITCH, WIPER AND WASHER SWITCH AND SPIRAL CABLE Push into the light control switch and headlight dimmer switch until the claw is latched. Employ the same manner described above to the wiper and washer switch. Install the spiral cable. Connect the airbag connector to the spiral cable. Connect the 3 connectors to the spiral cable, light control switch and headlight dimmer switch and wiper and washer switch.
- INSTALL COLUMN UPPER AND LOWER COVERS Install the column upper and lower covers with the 3 screws.
- INSTALL INSTRUMENT FINISH PANEL Connect the DLC3. Install the lower No. 1 instrument finish panel with the bolt and screw. Connect the hood lock release lever and install the 2 screws.
- CENTER SPIRAL CABLE Check that the front wheels are facing straight ahead. Turn the cable counterclockwise by hand until it becomes harder to turn. Then rotate the cable clockwise about 2.5 turns to align the marks. HINT: The cable will rotate about 2.5 turns to either left or right of the center.
- INSTALL STEERING WHEEL Align the matchmarks on the steering wheel and main shaft assembly. Install the steering wheel set nut. Torque: 50 N.m (500 kgf.cm, 35 ft.lbf) Connect the connector.
- INSTALL STEERING WHEEL PAD NOTE: Never use airbag parts from another vehicle. When replacing parts, replace with new ones. Make sure the wheel pad is installed with the specified torque. If the wheel pad has been dropped, or there are cracks, dents or other defects in the case or connector, replace the wheel pad with a new one. When installing the wheel pad, take care that the wirings do not interfere with other parts and that they are not pinched between other parts. Connect the airbag connector. Install the steering wheel pad after confirming that the circumference groove of the Torx screws is caught on the screw case. Using a Torx socket wrench (T30), torque the 2 screws. Torque: 8.8 N.m (90 kgf.cm, 78 in.lbf)
- CHECK STEERING WHEEL CENTER POINT