lai_Corolla-00-02

2002 STEERING Power Steering System - Corolla
2002 STEERING
Power Steering System - Corolla
STEERING SYSTEM
PRECAUTION
l Care must be taken to replace parts properly because they could affect the performance of the steering
system and result in a driving hazard.
l The Corolla is equipped with an SRS (Supplemental Restraint System) such as the driver airbag and
front passenger airbag. Failure to carry out service operation in the correct sequence could cause the
SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing
(including removal or installation of parts, inspection or replacement), be sure to read the
precautionary notices in the RS section.
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in the order shown. If necessary, repair or replace these parts.
Fig. 1: Troubleshooting Problem Symptoms Table

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
DRIVE BELT
INSPECTION
Inspect Drive Belt
NOTE: l Cracks on the rib side of a belt are considered acceptable. If the missing
chunks from the ribs are found on the drive belt, it should be replaced.
Fig. 2: Identifying Belt Defects

l After installing a drive belt, check that it fits properly in the ribbed
grooves.
Fig. 3: Inspecting Belt Installation

l Check with your hand to confirm that the drive belt has not slipped out of
the groove on the bottom of the pulley.
Visually check the drive belt for excessive wear, frayed cords, etc.
If any defect has been found, replace the drive belt.
POWER STEERING FLUID

BLEEDING
1. Check fluid level. See INSPECTION .

2. Jack up front of vehicle and support it with stands .
3. Turn steering wheel .
With the engine stopped, turn the steering wheel slowly from lock to lock several times.
4. Lower vehicle .
5. start Engine .
Run the engine at idle for a few minutes.
6. Turn steering wheel :

a. With the engine idling, turn the steering wheel to left or right full lock position and keep it there
for 2 - 3 seconds, then turn the steering wheel to the opposite full lock position and keep it there
for 2 - 3 seconds.
b. Repeat ( ) several times.
7. Stop engine .
8. Check for foaming or emulsification .
If the system has to be bled twice specifically because of foaming or emulsification, check for fluid
leaks in the system.
9. Check fluid level . See INSPECTION .

Fig. 4: Inspecting Brake Fluid For Air Bubbles

INSPECTION
1. Check fluid level :

a. Keep the vehicle level.
NOTE: HINT: Check that the fluid level is within the HOT level range on
the reservoir. If the fluid is cold, check that it is within the COLD
level range.
b. With the engine stopped, check the fluid level in the oil reservoir.
If necessary, add fluid. Fluid: ATF DEXRON(R)II or III .
c. Start the engine and run it at idle.

d. Turn the steering wheel from lock to lock several times to boost fluid temperature. Fluid
temperature: 80°C (176°F) .
Fig. 5: Identifying Brake Fluid Reservoir Fluid Level Marks

e. Check for foaming or emulsification.
If there is foaming or emulsification, bleed power steering system. See REPLACEMENT .

Fig. 6: Inspecting Brake Fluid For Air Bubbles

f. With the engine idling, measure the fluid level in the oil reservoir.
g. Stop the engine.
h. Wait a few minutes and remeasure the fluid level in the oil reservoir. Maximum fluid level
rise: 5 mm (0.20 in.)
If a problem is found, bleed power steering system. See REPLACEMENT .
i. Check the fluid level.

Fig. 7: Measuring Brake Fluid Level Fluctuation

2. Check steering fluid pressure :

a. Disconnect the pressure feed tube from the PS gear. See REMOVAL .
NOTE: Check that the valve of the SST is in the open position.
Fig. 8: Installing Brake Fluid Pressure Gauge

b. Connect SST, as shown in the illustration below. SST 09640-10010 (09641-01010, 09641-
01020, 09641-01030).
c. Bleed the power steering system. See REPLACEMENT .
d. Start the engine and run it at idle.
e. Turn the steering wheel from lock to lock several times to boost fluid temperature. Fluid
temperature: 80°C (176°F) .
NOTE: l Do not keep the valve closed for more than 10 seconds.
l Do not let the fluid temperature become too high.
Fig. 9: Diagramming Brake Fluid Pressure Test With Valve Closed

f. With the engine idling, close the valve of the SST and observe the reading on the SST.
Minimum fluid pressure: 6,374 kPa (65 kgf/cm2 , 925 psi) .
g. With the engine idling, open the valve fully.
NOTE: Do not turn the steering wheel.

Fig. 10: Diagraming Brake Fluid Pressure Test With Valve Open Wheels Centered
h. Measure the fluid pressure at engine speeds of 1,000 rpm and 3,000 rpm. Difference fluid
pressure: 490 kPa (5 kgf/cm2 , 71 psi) or less .
NOTE: l Do not maintain lock position for more than 10 seconds.

l Do not let the fluid temperature become too high.
i. With the engine idling and valve fully opened, turn the steering wheel to full lock. Minimum
fluid pressure: 6,374 kPa (65 kgf/cm2 , 925 psi) .
j. Disconnect the SST. SST 09640-10010 (09641-01010, 09641-01020, 09641-01030).
k. Connect the pressure feed tube to the PS gear. See INSTALLATION .
l. Bleed the power steering system. See REPLACEMENT .
Fig. 11: Diagraming Brake Fluid Pressure Test With Valve Open Wheels At Full Lock
Position
STEERING WHEEL
INSPECTION
1. Check steering wheel freeplay :

a. Stop the vehicle and face the tires straight ahead.
b. Rock the steering wheel gently up and down with a finger lightly, check the steering wheel
freeplay. Maximum freeplay: 30 mm (1. 18 in.) .
Fig. 12: Inspecting Steering Wheel Free Play

2. Check steering effort :

a. Center the steering wheel.
b. Remove the steering wheel pad. See step 1 under REMOVAL.
c. Start the engine and run it at idle.
NOTE: Take the tire type, pressure and contact surface into consideration
before making your diagnosis.
d. Measure the steering effort in both directions. Steering effort (Reference): 4.9 N.m (50
kgf.cm, 43 in..lbf) .
e. Install the steering wheel set nut. Torque: 34 N.m (350 kgf.cm, 25 ft.lbf) .
Fig. 13: Installing Steering Wheel Set Nut

f. Install the steering wheel pad. See 14 in installation under STEERING COLUMN.
STEERING COLUMN
COMPONENTS
ACC, DTCs will be recorded.
1. Remove steering wheel pad :

a. Place the front wheels facing straight ahead.
b. Remove the 2 steering wheel lower No. 2 covers.
c. Using a torx socket wrench, loosen the 2 torx screws until the groove along the screw
circumference catches on the screw case.
Fig. 18: Locating Steering Pad Torx Screws

WARNING: l When storing the wheel pad, keep the upper surface of
the pad facing upward.
l Never disassemble the wheel pad.
l When removing the wheel pad, take care not to pull the
airbag wire harness.
Fig. 19: Locating Air Bag Connector & Identifying Safe Air Bag Handling Procedures
d. Pull out the wheel pad from the steering wheel and disconnect the airbag connector.
2. Remove steering wheel :
a. Disconnect the connector.
b. Remove the steering wheel set nut.
c. Place matchmarks on the steering wheel and main shaft assembly.
Fig. 20: Matchmarking Steering Wheel & Main Shaft

d. Using SST, remove the steering wheel. SST 09950-50013 (09951-05010, 09952-05010, 09953-
05020, 09954-05021).
3. Remove front door scuff plate and cowl side trim .
4. Remove lower LH instrument finish panel :
a. Disconnect the hood lock control cable.
b. Remove the 2 bolts and lower LH instrument finish panel.
5. Remove the 2 bolts and lower LH instrument panel insert.
6. Remove column upper and lower covers :

a. Remove the 3 screws and column lower cover.
b. Remove the screw and column upper cover.
7. Remove combination switch with spiral cable :
a. Disconnect the 3 connectors.
b. Disconnect the airbag connector.
c. Remove the 3 screws and combination switch with spiral cable.
NOTE: Do not disassemble the cable or apply oil to it.
8. Remove spiral cable .

9. Remove the clip and No. 2 heater to register duct .
10. Remove the 5 bolts and column hole cover .
11. Disconnect sliding yoke :
a. Place matchmarks on the sliding yoke and control valve shaft.
Fig. 21: Matchmarking Sliding Yoke & Control Valve Shaft

b. Loosen the bolt A and remove the bolt B.

12. Remove steering column assembly :
a. Disconnect the connectors.
b. Remove the 2 column assembly set bolts, nuts and steering column assembly.
13. Remove the bolt A and sliding yoke .
DISASSEMBLY
NOTE: When using a vise, do not overtighten it.
1. w/ Key cylinder lamp : Remove the clip and key cylinder lamp assembly.
2. Remove column upper bracket and column upper clamp :
a. Using a centering punch, mark the center of the 2 tapered-head bolts.
b. Using a 3 - 4 mm (0.12 - 0.16 in.) drill, drill into the 2 bolts.
c. Using a screw extractor, remove the 2 bolts, column upper bracket and column upper clamp.
Fig. 22: Removing Tapered-Head Bolts

INSPECTION
1. Inspect steering lock operation :
Check that the steering lock mechanism operates properly.

Fig. 23: Inspecting Steering Lock Operation

2. If necessary, replace key cylinder :

a. Place the ignition key at the ACC position.
b. Push down the stop pin with a screwdriver, and pull out the cylinder.
c. 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 :
a. Remove the 2 screws and slide the ignition switch with key unlock warning switch out of the
column upper bracket.
b. 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 :
a. Remove the 2 screws and key interlock solenoid.
b. Install a new key interlock solenoid with the 2 screws.
Fig. 24: Replacing Key Interlock Solenoid

REASSEMBLY
1. Install column upper bracket and column upper clamp :

a. Install the column upper bracket and column upper clamp with the 2 new tapered-head bolts.
b. 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.
Fig. 25: Locating Tapered-Head Bolts

INSTALLATION
1. Temporarily install the sliding yoke and bolt A .

2. Install steering column assembly :
a. Install the steering column assembly with the 2 set bolts and nuts. Torque: 26 N.m (260
kgf.cm, 19 ft.lbf)
b. Connect the connectors.
3. Connect sliding yoke :
a. Align the matchmarks on the sliding yoke and control valve shaft.
Fig. 26: Locating Sliding Yoke & Control Valve Shaft Matchmarks
b. Install the bolt B. Torque: 35 N.m (360 kgf.cm, 26 ft.lbf) .

c. 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 :
a. Install the combination switch with spiral cable with the 3 screws.
b. Connect the airbag connector.
c. Connect the 3 connectors.
8. Install column upper and lower covers
a. Install the column upper cover with the screw.
b. 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 :
a. Connect the hood lock control cable.
b. 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 :
a. Check that the front wheels are facing straight ahead.
b. 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.
Fig. 27: Locating Spiral Cable Matchmarks

c. Then rotate the spiral cable clockwise about 2.5 turns to align the marks.
13. Install steering wheel :
a. Align the matchmarks on the steering wheel and main shaft assembly.
b. Install the steering wheel set nut. Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) .
c. Connect the connector.
NOTE: l Never use airbag parts from another vehicle. When replacing
parts, replace with new ones.
l Make sure the wheel pad is installed with the specified torque.
l If the wheel pad has been dropped, or if there are cracks, dents or
other defects in the case or connector, replace the wheel pad with
a new one.
l 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.
14. Install steering wheel pad :

a. Connect the airbag connector.
b. Install the wheel pad after confirming that the circumference groove of the torx screws is caught
on the screw case.
c. Using a torx socket wrench, install the 2 screws. Torque: 8.8 N.m (90 kgf.cm, 78 in..lbf) .
d. Install the 2 steering wheel lower No. 2 covers.
15. Check steering wheel center point .
Fig. 28: Locating Steering Pad Torx Screws

POWER STEERING VANE PUMP

COMPONENTS
2. Loosen the drive belt tension by turning the drive belt tensioner arm clockwise, and remove the
drive belt.
NOTE: Take care not to spill fluid on the drive belt.
Fig. 31: Removing Serpentine Belt

3. Remove the clip and disconnect the suction hose.

4. Remove oil pressure switch :
a. Disconnect the connector.
CAUTION: Be careful not to drop the pressure switch.
b. 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.
Fig. 32: Removing Pressure Feed Tube

6. Remove vane pump pulley :

a. Using SST, stop the pulley rotating and loosen the nut.
b. 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.
Fig. 33: Removing Vane Pump Pulley

DISASSEMBLY
1. Measure PS vane pump rotating torque :

a. Check that the vane pump rotates smoothly without abnormal noise.
b. Temporarily install the vane pump pulley set nut.
c. 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 :
a. Remove the bolt from the bracket of the suction port union.
b. Remove the 2 suction port union set bolts and suction port union.
c. 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 :
a. Remove the pressure port union.
b. 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 :

a. Remove the 4 bolts and rear housing.
b. Remove the O-ring from the rear housing.
c. Remove the wave washer and side plate.
d. Remove the O-ring from the side plate.
CAUTION: Be careful not to drop the plate.
Fig. 34: Disassembling Vane Pump Components

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 :
a. Using snap ring pliers, remove the snap ring from the front housing.
b. Wind vinyl tape on the serrated part of the vane pump shaft.
c. Press out the vane pump shaft with the bearing.
NOTE: Be careful not to damage the oil seal lip.
Fig. 35: Locating & Identifying Vane Pump Shaft Components

INSPECTION
1. Using a micrometer and caliper gauge, measure the oil clearance between vane pump shaft and
bushing:
Standard clearance: 0.03 - 0.05 mm (0.0012 - 0.0020 in.) .
Maximum clearance: 0.07 mm (0.0028 in.) .
Fig. 36: Measuring Vane Pump Shaft To Bushing Oil Clearance

If it is more than the maximum, replace the front housing and vane pump shaft.
2. Inspect vane pump rotor and vane plates :

a. Using a micrometer, measure the height, thickness and length of the 10 vane plates.
Minimum height: 8.6 mm (0.339 in.) .
Minimum thickness: 1.397 mm (0.05500 in.) .
Minimum length: 14.991 mm (0.59016 in.) .
Fig. 37: Measuring Vane Plates

NOTE: HINT: There are 5 vane plate lengths corresponding to the following vane
pump rotor and cam ring marks: Inscribed mark: 1, 2, 3, 4 or None .
Fig. 38: Locating Rotor & Cam Ring marks

Fig. 39: Measuring Rotor Groove & Plate Clearance

Fig. 40: Rotor & Cam Ring Identification/Specifications Chart

b. Using a feeler gauge, measure the clearance between the vane pump rotor groove and vane
plate. Maximum clearance: 0.03 mm (0.0012 in.) .
If it is more than the maximum, replace the vane plate and/or vane pump rotor with the one
having the same mark stamped on the cam ring.
3. Inspect flow control valve :

a. Coat the valve with power steering fluid and check that it falls smoothly into the valve hole by
its own weight.
Fig. 41: Inspecting Flow Control Valve

NOTE: Install a new flow control valve with the same inscribed mark as the old
one. Inscribed mark: A, B, C, D, E or F .
Fig. 42: Locating Flow Control Valve Marks

Fig. 43: Testing Flow Control Valve

b. Check the flow control valve for leakage. Close one of the holes and apply compressed air of
392 - 490 kPa (4 - 5 kgf/cm2 , 57 - 71 psi) into the opposite side hole, and confirm that air does
not come out from the end hole.
If necessary, replace the flow control valve.
4. Inspect spring :
Using vernier calipers, measure the free length of the spring. Minimum free length: 33.2 mm (1.307
in.) .
If it is less than the minimum, replace the spring.

Fig. 44: Measuring Flow Control Valve Spring Length

REPLACEMENT
1. If necessary, replace oil seal :
CAUTION: Be careful not to damage the bushing of the front housing.

Fig. 45: Removing Oil Seal

a. Using SST, tap out the oil seal from the front housing. SST 09631-10030.
b. Coat a new oil seal lip with power steering fluid.
NOTE: Make sure to install the oil seal facing in the correct direction.
Fig. 46: Installing Oil Seal

c. Using SST, press in the oil seal. SST 09950-60010 (09951-00340), 09950-70010 (09951-
07100).
2. If necessary, replace bearing :
a. Press out the bearing from the vane pump shaft.
CAUTION: Be careful not to damage the vane pump shaft.
b. Using snap ring expander, replace the snap ring with new one.
c. Coat a new bearing with power steering fluid.
d. Press in the bearing to the vane pump shaft.
Fig. 47: Removing & Installing Vane Pump Shaft Bearing

REASSEMBLY
1. Coat parts indicated by arrows with power steering fluid . See COMPONENTS under POWER
STEERING VANE PUMP.
2. Install vane pump shaft with bearing :
a. Wind vinyl tape on the serrated part of the vane pump shaft.
CAUTION: Be careful not to damage the oil seal.
b. Using SST, press in the vane pump shaft with the bearing. SST 09608-04031.
c. Using snap ring pliers, install a new snap ring to the front housing.
CAUTION: Be careful not to damage the pins.

Fig. 48: Locating & Identifying Vane Pump Shaft Components

3. Using a plastic hammer, tap in 2 new straight pins to the front housing.
NOTE: Align the holes of the cam ring with the 2 straight pins.
4. Install the cam ring with the inscribed mark facing outward.
5. Install the vane pump rotor with the inscribed mark facing outward.
Fig. 49: Installing Vane Pump Rotor

6. Install 10 vane plates and gasket :

a. Install the 10 vane plates with the round end facing outward.
CAUTION: Be careful of the direction of the gasket.

Fig. 50: Installing Vane Plates

b. Install a new gasket on the front housing.

7. Install side plate :
a. Coat a new O-ring with power steering fluid and install it to the side plate.
b. 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.
Fig. 51: Installing Wave Washer

9. Install rear housing :

a. Coat a new O-ring with power steering fluid and install it to the rear housing.
b. 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 :
a. Install the spring.
b. Install the flow control valve facing in the correct direction. See COMPONENTS under
POWER STEERING VANE PUMP.
11. Install pressure port union :
a. Coat a new O-ring with power steering fluid and install it to the pressure port union.
b. 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 :
a. Coat a new O-ring with power steering fluid and install it to the suction port union.
b. Install the suction port union with the 2 union set bolts. Torque: 13 N.m (130 kgf.cm, 10
ft.lbf) .
c. 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.
INSTALLATION
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 :
a. Install the vane pump pulley and nut to the vane pump shaft.
Fig. 52: Installing PS Vane Pump Pulley

b. 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).
NOTE: Make sure that the stopper of the pressure feed tube touches the
pressure feed No. 2 tube as shown in the illustration, then torque the
union bolt.
Fig. 53: Locating pressure feed tube, stopper & union bolt
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) .
CAUTION: Be careful of oil on the connector.
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 .
Fig. 54: Installing Serpentine Belt

7. Install the RH engine under cover with the 4 bolts and 2 screws .
8. Bleed power steering system . See REPLACEMENT .
POWER STEERING GEAR

COMPONENTS
Fig. 58: Indentifying Power Steering Gear Components (4 Of 4)

REMOVAL
NOTE: Remove the steering wheel assembly before the steering gear removal,
because there is possibility of breaking of the spiral cable.
1. Place front wheels facing straight ahead .

2. Remove steering wheel pad . See step 1 under REMOVAL.
3. Remove steering wheel . See 2 under REMOVAL.
4. Remove the 8 bolts, 4 screws and RH and LH engine under covers.
5. Disconnect RH and LH tie rod ends. See FRONT AXLE HUB & WHEEL BEARING .
6. Remove column hole cover
Remove the 5 bolts and column hole cover.
7. Disconnect sliding yoke . See 11 in REMOVAL under STEERING COLUMN.

8. Disconnect lower ball joint from lower suspension arm .
9. Remove the 2 nuts and brace.
10. Remove front sub-frame and lower suspension arm :
a. Using an engine support fixture, support the engine.
b. Remove the 14 bolts, 3 nuts and front sub-frame and lower suspension arm.
Fig. 59: Locating Mounting Bolts & Nuts Sub-Frame/Lower Suspension Arm
11. Remove the bolt and engine rear mount insulator from the engine rear mount bracket.
12. Remove engine rear mount bracket .
l A131L A/T:
Remove the 2 bolts, drive shaft heat insulator set nut and engine rear mount bracket.
l M/T, A245E A/T:
Remove the 3 bolts, drive shaft heat insulator set nut and engine rear mount bracket.
13. Remove Rack Boot Heat Insulator
Remove the bolt, nut and rack boot heat insulator.
14. Disconnect 2 Tube Clamps

Remove the 2 bolts and 2 tube clamps.
15. Disconnect Return Hose
Remove the clip and disconnect the return hose.
16. Using SST, disconnect the pressure feed tube . SST 09023-12700.
Fig. 60: Disconnecting Pressure Feed Tube

17. Remove 2 grommets and brackets :

a. Remove the bolt A.
Fig. 61: Locating Bolt "A"

b. Remove the bolt, nut, bracket and grommet.

c. Employ the same manner described above to the other side.
18. Remove PS gear assembly :
a. Slide the PS gear assembly to the RH side of the vehicle.
Fig. 62: Removing PS Gear Assembly

NOTE: Do not damage the turn pressure tubes.
b. Slide the PS gear assembly to the LH side and pull it out.
DISASSEMBLY
1. SECURE PS GEAR ASSEMBLY IN VISE
Using SST, secure the PS gear assembly in a vise. SST 09612-00012.

Fig. 63: Securing PS Gear In Vise

2. Remove 2 turn pressure tubes :

a. Using SST, remove the 2 turn pressure tubes. SST 09023-38200.
Fig. 64: Identifying Pressure Tube Union Nuts

b. Remove the 4 O-rings from the 2 turn pressure tubes.

3. Remove RH and LH tie rod ends and lock nuts :
a. Place matchmarks on the tie rod end and rack end.
Fig. 65: Matchmarking Tie Rod & Rack End

b. Loosen the lock nut, and remove the tie rod end and lock nut.
4. Remove RH And LH Clips, Rack Boots And Clamps
CAUTION: Be careful not to damage the boot.

Fig. 66: Removing Clamps

a. Using pliers, loosen the clamp.
NOTE: Mark the RH and LH rack boots.
b. Remove the clip and boot.

5. Remove RH And LH Rack Ends And Claw Washers
CAUTION: Avoid any impact on the steering rack.

Fig. 67: Unstaking Washer

a. Using a chisel and hammer, unstake the washer.
NOTE: l Use SST 09922-10010 in the direction shown in the

illustration.
l Mark the RH and LH rack ends.
Fig. 68: Remove Rack End & Claw Washer

b. Using SST, remove the rack end and claw washer. SST 09922-10010.
NOTE: Use SST 09922-10010 in the direction shown in the illustration.

Fig. 69: Removing Rack Guide Spring Cap Lock Nut

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 :
a. Using a hexagon wrench (19 mm), remove the rack guide spring cap.
b. Remove the rack guide spring, conical spring washer, rack guide subassembly.
8. Remove rack housing cap .
Fig. 70: Removing Control Valve Shaft Self-Locking Nut

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 :
a. Place matchmarks on the control valve housing and rack housing.
Fig. 71: Matchmarking Control Valve & Rack Housing

b. Remove the 2 bolts and control valve housing with the control valve assembly.
c. Remove the gasket from the control valve housing.
11. Remove control valve assembly and oil seal :
a. 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.

Fig. 72: Removing Control Valve Assembly

b. Using a plastic hammer, tap out the control valve assembly with the oil seal from the control
valve housing.
c. Remove the oil seal from the control valve assembly.
Fig. 73: Removing Oil Seal From Control Valve

12. Remove cylinder end stopper :

a. Using SST, turn the cylinder end stopper clockwise until the wire end is visible through the
service hole. SST 09631-10021
b. 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.

Fig. 74: Remove Steering Rack Bushing

a. Using SST, press out the steering rack with the bushing. SST 09612-24014 (09612-10061).
b. Remove the O-ring from the bushing.
CAUTION: Do not damage the rack housing.

Fig. 75: Remove Steering Rack Oil Seal

14. Using SST, press out the oil seal . SST 09950-60010 (09951-00260), 09950-70010 (09951-07360).
INSPECTION
INSPECT STEERING RACK
a. Using a dial indicator, check the steering rack for runout and for teeth wear and damage. Maximum
runout: 0.30 mm (0.0118 in.)
Fig. 76: Measuring Steering Rack Runout

b. Check the back surface for wear and damage.
REPLACEMENT
1. If necessary, replace oil seal and bearing :

a. Using SST, press out the oil seal and bearing from the control valve housing. SST 09950-60010
(09951-00260), 09950-70010 (09951-07100).
Fig. 77: Identifying Control Valve Housing Oil Seal & Main Bearing
NOTE: Make sure to install the oil seal facing in the correct direction.
Fig. 78: Installing Control Valve Housing Oil Seal

c. Using SST, press in the oil seal. SST 09950-60010 (09951-00180, 09951-00320, 09952-06010),
09950-70010 (09951-07100).
d. Coat a new bearing with molybdenum disulfide lithium base grease.
e. Using SST, press in the bearing. SST 09950-60010 (09951-00190, 09951-00360, 09952-
06010), 09950-70010 (09951-07100).
Fig. 79: Installing Control Valve Housing Main Bearing

2. If necessary, replace 2 bearings :

a. Using SST, press out the bearing from the steering rack housing. SST 09950-70010 (09951-
07100).
Fig. 80: Removing Control Valve Housing Side Bearing (1 Of 2)

b. Using SST, press out the bearing from the steering rack housing. SST 09950-70010 (09951-
07100).
Fig. 81: Removing Control Valve Housing Side Bearing (2 Of 2)

c. Coat a new bearing with molybdenum disulfide lithium base grease.

d. Using SST, press in the bearing. SST 09950-60010 (09951-00220, 09951-00280, 09952-
06010), 09950-70010 (09951-07100).
Fig. 82: Installing Control Valve Housing Side Bearing (1 Of 2)

e. Coat a new bearing with molybdenum disulfide lithium base grease.

f. Using SST, press in the bearing. SST 09950-60010 (09951-00280), 09950-70010 (09951-
07100).
Fig. 83: Installing Control Valve Housing Side Bearing (2 Of 2)

3. If necessary, replace oil seal :
CAUTION: Be careful not to damage the bushing.
NOTE: As shown in the illustration, from the opposite side of SST

confirm that its claws are firmly caught on the oil seal.
Fig. 84: Removing Oil Seal From Bushing

a. Using SST, remove the oil seal from the bushing. SST 09612-24014 (09613-22011).
CAUTION: Make sure to install the oil seal facing in the correct
direction.
Fig. 85: Installing Oil Seal To Bushing

c. Using SST, press in the oil seal. SST 09950-60010 (09951-00230, 09951-00370, 09952-06010),
09950-70010 (09951-07100).
4. If necessary, replace teflon ring :
CAUTION: Be careful not to damage the groove for the teflon ring.
Fig. 86: Removing "O" Ring From Teflon Ring

a. Using a screwdriver, remove the teflon ring from the steering rack.
CAUTION: Be careful not to overexpand the teflon ring.

Fig. 87: Preparing Teflon Ring For Installation

b. Expand a new teflon ring with your fingers.

c. Coat the teflon ring with power steering fluid.
Fig. 88: Installing & Settling Teflon Ring

d. Install the teflon ring to the steering rack and settle it down with your fingers.
CAUTION: Be careful not to damage the teflon ring.

Fig. 89: Installing Teflon Ring On Steering Rack

e. Carefully slide the tapered end of SST over the teflon ring until it fits to the steering rack. SST
09630-24014 (09631-24031).
5. If necessary, replace 4 teflon rings :
a. Using a screwdriver, remove the 4 teflon rings from the control valve assembly.
Fig. 90: Removing Teflon Rings

NOTE: Be careful not to damage the grooves for the teflon ring.
NOTE: Be careful not to overexpand the teflon ring.
b. Expand 4 new teflon rings with your fingers.

c. Coat the teflon rings with power steering fluid.
d. Install the teflon rings to the control valve assembly, and settle them down with your fingers.
e. Carefully slide the tapered end of SST over the teflon rings until them fit to the control valve
assembly. SST 09631-20081
Fig. 91: Identifying SST 09631-20081 & Locating Teflon Rings

NOTE: Be careful not to damage the teflon rings.
REASSEMBLY
1. Coat parts indicated by arrows with power steering fluid or molybdenum disulfide lithium base
grease .
2. Install oil seal :
a. Coat a new oil seal lip with power steering fluid.
direction.
Fig. 92: Pressing Oil Seal

b. 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
Fig. 93: inspecting steering rack teeth & Installing SST 09631-16020
a. Install SST to the steering rack. SST 09631-16020

b. Coat SST with power steering fluid.
c. Install the rack into the rack housing.
d. Remove the SST.

4. Install Bushing
a. Coat a new O-ring with power steering fluid and install it to the bushing.
b. To prevent oil seal lip damage, wind vinyl tape on the steering rack end, and apply power
steering fluid.
Fig. 94: Identifying Bushing Installation Direction

CAUTION: l Make sure to install the bushing facing in the correct

direction.
l Be careful not to damage the oil seal lip.
Fig. 95: Installing Bushing Into Rack Housing

c. Install the bushing into the rack housing.

5. Install cylinder end stopper :
a. Align the installation hole for the wire of the cylinder end stopper with the slot of the rack
housing.
b. Install a new wire into the cylinder end stopper.
c. Using SST, turn the cylinder end stopper clockwise 150 ° 50°. SST 09631-10021.
6. Air Tightness Test
a. Install SST to the rack housing. SST 09631-12071.
Fig. 96: Testing Air Tightness Of Rack Housing

b. Apply 53 kPa (400 mmHg, 15.75 in.Hg) of vacuum for about 30 seconds.
c. 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 :

a. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft.
Fig. 97: Installing Control Valve Assembly

b. Coat the teflon rings with power steering fluid.
CAUTION: Be careful not to damage the teflon rings and oil seal.
c. Install the control valve assembly into the control valve housing.
8. Install Oil Seal
a. Coat a new oil seal lip with power steering fluid.
direction.
Fig. 98: Installing Control Valve Oil Seal

b. Using SST, press in the oil seal. SST 09612-22011.

9. Install control valve housing with control valve assembly :
a. Place a new gasket on the rack housing.
b. Align the matchmarks on the control valve housing and rack housing.
Fig. 99: Aligning Control Valve & Rack Housing Matchmarks

c. 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.
Fig. 100: Installing Self-Locking Nut

11. Install Rack Housing Cap

a. Apply sealant to 2 or 3 threads of the rack housing cap.
Sealant : Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent.
b. Install the rack housing cap. Torque: 59 N.m (600 kgf.cm, 43 ft.lbf)
c. Using a punch and hammer, stake the 2 parts of the rack housing cap.
Fig. 101: Staking Rack Housing Cap

12. Install Rack Guide Subassembly, Conical Spring Washer, Rack Guide Spring And Rack Guide
Spring Cap
a. Install the rack guide subassembly, conical spring washer and rack guide spring.
b. 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.
c. Temporarily install the rack guide spring cap.
13. Adjust Total Preload
a. To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the RH and
LH rack ends.
b. Using a hexagon wrench (19 mm), install the rack guide spring cap.
Fig. 102: Adjusting Preload (1 Of 3)

Torque: 25 N.m (250 kgf.cm, 18 ft.lbf)

c. Using a hexagon wrench (19 mm), return the cap 12°.

d. Using SST, turn the control valve shaft right and left 1 or 2 times.
SST 09616-00011
e. Using a hexagon wrench (19 mm), loosen the rack guide spring cap until the rack guide spring
is not functioning.
f. 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

a. 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
b. Temporarily install the lock nut.
c. 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.
Fig. 105: Installing Rack Guide Spring Cap Lock Nut

HINT: Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).
d. Recheck the total preload. Preload (turning) : 0.8 - 1.4 N.m (8 - 14 kgf.cm, 6.9 - 12.2 in..lbf).
e. 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.
Fig. 106: Installing Claw Washers & Rack Ends

a. Install a new claw washer, and temporarily install the rack end.

Use a torque wrench with a fulcrum length of 380 mm (14.96 in.).
Fig. 107: Installing Rack End

b. 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.

Fig. 108: Staking Claw Washer

c. Using a brass bar and a hammer, stake the washer.

d. 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.
Fig. 109: Locating Steering Rack Hole

a. Make sure that the steering rack hole is not clogged with grease.
CAUTION: Be careful not to damage or twist the boots.
b. Install the boot clip and a new clamp.

c. Using SST, tighten the clamp as shown in the illustration. SST 09521-24010.
Fig. 110: Tightening Boot Clamps

d. Employ the same manner described above to the other side.

17. Install RH and LH tie rod ends and lock nuts :
a. Screw the lock nut and tie rod end onto the rack end until the matchmarks are aligned.
Fig. 111: Aligning Tie Rod End & Rack End Matchmarks
b. After adjusting toe-in, See SPECIFICATIONS & PROCEDURES in ALIGNMENT under

STEERING. Torque the nut. Torque: 56 N.m (570 kgf.cm, 41 ft.lbf)
18. Install 2 turn pressure tubes :
a. Coat 4 new O-rings with power steering fluid and install them to the 2 turn pressure tubes.
NOTE: l Use a torque wrench with a fulcrum length of 250 mm (9.84

in.).
l This torque value is effective in case that SST is parallel to a
torque wrench.
Fig. 112: Installing Pressure Tubes

b. Using SST, install the 2 tubes. Torque: 11 N.m (112 kgf.cm, 8 ft.lbf) . SST 09023-38200.
INSTALLATION
CAUTION: Do not damage the turn pressure tubes.

Fig. 113: Installing PS Gear Assembly

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
a. Install the grommet and bracket with the bolt and nut. Torque: 71 N.m (720 kgf.cm, 52 ft.lbf) .
b. Employ the same manner described above to the other side.
c. Install the bolt A. Torque: 5.4 N.m (55 kgf.cm, 48 in..lbf) .
Fig. 114: Locating Bolt "A"

NOTE: l Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).
Fig. 115: Identifying Fulcrum Length & Usage Angle

l This torque value is effective in case that SST is parallel to a torque

wrench.
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

l 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)
l 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)

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 :
a. Install the front sub-frame and lower suspension arm with the 14 bolts and 3 nuts.
Fig. 116: Locating Bolts & Nuts Sub-Frame/Lower Suspension Arm

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)

b. 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 .
15. Install the RH and LH engine under covers with the 8 bolts and 4 screws .
NOTE: Do it with the front of the vehicle jacked up.
16. Place front wheels facing straight ahead .

17. Center Spiral Cable .
18. Install steering wheel :
a. Align the matchmarks on the steering wheel and steering column main shaft.
b. Temporarily tighten the steering wheel set nut.
c. Connect the connector.
19. Bleed power steering system. . See REPLACEMENT .
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 2e in INSPECTION under STEERING WHEEL.
23. Check front wheel alignment . See SPECIFICATIONS & PROCEDURES in WHEEL
ALIGNMENT article..

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2002 STEERING Power Steering System - Corolla

Power Steering System - Corolla

Fig. 1: Troubleshooting Problem Symptoms Table

Inspect Drive Belt

Fig. 2: Identifying Belt Defects

Fig. 3: Inspecting Belt Installation

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

If any defect has been found, replace the drive belt.

POWER STEERING FLUID

1. Check fluid level. See INSPECTION .

Run the engine at idle for a few minutes.

6. Turn steering wheel :

9. Check fluid level . See INSPECTION .

Fig. 4: Inspecting Brake Fluid For Air Bubbles

1. Check fluid level :

If necessary, add fluid. Fluid: ATF DEXRON(R)II or III .

c. Start the engine and run it at idle.

Fig. 5: Identifying Brake Fluid Reservoir Fluid Level Marks

e. Check for foaming or emulsification.

If there is foaming or emulsification, bleed power steering system. See REPLACEMENT .

Fig. 6: Inspecting Brake Fluid For Air Bubbles

If a problem is found, bleed power steering system. See REPLACEMENT .

i. Check the fluid level.

Fig. 7: Measuring Brake Fluid Level Fluctuation

2. Check steering fluid pressure :

Fig. 8: Installing Brake Fluid Pressure Gauge

Fig. 9: Diagramming Brake Fluid Pressure Test With Valve Closed

NOTE: Do not turn the steering wheel.

NOTE: l Do not maintain lock position for more than 10 seconds.

1. Check steering wheel freeplay :

Fig. 12: Inspecting Steering Wheel Free Play

2. Check steering effort :

Fig. 13: Installing Steering Wheel Set Nut

ACC, DTCs will be recorded.

1. Remove steering wheel pad :

Fig. 18: Locating Steering Pad Torx Screws

Fig. 20: Matchmarking Steering Wheel & Main Shaft

6. Remove column upper and lower covers :

c. Remove the 3 screws and combination switch with spiral cable.

NOTE: Do not disassemble the cable or apply oil to it.

8. Remove spiral cable .

Fig. 21: Matchmarking Sliding Yoke & Control Valve Shaft

b. Loosen the bolt A and remove the bolt B.

NOTE: When using a vise, do not overtighten it.

Fig. 22: Removing Tapered-Head Bolts

1. Inspect steering lock operation :

Check that the steering lock mechanism operates properly.

Fig. 23: Inspecting Steering Lock Operation

2. If necessary, replace key cylinder :

HINT: Make sure the key is at the ACC position.

3. Inspect ignition switch .

b. Install a new key interlock solenoid with the 2 screws.

Fig. 24: Replacing Key Interlock Solenoid

NOTE: When using a vise, do not overtighten it.

1. Install column upper bracket and column upper clamp :

Fig. 25: Locating Tapered-Head Bolts

1. Temporarily install the sliding yoke and bolt A .

b. Install the bolt B. Torque: 35 N.m (360 kgf.cm, 26 ft.lbf) .

5. Install the No. 2 heater to register duct with the clip .

Fig. 27: Locating Spiral Cable Matchmarks