POWER STEERING SYSTEM

POWER STEERING SYSTEM
51–1
POWER STEERING
–
POWER STEERING SYSTEM
POWER STEERING SYSTEM
510GU–01
PRECAUTION
1.
HANDLING PRECAUTIONS FOR SRS AIRBAG SYSTEM (SEE PAGE 60–1)
NOTICE:
Some service operations affect the SRS airbag. Be sure to read the precautionary notice for the SRS
airbag before servicing.
2.
PRECAUTIONS FOR REMOVAL, INSTALLATION AND REPLACEMENT OF ELECTRONIC MOTOR POWER STEERING COMPONENTS
(a) Be sure to align the front wheels straight ahead when removing and installing the steering gear assy.
(b) When disconnecting the sliding yoke of the steering column and the pinion shaft of the steering gear
assy, be sure to put matchmarks before starting the operation.
(c) When any component related to the steering system has been removed and either reinstalled or replaced, perform steering center point adjustment (zero point calibration) (see page 05–1211).
(d) When disconnecting the connector related to the electronic motor power steering system, turn the
power switch on (IG) (the engine and the hybrid system are stopped), center the steering wheel, turn
the power switch off, and then disconnect the connector.
(e) When reconnecting the connector related to the electronic motor power steering system, ensure that
the power switch is off. Center the steering wheel and then turn the power switch on (IG) (the engine
and the hybrid system are stopped).
NOTICE:
Do not turn the power switch on (IG) (the engine and the hybrid system are stopped) when the steering wheel is not centered.
(f)
If procedures (d) and (e) are not carried out properly, the steering center point (zero point) will deviate,
which may lead to a difference in steering effort between right and left. If there is a difference in steering
effort between right and left, perform steering center point adjustment (zero point calibration)
(see page 05–1211).
NOTICE FOR INITIALIZATION:
When disconnecting the negative (–) battery terminal, initialize the following systems after the terminal is reconnected.
System Name
See Page
Power Window Control System
01–28
NOTICES FOR HYBRID SYSTEM ACTIVATION:
When the warning lamp is illuminated or the battery has been disconnected and reconnected,
pressing the power switch may not start the system on the first try. If so, press the power switch
again.
With the power switch’s power mode changed to ON (IG), disconnect the battery. If the key is
not in the key slot during reconnection, DTC B2799 may be output.
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51–2
POWER STEERING
–
POWER STEERING SYSTEM
510GV–01
SYSTEM DESCRIPTION
A rack and pinion type steering gear is used on all models.
The Prius uses a vehicle–speed sensing type EPS (Electric Power Steering) as standard equipment
on all models.
COMPONENTS:
Power Steering ECU Assy
Steering Wheel Assy
Power Steering Motor Assy
Steering Column Assy
Steering Gear Assy
POWER STEERING
TORQUE FLOWCHART:
ECU
Motor
Steering
Gear
Steering
Column
Steering
Wheel
G30700
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51–3
POWER STEERING
–
POWER STEERING SYSTEM
510GW–01
PROBLEM SYMPTOMS TABLE
Symptom
Inspection Area
See page
Steering is heavy.
Front tires (improperly inflated, unevenly worn)
Front wheel alignment (Incorrect)
Front suspension (Lower ball joint)
Steering gear assy
Torque sensor (built into steering column)
Steering column assy
Power steering motor
Battery and power source system
Power steering ECU
Steering effort differs between right and left or is uneven.
Steering center point (zero point) (not recorded completely)
Front tires (improperly inflated, unevenly worn)
Front wheel alignment (Incorrect)
Front suspension (Lower ball joint)
Steering gear assy
Torque sensor (built into steering column)
Steering column assy
Power steering motor
Power steering ECU
While driving, steering effort does not change in accordance with
vehicle speed or steering wheel does not return properly.
Front suspension
Speed sensor
Skid control ECU
Combination meter
Engine speed detection circuit
Torque sensor (built into steering column)
Power steering motor
Power steering ECU
28–1
26–6
26–22
51–6
50–8
50–8
50–8
50–16
05–1211
28–1
26–6
26–22
51–6
50–8
50–8
50–8
50–16
26–6
32–68
50–8
50–8
50–16
Front suspension
Steering intermediate shaft
Steering gear assy
26–6
Friction sound occurs when turning steering wheel during low
speed driving.
Power steering motor
Steering column assy
50–8
50–8
High–pitched sound (squeaking) occurs when turning steering
wheel slowly with vehicle stopped.
Power steering motor
50–8
Steering wheel vibrates and noise occurs when turning steering
wheel from lock to lock.
Power steering motor
Steering column assy
50–8
50–8
Knocking (or clunking) sound occurs when turning steering wheel
back and forth while power steering is in operation.
50–8
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51–4
POWER STEERING
–
POWER STEERING SYSTEM
510GX–01
ON–VEHICLE INSPECTION
1.
CHECK STEERING EFFORT (TORQUE)
NOTICE:
Some service operations affect the SRS airbag. Be sure to
read the precautionary notice for the SRS airbag before
servicing.
(a) Stop the vehicle on a level, paved road and align the
wheels straight ahead.
(b) Disconnect the negative (–) battery terminal
(see page 60–1).
(c) Remove the horn button assy (see page 60–20).
(d) Connect the negative (–) battery terminal.
(e) Using a torque wrench, check if the steering wheel set nut
is properly tightened.
Torque: 50 N·m (510 kgf·cm, 37 ft·lbf)
(f)
Turn the power switch on (IG) (the engine and the hybrid
system are stopped) so that power steering is ready to operate.
(g)
(h)
(i)
Turn the steering wheel 90 degrees to the right and check
steering effort (torque) while turning. Check in the opposite direction using the same manner.
Steering effort (Reference):
5.5 N·m (56 kgf·cm, 49 in.·lbf)
Align the front wheels straight ahead.
Disconnect the negative (–) battery terminal
(see page 60–1).
Install the horn button assy (see page 60–20).
Connect the negative (–) battery terminal.
Clear the DTCs (see page 05–1402).
Perform initialization (see page 01–28).
Inspect the airbag warning light (see page 05–1397).
(j)
(k)
(l)
(m)
(n)
2.
CHECK STEERING WHEEL FREEPLAY
(a) Turn the power switch on (IG) so that power steering is ready to operate.
(b) Align the wheels straight ahead.
(c) Gently turn the steering wheel right and left with your finger and check steering wheel freeplay.
Maximum freeplay: 30 mm (1.18 in.)
If the freeplay is out of specifications, replace the sliding yoke sub–assy or the steering gear assy with a new
one.
G29440
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51–5
POWER STEERING
–
STEERING GEAR ASSY
STEERING GEAR ASSY
510GY–01
COMPONENTS
Steering Sliding Yoke Sub–assy
Tie Rod End
Sub–assy RH
Column Hole Cover
Silencer Sheet
Steering Intermediate Shaft
Clip
Clip
Steering Rack
Boot Clip
Steering Rack
Boot No.1
Steering Column Hole
Cover Sub–assy No.1
58 (591, 43)
35 (360, 26)
Steering Rack
End Sub–assy
Steering Rack
End Sub–assy
83 (846, 61)
*60 (612, 44)
49 (500, 36)
Steering Rack Boot
No.2 Clamp
74 (749, 54)
Steering Rack Boot
No.1 Clamp
Steering Rack
Boot Clip
83 (846, 61)
*60 (612, 44)
Clip
19 (194, 14)
49 (500, 36)
19 (194, 14)
Front Stabilizer
Bracket No.1 RH
Steering Rack
Boot No.2
74 (749, 54)
Front Stabilizer
Link Assy RH
Tie Rod End
Sub–assy LH
74 (755, 55)
74 (755, 55)
Front Stabilizer
Bar Bush No.1
Front Stabilizer
Bracket No.1 LH
74 (755, 55)
Front Stabilizer
Link Assy LH
74 (755, 55)
Front Stabilizer Bar
* For use with SST
Non–reusable part
N⋅m (kgf⋅cm, ft⋅lbf)
: Specified torque
Molybdenum disulfide lithium base grease
Silicon grease
G29820
2004 Prius – Preliminary Release (RM1075U)
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Date:
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51–6
POWER STEERING
–
STEERING GEAR ASSY
510GZ–01
OVERHAUL
1.
2.
PLACE FRONT WHEELS FACING STRAIGHT AHEAD
REMOVE COLUMN HOLE COVER SILENCER SHEET (SEE PAGE 50–8)
3.
(a)
SEPARATE STEERING SLIDING YOKE SUB–ASSY
Fix the steering wheel assy with the seat belt in order to
prevent rotation and damage to the spiral cable.
(b)
Put matchmarks on the sliding yoke sub–assy and the intermediate shaft.
Loosen bolt A and remove bolt B to separate the sliding
yoke sub–assy.
G29446
(c)
Matchmarks
Bolt A
Bolt B
G29896
4.
Clip A
Clip B
SEPARATE STEERING COLUMN HOLE COVER
SUB–ASSY NO.1
(a) Remove clip A and separate the column hole cover No.1
from the body.
NOTICE:
Do not damage clip B.
G28294
5.
REMOVE FRONT WHEELS
6.
SEPARATE TIE ROD END SUB–ASSY LH (SEE PAGE 30–7)
7.
SEPARATE TIE ROD END SUB–ASSY RH
HINT:
Perform the same procedure as for the LH.
8.
REMOVE FRONT STABILIZER LINK ASSY (SEE PAGE 26–25)
HINT:
Remove both LH and RH.
9.
REMOVE FRONT STABILIZER BRACKET NO.1 LH (SEE PAGE 26–25)
10. REMOVE FRONT STABILIZER BRACKET NO.1 RH
HINT:
Perform the same procedure as for the LH.
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51–7
POWER STEERING
STEERING GEAR ASSY
11.
(a)
Intermediate
Shaft
Matchmarks
G28290
LH:
–
REMOVE STEERING INTERMEDIATE SHAFT
Move the column hole cover No.1 to the upper side of the
vehicle and put matchmarks on the intermediate shaft
and the steering gear assy.
NOTICE:
Do not damage the hole cover No.1 when moving it.
(b) Remove the bolt and remove the intermediate shaft from
the inside of the vehicle.
(c) Remove the column hole cover No.1 from the steering
gear assy.
NOTICE:
Do not damage the hole cover No.1 clip.
12.
(a)
RH:
REMOVE STEERING GEAR ASSY
Remove the 4 bolts and remove the steering gear assy
from the left side of the vehicle.
HINT:
Be careful not to hit the stabilizer bar when removing the steering gear assy.
G28292
13.
(a)
SST
FIX STEERING GEAR ASSY
Using SST wrapped with protection tape, secure the
steering gear assy in a vise.
SST 09612–00012
HINT:
Remove and reinstall the SST as needed.
Vinyl Tape
G28295
14.
(a)
(b)
REMOVE TIE ROD END SUB–ASSY LH
Put matchmarks on the tie rod end sub–assy LH and the
rack end.
Remove the tie rod end sub–assy LH and the lock nut.
Matchmarks
F40050
15. REMOVE TIE ROD END SUB–ASSY RH
HINT:
Perform the same procedure as for the LH.
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POWER STEERING
–
STEERING GEAR ASSY
16.
(a)
INSPECT TIE ROD END SUB–ASSY LH
Secure the tie rod end sub–assy LH boll joint in a vise
through aluminum plates.
NOTICE:
Do not overtighten the vise.
(b) Install the castle nut to the stud bolt.
(c) Flip the ball joint back and forth 5 times or more.
(d) Set a torque wrench to the nut, turn the ball joint continuously at a rate of 3 to 5 seconds per turn, and check the
ZK8184
turning torque on the 5th turn.
Turning torque:
2.0 N⋅m (20.4 kgf⋅cm, 18 in. lbf) or less
If turning torque is out of specifications, replace the tie rod end
sub–assy LH with a new one.
INSPECT TIE ROD END SUB–ASSY RH
17.
HINT:
Perform the same procedure as for the LH.
18. REMOVE STEERING RACK BOOT CLIP
(a) Using pliers, remove the 2 rack boot clips (RH and LH).
19.
(a)
REMOVE STEERING RACK BOOT NO.2 CLAMP
Using a screwdriver, unstake and remove the rack boot
clamp No.2.
NOTICE:
Do not damage the rack boot No.2.
G29447
20. REMOVE STEERING RACK BOOT NO.1 CLAMP
HINT:
Perform the same procedure as for the rack boot clamp No.2.
21. REMOVE STEERING RACK BOOT NO.2
22. REMOVE STEERING RACK BOOT NO.1
23. REMOVE STEERING RACK END SUB–ASSY
LH:
SST
(a) Using 2 SST, remove the rack end sub–assy (LH side).
SST 09922–10010
NOTICE:
Use the SST in the correct direction as shown in the
illustration.
Securely hold the steering rack.
SST
G28298
2004 Prius – Preliminary Release (RM1075U)
Author:
Date:
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51–9
POWER STEERING
–
STEERING GEAR ASSY
(b)
Using 2 SST, hold the steering rack LH side and remove
the rack end sub–assy (RH side).
SST 09922–10010
NOTICE:
Use the SST in the correct direction as shown in the
illustration.
Securely hold the steering rack.
RH:
SST
SST
G28299
24.
(a)
SST
G28296
INSPECT TOTAL PRELOAD
Using SST, inspect total preload.
SST 09616–00011
Preload (turning):
0.6 to 1.2 N⋅m (6.1 to 12.2 kgf⋅cm, 5 to 11 in.⋅lbf)
NOTICE:
Inspect around the steering rack center position.
If total preload is out of specifications, replace the steering gear
assy with a new one.
25.
(a)
INSTALL STEERING RACK END SUB–ASSY
Fill up the ball joints of the RH and LH rack ends with molybdenum disulfide lithium base grease.
G29137
RH:
(b)
SST
Fulcrum
Length
SST
G28300
Using 2 SST, hold the steering rack LH side and install the
rack end sub–assy (RH side).
SST 09922–10010
Torque: 60 N⋅m (612 kgf⋅cm, 44 ft⋅lbf)
NOTICE:
Use a torque wrench with a fulcrum length of 345 mm
(13.58 in.).
Use the SST in the correct direction as shown in the
illustration.
Securely hold the steering rack.
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POWER STEERING
–
STEERING GEAR ASSY
(c)
LH:
SST
Fulcrum
Length
G28302
Using 2 SST, install the rack end sub–assy (LH side).
SST 09922–10010
Torque: 60 N⋅m (612 kgf⋅cm, 44 ft⋅lbf)
NOTICE:
Use a torque wrench with a fulcrum length of 345 mm
(13.58 in.).
Use the SST in the correct direction as shown in the
illustration.
Securely hold the steering rack.
26.
(a)
INSTALL STEERING RACK BOOT NO.2
Apply silicon grease to the inside of the small opening of
the rack boot No.2.
(b) Install the rack boot No.2 in the groove on the rack housing.
NOTICE:
Make sure that the rack boot No.2 is not twisted.
C57755
27. INSTALL STEERING RACK BOOT NO.1
HINT:
Perform the same procedure as for the rack boot No.2.
28. INSTALL STEERING RACK BOOT NO.2 CLAMP
(a) Install a new rack boot clamp No.2 to the rack boot No.2.
NOTICE:
Do not damage the rack boot No.2.
(b) While pushing SST to the rack housing, pinch the rack
boot clamp No.2 so that clearance is within specifications.
SST 09521–24010
Clearance: 3.0 mm (0.12 in.) or less
3.0 mm (0.12 in.) or less
NOTICE:
F40084
Make sure that the rack boot No.2 is not twisted.
29. INSTALL STEERING RACK BOOT NO.1 CLAMP
SST 09521–24010
HINT:
Perform the same procedure as for the rack boot clamp No.2.
30. INSTALL STEERING RACK BOOT CLIP
(a) Using pliers, install the 2 rack boot clips to the RH and LH rack boots.
SST
2004 Prius – Preliminary Release (RM1075U)
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Date:
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POWER STEERING
–
STEERING GEAR ASSY
31.
(a)
INSPECT STEERING GEAR ASSY
Using SST, turn the pinion shaft and check that the RH
and LH rack boots expand and contract smoothly.
SST 09616–00011
If the rack boot does not expand and contract smoothly, reinstall
it with a new rack boot clamp.
SST
G28297
32.
(a)
INSTALL TIE ROD END SUB–ASSY LH
Screw the lock nut and the tie rod end sub–assy LH on the
rack end sub–assy until the matchmarks are aligned and
temporarily tighten the lock nut.
HINT:
Fully tighten the lock nut after adjusting toe–in.
Matchmarks
F40050
33. INSTALL TIE ROD END SUB–ASSY RH
HINT:
Perform the same procedure as for the LH.
LH:
34.
(a)
RH:
G28292
INSTALL STEERING GEAR ASSY
Install the steering gear assy from the left side of the vehicle.
HINT:
Be careful not to hit the stabilizer bar when installing the steering gear assy.
(b) Install the column hole cover No.1 to the steering gear
assy.
(c) Install the steering gear assy to the crossmember with the
4 bolts.
Torque: 58 N⋅m (591 kgf⋅cm, 43 ft⋅lbf)
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POWER STEERING
–
STEERING GEAR ASSY
35.
(a)
INSTALL STEERING INTERMEDIATE SHAFT
Move the column hole cover No.1 to the upper side of the
vehicle, align the matchmarks, and install the intermediate shaft from the inside of the vehicle.
NOTICE:
Do not damage the hole cover No.1 when moving it.
(b) Install the bolt.
Torque: 35 N⋅m (360 kgf⋅cm, 26 ft⋅lbf)
Matchmarks
(c) Fit the recessed part on the column hole cover No.1 to the
G28290
steering gear assy.
NOTICE:
Make sure that the hole cover No.1 is securely installed.
36. INSTALL FRONT STABILIZER BRACKET NO.1 LH (SEE PAGE 26–25)
37. INSTALL FRONT STABILIZER BRACKET NO.1 RH
HINT:
Perform the same procedure as for the LH.
38. INSTALL FRONT STABILIZER LINK ASSY (SEE PAGE 26–25)
39. INSTALL TIE ROD END SUB–ASSY LH (SEE PAGE 30–7)
40. INSTALL TIE ROD END SUB–ASSY RH
HINT:
Perform the same procedure as for the LH.
41. INSTALL FRONT WHEELS
Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf)
Intermediate
Shaft
42.
Clip A
Clip B
INSTALL STEERING COLUMN HOLE COVER
SUB–ASSY NO.1
(a) Install clip B to the vehicle body and install the column
hole cover No.1 to the vehicle body with clip A.
NOTICE:
Make sure that the hole cover No.1 lip fits on the dash panel
correctly.
G28294
43.
(a)
Matchmarks
Bolt A
(b)
INSTALL STEERING SLIDING YOKE SUB–ASSY
Align the matchmarks and install the sliding yoke sub–
assy to the intermediate shaft with bolt B.
Torque: 35 N⋅m (360 kgf⋅cm, 26 ft⋅lbf)
Tighten bolt A.
Torque: 35 N⋅m (360 kgf⋅cm, 26 ft⋅lbf)
Bolt B
G29896
44.
45.
46.
47.
INSTALL COLUMN HOLE COVER SILENCER SHEET (SEE PAGE 50–8)
PLACE FRONT WHEELS FACING STRAIGHT AHEAD
INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (SEE PAGE 26–6)
PERFORM STEERING ANGLE SENSOR ZERO POINT CALIBRATION (SEE PAGE 05–1211)
2004 Prius – Preliminary Release (RM1075U)
Author:
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