Operation CHARM: Car repair manuals for everyone.
Home >> Toyota >> 2007 >> Yaris L4-1.5L (1NZ-FE) >> Repair and Diagnosis >> Steering and Suspension >> Steering >> Steering Column >> Service and Repair >> For Sedan

For Sedan

STEERING COLUMN ASSEMBLY (for Sedan)

COMPONENTS (Part 1):




COMPONENTS (Part 2):




COMPONENTS (Part 3):




COMPONENTS (Part 4):




COMPONENTS (Part 5):





COMPONENTS (Part 6):




COMPONENTS (Part 7):





REMOVAL

CAUTION: Some of these service operations affect the SRS airbag system. Read the precautionary notices concerning the SRS airbag system before servicing.

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
3. REMOVE STEERING PAD





4. REMOVE STEERING WHEEL ASSEMBLY
(a) Remove the nut and place matchmarks on the steering wheel assembly and steering column assembly.





(b) Using SST, remove the steering wheel assembly.

NOTICE: Apply a small amount of grease to the threads and tip of the SST center bolt before using.





5. REMOVE STEERING COLUMN COVER
(a) Remove the 3 screws, disengage the 2 claws, release the tilt lever and remove the steering column lower cover.





(b) Disengage the claw and remove the steering column upper cover.
6. REMOVE COMBINATION SWITCH ASSEMBLY
(a) Disconnect all connectors from the turn signal switch with spiral cable.





(b) Disengage the clamp indicated by the arrow in the illustration and remove the combination switch assembly from the steering column assembly.
7. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER CENTER
8. REMOVE INSTRUMENT PANEL FINISH PANEL END LH
9. REMOVE INSTRUMENT PANEL FINISH PANEL END RH
10. REMOVE INSTRUMENT CLUSTER FINISH PANEL
11. REMOVE COMBINATION METER ASSEMBLY
12. SEPARATE FRONT DOOR OPENING TRIM WEATHERSTRIP RH
13. SEPARATE FRONT DOOR OPENING TRIM WEATHERSTRIP LH
14. REMOVE FRONT PILLAR GARNISH RH
15. REMOVE FRONT PILLAR GARNISH LH
16. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY
17. REMOVE UPPER INSTRUMENT PANEL SUB-ASSEMBLY





18. DISCONNECT POWER STEERING ECU
(a) Detach the power steering motor harness and torque sensor wire harness clamps from the power steering ECU side.
(b) Disconnect the 2 steering column assembly connectors from the power steering ECU.
19. REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY LH
20. REMOVE INSTRUMENT LOWER PANEL FINISH PANEL SUB-ASSEMBLY





21. REMOVE INSTRUMENT PANEL SUB REINFORCEMENT
(a) Remove the 2 bolts and remove the reinforcement instrument panel sub.





22. REMOVE COLUMN HOLE COVER SILENCER SHEET
(a) Pull back the floor carpet, remove the 2 clips and remove the column hole cover silencer sheet.





23. REMOVE NO.2 STEERING INTERMEDIATE SHAFT ASSEMBLY
(a) Loosen bolt A.
(b) Place matchmarks on the steering intermediate assembly and steering gear assembly.
(c) Remove bolt B and detach the steering intermediate assembly from the steering gear assembly.
(d) Place matchmarks on the steering intermediate assembly and steering column assembly.
(e) Remove bolt C and detach the steering intermediate shaft assembly from the steering column assembly.





24. REMOVE BRAKE PEDAL PAD (for Automatic Transaxle)
(a) Using needle-nose pliers, remove the brake pedal return spring.
(b) Remove the clip from the brake master cylinder push rod clevis pin.
(c) Remove the brake master cylinder push rod clevis pin and detach the push rod clevis from the brake pedal.
(d) Remove the bolt, nut and 2 brake pedal bushes, and remove the brake pedal assembly.
25. REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS (for Manual Transaxle)
26. REMOVE BRAKE PEDAL SUPPORT (for Manual Transaxle)





27. REMOVE STEERING COLUMN ASSEMBLY
(a) Disconnect all connectors and detach all wire harness clamps from the steering column assembly.
(b) Remove the bolt and 2 nuts and remove the steering column assembly from the instrument panel reinforcement assembly.

DISASSEMBLY





1. REMOVE STEERING SLIDING YOKE SUB-ASSEMBLY
(a) Place matchmarks on steering intermediate shaft assembly No. 2 and the steering sliding yoke.
(b) Remove bolt A and remove the steering sliding yoke from steering intermediate shaft No. 2.





2. REMOVE TRANSPONDER KEY AMPLIFIER
(a) Disengage the 2 claws and slide the transponder key amplifier in the direction shown in the illustration, to detach it from the steering column upper with switch bracket assembly.
3. REMOVE STEERING COLUMN UPPER WITH SWITCH BRACKET ASSEMBLY
(a) Fix the steering column assembly in a vise between aluminum plates.

NOTICE: Do not overtighten the vise.

(b) Using a drill, drill a hole in each of the 2 steering lock set bolts, to insert an screw extractor.





(c) Using the screw extractor, remove the 2 steering lock set bolts and remove the steering column upper with switch bracket assembly and steering column clamp upper.
4. REMOVE IGNITION SWITCH LOCK CYLINDER ASSEMBLY
(a) Turn the ignition switch to on (ACC).





(b) Insert the tip of a screwdriver into the hole in the steering column bracket assembly upper, as shown in the illustration, and pull the ignition switch lock cylinder assembly out until its claw comes into contact with the stopper of the steering column bracket assembly upper.

NOTICE: Pull the ignition switch lock cylinder assembly out until its claw comes into contact with the stopper of the steering column bracket assembly upper. Otherwise, the following procedure cannot be conducted properly.





(c) Insert the tip of a screwdriver into the hole in the steering column bracket and tilt it downward, as shown in the illustration, to disengage the claw of the ignition switch lock cylinder. Then pull out the ignition switch lock cylinder.





5. REMOVE UN-LOCK WARNING SWITCH ASSEMBLY
(a) Push up the unlock warning switch assembly center portion to disengage the 2 claws.

HINT: Slide the unlock warning switch assembly, in the direction shown by the arrow in the illustration, to remove it.





6. REMOVE KEY INTER LOCK SOLENOID
(a) for Automatic Transaxle:
(1) Remove the 2 screws and remove the key lock solenoid from the steering column bracket assembly upper.





7. REMOVE IGNITION OR STARTER SWITCH ASSEMBLY
(a) Disengage the 2 claws and remove the ignition (starter) switch assembly from the steering column bracket assembly upper.

REASSEMBLY





1. INSTALL IGNITION OR STARTER SWITCH ASSEMBLY
(a) Engage the 2 claws to install the ignition (starter) switch assembly onto the steering column bracket assembly upper.





2. INSTALL KEY INTER LOCK SOLENOID
(a) for Automatic Transaxle:
(1) Install the key interlock solenoid onto the steering column bracket assembly upper with the 2 screws.





3. INSTALL UN-LOCK WARNING SWITCH ASSEMBLY
(a) Engage the 2 claws to install the un-lock warning switch assembly onto the steering column bracket assembly upper.

HINT: Slide the unlock warning switch assembly, in the direction shown by the arrow in the illustration, to install it.

4. INSTALL IGNITION SWITCH LOCK CYLINDER ASSEMBLY
(a) Turn the ignition switch to on (ACC).





(b) Install the ignition switch lock cylinder assembly into the steering column bracket assembly upper.
(c) Make sure that the ignition switch lock cylinder assembly is securely fixed onto the ignition switch lock cylinder assembly.





5. INSPECT STEERING LOCK OPERATION
(a) Remove the key and check that the steering lock function is activated.





(b) Insert the key, turn the ignition switch to on (ACC) and check that the steering lock function is inactivated.
6. INSTALL STEERING COLUMN UPPER W/SWITCH BRACKET ASSEMBLY
(a) Fix the steering column assembly in a vise between aluminum plates.

NOTICE: Do not overtighten the vise.





(b) Install the steering column upper with switch bracket assembly and steering column clamp upper with 2 new steering lock set bolts, and then tighten the bolts until their heads come off.





7. INSTALL TRANSPONDER KEY AMPLIFIER
(a) Engage the 2 claws and install the transponder key amplifier onto the steering column upper with the switch bracket.





8. INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY
(a) Align the matchmarks on steering intermediate shaft assembly No. 2 and steering sliding yoke and provisionally install them with the bolt.

INSTALLATION





1. INSTALL STEERING COLUMN ASSEMBLY
(a) Install the steering column assembly onto the instrument panel reinforcement assembly with the bolt and 2 nuts.
Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
(b) Connect all the connectors and clamp the wire harnesses onto the steering column assembly bracket.
2. INSTALL BRAKE PEDAL (for Automatic Transaxle)
(a) Apply MP grease No. 2 to the brake master cylinder push rod clevis pin and installation surfaces.
(b) Install the 2 brake pedal bushes, and install the brake pedal with the nut and brake pedal shaft.
Torque: 37 N*m (375 kgf*cm, 27 ft.*lbf)





(c) Apply lithium soap base glycol grease to the brake master cylinder push rod clevis pin and installation surfaces.
(d) Connect the brake master cylinder push rod clevis to the brake pedal with the brake master cylinder push rod clevis pin, install the clip onto the brake master cylinder push rod clevis pin, and then install the brake pedal return spring.
3. INSTALL BRAKE PEDAL SUPPORT (for Manual Transaxle)
4. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS (for Manual Transaxle)





5. INSTALL NO.2 STEERING INTERMEDIATE SHAFT ASSEMBLY
(a) Connect all the connectors and clamp the wire harnesses onto the steering column assembly bracket.
(b) Align the matchmarks on steering intermediate shaft assembly No. 2 and the steering sliding yoke and provisionally install them with bolt C.
Torque: 28 N*m (290 kgf*cm, 21 ft.*lbf)
(c) Align the matchmarks on the steering sliding yoke and steering gear assembly and install them with bolt B.
Torque: 28 N*m (290 kgf*cm, 21 ft.*lbf)
(d) Tighten bolt A.
Torque: 28 N*m (290 kgf*cm, 21 ft.*lbf)





6. INSTALL COLUMN HOLE COVER SILENCER SHEET
(a) Install the column hole cover plate with the 2 clips.
(b) Install the floor carpet.





7. INSTALL INSTRUMENT PANEL SUB REINFORCEMENT
(a) Align the 2 claws and install the reinforcement instrument panel sub with the 2 bolts.
8. INSTALL INSTRUMENT LOWER PANEL FINISH PANEL SUB-ASSEMBLY
9. INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY LH





10. INSTALL POWER STEERING ECU
(a) Connect the 2 steering column assembly connectors to the power steering ECU.
(b) Install the power steering motor harness and torque sensor wire harness clamps onto the side of the power steering ECU.
(c) Tilt the steering column assembly up and down to make sure that the power steering motor harness and torque sensor wire harness do not interfere with any components.
11. INSTALL UPPER INSTRUMENT PANEL SUB-ASSEMBLY
12. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY
13. INSTALL FRONT PILLAR GARNISH RH
14. INSTALL FRONT PILLAR GARNISH LH
15. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH
16. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH
17. INSTALL COMBINATION METER ASSEMBLY
18. INSTALL INSTRUMENT CLUSTER FINISH PANEL
19. INSTALL INSTRUMENT PANEL FINISH PANEL END RH
20. INSTALL INSTRUMENT PANEL FINISH PANEL END LH
21. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER CENTER





22. INSTALL COMBINATION SWITCH ASSEMBLY
(a) Install the combination switch assembly onto the steering column assembly with the clamp.
(b) Connect all the connectors to the turn signal switch with spiral cable.





23. INSTALL STEERING COLUMN COVER
(a) Engage the claw to install the steering column upper cover.





(b) Engage the 2 claws to install the steering column lower cover.
(c) Install the 3 screws.





24. INSTALL STEERING WHEEL ASSEMBLY
(a) Align the matchmarks and install the steering wheel assembly onto the steering column assembly.
(b) Install the nut.
Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf)
(c) Connect all connectors to the spiral cable.
25. INSTALL STEERING PAD
26. POSITION FRONT WHEELS FACING STRAIGHT AHEAD
27. CHECK SRS WARNING LIGHT
28. PERFORM CALIBRATION OF TORQUE SENSOR ZERO POINT

pro multis · About Operation CHARM