toyota rav4 1994-2000 steering system - hệ thống lái trên xe toyota rav4 đời 1994-2000

HỆ THỐNG LÁI TRÊN XE TOYOTA RAV4 ĐỜI 1994-2000

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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.

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STEERING TROUBLESHOOTING

TROUBLESHOOTING

PROBLEM SYMPTOMS TABLE

Use the table below to help you find the cause of the problem The numbers indicate the priority of the likelycause of the problem Check each part in the order shown If necessary, repair or replace these parts

Hard steering

1 Tires (Improperly inflated)

2 Power steering fluid level (Low)

3 Drive belt (Loose)

4 Front wheel alignment (Incorrect)

5 Steering system joints (Worn)

6 Suspension arm ball joints (Worn)

7 Steering column (Binding)

8 Power steering vane pump

9 Power steering gear

SA−2 SR−5 SR−3 SA−4

− SA−45

− SR−31 SR−44

Poor return

1 Tires (Improperly inflated)

2 Front wheel alignment (Incorrect)

3 Steering column (Binding)

SA−2 SA−4

− SR−44

Excessive play

2 Suspension arm ball joints (Worn)

3 Intermediate shaft, Sliding yoke (Worn)

4 Front wheel bearing (Worn)

− SA−45

− SA−4 SR−44

Abnormal noise

1 Power steering fluid level (Low)

3 Power steering vane pump

SR−5

− SR−31 SR−44

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INSPECT DRIVE BELT

Belt tension gauge:

DENSO BTG−20 (95506−00020)Borroughs No BT−33−73F

Drive belt tension:

New belt: 95 − 145 lbf Used belt: 60 − 100 lbf

If the belt tension is not as specified, adjust it

HINT:

5 minutes on a running engine

run-ning engine for 5 minutes or more

ribbed grooves

slipped out of the groove on the bottom of the pulley

min-utes and recheck the belt tension

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R11229

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STEERING POWER STEERING FLUID

POWER STEERING FLUID

BLEEDING

1 CHECK FLUID LEVEL (See page SR−5 )

2 JACK UP FRONT OF VEHICLE AND SUPPORT IT WITH STANDS

3 TURN STEERING WHEEL

With the engine stopped, turn the wheel slowly from lock to lockseveral times

4 LOWER VEHICLE

5 START ENGINE

Run the engine at idle for a few minutes

6 TURN STEERING WHEEL

lock and keep it there for 2−3 seconds, then turn thewheel to the opposite full lock and keep it there for 2−3 se-conds

7 STOP ENGINE

8 CHECK FOR FOAMING OR EMULSIFICATION

If the system has to be bled twice specifically because of ing or emulsification, check for fluid leaks in the system

foam-9 CHECK FLUID LEVEL (See page SR−5 )

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1 CHECK FLUID LEVEL

reservoir

If necessary, add fluid

Fluid: ATF DEXRON® II or III

HINT:

Check that the fluid level is within the HOT LEVEL range on thereservoir If the fluid is cold, check that it is within the COLDLEVEL range

boost fluid temperature

Fluid temperature: 80°C (176°F)

If there is foaming or emulsification, bleed power steering

reservoir

Maximum fluid level rise: 5 mm (0.20 in.)

If a problem is found, bleed power steering system

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STEERING POWER STEERING FLUID

2 CHECK STEERING FLUID PRESSURE

09641−01060)

NOTICE:

Check that the valve of the SST is in the open position.

boost fluid temperature

Fluid temperature: 80°C (176°F)

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OilReservoir

PS VanePump

PS Gear

SSTClosed

Z15499

OilReservoir

PS VanePump

PS Gear

SSTOpen

Z15500

OilReservoir

PS VanePump

ob-serve the reading on the SST

Minimum fluid pressure:

7,355 kPa (75 kgf/cm 2 , 1067 psi) NOTICE:

S Do not keep the valve closed for more than 10 conds.

se-S Do not let the fluid temperature become too high.

and 3,000 rpm

Difference fluid pressure:

490 kPa (5 kgf/cm 2 , 71 psi) or less NOTICE:

Do not turn the steering wheel.

steering wheel to full lock

Minimum fluid pressure:

7,355 kPa (75 kgf/cm 2 , 1067 psi) NOTICE:

S Do not maintain lock position for more than 10 conds.

se-S Do not let the fluid temperature become too high.

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SR0FE−01

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STEERING AIR CONTROL VALVE

AIR CONTROL VALVE

INSPECTION

INSPECT AIR CONTROL VALVE

hose of the air control valve is pinched

re-leased

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1 CHECK STEERING WHEEL FREEPLAY

With the vehicle stopped and tires facing straight ahead, rockthe steering wheel gently back and forth with light finger pres-sure

Freeplay should not exceed the maximum

Maximum freeplay: 30 mm (1.18 in.)

2 CHECK STEERING EFFORT

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STEERING NON−TILT STEERING COLUMN

NON−TILT STEERING COLUMN

COMPONENTS

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1996 RAV4 (RM447U)

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the groove along the screw circumference catches on thescrew case.

dis-connect the airbag dis-connector

CAUTION:

S When storing the wheel pad, keep the upper surface

of the pad facing upward.

S Never disassemble the wheel pad.

NOTICE:

When removing the wheel pad, take care not to pull the bag wire harness.

air-2 REMOVE STEERING WHEEL

assembly

09953−05020, 09954−05020)

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1996 RAV4 (RM447U)

3 REMOVE LOWER FINISH PANEL

con-trol lever from the panel

4 REMOVE INSTRUMENT PANEL LOWER INSERT

Remove the 3 screws

5 Non−tilt Steering Column:

REMOVE UPPER AND LOWER COLUMN COVERS

6 Tilt Steering Column:

REMOVE UPPER AND LOWER COLUMN COVERS

Remove the 3 screws

7 REMOVE NO.2 HEATER TO REGISTER DUCT

Remove the clip

8 REMOVE COMBINATION SWITCH WITH SPIRAL CABLE

9 REMOVE SPIRAL CABLE (See page BE−14 ) NOTICE:

Do not disassemble the cable or apply oil to it.

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10 DISCONNECT NO.2 INTERMEDIATE SHAFT

on the control valve shaft and No.2 intermediate shaft

11 REMOVE NO.2 INTERMEDIATE SHAFT

12 REMOVE STEERING COLUMN PROTECTOR

Remove the bolt

13 REMOVE STEERING COLUMN ASSEMBLY

REMOVE SLIDING YOKE

shaft and sliding yoke

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When using a vise, do not overtighten it.

1 REMOVE STEERING COLUMN UPPER BRACKET AND STEERING COLUMN UPPER CLAMP

ta-pered−head bolts

2 REMOVE STEERING MAIN SHAFT ASSEMBLY

shaft assembly

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1 INSPECT STEERING LOCK OPERATION

Check that the steering lock mechanism operates properly

2 IF NECESSARY, REPLACE IGNITION KEY CYLINDER

cylin-der, and pull it out

HINT:

Make sure that the ignition key is at the ACC position

3 INSPECT IGNITION SWITCH (See page BE−11 )

4 IF NECESSARY, REPLACE IGNITION SWITCH

5 INSPECT KEY UNLOCK WARNING SWITCH (See page BE−11 )

6 IF NECESSARY, REPLACE KEY UNLOCK WARNING SWITCH

7 IF NECESSARY, REPLACE STEERING MAIN SHAFT BUSHING

bush-ing, and remove the bushing from the steering columntube

disul-fide lithium base grease

column tube, then install the bushing until the projectionsare firmly engaged in the holes

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IF NECESSARY, REPLACE BEARING

base grease

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1 INSTALL STEERING MAIN SHAFT ASSEMBLY

shaft assembly

Insert the bracket pin into the column tube hole

breaks off

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CONNECT SLIDING YOKE

and connect them

Torque: 35 N·m (360 kgf·cm, 26 ft·lbf)

2 Non−Tilt Steering Column:

INSTALL STEERING COLUMN ASSEMBLY

2 nuts

INSTALL STEERING COLUMN ASSEMBLY

4 INSTALL STEERING COLUMN PROTECTOR

Torque the bolt

Torque: 5.0 N·m (50 kgf·cm, 44 in.·lbf)

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INSTALL NO.2 INTERMEDIATE SHAFT

INSTALL No.2 INTERMEDIATE SHAFT

7 CONNECT NO.2 INTERMEDIATE SHAFT

control valve shaft, and connect them

8 INSTALL SPIRAL CABLE (See page BE−14 )

9 INSTALL COMBINATION SWITCH WITH SPIRAL CABLE

10 INSTALL NO.2 HEATER TO REGISTER DUCT

INSTALL UPPER AND LOWER COLUMN COVERS

screws

INSTALL UPPER AND LOWER COLUMN COVERS

screws

13 INSTALL INSTRUMENT PANEL LOWER INSERT

Tighten the 3 screws

14 INSTALL LOWER FINISH PANEL

15 CENTER SPIRAL CABLE

the center

HINT:

The spiral cable rotates approx 5 turns maximum

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1996 RAV4 (RM447U)

16 INSTALL STEERING WHEEL

shaft assembly

17 INSTALL STEERING WHEEL PAD NOTICE:

S Make sure that the pad is installed to the specified torque.

S If the 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.

S When installing the pad, take care that the wiring does not interfere with other parts and is not pinched between other parts.

groove of the torx screws are caught on the screw case

18 CHECK STEERING WHEEL CENTER POINT

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STEERING TILT STEERING COLUMN

TILT STEERING COLUMN

COMPONENTS

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1996 RAV4 (RM447U)

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1 REMOVE 3 TENSION SPRINGS

HINT:

Remove the springs with the tilt function at maximum tilt up

2 REMOVE STEERING COLUMN UPPER BRACKET AND STEERING COLUMN UPPER CLAMP

(See page SR−15 )

3 REMOVE COMBINATION SWITCH BRACKET

Remove the 2 bracket set bolts

4 REMOVE STEERING COLUMN UPPER TUBE WITH STEERING MAIN SHAFT

column tube

5 REMOVE TILT LEVER RETAINER

Using screwdriver, remove the retainer from the steering umn upper tube

col-NOTICE:

Tape the screwdriver tip before use.

6 REMOVE STEERING MAIN SHAFT

NOTICE:

Do not bend the universal joint of the shaft more than 20°.

the shaft

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from the shaft

7 REMOVE TILT STEERING PAWL

No.2 shaft

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When using a vise, do not overtightened it.

1 COAT WITH MOLYBDENUM DISULFIDE LITHIUM BASE GREASE (See page SR−22 )

2 INSTALL TILT STEERING PAWL

install the pawl

NOTICE:

Tap the shaft completely into the steering column upper tube.

3 INSTALL STEERING MAIN SHAFT

col-lar to the shaft

NOTICE:

Be careful not to damage the collar.

the shaft

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Do not bend the universal joint of the shaft more than 20°.

6 INSTALL COMBINATION SWITCH BRACKET

Torque the 2 bracket set bolts

7 INSTALL 3 TENSION SPRINGS

HINT:

Install the springs with the tilt function at maximum tilt up

8 INSTALL STEERING COLUMN UPPER BRACKET AND STEERING COLUMN UPPER CLAMP

(See page SR−18 )

9 CHECK TILT STEERING OPERATION

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137 (1, 400, 101)

206 (2, 100, 152)

127 (1, 300, 94)

Engine Under Cover

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Pressure Feed No.2 Tube

Side Front Plate

Pressure Port Union

Flow ControlValve

Pump Front Bracket

Flow ControlSpring Seat

z Gasket

z Shorter Staright Pin

Air Control Valve

z O−Ring

z Snap Ring

z O−Ring

z Union Seat

z Longer Straight Pin

Vane Pump Shaft

Pump Bracket

z Snap Ring

Cam RingSide Rear Plate

Vane PlateWave Washer

Vane Pump Rotor

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1 REMOVE RH AND LH ENGINE UNDER COVERS

Remove the 13 bolts

2 REMOVE FRONT EXHAUST PIPE

Remove the 2 bolts, 3 nuts and 2 gaskets

3 REMOVE STABILIZER BAR WITH LINK (See page SA−48 )

4 DISCONNECT RH AND LH LOWER SUSPENSION ARMS (See page SA−40 )

5 REMOVE 2 PS GEAR ASSEMBLY SET BOLTS AND NUTS

6 REMOVE FRONT SUSPENSION CROSSMEMBER SEMBLY (See page SA−40 )

AS-7 DISCONNECT 2 TUBE CLAMPS

Remove the bolt

8 DISCONNECT 2 VACUUM HOSES

9 DISCONNECT RETURN HOSE NOTICE:

Take care not to spill fluid on the drive belt.

10 REMOVE DRIVE BELT

Loosen the 2 bolts

11 DISCONNECT PRESSURE FEED TUBE

Using SST, disconnect the tube

12 REMOVE PS VANE PUMP ASSEMBLY WITH PUMP BRACKET

Remove the 3 bolts

13 REMOVE PRESSURE FEED TUBE

Remove the union bolt, gasket and tube from the PS vanepump assembly

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1 MEASURE PS VANE PUMP ROTATING TORQUE

Remove the 2 bolts

3 REMOVE VANE PUMP PULLEY

set nut

4 REMOVE AIR CONTROL VALVE

Remove the union seat

5 REMOVE PRESSURE FEED NO.2 TUBE

Remove the union bolt and 2 gaskets

6 REMOVE SUCTION PORT UNION

7 REMOVE PRESSURE PORT UNION

Remove the O−ring from the union

8 REMOVE FLOW CONTROL VALVE AND SPRING

9 REMOVE FLOW CONTROL SPRING SEAT

1.0 mm pitch, 50 mm length)

Reference Bolt: 91651−60650

hous-ing

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ser-rated part of the vane pump shaft.

plate

11 REMOVE CAM RING AND 10 VANE PLATES

12 REMOVE VANE PUMP SHAFT WITH VANE PUMP TOR AND SIDE FRONT PLATE

RO-13 REMOVE VANE PUMP ROTOR AND SIDE FRONT PLATE

pump shaft

14 REMOVE SHORTER STRAIGHT PIN

Using pliers, remove the pin from the side front plate

15 REMOVE LONGER STRAIGHT PIN

Using pliers, remove the pin from the front housing

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W01200

Micrometer

CaliperGauge

1 MEASURE OIL CLEARANCE BETWEEN VANE PUMP SHAFT AND BUSHING

Using a micrometer and a caliper gauge, measure the oil ance

clear-Standard clearance:

0.03 − 0.05 mm (0.0012 − 0.0020 in.) Maximum clearance: 0.07 mm (0.0028 in.)

If it is more than the maximum, replace the front housing andvane pump shaft

2 INSPECT VANE PUMP ROTOR AND VANE PLATES

length of the 10 plates

Minimum height: 8.1 mm (0.319 in.) Minimum thickness: 1.797 mm (0.0707 in.) Minimum length: 14.988 mm (0.59008 in.)

the rotor groove and plate

Maximum clearance: 0.03 mm (0.0012 in.)

If it is more than the maximum, replace the plate and/or rotorwith one having the same mark stamped on the cam ring

Inscribed mark: 1, 2, 3, 4 or None

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Vane plate part number

Vane plate length mm (in.) None 44345−12010 14.996−14.998

3 INSPECT FLOW CONTROL VALVE

check that it falls smoothly into the valve hole by its ownweight

com-pressed air into the opposite side, and confirm that airdoes not come out from the end hole

If necessary, replace the valve with one having the same letter

as inscribed on the front housing

Inscribed mark: A, B, C, D, E or F

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Using calipers, measure the free length of the spring.

Minimum free length: 36.0 mm (1.42 in.)

If it is not within the specification, replace the spring

5 IF NECESSARY, REPLACE OIL SEAL

remove the oil seal

NOTICE:

Be careful not to damage the bushing of the front housing.

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1 COAT WITH POWER STEERING FLUID (See page SR−31 )

2 INSTALL LONGER STRAIGHT PIN

Using a plastic hammer, tap in a new pin to the front housing

NOTICE:

Be careful not to damage the pin.

3 INSTALL SHORTER STRAIGHT PIN

Install a new pin to the side front plate

NOTICE:

Be careful not to damage the pin.

4 INSTALL SIDE FRONT PLATE AND VANE PUMP TOR

them to the plate

facing outward

NOTICE:

Make sure to install the plate facing the correct direction.

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STEERING POWER STEERING VANE PUMP

6 INSTALL CAM RING

Align the holes of the cam ring and 2 straight pins and install thering with the inscribed mark facing outward

7 INSTALL VANE PLATES

Install the 10 plates with the round end facing outward

8 INSTALL SIDE REAR PLATE

to the plate

the plate

9 INSTALL WAVE WASHER

Install the washer so that its protrusions fit into the slots in theside rear plate

10 INSTALL REAR HOUSING

to the housing

housing

NOTICE:

Be careful not to damage the O−ring.

11 INSTALL FLOW CONTROL SPRING SEAT

to the flow control spring seat

NOTICE:

S Be careful not to damage the O−ring.

S Make sure to install the seat facing the correct tion.

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12 INSTALL SPRING AND FLOW CONTROL VALVE

Install the valve facing the correct direction

13 INSTALL PRESSURE PORT UNION

to the union

14 INSTALL SUCTION PORT UNION

to the union

15 INSTALL PRESSURE FEED NO.2 TUBE

Torque the union bolt with a new gasket on each side of thetube

HINT:

Pressure feed No.2 tube installation angle is 2.5°

16 INSTALL AIR CONTROL VALVE

17 INSTALL VANE PUMP PULLEY

18 INSTALL PUMP BRACKET AND PUMP FRONT BRACKET

Temporarily tighten the 2 bolts

19 MEASURE PS VANE PUMP ROTATING TORQUE (See page SR−34 )

Tiêu đề	Toyota RAV4 1994-2000 Steering System - Hệ thống lái trên xe Toyota RAV4 đời 1994-2000
Trường học	Toyota University
Chuyên ngành	Automotive Engineering
Thể loại	Technical Manual
Năm xuất bản	1996
Thành phố	Toyota City

Định dạng
Số trang	61
Dung lượng	1,29 MB