Hilux 2015 2018 manual steering he thong lai

Tài liệu hướng dẫn sửa Hệ thống lái trên xe Hilux 2015 2018 manual steering he thong lai . Cung cấp các thông tin cần thiết cho Kỹ thuật viên tiến hành chẩn đoán, sửa chữa nhanh chóng, chính xác, hiệu quả

POWER ASSIST SYSTEMS POWER STEERING SYSTEM ON-VEHICLE INSPECTION

PROCEDURE

for 1GR-FE: Click hereEngine / Hybrid System>1GR-FE ENGINE MECHANICAL>DRIVE BELT>ON-VEHICLE INSPECTION

for 1GD-FTV: Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>DRIVE BELT>ON-VEHICLE INSPECTION

for 2GD-FTV: Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>DRIVE BELT>ON-VEHICLE INSPECTION

for 1TR-FE: Click hereEngine / Hybrid System>2TR-FE ENGINE MECHANICAL>DRIVE BELT>ON-VEHICLE INSPECTION

for 2TR-FE: Click hereEngine / Hybrid System>2TR-FE ENGINE MECHANICAL>DRIVE BELT>ON-VEHICLE INSPECTION

NOTICE:

Do not allow foreign matter in the oil reservoir sub-assembly

NOTICE:

Do not allow foreign matter in the oil reservoir sub-assembly

1.INSPECT DRIVE BELT

2.BLEED AIR FROM POWER STEERING SYSTEM

Check the fluid level

With the engine idling, turn the steering wheel to the left or right full lock position and hold it there for 2 to 3

seconds Then turn the steering wheel to the opposite full lock position and hold it there for 2 to 3 seconds

Check for foaming or emulsification If the system has to

be bled twice because of foaming or emulsification, check

for fluid leaks in the system

3.CHECK FLUID LEVEL

Keep the vehicle level

a.

With the engine stopped, check the power steering fluid

level in the oil reservoir If necessary, add power steering

fluid

Power steering fluid:

Automatic transmission Fluid DEXRON II or III or

equivalent

HINT:

If the fluid is hot, check that the fluid level is within the

HOT range on the oil reservoir If the fluid is cold, check

that the fluid level is within the COLD range

b.

Start the engine and run it at idle

c.

Turn the steering wheel to the left or right full lock position,

and then turn the steering wheel to the opposite full lock

position Repeat this several times to raise the fluid

temperature

Standard fluid temperature:

40 to 80°C (104 to 176°F)

d.

Check for foaming or emulsification If foaming or

emulsification is identified, bleed air from the power

Wait a few minutes and remeasure the fluid level in the oil reservoir

Maximum fluid level increase:

*a Engine idling

*b Engine stopped

*c 5 mm or less

4.CHECK STEERING FLUID PRESSURE

Disconnect the pressure feed tube

for 1GR-FE: Click hereSteering>POWER ASSIST SYSTEMS>VANE PUMP(for 1GR-FE)>REMOVAL

for 1GD-FTV, 2GD-FTV: Click hereSteering>POWER ASSIST SYSTEMS>VANE PUMP(for 1GD-FTV, 2GD-FTV)>REMOVALfor 1KD-FTV, 2KD-FTV: Click hereSteering>POWER ASSIST SYSTEMS>VANE PUMP(for 1KD-FTV, 2KD-FTV)>REMOVALfor 1TR-FE, 2TR-FE: Click hereSteering>POWER ASSIST SYSTEMS>VANE PUMP(for 1TR-FE, 2TR-FE)>REMOVAL

for 5L-E: Click hereSteering>POWER ASSIST SYSTEMS>VANE PUMP(for 5L-E)>REMOVAL

Check that the valve of SST is in the open position

Check that the valve of SST is in the open position

Turn the steering wheel to the left or right full lock position Then turn the steering wheel to the opposite full lock

position Repeat this several times to raise the fluid temperature

Standard fluid temperature:

*3 Vane Pump Assembly

Measure the fluid pressure at engine speeds of 1000 rpm

and 3000 rpm

Standard fluid pressure difference:

490 kPa (4.99 kgf/cm , 71 psi) or less

NOTICE:

Do not turn the steering wheel

If the pressure difference is not within the specified range,

check for fluid leaks and replace parts as necessary

i.

2

*a Open

With the engine idling and the valve fully opened, turn the

steering wheel to the full lock position

Maximum fluid pressure:

Connect the pressure feed tube

for 1GR-FE: Click hereSteering>POWER ASSIST SYSTEMS>VANE PUMP(for 1GR-FE)>INSTALLATION

for 1GD-FTV, FTV: Click hereSteering>POWER ASSIST SYSTEMS>VANE PUMP(for 1GD-FTV,

5.CHECK STEERING RESISTANCE

Center the steering wheel

Measure the steering resistance in both directions

Standard steering resistance (Reference):

POWER ASSIST SYSTEMS POWER STEERING SYSTEM PRECAUTION

HANDLING PRECAUTIONS FOR STEERING SYSTEM

Care must be taken when replacing parts Incorrect replacement could affect the performance of the steeringsystem and result in a driving hazard

a.

POWER ASSIST SYSTEMS POWER STEERING SYSTEM PROBLEM SYMPTOMS TABLE

HINT:

Use the table below to help determine the cause of problem symptoms If multiple suspected areas are listed, thepotential causes of the symptoms are listed in order of probability in the "Suspected Area" column of the table Checkeach symptom by checking the suspected areas in the order they are listed Replace parts as necessary

Power Steering System

Hard steering

Tires (improperly inflated)Power steering fluid level (low)Front wheel alignment (incorrect)Steering system joints (worn) -Suspension arm ball joints (worn) -Power steering vane pump assembly (for 1GR-FE)

Power steering vane pump assembly (for 1GD-FTV,2GD-FTV)

Power steering vane pump assembly (for 1KD-FTV,2KD-FTV)

Power steering vane pump assembly (for 1TR-FE,2TR-FE)

Power steering vane pump assembly (for 5L-E)Power steering link assembly

Poor return

Tires (improperly inflated)Front wheel alignment (incorrect)

-Power steering link assembly

Excessive free play

Steering system joints (worn) Suspension arm ball joints (worn) -Intermediate shaft sliding yoke (worn) -Front wheel bearing (for 2WD)

-Front wheel bearing (for 4WD and Pre-Runner)Power steering link assembly

Abnormal noise

Power steering fluid level (low)Steering system joints (worn) -Power steering vane pump assembly (for 1GR-FE)

Power steering vane pump assembly (for 1GD-FTV,2GD-FTV)

Power steering vane pump assembly (for 1KD-FTV,2KD-FTV)

Power steering vane pump assembly (for 1TR-FE,2TR-FE)

Power steering vane pump assembly (for 5L-E)Power steering link assembly

POWER ASSIST SYSTEMS VANE PUMP(for 1GD-FTV, 2GD-FTV) DISASSEMBLY

CAUTION / NOTICE / HINT

Using a SST, secure the vane pump assembly

SST

09630-00014 (09631-00132)

a.

2.REMOVE FLOW CONTROL VALVE

Using a 27 mm socket wrench, remove the

pressure port union from the front housing

a.

Using a screwdriver, remove the O-ring from the

pressure port union

b.

Remove the flow control valve from the front

housing

c.

Remove the flow control valve compression spring

from the front housing

d.

Remove the bolt and suction port union from the vane pump assembly

a.

Remove the O-ring from the suction port union

b.

4.REMOVE REAR HOUSING

Remove the 4 bolts and rear housing from the front housing

a.

Remove the O-ring from the rear housing.

b.

5.REMOVE SHAFT WITH PULLEY

Using a screwdriver, remove the vane pump shaft

snap ring from the shaft with pulley

a.

Remove the shaft with pulley from the front

housing

b.

6.REMOVE VANE PUMP ROTOR

Remove the 10 vane pump plates from the vane pump rotor

7.REMOVE VANE PUMP CAM RING

Remove the front vane pump side plate from the front housing

a.

Remove the O-ring from the front vane pump side plate

b.

Remove the O-ring from the front housing.

c.

Using a screwdriver, pry out the vane pump

housing oil seal

HINT:

Tape the screwdriver tip before use

a.

*a Protective Tape

POWER ASSIST SYSTEMS VANE PUMP(for 1GD-FTV, 2GD-FTV) INSPECTION

PROCEDURE

1.INSPECT CLEARANCE BETWEEN VANE PUMP SHAFT AND BUSHING IN FRONT HOUSING

Using a micrometer, measure the diameter (a) of

the shaft with pulley

a.

Using a caliper gauge, measure the inside diameter

(b) of the front housing

If the clearance is more it is more than the

maximum, replace the shaft with pulley

c.

2.INSPECT VANE PUMP ROTOR AND VANE PUMP PLATE

Using a feeler gauge, measure the clearance

between the side face of the vane pump rotor

groove and the vane pump plates

Maximum clearance:

0.025 mm (0.000984 in.)

If the clearance is more than the maximum,

replace the vane pump plates, vane pump rotor

and vane pump cam ring

HINT:

Refer to the following table to select an

appropriate combination of vane pump rotor,

vane pump cam ring and vane pump plates

Combination of Vane Pump Rotor, Vane Pump

Cam Ring and Vane Pump Plates:

3.INSPECT FLOW CONTROL VALVE

Check the flow control valve for leakage Close one of the holes and apply compressed air at 392 to 490 kPa

(4.00 to 4.99 kgf/cm , 56.9 to 71.0 psi) to the hole on the opposite side Confirm that the air does not flow out

of the end hole

NOTICE:

Make sure to use clean and dry air

a.

2

If there is leakage, replace the flow control valve.

·

Refer to the following table to select anappropriate combination of front housingand flow control valve

4.INSPECT FLOW CONTROL VALVE COMPRESSION SPRING

Using a vernier caliper, measure the free length of the flow control valve compression spring

Minimum free length (A) (Reference):

30.26 mm (1.19 in.)

a.

If the length is less than the minimum, replace the

flow control valve compression spring

5.INSPECT PRESSURE PORT UNION

If the union seat in the pressure port union is severely damaged, replace the pressure port union

a.

POWER ASSIST SYSTEMS VANE PUMP(for 1GD-FTV, 2GD-FTV) INSTALLATION

PROCEDURE

Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>ENGINE ASSEMBLY>INSTALLATION

Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>DRIVE BELT>INSTALLATION

Click hereSteering>POWER ASSIST SYSTEMS>POWER STEERING SYSTEM>ON-VEHICLE INSPECTION

Install the vane pump with the 2 bolts

Torque:

21 N*m (214 kgf*cm, 15 ft.*lbf)

a.

Install a new gasket to the pressure feed tube assembly

a.

Install the union bolt and connect the pressure feed

tube to the vane pump assembly

Torque:

49 N*m (500 kgf*cm, 36 ft.*lbf)

HINT:

Make sure that the stopper of the pressure feed

tube touches the front housing

b.

*a Stopper

Connect the oil reservoir to pump hose to the vane pump assembly and slide the hose clip

a.

Connect the connector to the power steering oil pressure switch

b.

6.ADD POWER STEERING FLUID

7.ADJUST POWER STEERING FLUID

8.CHECK FOR POWER STEERING FLUID LEAK

POWER ASSIST SYSTEMS VANE PUMP(for 1GD-FTV, 2GD-FTV) REASSEMBLY

CAUTION / NOTICE / HINT

Using SST and a press, press in a new vane pump

housing oil seal

2.INSTALL SHAFT WITH PULLEY

Coat the inside surface of the bushing in the front housing with power steering fluid

a.

Power Steering Fluid

Install the shaft with pulley to the front housing

·

Be careful not to damage the vane pumphousing oil seal

·

Coat a new O-ring with power steering fluid and

install it to the front housing

a.

Power Steering Fluid

Coat a new O-ring with power steering fluid and

install it to the front vane pump side plate

b.

Power Steering Fluid

Install in this Direction

Install the front vane pump side plate to the front

housing while aligning the semicircle-shaped cuts

of both parts

NOTICE:

Be sure to install the front vane pump side plate

in the correct position and with the correct

orientation

c.

Install in this Direction

4.INSTALL VANE PUMP CAM RING

With the inscribed mark facing upward, install the vane pump cam ring to the front housing while aligning thesemicircle-shaped cuts of both parts

NOTICE:

Be sure to install the vane pump cam ring in the correct position and with the correct orientation

a.

*a Inscribed Mark

Install in this Direction

5.INSTALL VANE PUMP ROTOR

Install the vane pump rotor to the front housing

HINT:

The top and bottom of the vane pump rotor are

symmetrical

a.

Install in this Direction

Coat the 10 vane pump plates with power steering

*a Outward

*b Inward

6.INSTALL VANE PUMP SHAFT SNAP RING

Using a screwdriver and snap ring expander, install

a new vane pump shaft snap ring to the shaft with

pulley

a.

7.INSTALL REAR HOUSING

Coat the vane pump rear housing of the shaft sub-assembly with pulley and the surrounding surface with powersteering fluid

a.

Coat a new O-ring with power steering fluid and install it to the rear housing

b.

Align the straight pin of the rear housing with the

hole created by the semicircle-shaped cuts of the

vane pump cam ring, front vane pump side plate

and front housing

NOTICE:

Make sure that the O-ring is not out of position

before installing the rear housing

8.INSPECT ROTATING TORQUE

Check that the vane pump assembly rotates smoothly without abnormal noise

a.

Temporarily install the service bolt

Recommended Service Bolt:

b.

*a Service Bolt

Item Specified Condition

Thread Diameter 10 mm (0.394 in.)Thread Pitch 1.25 mm (0.0492 in.)Bolt Length 50 mm (1.97 in.)

Using a torque wrench, check the pump rotating torque

Standard rotating torque:

0.27 N*m (3 kgf*cm, 2 in.*lbf) or less

If the rotating torque is not as specified, check the installation of the housing oil seal

c.

Coat a new O-ring of suction port union with power steering fluid

10.INSTALL FLOW CONTROL VALVE

Coat the flow control valve compression spring and flow control valve with power steering fluid

69 N*m (704 kgf*cm, 51 ft.*lbf)

POWER ASSIST SYSTEMS VANE PUMP(for 1GD-FTV, 2GD-FTV) REMOVAL

PROCEDURE

Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>DRIVE BELT>REMOVAL

Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>ENGINE ASSEMBLY>REMOVAL

2.DRAIN POWER STEERING FLUID

Slide the hose clamp and disconnect the oil

reservoir to pump hose

a.

Drain the power steering fluid

b.

Disconnect the power steering oil pressure switch

connector from the power steering oil pressure

6.REMOVE VANE PUMP ASSEMBLY 44320

Remove the 2 bolts and vane pump assembly

a.

POWER ASSIST SYSTEMS VANE PUMP(for 1GD-FTV, 2GD-FTV) COMPONENTS

ILLUSTRATION

*1 FAN AND GENERATOR V BELT *2 NO 1 OIL RESERVOIR TO PUMP HOSE

*7 POWER STEERING OIL PRESSURE SWITCHCONNECTOR *8 UNION BOLT

Tightening torque for "Major areas involvingbasic vehicle performance such as

moving/turning/stopping" : N*m (kgf*cm,ft.*lbf)

● Non-reusable part

*1 FLOW CONTROL VALVE *2 FRONT VANE PUMP SIDE PLATE

*3 POWER STEERING SUCTION PORT UNION *4 REAR HOUSING

*7 VANE PUMP HOUSING OIL SEAL *8 VANE PUMP ROTOR

*9 VANE PUMP SHAFT SNAP RING *10 BUSHING

-Tightening torque for "Major areas involvingbasic vehicle performance such as

moving/turning/stopping" : N*m (kgf*cm,ft.*lbf)

● Non-reusable part

STEERING COLUMN STEERING COLUMN ASSEMBLY COMPONENTS

ILLUSTRATION

ILLUSTRATION

*A for Entry and Start System *B for Smart Entry and Start System

*1 STEERING COLUMN LOWER COVER *2 STEERING COLUMN UPPER COVER

-*1 COMBINATION SWITCH ASSEMBLY WITHSPIRAL CABLE SUB-ASSEMBLY *2 NO 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

*3 STEERING COLUMN ASSEMBLY *4 STEERING SLIDING WITH COUPLING YOKESUB-ASSEMBLY

*5 STEERING SLIDING YOKE *6 NO 2 STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY

Tightening torque for "Major areas involvingbasic vehicle performance such as

moving/turning/stopping" : N*m (kgf*cm,ft.*lbf)

N*m (kgf*cm, ft.*lbf) : Specified torque

-*1 COMBINATION SWITCH ASSEMBLY WITHSPIRAL CABLE SUB-ASSEMBLY *2 STEERING COLUMN ASSEMBLY

*3 NO 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY *4 STEERING SLIDING WITH COUPLING YOKESUB-ASSEMBLY

*5 STEERING SLIDING YOKE *6 NO 2 STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY

Tightening torque for "Major areas involvingbasic vehicle performance such as

moving/turning/stopping" : N*m (kgf*cm,ft.*lbf)

N*m (kgf*cm, ft.*lbf) : Specified torque

*A for Entry and Start System *B for Smart Entry and Start System

*C for Automatic Transmission *D w/ Engine Immobiliser System

*1 IGNITION OR STARTER SWITCH ASSEMBLY *2 IGNITION SWITCH LOCK CYLINDER ASSEMBLY

*3 KEY INTERLOCK SOLENOID *4 STEERING COLUMN ASSEMBLY

*5 STEERING LOCK ACTUATOR OR UPPERBRACKET ASSEMBLY *6 TRANSPONDER KEY COIL

*7 UN-LOCK WARNING SWITCH ASSEMBLY *8 TAPERED-HEAD BOLT

1.REMOVE STEERING SLIDING WITH COUPLING YOKE SUB-ASSEMBLY

45206A

a.

DIAGNOSIS SYSTEMDTC CHECK / CLEARDATA LIST / ACTIVE TESTDIAGNOSTIC TROUBLE CODE CHARTSteering Lock does not Lock

Unable to Unlock Steering Wheel (Engine cannot Start)STEERING SYSTEM

PRECAUTIONPROBLEM SYMPTOMS TABLEON-VEHICLE INSPECTIONADJUSTMENT

STEERING COLUMN ASSEMBLYCOMPONENTS

REMOVALDISASSEMBLYINSPECTIONREASSEMBLYINSTALLATIONSTEERING WHEELSTEERING PAD SWITCHSTEERING GEAR / LINKAGE

Audio / Visual / Telematics

© 2012 TOYOTA MOTOR CORPORATION All Rights Reserved

STEERING COLUMN STEERING COLUMN ASSEMBLY INSPECTION

PROCEDURE

Measure the length of the steering main shaft

Standard length (A):

422.7 mm (1.39 ft.)

a.

STEERING COLUMN STEERING COLUMN ASSEMBLY INSTALLATION

PROCEDURE

Click hereSteering>STEERING GEAR / LINKAGE>STEERING GEAR>INSTALLATION

Click hereVehicle Interior>SUPPLEMENTAL RESTRAINT SYSTEMS>KNEE AIRBAG ASSEMBLY>INSTALLATION

Install the steering column assembly with the 2 nuts and bolt

2.INSTALL NO 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY 45025D

Install the steering column hole cover

sub-assembly with the 3 bolts

5.INSTALL COMBINATION SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY

Attach the 3 claws to install the combination switch assembly with spiral cable sub-assembly to the steering

Attach the 2 claws and 2 guides to install the steering column upper cover

a.

Attach the 2 claws and 6 guides to install the steering column lower cover

a.

Click hereSteering>STEERING COLUMN>STEERING WHEEL>INSTALLATION

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>INITIALIZATION

for Type A: Click hereVehicle Interior>SUPPLEMENTAL RESTRAINT SYSTEMS>AIRBAG SYSTEM(for Type A)>DIAGNOSISSYSTEM

for Type B: Click hereVehicle Interior>SUPPLEMENTAL RESTRAINT SYSTEMS>AIRBAG SYSTEM(for Type B)>DIAGNOSISSYSTEM

Install the 3 screws

b.

9.PLACE FRONT WHEELS FACING STRAIGHT AHEAD

11.CHECK SRS WARNING LIGHT

STEERING COLUMN STEERING COLUMN ASSEMBLY REASSEMBLY

CAUTION / NOTICE / HINT

NOTICE:

PROCEDURE

HINT:

When replacing the steering lock actuator assembly, refer to the Service Bulletin

When using a vise, place aluminum plates between the part and vise

·

When using a vise, do not overtighten it

·

1.INSTALL STEERING LOCK ACTUATOR OR UPPER BRACKET ASSEMBLY (for

Smart Entry and Start System)

2.INSTALL KEY INTERLOCK SOLENOID (for Automatic Transmission) 85432

Install the key interlock solenoid to the steering

column upper with switch bracket with the screw

a.

Click hereEngine / Hybrid System>1GR-FE STARTING>IGNITION SWITCH>INSTALLATION

Click hereVehicle Interior>DOOR LOCK>UNLOCK WARNING SWITCH>INSTALLATION

Click hereVehicle Interior>THEFT DETERRENT / KEYLESS ENTRY>TRANSPONDER KEY AMPLIFIER>INSTALLATION

Make sure that the ignition switch lock cylinder assembly is in the ACC position

a.

Install the ignition switch lock cylinder assembly

b.

6.INSPECT STEERING LOCK OPERATION

Check that the steering lock mechanism is activated when the key is removed

a.

Check that the steering lock mechanism is deactivated when the key is inserted and turned to the ACC position

If there is any abnormality, replace the ignition switch lock cylinder assembly

b.

7.INSTALL STEERING LOCK ACTUATOR OR UPPER BRACKET ASSEMBLY 45020B

Install the steering column upper with switch

bracket assembly with the tapered-head bolt

a.

Tighten the tapered-head bolt until the bolt head

breaks off

b.

8.INSTALL TRANSPONDER KEY COIL (w/ Engine Immobiliser System) 89782

9.INSTALL STEERING SLIDING WITH COUPLING YOKE SUB-ASSEMBLY 45206A

Align the matchmarks on the steering sliding with coupling yoke sub-assembly and steering main shaft