Steering Column: Service and Repair

STEERING COLUMN ASSY (2003 MY) OVERHAUL
1. PRECAUTION
2. SEPARATE BATTERY NEGATIVE TERMINAL
3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
4. REMOVE STEERING WHEEL COVER LOWER NO.2





5. REMOVE HORN BUTTON ASSY

NOTICE: If the airbag connector is disconnected with the ignition switch at ON, DTCs will be recorded.

a. Using a torx socket wrench, loosen the 2 torx screws until the groove along the screw circumference catches on the screw case.





b. Pull out the wheel pad from the steering wheel and disconnect the airbag connector.
c. Disconnect the terminal and horn connector.

CAUTION:
^ When storing the wheel pad, keep the upper surface of the pad facing upward.
^ Never disassemble the wheel pad.

NOTICE: When removing the wheel pad, take care not to pull the airbag wire harness.





6. REMOVE STEERING WHEEL ASSY
a. Remove the steering wheel assy set nut.
b. Place matchmarks on the steering wheel assy and main shaft assy.
c. Using SST, remove the steering wheel assy.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)





7. REMOVE STEERING COLUMN COVER LWR
a. Remove the 3 screws and steering column cover LWR.
8. REMOVE STEERING COLUMN COVER UPR
9. REMOVE SPIRAL CABLE SUB-ASSY
10. REMOVE HEADLAMP DIMMER SWITCH ASSY
11. REMOVE WINDSHIELD WIPER SWITCH ASSY
12. REMOVE INSTRUMENT PANEL FINISH PANEL SUB-ASSY LOWER
13. REMOVE INSTRUMENT PNL INSERT SUB-ASSY LWR LH
14. SEPARATE STEERING INTERMEDIATE SHAFT SUB-ASSY





a. Loosen the bolt A and remove the clamp from the steering column hole cover No.1.
b. Separate the steering column hole cover No.2 from the steering column hole cover No.1.
c. Loosen the bolt B.





d. Place matchmarks on the steering intermediate shaft sub-assy and steering gear assy.
e. Remove the bolt and separate the steering intermediate shaft sub-assy.





15. REMOVE STEERING COLUMN ASSY
a. Separate the connectors and wire harness clamps.
b. Remove the 2 bolts, 2 nuts and steering column assy from the instrument panel reinforcement assy.





16. REMOVE STEERING INTERMEDIATE SHAFT SUB-ASSY
a. Place matchmarks on the steering intermediate shaft sub-assy and steering shaft universal joint assy.
b. Remove the bolt and steering intermediate shaft sub-assy.
17. REMOVE STEERING COLUMN HOLE COVER SUB-ASSY NO.2





18. REMOVE STEERING SHAFT UNIVERSAL JOINT ASSY
a. Place matchmarks on the steering shaft universal joint assy and steering main shaft assy.
b. Remove the bolt and steering shaft universal joint assy from the steering main shaft assy.
19. REMOVE KEY CYLINDER LAMP ASSY (W/ ILLUMINATED ENTRY SYSTEM)





20. REMOVE TRANSPONDER KEY AMPLIFIER (W/ ENGINE IMMOBILIZER SYSTEM)
a. Widen the claw hung on the upper bracket by approximately 1.0 mm (0.039 inch) using a screwdriver.
b. Pull the transponder key amplifier toward the rear of the vehicle with the claw open.

NOTICE: Take care not to use excessive force to prevent the case from being damaged.





21. REMOVE STEERING COLUMN UPPER W/SWITCH BRACKET ASSY
a. Using a centering punch, mark the center of the 2 tapered-head bolts.
b. Using a 3 - 4 mm (0.12 - 0.16 inch) drill, drill into the 2 bolts.
c. Using a screw extractor, remove the 2 bolts and steering column upper w/switch bracket assy.
22. REMOVE STEERING COLUMN CLAMP UPPER
23. REMOVE STEERING MAIN SHAFT ASSY





a. Using a snap ring expander, remove the steering main shaft snap ring (outer side).





b. Using a brass bar and a hammer, remove the steering main shaft assy and steering main shaft bushing.

NOTICE: Be careful not drop the steering main shaft assy.





c. Using a snap ring expander, remove the steering main shaft snap ring (inner side).





d. Measure the steering main shaft length.
Standard length: 504.1 ± 1 mm (19.846 ± 0.039 inch)





24. REMOVE IGNITION SWITCH LOCK CYLINDER ASSY
a. Place the ignition switch lock cylinder assy at the ACC position.
b. Push down the stop pin with a screwdriver, and pull out the cylinder assy.





25. REMOVE UN-LOCK WARNING SWITCH ASSY
a. Separate the un-lock warning switch assy connector from the ignition or starter switch assy.
b. Remove the un-lock warning switch assy by pushing up the center part and releasing the 2 claws.





c. Disengage the secondary locking device.
d. Using a small screwdriver, disengage the locking lug of the terminals 2 and 4, and pull the terminals out from the un-lock warning switch assy rear side.
26. REMOVE KEY INTER LOCK SOLENOID
a. Remove the 2 screws and solenoid from the steering column bracket assy.
27. REMOVE IGNITION OR STARTER SWITCH ASSY
a. Remove the 2 screws and ignition or starter switch assy from the steering column bracket assy UPR.
28. INSTALL IGNITION OR STARTER SWITCH ASSY
a. Install the ignition or starter switch assy to the steering column bracket assy UPR with the 2 screws.
29. INSTALL KEY INTER LOCK SOLENOID
a. Install the solenoid to the steering column bracket assy with the 2 screws.





30. INSTALL UN-LOCK WARNING SWITCH ASSY
a. Install the un-lock warning switch assy.
b. Connect the terminals 2 and 4 of the un-lock warning switch assy connector.
c. Connect the un-lock warning switch assy connector to the ignition or starter switch assy.
31. INSTALL IGNITION SWITCH LOCK CYLINDER ASSY
a. Make sure the ignition switch lock cylinder assy at the ACC position.
b. Install the ignition switch lock cylinder assy.
32. INSPECT STEERING LOCK OPERATION
a. Check that the steering lock mechanism is activated when removing the key.
b. Check that the steering lock mechanism is deactivated when inserting the key and turning it to ACC position.





33. INSTALL STEERING MAIN SHAFT ASSY
a. Using a snap ring expander, install a new steering main shaft snap ring (inner side) to the steering main shaft assy.
b. Install the steering main shaft assy to the steering column tube.





c. Using a snap ring expander, install a new steering main shaft snap ring (outer side) to the steering main shaft assy.





34. INSTALL STEERING MAIN SHAFT BUSH
a. Using SST and a hammer, install a new steering main shaft bush.
SST 09608-06041





35. INSTALL STEERING COLUMN UPPER W/SWITCH BRACKET ASSY
a. Temporarily install the steering column upper w/switch bracket assy and steering column upper clamp with 2 new tapered-head bolts.
b. Tighten the 2 tapered-head bolts until the bolt heads break off.
36. INSTALL KEY CYLINDER LAMP ASSY (W/ ILLUMINATED ENTRY SYSTEM)





37. INSTALL TRANSPONDER KEY AMPLIFIER (W/ ENGINE IMMOBILIZER SYSTEM)
a. Align the transponder key amplifier with the installation position of the upper bracket with the amplifier inclined.
b. Push the transponder key amplifier up and connect it to the upper bracket.

NOTICE: Take care not to push the amplifier up with excessive force to prevent it from being damaged.





38. INSTALL STEERING SHAFT UNIVERSAL JOINT ASSY
a. Align the matchmarks on the steering universal joint assy and steering main shaft assy.
b. Install the steering universal joint assy with the bolt.
Torque: 35 Nm (360 kgf-cm, 26 ft. lbs.)





39. INSTALL STEERING COLUMN HOLE COVER SUB-ASSY NO.2
a. Install the steering column hole cover sub-assy No.2 to the steering intermediate shaft sub-assy.





40. TEMPORARILY TIGHTEN STEERING INTERMEDIATE SHAFT SUB-ASSY
a. Align the matchmarks on the steering intermediate shaft sub-assy and steering main shaft assy.
b. Temporarily install the steering intermediate shaft sub-assy with the bolt.





41. INSTALL STEERING COLUMN ASSY
a. Install the steering column assy with the 2 bolts and nuts.
Torque: 21 Nm (210 kgf-cm, 15 ft. lbs.)
b. Connect the connectors.
c. Connect the wire harness clamps to the steering column tube.
42. CONNECT STEERING INTERMEDIATE SHAFT SUB-ASSY





a. Align the matchmarks on the intermediate shaft sub-assy and steering gear assy.
b. Install the bolt.
Torque: 35 Nm (360 kgf-cm, 26 ft. lbs.)





c. Tighten the bolt A.
Torque: 35 Nm (360 kgf-cm, 26 ft. lbs.)
d. Install the steering column hole cover No.2 to the steering hole cover No. 1.
e. Connect the clamp to the steering column hole cover No. 1 and tighten the bolt B.
43. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
44. INSPECT SPIRAL CABLE SUB-ASSY
45. INSTALL SPIRAL CABLE SUB-ASSY
46. CENTER SPIRAL CABLE





a. Check that the ignition switch is OFF.
b. Check that the battery negative terminal is separated.

NOTICE: Do not start the operation for 90 seconds after removing the terminal.

c. Turn the cable counterclockwise by hand until it becomes harder to turn.





d. Then rotate the cable clockwise about 2.5 turns to align the marks.

HINT: The cable will rotate about 2.5 turns to either right or left of the center.

47. INSTALL STEERING WHEEL ASSY
a. Align the matchmarks on the steering wheel assy and steering main shaft assy.
b. Install the steering wheel assy set nut.
Torque: 50 Nm (510 kgf-cm, 37 ft. lbs.)
c. Connect the connector.
48. INSTALL HORN BUTTON ASSY

NOTICE:
^ Never use airbag parts removed from another vehicle. When replacing parts, replace with new ones.
^ Make sure the wheel pad is installed with the specified torque.
^ It the wheel 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.
^ When installing the wheel pad, take care so that the wirings do not interfere with other parts and that they are not pinched between other parts.

a. Connect the terminal.
b. Connect the airbag connector.





c. Install the steering wheel pad after confirming that the circumference groove of the torx screws is caught on the screw case.
d. Using a torx socket wrench, torque the 2 screws.
Torque: 8.8 Nm (90 kgf-cm, 78 inch lbs.)
49. INSPECT SRS WARNING LIGHT