Reassembly (from 07/2011)

STEERING COLUMN: STEERING COLUMN ASSEMBLY (for Hatchback): REASSEMBLY

1. INSTALL POWER STEERING MOTOR ASSEMBLY

NOTICE:
* Do not drop the power steering motor assembly, strike it with tools or subject it to impacts.
* If the power steering motor assembly is subjected to an impact, replace it with a new one.
* Do not pull the wire harness of the power steering motor assembly.
* Do not allow any moisture to come into contact with the power steering motor assembly.
* Do not loosen any bolts not mentioned in the procedure.
* Do not allow any foreign objects to contaminate the power steering motor assembly.





(a) Apply grease to the serrated part of the electric power steering column sub-assembly.

NOTICE:
First wipe off the existing grease from the serrated part, and then apply the dedicated grease supplied with a new power steering motor assembly or electric power steering column sub-assembly.

(b) Temporarily install the power steering motor assembly to the electric power steering column sub-assembly with the 2 bolts.

NOTICE:
When temporarily installing the 2 bolts to the power steering motor assembly, do not tighten them all the way down.

(c) Secure the steering column assembly in a vise using aluminum plates.





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NOTICE:
* Do not overtighten the vise, as the steering column assembly may become deformed.
* Secure the power steering motor assembly so that it is directly upright.
* Support the steering column assembly with a wooden block or similar item to ensure that it does not fall.

(d) Using SST, turn the steering main shaft once 180 degrees to the left and then 180 degrees to the right at a speed of 60 rpm, and repeat 2 to 3 times to adjust the axis centering of the power steering motor assembly.

SST : 09616-00011





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(e) Tighten the 2 bolts.

Torque : 19 Nm (189 kgf-cm, 14 ft-lbf)

(f) Using SST, measure the turning torque of the steering main shaft.

SST : 09616-00011





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Turning torque - Torque : 1.45 Nm (14.8 kgf-cm, 12.8 in-lbf) or less

NOTICE:
Ensure that there is no abnormal resistance during rotation.

If the torque is not as specified, readjust the axis centering of the power steering motor assembly.

(g) Install a new clamp and tape to the wire harness as shown in the illustration.





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NOTICE:
* Wrap the tape around the area marked as "A" in the illustration more than 1.5 times.
* Wrap the tape around the area marked as "B" in the illustration more than 2 times.
* As heat from the power steering motor assembly may generate smoke, use heat resistant tape (resistant to 100°C (212°F) or more).

2. INSTALL IGNITION OR STARTER SWITCH ASSEMBLY

(a) Engage the 2 claws to install the ignition or starter switch assembly onto the upper steering column bracket assembly.

3. INSTALL KEY INTER LOCK SOLENOID (for Automatic Transaxle)

(a) Install the key inter lock solenoid onto the upper steering column bracket assembly with the screw.

4. INSTALL UN-LOCK WARNING SWITCH ASSEMBLY





(a) Engage the 2 claws to install the un-lock warning switch assembly onto the upper steering column bracket assembly.

HINT
Slide the un-lock warning switch assembly, in the direction shown by the arrow in the illustration, to install it.

5. INSTALL IGNITION SWITCH LOCK CYLINDER ASSEMBLY

(a) Turn the ignition switch to ACC.





(b) Install the ignition switch lock cylinder assembly into the upper steering column bracket assembly.

(c) Make sure that the ignition switch lock cylinder assembly is securely fixed onto the ignition switch lock cylinder assembly.

6. INSTALL UPPER STEERING COLUMN BRACKET ASSEMBLY

(a) Set 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 with a new steering lock set bolt, and then tighten the bolt until its head comes off.





7. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

(a) Align the matchmarks on the No. 2 steering intermediate shaft assembly and the steering column assembly and provisionally install them with the bolt.

HINT
When either the steering column assembly or the No. 2 steering intermediate shaft assembly is replaced with a new one, they have no matchmarks, so align the marking (pink) on the steering column assembly shaft with the slit of the No. 2 steering intermediate shaft assembly, and install them.





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8. INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY

(a) Align the matchmarks on the No. 2 steering intermediate shaft assembly and the steering sliding yoke and provisionally install them with the bolt.





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