Toyota Camry 2007-2009 Service Manual - Power_Steering

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POWER STEERING – POWER STEERING SYSTEM

POWER STEERING SYSTEM

PRECAUTION

NOTICE: When disconnecting the cable from the negative (-) battery terminal, initialize the systems after the cable is reconnected (See page IN-43).

1. HANDLING PRECAUTIONS FOR STEERING SYSTEM

(a) Care must be taken when replacing parts. Incorrect

replacement may affect the performance of the steering system and result in driving hazards.

2. HANDLING PRECAUTIONS FOR SRS AIRBAG SYSTEM

(a) The vehicle is equipped with SRS (Supplemental

Restraint System), such as airbags. If service operation is not carried out properly, in a step by step fashion, sudden deployment of the airbags may result in serious injury. Before servicing (including removal or installation of parts, inspe ction or replacement), be sure to read the precautionary notice for the supplemental restraint system (See page RS-1).

3. PRECAUTIONS FOR REMOV AL, INST ALLA TION AND REPLACEMENT OF ELECTRONIC MOTOR POWER STEERING COMPONENTS

(a) Be sure to turn the front wheels straight ahead when

removing and installing the power steering link assembly.

(b) If disconnecting the steering intermediate shaft sub-

assembly and the power steering link assembly, be sure to put matchmarks before starting the operation.

power steering ECU assembly, clear the rotation angle sensor calibration value, initialize the rotation angle sensor, and calibrate torque sensor zero point (See page PS-13).

PS–1

PS–2

POWER STEERING – POWER STEERING SYSTEM

POWER STEERING SYSTEM

Symptom Suspected Area See page

Steering is heavy.

Steering effort differs between right and left or is uneven.

While driving, steering effort does not change in accordance with vehicle speed or the steering wheel does not return properly.

A knocking (or cranking) sound occurs when turning the steering wheel back and forth while power steering is in operation.

Noise occurs when turning the steering wheel during low speed driving.

A high-pitched sound (squeaking) occurs when turning the steering wheel slowly with the vehicle stopped.

The steering wheel vibrates and noise occurs when turning the steering wheel from lock to lock.

PROBLEM SYMPTOMS TABLE

HINT: Use the table below to help determine the cause of the problem. The numbers indicate likely causes of the problem in descending order. Check each part in order. If necessary, repair or replace faulty parts.

1. Front tires (Improperly inflated, unevenly worn) TW-3

2. Front wheel alignment (Incorrect) SP-4

3. Front suspension (Lower ball joint) SP-24

4. Steering column assembly SR-35

5. Torque sensor (Built into steering link assembly) -

6. Power steering motor -

7. Speed sensor -

8. Skid control ECU -

9. Battery and power source system -

10. Power steering ECU power source voltage and relay -

11. Power steering ECU PS-68

1. Calibration of turning angle sensor output and torque sensor zero point is not completed

2. Front tires (Improperly inflated, unevenly worn) TW-3

3. Front wheel alignment (Incorrect) SP-4

4. Front suspension (Lower ball joint) SP-24

5. Power steering link assembly PS-58

6. Torque sensor (Built into steering link assembly) -

7. Steering column assembly SR-35

8. Power steering motor -

9. Power steering ECU PS-68

1. Front suspension (Lower ball joint) SP-24

2. Speed sensor -

3. Skid control ECU -

4. Combination meter -

5. Engine speed detection circuit -

6. Torque sensor (Built into steering link assembly) -

7. Power steering motor -

8. Power steering ECU PS-68

1. Front suspension (Lower ball joint) SP-24

2. Steering intermediate shaft -

3. Power steering link assembly PS-58

1. Power steering link assembly PS-58

2. Steering column assembly SR-35

1. Power steering motor

1. Power steering link assembly PS-58

2. Steering column assembly SR-35

PS-13

POWER STEERING – POWER STEERING SYSTEM

ON-VEHICLE INSPECTION

1. CHECK STEERING EFFORT (TORQUE) NOTICE: Some service operations affect the SRS airbags. Be sure to read the precautionary notice for the SRS airbags before servicing (See page RS-1).

(a) Stop the vehicle on a level, paved surface and align

the wheels straight ahead.

(b) Disconnect the cable from the negative (-) battery

terminal.

CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

terminal.

(e) Using a torque wrench, check if the steering wheel

set nut is properly tightened.

Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf)

(f) Turn the power switch on (READY) so that the

power steering is available.

PS–3

C132536

(g) Turn the steering wheel 90 degrees to the right and

check steering effort (torque) while turning. Check in the opposite direction using the same manner.

Steering effort (Reference):

6.0 N*m (60 kgf*cm, 53 in.*lbf) or less

Inspect the power steering system if the value is not

within the specified range (See page PS-1). (h) Align the front wheels straight ahead. (i) Disconnect the cable from the negative (-) battery

terminal. (j) Install the steering pad (See page RS-346). (k) Connect the cable to the negative (-) battery

terminal. (l) Clear the DTCs (See page RS-41). (m) Perform initialization.

NOTICE:

Some systems need initialization after

reconnecting the cable to the negative battery

terminal (See page IN-43).

(n) Inspect the airbag warning light (See Page RS-33).

PS–4

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

ELECTRONIC POWER STEERING SYSTEM

PRECAUTION

1. NOTICE FOR INITIALIZATION

(a) When disconnecting the negative (-) battery

terminal, initialize the following systems after the terminal is reconnected.

System Name See procedure

SFI System (See page IN-43)

2. HANDLING PRECAUTIONS

(a) When handling the electronic parts:

(1) Avoid any impact to electronic parts such as

ECUs and relays. Replace these parts with new ones if dropped or subjected to a severe blow.

(2) Do not expose any electronic parts to high

temperature or humidity.

(3) Do not touch the connector terminals in order to

prevent deformation or malfunctions due to static electricity.

(4) If the power steering ECU assembly has been

replaced with a new one, initialize the rotation angle sensor value and calibrate the torque sensor zero point (See page PS-13).

(b) When handling the power steering link assembly:

(1) Avoid any impact to the power steering link

assembly, especially to the motor or torque sensor. Replace these parts with new ones if dropped or subjected to a severe blow.

(2) Do not pull on the wire harness when moving the

power steering link assembly.

(3) If the power steering link assembly has been

replaced with a new one, clear the rotation angle sensor calibration value, initialize the rotation angle sensor value, and calibrate the torque sensor zero point (See page PS-13).

connectors: (1) Turn the power switch on (IG), center the

steering wheel, and turn the power switch off again before disconnecting the connectors related to the electronic power steering system.

(2) Ensure that the power switch is off before

reconnecting the connectors related to the electronic power steering system. After reconnection, center the steering wheel and turn the power switch on (IG).

NOTICE: Do not turn the power switch on (IG) when the steering wheel is not centered.

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

(3) If the above operations are not carried out

properly, the steering center point (zero point) will deviate, which may lead to a difference in steering effort between right and lef t. If there is a difference in steering effort between right and left, perform steering zero point calibration (See page PS-13).

3. PRECAUTIONS FOR CAN COMMUNICATION

(a) CAN communication is used to receive information

from the skid control ECU, power steering ECU,

hybrid vehicle control ECU, and steering angle

sensor and to transmit warnings to the combination

meter. It is also used for communication between

terminals Tc and Ts of the DLC3. If there are any

problems in the CAN communication lines, DTCs

indicating communication line malfunctions are

output. (b) Perform troubleshooting for communication line

problems if CAN communication DTCs are output.

Be sure to start troubleshooting on the electronic

power steering system only when data

communication is normal. (c) Temporary fixing or rep air with byp ass wiring, etc. is

impossible because the length and path of each

CAN communication line is specified.

PS–5

Bypass Wire

F045104E02

4. BUS LINE REPAIR

(a) After repairing the bus line with solder, wrap the

repaired part with electrical tape.

NOTICE:

• The CANL bus line and CANH bus line must be installed together all the times. When installing, make sure to twist them. CAN bus lines are likely to be influenced by electrical noise if they are not twisted.

• The difference in length between the CANL bus line and CANH bus line should be 100 mm (3.937 in.) or less.

• Leave approximately 80 mm (3.150 in.) loose in the twisted wires around the connector.

(b) Do not use bypass wiring between the connectors.

NOTICE: The ability of the twisted bus lines to resist interference will be lost if bypass wiring is used.

C106492E01

PS–6

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

PARTS LOCATION

HYBRID VEHICLE CONTROL ECU

POWER STEERING LINK

- TORQUE SENSOR

- POWER STEERING MOTOR

- ROTATION ANGLE SENSOR

COMBINATION METER

- PS WARNING LIGHT

POWER STEERING ECU

SKID CONTROL ECU

DLC3

MAIN BODY ECU (INSTRUMENT PANEL J/B)

B150822E01

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

SYSTEM DIAGRAM

PS–7

Motor Rotation Angle Sensor

Torque Sensor

Skid Control ECU

Power Steering ECU Assembly

- Motor Relay

- Power Source Relay

- Motor Current Sensor

- Temperature Sensor

EPS Motor

CAN

Steering Angle Sensor

Hybrid Vehicle Control ECU

Combination Meter

Main Body ECU (Instrument Panel J/B)

Transmitting ECU

(transmitter)

Hybrid Vehicle Control ECU Power Steering ECU Assembly T/M variation information signal CAN

Receiving ECU Signals Communication method

B139367E01

PS–8

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

Transmitting ECU

(transmitter)

Hybrid Vehicle Control ECU Power Steering ECU Assembly Ready signal CAN Hybrid Vehicle Control ECU Power Steering ECU Assembly Ambient temperature signal CAN Hybrid Vehicle Control ECU Power Steering ECU Assembly Intake air temperature signal CAN

Hybrid Vehicle Control ECU Power Steering ECU Assembly

Hybrid Vehicle Control ECU Power Steering ECU Assembly Hybrid Vehicle Control ECU Power Steering ECU Assembly TC terminal condition CAN

Skid Control ECU Power Steering ECU Assembly Skid Control ECU Power Steering ECU Assembly Additional torque target signal CAN

Skid Control ECU Power Steering ECU Assembly Vehicle speed (SP1) status signal CAN Skid Control ECU Power Steering ECU Assembly Target steering angle signal CAN

Skid Control ECU Power Steering ECU Assembly Skid Control ECU Power Steering ECU Assembly Vehicle speed (SP1) signal CAN

Skid Control ECU Power Steering ECU Assembly Test mode signal CAN Skid Control ECU Power Steering ECU Assembly VSC controlling signal CAN

Skid Control ECU Power Steering ECU Assembly ABS controlling signal CAN Steering Angle Sensor Power Steering ECU Assembly Steering Angle Sensor Power Steering ECU Assembly +B open circuit signal CAN

Steering Angle Sensor Power Steering ECU Assembly Sensor malfunction signal CAN Steering Angle Sensor Power Steering ECU Assembly Steering angle signal CAN

Steering Angle Sensor Power Steering ECU Assembly

Main Body ECU

(Instrument Panel J/B)

Power Steering ECU Assembly Skid Control ECU EPS pinion angle invalid signal CAN Power Steering ECU Assembly Skid Control ECU

Power Steering ECU Assembly Skid Control ECU Power Steering ECU Assembly Hybrid Vehicle Control ECU EPS idle up request signal CAN

Power Steering ECU Assembly Skid Control ECU EPS torque sensor value signal CAN Power Steering ECU Assembly Skid Control ECU EPS pinion angle signal CAN Power Steering ECU Assembly Skid Control ECU EPS assisting current signal CAN Power Steering ECU Assembly Combination Meter EPS light ON request signal CAN Power Steering ECU Assembly Combination Meter EPS diagnostic information signal CAN

Receiving ECU Signals Communication method

Engine variation information signal

Vehicle destination information signal

Output command value (to EPS) signal

Target steering angle and additional torque valid signal

Data continuity (valid/invalid) signal

Zero point memory (in sensor) valid/invalid signal

Zero point (stored in steering angle sensor) signal

Power Steering ECU Assembly Vehicle model signal CAN

EPS assisting current invalid signal

EPS torque sensor value invalid signal

CAN

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

PS–9

SYSTEM DESCRIPTION

1. DESCRIPTION

(a) The EPS system generates assist torque to assist

steering effort through the operation of the motor installed on the power steering link assembly. The direction and amount of power assistance are determined by signals from the torque sensor, and controlled in accordance with vehicle speed. As a result, steering effort is controlled to be light during low speed driving and moderately high during high speed driving.

2. FUNCTIONS OF COMPONENTS

Components Function

Calculates degree of assistance needed based on steering torque and vehicle speed. Drives the motor based on motor electric angle

Power Steering ECU Assembly

Torque Sensor Detects steering effort generated when the steering wheel is turned. Power Steering Motor Hybrid Vehicle Control ECU Transmits ready signal to the power steering ECU.

obtained from the motor rotation angle sensor. Boosts battery voltage to generate motor drive voltage. Restricts power assistance to protect the system if the motor and ECU

overheat.

Located coaxially with the rack shaft. Its rotation is converted to the rectilinear motion of the steering rack via the ball screw nut and ball.

PS–10

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

3. OPERATION EXPLANATION

Torque Sensor Portion:

Input Shaft

To Power Steering ECU Assembly

Output Shaft

Torsion Bar

Torque Sensor

Power Steering Motor Portion:

From Power Steering ECU Assembly

Ball Screw Nut

Ball

Steering Rack

Power Steering Motor

To Power Steering ECU Assembly

Motor Rotation Angle Sensor

C106460E02

(a) The torque sensors is mounted on the input shaft to

the main shaft and on the output shaft to the pinion shaft. The input and output shafts are joined by a torsion bar.

(b) If the steering wheel is turned, the torsion bar twists,

resulting in a difference in the rotation angle detected by the torque sensor. The power steering ECU assembly calculates torque based on this difference.

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

proper assisting torque, according to vehicle speed, based on the torque obtained in the previous step. Then the ECU controls the motor drive circuit in order to allow it to generate assisting torque.

(d) A ball screw nut is attached to the motor shaft. It

converts the rotational motion of the motor into the rectilinear motion of the steering rack via the ball.

(e) The assisting force generated in the above process

will reduce the steering effort required by the driver.

PS–11

PS–12

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

HOW TO PROCEED WITH TROUBLESHOOTING

Perform troubleshooting according to the following flowchart. HINT:

• For further details, see the page given.

• *: Use the intelligent tester.

VEHICLE BROUGHT TO WORKSHOP

CUSTOMER PROBLEM ANALYSIS

CHECK DTC AND FREEZE FRAME DATA*

(a) Record the DTCs and freeze frame data.

CLEAR DTC AND FREEZE FRAME DATA*

PROBLEM SYMPTOM CONFIRMATION

SYMPTOM DOES NOT OCCUR (GO TO STEP

SYMPTOM OCCURS (GO TO STEP 7)

SYMPTOM SIMULATION

CHECK DTC*

(a) Recheck for DTCs.

HINT:

• Refer to the diagnostic trouble code chart if any DTCs are output.

• If any CAN communication system DTCs are output, perform troubleshooting on the CAN communication system first (See page CA-7).

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

PROBLEM SYMPTOMS TABLE

DTC CHART

PS–13

• If communication to the power steering ECU assembly is not established through the intelligent tester, inspect terminals SIL of the DLC3 and power steering ECU assembly, and inspect the IG circuit of the power steering ECU assembly.

NORMAL SYSTEM CODE IS OUTPUT : GO T O STEP 8

TROUBLE CODE IS OUTPUT: GO TO STEP 9

END

CIRCUIT INSPECTION*

IDENTIFICATION OF PROBLEM

REPAIR OR REPLACE

CONFIRMATION TEST

PS–14

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

CALIBRATION

1. ROTATION ANGLE SENSOR VALUE INITIALIZATION AND TORQUE SENSOR ZERO POINT CALIBRATION NOTICE: Clear the rotation angle sensor calibration value, initialize the rotation angle sensor value, and calibrate the torque sensor zero point if any of the following has occurred:

• The power steering ECU assembly has been

replaced.

• The power steering link assembly has been

replaced.

• Steering effort differs between left and right.

(a) Inspection before calibration

(1) Connect the intelligent tester (with CAN VIM) to

the DLC3. (2) Turn the power switch on (IG). (3) Turn the intelligent tester on. (4) Select "IG SUPPLY" from the data list. (5) Check the IG power supply voltage on the tester

screen.

DLC3

Intelligent Tester

C131977E01

Tester Display Measurement Item/Range Inspection Condition Reference Value

IG SUPPLY

ECU power source voltage/

Min.: 0 V, Max.: 25.5 V

Power switch on (IG) 10 to 14 V

Standard voltage:

10 to 14 V NOTICE: If the IG power supply voltage is 10 V or less, calibration cannot be performed. In this case, charge or replace the battery, and then perform calibration.

DLC3

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

Intelligent Tester

C131977E01

PS–15

(b) Rotation angle sensor calibration value clear,

rotation angle sensor value initialization, and torque sensor zero point calibration.

NOTICE:

• If DTC C1516 (Torque Sensor Zero Point Adjustment Incomplete) is stored, the torque sensor zero point cannot be calibrated. Clear the DTC before starting calibration.

• If DTC C1526 (Rotation Angle Sensor Initialization Incomplete) is stored, the rotation angle sensor value cannot be initialized. Clear the DTC before starting initialization.

(1) Connect the intelligent tester (with CAN VIM) to

the DLC3. (2) Turn the power switch on (IG). (3) Turn the intelligent tester on. (4) Select "TRQ SENSOR ADJ". (5) Follow the procedures on the tester display to

clear the rotation angle sensor calibration value,

initialize the rotation angle sensor value, and

calibrate the torque sensor zero point.

NOTICE:

• When initializing the rotation angle sensor value, observe the following to stabilize sensor voltage: After turning the power switch on (IG), wait for at least 2.5 seconds before turning the steering wheel. Do not turn the steering wheel quickly.

• The steering wheel will vibrate during torque sensor zero point calibration. Do not touch the steering wheel while it is vibrating or for 2 seconds after it stops.

PS–16

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

PROBLEM SYMPTOMS TABLE

ELECTRONIC POWER STEERING SYSTEM

Symptom Suspected Area See page

1. Front tires (Improperly inflated, unevenly worn) TW-3

2. Front wheel alignment (Incorrect) SP-4

3. Front suspension SP-24

4. Power steering link assembly PS-61

Steering is heavy.

Steering effort differs between right and left, or is uneven.

While driving, steering effort does not change in accordance with vehicle speed, or the steering wheel does not return to its centered position easily.

Friction sounds occur when turning the steering wheel during low speed driving.

High-pitched sounds (squeaking) occur when turning the steering wheel slowly with the vehicle stopped.

The steering wheel vibrates and noise occurs when turning the steering wheel with the vehicle stopped.

PS warning light remains on. PS warning light remains on PS-50 PS warning light does not come on. PS warning light does not come on PS-54

5. Steering column assembly SR-35

6. Battery and power source system -

7. Power source voltage of power steering ECU assembly PS-50

8. Power steering ECU assembly PS-68

9. Vehicle condition (The steering wheel is turned from left to right repeatedly with the vehicles stopped or a heavy load is continuously applied to the vehicle)

1. Power steering ECU assembly (Steering center point is not recorded correctly)

2. Front tires (Improperly inflated, unevenly worn) TW-3

3. Front wheel alignment (Incorrect) SP-4

4. Front suspension SP-24

5. Power steering link assembly PS-61

6. Steering column assembly SR-35

7. Power steering ECU assembly PS-68

1. Speed sensor BC-273

2. Skid control ECU BC-289

3. Power steering link assembly PS-61

4. Power steering ECU assembly PS-68

1. Power steering link assembly PS-61

2. Power steering ECU assembly PS-68 Power steering link assembly PS-61

1. Power steering link assembly PS-61

2. Steering column assembly PS-68

PS-13

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

TERMINALS OF ECU

1. TERMINALS OF ECU

PS–17

A66 A68

A67

HINT: The power steering ECU assembly uses waterproof connectors. Therefore, voltage or waveforms cannot be checked with the connectors connected to the vehicle.

Terminal No. (Symbols) Wiring Color Terminal Description

A66-2 (CANH) B High-level CAN bus line A66-3 (CANL) W Low-level CAN bus line

A66-4 (PIG) W Power source

A66-5 (PGND) B Power ground

A66-9 (IG) O IG power source

A67-1 (RZG) W Rotation angle sensor power source circuit ground

A67-2 (SRZG) BR Rotation angle sensor shield ground

A67-3 (RZV) G Rotation angle sensor power source A67-4 (TRQV) P Torque sensor power source A67-6 (TQG1) L Torque sensor power source circuit ground A67-7 (RZSN) B SIN phase input signal (Rotation angle sensor) A67-8 (RZCS) R COS phase input signal (Rotation angle sensor)

A67-9 (INSN) B SIN phase input signal (Torque sensor input shaft side)

A67-10 (INCS) R COS phase input signal (Torque sensor input shaft side)

A67-11 (OUSN) W SIN phase input signal (Torque sensor output shaft side) A67-12 (OUCS) G COS phase input signal (Torque sensor output shaft side) A67-13 (TQG2) Y Torque sensor detection circuit ground

A68-1 (V) R V phase motor output

A68-2 (U) B U phase motor output

A68-3 (W) W W phase motor output

C116647E02

A66

2. INSPECT WIRE HARNESS SIDE CONNECTOR

A68

A67

C116648E02

PS–18

Terminal No. (Symbols) Wiring Color Terminal Description Condition Specified Conditi on

A66-4 (PIG) - A66-5 (PGND) W - B Power source Always 10 to 14 V

A66-5 (PGND) - Body ground B - Body ground Power ground Always Below 1 Ω

A66-9 (IG) - A66-5 (PGND) O - B IG power source Power switch on (IG) 10 to 14 V A68-2 (U) - A68-3 (W)/A68-1 (V) B - W/R U phase motor output Always Below 1 Ω A68-3 (W) - A68-2 (U)/A68-1 (V) W - BR W phase motor output Always Below 1 Ω

A68-1 (V) - A68-2 (U)/ A68-3 (W) R - B/W V phase motor output Always Below 1 Ω

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

DIAGNOSIS SYSTEM

CANH

SIL

1. CHECK DLC3

(a) The vehicle's ECU uses ISO 15765-4 for

communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format.

CANL

Symbols (Terminal No.) Terminal Description Condition Specified Condition

SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω

BAT (16) - Body ground Battery positive Always 10 to 14 V

CANH (6) - CANL (14) CAN bus line

CANH (6) - CG (4) HIGH-level CAN bus line

CANL (14) - CG (4) LOW-level CAN bus line

CANH (6) - BAT (16) HIGH-level CAN bus line

CANL (14) - BAT (16) LOW-level CAN bus line

BAT

H100769E16

Power switch off Power switch off Power switch off Power switch off Power switch off

54 to 69 Ω 200 Ω or higher 200 Ω or higher

6 kΩ or higher 6 kΩ or higher

NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the power switch, any other switches or the doors.

If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector.

DLC3

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

Intelligent Tester

C131977E01

B150816

(b) Connect the cable of the intelligent tester (with CAN

VIM) to the DLC3, turn the power switch on (IG) and attempt to use the intelligent tester. If the screen displays a communication error message, a problem exists in the vehicle side or tester side. HINT:

• If communication is normal when the tool is connected to another vehicle, inspect the DLC3 on the original vehicle.

• If communication is still impossible when the tool is connected to another vehicle, the problem is probably in the tool itself. Consult the Service Department listed in the tool's instruction manual.

2. P/S WARNING LIGHT

(a) Check that the PS warning light comes on when the

power switch is turned on (IG) and goes off in approximately 3 seconds. If the warning light does not come on or remains on, inspect the PS warning light circuit.

Trouble Area See Procedure

PS warning light circuit (Remains on) PS-50 PS warning light circuit (Does not come

on)

PS-54

PS–19

DLC3

DTC CHECK / CLEAR

1. CHECK FOR DTCs

(a) Connect the intelligent tester (with CAN VIM) to the

DLC3. (b) Turn the power switch on (IG). (c) Turn the intelligent tester on. (d) Read the DTCs by following the display on the

intelligent tester.

HINT:

Refer to the intelligent tester operator's manual for

further details.

Intelligent Tester

C131977E01

PS–20

DLC3

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

2. CLEAR DTCs

(a) Connect the intelligent tester (with CAN VIM) to the

DLC3. (b) Turn the power switch on (IG). (c) Turn the intelligent tester on. (d) Clear the DTCs by following the display on the

intelligent tester.

HINT:

Refer to the intelligent tester operator's manual for

further details.

Intelligent Tester

C131977E01

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

FREEZE FRAME DATA

1. FREEZE FRAME DATA NOTICE:

• It is difficult to show the specified values

(judgement values) clearly because freeze frame data values change significantly due to differences in measurement conditions, surroundings, or vehicle conditions. For this reason, there may be a problem even when the values are within specifications.

• T urn the power switch on (IG) and p ark the vehicle

on level ground. Check the freeze frame data by using the intelligent tester.

(a) Connect the intelligent tester (with CAN VIM) to the

DLC3.

(b) Turn the power switch on (IG) and check the freeze

frame data by following the prompts on the intelligent tester's display screen.

PS–21

DLC3

Intelligent Tester

Tester Display Item Description/Range Inspection Condition Reference Value

SPD

ENGINE REV

MOTOR ACTUAL

COMMAND VALUE

STR ANGL VEL

THERMISTOR TEMP

PIG SUPPLY

IG SUPPLY

STR SENS SIG

TRQ1

C131977E01

Vehicle speed from meter/ Min.: 0 km/h (0 mph), Max.: 300 km/h (186 mph)

Engine revolution/ Min.: 0 rpm, Max.: 12.800 rpm

Amount of current to motor/ Min.: -128 A, Max.: 127 A

Demanded amount of current to motor/ Min.: -128 A, Max.: 127 A

Steering angle speed/ Min.: -4.096 deg/sec, Max.: 4.064 deg/sec

ECU substrate temperature/ Min.: -50°C, Max.: 205°C

Power source voltage to activate motor/ Min.: 0 V, Max.: 25.5 V

ECU power source voltage/ Min.: 0 V, Max.: 25.5 V

Steering angle sensor signal status/ OK or NG

Torque sensor 1 rotation angle/ Min.: 0 deg, Max.: 360 deg

1. Vehicle is stopped

2. V ehicle is driven at a constant speed

Engine is running at a constant speed

Power steering is in operation

Steering wheel is turned

Power switch on (IG) -

Power steering is in operation 10 to 14 V

Power switch on (IG) 10 to 14 V

Steering wheel is turned

1. 0 km/h (0 mph)

2. No significant fluctuation

No significant fluctuation Value changes in proportion to

steering effort Value changes in proportion to

steering effort

Value changes in proportion to steering speed

Value changes from 0 to 360° every 22.5° of steering angle

PS–22

Tester Display Item Description/Range Inspection Condition Reference Value

TRQ2

TRQ1 ZERO VAL

TRQ2 ZERO VAL

STEERING TORQU

MOTOR ROTATE

COMMAND VALUE 2

PIG2 VOLTAGE

MOTOR VOLTAGE

MTR TERMINAL (U)

MTR TERMINAL (V)

MTR TERMINAL (W)

IG ON/OFF TIMES

MTR OVERHEAT

MTR LOW POWER

ENG REV INTER

STR ANGL INTER

SPD SIG INVALID

BATTERY VOLTAGE

PS ASSIST SIG

# CODES

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

Torque sensor 2 rotation angle/ Min.: 0 deg, Max.: 360 deg

Zero point value of torque sensor 1/ Min.: 0 deg, Max.: 360 deg

Zero point value of torque sensor 2/ Min.: 0 deg, Max.: 360 deg

Steering torque/ Min.: -7.0 N*m, Max.: 7.0 N*m

Motor rotation angle/ Min.: 0 deg, Max.: 360 deg

Demanded amount of current to motor 2/ Min.: -128 A, Max.: 127 A

Motor drive voltage/ Min.: 0 V, Max.: 64 V

Motor power source voltage/ Min.: 0 V, Max.: 64 V

Motor terminal voltage (U phase)/ Min.: 0 V, Max.: 64 V

Motor terminal voltage (V phase)/ Min.: 0 V, Max.: 64V

Motor terminal voltage (W phase)/ Min.: 0 V, Max.: 64 V

Number of times IG switch is turned on after DTC detection/ Min.: 0 time, Max.: 255 times

Continuous overheat prevention control record/ REC or UNREC

PIG power source voltage drop record/ REC or UNREC

Record of power revolution signal interruption/ REC or UNREC

Record of steering angle sensor signal interruption/ REC or UNREC

Record of vehicle speed signal invalid/ REC or UNREC

Battery voltage/ Min.: 0 V, Max.: 25.5 V

Power steering assist signal/ ON or OFF

Number of detected DTCs when freeze frame data is stored/ Min.: 0, Max.: 255

Steering wheel is turned

Steering wheel is not turned (without load)

Steering wheel is turned

Power steering is in operation 27 to 34 V

Power steering is in operation 0 to 34 V

- 10 to 14 V

Power switch on (IG) -

Value changes from 0 to 360° every 22.5° of steering angle

Values differ depending on vehicle

Value changes in proportion to steering effort

Value changes from 0 to 360° every 5° of steering angle

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

FAIL-SAFE CHART

If a problem occurs in the electronic power steering system, the PS warning light will come on in the combination meter and steering power assistance will be stopped, fixed at a particular point, or decreased simultaneously to protect the system.

DTC No. Malfunction Fail-safe

C1511 C1512 C1513 C1521 C1522 C1523 C1524 C1528 Motor Rotation Angle Sensor Malfunction C1531 C1532 C1555 Motor Relay Welding Failure

C1533 ECU Malfunction

C1534 ECU Malfunction

C1541 Vehicle Speed Signal Malfunction U0129 Lost Communication With Skid Control ECU

Torque Sensor Circuit Malfunction

Motor Circuit Malfunction

ECU Malfunction

Power assistance stops.

System overheat prevention control continues without using the substrate temperature sensor.

Torque sensor zero point and rotation angle sensor calibration value are set to the default values.

Amount of power assistance is fixed for a speed of 100 km/h (62 mph).

PS–23

HINT: The amount of power assistance may be decreased to prevent the motor and ECUs from overheating if the steering wheel is continuously turned when the vehicle is either stopped or driven at a low speed, or if the steering wheel is kept at either full lock position for a long time. In that case, the amount of power assistance will return to normal if the steering wheel is not turned for approximately 10 minutes with the engine idling.

PS–24

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

DATA LIST / ACTIVE TEST

1. DATA LIST

HINT: By accessing the data list displayed on the intelligent tester, values of switches, sensors and other related parts can be checked without removing any parts. Reading the data list is the first step in troubleshooting and is one method to shorten labor time.

(a) Connect the intelligent tester (with CAN VIM) to the

DLC3. (b) Turn the power switch on (IG). (c) Operate the intelligent tester according to the steps

on the display and select the data list.

DLC3

Intelligent Tester

Tester Display Measurement Item/Range Normal Condition Reference Value

SPD

ENGINE REV

MOTOR ACTUAL

COMMAND VALUE

STR ANGL VEL

THERMISTOR TEMP

PIG SUPPLY

IG SUPPLY

STR SENS SIG

TRQ1

TRQ2

TRQ1 ZERO VAL

C131977E01

Vehicle speed from meter/ Min.: 0 km/h (0 mph), Max.: 300 km/h (186 mph)

Engine revolution/ Min.: 0 rpm, Max.: 12.800 rpm

Amount of current to motor/ Min.: -128 A, Max.: 127 A

Demanded amount of current to motor/ Min.: -128 A, Max.: 127 A

Steering angle speed/ Min.: -4.096 deg/sec, Max.: 4.064 deg/sec

ECU substrate temperature/ Min.: -50°C, Max.: 205°C

Power source voltage to activate motor/ Min.: 0 V, Max.: 25.5 V

ECU power source voltage/ Min.: 0 V, Max.: 25.5 V

Steering angle sensor signal status/ OK or NG

Torque sensor 1 rotation angle/ Min.: 0 deg, Max.: 360 deg

Torque sensor 2 rotation angle/ Min.: 0 deg, Max.: 360 deg

Zero point value of torque sensor 1/ Min.: 0 deg, Max.: 360 deg

1. Vehicle is stopped

2. V ehicle is driven at a const ant speed

Engine is running at a constant speed

Power steering is in operation

Steering wheel is turned

Power switch on (IG) -

Power steering is in operation 10 to 14 V

Power switch on (IG) 10 to 14 V

Steering wheel is turned

Steering wheel is not turned (without load)

1. 0 km/h (0 mph)

2. No significant fluctuation

No significant fluctuation Value changes in proportion to

steering effort Value changes in proportion to

steering effort

Value changes in proportion to steering speed

Value changes from 0 to 360° every 22.5° of steering angle

Values differ depending on vehicle

Tester Display Measurement Item/Range Normal Condition Reference Value

TRQ2 ZERO VAL

STEERING TORQU

MOTOR ROTATE

COMMAND VALUE 2

PIG2 VOLTAGE

MOTOR VOLTAGE

MTR TERMINAL (U)

MTR TERMINAL (V)

MTR TERMINAL (W)

IG ON/OFF TIMES

MTR OVERHEAT

MTR LOW POWER

ENG REV INTER

STR ANGL INTER

SPD SIG INVALID

BATTERY VOLTAGE

PS ASSIST SIG

# CODES

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

Zero point value of torque sensor 2/ Min.: 0 deg, Max.: 360 deg

Steering torque/ Min.: -7.0 N*m, Max.: 7.0 N*m

Motor rotation angle/ Min.: 0 deg, Max.: 360 deg

Demanded amount of current to motor 2/ Min.: -128 A, Max.: 127 A

Motor drive voltage/ Min.: 0 V, Max.: 64 V

Motor power source voltage/ Min.: 0 V, Max.: 64 V

Motor terminal voltage (U phase)/ Min.: 0 V, Max.: 64 V

Motor terminal voltage (V phase)/ Min.: 0 V, Max.: 64V

Motor terminal voltage (W phase)/ Min.: 0 V, Max.: 64 V

Number of times IG switch is turned on after DTC detection/ Min.: 0 time, Max.: 255 times

Continuous overheat prevention control record/ REC or UNREC

PIG power source voltage drop record/ REC or UNREC

Record of power revolution signal interruption/ REC or UNREC

Record of steering angle sensor signal interruption/ REC or UNREC

Record of vehicle speed signal invalid/ REC or UNREC

Battery voltage/ Min.: 0 V, Max.: 25.5 V

Power steering assist signal/ ON or OFF

Number of detected DTCs when freeze frame data is stored/ Min.: 0, Max.: 255

Steering wheel is not turned (without load)

Steering wheel is turned

Power steering is in operation 27 to 34 V

Power steering is in operation 0 to 34 V

- 10 to 14 V

Power switch on (IG) -

Values differ depending on vehicle

Value changes in proportion to steering effort

Value changes from 0 to 360° every 5° of steering angle

PS–25

PS–26

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

DIAGNOSTIC TROUBLE CODE CHART

HINT: If a trouble code is displayed during the DTC check, check the circuit indicated by the DTC. For details of each code, turn to the page for the respective DTC code in the DTC chart

ELECTRONIC POWER STEERING SYSTEM DIAGNOSTIC TROUBLE CODE CHART:

DTC Code Detection Item Trouble Area See page

1. Wire harness

C1511 Torque Sensor Circuit Malfunction

C1512 Torque Sensor Circuit Malfunction

C1513 Torque Sensor Circuit Malfunction

C1515 Torque Sensor Zero Point Adjustment Undone - PS-28 C1516 C1521 Motor Circuit Malfunction Power steering ECU assembly PS-33

C1522 Motor Circuit Malfunction Power steering ECU assembly PS-33

C1523 Motor Circuit Malfunction

C1524 Motor Circuit Malfunction

C1525 Rotation Angle Sensor Initialization Undone - PS-28 C1526 Rotation Angle Sensor Initialization Incomplete - PS-30

C1528 Motor Rotation Angle Sensor Malfunction

C1531 ECU Malfunction Power steering ECU assembly PS-33 C1532 ECU Malfunction Power steering ECU assembly PS-33 C1533 ECU Malfunction Power steering ECU assembly PS-33 C1534 ECU Malfunction Power steering ECU assembly PS-33

C1541 Vehicle Speed Signal Malfunction

C1551 IG Power Supply Voltage Malfunction Power steering ECU assembly PS-44

C1552 PIG Power Supply Voltage Malfunction

C1554 Power Supply Relay Failure Power steering ECU assembly PS-33 C1555 Motor Relay Welding Failure Power steering ECU assembly PS-33

C1581 Assist Map Number Un-Writing

U0073 Control Module Communication Bus OFF CAN communication system PS-49

Torque Sensor Ze ro Point Adjustment Incomplete

2. Torque sensor (built into power steering link

assembly)

3. Power steering ECU assembly

1. Wire harness

2. Torque sensor (built into power steering link

assembly)

3. Power steering ECU assembly

1. Wire harness

2. Torque sensor (built into power steering link

assembly)

3. Power steering ECU assembly

- PS-30

1. Wire harness

2. Power steering motor (built into power

steering link assembly)

3. Power steering ECU assembly

1. Wire harness

2. Power steering motor (built into power

steering link assembly)

3. Power steering ECU assembly

1. Motor rotation angle sensor (built into power

steering link assembly)

2. Wire harness

3. Power steering earth wire

4. Power steering ECU assembly

1. Speed sensor circuit

2. Skid control ECU

3. CAN communication system

4. Power steering ECU assembly

1. EPS fuse

2. Wire harness

3. Power steering ECU assembly

1. Hybrid vehicle control ECU

2. Main body ECU (Instrument panel J/B)

3. Power steering ECU assembly

PS-24

PS-35

PS-38

PS-42

PS-45

PS-47

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

DTC Code Detection Item Trouble Area See page

U0100 Lost Communication with ECM/PCM "A"

U0129 Lost Communication with Skid Control ECU

U0293 Lost Communication with HV ECU

1. CAN communication system

2. Hybrid vehicle control ECU

1. CAN communication system

2. Skid control ECU

1. CAN communication system

2. Hybrid vehicle control ECU

PS–27

PS-49

PS–28

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

DTC C1511 Torque Sensor Circuit Malfunction DTC C1512 Torque Sensor Circuit Malfunction DTC C1513 Torque Sensor Circuit Malfunction

DESCRIPTION

The torque sensor converts rotation torque input to the steering wheel into an electrical signal and sends it to the ECU. Based on this signal, the ECU detects steering effort.

DTC No. Detection Item Trouble Area

• Wire harness

C1511 Torque sensor (TRQ1) signal error or stop

C1512 Torque sensor (TRQ2) signal error or stop

C1513 Deviation between torque sensors

• Torque sensor (built into power steering link assembly)

• Power steering ECU assembly

• Wire harness

• Torque sensor (built into power steering link assembly)

• Power steering ECU assembly

• Wire harness

• Torque sensor (built into power steering link assembly)

• Power steering ECU assembly

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

WIRING DIAGRAM

A71 Torque Sensor

PS–29

A67 Power Steering ECU Assembly

INCS

INSN

TRQV

OUCS

OUSN

TQG2

TQG1

INCS

INSN

TRQV

OUCS

OUSN

TQG2

TQG1

C106487E10

PS–30

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

INSPECTION PROCEDURE

CHECK HARNESS AND CONNECTOR (POWER STEERING ECU ASSEMBLY - TORQUE

SENSOR)

Wire Harness Side Connector Front View:

A71 Torque Sensor

INSN

TRQV

INCS

OUCS

OUSN

TQG1

TQG2

A67

Power Steering ECU Assembly

TQG1

TQG2

INSN

INCS

OUSN

TRQV

OUCS

C116652E02

(a) Disconnect the A67 connector from the power steering

ECU assembly. (b) Disconnect the A71 connector from the torque sensor. (c) Measure the resistance according to the value(s) in the

table below.

Standard resistance

Tester connection

(Symbols)

A71-1 (INCS) - A67-10 (INCS) Always Below 1 Ω

A71-2 (INSN) - A67-9 (INSN) Always Below 1 Ω

A71-4 (TRQV) - A67-4 (TRQV) Always Below 1 Ω

A71-5 (OUCS) - A67-12

(OUCS)

A71-6 (OUSN) - A67-11

(OUSN)

A71-7 (TQG2) - A67-13

(TQG2)

A71-8 (TQG1) - A67-6 (TQG1) Always Below 1 Ω

A71-1 (INCS) - Body ground Always 10 kΩ or higher A71-2 (INSN) - Body ground Always 10 kΩ or higher

A71-4 (TRQV) - Body ground Always 10 kΩ or higher A71-5 (OUCS) - Body ground Always 10 kΩ or higher A71-6 (OUSN) - Body ground Always 10 kΩ or higher

A71-7 (TQG2) - Body ground Always 10 kΩ or higher

A71-8 (TQG1) - Body ground Always 10 kΩ or higher

Condition Specified condition

Always Below 1 Ω

INSPECT POWER STEERING LINK ASSEMBLY (TORQUE SENSOR)

Torque Sensor:

A71

C102953E11

REPAIR OR REPLACE HARNESS OR CONNECTOR

(a) Measure the resistance according to the value(s) in the

table below.

Standard resistance

Tester connection

(Symbols) A71-1 (INCS) - A71-7 (TQG2) Always 90 to 170 Ω A71-2 (INSN) - A71-7 (TQG2) Always 300 to 430 Ω

A71-4 (TRQV) - A71-8 (TQG1) Always 4 to 14 Ω A71-5 (OUCS) - A71-7 (TQG2) Always 90 to 170 Ω A71-6 (OUSN) - A71-7 (TQG2) Always 300 to 430 Ω

Condition Specified condition

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

NOTICE: If replacing the power steering link assembly, clear the rotation angle sensor calibration value, initialize the rotation angle sensor value, and calibrate the torque sensor zero point (See page PS-13).

PS–31

REPLACE POWER STEERING ECU ASSEMBLY

(a) Replace the power steering ECU assembly (See page

PS-68).

INITIALIZE ROTATION ANGLE SENSOR AND CALIBRATE TORQUE SENSOR ZERO POINT

(a) Initialize the rotation angle sensor value and calibrate the

torque sensor zero point (See page PS-13).

RECONFIRM DTC

REPLACE POWER STEERING LINK ASSEMBLY (See page PS-58)

END

(a) Check for DTCs (See page PS-17).

Result

DTC Condition Proceed to DTC is not output A DTC C1511, C1512, or C1513 is output B

REPLACE POWER STEERING LINK ASSEMBLY (See page PS-58)

PS–32

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

DTC C1515 Torque Sensor Zero Point Adjustment Undone DTC C1525 Rotation Angle Sensor Initialization Undone

DESCRIPTION

These DTCs do not indicate a malfunction. The power steering ECU assembly outputs these DTCs when it determines that rotation angle sensor value initialization and torque sensor zero point calibration have not been performed. When IG terminal voltage is 9 V or less, rotation angle sensor initialization and torque sensor zero point calibration cannot be performed.

DTC No. DTC Detection Condition Procedure

C1515

C1525

This DTC is detected when torque sensor zero point calibration has not been performed.

This DTC is detected when rotation angle sensor value initialization has not been performed.

INSPECTION PROCEDURE

There is no malfunction if this DTC is not output again after performing zero point calibration.

There is no malfunction if this DTC is not output again after performing rotation angle sensor value initialization.

INITIALIZE ROTATION ANGLE SENSOR AND CALIBRATE TORQUE SENSOR ZERO POINT

(a) Initialize the rotation angle sensor and calibrate the

torque sensor zero point (See page PS-13).

RECONFIRM DTC

(a) Check for DTCs (See page PS-17).

Result

Result Proceed to

DTCs are still output after performing rotation angle sensor value initialization and steering zero point calibration 3 times.

DTCs are still output after performing rotation angle sensor value initialization and steering zero point calibration once or twice.

Normal system code is output. C

HINT: Replace the power steering ECU assembly if DTCs are still output after performing rotation angle sensor value initialization and steering zero point calibration 3 times.

Go to step 1

END

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

REPLACE POWER STEERING ECU ASSEMBLY

(a) Replace the power steering ECU assembly (See page

PS-68).

INITIALIZE ROTATION ANGLE SENSOR AND CALIBRATE TORQUE SENSOR ZERO POINT

(a) Initialize the rotation angle sensor value and calibrate the

torque sensor zero point (See page PS-13).

RECONFIRM DTC

(a) Check for DTCs (See page PS-17).

Result

Result Proceed to

DTCs are still output after performing rotation angle sensor value initialization and steering zero point calibration 3 times.

DTCs are still output after performing rotation angle sensor value initialization and steering zero point calibration once or twice.

Normal system code is output. C

PS–33

HINT: Replace the power steering link assembly if DTCs are still output after performing rotation angle sensor value initialization and steering zero point calibration 3 times.

Go to step 4

END

REPLACE POWER STEERING LINK ASSEMBLY (See page PS-58)

PS–34

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

DTC C1516

Torque Sensor Zero Point Adjustment Incomplete

DTC C1526 Rotation Angle Sensor Initialization Incomplete

DESCRIPTION

DTC No. DTC Detection Condition Procedure

C1516

C1526

Steering zero point calibration is incomplete due to the steering wheel being touched during calibration.

Rotation angle sensor value initialization is incomplete due to the steering wheel being touched during calibration.

INSPECTION PROCEDURE

CLEAR DTC

There is no malfunction if this DTC is not output again after clearing the DTCs and torque sensor calibration value, and performing zero point calibration.

There is no malfunction if this DTC is not output again after clearing the DTCs and torque sensor calibration value, and performing rotation angle sensor value initialization.

(a) Clear the DTCs (See page PS-17).

INITIALIZE ROTATION ANGLE SENSOR AND CALIBRATE TORQUE SENSOR ZERO POINT

(a) Initialize the rotation angle sensor and calibrate the

torque sensor zero point (See page PS-13).

RECONFIRM DTC

(a) Check for DTCs (See page PS-17).

Result

Result Proceed to

DTCs are still output after performing rotation angle sensor value initialization and steering zero point calibration 3 times.

DTCs are still output after performing rotation angle sensor value initialization and steering zero point calibration once or twice.

Normal system code is output. C

HINT: Replace the power steering ECU assembly if DTCs are still output after performing rotation angle sensor value initialization and steering zero point calibration 3 times.

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

PS–35

Go to step 2

END

REPLACE POWER STEERING ECU ASSEMBLY

(a) Replace the power steering ECU assembly (See page

PS-68).

CLEAR DTC

(a) Clear the DTCs (See page PS-17).

INITIALIZE ROTATION ANGLE SENSOR AND CALIBRATE TORQUE SENSOR ZERO POINT

RECONFIRM DTC

(a) Initialize the rotation angle sensor value and calibrate the

torque sensor zero point (See page PS-13).

(a) Check for DTCs (See page PS-17).

Result

Result Proceed to

DTCs are still output after performing rotation angle sensor value initialization and steering zero point calibration 3 times.

DTCs are still output after performing rotation angle sensor value initialization and steering zero point calibration once or twice.

Normal system code is output. C

HINT: Replace the power steering link assembly if DTCs are still output after performing rotation angle sensor value initialization and steering zero point calibration 3 times.

Go to step 6

END

PS–36

REPLACE POWER STEERING LINK ASSEMBLY (See page PS-58)

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

DTC C1521 Motor Circuit Malfunction DTC C1522 Motor Circuit Malfunction DTC C1531 ECU Malfunction DTC C1532 ECU Malfunction DTC C1533 ECU Malfunction DTC C1534 ECU Malfunction DTC C1554 Power Supply Relay Failure DTC C1555 Motor Relay Welding Failure

PS–37

DESCRIPTION

If the power steering ECU assembly detects these DTCs, it will shut off the motor current sensor, power source relay, motor relay circuit (built into the power steering ECU assembly) and stop power assistance. However, power assistance will continue if DTC C1533 or C1534 is output.

DTC No. DTC Detection Item Trouble Area

C1521 Motor overcurrent Power steering ECU assembly C1522 Motor current sensor malfunction Power steering ECU assembly C1531 ECU internal malfunction (CPU malfunction) is detected Power steering ECU assembly

C1532

C1533 C1534 ECU internal malfunction (EEPROM error) is detected Power steering ECU assembly

C1554 Power source relay malfunction is detected. Power steering ECU assembly C1555 Motor relay malfunction is detected. Power steering ECU assembly

ECU internal malfunction (Peripheral circuit malfunction) is detected

ECU internal malfunction (Substrate temp sensor malfunction) is detected

Power steering ECU assembly

INSPECTION PROCEDURE

RECONFIRM DTC

(a) Check for DTCs (See page PS-17).

OK:

DTCs are not output. NOTICE: If replacing the power steering ECU assembly, initialize the rotation angle sensor value and calibrate the torque sensor zero point (See page PS-

13).

REPLACE POWER STEERING ECU ASSEMBLY (See page PS-68)

PS–38

USE SIMULATION METHOD TO CHECK

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

DTC C1523 Motor Circuit Malfunction DTC C1524 Motor Circuit Malfunction

DESCRIPTION

The power steering ECU assembly supplies current to the power steering motor through this circuit.

DTC No. DTC Detection Item Trouble Area

• Wire harness

C1523 Excessively large current deviation

C1524 Voltage error between motor terminals

WIRING DIAGRAM

• Power steering motor (built into power steering link assembly)

• Power steering ECU assembly

• Wire harness

• Power steering motor (built into power steering link assembly)

• Power steering ECU assembly

PS–39

Power Steering Motor

A69

Power Steering ECU Assembly

(Shielded)

A68

B124179E02

PS–40

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

INSPECTION PROCEDURE

CHECK HARNESS AND CONNECTOR (POWER STEERING ECU ASSEMBLY - POWER

STEERING MOTOR)

Wire Harness Side Connector Front View:

Power Steering Motor

A69

A68 Power Steering ECU Assembly

C116653E03

(a) Disconnect the A68 connector from the power steering

ECU assembly.

(b) Disconnect the A69 connector from the power steering

motor.

table below.

Standard resistance

Tester Connection Condition Specified Condition A68-1 (V) - A69-2 (V) Always Below 1 Ω A68-2 (U) - A69-3 (U) Always Below 1 Ω

A68-3 (W) - A69-1 (W) Always Below 1 Ω A68-1 (V) - Body ground Always 10 kΩ or higher A68-2 (U) - Body ground Always 10 kΩ or higher

A68-3 (W) - Body ground Always 10 kΩ or higher

REPAIR OR REPLACE HARNESS OR CONNECTOR

INSPECT POWER STEERING LINK ASSEMBLY (POWER STEERING MOTOR)

Power Steering Motor:

(a) Measure the resistance according to the value(s) in the

table below.

Standard resistance

C116649E01

Tester Connection Condition Specified Condition

A69-3 (U) - A69-2 (V) Always Below 1 Ω A69-2 (V) - A69-1 (W) Always Below 1 Ω A69-1 (W) - A69-3 (U) Always Below 1 Ω

A69-3 (U) - Motor body Always 10 kΩ or higher A69-2 (V) - Motor body Always 10 kΩ or higher

A69-1 (W) - Motor body Always 10 kΩ or higher

NOTICE:

• If replacing the power steering link assembly, clear the rotation angle sensor calibration value, initialize the rotation angle sensor, and calibrate the torque sensor zero point (See page PS-13).

• If replacing the power steering ECU assembly, initialize the rotation angle sensor value and calibrate the torque sensor zero point (See page

PS-13).

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

PS–41

REPLACE POWER STEERING ECU ASSEMBLY (See page PS-68)

REPLACE POWER STEERING LINK ASSEMBLY (See page PS-58)

PS–42

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

DTC C1528 Motor Rotation Angle Sensor Malfunction

DESCRIPTION

The motor rotation angle sensor detects the motor rotation angle and sends this informatio n to the powe r steering ECU assembly.

DTC No. DTC Detection Item Trouble Area

• Motor rotation angle sensor (built into power steering link assembly)

• Wire harness

• Power steering earth wire

• Power steering ECU assembly

C1528

WIRING DIAGRAM

Motor rotation angle sensor malfunction (e.g. An open, short to ground, or short to B+ in the rotation angle sensor circuit)

Power Steering Motor (Rotation Angle Sensor)

RZV

A70

RZSN

RZCS

RZG

A70

(Shielded)

Power Steering ECU Assembly

A67

SRZG

RZV

A67

RZSN

A67

RZCS

A67

RZG

A67

C106486E05

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

INSPECTION PROCEDURE

CHECK POWER STEERING EARTH WIRE (POWER STEERING LINK ASSEMBLY - BODY

GROUND)

PS–43

(a) Check the installation condition of the power steering

earth wire connected to the power steering link assembly.

OK:

The power steering earth wire is securely installed to the power steering link assembly and body ground.

CHECK HARNESS AND CONNECTOR (POWER STEERING ECU ASSEMBLY - MOTOR

ROTATION ANGLE SENSOR)

Wire Harness Side Connector Front View:

A70 Motor Rotation Angle Sensor

RZG

RZSN

RZV

A67

Power Steering ECU Assembly

RZG

RZCS

REINSTALL POWER STEERING EARTH WIRE

(a) Disconnect the A70 connector from the power steering

link assembly.

(b) Disconnect the A67 connector from the power steering

ECU.

table below.

Standard resistance

Tester connection

(Symbols)

A70-1 (RZSN) - A67-7 (RZSN) Always Below 1 Ω

A70-2 (RZG) - A67-1 (RZG) Always Below 1 Ω

A70-3 (RZV) - A67-3 (RZV) Always Below 1 Ω A70-4 (RZCS) - A67-8 (RZCS) Always Below 1 Ω A70-1 (RZSN) - Body ground Always 10 kΩ or higher

A70-2 (RZG) - Body ground Always 10 kΩ or higher A70-3 (RZV) - Body ground Always 10 kΩ or higher

A70-4 (RZCS) - Body ground Always 10 kΩ or higher

Condition Specified condition

RZSN

RZCS

RZV

C116654E03

REPAIR OR REPLACE HARNESS OR CONNECTOR

PS–44

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

INSPECT POWER STEERING LINK ASSEMBLY (MOTOR ROTATION ANGLE SENSOR)

Motor Rotation Angle Sensor:

RZG

RZCS

REPLACE POWER STEERING ECU ASSEMBLY

RZSN

A70

RZV

B150840E01

(a) Measure the resistance according to the value(s) in the

table below.

Standard resistance

Tester connection

(Symbols)

A70-1 (RZSN) - A70-2 (RZG) Always 50 to 140 Ω

A70-3 (RZV) - A70-2 (RZG) Always 50 to 140 Ω

A70-4 (RZCS) - A70-2 (RZG) Always 15 to 45 Ω

Condition Specified condition

REPLACE POWER STEERING LINK ASSEMBLY (See page PS-58)

(a) Replace the power steering ECU assembly (See page

PS-68).

INITIALIZE ROTATION ANGLE SENSOR AND CALIBRATE TORQUE SENSOR ZERO POINT

(a) Initialize the rotation angle sensor value and calibrate the

torque sensor zero point (See page PS-13).

RECONFIRM DTC

(a) Check for DTCs (See page PS-17).

Result

DTC Condition Proceed to DTC is not output A DTC C1528 is output B

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

PS–45

END

REPLACE POWER STEERING LINK ASSEMBLY (See page PS-58)

PS–46

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

DTC C1541 Vehicle Speed Signal Malfunction

DESCRIPTION

The power steering ECU assembly receives vehicle speed signals from the skid control ECU via CAN communication. The ECU provides appropriate assisting force in accordance with the vehicle speed, based on the signals. If the ECU detects this DTC, it adjusts the amount of power assist an ce for dr iving at a speed of 100 km/h (62 mph) and continues the system control.

DTC No. DTC Detection Condition Trouble Area

• Speed sensor circuit

C1541

This DTC is detected when vehicle speed signals via CAN communication are cut off for 3 seconds or more.

INSPECTION PROCEDURE

CHECK DTC OUTPUT (CAN COMMUNICATION SYSTEM)

• Skid control ECU

• CAN communication system

• Power steering ECU assembly

(a) Check if DTC U0073 or U0129 is output.

Result

DTC is not output A DTC U0073 or U0129 is output B

HINT:

• DTC U0073 indicates a CAN communication

• DTC U0129 indicates a skid control ECU

CHECK DTC OUTPUT (BREAK CONTROL SYSTEM)

(a) Check for DTCs of the ABS system.

Result

DTC Condition Proceed to

malfunction in the electronic power steering system. communication malfunction in the electronic power

steering system.

GO TO CAN COMMUNICATION SYSTEM (See page CA-7)

DTC Condition Proceed to DTC is not output A DTC C0200, C0205, C0210, C0215, C1235, C1236,

C1238, or C1239 is output

NOTICE: If replacing the power steering ECU assembly, initialize the rotation angle sensor value and calibrate the torque sensor zero point (See page PS-

13).

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

PS–47

REPLACE POWER STEERING ECU ASSEMBLY (See page PS-68)

GO TO BRAKE CONTROL SYSTEM (SPEED SENSOR CIRCUIT) (See page BC-21)

PS–48

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

DTC C1551 IG Power Supply Voltage Malfunction

DESCRIPTION

If the power steering ECU assembly determines that there is a malfunction in the IG circuit inside the ECU, it outputs this DTC. This DTC is not output when there is an open circuit in the wire harness connected to terminal IG or a battery voltage drops.

DTC No. DTC Detection Condition Trouble Area

C1551 IG power source circuit malfunction inside ECU Power steering ECU assembly

INSPECTION PROCEDURE

REPLACE POWER STEERING ECU ASSEMBLY

(a) Replace the power steering ECU assembly (See page

PS-68).

NOTICE: If replacing the power steering ECU assembly, initialize the rotation angle sensor value and calibrate the torque sensor zero point (See page PS-

13).

END

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

DTC C1552 PIG Power Supply Voltage Malfunction

DESCRIPTION

This circuit supplies power to drive the power steering motor.

DTC No. DTC Detection Condition Trouble Area

C1552

WIRING DIAGRAM

This DTC is detected when power source voltage drops or remains high.

No. 1 Engine Room Relay Block

• EPS fuse

• Wire harness

• Power steering ECU assembly

PS–49

Power Steering ECU Assembly

Battery

INSPECTION PROCEDURE

INSPECT FUSE (EPS FUSE)

EPS

A66

PIG

PGND

(a) Remove the EPS fuse from the engine room relay block. (b) Check resistance of the EPS fuses.

OK:

Below 1 Ω

B139365E01

REPLACE FUSE

PS–50

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

CHECK HARNESS AND CONNECTOR (POWER STEERING ECU ASSEMBLY - BATTERY)

Wire Harness Side Connector Front View:

A66 Power Steering ECU Assembly

PIG

C110951E28

CHECK HARNESS AND CONNECTOR (POWER STEERING ECU ASSEMBLY - BODY

GROUND)

Wire Harness Side Connector Front View:

A66 Power Steering ECU Assembly

(a) Disconnect the A66 connector from the power steering

ECU assembly.

(b) Measure the voltage according value(s) in the table

below.

Standard voltage

Tester Connection Condition Specified Condition

A66-4 (PIG) - Body ground Always 10 to 14 V

REPAIR OR REPLACE HARNESS OR CONNECTOR

(a) Measure the resistance according value(s) in the table

below.

Standard resistance

Tester Connection Condition Specified Condition

A66-5 (PGND) - Body ground Always Below 1 Ω

NOTICE: If replacing the power steering ECU assembly, initialize the rotation angle sensor value and calibrate the torque sensor zero point (See page PS-

13).

PGND

C110951E29

REPAIR OR REPLACE HARNESS OR CONNECTOR

REPLACE POWER STEERING ECU ASSEMBLY (See page PS-68)

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

PS–51

DTC C1581 Assist Map Number Un-Writing

DESCRIPTION

The power steering ECU assembly outputs this DTC when it determines that the assist map is not written in the ECU. HINT: The assist map is data written in the power steering ECU assembly to control the degree of assistance. The assist map is selected based on the vehicle's specified communication data (designation and grade package information).

DTC No. DTC Detection Item Trouble Area

C1581

Assist map is not written in the power steering ECU assembly.

INSPECTION PROCEDURE

PERFORM ASSIST MAP WRITING

• Hybrid vehicle control ECU

• Main body ECU (Instrument panel J/B)

• Power steering ECU assembly

END

(a) Turn the power switch on (IG), and wait for 30 seconds

or more. HINT: The assist map is automatically written when approximately 30 seconds have elapsed after the power switch is turned on (IG). DTC C1581 will be cleared after the assist map is written.

(b) Check for DTCs.

OK:

DTC C1581 is not output.

CHECK CAN COMMUNICATION SYSTEM

(a) Using the intelligent tester, check for DTCs and confirm

that there are no problems in the CAN communication system.

OK:

DTCs are not output.

Go to step 2

GO TO CAN COMMUNICATION SYSTEM (See page CA-7)

PS–52

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

CHECK HYBRID VEHICLE CONTROL ECU

(a) Check if the correct hybrid vehicle control ECU for the

engine type and drivetrain of the vehicle is installed.

OK:

The correct hybrid vehicle control ECU is installed.

CHECK MAIN BODY ECU (INSTRUMENT PANEL J/B)

(a) Check if the correct main body ECU (instrument panel J/

B) for the model and grade of the vehicle is installed.

OK:

The correct main body ECU (instrument panel J/B). NOTICE: If replacing the power steering ECU assembly, initialize the rotation angle sensor value and calibrate the torque sensor zero point (See page PS-

13).

REPLACE HYBRID VEHICLE CONTROL ECU (See page HV-570)

REPLACE MAIN BODY ECU (INSTRUMENT PANEL J/B)

REPLACE POWER STEERING ECU ASSEMBLY (See page PS-68)

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

PS–53

DTC U0073 Control Module Communication Bus OFF DTC U0100 Lost Communication with ECM/PCM "A" DTC U0129 Lost Communication with Skid Control ECU DTC U0293 Lost Communication with HV ECU

DESCRIPTION

The power steering ECU assembly receives signals from the hybrid vehicle control ECU, skid control ECU and steering control ECU via CAN communication.

DTC No. DTC Detection Item Inspection Area

U0073 CAN communication error (CAN bus is off) CAN communication system U0100

U0129 Skid control ECU communication error

U0293

Hybrid vehicle control ECU communication error

• CAN communication system

• Hybrid vehicle control ECU

• CAN communication system

• Skid control ECU

• CAN communication system

• Hybrid vehicle control ECU

HINT:

• When two or more DTCs starting with "U" are output simultaneously, inspect the connectors and wire harness of each ECU.

• If the power steering ECU assembly detects DTC U0129 only, it adjusts the amount of power assistance for driving at a speed of 100 km/h (62 mph) and continues system control.

INSPECTION PROCEDURE

Refer to the U0073 (CAN communication system) (See page CA-64). Refer to the U0100 (CAN communication system) (See page CA-40). Refer to the U0129 (CAN communication system) (See page CA-42). Refer to the U0293 (CAN communication system) (See page CA-40).

PS–54

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

PS Warning Light Remains ON

DESCRIPTION

The power steering ECU is connected to the combination meter via CAN communication. If any of the following are detected, the PS warning light remains on.

• The power steering ECU connectors are disconnected from the power steering ECU.

• There is a malfunction in the power steering ECU internal circuit.

• There is an open in the harness between the combination meter and power steering ECU assembly.

WIRING DIAGRAM

Combination Meter Assembly

CANH

CANL

Main Body ECU (Instrument Panel J/B)

From Battery

IG1 Relay

Power Steering ECU Assembly

CANH

A66

CANL

A66

ECU IG No. 2

A66

IG1D

A66

PGND

B139366E01

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

INSPECTION PROCEDURE

CHECK HARNESS AND CONNECTOR

PS–55

(a) Check the indication of the PS warning light while

wiggling the power steering ECU assembly connector and wire harness up and down, and right and left.

OK:

PS warning light indication does not change.

INSPECT CAN COMMUNICATION SYSTEM

INSPECT FUSE

(a) Using the intelligent tester, check for DTCs and confirm

that there are no problems in the CAN communication system.

OK:

(a) Remove the ECU-IG LH fuse from the instrument panel

J/B.

(b) Check the resistance of the ECU-IG LH fuse.

OK:

REPAIR OR REPLACE HARNESS OR CONNECTOR

DTCs are not output.

GO TO CAN COMMUNICATION SYSTEM (See page CA-7)

Below 1 Ω

REPLACE FUSE

PS–56

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

INSPECT POWER STEERING ECU ASSEMBLY

Wire Harness Side Connector Front View:

A66

Power Steering ECU Assembly

C110951E30

CHECK HARNESS AND CONNECTOR (POWER STEERING ECU ASSEMBLY - BODY

GROUND)

Wire Harness Side Connector Front View:

A66 Power Steering ECU Assembly

(a) Disconnect the A66 connector from the power steering

ECU assembly.

(b) Measure the voltage according to the value(s) in the

table below.

Standard voltage

Tester Connection Condition Specified Condition

A66-9 (IG) - Body ground Power switch on (IG) 10 to 14 V

REPAIR OR REPLACE HARNESS OR CONNECTOR

(a) Measure the resistance according to the value(s) in the

table below.

Standard resistance

Tester Connection Condition Specified Condition

A66-5 (PGND) - Body ground Always Below 1 Ω

PGND

C110951E29

REPAIR OR REPLACE HARNESS OR CONNECTOR

DLC3

METER:

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

INSPECT COMBINATION METER ASSEMBLY

(a) Connect the intelligent tester (with CAN VIM ) to the

DLC3. (b) Turn the power switch on (IG). (c) Perform the ACTIVE TEST according to the display on

the tester.

Intelligent Tester

C131977E01

Tester Display Test Part Control Range Diagnostic Note

EPS INDIC PS indicator light OFF/ON OFF / ON -

PS–57

OK:

The PS warning light comes on or goes off

according to the tester operation. NOTICE: If replacing the power steering ECU assembly, initialize the rotation angle sensor value and calibrate the torque sensor zero point (See page PS-

13).

REPLACE COMBINATION METER ASSEMBLY (See page ME-64)

REPLACE POWER STEERING ECU ASSEMBLY (See page PS-68)

PS–58

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

PS Warning Light does not Come ON

WIRING DIAGRAM

Combination Meter Assembly

CANH

CANL

Main Body ECU (Instrument Panel J/B)

From Battery

IG1 Relay

Power Steering ECU Assembly

CANH

A66

CANL

A66

ECU IG No. 2

A66

IG1D

INSPECTION PROCEDURE

INSPECT CAN COMMUNICATION SYSTEM

PGND

A66

B139366E01

(a) Using the intelligent tester, check for DTCs and confirm

that there are no problems in the CAN communication system.

OK:

DTCs are not output.

POWER STEERING – ELECTRONIC POWER STEERING SYSTEM

PS–59

INSPECT COMBINATION METER ASSEMBLY

(a) Connect the intelligent tester (with CAN VIM ) to the (b) Turn the power switch on (IG).

DLC3

Intelligent Tester

C131977E01

DLC3.

the tester.

GO TO CAN COMMUNICATION SYSTEM (See page CA-7)

COMBINATION METER:

Tester Display Test Part Control Range Diagnostic Note

EPS INDIC PS indicator light OFF/ON ON / OFF -

OK:

The PS warning light comes on or goes off

according to the tester operation. NOTICE: If replacing the power steering ECU assembly, initialize the rotation angle sensor value and calibrate the torque sensor zero point (See page PS-

13).

REPLACE COMBINATION METER ASSEMBLY (See page ME-64)

REPLACE POWER STEERING ECU ASSEMBLY (See page PS-68)

PS–56

STEERINGPOWER STEERING

POWER STEERING – POWER STEERING LINK

POWER STEERING LINK

COMPONENTS

27 (275, 20)

NO. 1 FRONT STABILIZER BAR BUSHING

FRONT STABILIZER BAR

35 (360, 26)

COTTER PIN

x 2

NO. 1 FRONT STABILIZER

BRACKET LH

NO. 1 FRONT STABILIZER

BRACKET RH

NO. 1 FRONT

STABILIZER BAR

BUSHING

STEERING INTERMEDIATE

SHAFT ASSEMBLY

POWER STEERING

LINK ASSEMBLY

Non-reusable part

49 (500, 36)

N*m (kgf*cm, ft.*lbf)

70 (714, 52)

49 (500, 36)

COTTER PIN

: Specified torque

C140307E01

POWER STEERING – POWER STEERING LINK

PS–57

STEERING RACK BOOT CLIP

NO. 1 STEERING

RACK BOOT

TIE ROD

ASSEMBLY RH

74 (755, 55)

NO. 1 STEERING

RACK BOOT CLAMP

103 (1,050, 76)

* 74 (755, 55)

STEERING RACK

END SUB-ASSEMBLY

CLAW WASHER

103 (1,050, 76)

* 74 (755, 55)

STEERING RACK

END SUB-ASSEMBLY

NO. 2 STEERING

RACK BOOT CLAMP

NO. 2 STEERING RACK BOOT

Apply silicone grease

Non-reusable part

N*m (kgf*cm, ft.*lbf)

74 (755, 55)

: Specified torque

STEERING RACK BOOT CLIP

TIE ROD

ASSEMBLY LH

* For use with SST

C140308E01

PS–58

POWER STEERING – POWER STEERING LINK

REMOVAL

1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

3. REMOVE FRONT WHEELS

4. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY

(a) Secure the steering wheel with the seat belt in order

to prevent rotation. HINT: This operation is useful to prevent damage to the spiral cable.

C140313

(b) Remove the bolt and slide the steering intermediate

shaft assembly.

NOTICE: Do not separate the steering intermediate shaft assembly from the power steering link assembly.

Front

C140294E01

assembly and the power steering link assembly.

(d) Separate the steering intermediate shaft assembly

from the power steering link assembly.

5. SEPARATE TIE ROD ASSEMBLY LH

(a) Remove the cotter pin and the nut.

Matchmarks

C140295E01

Hold

Turn

POWER STEERING – POWER STEERING LINK

(b) Using SST, separate the tie rod assembly LH from

the steering knuckle.

SST 09628-00011 NOTICE:

• Hang SST with a string, etc. to prevent it from

SST

falling.

• Do not damage the front disc brake dust cover.

• Do not damage the ball joint dust cover.

• Do not damage the steering knuckle.

6. SEPARATE TIE ROD ASSEMBLY RH SST 09628-00011

HINT: Perform the same procedure as for the LH side.

C133488E01

7. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

HINT: Refer to the instructions for REMOVAL of the ENGINE ASSEMBLY (See page EM-89).

8. REMOVE NO. 1 FRONT STABILIZER BRACKET LH (See page SP-28)

PS–59

Protective Tape

C140296

SST

C140297E01

9. REMOVE NO. 1 FRONT STABILIZER BRACKET RH (See page SP-29)

10. REMOVE POWER STEERING LINK ASSEMBLY

(a) Remove the 2 bolts, 2 nuts, and the power steering

link assembly from the front frame assembly.

NOTICE: Because the nut has its own stopper , do not turn the nut. Loosen the bolt with the nut fixed.

DISASSEMBLY

1. SECURE POWER STEERING LINK ASSEMBLY

(a) Using SST, secure the power steering link

assembly.

SST 09612-00012

HINT: Tape the SST before use.

PS–60

POWER STEERING – POWER STEERING LINK

2. REMOVE TIE ROD ASSEMBLY LH

(a) Put matchmarks on the tie rod assembly LH and the

steering rack end sub-assembly.

(b) Loosen the lock nut, and remove the tie rod

assembly LH and the lock nut.

3. REMOVE TIE ROD ASSEMBLY RH

HINT:

Matchmarks

Perform the same procedure as for the LH side.

C132045E01

C140298

4. REMOVE STEERING RACK BOOT CLIP

(a) Using pliers, remove the 2 steering rack boot clips.

5. REMOVE NO. 2 STEERING RACK BOOT CLAMP

(a) Using pliers and a screwdriver, remove the No. 2

steering rack boot clamp as shown in the illustration.

NOTICE: Be careful not to damage the steering rack boot.

6. REMOVE NO. 1 STEERING RACK BOOT CLAMP

HINT: Perform the same procedure as for the No. 2 steering rack boot clamp.

7. REMOVE NO. 2 STEERING RACK BOOT

8. REMOVE NO. 1 STEERING RACK BOOT

9. REMOVE STEERING RACK END SUB-ASSEMBLY

(a) Using a screwdriver and a hammer , unst ake the RH

and LH claw washers.

NOTICE: Avoid any impact to the steering rack.

C140315

Hold

POWER STEERING – POWER STEERING LINK

(b) Using SST, remove the steering rack end sub-

Turn

assembly (RH side) and the claw washer.

SST 09922-10010 NOTICE: Use SST 09922-10010 as shown in the illustration.

PS–61

SST

Turn

SST

Hold

SST

C140300E01

assembly (LH side) and the claw washer.

SST 09922-10010 NOTICE: Use SST 09922-10010 as shown in the illustration.

HINT: Using SST, hold the rack and remove the steering rack end sub-assembly.

C140301E01

PS–62

POWER STEERING – POWER STEERING LINK

INSPECTION

1. INSPECT TIE ROD ASSEMBLY LH

(a) Secure the tie rod assembly LH in a vise. (b) Install the nut to the stud bolt. (c) Flip the ball joint back and forth 5 times or more.

(d) Using a torque wrench, turn the nut continuously at

a rate of 3 to 5 seconds per turn and take the torque reading on the 5th turn.

Torque: Turning torque

0.98 to 3.92 N*m (10 to 40 kgf*cm, 8.7 to

34.7 in.*lbf)

If the turning torque is not within the specified range, replace the tie rod assembly LH.

Torque Sensor:

SST

P44

ZK08184E01

C140304E01

C102953E05

2. INSPECT TIE ROD ASSEMBLY RH

HINT: Perform the same procedure as for the LH side.

3. INSPECT TOTAL PRELOAD

(a) Temporarily install the left and right steering rack

ends to prevent steering rack over stroke.

(b) Using SST and a torque wrench, inspect total

preload.

SST 09616-00011 Torque: Preload (turning)

1.0 to 2.0 N*m (10 to 20 kgf*cm, 8.9 to

17.7 in.*lbf)

If the turning torque is not as specified, replace the power steering link assembly.

4. INSPECT POWER STEERING LINK ASSEMBLY (TORQUE SENSOR)

(a) Measure the resistance according to the value(s) in

the table below.

Resistance

Tester connection

(Symbols) P44-1 (INCS) - P44-7 (TQG2) Always 90 to 170 Ω P44-2 (INSN) - P44-7 (TQG2) Always 300 to 430 Ω

P44-4 (TRQV) - P44-8 (TQG1) Always 4 to 14 Ω P44-5 (OUCS) - P44-7 (TQG2) Always 90 to 170 Ω P44-6 (OUSN) - P44-7 (TQG2) Always 300 to 430 Ω

Condition Specified condition

POWER STEERING – POWER STEERING LINK

PS–63

Power Steering Motor:

5. INSPECT POWER STEERING LINK ASSEMBLY (POWER STEERING MOTOR)

(a) Measure the resistance according to the value(s) in

the table below.

Resistance

P43

C110602E02

Tester connection

(Symbols)

P43-3 (U) - P43-2 (V) Always Below 1 Ω P43-2 (V) - P43-1 (W) Always Below 1 Ω P43-1 (W) - P43-3 (U) Always Below 1 Ω

Condition Specified condition

PS–64

Fulcrum Length

Turn

SST

POWER STEERING – POWER STEERING LINK

REASSEMBLY

NOTICE: When installing, coat the parts indicated by arrows with silicone grease (See page PS-56).

1. INSTALL STEERING RACK END SUB-ASSEMBLY

(a) Install 2 new claw washers.

HINT: Align the claws of the claw washer with the steering rack grooves.

(b) Using SST, install the steering rack end sub-

assembly (LH side).

SST 09922-10010 Torque: Without SST

Hold

SST

NOTICE:

• Use SST 09922-10010 as shown in the

• Use a torque wrench with a fulcrum length of

• This torque value is effective when SST is

HINT: Using SST, hold the steering rack and install the steering rack end sub-assembly.

103 N*m (1,050 kgf*cm, 76 ft.*lbf) With SST 74 N*m (755 kgf*cm, 55 ft.*lbf)

illustration.

345 mm (13.58 in.).

parallel to the torque wrench.

Hold

SST

Turn

C140302E01

Fulcrum Length

C140303E01

assembly (RH side).

SST 09922-10010 Torque: Without SST

103 N*m (1,050 kgf*cm, 76 ft.*lbf) With SST 74 N*m (755 kgf*cm, 55 ft.*lbf)

NOTICE:

• Use SST 09922-10010 as shown in the illustration.

• Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).

• This torque value is effective when SST is parallel to the torque wrench.

HINT: Using SST, hold the steering rack and install the steering rack end sub-assembly.

POWER STEERING – POWER STEERING LINK

(d) Using a brass bar and a hammer, stake the 2 claw

washers.

NOTICE: Avoid any impact to the steering rack.

C100974

(e) Ensure that the holes of the rack ends are not

clogged with grease. HINT: If the hole is clogged, the pressure inside the boot will change after it is assembled and the steering wheel is turned.

C140314

PS–65

Install from the end

Install from the side

Do not expand steering rack boot clamp.

(A)

C100988

2. INSTALL NO. 2 STEERING RACK BOOT

(a) Apply silicone grease to the inside of the small

opening of the No. 2 steering rack boot.

(b) Temporarily install a new No. 2 steering rack boot

clamp to the large opening of the No. 2 steering rack boot at the position shown by arrow (A).

NOTICE:

• Use a new No. 2 steering rack boot clamp.

• Do not expand the No. 2 steering rack boot clamp more than necessary for installation.

• Do not deform the No. 2 steering rack boot clamp.

• Tightening force of the No. 1 steering rack boot clamp becomes uneven if it is installed after being expanded as shown in the illustration. As a result, rust is caused by water entering from the clearance between the boot and rack housing, causing a malfunction.

• Use only the supply parts which are applicable to the vehicle to secure the boot.

C112238E03

PS–66

POWER STEERING – POWER STEERING LINK

HINT: After disengaging the claw of a new No. 2 steering rack boot clamp, temporarily install it from the end without expanding the clamp diameter more than necessary.

housing.

NOTICE:

• Be careful not to damage or twist the boot.

• Do not damage the No. 2 steering rack boot.

• Ensure that the No. 2 steering rack boot clamp is installed before installing the No. 2 steering rack boot to the rack housing.

3. INSTALL NO. 1 STEERING RACK BOOT

HINT: Perform the same procedure as for the No. 2 steering rack boot.

4. INSTALL NO. 2 STEERING RACK BOOT CLAMP

(a) Using pliers and a screwdriver, install the No. 2

steering rack boot clamp.

NOTICE:

• Be careful not to damage the No. 2 steering rack boot.

• Do not twist the No. 2 steering rack boot.

SST

C140305

C140306E01

5. INSTALL NO. 1 STEERING RACK BOOT CLAMP

HINT: Perform the same procedure as for the No. 2 steering rack boot clamp.

6. INSTALL STEERING RACK BOOT CLIP

(a) Using pliers, install the 2 boot clips. (b) Using SST, turn the pinion and check that the rack

boots expand and contract smoothly.

SST 09616-00011

7. INSTALL TIE ROD ASSEMBLY LH

(a) Install the lock nut and the tie rod assembly LH to

the steering rack end sub-assembly until the matchmarks are aligned. HINT: After adjusting toe-in, tighten the lock nut.

Matchmarks

C111423E02

8. INSTALL TIE ROD ASSEMBLY RH

HINT: Perform the same procedure as for the LH side.

POWER STEERING – POWER STEERING LINK

INSTALLATION

1. INSTALL POWER STEERING LINK ASSEMBLY

(a) Install the power steering link assembly with the 2

bolts and 2 nuts.

Torque: 70 N*m (714 kgf*cm, 52 ft.*lbf) NOTICE: Because the nut has its own stopper , do not turn the nut. Tighten the bolt with the nut fixed.

2. INSTALL FRONT STABILIZER BAR (See page SP-30)

3. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

HINT: Refer to the instructions for INSTALLATION of the ENGINE ASSEMBLY (See page EM-102).

C140296

4. CONNECT TIE ROD ASSEMBLY LH

(a) Connect the tie rod assembly LH to the steering

knuckle with the nut.

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

(b) Install a new cotter pin.

NOTICE: Further tighten the nut up to 60° if the holes for the cotter pin are not aligned.

PS–67

Matchmarks

C140295E01

5. CONNECT TIE ROD ASSEMBLY RH

HINT: Perform the same procedure as for the LH side.

6. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY

(a) Align the matchmarks on the steering intermediate

shaft assembly and the power steering link assembly.

(b) Install the bolt.

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

7. INSTALL FRONT WHEELS Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)

8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

9. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

Front

C140294E01

10. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

HINT: (See page SP-4)

PS–68

POWER STEERING – POWER STEERING LINK

11. PERFORM INITIALIZATION NOTICE: Some systems need initialization after reconnecting the cable to the negative battery terminal (See page

IN-43).

12. INITIALIZE ROTATION ANGLE SENSOR AND CALIBRATE TORQUE SENSOR ZERO POINT

HINT: (See page PS-13)

PS–68

STEERINGPOWER STEERING

POWER STEERING – POWER STEERING ECU

POWER STEERING ECU

COMPONENTS

POWER STEERING

ECU ASSEMBLY

8.5 (87, 75 in.*lbf)

N*m (kgf*cm, ft.*lbf)

: Specified torque

C140309E01

POWER STEERING – POWER STEERING ECU

REMOVAL

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

2. REMOVE AIR CLEANER INLET ASSEMBLY (See page EM-90)

3. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See page ES-395)

4. REMOVE AIR CLEANER CASE SUB-ASSEMBL Y (See page EM-90)

5. SEPARATE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY (See page BR-27)

6. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH (See page WW-9)

7. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH (See page WW-9)

8. REMOVE FRONT FENDER TO COWL SIDE SEAL LH (See page WW-9)

PS–69

9. REMOVE FRONT FENDER TO COWL SIDE SEAL RH (See page WW-9)

10. REMOVE COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See page WW-10)

11. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (See page WW-10)

12. REMOVE COWL TOP PANEL OUTER SUBASSEMBLY (See page ES-403)

13. REMOVE POWER STEERING ECU ASSEMBLY

(a) Disconnect the connector and separate the hose

clamp from the power steering ECU assembly.

C140290

PS–70

POWER STEERING – POWER STEERING ECU

(b) Release the locks of the 2 power steering ECU

assembly connectors and disconnect the connectors.

C140291

C140293

ECU assembly.

POWER STEERING – POWER STEERING ECU

INSTALLATION

1. INSTALL POWER STEERING ECU ASSEMBLY

(a) Install the power steering ECU assembly with the

bolt and 2 nus.

Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf)

C140293

(b) Connect the 2 power steering ECU assembly

connectors and securely lock the connectors as shown in the illustration.

PS–71

C140292

PS–72

POWER STEERING – POWER STEERING ECU

the power steering ECU assembly.

2. INSTALL COWL TOP PANEL OUTER SUBASSEMBLY (See page ES-405)

3. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (See page WW-13)

4. INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See page WW-14)

5. INSTALL FRONT FENDER TO COWL SIDE SEAL RH (See page WW-14)

6. INSTALL FRONT FENDER TO COWL SIDE SEAL LH (See page WW-14)

C140290

7. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH (See page WW-14)

8. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH (See page WW-15)

9. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY (See page BR-33)

10. INST ALL AIR CLEANER CASE SUB-ASSEMBLY (See page EM-113)

11. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See page ES-398)

12. INST ALL AIR CLEANER INLET ASSEMBLY (See page

EM-113)

13. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

14. PERFORM INITIALIZATION NOTICE: Some systems need initialization after reconnecting the cable to the negative battery terminal (See page

IN-43).

15. INITIALIZE ROTATION ANGLE SENSOR AND CALIBRATE TORQUE SENSOR ZERO POINT

HINT: (See page PS-13)

Toyota Camry 2007-2009 Service Manual - Power_Steering

Specifications and Main Features

Frequently Asked Questions

User Manual