Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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Some 2009 – 2010 Corolla and Matrix vehicles may exhibit a clunk, pop, or knocking noise when turning the steering wheel to the left or right. A new intermediate shaft has been developed to address this condition. Use the following repair procedure to remove and replace the steering intermediate shaft. Repair Procedure 1. Install a steering wheel lock to ensure the wheels are straight and the steering wheel is centered before removing the steering intermediate shaft. Make sure the steering wheel and front wheels remain stationary. Once the intermediate shaft is removed, do NOT allow the steering wheel to spin freely. 2. Remove the column hole silencer sheet. 3. Place a matchmark on the No. 2 steering intermediate shaft that will later be copied onto the new part, and remove the bolt. 4. Place a matchmark on the upper portion of the No. 2 steering intermediate shaft. 5. Remove the bolt and the No. 2 steering intermediate shaft assembly from the steering column assembly. 6. Place the matchmarks on the NEW steering intermediate shaft sub-assembly. A. Place the NEW steering intermediate shaft next to the original steering intermediate shaft assembly (removed in the previous step). B. Transfer the matchmarks on the original steering intermediate shaft to the same locations on the NEW steering intermediate shaft. Figure 5. 1 Original Steering Intermediate Shaft 7. Install the NEW No. 2 intermediate shaft and line up the matchmarks and tighten the bolt. Torque: 35 N*m (360 kgf*cm, 26 ft*lbf) 8. Install the No. 2 intermediate shaft onto the No. 1 intermediate shaft and line up the matchmarks, and tighten the bolt. Torque: 35 N*m (360 kgf*cm, 26 ft*lbf) 9. Reinstall the column hole silencer sheet. 10. Road test the vehicle to verify the repair and con?rm that the steering wheel is centered.

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Hose Fittings, Pressure and Return Line at Steering Gear and Pump The tube portion of the power steering hose assembly may disengage from the connector assembly for any of the following reasons: if not fully assembled. if snap ring is missing. if female port in power rack and pinion steering gear or power steering pump (3A674) is too shallow. if tube nut, power steering pressure hose (3A719) or power steering return hose end is not machined or formed properly. If the tube disengages at the steering gear housing fitting or power steering pump, check for a snap ring in the connector assembly before attempting to seat the tube into the connector assembly. The tube is fully engaged in its connector assembly when the snap ring (part of the connector assembly) is seated in the groove machined in the tube for this purpose. The tube will not pull out once properly engaged. Attempt to pull out using hand force. If the tube does not pull out, verify by properly filling system, starting the engine and turning the steering wheel lock- to-lock with the wheels on the ground and fully loaded. Check for leaks. If a leak still occurs, replace hose assembly with the correct service hose assembly which has the connector assembly pre-installed. Hose(s), Pressure—3.0L (2V) Engine Removal 1. Open hood. 2. Disconnect battery ground cable (14301). Refer to Section 14-01. 3. Remove drive belt (8620). Refer to Section 03-05. 4. Disconnect power steering left turn pressure hose (3A714) from power steering pump fitting. 5. Raise vehicle on hoist. Refer to Section 00-02. 6. Remove RH wheel and tire and two-piece splash shield from wheel well. 7. Disconnect both pressure line mounting brackets from engine assembly. 8. Lower vehicle. 9. Remove air cleaner outlet tube. Refer to Section 03-12. 10. From behind engine, remove two push-pin retainers at top of steering gear heat shield and pull steering gear heat shield away from steering rack. 11. Remove bolt through pressure line mounting bracket from top rear of steering shaft U-joint shield (3F540). 12. Using a crows-foot wrench, disconnect power steering left turn pressure hose at power steering rack fitting. 13. Remove power steering left turn pressure hose out through engine compartment. Installation 1. Follow removal procedure in reverse order. 2. Install new O-rings on power steering left turn pressure hose. 3. Fill and bleed power steering system with Motorcraft MERCON Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent meeting Ford MERCON specification. Check system for leaks and proper operation. Refer to Section 11-00. Power Steering System—3.0L (2V) Engine

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Removal All Vehicles 1. Disconnect the battery ground cable. 2. Center the steering wheel. Lock in position, remove the ignition key. 3. Disconnect the steering column shaft from the flexible coupling. Rotate the clamp plate to disengage. 4. CAUTION: When removing the floor seal do not damage the sealing clips. Remove the floor seal from the bulkhead. 1. Release the retaining clips. 2. Disconnect the upper retaining clip. 3. Remove the floor seal. 5. Loosen the left-hand side front wheel nuts. 6. Raise and support the vehicle. For additional information, refer to Section 100-02. 7. Remove the wheel. 8. Remove the radiator splash shield. 9. Disconnect the fluid cooler line. Allow the fluid to drain into a suitable container. 10. Lower the vehicle. Vehicles with 2.0L engine 11. Detach the high-pressure tube support bracket. 12. Detach the high-pressure tube. Disconnect the power steering pressure (PSP) switch electrical connector. Detach the tube support bracket. Cut the three cable ties. 14. Remove the accessory drive belt. For additional information, refer to Section 303-05. 15. Lower the vehicle. 16. Detach the coolant hose clamp. 17. Detach the coolant expansion tank. Position the tank to one side. 18. Using the special tool, remove the power steering pump pulley. 19. Disconnect the power steering pump high-pressure tube union. Allow the fluid to drain into a suitable container.

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SYMPTOM The power steering pump whines, buzzes, or hums after driving for 30 minutes in temperatures of 35 to 40 degrees F (2 to 5 degrees C). PROBABLE CAUSE The power steering pump reservoir is defective. CORRECTIVE ACTION Flush the power steering system with clean power steering fluid, then replace the power steering reservoir. DIAGNOSIS 1. Run the engine until it reaches normal operating temperature (the cooling fans cycle twice). 2. Listen for abnormal noises from the power steering pump while the steering wheel is centered and not being turned. • If the pump whines, buzzes, or hums, go to REPAIR PROCEDURE. • If the noise is not coming from the pump, this service bulletin does not apply. Check for other possible causes of the noise. 3. Inspect the power steering reservoir. Is there a white dot on the reservoir cover, with one of its ribs pointing toward the reservoir holder? Yes – This vehicle already has the revised power steering reservoir. Continue with normal troubleshooting procedures. No – Go to REPAIR PROCEDURE. POWER STEERING RESERVOIR COVER 2. Drain the fluid from the power steering system: • Connect a suitable diameter drain hose to the disconnected return hose. • Hold the end of the drain hose in a suitable container. • Start the engine, and run it at idle while you turn the steering wheel lock-to-lock several times. • When the fluid stops running out of the hose, shut off the engine. • Discard the used fluid.

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Removal All Vehicles 1. Disconnect the battery ground cable. 2. Center the steering wheel. Lock in position, remove the ignition key. 3. Disconnect the steering column shaft from the flexible coupling. Rotate the clamp plate to disengage. 4. CAUTION: When removing the floor seal do not damage the sealing clips. Remove the floor seal from the bulkhead. 1. Release the retaining clips. 2. Disconnect the upper retaining clip. 3. Remove the floor seal. 5. Loosen the left-hand side front wheel nuts. 6. Raise and support the vehicle. For additional information, refer to Section 100-02. 7. Remove the wheel. 8. Remove the radiator splash shield. 9. Disconnect the fluid cooler line. Allow the fluid to drain into a suitable container. 10. Lower the vehicle. Vehicles with 2.0L engine 11. Detach the high-pressure tube support bracket. 12. Detach the high-pressure tube. Disconnect the power steering pressure (PSP) switch electrical connector. Detach the tube support bracket. Cut the three cable ties. 13. Remove the PSP switch.