#4

PRECAUTION:

^ The 4Runner is equipped with SRS, which consists of a driver airbag, front passenger airbag, side airbag, and curtain shield airbag. Failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if a mistake is made in servicing the SRS, it is possible that the SRS may fail to operate when required. Before performing servicing (including removal or installation of parts, inspection. or replacement), be sure to read the following items carefully, then follow the correct procedures described in the repair manual.

^ Wait at least 90 seconds AFTER the ignition switch is turned to the LOCK position and the negative (-) terminal cable is disconnected from the battery. (The SRS is equipped with a back-up power source so that if work is started within 90 seconds from disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.)

^ Do not expose the horn button assembly, front passenger airbag assembly, airbag sensor assembly center, airbag front sensor, front seat airbag assembly, side airbag sensor assembly, curtain shield airbag assembly, airbag sensor rear, or seat position airbag sensor directly to hot air or flames.

NOTE: ^ Malfunction symptoms of the SRS are difficult to confirm, so the DTCs are the most important source of information when troubleshooting. When troubleshooting the SRS, always inspect the DTCs before disconnecting the battery.

^ Even in cases of a minor collision when the SRS does not deploy, the horn button assembly, front passenger airbag assembly, airbag sensor assembly center, airbag front sensor, front seat airbag assembly, side airbag sensor assembly, curtain shield airbag assembly, airbag sensor rear, and seat position airbag sensor should be inspected.

^ Before repair work, remove the airbag sensor if any kind of shock is likely to occur to the airbag sensor during the operation.

^ Never use SRS parts from another vehicle. When replacing parts, replace them with new ones.

^ Never disassemble and repair the horn button assembly, front passenger airbag assembly, airbag sensor assembly center, airbag front sensor, front seat airbag assembly, side airbag sensor assembly, curtain shield airbag assembly, airbag sensor rear, or seat position airbag sensor in order to reuse them.

^ If the horn button assembly, front passenger airbag assembly, airbag sensor assembly center, airbag front sensor, front seat airbag assembly, side airbag sensor assembly, curtain shield airbag assembly, airbag sensor rear, or seat position airbag sensor has been dropped, or if there are any cracks, dents, or other defects in the case, bracket, or connector, replace it with a new one.

^ Use a volt/ohmmeter with high impedance (10 kOhms/V minimum) for troubleshooting the electrical circuits.

^ Information labels are attached to the periphery of the SRS components. Follow the instructions on the notices.

^ After work on the SRS is completed, perform the SRS warning light check.

^ When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and audio system will be cancelled. So before starting work, make a record of the contents memorized in the audio memory system. When work is finished, reset the audio system as they were before and adjust the clock. To avoid erasing the memory in each memory system, never use a back-up power supply from outside the vehicle.

^ If the vehicle is equipped with a mobile communication system, refer to the preceding Precaution.

1. Place the front wheels facing straight ahead with the engine running.

2. Record the radio presets.

3. Turn the key to the OFF position and remove the keys from the ignition.

4. Disconnect the negative (-) battery terminal.

5. Remove the front wheels.

6. Remove the 6 bolts and the engine under cover assembly rear.

7. Remove the 4 bolts and the engine under cover sub-assembly No. 1.

8. Remove the 2 nuts and the front stabilizer link assembly LH.

NOTE: If the front stabilizer link ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud.








9. Remove the 2 nuts and the front stabilizer link assembly RH.








10. Remove the 2 bolts and the front stabilizer bracket No. 1 LH.

11. Remove the 2 bolts and the front stabilizer bracket No. 1 RH.

12. Remove the 2 front stabilizer bar bushings No. 1.

13. Remove the front stabilizer bar.

14. Separate the tie rod end sub-assembly LH.

A. Remove the cotter pin and nut.

B. Using the SST, separate the tie rod end from the steering knuckle arm.

SST P/N: 09628-62011









15. Separate the tie rod end sub-assembly RH.

A. Remove the cotter pin and nut.

B. Using the SST, separate the tie rod end from the steering knuckle arm.

SST P/N: 09628-62011


16. Remove the steering sliding yoke.








A. Mark matchmarks on the steering sliding yoke, steering intermediate shaft sub-assembly No. 2, and steering intermediate shaft assembly.

B. Remove bolt A and bolt B from the steering sliding yoke.

C. Slide the steering sliding yoke up and separate it from the steering intermediate shaft sub-assembly No. 2.

D. Pull down the steering sliding yoke from the steering intermediate shaft assembly to remove.

17. Remove steering intermediate shaft No. 2.

A. Mark the matchmarks on the power steering gear assembly and steering intermediate shaft sub-assembly No. 2.

B. Remove bolt C and the intermediate shaft sub-assembly No. 2 from the power steering gear assembly.


18. Disconnect the pressure feed tube assembly.








A. Using the 17 mm Union nut wrench (or equivalent), loosen the flare nut and disconnect the pressure feed tube.








B. Remove the 2 bolts and separate the pressure feed tube assembly from the frame sub-assembly.








19. Disconnect the steering gear outlet return tube.

A. Remove the clip and disconnect the return hose.









B. Using the 17 mm Union nut wrench (or equivalent), remove the outlet return tube.








20. Remove the 2 bolts, 2 nuts, and power steering link assembly.

NOTE: Be sure to only turn the bolt as the nut has a detent.

HINT: After loosening the 2 bolts, raise the bolt from the frame. Slide the power steering gear assembly and the bolt as a unit to the position where the bolt can be pulled out.








21. Carefully secure the power steering gear assembly in a vise (if available, use SST P/N: 09612-00012-01).

22. Remove the rack guide.








A. Using the SST, remove the lock nut as shown in the illustration.

SST P/N: 09922-10010-01








B. Using a hexagon wrench (24 mm), remove the rack guide spring cap.

C. Remove the spring and rack guide.

23. Install the rack guide spring.

A. Install the rack guide and new spring (P/N: 44215-35010).

B. Apply sealant to 2 or 3 threads of the rack guide spring cap.

Sealant: Three Bond 1344, Loctite 242, or equivalent.









C. Using a hexagon wrench (24 mm), temporarily install the spring cap.

24. Adjust the total preload.








A. Using a hexagon wrench (24 mm), tighten the rack guide spring cap.

Torque: 25 N.m (250 kgf.cm, 18 ft.-lbf)

B. Turn the cap an additional 30°counterclockwise.








C. Using the SST, turn the control valve shaft right and left 1 or 2 times.

^ SST P/N: 09616-00010-02


D. Using a hexagon wrench (24 mm), loosen the cap until the rack guide spring has no tension.








E. Using the SST, a torque wrench, and a hexagon wrench (24 mm), tighten the cap until the preload is within specification.

^ SST 09616-00010-02

Preload (turning): 1.4 to 1.6 N.m (14.3 to 16.3 kgf.cm, 12.4 to 14.2 in..lbf)


NOTE: When making the adjustment, be sure to turn the cap in the clockwise direction.

F. Apply sealant to 2 or 3 threads of the lock nut.

Sealant: Three Bond 1344, Loctite 242, or equivalent

G. Temporarily install the lock nut.








H. Using a hexagon wrench (24 mm), holding the rack guide from rotating, and using the SST, torque the nut.

^ SST 09922-10010-01

Torque: 69 N.m (700 kgf.cm, 51 ft.-lbf) for use with SST


I. Recheck the total preload.

Preload (turning): 1.4 to 1.6 N.m (14.3 to 16.3 kgf.cm, 12.4 to 14.2 in.-lbf)








25. Install the power steering link assembly into the vehicle with the 2 bolts and 2 nuts. Torque: 100 N.m (1,020 kgf.cm, 74 ft.-lbf)

NOTE: The nut has a detent, so never turn the nut. Be sure to turn the bolt.

NOTE: Insert the bolts and position it with the power steering gear assembly as a unit.

Then install the bolts on the frame.








26. Install the front stabilizer bar.

27. Install the 2 front stabilizer bar bushings No. 1.

NOTE: ^ Install the bushing to the inner side of the bushing stopper on the stabilizer bar.









^ Install the stabilizer bushing No. 1 as shown in the illustration.

28. Install the front LH bushing and bracket with 2 bolts.

Torque: 40 N.m (410 kgf.cm, 30 ft.-lbf)








29. Install the front RH bushing and bracket with 2 bolts.

Torque: 40 N.m (410 kgf.cm, 30 ft.-lbf)

30. Install the front stabilizer link assembly LH with the 2 nuts.

Torque: 70 N.m (710 kgf.cm, 52 ft.-lbf)

NOTE: If the front stabilizer link ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud.








31. Install the front stabilizer link assembly RH with the 2 nuts.

Torque: 70 N.m (710 kgf.cm, 52 ft.-lbf)

32. Connect the steering gear outlet return tube.

A. Using the 17 mm Union nut wrench (or equivalent), connect the outlet return tube.

Torque: 44 N.m (440 kgf.cm, 32 ft.-lbf)

HINT: ^ Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).









^ This torque wrench should be held as shown in the illustration.








B. Install the hose with the clip.

33. Connect the pressure feed tube assembly.








A. Install the pressure feed tube assembly to the frame sub-assembly with the 2 bolts.

Torque: 28 N.m (286 kgf.cm, 21 ft.-lbf)

B. Using the 17 mm Union nut wrench (or equivalent), tighten the flare nut and connect the pressure feed tube.

Torque: 44 N.m (440 kgf.cm, 32 ft.-lbf)

NOTE: ^ Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).








^ This torque wrench should be held as shown in the illustration.








34. Install the steering intermediate shaft No. 2.

A. Align the matchmarks on the power steering gear assembly and steering intermediate shaft No. 2.

B. Install the steering intermediate shaft No. 2 to the power steering gear assembly with the bolt.

Torque: 36 N.m (360 kgf.cm, 27 ft.-lbf)


35. Install the steering sliding yoke.

A. Align the matchmarks on the steering column and steering slide yoke.

B. Install the steering sliding yoke to the steering column assembly and slide it upward.

C. Align the matchmarks on the intermediate shaft sub-assembly No. 2 and steering sliding yoke.

D. Install the sliding yoke to the intermediate shaft sub-assembly No. 2 with the bolt A and bolt B.

Torque: Bolt A, B: 36 N.m (370 kgf.cm, 27 ft.-lbf)


36. Connect the tie rod end sub-assembly LH.

A. Connect the tie rod end to the steering knuckle arm.

B. Install the nut and cotter pin.

Torque: 91 N.m (928 kgf.cm, 67 ft.-lbf)


37. Connect the tie rod end sub-assembly RH.

A. Connect the tie rod end to the steering knuckle arm.

B. Install the nut and cotter pin.

Torque: 91 N.m (928 kgf.cm, 67 ft.-lbf)


38. Install the engine under cover sub-assembly No. 1 with the 4 bolts.

39. Install the engine under cover assembly rear with the 6 bolts.

40. Install the front wheel.

Torque: 112 N.m (1,142 kgf.cm, 83 ft.-lbf)

41. Place the front wheels facing straight ahead.

42. Add power steering fluid.

43. Bleed the power steering fluid.

A. Check the fluid level.

B. Ensure that the front of the vehicle is slightly higher than the rear of the vehicle to aid in air bleeding of the steering rack.

C. Turn the steering wheel. With the engine stopped, turn the wheel slowly from lock to lock several times.

D. Lower the vehicle.

E. Reconnect the negative (-) battery terminal.

F. Start the engine. Run the engine at idle for a few minutes.

G. Turn the steering wheel.

a. With the engine idling, turn the wheel to left or right full lock position and keep it there for 2 to 3 seconds. Then turn the wheel to the opposite full lock position and keep it there for 2 to 3 seconds.

b. Repeat step "a" several times.


H. Stop the engine.









I. Check for foaming or emulsification. If the system has to be bled twice because of foaming or emulsification, check for fluid leaks in the system.

J. Check the fluid level.

44. Check the power steering fluid leakage.

45. Inspect and adjust the wheel alignment. Inspect the vehicle alignment using the instructions provided on the Technical Information System (TIS): 2003 or 2004 model year 4Runner Repair Manual: Front Suspension: Front Wheel Alignment: Adjustment.

46. Return to "Diagnostic Procedure", step 4, to continue procedure.

NOTE: Prior to returning the vehicle to the vehicle to the customer, re-initialize the power windows and moon roof. Refer to TSB No. PG021-02, "Back Door Power Window Initialization During PDS," and TSB No. EL009-04, "Power Window/Roof Initialization Procedures."