‘STEERING 164 STEERING TABLE OF CONTENTS POWER STEERING SYSTEM + Deseription and operation ‘STEERING AND STEERING CONTROL ASSEMBLY : + Removalinstaliation + Checks and Inspections POWER STEERING PUMP + Removalinstallation .. + Pump functional check + Replacement of power steering pump drive bett ‘Check and adjustment of power ‘steering pump drive belt tensior POWER STEERING FLUID RESEI 23-45 23-15 HIDRAULIC SYSTEM SERVICING AND BLEEDING OPERATIONS POWER STEERING FUNCTIONAL CHECK ... 23-16 TECHNICAL CHARACTERISTICS AND SPECIFICATIONS .. + Fluids and lubricants = Tightening torques. + Special tools... TROUBLESHOOTING PROCEDURE. 23-4@ STEERING 18a ILLUSTRATED INDEX [STEERING COLUMN POWER STEERING FLUID RESERVORR (page 23: 18) HIDRAULC SYSTEM SERVICING AND ‘BLEEDING OPERATIONS (page 23-18) REPLACEMENT OF POWER STEERING. PUMP ORIVE BELT (page 23-16) ‘CHECK AND ADJUSTMENT OF POWER STEERING PUMP DRIVE BELT TENSION (page 23 -15) a A tr S WPESS STEERING AND STEERING CONTROL ASSEMBLY (page 22-8) REMOVALINSTALLATION (pege 23 -8) POWER STEERING PUMP REMOVALINSTALLATION (page 23-14) BUMP FUNCTIONAL CHECK (page 23-18) [STEERING BOX page 23-10) REMOVALINSTALLATION (page 23-11) (CHECKS. AND INSPECTIONS (page 23-93)STEERING 164 POWER STEERING SYSTEM DESCRIPTION AND OPERATION ‘The steering system is provided with a rack type power ‘STEERING PUMP ‘SUPPLY HOSE. STEERING BOX RESERVOIR DELIVERY HOSE. 2 io steering which enhances the driving comfort and in- creases the driving safety. ‘The system main components are: a vane pump provided with a flow rate and maximum pressure valve, a supply reservoir lacated in the engine compartment, a rack type Steering box and a pipe coil used to coo! off the fluid. The steering pump is driven by the engine through a bet, and provides a supply pressure variable from 3.5 bar (60.75 psi) in “neutral” position to a maximum of 85 bar (1232.5 psi) in “tull steering” Inside the pump is located a quick minimum contral valve which determines an increase in engine speed when the system works al pressure higher than 16 bar (232 PSI), ‘The power steering assembly is similarto arack mechani- cal steering; the diferenceis thatthe power steering uses a box inside which there is a double effect piston, joint to the rack rod, that moves inside an actuating cylinder. Another difference is that in the worm screw seat, where ts located a distribution valve with related ducts. The valve is controlled by a torsion device located on the worm screw end. DISTRIBUTION VALVE.2 eo STEERING Depending on the torsion transmitted by the steering wheel to the device, fluid from pump is delivered fo the teservoir or to one of the two chambers A and B in the OPERATING CYLINDER PIsTOR 164 actuating cylinder. Force generated by fluid pressure on the piston lateral surface determines tts movement, the frovement of the rack and hence of the wheels. Rack NOTE: SHOULD STEERING PUMP, actuating cy!- Inder or distribution valve fall to operate, the power steering system works as a nor- mal mechanical steering box; this maftunc- tlon Is sensed by the steering wheel as an Increase of force required to turn the steer- Ing wheel. ‘NOTE: ‘The power steering system is self purging; purging is obtained by fully steering toward Jett or right with engine running and vehicle ‘stopped. This operation must be carried-out any time the connecting hoses are removed or installed.STEERING 164 STEERING AND STEERING CONTROL ASSEMBLY SUPPORT SC ramrcousm oS x “. XN 4 NN V (INTERMEDIATE SHAFT INTERMEDIATE SHAFT EAD 2? cS N NX N Mw LOWER PROTECTION N a vrrenprorecron > ‘The assembly includes the steering wheel and the stear- ing column. The steering column is connected to the steering box by means of an intermediate shatt provided 2 —_—=_ with two universal joints to make omokimetic the move- Ment transmission. This solution gives the possibility to ‘Send a more even toad to the steering wheel, distributing ‘the seizings that arise on the steering column. The steering column - intermediate shaft assembly is telescopic to permit axial adjustment of the steering wheel. REMOVAL/INSTALLATION WARNING: Before carryng-out any opration on the air bag system, It is exsentlal to prevent accl- dental actuation of the bag performing the following oprations: Disconnect (+) and (-) leads from the 1. Remove two screws securing the module to the steering wheel using a suitable wrench (Torsan No.30), NOTE: — Replace screws at any removal. WARNING: OPERATE WITH PRECAUTION! THE AIR BAG MODULE CONTAINS A BLASTING CHARGE THAT PRODUCES GAS (see Group 00: "SAFETY DEVICE! 2. Partially extract air bag from steering wheel and dis- connect electrical connector. 3. Remove air bag module. NOTE: Stow the air bag module in the relevant ‘safety container just after removal. 23-5‘AIRBAG MOOULE ELECTRICAL CONNECTION ‘SCREW Remove knees protection panel. 5. Rotate the steering wheel by 90° lettwards, and remove the left-side shrouds fixing screws, then rotate itby 180° rightwards and remove the right-side fixing screw. 6. Disconnect electrical connections and remove shrouds, a ELECTRICAL CONNECTIONS. uppen sHRoUD LOWER SHROUD 7. Disconnect horn electrical connector. 8. Loosen central nut securing steering whee! to steer- ing column, 8. Remove tongue spring. STEERING 1210185 ibe C7121 WoT SECURING STEERING WHEEL WORN ELECTRICAL CONNECTOR 10. Remove steering wheel using tool No. 1.821.214.000. CAUTION: Do not rotate steering wheel whlist per- forming this operation to prevent breakage of steering wheel electric contact spiral spring. 11, Extract the electric contact group, paying attention not to damage the reference spring. 23-6‘STEERING 164 12. Disconnect the connector cable. CONNECTOR CABLE On reassembly, ensure the electric contact group reference spring is properly positioned. ‘and the cable of electric connector is seated in its housing. NOTE: Ensure the wheels are perfectly straight before carrying-out the following opere- tions. 13. Remove screws and multiple switch, leaving it con- nected to wiring harness. MULTIPLE swrrcH (MULTPLE SWITCH ATTACHING SCREW 14. Remove relays support plate secured to steering column, leaving it connected to wiring hamess. 23-7 . Disconnect ground correction tromrear side of staer- Ing column. . Withdraw and remove plastic protection located on hutch pump. . Disconnect electrical connections from ignition ‘switch and radio inhibitor switch. . Fremove steering column support securing bol, re- lated bushing and nut. . Loosen nut and remove steering wheel adjustment fever. Remove steering column support assembly recover- ing key located on the splined part. 7 ELECTRICAL CONNECTION 1GNTTION SWITCH LECTRICAL CONNECTION Hanon swrTcH by STEERING COLUMN SUPPORT stetanawuee. ‘ADUUSTMENT LEVER #OLT SECURING UNIVERSAL JOINT ‘TO INTERMEDIATE SHAFT END.2 _—e_ 21. Remove upper cover of intermediate shat universal joint. 23. Remove bolt securing intermediate shaft universal point to steering box pinion. 24. Remove intermadiate shat. STEERING WOLT SECURING UNIVERSAL OTTO STEERING BOX PaRwCH STEERING COLUMN DISASSEMBLY/REASSEMBLY 1. Slide out intermediate shatt end from steering cot umn support. Remove steering column retaining tlange. Slide out complete steering column together with bearing and snap ring. 2. 3. NOTE: Lubricate steering column betore reassem- bly.STEERING 164 Remove steering wheel rotation angle sensor (for“S” version only). Remove phonic wheel from steering column (for“S* version only). NOTE: When assembling carry-out phonic whee! adjustment (See Group 21:"CONTROLLED DAMPING SUSPENSIONS"). 6. Using pin and hammer, loosen ignition block secur- ng screw. 7. Remove ignttion block sliding out electrical connec- tion from column. ATTACHING BOLT raNmion swrrcr \ STEERING COLUMN, —_—o 8. Using appropriate tool, extract needie bearing from column support. NOTE: When Installing, lubricate column support ‘seat and Insert needie bearing using theap- propriate tool. EEDLE DEARING TECK Spegreph (SECO Ergon Rubber t ‘Grease Hos AEINAGH Steal B2 HA ‘STEERING COLURIN SUPPORT LAW 142i 98.000 SE San IN &. Remove column bearing retaining ring. 10. Using appropriate tool, extract ball bearing trom ool- umn. NOTE. Perform reassembly using the appropriate tool. suae1.117.000 FLANGE RETAING BOLT BALL BEARING ‘STEERING COLUMN, 23-9@ STEERING te CHECKS AND INSPECTIONS 1, Inspect needle bearing and ball bearing tor damage: inspect relevant seats in column support for scratches. 2. _ Inspect for absence of play betweensteering column ‘and needle bearing; check that column is not off center. 3. Check for integrity of steering lock recess. BALL BEARING 4. Check universal joint crosses for excessive play. 5. Inspectthat splined shafl teeth are not damaged and = Ss sumed our 164 STEERING BOX The steering box, similar to a mechanical one tor the pinion-track coupling, is integrated by a hydraulic servo mechanism. This servo includes an actuating cylinder inside which there is a piston connected o the wheels by means of link rods, and a distribution valve that allows pressurized fluid passage fromthe pump te the actuating ‘tylinderleft andright chambers. The valve has an internal rigid connection, by means of bayonet type fitting, that guarantees the steering operation should a hydraulic system failure occur. 23-1016a ‘The powering steering of “S" version is provided with a recovery spring, located on the assembly upper part, to faciltate and optimize the steering wheel return (Hidro Racing System - HRS). REMOVAL/INSTALLATION 1. Remove upper cover on steering intermediate shaft universal joint. UPPER PROTECTION 271044 Ribs QT tot Hm) 2. Remove lower cover. 3. Disconnect steering intermediate shatt from steering box pinion. seuss STEERING @ 4, Remove tront left wheel. 5. Remove wheelarch rear liner. WHEELARCH REAR PROTECTION 6. _Drainthe power steering reservoir by sucking out the oil by means of a syringe. 7. Disconnect oil delivery and return hoses from the steering box.~£ 8. Using a suitable tool, extract the steering tie-rod ball joint (on both sides). nose) el azies.000 23- STEERING 164 %. Remove steering box bulkhead. 10. Remove bolts securing steering box to frame. a At installation first tighten bolt on pinion side of Tt] steering box. 11. Slide out steering box trom lett wheelarch side. NOTE: Atinstallation,carry-out frontwhoeistoe-in ‘adjustment (see Group 21). 12164 =_— 2 12. Loosen locknut. CHECKS AND INSPECTIONS 13. Unscrew steering link rod and remove trom arm. . 1. Check that the ball joints are not damaged or wom, NOTE: Measure distance “A” to be observed at ‘and that they are free to rotate in their seats without sticking or excessive play. Check that link rods are not damaged or distorted. ‘Check that rubber boots are in good condition. Installation, on 14. Remove boot. At installation, lubricate contacting area be- tween boot and steering rod with silicon grease: in such a way that after clamp installation, closed at last but one or last but two tooth, the link rod could rotate treely inside boot, 23-13@ STEERING —e= POWER STEERING PUMP REMOVAL/INSTALLATION 1 2. 3. 4. Working inside the right front fender, remove front Place vehicle on auto lift. Place vehicle on an appropriate jack Remove right front wheel. Protection and Ii the rear protection portion that covers steering pump. Remove plastic protection of steering pump drive belt. Disconnect hases from pump; collect hydraulic fluid, POWER STEERING PUM 22210369 Ride dS to 50Nm) 164 ‘Thoroughly clean hidraulic fitings using ben- zene. 7. _Adequately plug puripholes from which hoses were disconnected. 8. Using too! No. 1.822.104.000 loosen bolts located in. ‘the tension adjustment holes, and remove them. 9. Loosen andremove upper securing bolt and bolts se- curing pulley. 10. Remove pulley with related drive bet, and steering pump.164 PUMP FUNCTIONAL CHECK Carryout the pump functional check running the engine ‘at a speed of 1000 to 4000 R.P.M., blocking the fluid delivery hose and checking that pressure rises to 85 bar (12825 psi); replace pump assembly if this condition is. ‘not met. REPLACEMENT OF POWER STEERING PUMP DRIVE BELT ‘See Group 00. CHECK AND ADJUSTMENT OF POWER STEERING PUMP DRIVE BELT TENSION. See Group 00. ‘POWER STEERING FLUID RESER- VOIR ‘The reservoir is made of plastic material and is located in front of the firewall. To remove the reservoir, disconnect securing clamp and hoses underneath. The fluid level check shall be carried-out with engine running: top-up to normal level. NOTE: Bieed the systern any-time a component Is removed. CAUTION: Use specified fluids only; to top-up: the system always use fluid from sealed con- tainers, opened just betore use. NOTE: Thecheck of fluld level must be carried-out with vehicle standing on a tiat surface. NOTE: The servicing capacity of the system Is 0.9 kg (2 Ibs). STEERING @ cuawe Pwo POWER STEERING FLUO RESERVOAR ‘ —“, HYDRAULIC SYSTEM SERVICING AND BLEEDING OPERATIONS 1. Disconnect the reservoir breather hose. 2. Flemove the plug and service the reservoir ewe \\ [Pe] [een] 23-15_—eo Slacken the intake union on the pump untitollcomes, ‘out, then tighten to specified torque. With engine ‘dling, and without leaving the reservoir run dry, tum the steeringwhael completely severaltimes;thentop up the reservoir to the maximum level mark, STEERING 16a POWER STEERING FUNCTIONAL CHECK Check the steering whee! rotation torque with engine running; the required torque shall be between 0.6 daN with engine at idle speed, and 0.75 daN with accelerator pedal fully down. i these values are not met, check system pressure as follows: insert a pressure gauge, using a "Tee fitting, on the thud Replace steering pump 43 | PUMP SEALING RINGS CHECK = Check pump shaft sealing rings for wear or damage End of test A 23-20STEERING 164 £2 GRADUAL STIFFENING OF STEERING ACTION TEST B TEST STEPS DISTRIBUTOR CHECK - " Chack distributor for integrity and efficiency of seals Gany-out step B2 Replace steering box Be OIL LEAKS CHECK + Check steering box for oll leakage | 2s | ‘SYSTEM PRESSURE CHECK (Check that pump supply pressure does not decrease below 49.7 psi (3.5 bar) with steering to neutral posi- tion Carry-out step BS Replace steering box Cany-out step BA Replace steering pump B4 | PUMP BELT CHECK Check pump drive belt is not toose, damaged or broken Restore propertension of belt; replace belt it necessary 23-21 End of test BSTEERING _e SUDDEN STIFFENING OF STEERING ACTION | TEST C TEST STEPS RESULTS REMEDY C1 | PIPES CHECK = Check pipes routing for breakage Loy > Replace affected pipes End of test C eC 23-22164 ‘STEERING NOISE/KNOCKS DURING STEERING OPERATION TEST D TEST STEPS OIL LEVEL CHECK = Check level of oil in the circuit D2 | TRAPPED AIR CHECK = Check for presence of air in the system D3 | TANK FILTER CHECK - Check tank filter for excessive ditt or obstruction Q® |QO® Carry-out step D2 Top-up oll to proper- level Cary-out step D3 Bleed system by rolat- ing the steering wheel several times to end of travel in both direc: tions: # noise is stil Present, replace steer- Ing box Cary-out step D4 Replace tank D4_| ATTACHMENTS CHECK = Check steering component attaching screwstorloose- ness Q® | QO Cay-out step DS Tighten screws to pre- scribed torque 23-23 {Cont.d)STEERING 2 184 NOISE/KNOCKS DURING STEERING OPERATION | TESTD | TEST STEPS RESULTS: | REMEDY D5 | RODS AND JOINTS CHECK + Gheoksteering rods and spherical joints fordamage or ey > Replace rodsorjoints wear —_ End of test D 23-24ea STEERING CONTINUOUS NOISE EST STEPS a T PUMP CHECK + Disconnect belt from steering pump and note if noise GS | is stil present REMEDY Replace pump End of test E 23-25STEERING 164 DAMAGED STEERING BOX BELLOWS TEST F “| TEST STEPS RESULTS REMEDY 1 | BELLOWS CHECK = Check steering box bellows for damage or aging Gey > Replace bellows End of test F 23-26STEERING Q a, NOISY INTERMEDIATE STEERING SPINDLE | TEST G TEST STEPS RESULTS. REMEDY UNIVERSAL JOINTS CHECK - Check intermediate steering spindle universal joint spider tor excessive play G2 | SPLINED COUPLING CHECK Check splined coupling of steering column and inter- mediate steering spindle for excessive play > Cany-out step G2 By > Replace intermediate steering spindle > Replace defective items End of test G -_- HO TT S927/@ STEERING —_e 164 NOISY STEERING COLUMN TEST H TEST STEPS. RESULTS REMEDY H1 | BEARINGS CHECK - Check steering column suppor bearings for wear or > Carry-out step H2 damage Replace affected bearings H2_| STEERING COLUMN CHECK ~ Check steering column for interference with multiple switch shells Carry-out step H3 Instali muttiple switch shells properly H3_| JOINT ATTACHMENTS CHECK Q | B® |Q@ - Check universal joint attachment nuts at spindle ends > Torque nuts to pre- for proper torque scribed value End of test HSTEERING 164 DIFFICULT SLIDING OR MISSED LOCKING OF STEERING COLUMN | TESTI TEST STEPS RESULTS 11 | STEERING COLUMN SUPPORT ATTACHMENT CHECK - Check for excessive torque of steering column to car body attachment screw > Camy-out step Iz > Re-torque screw to proper value 12 | ADJUSTMENT LEVER ATTACHMENT CHECK Camy-out step 13 = Check steering whee! axial adjustment lever attaching rut for excessive torque > Re-torque nut to proper value #3. | SPLINED COUPLING LUBRICATION CHECK Q | Q® |Q® = Check for proper Iubrication of splined coupling of steering column and intermediate steering spindle > Lubricate splined coupling as required End of test | 23-29