Chery A15 Maintenance Manual

Chapter Two: Steering System

A15 series’ steering system is equipped with standard power steering gear and
optional mechanical steering gear.
The power steering gear adopted by A15 series is actually a mechanical gear rack
steering gear equipped with a power assisted device powered by engine and features
parts including steering oil pump, steering control valve and power cylinder, etc.
Working process: engine power drives steering oil pump through multi-wedge, and
steering oil pump aspirates the power assistant oil in oil tank (ATF oil), and presses
the oil into steering control valve, then the pressure oil distributed by control valve
enters into power cylinder to actuate working piston. Since the working piston is
connected with one end of steering rack, the pressure oil provides function of
power-assisted steering through the working piston.
In case the power steering gear fails, the driver shall still be able to complete the
steering independently.
Optional mechanical steering gear is a gear rack steering gear, which is powered by
the driver’s physical energy (hand power), and the power is entirely transmitted by
mechanical parts.

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 Chery A15 Maintenance Manual

I. Disassembly/Assembly and Inspection of Steering Post

Figure: Exploded View of Steering Post

1-Safety airbag and horn button cap 2-Nut (40Nm) 3-Spring washer 4. Steering wheel
5-Serrate adapter sleeve 6-Spring 7-Lower ornament cover 8-Upper ornament cover
9-Steering gear lock shell and steering post switch 10-Supporting ring 11-Steering post
12-Nut (30Nm) 13-Steering post universal joint 14-Hexagon bolt 15-Spring
16-Steering post lower bearing 17-Check screw 18-Washer 19-Steering post tube
20-Nut (20Nm) 21-Steering post tube bracket

1. Structure of Steering Post (as shown in the figure)

2. Assembly Steps of Steering Post:
1). Assemble bracket ring and steering shaft lock shell spring with an assembling
press. Apply small amount of lubricant grease around lower bearing and lower inner
wall of steering post tube, and then press the lower bearing into the steering post tube
with an assembling press. (Note: be careful not to move upper and lower universal
joints of steering post tube.)

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2). Insert the steering post into post tube from the steering wheel end.
3). Lock the steering post onto universal joints with bolts.
4). Fix steering gear lock shell onto steering post tube. Note: Adjust the relative height
of lock shell and post tube according to the height of preassembled ignition lock
barrel and combination switch shield.
5). Fit the serrate adapter sleeve onto steering post, and press it into the position with
an assembling press by only one stroke to achieve tight fit.
6). A layer of lithium lubricant grease shall be evenly applied to the contact ring.

II. Disassembly/Assembly of Power Steering Gear and Clearance

Adjustment
1. Assembling Power Steering Gear
1). Assemble steering gear and steering knuckle tie rod assembly onto subframe, and
tighten the 4 set bolts to specified torque 30Nm.

2). Connect properly the power steering oil pipe.

Tightening torque for oil return tube,
high-pressure oil pipe and steering gear connector
is 30±3Nm.

3). Tightening torque of the hollow bolt connecting

high-pressure oil pipe and power steering pump is
45±3Nm.

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2. Checking Power Steering System

An exhaust is necessary when the hydraulic oil in oil tank looks like emulsified or
pump noise is too loud (max. 80db under normal condition). Exhaust procedure: jack
up two front wheels, start engine and turn the steering wheel to both left and right
extreme positions (do not stay for longer than 2 seconds at extreme positions after
reached), and repeat turning for several times to gradually exhaust the air in the
system from oil tank. During the procedure, keep adding hydraulic oil into oil tank
with the decrease of oil level until a specified level is reached.
3. Checking Belt Tension
Worn-out, cracked or blown belt shall be replaced in time. To check belt tension,
apply moderate pressure with a thumb on a position between the pulleys, and belt
displacement shall be approximately 10mm. In case the belt is found loose, please
contact the nearest Chery service station for regulation and maintenance.
4. Precautions when Checking Power Steering Gear
Turning steering wheel to extreme positions is prohibited in normal operation, and the
dwell time is not allowed to exceed 10 seconds in the case of necessity. In case of
interference check in the minimum turning radius test on assembly PG, the dwell time
of steering wheel at extreme positions is also not allowed to exceed 10 seconds. When
a loud noise from power steering oil pump is heard during steering, turn back the
steering wheel a little until the noise is gone. Unoiled working of power steering
pump is strictly prohibited. If steering is felt heavy in operatoin, stop the vehicle
immediately to check and repair.

III. Inspection Items of Power Steering System

Bent steering post, worn or damaged safety coupling, inelastic spring shall be repaired
or replaced.
1. Routine Inspection
(1). Check if the set bolts are loose.
(2). Check if the steering wheel free play is appropriate, and adjust or replace steering

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system parts if not.

2. Checking Steering Knuckle Tie Rod
(1). Check tie rod ball, and replace if it is found loose in ball joint.
(2). Check tie rod ball dust boot and repair or replace it if it is damaged.
3. Checking Steering Gear
(1). Check steering gear dust cover and replace any cracked one to prevent water and
dust from entering the parts and causing early part damage. Check if the dust cover
clamp is well fixed.
(2). Check steering gear clearance and adjust if not proper.
4. Checking Hydraulic Assistant Pump
(1). Check assistant pump and replace if it is found blocked.
(2). Check assistant pump bearing and replace if abnormal sound is heard.
(3). Check hydraulic system and replace if leakage is found.

IV. Airtightness Inspection of Power Steering System

Airtightness inspection of power steering system shall be perform when warming up
the vehicle. Inspection steps:
(1). Turn the steering wheel quickly to left and right extreme positions and hold still
to maximize the system pressure.
(2). Visually inspect steering control valve, rack gear seal, vane pump (power steering
pump), oil pipe connection, and replace sealing elements if oil leakage is found.
(3). Check oil tank, and then the airtightness of power steering system if the oil tank is
short of ATF oil.
(4). If the gear rack sealing element in power steering gear shell is not working, ATF
oil may flow into corrugated tube, in this case all sealing rings in the steering system
shall be replaced.
(5). Check the oil pipe connection of power steering system, in case of oil leakage
check for cause and reconnect it.

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V. Inspection and Replacement of Hydraulic Assistant Oil

1. Checking Oil Mass
(1). Idle run the engine, and repeat the operation of turning steering wheel from one
extreme position to the other to increase power steering oil temperature to 40-80ºC.
(2) Check oil mass in oil tank, the oil level shall reach “MAX” mark. In case of low
oil level, check all parts for leakage before adding power steering oil to the “MAX”
mark as required.

Note: It is recommended to use a special device to vacuumize the oil tank when
adding power steering oil, otherwise the following procedure shall be followed
when adding power steering oil and exhausting air (e.g. when repairing): add
power steering oil to reach the max level in oil tank assembly, and run the engine
at low (idle) speed to drive steering pump and fill quickly the steering system
with hydraulic oil. The engine is only allowed to idle run when adding oil to dirve
vane pump, meanwhile hydraulic oil shall be added in time to avoid low oil level
and air intake by vanes.
2. Replacing Hydraulic Oil
(1). Jack up front axle and drain old oil from oil tank and return tube.
(2). Idle run the engine, turn the steering wheel to extreme positions when draining
until all hydraulic oil is drained out.
Note: This procedure must be completed as quickly as possible to protect
hydraulic assistant pump.
(3). Add power steering oil.
(4). Exhaust air in steering hydraulic system.

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3. Exhausting Air in Steering Hydraulic System

(1) Check oil level and add oil if necessary.
(2). Idle run the engine and keep turning steering wheel from left extreme position to
right extreme position until no bubble or foam is seen in oil tank. In case that oil level
falls, keep adding hydraulic oil until the specifed level (MAX) is reached.
(3). Air exhaust is relatively difficult for this model. Any bubble in system will cause
abnormal sound in hydraulic assistant pump.

VI. Inspection of Power Steering Pump Output Pressure

Check power steering pump for output oil pressure to determine if there is any fault
with power steering pump or steering gear. To measure exactly output oil pressure of
power steering pump, make oil tank level normal and power steering pump belt
tension compliant before measuring.
Measure the output oil pressure of power steering pump with a pressure gauge by
connecting the pressure gauge and hand valve serially in the system. At the moment
the engine stops rotating, dismount the pressure line from the power steering pump,
and connect one end of pressure gauge to the vent hole joint of the pump, the other
end of hand valve to the input hole of steering control valve, thus serially connecting
pressure gauge and hand valve in the pressure pipeline of power steering pump and
steering control valve.
Steps for checking power steering pump output oil pressure:
(1). Fully open hand valve.
(2). Start and idle run the engine.
(3). Turn steering wheel between left and right extreme positions for several times to
warm up steering oil to 80ºC, meanwhile maintain a normal oil level.
(4). Measure static oil pressure when the engine speed is 800r/min. The pressure
gauge reading shall be at least 300kPa (the minimal pressure when no steering) under
good condition of power steering pump.
(5) Slowly shut hand valve until gauge hand is stable, then read the pressure value,

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which shall be at least 6.2-6.9Mpa; any lower value indicates low output pressure of
steering pump and ineffective power assisted steering. The power steering pump is at
fault, and need repair or replacement.

VII. Fault Diagnosis and Troubleshooting of Power Steering System

Common faults of hydraulic power steering system include oil leakage at hydraulic
transmission part, air intake, power steering pump failure, steering control valve
damage and mechanical transmission part damage, etc. The symptom may be heavy
steering, steering noise, unsmooth steering and steering vibration, etc. Fault diagnosis
shall be carried out immediately after fault occurs to power steering system to
eliminate the fault in a timely manner.
(I). Heavy Steering
1. Symptom
Steering of vehicle equipped with power-assisted steering becomes heavy instead of
easy, or it becomes difficult to turn the steering wheel.
2. Possible Causes
Generally speaking, heavy steering is caused by hydraulic steering assistant system
failure or insufficient assistance, damaged mechanical transmission or improper
adjustment, the specific cause may be:
(1). Oil tank leakage or oil level lower than required value.
(2). Bad sealing of oil pipe connection and leakage.
(3). Air enters steering hydraulic circuit.
(4). Oil pipeline is distorted and oil circuit is blocked.
(5). Insufficient tension of power steering pump belt, skidding belt.
(6). Internal wear of steering oil pump and severe leakage make the oil pump output
pressure lower than standard value.
(7). Pressure regulator failure in the oil pump results in too low output pressure.
(8). Internal leakage of steering control valve and hydraulic cylinder.
(9). Damaged steering gear or improper adjustment.

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3. Fault Diagnosis and Troubleshooting

(1). Check tire pressure and inflate as required in case of low pressure.
(2). Check oil pipe connections of steering hydraulic system, and tighten them if
leakage is found; check oil pipes, and replace damaged, distorted or cracked ones.
Adjust pretightening force of rack convex piece or replace steering gear rack if
necessary.
(3). Check steering gear rack and the turning condition at the center wheel position,
and check the rack bent and the adjustment of rack convex piece in case of excessive
turning torque. Adjust pretightening force of rack convex piece or replace steering
gear rack if necessary.
(4). Check steering control valve to see if there is any blockage or bad returning, and
replace the steering control valve when necessary.
(5). Disassemble and inspect hydraulic cylinder, and replace damaged parts.
(6). Make adjustments on ball pin at each connection of steering transmission
mechanism to insure smooth operation.
(II). Steering Wheel Vibration
1. Symptom
Steering wheel vibrates during operation when the engine is working, especially at the
extreme positions.
2. Possible Causes
(1). Steering oil pump belt skids.
(2). Too low oil tank level.
(3). Air enters steering hydraulic circuit.
(4). Insufficient steering oil pump output pressure.
(5). Blocked pressure regulator piston in steering oil pump.
3. Fault Diagnosis and Troubleshooting
(1). Check steering oil pump transmission belt to see if there is any skidding or
damage, and tighten or replace the belt when necessary.
(2). Check oil tank level for consistency, and add steering oil as required.
(3). Check all pipe joints in steering hydraulic system and eliminate any leakage
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found, then exhaust the air in oil circuit.

(4). Check steering oil pump output pressure. In case of underpressure, disassemble
the oil pump and check for wear or internal leakage, check pressure limiting valve and
pressure regulator piston for leakage or blockage, pressure regulator spring for weak
spring force, and oil pump sealing for damage. Identify fault cause and repair, or
replace oil pump if necessary.
(III). Light or Off-tracking Steering Wheel in Straight Running
1. Symptom
Vehicle is not going right ahead when running on a straight line and keeps going off
track towards one side.
2. Possible Causes
(1). Damaged or too soft steering control valve torsion bar is not able to overcome
reverse transmission resistance of steering gear, keeping valve bush from timely
returning.
(2). Movement of valve plug and valve bush is retarded due to contaminated oil.
(3). Steering control valve plug deviates from center position.
(4). Blocked pressure regulator piston of steering pump overflows pump oil and
causes large pressure difference between left and right cavities of power cylinder.
(5). Too large joint clearance of steering transmission system, or loose connecting
pieces, or severe wear.
3. Fault Diagnosis and Troubleshooting
(1). First check steering transmission mechanism for loose connecting piece, too large
component clearance and loose transmission to eliminate steering transmission
mechanism faults.
(2). Check if the oil is contaminated. New or overhauled vehicles sometimes have
contaminated oil for poor compliance with the oil-replacing requirement during
running-in period. Any contaminated oil shall be replaced.
(3). Check steering control valve. First turn the steering wheel with the engine not
working, and determine by hand feeling if the steering control valve is operating
smoothly. Disassemble and inspect in case of suspected situation.
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(4). Finally check the performance of steering oil pump pressure regulator to see if the
regulator piston is blocked. Check steering oil pump output pressure to facilitate
determination when necessary.
(IV). Steering Noise
1. Symptom
Too large noise occurs during steering.
2. Possible Causes
Too large noise from steering system during steering is considered to be a normal
phenomenon, and it is common that steering pump makes noise in the first 2-3
minutes after the engine is started in cold weather (-20ºC or lower). However, too
much noise or those affect steering performance are deemed as fault. The cause for
such fault may include:
(1). Loose steering transmission mechanism causes too large noise.
(2). Damaged or worn-out power steering pump or air in the oil causes too large
noise.
(3). Loose or skidding power steering pump transmission belt causes too large noise.
(4). Poor performance of steering control valve.
(5). Loose oil pipe connection or cracked oil pipe.
(6). Blocked oil filler strainer or too much deposition in hydraulic circuit.
3. Fault Diagnosis and Troubleshooting
(1). If a “click” sound is heard when steering, it may be caused by loose steering post
shaft adapter, steering knuckle tie rod or ball joint. Check these parts and fasten or
replace them if necessary. If steering post shaft wiggles badly, the steering post
assembly shall be replaced. Loose steering gear shall be fastened, and lubricant sites
at connections shall be lubricated. In addition, loose steering pump transmission belt
also makes “click” sound, so also check the belt and tighten or replace it to eliminate
the noise.
(2). If a “quack” sound is heard when steering especially when turning the steering
wheel from one extreme position to the other, it may be caused by skidding power
steering pump transmission belt. Check the belt tension and wearing condition, and
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tighten or replace it if necessary.

(3). If a “cluck” sound is heard when steering, it may be the aerodynamic noise
caused by air bubbles in flowing oil. First check the oil level, and add to the specified
level if it is too low before checking and eliminating fault. Then check to see if the
hose is damaged or the clamp is loose, allowing air to enter the system. Replace
damaged hose or clamp when necessary. In case air is found in power steering system
oil, exhaust the air to eliminate aerodynamic noise. If a “hissing” or a squealing sound
is made by steering pump while there is no air leakage in hydraulic system with the
transmission belt tension being normal, it may be caused by blocked oil circuit or
worn-out or damaged oil pump, which shall be repaired or replaced.
(4). If a large “hissing” sound is heard from steering gear when steering wheel is at
extreme positions or slowly turned in situ, it may be caused by bad performance of
steering control valve. Replace the control valve and recheck to eliminate the noise.

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