CHAPTER 7 STEERING

NOTICE 145
FAILURE SYMPTOM TABLE 145
PART-1 MANUAL STEERING 146
SECTION-1 STRUCTURE AND PARAMETER 146
1. STEERING SYSTEM 146
2. STEERING GEAR MECHANISM 147
3. STEERING TIE ROD END ASSY 147
4. STEERING COLUMN 148
5. STEERING UNIVERSAL JOINT 148
6. STEERING WHEEL 148
SECTION-2 MAINTENANCE OPERATION 149
1. STEERING WHEEL 149
2. STEERING COLUMN 151
3. STEERING GEAR ASSY 157
4. STEERIGN GEAR HOUSING 158
PART-2 HYDRAULIC POWER STEERING 167
SECTION-1 INSPECTION ON VEHICLE 167
SECTION-2 CONFIGURATION AND PARAMETERS 171
1. POWER STEERING PUMP 172
2. STEERING COLUMN AND STEERING TIE ROD 174
3. STEERING TIE ROD END ASSY 176
4. STERRING COLUMN 176
5. STEERING UNIVERSAL JOINT 176
6. STEERING WHEEL 177
SECTION-3 MAINTENANCE OPERATION 177
1. POWER STEERING PUMP 177
2. STEERING WHEEL 179
3. STEERING COLUMN 181
4. POWER STEERING TIE ROD ASSY 187
PART-3 ELECTRICAL POWER STEERING 193
SECTION-1 SUMMARY 193
SECTION-2 MAIN SPECIFICATIONS 196
SECTION-3 CIRCUIT DIAGRAM 197
SECTION-4 CONNECTION END TABLE 198
SECTION-5 DIAGNOSING FAILURE CODE 199
SECTION-6 CONTROL FLOW CHART 200
SECTION-7 FAILURE CODE DIAGNOSIS 201
SECTION-8 MAINTENANCE OPERATION FOR EPS STEERING SYSTEM 203
SECTION-9 MECHANICAL CHECK 209

13
SECTION-10 EPS NORMAL FAILURE DIAGNOSIS AND FAILURE-EXCLUSION METHOD
210
NOTICE:
1. About the steering system
Must be careful to replace parts, the wrong replacement may affect the steering
system and even lead to drive danger.
2. About the SRS-40 Airbag
Some types of Xiali vehicles have the supplemental restraint system, such as the
Safety Airbag. The wrong repairing order may lead to the explosion of the Safety
Airbag during the repairation and even the serious accident. Before the servicing
(including the remove and installation, inspect or replace), the notices for
supplemental restraint system must be read.
FAILURE SYMPTOM TABLE
NOTE:
The following table is useful to find the reasons of the problems. The numbers represent the
possible failure and the part-checking order. If necessary, repaire or replace these parts.
Symptom Possible reasons
1. Tire (improper air charge)
2. Power steering oil (insufficient)
3. Front wheel alignment (incorrect)
4. Steering connection ball head (wear)
heavy steering 5. Suspension arm ball stud (wear)
6. Steering column (locked)
7. Vane pump assy
8. Rack and pinion steering gear assy
9. Electrical power steering system failure
1．Tire (improper air charge)
2．Front wheel alignment (incorrect)
Steering align insufficiency
3．Steering column (locked)
4．Rack and pinion steering gear assy
1．Steering connection ball head (wear)
2．Suspension arm ball stud (wear)
Excessive free clearance
3．Front wheel beering (wear)
4．Rack and pinion steering gear assy
1．Power steering oil (insufficient)
2．Steering connection ball head (worn)
Exceptional noise 3．Vane pump assy
4．Rack and pinion steering gear assy
5．Electrical power steering system pump

14
 PART 1 MANUAL STEERING SYSTEM
SECTION 1 STRUCTURE AND PARAMETER
1. STEERING SYSTEM
The steering employs ithe rack and pinion type. The steering gear of this type features simple
construction and has a good operating feeling.

15
2. STEERING GEAR
The steering gear assy consists of a steering pinion, a steering rack, a steering rack housing, a
steering rack guide, a rack boot and a steering rack end.
The steering pinion has six helical gear teeth. And it is supported with two bearings. The steering
gear has such construction that the back side of the steering rack is pushed bu means of a spring
with the rack guide interposed in order that the steering rack may be pushed at all times against the
pinion tooth surface with an adequate force.
The rack boot is secured between the housing and rack end by means of a band. This complete
sealing prevents any ingress of water or dust.

Rack end Rack

Pinion Rack housing Boots

Oil seal
Rack guide Pinion
Radial ball bearing
Rack guide
Spring cap

Lock nut Needle roller bearing

Spring Rack

3. STEERING ROD ENDS

The tie rod ends employ resin ball joint seats. They are the maintenance-free type in which
disassembly can not be made.
The toe-in adjustment can be carried out by means of the tie rod and tie rod ends.
Resin integral type seat

Tie fod end

Dust
boots

16
4. STEERING COLUMN

5. STEERING SHAFT UNIVERSAL JOINT

6. STEERING WHEEL
Steering wheel is four-spoke type which is made of
Polyurethane.

17
 SECTION 2 MAINTENANCE OPERATION

1. STEERING WHEEL
REMOVAL
1) Disconnect the battery negative (-) terminal.
2) Remove the steering wheel pad lock nut.

3) Hold the steering wheel pad at its lower

end by your fingers. Then, detach the
steering wheel pad by pulling it toward
your side. Disconnect the wiring harness
connector.

4) Remove the steering wheel lock nut.

5) Remove the steering wheel, using the

09609-20011-000
following SST.
SST: 09609-20011-000

18
INSTALLATION
1) Fit the steering wheel and tighten the lock nut.
Tightening Torque: 34.3 - 53.9N·m (3.5 - 5.5kgf·m)

2) Connect the wiring harness connector, install the

steering wheel pad.
3) Install the steering wheel pad fixing bolt.
4) Connect the battery negative (-) terminal.

19
2. STEERING COLUMN
COMPONENTS

T : Tightening torque
Unit: kgf.m
★ : Non-reusable parts

T: 3.5-5.5

T: 2.5-3.5

Fig.

7-12
REMOVAL
1) Disconnect the battery negative (-) terminal.
2) Remove the steering wheel.

3) Detach the instrument lower finish panel (Detach

underside two screws, open upside two clips) and
steering column lower cover (Detach five screw).

20
4) Remove the instrument panel lower
reinforcement. (Remove two bolts)

5) Remove decorating ash tray, prize up controlling

panel with cloth packing screwdriver, Disconnect
safety caution switch connector.

6) Remove the fuse box and the bracket. (Remove

five bolts)

7) Remove the connectors for the multi-

use lever switch and engine key switch.

8) Remove the bolt of the universal joint.

Fig. 7-

9) Steering column assy removal

21
(1) Remove two bolts and two nuts.
(2) Remove the steering column assy
from the body.

10) Remove the steering column upper

cover and multi-use lever switch from the
steering column assy.

DISASSEMBLY
1) Detach the snap ring and plate washer located
at the lower side of the steering main shaft.

2) Detach the snap ring located at the

upper side of the steering main shaft.

3) Steering main shaft subassy removal

(1) Switch the key to ACC.
(2) Remove the steering main shaft
Stopper
subassy by tapping the main shaft lightly
with a plastic hammer.

22
(3) Remove the stopper from the steering
main shaft.

(4) Detach the snap ring from the steering

main shaft.

INSPECTION
INSPECT THE FOLLOWING PARTS

Fig.
7-23

23
ASSEMBLY
1) Assemble of steering main shaft
(1) Fit a new snap ring to the steering main shaft.
(2) Place the stopper on the bearing.

2) Switch the key to ACC. Insert the

main shaft (with the bearing) into the
steering column, using a plug wrench.

Plug rench

3) Fit the new snap ring to the upper side

of the steering main shaft.

4) Install the plate washer and snap ring.

Plate wahser

Snap ring

5) Install the multi-use lever switch to the

steering column.

24
INSTALLATION
1) Steering column assy installation
(1) Install the steering column upper cover
to the steering column.
(2) Tighten the attaching bolt of the
universal joint.
Tightening Torque: 20 - 25N·m(2.5 - 2.5kgf·m)

(3) Install the steering column with the

three bolts and two nuts.
Tightening Torque:
Bolt: 15 - 22N·m
Nut: 10 - 16 N·m

2) Install the connector for the multi-use

lever and engine key switch.

3) Install the instrument panel lower

reinforcement.
4) Install the instrument lower finish panel and
steering column lower cover.
5) Install the steering wheel.
6) Install the battery negative (–) terminal.

3. STEERING GEAR ASSY

COMPONENTS

25
 T : Tightening torque
Unit: kgf.m
★ : Non-reusable parts

T: 2.5-3.5

T: 1.0-2.0

T: 4.0-5.5

T: 3.0-4.5

REMOVAL
1) Jack up the vehicle at the front side.
Support the body with safety stands.
2) Remove the front wheel.

3) Remove steering column hole cover

subassy. (four bolts)

4) Steering universal joint removal.

(1) Remove the bolt.
(2) Remove universal joint.
5) Tie rod end removal Fig.
(1) Remove the cotter pins and castle nuts.
(2) Remove the tie rod end from the knuckle arm,
using the following SST.
SST: 09611-87701-000

26
6) Steering gear assy removal
(1) Remove the four bolts of steering rack housing
bracket clips.

(2) Remove the steering gear assy from the vehicle.

4. STEERING GEAR HOUSING

Components (See the next page)
Disassembly
1) Clamp the mounting section of the steering rack
housing in a vice with copper sheets or aluminum

Copper or
Aluminum sheets

27
 T : Tightening torque
Unit:kgf.m
★ : Non-reusable parts

28
2) Tie rod end removal
(1) Before the steering tie rod end is removed, put a
mark on the rack end section in order that this mark
may be used as guide to ensure easier toe-in
adjustment during the reassembly.
(2) Slacken the lock nut. Remove the tie rod end
from the rack end.
3) Remove the boot band No.2 and rack boot
band. Remove the rack boot.
4) Steering rack end removal
(1) Slacken the rack end plug, using the flat
sections of the steering rack (width across flats:
19 mm) and the flat sections of the rack end plug
(width across flats: 26 mm).
(2) Remove the steering rack end from the
steering rack.
(3) Remove the rack end plug from the steering
rack end.
5) Remove the lock nut (hexagon nut), using the
following SST.
SST: 09617-22030-000

6) Rack guide spring cap removal

(1) Remove the rack guide spring cap, using a
simple spinner.
Simple Spinner (Width across flats: 17 mm)
(2) Remove the compression spring and rack
guide from the steering rack housing

7) Remove the steering rack.

NOTE:
(1) Be sure to draw out the rack toward the
housing side so that the rack bush may not be
damaged by the rack tooth surface.

29
(2) Draw out the rack straight, not allowing the rack to rotate.

8) Remove the oil seal, using a common screwdriver or the like. Be careful not to damage the
housing during the removal.

9) Detach the snap ring, using a snap ring expander.

10) Remove the steering pinion, together with the bearing, from the steering rack housing.

11) Radial ball bearing removal

(1) Detach the shaft snap ring, using a snap ring ex- pander.
(2) Remove the bearing, using the following SST.
SST: 09950-20014-000

INSPECTION

30
INSPECT THE FOLLOWING PARTS.

ASSEMBLY
1) Apply grease to the following sections.

31
2) Radial ball bearing installation
(1) Install the bearing to the steering pinion, using
the following SST.
SST: 09612-10061-000

(2) Attach the shaft snap ring, using a snap ring

expander

Apply grease

3) Steering pinion installation

(1)Install the steering pinion to the steering rack
housing, using the following SST.
SST: 09309-87102-000

Rack guide

Compression
(2) Attach the snap ring, using a snap ring Spring

expander.

Rack guide spring cap

Simple
Spinner
(3) Install the oil seal to the steering rack
housing, using the following SST.
SST: 09309-87201-000

Start torque 3~6kgf.m

Simple
4) Assembly of steering rack Snipper
(1) Apply No. 2 lithium grease to the tooth
surface and whole peripheral portion of the
steering rack

13
(2) Assemble the steering rack, paying attention not
to scratch the rack bush.

5) Assemble the rack guide, compression spring and

rack guide spring cap to the steering rack housing.

Fig. 7-
59

6) Rack preload adjustment

(1) Tighten the rack guide spring cap, using a
simple spinner.
Tightening Torque: 6.86 N·m (0.7kgf·m) Fig. 7-
(2) Move the steering rack back and forth about 15 60
times so as to settle the steering rack. Then, proceed
to tighten the rack guide spring cap again.
Tightening Torque: 12.25N·m (1.25 kgf·m)
(3) Back off the rack guide spring cap 45°+10°, using a
0°
simple spinner
(4) Measure the rack preload, using the following
SST.
SST: 09616-87701-000 Fig. 7-
Specified Value [Starting Torque]: 61
29.4 - 58.8 N·m (3 - 6 kgf·m)
(5) If the preload does not comply with the
specification, repeat the operations (1) through (4).

7) Hexagon nut (lock nut) installation

(1) Tighten the lock nut using the SST, while
holding the rack guide, spring cap with a simple
spinner so as to prevent the rack guide spring cap
Fig. 7-
from turning during the tightening. 62
SST：09617-22030-000
Tightening Torque: 34.3 - 44.1N·m (3.5 - 4.5kgf·m)
(2) Check the pinion starting torque again.

14
SST：09616-87701-000
Specified Value [Starting Torque]: 29.4 - 58.8 N·m
NOTE:
The actual reading of the torque wrench will be a product that is obtained by multiplying the figure
above by the following figure given below:

The actual reading of the torque wrench = moment×coeficient

8) Steering rack end installation
(1) Screw the rack end plug into the rack end.
(Set the rack end plug in such a way that the side having a larger flange comes to the rack end
side.)
(2) Under the condition described in (1), tighten the rack end to the steering rack.
(3) Secure the steering rack. Tighten the rack end plug.
Tightening Torque: 49 - 63.7 N·m (5.0 - 6.5 kgf·m)
9) Install the steering rack boot. Install the boot band No.2 and rack boot band.
10) Tie rod end installation
(1) Screw in the lock nut and tie rod end into the rack end up to the mating mark. Tighten the lock
nut temporarily.
(2) Tighten the lock nut securely after the toe-in check and adjustment have been carried out.

15
INSTALLATION
1) Steering rack assy installation
(1) Install the grommet to the steering rack assy.
Then, insert it to the vehicle.
NOTE:
Be very careful not to damage the steering rack boot
during the insertion.
(2) Install the steering universal joint to the steering
pinion. Tighten the bolt temporarily.
(3) Install the steering rack assy to the body.
Tightening Torque: 40 - 55N·m (4.0 - 5.5 kgf·m)
2) Tighten the attaching bolt of the steering
universal joint.
Tightening Torque: 20 - 25 N·m
NOTE:
When tightening the bolt, be sure to limit the
protruding length of the serration sections of the
universal joint and pinion to 5 mm.

3) Tie rod end installation

(1) Install the tie rod end to the knuckle. Tighten the
castle nuts.
Tightening Torque: 30 - 55 N·m
(2) Install new cotter pins.
4) Install the wheel, and Jack down the vehicle.
5) Check the steering wheel play.
6) Perform the toe-in adjustment.
7) Confirm the straight-ahead position of steering
wheel.

13
 PART 2 HYDRAULIC POWER STEERING SYSTEM
SECTION 1 INSPECTION ON VEHICLE
1. INSPECT DRIVE BELT
Visually check the belt for excessive wear, frayed
cords, etc. If any defect has been found, replace the
drive belt.
HINT:
Cracks on the rib side of a belt are considered
acceptable. If the missing chunks from the ribs are
found on the belt, it should be replaced.
2. DRAIN AIR FROM THE
POWER STEERING SYSTEM
(1) Check the fluid level.
(2) Rise the front of the vehicle with jack and then hold it.
(3)Turn the steering wheel
When the engine is off, turn the steering wheel from lock to lock slowly and repeat that several
times.
(4) Reduce the height of the vehicle.
(5) Start the engine and run it at idle for several Normal Abnormal
minutes.
(6) Turn the steering wheel.
(1) With the engine idling, turn the steering
wheel to a lock position and keep that for 2-3
seconds. Turn reversely and keep that for another
2-3 seconds.
(2) Repeat operation (1) for several times.
(7) Stop the engine.
(8) Check for foaming or emulsification.
If the system needs to be bleeded twice as there is
foaming or emulsification, at the same time
inspect whether it leaks.
(9) Check the fluid level.

3. CHECK THE FLUID LEVEL. Normal Abnormal

(1) Keep the vehicle in the road level.
(2) When the engine stopped, check the fluid level
in the oil reservoir. If necessary, fill fluid.

14
 OIL: Q/SAH·01-2006, Manufacture: Aogina, Shenyang
HINT:
Check that the fluid level is within the HOT LEVEL range. If the fluid is cold, chech that it is
within the COLD LEVEL range.
(3) Start the engine and run it at idle.
(4) Turn the steering wheel from lock to lock
Less than 5mm (0.20in.)
several times to increase oil temperature.
OIL temperature: 75-80℃ (167-176°F)
(5) Check for foaming or emulsification.
If there is foaming or emulsification, bleed air from
the power steering system.
(6) With the engine idling, check the fluid level in
the oil reservoir.
Idle engine Stop engine
(7) Stop the engine.
R11786
(8) Wait a few minutes and recheck the fluid level
in the oil reservoir.
Maximum fluid level rise: 5 mm (0.20 in.)
If a problem is found, bleed air from the power steering system.
(9) Check the fluid level.
4. CHECK STEERING FLUID PRESSURE.
(1) Disconnect the pressure feed tube from the PS vane pump.
(2) Connect SST, as shown in the illustration below.
SST: 09640-10010(09641-01010, 09641-01020,09641-01030)
NOTE:
Check if the valve of the SST is in the open position.
(3) Bleed air from the power steering system.
(4) Start the engine and run it at idle.
(5) Turn the steering wheel from lock to lock several times to increase oil temperature.
OIL temperature: 75-80 °C (167-176 °F)

15
 Connecting hose
Pressure
Supply hose

Connector

(6) With the engine idling, close the valve of the

SST and observe the reading on the SST.
Reservoir
Minimum oil pressure: 5.2 MPa
NOTE:
Steering
Do not maintain lock position for more than 5 gear Off
seconds. Power
Steering
Do not let the oil temperature become too high. Vane pump
(7) With the engine idling and the valve fully
opened, turn the steering wheel to full lock position.
Minimum fluid pressure: 5.2 MPa Reservoir
NOTE: Lock position

Do not maintain lock position for more than 5 Steering On

Gear
seconds. Power
Do not let the oil temperature become too high. Steering
Vane pump

(8) Disconnect the SST.

SST 09640-10010(09641-01010，
09641-01020，09641-01030)
(9) Connect the pressure feed tube to the PS vane pump.

16
(10) Bleed the power steering system.

5. CHECK THE STEERING MOMENT

(1) Keep the steering wheel centering.
(2) Disassemble the horn button assy.
(3) Start the engine and keep it idle.
(4) Measure steering moments of both sides.
Steering moment (for reference)
Less than 7N·m
Note:
The type, pressure and contact surface of the tyre should be considered before inspection.
(5) Install the steering wheel alignment nut.
Tightening torque: 45N·m
(6) Install the horn button assy.

17
 SECTION 2 STRUCTURES AND PARAMETER

HYDRAULIC POWER STEERING SYETEM

Input shaft

Reservoir
Control valve

Steering gear housing

Power cylinder

Power steering pump

18
1 POWER STEERING VANE PUMP

Fastening torque
Unite:

plug
Pressure port

Union bolt

Pressure feed tube end

NOTICE:
Pressure port gasket
19
1. Check leaks around the oil outlet and the corresponding maintenance:
(1). It’s normal if area near the socket has been oiled,no evidence not goes to the greater, and it
has no visible moistem evidence.
(2). Please change the pressure port gasket if there is a leak and tighten the bolt
Tightening torque: 54 N•m
(3). Please replace the PS vane pump if there is a leak between the union bolt and the vane
pump.
(4). Please replace the PS vane pump if the oil plug leaks that is near the oil outlet.
2. Check oil leaks near the head of the shaft and the
corresponding maintence:
(1). It’s normal if area near the socket has been
oiled, no evidence goes to the greater.
(2). It’s normal if you don’t have wet feeling
when you touch this component
(3). Please replace the PS vane pump if there is
oil leak.
(4). It’s normal there is a sound of the open of the
safety velve when the steering wheel to the lock
position. (Attention: Do not maintain lock position
for more than 5 seconds, otherwise the PS vane pump
will be destoried.)
(5). It’s normal there is a sound when the vehicle
starts at winter, after the engine started, the sound
disappeared.
(6). The leak of return tube (there is air in the oil
reservoir) will leads to steering sound. Bleed air from
the system.
(7). You need to fill fluid in time when hearing
sounds during steering due to the lack of fluid in the
reservoir.
(8). Please replace a drive belt or adjust the tensior
force of the drive belt, if there is a sound that the diver
belt leads to.

20
2 STEERING COLUMN AND STEERING GEAR
The steering employs ithe rack and pinion type. The steering gear of this type features simple
construction and has a good operating feeling.

21
Power steeting gear assy with tier rod
The power steering gear assy consists of a steering gear, a rack boot and a steering rack end.
The rack boot is secured between the housing and rack end by means of a band. This complete
sealing prevents any ingress of water or dust.

Rack boot Right steering

◆Right steering
Clamp Rack boot Rack boot clamp

Right end Nut

Sub-assembly ◆O seal
◆O seal
Right oil tube
Sub-assembly

Right oil tube

Sub-assembly
◆O seal ◆O seal

Rack end
Sub-assembly Steering gear
Assembly
Rack end
Rack end Sub-assembly
Sub-assembly Steering
Gear assembly
Rack end
Sub-assembly

◆Left steering
◆Un-reusable Parts Rack boot clamp
Power steering oil Left steering
Rack boot Rack boot Nut Left end sub-assembly
Clamp

22
3 STEERING ROD ENDS
The tie rod ends employ resin ball joint seats. They are the maintenance-free type in which
disassembly can not be made.
The toe-in adjustment can be carried out by means of the tie rod and tie rod ends.

Resin integral type seat

Tie rod end

Dust boots

4 STEERING COLUMN

5 STEERING UNIVERSAL JOINT

23
6 STEERING WHEEL
Steering wheel with four spokes which is made of Polyurethane.

24
 SECTION 3 MAINTENANCE OPERATION
1 POWER STEERING PUMP
Removal
1) Disconnect the air cleaner tube assy
Disconnect two clips of air cleaner, and take the
cover and air cleaner core out.

2) Remove three bolts to take air cleaner out.

3) Remove the return tube of power steering pump,

and bleed the power steering oil.

4) Remove the generator belt, loosen the bolts on

13
the up side and low side of power steering vane pump, and adjustment nut. Then, take drive belt
out.

5) Uplift the vehicle; remove union bolts and the

attached bolts of power steering pump.

INSTALLATION
1. Temporarily install two installation-bolts and
adjustment nut of power steering pump; then,
install the drive belt and generator belt.
2. Tighten nuts and bolts in order in the figure.
The belt deflection of generator:
New belt: 7-9mm/98N.
Used belt: 11.5-13.5 mm/98N.
PartsTightening torque 31-56N·m of part ②and
③ bolts.
Power steering belt:
New belt 5-6mm/98N
Used belt 6-8 mm/98N
3. Install pressure feed tube and returns tube.
Tighten torque of return tube: 54N·m.

4. after installation, fill the steering oil, bleed air,

check the leakage at ideling.

14
2 STEERING WHEEL
REMOVAL
1). Disconnect the battery negative (–) terminal.
2). Remove the steering wheel pad lock bolt.

3). Hold the steering wheel pad at its lower end by

your fingers. Then, detach the steering wheel pad
by pulling it toward your side. Disconnect the
connector.

4). Remove the steering wheel lock nut

5). Remove the steering wheel, using the following

SST.
SST: 09609-20011-000 09609-20011-000

13
INSTALLATION
1). Fit the steering wheel and tightens the lock nut.
Tightening Torque: 34.3 - 53.9N·m (3.5 - 5.5kgf·m)

2). Connect the connector，Install the steering

wheel pad.
3). Install the steering wheel pad lock bolt.
4). Connect the battery negative (-) terminal.

3. STEERING COLUMN
COMPONENTS
REMOVAL

T : Tightening torque
Unit: kgf.m
★ : Non-reusable parts

T:3.5-5.5

T:2.5-3.5

Fig.
7-12
1) Disconnect the battery negative (–) terminal.

13
2) Remove the steering wheel.

3) Detach the instrument lower finish panel (Detach

underside two screws, open upside two clips) and
steering column lower cover (Detach five screw).

4) Remove the instrument panel lower

reinforcement. (Remove two bolts)

5) Remove ash tray, prize up controlling

panel with cloth packing screwdriver,
Disconnect safety caution switch
connector.

6) Remove the fuse box and the bracket. (Remove

five bolts)

14
7) Remove the connectors for the multi-use lever switch and engine key switch.

8)Remove the bolt of the universal joint.

9) Steering column assy removal

(1) Remove two bolts and two nuts.
(2) Remove the steering column assy
from the body.

10) Remove the steering column upper cover and

multi-use lever switch from the steering column
assy.

DISASSEMBLY
1) Detach the snap ring and plate washer located
at the lower side of the steering main shaft.

2) Detach the snap ring located at the upper side

of the steering main shaft.

15
3) Steering main shaft subassy removal
(1) Switch the key to ACC.
(2) Remove the steering main shaft subassy by
tapping the main shaft lightly with a plastic
hammer.
Stopper
(3) Remove the stopper from the steering main
shaft.

(4) Detach the snap ring from the steering main

shaft.

16
INSPECTION
Inspect the following parts.

ASSY
1) Assy of steering main shaft.
(1) Fit a new snap ring to the steering main shaft.
(2) Place the stopper on the bearing.

2) Switch the key to ACC. Insert the main shaft

(with the bearing) into the steering column, using a
plug wrench.

Plug wrench

3) Fit the new snap ring to the upper side of the

steering main shaft.

17
4) Install the plate washer and snap ring.
Plate washer

Snap ring

5) Install the multi-use lever switch to the steering

column.

INSTALLATION
1) Steering column assy installation
(1) Install the steering column upper cover to the
steering column.
(2) Tighten the attaching bolt of the universal joint.
Tightening Torque: 20 - 25N·m (2.5 -
2.5kgf·m)

(3)Install the steering column with the three bolts

and two nuts.
Tightening Torque:：
Bolt：15 - 22N·m
Nut：10 - 16 N·m

18
2) Install the connector for the multi-use lever and
engine key switch.
3) Install the instrument panel lower reinforcement.
4) Install the instrument lower finish panel and
steering column lower cover.
5) Install the steering wheel.
6) Install the battery negative (–) terminal.

4 STEERING GEAR ASSY

COMPONENTS

T :Tightening torque
Unit : kg-m
★ : Non-reusable parts

① Cotter pin
② Castle nut
③ Steering rack
Housing No.1 bracket
④ Steering gear Ay
⑤ Ball joint
⑥ Universal joint

19
REMOVAL
1) Jack up the vehicle at the front side. Support the
body with safety stands.
2) Remove the front wheel.

3) Remove steering column hole cover assy. (four

bolts)

4) Steering universal joint removal

(1)Remove the bolts.
(2)Remove the universal joint

5) Tie rod end removal

(1) Remove the cotter pins and castle nuts.
(2) Remove the tie rod end from the knuckle arm,
using the following SST.
SST: 09611-87701-000

6) Steering gear assy removal

(1) Detach the pressure feed tube and return tube.

(2) Remove the four pieces of steering rack housing

bracket set bolts.

20
(3) Remove the steering gear assy from
the vehicle.

DISASSEMBLY
1) Clamp the mounting section of the steering rack
housing in a vice with copper sheets or aluminum
sheets interposed.
Copper sheets or
Aluminum sheets

2) Tie rod end removal

(1) Before the steering tie rod end is removed, put a
Lock nut
mark on the rack end section in order that this mark
Tie rod end Rack end
may be used as guide to ensure easier toe-in
adjustment during the reassembly.

(2) Slacken the lock nuts. Remove the tie rod end from Mark
the rack end.

(3) Remove the boot band No.2 and rack boot band
Remove the rack boot.

Width across Withd across flats:

Flats: 19 mm 26 mm

3) Steering rack end removal

(1) Slacken the rack end plug, using the flat sections
Steering rack end assembly
Steering rack 21
of the steering rack (width across flats: 19 mm) and the flat sections of the rack end plug (width
across flats: 26 mm).

Installation:
1) Steering rack end installation.
(1) Screw in the rack end plug into the
rack end.
(2) Tighten the rack end to the steering
rack.
Tightening Torque: 62 N·m.
(3) Secure the steering rack.
NOTE：
If the hole is jammed, the pressure in the dustproof cover will change when you turn the steering
wheel.
(4) Install the lock reed of dustproof cover, the clip
duct of dustproof, and dustproof of steering rack. Lock nut
Tie rod end installation Tie rod end Rack end
(1) Screw in the lock nut and tie rod end into the
rack end up to the mating mark. Tighten the lock
nut tempo rarily.
Mark
NOTE：Tighten the lock nut securely after the toe-
in adjustment

INSTALLATION
STEERING RACK ASSY INSTALLATION
(1) Install the grommet to the steering rack assy. Then, insert it to the vehicle.
NOTE:
Be very careful not to damage the steering rack boot during the insertion.
(2) Install the steering universal joint to the steering pinion. Tighten the bolt temporarily.

(3) Install the steering rack assy to the body.

Tightening Torque：40-55 N·m

22
(4) Tighten the attaching bolt of the steering
universal joint.
Tightening Torque: 20-25 N·m.
NOTE:
When tightening the bolt, be sure to limit the
protruding length of the serration sections of the
universal joint and pinion to 5 mm.

(5) Install tie rod high-pressure tube and return tube.

Tightening Torque：20 - 36 N·m

23
2) Tie rod installation
(1) Install the tie rod end to the knuckle.
Tighten the castle nuts.
Tightening Torque：30-55 N·m.
(2) Install new cotter pins.
(3) Install the wheel.
(4) Check the steering wheel play.
(5) Perform the toe-in adjustment.
(6) Confirm the straight-ahead position of steering
wheel.

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 PART 3 ELECTRICAL POWER STEERING SYSTEM
SECTION 1 SUMMARY
Vehicle electrical power steering system is a new generation of mechanical power steering
system. It consists of EPS controller, torque sensor, motor assy and mechanical column. The
principle of vehicle electrical power steering is that EPS controller decides the quantity and
direction of steering torque according to a certain arithmetic with the torque sensor, velocity
sensor, engine ratation speed sensor, etc, and then drives the motor to operate steering through a
gear reduction device.

Figure 8-3-1

25
1.1 EPS controller
EPS controller is mounted under the driver instrument panel. EPS controller is a precise
control part consisting of microcomputer, A/D (analog/digital) converter, I/O (input/output)
interface, etc.
It is a critical part of vehicle electrical power steering system. It not only takes the vehicle the
optimal operating function, but also has self-diagnosis and fail-safe functions.
Self-diagnosis function
When the driver has turned on the vehicle electric power, ‘EPS’ controller indicator is always
on (indicate the vehicle has the electrical power steering system). During process that the driver
starts the engine, EPS controller takes on the self-diagnosis for the following components. When
there is no malfunction for the following components, EPS indicator turns off automatically , or
EPS light is always on or flashing. Then we can diagnose the fault by connecting the diagnosis I/O
terminal B1 to the negative of the battery. The failure codes are shown in the failure codes table.
 Torque sensor
 Velocity sensor
 Engine rotation speed sensor
 Circuit
 Battery
 Motor
 EPS controller
Notice:
When the ignition switch is on and the engine stops, EPS controller will output DTC22 failure
code. So, when inspecting the DTC22 failure code, the engine must start and then the DTC22
failure code disappears automatically.
Fail-safe functions
When the EPS system operates abnormally, EPS controller will cut off the EPS system power,
and switches it to mechanical steering system without power assistance with the EPS light
constantly on (or flashing).
1.2 steering column assy
 Motor
The motor mounted on the steering column consists of a worm, a worm wheel and direct
current motor. When the worm and the worm wheel mounted on the steering column mesh
together, it slows down the motor speed and then transmits the torque from the motor to the
output shaft.
Connect torque sensor
Control box

Controller
worm Spline Motor
26 Mounting
Screw
 ● Torque sensor
Torque sensor consists of slip block, steel ball, input and output shafts, and potentiometer. It
acquires the quantity and direction of operating torque on the steering wheel and then changes it to
voltage and transmits it to the P/S control box finally.
There is a torque rod in the inter hole of the output shaft which is connected to the torque rod.
There is a spiral groove on the outer face of the output shaft. Steel ball is mounted in the ball hole
between the spiral groove on the outer face of the output shaft and the interface of the sliding
block. The sliding block, relative to the input shaft, slides in the spiral direction. When turn the
steering wheel, the torque is transmitted to the torque rod by the input shaft. As the torque rod is an
elastic shaft, an angle displacement takes place between the torque rod and the output shaft, which
induces an angle displacement between the turning directions of input and output shafts and also a
displacement of the sliding block in its axes direction. These biases let the sliding block move in
the axes direction, and the displacement is converted to turning angle of the potentiometer, then
converted to voltage signal and finally conveyed to the P/S controller. The controller gets the
signal of the quantity and direction of the operation torque on the steering wheel.
Connect to control box
Protection cover

Housing

Sensor

Slider

Output shaft
Connecting position of the
sensor, input and output shafts

1.3 VSS(vehicle velocity sensor)

Vehicle velocity sensor is placed on the transmission (or other components). It produces pulse
signal in ratio to the vehicle velocity.
1.4 Engine speed signal
The ignition coil signal (or signal of electrical injection ECU) is taken as the engine speed
signal.

SECTION 2 MAIN SPECIFICATIONS

2.1 steering operation and installation condition
2.1.1 Operating temperature: -40℃ - +85℃

27
2.1.2 Operating voltage: (9 - 16V) DC
2.1.3 Mounting position: inside of the vehicle
2.1.4 The rotation angle of the input shaft: more than ±1.5 circles.
2.1.5 The turning velocity of the steering wheel: 10 circles/second to 15 circles/second.
2.2 Mechanical performance of steering assy
2.2.1 The dynamic friction torque: ≤1.0 N·m
2.2.2 Disturbance of the dynamic friction torque: ≤0.85 N·m.
2.3 Motor assy basic parameters.
2.3.1 Type: direct current permanent magnetic control motor.
2.3.2 Specific operating time: 3 minutes intervals continuously once
2.3.3 Specific power: 170 W (nominal value)
2.3.4 Specific operating voltage: 12V DC
2.3.5 Specific motor velocity: (1050±300 r)/min
2.3.6 Specific operating current: 30A±3A
2.3.7 Specific output torque: 1.6N·m±0.16N·m
2.3.8 Rotation direction: double directions.

28
 SECTION 3 CIRCUIT CHART

Right
Left
Right

Left

Plug C Plug B Plug A

29
 SECTION 4 CONNECTING TERMINAL TABLES
(The positions of terminals are indicated in the Circuit Chart. 12VDC is the battery voltage)
Terminal I/O
Connecting component Signal status
No. signal
B1 Failure eliminating Input Signal float in the normal status. Effective when
terminal connected to the battery negative terminal.
B2 Diagnosis terminal Input Signal float in the normal status. Effective when
connected to the battery negative terminal.
B3 EPS indicator output 12VDC potential signal，high level availability
B4 Engine signal Input Square signal or pulse signal with a 12V peak
value
B5 Vehicle velocity signal Input Square signal with a 12V peak value
B6 Ignition signal Input 12VDC potential signal，high level availability
B7 Battery＋ Input Positive terminal 12VDC of persistent power
supply (battery)
B8 Battery－ Input Negative terminal 12VDC of persistent power
supply (battery)
A9 Free
A10 Free
A11 Motor Output Pulse signal with a 12V peak value, changeable
pulse width
A12 Motor Output Pulse signal with a 12V peak value, changeable
pulse width
C1 Free
C2 Torque sensor battery Output Positive pole with 5VDC voltage
C3 Torque sensor ground Output Negative pole with 5VDC voltage
wire
C4 Torque sensor Output 1.0VDC ~ 4.0VDC analog voltage signal.
secondary circuit
C5 Torque sensor main Input 1.0VDC ~ 4.0VDC analog voltage signal.
circuit

13
 SECTION 5 DIAGNOSIS FAILURE CODE
(Mentioned above) EPS controller possesses the perfect self-diagnosis function. Find out the
failure according to 7.4 Diagnosis Flow Chart.

14
 SECTION 6 CONTROL FLOW CHART

Torque sensor on steering column Battery Vehicle speed sensor to

To sense the quantity and direction sense vehicle speed
of Steering torque

Rotate speed sensor to sense EPS controller Diagnosis trouble code

the engine speed output
Singlechip and interface circuits
Engine and vehicle speed
inspecting management circuits
Torque, voltage, current,
temperature inspecting
management circuits
Any safety and memory circuits
The best power assistant
arithmetic Safe-diagnosis
Motor The best power resistance Mechanical protection
Steering assistant function arithmetic assembly
Alignment arithmetic Electrical protection circuit
Vehicle actual state arithmetic
Any compensation arithmetic
Software redundance arithmetic

15
 SECTION 7 FAILURE CODE DIAGNOSE
7.1 Display the diagnosis trouble code (DTC).
1) Connect the diagnosis terminal B2 to the negative of the power (battery) with maintaining
line.
2) Chock the left and right wheels and lift the parking brake.
3) Start engine (DTC22 will be show, if engine does not start)
4) EPS Indicator begins to indicate all failure codes. DTC are all always displayed orderly from
the smallest code. Each code is displayed 3 times.
7.2 Eliminate DTC
● As the DTC is stored in the redundant storage of the EPS controller. So, after the maintenance,
when the engine ignited and starts normally, do connect the B1 terminal to the negative pole of
electrical power (accumulator) for more than 5s. When DTC12 is indicated, disconnect them.
7.3 Notices in failure diagnosing
Notices in recognizing failure code
● Do not connect positive pole of electrical power (battery) to B1, B2 terminals.
● When the ignition switch is on while the engine does not start, DTC22 is indicated.
But when the engine starts and DTC22 is not indicated, that means no failure happens
● Write down the failure code that is shown
7.4 Diagnosis flow chart

Step Oprration Yes No

1) Make sure battery pressure is more Inspection of EPS

than 11v, or high. indication light circuit.
2) Take care of the EPS light, when the Enter the second
1
ignition switch is on step
3) When the ignition light is on, is ’EPS’
light on for about 2 seconds?
1) Connect the two diagnosis Inspection of EPS
Terminals with connecting line. indication light circuit.
2) Chock the wheels, and put M/T to the
Enter the third
2 middle position (A/T to P position) and
step
then lift the parking brake.
3) Start the engine
4) Does “EPS” light flash?
Does “EPS” light show DTC12? Check and repair base
3 on the corresponding
code in flow chart.

Warming:
Once the inspection and maintenance are finished, check the system as the following order:

16
 1) When the engine is ignited and runs normally, connect the B1 terminal to the negative pole of
the electrical power (accumulator) for more than 5 seconds. When DTC12 shows on, disconnect it to
clear DTC stored in EPS controller.
2) Take the specified test.
3) Wedge wheels with blocks, and take M/T to the middle. (A/T to P position)
4) Connect the B2 terminal to the negative pole of the electrical power (battery) with
maintaining line.
5) Start the engine and check the ‘EPS’ indicator.
6) Check whether the diagnosis code shown is DTC12.

NOTES:
● When the ignitior switch is on and the engine stops, DTC22 will be shown. But when the engine
starts, DTC12 will be shown and that means its normal.
●When there are two or even more malfunctions, the diagnosis codes always turn on alternatively
from the smallest code.

Conclusion
EPS controller electrical circuit board has the self-diagnosis function. When each simulation
malfunction appears, EPS controller electrical circuit board should stop working, that means the
motor, electromagnetic clutch, the relay are all of open status and EPS light is always on. Turn on the
self-diagnosis switch, and the corresponding DTC shows.
1> The code of DTC25 will be shown, when the frequency of engine signal is more than
500HZ or less than 13HZ.
2> The code of DTC22 will be shown, when engine signal is zero.
3> When the clutch is at open or short circuit, DTC51 code shows on. (Only aimed to DFL-01
type)
4> the code of DTC54 will be shown, when the battery pressure is less than 8v.
5> When the increasing circuit is abnormal, that means there is no increasing voltage, DTC55
turns on.
6> When the operating voltage of the sensor is abnormal, that is the voltage too high or too low,
DTC14 turns on.
7> When the main circuit of the sensor is open or short, DTC11 turns on.
8> When the secondary circuit of the sensor is open or short, DTC15 turns on.
9> When the outputs of the main and secondary circuits are different greatly, DTC13 turns on.
10> When the voltages on the two ends of the direct current motor are too high or too low,
DTC41 will shown.
11> When the actual currents on the two ends of the direct current motor are too high, DTC42
will be shown.
When the actual currents on the two ends of the direct current motor are too low, DTC45 will be
shown.
When the vehicle signal is open during driving, DTC24 will be shown.

17
18
 SECTION 8 EPS MAINTENANCE OPERATION-
DISMANTLING ORDER
1. Remove the steering wheel pad lock bolt (a
bolt) and open the steering wheel cover.
2. Disconnect the connector of horn.
3. Remove the steering wheel lock nut.
4. Remove the steering wheel, using SST (special
tools).
5. Remove the instrument lower finish panel (two
bolts).
6. Remove steering column lower cover (five
bolts).
7. Remove the instrument panel lower
reinforcement (two bolts).
8. Remove two fuse boxes in the carbin (three
bolts).

9. Disconnect the combination switches (three).

10. Disassemble the ignition switch.
Disconnect EPS (three connectors)

19
11. Disconnect two fuse box brackets (two bolts).

12. Disassemble EPS, ECU bracket (two bolts).

Remove EPS controller.

20
13. Remove mounting board on the steering
column (two bolts).
14.Disassemble the two bolts on the combinatior
switch.
15. Disassemble the upper cover of the steering
column.
16. Remove the bolts on the shaft connector.
17. Remove the nuts on the lower mounting
board of the steering column (two nuts).

18. Take down the steering column assy .

19. Remove the motor

1) Disassembie: motor and the speed reduction
Worm are connected by spline. Loosen the
Bolts which connect the motor and the
Cover to dismantle the motor.
.

2) Installation: To make sure the motor shaft

and worm are coaxial and the motor works at
its best status, screw the bolts in place
temporarily by your fingers before fastening
the bolts of the motor. Turn the steering wheel

21
with the right hand, and hold the motor with the left hand to watch whether the motor swings. If
swinging, fasten the bolts. If yes, adjust the motor until it stops swinging and then fasten it. If
adjustment can’t be finished, replace the motor and repeat the operation above.
The tightening torque of the motor bolts is 20～30N•m.
20. Remove the torque sensor
1) Disassemble
(1) Remove bolts on the torque
Sensor protection cover.
Dismantle the torque sensor protection
cover.

(2) Loosen the attaching bolt of the sensor.

(3) Disassemble torque sensor.

22
2) Installation
Put the sensor into EPS mounting hole.
Put the rock bearing of the sensor into the
Mounting
sliding block’s mounting groove. Install the groove
adjustment bolt finally.

3) Adjustment
Connect one connector of the multimeter to
the main circuit of the sensor’s connector
(white wire C5) and the other to the earth.
Check whether the main circuit voltage of
the sensor is 2.5±0.05V. If not, relax the lock
bolts, and knock the sensor gently. Adjust
the main circuit of the sensor to voltage of
return to 2.5±0.05V.

The symmetry specifications of the two outputs is

required as shown in the rirht figure:
Output voltage (V):
Main circuitC5 4.17× (1±4 % )V
Secondary circuitC4 0.83×(1±4
% )V
When operationg voltage C2 is +5×(1±0.1
% )V ， the intersection point voltage of the
main circuit and the secindary circuit is
2.5×(1±4 % )V. At any position else, a voltage
of A8+ V A10=5× (1±4%) V should be
satisfied.
Suggestion: Before adjust the sensor voltage,

23
dismantle the sensor and turn the sliding block to another angle.
Notices:
1) Any force should not be applied on the steering wheel while adjusting the voltage.
2) When fastening the sensor, the tightening torque is 6 - 7 N·m
After having fastened the sensor, injecting sealant into the groove to prevent the sensor from
loosening.
21. The requirement to mount the lower transmission shaft and the steering column assy. In order to
get the best performance for the power steering gear assy, the installation process to mount the lower
transmission shaft should be as the following:
1) Align the bearing seat with yellow mark as shown in the figure.
2) Align the yellow mark with the open groove of the upper universal joint yoke.
3) Fasten the washer-bolt using with torque wrench with a tightening torque of 20-30N·m.

24
 SECTION 9 MECHANICAL INSPECTION
9.1 Check the steering wheel free play
Move the steering wheel in the axis direction and the horizontal direction to check whether the
steering wheel is relaxed or clickes.
If there is any fault, repair or replace it.
When the engine stops and the vehicle stops on the ground with the wheel toward the front, check the
steering wheel.
The range of steering wheel free play: 1-10mm.
If the steering wheel moves out of the specified free play range, inspect it as following. If there is any
failure, replace the component.
●Check steering tie rod end ball for wear.
●Check ball stud for wear.
●Check steering shaft connector for wear.
●Check steering pinions or rack and pinion for wear or crack.
●Check any component else for loosen.
9.2 Steering torque inspection
1) Vehicle stands on the level road with steering wheels toward the front.
2) Check whether the tyre charge pressure meets the requirements (see the tyre instruction)
3) Start the engine and at idle conditior.
4) Measure the steering torques in two directions. Steering torque (reference): less than 7N•m.
HINT: Consider the tyre type, pressure and contact surface before judgement.

25
 SECTION 10 ORDINARY EPS MALFUNCTION
ANALYSIS AND TROUBLE SHOOTING
10.1 Abnormal noise
Reason
Abnormal steering noise
Trouble shooting
Replace the motor
10.2 Deflection
Reason
The mechanical friction leads to the sensor potential offsetting from the designed value.
Trouble shooting
Adjust it according to the torque sensor adjusting method.
10.3 Malfunction
Connect the diagnosis switch (terminal B2) to the earth. EPS indicator light is flashing. P/S
controller box outputs failure code.

Diagnosis code Reason Remedies

41；42；43；44；45；51 Motor failure Replace the motor
11；13；14；15 Sensor failure Replace the sensor
52；54；55 Controller failure Replace the controller
22 None of engine speed Check whether there is signal
signal input on the speed signal line. If
not, connect it well.
21；23；24 None vehicle signal input Inspect whether there is
vehicle velocity signal. If not,
connect it well.

26