Service Manual

Servolectric® EPSapa
Types 7806, 7818, 7828, 7838

Robert Bosch Automotive Steering GmbH

73522 Schwäbisch Gmünd
Germany
Telefon +49 7171 31-7936
global.service@bosch.com
7806 F 2015-11 en V01 | Version 01 | 06.11.2015 https://steering-service.com
Safety Instructions en

Safety Instructions
 These instructions are to be referred to when carrying out necessary service work and repair on the Bosch
Automotive Steering unit.
 Read these instructions first before starting the service work.
 Authorized, specialized staff must make sure that the product works perfectly again after the service work has
been completed.
 Bosch Automotive Steering units may only be repaired in workshops with
- staff trained by Robert Bosch Automotive Steering GmbH
- specified equipment and special tools corresponding to the work to be performed
- original Bosch spare parts
 This manual should only be used by technicians whose practical and theoretical training in our Global Service
Training Centre is supplemented by this reference book and by service information.
 As a basic principle, only work listed in the instructions may be carried out on the steering gear. Additional
changes or adaptations are not permitted and could cause a safety-critical deficiency. However, if in exceptional
circumstances, other work should be necessary, then separate information which is only applicable for this case
will be provided (e.g. service information).
 All work on Bosch Automotive Steering units must be carried out with great care and conscientiousness. This
applies in particular to units and transmission parts from vehicles which have been involved in accidents.
 Before removing the hydraulic unit, any operating fluid (e.g. lubricant) must be drained without residue and must
be routed through company-internal disposal.
 All metal parts which can no longer be used must be recycled in metal recycling. Other parts (e.g. seals) must be
disposed of properly according to the respective applicable regulations.
 The manufacturer will not be held liable for damage and associated consequences caused by improper and/or
unqualified repair.

The numbers indicated in round brackets refer to the picture numbers used in the figures.
The numbers indicated in square brackets refer to the used tools.

Important notes
These instructions are not subject to the change management service.
Pay attention to further written service information.

Protection notice:
Passing on or reproducing this document, utilizing, and communicating its content is prohibited, unless expressly
permitted. Contraventions obligate compensation in damages. All rights reserved in the event of patent and utility
model registration.

®
Servolectric is a registered trademark of Robert Bosch Automotive Steering GmbH.

List of changes
Index Date of issue Author Chapter Comment
01 11/2015 NJ | OTG - Initial version

II 7806 F 2015-11 en V01

en Contents

Contents
1 Symbols Used ............................................................................................................................................... 5
2 Design and Function..................................................................................................................................... 6
2.1 Steering gear................................................................................................................................................... 6
2.2 Torque sensor ................................................................................................................................................. 7
2.3 Servo unit ........................................................................................................................................................ 8
2.4 Recirculating ball gear .................................................................................................................................... 9
2.5 Essential software functions ......................................................................................................................... 10

3 Maintenance ................................................................................................................................................ 11
3.1 Maintenance interval ..................................................................................................................................... 11
3.2 Maintenance work ......................................................................................................................................... 11
3.2.1 Checking the valve body ............................................................................................................................... 11
3.2.2 Checking the mountings and the electrical connections ............................................................................... 11
3.2.3 Checking the straight ahead driving positions of steering gear and vehicle ................................................. 11
3.2.4 Inspecting the straight ahead driving position ............................................................................................... 12
3.2.5 Checking the steering gear for play .............................................................................................................. 12
3.2.6 Visual inspection ........................................................................................................................................... 12
3.2.7 Test driving .................................................................................................................................................... 12

4 Diagnostics .................................................................................................................................................. 12
4.1 Identification data and vehicle parameters ................................................................................................... 12
4.2 Reading and clearing the fault code ............................................................................................................. 13
4.3 Display of voltages, vehicle signals and internal values ............................................................................... 13
4.4 Calibrating the steering angle sensor ........................................................................................................... 13
4.5 ZF-TESTMAN ............................................................................................................................................... 13

5 Replacing the Steering Gear Output ........................................................................................................ 14

5.1 Removing the steering gear output ............................................................................................................... 15
5.2 Checking the component parts ..................................................................................................................... 15
5.3 Reassembling the steering gear output ........................................................................................................ 16
5.4 Documentation covering „A“ characteristics ................................................................................................. 16

6 Replacing the Steering Gear ...................................................................................................................... 17

6.1 Removing the steering gear .......................................................................................................................... 17
6.1.1 Preparatory work ........................................................................................................................................... 17
6.1.2 Removing the steering gear .......................................................................................................................... 17
6.2 Reinstalling the steering gear ....................................................................................................................... 18
6.2.1 Preparatory work ........................................................................................................................................... 18
6.2.2 Reinstalling .................................................................................................................................................... 18

7 Putting the Steering Gear into Operation ................................................................................................. 19

7.1 Calibrating the steering angle sensor ........................................................................................................... 19
7.1.1 Prerequisites ................................................................................................................................................. 19
7.1.2 Calibrating ..................................................................................................................................................... 19

7806 F 2015-11 en V01 III

Contents en

7.2 Coding the software end stops ..................................................................................................................... 20

7.2.1 Prerequisites ................................................................................................................................................. 20
7.2.2 Coding ........................................................................................................................................................... 20

8 Troubleshooting .......................................................................................................................................... 21
8.1 Electric section .............................................................................................................................................. 21
8.2 Mechanical section........................................................................................................................................ 22

9 Test Report: Servolectric EPSapa ............................................................................................................. 23

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en Symbols Used | 1

1 Symbols Used
Pictograms used in this document:
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE
NOTICE is used to address practices not related to physical injury.

Application notes and other useful information.

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2 | Design and Function en

2 Design and Function

EPSapa stands for Electronic Power Steering – Axis Parallel Type, meaning that the servo unit is arranged parallel
to the rack axis.

2.1 Steering gear

Servolectric EPSapa consists of the following components:

1 2 3 4 5

15
6

- - - parts not visible or

14 13 12 11 10 9 8 7 inner components

Fig. 1: Servolectric EPSapa steering gear

Number Description Number Description

1 Housing 2 Rack
3 Steering input shaft 4 Torque sensor
5 Sensor cable 6 Steering pinion
7 Yoke 8 Electronic control unit
9 Electric servo motor 10 Servo-end through drive
11 Bellows 12 Tie rod
13 Axial joint 14 Outer ball joint
15 Valve body

The system consists of a housing (1) with a rack (2). The input shaft consists of the steering input shaft (3) and the
steering pinion (6). The steering torque supplied by the steering wheel is transmitted to the input shaft by the
steering column and the intermediate shaft.
The yoke (7) presses the rack (2) against the steering pinion (6) so as to keep the clearance constant and play-free.
A one-time adjustment of the adjusting screw on the yoke is done at the manufacturer; this screw may not be
readjusted in the field. The steering input shaft (3) transforms the radial movement into a linear one and transmits
the movement to the rack (2).
The torque sensor (4) is arranged on the input shaft. Its task is to measure the steering torque and to transmit it to
the electronic control unit (8). The servo motor generates an assistance torque. Transmission to the rack (2) takes

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place via the servo-end through drive (10). The rack (2) moves as a consequence of the torques transmitted by the
steering pinion (6) and the servo-end through drive (10).
The axial joints (13) with the tie rods (12) and the outer ball joints (14) are arranged at the ends of the rack (2); they
transmit the movement of the rack (2) to the road wheels.
Even in the event of a failure of the vehicle electrical system or the electric assistance the vehicle can still be
steered thanks to the mechanical connection between the steering wheel and the road wheels.

2.2 Torque sensor

16 3 17 18 19 6

22 21 20

Fig. 2: Torque sensor

Number Description Number Description

3 Steering input shaft 6 Steering pinion
16 Torsion bar 17 Magnet ring
18 Sensor module 19 Clock spring
20 Connector 21 Index magnet (optional)
22 Index sensor (optional)

The torque sensor (4) measures the steering torque the driver exerts on the steering wheel. The control unit (8)
uses the measured value to calculate the steering assistance to be provided by the motor.
On the torque sensor (4) the steering input shaft (3) and the steering pinion (6) are connected with each other by
means of a torsion bar (16). A magnet ring (17) is fitted to the steering input shaft (3). If now the driver exerts a
steering torque on the steering wheel, the torsion bar (16) and, as a consequence, also the magnet ring (17), are
rotated in relation to the sensor module (18).
Via the torsion of the torsion bar (16) the contactless sensor (18) measures the steering torque exerted. The clock
spring (19) transmits the signal coming from the torque sensor (4) to the housing connector (20). The sensor cable
(5) towards the servo motor is plugged in the connector (20).
As an option, an index magnet (21) and an index sensor (22) can be fitted to the torque sensor (4). The index
sensor (22) supplies a signal to the control unit (8) at each full steering wheel turn. This signal is required for
steering gear calibration as well as for the active return to the straight ahead position of the steering wheel.

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2 | Design and Function en

2.3 Servo unit

23

Fig. 3: Servo unit

Number Description Number Description

8 Electronic control unit 9 Electric servo motor
23 Toothed disc, small

The servo unit is also called power pack. It consists of the electronic control unit (8) and the electric servo motor (9)
and is fitted to the steering housing (1) parallel to the rack (2). The control unit (8), fitted to the electric servo motor
(9), is connected mechanically to the servo motor (9) housing in a way making the two inseparable.
The control unit (8) acquires various input signals such as steering torque, vehicle driving speed, revolution of the
combustion engine, steering angle, and steering velocity. The steering torque signal is compared with the
characteristic stored in the control unit, so that the steering assistance required can be determined based on this
data.
The servo motor (9) is connected with the housing of the servo-end through drive (10). Dependent on the actuation
by the control unit the electric servo motor (9) generates a torque, which is transmitted by a toothed disc (23)
arranged on the motor shaft.
Via a toothed belt the servo motor (9) transmits the power to the recirculating ball gear. The effective steering power
at the rack (2) is the sum of the power of the steering torque applied at the steering wheel and the power of the
steering assistance supplied by the servo motor (9).

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2.4 Recirculating ball gear

27

28 26 25

2 24 23

Fig. 4: Recirculating ball gear

Number Description Number Description

2 Rack 23 Toothed disc, small
24 Toothed belt 25 Toothed disc, large
26 Ball recirculation nut 27 Ball return channel
28 Balls/ball chain

There is a mechanical connection between the servo motor and the servo-end through drive. Via a toothed belt and
recirculating ball gear the radial drive movement of the servo motor is converted into a linear movement of the rack.
Via a large toothed disc (25) the toothed belt (24) drives the recirculating ball gear. In the recirculating ball gear the
ball chain (28) is led back through an internal ball return channel (27) in the ball recirculation nut (26). The rotation
of the recirculating ball gear causes the rack (2) to move to the left or to the right.

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2 | Design and Function en

2.5 Essential software functions

Vehicle speed-dependent assistance
The servo assistance provides a steering assistance to the driver which is dependent on vehicle speed. At low
driving speed the steering gear provides a high degree of assistance, while assistance is lesser at high speed.
Active return
Dependent on the steering angle and other conditions such as for example vehicle driving speed or steering
velocity the steering wheel is actively caused to return to its mid-position.
Steering wheel damping
Road bumps are compensated by the steering gear so that such bumps are not felt at the steering wheel or are
only hardly noticeable.
Software end stops
Steering assistance is reduced at the ends of the rack, thus protecting the mechanical components and the control
unit.
Friction compensation
An additional motor torque is generated to compensate a friction of the steering gear, if any.
Inertia compensation
An additional motor torque is generated to compensate inertia of the steering gear, if any.
Overheating protection
If a temperature determined by the vehicle manufacturer (e.g., 120°C) is exceeded in the control unit the electric
assistance will be reduced or cut off.
Power reduction in the event of over- or undervoltage
If the voltage drops below 9.5 V in the vehicle electrical system or if it exceeds 16 V the electric assistance will be
reduced or cut off.
Straight ahead position correction
A compensation of the steering torque during straight ahead driving prevents a pulling away of the vehicle to one
side, which might be caused by irregularly worn treads, road gradient or crosswind.
Tyre imbalance compensation
Compensates vibrations that may be caused by a tyre imbalance.
Universal joint compensation
Compensates variations of the steering torque transmitted which may be caused by the universal joints.

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3 Maintenance
The Servolectric EPSapa steering gear is maintenance-free. We recommend, however, to adhere to the
maintenance intervals indicated below.

3.1 Maintenance interval

For more road safety, Robert Bosch Automotive Steering GmbH recommends to do maintenance work on the
steering system after every 50,000 driven kms.

3.2 Maintenance work

3.2.1 Checking the valve body
1. Check the bellows and the valve body.
2. If the valve body is open it has to be replaced.
3. If a bellows is replaced for being defective, then also the valve body has to be replaced.

3.2.2 Checking the mountings and the electrical connections

1. Check the mountings and the electrical connections on the steering gear and the transmission components.
2. Check the bellows.
3. If required, re-tighten the screws (conform to vehicle manufacturer’s instructions).
4. If damaged, replace defective components.

3.2.3 Checking the straight ahead driving positions of steering gear and vehicle
Variant with marks
1. Place the front wheels on swivel plates and determine the total number of steering wheel turns.
2. From the steering lock stop, rotate the steering wheel back half the number of total steering wheel turns.
3. Continue to rotate until the marks on the protective cap of the steering input shaft and on the sensor cover
coincide (refer to Fig. 5).

Fig. 5: Marks on the protective cap of the steering input shaft and on the sensor cover

Variant without marks

1. Rotate the steering gear from lock to lock.
2. From the steering lock stop, rotate the steering wheel back half the number of total steering wheel turns.

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4 | Diagnostics en

3.2.4 Inspecting the straight ahead driving position

If a correction of the setting is required, it might well be that such a necessity is originated by an earlier
accidental occurrence.

1. Check whether the steered wheels are in the straight ahead driving position.
2. Correct, if required, by screwing the ball joint on the tie rod further in or out.

If the vehicle was involved in an accident, check the following:

1. Check whether the steering gear is installed in a twisted position.
2. Check the transmission parts for bending, cracks or torsion.
3. Damaged parts must be replaced.

3.2.5 Checking the steering gear for play

CAUTION
Danger caused by a stiff operation of the steering gear!
A one-time adjustment of the adjusting screw on the yoke is done at the manufacturer’s plant.
 Do not readjust the adjusting screw in the field.

1. Rotate the steering wheel: a steering motion of the front wheels must occur without any delay.
2. Replace defective parts if required.

3.2.6 Visual inspection

1. Check the entire steering system for damages.
2. The mail indicator light on the dashboard must switch off after engine start.
3. If it does not, read out the fault codes and clear the stored faults.

3.2.7 Test driving

1. Carry out a test drive on a ground closed for traffic.
2. Check the following steering gear functions:
- steering efforts
- return to the straight ahead driving position
- play
- noise
- mail indicator light

4 Diagnostics
The following data and functions are integrated in the control unit. These functions can be implemented using the
ZF-TESTMAN or a suitable diagnostic tool.

4.1 Identification data and vehicle parameters

This function shows vehicle-specific and steering system-specific information provided by the control unit, such as:
 ECU date of manufacture
 ECU date of installation
 ECU serial number
 Vehicle identification number (VIN)
 Material numbers
 Steering system parameters

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4.2 Reading and clearing the fault codes

This function displays fault code entries stored in the control unit and/or clears them. Active fault codes are re-
entered after switching the ignition off and on again.

4.3 Display of voltages, vehicle signals and internal values

The „monitoring“ function for example displays the following parameters:
 voltages
 battery voltage
 vehicle signals
 vehicle speed
 steering torque
 internal values
 EPS system status

4.4 Calibrating the steering angle sensor

In the calibrating operation the straight ahead driving position of the steering gear and the straight ahead driving
position of the electric control are matched to each other.

4.5 ZF-TESTMAN
Connect the ZF-TESTMAN to the diagnostic socket on the vehicle (refer to Fig. 6).

Fig. 6: ZF-TESTMAN and tools required

Number Description Ordering ref. number

1-4 ZF-TESTMAN + tools ZFF 6008 208 450
1 ZF-TESTMAN IAM edition (software only) ZFF 6008 208 400
2 USB cable ZFF 6008 207 026
3 DPA ZFF 6008 208 017
4 ZF adapter ZFF 6008 207 050

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5 | Replacing the Steering Gear Output en

5 Replacing the Steering Gear Output

The steering gear output consists of the axial joints with the tie rods (131), the bellows (124) and the outer ball
joints (135/136).

Replacing the steering gear output in the installed condition.

After replacement, reset the existing values of the software end stops using either the ZF-TESTMAN or a
suitable diagnostic tool and code the software end stops (refer to Chapter 0).

Fig. 7: Replacing the steering gear output

Number Description Number Description

60 Valve body 123 Hose clip
123.1 Band clip 124 Bellows
131 Axial joint with tie rod 131.1 Hexagon nut
135 Outer ball joint 136 Outer ball joint

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5.1 Removing the steering gear output

NOTE
Risk of damaging the rack or the valve body!
Axial joints with tie rods should always be supported at the rack while they are unscrewed or fastened, for
otherwise the teeth and bearings of the rack or the valve body might be damaged.

NOTE
Risk of damaging the rack!
 Do not steer against the lock stops when no axial joints are mounted.

1. Push off the outer ball joints (135/136).

2. Undo the hexagon nut (131.1) and, while doing so, support it at the axial joint (131).
3. Screw the outer ball joints off (135/136).
4. Mark the positions of the hose clip (123) and the band clip (123.1).
5. Remove the hose clip (123) and the band clip (123.1).
6. Remove the bellows (124).
7. Unscrew the axial joints (131) using a suitable tool and, while doing so, use a suitable tool to support them at
the rack.

5.2 Checking the component parts

NOTE
This check requires expert knowledge and reasonable diligence!
The fitter has to decide on his own responsibility whether the parts have to be replaced or not.

1. Clean all component parts that can be reused.

2. Check all parts for wear, corrosion, damages caused by pressure, and for any other defects and decide whether
they are reusable or not.

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5 | Replacing the Steering Gear Output en

5.3 Reassembling the steering gear output

NOTE
Risk of damaging the steering gear!
 If the maximum permissible tightening torque is exceeded when tightening the axial joints, these must
be scrapped.
 The tightening torques indicated apply to a manual tightening using a torque wrench.
 When screwing in the axial joints, hold them in place with the help of a suitable tool.

NOTE
Risk of damaging the rack or the valve body!
Axial joints with tie rods should always be supported at the rack while they are unscrewed or fastened, for
otherwise the teeth and bearings of the rack or the valve body might be damaged.

Prior to reassembling the steering gear thoroughly clean all components. Before fitting them again, check
all components for wear or other defects.
The tightening torques indicated apply to a manual tightening using a torque wrench.
Prior to starting your reassembly work look into the spare parts list to find out whether there are any
tightening torques indicated, or whether it gives any information on the installed position of special-
purpose screws and brackets. If it does not contain any such data, the values or descriptions given on the
following pages shall apply.
When steering gear components were replaced, the steering system must be put into operation again
(refer to Chapter 0).

1. Screw the axial joint (131) on, using a suitable tool.

2. Screw it in further, using a suitable tool:
Thread size M 14 x 1.5 M 16 x 1.5 M 18 x 1.5
Tightening torque 85 Nm ± 5 Nm 105 Nm ± 5 Nm 115 Nm ± 5 Nm

3. Grease and fit the bellows (124).

4. Fit the hose clip (123) and the band clip (123.1) in their positions as marked earlier.
5. Screw on the hexagon nut (131.1) and the outer ball joint (135/136).
6. Check the wheel alignment (conform to vehicle manufacturer’s instructions) and correct if necessary.
7. Tighten the hexagon nut (131.1) (conform to vehicle manufacturer’s instructions), or as follows:
Thread size M 14 x 1.5 M 16 x 1.5
Tightening torque 50 Nm ± 5 Nm 70 Nm ± 7 Nm

5.4 Documentation covering „A“ characteristics

On the grounds of product liability and as a proof that due care has been exercised, it is necessary that the „A“
characteristics be documented.
This means that the correct implementation of all work described in this chapter must be written down in a report.
This report must be kept for 15 years and in a way ensuring that it can be traced at any time. In a possible case of
product liability such a report will serve as a proof of exoneration (for the report refer to Chapter 9).

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6 Replacing the Steering Gear

 The descriptions below are generally valid and refer to work carried out on Bosch Automotive Steering
units.
 All work must be carried out in the order described below.
 Used parts may not be reused any more.

6.1 Removing the steering gear

DANGER
Danger caused by steering gear failure!
Damages caused during disassembly may entail a failure of the steering gear.
 Absolute cleanliness is a must in all work carried out.
 Do not use any force. Sealing elements must not be damaged.
 Conform to vehicle manufacturer’s instructions.

6.1.1 Preparatory work

1. Rotate the steering wheel to the straight ahead position.
2. Lock the steering column lock in the straight ahead position if this is possible.
3. Turn the ignition off.
4. Disconnect the negative pole of the battery.

6.1.2 Removing the steering gear

1. Mark the installed position of the steering gear.
2. Pull off the electric plug-in connectors which connect the steering gear to the vehicle electrical system.
3. If the steering gear outputs remain on the vehicle, they must be disassembled from the Servolectric EPSapa.
4. Remove the Servolectric EPSapa (conform to vehicle manufacturer’s instructions).

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6.2 Reinstalling the steering gear

WARNING
Danger caused by steering system components damaged as a result of an accident!
In the event of the steering gear being replaced as a result of an earlier accidental occurrence, the
remaining elements of the steering system such as: tyres, wheel rims, axles, axle suspensions and
mechanical connecting parts, must be checked for damages.
 Repair or replace damaged parts if required.
 Conform to vehicle manufacturer’s instructions.

NOTE
Risk of damage to the steering gear!
 Tightening torques apply to a manual tightening using a torque wrench.
 As a rule, self-locking nuts, screws, sealing elements and retaining elements must be replaced.

6.2.1 Preparatory work

1. Rotate the steering gear to the straight ahead position.
2. Lock the steering column lock in the straight ahead position if this is possible.
3. Turn the ignition off.
4. Disconnect the negative pole of the battery.

6.2.2 Reinstalling
1. Check whether the Servolectric EPSapa is in the straight ahead driving position:
- On the variant with markings, the mark of the protective cap on the steering input shaft and the mark on the
sensor cover must coincide (refer to Fig. 5).
- On the variant without markings rotate the steering wheel back half the total number of steering wheel turns,
starting from the steering stop.
2. Reinstall the Servolectric EPSapa in the position it occupied at its initial installation and fasten it with screws,
nuts, washers etc. (conform to vehicle manufacturer’s instructions).
3. If the steering gear outputs remained on the vehicle, they must be fitted to the Servolectric EPSapa again.
4. Fit the axial joints to the steering gear.
5. Plug in the electric plug-in connectors which connect the steering gear to the vehicle electrical system.
6. Connect the negative pole of the battery.
7. Check the wheel alignment (conform to vehicle manufacturer’s instructions) and correct it if necessary.

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7 Putting the Steering Gear into Operation

Before the vehicle is put into operation the assistance characteristic assigned to it as well as special
functions, if any, must be programmed using a suitable diagnostic tool. We recommend to have this done
by an authorised service partner.
If no programming of the assistance characteristic takes place, the steering system (Servolectric mail
indicator light is off) will start to operate using a characteristic that is not assigned to the vehicle. As this
characteristic is not matched to the vehicle concerned, any driving on public roads is not permissible.

If a steering angle sensor is fitted to the steering gear, this sensor must be calibrated and initialised to
ensure a correct starting up of the steering system.

7.1 Calibrating the steering angle sensor

Calibrate the optional steering angle sensor using the ZF-TESTMAN or a suitable diagnostic tool.

The calibrating operation serves to match the straight ahead driving position of the steering gear with that of the
electric control unit.

7.1.1 Prerequisites
 Battery voltage: 9…16 V
 Vehicle is at standstill
 Steering gear mounted to the axle measuring stand in the straight ahead position

7.1.2 Calibrating

Fig. 8: Calibrating the steering angle sensor

1. Turn the ignition on, start the driving engine and observe a waiting time of 2 seconds.
2. Start the calibrating operation with the ZF-TESTMAN.
3. Rotate the steering wheel 45° to the left, steering velocity less than 200°/s.
4. Rotate the steering wheel to the straight ahead position.
5. Rotate the steering wheel 45° to the left.
6. Finish the calibrating operation with the ZF-TESTMAN.
7. Turn the ignition off to save the calibration.

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7 | Putting the Steering Gear into Operation en

7.2 Coding the software end stops

Prior to Coding the software end stops, existing values, if any, must be reset with the ZF-TESTMAN or a
suitable diagnostic tool.

7.2.1 Prerequisites
 Engine and ignition are on.
 Battery voltage: 9...16 V
 Steering gear in the straight ahead position
 Low speed: 5 - 10 km/h
 No error messages in the control unit
 Front axle measured and adjusted
 No brake actuated

7.2.2 Coding

Fig. 9: Coding the software end stops

1. At a driving speed between 5 and 10 km/h rotate the steering wheel approx. 400° to the left until reaching the
stop.
2. At the left-hand stop firmly push the steering wheel against the stop for a short time; to this effect slowly raise
the steering effort to 5 - 10 Nm.
3. Rotate the steering wheel approx. 400° to the right until reaching the stop.
4. At the right-hand stop firmly push the steering wheel against the stop for a short time; to this effect slowly raise
the steering effort to 5 - 10 Nm.
5. Rotate the steering wheel to the straight ahead position.
6. Park the vehicle.
7. Turn the ignition off to save the software end stops.

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8 Troubleshooting
8.1 Electric section
Fault Cause
No steering Error in electric assistance
assistance available
Cable connection on steering gear
or vehicle wiring harness defective
or not plugged in correctly
Voltage supply for steering gear
too low
Incorrect CAN bus signal at vehicle
signal connector
No or poor return to Error in electric assistance
straight ahead driving
No or poor return to Steering angle sensor not
straight ahead driving calibrated
Remedial action
 Read out the fault codes with the ZF-
TESTMAN or a diagnostic tool
 Remedy the cause or replace steering gear
 Check cable connection and plug in correctly
 Replace vehicle wiring harness or steering
gear if cable connection is damaged
 Check supply voltage on steering gear for
underload; specified value: higher than 9 V
 Remedy the cause. Check or replace fuse
and wiring harness on the vehicle
 Check differential voltage between CAN L
and CAN H; specified value: 0.1...1.0 V
(value varying)
 Check terminating resistor between CAN L
and CAN H; specified value: approx. 60 Ω
 Physical check of CAN bus
 Read out the fault codes with the ZF-
TESTMAN or a diagnostic tool
 Remedy the cause or replace steering gear
 Calibrate sensor (refer to Chapter 7.1)

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8 | Troubleshooting en

8.2 Mechanical section

Fault Cause Remedial action
Noise in steering Mechanical defect or damage in  Replace steering gear
column or steering steering gear
gear
Precise straight Play in steering input line  Check steering input line for freedom from
ahead driving play
impossible
 Replace defective components
Play in steering gear  Check steering gear for freedom from play
 Replace defective components
Wheel alignment misadjusted  Check wheel alignment and correct if
necessary (conform to vehicle manufacturer’s
instructions)
Steering angle sensor not  Calibrate sensor (refer to Chapter 7.1)
calibrated
No or poor return to Stiff operation of mechanical parts  Check all transmission parts for ease of
straight ahead driving operation
 Replace defective parts

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 en Test Report: Servolectric EPSapa | 9

9 Test Report: Servolectric EPSapa

Order number: Date:

Manufactoring Manufactoring
Version No.: No.: date:

Documentation of „A“ characteristics

Specified tightening torques for axial joints:
Thread size M 14 x 1.5 M 16 x 1.5 M 18 x 1.5
Tightening torque 85 Nm ± 5 Nm 105 Nm ± 5 Nm 115 Nm ± 5 Nm

LH axial joint Nm Specified value Nm

RH axial joint Nm Specified value Nm

Maintenance interval
Original for duplication

After every 50,000 kms

Maintenance work
O.K. Not O.K.

Mounting and electric connections checked?

Straight ahead driving positions of steering gear and vehicle
checked?
Steering gear checked for play?

Visual inspection carried out?

Test drive done?

Read out fault codes?

Inspected by (name): Date:

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