YUAN Service Manual

Electric Power-assist Steering System (EPS)

Content
Electric Power-assist Steering System (EPS)......................................................................1
1. EPS System Overview...............................................................................................................2
1.1 Functions of EPS System...................................................................................................2
1.2 Working Principle of EPS System.......................................................................................2
2. Circuit Diagram of the EPS System..........................................................................................4
2.1 Definition of Electrical Interface between EPS System and Full Vehicle Wiring................5
3. Notes for Maintenance...............................................................................................................6
3.1 Servicing Notes...................................................................................................................6
3.1.1 State of Start button..................................................................................................6
3.1.2 Notes for Servicing EPS Steering Column...............................................................6
3.2 Troubleshooting Table.........................................................................................................7
3.3 General Troubleshooting Information.................................................................................7
3.4 Steering Wheel Free Travel Inspection...............................................................................7
4 Servicing of Steering Wheel and Steering Column.......................................................................9
4.1.1 Structure of Steering Wheel and Steering Column Assembly..................................9
4.1.2 Disassembly & Assembly of Steering Wheel and Steering Column Assembly......10
4.1.3 Serving of EPS Motor.............................................................................................14
4.2 Servicing of Steering gears Tie Rod Assembly.................................................................15
4.2.1 Structure of Steering gears Tie Rod Assembly......................................................15
4.2.2 Disassembly............................................................................................................16
4.2.3 Inspection................................................................................................................18
4.2.4 Assembly................................................................................................................19
5. EPS System Self-diagnosis and Troubleshooting......................................................................21
5.1 Method of Troubleshooting with the Diagnostic Apparatus...............................................21
5.1.1 DTC Troubleshooting Methods...............................................................................21
5.1.2 Power Voltage Failure Inspection...........................................................................24
5.1.3 EPS ECU Failure....................................................................................................26
5.1.4 Current Failure........................................................................................................27
5.1.5 Torque Sensor Failure Inspection...........................................................................28
5.1.6 Motor Failure Inspection.........................................................................................29
5.1.7 Inspection of Other Signal Harness........................................................................31
6. EPS System Self-diagnosis and Troubleshooting......................................................................33
6.1 EPS Torque & Angle Signal Centering Calibration............................................................33

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1. EPS System Overview

EPS (Electric Power-assistant Steering -- not work, and when the steering wheel torque
EPS, hereinafter referred to as EPS) System is beyond the dead zone, the motor will apply
is a steering system that provides steering assist torque according to the steering wheel
power generated by motor to assist driver deviation angle so as to ensure steering ease
carrying out steering operations. Like any at low speed and steering stability and better
other control systems, this system consists of steering feel at high speed.
sensors (torque and steering wheel angle
sensor and vehicle speed sensor), the 2. Return-to-center function
controller (EPS electronic control unit), the Thanks to the kingpin caster angle and
actuator (booster motor) and relevant kingpin inclination angle, the steering wheel
mechanical components. has automatic return-to-center tendency while
1.1 Functions of EPS System steering. On the basis of the mechanical
steering mechanism EPS System has added
Based on the mechanical steering system, motor and deceleration mechanism. EPS
EPS System applies the latest electric and exercises motor control to return steering to
electronic technology as well as high center with EPS ECU, and carries out vehicle
performance motor control technology to steering to center action together with the
vehicle steering system. Some improvements aligning torque generated by front wheel
have been made on the basis of previous alignment so as to turn the steering wheel
vehicle steering system, and added following back to center rapidly while damping
parts: ECU, torque sensor, booster motor, etc. shuddering of the wheel and maintaining road
The System has replaced traditional feel. .This enhances steering sensitivity and
mechanical hydraulic mechanism with motor- stability, and optimizes return-to-center
driven transmission mechanism which tendency and reduces the convergence time.
provides the driver with real-time steering The return-to-center control is conducted
wheel power assistance in various through adjustment of the aligning
environmental conditions. compensation current, generating an aligning
torque which returns the steering wheel to
EPS System is generally comprised of center in certain direction.
following parts: (a) torque and steering wheel
angle sensor, (b) EPS ECU, (c) motor and (d) 3. Damping control function
relevant mechanical parts. For EPS System, When the vehicle travels at high speed, the
the amount power boosting supplied by the EPS provides damping control through control
motor is adjusted and controlled by EPS ECU of damping compensating current for better
in real time. Depending on different vehicle road feel for driver and improve steering
speed, different power boosting is given to stability for high-speed driving.
improve steering properties of vehicle and 1.2 Working Principle of EPS System
relieve steering force for parking and low-
speed driving while improving steering stability
for high speed driving, thereby enhancing
vehicle safety. During vehicle steering, the torque sensor
detects torque signals, and processes the
magnitude and direction of steering wheel
EPS system boasts following functions: angle signals and sends to EPS ECU. At the
same time, ECU receives vehicle speed
1. Boosting control function signals from EPS System, then based on the
The EPS boosting properties are speed signals of vehicle speed sensor and torque
sensitive that is, with same input of steering sensor, EPS ECU decides motor’s rotation
torque, the target current of the motor and direction and magnitude of assist torque.
changes with vehicle speed, thereby providing Simultaneously the current sensor detects
better steering ease and feel. EPS provides circuit current, monitors drive circuit and
diverse boosting features. When the torque eventually drive circuit drives the operation of
exerted on the steering wheel by the driver is motor to implement assist steering. The
within the range of dead zone, the motor does working principle of EPS System is shown in

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Figure 1-1.

Torque and steering Steering

ECU

Steering mechanism
wheel angle sensor wheel

CAN Drive circuit EPS motor

Vehicle speed signal

Drive circuit signals

Figure 1-1 Working Principle of the EPS System

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2. Circuit Diagram of the EPS System

1#IG1 Power

Gateway controller

Hella torque and angle

sensor

Ignition signal

Brushless C-EPS ECU

Phase Phase Phase
A B C

EPS motor

Figure 2-1 Schematic Circuit Diagram of the EPS System

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2.1 Definition of Electrical Interface between EPS System and Full Vehicle Wiring

Resolver signal Torque and angle Full Vehicle signals

signals

Motor power supply

Figure 2-2 EPS ECU (viewing from the incoming direction)

Table 2-1 Definition of EPS ECU Pins

Testing Testing
Terminal description Standard value
terminal condition
Motor power supply
A1 Always 10-14VDC
(+)
Motor power supply Impedance between A2 and vehicle body
A2 Always
(-) less than 1Ω
PE3-1 NC None None
PE3-2 NC None None
PE3-3 NC None None
PE3-4 NC None None
ON position
PE3-5 CAN-H (500kbps) 2.5V or 3.5V
power
ON position
PE3-6 CAN-L (500kbps) 1.5V or 2.5V
power
PE3-7 NC None None
ON position
PE3-8 Ignition signal 9-16V
power
ON position Impedance between this terminal and
PE2-1 GND2
power vehicle body less than 1Ω
ON position Impedance between this terminal and
PE2-2 GND1
power vehicle body less than 1Ω
ON position
PE2-3 VCC2 5VDC
power
ON position
PE2-4 VCC1 5VDC
power
ON position 0.5-4.5V
PE2-5 PWM_T2
power
ON position 0.5-4.5V
PE2-6 PWM_T1
power
PE2-7 PWM_S
PE2-8 PWM_P
PE1-1 EXC_POS_R2
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Always Impedance between this terminal and
PE1-2 GND
vehicle body less than 1Ω
Always Impedance between this terminal and
PE1-3 GND
vehicle body less than 1Ω
PE1-4 EXC_POS_R1
PE1-5 EXC_COS_S2
PE1-6 EXC_COSLO_S4
PE1-7 EXC_SINLO_S3
PE1-8 EXC_SIN_S1

3. Maintenance Note
3.1 Servicing Notes

3.1.1 State of Start button

The keyless Start button is shown in the right

figure, and its light color is defined in Table 3-1.

Figure 3-1 Start Button

Table 3-1 State of Start Button

Vehicle state
Button state description Indicator Engine state
color
Smart key detected in the vehicle, can start engine. Green OFF
Smart key not detected in the vehicle, cannot start
No lighting/off OFF
engine.
ACC position/ON position Orange OFF
Engine starting No lighting/off Starting

3.1.2 Notes for Servicing EPS Steering to reset the steering wheel angle signal in strict
compliance with the following situations:
Column
①After removing and replacing electronic power
steering column assembly, center the steering
(1) SRS Operation Notes wheel by driving the vehicle straight at low
speed and then park the car. Reset steering
This vehicle is equipped with SRS including
wheel angle signal and clear DTC with a
front dual airbags, side airbags and side curtain
diagnostic apparatus after parking.
airbags. Failure of operation in right order may
cause accidental airbag opening and unfolding ②After removing and replacing the intermediate
during maintenance and result in serious shaft assembly, center the steering wheel by
accidents. So before maintenance (including driving the vehicle straight at low speed and
removing, installing, checking or replacing then park the car. Reset steering wheel angle
parts), it is necessary to read the Notes for signal and clear DTC with a diagnostic
SRS. (For details, refer to Chapter 6.) apparatus.
(2) The EPS System has active return-to-center ③After removing and replacing the steering
control function. After removing or replacing any gears, carry out four-wheel alignment to adjust
part of the system (including electronic power toe-in, center the steering wheel by driving the
steering column, intermediate shaft assembly, vehicle straight at low speed and then park the
mechanical steering gears, EPS electronic car. Reset the steering wheel angle signal and
control unit, steering wheel, etc.), it is required clear DTC with a diagnostic apparatus.
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(3) When operating EPS steering column off-centered and damaged.
assembly:
(b) Before disconnecting the steering column
①Avoid impacting the steering column or intermediate shaft, keep the vehicle in
assembly, especially the motor and the power-off state. Do not move wheels
deceleration mechanism. If the steering column after disconnecting the above parts. Failure
assembly falls off or suffers severe impact, to do so may lead to inaccurate positioning
replace it with a new assembly. of these parts during installation.
②Please do not pull the wiring harness while (c) The duration of turning the steering wheel
moving the steering column assembly. to the limiting position shall not exceed 5
seconds, otherwise it could damage the
③When the steering column assembly is not motor.
installed onto the vehicle, please do not release
the angle adjusting lever.
3.2 Troubleshooting Table
(4) When disconnecting or reconnecting the
steering column assembly: Utilize the table to find failure causes. Numerals
(a) Before disconnecting the steering column in the table indicate possible sequence of
or intermediate shaft from the steering occurrence. Please check each part in this
gears, it is necessary to keep vehicle order. When necessary, repair or replace the
wheels forward and put the vehicle into the faulty parts or carry out adjustment.
power-off state, otherwise it will cause the
clock spring on the steering column to be Troubleshooting of EPS System is shown in
Table 3-2.

Table 3-2 EPS System Troubleshooting Table

Symptoms Possible causes Symptoms Possible causes
1) Tire (improper inflation) 1) Steering knuckle (worn out)
2) Front wheel alignment (incorrect) 2) Suspension control arm ball
3) Steering knuckle (worn out) joint (worn out)
Excessive
Heavy 4) Suspension control arm ball joint clearance 3) Intermediate shaft and slip yoke
steering (worn out) (worn out)
5) Steering column assembly (faulty) 4) Front wheel bearing (worn out)
6) Steering gears (faulty) 5) Steering gears (faulty)
7) EPS ECU (faulty) 1) Deceleration mechanism (worn
out)
Abnormal
2) Steering gears (worn out)
1) Tire (improper inflation) noises
3) EPS motor (faulty)
Insufficient 2) Front wheel alignment (incorrect) 4) Steering gears (faulty)
return-to- 3) Steering column (bent) 1) EPS motor (faulty)
center 4) Steering gears (faulty) Steering
2) Steering column assembly
5) EPS ECU (faulty) wheel
(faulty)
wobbling
3) EPS ECU (faulty)

3.3 General Troubleshooting come on immediately, and corresponding

Information failure causes can be identified according to the
flashing frequency.
EPS indicator 3.4 Steering Wheel Free Travel
After start-up of the engine, EPS indicator will Inspection
go on for 2 to 3 seconds and then go off. This
means EPS indicator and system are running Steering wheel free travel inspection methods
normally. are as follows:
1) Stop the vehicle and keep tires forward;
If anything went wrong with the system after 2) Rotate the steering wheel gently to left or
engine start-up, the failure warning light should right, and check its free travel. As shown in
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Figure 3-2, the maximum free travel of the
steering wheel is no more than 30mm. If the
free travel exceeds the maximum value, it is
required to check the steering system.

≤30mm

Figure 3-2 Diagram for Steering Wheel Free

travel

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4 Servicing of Steering Wheel and Steering Column
4.1.1 Structure of Steering Wheel and Steering Column Assembly

Shown in Figure 4-1.

Plastic nut clip 25 EPS motor Steering wheel 40

assembly assembly

Cardan joint CV
boot assembly I

Cardan joint
CV boot
assembly II

Steering column
assembly

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35 35

30 30 Nm Pre-tightening
Extension Intermediate torque
shaft shaft
assembly

Figure 4-1 Steering Wheel and Steering Column Assembly Structure Diagram

4.1.2 Disassembly & Assembly of Steering position, DTC will be recorded.

Wheel and Steering Column Assembly ①As shown in Figure 4-2, use a tool to loosen
the two inner hexagon screws via small holes at
1) Disassembly both sides of steering wheel.

Partial servicing operation may affect SRS.

Before servicing the steering column, please
read Notes for SRS. (Please refer to Section
VIII of Chapter VI for disassembly of airbags)

(1) Ensure front wheels face forward straight

ahead;

(2) Disconnect battery negative terminal; Figure 4-2

(3) Remove DAB module (driver airbag ②Take out DAB module assembly from the
module). steering wheel.

Note: ③Use a pick to release airbag connector clip,

and unplug the connector.
Once the airbag ECU monitors any failure in
airbag parts and SRS circuit, it will store DTC in Note: Do not pull the airbag wiring harness
the memory and send corresponding while removing DAB module assembly, and
information to the dashboard so as to light up make sure DAB module assembly is placed
the airbag failure indicator. If the airbag with its upper surface facing upward; do not
connector is disconnected in a state of ON disassemble DAB module assembly.
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(4) Remove the steering wheel assembly.

①Pull out remaining wiring harness connectors;

②Loosen hexagon flange set bolt for the Use a

steering wheel, as shown in Figure 4-3. Phillips
screwdriver

adjusting lever
Release the
downward
to loosen the
three screws
and release
Steering wheel set the adjusting
bolt lever to
remove the
lower cover

Figure 4-5

(6) Remove clock spring and combination

switch.

①Unplug all the connectors connected to clock

Figure 4-3 spring and combination switch.
③Make matching mark on the steering shaft of ②Use a Phillips screwdriver to loosen the three
steering wheel assembly and steering column mounting screws of combination switch (two of
assembly properly, as shown in Figure 4-4. them in the front, and one in the back), as
shown in Figure 4-6, and remove the
④Use a special tool to remove the steering combination switch.
wheel assembly.

Loosen
the three
mounting
Matching mark screws

Figure 4-4 Figure 4-6

(5) Remove the combination switch cover. (7) Unplug the connector from the steering shaft
lock.
①. Pull open and remove the upper cover in a
bottom up direction by aligning the plastic clips (8) Remove the universal joint bellow assembly
of the upper and lower combination switch. I.

②Use a Phillips screwdriver to loosen the three Unscrew the two plastic nut clips to remove the
mounting screws on the lower cover, and universal joint bellow assembly I, as shown in
release the steering column angle adjusting Figure 4-7.
lever downward to remove the lower cover, as
shown in Figure 4-5.
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Matching
mark

Loosen the two plastic nuts Figure 4-9

②Loosen the bolt connecting steering column

Figure 4-7 assembly and intermediate shaft assembly, as
shown in Figure 4-10.
(9) Release the connection between
intermediate shaft assembly and extension
shaft assembly.

①Make matching mark at the position of

matching intermediate shaft lower-end with
steering gears input shaft properly, as shown in
Figure 4-8.
② AT this time, rotate steering wheel to a place
convenient for operation. Then loosen the bolt
and remove the intermediate shaft.

Loosen this bolt

Figure 4-10

(11) Remove the steering column assembly

Matching ①Unplug the motor connector and the torque

mark sensor connector from the EPS ECU.

②Remove the brake lamp switch, as shown in

Figure 4-11.
Figure 4-8

(10) Remove the intermediate shaft assembly

①Make matching marks at the joint of steering

column assembly and intermediate shaft
assembly, as shown in Figure 4-9.

Brake lamp switch

Figure 4-11

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column; if the steering shaft lock runs
abnormally, it is required to replace the shaft
③Loosen the hexagon flange bolt at the lower lock.
mounting bracket of the steering column, as
shown in Figure 4-12. (2) Install the steering shaft lock

Align the shaft lock boss to the lock hole in the

column, use two new anti-theft bolts to fix shaft
lock bracket and shaft lock onto the column,
and tighten the bolts till the heads break off.

(3) Install the steering column assembly

①Align against the lower mounting hole and

Loosen this bolt insert the mounting bolt, Aligning it with the
lower mounting hole.
Figure 4-12
②Release the steering column angle adjusting
lever, aligning it with two mounting holes of
upper mounting bracket, and screw in two nuts.
(12) Remove the steering shaft lock
③The tightening torque of the nut at upper
Loosen the two anti-theft bolts shown in Figure mounting point is 35Nm and that of the bolt at
4-11 to remove the steering shaft lock. lower mounting point is 35Nm.

④Connect the steering shaft lock connector.

(4) Connecting steering column assembly with

intermediate shaft assembly.

①Place the intermediate shaft assembly onto

the steering column assembly output shaft,
align marks made before, and ensure that the
bolt hole in intermediate shaft aligns with the
groove in steering column output shaft. At this
point, it means they have been assembled in
place.

Figure 4-11 ②Tighten the bolt to a torque of 30Nm.

Note: Make sure you screw in the bolt from the

threadless side. Screwing in from the other side
2) Assembly will not bring about effective tightening and can
cause accident. There is a milled surface at the
(1) Check whether the shaft lock is faulty side of threadless cardan joint yoke. Please
screw in the bolt from this surface, as shown in
Connect the connector to the removed shaft Figure 4-12.
lock. Press the start-up button to power-on, and
the steering shaft lock should unlock; press the
start-up button to power-off, and the steering
shaft lock should lock.

Replace with a new if the steering shaft lock, if

it works normally, then it shows the old lock is
defective and should be replaced. unplug the
connector and install the lock onto the steering

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plastic clip.

(7) Install combination switch and clock spring.

Tighten three mounting bolts by aligning them

with the position of combination switch, and
connect the connector.

(8) Install combination switch covers

The surface is milled. Please screw in ①Install the lower cover, and tighten three set
the bolt from this surface. bolts.

Figure 4-12 ②Install the upper cover, and clip it onto the
lower cover.
(5) Connecting intermediate shaft with
extension shaft assembly. (9) Center the clock spring

①Place the intermediate shaft onto the Note: Incorrectly installing the clock spring
extension shaft assembly, align marks made could cause damage, so please be sure to
before, and ensure that the bolt hole in center the spring. Before centering, please turn
intermediate shaft is aligned with the groove in the clock spring to the left limit. Then turn it to
extension shaft assembly, which means they right till reaching the right limit, count its full
have been installed in place. rotations, and then turn it to left for half the
rotation (If the total number of rotations is 5,
②Tighten the bolt to a torque of 30Nm. then turn back for 2.5 rotations) to make the
end of clock spring with the connector facing
Note: Make sure you screw in the bolt from the upward, as shown in Figure 4-14.
threadless side. Screwing in from the other side
would not bring about effective tightening, but
Make the end with
even cause accident. There is a milled surface interface facing
at the side of threadless cardan joint yoke. upward
Please screw in the bolt from this surface, as
shown in Figure 4-13.

Figure 4-14

The surface (10) Install the steering wheel assembly

is milled.
Please screw Align marks on the steering steel and column
the bolt from made before, and fix the nut to a tightening
this surface. torque of 40Nm.

(11) Install DAB module assembly

Figure 4-13 ①Connect the connector.

(6) Install the cardan joint CV boot assembly I. ②Align the two fastening bolts with DAB
module, and tighten them to a torque of 8.8Nm.
Install the CV boot in place, and fasten the

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Note:

① Do not use airbag parts removed from

another vehicle. new parts should be used
for replacement.

② Assure DAB module assembly is installed

to specified torque. Remove
two bolts
③ If DAB module assembly falls to the ground here
or has cracks, dents or other defects,
replace with a new assembly.

④ When installing DAB module assembly,

make sure there is no interference between
wires and other parts, and no wires are
clamped.

(12) Connect the battery negative terminal.

Figure 4-15
(13) Check SRS warning light.
(3) Check that the motor has smooth rotation
4.1.3 Servicing of EPS Motor
without odor. Replace with a new motor in case
of stucking or odor smelled.
Note: During disassembly and assembly, keep
the deceleration mechanism housing away from
dust, dirt or other foreign bodies. Turning the
ignition switch to ON position is not allowed 2) Assembly
when the motor is not connected.
Install the removed parts in the reverse order of
1) Disassembly removal.

(1) Remove the steering column assembly Note:

following aforementioned steps;
The motor wiring harness should face correct
(2) Remove 2 bolts, and remove the motor from direction, as shown in Figure 4-16.
the steering column, as shown in Figure 4-15.
Before tightening bolts, turn the motor to left
and right 45° 2-3 times. Then check contact of
the motor fitting surface, and alternately tighten
bolts to a torque of 25N·m and fix the motor
properly.

Facing direction of motor outgoing line

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Figure 4-16 (2) Start the engine.

Upon finishing the installation, start the engine (3) Turn the steering wheel 2-3 times at a rate
to idle running, and turn the steering wheel from of 1 round per second (Noise produced should
left limit to right limit several times. Make sure be lower than sound of the engine, and hard to
EPS indicator works normally. perceive).

Note:

After replacing the motor, carry out the following During inspections for the above conditions, if
inspections: abnormal noise or vibration arises in the motor,
it may be an aging motor. Replace with a new
(1) Park the vehicle outdoor on the ordinary motor and then check it again.
road.

4.2 Servicing of Steering Gears Tie Rod Assembly

4.2.1 Structure of Steering gears Tie Rod Assembly

As shown in Figure 4-1, 4-2 and 4-3.

Cardan joint upper CV

boot assembly

Cardan joint assembly

Right steering knuckle
assembly
Lower steering shaft

Cardan joint lower CV

boot assembly

Split pin

Right front suspension lower

control arm assembly

Pre-tightening torque Left front suspension lower

control arm

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Mechanical 138 138

steering system
tie rod assembly

Front subframe
assembly

Pre-tightening
toque: N·m

Left outer tie

rod assembly

74

74

Mechanical steering Right outer tie

Pre-tightening gears assembly rod assembly
torque: N·m

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4.2.2 Disassembly 16. Separate connection between left outer tie

rod assembly and steering knuckle.
(a) Remove split pin and hexagon slotted nut.
1. Place front wheels straight ahead.
(b) Separate left outer tie rod assembly from the
2. Fasten the steering wheel.
steering knuckle.
(a) Fasten the steering wheel using a seat belt
to prevent rotation.
Remove
Note:
split pin and
The above operation helps prevent damage to hexagon
the spiral cable. slotted nut
3. Remove the cardan joint upper CV boot
assembly.
4. Separate the lower steering shaft assembly.
5. Separate the cardan joint lower CV boot
assembly.
(a) Separate connection between cardan joint
lower CV boot frame clips A and B and the
vehicle body.
17. Separate connection between right outer tie
Caution: rod assembly and steering knuckle.
Do not damage clips on the frame. Note:
Carry out the same operation procedure as that
Clip A of left corresponding assembly.
18. Separate the left front suspension lower
control arm assembly.

Remove 2 nuts
and 1 bolt

Clip B
6. Remove front wheels.
7. Separate connection between rear
suspension assembly and front subframe
assembly.
8. Remove No. 2 engine splash shield. 19. Separate the right front suspension lower
control arm assembly.
9. Remove the rear left engine splash shield.
Note:
10. Remove the rear right engine splash shield.
To remove right lower control arm, carry out the
11. Remove the front suspension bracket lower same procedure as removal of left lower control
reinforcement. arm.
12. Remove left front suspension cross member 20. Remove the left front suspension cross
reinforcement. member rear bracket.
13. Remove right front suspension cross 21. Remove the right front suspension cross
member reinforcement. member rear bracket.
14. Separate left front stabilizer bar assembly. 22. Remove the front subframe assembly.
15. Separate right front stabilizer bar assembly.
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23. Remove the cardan joint lower CV boot
assembly.
(a) Remove the cardan joint lower CV boot Fitting
assembly from mechanical steering gears tie mark
rod assembly.
24. Remove the lower steering shaft.
(a) Make fitting mark on the lower steering shaft
and the steering gears housing properly.
(b) Remove the lower steering shaft from
mechanical steering gears tie rod assembly.

28. Remove the right outer tie rod assembly.

Fitting
mark Note:
Carry out the same removal procedure as that
of left outer tie rod assembly.

4.2.3 Inspection

1. Check the left tie rod outer joint

subassembly.
25. Remove the mechanical steering gears tie (a) Fasten the left tie rod outer joint
rod assembly. subassembly to a vise.
(a) Remove 2 bolts, 2 nuts and the mechanical Caution:
steering gears tie rod assembly from the front
subframe assembly. Do not over tighten the vise.
(b) Install nuts on the stud bolt.
(c) Rock the bolt back and forth 5 times.
(d) Put the torque wrench on the nut,
continuously rotate the ball joint at a rate of 3-5
seconds a round, and check torque of the 5 th
round.
Standard torque: 0.5-3.5N·m
Note:
If the torque is beyond the specified range,
replace with a new left tie rod outer joint
subassembly.
2. Check the right ties rod outer joint
subassembly.
26. Fasten the mechanical steering gears tie Note:
rod assembly.
Carry out the same inspection procedure as
27. Remove the left outer tie rod assembly. that of left tie rod outer joint subassembly.
(a) Make fitting mark on the left outer tie rod 3. Check the steering gear noload torque.
assembly and the inner tie rod properly.
Use a torque wrench to check the steering gear
(b) Remove the left outer tie rod assembly and noload torque.
the tie rod lock nut.
Standard torque: 0.5-1.1N·m
Caution:
Check the position near the center of steering
gears rack.
Note:
If the total pre-tightening torque is beyond

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specified range, replace with a new steering
gears assembly.
4. Inspection of the waveform CV boot.
Use a special tool to rotate the pinion, and
check left and right CV boots for steady
expansion and shrinkage.
Caution:
If the CV boot fails to achieve steady expansion
and shrinkage, replace with a new rack CV boot
and clamp.
5. Inspection of the steering tie rod ball joint end
CV boot
Press hard the CV boot with fingers to check for
cracks or damage. 4. Install the lower steering shaft.
Note: (a) Align the fitting marks; install the lower
steering shaft onto the mechanical steering
If cracks or damage appear in the CV boot, it is gears tie rod assembly.
necessary to replace the steering tie rod outer
joint. (b) Install the bolt.
Pre-tightening torque: 35 N·m
4.2.4 Assembly

1. Install the left outer tie rod assembly.

(a) Connect tie rod lock nut and left outer tie rod Fitting mark
assembly to the mechanical steering gears to
align with the fitting marks.
Note:
Adjust the toe-in and then tighten the lock nut.

Fitting mark

5. Install the cardan joint lower CV boot.

(a) Align the upper round hole of cardan joint
lower CV boot to the boss on the steering gears
housing to install the hole cover.

2. Install the right outer tie rod assembly.

Note:
Carry out the same installation procedure as
that of left outer tie rod assembly.
3. Install the mechanical steering gears tie rod
assembly.
(a) Use 2 bolts and 2 nuts to install the
mechanical steering gears tie rod assembly
onto the front subframe assembly.
Pre-tightening torque: 138 N·m

6. Install the front subframe assembly.

7. Install the left front suspension crossmember
rear bracket.
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 BYD SC Passenger Car Service Manual
8. Install the right front suspension
crossmember rear bracket.
9. Connect the left front suspension lower
control arm subassembly.
10. Connect the right front suspension lower
control arm subassembly.
11. Connect the left outer tie rod assembly.
(a) Use a hexagon slotted nut to connect the
left outer tie rod assembly to the steering
knuckle.
Pre-tightening torque: 49 N·m
Caution:
If the split pin is not aligned to its hole, further
screw the nut 60°.
(b) Install a new split pin.
12. Connect the right outer tie rod assembly.
Note: carry out the same installation procedure
as that of left outer tie rod assembly.
13. Install the left front stabilizer bar link
assembly.
14. Install the right front stabilizer bar link
assembly.
15. Install the left front suspension
crossmember reinforcement.
16. Install the right front suspension cross
member reinforcement.
17. Install the engine front suspension bracket
lower reinforcement.
18. Install the rear left engine splash shield.
19. Install the rear right engine splash shield.
20. Install No. 1 engine splash shield.
21. Install No. 2 engine splash shield.
22. Connect the cardan joint lower CV boot
assembly.
(a) Connect the clamp on the lower CV boot
assembly frame with the vehicle body dash
panel.
23. Connect the cardan joint assembly with the
lower steering shaft.
24. Install the cardan joint upper CV boot.
25. Install front wheels.
Pre-tightening toque: 108 N·m
26. Adjust four-wheel alignment.
Note:
After finishing four-wheel alignment, tighten the
tie rod lock nut to 74 N·m

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5. EPS System Self-diagnosis and Troubleshooting
5.1 Method of Troubleshooting with the Diagnostic Apparatus

When a failure happens on the EPS system, use the special hand-held fault diagnostic apparatus
(ED400) to read DTC, and then read fault types according to the apparatus.

● Connect the diagnostic apparatus to the vehicle fault diagnosis connector (DLC3), as shown in
the picture below.

Table 5-1

A1-vehicle ON position
B Motor (-) 0-12V
body power
A2-vehicle ON position
R Motor (+) 0-12V
body power
Hand-held tester

Figure 5-1

● Read DTC based on the Notes on the diagnostic apparatus. The troubleshooting method is
shown below:

5.1.1 DTC Troubleshooting Methods

Table 5-2 DTC Troubleshooting Methods

DTC
Fault type Fault analysis Troubleshooting procedure
No.
1. Connector loose or detached. Yes: refix it. No: to
Steering assist
Step 2.
power supply
2. Wiring harness open or short. Yes: repair the
abnormal, assist
harness. No: to Step 3.
Assist current motor failure,
C1B00 3. Steering assist power supply abnormal. Yes:
output failure wiring harness
repair the circuit. No: to Step 4.
open or short, or
4. Steering assist motor faulty. Yes: replace the
EPS ECU
motor. No: to Step 5.
internal failure
5. EPS ECU failure: replace EPS ECU.

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1. Connection between the connector and EPS ECU
Steering assist
loose or detached. Yes: refix it. No: to Step 2.
power supply
2. Wiring harness between EPS and the battery
abnormal, wiring
Power voltage open. Yes: repair the harness. No: to Step 3.
C1B01 harness open or
failure 3. Steering assist power supply abnormal or battery
short, or EPS
voltage too low. Yes: repair power or replace with a
ECU internal
new battery. No: to Step 4.
failure
4. EPS ECU failure: replace EPS ECU.
EPS ECU 1. Connector loose or detached. Yes: refix it. No: to
internal failure, Step 2.
EPS ECU system power 2. Wiring harness open or short. Yes: repair the
C1B02
failure abnormality, harness. No: to Step 3.
wiring harness 3. EPS ECU failure: replace EPS ECU.
open or short
1. Connector loose or detached. Yes: refix it. No: to
Step 2.
Steering assist
2. Wiring harness open or short. Yes: repair the
motor failure,
harness. No: to Step 3.
steering assist
3. Steering assist power supply abnormal or battery
C1B03 Motor failure power supply
voltage too low. Yes: repair circuit or replace with a
abnormal, or
new battery. No: to Step 4.
EPS ECU
4. Steering motor faulty. Yes: replace the motor. No:
internal failure
to Step 5.
5. EPS ECU failure: replace EPS ECU.
1. Connector loose or detached. Yes: refix it. No: to
Torque sensor
Step 2.
failure,
2. Wiring harness open or short. Yes: repair the
mechanical
harness. No: to Step 3.
Torque sensor assembly stuck
C1B04 3. Mechanical assembly stuck or loose. Yes:
failure or loose, wiring
eliminate the failure. No: to Step 4.
harness open or
4. Torque sensor faulty. Yes: replace the torque
short, EPS ECU
sensor. No: to Step 5.
internal failure
5. EPS ECU failure: replace EPS ECU.
C1B05 System Prolonged 1. Prolonged steering wheel rotation in one place.
temperature turning of Yes: stop turning and let ECU cool down. No: to
too high steering wheel, Step 2.
EPS ECU 2. Wiring harness short. Yes: repair the harness. No:
internal failure, to Step 3.
steering assist 3. Steering assist motor faulty. Yes: replace the
motor or wiring motor. No: to Step 4.

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4. EPS ECU failure: replace EPS ECU.
harness short-
1. Connector loose or detached. Yes: refix it. No: to
Step 2.
CAN bus open
2. Wiring harness open or short. Yes: repair the
Vehicle speed or short, EPS
C1B06 harness. No: to Step 3.
sensor failure ECU internal
3. ABS faulty. Yes: please check ABS system. No: to
failure
Step 4.
4. EPS ECU failure: replace EPS ECU.
1. Connector loose or detached. Yes: refix it. No: to
Engine speed
Step 2.
sensor, wiring
2. Wiring harness open or short. Yes: repair the
Engine speed harness open or
C1B08 harness. No: to Step 3.
sensor short, or EPS
3. Engine speed sensor faulty. Yes: replace the
ECU internal
sensor. No: to Step 4.
failure
4. EPS sensor failure: replace EPS ECU.
1. Connector loose or detached. Yes: refix it. No: to
Step 2.
No torque
2. Wiring harness open or short. Yes: repair the
Torque sensor sensor
C1B09 harness. No: to Step 3.
not calibrated calibration at
3. Torque sensor faulty. Yes: replace the sensor. No:
shipping
to Step 4.
4. EPS sensor failure: replace EPS ECU.
1. Connector loose or detached. Yes: refix it. No: to
Step 2.
Angle signal 2. Can be calibrated with diagnostic apparatus. Yes:
C1B0 Angle signal zero point not calibrate angle zero point. No: to Step 3
A not calibrated calibrated in 3. Calibration still unsuccessful despite being carried
assembly line out a number of times. Yes: replace the steering
column. No: to Step 4.
4. EPS controller failure: replace EPS ECU.
1. Connector loose or detached. Yes: refix it. No: to
Wiring harness
CAN bus Step 2.
open or short, or
U0298 communicatio 2. Wiring harness open or short. Yes: repair the
EPS ECU
n failure harness. No: to Step 3.
internal failure
3. Replace EPS ECU.

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5.1.2 Power Voltage Failure Inspection
Circuit diagram
1#IG1 Power

Ignition signal

EPS Motor

Figure 5-2

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Power voltage failure inspection

Ste
Diagnostic operation Criterion Yes No
p
Check whether connector B23 is connected Go to the next
1 Normal or not To Step 3
to EPS ECU normally step
Completed or
2 Fasten the connector properly To Step 8
not
Check whether the voltage of EPS ECU
Go to the next
3 B23-1 is 10-14V, and B23-2 is connected to Normal or not To Step 7
step
ground
Check whether fuse F3/1 is conductive and
Conductive or Go to the next
4 resistance between B23-2 and ground is To Step 6
not step
less than 1Ω
Completed or
5 Replace the fuse or wiring harness To Step 8
not
Repair
Check the relevant wiring harness for short Repair the
6 Normal or not power
or open circuit wiring harness
system
Completed or Go to the
7 Replace EPS ECU
not next step
DTC persists
8 Use a diagnostic apparatus to clear DTC To Step 7 System OK
or not

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5.1.3 EPS ECU Failure
Circuit diagram
1#IG1 Power

Ignition signal

EPS Motor

Figure 5-3

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Inspection steps
EPS ECU Failure Inspection
Ste
Diagnostic operation Criterion Yes No
p
Check whether connector G86 is connected Go to the next
1 Normal or not To Step 3
to EPS ECU normally step
Completed or
2 Fasten the connector properly To Step 8
not
Check whether the voltage of EPS ECU Go to the next
3 Normal or not To Step 7
G86-8 is 10-14V step
Check whether fuse F2/8 is conductive and
Conductive or Go to the next
4 resistance between B23-2 and ground is To Step 6
not step
less than 1Ω
Completed or
5 Replace the fuse or wiring harness To Step 8
not
Check the relevant wiring harness for short Repair the Repair the
6 Normal or not
or open circuit power system wiring harness
Completed or Go to the
7 Replace EPS ECU
not next step
DTC persists
8 Use a diagnostic apparatus to clear DTC To Step 7 System OK
or not
5.1.4 Current Failure
Inspection Steps
Current Failure Inspection
Ste
Diagnostic operation Criterion Yes No
p
Check whether connector B23 is Go to the next
1 Normal or not To Step 3
connected to EPS ECU normally step
2 Fasten the connector properly Completed or not To Step 11
Check whether the voltage of EPS ECU
Go to the next
3 B23-1 is 10-14V, and B23-2 is Normal or not To Step 7
step
connected to ground
Check whether fuse F3/1 is conductive
Go to the next
4 and resistance between B03-2 and Conductive or not To Step 6
step
ground is less than 1Ω
5 Replace the fuse or wiring harness Completed or not To Step 11
Check the relevant wiring harness for Repair the Repair the
6 Normal or not
short or open circuit power system wiring harness
Check whether the steering motor is Go to the next
7 Normal or not To Step 9
faulty step

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8 Replace the steering motor Completed or not To Step 10
Go to the
9 Replace EPS ECU Completed or not
next step
Use a diagnostic apparatus to clear DTC persists or
10 To Step 1 System OK
DTC not

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5.1.5 Torque Sensor Failure Inspection
Circuit diagram

Hella torque and angle sensor

EPS ECU

Figure 5-4

Torque Sensor Failure Inspection

Ste Diagnostic operation Criterion Yes No
p
1 Check whether the connector is connected to Normal or not To Step 3 Go to the
EPS ECU normally next step
2 Fasten the connector properly Completed or not To Step 9
3 Check the torque sensor wiring harness for Normal or not To Step 5 Go to the
open or short circuit next step
4 Repair wiring harness failure Completed or not To Step 9
5 Check whether the mechanical assembly Normal or not To Step 7 Go to the
gets stuck or loose next step
6 Replace the steering column Completed or not To Step 9
7 Check whether the torque sensor signal is Normal or not To Step 6 Go to the
normal (ensure that EPS ECU connectors next step

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are connected when checking)
8 EPS ECU failure: replace EPS ECU Completed or not To Step 9
9 Use a diagnostic apparatus to clear DTC DTC persists or To Step 1 System
not OK

5.1.6 Motor Failure Inspection

Circuit diagram

Brushless C-EPS ECU

Phase A Phase B Phase C

Figure 5-5

Motor Failure Inspection

Ste
Diagnostic operation Criterion Yes No
p
1 Check whether the connector is connected Normal or not To Step 3 Go to the next

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to EPS ECU normally step
Completed or
2 Fasten the connector properly To Step 11
not
Check whether the voltage of EPS ECU
Go to the next
3 B23-1 is 10-14V, and B23-2 is connected to Normal or not To Step 7
step
ground
Check whether fuse F3/1 is conductive and
Conductive Go to the next
4 resistance of B23-2 to ground is less than To Step 6
or not step
1Ω
Completed or
5 Replace the fuse or wiring harness To Step 6
not
Check the corresponding wiring harness for Repair the Repair the
6 Normal or not
short or open circuit power system wiring harness
Go to the next
7 Check whether the steering motor is faulty Normal or not To Step 9
step
Completed or
8 Replace the steering motor To Step 10
not
Completed or Go to the
9 Replace EPS ECU
not next step
DTC persists
10 Use a diagnostic apparatus to clear DTC To Step 1 System OK
or not

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5.1.7 Inspection of Other Signal Harness

Circuit diagram

Gateway controller

Brushless C-EPS ECU

Figure 5-6

Inspection of Other Signal Harness

Step Diagnostic operation Criterion Yes No

1 System self-diagnosis process Completed or Go to the To Step
not next step 4
2 1. Battery load test Voltage 10- Go to the To Step
2. Charging system load test 14V or not next step 5
3 1. Turn to OFF Normal or not To Step 6 To Step
2. Disconnect wiring harness connector on EPS 4
ECU

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3. Check the conductivity of connection between
EPS ECU wiring harness terminal B23-2 and
vehicle body
4 Repair self-checking circuit Completed or To Step 1 Repair
not
5 Repair the battery or charging system Normal or not To Step 8
6 CAN bus harness inspection Normal or not To Step 8 To Step
Unplug connector G86, and measure voltage of 8
wiring harness terminals G86-5 and G86-6
1. Check whether vehicle body grounding voltage of
G86-5 is always 2.5-3.5V
2. Check whether vehicle body grounding voltage of
G86-6 is always 1.5-2.5V
7 Replace the wiring harness Normal or not Go to the
next step
8 Use a diagnostic apparatus to clear DTC DTC persists To Step 1 System
or not OK

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6. EPS System Self-diagnosis and Troubleshooting

6.1 EPS Torque & Angle Signal Centering Calibration

EPS sensor is a Hella sensor integrating torque and angle signals. To prevent uncalibrated torque
and angle signals from causing EPS power assistance abnormality, standardized calibration
procedure for torque and angle signal is therefore established.

(1) Conditions where signal calibration is required:

a) Both torque signal and angle signal need calibration after the vehicle leaves the final assembly line
and receives four-wheel alignment;

b) Both torque and angle signal calibrations are needed after replacement of the EPS column;

c) Both torque and angle signal calibrations are needed after EPS ECU is replaced or the software
program is updated;

d) The angle signal needs calibration after the steering wheel, cardan joint and steering gears are
removed or replaced.

(2) Calibration procedure

After four-wheel alignment, carry out EPS torque signal and angle signal calibration following the
steps below.

1) Calibrate torque signal. The calibration helps avoid unbalanced left and right electronic steering
assist caused by sensor not properly centered during assembly. In the course of calibration, ensure
that the steering wheel is free from applied force so that the sensor has no residual torque. Please
see Figure 1 Torque Signal Calibration Procedure for details.

2) Calibrate angle signal. As a Hella sensor torque sensor has no mechanical zero point, it needs to
store a steering wheel angle center point in EPS ECU memory through a diagnostic apparatus when
the vehicle leaves the assembly line, so that an initial position memory could be accessed after the

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system is powered on again. Please see Figure 2 Angle Signal Calibration Procedure for details.

3) Clear DTC. If the angle signal is not calibrated, EPS ECU will record this failure. So after angle
signal calibration, DTCs recorded by ECU should be cleared. Clearing remaining DTCs in ECU is
very important in the maintenance and troubleshooting of a vehicle after it leaves the final assembly
line.

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Figure 1 Torque Signal Calibration Procedure:

Steering wheel free from applied

force (very important)

Enter the SC model interface with

a diagnostic apparatus (make
sure the car power is at ON
position)

BYD EPS

Select BYD EPS

diagnostic interface

Read computer version

Read system failure
Clear DTC
Parameter adjustment
Angle signal calibration
Torque signal calibration

Select
■6. Torque signal calibration
Enter torque signal calibration
interface

Read current zero point

Current torque set to zero
point

Select Manually calibrate

Set current torque to signal
zero point

Displays Diagnostic apparatus displays:

Yes ‘Operation No Operation error/command error
successful’?

Press any key to return

to the previous menu Multiple calibrations still unsuccessful

Replace steering column/replace EPS controller/check whether

full vehicle CAN network runs normally

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Figure 2 Angle Signal Calibration Procedure

After four-wheel alignment of the vehicle, both

steering wheel and tires should be in center
positions with steering wheel free from applied
force (very important)

Enter the SC model interface with a

diagnostic apparatus (Power at ON
position)

BYD EPS
Select BYD EPS
diagnostic interface

Read computer version

Read system failure
Clear DTC
Parameter adjustment
Angle signal calibration
Torque signal calibration

Select
■5. Angle signal calibration
Enter angle signal calibration
interface

□[Link] current zero point

■[Link] current angle as zero point

Select
■[Link] current angle as zero point
to carry out angle centering-value
calibration

Manually calibrate
signal

Diagnostic apparatus displays: Diagnostic apparatus displays:

Operation successful Displays
Press any key to return to the Yes ‘Operation No Operation error/command error
previous menu successful’?

Multiple calibrations still not successful

Replace steering column/replace EPS

controller/check whether vehicle CAN network
runs normally

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Figure 3 DTC Clearing Procedure

BYD EPS

Select BYD EPS diagnostic

interface

Read computer version

Read system failure
Clear DTC
Parameter adjustment
Angle signal calibration
Torque signal calibration

Select

■3. Clear DTC

Diagnostic apparatus displays:

DTC cleared

Press any key to return to the

previous level

Select

■2. Read system failure

Diagnostic apparatus
displays:

No system failure

DTC cleared
successfully

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