Chapter 4 Steering System
Contents
1. fix Insert harness connector into signal switch and wiper switch Fix signal switch cover Fixture 4 Install steering wheel in steering shaft Screw bolts with 22 5 27 5 Nm Screw bolts with 22 5 27 5 Nm Fixture Screw steering nuts and shaft nuts with 27 33Nm 5 Check forwards position of the steering institution Steering column replace Points of attention Observe safety regulation during operating air bag Remove procedure 1 Remove air bag unit and the steering wheel with air bag 2 Loosen the bolts 3 Loosen the safety bolts Drill holes on safety bolts with electric screwdriver to pull out the bolts 4 Remove steering column Points of attention Don t turn ignition switch in LOCK position 5 Remove up steering shaft and lower steering guide bearing from pillar 6 Remove lower steering guide bearing from pillar 7 Replace steering column Steps of installation 1 Insert steering column screw Points of attention Note guide ears on shell 2 Use 4 bolts to fix the shell and pillar 3 Use bolts to fix ignition lock shell and shaft shell 4 Insert new shaft into pillar Points of attention Don t turn steering and ignition lock in LOCK position 5 Push guide bearing into pillar 6 Insert and fix steering shaft 7 Screw bolts 8 Install steering wheel with air bag and air bag components Fixture Screw shaft flange bolts to 22 5 27 5Nm Screw gear flange bolts t2. installation 1 Remove transmission belt and loosen adjust 1 Put the tank into support and screw bolts bolts Connect two hoses and fix clamp 2 Check if any leakage in system Power steering liquid 2 Remove high pressure hose and pipe from steering pump The fluid will flow into the container Please observe the safety regulation 3 Remove the pump from front support Steps of installation 1 Put the pump on the support Fixture 22 28Nm 2 Install strengthen transmission belt 3 Connect high pressure hose and pipe on steering pump again Power steering Disassembly procedure 1 Loosen two connectors and remove out 2 Remove tank from support Rinse power steering system Attention Use suitable steering fluid when filling or replacing fluid otherwise it will damage hose and seal 1 Lift vehicle to run wheel freely Suck out fluid from tank Remove fluid hose from connector Insert outlet of hose into tank Put hose into container Run engine at idle Ask assistant to fill fluid into tank 7 Turn steering wheel left and right Attention Don t turn to end for starring wheel to keep on Otherwise it will cause over heat for system or damage pump and pivot 8 Continues to drain out all old fluid 9 Resin system with 0 9L new fluid 10 Check if all fluid is drained out 11 Remove the cock of pump Points of attention Don t use the fluid drained out 12 Connect hose and tank 13 Turn off en
3. or if the free play is too large If so replace the universal coupling assembly 2 Steering column check all the covers of the steering column stand with the spaces from the slot bottom within 1 00mm If not make proper replacements Check to see if the steering column is bent cracked or deformed Installation The order of installation steps is just the opposite to that for removal Attention Apply alkali based lubricating grease on the interior slot of the rubber sleeve of the steering column and tighten the associated bolts and screw nuts with the specified torque Manual Steering Gear Manual steering gear components 1 Bolts 2 Right supporting frame 3 Right supporting frame sleeve 4 Right steering horizontal lever joints assembly 5 Right horizontal lever 6 Steering gear washer 7 Gear bearing stopper 8 O shaped ring 9 Left horizontal lever 10 Left steering horizontal lever joints assembly 11 Left supporting frame sleeve 12 Left supporting frame 13 Bolt II Removal of power steering gear assembly 1 Removal Disassembly procedure 1 Put steering wheel forward and lock steering remove steering shaft 4 Turn steering pivot left into gap of wheel pull the lever into engine compartment 5 Push down and backwards to remove steering pivot 2 Loosen the nuts on two ends of steering transverse lever and push out the ends of lever from steering node Steps of installation 1 Turn s
4. rod end 22 Check nut 23 Tie rod ripple cowl hoop 24 Ripple cowl 25 Steering box 26 Tie rod in band ball unit 27 Limiting stopper 28 Tube 29 Oil pipe clip 30 Hydraulic piping 31 Hydraulic piping 32 Trust sealing ring Power steering service schematic diagram Ni UA Ny Steering oil pipe ii Steering oil pump gt L Steering oil tank h Re Power steering gear htl E ka DOLE ht J r ae z a F og Steering system fizzy noise Identification Fizzy noise is heard during Engine running or steering wheel turning 1 l If the fizzy noise becomes loud When ia comparing with other normal vehicle Je pen 2 If the fizzy noise becomes loud If vil steering fluid level is too low MED POSE 3 Fill fluid into the system sl Does customer still complain aces pe LAN Is the noise from inside of vehicle TO step5 TO step7 The noise may enter passenger compartment through outlet of front TO step6 TO step7 instrument panel Repair or replace steering pillar seal Droes customer atti eompiain o TOSI System pect 7 Make sure the lay for steering hose and pipe is correct not touch with front instrument panel Repair or replace hose and pipe if necessary Does customer still complain Confirm The source of noise Check steering pump and steering institute TO step System perfect TO step8 System perfect Repair or replace parts if nec
5. Ignition switch Lock core sets not correct If need to replace part refer The ignition switch lock core replacing Lock core damage If need to Replace part refer The ignition switch lock core replacing On Close and locking position demand larger locking force Problem gt Lock core damage If need to piar part refer The ignition switch lock core replacing Steering wheel looseness 1 Check steering wheel installation refer The steering wheel replace 2 To fix steering wheel installation nuts refer The steering wheel replace 2 Steering wheel replace refer steering wheel replace Check steering intermediate shaft refer The power steering box replace Replace steering intermediate shaft refer The power steering box replace Steering wheel installation nut is loose Steering intermediate shaft wear out or damage Steering shaft check chatter When turning steering wheel Check steering shaft plastics pin whether can feel clearance sheering some symptom as follows If steering shaft pin is no serious damage Steering shaft from flank slight dash have advise to replace steering shaft Steering column looseness eben Steering column installation bolt loose column installation bolt loose Screw bolts to Screw bolts to specified torque torque Check steering column assembly Steering column stay unit loose or damage l Repair or replace steering column assembly
6. Steering wheel looseness 1 Check Steering wheel installation Steering wheel installation nut looseness 2 Fix steering installation nut again Steenie heel 1 Check steering wheel 2 Replace steering wheel Check steering intermediate shaft Replace steering intermediate shaft r Steering intermediate shaft wear or damage Service guide Replace ignition switch core Removal 1 Remove plastic cover 2 Insert needle into lock hole and pull out the core from lock seat Steps of installation 1 Push the moving block to the direction shown in the figure 2 Insert the core into the seat Steering shaft replace Disassembly procedure 1 Remove steering wheel from shaft Points of attention Don t knock steering when install or remove 2 Loosen switch cover bolts Remove signal switch left and wiper switch right Loosen the bolts between up down shaft 3 Loosen moving bolts on steering column under instrument cluster 4 Remove steering column 5 Remove up steering shaft Points of attention The lower guide bearing is a rubber bearing Carefully remove the bearing Don t put steering lock in lock position Steps of installation 1 Insert new up shaft into steering column Insert lower guide pipe into rubber bearing Push the bearing to the end 2 Connect separate block support lower support with bolts Use new locknuts Fixture Screw support and lower support with 13 17Nm 3 Insert shaft flange and
7. Torque specifications Application Specifications Steering box installation nut 70 80Nm Tie rod and rack fixture nut 63 77Nm Tie rod end plane and steering knuckle fixture nut 32 38Nm Power steering pump installation bolt 22 28Nm Steering column and crosstree 13 17Nm Steering knuckle and steering box 22 5 27 5Nm Steering wheel and steering shaft nut 27 33Nm Steering shaft flange clamping bolt 22 5 27 5Nm Nipple torque specifications Application Specifications Power steering oil hosepipe and power steering 2 3Nm pump socket Power steering oil hosepipe and power steering 2 3Nm storage tank socket Power steering high pressure hosepipe and power 8 mgn p pip p 20 35Nm steering pump socket Power steering high pressure hosepipe and power is gn p pip p 97 33Nm steering box inlet nipple power steering box oil inlet and power steering 27 33Nm box socket ower Steering box gusher pipe and power p g g pip p 97 33Nm steering box socket ower Steering box gusher pipe and power p g g pip p 97 33Nm steering oil return pipe socket Manipulate part overhaul Steering wheel and steering column decompose view 1 Steering universal coupling shaft and universal coupling 2 3 Bolts 4 Steering core shaft assembly 5 Bolts 6 Jump ring 7 Washer 8 Spring 9 Steering column Steering wheel free play inspection In the assembled mode check the free play of the steering wheel while the car is driving in strai
8. ck fluid level in tank Fill fluid if necessary 5 4 Start engine Points of attention Don t turn steering to the end and keep on It will damage pump 5 5 Ask assistant to turn steering left right for several times 5 6 Confirm leaking position and fix 6 Go to following steps if repairing 6 1 Clean leaking position before removing 6 2 Replace the seal 6 3 Check if the seal is broken 6 4 Screw bolts to specified torque 6 5 Fill fluid to system Full filling draining air 6 6 Draining air in system Power steering box diagnosis procedure 1 Check if any leakage around connector 2 Replace steering pivot if leak appears between following parts Wrest lever Input shaft 3 Replace pivot if leak appears on driver s side and is not affected by steering 4 Replace pivot if leak appears on top cover and spray fluid when steering turn to left end Replace transmission shaft if there are serious corrosion dots on the shaft Clear the shaft surface with cloth if the corrosion on seal area is tiny Replace the shaft if there still is leakage after clearing Suggestion to replace seal Following parts needs special seal Steering pivot Drive shaft of pump Go to following steps if one of above leaks appears 1 Check seal section 2 Clear seal section 3 Replace seal Power steering pump replace Points of attention Residual fluid will flow out into the container Disassembly procedure Steps of
9. essary Does customer still complain Steering system chatter noise NR Ensure power steering wear refer hydraulic Power steering system piping wear a piping replace Fixture steering box nut torque refer Steering box looseness oo fastener specifications Tie rod one end or both ends looseness Repair or replace tie rod end if necessary Repair or replace the universal joint refer if Steering universal joint looseness necessary Power steering box diagnosis Fizzy noise Some noise will be heard during steering in fixed place under conventional condition Check if any leakage for system Check if air in system Turn sharply needs too much force in short time Check if any leakage for inner pressure Check if the pressure in the pump is nor enough Check if the fluid level is too low Power steering box and steering pump leak Following symptoms show the leakage in system Obvious fluid leak on steering pivot or pump Loud noise is heard during park brake or cooling engine Lost power steering when park brake Heavy steering Check procedure Go on following steps when check outside leak in system 1 Wipe doubt section 2 Check if too much fluid in the tank 3 Check if following situations appear in system Air mixed in fluid Over flow 4 Check following parts Hose connector O ring 5 Confirm leaking position with following methods 5 1 Turn off engine 5 2 Wipe whole system 5 3 Che
10. ght line The free play of the steering wheel in the circumferential direction should be no larger than 0 30mm In the case that the free play goes beyond the specified value the following items should be checked to see if the joint of the steering horizontal lever is worn out when a torque of over Q 2N m is applied the joint should be moved if the lower ball knuckle is worn out if the steering shaft universal coupling is worn out if the steering small gears or gear rack 1s worn out or damaged and if the fixture or joining of the parts is loose Control institute Steering wheel Removal Remove the battery jumper wires remove the steering wheel label cover assembly remove the steering shaft screw nut To facilitate positioning in the installation matching signs are to be made on the steering wheel and the steering shaft then remove the steering wheel with the special purpose remover Removal of the steering column assembly 1 Remove the wire bundle of the steering wheel cover and horn switch 2 Remove the fastening screw nuts the steering wheel 3 Remove the combination switch assembly 4 Remove the joining bolt for the steering column and steering power tilt 5 Remove the four fastening screws for the steering column Inspection I The steering shaft and universal coupling check to see if the steering shaft is bent or if the spine is damaged check to see if there are any cracks on the universal coupling
11. gine 14 Fill fluid into tank 15 Check if any leak in tank 16 Drain out air of system AnNRWN Power steering box replace Disassembly procedure 1 Remove 3 bolts first 3 Remove bolts on left right transverse lever 6 Push lower end of node to side of steering pivot to disconnect up end with steering pillar
12. o 22 5 27 5 Nm Screw steering wheel and shaft bolts to 27 33Nm 10 Check forwards position for steering mechanics Description and operation Description Steering wheel and steering column Steering component can realize the functions besides of steering 1 Steering column Steering can absorb energy When crashing happens the pillar will shrink to reduce the probability to hurt driver 2 Ignition switch and steering lock Ignition switch and steering lock can prevent stealing vehicle 3 Multi purpose operation lever Multi purpose operation lever can control following parts High beam of head lamp Windshield wiper and cleaner Remove and re install steering pillar Use specified bolts to fix the pillar to make sure absorb engine action Be careful to remove or transport the pillar 1 The drawer to remove steering wheel is not recommended one 2 The top of pillar is knock badly 3 Something leans against the pillar 4 The pillar falls off Power steering system Exterior identify Power steering box 1 Steering tie rod socket unit 2 Fixed ring 3 Dust cap 4 Lock 5 Check nut 6 Tie rod ripple cowl hoop 7 Ripple cowl 8 Steering box shell ripple cowl clamp 9 Lock nut 10 Tie rod in band ball 11 Limiting stopper 12 Circlet 13 Facing ring 14 Searing ring 15 Bearing 16 Nut 17 Cover cap 18 Lock nut 19 Dust cap 20 Circlet 21 Tie
13. teering pivot upwards and push the pivot into gap of wheel 2 Insert pivot into front surround 3 Screw the nuts between the support and front surround not tighten Fixture Fixture Install pivot on front surround with Screw steering gimbal assembly with 70 80Nm 22 5 27 5Nm Insert two ends of lever and screw with steering node Description and operation Use new nuts with 32 38Nm Instruction for steering system 4 Put the pivot forwards The turning of steering will produce 5 Install steering gimbal assembly following actions 1 The motion of steering will transfer to small gear 2 The motion of small gear will transfer to gear 3 The teeth of small gear will be joggled with rack 4 Rack will move under the force 5 The force will transfer from transverse lever to steering node 6 Steering knuckle turn wheel Steering wheel and steering column Common problem and treatment measure Lock system incapable open lock Check this part Lock core possible be damage If need to replace part refer switch lock core replacing a ae If need to replace part refer The ignition Ignition switch is wear out or damage Monee switch lock core replacing Lock system cannot lock u Check unit 66 The ignition 66 Following parts possible be damage If need to replace part refer switch lock core replacing The ignition On close and locking position cannot pull out key Demand adjust Lock core
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