Steering System - Power Ford Crown Victoria I

DESCRIPTION & OPERATION

Electronic Variable Orifice (EVO) system is designed to regulate power steering effort according to vehicle speed and steering wheel rotation rate. System provides full assist at low vehicle speed for light parking effort, and minimum assist at high vehicle speed for improved handling and road feel. Full power steering assist returns during evasive maneuvers.

During periods of system malfunction, system will provide full power steering assist at all times. Diagnostic codes are accessible through service diagnostic connector. EVO system consists of speed and steering sensors, control module, actuator and interconnecting wiring. (Scheme 1)

Steering wheel rotation sensor and Vehicle Speed Sensor (VSS) feed information to EVO control module, which electronically regulates EVO actuator valve assembly on power steering pump. Steering wheel rotation sensor is an optical or photo-cell sensor located at lower end of steering column. Sensor mounts on steering column and establishes rate of steering wheel rotation. Sensor and sensor ring are removed separately.

VSS is mounted on transmission and sends electrical signals to control module. Current produced by sensor increases and decreases linearly, according to vehicle speed. Current is constant at 80 MPH or faster. EVO actuator assembly generates a differential pressure, according to flow and current input, to control spool valve in power steering pump. EVO is inside actuator valve. EVO control module contains a microprocessor, which analyzes input signals from VSS and steering wheel rotation sensor. On models with air suspension, EVO module and air suspension module are integrated.

TROUBLE SHOOTING

Refer to TROUBLE SHOOTING - BASIC PROCEDURES article in the GENERAL TROUBLE SHOOTING section.

CAPACITY

Fluid capacity is approximately 1.6 pts. (.75L).

FLUID TYPE

Use synthetic Mercon ATF (ESR-M2C163-A2).

FLUID LEVEL CHECK

Check fluid level every 7500 miles. If vehicle is driven less than 12,000 miles a year, check fluid every 3000 miles. Clean dirt and grease from filler cap area to avoid fluid contamination. Check fluid level with engine off and fluid at operating temperature. Maintain fluid at MAX level in reservoir. DO NOT overfill.

Scheme 1

HYDRAULIC SYSTEM BLEEDING

Note. Abnormal noise originating from power steering system may be caused by air trapped in system.

1. Raise front wheels off ground and support vehicle. Start engine. Turn steering wheel from side to side several times. Avoid holding wheel in full left or right position. Fluid level should remain visible.
2. Return wheels to center position. Operate engine for 2-3 minutes. Lower and road test vehicle. Recheck fluid level. Fluid containing air will have a milky appearance. All air should be eliminated to obtain normal steering. If air in system cannot be eliminated by performing steps 1) and 2), go to next step.
3. Check and fill reservoir to MAX mark. Disconnect and ground ignition coil lead. Raise and support front of vehicle. Crank engine while turning steering wheel. DO NOT hold wheel on stops. Add fluid if necessary. Attach coil lead. Install Rotunda Vacuum Tester (021-00014) to power steering pump reservoir. Start engine. NOTE: DO NOT use engine as vacuum source to purge air from power steering system.
4. Apply 20-25 in. Hg vacuum to reservoir for approximately 3 minutes with engine idling. As air is purged from system, vacuum will decrease. Maintain sufficient vacuum until fluid level stabilizes. Release vacuum. Check fluid level and fill as necessary.
5. Start engine. Turn steering wheel from stop to stop while checking for air in system. If condition is severe, repeat procedure until all air is removed. Lower and road test vehicle.

ADJUSTMENTS

Serpentine Belt

On vehicles with serpentine belts, belt tension is adjusted automatically.

Checking Belt Tension

Automatic belt tensioner has belt wear indicator marks located on top of tensioner housing. If tension indicator mark is not between wear indicator marks, belt is worn or incorrect belt is installed. When accessory drive belt is replaced or reinstalled after service procedure, belt may not sit properly in pulley grooves until engine runs for several minutes. On used belt reinstallation, recheck belt wear indicator marks after engine has been run for at least 5 minutes.

SECTOR SHAFT MESH LOAD

1. Deactivate driver's side air bag system. To deactivate air bag system, disconnect and shield negative battery cable. Disconnect positive battery cable. To avoid accidental air bag deployment, wait one minute before proceeding, allowing back-up power supply to deplete. Remove nuts securing air bag module. Install Rotunda Air Bag Simulator (105-00010) to harness at top of steering wheel.
2. Mark pitman arm-to-sector shaft relation for installation reference. Disconnect pitman arm from sector shaft. Disconnect fluid return line at power steering reservoir and cap reservoir line. Place steering gear return line in clean container. Rotate steering wheel stop to stop several times to discharge fluid from steering gear.
3. If vehicle is equipped with tilt steering wheel, place wheel in center tilt position. Turn steering wheel to within 45 degrees of left stop. Using an INCH-lb. torque wrench on steering wheel nut, measure rotational drag required to turn gear about 1/4 turn from 45-degree position. Record reading.
4. Turn steering wheel to center position and measure torque required to rotate sector shaft back and forth across center position. Reading should be 8-12 INCH lbs. (.9-1.4 N.m) on vehicles with less than 5000 miles.
5. On vehicles with more than 5000 miles, reading should be 5-9 INCH lbs. (.6-1.0 N.m) greater than torque reading obtained when turning away from position 45 degrees from left stop.
6. If adjustment is necessary, loosen adjuster lock nut. (Scheme 2)Turn adjuster screw to adjust sector shaft mesh load. Tighten adjuster lock nut. Recheck rotational turning torque. Reconnect return line. Add fluid and reconnect pitman arm. Tighten pitman arm retaining nut to specification. See «TORQUE SPECIFICATIONS»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power__torque-specifications).
7. Reactivate driver's side air bag. To reactivate air bag system, disconnect and shield negative battery terminal. Disconnect positive battery terminal. To avoid accidental air bag deployment, wait one minute before proceeding, allowing back-up power supply to deplete. Disconnect air bag simulator. Reconnect air bag connector. Install air bag module on steering wheel. Connect battery terminal. Turn ignition to ON position. Air bag indicator light should illuminate for about six seconds, then go out. Wait one minute. If light does not illuminate again or warning tone does not sound, air bag system is functional.

Scheme 2

REMOVAL & INSTALLATION

Note. DO NOT weld, heat or bend steering linkage to repair or straighten components. When installing NEW cotter pins, tighten nut to lower specified torque, then tighten nut to next slot that aligns with stud hole. DO NOT hammer on ball studs. Ensure threads are clean and lubricated before tightening.

Removal

1. Disconnect EVO wiring harness connector from EVO actuator valve assembly. Remove power steering pump. See «POWER STEERING PUMP R & I»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power) under REMOVAL & INSTALLATION.
2. Place pump in vise. Using 6-mm Allen wrench, remove EVO actuator valve assembly. (Scheme 3)

Installation

1. Install EVO actuator valve assembly into power steering pump. Tighten to specification. See «TORQUE SPECIFICATIONS»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power__torque-specifications) .
2. To complete installation, reverse removal procedure. Refill and bleed hydraulic system. See «HYDRAULIC SYSTEM BLEEDING»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power__hydraulic-system-bleeding) under LUBRICATION.

Scheme 3

Remove 2 screws and electrical connector to remove sensor. To replace sensor ring, steering column and shaft must be removed. See STEERING COLUMN article.

Raise and support vehicle. Remove VSS retaining bolt. Remove VSS and driven gear from transmission. Disconnect electrical connector. Remove drive gear retainer and drive gear from VSS. To install, reverse removal procedure. Ensure NEW "O" ring is properly seated in VSS housing.

1. Raise and support vehicle. Remove cotter pins and castle nuts. Using Tie Rod End Remover (T00L-3290-D), separate inner tie rod ends, idler arm and pitman arm from center link. Remove center link from vehicle.
2. To install, reverse removal procedure. Ensure idler arm stud seal is in place. Lower vehicle and adjust toe-in. See «WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES»(/ford/crown-victoria/i-1992-1997/remont/wheel-alignment/#wheel-alignment-specifications-procedures) article in the WHEEL ALIGNMENT section. Tighten tie rod end clamp nuts to specification. See «TORQUE SPECIFICATIONS»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power__torque-specifications) .

1. Raise and support vehicle. Check idler arm by applying a vertical force of 25 lbs. (11 kg) at center link end of idler arm. Replace idler arm when vertical lash exceeds .13" (3.3 mm).
2. Using Tie Rod End Remover (T00L-3290-D), separate center link from idler arm. Remove 2 idler arm mounting bolts. If idler arm support is disconnected from frame for other work, support idler arm with wire to prevent rotation (if equipped with threaded type bushing). To install, reverse removal procedure.

1. Raise and support vehicle. Mark pitman arm-to-steering shaft for installation reference. Remove center link ball joint stud cotter pin and nut.
2. Using Tie Rod End Remover (T00L-3290-D), separate center link from pitman arm. DO NOT hammer on end of puller. Remove pitman arm retaining nut. Using Pitman Arm Puller (T64P-3590-F), separate pitman arm from steering gear. To install, reverse removal procedure.

Drain power steering pump reservoir by disconnecting fluid return line at reservoir. DO NOT reuse fluid. Disconnect pressure hose at pump. DO NOT remove fitting from pump. Plug hoses to prevent contamination. Remove mounting bolts and pump. To install, reverse removal procedure. Check belt tension. Refill and bleed pump. See HYDRAULIC SYSTEM BLEEDING under LUBRICATION.

POWER STEERING PUMP PULLEY

Remove power steering pump. See POWER STEERING PUMP R & I . Install Pulley Remover (T69L-10300-B) on pulley hub. Remove pulley. Install power steering pump pulley using Pulley Installer (T65P-3A733-C). Install pulley flush with shaft.

Disconnect inlet and return hoses. Drain reservoir. Remove 2 retaining nuts and remove reservoir tank. To install, reverse removal procedure.

1. Remove stone shield. Disconnect hydraulic lines from steering gear and mark for installation reference. Plug lines and ports to prevent contamination.
2. Remove flexible coupling bolts. Raise and support vehicle. Remove sector shaft nut. Mark pitman arm and sector shaft for installation reference (if necessary). Using Puller (T64P-3590-F), remove pitman arm.
3. Support steering gear and remove gear attaching bolts. Remove flexible coupling clamp bolts. Separate steering gear from coupling and remove from vehicle.

1. Turn steering wheel to straight-ahead position. Center steering gear input shaft with centerline of flats facing 4 o'clock. Slide steering gear input shaft into flex coupling and into place on frame side rail. Install and tighten attaching bolts.
2. Ensure wheels are in straight-ahead position and install pitman arm, lock washer and nut on sector shaft. Tighten nut to specification. See «TORQUE SPECIFICATIONS»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power__torque-specifications) . Move flex coupling into place on steering gear input shaft and install attaching bolt.
3. Install and tighten pressure and return lines to steering gear. Fill reservoir and bleed system. See «HYDRAULIC SYSTEM BLEEDING»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power__hydraulic-system-bleeding) under LUBRICATION. Reinstall stone shield.

Raise and support vehicle. Loosen adjusting sleeve clamp bolts. Remove castle nuts and cotter pins from tie rod ends. Using Tie Rod End Remover (T00L-3290-D), remove tie rod ends from steering knuckles. Unscrew tie rod ends from adjusting sleeves, noting number of turns necessary for installation reference.

1. Apply penetrating oil to clamps, tie rod threads and adjusting sleeves. Wipe threads clean. Lubricate threads with chassis lube. Install adjusting sleeve clamps. Thread tie rod ends same number of turns required during removal.
2. Ensure both ends are equal distance (within 3 threads) into sleeve. Install castle nuts, using NEW cotter pins. Properly position adjusting sleeve clamps. Lower vehicle and adjust toe-in. See «WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES»(/ford/crown-victoria/i-1992-1997/remont/wheel-alignment/#wheel-alignment-specifications-procedures) article in the WHEEL ALIGNMENT section. Tighten tie rod end clamp nuts to specification. See «TORQUE SPECIFICATIONS»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power__torque-specifications) .

POWER STEERING PUMP

Manufacturer does not recommended disassembly and repair. EVO actuator is only component of pump assembly separately serviced. Should further service be required, replace pump assembly.

Scheme 4

1. Drain steering gear and mount in holding fixture. Remove lock nut and washer from adjusting screw. Turn input shaft to either stop. Turn input shaft back 1 5/8 turns to center gear. Centerline of flats on pinion spline should face 4 o'clock position.
2. Remove sector shaft cover bolts. Tap lower end of sector shaft with a soft hammer. Lift cover and shaft from housing as an assembly. Discard "O" ring.
3. Turn sector shaft cover counterclockwise to remove cover from adjusting screw. Remove valve housing attaching bolts and identification tag. Lift control valve housing from steering gear housing, while holding piston to prevent it from rotating off worm shaft.
4. Remove and discard control valve housing-to-gear "O" rings. Hold piston and ball bearing nut assembly so ball bearing guides face upward. Remove ball guide clamp screws and clamp.
5. Place finger over opening in ball bearing guide, and turn piston and ball bearing nut so ball bearing guide is over a clean container. Allow guide tubes to drop into container. Rotate input shaft from stop to stop until at least 27 balls fall into container.
6. Remove valve assembly from piston. Ensure all ball bearings have been removed. Install valve assembly in holding fixture. Loosen Allen head set screw at control valve housing.
7. Using Adjuster/Lock Nut Wrench (T66P-3553-B) and Spacer Valve Housing-to-Piston Holder (T66P-3553-C), remove worm bearing race lock nut. (Scheme 4) Carefully slide pinion shaft, worm and valve assembly out of valve housing. Slightest cocking of spool may cause it to jam in housing and damage sleeve.
8. Remove snap ring from lower end of housing. Using Adapter (T58L-101-A) and Impact Slide Hammer (T59L-100-B), remove and discard dust seal. Remove and discard pressure seal in same manner.
9. Using adapter and impact slide hammer, remove and discard dust seal from rear of valve housing. Carefully insert Bearing Remover/Installer (T65P-3524-A2) in valve body assembly opposite oil seal. Gently tap bearing and seal out of housing, and discard seal.
10. If valve bore is damaged, remove inlet and outlet tube seats with Brass Tube Remover (T74P-3504-L). Remove Teflon rings only if scratched or worn. Insert a knife blade under rings and cut them off. Avoid scratching valve sleeve. Remove plastic ring and "O" ring from piston and ball bearing nut.

Scheme 5

1. Install Mandrel (T75L-3517-A1) over rotary valve sleeve. Slide one Teflon ring over mandrel. Slide Pusher (T75L-3517-A2) over mandrel. Rapidly push down on pusher, forcing Teflon ring down ramp and into fourth groove of rotary valve sleeve.
2. Repeat procedure 3 more times, adding Spacer (T75L-3517-A3) under mandrel each time. After installing 4 Teflon rings, apply gear lubricant to rotary valve sleeve and Teflon rings. Install one spacer over input shaft as a pilot for installing sizing tube.
3. Slowly install Sizing Tube (T75L-3517-A4) over rotary valve sleeve valve end of worm shaft onto Teflon rings. Ensure rings are NOT bent. Sizing tube must be able to slide over rings. Remove sizing tube and check condition of Teflon rings. Teflon rings must turn freely in grooves.
4. Coat new tube seats with petroleum jelly. Install new tube seats using Brass Tube Installer (T74P-3504-M). Coat bearing and seal surface of housing with petroleum jelly. Position bearing in control valve housing. Press bearing with metal-covered side facing outward. Ensure bearing rotates freely.
5. Dip NEW oil seal in gear lube. Place seal in housing, metal side out. Drive seal into housing until outer edge does not quite clear snap ring groove. Place snap ring in housing. Drive snap ring in until seated in groove.
6. With rubber side out, drive dust seal in position behind groove in input shaft. Lubricate seals and sector shaft bore. Place dust seal on Shaft Seal Installer (T77L-3576-A) so raised lip of seal is toward tool.
7. Slide pressure seal on tool with flat of pressure seal against flat of dust seal. Carefully insert seals into sector shaft bore with tool until they clear snap ring groove. DO NOT bottom seals against bearing. Install snap ring.
8. Dip NEW "O" ring in gear lubricant. Install "O" ring on piston and ball nut. Install a NEW plastic ring on piston and ball nut. DO NOT stretch plastic ring any more than necessary. Mount valve housing in holding fixture (flanged end up).
9. Lubricate valve sleeve rings. Install worm and valve in gear housing. Using Adjuster/Lock Nut Wrench (T66P-3553-B) and Spacer Valve Housing-to-Piston Holder (T66P-3553-C), install and tighten race nut to specification. See «TORQUE SPECIFICATIONS»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power__torque-specifications). (Scheme 4)
10. Install Allen head set screw through control valve housing. Tighten set screw to specification. See «TORQUE SPECIFICATIONS»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power__torque-specifications). Place piston on bench, with ball bearing guide holes facing up. Insert worm shaft so first groove is aligned with hole nearest center of piston.
11. Place ball guide in piston. While turning worm shaft clockwise, as viewed from input end of shaft, place at least 27 ball bearings in ball bearing guide. (Scheme 5) If all ball bearings have not been fed into guide upon reaching right stop, rotate input shaft back and forth while installing remaining ball bearings. NOTE: After installing all ball bearings, DO NOT rotate input shaft more than 3 turns from right stop, or ball bearings will fall out.
12. Secure guides in ball bearing nut with clamp and tighten screws to specification. See «TORQUE SPECIFICATIONS»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power__torque-specifications). (Scheme 5) Apply petroleum jelly to seal on piston. Place NEW "O" ring on valve housing. Slide piston and valve into gear housing. Align oil passage in valve housing with passage in gear housing.
13. Position NEW "O" ring in gear housing oil passage. Install, but do not tighten, identification tag and attaching bolts. Rotate ball nut so teeth are parallel with sector teeth. Tighten valve housing bolts to specification. Install sector shaft cover "O" ring in gear housing. Turn input shaft to center piston.
14. Apply petroleum jelly to sector shaft journal. Position sector shaft and cover assembly in gear housing. Rotate input shaft one turn on either side of center. Install and tighten cover bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power__torque-specifications). Adjust sector shaft. See «SECTOR SHAFT MESH LOAD»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power__sector-shaft-mesh-load) under ADJUSTMENTS.

TESTING

Note. Before testing, check fluid level, belt tension, pump pulley, tire pressure and engine idle speed.

Minimum Flow Test

1. Connect Power Steering System Analyzer (014-00207) between pressure line and pump, with gauge between pump and tester valve. Add power steering fluid if needed. Start engine and allow to idle for approximately 2 minutes with idle set to specification. Record flow, gallons/minute (liters/minute).
2. If flow is less than 1.5 gallons/minute (5.7 liters/minute), power steering pump may require service, but continue diagnosis. If pressure is above 150 psi (10.5 kg/cm 2 ) at idle, check hoses for restrictions.
3. Partially close gate valve on tester to build up pressure to 740 psi (52.0 kg/cm 2 ). Observe and record flow. If flow is below minimum specification, service power steering pump. See «POWER STEERING PUMP FLOW TEST SPECIFICATIONS»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power) table. Proceed to «RELIEF PRESSURE TEST»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power__relief-pressure-test) .

Relief Pressure Test

1. With Power Steering Analyzer still connected, completely close and partially open gate valve 3 times. DO NOT allow valve to remain closed for more than 5 seconds.
2. Observe and record pressure. If pressure is not within relief pressure specification, replace power steering pump assembly. See «POWER STEERING PUMP PRESSURE TEST SPECIFICATIONS»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power) .
3. Increase idle to approximately 1500 RPM. Observe and record flow. If flow is greater than maximum flow specification, replace pump assembly. See «POWER STEERING PUMP FLOW TEST SPECIFICATIONS»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power) .
4. Return engine to idle speed. Have an assistant turn steering wheel to left and right stop. Record pressure and flow at both stops. Pressure developed at both stops should be approximately equal to maximum pressure recorded when closing gate valve.
5. Flow should now drop below .5 gallon/minute (1.9 liters/minute). If pressure is less than specified or flow is greater than specified, excessive internal leakage is indicated. Remove and overhaul power steering gear.
6. Have an assistant turn steering wheel slightly in both directions and then release quickly. Observe pressure gauge. Pressure should start climbing from minimum flow pressure and snap back to minimum when steering wheel is released.
7. If pressure drops slowly or sticks, steering gear is sticking or steering column is binding. Check column prior to steering gear replacement. Also check steering linkage and ball joints; repair or replace as necessary. Remove analyzer and reconnect pressure line.

POWER STEERING PUMP PRESSURE TEST SPECIFICATIONS

POWER STEERING PUMP FLOW TEST SPECIFICATIONS

STEERING WHEEL TURNING EFFORT CHECK

1. Ensure front wheels are properly aligned and tire pressure is correct before performing procedure. Park vehicle on dry concrete and set parking brake. Allow engine to idle 2-3 minutes to warm power steering fluid to operating temperature.
2. With engine running, attach a pull gauge to rim of steering wheel, and measure pull required to turn steering wheel one revolution in each direction from center. Steering wheel static turning effort should be approximately 7.5 lbs. (3.4 kg).

EVO SYSTEM TESTING (WITHOUT AIR SUSPENSION)

Use EVO System Tester (105-00007) to activate system diagnostics. EVO diagnostic connector is located trunk, behind right quarter panel. Jumper test wire must be fabricated to connect EVO control module test connectors to EVO system tester. (Scheme 6) See PINPOINT TEST A.

Scheme 6

EVO SYSTEM TESTING (WITH AIR SUSPENSION)

1. Use SUPER STAR II Tester (007-0041A) to activate system diagnostics. Air suspension/EVO diagnostic connector is located behind right quarter panel. To enter diagnostics, turn ignition off.
2. Connect SUPER STAR II Tester to diagnostic connector with button released. Turn ignition on. Turn air suspension off, then on. Wait 2 seconds. Depress and latch activation button on SUPER STAR II Tester.
3. Code 10 followed by Code 12 or 13 should be displayed. Open and close all four doors and turn steering wheel. Release SUPER STAR II tester button, wait at least 2 seconds, and depress button. SUPER STAR II tester will display Code 11 if system is okay, or trouble code(s) if problem is found. Turn ignition off to exit testing. See «PINPOINT TEST B»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power__pinpoint-test-b-service-bay-diagnostics) through F.

VARIABLE ASSIST TROUBLE CODES

PINPOINT TESTS

PINPOINT TEST DIRECTORY

Note. In following diagnostic tests, illustrations are provided courtesy of Ford Motor Co.

Scheme 7

1. Check Connections Verify EVO actuator valve (on power steering pump) and EVO harness connectors (in trunk) are firmly seated. If connectors are not firmly seated, make proper connections and go to next step. If connections are seated properly, go to next step.
2. Control Module Check Turn ignition off. Locate diagnostic connector (in trunk). Connect EVO system tester to jumper wire and to connector in upper glove compartment. Start engine. Test light will illuminate for one second. If light illuminates for one second, go to next step. If test light flickers or does not illuminate, go to step 32).
3. Actuator Output Circuit Check If Code 6 flashes once and does not repeat, circuit is okay. Go to next step. If Code 6 repeats after 2 second delay, go to step 8).
4. Steering Wheel Sensor Test Start engine. Turn steering wheel lock to lock. Steering wheel must be rotated in one direction at least 220 degrees. If test light illuminates, go to next step. If test light does not illuminate, go to step 20).
5. VSS Check Drive vehicle at least 15 MPH on straight road. Do not turn steering wheel, if possible. If test light remains illuminated for all speeds above 15 MPH, go to next step. If test light turns off at any speed above 15 MPH, go to step 28).
6. VSS Check Reduce vehicle speed to less than 10 MPH. If test light turns off, go to next step. If test light remains illuminated, go to step 28).
7. Service Power Steering Perform pump flow and pressure tests, and repair or replace (as required). See «HYDRAULIC SYSTEM PRESSURE & FLOW TEST»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power) under TESTING. Repair power steering components as required.
8. Code 6 Activated: EVO Actuator Valve Check Check for short to ground or open circuit. Ensure EVO wiring harness connectors are properly seated. Verify EVO actuator and harness are undamaged. Repair damaged components as necessary. If connections are not seated, make proper connections and go to step 2). If connections are properly seated, go to next step.
9. Actuator Valve Circuit Resistance Check Verify ignition is off. Locate and disconnect harness connectors at EVO control module. Using an ohmmeter, measure resistance between pins No. 13 and 14 of harness connector. Resistance should be 7-18 ohms. (Scheme 7) If resistance is greater than 1000 ohms, circuit is open. Go to «PINPOINT TEST B»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power__pinpoint-test-b-service-bay-diagnostics), step 3. If resistance is less than 7 ohms, go to next step. If resistance is greater than 18 ohms, but less than 1000 ohms, go to step 11). (Scheme 7): Identifying EVO Control Module Connector Pins
10. Wiring Continuity Check Verify ignition is off. Disconnect actuator valve connector, located on power steering pump. Test continuity between valve connector and module connector. If continuity does not exist, repair wiring or connector (as required) and go to step 1). If continuity exists on BOTH circuits, go to next step.
11. Actuator Valve Resistance Check Disconnect EVO harness connector at actuator valve. Using an ohmmeter, measure resistance between valve pins. If resistance is 5-20 ohms, go to next step. If resistance is not 5-20 ohms, replace actuator valve. NOTE: Always check for pin damage on components before replacement.
12. Wiring Harness Short To Ground Check Verify ignition is off. Disconnect EVO control module harness connector from module. Go to next step.
13. Wiring Harness Short To Ground Check (Greater Than 1000 Ohms) Using an ohmmeter, measure resistance at control module connector between pins No. 5 and 13. If resistance is greater than 1000 ohms, go to step 15). If resistance is less than 1000 ohms, go to next step.
14. Wiring Harness Short To Ground Check (Less Than 10 Ohms) Using an ohmmeter, measure resistance at control module connector between pins No. 5 and 13. If resistance is less than 10 ohms, service harness and go to next step. If resistance is greater than 10 ohms, next step.
15. Resistance Check (Pin No. 14 Less Than 10 Ohms) Using an ohmmeter, measure resistance at control module connector between pins No. 5 and 14. If resistance is less than 10 ohms, service harness. If resistance is greater than 10 ohms, go to next step.
16. Resistance Check (Pin No. 14 Greater Than 1000 Ohms) Using an ohmmeter, measure resistance at control module connector between pins No. 5 and 14. If resistance is greater than 1000 ohms, go to next step. If resistance is less than 1000 ohms, go to step 18).
17. Harness Short To Battery Positive Check Turn ignition on. With EVO actuator valve assembly connector disconnected, measure voltage at control module connector between pins No. 5 and 13 and pins No. 5 and 14. If voltage is greater than 5 volts, repair wiring and go to step 1). If voltage is less than 5 volts, go to next step.
18. Short Circuit Check (Circuits No. 330 & 353 Less Than 10 Ohms) Turn ignition off. Verify EVO harness connector is disconnected at actuator valve. Using an ohmmeter, measure resistance at control module connector between pins No. 13 and 14. If resistance is less than 10 ohms, repair harness and go to step 1). If resistance is greater than 10 ohms, go to next step.
19. Short Circuit Check (Circuits No. 330 & 353 Greater Than 1000 Ohms) Turn ignition off. Verify EVO harness connector is disconnected at actuator valve. Using an ohmmeter, measure resistance at control module connector between pins No. 13 and 14. If resistance is less than 1000 ohms, go to step 1). If resistance is greater than 1000 ohms, replace EVO control module. NOTE: Always check for pin damage on components before replacement.
20. Steering Wheel Rotation Sensor Connector Check Verify steering wheel rotation sensor connector, at base of steering column, is properly seated. If connector is properly seated, go to next step. If connector is NOT properly seated, make proper connection and go to step 1).
21. Steering Wheel Rotation Sensor Check Turn ignition off. Disconnect EVO control module harness connector. Examine wiring harness for damage. Verify following wires correspond to these pin numbers: Red/Yellow wire (circuit No. 834) in pin No. 1 Red/White wire (circuit No. 835) in pin No. 6 Yellow/Black wire (circuit No. 837) in pin No. 12 If damaged or crossed wires are found, repair harness and go to step 1). If wires are okay, go to next step.
22. Steering Wheel Rotation Sensor Signal Check With control module connector disconnected, start engine. Using an analog ohmmeter set to 1-k/ohm scale, measure resistance between pins No. 1 and 5 and pins No. 5 and 6 while slowly rotating steering wheel. If meter needle swings for both circuits, steering wheel rotation sensor is functional. Replace EVO control module and re-test system. If meter does NOT swing for both circuits, go to next step. NOTE: Resistance values will vary between ohmmeters. Needle on all meters should swing from a lower to higher resistance and back, approximately every 9 degrees of steering wheel rotation.
23. Steering Wheel Rotation Sensor Wire Check Turn ignition off. Disconnect EVO control module connector at module. Disconnect connector at steering sensor. Inspect and repair connectors as necessary. Test continuity of circuits No. 834 (Red/Yellow wire), No. 835 (Red/White wire) and No. 837 (Yellow/Black wire) between sensor connector and module connector. If no continuity exists on ANY circuit, repair harness. If continuity exists on ALL circuits, go to next step.
24. Short Circuit Check Turn ignition off. Disconnect steering wheel rotation sensor. Disconnect EVO control module 14-pin connector. Measure resistance between following pins in EVO harness: Pins No. 1 and 6 Pins No. 1 and 12 Pins No. 6 and 12 If resistance is greater than 1000 ohms, go to step 26). If resistance is less than 10 ohms, go to next step.
25. Short Circuit Check Turn ignition off. Disconnect steering wheel rotation sensor. Disconnect EVO control module 14-pin connector. Measure resistance between following pins in EVO harness: Pins No. 1 and 6 Pins No. 1 and 12 Pins No. 6 and 12 If resistance is less than 10 ohms, service wire(s) as necessary and go to step 1). If resistance is greater than 10 ohms, go to next step.
26. Testing Steering Wheel Rotation Sensor Power Turn ignition on. Using a voltmeter, measure voltage between pins No. 5 and 12. If voltage is zero, circuit is open or shorted. Repair harness and go to step 1). If battery voltage is indicated, go to next step.
27. Testing Steering Wheel Rotation Sensor Power Circuit Verify ignition is on. Using a voltmeter, measure voltage between circuits No. 298 and 837 at steering sensor connector. If battery voltage is indicated, replace steering sensor. If battery voltage is not indicated, replace EVO control module. NOTE: Always check for pin damage on components before replacement.
28. VSS Connector Check Verify VSS connector is properly seated. If connector is properly seated, go to next step. If connector is NOT properly seated, make proper connection and go to step 1).
29. VSS Check Turn ignition off. Disconnect EVO control module 14-pin harness connector. Examine wiring harness for damage. Verify following circuits correspond to these pin numbers: Gray/Black wire (circuit No. 679) in pin No. 9 Gray/Red wire (circuit No. 359) in pin No. 8 If damaged or crossed wires are found, repair harness and go to step 1). If wires are okay, go to next step.
30. Testing VSS Ground Circuit Test continuity of VSS ground circuit No. 359. Check continuity between pins No. 5 and 8 of 14-pin EVO harness connector. If circuit is open, repair harness or ground eyelet (as necessary), and go to step 1). If continuity is present, go to next step.
31. Testing VSS Raise vehicle on a lift. Start engine. Verify speedometer operation. If speedometer works properly, replace EVO control module. If speedometer reads zero at all times, go to step 1). NOTE: Always check for pin damage on components before replacement.
32. Test Light Check Connect EVO diagnostic light or EVO system tester in another vehicle to ensure tester is functional. Check bulb condition. If test and bulb are good, go to next step. If tester or bulb are faulty, replace as necessary. Go to step 2).
33. EVO Control Module Check Ensure ignition is off. Connect EVO system test light to connector in trunk. Start engine. If test light comes on, go to step 3). If test light does not illuminate, go to next step.
34. EVO Control Module Check Ensure ignition is off. Connect EVO system test light to connector in trunk. Start engine. If test light does not flicker, go to next step. If test light flickers, replace EVO control module.
35. EVO Control Module Check Verify ignition is off. Ensure 14-pin connector is firmly connected to module located in trunk. If connections are firmly secured, go to next step. If connections are not firmly secured, go to step 2). NOTE: Always check for pin damage on components before replacement.
36. Power Feed Check Ensure ignition is off. Disconnect 14-pin connector from EVO module in trunk. Turn ignition on. Using voltmeter, measure voltage between pins No. 5 and 7. If battery voltage is indicated, replace EVO control module. If no voltage is indicated, check for open circuit or short circuit in circuit No. 298 (Purple/Orange wire). Repair as necessary. Go to step 1).

PINPOINT TEST B: SERVICE BAY DIAGNOSTICS

1. Entering Auto Test See «SUSPENSION - REAR ELECTRONIC AIR»(/ford/crown-victoria/i-1992-1997/remont/electronic-suspension/#suspension-rear-electronic-air) article in SUSPENSION. After entering auto test, go to next step.
2. Determining Required Test (Diagnostic Trouble Codes DTC 16, 17 & 18) Read and record displayed Diagnostic Trouble Codes (DTCs). Each code must be serviced individually. If DTC 16, 17 or 18 is displayed, go to «PINPOINT TEST C»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power__pinpoint-test-c-evo-wiring) , step 1). If DTC 16, 17 or 18 is not displayed, go to next step.
3. Determining Required Test (DTC 74) Read and record displayed Diagnostic Trouble Codes (DTCs). Each code must be serviced individually. If DTC 74 is displayed, go to «PINPOINT TEST D»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power__pinpoint-test-d-steering-sensor-diagnostics) , step 1). If DTC 74 is not displayed, go to next step.
4. Determining Required Test (Code 55) Read and record displayed DTCs. Each code must be serviced individually. If DTC 55 is displayed, go to «PINPOINT TEST E»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power__pinpoint-test-e-vehicle-speed-sensor) , step 1). If DTC 55 is not displayed, go to next step.
5. Determining Required Test (DTC 11) Read and record displayed DTC. Each code must be serviced individually. If DTC 11 is displayed, refer to «HYDRAULIC SYSTEM PRESSURE & FLOW TEST»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power) under TESTING. If DTC 11 is not displayed, go to next step.
6. Determining Required Test (All Other DTCs) Read and record displayed DTC. Each code must be serviced individually. If DTCs other than 11, 16, 17, 18, 55 and 74 are displayed, refer to «SUSPENSION - REAR ELECTRONIC AIR»(/ford/crown-victoria/i-1992-1997/remont/electronic-suspension/#suspension-rear-electronic-air) article in the SUSPENSION section. If DTCs 11, 16, 17, 18, 55 and/or 74 are not displayed, go to PINPOINT TEST C, step 1).

PINPOINT TEST C: EVO WIRING

1. Actuator Valve Check (Short Or Open Circuit) Turn ignition off. Verify all harness connectors are firmly seated. If connectors are not firmly seated, make proper connections and go to «PINPOINT TEST B»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power__pinpoint-test-b-service-bay-diagnostics) , step 1). If connections are seated properly, go to next step.
2. DTC 16 Actuator Valve Check (Short Or Open Circuit) Turn ignition off. Retrieve and record all DTCs. If DTC 16 is displayed, go to step 7). If DTC 16 is not displayed, go to next step.
3. DTC 17 Actuator Valve Check (Short Or Open Circuit) Turn ignition off. Retrieve and record all DTCs. If DTC 17 is displayed, go to step 5). If DTC 17 is not displayed, go to next step.
4. DTC 18 Actuator Valve Check (Short Or Open Circuit) Turn ignition off. Retrieve and record all DTCs. If DTC 18 is displayed, go to step 6). If DTC 18 is not displayed, go to next step.
5. Actuator Valve Resistance Check Turn ignition off. Disconnect EVO control module connectors (located in trunk). Using an ohmmeter, measure resistance between connector pins No. 14 and 26. Resistance greater than 1000 ohms indicates an open circuit. Repair as necessary. If resistance is 7-18 ohms, go to next step. If resistance is not 7-18 ohms, go to step 7).
6. Continuity Check Turn ignition off. Unplug EVO actuator valve connector. Check continuity of circuit No. 330 (Yellow/Light Green wire) between actuator connector and EVO control module connector. Check continuity of circuit No. 353 (Light Blue wire) between actuator connector and EVO control module connector. If continuity exists in both circuits, go to next step. If no continuity exists in either or both circuits, repair harness as necessary. Go to step 1).
7. Actuator Valve Check Turn ignition off. Unplug EVO actuator valve connector. Measure resistance between EVO actuator valve connector. If resistance is 5-20 ohms, go to next step. If resistance is less than 5 ohms or greater than 20 ohms, replace EVO actuator valve. NOTE: Always check for pin damage on components before replacement.
8. EVO Actuator Valve Resistance Check Unplug EVO actuator valve harness connector. Using ohmmeter, measure resistance between EVO actuator valve pins. If resistance is greater than 20 ohms or less than 5 ohms, go to step 10). If resistance is 5-20 ohms, go to next step.
9. Wiring Harness Short Circuit Check Ensure ignition is off. Unplug EVO actuator valve harness connector. Unplug EVO control module harness connector. Go to next step.
10. Wiring Harness Short Circuit Check Using an ohmmeter, measure resistance between pins No. 14 and 21 on harness connector. If resistance is greater than 1000 ohms, go to step 12). If resistance is less than 1000 ohms, go to next step.
11. Wiring Harness Short Circuit Check Using an ohmmeter, measure resistance between pins No. 14 and 21 on harness connector. If resistance is greater than 10 ohms, go to step 14). If resistance is less than 10 ohms, repair harness.
12. Wiring Harness Short Circuit Check (Resistance Less Than 10 Ohms) Measure resistance between pins No. 21 (ground) and No. 26. If resistance is greater than 10 ohms, go to next step. If resistance is less than 10 ohms, harness is shorted to ground. Repair harness.
13. Wiring Harness Short Circuit Check (Resistance Greater Than 1000 Ohms) Measure resistance between pins No. 21 (ground) and No. 26. If resistance is greater than 1000 ohms, go to next step. If resistance is less than 1000 ohms, go to step 15).
14. Harness Short To Battery Positive Check Turn ignition on. Disconnect EVO actuator valve. Using a voltmeter, measure voltage at control module connector between pins No. 14 and 21, and between pins No. 21 and 26. If voltage is greater than 5 volts, repair short to battery voltage. Go to «PINPOINT TEST B»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power__pinpoint-test-b-service-bay-diagnostics) , step 1). If voltage is less than 5 volts, go to next step.
15. Short Circuit Check (Resistance Less Than 10 Ohms) Turn ignition off. Verify EVO actuator valve is disconnected from harness. Using an ohmmeter, measure resistance at control module connector between pins No. 14 and 26 on harness connector. If resistance is greater than 10 ohms, go to next step. If resistance is less than 10 ohms, circuit is shorted. Repair harness as necessary. Go to «PINPOINT TEST B»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power__pinpoint-test-b-service-bay-diagnostics) , step 1).
16. Short Circuit Check (Resistance Greater Than 1000 Ohms) Turn ignition off. Verify EVO actuator valve is disconnected from harness. Using an ohmmeter, measure resistance at control module connector between pins No. 14 and 26 on harness connector. If resistance is greater than 1000 ohms, replace EVO control module. If resistance is less than 1000 ohms, go to «PINPOINT TEST F»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power__pinpoint-test-f-evo-control-module) , step 1).

PINPOINT TEST D: STEERING SENSOR DIAGNOSTICS

1. Steering Wheel Sensor Connection Check Ensure harness connection on steering wheel rotation sensor, located on lower portion of steering column, is properly seated. If connection is properly seated, go to next step. If connection is not seated properly, make proper connection and go to «PINPOINT TEST B»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power__pinpoint-test-b-service-bay-diagnostics) , step 1).
2. Steering Wheel Rotation Sensor Check Ensure ignition is off. Check harness for damage. Ensure pins in connectors are connected to proper circuits. See «CIRCUIT PIN IDENTIFICATION TABLE (STEERING WHEEL ROTATION SENSOR)»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power) . If harness is damaged, repair as necessary, then go to «PINPOINT TEST B»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power__pinpoint-test-b-service-bay-diagnostics) , step 1). If harness and circuits are okay, go to next step. CIRCUIT PIN IDENTIFICATION Application Pin No. Circuit No. 57 (1) 6 Circuit No. 834 18 Circuit No. 835 19 Circuit No. 837 (2) (1) Circuit No. 57 is ground circuit. (2) Circuit No. 837 connects with circuit 57.
3. Steering Wheel Rotation Sensor Signals Check Start engine. Using an analog ohmmeter set on 1K scale, measure resistance between pins No. 18 and 6 while rotating steering wheel. Measure resistance between pins No. 19 and 6 while rotating steering wheel. Needle should fluctuate approximately every 9 degrees of rotation. If needle fluctuation occurs for both circuits, shut engine off and replace EVO control module. If fluctuation does not occur for both circuits, go to next step.
4. Steering Wheel Rotation Sensor Wire Check Turn ignition off. Disconnect 26-pin connector from EVO control module in trunk. Unplug harness from steering wheel rotation sensor. Inspect for damage or improper connections. Repair as necessary. Test continuity of circuits No. 834 and 835 from steering wheel rotation sensor to EVO control module connector. Also check continuity between circuits No. 837 and 57.
5. Short Circuit Check (Resistance Greater Than 1000 Ohms) Turn ignition off. Unplug steering wheel rotation sensor and EVO control module connectors. Using an ohmmeter, measure resistance at steering sensor connector between pins No. 18 and 19. Measure resistance at steering sensor between pin No. 18 and 6. Measure resistance between pins No. 19 and 6 at EVO control module connector. If resistance is less than 1000 ohms, go to next step. If resistance is greater than 1000 ohms, go to step No. 7).
6. Short Circuit Check (Resistance Less Than 10 Ohms) Turn ignition off. Unplug steering wheel rotation sensor and EVO control module connectors. Using an ohmmeter, measure resistance at steering sensor connector between pins No. 18 and 19. Measure resistance at steering sensor between pin No. 18 and 6. Measure resistance between pins No. 19 and 6 at EVO control module connector. If resistance is less than 10 ohms, repair harness as necessary and go to «PINPOINT TEST B»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power__pinpoint-test-b-service-bay-diagnostics) , step 1). If resistance is greater than 10 ohms, go to next step.
7. Steering Sensor Power Circuit Check Turn ignition on. Using voltmeter, measure voltage between circuits No. 298 and 837 at steering sensor connector.

PINPOINT TEST E: VEHICLE SPEED SENSOR (VSS)

1. VSS Connection Check Ensure VSS connector, located on transmission, is properly seated. If connector is not seated properly, repair as necessary and go to «PINPOINT TEST B»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power__pinpoint-test-b-service-bay-diagnostics) , step 1). If connector is properly seated, go to next step.
2. VSS Check Turn ignition off. Disconnect EVO connectors. Check for harness damage. Ensure pins in connectors are connected to proper circuits. See «CIRCUIT PIN IDENTIFICATION TABLE (VEHICLE SPEED SENSOR)»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power) . If damage is found, repair as necessary and go to «PINPOINT TEST B»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power__pinpoint-test-b-service-bay-diagnostics) , step 1). If no damage is found, go to next step. CIRCUIT PIN IDENTIFICATION Application (Wire Color) Pin No. Circuit No. 359 (Gray/Red) 20 Circuit No. 679 (Gray/Black) 7
3. VSS Ground Circuit Check Using an ohmmeter, check continuity of circuit No. 875 (ground) between pins No. 6 and 20 on 26-pin connector at EVO control module. If no continuity exists, service wire or ground connection as necessary and go to «PINPOINT TEST B»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power__pinpoint-test-b-service-bay-diagnostics) , step 1). If continuity exists, go to next step. NOTE: Always check for pin damage on components before replacement.
4. VSS Check Ensure VSS connections are properly seated. Road test vehicle. Verify speedometer operation. If speedometer is inoperative or erratic, replace VSS. If speedometer functions, replace EVO control module.

PINPOINT TEST F: EVO CONTROL MODULE

1. EVO Control Module Check Turn ignition on. Ensure connections at EVO control module and air suspension switch are properly seated. Ensure air suspension switch is turned on. If connections are faulty or air suspension switch is off, repair connection and turn switch on. Go to «PINPOINT TEST B»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power__pinpoint-test-b-service-bay-diagnostics) , step 1). If connections are okay and switch is on, go to next step.
2. Power Feed Check Turn ignition off. Disconnect 26-pin connector from EVO control module. Turn ignition on. Using a voltmeter, measure voltage between pins No. 6 and 16, and between pins No. 1 and 6. If no voltage exists, repair harness as necessary. Go to «PINPOINT TEST B»(/ford/crown-victoria/i-1992-1997/remont/manual-power-steering/#steering-system-power__pinpoint-test-b-service-bay-diagnostics) , step 1). If battery voltage exists, replace EVO control module.

WHEEL ALIGNMENT

After performing appropriate service procedures, refer to WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article in the WHEEL ALIGNMENT section.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

EVO System Wiring Diagram (With Air Suspension). Scheme 8

EVO System Wiring Diagram (Without Air Suspension). Scheme 9

See also:
• TROUBLE SHOOTING - BASIC PROCEDURES
• COMPUTER RELEARN PROCEDURES
• STEERING COLUMN
• WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES
• SUSPENSION - REAR ELECTRONIC AIR
• TORQUE SPECIFICATIONS
• POWER STEERING PUMP R & I
• HYDRAULIC SYSTEM BLEEDING
• SECTOR SHAFT MESH LOAD
• RELIEF PRESSURE TEST
• PINPOINT TEST B
• PINPOINT TEST C
• PINPOINT TEST D
• PINPOINT TEST E
• PINPOINT TEST F