Electronic Power Steering System: Removal & Installation — Electronic Power Steering System — Electronic Steering

EPS Motor Removal and Installation

Note. Do not allow dust, dirt, or other foreign materials to enter the steering gearbox.

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Scheme 36: Removal

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Remove the steering gearbox (see «STEERING GEARBOX REMOVAL AND INSTALLATION»(ref-513192-S41212808702012110700000) ).
Remove the torque sensor 4P connector (A) from the connector bracket (B).
Remove the connector bracket mount bolt (A), then remove the EPS motor (B) and the O-ring (C).

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Scheme 38: Installation

Clean the mating surfaces of the EPS motor (A) and the steering gearbox.
Apply grease included in the motor set to the new O-ring (B), and carefully fit it on the EPS motor.
Apply steering grease to the EPS motor shaft (C).
Install the EPS motor on the steering gearbox by engaging the EPS motor shaft and the worm shaft (D).
Before tightening the bolts, turn the EPS motor two or three times to the right and left about 45 degrees. Make sure the EPS motor is evenly seated on the steering gearbox, and that the O-ring is not pinched between the mating surfaces.
Tighten the EPS motor mounting bolts (E) to the specified torque.
Install the torque sensor 4P connector to the connector bracket.
Install the steering gearbox (see «INSTALLATION»(ref-513192-S25397232202012110700000) ).

Steering Gearbox Removal and Installation

Special Tools Required

Ball Joint Thread Protector, 10 mm 07AAF-SECA120
Ball Joint Remover, 28 mm 07MAC-SL0A202
Ball Joint Thread Protector, 14 mm 071AF-S3VA000

Note these items during removal

Using solvent and a brush, wash any oil and dirt off the end of the steering gearbox, but avoid any electrical parts. Blow dry with compressed air.
Be sure to remove the steering wheel before disconnecting the steering joint or damage to the cable reel can occur.

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Scheme 39: Removal

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Do the 12 volt battery terminal disconnection procedure (see «USING THE GR8 BATTERY DIAGNOSTIC STATION»(ref-513168-S03188703672012110700000) ).
Raise and support the vehicle (see «LIFT AND SUPPORT POINTS»(ref-513149-S02552738632012110700000) ).
Remove the front wheels.
Tilt the steering column to the center position.
Remove the steering joint cover (A).
Hold the lower slide shaft (A) on the column with a piece of wire (B) between the joint yoke (C) of the lower slide shaft and joint yoke (D) of the upper shaft to prevent the lower slide from pulling out.
Remove the steering joint bolt (A) from the steering joint (B).
Center the steering wheel spokes, and install a commercially available steering wheel holder tool (A).
Disconnect the steering joint by moving the steering joint toward the column.
Remove the center guide (A) (if equipped) from the top of the pinion shaft (B), and discard it. The center guide is for factory assembly use only.
Remove the cotter pin (A) from the tie-rod end ball joint, then remove the nut (B) on both sides.
Disconnect the tie-rod end ball joint from the knuckle using the ball joint remover and the ball joint thread protector on both sides (see «BALL JOINT REMOVAL»(ref-513157-S03299087862012110700000) ).
Remove the lock pin (A) from the lower arm ball joint, and remove the castle nut (B) from both sides.
Disconnect the lower arm ball joint and the knuckle using the ball joint remover and the ball joint thread protector (see «BALL JOINT REMOVAL»(ref-513157-S03299087862012110700000) ) on both sides.
Remove the stabilizer link from the stabilizer bar (see «STABILIZER LINK REMOVAL/INSTALLATION»(ref-513180-S31760833192012110700000) ) on both sides.
Raise and supprot the vehicle (see «LIFT AND SUPPORT POINTS»(ref-513149-S02552738632012110700000) ).
Remove the splash shield (see «SPLASH SHIELD REPLACEMENT»(ref-513179-S41212899722012110700000) ).
Disconnect the EPS motor 2P connector (A), and torque sensor 4P connector (B) from the torque sensor. NOTE: Wrap the connectors with the vinyl tape to avoid contamination from grease or water.
Remove the secondary HO2S harness bracket (A) from the steering gearbox. NOTE: Do not disconnect the secondary HO2S 4P connector and the secondary HO2S.
Place a jack (A) under the engine oil pan.
Remove the torque rod (A). NOTE: Make sure the tab (B) on the bolt head aligned with the guide (C) on the front subframe.
Attach a transmission jack (A) to the middle of the front subframe (B), and support the front subframe securely by raising the transmission jack.
Remove the front subframe mounting bolts (C).
Lower the front subframe and the steering gearbox as an assembly by lowering the transmission jack slowly.
Remove the steering gearbox (A) from the front subframe (B).
Remove the pinion shaft grommet (A) from the top of the torque sensor.

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Scheme 53: Installation

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Install the pinion shaft grommet (A). Align the ledge portion (B) in the pinion shaft grommet with the lug portion (C) on the torque sensor 3P connector. The grommet must not have a gap at the mating surface of the grommet and torque sensor.
Place the steering gearbox (A) on the front subframe (B).
Loosely install the stiffener plates (C), and new gearbox mounting bolts, then tighten the bolts to the specified torque in the sequence shown.
Turn the lip (D) of the pinion shaft grommet to ease installation.
Set the front subframe (A) with the steering gearbox on the transmission jack, and support it.
Carefully raise the front subframe with the transmission jack, and pass the pinion shaft into the passenger's compartment. NOTE: Be sure that the pinion shaft grommet (B) is securely in place. Make sure the lip of the pinion shaft grommet is not turned up. Incorrect installation can cause leakage of water and mud, or noise. Take care not to damage the lower arm ball joint boot with the edge of the knuckle, etc.
Loosely install new front subframe mounting bolts, then tighten the bolts to the specified torque in the sequence shown.
Install the torque rod (A). NOTE: Be sure to install the torque rod with the "UP" mark facing up.
Install the bolt with the tab (B) on the bolt head aligned with the guide (C) on the front subframe, then tighten the new torque rod mounting bolt and nut in the numbered sequence shown.
Remove the jack (A).
Install the secondary HO2S harness bracket (A) on the steering gearbox.
Remove the vinyl tape from the connectors.
Connect the EPS motor 2P connector (A) and the torque sensor 4P connector (B) to the torque sensor.
Install the splash shield (see «SPLASH SHIELD REPLACEMENT»(ref-513179-S41212899722012110700000) ).
Install the stabilizer links to the stabilizer bar (see «STABILIZER LINK REMOVAL/INSTALLATION»(ref-513180-S31760833192012110700000) ).
Lower the vehicle.
Wipe off any grease contamination from the tapered section and threads of the tie-rod end ball joint. Connect the tie-rod and (A) to the knuckles. Install the nut (1), and tighten to the specified torque on both sides.
Install the new cotter pin (C), and bend it as shown on both sides.
Wipe off any grease contamination from the tapered section and threads of the ball joint. Connect the lower arm (A) to the knuckle. Install a new castle nut (B) and tighten it to the specified torque on both sides. NOTE: Be careful not to damage the lower ball joint boot (C). Check the ball joint boot for deformation before connecting the knuckle. Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the joint pin clip hole. Do not align the castle nut by loosening it.
Install the lock pin (D).
Install the front wheels, then set the wheels in the straight ahead position. NOTE: Before installing the wheel, clean the mating surfaces between the brake disc and the inside of the wheel.
Cut the wire (A).
Slip the lower end of the steering joint (B) onto the pinion shaft (C) taking care to align the gap (D) within the angle shown.
Remove the steering wheel holder tool.
Align the bolt hole (A) on the steering joint with the groove (B) around the pinion shaft, then loosely install the lower steering joint bolt (C). Be sure that the joint bolt is securely in the groove in the pinion shaft.
Pull on the steering joint to make sure that the steering joint is fully seated, then tighten the lower joint bolt to the specified torque.
Install the steering joint cover (A). NOTE: Check the steering joint cover for damage and cracks. If the steering joint cover is cracked, replace the steering joint cover.
With the tires raised off the ground, check for the following symptoms by turning the steering wheel fully to the right and left several times. Symptom Probable cause Rubbing sound coming from the lower steering column area. Steering column joint is contacting the cover. Grating sound from the lower steering column area, or a rough feeling during steering. Poor engagement of the pinion shaft serrations. Noise from around the steering wheel during steering. Poor engagement of the SRS cable reel with the steering wheel, or a damaged cable reel.
Do the 12 volt battery terminal reconnection procedure (see «USING THE GR8 BATTERY DIAGNOSTIC STATION»(ref-513168-S03188703672012110700000) ).
Do the memorizing of the torque sensor neutral position (see «MEMORIZING THE TORQUE SENSOR NEUTRAL POSITION»(ref-513192-S40795125382012110700000) ).
After installation, check these items: Start the engine, allow it to idle, and turn the steering wheel from lock to lock several times. Check that the EPS indicator does not come on. Check the steering wheel spoke angle. If steering spoke angles to the right and left are not equal (steering wheel and rack are not centered), correct the engagement of the joint/pinion shaft serrations, then adjust the front toe by turning the tie-rod ends, if necessary.
Check the wheel alignment, and adjust it if necessary (see «WHEEL ALIGNMENT»(ref-513157-S15229307132012110700000) ).

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Scheme 65: Rack End Removal and Installation

Removal

Note. Do not allow dust, dirt, or other foreign materials to enter the steering gearbox.

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Scheme 66: Removal

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Remove the steering gearbox (see «STEERING GEARBOX REMOVAL AND INSTALLATION»(ref-513192-S41212808702012110700000) ).
Remove the heat shield (A).
Remove the tie-rod ends and the locknut from the rack end.
Remove the boot band (A), and discard them. Remove the tie-rod clip (B), and pull the boot (C) away from the end of the steering gearbox.
Hold the gearbox housing using a C-clamp (A) and wooden blocks (B) to a work bench as shown. Do not clamp the cylinder part of the gearbox housing in a vise.
Unbend the lock washer (A).
Hold the flat surface sections (A) of the steering rack (B) with one wrench, and unscrew both rack end (C) with another wrench. Be careful not to damage the rack shaft surface with the wrench.
Remove the lock washer (D) and the rubber stop (E).

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Scheme 71: Installation

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Hold the gearbox housing using a C-clamp (A) and wooden blocks (B) to a workbench as shown. Do not clamp the cylinder part of the gearbox housing in the vise.
Install a new rubber stop (A) and a new lock washer (B). Align the lock washer tabs (C) with the slots (D) on the rack end (E) while holding the lock washer in place. Repeat this step for the other side of the rack shaft.
Hold the flat surface sections of the steering rack with one wrench, and tighten both rack ends with another wrench. Be careful not to damage the rack surface with the wrench.
Bend the new lock washer (A) back against the flat spots (B) on the rack end joint housing.
Apply multipurpose grease to the circumference of the rack end joint housing (A).
Apply a light coat of silicone grease to the boot grooves (B) on the rack end. NOTE: Make sure not to get any silicone grease on the terminal part of the connectors and switches, especially if you have silicone grease on your hands or gloves.
Center the steering rack within its stroke.
Clean off any grease or contamination from the boot installation grooves (A) around on the gearbox housing. Install the boots (B) on the rack ends with the tie-rod clips (C), and fit the boot end in the installation grooves in the housing properly.
After installing the boots, wipe the grease off the threaded section (D) of the rack end.
Install the new boot bands by aligning the tabs (A) with the holes (B) of the band.
Close the ear portion (A) of the boot band (B) with commercially available boot band pliers, Oetiker 1098 or equivalent (C).
Slide the rack shaft right and left to be certain that the boots are not deformed or twisted.
Install the tie-rod end and the locknut to the rack end.
Install the heat shield (A), then tighten the bolts to the specified torque.
Install the steering gearbox (see «INSTALLATION»(ref-513192-S25397232202012110700000) ).

Rack Guide Removal/Installation