INSPECTION AND VERIFICATION
- Verify the customer concern.
- Visually inspect for obvious signs of damage and system integrity. Visual Inspection Mechanical Electrical Tire condition/pressure Fluid level Leaks Security, condition and correct installation of suspension components Security, condition and correct installation of steering system components Fuses Harnesses for damage/corrosion Electrical connector(s) Damaged/corroded pins CAUTION: If a steering gear assembly is returned under warranty with leaking output shaft seals, but there is also damage to the steering gear boot/boots the steering gear warranty will be invalid. This is due to the steering gear output shaft seals being damaged due to foreign materials entering the steering gear boot and damaging the steering gear output shaft seals thereafter.
- If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
- If the concern is not visually evident, verify the symptom and refer to the symptom chart.
SYMPTOM CHARTS
| WARNING | It is not possible to CHECK the torque of a patchlock bolt, if the torque is suspected to be low, the bolt must be REMOVED/DISCARDED and a new bolt MUST be INSTALLED and torque to the correct value. |
Note. If the module or a component is suspect and the vehicle remains under manufacturer warranty, refer to the Warranty Policy and Procedures manual (section B1.2), or determine if any prior approval programme is in operation, prior to the installation of a new module/component.
Steering Linkage Inspection and Backlash (Free play) Check
| CAUTION | Steering gear boots must be handled carefully to avoid damage. Use new clamps when installing steering gear boots. |
Inspect the boots for cuts, deterioration, twisting or distortion. Check the steering gear boots to make sure they are tight. Install new boots or clamps as required.
Note. The following steps must be carried out with assistance.
- With the wheels in the straight ahead position, gently turn the steering wheel to the left and the right to check for free play.
- Free play should be between 0 and 6 mm (0 and 0.24 in) at the steering wheel rim. If the free play exceeds this limit, either the ball joints are worn, the lower steering column joints are worn or the backlash of the steering gear is excessive. CAUTION: DO NOT attempt to adjust the steering gear yoke. Failure to follow this instruction will invalidate the steering gear warranty.
- The backlash of the steering gear cannot be adjusted, install a new steering gear if excessive backlash is diagnosed.
- Grasp the steering wheel firmly and move it up and down and to the left and right without turning the wheel to check for column bearing wear, steering wheel or steering column.
Power Steering Pressure Test
Test Equipment
| Item | Part Number | Description |
|---|---|---|
| 1 | 211-011 | Pressure Gauge Hose |
| 2 | 211-011-08 | Pump Return Hose |
| 3 | 211-011-07 | Pump Return Hose Connector |
| 4 | 211-011-03/2 | Test Equipment to High Pressure Hose Adaptor |
| 5 | 211-011-03/1 | Pump High Pressure Outlet to Hose Adaptor |
| 6 | 211-011-02 | Pump Adaptor to Control Valve Hose |
| 7 | 211-011-01 | Control Valve |
| 8 | 211-011 | Pressure Gauge |
| 9 | 'O' Ring Seal |
The measurement of the maximum system pressure, (which is governed by the pressure relief valve) is achieved by inserting the Service Tool (pressure gauge and adaptors) into the fluid circuit of the power steering system. Run the engine at idle speed, turn the steering from lock to lock and read the maximum pressure recorded on the gauge.
Installing Test Equipment
To install the pressure test equipment
- Place a suitable drain tray below the power steering pump.
- Install a hose clamp on the reservoir to pump hose prior to disconnecting any hoses, to avoid unnecessary loss of fluid.
- Disconnect the hose from the power steering pump high pressure outlet.
- Install the pump outlet to hose adaptor (5). Do not omit the 'O' ring seal (9).
- Connect the power steering pump adaptor to control valve hose (6) of the test equipment.
- Install the adaptor (4) in the high pressure hose previously removed from the power steering pump outlet.
- Connect the connector (3) of the test equipment hose (2) to the adaptor (4).
- Remove the hose clamp from the reservoir hose.
- Start the engine to check the system pressure.
With the control valve (7) OPEN and the engine idling, the following system pressures may be checked
- During turning when static (dry parking pressure).
- When the steering is held on full lock (maximum system pressure or pressure relief).
- With the steering at rest (idle pressure or back pressure).
| CAUTION | To avoid excessive heating of the power steering pump when checking the pressure, do not close the valve for more than 5 seconds maximum. |
| CAUTION | When checking the pump pressure DO NOT drive the vehicle with the test equipment installed. |
With the control valve (7) CLOSED the power steering pump maximum output pressure can be checked.
Removing Test Equipment
To remove the test equipment
- Install a hose clamp on the reservoir to power steering pump hose.
- Removing the test equipment is a reversal of the installation instructions.
- Install a new 'O' ring seal (9) to the power steering pump high pressure outlet to hose connection.
- Install the original hose to the power steering pump.
- Remove the clamp from the reservoir to the power steering pump hose.
- Top-up the reservoir fluid.
- Bleed the power steering system. Refer to: «Power Steering System Bleeding»(ref-568510-S13173244032013072200000) .