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Steering - Evolution: Diagnosis Mitsubishi Lancer IX

Manual & Power Steering 19 illustrations ~2816 words

POWER STEERING DIAGNOSIS TROUBLESHOOTING STRATEGY

Use these steps to plan you diagnostic strategy. If you follow them carefully, you will be sure that you have exhausted most of the possible ways to find a power steering fault.

  1. Gather information from the customer.
  2. Verify that the condition described by the customer exists.
  3. Find the malfunction by following the Symptom Chart.
  4. Verify malfunction is eliminated.

Scheme 12

Scheme 12: SYMPTOM CHART
Scheme 12: SYMPTOM CHART

Scheme 13

Scheme 13: DIAGNOSIS
Scheme 13: DIAGNOSIS
  1. STEP 1. Check for looseness at the steering shaft coupling section and at the steering wheel linkage. Q: Is there any looseness? YES: Repair or replace the part. Then go to Step 3 . NO: Go to Step 2.
  2. STEP 2. Check the steering wheel free play. With the engine running (hydraulic operation), set the front wheels straight ahead. Measure the play on the steering wheel circumference before the wheels start to move when slightly moving the steering wheel in both directions. Limit: 30 mm (1.2 inch) If the free play exceeds the limit value, set the steering wheel straight ahead with the engine stopped. Load approximately 5 N (1.1 pound) towards the steering circumference and check the play. Standard value (steering wheel play with engine stopped): 10 mm (0.4 inch) or less Q: Does the play exceed the standard value? YES: Remove the steering gear box (Refer to «POWER STEERING GEAR BOX AND LINKAGE»(ref-183225-S27455727542005081200000) ) and check the total pinion torque (Refer to «POWER STEERING GEAR BOX AND LINKAGE»(ref-183225-S27455727542005081200000) ). Then go to Step 3. NO: Go to Step 3.
  3. STEP 3. Check the steering wheel play. Verify that the steering wheel play is not excessive. Q: Is the steering wheel play excessive? YES: Repeat to Step 1. NO: The procedure is complete.

Scheme 14

Scheme 14: DIAGNOSIS
Scheme 14: DIAGNOSIS
  1. STEP 1. Check the power steering oil pump drive belt tension. Refer to «SPECIFICATIONS & DRIVE BELT ROUTING - EVOLUTION»(ref-166725) article. Q: Is the power steering oil pump drive belt tension within the standard value? YES: Go to Step 2. NO: Adjust the tension. (Refer to «SPECIFICATIONS & DRIVE BELT ROUTING - EVOLUTION»(ref-166725) article). Then go to Step 9 .
  2. STEP 2. Check the drive belt for damage. Q: Is the drive belt damaged? YES: Replace the drive belt. Then go to Step 9 . NO: Go to Step 3.
  3. STEP 3. Check the fluid level. Park the vehicle on a flat, level surface, and then start the engine. Turn the steering wheel several times to raise the temperature of the fluid to approximately 50 - 60°C (122 - 140°F). With the engine running, turn the wheel all the way to the left and right several times. Check the fluid in the oil reservoir for foaming or milkiness. Check the difference of the fluid level when the engine is stopped, and while it is running. Q: Is the check result OK? YES: Go to Step 4. NO: Bleed the air (Refer to «POWER STEERING SYSTEM AIR BLEEDING»(ref-183225-S28390124022005081200000) ). Then go to Step 9 .
  4. STEP 4. Check the each hose for crushing or twisting. Q: Is any hose crushed or twisted? YES: Repair or replace the hose. Then go to Step 9 . NO: Go to Step 5.
  5. STEP 5. Check for oil leaks. Q: Are there oil leaks? YES: Repair it. Then go to Step 9 . NO: Go to Step 6.
  6. STEP 6. Check the wheel alignment (camber and caster). Refer to «WHEEL ALIGNMENT»(ref-170069-S27323213642004122900000) . . Q: Is the alignment incorrect? YES: Repair it. Then go to Step 9 . NO: Go to Step 7.
  7. STEP 7. Check the gear box rack piston seal for damage. Q: Is there damage? YES: Replace it. Then go to Step 9 . NO: Go to Step 8.
  8. STEP 8. Check for excessive tie rod end ball joint breakaway torque. Refer to «STEERING ANGLE CHECK»(ref-183225-S17285395872005081200000) . Q: Is there fault? YES: Replace the part. Then go to Step 9. NO: Go to Step 9.
  9. STEP 9. Check the steering wheel operation. Verify that the steering wheel operation is not difficult. Q: Is the steering wheel operation difficult? YES: Repeat from Step 1 . NO: The procedure is complete.

DIAGNOSIS

  1. STEP 1. Check for proper oil pump and steering gear installation. Q: Is the oil pump and the steering gear installation correct? YES: Go to Step 2. NO: Repair it. Then go to Step 4 .
  2. STEP 2. Check for interference of other parts with the steering column and the power steering hoses. Q: Is there interference? YES: Correct the interference. Then go to Step 4 . NO: Go to Step 3.
  3. STEP 3. Check for noise from inside the oil pump or the steering gear. Q: Is there noise? YES: Replace the part. Then go to Step 4. NO: Go to Step 4.
  4. STEP 4. Check for rattling noise. Confirm that no noise is generated. Q: Is there noise? YES: Repeat from Step 1 . NO: The procedure is complete.

Scheme 15

Scheme 15: DIAGNOSIS
Scheme 15: DIAGNOSIS
  1. STEP 1. Check the fluid level. Park the vehicle on a flat, level surface, and then start the engine. Turn the steering wheel several times to raise the temperature of the fluid to approximately 50 - 60°C (122 - 140°F). With the engine running, turn the wheel all the way to the left and right several times. Check the fluid in the oil reservoir for foaming or milkiness. Check the difference of the fluid level when the engine is stopped, and while it is running. Q: Is the check result OK? YES: Go to Step 2. NO: Bleed the air (Refer to «POWER STEERING SYSTEM AIR BLEEDING»(ref-183225-S28390124022005081200000) ). Then go to Step 3 .
  2. STEP 2. Check for seizure in the oil pump. Q: Is there seizure? YES: Replace the part. Then go to Step 3. NO: Go to Step 3.
  3. STEP 3. Retest the system. Confirm that no noise is generated. Q: Is there noise? YES: Repeat from Step 1 . NO: The procedure is completed.
  1. STEP 1. Check the drive belt tension. Refer to «CHECKING DRIVE BELTS»(ref-166725-S27137156852004092800000) . Q: Is the drive belt tension incorrect? YES: Adjust the belt tension. (Refer to «ADJUSTING DRIVE BELTS»(ref-166725-S21891744272004092800000) ). Then go to Step 3 . NO: Go to Step 2.
  2. STEP 2. Check for seizure in the oil pump. Q: Is there seizure? YES: Replace the part. Then go to Step 3. NO: Go to Step 3.
  3. STEP 3. Retest the system. Confirm that no noise is generated. Q: Is there noise? YES: Repeat from Step 1 . NO: The procedure is complete.

Scheme 16

Scheme 16: DIAGNOSIS
Scheme 16: DIAGNOSIS
  1. STEP 1. Check the fluid level. Park the vehicle on a flat, level surface, and then start the engine. Turn the steering wheel several times to raise the temperature of the fluid to approximately 50 - 60°C (122 - 140°F). With the engine running, turn the wheel all the way to the left and right several times. Check the fluid in the oil reservoir for foaming or milkiness. Check the difference of the fluid level when the engine is stopped, and while it is running. Q: Is the check result OK? YES: Go to Step 2. NO: Bleed the air (Refer to «POWER STEERING SYSTEM AIR BLEEDING»(ref-183225-S28390124022005081200000) ). Then go to Step 4 .
  2. STEP 2. Check each hose for crushing or twisting. Q: Is any hose crushed or twisted? YES: Repair or replace the hose. Then go to Step 4 . NO: Go to Step 3.
  3. STEP 3. Check the steering gear for damage. Q: Is there damage? YES: Repair or replace the part. Then go to Step 4. NO: Go to Step 4.
  4. STEP 4. Retest the system. Confirm that no noise is generated. Q: Is there noise? YES: Repeat from Step 1. NO: The procedure is complete.
  1. STEP 1. Check the oil pump or oil pump bracket installation. Q: Is the oil pump or the oil pump bracket installation correct? YES: Go to Step 2. NO: Repair it. Then go to Step 3 .
  2. STEP 2. Check the oil pump for damage. NOTE: If a slight "beat noise" is produced by the oil pump when the steering wheel is turned fully and held in that position, this is not a malfunction. Q: Is there damage? YES: Replace the oil pump. Then go to Step 3. NO: Go to Step 3.
  3. STEP 3. Retest the system. Confirm that no noise is generated. Q: Is there noise? YES: Repeat from Step 1 . NO: The procedure is complete.

Scheme 17

Scheme 17: DIAGNOSIS
Scheme 17: DIAGNOSIS

Scheme 18

Scheme 18
Scheme 18

Scheme 19

Scheme 19
Scheme 19
  1. STEP 1. Check for interference of the wheel and the vehicle body. If interfering, adjust the steering angle. Place the front wheel on a turning radius gauge and measure the steering angle. Standard value: If the steering angle is not within the standard value, adjust the toe-in. Standard value: 0+/-2 mm (0+/-0.08 inch) Adjust the toe-in by undoing the clip and jam nut, and turning the left and right tie rod turnbuckles by the same amount (in opposite directions). NOTE: The toe will move out as the left turnbuckle is turned toward the front of the vehicle and the right turnbuckle is turned toward the rear of the vehicle. Q: Is the steering angle normal? YES: Go to Step 2. NO: Adjust the steering angle. Then go to Step 3 .
  2. STEP 2. Check the steering gear for damage. Q: Is there damage? YES: Repair or replace the part. Then go to Step 3. NO: Go to Step 3.
  3. STEP 3. Retest the system. Confirm that no noise is generated. Q: Is there noise? YES: Repeat from Step 1 . NO: The procedure is complete.

INSPECTION PROCEDURE 9: Vibration

Note. A slight vibration may be felt when the stationary steering effort is made due to the condition of the road surface. To check whether the vibration actually exists or not, test-drive the vehicle on a dry concrete or asphalt surface. A very slight amount of vibration is not a malfunction.

Scheme 20

Scheme 20: DIAGNOSIS
Scheme 20: DIAGNOSIS
  1. STEP 1. Check the fluid level. Park the vehicle on a flat, level surface, and then start the engine. Turn the steering wheel several times to raise the temperature of the fluid to approximately 50 - 60°C (122 - 140°F). With the engine running, turn the wheel all the way to the left and right several times. Check the fluid in the oil reservoir for foaming or milkiness. Check the difference of the fluid level when the engine is stopped, and while it is running. Q: Is the check result OK? YES: Go to Step 2. NO: Bleed the air (Refer to «POWER STEERING SYSTEM AIR BLEEDING»(ref-183225-S28390124022005081200000) ). Then go to Step 3 .
  2. STEP 2. Check the steering gear for damage. Q: Is there damage? YES: Repair or replace the part. Then go to Step 3. NO: Go to Step 3.
  3. STEP 3. Retest the system. Confirm that no vibration is generated. Q: Is there vibration? YES: Repeat from Step 1 . NO: The procedure is complete.
  1. STEP 1. Check for loosening of the pressure and return tube flare nut. Q: Is the flare nut loose? YES: Tighten it to 15+/-3 N.m (11+/-2ft-lb). Then go to Step 3 . NO: Go to Step 2.
  2. STEP 2. Check the hose connection and the clamp installation. Refer to «INSPECTION»(ref-183225-S19907636542005081200000) . Q: Are they correct? YES: Go to Step 3. NO: Repair or replace the part. Then go to Step 3.
  3. STEP 3. Retest the system. Check that no oil is leaking. Q: Is there oil leakage? YES: Repeat from Step 1 . NO: The procedure is complete.
  1. STEP 1. Check the hose for damage or clogging. Q: Is the hose damaged or clogged? YES: Repair or replace it. Then go to Step 2. NO: Go to Step 2.
  2. STEP 2. Retest the system. Check that no oil is leaking. Q: Is there oil leakage? YES: Repeat from Step 1 . NO: The procedure is complete.
  1. STEP 1. Check the oil reservoir for damage. Q: Is there damage? YES: Repair or replace it. Then go to Step 3 . NO: Go to Step 2.
  2. STEP 2. Check for overflowing. Q: Is there oil overflowing from the reservoir? YES: Adjust fluid level. Then go to Step 3. NO: Go to Step 3.
  3. STEP 3. Retest the system. Q: Is there oil leakage? YES: Repeat from Step 3 . NO: The procedure is complete.
  1. STEP 1. Check the oil pump body for damage. Q: Is there damage? YES: Replace the part. Then go to Step 3 . NO: Go to Step 2.
  2. STEP 2. Check the O-ring or oil seal for damage. Q: Is there damage? YES: Replace the part. Then go to Step 3. NO: Go to Step 3.
  3. STEP 3. Retest the system. Check that no oil is leaking. Q: Is there oil leakage? YES: Repeat from Step 1 . NO: The procedure is complete.
  1. STEP 1. Check the steering gear housing for damage. Q: Is there damage? YES: Replace the part. Then go to Step 3 . NO: Go to Step 2.
  2. STEP 2. Check the oil-ring or oil seal for damage. Q: Is there damage? YES: Replace the part. Then go to Step 3. NO: Go to Step 3.
  3. STEP 3. Retest the system. Check that no oil is leaking. Q: Is there oil leakage? YES: Repeat from Step 3 . NO: The procedure is complete.

Scheme 21

Scheme 21: SPECIAL TOOLS
Scheme 21: SPECIAL TOOLS

Scheme 22

Scheme 22
Scheme 22

Scheme 23

Scheme 23
Scheme 23

Scheme 24

Scheme 24: STEERING WHEEL FREE PLAY CHECK
Scheme 24: STEERING WHEEL FREE PLAY CHECK
  1. With the engine running (hydraulic operation), set the front wheels straight ahead.
  2. Measure the play on the steering wheel circumference before the wheels start to move when slightly moving the steering wheel in both directions. Limit: 30 mm (1.2 inch)
  3. When the play exceeds the limit, check for the play on the steering shaft and steering linkage connection. Correct or replace.
  4. If the free play still exceeds the limit value, set the steering wheel straight ahead with the engine stopped. Load 5 N (1.1 pound) towards the steering wheel circumference and check the play. Standard value (steering wheel play with the engine stopped): 10 mm (0.4 inch) or less
  5. If the play exceeds the standard value, remove the steering gear (Refer to «POWER STEERING GEAR BOX AND LINKAGE»(ref-183225-S27455727542005081200000) ) and check the total pinion torque (Refer to «POWER STEERING GEAR BOX AND LINKAGE»(ref-183225-S27455727542005081200000) ).

Scheme 25

Scheme 25: STEERING ANGLE CHECK
Scheme 25: STEERING ANGLE CHECK

Scheme 26

Scheme 26
Scheme 26

Scheme 27

Scheme 27
Scheme 27
  1. Place the front wheel on a turning radius gauge and measure the steering angle. Standard value
  2. If the steering angle is not within the standard value, adjust the toe-in as follows. Standard value: 0+/-2 mm (0+/-0.08 inch) Loosen the jam nut, and unclip the bellows. Adjust the toe-in by turning the left and right tie rod turnbuckles by the same amount (in opposite directions). NOTE: The toe will move out as the left turnbuckle is turned toward the front of the vehicle and the right turnbuckle is turned toward the rear of the vehicle. Tighten the jam nut to the specified torque, and tighten the bellows by the clip. Tightening torque: 52+/-2 N.m (38+/-2 ft-lb)
  3. Recheck the steering angle.

OIL PUMP PRESSURE TEST

Required Special Tools

  1. MB990662: Power Steering Oil Pressure Gauge
  2. MB991548: Power Steering Oil Pressure Gauge Adapter (Pump Side)
  3. MB991549: Power Steering Oil Pressure Gauge Adapter (Hose Side)

Scheme 28

Scheme 28
Scheme 28
  1. Disconnect the pressure hose from the oil pump, and then connect special tools MB991548, MB990662 and MB991549.
  2. Bleed air, then turn the steering wheel several times while the vehicle is not moving so that the temperature of the fluid rises to approximately 50 - 60°C (122 - 140°F).
  3. Start the engine and idle it at 1,000+/-100 r/min. CAUTION: The pressure gauge shut-off valve must not remain closed for more than 10 seconds.
  4. Fully close the shut-off valve of the pressure gauge and measure the oil pump relief pressure to confirm that it is within the standard value range. Open it again immediately after checking the pressure. Standard value: 8.4 - 9.0 MPa (1,219 - 1,306 psi)
  5. If it is not within the standard value, replace the oil pump.
  6. Check whether or not the hydraulic pressure is the standard value when no-load conditions are created by fully opening the shut-off valve of the pressure gauge. Standard value: 0.2 - 0.8 MPa (29 - 116 psi)
  7. If it is not within the standard value, the probable cause is a malfunction of the oil line or steering gear, so check these parts and repair as necessary.
  8. Turn the steering wheel all the way to the left or right; then check whether or not the retention hydraulic pressure is the standard value. Standard value: 8.4 - 9.0 MPa (1,219 - 1,306 psi)
  9. If not the standard value, overhaul the steering gear. Remeasure fluid pressure.
  10. Remove special tools MB991548, MB990662 and MB991549, and then the pressure tube flare nut to the specified torque. Tightening torque: 18+/-3 N.m (13+/-2 ft-lb)
  11. Bleed the system (Refer to «POWER STEERING SYSTEM AIR BLEEDING»(ref-183225-S28390124022005081200000) ).

INSPECTION

  1. Check the drive belt for cracks.
  2. Check the pulley for uneven rotation.

Scheme 29

Scheme 29: REMOVAL AND INSTALLATION
Scheme 29: REMOVAL AND INSTALLATION

Scheme 30

Scheme 30
Scheme 30

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