Service Manual2005 POWER STEERING GEAR

SECTION 6C

POWER STEERING GEAR

Caution : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

SPECIFICATIONS

General Specifications

Application			Description
Capacity			1.0 Liter (1.06 qt)
Lubricant			Power Steering Fluid DEXRON®-II or III
Type			Rack&Pinion
Rack Gain			47.88 mm/rev
Rack Stoke			146±1.0mm
Steering Angle	Inner		40°
Steering Angle	Outer		32°
Rack	Straigat(Beding Limit)		0.1mm
Greese	Option	Rack Gear	Multi-purpose Greese SAE J310a
Greese	Option	.	Ball Joint	Multi-purpose Greese SAE J310a

Fastener Tightening Specifications

Application	N•m	Lb-Ft	Lb-In
Adjuster Plug .	7 (minus 30°- 40°)	- .	62 (minus 30°- 40°)
Adjuster Plug Locknut	75	56	-
Control Module Bracket Bolts	7	-	62
Dash Seal Retaining Ring Nuts	7	-	62
Hydraulic Cylinder Line Fittings - Cylinder End	28	21	-
Hydraulic Cylinder Line Fittings - Valve End	18	13	-
Inner Tie Rods	100	74	-
Intermediate Shaft Pinch Bolts - Upper and Lower	25	18	-
Maximum Pinion Preload	1	-	9
Outer Tie Rod Adjusting Nut	64	47	-
Outer Tie Rod Nuts	50	37	-
Pinion Locknut	30	22	-
Steering Gear Inlet and Outlet Pipe Fittings	28	21	-
Steering Gear Mounting Bracket Nuts and Bolts	60	44	-
Transaxle Center Bracket-to-Engine Bolt	80	59	-
Transaxle Center Bracket-to-Transaxle Bolts	80	59	-
SSPS Control Module Bolts	9	-	80

SPECIAL TOOLS

Special Tools Table

	KM-507-B Ball Joint Remover
	KM-J-26610 Installer

J-42459

Rack Guide Spring

Cap Wrench

DIAGNOSIS

Power Rack and Pinion Steering Gear

Hissing Noise

Checks	Action
Check the intermediate shaft joints for looseness.	Tighten the intermediate shaft joints.
Check the power steering hose for contact with other components.	Be sure the power steering hose is correctly fitted into the hose clips.

Rattling Noise in Steering Gear

Checks	Action
Check the power steering hose for contact with the body.	Be sure the power steering hose is correctly fitted into the hose clips.
Check the steering gear for insufficient lubrication.	Lubricate the steering gear.
Check the steering gear mounting for improper installation.	Tighten the steering gear mounting bracket nuts and bolts.
Check the outer tie rods for improper installation.	Tighten the outer tie rod joints. Replace the outer tie rods.

Poor Return of Steering Wheel to Center

Checks	Action
Check the steering wheel for contact with the turn signal housing.	Adjust the turn signal housing.
Check the intermediate shaft joints for binding or looseness.	Replace the intermediate shaft.
Check the power steering pump flow control valve for sticking and improper alignment.	Replace the power steering pump.
Check the wheel alignment.	Align the wheels.
Check the wheel bearings for wear or damage.	Replace the wheel bearings.
Check the intermediate shaft joints for improper installation.	Adjust the intermediate shaft between the steering gear and the steering column. Replace the intermediate shaft.
Check the outer tie rods and the ball joints for binding or looseness.	Tighten the tie rods and the ball joints. Replace the tie rods and the ball joints.
Check the steering gear adjustments.	Perform a straight-ahead check.
Check the steering column shaft seal for rubbing on the shaft.	Replace the dash seal.
Check the steering shaft bearings for binding.	Replace the stub shaft bearings.

Momentary Increase in Effort When Turning the Wheel Quickly

Checks	Action
Check the power steering pump for internal leaks.	Replace the power steering pump.
Check the hoses for damage or restricted flow.	Replace the power steering hoses and/or pipes.
Check the power steering fluid level.	Fill the power steering fluid reservoir.
Check the power steering pump flow control valve for sticking and improper operation.	Replace the power steering pump.

Steering Surges or Jerks When Turning with Engine Running

Checks	Action
Check the power steering pump for insufficient pressure.	Replace the power steering pump.
Check the power steering pump flow control valve for sticking and improper operation.	Replace the power steering pump.
Check the power steering pump serpentine belt for slippage.	Tighten the power steering serpentine belt.
Check for air contamination in the power steering system.	Bleed the power steering system.

Steering Vibrates During Low Speed or Static Steering

Checks	Action
Check for air contamination in the power steering system.	Bleed the power steering system.
Check the power steering pump serpentine belt for looseness.	Tighten the power steering serpentine belt.

Excessive Wheel Kickback or Loose Steering

Checks	Action
Check for air contamination in the power steering system.	Bleed the power steering system.
Check the wheel bearings for wear or damage.	Replace the wheel bearings.
Check the steering gear mounting for improper installation.	Tighten the steering gear mounting bracket nuts and bolts.
Check the intermediate shaft joints for improper installation.	Adjust the intermediate shaft between the steering gear and the steering column. Replace the intermediate shaft.
Check the outer tie rods and the ball joints for looseness.	Tighten the tie rods and the ball joints. Replace the tie rods and the ball joints.

Hard Steering or Lack of Assist (Especially During Parking)

Checks	Action
Check the intermediate shaft joints for improper installation.	Adjust the intermediate shaft between the steering gear and the steering column. Replace the coupling flange.
Check the power steering pump flow control valve for sticking and improper installation.	Replace the power steering pump.
Check the power steering pump for insufficient pressure.	Replace the power steering pump.
Check the power steering pump for internal leaks.	Replace the power steering pump.
Check for a loose or a worn intermediate shaft.	Tighten the intermediate shaft. Replace the intermediate shaft, as needed.
Check the power steering pump serpentine belt tension.	Tighten the power steering serpentine belt.

Power Rack and Pinion steering Gear Bench Testing

Removal, Setup and Testing Procedure

Notice : Pressure checks or pressure and flow checks may also be conducted using this setup.

Disconnect and remove the power steering gear. Refer to "Rack and Pinion Assembly" in this section.
Place the power steering gear on a bench next to the vehicle.
Disconnect the pressure line at the point where the hose connects to the pipe. Extend this line to reach the power steering gear on the bench.
Disconnect the return line from the the power steering fluid reservoir. Extend this line to reach the power steering gear on the bench.
Connect the power steering pipes to the power steering gear.
Start the engine and allow it to idle for 10 seconds.
Check the power steering fluid level. Refer to Section 6A, Power Steering System.
Start the engine and turn the rack and pinion stub shaft a full turn in each direction. Hold the shaft against each stop for 5 seconds.
Inspect for possible leak points. Refer to Section 6A, Power Steering System.

Installation Procedure

Stop the engine.
Disconnect the power steering pipes from the power steering gear.
Remove the extensions and reconnect the pressure and return lines.
Install and connect the power steering gear. Refer to "Rack and Pinion Assembly" in this section.
Start the engine and allow it to idle for 10 seconds.
Check the power steering fluid level. Refer to Section 6A, Power Steering System.

Speed Sensitive Power Steering System

Speed Sensitive Power Steering System Operating With Full Assist at All Times

Step	Action	Value(s)	Yes	No
1	Perform an initial inspection of the power steering system. Is the system operational?	-	Go to Step 2	Go to Section 6A, Power Steering System
2	Check the speedometer. Is the speedometer inoperative?	-	Go to Section 5A, ZF4HP16 Automatic Transaxle	Go to Step 3
3	Check the diagnostic trouble codes (DTCs) at the engine control module (ECM). Is ECM Code 24 set?	-	Go to Section 1F, Engine Controls	Go to Step 4
4	Turn the ignition ON. Disconnect the SSPS solenoid actuator electrical connector at the power steering gear. Probe terminal 1 of the SSPS actuator connector with a voltmeter. Is the voltage equal to the specified value?	≈ 3 v	Go to Step 6	Go to Step 5
5	Repair the open or short in the circuit between terminal 1 of the SSPS solenoid actuator electrical connector and terminal 2 on the speed sensitive power steering (SSPS) control module connector. Is the repair complete?	-	System OK	-
6	Remove the SSPS solenoid actuator from the power steering gear. Turn the actuator upside down to position the pintle. Stimulate the actuator by connecting it to the battery. Does the actuator click?	-	Go to Step 8	Go to Step 7
7	Replace the SSPS solenoid actuator. Is the repair complete?	-	System OK	-
8	Turn the ignition OFF. Remove the SSPS control module from the control module bracket. Disconnect the SSPS control module connector. Connect a test light from terminal 5 on the SSPS control module connector to ground. Turn the ignition ON. Is the test light on?	-	Go to Step 14	Go to Step 9
9	Check the ignition fuse. Is the ignition fuse open?	-	Go to Step 10	Go to Step 11
10	Replace the ignition fuse. Is the repair complete?	-	System OK	-
11	Check for an open or short in the circuit between terminal 5 of the control module connector and the I/P fuse block. Is the connection faulty?	-	Go to Step 12	Go to Step 13
12	Repair the open or short in the circuit between terminal 5 of the SSPS control module connector and the I/P fuse block. Is the repair complete?	-	System OK	-
13	Repair the power feed to ignition fuse F12. Is the repair complete?	-	System OK	-
14	Turn the ignition OFF. Connect a test light from terminal 8 of the SSPS control module connector to B+. Is the test light on?	-	Go to Step 16	Go to Step 15
15	Repair the open in the ground circuit between terminal 8 of the SSPS control module connector and G303. Is the repair complete?	-	System OK	-
16	Check for a short to B+ or an open in the circuit between terminal 1 of the SSPS control module connector and terminal 2 of the SSPS solenoid actuator connector. Is the connection faulty?	-	Go to Step 17	Go to Step 18
17	Repair the short to B+ or an open in the circuit between terminal 1 of the SSPS control module connector and terminal 2 of the SSPS solenoid actuator connector. Is the repair complete?	-	System OK	-
18	Replace the SSPS control module. Is the repair complete?	-	System OK	-

Speed Sensitive Power Steering System Operating With Decreased Assist at All Times

Step	Action	Value(s)	Yes	No
1	Check the speedometer. Is speedometer inoperative?	-	Go to Section 5A, ZF4HP16 Automatic Transaxle	Go to Step 2
2	Disconnect the SSPS solenoid actuator at the power steering gear. Is the symptom still present?	-	Go to Section 6A, Power Steering System	Go to Step 3
3	Replace the speed sensitive poser steering (SSPS) control module. Is repair complete?	-	System OK	-

General Operation

If IGN is turned ON, the warning lamp blinks three times for 3sec and then OFF.The SSPS control module has the self-diagnostic feature. If any malfunction occurs, the controller illuminates the warning lamp as well as shut off the current to the magnetic coil to result in heavy power steering effort for safety.Trouble codes are displayed and erased by the SCAN-100.

Trouble Code

DTC	Trouble	Default Action
C1104	Ignition Voltage Over	.
C1105	Ignition Voltage Low	.
C1212	Vehicle Speed Sensor	Warning lamp ON, Actuator OFF
C1604	ECU(EEPROM Error)	.
C2203	Testing Current	.

Diagnostic System Check – Variable Effort Steering

Test Description

The numbers below refer to the step numbers on the diagnostic table.

Lack of communication may be due to a partial malfunction of the serial data circuit or due to a total malfunction of the serial data circuit. The specified procedure will determine the particular condition.

Step	Action	Value(s)	Yes	No
1	Install a scan tool. Turn ON the ignition.	-	Go to Step 2	-
2	Select the ECM display DTC function on the scan tool. Does the scan tool display any DTCs?	-	Go to Diagnostic System Check – Engine Controls	Go to Step 3
3	Select the SSPS display DTC function on the scan tool. Does the scan tool display any DTCs	-	Go to Diagnostic Trouble Code(DTC) List	Go to Symptoms – Power Steering System

Diagnostic Trouble Code (DTC) C1104

Ignition Voltage Over

Circuit Description

The speed sensitive power steering (SSPS) module checks the system voltage to make sure that the voltage stays within the proper range. Damage to components, and incorrect input can occur when the voltage is out of range. The SSPS module monitors the system voltage over an extended length of time. If the SSPS module detects an excessively low system voltage, DTC C1104 will set.

Conditions for Running the DTC

The vehicle speed is above 8 km/h (5 mph).
The system voltage is between 9-16 volts.

Conditions for Setting the DTC

The SSPS control module detects a system voltage above 16 volts for less than 1 second.

Action Taken When the DTC Sets

The SSPS warning light will illuminate.
Power steering assist will default to partial steering assist.
The SSPS control module will store a DTC C1104 in memory.

Conditions for Clearing the DTC

The SSPS warning lamp will turn OFF when conditions for the fault are no longer present.
Use a scan tool in order to clear the DTC.

Diagnostic Aids

A poor connection at the SSPS control module. Inspect the harness connectors for backed out terminals, improper mating, improperly formed or damaged terminals, and poor terminal to wire connections.
A damaged wiring harness. Inspect the wiring harness for damages, if the wiring harness appears to be in good condition, observe the display on the DMM while moving the connectors and wiring harnesses related to the actuator. A change in the DMM display during the test will indicate the location of the fault.

DTC C1104 - Ignition Voltage Over

Step	Action	Value(s)	Yes	No
1	Did you perform the Variable Effort Steering Diagnostic System Check?	-	Go to Step 2	Go to Diagnostic System Check - Variable Effort Steering
2	Turn ON the ignition, with the engine OFF. Use a scan tool in order to clear the DTCs. Operate the vehicle within the Conditions for Running the DTCs. Did the DTC fail this ignition?	-	Go to Step 3	System OK
3	Replace the power steering control module. Is the repair complete?	-	Go to Step 4	-
4	Operate the system in order to verify the repair. Did you correct the condition?	-	System OK	Go to Step 2

Diagnostic Trouble Code (DTC) C1105

Ignition Voltage Over

Circuit Description

Conditions for Running the DTC

The vehicle speed is above 8 km/h (5 mph).
The system voltage is between 9-16 volts.

Conditions for Setting the DTC

The SSPS control module detects a system voltage above 16 volts for less than 1 second.

Action Taken When the DTC Sets

The SSPS warning light will illuminate.
Power steering assist will default to partial steering assist.
The SSPS control module will store a DTC C1104 in memory.

Conditions for Clearing the DTC

The SSPS warning lamp will turn OFF when conditions for the fault are no longer present.
Use a scan tool in order to clear the DTC.

Diagnostic Aids

A poor connection at the SSPS control module. Inspect the harness connectors for backed out terminals, improper mating, improperly formed or damaged terminals, and poor terminal to wire connections.
A damaged wiring harness. Inspect the wiring harness for damages, if the wiring harness appears to be in good condition, observe the display on the DMM while moving the connectors and wiring harnesses related to the actuator. A change in the DMM display during the test will indicate the location of the fault.

DTC C1105 - Ignition Voltage Over

Step	Action	Value(s)	Yes	No
1	Did you perform the Variable Effort Steering Diagnostic System Check?	-	Go to Step 2	Go to Diagnostic System Check - Variable Effort Steering
2	Turn ON the ignition, with the engine OFF. Use a scan tool in order to clear the DTCs. Operate the vehicle within the Conditions for Running the DTCs. Did the DTC fail this ignition?	-	Go to Step 3	System OK
3	Check for an open or poor connection on the ground circuit of the SSPS control module. Did you find and correct the condition?	-	Go to Step 7	Go to Step 4
4	Check for a poor connection on the ignition circuit of the SSPS control module. Did you find and correct the condition?	-	Go to Step 7	Go to Step 5
5	Check for a poor connection at the SSPS control module. Did you find and correct the condition?	-	Go to Step 7	Go to Step 6
6	Replace the SSPS control module. Did you complete the replacement?	-	Go to Step 7	-
7	Operate the system in order to verify the repair. Did you correct the condition?	-	Go to Step 7	Go to Step 2

Diagnostic Trouble Code (DTC) C1212

Vehicle Speed Sensor

Circuit Description

The vehicle speed sensor (manual transmission) or the transmission control module (TCM) transmits a processed vehicle speed signal (VSS) to the speed sensitive power steering (SSPS) control module. The SSPS control module uses the speed signal and the characteristic curve programmed in the microprocessor to determine the electric current variable for the power steering fluid flow control valve actuator.

Conditions for Running the DTC

Engine is running
Scan tool Idle Switch parameter is indicating OFF

Conditions for Setting the DTC

The power steering control module detects that the vehicle speed signal (VSS) is no longer present.

Action Taken When the DTC Sets

Power steering assist will default to full steering assist.
The SSPS control module will store a DTC C1212 in memory.

Conditions for Clearing the DTC

The SSPS warning lamp will turn OFF when conditions for the fault are no longer present.
Use a scan tool in order to clear the DTC.

Diagnostic Aids

Check for the following conditions if a history or intermittent DTC is indicated.

A poor connection at the SSPS control module. Inspect the harness connectors for backed out terminals, improper mating, improperly formed or damaged terminals, and poor terminal to wire connections.
A damaged wiring harness. Inspect the wiring harness for damages. If the wiring harness appears to be in good condition, observe the display on the DMM while moving the connectors and wiring harnesses related to the actuator. A change in the DMM display during the test will indicate the location of the fault.

DTC C1212 - Ignition Voltage Over

Step	Action	Value(s)	Yes	No
1	Did you perform the Variable Effort Steering Diagnostic System Check?	-	Go to Step 2	Go to Diagnostic System Check - Variable Effort Steering
2	Install a scan tool. Raise the vehicle's drive wheels. Start the engine. Place the transmission into drive for an automatic transmission or third gear for a manual transmission. With the scan tool, observe the Vehicle Speed parameter in the Speed Sensitive Steering data list. Does the Vehicle Speed parameter match the speedometer display?	-	Go to Step 6	Go to Step 3
3	Check for an open or poor connection on the vehicle speed circuit of the SSPS control module. Did you find and correct the condition?	-	Go to Step 6	Go to Step 4
4	Check for a poor connection on the ground circuit of the SSPS control module. Did you find and correct the condition?	-	Go to Step 6	Go to Step 5
5	Replace the SSPS control module. Did you complete the replacement?	-	Go to Step 6	-
6	Operate the system in order to verify the repair. Did you correct the condition?	-	System OK	Go to Step 2
7	Operate the system in order to verify the repair. Did you correct the condition?	-	Go to Step 7	Go to Step 2

Diagnostic Trouble Code (DTC) C1604

ECU(EEPROM Error)

Circuit Description

The internal fault detection is handled inside the control module. No external circuits are involved.

Conditions for Running the DTC

The microprocessor runs the program to detect an internal fault when power up is commanded. The only requirements are voltage and ground. This program runs even if the voltage is out of the valid operating range.

Conditions for Setting the DTC

The control module detects an internal write malfunction.
The control module detects an internal checksum malfunction.

Action Taken When the DTC Sets

The SSPS warning light will illuminate.
Power steering assist will default to partial steering assist.
The microprocessor refuses all additional inputs.

Conditions for Clearing the DTC

The SSPS warning lamp will turn OFF when conditions for the fault are no longer present.
Use a scan tool in order to clear the DTC.

Diagnostic Aids

Check for the following conditions if a history or intermittent DTC is indicated.

A poor connection at the SSPS control module. Inspect the harness connectors for backed out terminals, improper mating, improperly formed or damaged terminals, and poor terminal to wire connections.
A damaged wiring harness. Inspect the wiring harness for damages. If the wiring harness appears to be in good condition, observe the display on the DMM while moving the connectors and wiring harnesses related to the circuits. A change in the DMM display during the test will indicate the location of the fault.

DTC C1604 - Ignition Voltage Over

Step	Action	Value(s)	Yes	No
1	Did you perform the Variable Effort Steering Diagnostic System Check?	-	Go to Step 2	Go to Diagnostic System Check - Variable Effort Steering
2	Install a scan tool. Turn ON the ignition, with the engine OFF. Use a scan tool in order to clear the DTCs. Operate the vehicle within Conditions for Running the DTC. Did the DTC fail this ignition?	-	Go to Step 3	Go to Step 4
3	Replace the SSPS control module. Did you complete the replacement?	-	Go to Step 4	-
4	Operate the system in order to verify the repair. Did you correct the condition?	-	System OK	Go to Step 2

Diagnostic Trouble Code (DTC) C2203

Testing Current

Circuit Description

The variable effort steering (VES) system uses the speed sensitive power steering (SSPS) control module to control current to an electromagnetic rotary actuator. The SSPS control module commands current from 0.50-1.05 amperes to the actuator. At low speeds, approximately 1 ampere of current is commanded, which provides full power assist. At medium speeds, 0.78-0.90 amperes of current is commanded and moderate steering is provided. At high speeds, the SSPS control module will command a current between 0.50-0.77 amperes, which provides minimal steering assist. The lower the commanded current, the less power steering assist is provided.

Conditions for Running the DTC

Ignition voltage is between 9-16 volts.

Conditions for Setting the DTC

One of the following conditions exist in the VES actuator or in the circuits to the actuator:

An open circuit
A short to ground
A short to voltage

Action Taken When the DTC Sets

The SSPS warning light will illuminate.
Power steering assist will default to partial steering assist.
A DTC C2203 is stored in memory.

Conditions for Clearing the DTC

The SSPS warning lamp will turn OFF when conditions for the fault are no longer present.
Use a scan tool in order to clear the DTC.

Diagnostic Aids

Check for the following conditions if a history or intermittent DTC is indicated.

A poor connection at the SSPS control module. Inspect the harness connectors for backed out terminals, improper mating, improperly formed or damaged terminals, and poor terminal to wire connections.
A damaged wiring harness. Inspect the wiring harness for damages. If the wiring harness appears to be in good condition, observe the display on the DMM while moving the connectors and wiring harnesses related to the circuits. A change in the DMM display during the test will indicate the location of the fault.

Test Description

The numbers below refer to the step numbers on the diagnostic table.

Tests if the Commanded Current parameter is at the specified value in the active state.
Tests if the resistance of the VES actuator is in the specified range.
Tests the high effort control circuit for an open or short to voltage.
Tests the low effort control circuit for a short to ground.
Tests for poor connections at the VES actuator harness connector.

DTC C2203 - Ignition Voltage Over

Step	Action	Value(s)	Yes	No
1	Did you perform the Variable Effort Steering Diagnostic System Check?	-	Go to Step 2	Go to Diagnostic System Check - Variable Effort Steering
2	Install a scan tool. Start the engine. With the scan tool, observe the SSS Commanded Current parameters in the Speed Sensitive Steering data list. Does the scan tool indicate that the SSS Commanded Current parameter is within specified range?	-	Check for intermittent and poor connections in wiring systems	Go to Step 3
3	Turn OFF the ignition. Disconnect the VES actuator harness connector. Measure the resistance of the VES actuator. Does the resistance measure within the specified range?	-	Go to Step 4	Go to Step 10
4	Check the VES actuator and actuator harness for a short to ground. Was a short to ground located?	-	Go to Step 5	Go to Step 6
5	Visually inspect the actuator harness for any cut, chaffed or damaged wires. Did you find and correct the condition?	-	Go to Step 14	Go to Step 12
6	Check the high effort control circuit of the VES actuator for a short to ground. Did you find and correct the condition?	-	Go to Step 14	Go to Step 7
7	Check the high effort control circuit of the VES actuator for an open or short to voltage. Did you find and correct the condition?	-	Go to Step 14	Go to Step 8
8	Check the low effort control circuit of the VES actuator for a short to ground. Did you find and correct the condition?	-	Go to Step 14	Go to Step 9
9	Check the low effort control circuit of the VES actuator for an open or short to voltage. Did you find and correct the condition?	-	Go to Step 14	Go to Step 11
10	Inspect for poor connections at the harness connector of the VES actuator. Did you find and correct the condition?	-	Go to Step 14	Go to Step 12
11	Inspect for poor connections at the harness connector of the SSPS control module. Did you find and correct the condition?	-	Go to Step 14	Go to Step 13
12	Replace the VES actuator. Did you complete the repair?	-	Go to Step 14	-
13	Replace the power steering control module. Did you complete the replacement?	-	Go to Step 14	-
14	Operate the system in order to verify the repair. Did you correct the condition?	-	System OK	Go to Step 2