Front Wheel Steering Steering System

Front Wheel Steering

Specifications
Torque
Description Value
Bolt - Power Steering Gear Inlet Tube to Power Assisted 35-40 Nm
Steering Pump
Nut - Steering Rod Ball Joint to Steering Arm 35-40 Nm
Bolt - Steel On-Road Wheel Bolt 115-130 Nm
Bolt - Steering Gear to Front Sub Frame 100-130 Nm
Bolt - Steering Gear Return Tube to Steering Gear 20-26 Nm
Bolt - Steering Gear Inlet Tube to Steering Gear 20-26 Nm
Bolt - Steering Column to Steering Gear Input 105-126 Nm
Bolt - Front Sub Frame Support Plate 64-77 Nm
Nut - Anti Roll Bar Link to Anti Roll Bar 40-60 Nm
Nut - Steering Rod to Steering Arm 35-45 Nm
Bolt - Steering Column to Steering Gear Input Shaft 18-25 Nm

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Bolt - Power Assisted Steering Pump to Mounting Bracket 19-25 Nm

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Steering System Front Wheel Steering

Parameter
Type Hydraulic servo assisted steering gear which can reach the
linear gear ratio steering system
Steering Column:
Type Folding and energy absorbing type, the steering wheel can tilt
up and down
Steering Wheel Diameter 370 mm
Turns of Steering Wheel - Lock to Lock 3
Steering Circumference:
Minimum Curve Radius 11.3 m
Total Gear Ratio 15.44: 1
Power Assisted Steering:
Operation Pressure: 90 bar

Flow: 6-7.5 L/Min.

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Nominal Value 7.5 L

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Front Wheel Steering Steering System
Description and Operation
System Component Layout
Steering System Component Layout

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1. Power Steering Oil Reservoir Assembly 4. Steering Column Assembly
2. Steering Gear Inlet Tube 5. Power Steering Gear Assembly
3. Power Assisted Steering Pump 6. Steering Gear Return Tube

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Steering System Front Wheel Steering

Steering Column Component Layout

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1. Steering Column Assembly 4. Bolt - Steering Column to Steering Gear
2. Bolt (2) 5. Steering Column Upper Trim Panel Assembly
3. Bolt (2) 6. Steering Column Lower Trim Panel Assembly

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Front Wheel Steering Steering System
Steering Gear Assembly Component Layout

1. Steering Gear Assembly
2. Steering Mechanism Heat Shield
3. Bolt - Steering Mechanism Heat Shield
4. Steering Gear Outer Ball Joint
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5. Bolt - Steering Gear to Sub Frame Bracket
6. Cotter Pin - Steering Gear to Steering Knuckle
7. Nut - Steering Gear to Steering Knuckle
8. Gaiter

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Steering System Front Wheel Steering

Power Assisted Steering Pump Assembly

Component Layout

1. Power Steering Reservoir Assembly
2. Power Steering Reservoir Cover
3. Power Assisted Steering Pump to Steering Gear Inlet
Tube Assembly
4. Steering Gear Inlet Tube Set Bolt
5. Power Assisted Steering Pump
6. Reservoir to Steering Pump Suction Pipe Assembly
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7. Clamp
8. Screw - Power Steering Reservoir Bracket
9. Steering Return Tube Assembly
10. Steering Return Tube Snap Fit
11. Steering Return Tube Clamp

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Front Wheel Steering
Description
General Description
The steering system mainly consists of a two-piece collapsible
steering column, a power steering gear, a power assisted
steering pump, a pressure sensor, a power steering oil
reservoir, steering oil cooler and steering oil hard tube and
hose.
Steering Column
The steering column is an adjustable mechanism, it takes the
movement of the engine and steering system compartment
position into account when the vehicle is subjected to a strong
impact. The steering column is fitted on the instrument panel
tube beam, and the upper part of it can slide away from the
driver while the lower part can crumple. The steering wheel
tilt is adjustable, there are a balance spring and a position-limit
gasket at the adjustment end for easy tilt adjustment. There is
a double-walled seal retainer between the steering column and
the dash panel. The steering wheel is 370 mm in diameter, it
consists of a centre hub, a frame cast and the special materials
casting on the cast, and the steering wheel centre hub is
connected to the steering column with the spline groove.
All switches such as the horn switch and the entertainment
1. Input Shaft
2. Torsion Bar
3. Stopper Snap Ring
4. Lubricant Seal Ring
5. Valve Casing
6. Teflon (PTTE) Seal Ring (4)
7. Outer Column Spool
The steering valve unit and the steering gear are integrated
as an unit and its operating principle is: use the least force
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Steering System
control switch are connected to the rotary coupler joint by
the connecting wire. An airbag located in the steering wheel
centre and under the plastic cover protects the driver's face
and upper part of the body.
Power Steering Gear
The power steering gear is fitted in a proper position which
is located under the front sub frame rear member. As the
mounting point of the power steering gear and the suspension
rotation fulcrum are determined by the precisely machined
rigid front sub frame, in any time, it can keep the relative
design geometric dimension between the steering gear rack
mechanism and the suspension. The power steering gear is
set by two bolts. Three turns are needed when turning the
power steering gear from one side to the other side of the
lock position, the total gear ratio of the gear rack is 15.44:1,
and the motion range of the steering gear rack is covered by
the rubber bellows protector. One end of the steering rod is
assembled on the steering gear with threads and secured by
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the lock nut, and it functions as adjustment of steering system
alignment. The other end is secured to the steering arm which
extends from the front hub with the lock nuts.
Steering Valve Unit
8. Pinion Shaft
9. Bearing
10. Lubricant Seal Ring
11. Nut
12. Bearing
13. Pin - Pinion Shaft and Torsion Bar Connection
14. Pin - Rotor and Torsion Bar Connection
needed on the steering wheel to make the best assistant effect
(for example: turn when parking).
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Steering System
There are 4 holes on the steering valve unit casting housing,
they separately provide the pressure supply of the power
steering oil pump, the return of the power steering oil
reservoir, the fluid of steering valve unit to the circular surface
and the entire pump body. A check valve and a seal ring are
fitted in the pressure oil supply hole of the power assisted
steering pump.
The steering valve unit consists of an outer column spool,
rotor, torsion bar and pinion shaft. The steering valve unit
is a double shaft structure with the pinion shaft, and the pinion
shaft is connected to the steering column with the input shaft.
The steering valve unit is located in a housing, and the housing
is connected and secured to the paired casting on the steering
gear body with the screws.
The outer column spool is located in the main hole of the
steering valve unit, and 3 ring grooves are machined on its
outer surface in a machining way. The teflon seal rings located
between the ring grooves are used to seal the main hole of
the steering valve. The radial holes are drilled along the spool
wall in each ring groove. There is a machined hole on the
outer column spool to admit the input shaft. The 6 narrow
grooves are equally machined in the spool hole, the end of the
narrow grooves are sealed and not extended to the end of the
spool. The radial holes on the outer spool are drilled until
being connected to each narrow groove.
The outer end of the input shaft is machined with splines and
a lateral hole used for the torsion bar; the inner end of the
input shaft is also machined with the splines which is for gap fit
with the corresponding splines on the pinion shaft. The width
of the splines allows the torsion bar to turn several degrees
before the two splines engaged with each other. The splines
connection between the pinion shaft and the input shaft can
ensure that the steering system can be operated manually and
the torsion bar will not be overloaded when the steering assist
is invalid. The vertical narrow grooves laid alternately along
the circle of the input shaft are equally machined on the centre
circle of the input shaft.
The torsion bar is assembled in the rotor, and connected with
the input shaft and pinion shaft through a pin. The diameter
of the centre part of the torsion bar is slightly less than
the diameters of the both ends after being machined. The
smaller diameter allows the torsion bar to twist according to
the torque applied on the steering wheel, and this torque is
related to the grip of the tyre.
The machined teeth on the centre diameter of the pinion
shaft are for gap fit with the teeth on the steering gear. The
machined splines located in the hole which is on the upper of
the pinion shaft are for gap fit with the similar splines on the
rotor. The pinion shaft is located in a casting housing, and the
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Front Wheel Steering
housing is one part of the steering gear and rotated on a roller
bearing of the ball.
Power Assisted Steering Pump
The pressure of the steering system is provided by the impeller
type power assisted steering pump which is driven by the
crankshaft through the steering pump belt, when the engine
is running, the hydraulic oil is sucked from the reservoir by the
steering pump, the amount of the supplied oil and the pressure
are adjusted by the flow control valve of the steering pump, the
remaining oil returns to the inlet of the oil pump through the
internal oil path.
Warning: Take extra care when working on the hydraulic
pressure system, as the high pressure liquid can be very
hot. The pressure will be over 10000 KPa when the pump
is operating, personal injury may be caused if not care.
Power Steering Fluid Flow
The hydraulic pressure from the power assisted steering pump
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is sent to the steering valve through the steering pinion, the
control valve controls the hydraulic pressure and changes the
direction of fluid flow. The fluid is guided into the pressure
cylinder on the corresponding side of the steering gear, and the
propelling force of the steering gear rack is formed here. The
pressure oil returns from the pressure cylinder of the steering
gear through an annular passage of the return tube, and the
annular passage functions as cooling the power steering oil
before the power fluid returns to the steering oil reservoir.
The steering oil reservoir is a place for storing the power
steering fluid.
Power Steering Oil Reservoir
The power steering oil reservoir consists of reservoir body,
reservoir cap and filter assembly. There is a steering oil
reservoir level dipstick integrated with the reservoir cap and
an "O" seal ring fitted on the reservoir cap which helps to
prevent from leakage on the reservoir cap. There is an air
vent on the reservoir cap which allows the height of the
steering oil reservoir level to change during the operating.
The filter assembly is fitted at the bottom of the steering
oil reservoir. The filter is made of the subtle stainless steel
wire mesh which is molded in the filter bracket. The grain
matters in the steering oil reservoir can be filtered out by the
filter before the steering oil enters the oil supply line. The
filter is a maintenance-free component. The basic function of
the steering oil reservoir is to keep a certain amount of the
remaining steering oil so as to allow the steering oil to expand
and shrink under different temperatures. The height of the
steering oil level can ensure that the oil supply pipe is covered
with oil all the time in all operating conditions. Any air in the
hydraulic system will be ejected from the fluid in the steering
oil reservoir.
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Front Wheel Steering
The turning of the steering wheel is transmitted to the steering
valve which is fitted on the steering gear rack mechanism via
the steering column. The rotation of the turn is converted
to the rectilinear motion of the steering rack via the gear and
Steering System
rack. The high pressure flow on the steering gear provides
the steering assist when the engine is running and the power
assisted steering pump is operating.

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Steering System Front Wheel Steering

Operation
Neutral Position

1. Rotor
2. Torsion Bar
3. Spool
4. Pressure Oil Flow of Steering Gear Cylinder
The power steering fluid flows from the power assisted
steering pump to the steering valve when driving the vehicle
with the steering wheel facing straight ahead. Align the narrow
groove on the outer column spool with the narrow groove on
the rotor, this will cause the fluid pressure over the steering
valve. Partial pressure is applied to the inlet side and return
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5. Pressure Oil of Power Assisted Steering Pump
6. Return of Reservoir Tank
7. Supply of Reservoir Tank
side of the steering gear cylinder, this partial pressure is sensed
by the pistons on both sides of the steering gear cylinder. The
steering is kept in centre position because the pressure on
both sides of the steering gear cylinder is equal. Because a
majority of fluid has flowed into the steering oil reservoir, the
pressure on each side of the piston is very low.

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Front Wheel Steering
Turn Left
1. Rotor
2. Torsion Bar
3. Spool
4. Pressure Oil Flow of Steering Gear Cylinder LH
When turning the steering wheel counterclockwise, the rotor
and the torsion bar rotate in the same direction. The position
of the narrow groove on the rotor has been changed and not in
the centre alignment position, and the narrow groove blocks
the fluid from returning to the steering oil reservoir. After
this time, the hydraulic pressure flows from the power assisted
steering pump into the realigning narrow grooves on the rotor
and the outer column spool, the hydraulic pressure is guided
into the left side of the steering gear cylinder via the aligning
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Steering System
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5. Pressure Oil of Power Assisted Steering Pump
6. Return of Reservoir Tank
7. Oil Flow of Steering Gear Cylinder RH
narrow groove so as to increase the pressure of the cylinder
on the left side of the steering gear. The reflux inlet of the
cylinder on the right side of the steering gear is open, this
allows the fluid to flow from the cylinder piston on the right
side of the steering gear into the power steering oil reservoir.
The pressure difference of the cylinder pistons on the left side
and the right side of the steering gear generates the steering
assist.
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Steering System
Turn Right
1. Rotor
2. Torsion Bar
3. Spool
4. Oil Flow of Steering Gear Cylinder LH
When turning the steering wheel clockwise, the rotor and the
torsion bar rotate in the same direction. The position of the
narrow groove on the rotor has been changed and not in the
centre alignment position, and the narrow groove blocks the
fluid from returning to the steering oil reservoir. After this
time, the hydraulic pressure flows from the power assisted
steering pump into the narrow grooves realigned on the rotor
and the outer column spool, the hydraulic pressure is guided
into the right side of the steering gear cylinder via the aligning
narrow groove so as to increase the pressure of the cylinder
on the right side of the steering gear. The reflux inlet on the
left side of the cylinder is open, this allows the fluid to flow
from the piston on the left side of the steering gear into the
steering oil reservoir. The pressure difference on the left side
and the right side of the steering gear cylinder piston generates
the steering assist.
Accumulation Assist
The accumulation assist steering depends on the amount of
the wheel road resistance which has an opposite direction
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Front Wheel Steering
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5. Pressure Oil of Power Assisted Steering Pump
6. Return of Reservoir Tank
7. Pressure Oil Flow of Steering Gear Cylinder RH
with the front wheels rotation direction. When turning the
steering wheel to left or right, the rotary motion is transmitted
to the rotor shaft via the steering column, allowing the rotor
shaft and the steering wheel to turn with the same rotation
amount. The rotary motion is transmitted to the torsion bar
simultaneously. If the wheel resistance is very high (such as the
parking condition), the torsion bar will be twisted. The torsion
of the torsion bar means that the rotation amount of the
pinion and the spool is slightly less than the rotor. The narrow
grooves on the rotor and the torsion bar detach from the
alignment position due to the torsion of the torsion bar, and
cause the gap between the two narrow grooves to increase.
The bigger the road resistance of the steering rotary motion
from the wheels, the bigger the deflection amount between the
narrow grooves of the rotor and the torsion bar, the hydraulic
pressure passed through the appropriate side of the steering
gear cylinder increases with the rotation amount increasing.
When the road resistance of the wheels or the steering force
applied to the steering wheel decreases, the torque applied to
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Front Wheel Steering
the rotor decreases, the torsion bar is loosened, causing the
rotation amount between the narrow grooves of the rotor and
the torsion bar to decrease, so as to decrease the hydraulic
pressure applied to the appropriate side of the steering gear
cylinder.
1. Steering Oil Reservoir
2. Low Pressure Inlet Tube
3. Power Assisted Steering (PAS) Pump
4. Outlet
5. Flow Control/Safety Valve
After starting the engine, the power assisted steering pump
sucks the power steering fluid of the steering oil reservoir
into the low pressure inlet tube, the power steering fluid
changes into the high pressure fluid at the outlet after flowing
over the power assisted steering pump, the high pressure fluid
reaches the steering valve through a high pressure oil tube.
If the steering force has not been applied, the pressures on
both sides of the steering gear cylinder piston are equal, the
remaining fluid returns to the steering oil reservoir from the
steering valve through the power steering oil cooler tube. If
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Steering System
Hydraulic Circuit
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6. Steering Gear Cylinder Pressure Area
7. Steering Gear Rack Mechanism
8. Steering Valve Unit
9. Power Steering Oil Cooler Tube
the steering force used for turning to the any side has been
applied, the oil pressure is guided into the appropriate side of
the steering gear cylinder piston, the pressure provides the
steering assist and reduces the required steering force. The
discharged power steering fluid due to the movement of the
piston in the steering gear cylinder flows from the steering
valve and returns to the steering oil reservoir through the
power steering oil cooler tube. The power steering oil cooler
tube can decrease the temperature of the power steering fluid
and extend the life of the hoses and the seals of the system.
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Steering System Front Wheel Steering

Service Procedures a. Make sure there are no leaks from the steering
Power Assisted Steering System - Pressure Test system and the fluid level is maximum when
Inspection performing the test.
1. Test Device b. Start the engine when the test device valve is open.
c. When the engine is idling and in a normal operating
temperature, turn the steering wheel slowly and
hold it to the lock position.
d. Repeat this pressure test in the opposite lock
position.
e. The test pressure should increase from 5 bar to
90 bar slowly, the pressure may increase to 90 bar
according to road condition when steering is in the
full lock position.
f. When the engine is idling, release the steering wheel,
the pressure reading should be 5 bar or less.
a. Fit the pressure gauge T38001 and hose to the valve g. There may be a malfunction if the pressure is out

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assembly T38002 and tighten the union. of the value above.
b. Fit the 2 hoses T38003 to the valve assembly T38002 Adjustment
and tighten the union. 1. To determine if the steering pump or steering gear
2. Disconnect the battery negative terminal. is defective, close the test valve for a maximum of 5
seconds. If the test valve is closed for an extended
Caution: Care must be taken to ensure that the oil or period of time, the pump will be damaged.
other fluid does not enter or contaminate the alternator.
2. If the reading of pressure gauge is not between 85-95
3. Put a container to collect fluid which spills out from bar (the maximum pump pressure), the pump is
thePAS system. defective.
4. Clean the power assisted steering pump, connector 3. If the maximum pressure of the pump is correct, the
tube and tube joint. steering gear may be defective.
5. Remove the butt bolt securing the steering gear inlet 4. Stop the engine after the test has been completed.
tube to the power assisted steering pump. 5. Loosen the battery negative terminal.
6. Fit the union T38005 and seal washer to the power 6. Remove the power steering oil reservoir and put it
assisted steering pump. aside.
7. Fit the union T38004 to the power steering gear apply 7. Remove the test device union.
pipe with the butt bolt and seal washer.
8. Remove the union from the power assisted steering
8. Connect the hose T38003 to the T38004 and T38005. pump and power steering gear inlet tube.
9. Make sure all tubes and mountings DO NOT contact 9. Fit a new seal washer and fit the apply pipe to the
with rotation components. power assisted steering pump, tighten the butt bolt to
10. Hang the pressure gauge to a safe place under the 35-40 Nm.
bonnet. 10. Clean the chassis and surrounding area.
11. Connect the battery negative terminal. 11. Fit the power steering oil reservoir.
12. Start the engine and bleed the power assisted steering 12. Check the power assisted steering system fluid level.
system.
Capacity
Power Assisted Steering (PAS) System Bleeding Fluid
13. Check the power assisted steering pump fluid level and 13. Connect the battery negative terminal.
fill it fully.
14. Test procedures:

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Front Wheel Steering Steering System
Steering Rod wheels.
Removal Four-wheel Alignment
1. Raise the vehicle on a lift.
Warning: DO NOT work under the vehicle supported only
with a jack. It is essential to support the vehicle on safety
stands.
2. Remove the front wheels.
3. Loosen the lock nut on the steering rod.

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4. Remove the nut from the steering rod ball joint and
dispose it.
5. Fit a M10 nut to the steering rod ball joint so that it
is flush with the pin end.
6. Disengage the ball joint from the steering arm using the
tool T38008. Remove the M10 nut from the ball joint.

7. Unscrew the steering rod outside ball joint from the

power steering gear, mark the position of the lock nut.
Refit
1. Screw the steering rod to the mark position of the lock
nut and with the ball joint facing downward.
2. Connect the steering rod ball joint to the steering arm,
fit a new nut and tighten it to 35-40 Nm.
3. Fit the wheel and tighten the bolt to 115-130 Nm.
4. Lower the vehicle.
5. Check the wheel alignment parameter for the front

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Steering System Front Wheel Steering

Power Steering Gear Assembly 10. Support the rear of the sub frame with hydraulic
Removal pressure lifting equipment.
1. Raise the vehicle on a lift. 11. Loosen the 2 mounting bolts securing the rear of the
2. Move the floor carpet and slide the steering column front sub frame support plate.
seal down in order to expose the bolt securing the joint 12. Loosen the 2 bolts securing the front sub frame to the
to the power steering gear. rear of the white body.

Caution: Before disconnecting any parts of the steering

linkage, ensure the wheels are positioned straight
ahead and the steering wheel is prevented from turning.
Unrestricted turning of the steering wheel will damage
the SRS rotary coupler.
3. Remove the bolt securing the joint to the power
steering gear and dispose it.

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13. Support rear of the sub frame with hydraulic pressure
lifting equipment.
14. Remove the 2 centre bolts and rear bolt which set the
sub frame and the sub frame strut bar to the vehicle
body and dispose them, collect the washer.
15. Lower the rear of the sub frame.
16. Put a container to collect the spilled fluid.
4. Loosen the joint from the power steering gear. 17. Remove the tube union which sets the power steering
5. Remove the front wheels. gear return tube to the power steering gear, and
dispose the O-ring.
6. Remove the nut securing the steering rod to the
steering arm. Fit a M10 nut to the ball pin so that it 18. Remove the tube union which sets the power steering
is flush with the pin end. gear inlet tube to the power steering gear, and dispose
the O-ring.
7. Loosen the steering rod ball joint from the steering
arm using the tool T38008. Remove the M10 nut from 19. Remove the 2 bolts securing the power steering gear
the ball pin. to the sub frame.

20. Pull out the power steering gear from the driver side.
21. Remove the power steering gear input shaft seal ring.
22. Mark the positions of each steering rod end lock nut
and take them as a reference of fitting.

8. Remove the nut securing the anti roll bar link to the
anti roll bar and loosen the anti roll bar link.
9. Put the anti roll bar aside.

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Front Wheel Steering Steering System
Power Assisted Steering Pump
Removal
1. Disconnect the battery earth lead.
2. Lift the front of the vehicle.
Warning: DO NOT work under the vehicle supported only
with a jack. It is essential to support the vehicle on safety
stands.

23. Remove the steering rod end and lock nut from the 3. Put a container to collect the spilled fluid.
power steering gear. 4. Remove the inlet joint and outlet joint of the power
Refit assisted steering pump.

1. According to the thread mark noted during the

removal, centre the power steering gear and set each
lock nut to the steering rod.
2. Set the steering rod ball joint to the lock nut of the
steering gear, make the steering rod ball joint face up.
3. Fit the power steering gear input shaft seal to insure

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that the dent on the seal is located at the raised "mark"
on the gear.
4. Position the power steering gear onto the sub frame, 5. Remove the auxiliary drive belt.
be careful not to drop the steering gear input shaft seal.
Auxiliary Drive Belt
5. Fit the 2 upper bolts and tighten them to 100-130 Nm.
6. Remove the 3 service bolts securing the power assisted
6. Clean the tube union and the mating surface. steering pump pulley to the power assisted steering
7. Fit a new O-ring to the steering gear return tube, pump.
connect the tube and tighten the tube union to 20-26
Nm.
8. Fit a new seal washer to the steering gear inlet tube,
connect the tube and tighten the tube union to 20-26
Nm.
9. Lift the sub frame, then fit the washer, sub frame strut
bar and the new bolt securing the sub frame, and
tighten the bolt to 105-126 Nm.
10. Fit the bolt securing the sub frame strut bar to the
body and tighten the bolt to 64-77 Nm. 7. Remove the 3 service bolts connecting the power
11. Move the hydraulic pressure lifting equipment away. assisted steering pump to the bracket.
12. Fit the anti roll bar link to anti roll bar, then fit the nut
and tighten it to 40-60 Nm.
13. Connect the steering rod to the steering arm, fit new
nut and tighten it to 35-45 Nm.
14. Fit the wheel and tighten the bolt to 115-130 Nm.
15. Fit a new bolt securing the joint to the power steering
gear input shaft, then tighten the bolt to 18-25 Nm.
16. Secure the joint seal. Put the floor carpet to the
original place.
17. Bleed the power assisted steering system.
Power Assisted Steering (PAS) System Bleeding
18. Check the four-wheel alignment parameter.
8. Remove the power assisted steering pump.
Four-wheel Alignment

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Steering System Front Wheel Steering

Refit Power Steering Inlet Tube

1. Clean the power assisted steering pump and the mating Removal
surface. 1. Disconnect the battery earth lead.
2. Fit the 3 service bolts connecting the power assisted 2. Lift the vehicle.
steering pump to the bracket. 3. Put a container to collect the spilled fluid.
3. Fit the power assisted steering pump pulley to the 4. Remove the power steering gear inlet tube union, then
power assisted steering pump with the 3 service bolts. remove the seal washer and dispose it.
4. Fit the auxiliary drive belt.
Auxiliary Drive Belt

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Caution: To prevent damage to components, use two
wrenches simultaneously when loosening or tightening
the tube unions.
Caution: Plug the disconnected unions to prevent
5. Clean and fit the inlet joint and outlet joint of the
contamination entering.
power assisted steering pump.
6. Lower the vehicle. 5. Remove the tube union securing the power steering
gear inlet tube to the steering pump, remove the seal
7. Connect the battery earth lead.
washer and dispose it.
8. Bleed the power assisted steering system.
Caution: To prevent damage to components, place a
Power Assisted Steering (PAS) System Bleeding wood board or hard rubber at the bottom of the jack.
Caution: Plug the disconnected unions to prevent
contamination entering.
6. Remove the power steering gear inlet tube assembly
from the engine bay.
Refit
1. Clean the power steering gear inlet tube end and
mating surface.
2. Position the inlet tube into the engine bay.
3. Fit the power steering inlet tube to the pump with the
new seal washer, fit the tube union and tighten it to
35-40 Nm.
Caution: To prevent damage to components, place a
wood board or hard rubber at the bottom of the jack.
4. Fit the power steering gear inlet tube to the power
steering gear with the new seal washer, fit the tube
union and tighten it to 20-26 Nm.
Caution: To prevent damage to components, place a
wood board or hard rubber at the bottom of the jack.
5. Move the container away.

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Front Wheel Steering Steering System
6. Connect the pressure sensor connector. Steering Return Tube Assembly
7. Connect the battery earth lead. Removal
8. Bleed the power assisted steering system. 1. Remove the front bumper.

Power Assisted Steering (PAS) System Bleeding Front Bumper Assembly

2. Lift the vehicle
3. Put a container to collect the spilled fluid.
4. Loosen the clamp of the return tube assembly andPAS
pump.
5. Remove the tube union securing the steering gear
return tube to the power steering gear, remove the
washer and dispose it.

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Caution: Plug the disconnected unions to prevent
contamination entering.
6. Remove the 2 bolts securing the return tube assembly
to the body, and then remove the return tube assembly.

7. Take out the power steering gear return tube.

Refit
1. Clean the steering gear return tube end and mating
surface.
2. Position the steering gear return tube into the engine
bay.
3. Remove the plug from the power steering gear.
4. Position the steering gear return tube onto the power
steering gear and fit a new washer and tighten the tube
union to 20-26 Nm.

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Steering System Front Wheel Steering

Caution: To prevent damage to components, use two Power Assisted Steering (PAS) System Bleeding
wrenches simultaneously when loosening or tightening Adjustment
the tube unions. 1. Clean the power steering oil reservoir filler surrounding
5. Fit the set bolt and tighten it to 19-25 Nm.Remove and the fluid level indicator.
the plug and connect the steering gear return tube to
thePAS pump.
6. Move the container away.
7. Fit the front bumper assembly.
Front Bumper Assembly
8. Connect the battery earth lead.
9. Bleed the power assisted steering system.
Power Assisted Steering (PAS) System Bleeding

2. Unscrew the reservoir cover from the power steering

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oil reservoir, and fill the steering fluid until the level is
between the minimum and maximum lines.
Capacity
Fluid
Lubricant
Caution: Care must be taken to ensure that the oil or
other fluid does not enter or contaminate the alternator.
3. Start and idle the engine for 10 seconds, and then stop
it.
4. Fill the power steering oil reservoir.
5. Start the engine and fully turn the steering wheel from
lock to lock, and then stop the engine.
6. Refill the power steering oil reservoir.
7. Start and run the engine for 2 minutes and fully turn
the steering wheel from lock to lock.
Caution: DO NOT hold the steering gear at full lock point
for longer than 10 seconds.
8. Stop the engine.
9. Check the steering oil reservoir, and if the bubbles
come out, wait until the bubbles disappear, and then
refill the steering fluid to a level between the minimum
and maximum lines.
10. Fit the power steering oil reservoir filler cap.

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