ZEST BOLT Service Manual

STEERING CONTENTS 8.1 GENERAL INFORMATION.. ...................................................................................................................1 8.1.1 SPECIFICATIONS.... ...........................................................................................................................1. 8.1.2 SYSTEM LAYOUT. ..............................................................................................................................1. 8.1.3 GENERAL DISCRIPTION.. ..................................................................................................................2. 8.1.4 TIGHTENING TORQUES... ..................................................................................................................3. 8.1.5 SPECIAL TOOLS .................................................................................................................................5. 8.2 MAINTENANCE, INSPECTION AND TEST.. .........................................................................................6 8.2.1 PRELIMINARY INSPECTION.. .............................................................................................................6 8.2.2 REGULAR MAINTENANCE... ...............................................................................................................7 8.2.3 ON VEHICLE REPAIRS.. ......................................................................................................................8 8.2.3.1 STEERING WHEEL REMOVAL.. ..........................................................................................................8 8.2.3.2 STEERING COLUMN REMOVAL. ........................................................................................................9 8.2.3.3 INTERMEDIATE SHAFT REMOVAL. . ...............................................................................................10 8.2.3.4 ECU REMOVAL.... ..............................................................................................................................11 8.2.3.5 RACK & PINION ASSEMBLY REMOVAL.. .........................................................................................12 8.3 OVERHAULING.. ..................................................................................................................................14 8.3.1 OVERHAULING OF STEERING RACK & PINION ASSEMBLY.. .......................................................14 8.3.2 PRECAUTIONS.. ................................................................................................................................15 8.3.3 DISMANTLING, INSPECTION & ASSEMBLY. ...................................................................................15 8.3.3.1 DISASSEMBLY OF RACK & PINOIN. ................................................................................................15 8.3.3.2 INSPECTION OF DISMANTLED PARTS... ........................................................................................16 8.3.3.3 ASSEMBLY OF RACK & PINOIN. ......................................................................................................16 8.3.3.4 OBJ ON VEHICLE REMOVAL. ...........................................................................................................17 8.3.3.5 DO'S & DON’T'S.. ................................................................................................................................17 8.3.3.6 WHEEL ALIGNMENT. .........................................................................................................................18 8.4 TROUBLESHOOTING AND DIAGNOSIS.. ..........................................................................................20 A. GENERAL TROUBLESHOOTING. .....................................................................................................20 B. ELECTRICAL TROUBLESHOOTING. ................................................................................................22 C. MECHANICAL TROUBLESHOOTING. ...............................................................................................23 8.5 STEERING ANGLE CALIBRATION AND INITIALIZATION PROCESS. ............................................24 8.6 STEERING SYSTEM DTC CODES.. ....................................................................................................27 8.7 EPAS ECU REPLACEMENT AND SOFTWARE UPDATE PROCEDURE… ………...........................29