TABLE OF CONTENTS 1. GENERAL INFORMATION ........................................................................................................................1 A. TECHNICAL SPECIFICATION.............................................................................................................1 B. INTRODUCTION ..................................................................................................................................1 C. SYSTEM LAYOUT................................................................................................................................3 2. TIGHTENING TORQUES...........................................................................................................................4 3. SPECIAL TOOLS.......................................................................................................................................7 4. MAINTENANCE, INSPECTION AND TEST...............................................................................................8 A. PRELIMINARY INSPECTION..............................................................................................................8 B. REGULAR MAINTENANCE.................................................................................................................9 5. ON VEHICLE REPAIRS...........................................................................................................................12 A. STEERING WHEEL REMOVAL ........................................................................................................12 B. STEERING COLUMN REMOVAL......................................................................................................13 C. INTERMEDIATE SHAFT REMOVAL .................................................................................................16 D. ECU REMOVAL..................................................................................................................................16 E. MOTOR REMOVAL............................................................................................................................17 F. RACK & PINION ASSEMBLY REMOVAL ..........................................................................................18 6. STEERING RACK AND PINION ASSEMBLY EXPLODED VIEW...........................................................20 7. OVERHAULING OF STEERING RACK AND PINION ASSEMBLY........................................................22 A. PRECAUTIONS .................................................................................................................................22 B. DISASSEMBLY OF RACK & PINON .................................................................................................22 C. INSPECTION OF DISMANTLED PARTS...........................................................................................23 D. ASSEMBLY OF RACK & PINON........................................................................................................23 E. OBJ ON-VEHICLE REMOVAL...........................................................................................................24 F. PROCEDURE FOR ADJUSTING FREE PLAY/NOISE......................................................................25 8. DO’S & DON’TS.......................................................................................................................................26 9. WHEEL ALIGNMENT...............................................................................................................................29 TROUBLESHOOTING AND DIAGNOSIS...............................................................................................31 10. STEERING ANGLE CALIBRATION PROCESS.....................................................................................37 11. TUNING DATA SELECTION...................................................................................................................44 12. ELECTRIC POWER ASSISTED STEERING (EPAS) ECU REPLACEMENT AND SOFTWARE 13. UPDATE PROCEDURE IN FIELD............................................................................................................45 A. EPAS ECU REPLACEMENT – AUTOMATIC (IF FITTED).................................................................46 B. EPAS ECU FIELD SOFTWARE UPGRADE/RE FLASH – MANUAL.................................................47 STEERING
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