EPS (Electronic Power Steering)

EPS (Electronic Power Steering)

I Brief introduction
(I) Structural introduction
EPS’s structural diagram

1. Steering wheel assembly

2. Steering column assembly
3. Steering shaft with universal shaft
4. Steering gear assembly cardiagn.com

EPS (Electronic Power Steering) 185

 EPS (Electronic Power Steering)

(II) System’s working principle

Diagram of system’s working principle

(III) Maintenance parameter cardiagn.com

Project Standard
Type of manual steering gear Gear rack
Parameter of steering wheel φ375mm
Steering column and lower shaft Crumple level 3
Operating torque of steering wheel ≤ 5N·m
Power steering gear rack’s travel distance 134±1mm
Cord’s transmission ratio 46.82
Steering wheel’s number of turns 2.86±0.04

EPS (Electronic Power Steering) 186

 EPS (Electronic Power Steering)

(IV) Torque parameter

No.Project Torque Remark
1 Steering wheel’s fixing nut （N·m）
42~52
2 Steering column’s installing nut 20~25
3 Steering column’s installing bolt 20~30
4 Controller support’s fixing bolt 8~10
5 Connecting bolt of steering column assembly and steering shaft 30~35
6 assembly
Connecting bolt of steering shaft assembly and manual steering gear 30~35
7 Primary fixing bolt of manual steering gear 95~105
8 Secondary fixing bolt of manual steering gear 95~105
9 Toe-in adjusting nut of steering tie rod 45~55
10 Slotted nut of steering gear’s external ball 40~50

(V) Maintenance precautions

cardiagn.com
1. When checking steering system, park the car on dry and level ground
2. All bolts of spare parts in steering system must be tightened with standard torque
3. Check the wheel alignment after finishing the maintenance of steering column assembly, steering
gear and other steering part.
4. The system’s voltage standard is 9~18V.
5. Check the tire’s pressure often and make sure it meets the standard.
6. Once abnormal gap or front-sway appears, confirm which system or assembly the problem exists in,
and solve the problem.
7. Check whether the spare parts of steering system suffer abnormal crash, and replace the broken or
problematic parts immediately
8. It is unacceptable to weld any part of steering gear or system rod piece.
9. Check regularly whether any interference or abrasion is on EPS harness, or whether the connector is
loosen, and replace harness if necessary.
II Failure diagnosis
(I) Chart of diagnostic trouble codes for EPS
No.DTC Description
1 C1611 Failure happens in torque sensor’s main signal
2 C1613 The difference between primary and secondary circuit of
torque sensor is excessive
3 C1614 Torque sensor’s power failure
4 C1615 Failure of signal in torque sensor’s secondary circuit
5 C1621 Vehicle speed’s signal loss
6 C1622 Wheel speed’s signal loss
7 C1624 Vehicle speed’s reduction exceeds normal level
8 C1641 Motor’s circuit is open or I short-out; drive circuit is
9 C1642 abnormal
Motor’s practical current is far higher than estimated
current
EPS (Electronic Power Steering) 187
 EPS (Electronic Power Steering)

10 C1643 Motor’s current is too excessive

11 C1645 Motor’s practical current is far lower than estimated current
12 C1651 Angle transducer’s signal is abnormal
13 C1652 Controller’s relay fails
14 C1653 Power voltage is too low
15 C1654 Power voltage is too high
16 C1655 Drive failure (over-temperature, undervoltage)
17 U0073 EPS communication is down
18 U0100 Loss of communication with EMS/ECU
19 U0129 Loss of communication with ABS/BSM
20 C1611 Torque sensor-primary signal’s cross-border
21 C1612 Torque sensor-secondary signal’s cross-border

cardiagn.com
22 C1613 Torque sensor-sum of primary and secondary signal brakes
23 C1614 limit
Torque sensor-torque sampling overtime
24 C1661 Relay’s circuit is open
25 C1621 Battery’s voltage is too high
26 C1622 Battery’s voltage is too low
27 C1662 Current sensor-mid-current’s calibration error
28 C1663 Current sensor-excessive current
29 C1664 +5VA voltage error
30 C1632 EEPROM data consistency failure
31 C1643 Ignition signal loss
32 C1651 Motor-circuit’s short-out
33 C1667 Temperature sensor-MOSFET overheat
34 C1615 Angle sensor-PWM’s duty-ratio exceeds the limit
35 C1617 Angle sensor-angle’s calculation error
36 C1615 Angle sensor-PWM frequency is abnormal
37 C1616 Angle sensor-P or S signal sampling overtime
38 C1641 CAN- invalid vehicle speed
39 C1641 CAN- vehicle speed sampling is overtime
40 C1642 CAN- invalid wheel speed
41 C1642 CAN- wheel speed sampling is overtime
42 U1000 CAN-BUSOFF

EPS (Electronic Power Steering) 188

 EPS (Electronic Power Steering)

43 U1000 CAN-message transmission overtime

44 C1665 EPS controller-inside failure
(II) Failure diagnosis
No.Symptom Failure’s reason Solution Remark
Steering wheel’s ball joint Adjust the alignment Please refer
is loosen or the front and ball joint in steering to ”vehicle’s
wheel’s alignment is wheel steering system
inappropriate check”
Steering lever system is Check and adjust each
broken or suffer excessive joint part in steering
1 Vehicle’s deviation abrasion system according to the
instructions
Rack’s pre-tightening Adjust or repair the
degree is in maladjustment. rack’s pre-tightening

cardiagn.com
degree in the steering
gear
Harness connector is loosen Check and reconnect the Please refer
or in poor contact connectors, make sure to ”vehicle’s
they are connected steering system
Power-steering is firmly check”
sporadic or back to
2 Motor’s fuse is loosen or in Re-install the fuse, make
normal after
poor contact sure it is installed
restarting the engine.
properly
Motor’s failure Replace the motor
EPS controller’s failure Replace the EPS
controller

EPS (Electronic Power Steering) 189

 EPS (Electronic Power Steering)

(III) Diagnostic flow chart

Flow chart of combination instrument’s EPS warning light keeps lighting, no steering function

cardiagn.com

EPS (Electronic Power Steering) 190

 EPS (Electronic Power Steering)

III Vehicle’s steering system check

(I) Check
1. Check the installation
1). Check the installing situation of steering gear assembly, front suspension, axle and steering
column
2). Check whether there is any gap during axial movement
3). Check whether the fixing nuts and bolts of steering gear assembly are loosen
2. Check the free-running distance of steering wheel
1). Turn the steering wheel and keep the front wheels straight ahead. Start the engine, and slightly
turn the wheel left or right, tillthe front wheel starts to move, and measure the steering wheel’s
distance on the excircle
Steering wheel’s free-running distance: 30mm
2). If the measured value exceeds the standard, check the installing situation of all joints of steering
column and the steering assembly, and adjust or replace relevant spare parts if necessary.
3). If the free-running distance still exceeds 30mm, then shut down the engine and keep the front

cardiagn.com
wheels straight ahead. Apply a force of 5N along the steering wheel’s periphery and check the free-
running distance. If the distance exceeds 10mm, then it is necessary to check whether the steering
assembly is qualified.
4). If the distance still stays at limit, then keep the wheel straight when the engine is dead, apply a
force of 4±0.6N along the wheel’s periphery, and check the free-running distance.
Standard: <15mm
5). If the distance above exceeds the standard, then disassemble the steering gear and check pinion’s
total torque.
3. Check the middle position
1). Confirm whether steering gear assembly, column and
wheel are installed correctly.
2). Carry out middle position check after the front
wheels’ alignment. Please refer to “front wheels’
alignment”
3). Park the vehicle directly, and confirm the steering
wheel is in the middle position.
4). Loosen the locknut of tie rod and turn the adjustment
lever slightly, and confirm whether the steering wheel
still stays at middle position.
4. Check the steering wheel’s static steering force
1). Park the vehicle on dry and level ground, and pull up the brake handle.
2). Start the engine.
△Notice the tire’s pressure should stays in limit
3). Turn the steering wheel a circle from middle position, check the wheel’s steering force, and
whether any apparent fluctuation exists.
steering wheel’s steering force: <34N
acceptable fluctuation: <5.9N
EPS (Electronic Power Steering) 191
 EPS (Electronic Power Steering)

4). If the steering force exceeds the limit, please check or adjust the following parts:
(1). Check whether the lower suspension arm or steering tie rod’s ball joint is broken
(2). Check the steering gear’s preload and the driving torque of steering tie rod
(3). Check the driving torque of lower suspension arm’s ball joint
5. Check the steering wheel’s self-return
1). Turn the steering wheel for 90°, and drive the vehicle in 35km/h. Keep the speed for several
seconds, and loosen the steering wheel. The auto-return should be at least 70%.
△Notice During slow or sharp turn, check whether the
auto-return in left and right direction is same, by using
personal feeling. This check must be carried out on safe
roads, and keep personal safety as priority
6. Check the front wheels’ steering angle
1). After the toe-in check of front wheel, carry out
steering angle check. When the vehicle is still, and
engine is in idle speed, place the front wheel on steering

cardiagn.com
angle measurer, and check the maximum steering angle
of inner and external wheels.
Inner wheel: 35.1°±1.5°
External wheel: 30.6°±1.5°
△Notice if the measured value is not in the limit, adjust
the tie rod
7. Steering angle’s adjusting method
1). When the steering angle exceeds the limit, loosen the locknut of left and right steering tie rod, and
use wrench to adjust the tie rod till the angle meets the standard. Then tighten the locknut, and the
tightening torque is 45~55N.m. When re-adjust left and right tie rod, keep the left rod and right rod
equal
△Notice if the inner wheel’s steering angle exceeds limit, adjusting the tie rod to the outside will
increase inner wheel’s angle; when external wheel’s steering angle exceeds limit, adjusting the tie rod
to the outside will reduce external wheel’s angle. The vehicle’s toe-in is relevant to the adjustment of
other four wheels’ alignment and steering angle.
8. Check the dust cover of ball joint
1). Press the cover by fingers to check whether the dust cover is chap or broken
2). If any chap or damage exists on dust cover, replace the tie rod’s ball joint immediately.
△Notice dust cover’s chap or damage on surface may also cause ball joint to suffer damage.
9. Check the tie rod’s ball joint
1). Quickly sway the tie rod for 10 times
2). Use spring scale to measure the swinging resistance of tie rod
Standard: 0.5~3N.m. If the measured value exceeds the limit range, replace tie rod immediately.

IV Steering wheel assembly

(I) Disassembly
1. Open the engine hood

EPS (Electronic Power Steering) 192

 EPS (Electronic Power Steering)

2. Disconnect the negative cable of battery

△Notice
wait for at least 3 minutes after disconnecting the cable, in case of air bag’s explosion during
disassembly
3. Dismantle driver’s air bag assembly, please refer to
“driver’s air bag assembly”
4. Disassemble the steering wheel assembly
1). Turn the steering wheel, and make sure the front
wheels are on straight line
2). Lock the steering wheel
△Notice make marks before pulling out steering wheel,
and make sure the steering wheel’s position after
installation is the same as the one before.

3). Loosen the fixing nut of steering wheel

cardiagn.com
4). Pull out the steering wheel from steering shaft
△Notice pre-tighrten the fixing nut to steering wheel,
in case of injuring maintenance personnel when pulling
out the steering wheel
△Notice if the steering wheel cannot be pulled out
manually, it is OK to use professional tools

(II) Installation
1. Install the steering wheel assembly
1). Turn the clock spring clockwise till the stop position,
and turn it 3 circles counter-clockwise
2). Engage the steering wheel to the spline of steering
column
△Notice the locking slot, which is in the bottom of
steering wheel, must match the locating pin of spiral
cable
3). Install the fixing nut and washers
Tightening torque: 42~52N.m
4). Adjust the steering wheel’s steering angle to 0
△Notice after the dismounting of steering column, the wheel’s steering angle may be affected,
while the pilot lamp on dashboard hasn’t lighted. It is necessary to carry out steering wheel’s signal
calibration. After calibration, when the ignition switch is in “ON” position, EPS controller will
inspect each module of the system, and light the EPS pilot lamp. If self-inspection is normal, the pilot
lamp will die in 2 seconds.
2. Install driver’s air bag assembly
3. Connect the negative cable of battery
4. Close the engine hood

EPS (Electronic Power Steering) 193

 EPS (Electronic Power Steering)

V Steering column assembly

(I) Disassembly
1. Open the engine hood
2. Disconnect the negative cable of battery
△Notice wait for at least 3 minutes after disconnecting
the cable, in case of air bag’s explosion during
disassembly
3. Dismantle driver’s air bag assembly, please refer to “driver’s air bag assembly”
4. Disassemble the steering wheel assembly, please refer to “steering wheel assembly”
5. Disassemble the cladding of steering column, please refer to “cladding of steering column”
6. Disassemble the clock spring, please refer to “clock spring”
7. Dismantle the combination switch, please refer to “combination switch”
8. Dismantle the driver side’s back-plate, please refer to “driver side’s back-plate”
9. Disassemble the guard induction coil, please refer to “guard induction coil”

cardiagn.com
10. Dismantle the ignition lock assembly, please refer to
“ignition lock assembly”
11. Disassemble the steering column assembly
1). Disconnect the harness connector on steering column

2). Unfix the harness on steering column

3). Loosen the fixing bolt that connects the lower end of
steering column assembly and dashboard skeleton
4). Loosen the two fixing bolts that connect the upper
end of steering column and dashboard skeleton

5). Loosen the fixing bolt that connects steering column

assembly and steering shaft assembly with universl shaft
6). Take off the steering column assembly

EPS (Electronic Power Steering) 194

 EPS (Electronic Power Steering)

(II) Installation
1. Install the steering column assembly
1). Install the fixing bolt that connects the lower end of
steering column assembly and dashboard skeleton
Tightening torque 20~30N.m
2). Install the two fixing bolts that connect the upper end
of steering column assembly and dashboard skeleton
Tightening torque 20~25N.m
VI Steering shaft assembly with universal shaft
(I) Disassembly
1. Open the engine hood
2. Disconnect the negative cable of battery
△Notice wait for at least 3 minutes after disconnecting
the cable, in case of air bag’s explosion during
disassembly

cardiagn.com
3. Dismantle driver’s air bag assembly, please refer to “driver’s air bag assembly”
4. Disassemble the steering wheel assembly, please refer to “steering wheel assembly”
5. Disassemble the cladding of steering column, please refer to “cladding of steering column”
6. Disassemble the clock spring, please refer to “clock spring”
7. Dismantle the combination switch, please refer to “combination switch”
8. Dismantle the driver side’s back-plate, please refer to “driver side’s back-plate”
9. Disassemble the guard induction coil, please refer to “guard induction coil”
10. Dismantle the ignition lock assembly, please refer to “ignition lock assembly”
11. Disassemble the steering shaft assembly with universal shaft
1). Loosen the fixing bolt that connects steering column
and steering shaft

2). Loosen the fixing bolt that connects steering shaft

and steering gear
3). Take off the steering shaft assembly with universal
joint

EPS (Electronic Power Steering) 195

 EPS (Electronic Power Steering)

(II) Installation
1. Install the steering shaft assembly with universal joint
1). Tighten the fixing bolt that connects steering shaft
and steering gear
Tightening torque 30~35N.m

2). Tighten the fixing bolt that connects steering column

assembly and steering shaft assembly
Tightening torque: 30~35N.m
3). Adjust the steering wheel’s steering angle to 0

cardiagn.com
△Notice after the dismounting of steering column, the
wheel’s steering angle may be affected, while the pilot
lamp on dashboard hasn’t lighted. It is necessary to carry
out steering wheel’s signal calibration. After calibration,
when the ignition switch is in “ON” position, EPS
controller will inspect each module of the system, and
light the EPS pilot lamp. If self-inspection is normal, the
pilot lamp will die in 2 seconds.
2. Install the guard induction coil
3. Install the driver-side back-plate
4. Install the combination switch
5. Install the clock spring
6. Install the steering wheel assembly
7. Install the cladding of steering column
8. Install the driver’s air bag assembly
9. Connect the negative cable of battery
10. Close the engine hood

VII Steering gear assembly

(I) Disassembly
1. Disassemble the left-front wheel, please refer to “wheels”
2. Disassemble the right-front wheel, please refer to
“wheels”
3. Dismantle left-lower suspension arm assembly, please
refer to “lower suspension arm”
4. Dismantle right-lower suspension arm assembly, please
refer to “lower suspension arm”
5. Dismantle the front sub-frame assembly with stabilizer
bar and steering gear, please refer to “front sub-frame

EPS (Electronic Power Steering) 196

 EPS (Electronic Power Steering)

assembly”
6. Disassemble the steering gear assembly
1). Disassemble the two hex flange-face nuts and two
gear locknuts that connect gear assembly and front
subframe
2). Take off the steering gear assembly

(II) Installation

1. Install the steering gear assembly

cardiagn.com
1). Put the gear assembly on the installing position of front
sub-frame
2). Install the two hex flange-face nuts and two gear
locknuts that connect gear assembly and front sub-frame
Tightening torque 95~105N.m
3). Adjust the tie rod’s left and right length according to
the value before maintenance, and tighten the locknut
after the adjustment.
Tightening torque 45~55N.m
4). Adjust the steering wheel’s steering angle to 0
△Notice after the dismounting of steering column, the
wheel’s steering angle may be affected, while the pilot
lamp on dashboard hasn’t lighted. It is necessary to carry
out steering wheel’s signal calibration. After calibration,
when the ignition switch is in “ON” position, EPS
controller will inspect each module of the system, and
light the EPS pilot lamp. If self-inspection is normal, the
pilot lamp will die in 2 seconds.
2. Install the front sub-frame assembly with stabilizer bar and steering gear
3. Install the right lower suspension arm assembly
4. Install the left lower suspension arm assembly
5. Install the right-front wheel
6. Install the left-front wheel

EPS (Electronic Power Steering) 197