Opel Insignia: Repair Instructions

Wire to Wire Repair - Steering

Special Tools

• EL-38125-10 Splice Sleeve Crimping Tool (non GMNA)
• J-38125-5A Ultra Torch Special Tool
• J-38125-8 Splice Sleeve Crimping Tool (GMNA)

For equivalent regional tools, refer to Special Tools.

WARNING: In order to reduce the risk of personal injury, loss of high voltage isolation to ground and higher system impedance, do not attempt to repair any HV wiring, connector, or terminal that is damaged. High voltage coaxial type cables are not repairable. Never attempt to repair a coaxial type cable. The entire cable/harness or component must be replaced. In order to maintain system integrity and personal safety, never attempt to repair any high voltage wiring, cables, or terminals. Performing this procedure on high voltage circuits may result in serious injury or death.

NOTE: If the wiring harness internal to the transmission is damaged, the wiring harness must be replaced. The use of splice sleeves in an attempt to repair the internal transmission wires, connectors, or terminals could result in performance issues.

NOTE: Do not splice wires in Door Harness Grommets.

NOTE: The DuraSeal splice sleeves have the following 2 critical features:

• A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside.
• A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits.

Use only DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except high voltage and specialty cables. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves.

Splice Sleeve Selection

NOTE: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.

1. Open the harness by removing any tape:

• Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage.
• Use the DuraSeal splice sleeves on all types of insulation except Tefzel and coaxial.
• Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together.

2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.

Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors.

3. Strip the insulation:

• When adding a length of wire to the existing harness, use the same size wire as the original wire.
• Perform one of the following items in order to find the correct wire size:
  • Find the wire on the schematic and convert to regional wiring gauge size.
  • If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation.
• Strip approximately 5.0 mm (0.20 in) of insulation from each wire to be spliced.
• Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
• If the wire is damaged, repeat this procedure after removing the damaged section.

4. For high temperature wiring, slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure.

5. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests.

6.

The EL-38125-10 splice sleeve crimping tool has four crimp nests. The largest crimp nest (4) is used for crimping 10 and 12 gauge wires. The second largest crimp nest (3) is used for crimping 14 and 16 gauge wires. The third largest crimp nest (2) is used for crimping 18 and 20 gauge wires. The smallest crimp nest (1) is used for crimping 22 to 26 gauge wires. The crimp nests are referenced in the table (farther above) under the crimp tool nest color.

7.

The J-38125-8 splice sleeve crimping tool has three crimp nests. The largest crimp nest (3) is used for crimping 10 and 12 gauge wires. The second largest crimp nest (2) is used for crimping 14 and 16 gauge wires. The smallest crimp nest (1) is used for crimping 18 to 20 gauge wires. The crimp nests are referenced in the table (farther above) under the crimp tool nest color.

8. Use the splice sleeve crimp tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. For the four crimp nest tool, use the three largest crimp nests to crimp the splice sleeves. For the three crimp nest tool, use all three crimp nests to crimp the splice sleeves. Use the four and three crimp tool diagrams (above) and the table (farther above) to match the splice sleeve with the correct crimp nest. The crimp tool diagram callout numbers match the numbers in the table (under crimp tool nest color).

9.

Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.

10.

Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. Refer to Folded-Over Wire Repair for splicing wires of 0.35 mm or less (22, 24, 26 gauge sizes) and for splicing wires of different gauges.

11. Tightly close the handles of the crimp tool until the crimper handles open when released.

The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 6 for the opposite end of the splice.

12.

Using the heat torch, apply heat to the crimped area of the barrel.

13. Start in the middle and gradually move the heat barrel to the open ends of the tubing:

• The tubing will shrink completely as the heat is moved along the insulation.
• A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved.

Weatherpack™ Wiring Repair

NOTE: Some replacement pigtail connectors may be delivered without the terminated leads installed into the connector. For Weatherpack™ connectors, all terminated leads included in the package should to be installed into the connector. If the connector end view shows that a terminal is not occupied, the extra terminated lead(s) need to be installed and the end(s) sealed using a DuraSeal splice sleeve and taped back into the harness.

1. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. Refer to Folded-Over Wire Repair for splicing wires of 0.35 mm or less (22, 24, 26 gauge sizes) and for splicing wires of different gauges.

2. Tightly close the handles of the crimp tool until the crimper handles open when released.

The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Holding the DuraSEAL with one hand gently tug on the wire to ensure it is crimped in the DuraSeal.

3. Using the heat torch, apply heat to the crimped area of the barrel.

4.

Start in the middle and gradually move the heat barrel to the open ends of the tubing:

• The tubing will shrink completely as the heat is moved along the insulation.
• A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved.

5.

Tape the extra terminated lead(s) back into the harness.

High Temperature Wiring Repairs

Use the following procedures to perform high temperature wiring repairs:

1. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve.

2. Using the heat torch, apply heat to the high temperature heat shrink tubing.

3. Gradually move the heat from the center to the open end of the tubing:

• The tubing will shrink completely as the heat is moved along the insulation.
• A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved.

4. Replace any reflective tape and clips that may have been removed during the repair.

Connector Reconnection - Steering

Special Tools

EL-35616 Terminal Test Probe Kit

For equivalent regional tools, refer to Special Tools.

When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent.

An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition.

Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items:

• Loose, corroded, or painted terminal stud/fastener
• Wiring broken inside the insulation
• Poor connection between the male and female terminal at a connector
• A terminal not seated all the way into the connector body
• Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc.
• Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits.
• Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle.
• Wiring that comes in contact with hot or exhaust components
• Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern.
• Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions.
• Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation.

Testing for Terminal Fretting

Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface.

To correct a fretting condition disconnect the suspect connector and add dielectric grease / lubricant (Nyogel 760G or equivalent, meeting GM specification 9986087) to both sides of the connector terminals.

Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion.

Testing for Proper Terminal Contact

It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation.

Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.

Deformation is caused by probing the mating side of a connector terminal without the proper adapter.

Always use the EL-35616 kit when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves.

Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit.

Testing for Proper Terminal Contact in Bussed Electrical Centers

It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center. Use the EL-35616 kit to test for proper terminal contact. Failure to use the EL-35616 kit can result in improper diagnosis of the bussed electrical center.

Follow the procedure below in order to test terminal contact:

1. Separate the connector halves.

2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body.

3. Using an equivalent male terminal/terminated lead, verify that the retention force is significantly different between a known good terminal and the suspect terminal. Replace the female terminal in question.

Flat Wire Connectors

There are no serviceable parts for flat wire connectors on the harness side or the component side.

Follow the procedure below in order to test terminal contact:

1. Remove the component in question.

2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well.

3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation.

4. Insert the appropriate adapter into the flat wire harness connector in order to test the circuit in question.

Control Module/Component Voltage and Grounds

Poor voltage or ground connections can cause widely varying symptoms.

• Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Operate the component to test the ability of the circuit to carry sufficient current. Refer to Circuit Testing , and Power Distribution Schematics.
• Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point (screw or stud). Inspect the connections at the component and in splice packs, where applicable. Operate the component to test the ability of the circuit to carry sufficient current. Refer to Circuit Testing , and Ground Distribution Schematics.

Temperature Sensitivity

• An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot.
• Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable.
• If the intermittent is related to heat, review the data for a relationship with the following:
  • High ambient temperatures
  • Underhood/engine generated heat
  • Circuit generated heat due to a poor connection, or high electrical load
  • Higher than normal load conditions, towing, etc.
• If the intermittent is related to cold, review the data for the following:
  • Low ambient temperatures - In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion.
  • The condition only occurs on a cold start.
  • The condition goes away when the vehicle warms up.
• Information from the customer may help to determine if the trouble follows a pattern that is temperature related.
• If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required.

Electromagnetic Interference and Electrical Noise

Some electrical components/circuits are sensitive to electromagnetic interference or other types of electrical noise. Inspect for the following conditions:

• A mis-routed harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc. - These components may induce electrical noise on a circuit that could interfere with normal circuit operation.
• Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch - These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating.
• Installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc. - These accessories may create interference in other circuits while operating and the interference would disappear when the accessory is not operating. Refer to Checking Aftermarket Accessories.
• Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode.
• The generator may be allowing AC noise into the electrical system.

Incorrect Control Module

• There are only a few situations where reprogramming a control module is appropriate:
  • A new service control module is installed.
  • A control module from another vehicle is installed.
  • Revised software/calibration files have been released for this vehicle.

NOTE: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern.

• Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming.

Steering Linkage Outer Tie Rod Replacement

Preliminary Procedure

Remove the front tire and wheel assembly.

1. Steering Linkage Inner Tie Rod Nut
   Procedure
   Place match marks on the steering linkage inner tie rod nut and the steering linkage inner tie rod.
   NOTE: Do NOT tighten the steering linkage inner tie rod nut during installation.
   Tighten the nut after adjusting the front toe.
2. Steering Linkage Outer Tie Rod Nut
   CAUTION: Refer to Fastener Caution.
   Tighten
   First Pass: 35 N.m (26 lb ft)
   Final Pass: (30 - 45 degrees)
3. Steering Linkage Outer Tie Rod
   CAUTION: Do not free the ball stud by using a pickle fork or a wedge-type tool.
   Damage to the seal or bushing may result.

   Procedure

   1. Use the CH-24319 - B Universal Steering Linkage and Tie Rod Puller to separate the steering linkage outer tie rod from the steering knuckle.
   2. Clean the tapered surface of the steering knuckle.
   3. Inspect the steering linkage inner tie rod for bent or damaged threads. If necessary, replace the steering linkage inner tie rod. Steering Linkage Inner Tie Rod Replacement
   4. Install the front tire and wheel assembly. Tire and Wheel Removal and Installation
   5. Measure and adjust the front toe. Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment

   Special Tools

   CH-24319 - B Universal Steering Linkage and Tie Rod Puller Equivalent regional tools:Special Tools

STEERING GEAR BOOT REPLACEMENT

Preliminary Procedure

Steering Linkage Outer Tie Rod Replacement.

1. Steering Linkage Inner Tie Rod Nut
   Procedure
   Place match marks on the steering linkage inner tie rod nut and the steering linkage inner tie rod.
2. Steering Gear Boot Outer Clamp
3. Steering Gear Boot Inner Clamp
   Procedure
   1. Cut the steering gear boot inner clamp.
      DISCARD the clamp.
   2. Use the DT-35910 pliers to install the NEW steering gear boot inner clamp.

   NOTE: Position the NEW steering gear boot inner clamp on the steering gear boot before installing the boot on the steering gear.

   Special Tools
   DT-35910 Drive Axle Boot Clamp Pliers
   Equivalent regional tools:Special Tools

4. Steering Gear Boot
   Procedure
   1. After removing the steering gear boot, inspect the steering linkage inner tie rod for evidence of corrosion or contamination. If corrosion or contamination is evident, replace the steering gear.
   2. Install the steering gear boot and ensure the boot is seated in the assembly groove of the steering gear before installing the steering gear boot clamps.

STEERING GEAR HEAT SHIELD REPLACEMENT

1. Steering Gear Heat Shield Bolt[3x]
   CAUTION: Fastener Caution
   Tighten 9N.m (80 lb in)
2. Steering Gear Heat Shield

Electric Dual Pinion Rack and Pinion Steering Gear Replacement

Removal Procedure

CAUTION: Electrostatic discharge (ESD) can damage many solid-state electrical components. ESD susceptible components may or may not be labeled with the ESD symbol. Handle all electrical components carefully. Use the following precautions in order to avoid ESD damage:

• Touch a metal ground point in order to remove your body's static charge before servicing any electronic component; especially after sliding across the vehicle seat.
• Do not touch exposed terminals. Terminals may connect to circuits susceptible the ESD damage.
• Do not allow tools to contact exposed terminals when servicing connectors.
• Do not remove components from their protective packaging until required to do so.
• Avoid the following actions unless required by the diagnostic procedure:
  • Jumpering or grounding of the components or connectors.
  • Connecting test equipment probes to components or connectors.

    Connect the ground lead first when using test probes.

• Ground the protective packaging of any component before opening.

  Do not rest solid-state components on metal workbenches, or on top of TVs, radios, or other electrical devices.

CAUTION: During removal and installation, all EPS components including mechanical and/or electrical is extremely susceptible to damage. Dropping or prying on any EPS component may cause internal damage. If damage occurs or a part is dropped, the EPS component must be replaced.

CAUTION: Care must be taken during removal and installation of the Electronic Power Steering (EPS) components to not hit or break the EPS motor/controller module or module harness connectors. If the EPS motor/ controller module or module connectors are damaged, the complete component must be replaced.

1.

Disconnect the steering gear electrical connectors (1).

2. Remove the steering gear wiring harness clips (2) from the mounting points on the steering gear.

3.

Drivetrain and Front Suspension Cradle(1) - Remove.

4.

Front Stabilizer Shaft(1)@Steering Gear(2) - Reposition away.

5.

Steering Gear Bolt(1) - Remove[2x].

6. Remove the steering gear (2) from the drivetrain and front suspension cradle.

7. Transfer components as necessary.

Installation Procedure

1.

Position the steering gear (2) on the drivetrain and front suspension cradle.

CAUTION: Refer to Fastener Caution.

2. Steering Gear Bolt(1) - Install and tighten[2x].

Tighten

1. First Pass: 100 N.m (74 lb ft)
2. Final Pass: (45 - 60 degrees)

3.

Front Stabilizer Shaft(1)@Steering Gear(2) - Reposition.

4.

Drivetrain and Front Suspension Cradle(1) - Install.

5.

Connect the steering gear electrical connectors (1).

6. Install the steering gear wiring harness clips (2) in the mounting points on the steering gear.

7. Program the power steering control module.

8. Measure the wheel alignment.

STEERING LINKAGE INNER TIE ROD REPLACEMENT

Preliminary Procedures

1. Steering Gear Boot Replacement.

2. After removing the steering gear boot, inspect the steering linkage inner tie rod for evidence of corrosion or contamination. If corrosion or contamination is evident, replace the steering gear.

1. Steering Linkage Inner Tie Rod

CAUTION: Refer to Component Fastener Tightening Caution.

Procedure

1. Place a wrench on the flats of the steering linkage inner tie rod housing.
2. Rotate the steering linkage inner tie rod housing counterclockwise to remove the steering linkage inner tie rod from the steering gear rack.
3. Rotate the steering linkage inner tie rod housing clockwise to install the steering linkage inner tie rod to the steering gear rack.
   Use the CH-6321 wrench and a torque wrench to tighten the steering linkage inner tie rod to specification.
4. Measure and adjust the front toe.

Tighten 105 N.m (77 lb ft)

Special Tools
CH-6321 Inner Tie Rod Wrench
Equivalent regional tools:Special Tools

STEERING GEAR DRIVE COUPLING REPLACEMENT

Preliminary Procedure

Power Steering Assist Motor Replacement.

1. Steering Gear Drive Coupling

NOTE: The steering gear drive coupling connects the power steering assist motor to the steering gear.

Power Steering Assist Motor Replacement

Removal Procedure

CAUTION: Electrostatic discharge (ESD) can damage many solid-state electrical components. ESD susceptible components may or may not be labeled with the ESD symbol. Handle all electrical components carefully. Use the following precautions in order to avoid ESD damage:

• Touch a metal ground point in order to remove your body's static charge before servicing any electronic component; especially after sliding across the vehicle seat.
• Do not touch exposed terminals. Terminals may connect to circuits susceptible the ESD damage.
• Do not allow tools to contact exposed terminals when servicing connectors.
• Do not remove components from their protective packaging until required to do so.
• Avoid the following actions unless required by the diagnostic procedure:
  • Jumpering or grounding of the components or connectors.
  • Connecting test equipment probes to components or connectors.
    Connect the ground lead first when using test probes.
• Ground the protective packaging of any component before opening.

  Do not rest solid-state components on metal workbenches, or on top of TVs, radios, or other electrical devices.

CAUTION: During removal and installation, all EPS components including mechanical and/or electrical is extremely susceptible to damage. Dropping or prying on any EPS component may cause internal damage. If damage occurs or a part is dropped, the EPS component must be replaced.

CAUTION: Care must be taken during removal and installation of the Electronic Power Steering (EPS) components to not hit or break the EPS motor/controller module or module harness connectors. If the EPS motor/ controller module or module connectors are damaged, the complete component must be replaced.

1. Perform the strategy based diagnosis. Performing the strategy based diagnostics includes reviewing related bulletins, preliminary information and diagnostics.

NOTE:

• The power steering control module is part of the power steering assist motor.
• If communication with the OLD power steering control module cannot be established, then replace the entire steering gear as an assembly. Do NOT proceed with replacement of just the power steering assist motor.

2. Capture the key cycle count from the OLD steering gear control module. If the key cycle count from the OLD steering gear control module is NOT captured, it will NOT be possible to flash the NEW steering gear control module.

3. Steering Gear - Remove.

4.

CAUTION: Do NOT pry on the Power Steering Assist Motor electrical connector.
Prying on the Power Steering Assist Motor electrical connector could crack the Power Steering Assist Motor housing. If the Power Steering Assist Motor housing is cracked, the motor assembly must be replaced.

Remove the connector position assurance lock (1) from the electrical connector(2).

5. Discard the connector position assurance lock if damaged during removal.

6.

Depress connector tab (1) and disconnect the electrical connector (2) from the power steering assist motor(3).

7.

Power Steering Assist Motor Bolt(1) - Remove and DISCARD[2x].

8. Power Steering Assist Motor(2) - Remove.

9.

Remove the Steering Gear Drive Coupling(1) - Remove and DISCARD.

10. Power Steering Assist Motor Seal(2) - Remove and DISCARD.

NOTE:

• Inspection of the steering gear motor shaft and the inside of the steering gear housing is REQUIRED to ensure that there are NO signs of water intrusion or corrosion which MAY cause premature motor failure.
• If signs of water intrusion or corrosion ARE present then the steering gear MUST be replaced.

11. Inspect the steering gear motor shaft and inside of the steering gear housing for signs of water intrusion or corrosion. If no signs of water intrusion or corrosion are present proceed to the next step.

If signs of water intrusion or corrosion are present then replace the steering gear.

Installation Procedure

1.

Power Steering Assist Motor Seal(2) - Install NEW.

2. After the power steering assist motor seal (2) is placed on the power steering assist motor, apply a thin layer of grease to the seal.

3. Steering Gear Drive Coupling(1) - Install NEW.

4.

NOTE: The steering gear drive coupling and assist motor armature should be aligned with the gear inside of the steering gear housing to aid in installation, otherwise interference MAY occur.

Position the power steering assist motor (2) with the steering gear housing and start the power steering assist NEW motor bolt(1).[2x].

5. With the power steering assist motor bolt (1) started, completely install the power steering assist motor (2)to the steering gear housing.

CAUTION: Refer to Fastener Caution.

6. Power steering assist motor bolt (1) Install NEW and tighten[2x] 21 N.m (15 lb ft).

7.

Connect the electrical connector (1) to the power steering assist motor.

8. Verify connector (1) is fully seated by lightly pulling on the connector.

9.

NOTE: If the connector position assurance lock (1) was damaged during removal, discard it and skip step 8.

Install the connector position assurance lock (1) into the electrical connector (2) until fully seated.

10. Steering Gear - Install.

11. Transfer the key cycle count from the OLD steering gear control module to the NEW steering gear control module.

POWER STEERING CONTROL MODULE CALIBRATION

Steering Angle Sensor Centering and Software Endstop Learning

WARNING: An inaccurate or not centered steering angle sensor could limit the operation of the electric power steering and may result in personal injury.

Centering of the steering angle sensor and software endstop learning might be required after certain service procedures are performed. Some of these procedures are as follows:

• Steering angle sensor replacement
• Steering gear replacement
• Power steering assist motor replacement
• Steering column replacement
• Steering linkage inner tie rod replacement
• Steering linkage outer tie rod replacement

NOTE: It is necessary to perform the steering angle sensor centering BEFORE the software endstop learning.

Steering Angle Sensor Centering

For electronic power steering equipped vehicles WITH electronic stability control program and EXTERNAL Steering Angle Sensor, refer to Steering Wheel Angle Sensor Centering.

The centering procedure of the internal steering angle sensor (w/o electronic stability program) can be completed with the following steps: Conditions: Front axle measured and set, engine running, vehicle speed 0 km/h (0 MPH), internal steering angle sensor is activated.

1. Using the steering wheel, align the front wheels in the center forward position.

2. Using a scan tool, perform the Configuration/Reset Functions, Steering Wheel Angle Sensor Centering procedure.

3. Steer from the center position slowly 90º to the left.

4. Steer slowly back to the center position and then slowly 90º to the right.

5. Steer slowly back to the center position.

6. Perform the steering movements again.

7. Centering procedure is completed.

Software Endstop Learning

The software endstop learning procedure can be completed with the following steps:

Conditions: Front axle measured and set, vehicle speed 0 km/h (0 MPH), internal steering angle sensor is calibrated or external steering angle sensor sends a valid CAN signal.

1. Using a scan tool, perform the Configuration/Reset Functions, Power Steering Softstops Reset procedure and follow the on-screen instructions.

2. Using a scan tool, perform the Configuration/Reset Functions, Power Steering Softstops Learn procedure and follow the on-screen instructions.

3. Software endstop learning procedure is completed.

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