Steering: Testing and Inspection

Power Steering - Pressure Test
Check
1. Position absorbent cloth to catch spillage.
2. Remove bolt securing PAS high pressure pipe clip to PAS pump.
3. Loosen union securing high pressure pipe to PAS pump and release pipe.





4. K1.8 models: Fit adaptor LRT-57-034A to high pressure port of PAS pump.
5. KV6 & TD4 models: Fit adaptor LRT-57-042 to high pressure port of PAS pump.
6. Fit adaptor LRT-57-035 to existing high pressure hose.
7. Fit hose LRT-57-002 to each adaptor.
8. Fit pressure gauge LRT-57-005 to test valve LRT-57-001
9. Connect hoses LRT-57-002 to LRT-57-001 and tighten unions.
10. Ensure steering system and test equipment is free from leaks.
11. Maintain maximum fluid level during test.
12. With the test valve open, start the engine.
13. Pressure at idle should be between 5 and 7 bar.
14. With the engine at idle, slowly turn the steering wheel and hold on full lock.
15. Repeat procedure for other side.
16. Test pressure should rise significantly as steering wheel is rotated and continue to rise as full lock is approached, at full lock pressure should be:
^ TD4 & KV6 models: 112 to 120 bar. (maximum pump pressure)
17. With the engine at idle, release steering wheel. Pressure should read below 7 bar.
18. Pressures outside the above tolerance indicates a fault.
19. To determine if fault is in steering pump or steering rack, close the test valve for a maximum of 5 seconds.

CAUTION: Pump damage will occur if test valve is closed for longer periods.

20. If gauge does not register correct reading, suspect faulty pump.
21. If PAS pump pressure is correct and steering is heavy at idle and becomes light as engine RPM is increased, suspect pump flow rate.
22. If maximum pump pressure is correct, suspect steering rack.
23. On completion stop engine and remove test equipment.
24. Clean PAS pump and pipe union.
25. Fit new O-ring to high pressure pipe, align to PAS pump and tighten union to 25 Nm (18 ft. lbs.).
26. Fit bolt securing high pressure pipe clip and tighten to 8 Nm (6 ft. lbs.).
27. Check and top-up PAS fluid level.