Tilt Lever Replacement (EPS)
The content of this article reflects the changes identified in TSB Bulletin No. 06-02-35-012Date: May 18, 2006
SERVICE MANUAL UPDATE
Subject:
Revised Tilt Lever Replacement
Models:
2004-2006 Chevrolet Malibu
2005-2006 Pontiac G6
Tilt Lever Replacement (EPS)
Removal Procedure
1. Disable the SIR system.
2. Disconnect the negative battery cable.
3. Remove the steering column knee bolster.
Important:
DO NOT disconnect the adjustable brake pedal cable.
4. Loosen the lower steering column mounting bolt.
Note:
Once the steering column is lowered, the column is extremely susceptible to damage. Leaning on or pushing down on the column will result in damage to the intermediate shaft boot seal and could cause the jacket to bend or deform.
5. Remove the upper steering column mounting bolts (1).
6. Actuate the tilt lever to full "UNLOCK" position to release the coil spring tension.
7. Remove the L/H and R/H coil springs.
8. Remove and discard the torque prevailing nut.
9. Remove the tilt lever, thrust washer, bolt retainer, spacer, cam follower and the follower release.
10. Leave two tilt teeth and lever detent in assembled position. If the components are removed, follow the instructions for reassembly.
Installation Procedure
Important:
You MUST properly install the teeth into the upper column bracket to prevent steering column movement in the event of a collision.
1. If the tilt teeth and/or detent lever was removed, carefully reinstall in the correct orientation as shown.
^ Line up the teeth in the proper orientation.
^ Compress the tooth spring within compression bracket slot.
Important:
Grease the cam surface with P/N 89021688 (Canadian P/N 89021674). Subassemble spacer to bolt retainer.
2. Align with the tilt teeth and attach to the side of the tilt bracket.
3. Subassemble the cam follower to release the follower.
^ Align with the tilt teeth and attach to the side of the tilt bracket.
^ Align with the tilt teeth and attach to the side of the tilt bracket.
4. Assemble the tilt lever through components.
5. Attach the thrust washer and preassemble the new torque prevailing nut.
6. Hold the tilt lever, with light pressure, against the cam follower.
^ Actuate the lever to position against closed stop detent. Lever handle should be approximately parallel with the work surface.
Note:
Refer to Fastener Notice.
7. Continue to maintain light pressure on the tilt lever and tighten the nut.
Tighten
Tighten the torque prevailing nut until stamping surfaces are drawn together to 5.5 Nm (49 lb in).
8. Actuate the tilt lever to OPEN and CLOSED position several times while holding the tilt bracket in the proper alignment.
9. Adjust the nut torque until the load on the tilt lever handle is approximately 55 Nm (41 lb ft) to fully close lever.
^ Using a tool such as a mechanical force gage compare with a similar vehicle to confirm proper tilt lever closing force.
10. Compare with a similar vehicle to confirm proper tilt lever closing force.
Caution:
^ In order to ensure function of the steering column in a vehicle during a crash and in order to avoid personal injury to the driver, perform the following:
^ Tighten the steering column lower fasteners before you tighten the steering column upper fasteners. Failure to do this can damage the steering column.
^ Tighten the steering column fasteners to the specified torque. Overtightening the upper steering column fasteners could affect the steering column collapse.
11. Tighten the steering column fasteners in the following sequence:
Tighten
Tighten the lower steering column mounting thru bolt to 27 Nm (20 lb ft).
12. Tighten the left side upper steering column mounting bolt to 27 Nm (20 lb ft).
13. Tighten the right side upper steering column mounting bolt to 27 Nm (20 lb ft).
14. Install the steering column knee bolster.
15. Connect the negative battery cable.
16. Enable the SIR system.
17. Inspect the steering column components for correct operation.
18. Reprogram the steering system. Refer to Control Module References.
Tilt Lever Replacement (HPS)
Removal Procedure
1. Disable the SIR system.
2. Disconnect the negative battery cable.
3. Remove the steering column knee bolster.
4. Disconnect the steering column electrical connectors.
5. Disconnect the vehicle stability enhancement system (VSES) sensor harness connector at the steering column lower bearing. Open the steering column wire harness retainer clip.
Important:
DO NOT disconnect the adjustable brake pedal cable.
6. Loosen the lower steering column mounting bolt.
Note:
Once the steering column is lowered, the column is extremely susceptible to damage. Leaning on or pushing down on the column will result in damage to the intermediate shaft boot seal and could cause the jacket to bend or deform.
7. Remove the upper steering column mounting bolts (1).
8. Actuate the tilt lever to full "UNLOCK" position to release the coil spring tension.
9. Remove the L/H and R/H coil springs.
10. Remove and discard the torque prevailing nut.
11. Remove the tilt lever, thrust washer, bolt retainer, spacer, cam follower and the follower release.
12. Leave two tilt teeth and lever detent in assembled position. If the components are removed, follow the instructions for reassembly.
Installation Procedure
Important:
You MUST properly install the teeth into the upper column bracket to prevent steering column movement in the event of a collision.
1. If the tilt teeth and/or detent lever was removed, carefully reinstall in the correct orientation as shown.
^ Line up the teeth in the proper orientation.
^ Compress the tooth spring within compression bracket slot.
Important:
Grease the cam surface with P/N 89021688 (Canadian P/N 89021674). Subassemble spacer to bolt retainer.
2. Align with the tilt teeth and attach to the side of the tilt bracket.
3. Subassemble the cam follower to release the follower.
^ Align with the tilt teeth and attach to the side of the tilt bracket.
4. Assemble the tilt lever through components.
5. Attach the thrust washer and preassemble the new torque prevailing nut.
6. Hold the tilt lever, with light pressure, against the cam follower. Actuate the lever to position against closed stop detent. Lever handle should be approximately parallel with the work surface.
Note:
Refer to Fastener Notice.
7. Continue to maintain light pressure on the tilt lever and tighten the nut.
Tighten
Tighten the torque prevailing nut until stamping surfaces are drawn together to 5.5 Nm (49 lb in).
Important:
Do not bend the steering column energy absorbing straps located on the upper steering column mounting bracket during installation.
8. Loosely install the upper steering column mounting bolts (1).
9. Actuate the tilt lever to OPEN and CLOSED position several times while holding the tilt bracket in the proper alignment.
10. Adjust the nut torque until the load on the tilt lever handle is approximately 55 Nm (41 lb ft) to fully close lever. Compare with a similar vehicle to confirm proper tilt lever closing force.
Caution:
In order to ensure the intended function of the steering column in a vehicle during a crash and in order to avoid personal injury to the driver, perform the following:
^ Tighten the steering column lower fasteners before you tighten the steering column upper fasteners. Failure to do this can damage the steering column.
^ Tighten the steering column fasteners to the specified torque. Overtightening the upper steering column fasteners could affect the steering column collapse.
11. Tighten the steering column fasteners in the following sequence:
Tighten
Tighten the lower steering column mounting thru bolt to 27 Nm (20 lb ft).
12. Tighten the left side upper steering column mounting bolt to 27 Nm (20 lb ft).
13. Tighten the right side upper steering column mounting bolt to 27 Nm (20 lb ft).
14. Connect the VSES sensor harness at the steering column lower bearing.
15. Connect the steering column electrical connectors to the steering column.
16. Install the steering column knee bolster.
17. Connect the negative battery cable.
18. Enable the SIR system.
19. Inspect the steering column components for correct operation.