student workbook

70-1805-W 10-1831-T

Module 5: Steering and Suspension Systems

Automotive Technology Curriculum

2006 2005 Edition Student Test Workbook Packet

STEERING AND SUSPENSION SYSTEMS

Automotive Technology Module 5: Steering and Suspension Systems Student WorkbookTechnical Consultants: Roger Donovan Robin Ferguson

Project Coordinator: Erica Kassel

Editor: Janis Levsen

Produced by the Instructional Materials Laboratory 1400 Rock Quarry Center University of Missouri-Columbia Columbia, MO 65211 (800) 669-2465 http://www.iml.missouri.edu 2006 Edition Catalog no. 70-1805-W 2006. The Curators of the University of Missouri. All Rights Reserved.i

Graphic Artists: Chris Benedict Jacqueline Craig

AUTOMOTIVE TECHNOLOGY

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STEERING AND SUSPENSION SYSTEMSName: MODULE 5: STEERING AND SUSPENSION SYSTEMS STUDENT WORKBOOK TRACKING SHEETAssignment Sheet AS1-L1-UI AS1-L1-UII AS1-L2-UII AS1-L3-UII AS1-L1-UIII AS1-L1-UVI AS1-L2-UVI AS1-L1-UVII AS1-L2-UVII AS1-L3-UVII AS1-L1-UX AS1-L1-UXI AS1-L1-UXII AS1-L2-UXII AS1-L3-UXIII AS1-L1-UXIV AS1-L2-UXIV Job Sheet JS1-L2-UI JS2-L2-UI JS1-L4-UII JS2-L4-UII JS3-L4-UII JS1-L1-UIII Title of Assignment Sheet Steering and Suspension Systems Types of Steering Systems Conventional Steering System Components Rack-and-Pinion Steering Systems Steering Gear Concerns Energy-Absorbing Steering Column Air Bag Systems Suspension Systems Front Suspension Types and Components Rear Suspension Types and Components Electronic Suspension Control Systems Wheel Bearings Wheel Basics Tire Basics Wheel Balance and Runout Steering, Suspension, and Wheel Alignment Concerns Wheel Alignment Principles Title of Job Sheet Complete a Work Order With Concern, Cause, and Correction Identify and Interpret a Steering and Suspension Concern Inspect and Adjust Manual Steering Gear Lubricant Level Inspect and Adjust Power Steering Fluid Levels Diagnose Fluid Leaks in the Power Steering System Diagnose Manual and Power Steering Gear Concerns Instructor Guide Page # 1114 4750 7982 9194 141144 345348 355358 401404 433436 443446 623626 663666 707710 723726 787790 827830 845848 Instructor Guide Page # 1920 2124 105106 107108 109110 145146 Student Workbook Page # W 12 W 910 W 1112 W 1314 W 2122 W 103104 W 105106 W 121122 W 123124 W 125126 W 191192 W 203204 W 215216 W 217218 W 237238 W 245246 W 251252 Student Workbook Page # W 34 W 58 W 1516 W 1718 W 1920 W 2324 Date Instructors Initials Date Instructors Initials

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AUTOMOTIVE TECHNOLOGYMODULE 5: STEERING AND SUSPENSION SYSTEMS STUDENT WORKBOOK TRACKING SHEET PAGE 2Job Sheet JS1-L2-UIII JS2-L2-UIII JS3-L2-UIII JS1-L3-UIII JS2-L3-UIII JS3-L3-UIIII JS1-L4-UIII JS2-L4-UIII JS3-L4-UIII JS4-L4-UIII JS5-L4-UIII JS1-L1-UIV JS2-L1-UIV JS3-L1-UIV JS4-L1-UIV JS1-L2-UIV JS2-L2-UIV JS3-L2-UIV JS4-L2-UIV Title of Job Sheet Remove and Install a Manual Steering Gear Disassemble, Clean, and Inspect a Manual Steering Gear Reassemble and Adjust a Manual Steering Gear Remove and Install an Integrated Power Steering Gear Disassemble, Clean, and Inspect an Integrated Power Steering Gear Reassemble and Adjust an Integrated Power Steering Gear Inspect and Replace a Pitman Arm Inspect and Replace a Center Link Inspect and Replace Tie-Rod Ends Inspect and Replace an Idler Arm Inspect and Replace a Steering Damper Remove and Install a Manual Rack-andPinion Steering Gear Inspect and Replace Rack-and-Pinion Inner Tie-Rods and Bellows Boots Disassemble, Clean, and Inspect a Manual Rack-and-Pinion Steering Gear Reassemble and Adjust a Manual Rack-andPinion Steering Gear Remove and Install a Power Rack-and-Pinion Steering Gear Disassemble, Clean, and Inspect a Power Rack-and Pinion Steering Gear Reassemble and Adjust a Power Rack-andPinion Steering Gear Test and Diagnose Components of Electronically Controlled Steering Systems Using a Scan Tool Inspect and Test Nonhydraulic Electric Power-Assist Steering Replace Rack Boots (End Take-Off Units) Replace Rack Mount Bushings Test Power Steering System Pressure Instructor Guide Page # 155158 159160 161162 171174 175178 179180 195198 199200 201204 205206 207208 233234 235238 239240 241242 253254 255256 257258 259260 Student Workbook Page # W 2528 W 2930 W 3132 W 3336 W 3740 W 4142 W 4346 W 4748 W 4952 W 5354 W 5556 W 5758 W 5962 W 6364 W 6566 W 6768 W 6970 W 7172 W 7374 Date Instructors Initials

JS5-L2-UIV JS1-L3-UIV JS2-L3-UIV JS1-L1-UV

261262 267268 269270 287290

W 7576 W 7778 W 7980 W 8184

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STEERING AND SUSPENSION SYSTEMSMODULE 5: STEERING AND SUSPENSION SYSTEMS STUDENT WORKBOOK TRACKING SHEET PAGE 3Job Sheet JS1-L2-UV JS2-L2-UV JS3-L2-UV JS4-L2-UV JS5-L2-UV JS6-L2-UV JS7-L2-UV Title of Job Sheet Remove and Install a Power Steering Pump Inspect and Replace Power Steering Pressure Hoses Service a Power Steering Pump Inspect, Replace, and Adjust the Power Steering Pump Belt Flush the Power Steering Gear Flush the Power Steering Pump Identify Hybrid Vehicle Power Steering System Electrical Circuits Service and Safety Precautions Identify Vehicles Equipped With a Supplemental Restraint System (SRS) Disable and Enable a Supplemental Restraint System (SRS) Remove and Install a Steering Wheel on a Vehicle Equipped With a Supplemental Restraint System (SRS) Diagnose Steering Column Concerns and Remove and Install an Energy-Absorbing Steering Column Disassemble, Inspect, and Reassemble an Energy-Absorbing Steering Column Diagnose a Short- and Long-Arm (SLA) Suspension System Lubricate a Steering and Suspension System Inspect and Replace Conventional or GasCharged Shock Absorbers Inspect and Replace Air-Adjustable Shock Absorbers Inspect and Replace Stabilizer Bars and Bushings Inspect and Replace Strut Rods and Bushings Inspect and Replace Coil Springs Inspect and Replace Torsion Bar Springs Inspect and Replace Ball Joints Inspect and Replace Lower Control Arms and Bushings Inspect and Replace Upper Control Arms and Bushings Instructor Guide Page # 307310 311312 313316 317318 319320 321322 323324 Student Workbook Page # W 8588 W 8990 W 9194 W 9596 W 9798 W 99100 W 101102 Date Instructors Initials

JS1-L3-UVI JS2-L3-UVI JS3-L3-UVI

369370 371372 373374

W 107108 W 109110 W 111112

JS4-L3-UVI

375378

W 113116

JS5-L3-UVI JS1-L1-UVIII JS2-L1-UVIII JS1-L2-UVIII JS2-L2-UVIII JS3-L2-UVIII JS4-L2-UVIII JS1-L3-UVIII JS2-L3-UVIII JS3-L3-UVIII JS4-L3-UVIII JS5-L3-UVIII

379382 475480 481482 493496 497500 501502 503504 521524 525528 529530 531534 535538

W 117120 W 127132 W 133134 W 135138 W 139142 W 143144 W 145146 W 147150 W 151154 W 155156 W 157160 W 161164

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AUTOMOTIVE TECHNOLOGYMODULE 5: STEERING AND SUSPENSION SYSTEMS STUDENT WORKBOOK TRACKING SHEET PAGE 4Job Sheet JS1-L4-UVIII JS2-L4-UVIII JS3-L4-UVIII JS1-L1-UIX JS2-L1-UIX JS3-L1-UIX JS4-L1-UIX JS5-L1-UIX JS1-L2-UX JS2-L2-UX JS3-L2-UX JS4-L2-UX JS5-L2-UX Title of Job Sheet Diagnose Strut Suspension Systems Remove, Inspect, and Install Strut Assemblies Replace Strut Dampers, Springs, and Mounts Inspect and Replace Rear Leaf Springs Remove, Inspect, and Install Transverse Spring Systems Inspect and Replace Rear Coil Springs and Insulators Inspect and Replace Rear Suspension Control Arms and Bushings Inspect and Replace Rear Suspension Shock Absorbers Test Electronic Level Control Performance Leak Test an Electronic Level Control System Remove and Install an Electronic Level Control Compressor Test an Electronic Level Control Height Sensor Test and Diagnose Components of Electronically Controlled Suspension Systems Using a Scan Tool Service Nonsealed Tapered Roller Wheel Bearings Remove and Install Sealed Front-Wheel Bearings: Front-Wheel-Drive Vehicles Remove and Install Sealed Rear-Wheel Bearings: Front-Wheel-Drive Vehicles Remove, Inspect, and Install a Wheel Spindle/Knuckle Inspect and Inflate Tires Rotate Tires Dismount, Inspect, and Mount Tires Dismount, Inspect, and Mount a Tire on a Wheel Equipped With a Tire Pressure Sensor Repair Punctures in Tubeless Tires Inspect, Diagnose, and Calibrate a Tire Pressure Monitoring System Instructor Guide Page # 549552 553554 555558 589592 593594 595596 597600 601604 637638 639640 641642 643644 645646 Student Workbook Page # W 165168 W 169170 W 171174 W 175178 W 179-180 W 181182 W 183186 W 187190 W 193194 W 195196 W 197198 W 199200 W 201202 Date Instructors Initials

JS1-L2-UXI JS2-L2-UXI JS3-L2-UXI JS4-L2-UXI JS1-L1-UXIII JS2-L1-UXIII JS1-L2-UXIII JS2-L2-UXIII JS3-L2-UXIII JS4-L2-UXIII

679682 683684 685686 687688 751754 755756 771774 775778 779780 781782

W 205208 W 209210 W 211212 W 213214 W 219222 W 223224 W 225228 W 229232 W 233234 W 235236

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STEERING AND SUSPENSION SYSTEMSMODULE 5: STEERING AND SUSPENSION SYSTEMS STUDENT WORKBOOK TRACKING SHEET PAGE 5Job Sheet JS1-L4-UXIII JS2-L4-UXIII JS1-L1-UXIV JS1-L3-UXIV JS2-L3-UXIV JS3-L3-UXIV Title of Job Sheet Measure a Wheel-and-Tire Assembly for Radial and Lateral Runout Balance Wheel-and-Tire Assemblies Diagnose Various Steering, Suspension, and Wheel Alignment Concerns Measure and Correct Front-Wheel Alignment Measure and Correct Rear-Wheel Alignment Diagnose Alignment Concerns Caused by Damaged Components Instructor Guide Page # 799802 803804 831834 863866 867870 871876 Student Workbook Page # W 239242 W 243244 W 247250 W 253256 W 257260 W 261266 Date Instructors Initials

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STEERING AND SUSPENSION SYSTEMSAS1-L1-UI STEERING AND SUSPENSION SYSTEMSDirections Answer the following questions by writing all responses on this sheet. 1. Which components in Rudolf Ackerman's steering system allowed the front wheels to turn in an arc?NAME:

DATE:

2.

Which suspension system was superior to Ackerman's design in that it brought improved control and cushioned the vehicle against shocks?

3.

Which steering gear was introduced in the 1920s and is still used today.

4.

Are the steering system and suspension system closely related? Explain why or why not.

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AUTOMOTIVE TECHNOLOGY5. What are the four basic rules of undercar service? A.

B.

C.

D.

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STEERING AND SUSPENSION SYSTEMSJS1-L2-UI COMPLETE A WORK ORDER WITH CONCERN, CAUSE, AND CORRECTIONDirections: 1. The instructor will list a repair. Complete the work order on the following page for the repair. To receive credit, all sections of the work order must be complete. Credit received for completing work orderNAME(S):

DATE:

EVALUATION

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AUTOMOTIVE TECHNOLOGYSmiths Automotive Repair Customers Name: Address: Year/Make: Service Writer: Customer Authorization Signature: Customer Concern: Model: VIN: Technician: Date: Invoice #: Phone: Mileage:

Vehicle Service History Information:

Related Technical Service Bulletins:

Diagnostic Procedures Performed:

Cause:

Correction:

Labor Procedures and Costs

Estimated

Actual

Outside Labor Procedures and Costs

Total Labor Costs Parts Costs Quantity Part # Description

Total Parts Costs Labor Total Parts Total Sales Tax GRAND TOTAL

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STEERING AND SUSPENSION SYSTEMSJS2-L2-UI IDENTIFY AND INTERPRET A STEERING AND SUSPENSION CONCERNEquipment: Personal protective equipment (PPE) Scan tool Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.NAME(S):

DATE:

EVALUATION

3.

Identify the concern. If possible, ask the owner/driver the following questions. a. b. c. d. e. Under what conditions does the problem occur? Are there unusual sounds? Are there vibrations in the steering and suspension systems? Does the vehicle pull to one side or wander? How long has the problem existed? Is it getting worse?

4.

Test drive the vehicle under the conditions that the problem has been observed. CAUTION: Road test a vehicle only with the instructors approval. Before performing a road test, inspect the vehicle to ensure that the vehicle is safe and that a road test will not cause damage to the vehicle. Safety should be of prime importance during all road tests. Never drive in an unsafe manner in order to identify a problem. a. The road test should be performed by the individual who will perform the repairs.

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AUTOMOTIVE TECHNOLOGYb. c. Ask the owner/driver to ride along during the road test. The owner/driver can assist in identifying the source of any problems. Record all abnormal conditions in the following space.

5.

Isolate the cause of the problem. a. Interpret vehicle and major component identification numbers. b. VIN Vehicle certification labels Calibration decals

Research applicable vehicle and service information. Steering and suspension components and their operation Vehicle service history Service precautions Technical service bulletins

c.

Perform a visual inspection of the steering and suspension system. Look for damaged or broken components. Look for worn or misaligned components. Check fluid levels. Inspect related electrical sensors, corrector, controls, and wiring.

d.

Connect a scan tool and check for stored diagnostic trouble codes (DTCs). Record information in the space below.

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STEERING AND SUSPENSION SYSTEMSe. 6. Test the systems and components that could cause the problem. Eliminate good components until the cause is found.

Determine the necessary action and record in the following space.

Average of the above evaluations

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STEERING AND SUSPENSION SYSTEMSAS1-L1-UII TYPES OF STEERING SYSTEMSDirections Answer the following questions by writing all responses on this sheet. 1. Define the following terms. A. Conventional (linkage) steering system NAME:

DATE:

B.

Power steering

C.

Rack-and-pinion steering system

D.

Steering column

E.

Steering gear

2.

What type of design is commonly used in manual steering gears?

3.

What is the function of the hydraulic power piston in an integrated power steering gear?

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AUTOMOTIVE TECHNOLOGY4. When compared with the conventional steering system, what are two advantages of the rack-and-pinion steering system? A.

B.

5.

Which three linkage components in the conventional system are omitted in the rack-and-pinion system? A. B. C

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STEERING AND SUSPENSION SYSTEMSAS1-L2-UII CONVENTIONAL STEERING SYSTEM COMPONENTSDirections Answer the following questions by writing all responses on this sheet. 1. Write the component name in the blank beside each function given. A. B. C. D. E. F. Supports the wheel bearing, hub, and wheel-and-tire assembly Transfers gearbox movement to the linkage Functions similar to a shock absorber Reduces effort required to turn steering wheel Used by driver to turn steering gear Connects the center link to the steering knuckleNAME:

DATE:

2.

Explain how motion is transferred from the worm gear shaft to the sector gear shaft in a manual steering gear.

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AUTOMOTIVE TECHNOLOGY3. Answer the following questions about the principles of hydraulics. A. According to Pascal's law, what happens to a confined liquid when it is put under pressure?

B.

Explain what occurs with regard to fluid motion and multiplying force when the input piston is smaller than the output piston.

C.

How does Pascals law apply to the power steering system?

4.

What are the three common types of power steering pumps? A. B. C.

5.

What is the function of the rotary valve in the rotary valve integrated power steering system?

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STEERING AND SUSPENSION SYSTEMSAS1-L3-UII RACK-AND-PINION STEERING SYSTEMSDirections Answer the following questions by writing all responses on this sheet. 1. What does the rack in a manual rack-and-pinion steering system look like?NAME:

DATE:

2.

In a manual rack-and-pinion system, what is the function of the bellows boots at the ends of the housing?

3.

What three components make up the typical power rack-and-pinion steering unit? A. B. C.

4.

How does the proportional rack-and-pinion steering system operate?

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AUTOMOTIVE TECHNOLOGY5. Why is a vehicle with an EPS system able to provide steering assistance even if the engine is off?

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STEERING AND SUSPENSION SYSTEMSJS1-L4-UII INSPECT AND ADJUST MANUAL STEERING GEAR LUBRICANT LEVELEquipment: Hand tools Personal protective equipment (PPE) Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.NAME(S):

DATE:

EVALUATION

3.

Using service information, locate a procedure for adjusting the steering gear lubricant level. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section I, B.)

Using the procedure, inspect and adjust the lubricant level in the steering gear. Determine and record the type of lubricant used. Record any leaks found in the steering gear.


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STEERING AND SUSPENSION SYSTEMSJS2-L4-UII INSPECT AND ADJUST POWER STEERING FLUID LEVELSEquipment: Exhaust ventilation equipment Personal protective equipment (PPE) Thermometer Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.EVALUATION NAME(S):

DATE:

3.

Determine and record the type of power steering fluid used.

4. 5.

Ensure that the engine is off, make sure the wheels are straight, and wipe away any dirt from around the dipstick. Remove the dipstick and determine the level, condition, and temperature of the fluid. Record observations.

6. 7.

Using the correct fluid, fill the system to the proper level. Replace the dipstick. Connect the exhaust ventilation equipment.

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AUTOMOTIVE TECHNOLOGYCAUTION: Be sure to use approved exhaust ventilation equipment when operating a vehicle in an enclosed space. 8. 9. Start the engine. Let it idle while turning the steering wheel slowly from lock to lock two or three times. Shut off the engine. Disconnect the exhaust ventilation equipment. Repeat step 4 through step 8 to ensure that the fluid level is correct. Record observations in the following space.

NOTE: If the fluid is foamy, allow the vehicle to set a few minutes with the engine off so that the foam can dissipate. If foam is heavy, the vehicle may have to set for 1 hour. NOTE: If the dipstick has add and full marks instead of hot and cold full marks, maintain the fluid level between the add and full marks. If servicing an older system that does not use a dipstick, remove the reservoir cover or lid and adjust the fluid level to the reservoir's full mark. Average of the above evaluations

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STEERING AND SUSPENSION SYSTEMSJS3-L4-UII DIAGNOSE FLUID LEAKS IN THE POWER STEERING SYSTEMDATE: NAME(S):

Equipment: Exhaust ventilation equipment Personal protective equipment (PPE) Trouble light Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.

EVALUATION

3.

Raise the vehicle's hood and visually inspect the steering system for leaks. a. b. If the steering system is saturated with fluid, thoroughly clean all suspected components. Connect the exhaust ventilation equipment. CAUTION: Be sure to use approved exhaust ventilation equipment when operating a vehicle in an enclosed area. c. d. Start the engine and make three or four full lock-to-lock turns. Shut off the engine. Disconnect the exhaust ventilation equipment. Inspect the system for leaks. Record observations.

NOTE: In order to detect a slow leak, clean the steering system and drive the car for a distance before inspecting the system. NOTE: Hoses are usually not repairable; replace them.

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AUTOMOTIVE TECHNOLOGYCAUTION: Do not attempt to substitute a fuel hose or any other type of hose for a power steering hose. Use only hoses that have been approved for power steering systems and that have the correct pressure rating. Most other hoses cannot withstand the extreme pressure demands of a power steering system. 4. Recommend steps to repair any leaks found in the steering system. Write the recommendations below.

5.

Use proper lifting equipment to raise the vehicle. CAUTION: When lifting a vehicle, always use proper lifting equipment and observe all safety precautions. Inspect the undercar portion of the steering system for leaks. Record observations below. Recommend steps to correct any leaks. Write recommendations below.


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STEERING AND SUSPENSION SYSTEMSAS1-L1-UIII STEERING GEAR CONCERNSDirections Answer the following questions by writing all responses on this sheet. 1. What is the term for the condition in which the vehicle pulls in the direction of the drivers last steering maneuver after the steering wheel returns to the center?NAME:

DATE:

2.

What is the term for a condition in which the rear tires lose traction before the front tires?

3.

Define the term steering play.

4.

Name four things to check when diagnosing steering gear operation in a road test. A.

B.

C.

D.

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AUTOMOTIVE TECHNOLOGY5. List two factors that affect the effort required to turn the steering wheel. A. B.

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STEERING AND SUSPENSION SYSTEMSJS1-L1-UIII DIAGNOSE MANUAL AND POWER STEERING GEAR CONCERNSEquipment: Exhaust ventilation equipment Personal protective equipment (PPE) Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.EVALUATION NAME(S):

DATE:

3.

Connect the exhaust ventilation equipment. If inspecting a power steering system, start the vehicle's engine and run it at an idle. CAUTION: Be sure to use approved exhaust ventilation equipment when operating a vehicle in an enclosed area.

4.

Turn the steering wheel slowly from stop to stop. Respond to the questions below. a. Are there leaks in the system? (See JS3-L4-UII for a procedure to diagnose leaks in the power steering system.) Yes_____ No_____ b. c. d. e. Is there binding at any point? Is the same effort required to turn the steering wheel in both directions? Yes_____ No_____ Yes_____ No_____

Is excessive effort required to turn the wheel? Yes_____ No_____ Does the system make any unusual noises? Yes_____ No_____

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AUTOMOTIVE TECHNOLOGYf. Does the steering wheel jerk during turns? (This question applies only to power steering vehicles.) Yes_____ No_____ 5. Record the possible causes of any of the problems noted in step 4.

6.

After obtaining permission from the instructor, drive the car slowly and carefully. Observe if the steering wheel returns properly from both left and right turns. Record observations. CAUTION: Road test a vehicle only with the instructor's approval.

7.

After obtaining permission from the instructor, drive the car at highway speed and respond to the following questions. a. b. Does the car pull to one side or the other? Does the car wander? Yes_____ No_____ Yes_____ No_____

8.

After obtaining permission from the instructor, drive the car slowly over bumps and rough pavement. Note any gear rattle or clunk. Record observations.

9. 10.

Shut off the engine. Disconnect the exhaust ventilation equipment. Record the possible causes of any of the problems noted in step 6 through step 8 above.


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STEERING AND SUSPENSION SYSTEMSJS1-L2-UIII REMOVE AND INSTALL A MANUAL STEERING GEAREquipment: Hand tools Personal protective equipment (PPE) Torque wrench Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.EVALUATION NAME(S):

DATE:

3.

Use proper lifting equipment to raise the vehicle. CAUTION: When lifting a vehicle, always use proper lifting equipment and observe all safety precautions.

4.

Using service information, locate a procedure for removing the manual steering gear from the vehicle. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section I.)

Using the above procedure, remove the steering gear from the vehicle. Record observations.

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AUTOMOTIVE TECHNOLOGY5. Using the procedure outlined below, inspect the steering gear and related components. a. Inspect the gear mounting area of the vehicle frame for cracking or elongated holes. Repair a damaged frame-mounting area before reinstalling the gear. Record observations.

b.

Inspect the gear assembly for lubricant leaks or housing damage. Record observations.

c.

Inspect the flexible coupling. If the coupling is worn or damaged, replace it. Record observations.

6.

Using service information, locate a procedure for installing the vehicle's manual steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.

NOTE: Be sure to check and adjust the steering gear lubricant level if necessary. Refer to JS1-L4-UII for this procedure. Using the procedure, install the vehicle's manual steering gear. Record observations.

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STEERING AND SUSPENSION SYSTEMS7. Check steering gear operation. Record observations.

8.

Lower the vehicle.


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STEERING AND SUSPENSION SYSTEMSJS2-L2-UIII DISASSEMBLE, CLEAN, AND INSPECT A MANUAL STEERING GEARDATE: NAME(S):

Equipment: Hand tools Personal protective equipment (PPE) Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.EVALUATION

3. 4.

Remove the steering gear from the vehicle if required. Refer to JS1-L2-UIII for this procedure. Using service information, locate a procedure for disassembling the manual steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section II, A.)

NOTE: After removing the gear, thoroughly clean its exterior with a safety solvent. NOTE: Carefully count the number of balls removed from the ball nut. Do not lose any of the balls. Using the procedure, disassemble the manual steering gear. Record observations.

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AUTOMOTIVE TECHNOLOGY5. Using service information, locate a procedure for cleaning and inspecting the manual steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section II, B.)

Using the procedure, clean and inspect the manual steering gear. Fill out the checklist below. If an item is marked "NOT OK," explain the problem in the space below and determine the necessary action to correct it. Worm Shaft Ball Nut Ball Nut Grooves Ball Guides Worm Bearings Gear Housing Sector shaft teeth Sector shaft fit Sector shaft bearing Steel Balls Lash Adjuster Screw OK OK OK OK OK OK OK OK OK OK OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK

NOTE: Some worm adjuster bearings are not serviceable. Therefore, if a nonserviceable bearing is defective, replace the entire adjuster.


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STEERING AND SUSPENSION SYSTEMSJS3-L2-UIII REASSEMBLE AND ADJUST A MANUAL STEERING GEARDATE: NAME(S):

Equipment: Hand tools Personal protective equipment (PPE) Torque wrench Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.EVALUATION

3.

Using service information, locate a procedure for reassembling the manual steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section III.)

Using the procedure, reassemble the manual steering gear. Record observations below.

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AUTOMOTIVE TECHNOLOGY4. Using service information, locate a procedure for adjusting the manual steering gear. Ensure that the procedure includes all necessary specifications. Make sure that the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section III.)

Using the procedure, adjust the manual steering gear. Record observations below.

5.

Turn the worm shaft completely to the left and right several times. Note any binding or roughness. Record findings.

6.

Reinstall the steering gear on the vehicle. Refer to JS1-L2-UIII for this procedure.


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STEERING AND SUSPENSION SYSTEMSJS1-L3-UIII REMOVE AND INSTALL AN INTEGRATED POWER STEERING GEAREquipment: Drain pan Hand tools Personal protective equipment (PPE) Torque wrench Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.EVALUATION NAME(S):

DATE:

3.


4.

Using service information, locate a procedure for removing the power steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section I, A.)

Using the procedure, remove the power steering gear. Record observations below.

NOTE: Before removal, clean all dirt from around the fluid line connections at the steering gear.

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AUTOMOTIVE TECHNOLOGY5. Using the procedure outlined below, inspect the gear assembly. a. Inspect the gear assembly for fluid leakage and housing damage. Record observations.

b.

Also inspect the gear mounting area of the vehicle frame for cracking or elongated holes. Record observations.

NOTE: Repair a damaged frame before reinstalling the steering gear. Consult the instructor for the proper procedure. c. Inspect the pressure and return hoses. Record observations.

d.

Inspect the flexible coupling for wear or damage. Record observations.

6.

Using service information, locate a procedure for installing the power steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.

Using the procedure, install the power steering gear. Record observations.

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STEERING AND SUSPENSION SYSTEMS7. After installation, perform the following tasks. a. b. c. Be sure to replace all defective parts. Fill the steering reservoir and bleed the system. Inspect for leaks and repair any leaks found. Record observations.

d. e.

Lower the vehicle. Check the operation of the steering gear. Record observations.


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STEERING AND SUSPENSION SYSTEMSJS2-L3-UIII DISASSEMBLE, CLEAN, AND INSPECT AN INTEGRATED POWER STEERING GEAREquipment: Drain pan Hand tools Personal protective equipment (PPE) Various specialty tools Vise or holding fixture Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.NAME(S):

DATE:

EVALUATION

3. 4.

Remove the steering gear from the vehicle, if required. Refer to JS1-L3-UIII for this procedure. Using service information, locate a procedure for disassembling the power steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section II, AC.)

NOTE: Before disassembling the power steering gear, plug the fluid ports and thoroughly clean the gear's exterior with a safety solvent. NOTE: Some manufacturers do not service certain steering gear components and do not recommend disassembling the steering gear. Closely follow the manufacturer's directions for the vehicle.

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AUTOMOTIVE TECHNOLOGYUsing the procedure, disassemble the power steering gear. Record observations below.

5.

Using service information, locate a procedure for cleaning and inspecting the vehicle's power steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section II, D.)

Using the procedure, clean and inspect the vehicle's power steering gear. Use the checklist below to determine if the components are defective. NOTE: Thoroughly clean all parts in a clean safety solvent and blow-dry. Control Valve Assembly Piston Nut Worm Shaft Stub Shaft Sector Shaft Bushings Thrust Bearings Gear Housing Inlet Check Valve Steel Balls Ball Guides OK OK OK OK OK OK OK OK OK OK OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK

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STEERING AND SUSPENSION SYSTEMSIf any of the components in the list are marked "Not OK," determine the necessary action and record below.


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STEERING AND SUSPENSION SYSTEMSJS3-L3-UIII REASSEMBLE AND ADJUST AN INTEGRATED POWER STEERING GEAREquipment: Hand tools Personal protective equipment (PPE) Torque wrench Various specialty tools Vise or holding fixture Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.NAME)(S):

DATE:

EVALUATION

3.

Using service information, locate a procedure for reassembling the steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.

Using the procedure, reassemble the steering gear. Record observations.

NOTE: Be sure to replace all damaged or missing steering gear parts according to the instructor's directions. NOTE: During assembly, lightly coat all components with the appropriate power steering fluid.

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AUTOMOTIVE TECHNOLOGY4. Using service information, locate a procedure for adjusting the power steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section IV.)

Using the procedure, adjust the power steering gear. Record observations.

5.

Turn the worm shaft completely to the left and right several times. Note any binding or roughness. Record observations.

6.

Reinstall the steering gear on the vehicle if required. Refer to JS1-L3-UIII for this procedure.


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STEERING AND SUSPENSION SYSTEMSJS1-L4-UIII INSPECT AND REPLACE A PITMAN ARMEquipment: Ball stud taper-breaking tool Hand tools Personal protective equipment (PPE) Pitman arm puller Torque wrench Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.EVALUATION NAME(S):

DATE:

3.

Use proper lifting equipment to raise the vehicle. CAUTION: When lifting the vehicle, always use proper lifting equipment and observe all safety precautions.

4.

Inspect the pitman arm for wear or damage. Record observations in the space below.

5.

Using the procedure outlined below, remove and inspect the pitman arm. a. b. c. Place a mark on the sector shaft and pitman arm to aid in positioning the components during reassembly. Remove the cotter pin from the castellated nut that connects the pitman arm to the steering linkage. Using a taper-breaking tool, separate the pitman arm from the steering linkage.

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AUTOMOTIVE TECHNOLOGYd. e. 6. Remove the nut and lockwasher from the sector shaft. Using the pitman arm puller, remove the pitman arm from the steering sector shaft using the pitman arm puller.

Inspect the tapered hole and stud in the pitman arm and steering link. Replace any worn parts. Record observations in the space below.

7.

Using the procedure outlined below, install the pitman arm. a. Refer to the appropriate service information for torque specifications. Record the specifications below. Pitman Arm to Sector Shaft Pitman Arm to Steering Link b. ____________ ____________

Place the wheels in the straight-ahead position and center the steering wheel. Install the pitman arm on the sector shaft. Use the marks made before disassembly to position the guide properly. NOTE: If the pitman arm has a master spline, make sure the arm aligns with it.

c. d.

Install the lockwasher and nut on the sector shaft and torque to specifications. Connect the pitman arm to the steering linkage. Tighten the castellated nut to the specified torque. Continue to tighten the nut until the cotter pin can be inserted. CAUTION: If the opening in the castellated nut does not align with the hole in the stud, continue to tighten the nut to the next opening and insert the cotter pin. Never loosen a nut to align openings; doing so can result in steering system failure.

e. f.

If the ball socket construction provides a lubrication fitting or plug, lubricate the socket with an EP-type chassis lubricant. If the vehicle uses self-locking nuts instead of castellated nuts, discard the old nuts and replace them with new nuts of the identical design.

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STEERING AND SUSPENSION SYSTEMSg. Turn the wheels through a full left and right turn to check for smooth operation. Record observations in the space below.

8.

Lower the vehicle.


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STEERING AND SUSPENSION SYSTEMSJS2-L4-UIII INSPECT AND REPLACE A CENTER LINKDATE: NAME(S):

Equipment: Ball stud taper-breaking tool Hand tools Personal protective equipment (PPE) Torque wrench Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.EVALUATION

3.

Use proper lifting equipment to raise the vehicle. CAUTION: When lifting a vehicle, be sure to use proper lifting equipment and observe all safety precautions.

4.

Inspect the center link for wear or damage. Record observations in the space below.

5.

Using the procedure outlined below, remove and inspect the center link. a. b. Remove cotter pins and castellated nuts from all four connecting points. Using a taper-breaking tool, separate the center link from the pitman arm, idler arm, and the tie-rods.

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AUTOMOTIVE TECHNOLOGY6. Inspect the tapered studs and mounting holes of the center link and all connecting arms. Clean excessive grease and dirt from all parts. Replace worn parts. Record observations.

7.

Using the procedure outlined below, install the center link. a. Refer to the appropriate service information for the torque specifications. Record the specifications below. Pitman Arm to Center Link Idler Arm to Center Link Tie-Rods to Center Link b. ____________ ____________ ____________

Install the center link, tighten the connecting nuts to the specified torque, and install the cotter pins. NOTE: If an opening in a castellated nut does not align with the hole in the stud, continue to tighten the nut to the next opening and insert the cotter pin. Never loosen the nut to align openings.

c. d. e.

If the vehicle uses self-locking nuts instead of castellated nuts, discard the old nuts and replace with new ones of the same design. Lubricate all ball sockets on the center link with an EP-type chassis lubricant if possible. Turn the wheels through a full left turn and right turn to check for smooth operation. Record observations.

f. g.

Lower the vehicle. Check the toe and adjust as necessary. See the instructor for this procedure.


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STEERING AND SUSPENSION SYSTEMSJS3-L4-UIII INSPECT AND REPLACE TIE-ROD ENDSEquipment: Ball stud taper-breaking tool Hand tools Personal protective equipment (PPE) Torque wrench Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.EVALUATION NAME(S):

DATE:

3.


4.

Inspect the tie-rod assembly for wear or damage. Record findings.

5.

Using the procedure outlined below, remove and inspect the tie-rod end. a. Loosen the tie-rod sleeve clamp bolt on the tie-rod end that is being removed. NOTE: If the clamp bolt and the sleeve are rusty, spray them with penetrating oil before disassembly. b. Measure the distance from the edge of the tie-rod sleeve to the center of the tie-rod end socket. Record this measurement below for use during reassembly. Measurement ______________________________

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AUTOMOTIVE TECHNOLOGYc. d. Remove the cotter pin and castellated nut from the ball stud. Using a taper-breaking tool, separate the tie-rod from the center link or steering knuckle. CAUTION: Using a pickle fork to break the taper may destroy the ball socket. f. Thread the tie-rod end out of the adjusting sleeve. Count the number of turns required to remove the tie-rod end. Record the number below. Turns Required 6. ____________________________

Inspect the tie-rod sleeve for damage, distortion, bad threads, or severe rusting. If any of the above problems are found, replace the sleeve. Observe the condition of the sleeve. Record observations. Using the procedure outlined below, install the tie-rod end. a. Refer to the appropriate service information for the torque specifications. Record the specifications. Outer Tie-Rod to Steering Knuckle Inner Tie-Rod to Center Link Adjuster Sleeve Clamp Bolt b. _________ _________ _________

7.

Thread the tie-rod end into the sleeve and count the number of turns. Stop when the tie-rod end turns the same amount of times as recorded in step 5f. Repeat the measurement made in step 5b. If necessary, adjust the tie-rod in or out to match the previous measurement. Connect the tie-rod to the steering knuckle, tighten the nut to specified torque, and install the cotter pin. If the vehicle uses self-locking nuts instead of castellated nuts, discard the old nuts and replace them with new nuts of the identical design. Center both the inner and outer tie-rod ends in their sockets and tighten the clamp bolts to the specified torque.

c. d. e.

f.

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STEERING AND SUSPENSION SYSTEMSg. h. i. j. If the ball socket construction provides a lubrication fitting or plug, lubricate the socket with an EP-type chassis lubricant. Turn the wheels through a full left turn and full right turn to check for smooth operation. Check the toe and adjust as necessary. See the instructor for this procedure. Lower the vehicle.


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STEERING AND SUSPENSION SYSTEMSJS4-L4-UIII INSPECT AND REPLACE AN IDLER ARMEquipment: Ball stud taper-breaking tool Hand tools Personal protective equipment (PPE) Torque wrench Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.EVALUATION NAME(S):

DATE:

3.


4.

Using service information, locate a procedure for inspecting the vehicle's idler arm. Include any specific tolerances for idler arm wear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.

Using the procedure, inspect the idler arm for wear or damage. Record observations.

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AUTOMOTIVE TECHNOLOGY5. Using service information, locate a procedure for removing and installing the idler arm in the vehicle. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section VIII.)

Using the procedure, remove and install the idler arm. Record observations.

NOTE: After removing the idler arm, inspect the stud or mounting hole in the center link. If the hole is worn, replace the center link. Average of the above evaluations

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STEERING AND SUSPENSION SYSTEMSJS5-L4-UIII INSPECT AND REPLACE A STEERING DAMPEREquipment: Hand tools Personal protective equipment (PPE) Torque wrench Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.EVALUATION NAME(S):

DATE:

3.


4.

Inspect the steering damper for damage and leakage. Also make sure the damper is mounted securely. Record observations in the space below.

5.

Disconnect one end of the damper. Extend and compress the damper and note any problems. Answer the following questions. Is there tightness or binding during damper travel? Yes _______ No _________

Is there fluid leakage during damper travel? Yes _______ No _________

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AUTOMOTIVE TECHNOLOGYIs there skipping (lack of resistance) during damper travel? Yes _______ No _________

NOTE: If "Yes" is the answer to any of the above questions, replace the damper. 6. Disconnect both the frame and the linkage ends and remove the damper from the vehicle. Inspect all mounting brackets and grommets. Replace any broken or deteriorated hardware. Using the procedure outlined below, install a steering damper. a. Refer to the appropriate service information for torque specifications. Record specifications. Frame End Linkage End b. ______________ ____________

7.

Install the damper to the vehicle's frame and to the steering linkage. Tighten fasteners to the specified torque. Install new cotter pins where used. Turn the wheels through a full left turn and full right turn. Make sure the wheels turn smoothly. Record observations in the space below.

c.

8.

Lower the vehicle.


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STEERING AND SUSPENSION SYSTEMSJS1-L1-UIV REMOVE AND INSTALL A MANUAL RACK-AND-PINION STEERING GEAREquipment: Hand tools Personal protective equipment (PPE) Torque wrench Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.NAME(S):

DATE:

EVALUATION

3.

When necessary, use proper lifting equipment to raise the vehicle. CAUTION: When lifting a vehicle, always use proper lifting equipment and observe all safety precautions.

4.

Using service information, locate a procedure for removing the manual rack-and-pinion steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section II, A.)

Using the procedure, remove the manual rack-and-pinion steering gear. 5. Inspect the gear assembly for lubricant leaks or housing damage. Record observations.

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AUTOMOTIVE TECHNOLOGY6. Inspect the condition of the flexible coupling and rubber mounting bushings. Replace any worn or deteriorated parts. Record observations.

7.

Using service information, locate a procedure for reinstalling the manual rack-and-pinion steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section II, B.)

Using the procedure, reinstall the manual rack-and-pinion steering gear. 8. Check the operation of the steering system. Record observations.


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STEERING AND SUSPENSION SYSTEMSJS2-L1-UIV INSPECT AND REPLACE RACK-AND-PINION INNER TIE-RODS AND BELLOWS BOOTSEquipment: Hand tools Personal protective equipment (PPE) Specialty tools Torque wrench Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.NAME(S):

DATE:

EVALUATION

3.

Using the procedure outlined below, inspect the condition of the inner tie-rods and bellows boots. a. b. Squeeze the boot until the inner socket is felt. While squeezing the boot, have an assistant perform one of the following steps. 1. 2. c. Turn the steering wheel back and forth one-eighth to one-quarter of a turn. Push and pull on the tires and turn them in and out one-quarter of a turn. If the tie-rod feels loose, replace it.

To inspect hard plastic rod boots, perform the following steps. Lock the steering wheel and use proper lifting equipment to raise the vehicle. CAUTION: When lifting a vehicle, always use proper lifting equipment and observe all safety precautions.

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AUTOMOTIVE TECHNOLOGY With the vehicle off the ground, turn the wheels in and out while watching for movement in the tie-rods. If movement is detected, replace the tie-rods.

d.

Record observations and describe any repairs in the space below.

e.

If a more thorough inspection is necessary, perform the steps below. Remove the inner tie-rod boot clamps and slide the boot back to expose the rod. Turn the steering wheel back and forth while the wheels rest on the ground. Watch the sockets for movement. If movement is detected, replace the rod. Record observations and describe any repairs in the space below.

4.

Using service information, locate a procedure for removing the rack-and-pinion inner tie-rods. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section III, B.)

Using the procedure, remove the rack-and-pinion inner tie-rods. Record observations.

NOTE: It may be necessary to remove the rack-and-pinion unit before removing the inner tie-rod and bellows. If so, refer to JS1-L1-UIV for the procedure.

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STEERING AND SUSPENSION SYSTEMSNOTE: Some manual steering gears are filled with a liquid lubricant that may spill when removing the boot. When checking inner tie-rods on manual rack-and-pinion systems that contain a liquid lubricant, do not remove the boot unless removing the entire assembly or replacing the lubricant. 5. Using service information, locate a procedure for reinstalling the rack-and-pinion inner tie-rods. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section IV, G.)

Using the procedure, reinstall the rack-and-pinion inner tie-rods. 6. Check the operation of the steering system. Record observations.


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STEERING AND SUSPENSION SYSTEMSJS3-L1-UIV DISASSEMBLE, CLEAN, AND INSPECT A MANUAL RACK-ANDPINION STEERING GEAREquipment: Drain pan Hand tools Personal protective equipment (PPE) Specialty tools Vise or holding fixture Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.NAME(S):

DATE:

EVALUATION

3. 4.

Remove the steering gear from the vehicle, if required. Refer to JS1-L1-UIV for this procedure. Using service information, locate a procedure for disassembling the manual rack-and-pinion steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section III.)

Using the procedure, disassemble the manual rack-and-pinion steering gear. Record observations.

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AUTOMOTIVE TECHNOLOGY5. 6. Thoroughly clean all parts in a safety solvent and then blow-dry the parts. Inspect the parts and use the checklist below to identify any defective components. Gear housing Pinion Rack Pinion bearings Rack bearing Bellows boots Rack bushings Yoke spring OK OK OK OK OK OK OK OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK

Determine the necessary action for correcting any problems identified in the above chart and record below.


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STEERING AND SUSPENSION SYSTEMSJS4-L1-UIV REASSEMBLE AND ADJUST A MANUAL RACK-AND-PINION STEERING GEAREquipment: Hand tools Personal protective equipment (PPE) Specialty tools Torque wrench Vise or holding fixture Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.NAME(S):

DATE:

EVALUATION

3.

Using service information, locate a procedure for reassembling the manual rack-and-pinion steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section IV.)

Using the procedure, reassemble the manual rack-and-pinion steering gear. Record observations.

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AUTOMOTIVE TECHNOLOGY4. Using service information, locate a procedure for adjusting the manual rack-and-pinion steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Submit the procedure to the instructor. Have the instructor check the box to approve the procedure.

Using the procedure, adjust the manual rack-and-pinion steering gear. Record observations.

5.

Turn the pinion shaft through a couple of full left to right turns. Note any binding or roughness. Record observations.

6.

Reinstall the steering gear on the vehicle, if required. For this procedure, refer to JS1-L1-UIV.


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STEERING AND SUSPENSION SYSTEMSJS1-L2-UIV REMOVE AND INSTALL A POWER RACK-AND-PINION STEERING GEAREquipment: Drain pan Hand tools Personal protective equipment (PPE) Torque wrench Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.EVALUATION NAME(S):

DATE:

3.


4.

Using service information, locate a procedure for removing the power rack-and-pinion steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section I, A.)

Using the procedure, remove the power rack-and-pinion steering gear. Record observations below.

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AUTOMOTIVE TECHNOLOGY5. Using service information, locate a procedure for installing the power rack-and-pinion steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section I, B.)

Using the procedure, install the power rack-and-pinion steering gear. 6. Check operation of the power steering system. Record observations below.


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STEERING AND SUSPENSION SYSTEMSJS2-L2-UIV DISASSEMBLE, CLEAN, AND INSPECT A POWER RACK-ANDPINION STEERING GEAREquipment: Drain pan Hand tools Personal protective equipment (PPE) Specialty tools Vise or holding fixture Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.NAME(S):

DATE:

EVALUATION

3. 4.

Remove the steering gear from the vehicle, if required. For this procedure, refer to JS1-L2-UIV. Using service information, locate a procedure for disassembling the power rack-and-pinion steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section II.)

Using the procedure, disassemble the power rack-and-pinion steering gear. Record observations below.

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AUTOMOTIVE TECHNOLOGY5. 6. Thoroughly clean all parts with a safety solvent and blow-dry them. Use the following checklist to identify any defective components found during the inspection. Add components to the list if necessary. Gear Housing Rack Pinion and Control Valve Assembly Pinion Bearings Rack Bearing Bulkhead Seals Rack Bushings OK OK OK OK OK OK OK OK OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK

NOTE: Except for the sealing rings on the spool valve, service the valve and pinion assembly as a complete unit. Determine necessary action for correcting any problems identified in the above checklist and record below.


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STEERING AND SUSPENSION SYSTEMSJS3-L2-UIV REASSEMBLE AND ADJUST A POWER RACK-AND-PINION STEERING GEAREquipment: Hand tools Personal protective equipment (PPE) Specialty tools Torque wrench Vise or holding fixture Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.NAME(S):

DATE:

EVALUATION

3.

Using service information, locate a procedure for reassembling the steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section III.)

Using the procedure, reassemble the steering gear. Record observations below.

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AUTOMOTIVE TECHNOLOGY4. Using service information, locate a procedure for adjusting the steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.

Using the procedure, adjust the steering gear. Record observations.

5.

Turn the pinion through several complete left-to-right turns. Note any binding or roughness. Record observations.

6.

Reinstall the rack-and-pinion steering gear on the vehicle if required. For this procedure, refer to JS1-L2-UIV.


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STEERING AND SUSPENSION SYSTEMSJS4-L2-UIV TEST AND DIAGNOSE COMPONENTS OF ELECTRONICALLY CONTROLLED STEERING SYSTEMS USING A SCAN TOOLEquipment: EPS-capable scan tool Personal protective equipment (PPE) Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.NAME(S):

DATE:

EVALUATION

3.

Question the customer about the conditions when the problem occurred in order to reproduce the same condition for troubleshooting. Find out when the electric power-assist steering (EPS) indicator came on, such as while turning, when the vehicle was at a certain speed, on start-up, etc. Record the findings below.

4. 5. 6.

Locate the correct scan tool and software. With the ignition switch off, connect the scan tool to the data link connector (DLC). Turn the ignition to the run position and use the scan tool to retrieve the diagnostic trouble codes (DTCs)OBD I (on-board diagnostics generation I) and OBD II (on-board diagnostics generation II). Interpret the trouble codes. Record observations below.

7.

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AUTOMOTIVE TECHNOLOGY8. 9. 10. Perform a pinpoint test to locate the faults. Clear the codes. Perform the necessary procedures to correct the problem. Record below.

11.

After obtaining permission from the instructor, test drive the vehicle to ensure proper EPS operation. CAUTION: Road test a vehicle only with the instructor's approval.


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STEERING AND SUSPENSION SYSTEMSJS5-L2-UIV INSPECT AND TEST NONHYDRAULIC ELECTRIC POWER-ASSIST STEERINGEquipment: Digital multimeter (DMM) Personal protective equipment (PPE) Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.EVALUATION NAME(S):

DATE:

3. 4.

Use service information to locate the electric power-assist steering (EPS) components. Using service information, locate a procedure for inspecting and testing the EPS control unit. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section V, B.)

Using the procedure, inspect and test the control unit. Record observations below.

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AUTOMOTIVE TECHNOLOGY5. Using service information, locate a procedure for inspecting and testing the EPS rack-and-pinion motor. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section V, C.)

Using the procedure, inspect and test the rack-and-pinion motor. Record observations below.

6.

Using service information, locate a procedure for inspecting and testing the EPS pressure sensor. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section V, D.)

Using the procedure, inspect and test the pressure sensor. Record observations below.


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STEERING AND SUSPENSION SYSTEMSJS1-L3-UIV REPLACE RACK BOOTS (END TAKE-OFF UNITS)Equipment: Caliper Hand tools Personal protective equipment (PPE) Tie-rod puller Torque wrench Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.EVALUATION NAME(S):

DATE:

3.

Using service information, locate a procedure and specification for performing rack boot replacement. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section I.)

Using the procedure, replace the rack boots. Record observations.

4.

Check the wheel alignment and adjust if necessary.


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STEERING AND SUSPENSION SYSTEMSJS2-L3-UIV REPLACE RACK MOUNT BUSHINGSDATE: NAME(S):

Equipment: Hand tools Personal protective equipment (PPE) Torque wrench Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.EVALUATION

3.

Using service information, locate a procedure and specifications for performing rack mount bushing replacement. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section II.)

Using the procedure, replace the rack mount bushings on both sides of the vehicle. Record observations in the space provided.


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STEERING AND SUSPENSION SYSTEMSJS1-L1-UV TEST POWER STEERING SYSTEM PRESSUREEquipment: Adapter hose and fittings Drain pan Exhaust ventilation equipment Hand tools Personal protective equipment (PPE) Safety valve Shutoff valve 0 psi to 2,000 psi pressure gauge Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.EVALUATION NAME(S):

DATE:

3.

Using service information, locate a procedure for connecting power steering pressure testing equipment to the vehicle. The procedure must also list all pressure specifications and describe which type of power steering fluid the vehicle needs. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.

Using the procedure, draw a diagram in the space below of how the equipment should be connected.

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AUTOMOTIVE TECHNOLOGY4. Using the diagram, connect a pressure gauge and shutoff valve to the outlet side of the pump. Completely open the shutoff valve. NOTE: Be sure to clean around the fittings before removing them; doing so prevents fluid contamination. 5. 6. Fill the pump reservoir with the correct fluid and bleed the system. Connect the exhaust ventilation equipment. CAUTION: Be sure to use the approved exhaust ventilation equipment when operating a vehicle in an enclosed area. 7. 8. Start the engine and allow it to idle. With the tester valve still open, operate the engine at idle speed and read the gauge. The reading indicates the pump flow pressure. Be sure that the reading is within the specifications determined in step 3 of this job sheet. Record the pressure below. _______ psi 9. Check the pump's relief pressure. a. Close the test valve completely and then reopen it three times. Record the pressure each time the test valve opens and closes. CAUTION: Do not hold the valve closed for more than 5 seconds; doing so could damage the pump. 1. _______ psi 2. _______ psi 3. _______ psi b. Compare the readings to manufacturer's specifications and record observations below.

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STEERING AND SUSPENSION SYSTEMS10. Check the condition of the steering gear, power cylinder and control valve, and hydro-boost valve. a. Turn the steering wheel to the left and right stops and record the highest pressure. Left Stop __________ psi Right Stop __________ psi b. Compare these readings with the maximum pump output and record observations below.

11.

If the vehicle is equipped with hydro-boost brakes and does not pass the test under step 10, bypass the hydro-boost unit to isolate the cause of the problem. Record observations below. CAUTION: The vehicle does not have power-assisted brakes while the hydro-boost is bypassed.

12. 13. 14. 15.

Disconnect the pressure test equipment from the vehicle. Fill the power steering reservoir with the correct fluid and bleed the system. Shut off the engine. Disconnect the exhaust ventilation equipment. Using the results of the above tests, describe the condition of the power steering system below. If there are any problems during the test, determine necessary action.

Average of above evaluations

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STEERING AND SUSPENSION SYSTEMSJS1-L2-UV REMOVE AND INSTALL A POWER STEERING PUMPDATE: NAME(S):

Equipment: Belt tension gauge Drain pan Hand tools Personal protective equipment (PPE) Specialty tools Torque wrench Vise Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.EVALUATION

3.

Using service information, locate a procedure for removing the power steering pump. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section I, A.)

Using the procedure, remove the power steering pump. Record observations.

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AUTOMOTIVE TECHNOLOGY4. 5. Drain the fluid from the reservoir, if necessary, and clean the exterior of the pump with safety solvent. Inspect the power steering pump and mountings. Use the following checklist to indicate problems with the pump. Pulley Reservoir Mountings Hoses Drive Belt OK OK OK OK OK Not OK Not OK Not OK Not OK Not OK

Determine the necessary action for any item marked "Not OK" and record below.

NOTE: Replacement pumps generally are not equipped with a pulley. Remove the old pulley and install it on the new pump. Inspect the old pulley carefully. NOTE: Replacement pumps may or may not be equipped with a reservoir. Before installing an old reservoir on a new pump, make sure the reservoir is in good condition. 6. If necessary, replace the pulley that drives the new pump. a. Remove the pulley. Install a suitable pulley removal tool on the pulley hub. Place the removal tool in a bench vise with the pump pointing upward. Hold the pump and rotate the removal tool nut counterclockwise to remove the pulley. CAUTION: Do not apply inward or outward pressure on the pulley shaft to remove or install the pulley; doing so causes damage to the internal pump.

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STEERING AND SUSPENSION SYSTEMSb. Install the new pulley. 7. Place the pulley against the pump shaft. Screw the installation tool into the threaded hole in the pump shaft. Place the end of the tool in the vise with the pump extending upward. Hold the pump and turn the tool nut to install the pulley on the pump shaft.

Using the procedure outlined below, replace the reservoir, if necessary. a. Remove the reservoir. Support the pump housing securely in a vise or holding fixture. Remove the outlet fitting and O-ring. Remove any other retaining bolts. Using a wood block and a hammer (or a soft-faced hammer), tap around the flange of the reservoir to release it from the pump. CAUTION: Never tap around the flange with a steel hammer or pry directly on the reservoir. b. Remove and discard the pump to reservoir O-ring. Thoroughly clean the reservoir in a safety solvent and blowdry.

Install the new reservoir. Install a new reservoir O-ring seal and outlet fitting gasket on the pump housing. Coat the inside edge of the reservoir and the O-ring with petroleum jelly. Place the reservoir over the pump housing and carefully align all holes. Use a hammer and a block of wood to tap the reservoir into place.

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AUTOMOTIVE TECHNOLOGY 8. Install all retainers and tighten them to the specified torque. Using service information, locate a procedure for installing the power steering pump. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section I, E.)

Using the procedure, install the power steering pump. 9. Using service information, locate a procedure for adjusting the power steering belt. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section I, F.)

Using the procedure, adjust the power steering belt. 10. 11. Fill the power steering reservoir with the correct fluid and bleed the system. Inspect for and correct any leaks.


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STEERING AND SUSPENSION SYSTEMSJS2-L2-UV INSPECT AND REPLACE POWER STEERING PRESSURE HOSESDATE: NAME(S):

Equipment: Hand tools Personal protective equipment (PPE) Torque wrench Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.

EVALUATION

3.


4.

Inspect the power steering hoses. Use the following checklist to indicate problems with the hoses. Dampness and leakage at crimp joints Abnormal swelling Abrasions Cracks Soft or spongy feel Damaged or worn fittings Yes Yes Yes Yes Yes Yes No No No No No No

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AUTOMOTIVE TECHNOLOGYDetermine the necessary action for any item marked "Yes" and record below.

5.

Using service information, locate a procedure for removing the power steering pressure hoses. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.

Using the procedure, remove the power steering hose. Record observations below.

6.

Using service information, locate a procedure for installing the power steering pressure hoses. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.

Using the procedure, install the power steering hose. Record observations.

7. 8. 9.

Fill the reservoir with the specified fluid and bleed the system. Check for and repair any leaks. Flush the power system gear and pump. See JS5-L2-UV and JS6-L2-UV.


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STEERING AND SUSPENSION SYSTEMSJS3-L2-UV SERVICE A POWER STEERING PUMPEquipment: Hand tools Personal protective equipment (PPE) Specialty tools Torque wrench Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.EVALUATION NAME(S):

DATE:

3. 4.

If required, remove the pump from the vehicle. Refer to JS1-L2-UV for this procedure. Using service information, locate a procedure for disassembling the power steering pump. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section III, A.)

Using the procedure, disassemble the power steering pump. Record observations.

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AUTOMOTIVE TECHNOLOGY5. Thoroughly clean all the steering pump components in a safety solvent and blow-dry. Inspect the components. Use the chart below to indicate any problems with the components. Housing Rotor Shaft and bearings Reservoir Pulley Pressure Plate Thrust Plate Vanes Cam Ring OK OK OK OK OK OK OK OK OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK


6.

Using service information, locate a procedure for reassembling the power steering pump. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section III, C.)

Using the procedure, reassemble the power steering pump. Record observations.

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STEERING AND SUSPENSION SYSTEMS7. After assembly, manually rotate the shaft and check the pump for binding. The shaft should rotate freely. Some manufacturers give a turning torque specification for shaft rotation. Reinstall the power steering pump on the vehicle, if required. For this procedure, refer to JS1-L2-UV.

8.


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STEERING AND SUSPENSION SYSTEMSJS4-L2-UV INSPECT, REPLACE, AND ADJUST THE POWER STEERING PUMP BELTEquipment: Belt tension gauge Hand tools Personal protective equipment (PPE) Torque wrench Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.NAME(S):

DATE:

EVALUATION

3.

Inspect the power steering pump belt. Use the list of defects below to indicate problems with the power steering belt. Replace the belt if it is defective. Glazed Cracked Oil soaked Torn or split Improper alignment Yes Yes Yes Yes Yes No No No No No


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AUTOMOTIVE TECHNOLOGY4. Using service information, locate a procedure for removing, installing, and adjusting the power steering pump belt. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.

Using the procedure, remove and install the belt. 5. Using the procedure from step 4 above, adjust the power steering belt tension, if necessary. (For a general procedure, see Section I, F.)


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STEERING AND SUSPENSION SYSTEMSJS5-L2-UV FLUSH THE POWER STEERING GEAREquipment: Drain pan Exhaust ventilation equipment Hand tools Personal protective equipment (PPE) Torque wrench Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.EVALUATION NAME(S):

DATE:

3.

Use proper lifting equipment to raise the vehicle. CAUTION: When lifting a vehicle, always use proper equipment and observe all safety precautions. lifting

4. 5. 6.

Disconnect the return hose from the power steering pump. Place the pump end of the hose in a drain pan. Disable the ignition system so the vehicle cannot start. For the procedures to disable the ignition system, refer to specific service information. Fill the fluid reservoir with clean fluid to the specified full mark. With the ignition system disabled, crank the engine and turn the wheel from lock to lock. Have an assistant continue to add fluid until about 2 quarts push through the system. CAUTION: Do not crank the starter for more than 30 seconds at a time. Pause and let the starter cool between cranks. Exceeding 30second cranks could damage the starter.

7. 8.

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AUTOMOTIVE TECHNOLOGYCAUTION: Do not let the power steering pump run dry. 9. 10. 11. 12. 13. 14. 15. Reconnect the return hose to the power steering pump. Fill the fluid reservoir with clean fluid to the specified full mark. Crank the engine and turn the wheels from lock to lock to force air out of the system. Recheck the fluid level and add fluid if necessary. Lower the vehicle. Reconnect the ignition system. Connect the exhaust ventilation equipment. CAUTION: Be sure to use approved exhaust ventilation equipment when operating a vehicle in an enclosed area. 16. 17. 18. 19. Start the engine and turn the wheel from lock to lock to remove any remaining air in the system. After the engine reaches normal operating temperature, recheck the fluid and add fluid if necessary. Lower the vehicle. Shut off the engine. Disconnect the exhaust ventilation equipment.

Average of above evaluations

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STEERING AND SUSPENSION SYSTEMSJS6-L2-UV FLUSH THE POWER STEERING PUMPEquipment: Drain pan Exhaust ventilation equipment Hand tools Personal protective equipment (PPE) Torque wrench Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.EVALUATION NAME(S):

DATE:

3.


4. 5. 6. 7. 8.

Disconnect the gear end of the pressure hose. Place the gear end of the pressure hose in a drain pan. Disable the ignition system so the vehicle cannot start. For procedures to disable the ignition system, refer to specific service information. Fill the fluid reservoir with clean fluid to the specified full mark. With the ignition system disabled, crank the engine and turn the wheel from lock to lock. Have an assistant continue to add fluid until about 2 quarts push through the system. CAUTION: Do not crank the starter for more than 30 seconds at a time. Pause and let the starter cool between cranks. Exceeding 30second cranks could damage the starter. CAUTION: Do not let the power steering pump run dry.

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AUTOMOTIVE TECHNOLOGY9. 10. 11. 12. 13. 14. 15. Reconnect the pressure hose to the steering gear. Fill the fluid reservoir with clean fluid to the specified full mark. Crank the engine and turn the wheels from lock to lock to force the air out of the system. Recheck the fluid level and add fluid if necessary. Lower the vehicle. Reconnect the ignition system. Connect the exhaust ventilation equipment. CAUTION: Be sure to use approved exhaust ventilation equipment when operating a vehicle in an enclosed area. 16. 17. 18. 19. Start the engine and turn the wheel from lock to lock to remove any remaining air in the system. After the engine reaches normal operating temperature, recheck the fluid and add fluid if necessary. Lower the vehicle. Shut off the engine. Disconnect the exhaust ventilation equipment.


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STEERING AND SUSPENSION SYSTEMSJS7-L2-UV IDENTIFY HYBRID VEHICLE POWER STEERING SYSTEM ELECTRICAL CIRCUITS SERVICE AND SAFETY PRECAUTIONSEquipment: Personal protective equipment (PPE) Safety cones for the work area Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the space provided.NAME(S):

DATE:

EVALUATION

3.

Using service information, determine the locations of the high-voltage system components, including the high-voltage cables and service plug. Record in the space provided.

4.

Using service information, determine if special care is needed when handling any components of the high-voltage system. Record in the space provided.

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AUTOMOTIVE TECHNOLOGY5. Using service information, locate a procedure for deactivating the high-voltage system. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see section V, D.)

Using the procedure, deactivate the high-voltage system.


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STEERING AND SUSPENSION SYSTEMSAS1-L1-UVI ENERGY-ABSORBING STEERING COLUMNSDirections Answer the following questions by writing all responses on this sheet. 1. What holds the steering wheel to the steering shaft.NAME:

DATE:

2.

Why does the government require all vehicles to be equipped with an energy-absorbing steering column?

3.

Explain the design of the two-piece steering column and how it operates during a collision.

4.

What are the four principle components of the energy-absorbing steering column? A. B. C. D.

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AUTOMOTIVE TECHNOLOGY5. What is the purpose of the breakaway capsules in the column mounting bracket?

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STEERING AND SUSPENSION SYSTEMSAS1-L2-UVI AIR BAG SYSTEMSDirections Answer the following questions by writing all responses on this sheet. 1. Provide two different names for air bag systems. A. B. 2. Where is the driver-side air bag located?NAME:

DATE:

3.

Air bags are passive restraints. What does that statement mean?

4.

Are air bags alone adequate protection during a collision? Explain why or why not.

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AUTOMOTIVE TECHNOLOGY5. Write the air bag component name in the blank beside each description given. A. B. C. D. E. Contains bag as well as chemical that inflates the bag Lets the driver know if the system is functioning properly Types include mass, roller, and accelerometers Computer that stores electronic diagnostic codes Provides air bag electrical connection between the steering wheel and steering column Holds the air bag system wires

F.

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STEERING AND SUSPENSION SYSTEMSJS1-L3-UVI IDENTIFY VEHICLES EQUIPPED WITH A SUPPLEMENTAL RESTRAINT SYSTEM (SRS)Equipment: Personal protective equipment (PPE) Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration dec

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