Page 529 of 3229
SymptomPossible CauseAction
Power st eeri ng gearnois yPower st eeri ng fl uid l evell ow or cont aminatedSt eering gear int ernalcomponent s worn ordamaged
Check and t op-up t he power st eering fl ui d l evel if requi red.REFER t o: Power St eeri ng Sys t em Bl eeding (211-00 St eeringSys t em - General Informat ion, General Procedures ).Check for contaminated flui d. Check for exces s ive s t eering gearnoi s e. Ins tall a new s teeri ng gear as required. Refer t o t he newcomponent ins tal lati on note at t he t op of the Sympt om ChartSt eering columnnois ySt eering column fouli ng orunivers al joi nt s dryCheck t he s teeri ng column and universal joi nts . Rect ify asneces sary
Power st eeri ng feelsheavi er than normalt hrough it soperat ing range
Lack of power as si s tanceCheck t he power st eering pump pres s ure
Page 530 of 3229

Publi s hed: 11-May-2011
Steering System - General Information - Power Steering System Bleeding
General Procedures
Clean power s teering fluid res ervoir around t he fi ll er cap and flui di ndi cat or.1.
Check the power s teeri ng fluid, if aerat ed, wait unti l fl ui d i s freefrom bubbles then t op-up res ervoi r to UPPER l evel mark wit hrecommended fluid.
2.
3. CAUTION: Flui d mus t always be pres ent in theres ervoi r during bl eeding.
Remove t he fi ll er cap and fil l t o t he MAX level mark.
3.
Inst all t he fi ll er cap.4.
St art t he engi ne and allow to run for 10 s econds, s t op t he engi ne.5.
Check the power s teeri ng fluid, if aerat ed, wait unti l fl ui d i s freefrom bubbles then t op-up res ervoi r to UPPER l evel mark wit hrecommended fluid.
6.
St art t he engi ne and turn s teering ful ly lock to lock, s t op the engine.7.
Check and top-up power s t eering fluid level.8.
St art and run the engine for 2 mi nut es , turn the st eeri ng full y l ock t ol ock.9.
Check and top-up power s t eering fluid level.10.
Page 531 of 3229

Publi s hed: 11-May-2011
Steering System - General Information - Power Steering System Flushing
General Procedures
• NOTE: If heavy s teering or cont aminat ion wi thi n t he power s t eering s ys tem is found, i t is necess ary to carry out t hes ys t em flus h procedure as det ailed bel ow. If any component s have been replaced in t he power st eeri ng s ys t em t heprocedure below must be carri ed out in full.
• NOTE: Some vari ati on in the i ll us t rat ions may occur, but the es s ent ial informat ion i s always correct .
1. Remove the power s teeri ng fl uid res ervoi r cap.
2. Usi ng a s uit able s yri nge, remove the power s teering fluid fromt he power s t eering flui d res ervoir.
3. CAUTION: Be prepared to col lect escaping fluids .
• NOTE: Not e t he orient ati on of the cli p.
Det ach the power s teering fluid res ervoir.
Det ach but do not remove the power s teeri ng fl uidres ervoi r.
Releas e t he power s t eering flui d ret urn hos e from thepower st eeri ng fl uid reservoi r.
If a quick rel eas e coupli ng is fit ted to the powers teering return hos e, rel eas e the power s teeri ng fl uidret urn hos e from t he coupli ng by removi ng the cl ip.
4. CAUTION: Be prepared to col lect escaping fluids .
• NOTE: Make s ure that all openi ngs are s ealed. Us e newblanking caps.
Usi ng a s uit abl e blanking cap, cap the power s teeri ngres ervoir ret urn pi pe.
Page 532 of 3229

5. CAUTION: Be prepared to col lect escaping fluids .
• NOTE: Make s ure the ext ended pipe is not kinked or twi s tedand i s correctl y s ecured wit h hos e clips .
At t ach a s ui table pipe t o t he power s t eering return hos e toal low the flui d to drain.
6. NOTE: The s ui table funnel should have t he a capaci ty of 4l it res and O-ri ng s eal
• NOTE: The s uit abl e funnel mus t be t ightl y s eal ed t o thepower st eeri ng fl uid reservoi r to avoid fl uid l eakage.
Ins tal l a s ui table funnel ont o t he power s t eering flui dres ervoir.
7. W ARNING: Do not work on or under a vehi cl e s upportedonl y by a jack. Al ways support t he vehi cl e on s afet y s tands .
Rais e and s upport t he vehi cl e wi th the wheels jus t cl ear of t heground.
8. CAUTIONS:
Steps 8 and 9 mus t be carried out wit hin 2 - 3 s econds ofeach ot her. Failure t o fol low this ins truct ion may res ult i ndamage to the power s teeri ng s yst em.
Be prepared to col lect es caping fluids .
Us ing the s uit able funnel , top up t he power s teeri ng s ys t emwi th the s peci fi ed fl uid. Make s ure t he fluid level i s mai nt ainedat t wo t hirds full i n t he funnel.
Page 533 of 3229
9. CAUTIONS:
Be prepared t o collect es caping flui ds .
Do not al low the power s teeri ng fl uid l evel i n t he powers teering fluid res ervoir t o fal l bel ow t he mi ni mum powers teering fluid level. Failure t o fol low this ins truct ion may res ulti n damage to the power s teering s yst em.
Make s ure the engine is s wi tched off as s oon as t he ful l4 l it res of power s teeri ng fl uid has ent ered t he power s t eeringfluid res ervoir.
Fl ush the power s teeri ng s yst em.
St art t he engi ne
W it h ass i st ance turn the st eeri ng sl owly l ock to lock 3t imes at approximat ely 1 revolut ion every 5 seconds .
Conti nue to fl us h t he power s teeri ng s ys t em unt il 4l it res of power st eering fl ui d has been added to t hepower st eeri ng res ervoir. Thi s s houl d t akeapproximat ely 30 s econds .
10. CAUTION: Be prepared to col lect es caping fluids .
Remove t he s uit abl e funnel.
Page 534 of 3229
11. CAUTION: Be prepared to col lect es caping fluids .
Remove t he s uit abl e pipe to the power s teeri ng ret urn hos e.
12. CAUTION: Be prepared t o coll ect es capi ng fl uids .
• NOTE: Note the orientat ion of t he clip.
If a quick rel ease coupli ng is fit t ed to the power s teeri ng ret urnhos e, connect t he power st eering fl ui d ret urn hos e t o t hecoupl ing by i nst all ing t he cli p.
13. Ins tal l a new power st eeri ng fl ui d reservoi r.For addi ti onal informat ion, refer t o: Power St eeri ng Fl uidRes ervoi r (211-02 Power St eering, Removal and Inst all ati on).
Page 535 of 3229

Publ is hed: 05-Dec-2011
Power Steering -
Lubricants, Fluids, Sealers and AdhesivesItemspecificationCapacity
Recommended flui dPent ozi n CHF202Fil l to maxi mum mark on res ervoir
General Specification
ItemSpecification
PAS pump - 2.2 Di es elHit achi variable dis placement pump (VDP)PAS pump - 3.2 PetrolZF Conventi onal (fi xed di s pl acement ) pump wit h oi l cooler
PAS pump - 2.0 PetrolZF Conventi onal (fi xed di s pl acement ) pump wit h oi l cooler
PAS cooler - 3.2 Pet rolInt egral part of hos esSt eering gearW elded s t eel t ube des i gn for conventi onal gear (Vi st eon)
System operating pressure:
3.2 Pet rol125 Bar ± 5 (1813 ± 73 ps i)2.2 Dies el115 Bar ± 4 (1667 ± 58 ps i)
2.0 Pet rol115 Bar ± 4 (1667 ± 58 ps i)
Idle resi dual pres s ure4 bar ± 1 (58 ± 15 ps i)Flui d fl owCons tant
Maximum flow8.8 Lit ers per mi nute ± 0.5 l/min
Torque Specifications
DescriptionNmlb-ftHi gh-pres sure l ine t o power st eeri ng pump - 2.2 Dies el2015
Hi gh-pres sure l ine t o power st eeri ng pump - 3.2 Pet rol2518
Hi gh-pres sure l ine t o power st eeri ng pump - 2.0 Pet rol2720Power st eeri ng fl uid cooler107
Power st eeri ng fl uid l ine bolt s2720
Power st eeri ng fl uid pres s ure lines2518Power st eeri ng gear t o cros s member nuts10577
Power st eeri ng pump bolt s - All engines2418
Page 536 of 3229
Publi s hed: 11-May-2011
Power Steering - Power Steering
Des cript ion and Operat ion
COMPONENT LOCATION - TD4 DIESEL
• NOTE: Right Hand (RH) drive shown, Left Hand (LH) drive s imil ar
ItemPart NumberDescription1-Sucti on hose - res ervoir t o pump
2-Res ervoir
3-Fl ui d ret urn pipe - s t eering gear to res ervoir4-Hi gh pres s ure feed pipe - pump to s t eering gear
5-Power s teeri ng pump
6-Ti e-rod7-Bul khead s eal and gas ket
8-Val ve uni t
9-St eering gear10-Bol t
COMPONENT LOCATION - i6 PETROL
• NOTE: LH drive s hown, RH dri ve si mi lar