TSB_CHA084_R8
Service Bulletin Details
Public Details for: TSB_CHA084_R8
Technical service bulletin: partial repair of c-mdps motor, ecu, worm gear and/or steering column housing - this bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar
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GROUP CHA NUMBER 084 (Rev 8, 10/05/2021) MODEL All Applicable Models with C-MDPS DATE November 2018 TECHNICAL SERVICE BULLETIN SUBJECT: PARTIAL REPAIR OF C-MDPS MOTOR, ECU, WORM GEAR AND/OR STEERING COLUMN HOUSING NOTICE This bulletin has been revised to include additional information. New/revised sections of this bulletin are indicated by a black bar in the margin area. This bulletin provides information regarding the partial repair of the Motor Driven Power Steering (MDPS) Motor, Electronic Control Unit (ECU), Steering Column Housing, or Worm Gear Assembly on some 2010MY~ Kia models listed on page 8, equipped with a Column Motor Driven Power Steering (C-MDPS) unit . On some vehicles when the steering wheel is rotated a scraping noise can be heard originating from the lower bearing on the Worm Gear Assembly and does not affect the steering effort. Follow the MDPS Repair Flowchart (page 2) and the C-MDPS Common Concerns Flowchart (page 3), along with the MDPS DTC Table (page 4), and procedure outlined in this bulletin before replacing the C-MDPS Motor, ECU, Worm Gear Assembly, or Steering Column Housing. NOTICE If attempting to perform CHA084 worm gear repair and the parts are not available refer to CHA111 to perform the worm gear bearing replacement. WARNING* To prevent personal injury and damage to the clockspring, keep the steering wheel in the straight-ahead position whenever disconnecting any portion of the steering column. NOTICE • • • MDPS Repair Flowchart and Common Noise Flowchart are meant to be used as a reference guide only. See MDPS DTC table for more details. Note that some DTC(s) may be found in systems other than Electric Power Steering (EPS) in KDS. They may be found in the Brake/ABS/ESC system. Check all systems for DTC(s). Replacing the complete C-MDPS Steering Column Assembly is NOT allowed when the components failure is identified in the flowchart. In addition, replacing the Steering Column Housing is NOT allowed when the problem source is the C-MDPS Worm Gear Assembly (for applicable models). Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. Circulate To: X General Manager X Service Advisors X Technicians X Service Manager X Parts Manager X Body Shop Manager X Fleet Repair Page 2 of 9 SUBJECT: REPLACEMENT OF C-MDPS MOTOR, ECU, WORM GEAR ASSEMBLY AND/OR STEERING COLUMN HOUSING MDPS Repair Flowchart Vehicle in for MDPS related complaint. NOISE: Refer to C-MDPS Common Noise Concerns flowchart on page 3. C-MDPS Worm Gear* replacement, page 6. *Mobis C-MDPS only. • • • MIL is ON: DTC(s) Present / CAN Line Error. See DTC Table on page 4. Check MDPS connectors and wiring. Erase DTC(s) and re-check. If DTC(s) are still present, follow the recommended repair per DTC stored. ECU Related: C1112 C1604 C1623 C1687 C1688 C1704 C1705 C2412 C2413 NO MIL: No DTC(s) Present Sticking/Binding Refer to CHA060 TSB Motor Related: C2400 C2401 Column and Housing Related: Connectors/ Wiring Related: C1259 C1290 C1260, C1261, C1611, C1612, C1616, C1622, C1628, C1646, C1656, C1692, C1693, C1696, C1697 Replace the Column and Housing Assy. Check DTC(s) and Wiring at HECU/MDPS/EMS: Replace the MDPS ECU. Replace the MDPS Motor. • • • • Check connectors for poor connection. Check for connector corrosion. Check for connector damage or deformation. Check the DTC Diagnostic Guide on KGIS. Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: CHA084 (Rev 8) Multiple Models November 2018 Page 3 of 9 SUBJECT: REPLACEMENT OF C-MDPS MOTOR, ECU, WORM GEAR ASSEMBLY AND/OR STEERING COLUMN HOUSING C-MDPS Common Noise Concerns Flowchart Worm Gear C-MDPS Noise Inspection Steps Video: Worm Shaft Bearing Noise Applicable Models Only: Mobis C-MDPS 1. Check C-MDPS Noise present from the column and housing Noise present from C-MDPS motor Noise from C-MDPS Worm Shaft Bearing Problem Found Replace defective part: C-MDPS Worm Gear assembly or Steering Column and Housing or C-MDPS Motor assembly. No problem found 2. Check the C-MDPS Mounting Position Inspect cowl mounting and cross member bolt Inspect C-MDPS mounting bolts C-MDPS C-MDPS Mounts Problem Found Retighten bolt Problem Found Retighten U-joint bolt No problem found 3. Check U-Joint Mounting Bolt Inspect U-joint retaining bolt, check for noise after disassembling/re-assemble. U-Joint(s) No problem found Tie Rod End 4. Check Tire-Rod End Joint for Free Play Problem Found Replace defective part Problem Found Retighten bolt Problem Found Replace defective part No problem found 5. Check Steering Gear box Mounting Bolt Steering Gear Box No problem found 6. Check Steering Gear Box Noise Mounts No problem found 7. Check Steering Wheel Inspect the condition of the (Driver s Air bag) DAB wiring (ex. DAB, clock spring, multifunction switch-MFS ) Problem Found Replace defective part Clock Spring MFS IMPORTANT The Clockspring must be kept on center during installation of the Clockspring to prevent cable damage, this is also true when the MDPS column is removed – the steering shaft must be locked in position to prevent the Clockspring cable from becoming off-center. Failure to follow these instructions may result in a damaged Clockspring and will be subject to a dealer chargeback. Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: CHA084 (Rev 8) Multiple Models November 2018 Page 4 of 9 SUBJECT: REPLACEMENT OF C-MDPS MOTOR, ECU, WORM GEAR ASSEMBLY AND/OR STEERING COLUMN HOUSING MDPS DTC TABLE DTC Concern C1102 Battery Voltage Problem C1603 MDPS Thermal Protection C1611 CAN Time Out EMS C1616 CAN BUS OFF C1622 Vehicle Speed Signal Error C1696 C1697 SPAS Signal Error C1612 C1646 TCU Signal Error Check TCU and associated wiring. C1628 C1656 Instrument Cluster Signal Error Check instrument cluster and Associated wiring. C1692 C1693 VSM Signal Error Check VSM and associated wiring. C1259 Steering Angle Sensor Signal Error C1260 Steering Angle Sensor Signal Error C1261 Zero-Setting Error C1290 Torque Sensor Error C1112 Torque Sensor Voltage Error C1704 ECU Fail-Safe Relay Fault C1705 ECU Hardware Error C1604 ECU Over/Discharge Error C2413 ECU Hardware Error C2400 Motor Signal Error C2401 Motor Circuit Error C2412 Motor Voltage Supply Error C1623 C1687 C1688 Inspection Procedure Recommendation Check battery voltage condition. Recharge battery voltage. Investigate driving conditions if DTC is set. This DTC protects the motor from overheating. No replacement necessary. Check GDS condition. Check wiring and connector condition. C heck ECU CAN line. Check MDPS ground. Check EMS Can line. Check the chassis CAN line. Check the EMS Check SPAS and associated wiring. Repair as necessary. Erase DTC(s). MDPS Assy is not to be replaced. Reset steering angle sensor calibration and erase DTC(s). Check wiring and connector condition. If DTC returns, replace column and housing assembly. Reset steering angle sensor calibration. If DTC returns, inspect wiring and connector condition. First, erase DTC, then check wiring And connector condition. If DTC returns, replace column And housing assembly. Check wiring and connector condition Between torque sensor and ECU. If DTC returns, replace the MDPS ECU. First, erase DTC. Then check the wiring and connector at the ECU. If DTC returns, replace the MDPS motor. First, erase DTC. Then check the wiring and connector between the ECU and motor. First replace MDPS ECU. If DTC returns, replace the MDPS motor. CAN Time Out SAS 1. CAN Time Out VSM 2. 3. 4. If DTC returns, replace the MDPS ECU. VSM Signal Error 5. Check MDPS power connector and fuse. Check MDPS ground line. Check MDPS ECU/VSM CAN line. Check communication status with GDS. Check for DTC C1259. If present, replace the column and h ousing assembly. If DTC returns and MDPS is inoperable, replace MDPS ECU. If DTC returns and MDPS operation is normal, continue investigation into wiring issues. Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: CHA084 (Rev 8) Multiple Models November 2018 Page 5 of 9 SUBJECT: REPLACEMENT OF C-MDPS MOTOR, ECU, WORM GEAR ASSEMBLY AND/OR STEERING COLUMN HOUSING Replacement Procedure for Worm Gear Assembly (Mobis Only): 1. Remove the MDPS column and housing by referring to the “Steering System → Motor Driven Power Steering → MDPS Column and Housing → Repair Procedures” chapter in the applicable Shop Manual on KGIS. A Note: Be sure mark the steering column shaft to the intermediate shaft for reassembly purposes. *Refer to Clockspring Warning on page 1. 2. Using the worm shaft plug SST (B) loosen the worm shaft nut (C) and remove the worm shaft. C Torque Specifications for nut (C) Refer to page 8 for applicable model: 0K563 T9100FFF (34.9mm): 27.5 – 34.7 lb.ft (37.2 – 47.0 N.m (3.8 – 4.8 kgf·m) 0K563 Q2100FFF (42.0mm): 51.7 – 59.0 lb.ft (70.0 – 80.0 N.m (7.2 – 8.2 kgf.m) B 0K563 D6100FFF (44.9mm): 81.2 – 103.2 lb.ft (110.0 – 140.0 N.m (11.3 – 14.3 kgf.m) 3. Loosen the 5mm hex plug (D) and then remove the anti-rattle plug assembly. Torque Specifications for plug (D): 7.3 - 9.4 lb.ft (9.8 - 12.8 N.m, 1.0 - 1.3 kgf.m) D Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: CHA084 (Rev 8) Multiple Models November 2018 Page 6 of 9 SUBJECT: 4. REPLACEMENT OF C-MDPS MOTOR, ECU, WORM GEAR ASSEMBLY AND/OR STEERING COLUMN HOUSING Using a set of vise grips, remove the worm shaft assembly (E). Note: Reuse the flexible coupling unless there is visible damage or wear. Replace as needed. E 5. Apply grease to worm gear shaft (E) portion only (OK). Grease should not be applied to the bearing (NG). Note: Grease is included (20g) with worm gear assembly. E 6. Install the new worm shaft assembly (E) in the reverse order of removal. 7. Using a torque wrench and SST (B), tighten the shaft nut (C). Refer to torque specifications on step 2. 8. Re-install all removed parts in the reverse order of removal. Note: Be sure to follow the SAS Calibration, EPS Type Recognition as outlined on KGIS. Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: CHA084 (Rev 8) Multiple Models November 2018 Page 7 of 9 SUBJECT: REPLACEMENT OF C-MDPS MOTOR, ECU, WORM GEAR ASSEMBLY AND/OR STEERING COLUMN HOUSING Replacement Procedure for MDPS Motor: 1. Replace the MDPS motor by referring to the “Steering System → Motor Driven Power Steering → MDPS Motor → Repair Procedures” chapter in the applicable Shop Manual on KGIS. Note: Be sure mark the steering column shaft to the intermediate shaft for reassembly purposes if removing the steering column and housing assembly. Replacement Procedure for MDPS ECU: 1. Replace the MDPS ECU by referring to the “Steering System → Motor Driven Power Steering → MDPS ECU → Repair Procedures” chapter in the applicable Shop Manual on KGIS. Note: Be sure mark the steering column shaft to the intermediate shaft for reassembly purposes if removing the steering column and housing assembly. Replacement Procedure for Steering Column & Housing: 1. Replace the MDPS column and housing by referring to the “Steering System → Motor Driven Power Steering → MDPS Column and Housing → Repair Procedures” chapter in the applicable Shop Manual on KGIS. Note: Be sure mark the steering column shaft to the intermediate shaft for reassembly purposes. *Refer to Clockspring Warning on page 1. IMPORTANT Ensure all steps are closely followed within the Service information as additional KDS-related procedures are required. Ensure the Steering Angle Sensor (SAS) is calibrated and there are no DTCs after replacement of the MDPS Motor and/or ECU. Verify proper operation of the steering system and vehicle. Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: CHA084 (Rev 8) Multiple Models November 2018 Page 8 of 9 SUBJECT: REPLACEMENT OF C-MDPS MOTOR, ECU, WORM GEAR ASSEMBLY AND/OR STEERING COLUMN HOUSING AFFECTED VEHICLE RANGE: Model MDPS Supplier Model Year Range Mobis All Applicable Models 2010MY~ with C-MDPS Soul (AM), Optima (QF, TF, TF HEV), Cadenza (VG), and Forte (YD, YDm) Forte (BD, BDm, YD, YDm), Niro (DE, DE HEV/PHEV/ EV), Optima (JF/JFa, JF HEV/PHEV) Soul (PS, PS EV), Sorento (UMa) and Cadenza (YG) Rio (UB, SC), Sportage (SL, QL) and Sorento (XMa) Mando REQUIRED PART: Part Name Part Number C-MDPS Motor Refer to EPC C-MDPS ECU Refer to EPC Steering Column Housing Refer to EPC Figure REQUIRED TOOL AND WORM GEAR P/N (INCLUDES GREASE): Model/ Model Year MDPS Assy 2017-2018 YD(m) 2018-2019 PS/PS EV 2017-2018 JFa/UMa 2017 JF HEV Refer to EPC SST Part Number (Size) Image 56351 B3AAA FFF 0K563 T9100FFF (34.9mm) (NonIntegrated) 56351 C5AAA FFF 0K563 D6100FFF (44.9mm) 2019-2020 JFa, UMa 2018-2020 JF HEV 2017-2020 YG 2017 DE Worm Shaft Kit Part Number 56351 F6AAAFFF 56310-G5100 56310-G5300 56351 F2AAAFFF See Note Below* 2019-2020 BD(m) 2017 DE Refer to EPC 56310-G5101 56310-G5301 0K563 Q2100FFF (42mm) (Integrated) 56351 G3AAAFFF See Note Below* 2018-2020 DE/DE EV/ DE PHEV Refer to EPC *Note: DE requires the reference to MDPS assembly to ensure the proper part is installed; Integrated vs. Non-Integrated. Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: CHA084 (Rev 8) Multiple Models November 2018 Page 9 of 9 REPLACEMENT OF C-MDPS MOTOR, ECU, WORM GEAR ASSEMBLY AND/OR STEERING COLUMN HOUSING SUBJECT: WARRANTY INFORMATION: N Code: D61 C Code: ZZ4 Replacement P/N Qty. N/A 0 Op Time Replacement P/N Qty. PS, PS EV, YD 1.4 M/H 56351 B3AAAFFF JF, JF HEV, JFa 1.3 M/H 56351 C5AAAFFF 1.1 M/H 56351 F2AAAFFF Model All Models Listed Claim Type W Causal P/N Refer to EPC Qty. 1 Repair Description Labor Op Code Op Time C-MDPS Motor Replacement 56330R00 56331R00 Refer to LTS C-MDPS ECU Replacement 56345R00 Refer to LTS Steering Column Housing Replacement 56391R00 Refer to LTS Labor Op Code WARRANTY INFORMATION (WORM GEAR): N Code: Q55 C Code: ZZ1 Model Claim Type Causal P/N Qty. DE W JF, JF HEV, JFa, YG *Refer to EPC 0 Repair Description C-MDPS Worm Gear Replacement (for applicable models only) BD, BDm, DE, DE PHEV, DE EV 56351F01 1 1.3 M/H 56351 F6AAAFFF 1.1 M/H 56351 G3AAAFFF 1.2 M/H UMa 56351 C5AAAFFF 56351 F6AAAFFF *Note: Refer to EPC for Steering Column and Housing Assembly. WARNING* To prevent personal injury and damage to the clockspring, keep the steering wheel in the straight-ahead position whenever disconnecting any portion of the steering column. Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: CHA084 (Rev 8) Multiple Models November 2018