7828 M 2015-12 en V01 Ford CD4

Fitting Instructions
en General Notes for Removal and Installation

Servolectric® EPSapa | Type 7828 | Ford CD4
7828 M 2015-12 en V01 Ford CD4

11.12.2015
General Notes for Removal and Installation of EPSapa for Ford CD4
1 User information
1.1 Safety instructions

 These instructions are to be referred to when carrying out necessary service work and repair on the Bosch
Automotive Steering unit.
 Read these instructions first before starting the service work.
 Authorized, specialized staff must make sure that the product works perfectly again after the service work has
been completed.
 Bosch Automotive Steering products may only be repaired in workshops with
- staff trained by Robert Bosch Automotive Steering GmbH
- specified equipment and special tools corresponding to the work to be performed
- original Bosch spare parts
 This manual should only be used by technicians whose practical and theoretical training in our Global Service
training centre is supplemented by this reference book and by service information.
 As a basic principle, only work listed in the instructions may be carried out on the steering gear. Additional
changes or adaptations are not permitted and could cause a safety-critical deficiency. However, if in exceptional
circumstances, other work should be necessary, then separate information which is only applicable for this case
will be provided (e.g. service information).
 All work on Bosch Automotive Steering units must be carried out with great care and conscientiousness. This
applies in particular to units and transmission parts from vehicles which have been involved in accidents.
 Before removing the hydraulic unit, any operating fluid (e.g. lubricant) must be drained without residue and must
be routed through company-internal disposal.
 All metal parts which can no longer be used must be recycled in metal recycling. Other parts (e.g. seals) must be
disposed of properly according to the respective applicable regulations.
 The manufacturer will not be held liable for damage and associated consequences caused by improper and/or
unqualified repair.
The numbers indicated in round brackets refer to the picture numbers used in the figures.
The numbers indicated in square brackets refer to the used tools.
Robert Bosch Automotive Steering GmbH

73522 Schwäbisch Gmünd
Germany
Telephone +49 7171 31-7936
[email protected]
https://steering-service.com
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1 | User information en
1.2 Important notes

Pay attention to further written service information.
Protection notice:
Passing on or reproducing this document, utilizing, and communicating its content is prohibited, unless expressly
permitted. Contraventions obligate compensation in damages. All rights reserved in the event of patent and utility
model registration.
®
Servolectric is a registered trademark of Robert Bosch Automotive Steering GmbH.
List of changes
Index Date of issue Author Chapter Comment
01 12/2015 NJ | OTG - First issue
1.3 Symbols used

DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
NOTICE is used to address practices not related to physical injury.
Application notes and other useful information.
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en Removal | 2
WARNING
Steering parts are safety parts!
For safety reasons, work on the steering system may only be performed by trained expert staff. Work
performed incorrectly may lead to severe accidents.
When working on the steering system, observe ESD (Electro Static Discharge) regulations.
These instructions apply only

 when a Servolectric was already installed in the vehicle and you are installing a steering gear with the same part
number (visible on the type plate).
 when a steering gear from another manufacturer was installed in the vehicle which can be replaced by a
Servolectric that is designed for the same kind of installation.
2 Removal
CAUTION
Replace self-locking nuts, screws, seals, and locking elements with new parts.
If you are replacing the steering gear due to an accident, also check the other parts of the steering system
for damage (even if there is no visible damage), for instance tires, rims, axles, axle mountings, and
mechanical connecting parts.
If necessary, repair or replace defective parts.
1. Turn the steering wheel to the straight-ahead position. The front and rear-axle wheels must be in line.
2. Adjust the steering lock to straight-ahead position and if possible lock it.
3. Mark the installation position and the position of the Servolectric. The markings will be needed if the
Servolectric needs to be installed again.
4. Switch off the ignition and disconnect the battery negative pole to interrupt the electrical circuit.
5. Disconnect electrical plug connections for power supply.
6. If the tie rods are to remain in the vehicle, disconnect them from the Servolectric.
7. Remove Servolectric, observing the instructions of the vehicle manufacturer.
3 Installation
1. Check that the Servolectric is in the straight-ahead position. The markings of the steering spindle/protective
cover (if present) must match the housing.
2. Install Servolectric in the same location and position as first installation and anchor with screws, nuts, washers,
etc. (Observe the instructions of the vehicle manufacturer).
3. Attach the tie rods to the steering gear (Observe the instructions of the vehicle manufacturer).
4. Connect the vehicle's electrical plug connections.
5. Connect the negative pole of the battery.
6. Check and if necessary correct the wheel alignment according to the vehicle manufacturer's specifications.
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4 | Setting the steering system into operation en
4 Setting the steering system into operation

Before starting up the vehicle, use a diagnostic tester that is suitable or recommended by the vehicle manufacturer
to perform the following:
1. Program vehicle characteristic curve. If the vehicle characteristic curve is not programmed, vehicle specific
special features are not available.
2. Calibrate steering angle sensor by driving straight ahead with approximately 40 km/h.
3. Carry out vehicle specific coding.
4. Coding the software end stops by steering left and right.
5 Check function
1. Check function on a fenced-off site.
2. During the test drive, check the following steering functions:
-Active return
-Play
-Noise
-Malfunction indicator light
3. After the test drive, read off the error memory. No error may be entered in the error memory.
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7828 M 2015-12 en V01 Ford CD4 - EPSapa

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Fitting Instructions

en General Notes for Removal and Installation

1.1 Safety instructions

Robert Bosch Automotive Steering GmbH

1.2 Important notes

1.3 Symbols used

Application notes and other useful information.

2/4 7828 M 2015-12 en V01 Ford CD4

These instructions apply only

7828 M 2015-12 en V01 Ford CD4 3/4

4 Setting the steering system into operation

4/4 7828 M 2015-12 en V01 Ford CD4

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