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KOYO ELECTRIC PUMP FITTING GUIDE

Untitled Document

IMPORTANT INFORMATION RELATING TO HANDLING AND FITTING OF NEW ELECTRIC STEERING PUMPS TO SUIT PEUGEOT 307, PEUGEOT 407 AND CITROEN C4

Handling and fitting recommendations for aftermarket power-packs (3G series)

1 - Storage Conditions

The power pack should only be stored in a dry and clean environment and must not be stacked The storage temperature should be between -40 degrees C and + 90 degrees C. Whatever the type of Power-pack packaging, stacking in storage is forbidden.
The power pack must not be dropped, knocked or subjected to any shock.

2 - Handling

During installation-
*The protection caps (yellow) on the ports from the tank and the high pressure output, should be removed only just before connection, To avoid any risk of contamination of the power steering fluid.
*The protection cap on the electrical connectors should be removed only just before connection to avoid any rick of contamination or Damage.
*Do not pick or handle the Power Pack by the oil filler neck, otherwise there is a rick of damage to the reservoir or filler neck.

3-Vehicle Mounting

After mounting the power pack on the vehicle bracket, ensure that the screws and fixation bolts are tightened to the correct torque as Recommended by the vehicle manufacturer. Also check that the shock absorbers of the power-pack are correctly positioned and fitted.

Electrical connections

Disconnect the battery before starting-

The electrical connection phase of the power-pack should be done strictly without any ignition (ignition key must be off). *Remove the cap of the electrical connectors, and plug in the vehicle harness. A 'CLICK' should be heard during the connection. *Check the harness is correctly connected and routed to ensure no tightness of risk of damage.

Hydraulic Connections

*Remove the protection cap (yellow)
*Replace the 0-ring seals of the hydraulic connections before making any hydraulic connections.
*Connect the high pressure hydraulic connector on the power-pack.
*Tighten the connector to the correct torque as recommended by the vehicle manufacturer. The support of the hydraulic connection (vehicle side) should be well positioned at the bottom of the housing before tightening the connector; this is to ensure that no damage Is done to the power-pack or support.
*connect the low pressure hose on the tank input.
*Ensure there is no contact between the hydraulic hoses.

Hydraulic Circuit Filling
Requirements for filling the power steering circuit are as follows-
*The system must be free from any contamination before installing the power-pack.
*Power Steering Fluid should conform to the car makers recommendations, and should also conform to the class 9 of NAS 16138 norm Regarding cleanliness.
*The filling operation should be performed in a clean, dust free environment.
*The power-pack should not under any circumstances be started without power steering fluid, otherwise there is an IMMEDIATE and definitive risk of damage.
Electronic Tuning of the Generation 3 Power-Pack with Integral ECU
(VERY IMPORTANT TO FOLLOW)
The Power-Pack is delivered without any electronic tuning. In this case, the power-pack delivers a very low power steering assist, and the vehicle should not be driven on the road, until the electronic Installation is completed. The recommendations are as follows-
*The electronic tuning must be performed by an Auto Electric Specialist / Dealer, with the diagnostic tool recommended by the vehicle manufacturer.
To avoid any risk with the safety of the vehicle, the car should not be driven without the correct electronic tuning of the power-pack to the vehicle manufacturers specifications.

ANY BREACH OF THE ABOVE WILL RENDER ANY GUARANTEE OR WARRANTY NULL AND VOID