Contents: Removal ⇊ Installation ⇊
Warning! The models of vehicles covered in this manual are equipped with a supplemental restraint system (SRS). Before performing any work near the air bag unit, steering column or instrument panel, turn off the SRS to avoid injury from accidental deployment (see Chapter On-board electrical equipment). The SRS circuit wiring is easily identified by its yellow insulation. To avoid damaging the SRS system, Make sure that the steering shaft does not turn after removing the steering wheel. Lock the column with the ignition key with the front wheels straight ahead.
Removal
1. Park the car with the front wheels turned straight ahead. Disconnect the negative cable from the battery first, then the positive cable.
Warning! If the car stereo system is equipped with a security code, make sure you have the correct combination to activate the audio system before disconnecting the battery! Remove the steering column joint cover under the instrument panel.
2. Mark the position of the steering column intermediate shaft in relation to the rack and pinion input shaft, then loosen the clamping screw.
3. Set the parking brake. Loosen the wheel nuts. Jack up the front of the car and place it on supports. Remove the wheels.
4. Drain the PAS hydraulic fluid into a prepared container: disconnect the supply and return hydraulic lines from the rack and pinion housing.
Note: Do not loosen the union nut connections on the lines going to the steering gear pressure cylinder.
5. To minimize fluid loss, plug open ends of lines.
6. Release the steering rod ends from the steering knuckle arms (see Section Removal and installation tie rod ends).
7. Disconnect the λ-probe wiring connector (see Chapter Engine management) and remove the catalytic converter.
8. Disconnect the gear shift cable(s) (see Chapter Gear shift box).
9. Remove the reinforcement plates from the chassis and rack and pinion housing.
10. Support the steering gear from below and loosen its mounting bolts. Lower the rack and pinion assembly, carefully disengaging the intermediate shaft of the steering column from engagement with the input shaft of the mechanism. To avoid catching the rear beam, tilt the steering gear assembly slightly and remove it from under the car.
Installation
1. Place the steering gear assembly in its regular place and engage its input shaft with the intermediate shaft of the steering column (make sure that the alignment marks applied during dismantling are correctly aligned).
2. Screw in the rack and pinion assembly mounting bolts (remember to place washers under the bolt heads) and tighten them to the required torque.
3. Install the reinforcing plates and tighten the bolts securing them to the required torque.
4. Connect the tie rod ends to the steering knuckle (see Section Removal and installation the steering wheel).
5. Screw in the intermediate shaft clamp bolt and tighten it to the required torque.
6. Replace the hinge access cover, making sure both tabs engage with the corresponding holes in the floor panel.
7. Connect the PAS hydraulic lines to the steering gear housing. Fill the PAS reservoir with the required amount of fresh hydraulic fluid of the required grade (see Chapter Settings and ongoing maintenance).
8. Install the wheels. Lower the vehicle to the ground and tighten the wheel nuts to the specified torque (see Specifications in Chapter Settings and ongoing maintenance).
9. Bleed the power steering system (see Section Bleeding air from the hydraulic circuit of the power steering system).