Warning! The car models covered in this manual are equipped with an additional security system (SRS). Before doing any work near the airbag unit, steering column or instrument panel, turn off the SRS to avoid injury if it is accidentally deployed (see chapter Onboard electrical equipment). SRS circuit wiring is easily identified by the yellow color of the insulation. To avoid damage to the SRS system, make sure that the steering shaft does not turn after removing the steering wheel. Block the column with the ignition key with the front wheels straight ahead.
Withdrawal
1. Park the vehicle with the front wheels turned straight ahead. Disconnect the negative cable from the battery first, then the positive one.
Attention! If the stereo system installed in the car is equipped with a security code, before disconnecting the battery, make sure that you have the correct combination to activate the audio system! Under the instrument panel, remove the cover of the steering column connecting hinge.
2. Mark the position of the intermediate steering column shaft with respect to the rack and pinion input shaft, then loosen the pinch screw.
3. Apply the parking brake. Loosen the wheel nuts. Jack up the front of the car and place it on jack stands. Remove wheels.
4. Drain the PAS system hydraulic fluid into a prepared container: disconnect the supply and return hydraulic lines from the rack and pinion case.
Note. Do not loosen the fitting connections of the lines going to the pressure cylinder of the steering mechanism.
5. Seal the open ends of the lines to minimize fluid loss.
6. Release the tie rod ends from the steering knuckle arms (see Section Removal and installation of tips of steering draughts).
7. Disconnect the electrical wiring connector of the λ-probe (see chapter Engine management) and remove the catalytic converter.
8. Disconnect the cable (s) gear change drive (see chapter Gear box).
9. Remove the reinforcing plates from the chassis and rack and pinion housing.
10. Support the steering mechanism from below and give the bolts of its fastening). Lower the rack and pinion assembly while carefully disengaging the steering column intermediate shaft from the gear input shaft. In order not to catch the rear beam, slightly tilt the steering gear assembly, and remove it from under the car.
Installation
1. Place the steering gear assembly in its proper place and engage its input shaft with the intermediate shaft of the steering column (follow the correct alignment of the landing marks applied during dismantling).
2. Screw in the rack and pinion assembly mounting bolts (don't forget to put washers under the bolt heads) and tighten them to the required torque.
3. Install the reinforcing plates, tighten the bolts of their fastening with the required force.
4. Connect the tie rod ends to the steering knuckle (see Section Removal and installation of a steering wheel).
5. Screw in a coupling bolt of an intermediate shaft and tighten it with the demanded effort.
6. Replace the hinge access cover. Make sure that both latches fit into the mating holes in the floor panel.
7. Connect the PAS hydraulic lines to the steering box. Fill the PAS reservoir with the correct amount of fresh hydraulic fluid of the correct grade (see chapter Settings and ongoing maintenance).
8. Install wheels. Lower the vehicle to the ground and tighten the wheel nuts to the required torque (see Specifications to Chapter Settings and ongoing maintenance).
9. Bleed the power steering system (see Section Removing air from the hydraulic path of the power steering system).