PRE-RELEASE
Rear power steering pipes
| Rear power steering pipes |
| Removal |
| Important | ||
|
Always observe utmost cleanliness when working with hydraulic components. |
||
| 1. |
Remove the nut from the rear engine mounting.
|
|
| 2. |
Position the steering wheel in the straight-ahead driving position and fasten it with woven tape to the instrument panel.
Remove the bolts that hold the steering shaft to the steering gear, push the steering shaft upwards and withdraw it from the steering gear. 
|
|
| 3. |
Clamp the intake hose of the power steering pump and the return hose to the reservoir with two
30 07 739 Pinch-off pliers
.
|
|
| 4. |
6 cyl. petrol
: Remove the battery cover, battery and battery tray.
|
|
| 5. |
Petrol
: Slightly loosen the nuts which attach the exhaust pipe to the turbo so that the pipe can be rotated.
|
|
| 6. |
Raise the car.
|
|
| 7. |
Diesel
: Remove the lower engine cover.
|
|
| 8. |
Diesel
: Remove the forward exhaust pipe.
|
|
| 9. |
4 cyl. petrol
: Remove the forward mounting of the exhaust pipe.
|
|
| 10. |
Detach the exhaust pipe from the catalytic converter.
|
|
| 11. |
6 cyl. petrol
: Remove the exhaust pipe from the rearward exhaust manifold. Hang up the pipe with a strap.
|
|
| 12. |
Remove the RH side-cover.
|
|
| 13. |
Mark the position of the subframe relative to the body.
|
|
| 14. |
Remove the reinforcement plates.
|
|
| 15. |
Slowly lower the subframe by undoing the centre bolts. Use a pillar jack.
|
|
| 16. |
Undo the rear pipe clamps.
|
|
| 17. |
Remove the cable tie (LHD) from the rear pipe and the clamp that secures the pipe to the steering gear.
RHD : 
|
|
| 18. |
Place a bowl under the front pipe union and separate the union.
|
|
| 19. |
Place a bowl under the banjo nipple and undo the nipple from the steering gear. Remove the pipe.
RHD : 
|
|
| Re-assembly |
| 1. |
Position the pipe, starting from the rear.
6 cyl. petrol : Transfer the heat shield from the old pressure hose to the new hose. |
|
| 2. |
Remove the rear transit protection and screw by hand the banjo nipple into place with new seals.
|
|
| 3. |
Remove the front transport protection and lightly screw together the front pipe union.
|
|||||||
| 4. |
Fit the rear clamp to the steering gear.
RHD : 
|
|
| 5. |
LHD
: Fit the return hose with two cable ties.
|
|
| 6. |
Tighten the banjo nipple.
Tightening torque 30 Nm (22 lbf ft) 
LHD 6 cyl. diesel : Restrain the pipe so that it is not twisted when the nipple is tightened. Twisting will affect the clearance between the pressure pipe and the alternator. 
|
|
| 7. |
Check that the seal between the steering gear and the body is correctly positioned.
|
|
| 8. |
Raise the subframe with a pillar jack and screw in the centre bolts finger tight.
|
|||||||
| 9. |
Fit the reinforcement plates.
Tightening torque 65 Nm (48 lbf ft) 
|
|
| 10. |
Adjust the subframe so as to align with the previously made marks on the body. Tighten the subframe mounting bolts.
Tightening torque 100 Nm +45°(74 lbf ft +45°) |
|
| 11. |
6 cyl. diesel
: Check that the clearance between the pressure hose and the generator fastening heel is at least 15 mm.
If YES . Go to item 16. If NO. Go to item 12. 
|
|
| 12. |
Remove the push nut for upholding the bulkhead insulation.
|
|
| 13. |
Fit a cable tie mounting.
|
|
| 14. |
Fit the short cable tie loosely around the delivery line to the right of the existing cable tie.
|
|
| 15. |
Insert the long cable tie through the short one and the cable tie mounting.
Tighten the short cable tie around the line. Adjust the distance between the delivery line and the generator mounting heel to 15 mm using the long cable tie. |
|
| 16. |
Diesel
: Fit the forward exhaust pipe.
Tightening torque 6 cyl. diesel against the forward joint: 40 Nm (29 lbf ft) Tightening torque 4 cyl. diesel against the turbo: 25 Nm (18 lbf ft) |
|||||||
| 17. |
4 cyl. petrol and 6 cyl. diesel
: Fit the mounting.
|
|
| 18. |
Assemble the exhaust pipe to the catalytic converter.
Tightening torque 22 Nm (16 lbf ft) 
|
|
| 19. |
6-cyl petrol
: Assemble the exhaust pipe to the rearward exhaust manifold.
Tightening torque 40 Nm (30 lbf ft) |
|
| 20. |
Fit the pipe into the clamps.
|
|
| 21. |
Fit a new tie with holder to the pressure hose. Fit the return hose to the holder.
|
|
| 22. |
Tighten the front pipe union. Check that the rear pressure line hose connection is at least 5 mm from the subframe.
|
|
| 23. |
Fit the RH side-cover.
|
|
| 24. |
Diesel
: Fit the lower engine cover.
|
|
| 25. |
Lower the car.
|
|
| 26. |
Remove the pinch-off pliers.
|
|
| 27. |
Fit the nut to the rear engine mount.
Tightening torque 50 Nm (37 lbf ft) 
|
|
| 28. |
Petrol
: Tighten the bolts securing the exhaust pipe to the turbo.
Tightening torque 25 Nm (18 lbf ft) 
|
|
| 29. |
6 cyl.
: Fit the battery shelf, battery and battery cover.
|
|
| 30. |
Check that the wheels and steering wheel are in the straight-ahead position and attach the steering shaft to the steering gear. Remove the tape from the steering wheel.
Tightening torque 30 Nm (22 lbf ft) 
|
|
| 31. |
Fill the system with fluid and bleed as described in
Bleeding the power steering system
.
|
|
| 32. |
Check for any leakage at the hose connections.
|
|
| 33. |
Check the steering wheel position when driving straight ahead on a level road. Adjust if necessary.
|
|
