Steering without power assistance.
1. Remove the air conditioner.
2. If you have a headlight washer system installed, release the fluid reservoir and move it to the side.
3. Disconnect the battery ground wire.
4. Working with the center of the steering rack housing, remove both bolts and remove the bolt stops and spacer plate (photo).
Photo 4.4 Connection of the rod to the steering rack.
Pic. 8.4 Steering gear alignment diagram - left side. A= 325.0 mm (12.8 inches).
5. If the model is equipped with a steering shock absorber, disconnect the shock absorber brackets from the steering housing and remove the shock absorber.
Pic. 8.5 Location of the upper pinch bolt of the flexible coupling with the steering gear centered - indicated by an arrow (left-hand side)
6. Pull the cardboard panel from under the dashboard to gain access to the steering column shaft flex coupling.
7. Place the steering wheel and front wheels in position "straight ahead".
8. Unscrew the two pinch bolts on the flexible coupling at the base of the steering column shaft (photo).
Photo 4.8 Upper flexible coupling clamping bolt (indicated by arrow).
9. Remove the flexible coupling upwards from the gear.
10. Unscrew the steering mounting brackets and remove the rack and pinion gear case through the front right wheel arch (photo).
Photo 4.10 Rack with mounting bracket (indicated by an arrow).
11. Reassembly is carried out in the reverse order, but before connecting the flexible coupling to the gear, the steering must be centered as follows.
12. Jack up the front of the car and turn the steering gear until the distance between the center of the shim plate and the rib on the bracket is as specified (Pic. 8.4).
13. Place the steering wheel in position "straight ahead".
14. If you had a steering shock absorber, screw it to the steering housing and tighten the bolts to the specified torque.
15. Push the flexible coupling down and engage it with the gear, and then tighten the coupling bolt to the specified torque.
16. The top clamp should now be in position so that the pinch bolt is parallel to the steering boot. If this is not the case, then this indicates that the pinion is not in phase with the rack and the components need to be moved relative to each other as indicated in Section 6.
17. Check that the concave end of the mounting bracket faces down when the steering is installed.
18. If the gear cap has been disturbed, make sure that its recess aligns with the rib on the steering case.
Power steering.
19. The operations are similar to those just described for manual steering, except that the jet tubes (pressure tubes) and return tubes must be disconnected before disassembly procedure.
20. Disconnect the pressure tube coupling and loosen the return hose ring, then separate the couplings (photo).
Photo 4.20 Pressure pipe coupling (A) and return hose ring (IN) power steering.
21. Allow fluid to drain from open couplings, then wrap small plastic bags or tape around the couplings to prevent dirt from entering.
22. When reinstalling the steering, center it by counting the number of turns from stopper to stopper as you turn the pinion shaft. Then bring the steering to the desired state by turning the gear shaft from its extreme position by half the counted number of revolutions.
23. Install the flexible coupling onto the gear shaft (steering still centered), so that the upper pinch bolt is horizontal and on top of the gear shaft.
24. Reconnect the couplings, then fill and bleed the system as indicated in Section 13.
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