Removing and Installing

Power steering gear, removing and installing

Note: Removal and installation of the power steering gear described below is for a vehicle with A/C and ABS (vehicles with the greatest degree of removal and installation complexity).

Removing






- Disconnect battery ground strap.
- Pry off cover on sound damper with screwdriver.
- Remove both mounting bolts (arrows).
- Disconnect both crankcase ventilation breather hoses on cylinder head covers, and remove.
- Push sound damper back, lift up.
- Disconnect vacuum hose and remove sound damper.
- Remove strainer from brake fluid reservoir and draw brake fluid out of reservoir.

WARNING: Brake fluid is poisonous. It must never be extracted using suction by mouth through a hose.






- Disconnect hose line for clutch master cylinder from brake fluid reservoir.
- Remove check valve from brake booster.
- Mark brake line connections from brake master cylinder to ABS hydraulic unit, corresponding to markings VA and HA on back of hydraulic unit, and remove.






- Remove brake lines between ABS hydraulic unit, fittings -1- and -2-, and from brackets -4-.
- Carefully press brake line far enough toward front of vehicle so that it does not restrict removal of brake booster.

Note: After disconnecting the brake line, plug or cap all openings.






- If applicable, disconnect bracket for vacuum unit from left valve cover and set aside.
- Remove left-side storage shelf under instrument panel.
- Remove left footwell vent.






- Remove cover for center electric panel and/or relay panel.
- Disconnect center electric panel and/or relay panel and set aside.
- Remove bolt from brake booster clevis.
- Carefully pull back sound deadening mat around pedal bracket and remove mounting nuts for pedal bracket.






- Unclip fuel line from left side of instrument panel bracket and press toward front of vehicle.
- Carefully remove brake booster, being careful not to bend fuel and brake line.
- Remove mounting bolts for universal joint on steering gear pinion and steering column.







- Disconnect universal joint from steering gear pinion.
- Install hose clamps, Snap-On YA2850 or equivalent, on power steering return and pressure hoses.






- Disconnect return and pressure hoses from rotary slide valve housing.
- Guide pressure hose upward.

Note: On vehicles with Servotronic, disconnect harness connector from Servotronic valve.






- Remove both tie rods with carrier.
- Cut off cable tie attaching right wheel housing wiring harness.
- Remove right-side steering gear mounting bolt.






- Unclip harness connector for left front ABS wheel speed sensor from bracket.
- Remove bracket from wheel housing.
- Remove both front wheels.
- Remove steering gear mounting bolts on left and right wheel housing
- Pull steering gear toward front of vehicle slightly until it is clear of instrument panel seal.
- Push steering gear to left in left wheel housing hole so wiring harness can be pressed toward back on right side of steering gear and steering gear can be removed from opening in right wheel housing (two technicians required).

Note: When removing the steering gear, do not damage the steering gear boot.


Installing

Installation is the reverse of removal, with the following additional points:

- Install carrier in steering gear boot and fasten with both bolts.
- Install steering gear through opening in right wheel housing (two technicians required).
- Ensure correct routing of wiring harness, install cable tie.
- Carefully install instrument panel seal.
- Fasten steering gear on left and right wheel housing.
- Install mounting bracket for left-side ABS wheel speed sensor and clip on sensor connector.
- Remove left bolt from carrier for tie rod mounting.
- Install left tie rod in carrier and loosely thread in mounting bolt.
- Remove right tie rod from carrier.
- Install right tie rod in carrier and loosely thread in mounting bolt.
- Tighten both mounting bolts to specified torque only with vehicle standing on wheels.
- Ensure correct seat of carrier in steering gear boot.
- Fasten return and pressure hoses on rotary slide valve housing so hoses do not touch at any point.
- Remove hose clamps, Snap-On YA2850 or equivalent, from power steering return and pressure hose.
- Carefully place sound insulation mats under pedals.
- Install brake lines according to markings on ABS hydraulic unit.
- Install brake lines and fuel line in brackets.
- Bleed brake hydraulic system and check for leaks
- Ensure correct position of steering wheel.
- Connect battery Ground (GND) strap.
- Check and/or top off power steering fluid, check return and pressure hoses on rotary slide valve housing for leaks.