Power Steering Rack

Remove
1. Raise front of vehicle.

WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.

2. Remove front road wheels.
3. Remove and discard nuts securing track rod ball joints to steering arms.
4. Fit an M12 nut to each ball pin, flush with end of each pin.





5. Using LRT-57-043, separate ball pins from RH and LH steering arms. Remove M12 nuts and release ball pins from steering arms.





6. Remove pinch bolt securing steering column to PAS rack pinion.





7. KV6 models: Remove 2 nuts securing steering rack heat shield and remove heat shield.
8. KV6 models: Remove 2 bolts securing coolant rail to cylinder block.





9. TD4 manual models: Using tool LRT-37-050 release gear change rods from gear change linkage.
10. TD4 manual models: Remove 2 bolts securing gear change linkage to bulkhead and tie aside.





11. TD4 manual models: Remove bolt securing IRD coolant hose "P" clip.





12. TD4 auto models: Remove bolt securing IRD coolant hose "P" clip.





13. Remove 2 bolts and washers securing PAS rack clamp to bulkhead, discard bolts.
14. Remove PAS rack clamp.
15. Remove rubber mount.





16. Remove and discard 2 bolts securing PAS rack mounting to bulkhead.
17. Release PAS rack pinion from steering column.
18. Position container to collect PAS fluid spillage.





19. Remove bolt securing pipe bracket to PAS rack.
20. Release pipe unions and disconnect fluid pipes from PAS rack.

CAUTION: Always fit plugs to open connections to prevent contamination.

21. Remove and discard O-rings.
22. Remove bolt securing PAS pipes to clamp and loosen clamp bolt.
23. With assistance remove PAS rack from passenger side of vehicle.





24. Remove dust seal from pinion housing.

Refit
1. Fit PAS rack to vehicle from passengers side.
2. Fit dust shield to pinion housing.
3. Ensure pipe unions are clean.
4. Fit new O-rings to fluid pipes.
5. Fit fluid pipes to PAS rack but do not tighten at this stage.
6. Align fluid pipe bracket to PAS rack, fit bolt but do not tighten at this stage.
7. With assistance fit PAS rack pinion to steering column, ensuring column coupling is aligned with gear input flag.
8. Fit washers and new bolts securing steering rack mounting to bulkhead, but do not tighten at this stage. Ensure large washer is fitted to lower bolt.
9. Fit rubber mount and clamp to PAS rack.
10. Fit bolts securing clamp to bulkhead but do not tighten at this stage.
11. Tighten PAS rack mounting bolts to 45 Nm (33 ft. lbs.).
12. Tighten PAS rack clamp bolts to 45 Nm (33 ft. lbs.).
13. Tighten PAS rack fluid feed pipe union to 18 Nm (13 ft. lbs.).
14. Tighten PAS rack fluid return pipe union to 22 Nm (16 ft. lbs.).
15. Tighten fluid pipe bracket to 10 Nm (7.5 ft. lbs.).
16. Align PAS rack clamp and tighten bolt.
17. Align pipes to clamp fit bolt and tighten to 10 Nm (7.5 ft. lbs.).
18. Fit pinch bolt to steering column and tighten to 32 Nm (24 ft. lbs.).

CAUTION: Nuts and bolts must be tightened with the weight of the vehicle on the suspension.

19. Ensure tapers in track rod end and steering arm are clean and rubber boot is not damaged.
20. Fit ball joints to steering arms, fit new nuts and tighten to 55 Nm (41 ft. lbs.).
21. KV6 models: Align coolant rail to cylinder block, fit bolts and tighten to 9 Nm (7 ft. lbs.).
22. KV6 models: Position heat shield, fit nuts and tighten to 25 Nm (18 ft. lbs.)
23. TD4 manual models: Align IRD hose "P" clip fit bolt and tighten to 25 Nm (18 ft. lbs.).
24. TD4 manual models: Align gear change linkage to bulkhead, fit bolts and tighten to 25 Nm (18 ft. lbs.).
25. TD4 manual models: Connect gear change rods to gear change linkage.
26. TD4 auto models: Align IRD hose "P" clip fit bolt and tighten to 25 Nm (18 ft. lbs.).
27. Fit road wheel(s) and tighten nuts to 115 Nm (85 ft. lbs.).
28. Remove stands and lower vehicle.
29. Bleed PAS system.
30. Check and adjust front wheel alignment. Alignment