Removal/Installation

IMPORTANT The highest regard for cleanliness must always be observed when working with hydraulic components.





REMOVAL
1. Drain the fluid from the system as follows:
a. Drain the hydraulic fluid reservoir using oil suction devise.
b. Disconnect the return hose from the hydraulic fluid reservoir. Connect a slack hose to the return hose.
c. Plug the opening in the reservoir. Place the end of the hose in a container with a capacity for at least 1 liter.
d. Start the engine and let the power steering fluid be pumped out of the steering system. Turn the steering wheel to the left and righthand end positions twice to completely empty the system. Turn of the engine when the flow of the power steering fluid ceases. Take away the slack hose and plug the return hose.
2. Slacken the bracket, if applicable.
3. Remove the pressure hose from the pump. Plug the hose and openings on the pump. (The picture shows a 2.3i engine).





4. Remove the acoustic insulation from under the facia.
5. Unfasten the carpet and fold it back out of the way.
6. Peel back the rubber gaiter on the intermediate shaft.
7. Remove the pinch bolts from both universal joints on the intermediate shaft. Push the intermediate shaft up and disconnect it from the pinion shaft and then from the steering column shaft.
8. Remove the cover plate from the bulkhead, collecting the rubber gasket, seal and plastic bushing.





9. Remove the wheels.
10. Remove the rear part of the lefthand wing liner.
11. Measure and note the distance between the track rod end and the groove in the track rod.
12. Slacken the locknut.
13. Remove the nut securing the track rod ends to the steering swivel member.
14. Remove the track rod end from the steering swivel member using ball joint separator part No. 89 95 409. Use a spacer under the bolt if needed.
15. Unscrew the track rod end from the track rod.
16. Carry out points 11 - 15 on the righthand side of the car.
17. Remove the upper retaining screws for the stanchion between the subframe and the lefthand side wheel housing.
18. Remove the two bolts securing the steering gear.
19. Remove the lower bolts and take away the stanchion.
20 Pull down the discharge and return hoses. Lift away the cables and hoses in the engine compartment and lift out the steering gear through the lefthand wheel housing. Angle the front end of the assembly forwards so as not to damage the wing liner.





INSTALLATION
1. Lift the rack and pinion assembly through the lefthand wheel arch. Take care not to damage the rubber gaiters on the rack and ensure that the control valve does not snag on hoses or electrical leads inside the engine compartment.
2. Tighten the two bolts securing the steering gear (1).
Tightening torques: 70 Nm (52 ft. lbs.)

IMPORTANT On cars to chassis No. H 1003410, from 1987, a 2 mm thick washer sits between the left bracket of the assembly and the body.

3. Position the stanchion between the subframe and the wheel arch on the righthand side and fit the lower retaining bolts (2).
4. Tighten the top fixing bolt.
5. Tighten the lower fixing bolts
6. Screw the track rod end onto the track rod following the measurement noted previously, but do not tighten the lock nuts.
7. Tighten the nuts securing the track rod ends to the steering swivel members.
Tightening torques: 55 Nm (41 ft. lbs.)
8. Refit the rear part of the wing liner on the righthand side.
9. Refit the road wheels.
Tightening torques: 120 Nm (89 ft. lbs.)





10. Fit the plastic bush and seal on the pinion shaft.
11. Inspect the rubber gasket on the cover plate, fit the cover plate tightening its four retaining screws.
12. Ensure that the front wheels and the steering wheels are dead centered. Refit the intermediate shaft and tighten the pinch bolts in the two universal joints. Make sure that the top pinch bolt is below the stop on the end of the shaft and that the lower bolt is seated in the slot at the end of the pinion shaft.
Tightening torques: 26 Nm (19 ft. lbs.)
13. Fit the rubber gaiter onto the cover plate. Ensure that the cover plate goes into the grooves on the rubber gaiter properly.
14. Replace the carpet.
15. Refit the acoustic insulation.





16. Thoroughly clean the areas around the hydraulic connections at the pump and reservoir. Check the condition of the O-ring on the delivery hose. Lubricate it lightly with a little hydraulic fluid and connect the hose to the pump. (Pictured is a 2.3i engine).
17. Connect the return hose to the power steering fluid reservoir and tighten the hose clip.
18. Fit the bracket for the oil filler pipe (applies only to 2.0 liter engines).
19. Fill the reservoir to approximately. 15 mm over the filter with Saab PS Fluid 4634 part No. (45) 30 09 800. Screw on the filler cap.





20 Start the engine and let it run for about 2 seconds.
21. Unscrew the filler cap and top up the fluid to the maximum level. Screw the filler cap back on and start the motor.
22. Turn the steering wheel from left full lock to right full lock, three or four times. Stop the motor.
23. Unscrew the filler cap and top up the level to maximum. Replace the filler cap. Check the level after a test drive and top up if needed according to the above.

IMPORTANT: Never start the motor with the filler cap open, as fluid can spray out of the reservoir.

24. Check, and if necessary, adjust the toe-in.
25. Tighten the locknuts on the track rod.
Tightening torques: 70 Nm (52 ft. lbs.)
26. Check the position of the steering wheel and the operation of the steering system on the open road.
27. Inspect the system for any possible leaks.