GENERAL INFORMATION, Precautions when working with electrical equipment.
Dismantling
1. Put the car on a lift.
2. Disconnect the negative plug from the storage battery.
3. Turn out 4 screws of fastening of the bottom aerodynamic panel and remove the panel.
4. Remove the viscous fan clutch.
COOLING SYSTEM: Td6, REPAIR WORK, Viscous fan clutch.
5. Remove the air tube.
HEATING AND VENTILATION, REPAIR WORKS, Air filter - air intake.
6. Remove the two engine mount nuts.
7. Attach the chain to the motor mounting brackets and tension the chain with the weight of the motor.
8. Remove the front propeller shaft.
DRIVE SHAFTS, REPAIR WORKS, Cardan shaft - front.
9. Remove a protective cover of the right power shaft.
DRIVE SHAFTS, REPAIR WORKS, Seal - drive shaft - front - right.
10. Remove the differential seal.
FRONT AXLE MAIN GEAR AND DIFFERENTIAL, REPAIR WORK, Seal - differential output shaft.
11. Turn out the screw of the lower hinge of a steering shaft.
12. Turn the steering wheel to the straight ahead position, align the marks on the steering gear shaft and remove the ignition key.
CAUTION: Do not turn the steering wheel when the intermediate shaft or universal joint is disconnected as this will damage the rotating slip ring and steering wheel controls.
13. Disconnect the steering shaft from the gear shaft.
14. Release the vacuum pipeline from the three clamps on the left engine support.
15. Disconnect the vacuum supply hose from the tee.
CAUTION: Always plug fittings and openings to keep dirt out of the system.
16. Mark position of clips and remove clips of fastening to a subframe of a cable of the sensor of position of a body and the sensor.
17. Remove blocks from electric sockets of gauges of provision of a body.
18. Remove the steering shaft angle sensor connector block.
19. Install a container to collect the escaping fluid.
20. Loosen union nut, disconnect high pressure line from power steering pump and discard o-ring.
CAUTION: Before disconnecting or removing steering components, make sure that the surfaces adjacent to the connection points are free of dirt. Install plugs in fittings and piping to keep dirt out of the system.
21. Remove a nut of a bracket of fastening of the pipeline of a steering to an arm.
22. Loosen and disconnect the low pressure line from the fluid cooler.
23. If fitted to vehicle: Remove 2 nuts securing each anti-roll bar heat shield to body and 2 screws securing each heat shield to subframe. Remove heat shields.
24. Support the subframe with a jack.
25. Remove 2 screws securing the subframe to the cross member and 6 screws securing the subframe to the vehicle body. Discard the screws.
26. Together with an assistant, lower and remove the subframe assembly.
27. Mark position of unions of pressure head and drain pipelines on the case of the steering mechanism, turn out screws of unions and remove sealing rings.
CAUTION: Before disconnecting or removing steering components, make sure that the surfaces adjacent to the connection points are free of dirt. Install plugs in fittings and piping to keep dirt out of the system.
28. Separate 5 clamps fastening a vacuum hose to the case of the steering mechanism.
29. Remove the 2 bolts and 2 nuts of the steering gear assembly, discard the bolts and nuts.
30. Loosen the locknuts securing the tie rod ends.
31. Remove the tie rod ends from the tie rods. Remember the number of turns on the thread so as not to make a mistake when assembling.
32. Remove and discard retaining rings.
33. Remove locknuts.
Assembly
1. Screw the lock nuts onto the ends of the tie rods.
2. Fit the circlips on the ends of the tie rods so that the conical part of the ring faces the conical band of the tie rod.
3. Screw the tie rod ends onto the tie rods by turning them the number of revolutions recorded during removal.
4. Install the steering gear assembly and tighten the new bolts and nuts with a tightening torque of 100 N·m, then tighten the nuts by 90°.
5. Fix the vacuum pipeline on the case of the steering mechanism.
6. Clean the pipe fittings and connections from dirt.
7. Install new O-rings and connect the pipe fittings by tightening the M16 screw with a torque of 40 Nm, and the M14 screw with a torque of 36 Nm.
8. Clean the mating surfaces of the subframe and car body.
9. Together with an assistant, install the subframe assembly.
10. Wrap new screws and tighten 6 screws securing the subframe to the body with a torque of 165 Nm, then tighten the two rear bolts another 90o. Tighten the screws securing the subframe to the cross beam with a torque of 132.5 Nm.
11. Install anti-roll bar heat shields and tighten fasteners.
12. Lower the engine onto stands.
13. Tighten the nuts securing the engine brackets to the supports with a tightening torque of 100 Nm.
14. Wipe places of accessions of pipelines of the hydraulic booster.
15. Connect the hydraulic hose to the fluid cooler.
16. Install a new O-ring on the pipe fitting and connect the pipe to the pump by tightening the nut to 25 Nm.
17. Fix the pipeline of the hydraulic booster to an arm and tighten a nut of a fixing bracket with the moment of 10 Нм.
18. Connect block to a socket of the gauge of an angle of rotation of a steering shaft.
19. Attach blocks of electric sockets of forward gauges of vertical position of a body.
20. Route the sensor cables and secure them with the clamps in their original position.
21. Connect the vacuum hose to the tee.
22. Check the alignment of the marks on the steering gear shaft and attach the steering shaft. Install the steering shaft pivot screw and tighten to 24 Nm.
23. Install the differential seal.
FRONT AXLE MAIN GEAR AND DIFFERENTIAL, REPAIR WORK, Seal - differential output shaft.
24. Establish a protective cover of the right power shaft.
DRIVE SHAFTS, REPAIR WORKS, Seal - drive shaft - front - right.
25. Install the front driveshaft.
DRIVE SHAFTS, REPAIR WORKS, Cardan shaft - front.
26. Reinstall the lower aerodynamic panel and tighten the bolts to 45 Nm.
27. Replace the air tube.
HEATING AND VENTILATION, REPAIR WORKS, Air filter - air intake.
28. Install the viscous fan clutch.
COOLING SYSTEM: Td6, REPAIR WORK, Viscous fan clutch.
29. Connect the negative terminal to the battery.
30. Remove air from the system and add working fluid to the hydraulic booster reservoir.
STEERING, ADJUSTMENTS, Power Steering (PAS) - removal of air.
31. Check and, if necessary, adjust the angles of the front wheels.
STEERING, ADJUSTMENTS, Front wheel alignment - check and adjustment.
Comments on this article