Contents: Dismantling ⇩ Assembly ⇩
Before disconnecting the battery, make sure that all requirements and conditions contained in the section on disconnecting the battery are met.
GENERAL INFORMATION, Precautions when working with electrical equipment.
Dismantling
1. Place the vehicle on a lift.
2. Disconnect the negative terminal from the battery.
3. Remove the 4 screws securing the lower aerodynamic panel and remove the panel.
4. Remove the fan viscous coupling.
COOLING SYSTEM: Td6, REPAIR WORK, Viscous fan clutch.
5. Remove the air duct.
HEATING AND VENTILATION, REPAIR WORK, Air filter - air intake.
6. Remove the two engine mount nuts.
7. Attach the chain to the engine mounting brackets and tighten the chain by loading it with the weight of the engine.
8. Remove the front propeller shaft.
DRIVE SHAFTS, REPAIR WORK, Cardan shaft - front.
9. Remove the right drive shaft protective cover.
DRIVE SHAFTS, REPAIR WORK, Seal - drive shaft - front - right.
10. Remove the differential seal.
FRONT AXLE MAIN GEAR AND DIFFERENTIAL, REPAIR WORK, Seal - differential output shaft.
11. Remove the screw of the lower steering shaft joint.
12. Turn the steering wheel to the straight-ahead position, align the marks on the steering gear shaft and remove the key from the ignition switch.
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 pinion shaft.
14. Release the vacuum line from the three fasteners on the left engine mount.
15. Disconnect the vacuum supply hose from the tee.
CAUTION: Always plug the fittings and holes to protect the system from dirt.
16. Mark the position of the clamps and remove the clamps securing the body position sensor cable to the subframe and the sensor itself.
17. Remove the pads from the electrical connectors of the body position sensors.
18. Remove the steering angle sensor connector block.
19. Install a container to collect the leaking working fluid.
20. Loosen the union nut, disconnect the high pressure line from the power steering pump and discard the sealing ring.
CAUTION: Before disconnecting or removing steering components, make sure that the surfaces adjacent to the connections are free of dirt. Install plugs in the openings of the fittings and pipes to prevent dirt from entering the system.
21. Remove the nut securing the steering pipe to the bracket.
22. Loosen the fastening and disconnect the low pressure line from the working fluid cooler.
23. If installed on the vehicle: Remove the 2 nuts securing each anti-roll bar heat shield to the body and the 2 screws securing each heat shield to the subframe. Remove the heat shields.
24. Support the subframe using a jack.
25. Remove the 2 subframe-to-crossmember screws and the 6 subframe-to-car body screws. Discard the screws.
26. With the help of an assistant, lower and remove the subframe assembly.
27. Mark the position of the pressure and drain pipe fittings on the steering gear housing, unscrew the fitting screws and remove the sealing rings.
CAUTION: Before disconnecting or removing steering components, make sure that the surfaces adjacent to the connections are free of dirt. Install plugs in the openings of the fittings and pipes to prevent dirt from entering the system.
28. Disconnect the 5 fasteners securing the vacuum hose to the steering gear housing.
29. Remove the 2 bolts and 2 nuts securing the steering gear assembly and discard the bolts and nuts.
30. Loosen the locknuts securing the ends of the steering rods.
31. Remove the tie rod ends from the tie rods. Remember the number of thread turns to avoid mistakes during assembly.
32. Remove and discard the snap rings.
33. Remove the locknuts.
Assembly
1. Screw the locknuts onto the ends of the steering rods.
2. Place the retaining rings on the ends of the steering rods so that the conical part of the ring faces the conical belt of the rod.
3. Screw the tie rod ends onto the rods, turning them to the number of turns recorded during removal.
4. Install the steering gear assembly and tighten the new bolts and nuts to a tightening torque of 100 N·m, then tighten the nuts by 90°.
5. Fix the vacuum line to the steering gear housing.
6. Clean the pipe fittings and connection points from dirt.
7. Install new sealing rings and connect the pipe fittings, tightening the M16 screw to 40 Nm and the M14 screw to 36 Nm.
8. Clean the mating surfaces of the subframe and the car body.
9. Together with an assistant, install the subframe assembly.
10. Install new screws and tighten the 6 subframe-to-body mounting screws to 165 Nm, then tighten the two rear bolts another 90°. Tighten the subframe-to-crossmember mounting screws to 132.5 Nm.
11. Install the anti-roll bar heat shields and tighten the fasteners.
12. Lower the engine onto the supports.
13. Tighten the engine bracket mounting nuts to the supports with a tightening torque of 100 N·m.
14. Wipe the connection points of the power steering pipes.
15. Connect the hydraulic hose to the working fluid cooler.
16. Install a new sealing ring on the pipe fitting and connect the pipe to the pump, tightening the nut to a torque of 25 N·m.
17. Secure the power steering pipe to the bracket and tighten the retaining bracket nut to a torque of 10 N·m.
18. Connect the connector to the steering angle sensor connector.
19. Connect the electrical connector blocks of the front vertical body position sensors.
20. Route the sensor cables and secure them with clamps in their original position.
21. Connect the vacuum hose to the tee.
22. Check the alignment of the steering gear shaft marks and attach the steering shaft. Install the steering shaft joint screw and tighten it to 24 N·m.
23. Install the differential seal.
FRONT AXLE MAIN GEAR AND DIFFERENTIAL, REPAIR WORK, Seal - differential output shaft.
24. Install the right drive shaft protective boot.
DRIVE SHAFTS, REPAIR WORK, Seal - drive shaft - front - right.
25. Install the front propeller shaft.
DRIVE SHAFTS, REPAIR WORK, Cardan shaft - front.
26. Reinstall the lower aero panel and tighten the bolts to 45 Nm.
27. Reinstall the air duct.
HEATING AND VENTILATION, REPAIR WORK, Air filter - air intake.
28. Install the fan viscous coupling.
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 power steering reservoir.
STEERING, ADJUSTMENTS, Power assisted steering (PAS) - bleeding.
31. Check and, if necessary, adjust the front wheel alignment angles.
[Data taken from the website: LRMAN.RU]
STEERING, ADJUSTMENTS, Front wheel alignment angles - checking and adjustment.
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