1 - locknut of the tie rod end, 50–55 Nm; 2 - clamp; 3 - protective cover; 4 - clamp; 5 – steering rod, 80–100 Nm; 6 - lock washer; 7 - locknut, 50–70 Nm; 8 - plug; 9 - spring; 10 - emphasis; 11 - bushing; 12 - plug; 13 - locknut, 20–30 Nm; 14 - ball bearing; 15 - steering gear housing; 16 - collar; 17 - gear rack stopper; 18 - gear rack bushings; 19 - sealing ring; 20 - lock washer; 21 - tubes, 12–18 Nm; 22 - sealing ring; 23 - sealing ring; 24 - ball bearing; 25 - gear shaft and gear; 26 - sealing ring; 27 - body of the control valve; 28 – O-ring; 29 - needle bearing; 30 - gear rack; 31 - dust cover; 32 - tie rod end.
Withdrawal
1. Remove the cotter pins and unscrew the nuts securing the pins of the ball joints of the tie rod ends to the steering knuckles. With a puller 09568–31000, press the pins of the ball joints of the tie rod ends from the steering knuckles.
2. Remove the bolt connecting the universal joint and the steering gear shaft.
3. Drain the power steering hydraulic fluid.
4. Disconnect the pressure and return hoses from the steering gear housing.
5. Turn out bolts of fastening of a case of steering transfer.
6. Remove the rear engine mount.
7. Remove the anti-roll bar.
8. Move the steering gear and get it on the right side of the car.
Warning! When removing the steering gear, be careful not to damage the protective covers.
Inspection and pre-adjustment before installation
Fix the steering gear in a vise, the jaws of which are covered with soft material.
Warning! When fixing the steering gear in a vise, wrap the steering gear with a cloth and be careful not to damage it when squeezing the vise.
Gear preload
1. Measure the preload by turning the gear with special tool 09565-11100 one turn every 4-6 seconds. Also measure the starting force of the rack.
Full gear preload: 0.6 - 1.3 Nm.
Warning! Measure the preload on the full travel of the steering gear.
2. If the preload is not correct, first adjust the plug torque and recheck the gear preload.
3. If adjusting the plug tightening torque does not give positive results, check or replace the plug elements.
Tie Rod Deflection Resistance
1. Complete 10 tie rod deflections.
2. Use a dynamometer to measure the force required to deflect the tie rod.
Tie rod deflection force: 2–5 N
3. If the measured value is greater than the nominal value, replace the tie rod assembly.
Warning! If the measured value is below the nominal value and the tie rod turns smoothly and without play, it can be installed on the vehicle. However, if the measured value is below 4.3 N, replace the tie rod.
Checking the bellows
1. Visually inspect the bellows for damage or deterioration.
2. Make sure the protective cover is installed in the correct position.
3. If the bellows are defective, replace them.
Disassembly
1. Remove the tie rod end from the tie rod.
2. Use a screwdriver blade to remove the protective cover of the ball joint of the tie rod end.
3. Remove the clamp securing the corrugated protective cover.
4. Remove the clip securing the bellows.
5. Move the corrugated protective cover to the steering rod.
Warning! When replacing the bellows, check the steering gear for rust.
6. Remove the guide tube from the gear housing.
7. When moving the rack slowly, drain the fluid from the steering gear case.
8. Remove the plug.
9. With the gear turned clockwise until the rack is locked, loosen the self-locking nut.
10. With a chisel, bend the lock washer located between the steering rod and the gear rack.
11. Unscrew the steering rod from the gear rack.
Warning! When removing the tie rod, be careful not to turn the gear rack.
12. Loosen the locknut securing the plug.
13. Use the special tool 09565–21100 to remove the plug.
14. Remove the spring, stop and bushing from the steering gear case.
15. Turn out two bolts and remove the case of the valve.
16. Use a screwdriver blade to turn the rack stopper clockwise until the end of the retaining ring comes out of the groove in the steering gear housing.
17. When the end of the retaining ring comes out of the hole in the rack cylinder housing, use a screwdriver blade to turn the steering lock counterclockwise and remove the retaining ring.
18. Remove the rack stopper, bushing and rack from the steering gear case by moving them towards the gear.
Warning! After removing the steering gear, be sure to replace the crankcase side O-ring.
19. Remove the O-ring from the rack bushing.
20. Remove the O-ring from the rack bushing.
21. Using a plastic mallet, remove the valve body from its body.
22. Using special tool 09565–21000, remove the oil seal and ball bearing from the valve body.
23. Remove the ball bearing from the gear housing.
Warning! Be careful not to damage the valve cylinder in the steering gear housing.
24. Remove the needle bearing from the steering gear housing.
25. Using special tools 09573–21200, 09555–21000, remove the backwasher and oil seal from the steering gear housing.
Warning! Be careful not to damage the rack cylinder in the pinion housing.
Checking the rack
1. Check the toothed rack for damage or wear to the teeth.
2. Check the oil seal contact surfaces for damage.
3. Check the gear rack for deflection or twisting.
4. Check the O-ring for damage or wear.
5. Check the oil seal for damage or wear.
Gear valve check
1. Check the gear valve for damage or wear to the teeth.
2. Check the oil seal contact surfaces for damage.
3. Check the O-ring for damage or wear.
4. Check the oil seal for damage or wear.
Bearing check
1. Check the bearing for jamming or abnormal noise when it rotates.
2. Check the bearing for excessive play.
3. Check for missing needle bearing.
Other checks
1. Check the surface of the steering gear housing cylinder for damage.
2. Check the protective cover for damage, aging and cracks.
Assembly
1. Lubricate the sliding surface of the rack oil seal.
Recommended Lubrication: Power Steering Fluid Type 3
2. Install the reverse washer and oil seal in the steering gear housing in the position shown in the illustration.
3. Apply grease to the entire surface of the needle bearing.
Recommended lubricant: SAE J310, NLGI #2
4. Fix the needle bearing on the special tool 09432-21600 and install it in the steering gear housing until the tool touches the crankcase.
Warning! Pay attention to the installation direction of the needle bearing.
5. Lubricate the ball bearing and install with special tool 09222-21100.
Recommended lubricant: SAE J310, NLGI #2
Warning! Always use a new bearing.
6. Lubricate the oil seal surfaces of the rack bushing.
Recommended Lubrication: Power Steering Fluid Type 3
7. Install the oil seal into the rack bushing.
8. Lubricate the O-ring and install it in the rack bushing.
9. Lubricate the teeth of the rack and wrap it with adhesive tape.
Recommended lubricant: SAE J310, NLGI #2
Warning! Do not block the vent hole in the rack with grease.
10. Install the gear rack into the steering gear housing. Then install the bushing and rack stopper.
11. Press the gear rack stopper until a groove appears and, turning the stopper, install the retaining ring.
Warning! The circlip must not be visible through the hole in the rack housing.
12. Using special tool 09432-21600, install the oil seal and ball bearing into the valve body.
13. Lubricate the valve assembly with oil and recommended grease and install it in the steering gear housing.
- Recommended oil: PSF-3
- Recommended lubricant: SAE J310, NLGI #2
14. Lubricate with oil and with special tool 09434–14200 install the seal into the valve body.
15. Install the valve body assembly with O-ring into the steering gear case.
16. Install the lock washer and tie rod and caulk the collar of the washer in two places.
Warning! Align the tabs of the lock washer with the notches on the steering gear housing.
Warning! Always use a new lock washer.
17. With the gear turned all the way clockwise, tighten the self-locking nut.
18. Apply sealant to the threaded portion of the plug and tighten the plug to the correct torque.
Tightening torque: 50–70 Nm
19. Pin the cork in two places along its circumference.
20. Install the bushing, stop and spring in the order shown in the figure. Before installing, apply sealant to the threaded part of the plug.
21. Center the rack and place the cover on the steering gear case. Using the special tool 09565–21100, tighten the cover with a tightening torque of 20–25 Nm. Loosen the cap 10°and tighten the locknut to the correct torque.
22. Tighten the guide tube to the required tightening torque and install the rubber element on the adhesive.
Tightening torque: 50–70 Nm
23. Lubricate the bellows and install them in the tie rod groove.
24. Fasten the corrugated protective cover with a clamp.
Warning! A new collar and clip must be used to secure the bellows.
25. Check that the bellows are not twisted.
26. Fill the protective boot with lubricant, install it on the ball joint of the tie rod end and secure with a retaining ring.
27. Install the tie rods so that the left and right tie rods are the same length.
Tie Rod Length: 185.2±1mm
28. Check gear preload.
Installation
1. Install the steering gear rubber mount so that it lines up with the holes in the clamp and steering gear bracket.
2. Apply glue to the side of the cylinder where the rubber support is installed so that its split part does not open.
3. Check for fluid leaks.
4. Check that the steering wheel turns smoothly.
5. Adjust the front wheel alignment.
6. Install the rest of the parts according to the required tightening torques.