| Removal and Installation Special Tool(s) | | Alignment Pins, Subframe 205-524 (15-122) | | | Remover/Installer, Hose Clamp 303-397 | General Equipment Materials Name Specification Grease SA-M1C9107-A | | -
NOTE:Make sure that the road wheels are in the straight ahead position. Centralize the steering and lock it in position. | | | -
Detach the steering column shaft from the steering gear pinion. - Discard the steering column shaft to steering gear pinion retaining bolt.
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Remove the battery tray.
For additional information, refer to: Battery Tray - 2.0L Duratec-HE (MI4) (414-01 Battery, Mounting and Cables, Removal and Installation).
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Disconnect the powertrain control module (PCM) electrical connectors. | | | -
Remove the front wheels and tires.
For additional information, refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).
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Remove the left-hand front fender splash shield. | 7. Remove the components in the order indicated in the following illustration(s) and table(s). 1 - Steering gear to power steering fluid reservoir return line support brackets retaining bolts 8. To install, reverse the removal procedure. | | -
Fill and bleed the power steering system. For additional information, refer to: (211-00 Steering System - General Information) Power Steering System Filling - 1.6L Duratorq-TDCi (DV) Diesel (General Procedures), Power Steering System Bleeding - 1.6L Duratorq-TDCi (DV) Diesel (General Procedures). | Removal Details Item 2 : Steering gear to power steering fluid reservoir return line | | -
CAUTION:Cap the steering gear to power steering fluid reservoir return line to prevent fluid loss or dirt ingress. CAUTION:Cap the power steering fluid reservoir to prevent fluid loss or dirt ingress. Using the special tool, disconnect the steering gear to power steering fluid reservoir return line from the power steering fluid reservoir. - Allow the power steering fluid to drain into a container.
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CAUTION:Over bending of the exhaust flexible pipe may cause damage resulting in failure. Support the exhaust flexible pipe with a support wrap or splint. | | | -
CAUTION:Take care when removing the exhaust hanger insulator to prevent damage. Remove the exhaust hanger insulator. | | | -
CAUTION:Twisting the exhaust flexible pipe more than two degrees may cause damage resulting in failure. Detach the exhaust flexible pipe from the muffler and tailpipe assembly. - Discard the exhaust flexible pipe to muffler and tailpipe assembly retaining nuts.
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NOTE:Use a 5 mm Allen key to prevent the stabilizer bar link ball joint stud from rotating. Detach the stabilizer bar link from the stabilizer bar on both sides. | | | -
Remove the engine support insulator. | | | -
Remove the front axle crossmember retaining bolts on both sides. | | | -
Lower the front axle crossmember approximately 100 mm to remove the steering gear to power steering fluid reservoir return line. | | | -
CAUTION:Cap the steering gear valve body inlet and outlet to prevent fluid loss or dirt ingress. Disconnect the power steering lines from the steering gear valve body. - Remove the power steering lines clamp plate retaining bolt.
- Rotate the power steering lines clamp plate.
- Allow the power steering fluid to drain into a container.
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Remove and discard the power steering lines O-ring seals. | Installation Details Item 2 : Steering gear to power steering fluid reservoir return line | | -
Install new power steering lines O-ring seals. | | | -
Connect the power steering lines to the steering gear valve body. - Rotate the power steering lines clamp plate.
- Install the power steering lines clamp plate retaining bolt.
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NOTE:Use the front axle crossmember rear inner retaining bolts to locate the special tools. NOTE:Do not fully tighten the front axle crossmember rear inner retaining bolts at this stage. Using the transmission jack, wooden block and the special tools, position and align the front axle crossmember. | | | -
CAUTION:While tightening the front axle crossmember front retaining bolt and the front axle crossmember rear outer retaining bolts, make sure that the front axle crossmember does not move. Install the front axle crossmember front retaining bolt and the front axle crossmember rear outer retaining bolts on both sides. | | | -
Remove the front axle crossmember rear inner retaining bolts and the special tools. | | | -
Install the front axle crossmember rear inner retaining bolts on both sides. | | | -
Install the engine support insulator. | | | -
NOTE:Use a 5mm Allen key to prevent the stabilizer bar link ball joint stud from rotating. Attach the stabilizer bar link to the stabilizer bar on both sides. | | | -
CAUTION:Twisting the exhaust flexible pipe more than two degrees may cause damage resulting in failure. NOTE:Coat the exhaust flexible pipe studs with grease. NOTE:Install new exhaust flexible pipe to muffler and tailpipe assembly retaining nuts. Attach the exhaust flexible pipe to the muffler and tailpipe assembly. | | | -
CAUTION:Take care when installing the exhaust hanger insulator to prevent damage. NOTE:Check the exhaust hanger insulator for damage. Install a new exhaust hanger insulator if required. Install the hanger insulator. | | | -
CAUTION:Over bending of the exhaust flexible pipe may cause damage resulting in failure. Remove the exhaust flexible pipe support wrap or splint. | | | -
Using the special tool, connect the steering gear to power steering fluid reservoir return line to the power steering fluid reservoir. | |
