Belt - drive - PAS pump - ’k’ series

Refit

1. Clean remains of lubricant from PAS rack slider and clip.
2. Cut 2 hacksaw slots along thread of one of the discarded Torx bolts and use this to remove remains of patch lock from the 2 threaded holes in rack.
3. Fit the clip to slider.
4. Fit the slider and clip assembly to rack.
5. Apply grease supplied in gaiter kit to exposed rack shaft, slider and clip.
6. Fit gaiter sealing band.
7. Fit gaiter.
8. Fit gaiter sealing ring.
9. Align gaiter to slider and having ensured slider is correctly located, use track rod securing bolts to hold gaiter in position without tightening bolts so to activate Loctite.
10. Ensure gaiter is not twisted, and fit gaiter securing clips.
11. Fit fluid pipe support bracket and secure with bolt.
12. Ensure pipe unions and rack ports are clean.
13. Fit both ram feed pipes and tighten small diameter pipe union nuts to 18 Nm. and large diameter pipe union nuts to 24 Nm.
14. Fit clips to pipes.
15. Remove track rod securing bolts used to align gaiter, fit spacers, track rods and support plate to PAS rack.
16. Hold track rods parallel with PAS rack and tighten NEW Torx bolts to 100 Nm.
17. Fit PAS rack. See this section.

BELT - DRIVE - PAS PUMP - ’K’ SERIES

Service repair no - 57.20.02

Remove

1. Turn steering to full RH lock.

2. Remove 3 bolts securing RH splash shield.
3. Remove RH splash shield.

4. Fit a 13mm spanner to hexagon on belt tensioner and rotate clockwise to release tension on drive belt.
5. Hold tensioner in this position using a suitable pin not exceeding 3mm diameter.

NOTE: Fit pin through centre of hexagon into tensioner backplate.

6. Remove and discard drive belt.