Power steering rack - ’k’ series

Refit

1. Ensure body aperture seal is seated correctly in rear beam.
2. Feed rack into passenger side first, then manoeuvre pinion end into position.

CAUTION: Ensure slot in aperture seal is located to tab on pinion housing.

3. Raise rack and locate pinion through body aperture.

CAUTION: Take care not to dislodge aperture seal.

4. Align rack and loosely fit flange bolts securing rack to rear beam. DO NOT tighten.
5. Fit steering rack clamp and rubber, fit bolts and tighten to 38 Nm.
6. Tighten flange bolts securing steering rack to rear beam to 58 Nm.
7. Position engine steady bar mounting bracket to rear beam and tighten bolts to 60 Nm.
8. Fit engine steady bar. See ENGINE - ’K8’, Repairs.
9. Clean gear selector linkage and gear selector linkage ball joints.
10. Using tool 18G 1594 connect gear selector linkage ball joint to gear selector lever.
11. Using tool 18G 1594 connect gear change linkage ball joint to gear change lever.
12. Position each locknut on track rods with same amount of thread exposed as noted during removal.
13. Centralise steering rack and screw both track rod ends up to locknuts, with ball pins facing upwards.
14. Connect track rod ends and tighten NEW nuts to 45 Nm.
15. Fit road wheel(s) and tighten nuts to correct torque. See INFORMATION, Torque wrench settings.
16. Remove stand(s) and lower vehicle.
17. Connect column universal joint ensuring bolts are located in grooves. Tighten bolts to 28 Nm.
18. Fit universal joint cover and secure with studs and clips.
19. Reposition drivers footwell carpet.
20. Check and adjust front wheel alignment. See Adjustments.

POWER STEERING RACK - ’K’ SERIES

Service repair no - 57.10.01

Remove

1. Remove 2 clips securing column universal joint cover.
2. Pull back drivers footwell carpet and remove 2 studs securing cover to floor.
3. Remove cover.
4. Align road wheels to straight ahead position and remove starter key from steering lock.

5. Remove 2 bolts securing column universal joint. Slide joint up column and disconnect from steering rack pinion shaft.
6. Raise front of vehicle.

WARNING: Support on safety stands.

7. Remove road wheel(s).