Power steering rack - ’d’ series

6. Align rack and fit bolts and plain washers to pinion flange, DO NOT tighten.
7. Fit clamp rubber and clamp, tighten bolts to 38 Nm. Tighten bolts securing pinion flange end to 58 Nm.
8. Align gear change linkage to rear beam, fit bolts and tighten to 24 Nm. Connect ball joints using tool 18G 1594 .
9. Fit new exhaust manifold flange gasket and connect front pipe to manifold. Fit nuts and tighten to 50 Nm.
10. Fit nuts securing front pipe to support bracket and tighten to 25 Nm.
11. Position each locknut on tie-rods with same amount of thread exposed, as noted during removal.
12. Centralise steering rack and screw both tie-rod ends on to tie-rods up to locknuts, with ball pins facing downwards.
13. Connect tie-rod ends, fit nuts and tighten to 39 Nm. Align nuts to next split pin hole and fit new split pins.
14. Fit road wheel(s) and tighten nuts to correct torque. See INFORMATION, Torque wrench settings.
15. Remove stand(s) and lower vehicle.
16. Clean feed and return pipes and unions. Connect pipes to steering rack and tighten feed pipe union to 37 Nm and return pipe union to 28 Nm.
17. Align pipe clip, fit bolt and tighten to 9 Nm.
18. Align engine steady rod to cylinder block, fit bolt and tighten to 45 Nm. Tighten engine rear steady rod through bolt to 80 Nm.
19. Connect column universal joint. Fit bolts, ensuring lower bolt is located in groove on pinion shaft, tighten bolts to 28 Nm.
20. Fit universal joint cover, fit clips and retaining studs.
21. Position footwell carpet.
22. Check and adjust front wheel alignment. See Adjustments.
23. Bleed power steering system. See Adjustments.

POWER STEERING RACK - ’D’ SERIES

Service repair no - 57.10.01

Remove

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

4. Remove 2 bolts securing column universal joint, slide joint up column and disconnect from steering rack pinion shaft.