Manual steering rack – 1.6

4. Feed rack in from driver's side over exhaust and gear change rod far enough for track rod to clear crossmember. Feed rack back towards driver's side and align and locate to crossmember.
5. Fit bolts to driver's side.
6. Fit mounting rubber, passenger's side and position bracket.
7. Fit and tighten steering rack bolts to 42 Nm.
8. Tighten steering rack bolts on drivers side to 42 Nm.
9. Centralise rack and remove plugs from pipes.
10. Align gear linkage bracket to cross member and fit and tighten bolts to 25 Nm.
11. Lever down power unit and remove block.

12. Connect lower gearchange rod ball joint using tool 18G 1594; ensure dust cover is correctly positioned.
13. Raise exhaust and connect centre mountings.
14. Fit new manifold flange gasket and connect front pipe to manifold, fit nuts and tighten to 50 Nm.
15. Position engine steady bracket to transmission, fit and tighten steady bracket bolts to 100 Nm.
16. Position engine steady bracket, Fit and tighten steady bracket bolts to 63 Nm.
17. Connect engine steady rod to gearbox bracket.
18. Fit and tighten bolt, steady rod to bracket to 85 Nm.
19. Tighten bolt, steady rod to bracket, gearbox end to 45 Nm.
20. Connect track rod ends to steering arms, fit and tighten nuts to 44 Nm and fit new split pins.
21. Align steering to straight ahead position and connect column universal joint to pinion, fit and tighten bolts to 22 Nm.
22. Position universal joint cover and fit cover retaining clips and studs.
23. Position footwell carpet.
24. Fit road wheel and tighten nuts to 100 Nm.
25. Remove stand(s) and lower vehicle.
26. Check and adjust front wheel alignment, see Adjustments.

MANUAL STEERING RACK – 1.6

Service Repair No. 57.10.01

Remove

1. Raise front of vehicle.

WARNING: Support on safety stands.

2. Remove road wheel(s).

3. Remove 2 clips securing column universal joint cover.
4. Pull back driver's footwell carpet.
5. Remove studs securing column universal joint cover to floor and remove cover.

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