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Steering Gear, Remove and Install
Note: The front axle
body must be removed to remove the steering gear. Steering gear of
EHPS Gen. II must not be combined with an electro-hydraulic supply
unit of Gen. I. If in doubt, the electro-hydraulic supply unit must
also be replaced.
 Remove
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Remove front axle body – see operation "Front Axle Body,
Remove and Install" in group "E".
On LHD vehicles: Remove engine damping block bracket (1) at the
rear of engine damping block.
If fitted: Remove pressure- and return line bracket (2) from
steering gear.
Remove pressure line (3) and return line (4) from steering gear.
Fluid will escape – place collecting pan underneath.
Unclip steering wiring harness from front axle body – note
cable routing.
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Remove electro-hydraulic supply unit from front axle body:
On vehicles with round fluid reservoir (I): Remove fastening
nuts (1) and (2) from steering gear and front axle body. Remove
electro-hydraulic supply unit with pressure and return line from
steering gear and front axle body.
On vehicles with angular fluid reservoir (II): Remove fastening
nuts (3) and (4) from steering gear and front axle body. Remove
electro-hydraulic supply unit with pressure and return line from
steering gear and front axle body.
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Release bellows retaining straps (1) and (2) on left and right.
Pull off both bellows from steering gear and push up onto tie rod.
Detach tie rod (4) right and left from steering gear using
KM-6004-1 (SW 32) or KM-6004-2 (SW 34) -Using an open ended spanner
hold the steering rack against the flattening on the steering shaft
side.
Detach steering gear fastening nuts (2) from front axle body on
both sides. Remove steering gear from front axle body.
Install
Reattach steering gear to the front axle body using new
fastening bolts and new fastening nuts – tightening torque 45
Nm / 33 lbf. ft. + 45° + 15°.
Clean thread on rack and coat with locking compound. Attach tie
rods on right and left with KM-6004-1 (SW 32) or KM-6004-2 (SW 34)
to steering gear – tightening torque 90 Nm / 66 lbf. ft.
Counterhold with open-ended wrench at flattened area of rack on
steering shaft side. Slide both folding covers onto steering gear
– ensure that the folding cover is seated in the grooves
(arrows) of the steering gear and the tie rod.
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For vehicles with retaining clamps: Attach folding covers to
steering gear using new retaining clamps and KM-J-22610.
For vehicles with retaining straps: Attach folding covers to
steering gear using new retaining straps – forcefully pull
retaining strap closed and cut off excess.
Reattach bellows on the tie rod with new retaining bands left
and right- ensure that bellows sit in tie rod grooves.
Position electro-hydraulic supply unit with bracket on steering
gear and front axle body – note steering wiring harness.
Attach bracket for electro-hydraulic supply unit TO front axle
body – tightening torque 22 Nm / 16 lbf. ft. Attach bracket
for electro-hydraulic supply unit to steering gear –
tightening torque 22 Nm / 16 lbf. ft.
Clip steering wiring harness onto front axle body – ensure
correct cable routing.
Attach pressure and return line with new seal rings to steering
gear – tightening torque 30 Nm / 22 lbf. ft. (TRW), 27.5 Nm /
20.5 lbf. ft. (Delphi).
If fitted: Attach bracket for pressure and return line steering
gear – tightening torque 4 Nm / 3 lbf. ft.
On LHD vehicles: Attach engine damping block bracket to rear of
engine damping block – tightening torque 55 Nm / 40.5 lbf.
ft.
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Note: In vehicles up
to MY 03, attachment of the steering wiring harness no longer takes
place on the front frame after replacement of the electro-hydraulic
supply unit, but with a cable tie to the ABS bracket (see
magnifying glass in Figure I). Figure II shows attachment of the
steering wiring harness in vehicles from MY 03.
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Install front axle body – see operation "Front Axle Body,
Remove and Install" in group "E".
Inspect
Charge and bleed hydraulic system – see operation
"Hydraulic System, Charge and Bleed".
Check straight-ahead position, and adjust if necessary –
see operation "Straight-ahead Position, Check and Adjust".
Check toe-in, and adjust if necessary – see operation
"Chassis Alignment" and "Toe-in, Adjust" in group "E".
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