Vauxhall Workshop Service and Repair Manuals

Replace steering gear (ZF)

Note:   Only front axle body is released. The guide joints remain attached to the steering knuckle.

  Remove

2.   Remove intermediate shaft from steering gear. •   Remove clamp bolt (1) of intermediate shaft. Note:   Bolt is accessible from the passenger compartment. •   Detach intermediate shaft from steering wheel. 3.   Remove rubber sleeve from steering gear (2).

5.   Release 2x tie rod ends (6) from steering knuckle (5) •   Attach CH-47658 (1) – Place CH-47658 (1) in position with a suitable sleeve (4) Note:   To centre CH-47658 , CH-47658 must be inserted with a suitable socket (3). – Fasten CH-47658 (1) to hex (2) •   Unscrew tie rod end nut •   Detach CH-47658 (1) – Release at hex (2)

6.   Detach 2x tie rod ends from steering knuckle •   Press tie rod end out of steering knuckle using KM-161-B (1) combined with KM-161-2

7.   Detach lower engine compartment cover •   Release 8 bolts (1)

8.   Remove front exhaust pipe. •   Remove 3 nuts for connecting the front pipe to the particle filter / rear catalytic converter (1). •   Remove 3 nuts for connecting the pipe to the front catalytic converter (2). •   Remove the bracket from the oil pan (3). •   Remove the exhaust pipe. Note:   The flexible part of the pipe must not be bent by more than 5°.

9.   Remove rear engine damping block from transmission. •   Unscrew 3 bolts (1)

11.   Remove triangular plate. •   Unscrew 6 bolts (1) (2).

12.   Remove centre bolts from axle housing (1) 2x.

13.   On LHD vehicles: Remove engine damping block bracket (1) at the rear of engine damping block. 14.   Detach rear engine damping block (2) Note:   Illustration shows front axle body removed. •   Unscrew bolt connection 15.   Remove supply line (3) and return line (4) from steering gear Note:   Oil runs out - use catchment tray

16.   Remove electro-hydraulic supply unit from front axle body •   Release 2x wiring harness plug (1) and (2) and remove from electro-hydraulic supply unit •   Remove 3x nuts (3) and (4) from steering gear and front axle body •   Remove electro-hydraulic supply unit with supply and return line from steering gear and front axle body

17.   Remove tie rods on both sides of steering gear •   Detach 2x retaining strap (1) and (2) •   Remove 2x boot from steering gear •   Detach 2x tie rod (4) from steering gear with KM-6004-2 – counterhold with an open-ended wrench on the toothed rack flat on the steering shaft side Note:   Counterholding is no longer necessary in vehicles as of model year 2006. 18.   Remove steering gear from front axle body •   Remove 2x nut (2) from front axle body •   Remove 2x bolt •   Remove steering gear

  Install

27.   Fit bolts for front axle housing. •   Fit triangular plates, insert the following new bolts and leave slack. – Tighten 2x bolts (2) for front axle housing to 90 Nm +45° +15° . – Tighten 4x bolts (1) for triangular plates to vehicle underbody 65 Nm

28.   Insert centre bolts for front axle body and leave slack •   Tighten 2x bolts for front axle housing (1) to 90 Nm +45° +15° .

33.	Charge and bleed hydraulic system

34.	Check straight-ahead position, adjust if necessary

35.	Check toe-in, adjust if necessary