vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

ABOUT US
Power Steering Control Module Calibration > < Power Steering Pump Pulley Replacement

Astra J

Steering Gear Replacement (Electronic Power Steering)

Special Tools

•  CH-904   Base Frame
•  CH-49289   Centering Frame
•  EN-45059   Angle Meter

For equivalent regional tools, refer to Special Tools .

Removal Procedure

1. Disconnect the battery. Refer to Battery Negative Cable Disconnection and Connection .

           2595021



Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components:
    •  The steering column
    •  The intermediate shaft(s)
    •  The steering gear
After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil.

2. Remove the lower steering intermediate shaft bolt (1).
3. Detach the steering intermediate shaft from the steering gear.
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
5. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation .
6. Remove the front compartment insulator, if equipped Front Compartment Insulator Replacement .
7. Remove the engine shield, if equipped. Refer to Engine Shield Replacement .
8. Remove the exhaust front pipe. Refer to Exhaust Front Pipe Replacement .
9. Loosen the steering linkage outer tie rod from the steering knuckle. Refer to Steering Linkage Outer Tie Rod Replacement .

           2190441



10. Remove and DISCARD the lower stabilizer link shaft nut (2) on both sides.
11. Remove stabilizer shaft link (1) from stabilizer shaft.
12. Remove stabilizer link shaft (1) from stabilizer.

           2190435



13. Remove 4 fasteners (1) of engine side cover on both sides.

           2190436



14. Remove 4 fasteners (1) of front engine compartment cover.

           2028084



15. Remove the front (1) and the rear (2) transmission mount bracket bolts.

           2371688




Note:  The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.
16. Assemble the CH-49289   centering frame (1) according to the details provided in the SPX installation manual.
17. Support the CH-904   base frame on a jack.
18. Support the CH-49289   centring frame on the CH-904   base frame .

           2028250




Note:  Positioning pins (2, 3) of CH-49289   adapter MUST stick into holes of suspension frame.

Note:  The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.
19. Install the CH-49289   centring frame according to the details provided in the SPX installation manual.
20. Check if wheel alignment is required.
  Move out positioning pins (1) and try to insert into underbody holes. If guide pins can NOT be inserted, the Wheel Alignment Measurement is required after installation of the suspension frame.

           2190434



21. Remove 2 rear suspension frame bolts (2).
  Remove rear frame reinforcements (1).

           2190437



22. Lower the front suspension frame assembly. Lower the suspension frame max. 55 mm (2.165 in) . Bent the engine side cover aside.

           2192066




Note:  Connector latches are difficult to access
23. Disconnect electrical connector (3).
  23.1 Release the lock (2) by moving in direction of arrow, use suitable screwdriver.
  23.2 Push down the latch (1) and pull off the electrical connector, use suitable screwdriver.

           2192082



24. Disconnect electrical connector (2).
  24.1 Gently lift latch (3), using angled screwdriver.
  24.2 Pull off electrical connector (2).
25. Disconnect electrical connector (1).
  25.1 Gently lift latch (4), using angled screwdriver.
  25.2 Pull off electrical connector (1).

           2190443



26. Carefully disconnect 2 wiring harness plugs (3) from the steering gear with a suitable tool.
27. Remove 2 wiring harness bracket bolts (4).
28. Remove bracket (2) from vehicle.
29. Remove wiring harness retainer (1) from steering gear.

           2190438



30. Remove and DISCARD the 2 right stabilizer shaft (1) insulator clamp bolts (2).
  Suspend stabilizer shaft (1) to body.

           2190439



31. Remove and DISCARD the 2 steering gear bolts (4) and nuts (1, 3) from front suspension frame.
32. Carefully remove steering gear (2) through right wheel house.
33. Replace assembly parts if necessary:
  •  Replace outer tie rod. Refer to Steering Linkage Outer Tie Rod Replacement .
  •  Replace inner tie rod. Refer to Steering Linkage Inner Tie Rod Replacement .
  •  Replace steering gear boot. Refer to Steering Gear Boot Replacement .

Installation Procedure


           2190439



Caution: Ensure that the steering column dash seal is installed properly onto steering gear rack pinion housing. The sealing lip MUST rest on lower steering column cover surface evenly. To ease installation of the seal, apply liquid soap to the sealing lip. After installation, verify that the seal lip does not protrude into the vehicle's interior. Improper installation could result in poor sealing performance and water intrusion into the vehicle.


Note:  Check correct wiring routing in order to assure correct installation.
1. Carefully insert steering gear (2) through right wheel house and position steering gear into installation position.
Warning:  Refer to Torque-to-Yield Fastener Warning .

Caution: Refer to Fastener Caution .
2. Tighten the NEW steering gear bolts (4) and nuts (1, 3) a first pass to 110 N·m (81 lb ft) .
3. Tighten the NEW steering gear bolts (4) and nuts (1, 3) a final pass to an additional 150 - 165 degrees , using the EN-45059   meter .

           2190443



4. Install and tighten 2 wiring harness bracket bolts (4) to 9 N·m (80 lb in) .
5. Tighten wiring harness retainer (1) to steering gear.

           2192082




Note:  Connector latches are difficult to access
6. Connect electrical connector (1) until you hear it clicks.
7. Connect electrical connector (2) until you hear it clicks.

           2192066




Note:  Connector latches are difficult to access
8. Connect electrical connector (3) until you hear it clicks.
9. Push back lock (2) in opposite direction of arrow until you hear it clicks.

           2190438



10. Position stabilizer shaft (1) and bracket onto suspension frame.
11. Install and tighten the NEW right stabilizer shaft insulator clamp bolts (2) a first pass to 22 N·m (16 lb ft) .
12. Tighten the NEW stabiliser shaft insulator clamp bolts (2) a final pass to an additional 30 degrees , using the EN-45059   meter .

           2190437



13. Raise the frame (1) carefully, using CH 49289   centering frame (2).

           2028250




Note:  Positioning pins (1) of CH-49289   centring frame MUST be extended in order to guide into underbody holes.
14. Check for proper position of the suspension frame by inserting the positioning pins (1) into the underbody holes.

           2190434



15. Install the frame reinforcements (1).
16. Install the frame rear bolts (2) and tighten to 160 N·m (118 lb ft) .

           2371688




Note:  The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.
17. Lower the CH-49289   centring frame (1) with the CH-904   base frame and a jack.
18. Remove the CH-49289   centring frame from the CH-904   base frame .
19. Disassemble the CH-49289   centering frame (1) according to the details provided in the SPX installation manual.

           2028084



20. Install the front transmission mount bolt (1) and tighten to 58 N·m (43 lb ft) .
21. Install the rear transmission mount bracket bolt (2) and tighten to 100 N·m (74 lb ft) .

           2190435



22. Install and tighten 4 fasteners (1) of engine side cover on both sides.

           2190436



23. Install and tighten 4 fasteners (1) of front engine compartment cover.
24. Install the front compartment insulator, if equipped Front Compartment Insulator Replacement .
25. Install the engine shield, if equipped. Refer to Engine Shield Replacement .
26. Install the exhaust front pipe. Refer to Exhaust Front Pipe Replacement .
27. Tighten the steering linkage outer tie rod to the steering knuckle. Refer to Steering Linkage Outer Tie Rod Replacement .

           2190441



28. Install and tighten the NEW lower stabilizer link shaft nut (2) on both sides to 65 N·m (48 lb ft) .
29. Lower the vehicle.

           2027661



30. Install the lower intermediate steering shaft bolt and tighten to 34 N·m (26 lb ft) .
31. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation .
32. Connect the battery. Refer to Battery Negative Cable Disconnection and Connection .
33. Check and adjust wheel alignment. Refer to Wheel Alignment Measurement .
34. Center the steering angle sensor and learn the softend stops. Refer to Power Steering Control Module Calibration .
35. Program the power steering control module. Refer to Power Steering Control Module Programming and Setup .
36. Program Volatile Memory. Refer to Volatile Memory Programming .

Power Steering Control Module Calibration > < Power Steering Pump Pulley Replacement