Steering Gear, Overhaul (Manual/EPS)
 Remove, Disconnect Remove steering gear - see operation "Manual Steering Gear, Remove and Install", "Steering Gear, Remove and Install (Vehicles with EPS, without Air Conditioning)", "Steering Gear, Remove and Install (Vehicles with EPS and Air Conditioning)".
 Disassemble Remove both left and right rubber bearing rings and bulkhead weatherstrip from steering casing. Unbolt left and right tie rod end from tie rods. Note adjustment dimensions. Loosen lock nut. Remove retaining bands for left and right bellows and remove both bellows (see illus. I). Unbolt tie rod with axial joint from steering rack. Steering gear must lie open on workbench and must not be clamped in vice. Counterhold steering rack with open-ended wrench (see illus. II). If necessary, replace plastic ring for tie rod stop. Release sheet metal hex nut for adjustment bolt with KM-285 (1) (see illus. III). | 
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Disassemble Unbolt adjustment screw (1) and remove thrust spring from adjustment screw aperture. Remove circlip (2) in front of ball bearing using Pliers KM-J-4245. Remove pinion and steering rack from steering casing. Pinion may only be replaced in assembly with ball bearing. Lever guide segment out of adjustment aperture. The guide segment is seated under suction in casing aperture, due to O-ring (see illus. II). Replace O-ring.
 Important! Further disassembly of steering casing is not anticipated.
 Clean Clean all parts. | 
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 Inspect Check all parts for wear and damage and replace if necessary. If steering rack bearing bushing is damaged, always replace steering casing assembly.
 Assemble Lubricate pinion and steering rack with steering grease. In addition, fill the interior of steering housing between the pinion and steering rack bushing evenly with steering grease (see illus. I, arrow). Guide steering rack and pinion (see illus. II, arrow) into steering housing. Dimension 1 - 25 mm/1 in. must protrude equally on both sides of casing. Secure ball bearing pinion in steering casing with new circlip. Outside slanted side of circlip points away from ball bearing circlip must sit correctly in groove. | 
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Assemble Bolt both tie rods with axial joint to steering rack - 70 Nm / 52 lbf. ft. Use commercially available open-ended wrench (crow foot) - wrench size 32. Counterhold steering rack with open-ended wrench.
Important! Steering gear must lie open on workbench and must not be clamped in vice.
Assemble Insert guide segment and thrust spring in adjustment screw opening and screw adjustment screw up to noticeable resistance in steering casing. Recommended torque - 11 Nm / 8 lbf. ft. Steering gear in straight ahead position.
 Adjust Tighten adjustment bolt to 11 Nm / 8 lbf. ft. Then turn back adjustment bolt min. 50 ° (I) - max. 70 ° (II) and check to determine whether the steering rack can move freely over the entire range of the pinion mesh. Tighten lock nut with KM-285 (1) - tightening torque 75 Nm / 55 lbf. ft. Counterhold adjustment bolt.
 Install, Connect Slide bellows on tie rods and steering gear and secure with retaining bands. Screw tie rod ends on tie rods. (Note specified adjustment value). Tighten tie rod end lock nuts on tie rods - tightening torque 50 Nm / 37 lbf. ft. | 
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Install, Connect Install steering gear - see operation "Manual Steering Gear, Remove and Install", "Steering Gear, Remove and Install (Vehicles with EPS, without Air Conditioning)", "Steering Gear, Remove and Install (Vehicles with EPS and Air Conditioning)".
Inspect Check toe-in - see operation "Chassis Alignment" in group "E". Subsequent to adjustment operations, check that steering resets automatically after negotiating curves during test drive. In addition, the following conditions must obtain after operations on the steering:
1 The clamp bolt for steering pinion must lie horizontally in top position.
2 The steering wheel must be centred on the steering shaft. (Steering wheel spokes slanting downwards from the centre).
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Re 1: |
If the clamp bolt is slanted - e.g. pinion is displaced one cog on the rack (installation mistake) - steering pinion position must be corrected immediately. |
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Re 2: |
If the steering wheel deviates from the centre position by more than ± 5 ° (steering pinion clamp bolt must be located on top and horizontal), position steering wheel in centre position - see operation "Steering Wheel in Centre Position, Position (Vehicles without Airbag)" or "Steering Wheel in Centre Position, Position (Vehicles with Airbag)". |
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