Removal and installation of the hydraulically strengthened steering mechanism

Warning! Some of the car models discussed in this manual are equipped with an additional security system (SRS). Before doing any work near the airbag unit, steering column or instrument panel, turn off the SRS to avoid injury if it is accidentally deployed (see chapter Onboard electrical equipment). SRS circuit wiring is easily identified by the yellow color of the insulation.

Note. Before removing the steering mechanism, the steered wheels of the car should be brought to a straight position, then the steering column should be locked by removing the key from the ignition switch.

Diamante Models

Front wheel steering

Removing

1. Disconnect the negative cable from the battery.

Attention! If the stereo system installed in the car is equipped with a security code, before disconnecting the battery, make sure that you have the correct combination to activate the audio system!

2. Drain the power steering fluid.

3. Disconnect a reception pipe of system of release of the fulfilled gases.

4. On all-wheel drive (AWD) models, remove the transfer case assembly.

5. Turn out a coupling bolt of fastening of the bottom hinge of a shaft of a column to an input shaft of rack and pinion.

6. Remove cotter pins, give castellated nuts and release tie rod ends from steering knuckles.

7. Remove the left and right frame beams.

8. Remove the mounting collars of the stabilizer bar.

9. On models with rear wheel steering (4WS) disconnect the hydraulic lines going to the rear pump assembly.

10. Turn out bolts of fastening of assembly collars and remove assembly of the steering mechanism. Remove the assembly from under the vehicle through the right wheel arch.

Installation

1. Get the steering mechanism assembly to its regular place, screw in the fixing bolts and tighten them with the required force (70 Nm), - check the correct installation of the rubber bushings of the mounting clamps relative to the support beam. Screw in the coupling bolt of the shaft connection.

2. Connect the pressure and return lines to the steering box and, if equipped, to the rear steering pump.

3. Install the frame beams and tighten the bolts of their fastening with the required force (60÷70 Nm).

4. Connect the tie rod ends to the steering knuckles.

5. On AWD models, install the transfer case assembly.

6. Establish a reception pipe of system of release of the fulfilled gases.

7. Add the required amount of hydraulic fluid to the steering reservoir and bleed the steering system.

8. Check the angles of the front wheels, if necessary, make the appropriate adjustments.

Rear wheel steering

Removing

1. Disconnect the negative cable from the battery.

Attention! If the stereo system installed in the car is equipped with a security code, before disconnecting the battery, make sure that you have the correct combination to activate the audio system!

2. Jack up the car and put it on stands.

3. Drain the power steering hydraulic fluid.

4. Remove the main muffler assembly (see chapter Power and exhaust systems).

5. Turn out bolts of the bottom support of shock-absorbers.

6. Support the rear differential with a trolley jack. Remove the two small beam support brackets.


7. Give big self-locking nuts of fastening of a beam from differential.

8. Turn out bolts of collars of fastening of oil lines.

9. Remove the pressure line pipes.

10. While holding the tie rod ends from turning, loosen their fixing nuts. Remove the ends from the tie rods.

11. Turn out fixing bolts and remove assembly of the back steering mechanism.

Installation

1. Attach the steering gear assembly to the frame beam. In order to determine the neutral position of the piston rod of the hydraulic cylinder, move it to the full length of its stroke.

2. Fit the tie rod ends into the trailing arm seats and screw on the mounting nuts. If necessary, adjust the length of the rods (the difference in the lengths of the opposite rods should not exceed 1 mm), then tighten the nuts to the required torque (58 Nm).

3. Replacing the O-rings, restore the original hydraulic line connections. Track the reliability of fastening of the lines in all provided intermediate clamps.

4. Install the large self-locking nuts on the differential side of the frame beam. Tighten the nuts to the required torque (110÷130 Nm).

5. Remove the differential support jack.

6. Install two small brackets.

7. Establish bolts of the bottom support of shock-absorbers.

8. Install the main muffler.

9. Fill the hydraulic path reservoir with the required amount of fluid and bleed the system.

10. Check wheel alignment. Make appropriate adjustments if necessary.

Galant Models

Models for 1993 issue.

Removing

1. Disconnect the negative cable from the battery.

Attention! If the stereo system installed in the car is equipped with a security code, before disconnecting the battery, make sure that you have the correct combination to activate the audio system!

2. Disconnect a reception pipe of system of release of the fulfilled gases.

3. Drain the power steering fluid.

4. Turn out a coupling bolt of fastening of the lower hinge of a shaft of a column to an input shaft of rack and pinion.

5. If equipped, remove the transfer case.

6. Remove cotter pins, give castellated nuts and release tie rod ends from steering knuckles.

7. Find triangular brackets (knitsy) near the mounting clamps of the anti-roll bar to the frame beam. Remove both knits and mounting clamps.

8. Support the center beam.

9. Give a through bolt from a round jet emphasis of a suspension bracket of the power unit.

10. Turn out back bolts of the central beam.

11. On front-wheel drive (FWD) models, disconnect the exhaust pipe from the exhaust system.

12. Disconnect the pressure line and return hose from the crankcase of the steering mechanism - in order to minimize leaks and to prevent dirt from entering the hydraulic path, immediately plug the open ends of the lines and connecting fittings.

13. Slightly lower the center beam.

14. Turn out bolts of fastening of mounting collars and remove assembly of the steering mechanism. Remove the assembly from under the car through the arch of the left wheel, after moving it to the right and tilting it to remove it from the beam.

Installation

1. Establish assembly of the steering mechanism on the regular place. Screw in the mounting bolts and tighten them with the required force (60÷80 Nm). When installing the rubber pads of the supports, make sure that their protrusions are aligned with the identification markings on the beam.

2. Connect the hydraulic lines to the steering box.

3. Reinstall the removed sections of the exhaust system.

4. Support the central beam with a jack, screw in the fixing bolts and tighten them with the required force (100 Nm).

5. Install the reaction stop bolt, screw a new nut onto it and tighten it to the required torque (65 Nm).

6. Establish elements of fastening of the stabilizer of cross-section stability.

7. Connect the steering rods and tighten the fixing nuts of their tips with the required force (34 Nm).

8. Install the transfer case, if equipped, - check the fluid level in its crankcase.

9. Fill the steering pump reservoir with the required amount of hydraulic fluid of the required grade (see chapter Settings and ongoing maintenance).

10. Bleed the path of the power steering system.

11. Check the angles of the front wheels, if necessary, make the appropriate adjustments.

Models since 1994 issue.

Removing

1. Steering gear installation details on Galant models are shown in the illustration.

2. Disconnect the negative cable from the battery.

Attention! If the stereo system installed in the car is equipped with a security code, before disconnecting the battery, make sure that you have the correct combination to activate the audio system!

3. Jack up the car and put it on stands.

4. Remove the front wheels.

5. Turn out a coupling bolt of fastening of the lower hinge of a steering column to an input shaft of rack and pinion.

6. Remove the anti-roll bar.

7. Remove the cotter pins, loosen the nuts and, using a special puller type MB991113, release the tie rod ends from the steering knuckle assemblies.

8. On models with electronic control, the operation of the hydraulic power steering system (EPS) Disconnect the wiring harness from the solenoid connector.

9. Remove the two triangular brackets located near the central beam.

10. Support the center beam with a jack. Remove the through bolt from the front reaction stop, then remove the beam mounting bolts.

11. Remove the central beam.

12. Support the power unit with a trolley jack and remove the rear torque strut through bolt.

13. Disconnect the pressure line and the return hose of the power steering hydraulic path from the rack and pinion housing, - plug the open ends of the lines and fittings immediately.

14. Turn out fixing bolts and take assembly of the steering mechanism through an arch of the left wheel.

Installation

1. Place the steering gear assembly in place and connect the steering column shaft to the rack and pinion input shaft.

2. Screw in the mounting bolts and tighten them to the required torque (69 Nm).

3. Screw in the tie bolt and tighten it to the required torque (18 Nm).

4. Connect the hydraulic lines to the steering box. Tighten the pressure line connector to 43 Nm. Track reliability of fixing on the union by a collar of a returnable hose.

5. Screw in and tighten as required (43 Nm) through bolt of the rear jet stop.

6. Jack up the center beam. Screw in the central fixing bolts. Tighten the front bolts with a force of 78÷88 Nm, rear - 69÷78 Nm.

7. Screw in the through bolt of the front reaction stop and tighten it to the required torque (43 Nm).

8. Install two triangular brackets and tighten the bolts of their fastening with the required force (69÷78 Nm).

9. Install the anti-roll bar.

10. Connect the steering rods to the steering knuckles, - tighten the nuts of the ball pins of the tips with the required force (27 Nm).

11. On models equipped with the EPS system, restore the connection of the corresponding electrical wiring.

12. Replace the wheels and lower the vehicle to the ground. Connect the negative wire to the battery.

13. Top up the steering pump reservoir with the required amount of hydraulic fluid of the required grade (see chapter Settings and ongoing maintenance) and bleed the hydraulic system.

14. Check up corners of installation of forward wheels, in case of need make corresponding correction.

Mirage Models

Models for 1992 issue.

Removing

1. Disconnect the negative cable from the battery.

Attention! If the stereo system installed in the car is equipped with a security code, before disconnecting the battery, make sure that you have the correct combination to activate the audio system!

2. Jack up the car and put it on stands.

3. Remove the front wheels.

4. Turn out a coupling bolt of fastening of the lower hinge of a steering column to an input shaft of rack and pinion.

5. Remove cotter pins, loosen nuts and release tie rod ends from steering knuckle assemblies.

6. Remove the anti-roll bar.

7. Disconnect the pressure line and the return hose of the power steering hydraulic path from the rack and pinion housing, - plug the open ends of the lines and fittings immediately.

8. Turn out fixing bolts and take assembly of the steering mechanism through an arch of the left wheel.

Installation

1. Place the steering gear assembly in place and connect the steering column shaft to the rack and pinion input shaft. Track reliability of a tightening of fixture.

2. Connect the hydraulic lines to the steering box.

3. Reinstall the anti-roll bar and rear transmission support bracket.

4. Connect steering drafts to rotary fists.

5. Replace the wheels and lower the vehicle to the ground. Connect the negative wire to the battery.

6. Top up the steering pump reservoir with the required amount of hydraulic fluid of the required grade (see chapter Settings and ongoing maintenance) and bleed the hydraulic system.

7. Check the angles of the front wheels, if necessary, make the appropriate adjustments.

Models since 1993 issue.

Removing

1. Steering gear installation details on Mirage models are shown in the illustration.

2. Drain the working fluid from the tract of the power steering system.

3. Disconnect the negative cable from the battery.

Attention! If the stereo system installed in the car is equipped with a security code, before disconnecting the battery, make sure that you have the correct combination to activate the audio system!

4. Jack up the car and put it on stands.

5. Remove the front wheels.

6. Disconnect electroconducting from the oxygen gauge and remove a reception pipe of system of release of the fulfilled gases.

7. Support the engine.

8. Turn out bolts of both jet stops.

9. Give fixing bolts and remove a central beam.

10. Mark the position of the input shaft of the rack and pinion relative to the lower hinge of the steering column. Turn out a coupling bolt and disconnect the hinge.

11. Remove cotter pins, release nuts and release tie rod ends from steering knuckle assemblies.

12. Disconnect the pressure line and the return hose of the power steering hydraulic path from the rack and pinion housing, - plug the open ends of the lines and fittings immediately.

13. Turn out fixing bolts and take assembly of the steering mechanism through an arch of the right wheel.

Installation

1. Place the steering mechanism assembly in its regular place and connect the steering column shaft to the input shaft of the rack and pinion - make sure that the landing marks applied during the dismantling process are aligned correctly.

2. Screw in the mounting bolts and tighten them to the required torque (70 Nm).

3. Screw in the tie bolt and tighten it to the required torque (18 Nm).

4. Connect the hydraulic lines to the steering gear housing - do not forget to replace the sealing rings.

5. Install the center beam.

6. Establish a reception pipe of system of release of the fulfilled gases.

7. Connect the electrical wiring to the oxygen sensor.

8. Connect the steering rods to the steering knuckles, - tighten the nuts of the ball pins of the tips with the required force (25 Nm).

9. Replace the wheels and lower the vehicle to the ground. Connect the negative wire to the battery.

10. Top up the steering pump reservoir with the required amount of hydraulic fluid of the required grade (see chapter Settings and ongoing maintenance) and bleed the hydraulic system.

11. Check the angles of the front wheels, if necessary, make the appropriate adjustments.