Installing Power-Steering Gear

Information 

• Make sure that the pre-fitted intermediate wire harness and the torque sensor connector are not damaged during installation. If one of these components is damaged, the complete steering gear must be replaced. 
• Always check the bellows and clamps for damage and make sure they are seated securely. Replace them if necessary to prevent water from leaking in. 
• When fitting the front-axle cross member, always fit the screws straight because if they are fitted crooked, the aluminium thread of the body can become damaged when tightening the screws. 

Information 

Following installation, seal the threaded joint securing tie rod to wheel bearing housing with wax as shown in -Illustration-  . Use Pfinder AP14/4 for this (see PIWIS Parts Information - PET).

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Applying wax on marked area (shown on threaded joint securing lower trailing arm)

1. Place power-steering gear in installation position.
2. Plug in battery connector -2-  and vehicle signal connector -3-  on the steering gear motor until they engage securely.

   The torque sensor connector -1-  (connector at the very top) was not disconnected when the front-axle cross member was removed.

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   Connectors on steering gear control unit

3. Fit front-axle cross member.

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   Front-axle carrier

   1. 3.1  Screw in fastening screws -5-  on the power-steering gear, but do not tighten to the specified torque.
   2. 3.2  Carefully move the front-axle cross member into installation position using the hydraulic lift.

      Make sure not to trap any lines and plug connections.

      Check that the lines are routed correctly.

   3. 3.3  Tighten fastening screws -1-  > Initial tightening 90 Nm (67 ftlb.)  > Final tightening + 90 > 
   4. 3.4  Tighten fastening screws -3-  > Initial tightening 90 Nm (67 ftlb.)  > Final tightening + 180 > 
   5. 3.5  Tighten fastening nuts -2-  and counter at the bolt using a Torx wrench. > Initial tightening 90 Nm (67 ftlb.)  > Final tightening + 90 > 
   6. 3.6  Clip in clips for coolant pipes and tighten fastening screws -4-  > Tightening torque 10 Nm (7.5 ftlb.) 
   7. 3.7  Tighten fastening screws -7-  > Initial tightening 90 Nm (67 ftlb.)  > Final tightening + 90 > 
   8. 3.8  Tighten fastening screws -5-  on the power-steering gear. > Initial tightening 30 Nm (22 ftlb.)  > Final tightening + 90> 
4. Fit universal joint on the steering gear.

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   Universal joint for steering column

   1. 4.1  Align pins for steering column in accordance with markings -1-  .

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      Steering in center position

   2. 4.2  Connect universal joint to the steering gear.
   3. 4.3  Insert fastening screw -1-  into universal joint and tighten it. > Initial tightening 20 Nm (15 ftlb.)  > Final tightening + 90> 
5. Fit tie rod on wheel bearing housing.

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   Fitting tie rod on wheel bearing housing

   1. 5.1  Guide in control arm spoiler (air guide for brake cooling) and clip it in at the back of the longitudinal arm.
   2. 5.2  Tighten fastening nut -1-  Counter with a > 9546 - screwdriver  at the ball-joint pin while doing this. > Tightening torque 85 Nm (63 ftlb.) 
6. Clip in ball joint on the level sensor linkage -1-  on the lower trailing arm.

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   Ball joint on level sensor