Dismantling
1. Raise the front of the car.
WARNING: Do not work under a vehicle that is only supported by a jack. Always install safety props.
2. Remove the front wheels.
3. Remove and discard the tie rod end ball stud nuts to the swingarms.
4. Screw an M12 nut onto each ball stud flush with the threaded end of the stud.
5. Using tool LRT-57-043, separate the ball studs from the left and right swing arms. Remove the M12 nuts and remove the ball pins from the pivot arms.
6. Turn away a bolt of fastening of a steering shaft to a driving gear wheel of the steering mechanism.
7. Models with KV6 engine: Remove the 2 steering heat shield mounting nuts and remove the shield.
8. Models with KV6 engine: Remove the 2 bolts securing the cooling system oil manifold to the cylinder block.
9. Models with Td4 engine and manual transmission: Using tool LRT-37-050, disconnect the control rods from the shift actuator.
10. Models with Td4 engine and manual transmission: Remove the 2 bolts securing the gear shift actuator to the bulkhead of the engine compartment.
11. Models with Td4 engine and manual transmission: Remove the bolt securing the coolant hose P-clip to the intermediate reduction gear housing.
12. Models with Td4 engine and automatic transmission: Remove the bolt securing the P-clip of the cooling system hose to the intermediate reduction gear housing.
13. Remove the 2 bolts and washers securing the steering clamp to the bulkhead of the engine compartment and discard the bolts.
14. Remove a collar of the steering mechanism.
15. Remove the rubber cushion.
16. Remove and discard the 2 steering gear-to-engine bulkhead bolts.
17. Disconnect the steering gear from the steering shaft.
18. Install a container to collect the power steering fluid (PAS).
19. Turn away a bolt of fastening of an arm of the pipeline to a case of the steering mechanism.
20. Loosen the fittings and disconnect the pipelines from the steering gear.
CAUTION: Always plug fittings and openings to keep dirt out of the system.
21. Remove and discard the o-ring.
22. Turn away a bolt of fastening of the collar fixing pipelines of the hydraulic booster, and loosen a bolt of an inhaling of a collar.
23. Models with KV6 engine: To facilitate removal of the steering gear, remove the right engine mount and lower the engine.
KV6 ENGINE - MODIFICATION K, Left cylinder head camshafts, Right engine hydraulic mount.
24. With the help of a partner, remove the steering gear from the passenger side of the car.
25. Remove the boot from the drive gear housing.
Installation
1. Install the steering gear on the passenger side of the vehicle.
2. Install the boot on the drive gear housing.
3. Models with KV6 engine: Install the right engine mount.
KV6 ENGINE - MODIFICATION K, Left cylinder head camshafts, Right engine hydraulic mount.
4. Clean the pipe fittings.
5. Establish new sealing rings on pipelines of system of the hydraulic booster.
6. Connect pipelines to the steering mechanism, but yet do not tighten unions finally.
7. Establish on a case of the steering mechanism an arm of fastening of pipelines. Reinstall the bolt, but do not completely tighten it yet.
8. Using a partner, connect the drive gear to the steering shaft. Make sure the position of the coupler is aligned with the pointer on the pinion shank.
9. Install and tighten new steering gear to engine bulkhead bolts, but do not fully tighten yet. Make sure the large washer is on the small bolt.
10. Put on a steering gear case a rubber pillow and a collar.
11. Wrap bolts of fastening of a collar to a partition of a motor compartment, but yet do not tighten them completely.
12. Tighten the steering gear mounting bolts with a torque of 45 Nm.
13. Tighten bolts of fastening of a collar of the steering mechanism with the moment of 45 Nm.
14. Tighten the inlet pipe union with a torque of 18 Nm.
15. Tighten the return pipe union with a torque of 22 Nm.
16. Tighten the piping bracket bolt to 10 Nm.
17. Align position of a collar of the steering mechanism and tighten a bolt.
18. Align the position of the pipelines and tighten the clamp bolt with a torque of 10 Nm.
19. Wrap a bolt of fastening of a steering shaft to a driving gear wheel of the steering mechanism and tighten it with the moment of 32 Nanometers.
WARNING: While tightening the nuts and bolts, the weight of the vehicle must be supported by the suspension.
20. Clear spherical fingers of tips of steering draughts and their seats on rotary levers. Check that the protective covers are not damaged.
21. Insert ball studs into pivot arms. Fit new nuts and tighten them to 55 Nm.
22. Models with KV6 engine: Connect the oil manifold of the cooling system to the cylinder block, tighten the bolts and tighten them to a torque of 10 Nm.
23. Models with KV6 engine: Install the heat shield, screw on the nuts and tighten them to 25 Nm.
24. Models with Td4 engine and manual transmission: Align the position of the P-clamp that secures the coolant hose to the intermediate reduction housing, tighten the bolt and tighten it to 25 Nm.
25. Models with Td4 engine and manual transmission: Align the position of the gear shift actuator with the bulkhead of the engine compartment, tighten the bolts and tighten them to a torque of 25 Nm.
26. Models with Td4 engine and manual transmission: Connect the control rods to the shift actuator.
27. Models with Td4 engine and automatic transmission: Align the position of the P-shaped clamp that secures the cooling system hose to the intermediate reduction housing, tighten the bolt and tighten it to 25 Nm.
28. Replace the wheel (wheels) and tighten the nuts to a torque of 115 Nm.
29. Remove props and lower the car.
30. Bleed the power steering system.
STEERING, ADJUSTMENTS, Removal of air from the power steering system.
31. Check and, if necessary, adjust the toe-in of the front wheels.
STEERING, ADJUSTMENTS, Checking and adjusting the angles of the front wheels.
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