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Home >> Chevrolet >> 2004 >> Optra Base, Automatic >> Repair and Diagnosis >> Steering >> Power Steering System >> Repair Instructions >> Steering Gear Replacement >> Installation Procedure
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Installation Procedure

    Fig 1: Identifying Alignment Mark Location
    GM1290982Courtesy of GENERAL MOTORS CORP.
  1. Install the rack and pinion assembly on the crossmember. The steering gear must be in a straight-ahead position and the steering wheel spokes must be vertical and pointing to the left. Align the marks on the shafts to ensure proper positioning. Seat the stub shaft into the intermediate shaft.
    2. Fig 2: View Of Steering Gear Mounting Bracket And Bolts
    GM1290986Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the bolts and nuts on the steering gear mounting bracket.

    Tighten:  Tighten the steering gear mounting bracket bolts and nuts to 60 N.m (44 lb ft)  .

    3. Fig 3: View Of Return Pipe Clip And Bolt
    GM1290084Courtesy of GENERAL MOTORS CORP.
  3. Install the return line into the clip on the crossmember.

    Tighten:  Tighten the return line clip bolt to 8 N.m (71 lb in)  .

  4. Position the transaxle center bracket in place and install the bolts securing the bracket to the engine and the transaxle, if equipped with manual transaxle.

    Tighten:  Tighten the transaxle center bracket-to-transaxle bolts and the transaxle center bracket-to-engine bolt to 80 N.m (59 lb ft)  .

  5. Install the transaxle center bracket, if equipped with an automatic transaxle. Refer to Transmission Mount Bracket Replacement in Automatic Transmission - ZF 4HP 16.
  6. Install the crossmember. Refer to Front Suspension Crossmember Replacement in Front Suspension.
    7. Fig 4: View Of Outer Tie Rod And Steering Knuckle
    GM1290872Courtesy of GENERAL MOTORS CORP.
  7. Connect the tie rod ends to the strut assembly.
  8. Install the outer tie rod nuts.

    Tighten:  Tighten the outer tie rod nuts to 50 N.m (37 lb ft)  .

    9. Fig 5: View Of Intermediate Shaft Lower Pinch Bolt
    GM1290983Courtesy of GENERAL MOTORS CORP.
  9. Install the lower intermediate shaft pinch bolt.

    Tighten:  Tighten the lower intermediate shaft pinch bolt to 25 N.m (18 lb ft)  .

    10. Fig 6: View Of Power Steering Gear And Pipes
    GM1290083Courtesy of GENERAL MOTORS CORP.
  10. Connect the power steering gear fluid inlet and outlet pipe.

    Tighten:  Tighten the steering gear inlet and outlet pipe fitting to 28 N.m (21 lb ft)  .

  11. Perform a front toe adjustment. Refer to Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment in Wheel Alignment.
  12. Install the wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  13. Lower the vehicle.
  14. Do a straight-ahead check. Refer to Rack and Pinion Preload Bearing Adjustment .
    15. NOTE: When adding fluid or making a complete fluid change, always use a power steering fluid meeting GM Spec. No. 9985010 or equivalent. Fluid for cold climates is also available through GM Dealerships; refer to Specifications for further information. Failure to use the proper power steering fluid can cause power steering hose and seal damage, fluid leaks and pump failure.
  15. Refill the power steering system and check for leaks. If leaks are found, correct the cause of the leak and bleed the system. Refer to Checking and Adding Power Steering Fluid .
  16. Connect the negative battery cable.
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