Steering - Removal, Replacement And Installation

• Control System (B4204T3 (Ca) (Us); 2001-2003)
  • Ball joint tie rod, protective bellow or tie rod, replacing
    • Notes
    • Removal
      • Removing wheels
      • Removing the ball joint for the tie rod
      • Removing the boot
      • Removing the tie rod
    • Installation
      • Installing the tie rod
      • Installing the boot
      • When replacing the right-hand tie rod
      • Installing the ball joint on the tie rod
      • Installing the front wheel (right-hand tie rod)
  • Checking power steering balance and pump pressure
    • Notes
    • Connect the test instrument
    • Checking the servo reservoir fluid level
    • Removing the steering wheel module
    • Checking the balance when turning the steering wheel
    • Interpreting the torque measurements
    • Checking the pump pressure
      • Pump pressure at the limit positions
      • Checking the pump capacity
      • Installing steering wheel module
      • Removing the test instrument
      • Filling and bleeding the servo system
  • Fault-tracing the power steering system
    • Notes
    • Connect the test instrument
    • Start the engine
    • Wait until the oil and power steering pump have reached operating temperature
    • Test
    • Checking the low pressure
    • Check the high-pressure hose
    • Checking the high pressure
    • Install the control valve
  • Oil delivery line power steering, replacing (LHD)
    • Notes
    • Removal
      • Notes
      • Preparations
      • Removing the delivery line from the power steering pump (does not apply to B4184SM/SJ)
      • Removing the delivery line from the power steering pump (B4184SM/SJ)
      • Removing the delivery line from the pipe clamps on the power steering side
    • Installation
      • Installing and aligning the delivery line on the steering gear side
      • Securing the delivery line on the steering gear side
      • Reinstalling components (Does not apply to B4184SM/SJ)
      • Installing the delivery line on the power steering pump (does not apply to B4184SM/SJ)
      • Installing the delivery line on the power steering pump (B4184SM/SJ)
      • Filling/bleeding the power steering system
  • Oil pressure line power steering, replacing (RHD)
    • Notes
    • Removal
      • Preparations
      • Removing the delivery line from the power steering pump (B4184SM/SJ)
      • Removing the support bracket from the cross member
      • Releasing the delivery line from the pipe clamps
    • Installation
      • Installing/aligning the delivery line on the steering gear side
      • Installing the support bracket on the cross member
      • Securing the delivery line on the steering gear side
      • Reinstalling components (does not apply to B4184SM/SJ)
      • Installing the delivery line on the power steering pump (B4184SM/SJ)
      • Installing the delivery line on the power steering pump (does not apply to B4184SM/SJ)
      • Filling/bleeding the power steering system
  • Oil return line power steering, replacing (LHD)
    • Notes
    • Removal
      • Preparations
      • Removing the pipe clamps on the return line
      • Complete removal of air intake hose and air cleaner (ACL) housing. Releasing the fusebox (turbocharged gasoline engines)
      • Draining oil from the power steering system
      • Removing the return line
    • Installation
      • General information
      • Aligning/securing return line
      • Securing the return line using pipe clamps
      • Connecting the return line to the fluid reservoir
      • Reinstalling the air intake hose, air cleaner (ACL) housing and fusebox (turbocharged gasoline engines)
      • Reinstalling components
      • Filling/bleeding the power steering system
  • Oil return line power steering, replacing (RHD)
    • Notes
    • Removal
      • Preparations
      • Removing the pipe clamps on the return line
      • Draining oil from the power steering system
      • Removing the return line
    • Installation
      • Notes
      • Aligning/securing return line
      • Connecting the return line to the fluid reservoir
      • Reinstalling components (does not apply to B4184SM/SJ)
      • Filling/bleeding the power steering system
  • Replacing the steering column
    • Removal
      • Preparations
      • Removing the steering column
      • Removing the intermediate plate
    • Installation
      • Installing the intermediate plate
      • Installing the steering column
      • Installing other components
  • Steering gear housing, replacing
    • Removing the steering gear housing from the steering column
    • Removing the ends of the ball joint
    • Removing the front exhaust pipe
    • Removing the steering gear housing
    • Checking the mounting for the steering gear housing
    • Installing the steering gear housing
    • Installing surrounding components
    • Installing the front exhaust pipe
    • Installing the steering gear housing on the steering column
    • Filling and bleeding the power steering system
    • Replacing the cross member
      • Preparations
      • Remove the lateral strut
      • Removing the central front-rear member
      • Removing the front exhaust pipe
      • Removing the steering gear housing from the cross member
      • Installing the cross member
      • Installing the gear selector lever in the transmission
      • Installing the central front-rear member
  • Steering gear, overall inspection
    • Notes
    • Checking steering gear for play
    • Checking steering gear housing for play
    • Adjusting pre-tension on pinion
  • Tracing leaks in the power steering pump
    • Replacing driveshaft retaining ring
    • Tighten pipe connections to pump and steering gear housing
    • Installing new control valve O-ring
    • Installing new return line in pump housing
    • Power steering pump, gasoline engine models, removing/installing
      • Notes
      • Power steering system, filling and bleeding
• Control System (B4204T4; 2003-2004)
  • Ball joint tie rod, protective bellow or tie rod, replacing
  • Checking power steering balance and pump pressure
  • Fault-tracing the power steering system
  • Oil delivery line power steering, replacing (LHD)
  • Oil pressure line power steering, replacing (RHD)
  • Oil return line power steering, replacing (LHD)
  • Oil return line power steering, replacing (RHD)
  • Replacing the steering column
  • Steering gear housing, replacing
  • Steering gear, overall inspection
  • Tracing leaks in the power steering pump
• Steering Gear (B4204T2 CVVT, Aw50-42; 2000)
  • Ball joint tie rod, protective bellow or tie rod, replacing
  • Checking power steering balance and pump pressure
    • Notes
    • Connect the test instrument
    • Position the manometer in the engine compartment so that it can be read off from the driver's seat
    • Check the oil level in the servo reservoir. Top up if necessary
    • Remove the steering wheel module
    • Checking balance when turning wheel to right
    • Checking the balance when turning the steering wheel to the left
    • Interpreting the torque measurements
    • Checking the pump pressure
      • Checking the pump pressure at the left limit position
      • Checking the pump pressure at the right limit position
      • Check the pump capacity if the pump pressure is incorrect
      • Install the steering wheel module
      • Remove the test instrument
      • Fill and bleed the servo system
  • Corrective action to counter leakage in the power steering pump
    • Replace the circlip for the drive shaft
    • Tighten the hose connectors to the pump and the steering gear housing
    • Install a new O-ring on the control valve
    • Install a new return hose in the pump housing
  • Fault-tracing the power steering system
  • Oil delivery line power steering, replacing (LHD)
  • Oil pressure line power steering, replacing (RHD)
  • Oil return line power steering, replacing (LHD)
  • Oil return line power steering, replacing (RHD)
  • Reconditioning the adjuster for the steering wheel position
    • Notes
    • Disassemble the adjuster for the steering wheel position
    • Assemble the adjuster for the steering wheel position
    • Install the steering column
  • Removing and installing the steering column
    • Notes
    • Preparations
    • Removing the steering wheel module
    • Removing the steering wheel
    • Removing the steering column, bracket and switch
    • Removing the steering column assembly
    • Removing the steering wheel lock
    • Removing the intermediate plate for the steering column
    • Installing the intermediate plate for the steering column
    • Installing the steering wheel lock
    • Installing the steering column assembly
    • Installing components for the steering column
    • Steering wheel, installation
    • Installing the steering wheel module
  • Removing and/or installing the power steering pump, gasoline powered cars
    • Notes
    • Remove the Poly V-belt from the power steering pump
    • Remove the oil pipe and the hose from the power steering pump.
    • Remove the power steering pump
    • Remove the pulley from the power steering pump
    • Install the pulley on the power steering pump. Use special tool 999 5444
    • Install the pulley on the power steering pump. Use special tool 999 5576/USA 999 2615
    • Install the power steering pump
    • Install the oil pipe and the hose on the power steering pump.
    • Install the Poly V-belt on the power steering pump
    • Fill and bleed the power steering system
  • Replacing the steering wheel lock and the lock cylinder for the steering wheel lock
    • Notes
    • Preparations
    • Replace the lock cylinder for the steering wheel lock
    • Replacing the steering wheel lock
    • Remove the steering wheel lock
    • Install the steering wheel lock
  • Steering gear housing, removing/installing
    • Removing the steering gear housing from the steering column
    • Removing the steering gear housing
    • Removing the central front-rear member
    • Removing the steering gear housing and surrounding components
    • Removing the oil pipe for the steering gear housing
    • Checking the steering gear housing mounting
    • Installing the steering gear housing
    • Installing the oil pipe for the steering gear housing
    • Installing the steering gear housing and surrounding components
    • Installing the central front-rear member
    • Installing the steering gear housing on the steering column
    • Filling and bleeding the power steering system
  • Steering gear, overall inspection