Removing
Place the vehicle on a two-post lift, apply the parking brake and turn off the ignition.
Set the front wheels to a straight ahead position.
Remove front wheels.
Remove the engine crankcase protection.
Remove the lower and side mudguards of the front fenders.
Unscrew the three screws securing the lower part of the bumper to the front suspension subframe and move the lower part of the bumper, releasing the subframe (replaceable nozzle Torx T30, extension, ratchet wrench).
Unscrew the nut 2, Figure 6-2, of the bolt for fastening the joint yoke 1 of the intermediate shaft of the steering column to the shaft 4 of the steering gear, remove the bolt 3 and disconnect the steering shaft from the steering gear shaft (wrench 13).
Unscrew the nuts securing the pins of the ball joints of the outer tips of the steering rods to the swing arms (interchangeable head 16, knob).
Press the ball pins out of the pivot arms (fixture Tav. 476).
For vehicles with a K7M engine, disconnect the muffler intake pipe from the exhaust manifold and lower it down.
Figure 11-1 - Removing the connecting bracket from the jet link: 1 - front suspension subframe; 2 - lower jet thrust; 3 - fastening bolt; 4 - connecting bracket; 5 - fastening bolt; 6 - gearbox housing
Unscrew and remove the bolt 3, Figure 11-1, fastening the connecting bracket 4 to the lower reaction rod 2 (interchangeable head 18, extension and collar).
Loosen the bolt 5 fastening the connecting bracket to the crankcase 6 of the gearbox and turn the bracket 4 away from the jet thrust 2 (interchangeable head 18, extension and collar).
Install the transmission rack 3 under the rear part of the subframe 2, Figure 11-2, of the front suspension and support the subframe (transmission rack type OMA 604).
Replace the two bolts of the front part of the front suspension subframe with two studs 1 of the tool for dismantling the power unit (interchangeable head 18, extension and wrench, stud driver, studs from the TAV tool kit. 1747).
Figure 11-2 - Installing tools for dismantling the front suspension subframe: 1 - studs from the TAV tool kit. 1747; 2 - front suspension subframe; 3 - transmission rack
Figure 11-3 - Disconnecting the connecting rods of the front suspension subframe: 1 - spar of the engine compartment; 2 - fastening bolt; 3 - stretching the stretcher; 4 - front suspension subframe
Unscrew and remove bolts 2, Figure 11-3, fastening braces 3 of the subframe 4 of the front suspension to the spars 1 of the engine compartment (interchangeable head 13, ratchet wrench).
Unscrew and remove the bolts securing the rear of the front suspension subframe (interchangeable head 18, extension and collar).
Lower the front suspension subframe by the amount necessary to gain access to the steering gear (transmission rack type OMA 604, "Automotive equipment" Pskov, TAV device. 1747).
Install clamps on the low and high pressure lines to the steering box (clip Ms. 583 - 2 pcs.).
For cars with K4M engine - unscrew the heat shield mounting bolts and remove the steering gear heat shield (interchangeable head 13, ratchet wrench).
Disconnect the pipe fitting 1, Figure 11-4, high pressure from the steering gear (wrench 17).
Disconnect the union of the pipeline 5 low pressure from the steering gear (wrench 17).
Figure 11-4 - Removing the steering gear: 1 - high pressure pipeline; 2 - bolts of fastening of the steering mechanism; 3 - sealing ring; 4 - steering mechanism; 5 - low pressure pipeline; 6 - front suspension subframe
Install technological plugs in the holes of the steering mechanism and on the pipelines (technological plugs).
For vehicles with a K7M engine, remove the oxygen sensor harness from the holder on the low pressure pipe.
Unscrew the bolts 2 fastening the steering mechanism to the subframe 6 of the front suspension and remove the mechanism complete with steering rods by moving it to the left (interchangeable head 18, ratchet wrench).
Installation
Attention. Reuse of the bolt and nut of the steering column intermediate shaft joint yoke to the steering gear shaft is not allowed. The bolt and nut must be replaced.
Attention. Do not reuse the front suspension subframe mounting bolts. Bolts must be replaced.
Attention. Before installing the pipelines, be sure to replace the O-rings on the pipeline fittings.
Install the steering gear to the front suspension subframe and secure with bolts. Bolt tightening torque 105 Nm (10.5 kgf·m) (interchangeable head 18, ratchet wrench, torque wrench).
Remove the process plugs from the steering gear holes and the high and low pressure lines.
Install a new O-ring and connect the high pressure pipe fitting to the steering gear. Connector tightening torque 21 Nm (2.1 kgf·m) (wrench 17, interchangeable insert 17 type 58 21 10 17 f. "Stahlwille", torque wrench type 50 18 00 04 f. "Stahlwille").
Install a new O-ring and connect the low pressure pipe union to the steering gear. Connector tightening torque 21 Nm (wrench 17, interchangeable insert 17 type 58 21 10 17 f. "Stahlwille", torque wrench type 50 18 00 04 f. "Stahlwille").
Remove the clamps from the low and high pressure lines of the power steering system.
For vehicles with a K7M engine, attach the oxygen sensor harness to the holder on the low pressure line.
For vehicles with a K4M engine, install the heat shield of the steering gear in place and secure with bolts. Bolt tightening torque 21 Nm (2.1 kgf·m) (interchangeable head 13, ratchet wrench, torque wrench).
Raise front suspension subframe (transmission rack type OMA 604, TAV device. 1747).
Install, without tightening, two new bolts securing the rear of the front suspension subframe (interchangeable head 18, extension and collar).
Unscrew the two studs of the tool for dismantling the power unit and wrap, without tightening, two new bolts securing the front part of the front suspension subframe (interchangeable head 18, extension and wrench, stud driver, studs from the TAV tool kit. 1747).
Tighten the subframe bolts according to the diagram.
Install the mounting bolts in the upper holes of the front suspension subframe braces and screw them into the corresponding holes in the side members of the engine compartment. Bolt tightening torque 21 Nm (2.1 kgf·m) (interchangeable head 13, ratchet wrench, torque wrench).
Connect the gearbox connecting bracket to the power unit lower tie rod and tighten the bolts that secure the bracket to the gearbox housing and to the tie rod. Bolt tightening torque 105 Nm (10.5 kgf·m) (interchangeable head 18, extension and collar).
For vehicles with a K7M engine, connect the muffler downpipe to the exhaust manifold.
Install the steering column intermediate shaft pivot yoke onto the steering gear shaft and secure with a new bolt and nut. Nut tightening torque 21 Nm (2.1 kgf·m) (interchangeable head 13, ratchet wrench, torque wrench).
Install the pins of the ball joints of the outer tips of the steering rods in the holes of the pivot arms and secure with the fastening nuts. Nut tightening torque 37 Nm (3.7 kgf·m) (interchangeable head 16, knob, torque wrench).
Fasten the lower part of the bumper to the front suspension subframe with three mounting screws (replaceable nozzle Torx T30, extension, ratchet wrench).
Install the lower and side mudguards of the front fenders.
Install the engine crankcase protection.
Install front wheels.
Pour working fluid into the reservoir of the power steering pump (power steering oil Mobil ATF 52475).
Removing air from the power steering system
Attention. To prevent damage to the power steering system, do not hold the steering wheel in extreme positions.
Remove air from the power steering system, for which:
- turn the steering wheel several times from one extreme position to another with the engine off;
- turn the steering wheel several times from one extreme position to another with the engine running;
- top up the oil level in the reservoir (power steering oil Mobil ATF 52475).
Start the engine and check the tightness of the power steering system, if an oil leak is detected, repair the malfunction.
Check and, if necessary, adjust the wheel alignment.