Figure 16-1 - Scheme of fastening the pipelines of the power steering system of vehicles with a K7M engine: 1 - bracket for fastening the high-pressure pipeline to the bracket for attaching mounted units; 2 - bracket for fastening the high pressure pipeline to the hydraulic pump; 3 - bracket for fastening the high pressure pipeline to the engine block; 4 - bracket with a groove for mutual orientation of low and high pressure pipelines; 5 bracket for fastening the low pressure pipeline to the steering mechanism; 6 - bracket for fastening the low pressure pipeline to the front suspension subframe; 7 - clamp for fastening the low pressure pipeline to the bracket of the electric fan of the engine cooling system
Figure 16-2 - Scheme of fastening the pipelines of the power steering system of vehicles with a K4M engine: 1 - clamp for fastening the low pressure pipeline to the bracket of the electric fan of the engine cooling system; 2 - bracket for fastening the high pressure pipeline to the engine block; 3 - bracket with a groove for the relative orientation of low and high pressure pipelines; 4 - bracket for fastening the high pressure pipeline to the pendulum support on the gearbox; 5 - bracket for fastening the low pressure pipeline to the steering mechanism; 6 - bracket for fastening the high pressure pipeline to the gearbox housing 7 - bracket for fastening the low pressure pipeline to the front suspension subframe
Low pressure line between power steering pump and reservoir
Removing
Set the car to a working post, brake with a parking brake and turn off the ignition.
Unscrew the cap of the reservoir of the power steering pump and pump out the working fluid (hand pump, process tank).
Unclench the fastening clamp and disconnect the pipeline from the tank (clamp pliers Mot. 1202-02).
Release the clamp, disconnect the pipeline from the power steering pump and remove the pipeline (clamp pliers Mot. 1202-02).
Install plugs in the openings of the pipeline, tank and pump (technological plugs).
Installation
Remove the plugs from the opening of the pipeline, tank and pump.
Install the pipeline on the fitting of the power steering pump and secure with a clamp (clamp pliers Mot. 1202-02).
Install the pipeline on the fitting of the hydraulic booster reservoir and secure with a clamp (clamp pliers Mot. 1202-02).
High pressure pipe between power steering pump and steering box
Removing
Place the vehicle on a two-post lift, apply the parking brake and turn off the ignition.
Remove the engine crankcase protection.
Install the clamp on the power steering pump low pressure pipe (clip Ms. 583).
For vehicles with K7M engine
Disconnect the ignition harness connector from the pressure sensor.
Unscrew the fitting and disconnect the high pressure pipe from the power steering pump (wrench 17).
Remove the right front wheel.
Remove the right side and lower front fender mudguards.
Unscrew the bolt securing the pipeline to the bracket of mounted units (interchangeable head 10, ratchet wrench).
Unscrew the nut securing the pipeline to the engine block (interchangeable head 13, ratchet wrench, wrench 13).
Disconnect the pipe fitting from the steering gear and remove the pipe (wrench 17).
Install plugs in the openings of the pipeline, pump and steering gear (technological plugs).
For vehicles with K4M engine
Remove fuel rail guard.
Disconnect the ignition harness connector from the pressure sensor.
Unscrew the bolt securing the pipeline to the cylinder block (interchangeable head 13, ratchet wrench).
Loosen the union and disconnect the high pressure pipe from the power steering pump (wrench 17).
Remove the left front wheel.
Remove the left side mudguard of the front fender.
Unscrew the bolts securing the pipeline to the gearbox and to the pendulum support of the gearbox (interchangeable head 13, ratchet wrench).
Loosen the heat shield mounting bolts and remove the steering gear heat shield (interchangeable head 13, ratchet wrench).
Disconnect the pipe fitting from the steering gear and remove the pipe (wrench 18).
Install plugs in the openings of the pipeline, pump and steering gear (technological plugs).
Installation
Attention. The sealing rings in the connectors of the pipeline fittings must be replaced when the pipelines are removed. O-rings must not be reused.
Remove the plugs from the opening of the pipeline, pump and steering gear.
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 high pressure pipe fitting to the power steering pump. 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").
For vehicles with K7M engine
Fix the pipeline with a bolt on the bracket of mounted units. Bolt tightening torque 21 Nm (2.1 kgf·m) (interchangeable head 10, ratchet wrench, torque wrench).
Secure the pipe with a bolt and nut to the cylinder block. Nut tightening torque 21 Nm (2.1 kgf·m) (interchangeable head 13, ratchet wrench, torque wrench, wrench 13).
Connect the ignition harness connector to the pressure sensor.
Install the right side and lower front fender mudguards.
Install the right front wheel.
For vehicles with K4M engine
Reinstall steering gear heat shield and secure with bolts. Bolt tightening torque 21 Nm (2.1 kgf·m) (interchangeable head 13, ratchet wrench, torque wrench).
Bolt the pipeline to the gearbox and to the gearbox pendulum. Bolt tightening torque 21 Nm (2.1 kgf·m) (interchangeable head 13, ratchet wrench, torque wrench).
Fix the pipeline with a bolt on the block of cylinders. Bolt tightening torque 21 Nm (2.1 kgf·m) (interchangeable head 13, ratchet wrench, torque wrench).
Connect the ignition harness connector to the pressure sensor.
Install fuel rail guard.
Install the left front fender side mudguard.
Install the left front wheel.
Operations for all vehicles (after installation of the high pressure pipeline):
- remove the clamp from the low pressure pipe of the power steering pump;
- install engine crankcase protection.
Low pressure pipe between power steering reservoir and steering box
Removing
Place the vehicle on a two-post lift, apply the parking brake and turn off the ignition.
Unscrew the cap of the reservoir of the power steering pump and pump out the working fluid (hand pump, process tank).
Remove the left front wheel.
Remove the left side mudguard of the front fender.
Remove the pipeline from the holder on the housing of the electric fan of the engine cooling system.
Release the fastening clamp, disconnect the pipeline from the power steering reservoir (clamp pliers Mot. 1202-02).
Remove the engine crankcase protection.
Remove the bolt securing the pipeline to the front suspension subframe (interchangeable head 10, ratchet wrench).
For cars with K4M engine - unscrew the heat shield mounting bolts and remove the steering gear heat shield (interchangeable head 13, ratchet wrench).
For vehicles with a K7M engine, remove the oxygen sensor harness from the holder on the low pressure pipe.
Disconnect the pipe fitting from the steering gear and remove the pipe (wrench 17).
Install plugs in the openings of the pipeline, tank and steering mechanism (technological plugs).
Installation
Attention. The sealing rings in the connectors of the pipeline fittings must be replaced when the pipelines are removed. O-rings must not be reused.
Remove the plugs from the opening of the pipeline, tank and steering gear.
Install a new O-ring and connect the low pressure pipe union 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 the pipeline on the fitting of the hydraulic booster reservoir and secure with a clamp (clamp pliers Mot. 1202-02).
Install the pipeline in the holder on the housing of the electric fan of the engine cooling system.
Secure the pipe with a bolt to the front suspension subframe. Bolt tightening torque 21 Nm (2.1 kgf·m) (interchangeable head 10, ratchet wrench, torque wrench).
Install the left front fender side mudguard.
Install the engine crankcase protection.
Install the left front wheel.
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).
For vehicles with a K7M engine, install the oxygen sensor harness into the holder on the low pressure line.
The general procedure for performing work on the installation of power steering pipelines.
Pour working fluid into the reservoir of the power steering pump (power steering oil Mobil ATF 52475).
Bleed air from the power steering system.
Start the engine and check the tightness of the power steering system, if an oil leak is detected, repair the malfunction.