B3EG0DK1 - 406D9 VARIABLE POWER STEERING

REMOVAL - REFITTING : STEERING ASSEMBLY TRACK RODS

1 - REMOVAL

Place the vehicle on a two-post ramp .

Remove the front wheels .

Immobilise the steering rack : using the tool [1] .

IMPERATIVE : the tool [1] must be positioned on the teeth of the rack, on the left for left-hand drive, on the right for right-hand drive .

Release the tracking adjusting nut .

Remove the nut from the steering ball joint .

detach the steering ball joint using the extractor [3] .

Remove the steering ball joint .

Unseat the pipe (1) from the gaiter (2) (According to specification) .

Remove the collar (3) .

Remove the collar (4) : Using a thin screwdriver (According to specification) .

Detach the sealing gaiter (2) .

NOTE : use a slip product (grease TOTAL N3924 / N3945) .

Apply maximum steering lock :

• to the left (left hand drive)
• to the right (right hand drive)

Turn the steering wheel approximately 1/8 turns in the opposite direction .

remove the 4 bolts of the tool [1a] .

Unscrew the threaded pins [1b] by a few turns .

Fit the tool [1] on the rack, the plate of the tool on the teeth side and the supports with ball joints at the bottom (sub-frame side) .

Position the tool [1] as far as possible in the teeth of the rack and so that the supports with ball joints of the tool [1] can come into contact with the mechanical components (sub-frame, anti-roll bar...) .

VARIABLE POWER STEERING

The ball joints of the tool [1] come into contact with the sub-frame .

Tighten the 4 bolts [1a] of the tool [1] .

IMPERATIVE : screw in the threaded pins [1b] by hand to create only simple contact of the ball joints of the tool [1] on the sub-frame .

Position the tool [2] on the connecting rod to be replaced .

NOTE : in the case of replacement of the connecting rod on the opposite side to the pinion, remove the gaiter but leave the tool [1] in place on the pinion side .

Remove the track rod : using the tool [2] .

2 - REFITTING

Refit the connecting rod to the rack .

Using the tool [2], tighten the connecting rod :

• 206 = tightening torque : 7 da.Nm
• 406 - 607 = tightening torque : 9 da.Nm
• 806 - EXPERT = tightening torque : 8 da.Nm
• BOXER = tightening torque : 12 da.Nm

remove the tool [1] .

Grease (TOTAL N3924 / N3945 grease) :

• the mating surfaces (A) of the rack gaiter(4)
• the rack

NOTE : do not apply grease at (B) .

Fit a new gaiter (2) .

WARNING : position the mating surfaces of the gaiter correctly at (C) and (D) .

fit the new retaining collar (4) and tighten it with the collar pliers [4] .

Check and adjust the track .

IMPERATIVE : fit the pipe (1) to the gaiter (2) (according to specification) .

Fit :

• the collar (3)
• the steering ball joint

Tightening torque of the steering ball joint on the pivot :

• 206 - 406 - 607 - 806 - EXPERT = 3.5 da.Nm
• BOXER = 7 da.Nm

Tighten the wheel bolts :

• 206 = 8.5 da.Nm
• 406 - 607 = 9 da.Nm
• 806 - EXPERT = 10 da.Nm
• BOXER 10Q - 14Q = 16 da.Nm
• BOXER 18Q = 18 da.Nm

Adjust the wheel alignment .

DYNAMIC STABILITY CONTROL

Programme the steering wheel angle sensor using the diagnostic equipment DIAG 2000 .