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Replace Steering Gear (Lhd) Opel Astra H

Steering Gear 16 illustrations ~1237 words

Warning: Before removing the front axle body, ensure that the engine mounting blocks are correctly fixed.

Warning: Before removing the intermediate steering spindle from the steering pinion or steering spindle, move the steering to the straight-ahead position and lock with the steering lock.

Note. The front axle body is released and lowered. The guide joints remain attached to the steering knuckle.

Remove

  1. 1. Turn steering wheel as far as the stop • Turn steering wheel and front wheels to the straight-ahead position. • Remove ignition key. • Allow steering lock to engage
  2. 2. Remove intermediate shaft from steering gear. • Remove clamp bolt (1) of intermediate shaft. • Detach intermediate shaft from steering wheel.

Note. Bolt is accessible from the passenger compartment.

  1. 3. Remove rubber sleeve from steering gear (2).
  1. 4. Secure radiator to upper brackets (1) • Insert 2x suitable tool.

Note. The illustration shows the bumper detached for clearer depiction.

  1. 5. Detach 2x front wheels • Remove 10x wheel bolts

Note. Mark position relative to the wheel hub.

  1. 6. Release 2x tie rod ends (6) from steering knuckle (5) • Attach CH-47658 (1) – Place CH-47658 (1) in position with a suitable sleeve (4) – Fasten CH-47658 (1) to hex (2) • Unscrew tie rod end nut • Detach CH-47658 (1) – Release at hex (2)

Note. To centre CH-47658 , CH-47658 must be inserted with a suitable socket (3).

  1. 7. Detach 2x tie rod ends from steering knuckle • Press tie rod end out of steering knuckle using KM-161-B (1) combined with KM-161-2
  1. 8. Detach lower engine compartment cover • Release 8 bolts (1)
  1. 9. Remove front exhaust pipe. • Remove 3 nuts for connecting the front pipe to the particle filter / rear catalytic converter (1). • Remove 3 nuts for connecting the pipe to the front catalytic converter (2). • Remove the bracket from the oil pan (3). • Remove the exhaust pipe.

Note. The flexible part of the pipe must not be bent by more than 5°.

  1. 10. Remove rear engine damping block from transmission. • Unscrew 3 bolts (1)
  1. 11. Place vehicle jack in position under the front axle housing.
  2. 12. Remove triangular plate. • Unscrew 6 bolts (1) (2).
  1. 13. Remove centre bolts from axle housing (1) 2x.

Important. The following work step is required so that the lower radiator pins are not damaged when lowering the front axle body.

  1. 14. Detach lower radiator bracket (1) • Unscrew 4x bolt.
  1. 15. Lower the front axle body at the rear with a hydraulic jack by max. 80 mm to allow adequate access to the steering gear.
  2. 16. For vehicles with TRW steering • For vehicles with manual transmission: detach shift guide bracket. – Detach shift guide lever clip – Unscrew 4x bolt • Detach rear engine damping block (1) bracket from engine damping block • Detach holder (2) • Remove supply line (3) and return line (4) from steering gear • Unclip wiring harness for steering from front axle body

Note. Oil runs out - use catchment tray

Note. Note wiring route

  1. 17. For vehicles with ZF steering • Detach rear engine damping block (1) bracket from engine damping block • Detach rear engine damping block (2) – Unscrew bolt connection • Remove supply line (3) and return line (4) from steering gear

Note. Illustration shows front axle body removed.

Note. Oil runs out - use catchment tray

  1. 18. Remove electro-hydraulic supply unit from front axle body • For ZF steering: Release 2x wiring harness plug (1) and (2) and remove from electro-hydraulic supply unit • Remove 3x nuts (3) and (4) from steering gear and front axle body • Remove electro-hydraulic supply unit with supply and return line from steering gear and front axle body
  2. 19. Remove tie rods on both sides of steering gear • Detach 2x retaining strap (1) and (2) • Remove 2x boot from steering gear • Detach 2x tie rod (4) from steering gear with KM-6004-2 – counterhold with an open-ended wrench on the toothed rack flat on the steering shaft side

Note. Counterholding is no longer necessary in vehicles as of model year 2006.

  1. 20. Remove steering gear from front axle body • Remove 2x nut (2) from front axle body • Remove 2x bolt • Remove steering gear

Install

  1. 21. Attach steering gear to front axle body • Insert 2x new bolt • Tighten 2x new nuts 45 Nm + 45° + 15°
  2. 22. Attach 2x tie rod to steering gear with KM-6004-2 90 Nm • counterhold with an open-ended wrench on the toothed rack flat on the steering shaft side

Note. Clean thread on rack and coat with locking compound.

Note. Counterholding is no longer necessary in vehicles as of model year 2006.

  1. 23. Attach 2x boot to steering gear • Place 2x boot on steering gear • Attach 2x new retaining clamp to steering gear with KM-J-22610 • Fit 2x boot to tie rod using new retaining strap

Note. Ensure that the boot sits in the grooves of the tie rod and steering gear

Note. Ensure that the boots sit in the grooves of the tie rod.

  1. 24. Attach electro-hydraulic supply unit with bracket to front axle body 22 Nm • Place electro-hydraulic supply unit with holder on steering gear and front axle body • Tighten 3x nut

Note. Note steering wiring harness

  1. 25. For ZF steering: Connect 2x wiring harness plug to electro-hydraulic supply unit
  2. 26. For ZF steering: Attach supply and return line to steering gear 16 Nm • Use 2x new seal rings
  3. 27. For TRW steering: Attach supply and return line to steering gear 30 Nm • Use 2x new seal rings
  4. 28. Attach supply and return line holder to steering gear
  5. 29. For vehicles with manual linkage: detach shift guide bracket. • Tighten 4x bolt 20 Nm • Attach shift guide lever clip
  6. 30. Attach rear engine damping block bracket to engine damping block 55 Nm
  7. 31. Raise front axle body with hydraulic jack.
  8. 32. Fit bolts for front axle housing. • Fit triangular plates, insert the following new bolts and leave slack. – Tighten 2x bolts (2) for front axle housing to 90 Nm +45° +15° . – Tighten 4x bolts (1) for triangular plates to vehicle underbody 65 Nm
  1. 33. Insert centre bolts for front axle body and leave slack • Tighten 2x bolts for front axle housing (1) to 90 Nm +45° +15° .
  1. 34. Lower vehicle jack.
  2. 35. Place engine support underneath, at the back on the transmission. • Tighten bolt to 80 nm .
  3. 36. Attach lower radiator bracket • Tighten 4x bolt 15 Nm .

Important. Ensure that the lower radiator pins sit correctly in the lower radiator brackets.

  1. 37. Attach front exhaust pipe. • Lubricate the bolts with bolt paste and fit the pipe between the front and rear catalytic converter. • Fit bracket to oil pan and tighten the bolts to 25 Nm .

Note. Use new gaskets and new nuts. Tighten to 25 nm .

Note. The flexible part of the pipe must not be bent by more than 5°.

  1. 38. Attach lower engine compartment cover. • Tighten 8x bolts to 5 Nm .
  2. 39. Charge and bleed hydraulic system
  3. 40. Remove 2x catch for radiator from bracket.
  4. 41. Attach front wheels • Tighten 10x wheel bolts 110 Nm
  5. 42. Check straight-ahead position, adjust if necessary
  6. 43. Check toe-in, adjust if necessary

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