Installation instructions
Installation is in reverse order.
Replace fastening screw of steering shaft whenever it has been removed. Ensure it is fitted correctly. Insert fastening screw (in correct position, not from the threaded side).
Push on universal joint (steering shaft) in correct position, with steering gear and steering wheel or airbag contact unit (spiral spring) in center position. When doing this, only place steering transmission screws in position (to facilitate assembly when pushing universal joint on). After the fastening screws of steering have been tightened, push universal joint on as far as it will go. When fitted correctly and tension-free, the universal joint is allowed to be at a maximum distance -arrows- of 4 mm from the outermost edge of steering gear dust boot. (Схема №103)
Replace steering gear fastening screws.
Screw threads must be clean and free of grease.
Ensure that no damage (scoring or similar damage) is caused to the steering rack.
If the tie rods are to be reused, detach them from removed steering gear and fit them on new steering gear. Insert new sealing rings -arrow- on steering gear. (Схема №104)
Note. The left clamp of the joint boot must be clamped so that the clamp lug -arrow- is in line with the steering pinion. (Схема №105) The right clamp of the joint boot must be clamped so that the clamp lug -arrow- points horizontally with the front axle carrier (suspension subframe) in the direction of travel. (Схема №105) Failure to do this can lead to constrictions on the left-hand side in the vicinity of the feed and return lines and on the right-hand side in the vicinity of the heat shield.
Fit joint boot (not twisted) and secure with new clamps -arrow- (use pliers for hose clamp NR.74, Workshop Equipment Manual, commercially available tools). (Схема №105)
Check the joint boot is not worn (cracks, slots) and that sealing surfaces are clean.
When fitting the ball joints, ensure that the conical seats are clean. Remove dirt or grease on conical seats, e. g. with a lint-free cloth. Do not use cleaning agent/solvent.
Observe airbag safety instructions --> 69 AW SAFETY REGULATIONS FOR HANDLING AIRBAGS AND... - AS OF MY 2003 (ALL MODELS) working on vehicles with airbag and belt tensioners.
Install airbag unit for driver. Refer to 69 58 19 Removing and installing driver's airbag unit - as of MY 2003 (All Models) .
Observe notes on steering-gear center position in the section on front track adjustment in --> 44 IN SUSPENSION ALIGNMENT, COMPLETE - AS OF MY 2003 (ALL MODELS) .
Calibrate steering-angle sensor. Refer to 45 60 05 Initializing and calibrating steering angle sensor - as of MY 2003 (All Models) .
Observe correct tightening torques --> 48 TW Tightening torques for steering - as of MY 2003 (All Models Except Cayenne S TIO Titan) .