Steering Gear Rubber Gaiters; Steering Gear; Electro-Hydraulic Power Steering Pump; Steering Gear Rubber Gaiter Outer Securing Clip - Opel Zafira B MPV 2006 Owners Workshop Manual

11·
Steering
9ear rubber
gaiters
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1 Remove the relevant track rod end as
described in Section 21.
2 Remove the inner and outer securing clips
(see illustration), then slide the gaiter off the
end of the track rod.
3 Thoroughly clean the track rod, then slide
the new gaiter into position. Note that a groove
is provided in the track rod for the outer end of
the gaiter to locate in.
4 Fit the gaiter securing clips, using new clips
if necessary, making sure that the gaiter is not
twisted.
5 Refit the track rod end as described in
Section 21.
6 Have the front wheel toe-setting checked
and adjusted at the earliest opportunity.
1a ~~itns~e• -
· remQ,vat anti refitting
Note: New steering gear mounting bolts will
be required for refitting.
Removal
1 Set the front wheels in the straight-ahead
position. Remove the ignition key and allow
the steering lock to engage.
2 Remove the front subframe as described in
Section 7.
3 On left-hand drive models, unbolt the rear
engine mounting/torque link bracket from the
subframe.
4 Where fitted, unbolt the support bracket
for the pressure and return lines from the
subframe.
5 Position a suitable container beneath
the steering gear fluid unions to catch spilt
hydraulic fluid.
6 Unscrew the union nuts and disconnect
the fluid pressure and return lines from the
steering gear (see illustration).
7 Note the routing of the wiring loom then
either disconnect it from the electro-hydraulic
pump (where possible) or release it from the
subframe. Note: On pumps supplied by TRW,
the wiring loom is supplied together with the
pump and cannot be separated.
8 Unscrew the mounting nuts and withdraw
the electro-hydraulic pump together with the
fluid reservoir and pressure/return lines from
the subframe and steering gear.
9 Unscrew the mounting bolts and remove
the steering gear from the subframe (see
illustration). If necessary, remove the anti-roll
bar first with reference to Section 8. The
manufacturers recommend that the mounting
bolts are renewed whenever removed.
10 If necessary, remove the track rod ends
and track rods with reference to Sections 21
and 22. Note: New steering gear assemblies
are available from Vauxha/1/0pel either with or
17.2 Steering gear rubber gaiter outer
securing clip
without the track rods fitted. Also remove the
rubber grommets from the pinion.
Refitting
11 Refit the track rods and track rod ends
with reference to Sections 22 and 21. Also
refit the rubber grommets to the pinion.
12 Clean any dirt from the steering gear and
subframe, then locate the steering gear in
position. Insert the new mounting bolts and
tighten to the specified torque, then through
the specified angles.
13 Where removed, refit the anti-roll bar with
reference to Section 8.
14 Refit the electro-hydraulic pump, together
with the fluid reservoir and pressure/return
lines to the subframe and steering gear, and
tighten the mounting nuts to the specified
torque.
15 Reconnect the wiring loom to the electro-
hydraulic pump and attach it to the subframe.
16 Fit new rubber sealing rings to the
pressure and return lines, then refit the lines to
the steering gear and tighten the union nuts to
the specified torque.
17 Where fitted, refit the support bracket for
the pressure and return lines to the subframe
and tighten the mounting bolts securely.
18 On left-hand drive models, refit the rear
engine mounting/torque link bracket to the
subframe and tighten to the specified torque.
19 Refit the front subframe as described in
Section 7.
20 Bleed the power steering hydraulic system
as described in Section 20.
21 Have the front wheel toe-setting checked
and adjusted at the earliest opportunity.
18.6 Hydraulic fluid line connections on
the steering gear
Suspension and steering 10•15
Removal
1 Remove the front subframe as described in
Section 7.
2 Position a suitable container beneath the
power steering pump fluid unions to catch
spilt hydraulic fluid.
3 Disconnect the pressure and return lines
from the power steering pump. Use a spanner
to unscrew the pressure line union nut. If
necessary, cut free the return line clip and
replace it with a screw-type clip.
4 Note the routing of the wiring loom then
either disconnect it from the electro-hydraulic
pump (where possible) or release it from the
subframe. Note: On pumps supplied by TRW,
the wiring loom is supplied together with the
pump and cannot be separated.
5 Unscrew the mounting nuts and withdraw
the electro-hydraulic pump, together with the
bracket, wiring and fluid reservoir from the
subframe and steering gear.
6 Unscrew the mounting nuts and remove the
electro-hydraulic pump and mounting bushes
from the bracket. Check the rubber mounting
bushes for wear and damage and renew them
if necessary.
Refitting
7 Refit the pump and bushes to the bracket
and tighten the mounting nuts.
8 Refit the electro-hydraulic pump and bracket
on the subframe and steering gear and tighten
the mounting nuts to the specified torque.
9 Reconnect the wiring loom (where
applicable) and secure it to the subframe.
Make sure that the loom is routed as noted
during removal.
10 Fit a new rubber sealing ring to the
pressure line, then reconnect the pressure
and return lines to the power steering pump.
Tighten the pressure line union nut securely,
and fit a new clip to the return line.
11 Refit the front subframe as described in
Section 7.
12 Bleed the power steering hydraulic system
as described in Section 20.
18.9 Steering gear mounting bolt retaining
nut (arrowed)