Steering Column: Service and Repair
Replacing steering column with/without SRSSpecial tools 5294 5295, 8695
Important!
Before working on cars fitted with SRS:
Note!
If car is to be rebuilt and fitted with later version of steering column (inertia-limited), a new steering column member must also be fitted.
J1
Preparations
Drive car forward on a level surface so that wheels are straight.
Disconnect battery negative lead.
Turn ignition key to position 1 so that steering lock is off.
J2
Remove sound insulation/knee guard 1 and side panel 2 on center console
With SRS: continue with J4.
Without SRS
J3
Remove steering wheel
Replace nut on steering shaft. This is to ensure that steering shaft does not fall out of upper mount when steering shaft is separated.
Without SRS: continue with J9.
With SRS
J4
Remove bag assembly
Turn steering wheel slightly in order to reach bolts. Undo bag assembly by removing the two torx bolts on back of steering wheel.
Undo connector and lift bag assembly clear. Ensure road wheels are still straight.
Important!
Do not switch on ignition while bag assembly is removed, as this will register a fault code, which will then need to be cancelled.
J5
Remove steering wheel bolt
J6
Lock contact reel
Release locking screw in end of plastic strip from its parking hole in steering wheel. Screw must always remain in plastic strip.
J7
Attach locking screw to contact reel pin
Contact reel is now locked in zero position
Important!
Do not turn steering wheel as this will cause pin to snap and necessitate replacement of whole contact reel!
J8
Remove steering wheel
Lift steering wheel clear and pull lead and plastic strip with screw through hole in middle.
Remove connector for contact reel on back of fascia.
Remove contact reel.
With and without SRS
J9
Pull up cover from lower steering shaft joint
(Does not apply to cars with power steering).
J10
Loosen upper bolts in upper and lower joints
Pry apart joints slightly with screwdriver.
J11
Pull down lower steering shaft so that upper joint is freed from upper steering shaft
J12
Remove upper and lower steering column covers
J13
Remove holder for wiper and indicator controls
Disconnect connector for wiper control.
Unscrew holder's two retaining bolts and lift holder over steering shaft.
J14
Note position of indicator switch lead and remove
This applies only to cars without anti-theft protection for steering lock starter switch. Others, continue to J16.
J15
Remove connector from starter switch
J16
Remove:
- Steering column's lower retaining bracket
- Steering column seal in bulkhead
- Defroster hose from heater unit.
For cars with inertia-limited steering column, go to J22.
The following five steps, J17-J21, apply to models being converted from earlier versions to inertia-limited steering column
J17
Remove:
- Bolts holding steering column member to fascia.
- Failure sensor and clip (2).
- Loosen tab clip (1) from cable harness on member
J18
Press steering column forward so that member comes free from fascia
The following section, J19, applies to cars without anti-theft protection for starter switch
J19
Remove steering column with member
The following section, J20, applies to cars with anti-theft protection for starter switch
J20
Drill and remove shearing bolt
Mark centre of bolt and drill hole of with suitable diameter for bolt extractor.
Remove anti-theft protection and connector from starter switch.
J21
Remove steering column and member
Continue from step J28, Installation
Removing inertia-limited steering column
J22
Remove steering column
Tap shearing bolts so that bolts and plastic washers slide out of their slots in member.
Note!
Check steering column does not get caught while passing through bulkhead.
J23
Remove steering column with steering lock
J24
Put steering column in vice
J25
Remove plastic washers
Use screwdriver to break off washers from rear edge.
J26
Remove shearing bolts
Use pipe wrench with teeth in good condition.
J27
Press steering lock from steering column
Use drift 5294 and counterhold 5295.
Note!
Install keys in lock and turn.
Installation
J28
Check steering column
Check upper steering shaft's collapsible coupling is intact. Its upper end (A) should not be able to move axially in relation to its lower end (B).
Check also total length:
Correct length 705.5 ± 1 mm (27.78 ± 0.4 in.).
If measurement is incorrect, replace whole steering column.
J29
Install new steering lock on new steering column
Install key and turn.
Check carefully that lock barrel is aligned with centre of steering column opening.
(Use marked line to align).
J30
Press on steering lock
Use drift 5294 and counterhold 5295.
For measurement, see illustration, J31.
Note!
Counterhold 5295 may only be applied to upper groove of steering tube. See illustration.
J31
Check lock operation
Remove key from lock. Turn steering shaft and check lock barrel locks it.
For models being converted from earlier versions to inertia-limited steering column:
J32
Install new member on fascia
J33
Place cable harness in tab-clip (1) on member and bend clip into place
J34
Attach bulb failure sensor (2) to member
New and converted versions:
J35
Install both plastic guides in member Turn guides so that washers face down
Note!
Spacer and washer are now a single unit.
J36
Position steering column and screw in shearing bolts without tightening
Pull steering column towards rear as far as it will go. Tighten shearing bolts more, but do not shear them yet.
J37
Install lower retaining bracket and bolts
First install rubber spacer and then bracket. Tighten bolts lightly.
J38
Position rubber seals in bulkhead
Smear seal with vaseline. Turn cone inward.
Install seal on steering column from engine compartment.
Check it is positioned correctly.
J39
Tighten upper attachment bolts, but do not shear them yet
J40
Tighten lower retaining bracket
Torque: 2O ± 5 Nm (14.7 ± 3.6 Ft. lbs.).
J41
Attach defroster hose
J42
Reconnect connector for ignition lock
J43
Join upper and lower steering shafts
Raise lower steering shaft. Attach universal joint to upper steering shaft. Tighten upper bolt. Install locking pin. Tighten bolt for lower universal joint. Install locking pin.
J44
Checking and adjusting steering shaft
This check should be carried out after any work on steering shaft.
Distance A between upper steering shaft joint and shoulder on lower steering shaft should be
when checking 10 - 19mm (.39 - .75 in.)
when adjusting 15 mm (.59 in.)
If check shows that distance is incorrect make following adjustment.
J45
Loosen upper bolted joint B of lower steering shaft universal joint
Loosen lower bolted joint C of upper steering shaft universal joint. Loosen bolts only enough for head to come free from universal joint.
J46
Adjust distance A, see J44, by moving steering shaft up or down
Ensure position of upper steering shaft does not change, as this can affect distance between steering wheel and steering column cover.
J47
Tighten bolted joints B and C
Torque: 23 ± 5 Nm (16.9 ± 3.6 Ft. lbs.).
J48
Attach holder for wiper and indicator controls and connect leads
Connect leads to indicator switch according to marks made earlier.
Connect earth lead to one of retaining bolts.
J49
Attach upper and lower steering column covers
With SRS:
Continue from step J60.
Without SRS:
J50
Install:
- spring seat
- spring
- steering wheel.
Torque: 6O ± 15 Nm (44.2 ± 11 Ft. lbs.).
J51
Check steering wheel does not contact steering column covers when turning
If it does, adjust distance A in illustration, as outlined in J52-J54.
J52
Loosen upper bolted joint B of lower steering shaft universal joint
Loosen bolt just enough for head to come free from joint.
J53
Adjust gap A between steering wheel and steering column cover
Adjust by carefully pushing lower steering shaft upward so that steering wheel is free from steering column cover. Recommended play: 1 - 2 mm (.04 - .O8 in.).
J54
Tighten bolted joint B on steering shaft universal joint
Torque: 23 ± 5 Nm (16.9 ± 3.6 Ft. lbs.).
Install locking pin.
Replace cover for lower steering shaft universal joint.
(Does not apply to cars with power steering).
J55
Shear shearing bolts
J56
Install side panel (2) and panel below fascia (1)
J57
Connect negative battery lead and test operation
J58
Check steering wheel position
J59
Dealing with rattle in steering shaft bearings
Increase pre-tension of bearings by placing one (if necessary two) flat washers between steering wheel and spring.
With SRS
J60
Check front wheels are straight
J61
When replacing contact reel, or if locking screw has been removed
Set contact reel to zero:
Turn contact reel right as far as end position, then turn three (3) revolutions to left.
Lock contact reel with screw in plastic strip.
J62
Install:
- bracket for contact reel
- contact reel
- connector behind fascia. Ensure lead does not get caught.
Important!
Do not turn steering wheel as this will cause contact reel pin to snap, and necessitate replacement of whole contact reel!
J63
Install steering wheel
Check road wheels are straight.
Pull lead from contact reel through hole in steering wheel. Set steering wheel so that contact reel pin is in centre of steering wheel hole.
Install nut to hold steering wheel and tighten with fingers. Remove screw in end of plastic strip and install in its parking hole in steering wheel.
J64
Attach tool 8695 in place of bag assembly
This is done to enable car to be driven without fault code being registered.
Connect negative lead.
J65
Check that steering wheel is straight
Drive car straight ahead on smooth surface to ensure that front wheels are pointing perfectly straight ahead.
J66
If steering wheel is not straight
- disconnect negative battery lead.
- replace locking screw in pin.
- remove tool 8695.
- remove steering wheel.
- set contact reel to zero, see J61.
- replace steering wheel straight and tighten screw with fingers.
- repeat steps J64 and J65.
When steering wheel is straight:
- Tighten bolt holding steering wheel. Torque: 60 Nm (44.2 Ft. lbs.).
- Check SRS-lamp is off (no fault codes registered).
- Disconnect negative battery lead again.
- Remove tool 8695.
J67
Install bag assembly
- Rest bottom of assembly on steering wheel.
- Reconnect connector.
- Place bag assembly in position and tighten torx bolts from rear. Torque 6 Nm (4.4 Ft. lbs.). Turn the steering wheel a little in order to reach the bolts.
Note!
Tighten right bolt first!
Ensure that cable does not get pinched on reassembly.
J68
Check operation
Check steering wheel turns easily and steering lock functions correctly.
Check bag assembly is fitted securely.
J69
Check for fault code
Turn ignition key to 2 position (ignition on).
Connect battery lead and check SRS-lamp.
J70
If fault code is displayed
If a fault code is displayed, it is probable that battery has been connected and ignition switched on while bag assembly was removed, and special tool 8695 was not installed during operation.
How to clear fault codes can be found at Air Bag Systems.