Procedures

Replacing The Steering Column/Steering Shaft/Seal/Bearing/Lower Steering Shaft Joint

Special Tools: 998 8695

Removal

Preparation

CAUTION: The battery must not be connected when the steering wheel module is removed or installed.

Disconnect the battery negative lead.

Turn the ignition switch to position I so that the steering wheel lock is disengaged.

Slacken off both the two torx screws (TX30) on the reverse of the steering wheel. Turn the steering wheel 90 degree in both directions to access the screws.

Disconnect the connector and lift off the steering wheel module.

Remove the locking screw for the contact reel for the SRS system from its parking hole. The screw must always remain in the plastic strap.

Removing the steering wheel

- Remove the steering wheel screw.
- Ensure that front wheels are pointing straight ahead.
- Lift off the steering wheel.

NOTE: Ensure that neither the connector nor the plastic strap with the locking screw catch in the steering wheel when its is lifted off.

Removing the cross member or the knee bolster

Removing the cross member (certain markets only)

- Remove the screw (1), separate the connector (2). Remove the soundproofing panel.
- Remove the polystyrene protection on the cross member.

- Push the floor carpet to one side. Remove the carpet bracket.

- Release the 2 screws from the cables by the left side of the cross member.
- Pull off the front door sill trim.
- Remove the screw. Carefully hold the panel to one side and remove the screws for the cross member.

- Remove the screws and nuts
- Remove the cross member.

Removing the knee bolster (certain markets only)

- Push the floor carpet to one side. Remove the carpet bracket.

- Remove the soundproofing panel.
- Remove the knee bolster.

Removing the steering column covers

- Remove the three screws from the lower steering column cover.
- Pull up the upper steering column cover.
- Remove the lower steering column cover.
- Remove the upper steering column cover from snap fasteners in the rubber collar.

SRS system

- Remove the SRS contact reel (three screws)
- Disconnect the connectors from the contact reel.
- Remove the control stalks. Disconnect the connectors from the control stalks.

Locking the contact reel
- Lock the contact reel in the "1 O'clock" position using the locking screw.
- Coat the slip ring surface using a thin layer of low-temperature grease, P/N 1161417-9.

Connector

- Disconnect the right connector from the bracket located over the steering column.
- Disconnect the connector for the ignition switch.
- Disconnect the connector for the immobilizer (where applicable).

Control module

Remove the control module for the immobilizer (where applicable).

The connectors and wiring harness

- Disconnect the connectors the from stop lamp switch and the accelerator pedal (AP) module.
- Remove the wiring from the steering column and the accelerator pedal (AP) module.
- Disconnect the cable trunk from the steering column and place it to one side.

Removing the mechanical cable for the ignition switch interlock

Remove the ignition switch interlock cable. (Applies to cars with automatic transmission.)

First turn the ignition key to position 1. Use flat nosed pliers on the cable. Press the lock hooks together and withdraw the cable from the ignition switch.

Steering shaft

Remove

- the screw securing the mounting for the lower steering shaft in the joint
- the joint from the lower steering shaft.

Removing the push rod

Remove the push rod from the brake pedal.

Removing the steering column

NOTE: The steering wheel lever for height adjustment must point along the steering shaft.

- Keep the brake pedal depressed the whole time.
- Remove both the screws holding the steering column.
- Remove the threaded plate.
- Remove the bracket located over the steering column.

NOTE: Do not damage the dashboard when removing the steering column.

- Detach the steering column from its guides.
- Move the steering column downwards and forwards at an angle. At the same time turn the steering column clockwise, so that the lower end is at the lowest point of the floor, just in front of the accelerator pedal (AP) beside the transmission tunnel.

Transferring components

Transfer
- the bracket for the immobilizer
- the lever for the adjusting the steering wheel height
- the steering wheel lock.

Transferring the bracket for the immobilizer
- Drill out the blind rivet.
- Transfer the bracket. Use a new blind rivet.

Transferring the lever for steering wheel height adjustment
- Fold down the lever.
- Remove the clamp holding the lever. Use a screwdriver.

NOTE: Do not damage the plastic handle.

- Transfer the lever. Install a new clamp.

Transferring the steering wheel lock
- Make a punch mark in the screws.
- Drill out the screws. First use a 3 mm drill bit. Then use a 8 mm drill bit.
- Transfer the steering wheel lock. Install the new security screws.
- Tighten the screws until the screw heads break off.

Installing the steering column

NOTE: The steering wheel lever for height adjustment must point along the steering shaft.

- Keep the brake pedal depressed the whole time.
- Position the steering column with the lower end at the lowest point of the floor just in front of the accelerator pedal (AP) beside the transmission tunnel.
- Move the steering column upwards and backwards at an angle. At the same time turn the steering column clockwise.
- Hook the steering column in to place in the guides.

Finishing

Install the push rod on the brake pedal and lock it using the clip.

Installing the bracket, threaded plate and screws

Install

- the bracket over the steering column
- the threaded plate
- the screws holding the steering column in the cowl panel. Tighten by hand
- the joint for the lower steering shaft
- a new screw and nut for the lower steering shaft mounting in the joint. Tighten to 30 Nm.

Tighten both the screws holding the steering column. Tighten to 50 Nm.

Installing the cable trunk and connectors

Install

- the cable trunk on the steering column
- the connectors for the stop lamp switch and the accelerator pedal (AP) module.

NOTE: Do not forget the rubber which prevents the accelerator pedal (AP) module from loosening.

- Clamp the wiring as shown in the figure.

Installing the connectors

Install

- the connector on the bracket which is located over the steering column
- the connectors for the SRS system contact reel
- the contact reel
- the connectors on the control stalks
- the control stalks
- the connector for the immobilizer
- the connector for the ignition switch.

Installing the mechanical cable for the ignition switch interlock

Install the cable for the key lock cable. (Applies to cars with automatic transmission.)

Installing the control module

Install the control module for the immobilizer.

Installing the steering column covers

Install the steering column covers.

NOTE: Do not damage the plastic hinge between the steering column covers.

Installing the cross member or the knee bolster

Installing the cross member (certain markets only)

- Install the cross member and the screws. Tighten to 20 Nm.

- Install the screws on the left-hand side of the cross member. Tighten to 20 Nm.
- Secure the wiring using tie straps.
- Press the panel into place. Install the screw.
- Press the door sill trim in.

Install:

- the carpet bracket
- the carpet
- the polystyrene protection on the cross member
- the connector (2)
- the screw (1) and the soundproofing panel.

Installing the knee bolster (certain markets only)

Install:

- the knee bolster. Tighten to 20 Nm
- the soundproofing panel
- the carpet bracket. Fold the floor carpet back into place.

Locking the contact reel

- Install the contact reel.
- Coat the slip ring surface using a thin layer of low-temperature grease, P/N: 1161417-9.
- Connect the connector to the contact reel.

Installing the steering wheel

Install the steering wheel and check the steering wheel position

NOTE: Check that the front wheels are pointing straight ahead.

- Pull the connector from the SRS system contact reel through the steering wheel.
- Install steering wheel carefully until both catches on contact reel are seated in recesses in steering wheel hub.
- Install the screw for the steering wheel and finger-tighten.

CAUTION: Do not turn the steering wheel when it is on the steering column. The contact reel is locked. It will be damaged if the steering wheel is turned.

- Remove the locking screw for the contact reel and transfer it to the parking hole.
- Connect tool 998 8695 to the contact reel cable.
- Connect the battery negative lead.
- Drive the car straight ahead and check the steering wheel position. Repeat the adjustment if the steering wheel position is incorrect.

The steering wheel screw

- Tighten the screw in the center of the steering wheel. Tighten to 40 Nm.

- Switch off the ignition.
- Remove the battery negative lead and tool 998 8695.

Installing the steering wheel module

NOTE: The battery negative lead must be removed.

- Turn the ignition switch to position I so that the steering wheel lock is disengaged.
- Position the lower section of the steering wheel module against the steering wheel (1).
- Connect the connector (2).
- Fold in the steering wheel module (3).
- Secure the module by tightening the Torx screws from the rear. Start with the right-hand screw. Turn the steering wheel to gain access to the screws.
- Tighten the steering wheel module screws. Tighten to 10 Nm.
- Ensure that the steering wheel turns easily and that the steering lock functions.

CAUTION: First switch on the ignition. Then connect the battery negative lead.

WARNING: Ensure that nobody is in the car when the battery is being connected. This is a safety precaution in case the airbag should deploy.

Diagnostic Trouble Codes (DTCs)

Check for any diagnostic trouble codes (DTCs) using a VADIS station.