Figure 16-1 - Diagram of fastening of pipelines of the power steering system of vehicles with the K7M engine: 1 - bracket for fastening the high-pressure pipeline to the bracket for fastening the mounted units; 2 - bracket for fastening the high-pressure pipeline to the hydraulic pump; 3 - bracket for fastening the high-pressure pipeline to the engine block; 4 - bracket with a groove for mutual orientation of low and high pressure pipelines; 5 bracket for fastening the low pressure pipeline to the steering gear; 6 - bracket for fastening the low pressure pipeline to the front suspension subframe; 7 - clamp for fastening the low pressure pipeline to the bracket of the electric fan of the engine cooling system
Figure 16-2 - Diagram of fastening of pipelines of the power steering system of vehicles with the K4M engine: 1 - clamp for fastening the low pressure pipeline to the bracket of the electric fan of the engine cooling system; 2 - bracket for fastening the high-pressure pipeline to the engine block; 3 - bracket with a groove for mutual orientation of low and high pressure pipelines; 4 - bracket for fastening the high-pressure pipeline to the pendulum support on the gearbox; 5 - bracket for fastening the low pressure pipeline to the steering gear; 6 - bracket for fastening the high-pressure pipeline to the gearbox housing 7 - bracket for fastening the low-pressure pipeline to the front suspension subframe
Low pressure line between power steering pump and reservoir
Removal
Place the vehicle on the work post, apply the parking brake and turn off the ignition.
Unscrew the cap of the power steering pump reservoir and pump out the working fluid (brush pump, process tank).
Loosen the clamp and disconnect the pipeline from the tank (pliers for elastic clamps Mot. 1202-02).
Loosen the clamp, disconnect the pipeline from the power steering pump and remove the pipeline (pliers for elastic clamps Mot. 1202-02).
Install plugs into the holes in the pipeline, tank and pump (technological plugs).
Installation
Remove the plugs from the opening of the pipeline, tank and pump.
Install the pipe onto the power steering pump nipple and secure with a clamp (pliers for elastic clamps Mot. 1202-02).
Install the pipeline onto the nipple of the power steering reservoir and secure it with a clamp (pliers for elastic clamps Mot. 1202-02).
High pressure line between power steering pump and steering gear
Removal
Place the vehicle on a two-post lift, apply the parking brake and turn off the ignition.
Remove the engine crankcase guard.
Install a clamp on the low pressure line of the power steering pump (clamp Ms. 583).
For cars with K7M engine
Disconnect the ignition system wiring harness connector from the pressure sensor.
Loosen the nipple and disconnect the high pressure line from the power steering pump (spanner 17).
Remove the right front wheel.
Remove the right side and lower mudguards from the front fender.
Loosen the bolt securing the pipeline to the bracket of the mounted units (replacement head 10, ratchet wrench).
Loosen the nut securing the pipeline to the engine block (replacement head 13, ratchet wrench, spanner 13).
Disconnect the pipe fitting from the steering gear and remove the pipe (spanner 17).
Install plugs into the openings of the pipeline, pump and steering gear (technological plugs).
For cars with K4M engine
Remove the fuel rail protection.
Disconnect the ignition system wiring harness connector from the pressure sensor.
Loosen the bolt securing the pipeline to the cylinder block (replaceable head 13, ratchet wrench).
Loosen the nipple and disconnect the high pressure line from the power steering pump (spanner 17).
Remove the left front wheel.
Remove the left side mudguard from the front fender.
Loosen the bolts securing the pipeline to the gearbox and to the gearbox pendulum support (replaceable head 13, ratchet wrench).
Loosen the heat shield mounting bolts and remove the steering gear heat shield (replaceable head 13, ratchet wrench).
Disconnect the pipe fitting from the steering gear and remove the pipe (spanner 18).
Install plugs into the openings of the pipeline, pump and steering gear (technological plugs).
Installation
Attention. The sealing rings in the pipe fitting connectors must be replaced when removing the pipes. Reuse of sealing rings is not permitted.
Remove plugs from the pipe opening, pump and steering gear.
Install a new sealing ring and connect the high pressure line fitting to the steering gear. Tightening torque of the nipple 21 N·m (2.1 kgf·m) (spanner 17, replaceable insert 17 type 58 21 10 17 f. "Stahlwille", torque wrench type 50 18 00 04 f. "Stahlwille").
Install a new sealing ring and connect the high pressure line fitting to the power steering pump. Tightening torque of the nipple 21 N·m (2.1 kgf·m) (spanner 17, replaceable insert 17 type 58 21 10 17 f. "Stahlwille", torque wrench type 50 18 00 04 f. "Stahlwille").
For cars with K7M engine
Secure the pipeline with a bolt to the bracket of the mounted units. Bolt tightening torque 21 Nm (2.1 kgf·m) (replacement head 10, ratchet wrench, torque wrench).
Secure the pipeline to the cylinder block with a bolt and nut. Nut tightening torque 21 Nm (2.1 kgf·m) (replaceable head 13, ratchet wrench, torque wrench, spanner 13).
Connect the ignition system wiring harness connector to the pressure sensor.
Install the right side and lower front fender mudguards.
Install the right front wheel.
For cars with K4M engine
Install the steering gear heat shield into place and secure with bolts. Tightening torque of bolts 21 Nm (2.1 kgf·m) (replaceable head 13, ratchet wrench, torque wrench).
Secure the pipeline with bolts to the gearbox and to the gearbox pendulum support. Tightening torque of bolts 21 Nm (2.1 kgf·m) (replaceable head 13, ratchet wrench, torque wrench).
Secure the pipeline with a bolt to the cylinder block. Bolt tightening torque 21 Nm (2.1 kgf·m) (replaceable head 13, ratchet wrench, torque wrench).
Connect the ignition system wiring harness connector to the pressure sensor.
Install fuel rail protection.
Install the left side mudguard of the front fender.
Install the left front wheel.
Operations for all vehicles (after installation of high pressure pipeline):
- remove the clamp from the low pressure line of the power steering pump;
- install engine crankcase protection.
Low pressure line between power steering reservoir and steering gear
Removal
Place the vehicle on a two-post lift, apply the parking brake and turn off the ignition.
Unscrew the cap of the power steering pump reservoir and pump out the working fluid (brush pump, process tank).
Remove the left front wheel.
Remove the left side mudguard from the front fender.
Remove the pipe from the holder on the housing of the electric fan of the engine cooling system.
Loosen the clamp, disconnect the pipeline from the power steering reservoir (pliers for elastic clamps Mot. 1202-02).
Remove the engine crankcase guard.
Loosen the bolt securing the pipeline to the front suspension subframe (replacement head 10, ratchet wrench).
For vehicles with K4M engine - unscrew the heat shield mounting bolts and remove the steering gear heat shield (replaceable head 13, ratchet wrench).
For vehicles with a K7M engine, remove the oxygen sensor wiring harness from the holder on the low-pressure pipeline.
Disconnect the pipe fitting from the steering gear and remove the pipe (spanner 17).
Install plugs into the holes in the pipe, tank and steering gear (technological plugs).
Installation
Attention. The sealing rings in the pipe fitting connectors must be replaced when removing the pipes. Reuse of sealing rings is not permitted.
Remove the plugs from the pipe opening, tank and steering gear.
Install a new sealing ring and connect the low pressure line fitting to the steering gear. Tightening torque of the nipple 21 N·m (2.1 kgf·m) (spanner 17, replaceable insert 17 type 58 21 10 17 f. "Stahlwille", torque wrench type 50 18 00 04 f. "Stahlwille").
Install the pipeline onto the nipple of the power steering reservoir and secure it with a clamp (pliers for elastic clamps Mot. 1202-02).
Install the pipe into the holder on the housing of the electric fan of the engine cooling system.
Secure the pipeline with a bolt to the front suspension subframe. Bolt tightening torque 21 Nm (2.1 kgf·m) (replacement head 10, ratchet wrench, torque wrench).
Install the left side mudguard of the front fender.
Install the engine crankcase guard.
Install the left front wheel.
For vehicles with K4M engine - install the steering gear heat shield in place and secure with bolts. Tightening torque of bolts 21 Nm (2.1 kgf·m) (replaceable head 13, ratchet wrench, torque wrench).
For vehicles with K7M engine - install the oxygen sensor wiring harness into the holder on the low pressure line.
General procedure for performing work on installing power steering pipelines.
Fill the power steering pump reservoir with working fluid (power Steering Oil Mobil ATF 52475).
Bleed the power steering system.
Start the engine and make sure the power steering system is tight; if an oil leak is detected, correct the problem.