Orlando

Steering Gear Replacement - Electronic Power Steering

Special Tools

For equivalent regional tools, refer to Special Tools .

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System .
2. Turn the front wheels to the straight forward position and secure the steering wheel from moving.



3. Remove and DISCARD the lower steering intermediate shaft bolt (1).
4. Remove the steering intermediate shaft from the steering gear.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
6. Remove the tyre and wheel assemblies. Refer to Tyre and Wheel Removal and Installation .
7. Remove the front compartment insulator, if equipped. Refer to Front Compartment Insulator Replacement .
8. Remove the exhaust front pipe. Refer to Exhaust Front Pipe Replacement : 2.0L Diesel LNP → LDE, LLU, LXT, LXV, L2W, 2H0, LFH .
9. Loosen the steering linkage outer track rod from the steering knuckle. Refer to Steering Linkage Outer Track rod Replacement .



10. Remove the lower stabiliser link shaft nut (2) on both sides.
11. Remove the stabiliser shaft link (1) from the stabiliser shaft.
12. Remove the stabiliser link shaft (1) from the stabiliser.



13. Remove the 2 fasteners (1) of the engine side cover on both sides.



14. Remove the 4 fasteners (1) of the front engine compartment cover.



15. Remove the front (1) and the rear (2) transmission mount bracket bolts.



16. Remove the 2 rear suspension frame bolts (2).

Remove rear frame reinforcements (1).

17. Assemble the CH-49289 adapter, for the assembly use attached installation manual.



18. Position and set the hydraulic lifter in connection with CH-904 frame and CH-49289 adapter (2) onto the suspension frame (1). Bend the front cover aside.
19. Lower the suspension frame max. 55 mm (2.165 in).




Note: Connector catches are difficult to access

20. Disconnect the electrical connector (3).

20.1.

Release the lock (2) by moving in direction of the arrow, use suitable screwdriver.

20.2.

Push down the latch (1) and pull off the electrical connector, use suitable screwdriver.




21. Disconnect the electrical connector (2).

21.1.

Gently lift latch (3), using angled screwdriver.

21.2.

Pull off the electrical connector (2).

22. Disconnect the electrical connector (1).

22.1.

Gently lift latch (4), using angled screwdriver.

22.2.

Pull off the electrical connector (1).




23. Carefully disconnect the 2 wiring harness plugs (3) from the steering gear with a suitable tool.
24. Remove the 2 wiring harness bracket bolts (4).
25. Remove the bracket (2) from vehicle.
26. Remove the wiring harness retainer (1) from the steering gear.



27. Remove and DISCARD the 2 right stabiliser shaft (1) insulator clamp bolts (2).

Suspend the stabiliser shaft (1) to body.




28. Remove and DISCARD the 2 steering gear bolts (4) and nuts (1, 3) from the front suspension frame.
29. Carefully remove the steering gear (2) through the right wheel house.
30. Replace the assembly parts if necessary:

•	Replace the outer tie rod. Refer to Steering Linkage Outer Track rod Replacement .

•	Replace the inner tie rod. Refer to Steering Linkage Inner Track Rod Replacement : Electronic Power Steering → Hydraulic Power Steering .

•	Replace the steering gear boot. Refer to Steering Gear Boot Replacement .

Caution: Ensure that the steering column dash seal is installed properly onto steering gear rack pinion housing. The sealing lip MUST rest on lower steering column cover surface evenly. To ease installation of the seal, apply liquid soap to the sealing lip. After installation, verify that the seal lip does not protrude into the vehicle's interior. Improper installation could result in poor sealing performance and water intrusion into the vehicle.

Note: Check correct wiring routing in order to assure correct installation.

1. Carefully insert the steering gear (2) through the right wheel house and position the steering gear into installation position.

Caution: Refer to Fastener Caution in the Preface section.

Caution: Refer to Torque-to-Yield Fastener Caution in the Preface section.

2. Tighten the NEW steering gear bolts (4) and nuts (1, 3) a first pass to 110 N·m (81 lb ft).
3. Tighten the NEW steering gear bolts and nuts a final pass to an additional 150 to 165 degrees, using the EN-45059 meter .



4. Install and tighten the 2 wiring harness bracket bolts (4) to 9 N·m (80 lb in).
5. Tighten the wiring harness retainer (1) to the steering gear.




Note: Connector catches are difficult to access.

6. Connect the electrical connector (1) until you hear it clicks.
7. Connect the electrical connector (2) until you hear it clicks.




Note: Connector catches are difficult to access.

8. Connect the electrical connector (3) until you hear it clicks.
9. Push back the lock (2) in opposite direction of the arrow until you hear it clicks.



10. Position the stabiliser shaft (1) and the bracket onto the suspension frame.
11. Install and tighten the NEW right stabilizer shaft insulator clamp bolts (2) a first pass to 22 N·m (16 lb ft).

Caution: Refer to Torque-to-Yield Fastener Caution in the Preface section.

12. Tighten the NEW stabilizer shaft insulator clamp bolts a final pass to an additional 30 degrees, using the EN-45059 meter .



13. Move out the positioning pins (1) of CH-49289 adapter.



14. Raise the frame (1) carefully, using CH-49289 adapter (2).




Note: Do NOT reuse old bolts

15. Install the frame reinforcements (1).
16. Install the 2 frame rear bolts (2) and tighten to 160 N·m (118 lb ft).



17. Install the front transmission mount bolt (1) and tighten to 100 N·m (74 lb ft).
18. Install the rear transmission mount bracket bolt (2) and tighten to 100 N·m (74 lb ft).



19. Install and tighten the 2 fasteners (1) of the engine side cover on both sides.



20. Install and tighten the 4 fasteners (1) of the front engine compartment cover.
21. Install the front compartment insulator, if equipped. Refer to Front Compartment Insulator Replacement .
22. Install the exhaust front pipe. Refer to Exhaust Front Pipe Replacement : 2.0L Diesel LNP → LDE, LLU, LXT, LXV, L2W, 2H0, LFH .
23. Tighten the steering linkage outer track rod to the steering knuckle. Refer to Steering Linkage Outer Track rod Replacement .



24. Install and tighten the lower stabiliser link shaft nut (2) on both sides to 35 N·m (26 lb ft).
25. Lower the vehicle.

Caution: Refer to Torque-to-Yield Fastener Caution in the Preface section.




26. Install the NEW lower intermediate steering shaft bolt and tighten a first pass to 25 N·m (18 lb ft).
27. Tighten the NEW lower intermediate steering shaft bolt a final pass to an additional 180 to 195 degrees, using the EN-45059 meter .
28. Install the tyre and wheel assemblies. Refer to Tyre and Wheel Removal and Installation .
29. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System .
30. Check and adjust the wheel alignment. Refer to Wheel Alignment Measurement .
31. Centre the steering angle sensor and learn the softened stops. Refer to Power Steering Control Module Calibration .
32. Program the power steering control module. Refer to Power Steering Control Module Programming and Setup .
33. Program volatile memory. Refer to Volatile Memory Programming .