Vauxhall ASTRA Owner's Manual page 202

correctly aligned with each other. Note that if
the shaft and column are not aligned
correctly, it will be impossible to insert the
clamp bolt. Insert the clamp bolt and tighten
securely.
24 Refit the air vent duct and footwell panels,
and clip the wiring loom channel to the
steering column. .
25 Refit the immobiliser/transponder unit to
the steering column using a reversal of the
removal procedure. On models with an
immobiliser/transponder without catch lugs,
refit the ignition lock cylinder as described in
Chapter 12, Section 4, then clip the unit onto
the ignition lock housing. On models with an
immobiliser/transponder with catch lugs, clip
the unit onto the ignition .Iock housing , then
refit the ignition lock cylinder as described in
Chapter 12. Where necessary, reconnect the
wiring then refit the protective cap.
26 Refit the column cover and tension
springs.
27 With the ignition key inserted in the
'Accessories' position, refit the ignition switch
to the steering lock housing, making sure that
theclip engages correctly.
28 Remove the ignition key then refit the
circular trim for the immobiliser/transponder.
29 Refit the indicator and wiper switches to
the housing on the column with reference to
Chapter 12, Section 4.
30 Refit the airbag contact unit to the
steering column making sure that the guide
pins enter the ir holes correctly and the
retaining clips are engaged correctly. Note: It
is important that the retaining clips are fully
engaged. If they are damaged in any way, the
complete contact unit must be renewed.
31 Carefully refit the wiring plug to the top of
the contact unit.
32 Refit the lower steering column shroud
followed by the upper shroud, and secure
with the retaining screws.
33 Refit the knob to the column adjuster lever
and tighten the screw.
34 Refit the steering wheel with reference to
Section 17.
19 Steering column
intermediate shaft -
removal and 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 footwell panels and air vent
duct from the driver'S footwell.
3 Mark the steeri.ng column intermediate
shaft upper and lower jOints in relation to the
steering column and steering gear piniori as
an aid to refitting, then unscrew both clamp
bolts (see illustrations).
4 Compress the telescopic intermediate shaft
and slide the joints from the column and
19.3a Intermediate shaft joint connection
to the steering gear pinion
pinion (see illustration). Withdraw the
intermediate shaft from inside the vehicle.
Inspection
5 Inspect the intermediate shaft universal
joints for excessive wear or damage. If either
joint is worn or damaged, the complete shaft
assembly must be renewed .
Refitting
6 Check that the front wheels and steering
wheel are still in the straight-ahead position,
and that the steering wheel is still locked.
7 Slide the intermediate shaft lower joint onto
the steering gear . pinion, aligning the
previously-made marks. Note that it will not
be possible to insert the clamp bolt if the
splines are not correctly aligned. Apply a little
locking fluid to the threads of the clamp bolt,
then insert it and tighten to the specified
torque.
8 Slide the upper end of the intermediate
shaft onto the column splines, aligning the
previously-made marks. Insert the clamp bolt
and tighten securely.
9 Refit the air vent duct and footwell panels to
the driver's footwell .
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20 Steering gear rubber gaiters ~
-renewal
~
"
1 Remove the relevant track rod end as
described in Section 24.
2 Remove the inner and outer securing clips
20.2 Outer clip for· the steering gear
rubber gaiter
Suspension and steering 10-15
19.3b Intermediate shaft joint connection
to the steering column
19.4 View of the pinion (steering gear
removed from the vehicle)
(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 24 .
. 6 Have the front wheel toe-setting checked
and adjusted at the earliest opportunity.
21 Steering gear -
removal and 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 4.
3 On LHD models, unbolt the rear engine
mounting bracket from the subframe.
4 Where fitted, uribolt the support bracket for
the pressure and return lines from the
10
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).
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