Defender. Manual — part 54
6. Secure the drop arm nut using the lock washer.
7. Remove the steering gear assembly from the vice.
8. NOTE: Install new bolts and tab washers.
With assistance, install the steering gear.
Install the tab washers.
Install the steering gear bolts and tighten to 65 Nm (48
lb.ft).
9. Secure the steering gear bolts using the tab washers.
10. Install the tie bar to the steering gear.
Loosely install the nuts and bolts.
11. Tighten the tie bar to panhard rod mount bracket nut to 83
Nm (61 lb.ft).
12. Tighten the tie bar to steering gear nuts and bolts to 85
Nm (63 lb.ft).
13. Secure the drag link to the drop arm.
Install the nut and tighten to 40 Nm (30 lb.ft).
Install the split pin.
14. NOTE: Install new nuts.
Install the panhard rod.
Tighten the nuts and bolts to 230 Nm (178 lb.ft).
15.
CAUTION: If power steering fluid comes into contact
with the paintwork, the affected area must be immediately
washed down with cold water.
• NOTE: Inspect the O-ring seal, if there is any indication of
damage install a new seal.
Connect the PAS feed pipe to the steering gear.
Tighten to 20 Nm (15 lb.ft).
16.
CAUTION: If power steering fluid comes into contact
with the paintwork, the affected area must be immediately
washed down with cold water.
• NOTE: Inspect the O-ring seal, if there is any indication of
damage install a new seal.
Connect the PAS return hose to the steering gear.
Tighten to 15 Nm (11 lb.ft).
17. Check the alignment and install the steering column lower
shaft to the steering gear.
Install the steering column lower shaft lower bolt and
tighten to 22 Nm (16 lb.ft).
18. Tighten the steering column lower shaft upper bolt to 22
Nm (16 lb.ft).
19. Remove the centralizing bolt from the steering gear.
20. Refill and bleed the PAS system.
For additional information, refer to: Power Steering System
Filling and Bleeding (211-00 Steering System - General
Information, General Procedures).
Power Steering - Power Steering Fluid Reservoir
Removal and Installation
Removal
1. Position drain tin beneath reservoir.
2. Slacken mounting bracket clamp bolt and raise reservoir to
gain access to feed and return hose retaining clips.
3. Slacken clips, disconnect hoses from reservoir, allow fluid to
drain.
4.
CAUTION: Plug connections to prevent ingress of dirt.
Discard fluid drained from system. Do not allow fluid to
contact paintwork, if spilled, remove fluid and clean area with
warm water.
Remove reservoir.
Installation
1. Position reservoir, connect feed and return hoses and tighten
clips to 3 Nm (2 lbf/ft).
2. Fit reservoir in clamp, tighten clamp bolt.
3. Fill reservoir between upper mark and end of dipstick with
power steering fluid.
For additional information, refer to:
Specifications
(211-00
Steering System - General Information, Specifications).
4. Bleed power steering system.
For additional information, refer to:
Power Steering System
Filling and Bleeding
(211-00 Steering System - General
Information, General Procedures).
Power Steering - Power Steering Pump
Removal and Installation
Removal
1. Disconnect the battery ground cable.
For additional information, refer to:
Battery Disconnect and
Connect
(414-01 Battery, Mounting and Cables, General
Procedures).
2. Remove the cooling fan.
For additional information, refer to:
Cooling Fan
(303-03
Engine Cooling - 2.4L Duratorq-TDCi HPCR (103kW/140PS) -
Puma, Removal and Installation).
3. Release the tension from the accessory drive belt.
Rotate the accessory drive belt tensioner clockwise.
4.
WARNING: Do not work on or under a vehicle
supported only by a jack. Always support the vehicle on safety
stands.
Raise and support the vehicle.
5. CAUTIONS:
Make sure that the area around the component is clean
and free of foreign material.
Make sure that all openings are sealed. Use new
blanking caps.
If power steering fluid comes into contact with the
paintwork, the affected area must be immediately washed
down with cold water.
Disconnect the power steering high-pressure pipe union.
Remove and discard the O-ring seal.
6. Remove the 2 bolts from the power steering pump.
7. Release the power steering fluid reservoir.
7. Release the power steering fluid reservoir.
Remove the 2 nuts.
8. Disconnect the power steering fluid reservoir supply hose.
Release the clip.
9. Remove the power steering pump.
Remove the bolt.
Installation
1. Install the power steering pump.
Tighten to 23 Nm (17 lb.ft).
2.
CAUTION: A 15 mm gap, or greater, must exist
between the power steering pump pulley and the hose, at the
rearmost edge of the pulley. Adjust the hose if required.
Connect the power steering fluid reservoir supply hose.
Secure the clip.
Check that the correct gap exists between the power
steering pump pulley and the hose.
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