Subject:
Installation of the steering column assembly
Vehicles:
| Astra-G with the following VINs : | |
|---|---|
| Antwerp | W5 244 165 - X5 033 674 (LHD) |
| W5 244 165 - X5 042 914 (RHD) | |
| Bochum | W2 216 529 - X2 043 456 |
| Ellesmere Port | W8 083 824 - X8 017 752 |
| Eisenach | W6 148 352 - X6 021 100 |
Condition:
The operation "Steering Column Assembly, Remove and Install" for the above vehicles has been extended due to constructive modifications.
Important:
The following instructions must be carried out in the stages specified, otherwise damage may be caused to the lower steering column support.
To remove:
Removal of the steering column is described in the Service Instructions, Astra-G, group M, under "Steering Column Assembly, Remove and Install".
To install:
Before re-inserting the steering column assembly, screw in the clamp bolt (2) on the crossmember (1) until only the bolt head projects from the steering column bracket.
| Then carefully insert the steering column assembly to stop in the crossmember - ensure that attaching parts and wiring harnesses are not damaged. | |||
|---|---|---|---|
| .P. G3758.tif | 9 | 7,5 | tiff;; |
Important:
In contrast to the description in the Service Instructions, the clamping effect of the steering column bracket must be determined with shims. To do so, push the shims in between the steering column bracket and the crossmember.
The shims are available in two different thicknesses (0.4 and 1.6 mm) - see parts list.
Determination is performed in 0.4 mm increments - beginning with an overall thickness of 4.0 mm. The overall thickness and the relevant number of shims required are listed in the following selection table:
| Shim thickness in mm | Number of shims | ||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|
| 0.4 | 2 | 1 | - | 3 | 2 | 1 | - | 3 | 2 | 1 | - |
| 1.6 | 2 | 2 | 2 | 1 | 1 | 1 | 1 | - | - | - | - |
| Total thickness | 4.0 | 3.6 | 3.2 | 2.8 | 2.4 | 2.0 | 1.6 | 1.2 | 0.8 | 0.4 | 0.0 |
Determination of the clamping effect
Note:
Both upper fastening bolts on the steering shaft must not yet be installed.
Beginning with an overall thickness of 4.0 mm, insert all 4 shims (1) (see parts list) together from below between the steering column bracket and the crossmember and tighten the clamp bolt - tightening torque 22 Nm/16 lbf. ft.
Then push the steering shaft with moderate lever effort (axially) in the direction of the arrow. If the grey guide sleeve (2) is thereby moved, release the clamp bolt and remove one shim (0.4 mm).
Re-insert shims (3.6 mm) and tighten clamp bolt - 22 Nm/16 lbf. ft. Push steering shaft back in direction of arrow, thereby noting the grey guide sleeve. Conduct this operational procedure (reducing the overall thickness of the shims) until the guide sleeve stays in the installation position.
| The steering column assembly can be installed as described in the Service Instructions once it is no longer possible to push the steering column with moderate lever effort. | |||
|---|---|---|---|
| .P. L0839.tif | 9 | 16 | tiff;; |
Parts:
| Part No. | Catalogue No. | |
|---|---|---|
| Shim set | 9 192 728 | 90 09 005 |
| Adjustable steering column 1) | 9 156 194 | 09 00 478 |
| Non-adjustable steering column 1) | 9 156 193 | 09 00 477 |
| Intermediate shaft (LHD) | 9 156 188 | 09 05 116 |
| Intermediate shaft (RHD) | 9 156 189 | 09 05 117 |
| 1) | up to the following VINs : | |
| Antwerp | X5 000 001 | |
| Bochum | X2 000 333 | |
| Ellesmere Port | X8 000 001 | |
| Eisenach | X6 000 001 | |
| the intermediate shaft must also be replaced. |
Time Allowances:
| M 0191 00 | Steering Column Assembly, Remove and Install | .7 hrs | |
|---|---|---|---|
| TC: 02, 11, 27, 40 | |||
| +: Transfer intermediate shaft | |||
| Add: | |||
| 008 | Determine axial play with shims | .3 hrs |
Important:
The specified time allowances do not include the time allowance for the vehicle set-up of .2 hrs.
For reimbursement of the vehicle set-up time of .2 hrs in warranty claims, enter the authorisation code ”T” and increase the main operation time allowance by .2 hrs.