2007 MINI Cooper 2002-05 STEERING Steering Gear - MINI
2002-05 STEERING Steering Gear - MINI
POWER STEERING FLUID SPECIFICATIONS Use Pentosin CHF 11 S. BLEEDING Thoroughly clean the reservoir and the parts in its immediate vicinity before removing the oil reservoir cap. No dirt must enter the system. To top up with engine stationary: fill oil reservoir until the level reaches the "MAX" mark on the dipstick. Start engine. Turn steering wheel twice to left and right lock. Check oil level while engine is stopped. Top up hydraulic fluid to "MAX" mark.
REMOVAL & INSTALLATION POWER STEERING GEAR Removal & Installation
Remove wheels. Remove stabilizer link for stabilizer bar on left and right stabilizer bar. Draw off oil from steering fluid reservoir After completing work, carry out electronic wheel alignment check. See SPECIFICATIONS & PROCEDURES article. Bleeding power steering If the power steering gear is replaced on vehicles up to 05/03, both tie rods must also be replaced. Draw hydraulic fluid out of tank. Do not reuse. Release nuts and press tie rod ends out of steering knuckle with special tool (32 3 090). During installation, replace self-locking nuts. See Fig. 1 .
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2007 MINI Cooper 2002-05 STEERING Steering Gear - MINI
Fig. 1: Pressing Tie Rod Ends Out Of Steering Knuckle Courtesy of BMW OF NORTH AMERICA, INC. Release nut (1) and remove steering spindle from steering gear. During installation, replace self-locking nut. Detach high-pressure line (2) and low pressure line (3). See Fig. 2 . Close off pipe connections with plugs. Replace sealing rings.
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2007 MINI Cooper 2002-05 STEERING Steering Gear - MINI
Fig. 2: Detaching High & Low Pressure Lines Courtesy of BMW OF NORTH AMERICA, INC. Release screw (1). Release nut (2) and remove heat shield. Release nut (3) and remove bracket for pressure line. See Fig. 3 .
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2007 MINI Cooper 2002-05 STEERING Steering Gear - MINI
Fig. 3: Removing Heat Shield & Bracket For Pressure Line Courtesy of BMW OF NORTH AMERICA, INC. Release screws (1). During installation, take particular care when reinstalling to ensure that the clip for the rubber mount is fitted and aligned correctly. Pay attention to different screw length (1) for vehicles up to 05/03.
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2007 MINI Cooper 2002-05 STEERING Steering Gear - MINI
Fig. 4: Identifying Screws Courtesy of BMW OF NORTH AMERICA, INC. Swing stabilizer bar (1) upward. Turn control head of steering gear (2) downwards in direction of bulkhead and remove to left side. See Fig. 5 .
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2007 MINI Cooper 2002-05 STEERING Steering Gear - MINI
Fig. 5: Swinging Stabilizer Bar Upward Courtesy of BMW OF NORTH AMERICA, INC. STEERING GEAR GAITER (BOOT) Removal & Installation
Remove wheels. To avoid damage to rack and to suspension mounting, move rack in as far as possible. Clean rack and tie rod. Grease toothed area of rack. The steering gear must be replaced if the polished surface of the rack is damaged (rust). Release nut on tie rod end. Press out tie rod end with special tool. See Fig. 1 . Replace self-locking nut. Apply a color marking (1) to tie rod. See Fig. 6 . This simplifies the electronic wheel alignment check. Release lock nut and remove tie rod end and lock nut. Release remove gaiter. Replace tensioning straps.
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2007 MINI Cooper 2002-05 STEERING Steering Gear - MINI
Fig. 6: Applying Color Marking To Tie Rod Courtesy of BMW OF NORTH AMERICA, INC. Tie rods with lock screw connection, tighten to specification. See TORQUE SPECIFICATIONS . See Fig. 7 .
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2007 MINI Cooper 2002-05 STEERING Steering Gear - MINI
Fig. 7: Identifying Tie Rod With Screw Connection Courtesy of BMW OF NORTH AMERICA, INC. Tie rods with clamping ring screw, tighten to specification. See TORQUE SPECIFICATIONS . See Fig. 8 .
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2007 MINI Cooper 2002-05 STEERING Steering Gear - MINI
Fig. 8: Identifying Tie Rod With Clamping Ring Screw Courtesy of BMW OF NORTH AMERICA, INC. During installation, grease tie rod at taper (1). See Fig. 9 . This prevents the gaiter from rotating when the tie rod rotates. Fit gaiter and tensioning straps.
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2007 MINI Cooper 2002-05 STEERING Steering Gear - MINI
Fig. 9: Identifying Taper Courtesy of BMW OF NORTH AMERICA, INC. EAR HOSE CLAMPS Removal & Installation
To remove an ear hose clamp, place special tool (32 1 260) at right angles to ear and cut ear open. See Fig. 10 .
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2007 MINI Cooper 2002-05 STEERING Steering Gear - MINI
Fig. 10: Removing Ear Hose Clamp Courtesy of BMW OF NORTH AMERICA, INC. The ear hose clamp can be fitted not only axially but also radially after the hook fastener has been opened.
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2007 MINI Cooper 2002-05 STEERING Steering Gear - MINI
Fig. 11: Installing Ear Hose Clamp Courtesy of BMW OF NORTH AMERICA, INC. Attach hook fastener and press ear together with special tool (32 1 260). See Fig. 12 .
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2007 MINI Cooper 2002-05 STEERING Steering Gear - MINI
Fig. 12: Attaching Hook Fastener Courtesy of BMW OF NORTH AMERICA, INC. Side cutter of special tool (32 1 260) can be used in areas which are difficult to access. See Fig. 13 .
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2007 MINI Cooper 2002-05 STEERING Steering Gear - MINI
Fig. 13: Slide Cutter Of Special Tool Courtesy of BMW OF NORTH AMERICA, INC. Gap (A) maximum is 1 mm. See Fig. 14 .
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2007 MINI Cooper 2002-05 STEERING Steering Gear - MINI
Fig. 14: Identifying Gap (A) Courtesy of BMW OF NORTH AMERICA, INC. PRESSURE LINE Removal & Installation
Draw hydraulic fluid out of tank. Do not reuse. After completing tasks, bleed power steering system. See BLEEDING . Release screw (1) and disconnect line. Replace seal. Seal off line and catch escaping hydraulic fluid in a suitable container.
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2007 MINI Cooper 2002-05 STEERING Steering Gear - MINI
Fig. 15: Releasing Screw & Disconnecting Line Courtesy of BMW OF NORTH AMERICA, INC. Slacken nut (1).
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2007 MINI Cooper 2002-05 STEERING Steering Gear - MINI
Fig. 16: Slackening Nut Courtesy of BMW OF NORTH AMERICA, INC. Release return line (1) so that pressure line (2) can be released and removed. See Fig. 17 . Replace sealing rings.
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2007 MINI Cooper 2002-05 STEERING Steering Gear - MINI
Fig. 17: Identifying Return & Pressure Lines Courtesy of BMW OF NORTH AMERICA, INC. SUCTION LINE Removal & Installation
Draw hydraulic fluid out of tank. Do not reuse. After completing tasks, bleed power steering system. See BLEEDING . Follow procedure on removing and installing ear hose clamp. See EAR HOSE CLAMPS . Release hose clamp (1) on supply reservoir and disconnect line. See Fig. 18 .
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2007 MINI Cooper 2002-05 STEERING Steering Gear - MINI
Fig. 18: Releasing Hose Clamp On Supply Reservoir Courtesy of BMW OF NORTH AMERICA, INC. Release hose clamp (1) and disconnect suction line. Catch hydraulic fluid in a suitable container. See Fig. 19 .
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2007 MINI Cooper 2002-05 STEERING Steering Gear - MINI
Fig. 19: Releasing Hose Clamp & Disconnecting Suction Courtesy of BMW OF NORTH AMERICA, INC. RETURN LINE Removal & Installation
Draw hydraulic fluid out of tank. Do not reuse. After completing tasks, bleed power steering system. See BLEEDING . Detach line (1) from supply reservoir. See Fig. 18 . Release banjo bolt (1) and remove return line. See Fig. 20 . Seal steering gear with plugs. Catch emerging fluid in a suitable container.
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2007 MINI Cooper 2002-05 STEERING Steering Gear - MINI
Fig. 20: Releasing Banjo Bolt & Removing Return Line Courtesy of BMW OF NORTH AMERICA, INC.
TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Application Pressure Line To To Steering Gear Return Line To Steering Gear Steering Gear To Front Axle Carrier Tie Rod Clamping Ring Screw Connection Adjustment Nut Tie Rod End To Swivel Bearing Tie Rod Lock Nut Screw Connection Adjustment Nut Pressure Hose To Power Steering Pump Heat Shield To Steering Gear Bracket, Pressure Line High Pressure Line To Rubber Mount Pressure Hose To Steering Gear Clamp
Ft. Lbs. (N.m) 26 (34) 30 (40) 41 (56) 33 (45) 38 (52) 46 (63) INCH Lbs. (N.m) 89 (10) 71 (8) 71 (8) 71 (8)
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