Installation AC B22 Install the ignition switch in the bearing housing

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Gabriel Bond
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1 Installation AC B22 Install the ignition switch in the bearing housing Lubricate contact areas of bearing housing with bearing grease.

2 AC B23 Installing as applies to cars with ignition switch interlock Note! The following actions apply only to cars equipped with ignition switch interlock. Turn the ignition switch to position 1 or 2. Press cable into place in ignition switch. Ensure that the cable locking tabs are securely engaged in ignition lock.

3 AC B24 Install bearing housing with ignition switch in place in the car Install: Connector. The bearing housing with ignition switch. Donot tighten the screws yet.

4 AC B25 Installing as applies to cars with electronic immobilizer Note! The following action applies only to cars with electronic immobilizer. Install the antenna ring onto the ignition switch. Make sure the connector is securely connected. Install the panel around the ignition switch.

5 AC B26 Actions for replacing bearing housing for steering shaft bearing Note! The actions below are carried out only when replacing the steering shaft bearing to the new version with studs. (Replaces the earlier version as a replacement part.) Drill out the existing holes in the bodywork to 7.5 mm (x 3)

6 AC B27 Thread the steering shaft bearing onto the steering shaft Ensure that lower bearing is lubricated with bearing grease. (The illustration displays the early version bearing housing.) Replacing late version steering shaft bearing: Remove the rubber seal gasket backing.

AC B28 Install the steering column with spring and washer Install in the following order: Early version: Washer, spring, washer Late versions: Spring, washer AC B29 Install the spacer ring Note!

7 AC B28 Install the steering column with spring and washer Install in the following order: Early version: Washer, spring, washer Late versions: Spring, washer AC B29 Install the spacer ring Note! Ensure that the spacer ring is the latest version for the car chassis number. Caution! One of the spacer rings must be metal, Otherwise the horn will not function. AC B30 Insert the steering column down through the firewall Turn the ignition switch to position 1.

AC B31 Push up the steering column into the bearing housing AC B32 Install the circlip and spacer on the steering shaft Check that the upper spacer ring is of the right type for the car chassis

8 AC B31 Push up the steering column into the bearing housing AC B32 Install the circlip and spacer on the steering shaft Check that the upper spacer ring is of the right type for the car chassis number. There are different versions of spacer ring. Make sure circlip is positioned correctly in the groove. Install nuts (early version; screws) for the lower bearing in the firewall. Tighten nuts to5 Nm (3.7 ft.lb.).

9 AC B33 Install lower steering shaft Tighten upper screw to lower joint to24 Nm (17.7 ft.lb.). Install locking pin. Install the upper joint screw with a new locknut. Tighten to24 Nm (17.7 ft.lb.). Install locking pin.

10 AC B34 Check the function of the ignition switch and steering Pull off security screws. Check if there is play in the locating pin before tightening the locating pin screw. Use adjuster strip kit to adjust before tightening. Tighten locating pin screw.

11 AC B35 Installing contact reel Check that the locking screw is positioned in the contact reel as illustrated. If the locking screw is not in the locked position or if the locking screw is removed the contact reel must be zeroed, see operation according to AA C14 - AA C16. Note: A new contact reel is zeroed at the factory and supplied with the locking screw installed. "Zeroed" means that the steering wheel can be turned to full lock in either direction without damaging the contact reel.

12 AA C14 Zeroing contact reel Turn the contact reel as far as possible to the left AA C15 Turn contact reel to the right First turn the contract reel back three (3) full turns to the right. Then continue turning the contact reel in the same direction, a quarter (1/4) turn to the screw hole. The screw hole should be over the lock position which is "8 o'clock" as illustrated.

13 AA C16 Install screw in contact reel lock position The contact reel is now zeroed and locked (secured). AC B36 Install contact reel Install: connector (1-pin) for signal cable connector (2-pin) to SRS ignition cable. Install the new connector behind the dashboard. anchor plate. contact reel (2 x Torx 25 screws). Torque tighten contact reel to:2.5 Nm (1.8 ft.lb). apply contact grease to the horn contact ring to ensure good contact in the signal cable.

14 AC B37 Installing the steering wheel covers and switch Install: turn signal lamps and intermittent wiper switch onto steering shaft (4 x Torx: 25 screws). lower steering wheel cover (2 x Torx: 25 screws). upper steering wheel cover (2 x Torx: 10 screw). AC B38 Installing steering wheel Follow the description in AA C17 - AA C23 for installing the steering wheel. AA C17 Install steering wheel Caution! Do not turn the steering wheel when the contact reel is locked as the contact reel pin will break off.

15 Allow the cable and the plastic strip to pass through the hole in the steering wheel. Install the steering wheel straight, without turning it. Caution! The steering wheel must be installed in the correct position in relation to front wheel alignment. Check that steering wheel was installed straight. It the steering wheel was not installed straight, it mustnot be turned on the steering column. Remove steering wheel without turning it and try again.

16 AA C18 Install steering wheel screw Caution! Do not use any tool. Finger tighten the screw. The steering whee l must never be turned while the contact reel is locked. AA C19 Unlocking the contact reel Remove the screw from the locking position in the contact reel. Do not detach the screw from the plastic strip.

17 Zoom Sized for Print Install the screw into the parking hole in the steering wheel. The contact reel is now unlocked (unsecured) and the steering wheel can be turned. AA C20 Install special tool

18 AA C21 Connect battery negative lead AA C22 Checking alignment of steering wheel/front wheels Drive the car on a flat surface. Carefully turn the steering wheel and check that it can be turned to full lock in each direction. Check that the steering wheel is in the correct position in relation to the alignment of the front wheels, by slowly driving the car straight forwards and/or backwards. Warning! Do not drive the car further than necessary to check the alignment of the steering wheel/front wheels. The steering wheel is not properly tightened and the steering wheel module has been removed! If alignment steering wheel/front wheels is OK: Continue with next operation. Tightening steering wheel center screw AA C23. If the steering wheel is not straight: Adjust so that the front wheels are straight according toremoval, Adjusting the front wheels AA C7 - AA C8. Remove steering wheel and lock contact reel according toremoval, Removing steering wheel AA C9 - C13. Then continue with Installing steering wheel AA C17 - AA C23. If the steering wheel will not turn to full lock: Adjust so that the front wheels are straight according toremoval, Adjusting the front wheels AA C7 - AA C8.

19 Remove steering wheel and lock contact reel according toremoval, Removing steering wheel AA C9 - AA C13. Zero contact reel according toinstallation, Zeroing contact reel AA C14 - AA C16. Then continue with Installing steering wheel AA C17 - AA C23.. AA C23 Tighten steering wheel screw When the steering wheel is straight Tighten the steering wheel center bolt (with 18 mm socket wrench). Tightening torques 34 Nm (25.1 ft.lb). AC B39 Installing airbag steering wheel module Follow the description in AA C24 - AA C33 for installing steering wheel module. AA C24 Installing steering wheel module Ignition off Warning! The battery must not be connected when the steering wheel module is removed or installed.

20 AA C25 Disconnect battery negative lead AA C26 Remove special tool Warning! Under no circumstances use an ohmmeter or other live measuring instrument to take readings on a disconnected, non-deployed airbag module. This could deploy the airbag!

21 AA C27 Turn the ignition switch to position 1 so that the steering wheel lock is unlocked

22 AA C28 Install the steering wheel module

Place the lower edge of the steering wheel module on the steering wheel (1) Connect SRS ignition cable connector the module (2). Fold module up into the steering wheel (3).

23 Place the lower edge of the steering wheel module on the steering wheel (1) Connect SRS ignition cable connector the module (2). Fold module up into the steering wheel (3). Check that the SRS ignition cable is not trapped. AA C29 Install module screws Install screws (2 x Torx 30) in countersunk holes in steering wheel. Turn the steering wheel to access the screws. Tightening torques steering wheel module in steering wheel = 8 Nm (5.9 ft.lb). Caution! Tighten the right screw first. This is important for the operation of the signal horn.

24 AC B40 Install soundproofing panel/knee bolster Replace knee bolster. M6 tighten to 8 Nm (5.9 ft.lb), M8 tighten to 20 Nm (14.8 ft.lb). (Install the lighting connector in the soundproofing panel if removed.) Install soundproofing panel (Torx 25). Hint: Test function of steering shaft and ignition switch, adjust if necessary. AC B41 Final check after reinstalling removed components Follow the description in AA C30 - AA C33 for the final check. Final check Warning! Ensure that nobody is in the car when the battery is being connected. AA C30

25 Turn the ignition key to position 2 AA C31 Then connect battery negative lead AA C32 Check any diagnostic trouble codes (DTCs) Read off SRS diagnostic trouble codes (DTCs) according to Service Manual for the appropriate SRS system, depending on the model year of the car. AA C33 Check function Check that the steering wheel can be turned easily. Check that the signal engages. AC C. Replacing ignition switch ( ) Note! For cars from the 1988 model year and later a protective panel has been introduced. The protective panel is positioned behind the dashboard and has been introduced to increase anti-theft protection. If the car is equipped with protective panel the ignition switch replacement is carried out according to the description under the method for replacing steering column and ignition switch. See:

26 - AC A. Replacing steering column and ignition switch, without SRS system. - AC B. Replacing steering column and ignition switch, with SRS system. AC C1 Removing ignition switch Remove soundproofing panel under the dashboard. Detach connector from ignition switch. Remove upper steering column cover and the panel by the ignition switch. Slacken off screw holding ignition switch. Insert the key into the ignition switch and turn to the starting position Press the catch in through the hole in the holder with an appropriate implement and remove the lock.

AC C2 Installing ignition switch Install as follows: insert key into lock, turn, push the catch in and remove the key. place lock into opening, release the catch by inserting the key again.

27 AC C2 Installing ignition switch Install as follows: insert key into lock, turn, push the catch in and remove the key. place lock into opening, release the catch by inserting the key again. tighten the locking screw and test the function. Later version 940: Tap in a new blind cover plug over catch. Reinstall steering wheel cover and panel by ignition switch. Connect connector to ignition switch. Reinstall soundproofing panel under dashboard.

J2 Remove sound insulation/knee guard 1 and side panel 2 on center console

J1 Preparations Drive car forward on a level surface so that wheels are straight. Disconnect battery negative lead. Turn ignition key to position 1 so that steering lock is off. J2 Remove sound insulation/knee