Power Steering Gear
Power Steering Gear
Special tools, testers and auxiliary items required
• Hose Clamps Up to 25 mm dia. (3094)
• Bolt for Steering Centering (VAS 6224)
• Torque Wrench (V.A.G 1331)
• Torque Wrench (V.A.G 1332)
• Open Socket Insert SW 19 and SW 22 (commercially available)
Removing
- Remove plenum chamber cover.
- Disconnect battery and remove if necessary.
CAUTION!
Bring steering wheel into center position and do not turn during repairs because this may damaged airbag unit spiral spring.
- Remove ignition key with steering wheel in center position.
- Move steering wheel slightly to engage steering lock.
- 'Remove drivers side storage compartment.
- Loosen bolt - arrow -.
- Secure steering column against slipping apart => [ Securing steering column before
removal. ] Steering Column, secure steering column before removal.
• If bulkhead boot is damaged, a new one must be installed.
• Make sure that bulkhead boot is seated correctly.
- Clamp off suction and return line using Hose Clamps Up to 25 mm dia. (3094).
- Remove front wheels.
- Loosen suspension strut/control arm threaded connection (only on left side of vehicle)
- Position suspension strut - 1 - in front of control arm - 2 - as seen in direction of travel.
- Loosen nut - 1 -, remove hex head bolt and remove both control arms - 2 - upward (only on left side of vehicle).
The slits in the wheel bearing housing must not be widened using a chisel or similar tool!
- Remove hex head bolt - 3 - and remove threaded connection - 4 -.
- Remove tie rod downward out of steering arm or press out.
• Do not use a chisel or similar tool between steering arm - 1 - and tie rod ball joint sealing washer - 2 - when removing tie rod, otherwise sealing washer could be damaged.
• Tie rod may only be pressed off steering arm over tie rod ball joint pin ends or driven with a wooden or rubber hammer.
- Secure wheel bearing housing - 1 - at left with help of tensioning band - 2 - at suspension strut - 3 -.
- Remove panel nut - arrow -.
- Pry out clips.
- Disengage electrical line
- Remove plastic cover
- On 6- and 8-cylinder engines, shield on driver side must be removed. Refer to => [ Shield ] Shield.
• In order to remove shield on driver side with 6-cylinder engines, front catalytic converter must be removed.
• In order to remove shield on driver side with 8-cylinder engines, front exhaust pipe must be removed.
- Loosen bolt - 1 - approximately one turn
- Remove bolts - 2 - and - 3 -
- Swing steering gear on driver side forward in direction of travel
- Place a pan underneath to catch hydraulic oil.
- Remove return line banjo bolt (22 mm AF) from steering gear.
With certain engine-transmission versions, banjo bolt can only be loosened from wheel housing.
To do this, use an open socket insert SW 22 (commercially available).
- Remove pressure line banjo bolt (SW 19 mm) - arrow - from steering gear.
With certain engine-transmission versions, banjo bolt can only be loosened from wheel housing.
To do this, use an open socket insert SW 19 (commercially available).
- Remove bolt - 1 -.
- Take out steering gear through left-hand wheel housing (second technician required).
• Make sure that bulkhead boot is not damaged by steering gear pinion.
Installing
Center removed steering gear using Bolt for Steering Centering (VAS 6224).
- To do this, remove hex socket-head bolt - 1 - from steering gear.
- Move steering rack until centering position on rack - arrow - aligns with thread - 2 -.
- Hand-tighten Bolt for Centering Steering Centering (VAS 6224).
- Steering gear in area of bulkhead boot seat is lubricated with lubricant G 052 745 A3.
- Position steering gear at plenum chamber (2nd technician needed).
Make sure threads and contact surfaces of bolts are free of oil and grease.
- Position bolt - 1 - but do not tighten yet.
- Swing steering gear on driver side forward in direction of travel
- Install return hose and tighten banjo bolt - 2 - (SW 22)
- Install pressure hose and tighten banjo bolt with check valve - 1 - (SW 19).
• Always use new seals for banjo bolt.
• Pressure and return hose must not touch or come in contact with other parts!
With certain engine-transmission versions, banjo bolts can only be tightened from wheel housing.
To do this, use an open socket insert SW 19 or SW 22 (commercially available).
- Reinsert bulkhead boot while noting installation location.
Tab on bulkhead boot must align with marking on body.
• Replace damaged bulkhead boot if necessary.
• Make sure that bulkhead boot is seated correctly!
- Position bolt - 2 - but do not tighten yet.
- Install and fasten bolt - 3 -
- Now tighten bolts - 1 - and - 2 -
- Release steering lock.
- Bring steering wheel to center position then place universal joint on steering pinion.
- Tighten bolt - arrow -
- Remove mounting device from steering column.
- Install driver's side stowage compartment.
- On 6-cylinder engines, install shield on driver side. Refer to => [ Shield ] Shield.
- Install plastic cover in wheel liner.
- Engage electrical line.
- Insert both upper control arm joint pins in wheel bearing housing and bend downward as much as possible using Pliers (T40067 ).
- Insert new bolt - 2 - and self-locking nut and tighten
- Insert fork-head suspension strut in control arm and hand tighten threaded connection - 1 -.
Bonded rubber bushings have a limited torsional range. Only tighten threaded connections at control arms if vehicle is in curb weight position. Refer to => [ Wheel Bearing, Lifting to Curb Weight Position ] Rear Suspension
- Insert tie rod in steering arm to stop.
• Install tie rod in steering arm - 1 - only by hand and do not stress tie rod end seal - 2 - when doing so.
- Install threaded connection - 4 - and tighten nut.
- Install bolt - 3 - and tighten
- Remove Bolt for Steering Centering (VAS 6224) from steering gear.
1 Socket head bolt
2 Threaded bore in steering gear
- Seal the steering gear using the multi-point socket head bolt - 1 - => [ Steering centering: ] Power-Assisted Steering Gear Assembly Overview
- After completing installation of steering gear, remove Hose Clamps Up to 25 mm dia. (3094).
- Connect or install battery and install plenum chamber cover.
- Mount wheels and tighten.
- Tighten suspension strut/control arm threaded connection to specified torque
- Check power steering fluid level. Refer to => [ Power Steering, Checking Fluid Level ] Testing and Inspection.
- Bleed steering system. Refer to => [ Steering System, Bleeding after Reconstructing ] Service and Repair
- Check steering system for leaks. Refer to => [ Steering System, Checking for Leaks ] Steering System, Checking for Leaks.
- Perform vehicle alignment. Refer to => [ Wheel Alignment ] Wheel Alignment.
Alignment must take place on a VW/Audi recommended alignment stand.