Power Steering Gear
Power Steering Gear
Special tools, testers and auxiliary items required
• Hose clamps up to dia. 25mm (3094)
• Hose clamp pliers (V.A.G 1275)
• Torque wrench (V.A.G 1331)
• Torque wrench (V.A.G 1410)
• Shop Crane Drip Tray (VAS 6208)
Removing
• If removal is not done on a door free hoist, the driver door cannot be opened far enough to disconnect the steering column from the power steering gear. If that is the case, disconnect the steering column from the power steering gear first.
• Further on in the removal procedure, the battery will be removed. The vehicle cannot be driven after that.
- First position the vehicle centered in front of a hoist so it can be pushed onto the hoist later.
- Pull the steering column as far up and back as possible.
- Move the driver seat forward to the stop.
- Fold the floor covering back in the universal joint area.
- Remove the bolt - 2 - for the universal joint - 1 -.
- Place the vehicle on the hoist.
- Remove the bumper trim - 1 -.
- Remove the headlamp/wheel housing liner trim - 2 -.
- Remove the cowl panel trim - 3 -.
- Remove the luggage compartment trim - 4 -.
- Remove the battery.
- Remove the noise insulation - arrow -.
- Remove the front wheels.
- Remove the stabilizer bar. Refer to => [ Stabilizer Bar ] Stabilizer Bar.
- Remove the locking bolt - arrow - on the power steering gear.
- Center the steering gear. Refer to => [ Centering Steering ] Centering Steering.
- Remove the universal joint - 1 - from the intermediate shaft - 3 -.
CAUTION!
An assembly aid is required so that the upper and lower parts of the steering column do not pull apart when removing the power steering gear.
If the upper and lower parts of the steering column are pulled too far apart or pushed too close together, the splines separate.
There may be rattling later if the splines are not in their original installation position.
- Secure the universal joint - 2 - with a cable tie - A - to the steering column - 1 -.
- Loosen the nut - 1 - from the left and right tie rod ends but do not remove it.
- Press the tie rod ball joints off the wheel bearing housing with the (3287 A) and remove the nut.
- Disengage the tie rods.
- Open the rear lid.
- Remove the left engine compartment trim - arrow -.
- Clamp off the suction hose - 1 - and return hose - 2 - with (3094).
- Remove the bolt - 1 - for the refrigerant line - 2 -.
- Remove the nut - 1 - and clamps - 2 -.
- Place the drip tray under the power steering gear.
- Remove the banjo bolt - 2 - and pressure line - 1 -.
- Remove the banjo bolt - 3 - and return line - 4 -.
- Seal the power steering gear connections with clean plugs.
- Seal pressure line - 1 - and return line - 4 - with a clean, lint-free cloth or the like.
- Remove the bolts - 1 - and the clamp - 2 -.
- Remove the balancing element - 3 - and mount - 4 -.
- Remove the bolts - arrows - (quantity: 4).
- Remove bolts - Arrows -.
- Remove the power steering gear forward.
- Then pull the power steering gear to the left as far as the stop and, while somewhat horizontal, tip back.
- When removing the power steering gear, guide bellows - 1 - past body - 2 - and drive shaft - 3 -.
- Remove the power steering gear to the left. Guide the boot past the body and upper transverse link.
Only if the power steering gear will be replaced:
1. Intermediate shaft, remove.
2. Cover; replace if damaged.
3. Clamping sleeve, replace.
4. Bellows, replace if damaged.
5. Clamping sleeve, replace.
6. Seal (under the bellows); always replace.
Installing
Installation is performed in the reverse order of removal. Observe the following when doing so:
Tightening specifications, refer to => [ Power Steering Gear Assembly Overview ] Power Steering Gear Assembly Overview.
If the steering gear was replaced:
- Note the intermediate shaft installation location:
- Place the intermediate shaft - 1 - on the power steering gear input shaft - 2 - so the groove - arrow - is vertical over the marking - 3 -.
- Only tension clamping sleeve - 3 - when cover - 2 - is installed on the body.
Installation, Continued
- Align the balancing element - 3 - in the center of the mount - 4 - and in the clamp - 2 -.
- Align the balancing element - 3 - so the intersecting point faces up.
- Tighten the bolts - 1 - parallel.
- Secure the pressure line - 1 - and return line - 2 - on the power steering gear as shown in the illustration.
- Install the pressure line - 1 - with a new banjo bolt - 2 - and new seals.
- Install the return line - 4 - with a new banjo bolt - 3 - and new seals.
- Make sure the wires do not touch any other components.
- Remove the (VAS 6224) - 2 - and install the locking bolt - 1 -.
- Install the bolt - 1 - for the refrigerant line - 2 -.
- Install the clamps - 2 - and tighten the nut - 1 -.
- Install the tie rod ends on the wheel bearing housing. Refer to => [ Power Steering Gear Assembly Overview ] Power Steering Gear Assembly Overview.
- Remove the (3094) from the suction hose - 1 - and return hose - 2 -.
- Install stabilizer bar. Refer to => [ Stabilizer Bar ] Stabilizer Bar.
- Install noise insulation.
- Install the battery.
- Install the bumper trim - 1 -.
- Install the headlamp/wheel housing liner trim - 2 -.
- Install the cowl panel trim - 3 -.
- Install the luggage compartment trim - 4 -.
- Remove the cable ties.
- Install the bolt - 2 - for the universal joint - 1 -.
- Bleed the steering. Refer to => [ Steering System, Bleeding after Replacing ] Service and Repair.
- Check power steering fluid level. Refer to => [ Power Steering, Checking Fluid Level ] Power Steering, Checking Fluid Level.
- Check all open line connections for leaks. Refer to => [ Steering System, Checking for Leaks ] Steering System, Checking For Leaks.
- Axle alignment is required, see Table. Refer to => [ When Vehicle Alignment is Necessary ] Description and Operation.