Steering Gear, Through MY 2008
Steering Gear, through MY 2008
Special tools, testers and auxiliary items required
• Torque wrench (V.A.G 1331)
• Torque wrench (V.A.G 1332)
• Engine/transmission jack (V.A.G 1383 A)
• Ball joint puller (3287 A)
• Vehicle Diagnosis, Testing and Information System (VAS 5051)
Removing
• The generation 2 steering gear is no longer available as a replacement part.
• Install a generation 3 steering gear if replacing a steering gear.
• In addition to this, the electrical wiring set from the E-box to the steering gear must be changed. It will be included with the new steering gear.
• The electrical wiring set is delivered complete together with the wiring for the service interval display.
• If the vehicle does not have a service interval display, then the 3-pin connector, not being used, must be sealed off with a flat terminal housing with contact seal (1J0 973 803).
- Disconnect battery.
- Remove the nuts - arrows - and remove foot well trim - 1 -.
- Remove the bolt - 1 - and remove the universal joint - 2 - from the steering gear.
- Remove the front wheels.
- Loosen nut of track rod ball joint, but do not unscrew yet.
CAUTION!
To protect thread, screw nut on pin a few turns.
- Press off track rod ball joint from wheel bearing housing using (3287A) and now unscrew nut.
- Remove lower noise insulation.
- Remove coupling rods from stabilizer.
- Remove nuts - arrows -.
- Remove pendulum support from transmission, unscrew bolts - 13 - to do so.
- Remove bracket for exhaust system from the subframe.
- Remove bolts - arrows - from heat shield.
Vehicles with Auxiliary Heater
- Remove bolts - arrows A - from heat shield.
- Remove bracket - 2 - from subframe.
- Remove bolt - arrow B - and slide exhaust pipe of auxiliary heater - 1 - upward.
Continuation for All Vehicles
- Remove heat shield from subframe.
- Now unscrew bolts - 3 -, - 6 -, - 11 - and - 14 - for steering gear and stabilizer.
- Secure subframe and brackets. Refer to => [ Subframe, Securing ] Subframe, Securing.
- Place (V.A.G 1383 A) under subframe.
- Place for example a block of wood - 1 - between (V.A.G 1383 A) and subframe.
- Remove bolts - 4 - and - 5 - and lower subframe with brackets slightly. Observe electrical wires when doing this.
- Remove heat shield - 1 - above exhaust system.
- Remove bolts - arrows -.
- Remove cable guide from subframe - arrow -.
- Unclip all other cable mounting points on steering gear.
- Disconnect all electrical connections from steering gear.
- Carefully lower subframe using (V.A.G 1383 A).
- Lift down steering gear from subframe.
- Set down steering gear as depicted in the illustration.
This prevents damage to the control module - 1 -.
Installing
Installation is performed in the reverse order of removal.
Steering gear threaded sleeves must sit in bracket holes.
• Coat seal on steering gear with lubricant, e.g. soft soap, before installing steering gear.
• After placing steering gear onto universal joint, make sure that seal on steering gear makes contact on assembly plate without kinks and opening to footwell is correctly sealed. Ingress of water and/or noises may be the result.
• Make sure sealing surfaces are clean.
Before fastening the bolts for subframe, position steering gear on subframe and fasten bolts for steering gear and stabilizer.
- Install the lower noise insulation.
- Bolt universal joint to steering gear.
- Connect battery.
- Perform a basic setting on the steering angle sensor (G85) with (VAS 5051).
If a new steering gear was installed, then the electromechanical steering must be adapted with the (VAS 5051).
- Adapt the electro-mechanical power steering with the (VAS 5051).
Suspension
Electromechanical Power Steering
01 - On Board Diagnostic (OBD) Capable Systems
Electromechanical Power Steering
Functions
Adapting the Electromechanical Power Steering
• If the vehicle has Park Assist, then the Power Steering Control Module (J500) must be re-coded after a new steering gear has been installed.
After installation, position of steering wheel must be checked with a road test.
If steering wheel is at an angle or a new steering gear was installed, vehicle must be aligned.
- Perform vehicle alignment. Refer to => [ Wheel Alignment Overview ] Wheel Alignment Overview.
Tightening Specifications
Tightening Specifications, Subframe to Body
Tightening Specifications, Pendulum Support to the Transmission
CAUTION!
From MY 2008, Heli-Coil inserts are installed in the threads for the pendulum support threaded connection in the 02Q manual transmissions. Differences
On these and all other transmissions, use strength class 10.9 bolts.
If, in the 02Q manual transmissions, there is not Heli-Coil insert, then use 8.8 strength class bolts and the appropriate tightening specification.
