Removing and installing hydraulic steering rack — VW

Removing and installing hydraulic steering rack
Special tools and workshop equipment required
Torque wrench
V.A.G 1331
Torque wrench
V.A.G 1332
Engine and gearbox jack
V.A.G 1383 A
Hose clamps, up to 25 mm
3094
Drip tray for workshop hoist
VAS 6208
Locating pins
T10096
Ball joint puller
3287 A
Removing
Remove plastic nuts
arrows
and remove trim from vehicle.
Remove bolt
1
and pull universal joint
2
off steering rack.
Remove front wheels.
Remove nuts on both sides from track rod ball joint (do not unscrew).
Note
Leave nut screwed on a few turns to protect thread on pin.
Press track rod ball joints off with
ball joint splitter
3287 A
.
Unscrew nuts of track rod ball joints and remove them from wheel bearing housing.
Clamp off hose from reservoir tank with
hose clamps to 25 mm
3094
.
Clamp off hose at vane pump with
hose clamps to 25 mm
3094
.
Remove lower noise insulation
Rep. gr.
50
Assembly overview - noise insulation
.
Remove left and right securing nuts of coupling rod
1
from anti-roll bar
3
.
Remove coupling rods
2
on both sides from anti-roll bar
3
.
Remove bolts
arrows
of exhaust system bracket.
For vehicles with auxiliary heater:
Note
Depending on the model variant and equipment, the exhaust system of the auxiliary heater must be partially removed in cars with an auxiliary heater.
WARNING
Danger of burns.
The silencer may be hot.
Before removing silencer, let it cool off.
Loosen nut for exhaust system clamp
arrow A
.
Remove bolts
arrows B
.
Unscrew bolts
arrow A
and
arrow B
further along exhaust pipe.
Remove exhaust pipe from vehicle.
Continuation for all vehicles:
Remove bolts
1
of pendulum support on gearbox.
Remove bolts
2
for steering rack.
Secure subframe with brackets
Chapter
.
Vehicles with subframe made of steel
Fix position of subframe
Chapter
.
Continuation for all vehicles
Place
engine and gearbox jack
V.A.G 1383 A
or
engine and gearbox jack
VAS 6931
under subframe.
Place a squared timber (or similar)
1
between
engine and gearbox jack
V.A.G 1383 A
or
engine and gearbox jack
VAS 6931
and subframe.
Remove bolts
1
and lower subframe slightly.
Note
Watch out for electrical wiring when lowering.
Unclip electrical wiring harness from cable guide
arrow
on subframe.
Position
drip tray for workshop hoist
VAS 6208
under subframe.
Unscrew hydraulic oil lines from steering rack and seal them with suitable workshop equipment.
Carefully lower subframe further until steering rack can be taken down off subframe.
Installing
Installation is performed in reverse sequence; note the following:
Note
Threaded sleeves of steering rack must seat in holes in brackets.
Moisten steering rack seal with lubricant, e.g. tyre assembly paste, before installing steering rack. Ensure sealing surfaces are clean.
After installing steering rack on universal joint, ensure that seal is seated correctly. Water may otherwise enter and/or noises occur.
Make sure that protective sleeves of track rods are not twisted or damaged.
Specified torques
Chapter
“
Assembly overview - subframe, made of aluminium
”
Chapter
“
Assembly overview - subframe, made of steel
”
Chapter
“
Assembly overview - hydraulic steering rack
”
Rep. gr.
26
Emission control; Assembly overview - emission control
General body repairs, exterior
Rep. gr.
66
Noise insulation; Assembly overview - noise insulation
.
Heating, ventilation, air conditioning system
Rep. gr.
82
Repairing auxiliary heater
Chapter
“
Bleeding the power steering system
”
On vehicles with ESP basic settings for
steering angle sender
G85
must be carried out using
Vehicle diagnostic tester
.
If a new steering rack has been installed the
power steering control unit
J500
must be adapted using
Vehicle diagnostic tester
.
Carry out basic setting for
power steering control unit
J500
using
Vehicle diagnostic tester
.
Note
Carry out a road test after the repair work. Make sure the steering wheel is in the straight-ahead position. If the steering wheel is not straight-ahead, wheels must be aligned
Chapter
.