Removing and installing power assisted steering box — VW

Instructions when working on the power assisted steering box

Absolute cleanliness is required when working on the power assisted steering.
Thoroughly clean connections and immediate vicinity before loosening.
Place parts on a clean surface and cover if not re-installing immediately.
Do not use fluffy cloth.
Only unpack parts immediately prior to fitting.
Only use genuine packed parts.
Disposal

=> Special information; Running gear No.2; Environmentally friendly and economical recycling of oil-filled old parts

Special tools and workshop equipment required

10-222 A Support
10-222 A/1 Support
3094 Hose clamps
V.A.G 1331 Torque wrench
V.A.G 1332 Torque wrench

V.A.G 1576 Torque wrench

4 - Kukko 128/2 Ball joint splitter

Additional information

Workshop Manual Caddy 1996 ▸, Polo Classic 1996 ▸, Polo Estate 1998 ▸, Engine mechanics
Special information, running gear

Removing

Lift vehicle until the load on the front axle is relieved.
Loosen hexagon nuts on drive shafts.
Remove cover from engine, if part of original equipment.
Remove the air cleaner (only on vehicles with oval air cleaner). To do this remove the screws indicated by the arrows.

Lay the air cleaner to the rear.
Fit support bar 10-222A together with legs 10-222 A/1.

Note:

Before fitting the support hooks of the support bar, remove hose and wire connections from engine in the area of the lifting eyes, so that they are not damaged.

Take weight of engine/gearbox assembly on the spindles.

Remove bolt (arrow) on engine console/sub-frame, right. If fitted remove connector mounting plate -A-.

Unbolt hexagon bolt (arrow) on left gearbox assembly mounting.

Clamp hose from reservoir with hose clamp 3094.

Clamp hose on vane pump with hose clamp 3094.

Vehicles ▸ 09.99

Press stowage compartment clips together in direction of arrows.
Fold stowage compartment down and pull out towards rear.

Vehicles 10.99 ▸

Release steering wheel height adjustment -1- and put steering wheel in highest position.
Remove bolts -1-.
Take off lower steering column switch trim -2-.

Remove securing screws -arrows-.
Take off cover -1-.
Remove securing screw right of steering column.
Remove screw -arrow A-.

Remove securing screws -arrows-.
Remove stowage compartment.

Continuation for all vehicles

Removing footwell cover.

Unscrew nuts -arrows- and pull connecting piece -A- out of connecting sleeve -B- in direction of arrow.
Raise vehicle.
Remove front wheels.
Remove Lambda probe from front exhaust pipe if fitted.
Removing front exhaust pipe.

=> Repair group 26; Removing and installing parts of exhaust system.
Running gear, Axles, Steering
Removing and installing parts of exhaust system.

Press track rods off steering arm.

1 -
Ball joint splitter (commercial type e.g. Kukko No. 128/2)

Mark installation positions of swivel joint bolts on wishbone.
Remove bolts (arrows).

On both sides, swing wheel with suspension struts outwards and support.
If front exhaust pipe bracket is fitted to sub-frame, remove it.
Remove bellows from seat on steering box.

Unbolt steering box from sub-frame -1- and secure e.g. with wire.
Unclip power assisted steering feed and pressure pipes from retainer on assembly/gearbox mounting.
Place gearbox jack V.A.G 1383 A under subframe.
Remove bolts -2- and -3- for sub-frame.
Lower sub-frame slightly using gearbox jack V.A.G 1383 A.

Disconnect hoses from steering box and seal with plastic bag and adhesive tape.
Seal power assisted steering box threaded holes with plastic sealing plugs.
Instead of plastic sealing plugs a plug consisting of
Part No. 113 301 229 A and banjo bolt
Part No. N 904 674 01
can be used. But when using these, several 16 mm ø sealing rings must be used so that the holes in the banjo bolt are sealed.
Remove steering box securing nuts (bolts remain in subframe).
Remove steering box to rear.

Installing

Install in reverse order.

Notes:

Use new sealing rings for hose/line connections.
When lifting the engine/gearbox assembly guide the lower half of the universal joint shaft -A- into the upper half -B- at the same time (second mechanic necessary).
Coat bellows with lubricant e.g. soft soap before pulling onto steering box.
Ensure sealing surfaces are clean.
After fitting the steering box to the universal joint shaft ensure that the seal lies against the assembly plate without kinking and that the opening to the footwell is correctly sealed.
Noises may be created and/or water may ingress.

Observe oil level in reservoir, after filling with hydraulic oil and starting engine. The oil level must sink.

If this is not the case, stop engine, unscrew pressure pipe at P.A.S. box and wait until hydraulic oil discharges.

Attach pipe again and start engine, top-up oil level.
Check front wheel alignment and position of steering wheel.

Tightening torques

Swivel joint to wishbone · 35 Nm
Hex nut for drive shaft to wheel hub · 265 Nm
Hexagon bolts for steering box/steering column connecting piece · 25 Nm
P.A.S. box to sub-frame · 30 Nm
Track rod to steering arm / Use new hexagon nuts! · 35 Nm

Sub-frame to body

1 -
30 Nm
2 -
70 Nm then 90°further
3 -
65 Nm