Removing and installing steering rack, 3rd generation, as of model year 2009 — VW

Removing and installing steering rack, 3rd generation, as of model year 2009
Special tools and workshop equipment required
Ball joint puller
T10187
Torque wrench
V.A.G 1331
Torque wrench
V.A.G 1332
Engine and gearbox jack
V.A.G 1383 A
Removing steering rack:
Disconnect battery.
Rep. gr.
27
Battery; Disconnecting and reconnecting battery.
Remove footwell trim by removing nuts
arrows
.
Unscrew bolt
arrow
from universal joint
1
and pull off universal joint in
direction of arrow
.
Remove front wheels.
Loosen nut on track rod ball joint but do not remove completely.
Caution
Leave nut screwed on a few turns to protect thread on pin.
Push track rod ball joint off wheel bearing housing and remove nut.
Ball joint puller
T10187
Remove lower noise insulation
Rep. gr.
50
Assembly overview - noise insulation
.
Disconnect pendulum support from gearbox by removing bolts
14
.
Detach exhaust system bracket from subframe
arrows
.
Unscrew bolts
arrows
from heat shield.
Remove heat shield from subframe.
Remove bolts
5
and
6
for steering rack.
Remove bolts
7
and
8
for anti-roll bar.
Fix position of subframe and brackets
Chapter
Place
engine and gearbox jack
V.A.G 1383 A
or
engine and gearbox jack
VAS 6931
1
under subframe.
Remove bolts
9
and
10
and lower subframe with bracket slightly. Observe electrical wiring.
Remove heat shield
1
over steering rack.
Remove bolts
arrows
.
Remove cable guide from subframe
arrow
.
Unclip all remaining cable clips on steering rack.
Separate all electrical connectors from steering rack.
Lower subframe using
engine and gearbox jack
V.A.G 1383 A
or
engine and gearbox jack
VAS 6931
far enough to be able to remove steering rack.
Set steering rack down as illustrated.
This prevents damage to the control unit
1
.
Installing
Installation is performed in reverse sequence; note the following:
Threaded sleeves of steering rack must seat in holes in left bracket.
Note
Coat seal on steering rack with suitable lubricant, e.g. soft soap, before installing steering rack.
After fitting the steering rack to the drive shaft, ensure that the seal is not kinked when lying against the assembly plate and that the opening to the footwell is correctly sealed. Otherwise, this can result in water leaks and/or noise.
Ensure sealing surfaces are clean.
Ensure that bellows are not damaged or twisted.
Before inserting subframe bolts, position steering rack on subframe and insert bolts for steering rack and anti-roll bar.
Carry out basic setting for
G85-Geber für Lenkwinkel
using
Vehicle diagnostic tester
.
After installation, position of steering wheel must be checked during road test.
If steering wheel is not in straight-ahead position or if a new steering rack was installed, front axle tracking must be checked and if necessary adjusted!
Check wheel alignment.
Chapter
If a new steering rack has been installed the
power steering control unit
J500
must be adapted using
Vehicle diagnostic tester
.
Perform basic settings for
power steering control unit
J500
using
Vehicle diagnostic tester
.
Specified torques
Chapter
“
Assembly overview - subframe, made of aluminium
”
Chapter
“
Assembly overview - subframe, made of steel
”
Chapter
“
Assembly overview - electromechanical steering rack, 3rd generation, as of model year 2009
”
Engine
Rep. gr.
26
Assembly overview - particulate filter with front exhaust pipe
Engine
Rep. gr.
10
Assembly mountings; Assembly overview - assembly mountings
General body repairs, exterior
Rep. gr.
66
Noise insulation; Assembly overview - noise insulation
.