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

Removing and installing steering rack, 3rd generation, RHD vehicles, 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
Disconnect battery
Rep. gr.
27
Battery; Disconnecting and reconnecting battery
.
Remove footwell trim
General body repairs, interior
Rep. gr.
68
Compartments, covers and trims; Removing and installing footwell trim
.
Unscrew nut
1
.
Pull out pin
2
and remove entire clip.
Push up footwell trim
3
in
direction of arrow
and remove.
Remove bolt
1
for universal joint and pull universal joint
2
off steering rack.
Loosen wheel bolts.
Raise vehicle.
Remove front wheels.
Remove lower noise insulation
Rep. gr.
50
Assembly overview - noise insulation
.
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
Detach exhaust system bracket from subframe
arrows
.
Disconnect pendulum support from gearbox by removing bolts
14
.
Unscrew bolts
arrows
from heat shield.
Remove heat shield from subframe.
Remove bolts
5
and
6
for steering rack.
Fix position of subframe
Chapter
.
Separate connector for extended service intervals on oil sump.
Place
engine and gearbox jack
V.A.G 1383 A
1
or
engine and gearbox jack
VAS 6931
under subframe.
Remove bolts
9
and
10
and lower subframe with bracket slightly. Observe electrical wiring.
Unscrew bolts
arrows
and remove heat shield
1
above steering rack.
Remove cable guide from subframe
arrow
.
Unclip all remaining cable clips on steering rack.
Separate connectors from steering rack.
Carefully lower subframe using
engine and gearbox jack
V.A.G 1383 A
or
engine and gearbox jack
VAS 6931
.
Lift off steering rack from subframe and remove to right.
Position steering rack as shown in diagram.
This prevents damage to the control unit
1
.
Installing
Installation is performed in reverse sequence; note the following:
Threaded sleeve of steering rack must be located in subframe hole.
Note
Coat seal on steering rack with suitable lubricant, e.g. soft soap, before installing steering rack.
After fitting the steering rack to the universal joint, make sure 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.
Before inserting subframe bolts, position steering rack on subframe and insert bolts for steering rack and anti-roll bar.
Carry out basic setting for
steering angle sender
G85
using
Vehicle diagnostic tester
.
After installation, position of steering wheel must be checked during road test.
If steering wheel is crooked or a new steering rack was installed, wheels must be aligned.
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
.
Note
If parking aid 2 is fitted in the vehicle, the
power steering control unit
J500
must be recoded
Vehicle diagnostic tester
.
Specified torques
Chapter
“
Assembly overview - subframe, made of aluminium
”
Chapter
“
Assembly overview - subframe, made of steel
”
Chapter
“
Electromechanical steering rack
”
Particulate filter with front exhaust pipe; Assembly overview - particulate filter with front exhaust pipe
Engine
Rep. gr.
26
Assembly overview - particulate filter with front exhaust pipe
Assembly mountings; Assembly overview - assembly mountings
Engine
Rep. gr.
10
Assembly overview - assembly mountings
General body repairs, exterior
Rep. gr.
66
Noise insulation; Assembly overview - noise insulation
.