Removing and installing subframe with steering rack, aluminium — VW

Removing and installing subframe with steering rack, aluminium
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
VAS 6931
or
engine and gearbox jack
V.A.G 1383 A
Removing
Disconnect battery
Rep. gr.
27
Battery; Disconnecting and reconnecting battery
.
Remove footwell trim
1
.
Unscrew bolt
arrow
from universal joint
1
and pull off universal joint in
direction of arrow
.
Caution
The following work must not be performed while the universal joint is separated from the electromechanical steering rack:
Switching on ignition
Turning the steering rack
Turning the steering column
Not adhering to these instructions will result in irreparable damage.
Loosen wheel bolts.
Raise vehicle.
Remove front wheels.
If fitted, remove lower noise insulation
General body repairs, exterior
Rep. gr.
66
Noise insulation; Assembly overview - noise insulation
.
Detach exhaust system bracket from subframe
arrows
.
Remove hexagon nut
1
from coupling rod
3
(left and right sides).
Pull out coupling rod
3
from anti-roll bar
2
on left and right side.
Remove nuts
arrows
on left and right sides of vehicle.
Pull swivel joint out of suspension link.
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
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.
Continuation for all vehicles:
If fitted, unscrew bolts
arrows
of heat shield and remove heat shield from subframe.
Disconnect pendulum support from gearbox by unscrewing bolts
1
and
2
.
Fix position of subframe
Chapter
.
Place
engine and gearbox jack
VAS 6931
or
engine and gearbox jack
V.A.G 1383 A
under subframe.
Place a squared timber (or similar)
1
between
engine and gearbox jack
VAS 6931
or
engine and gearbox jack
V.A.G 1383 A
and subframe.
Unscrew bolts
1
and lower subframe slightly with steering rack.
Caution
When lowering, take note of electrical wiring.
Loosen bolts
arrows
and remove shield
1
above steering rack.
Unclip wiring harness from cable guide
arrow
on subframe.
Unclip all remaining cable clips on steering rack.
Pull connectors
1
and
2
off steering rack.
Carefully lower subframe with steering rack further.
Secure subframe on
engine and gearbox jack
VAS 6931
or
engine and gearbox jack
V.A.G 1383 A
.
Installing
Install in reverse order of removal, observing the following:
Tighten nuts
arrows
.
Note
Tighten nuts
arrows
in unladen state
Chapter
.
Note
Coat seal on steering rack with suitable lubricant, e.g. soft soap, before installing steering rack.
After fitting the steering rack to the jointed 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.
Specified torques
Chapter
“
Assembly overview - subframe, aluminium
”
Chapter
“
Steering rack
”
Particulate filter with front exhaust pipe
Rep. gr.
26
Emission control; Assembly overview - emission control
Noise insulation
General body repairs, exterior
Rep. gr.
66
Noise insulation; Assembly overview - noise insulation
.
Carry out basic setting for
steering angle sender
G85
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
.
If a crooked steering wheel is determined during the road test even though
locating pins
T10096
were used, check wheel alignment. In this case the wheel alignment test results must be archived in the vehicle files.