Removing and installing subframe with steering rack, steel — VW

Removing and installing subframe with steering rack, steel
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 steering rack:
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.
Remove lower noise insulation
General body repairs, exterior
Rep. gr.
66
Noise insulation; Assembly overview - noise insulation
.
Detach exhaust system bracket from subframe
arrows
.
Loosen double clamp of exhaust system.
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
Disconnect pendulum support from gearbox by removing bolts
11
.
Fix position of subframe
Chapter
.
Place
engine and gearbox jack
VAS 6931
or
engine and gearbox jack
V.A.G 1383 A
1
under subframe.
Remove bolts
5
and
6
and lower subframe with
engine and gearbox jack
V.A.G 1383 A
.
Unscrew bolts
arrows
and remove shield
1
over 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 using
engine and gearbox jack
VAS 6931
or
engine and gearbox jack
V.A.G 1383 A
.
Secure subframe on
engine and gearbox jack
VAS 6931
or
engine and gearbox jack
V.A.G 1383 A
.
Installing
Install in reverse order. Note the following points:
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.
Install noise insulation
General body repairs, exterior
Rep. gr.
66
Noise insulation; Assembly overview – noise insulation
.
Install front wheels and tighten
Chapter
.
Specified torques
Chapter
“
Assembly overview - subframe, steel
”
Chapter
“
Steering rack
”
Chapter
“
Assembly overview - lower suspension link, swivel joint, steel
”
Bolts for pendulum support
Rep. gr.
10
Assembly mountings; Assembly overview - assembly mountings
.
Exhaust system bracket to subframe
Rep. gr.
26
Exhaust pipes/silencers; Assembly overview - silencer
.
Noise insulation
General body repairs, exterior
Rep. gr.
66
Noise insulation; Assembly overview - noise insulation
.
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.