Power Steering Gear, Removing and Installing

Power steering gear, removing and installing





Special tools, testers and auxiliary items required
^ Hose clamps 3094
^ Torque wrench V.A.G. 1 331
^ Torque wrench V.A.G. 1332
^ Engine and transmission jack V A.G 1383 A with universal transmission mount V.A.G. 1359/2

The following special tools are necessary for R32
Instructions when working on the power steering gear

Note:
^ Absolute cleanliness is required when working on the power steering system.
^ Thoroughly clean connections and immediate vicinity before loosening.
^ Place parts on a clean surface and cover if not reinstalling immediately.
^ Do not use huffy cloths.
^ Remove replacement parts from packaging immediately prior to installation.
^ Only use genuine packed Volkswagen parts.

Removing





- Remove plastic screws -1 -





- Remove cover - A - .





- Remove joint bolt - 1 - from steering shaft joint and remove universal joint steering gear in direction of - arrow -





- Clamp hose from reservoir using hose clamp 3094 .
- Clamp power steering pump hose using hose clamp 3094 .
- Remove noise insulation tray.





- Place oil pan under vehicle.
- Press tie rod end off steering arm. .
1 - Ball joint puller (commercial type) e.g. Matra V 176





For R32
- Press tie rod end off steering arm.





- If the bushing - 3 - is pressed out while pressing out tie rod, it must be pressed in again.
- Attach special tools as shown in the illustration, and tighten spindle to 50 Nm (36.8).
Then, the bushing is correctly positioned in the steering arm again.
1 - Assembly tool 3293
2 - Installing tool 40 - 503

Continued for all vehicles
- Disconnect hoses from steering gear and seal with plastic bag and adhesive tape.





The return line - 1 - can only be removed after first lowering the sub-frame.





- Seal power steering gear threaded holes with plastic sealing plugs.
- Remove hex bolts -1 - and - 2 - .





Vehicles with TDI engine
- Unbolt bracket for front exhaust pipe on subframe - arrow - and separate.

Continued for all vehicles
- Support sub-frame with engine and transmission jack V.A.G. 1 383A .





- Loosen hex bolt -1 -
- Remove hex bolts - 2 - and - 3 - .





- Lower subframe using engine and transmission jack V.A.G. 1 383A .
- Remove return line clamp -1 - and line at steering gear - 2
- Remove power steering gear bolts.
- Take power steering gear out to the rear.

Installing





Note:
^ Use new sealing O-rings for hose/line connections.
^ Coat steering gear O-ring seals with lubricant, e.g. soft soap, before installing steering gear.
^ After installation of steering gear to the universal joint shaft ensure that the seal lies against the assembly plate without kinking and opening to the footwell is correctly sealed. Noises may be created and/or water may ingress.
^ Make sure sealing surfaces are clean.

- Install power steering gear on sub-frame.





The threaded sleeve -1 - must seat on subframe hole.
- Install return line.
A gap of approximately 10 mm (0.39 inch) must exist between return line and power steering gear.
1 - Return line
2 - Hex nut, 22 Nm (16 ft. lbs.)
3 - Power steering gear
Installation is continued in reverse sequence

Fastener/location Tightening torques:
Power steering gear to sub-frame Use new bolts! 20 Nm (15 ft. lbs.) plus an additional 1/4 turn 90°
Subframe to body Use new bolts! 100 Nm (74 ft. lbs.) plus an additional 1/4 turn 90°
Universal joint to steering gear Use new bolts! 30 Nm (22 ft. lbs.)
Banjo bolt to steering gear M14 x 15 38 Nm (28 ft. lbs.)
Banjo bolt to steering gear M16 x 15 45 Nm (33 ft. lbs.)
Pendulum support to transmission 50 Nm (37 ft. lbs.)
Tie rod to steering arm Use new nuts! 45 Nm (33 ft. lbs.)