With Servotronic
CAUTION:
^ Keep work area and components clean.
^ Do not attempt to weld or straighten steering components.
NOTE:
^ The power steering uses hydraulic oil, Part No. G 002 000.
^ Components marked with an asterisk (*) are included in the repair kit and should always be replaced when servicing the system.
^ Moisten all seals with hydraulic oil before installing.
COMPONENT IDENTIFICATION AND INFORMATION
1. Steering gear housing/steering gear
- Removing and installing, refer to Replacement.
- Adjust toe after removing and installing
2. Seal*
- Always replace
- Pulling out, refer to Fig. 3 and Fig. 4, below.
3. Circlip
- Can only be removed and installed with steering rack removed
4. Retaining ring
- Slide on steering rack to stop
- Install in groove
5. Boot
- Can only be replaced with steering gear installed
- Adjust toe after replacing
6. Clamp
- Use screw-type clamps for repair
- Threads face toward bulkhead
7. O-ring*
- Always replace
8. Adjusting screw
- Adjusting steering gear play, refer to Fig. 7, below.
9. Hex bolt
- Tighten to: 20 Nm (15 ft lbs)
10. Cover
- Mount on steering gear housing
- The two adjacent holes face forward (direction of travel)
11. O-ring*
- Always replace
- Diameter: 35 x 2 mm
- Install in annular groove of steering gear housing
12. O-ring*
- Always replace
- 27 x 2.5 mm
- Install in annular groove of O-ring retainer
13. O-ring retainer
- Removing, refer to Fig. 5, below.
14. Compression spring
- Install in thrust piece
15. Thrust piece
16. Bolt
- Tighten to: 3 Nm (27 inch lbs)
- Mounts Servotronic to rotary valve housing
- Not marked with locking compound
17. Servotronic solenoid valve
- Cannot be removed and installed with steering gear installed
18. O-ring*
- Always replace
- 12 x1.5 mm
19. O-ring*
- Always replace
- 7x 1 mm
20. Strainer*
- Always replace
21. Washer
22. Socket-head bolt
- Tighten to: 20 Nm (15 ft lb)
23. Valve housing
24. O-ring retainer*
- Always replace
- Driving out, refer to Fig. 1, below.
- Driving in, refer to Fig. 2, below.
- Fill space between sealing lip and dust lip with multi-purpose grease
25. Spring pin*
- Always replace
- 2.5 x 6 mm
- Pull out with pliers before removing rotary valve housing
26. Rotary valve/steering pinion
- Drive out of steering gear housing, refer to Fig. 6, below.
27. O-ring*
- Always replace
- 60 x 2 mm
28. O-ring*
- Always replace
- 9 x 2 mm
29. Cap
- Tighten to: 50 Nm (37 ft lb)
- Secure with two punch marks offset 180°
30. Support ring*
- Always replace
- Pull onto cap
- Installation position, refer to Fig. 8, below.
31. O-ring
- Always replace
- 44 x 2.5 mm*
- Pull onto cap
32. Steering rack
- Remove cap and slide steering rack to left, out of steering gear housing
- Watch out for scoring in area of steering rack seal
- Installing, refer to Steering Rack, Installing, below.
Fig. 1 Driving out rotary valve housing O-ring retainer
Driving in rotary valve housing 0-ring retainer:
Fig. 2 Driving in rotary valve housing O-ring retainer
- Drive in fully.
Fig. 3 Installing seal puller
- Install commercial inside puller (e.g. Kukko 21/4) in seal.
Fig. 4 Pulling out steering rack seal
- Clamp steering gear housing in vise with jaw covers.
- Thread VW771 with VW771/15 onto inside puller and drive out steering rack seal.
Removing 0-ring retainer:
Fig. 5 Removing O-ring retainer
- Remove using standard circlip pliers.
Driving out rotary valve/steering pinion:
Fig. 6 Driving out rotary valve/steering pinion
- Hold pinion by hand and drive out of steering gear housing using firm blows from soft-faced hammer.
Adjusting steering play:
Fig. 7 Adjusting steering play
NOTE:
- Two technicians are required to make the adjustment
- Adjust with the engine not running and the vehicle standing on the ground.
- Illustration shows the steering gear removed.
First Technician:
- Put wheels in straight ahead position.
- Turn steering wheel back and forth (about 30° around center axis) and listen for rattling or knocking noise from steering gear.
Second Technician:
- Carefully turn adjusting screw (arrow in illustration) clockwise into cover, until rattling and knocking noise can no longer be heard from inside vehicle.
- Road test.
- Repeat adjustment if necessary.
Installation position of support ring:
Fig. 8 Installation position of support ring
1 in illustration = Cap
2 in illustration = Support ring
3 in illustration = O-ring
STEERING RACK, INSTALLING
NOTE:
^ Before installing steering rack, wash out steering gear housing with solvent and blow dry with compressed air.
^ Clean steering rack
^ Before installing, coat installation sleeve components, steering rack and steering rack seals with hydraulic oil.
^ All new repair kits include an installation sleeve.
- Insert steering rack seal by hand into steering gear housing and drive in fully.
- Install circlip using circlip pliers.
- Assemble installation sleeve parts (a in illustration) and (b in illustration), with both parts on level surface, as shown.
- By hand, press installation sleeve parts (a in illustration) and (b in illustration) into steering gear housing to stop.
- Use commercially available mandrel to drive installation sleeve (b in illustration) into steering gear housing and remove at opposite end.
- Slide steering rack in from opposite end through steering gear housing and through installation sleeve (a in illustration).
- Hold installation sleeve (a in illustration) in place by hand until flat end of steering rack has passed through.
- Remove installation sleeve (a in illustration) from steering rack.
- Screw on cap by hand, so that steering rack cannot fall out (preventing damage to seal).