Steering Gear, Generation I

Steering Pinion with Steering Angle Sensor

• Currently it is not possible to perform this repair.

Special tools, testers and auxiliary items required

• Torque Wrench 5-50 Nm (V.A.G 1331)

• Bracket (VW 540/2)

• Thrust Piece (3253/6) (quantity: 2)

• Vehicle Diagnosis, Testing and Information System (VAS 5051B)

Removing

- Remove steering gear. Refer to => [ Steering Gear ] Steering Gear.

- Clean the steering gear in the steering pinion area and install the plug and adjusting screw.

- Clamp the steering gear as illustrated.






1. (VW 540/2)

2. (3253/6) (quantity: 2)


- Remove thrust piece on steering pinion side. Refer to => [ Thrust Piece, Steering Pinion Side ] Thrust Piece, Steering Pinion Side.

- Position the steering gear so it is in the straight position.

- Disengage sensor wiring at steering gear housing.

- Remove the plug - arrow -.






- Remove the nut - arrow - from steering pinion.






• Steering rack moves up to stop when this is done.

- Position the steering so it is in the straight position.

- Remove the seal - 1 - from the cover.






- Remove cover - 2 -.

- Carefully lift seal from steering gear housing.

• No seal remnants must enter sensor or housing when doing this.

Prevent Contact with Electrical Components - arrow -!






• A locking mechanism - arrow - for the spiral spring is located on the sensor wire in the steering gear housing. When removing the sensor wire, make sure the spiral spring does not twist.






- Now disconnect harness connector of sensor wire at steering pinion.






• To do this, press connector terminal out of spiral spring housing using a screwdriver (3 mm blade width) as depicted in the illustration.

- Mark position of steering pinion on steering gear housing.

- Now pull steering pinion with steering torque sensor out of steering gear housing. Secure spiral spring against twisting using for example adhesive tape.






Installing






- Coat the steering pinion bearing - arrow - and splines with (G 052 192 A1).

• While doing this, no grease must enter the sensor or its vicinity!

The new steering pinion with steering angle sensor as an anti-twist mechanism - arrow -. This may only be removed after locking to sensor wire.






- Insert steering pinion into steering gear housing.

- Rotate steering pinion until spiral spring with sensor wire - arrow - can be locked. While doing this, the marking applied during removal must align with steering gear housing.






- Pull anti-twist element off the spiral spring.

- Place connector in spiral spring housing.

• Connector terminal is coded and fits only in one direction.

- Tighten the steering pinion with a new hex nut.






• Steering rack moves up to stop when this is done.

- Apply LOCTITE(R) (5910) to the plug threads.

- Fill the plug with grease (G 052 192 A1) , install it and tighten it.

- Position the steering so it is in the straight position.

- Coat the gasket - arrow - in the cover with grease (G 052 168 A1). Only apply a thin film of it.






- Install cover with new seal.

Further installation is in the reverse sequence to removal.

- Install and adjust thrust piece on steering pinion side. Refer to => [ Thrust Piece, Steering Pinion Side ] Thrust Piece, Steering Pinion Side.

- Install steering gear. Refer to => [ Steering Gear ] Steering Gear.

After installing, perform a steering angle sensor (G85) basic setting with the (VAS 5051B).

- Perform the adaptation and basic setting for the steering angle sensor (G269) with the (VAS 5051B).

Tightening specifications, refer to => [ Steering Gear Overview, Generation I ] Steering Gear Overview, Generation I.

- Perform vehicle alignment. Refer to => [ Wheel Alignment ] Wheel Alignment.