Power Steering Gear, Removing and Installing

Special tools and equipment
^ 3094 Clamps
^ VAG 1383A
^ Transmission jack
^ VAG 1332 Torque wrench
^ VAG 1331 Torque wrench

Power steering gear, instructions:
^ Absolute cleanliness is required when working on power steering system.
^ Thoroughly clean connections and immediate vicinity before loosening.
^ Place parts on a clean surface and cover if not re-installing immediately.
^ Do not use fluffy cloth.
^ Only unpack parts immediately prior to installation.
^ Only use genuine packed Volkswagen parts.

Removing
- Remove plastic nuts -1-.





- Remove cover -A-.





- Remove steering joint bolt.
- Pull universal joint off steering gear.





- Clamp hose from reservoir with hose clamp 3094.





- Clamp hose on power steering pump with 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





- Disconnect hoses from steering gear and seal with plastic wrap and adhesive tape.
Return line -1- can only be removed after lowering sub-frame.
- Seal power steering gear threaded holes with plastic plugs.





- Remove bolts -1- and -2-.
- Support sub-frame with engine/transmission jack VAG 1 383A.
- Remove bolts -1-.





- Remove bolts -2- and -3-.
- Lower sub-frame with engine/transmission jack VAG 1 383A.





- Remove return line clamp -1- and unscrew line fitting at steering gear -2-.
- Remove power steering gear bolts.
- Take power steering gear out to rear.

Installing

NOTE:
^ Use new O-rings for hose line connections.
^ Coat O-rings with lubricant before installing steering gear.
^ After connecting steering gear to universal joint shaft ensure seal lies against assembly plate without kinking and opening to footwell is correctly sealed. Otherwise noises or water leaks may be develop later.
^ Ensure sealing surfaces are clean.

- Install power steering gear on subframe.





Threaded sleeve -1- must seat in hole on sub-frame.





- Install return line.
A gap of approx. 10 mm (0.39 in.) must exist between return line and power steering gear.
1. Return line
2. Nut, 22 Nm (16 ft. lbs.)
3. Steering gear
Installation is performed in reverse sequence:
Tightening torque:
Power steering gear to sub-frame 20 Nm (15 ft. lbs.)+ 90° further
Use new bolts!
Sub-frame to body 100 Nm + (74 ft. lbs.) 90° further
Use new bolts!
Universal joint to steering gear 30 Nm (22 ft. lbs.)
Use new bolts!
Banjo bolt to steering 40 Nm (30 ft. gear M14 x 1.5 lb.)
Banjo bolt to steering gear M 16x 1.5 45 Nm (33 ft. lbs.)
Pendulum support to transmission 40 Nm (30 ft. lbs.)
Tie rod to steering arm 45 Nm (33 ft. lbs.)
Use new nuts!