Sensor Wire

Sensor Wire

• Currently it is not possible to perform this repair.

Special tools, testers and auxiliary items required

• Holding Fixture (VW 313)

• Thrust Pad (3253/6) qty. 2

• Torque Wrench 5-50 Nm (V.A.G 1331)

• Locking Pliers (VAS 6199)

• Gearbox Support (T10108)

• Special Wrench (T10304)

• 2 bolts M10 x 60

Removing

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

- Tension steering gear using 2 bolts M10 x 60 as depicted in the illustration.






- Clean steering gear in area of cover.

- Remove clamp for bellows at left - 1 - and pull off bellows from steering gear housing.






- Turn steering into straight ahead position using (T10304).

For this purpose, dimension - a - = 25.5 mm.

- Remove gasket - 1 - from cover - 2 -.






- Mark installation position of cover - 2 - to steering gear housing - arrow -.

- Remove cover - 2 -, unscrew bolts - 3 - to do this.

Prevent Contact with Electrical Components - arrow -!






- Observe general repair notes => [ Electrical Components ] Service Precautions for this.

During longer interruptions of work, cover the opened steering gear housing with e.g. foil to protect against moisture.

- Mark routing of sensor wire on steering gear housing.

- Unclip sensor wire on steering gear housing.

• A locking mechanism - arrow - for steering pinion spiral spring is located on sensor wire in steering gear housing. When removing sensor wire, make sure that spiral spring is twisted only as far until connector can be removed (twist a maximum of 30°).






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






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

- Pull locking mechanism in - direction of arrow - out of steering gear housing.






- Carefully pull sensor wire out of steering gear housing.

- Disconnect harness connector of sensor wire at Power Steering Control Module (J500).






- To do so, press button - A - in - direction of arrow - and then disconnect connector.

Installing

- Carefully guide sensor wire into steering gear housing.

- When doing this, insert connector terminal into housing of spiral spring, do not engage yet.

Connector terminal is coded and fits only in one direction.

• Twist spiral spring only as far until connector can be installed (max. 30°).

- Push locking mechanism into steering gear housing.

While doing this, make sure locking mechanism engages correctly in plastic ring of sensor unit - arrow -.






- Now engage connector in spiral spring housing.

- Connect harness connector of sensor wire to Power Steering Control Module (J500).






Connector must engage audibly.

- Clip sensor wire in on steering gear housing.

Pay attention to wire routing.

- Replace sealing ring on cover of steering pinion.

- Fill intermediate area above shaft oil seal in cover - arrow - completely with grease (G 052 192 A1) supplied.






Do not use other grease under any circumstances.

- Place cover on as marked during removal (Fig. ).

- Install new bolts and tighten them to the specification.

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

- Remove excess grease on cover of steering pinion and on steering pinion.

Install in reverse order of removal.

- Steering gear, installing => [ Steering Gear ] Steering Gear.

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

- Perform basic setting for Steering Angle Sensor (G85) via vehicle diagnostic tester "Guided Fault Finding".

- Then perform basic setting of steering system via vehicle diagnostic tester "Guided Fault Finding".