Power steering gear, removing and installing

WARNING: This page does not describe the selected car, but rather 17 other vehicles, including the 2009 Audi S4, 2009 Audi A4, 2008 Audi S4, 2008 Audi RS 4, and 2008 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

Fig 1: Identifying Hose Clamps 3094

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Hose clamps up to 25 mm dia. 3094

Fig 2: Bolt For Steering Centering VAS 6224

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Bolt for steering centering VAS 6224
Torque wrench V.A.G 1331
Torque wrench V.A.G 1332
Open socket insert SW 19 (commercially available)

Removing

Remove plenum chamber cover →
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET
Disconnect battery and remove if necessary. →
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET

CAUTION: Bring steering wheel into center position and do not turn during repairs because this may damaged airbag unit spiral spring.

Remove ignition key with steering wheel in center position.
Move steering wheel slightly to engage steering lock.
Remove drivers side storage compartment. →
- 68 - INTERIOR EQUIPMENT
- 68 - INTERIOR EQUIPMENT for BODY INTERIOR - CABRIOLET

Fig 3: Removing/Installing Lower Part Of Steering Column From Power Steering Gear

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Loosen bolt - arrow -.
Secure steering column against slipping apart Securing steering column before removal , secure steering column before removal.

Ensure bulkhead boot is seated correctly.

Fig 4: Identifying Hose Clamps 3094

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Clamp off suction and return line using hose clamps Hose Clamps Up to 25 mm dia. 3094.
Remove front wheels.

Fig 5: Positioning Suspension Strut In Front Of Link As Seen In Direction Of Travel

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Loosen suspension strut/link threaded connection (only on left side of vehicle)
Position suspension strut - 1 - in front of link - 2 - as seen in direction of travel.

Fig 6: Identifying Nut, Control Links & Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Loosen nut - 1 - , remove hex head bolt and remove both links - 2 - upward (only on left side of vehicle).

The slits in wheel bearing housing must not be widened using a chisel or similar tool!

Remove hex head bolt - 3 - and remove threaded connection - 4 -.
Remove tie rod downward out of steering arm or press out.

Fig 7: Identifying Steering Arm & Tie Rod Ball Joint Sealing Washer

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

Do not use a chisel or similar tool between steering arm - 1 - and tie rod ball joint sealing washer - 2 - when removing tie rod, otherwise sealing washer could be damaged.
Tie rod may only be pressed off steering arm over tie rod ball joint pin ends or driven with a wooden or rubber hammer.

Fig 8: Securing Wheel Bearing Housing At Left With Help Of Tensioning Band At Suspension Strut

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secure wheel bearing housing - 1 - at left with help of tensioning band - 2 - at suspension strut - 3 -.

Fig 9: Removing Panel Nut

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove panel nut - arrow -.
Pry out clips.
Disengage electrical line
Remove plastic cover

On 6- and 8-cylinder engines, shield on driver side must be removed → Shield, removing and installing .

In order to remove shield on driver side with 6-cylinder engines, front catalytic converter must be removed.
In order to remove shield on driver side with 8-cylinder engines, front exhaust pipe must be removed.

Fig 10: Identifying Bolts & Steering Lock

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Loosen bolt - 1 - approx. one turn
Remove bolts - 2 - and - 3 -
Swing steering gear on driver side forward in direction of travel
Place a pan underneath to catch hydraulic oil.

Fig 11: Removing Return Line Banjo Bolt (22 mm AF) From Steering Gear

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove return line banjo bolt (22 mm AF) from steering gear.

With certain engine-transmission versions, banjo bolt can only be loosened from wheel housing.

Fig 12: Identifying Pressure Line Banjo Bolt (19 mm AF)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove pressure line banjo bolt (SW 19 mm) - arrow - from steering gear.

With certain engine-transmission versions, banjo bolt can only be loosened from wheel housing.

To do this, use an open socket insert SW 19 (commercially available).

Fig 13: Identifying Bolts & Steering Lock

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolt - 1 -.
Take out steering gear through left-hand wheel housing (second technician required).

NOTE:

Ensure bulkhead boot is not damaged by steering gear pinion.

Installing

Fig 14: Centering Removed Steering Gear With Steering Centering Screw VAS 6224

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Center removed steering gear with steering centering screw VAS 6224.

To do this, remove hex socket-head bolt - 1 - from steering gear.
Move steering rack until centering position on rack - arrow - aligns with thread - 2 -.
Install steering centering screw VAS 6224 hand tight.
Steering gear in area of bulkhead boot seat is lubricated with lubricant G 052 745 A3.

Position steering gear at plenum chamber (2nd technician needed).

Make sure threads and contact surfaces of bolts are free of oil and grease.

Fig 15: Identifying Bolts & Steering Lock

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Position bolt - 1 - but do not tighten yet.
Swing steering gear on driver side forward in direction of travel

Fig 16: Installing Return Hose And Banjo Bolt & Pressure Hose And Banjo Bolt With Check Valve

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install return hose and tighten banjo bolt - 2 - (SW 22)
Install pressure hose and tighten banjo bolt with check valve - 1 - (SW 19).

NOTE:

Always use new seals for banjo bolt.
Pressure and return hose must not touch or come in contact with other parts!

With certain engine-transmission versions, banjo bolts can only be tightened from wheel housing.

To do this, use an open socket insert SW 19 (commercially available)

Reinsert bulkhead boot while noting installation location.

Tab on bulkhead boot must align with marking on body.

NOTE:

Replace damaged bulkhead boot if necessary.
Ensure bulkhead boot is seated correctly!

Fig 17: Identifying Bolts & Steering Lock

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Position bolt - 2 - but do not tighten yet.
Install and fasten bolt - 3 -
Tighten bolts - 1 - and - 2 -
Release steering lock.

Bring steering wheel to center position then place universal joint on steering pinion.

Fig 18: Removing/Installing Lower Part Of Steering Column From Power Steering Gear

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tighten bolt - arrow -
Remove mounting device from steering column.
Install drivers side stowage compartment. →
- 68 - INTERIOR EQUIPMENT
- 68 - INTERIOR EQUIPMENT for BODY INTERIOR - CABRIOLET
On 6-cylinder engines, install shield on driver side → Shield, removing and installing .

Install plastic cover in wheel liner.
Engage electrical line.

Fig 19: Inserting Both Upper Link Joint Pins In Wheel Bearing Housing And Bend Downward As Much As Possible Using Pliers T40067

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert both upper link joint pins in wheel bearing housing and bend downward as much as possible using assembly tool T40067.

Fig 20: Inserting Suspension Strut Forked Head Into Link

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert new bolt - 2 - and self-locking nut and tighten
Insert fork-head suspension strut in link and hand tighten threaded connection - 1 -.

Bonded rubber bushings have a limited torsional range. Only tighten threaded connections at links if vehicle is in curb weight position → Wheel bearing, lifting to curb weight position

Fig 21: Identifying Nut, Control Links & Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert tie rod in steering arm to stop.

Fig 22: Identifying Steering Arm & Tie Rod Ball Joint Sealing Washer

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

Install tie rod in steering arm - 1 - when doing so, only by hand and do not stress tie rod end seal - 2 -.

Fig 23: Identifying Nut, Control Links & Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install threaded connection - 4 - and tighten nut.
Install screw - 3 - and tighten

Fig 24: Centering Removed Steering Gear With Steering Centering Screw VAS 6224

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove steering centering screw VAS 6224 from steering gear.

1 - Socket head bolt

2 - Threaded hole in steering gear

Seal steering gear using hex socket head bolt - 1 - Steering centering:
After completing installation of steering gear, remove hose clamps Hose Clamps Up to 25 mm dia. 3094.
Connect or install battery and install plenum chamber cover. →
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET
Mount wheel and tighten. This information is contained in AESIS; Library; Additional Information; Wheels and Tire Guide

Tighten suspension strut/control arm threaded connection to specified torque
Check power steering fluid level → Power steering fluid level, checking .
Bleed steering system → Steering system, bleeding after reconstructing
Check steering system for leaks → Steering system, checking for leaks .

Perform vehicle alignment → Wheel alignment .

Alignment must take place on a VW/Audi recommended alignment stand.