Installing Power-Steering Gear

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WARNING: Steering-angle sensor not calibrated or calibrated incorrectly

Unexpected vehicle handling
Steering-angle sensor does not function
Malfunction in steering-angle sensor

→ After working on wheel suspension parts, when replacing the steering-angle sensor and after changing the wheel alignment values, calibrate the steering-angle sensor using PIWIS Tester II 9818 .

→ Keep the front wheels in straight-ahead position on the measuring platform during calibration.

→ On vehicles with electromechanical steering, also re-teach the electric steering lock settings.

Installation is performed in reverse order.
Observe specified tightening torques:

Steering gear to chassis subframe: Tightening torque 90 Nm (67 ftlb.) +90°

Heat shield to power-steering gear: Tightening torque 10 Nm (7.5 ftlb.)

Pressure line to power-steering gear: Tightening torque 32 Nm (24 ftlb.) +/-4 Nm (+/-3 ftlb.)

Return line to power-steering gear: Tightening torque 32 Nm (24 ftlb.) +/-4 Nm (+/-3 ftlb.)

Front-axle final drive to chassis subframe: Tightening torque 90 Nm (67 ftlb.) +90°

Universal joint to power-steering gear: Tightening torque 20 Nm (15 ftlb.) +90°

Heat shield to power-steering gear: Tightening torque 9 Nm (6.5 ftlb.)

Tie-rod ball to wheel bearing housing: Tightening torque 90 Nm (67 ftlb.)

Check the following during installation:
1. 1.1. Replace O-rings (on lines and steering gear).
  Ensure that no damage (scoring or similar damage) is caused to the rack-and-pinion.
2. 1.2. Push on universal joint (steering shaft) at the correct position, with steering gear and steering wheel or airbag contact unit (spiral spring) in center position. When doing this, only fit steering gear fastening screws (to make assembly easier when pushing on universal joint). After the fastening screws on the steering have been tightened, push the universal joint on as far as it will go. When fitted correctly and tension-free, the universal joint may be at a maximum distance -arrows- of 4 mm from the outermost edge of steering gear dust boot.
  
  Fig 1: Checking Universal Joint (Steering Shaft) Position
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 1.3. Observe mounting specifications for clamp on joint boot → 485319 REMOVING AND INSTALLING BELLOWS FOR STEERING-GEAR HOUSING