Volkswagen Passat B6 2005 - Electro-mechanical steering gear, assembly overview Стр.

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48 - 5

Electro-mechanical steering gear, assembly

overview

„ Universal joint

„ Hex head bolt

„ Torque specification Topic

48-3

„ Replace each time it is

removed

„ Electrical wiring

„ Power steering gear

„ With Power Steering Control

Module J500
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„ With Electro-mechanical
Power Steering Motor V187

„ With Engine Speed (RPM)

Sensor G28

„ With Steering Torque Sensor

G269

„ Can be tested in guided fault

finding using Vehicle
diagnosis, testing and
information system VAS
5051

„ Wheel bearing housing

„ Hex nut

„ Torque specification Topic

48-3

„ Self-locking

„ Replace each time it is

removed

„ Subframe

„ Hex head bolt

„ Torque specification Topic

48-3

„ Replace each time it is

removed

„ Shield

„ Torx bolt

„ Torque specification Topic

48-3

Steering gear, removing and installing

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Special tools, testers and auxiliary items

required

„ Torque wrench V.A.G 1331

„ Torque wrench V.A.G 1332

„ Engine/transmission jack V.A.G

1383 A

„ Ball joint puller 3287 A

Steering gear, removing

- Disconnect battery
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Repair Manual, Electrical Equipment, Repair Group 27,

Battery; Battery, disconnecting and connecting

- Remove footwell trim, thereby removing nuts - arrows -

.

- Remove bolt - 1 - and pull off universal joint - 2 - from

steering gear.

- Remove front wheels.

- Loosen tie rod end nut, do not remove.

Caution!

To protect threads, leave nut on stud a few turns.

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- Press off tie rod end from wheel bearing housing with ball
joint puller 3287A , and then remove nut.

- Remove lower sound insulation

Repair Manual, Body Exterior, Repair Group 50, Sound

insulation - Assembly overview

- Disconnect connecting links from stabilizer bar.

- Remove nuts - arrows - .

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- Remove support from transmission, removing bolts - 13 -

.

- Remove exhaust system bracket from subframe.

- Remove bolts - arrows - from heat shield.

Vehicles with auxiliary heater

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- Remove bolts - arrows A - from heat shield.

- Remove bracket - 2 - from subframe.

- Remove bolt - arrow B - and push exhaust pipe of

auxiliary heater - 1 - upward.

Continued for all vehicles

- Remove heat shield from subframe.

- Remove bolts - 3 - , - 6 - , - 11 - and - 14 - for steering

gear and stabilizer bar.

- Locate subframe and consoles 40-4, Subframe,

locating .
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- Place engine/transmission jack V.A.G 1383 A under

subframe.

- Place, for example, a piece of wood - 1 - between

engine/transmission jack V.A.G 1383 A and subframe.

- Remove bolts - 4 - and - 5 - , and lower subframe with

consoles slightly. When doing this, observe electrical
wiring.
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- Remove heat shield - 1 - from above steering gear.

- Remove bolts - arrows - .

- Remove cable guide from subframe - arrow - .

- Clip open all other cable fastening points on steering

gear.

- Unclamp all electrical connections from steering gear.

- Carefully lower subframe with engine/transmission jack

V.A.G 1383 A .

- Lift steering gear off from subframe.

- Set down steering gear as shown in illustration.

This way damage to control module - 1 - is prevented.

Steering gear, installing

Further installation is in reverse order of removal.

The threaded sleeves of steering gear must be seated in

holes of the consoles.

Note:

„ Coat steering gear O-ring seals with lubricant, e.g.

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liquid soap, before installing steering gear.

„ After placing steering gear onto the universal joint,

make sure that the seal lies against the assembly
plate without kinking and that the opening to the
footwell is correctly sealed. Water ingress and/or
noises may be the result.

„ Make sure sealing surfaces are clean.

Before inserting bolts for subframe, position steering gear

on subframe and insert bolts for steering gear and
stabilizer bar.

Steering, torque specifications 48-3, Steering, torque

specifications .

Front axle, torque specifications 40-3, Front axle, torque

specifications .

- Install lower sound insulation

Repair Manual, Body Exterior, Repair Group 50, Sound

insulation - Assembly overview

- Fasten universal joint to steering gear.

- Connect battery

Repair Manual, Electrical Equipment, Repair Group 27,

Battery; Battery, disconnecting and connecting

- Perform basic setting for steering angle sensor G85

using vehicle diagnosis, testing and information system
VAS 5051 Vehicle Diagnosis, Testing and Information
System VAS 5051 .

After installing check position of steering wheel during a

test drive.

If steering wheel is crooked, or if a new steering gear was

installed, the vehicle alignment must be checked.

- Perform vehicle alignment 44-7, Wheel alignment .

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If a new steering gear is installed, the Power Steering

Control Module J500 must be adapted using vehicle
diagnostic, testing and information system VAS 5051 .

- Perform basic setting for Power Steering Control Module

J500 using vehicle diagnosis, testing and information
system VAS 5051 .