Steering Pinion With Steering Angle Sensor

NOTE:

Currently it is not possible to perform this repair.

Special tools and workshop equipment required

Torque Wrench 5-50 Nm V.A.G 1331
Bracket VW 540/2
Thrust Piece 3253/6 (quantity: 2)
Vehicle Diagnosis, Testing and Information System VAS 5051B

Removing

-- Remove steering gear. Refer to STEERING GEAR .

-- Clean the steering gear in the steering pinion area and install the plug and adjusting screw.

-- Clamp the steering gear as illustrated.

Fig 1: Clamp Steering Gear

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VW 540/2
3253/6 (quantity: 2)

-- Remove thrust piece on steering pinion side. Refer to THRUST PIECE, STEERING PINION SIDE .

-- Position the steering gear so it is in the straight position.

-- Disengage sensor wiring at steering gear housing.

-- Remove the plug -arrow-.

Fig 2: Locking Bolt

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-- Remove the nut -arrow- from steering pinion.

Fig 3: Hex Nut From Steering Pinion

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NOTE:

Steering rack moves up to stop when this is done.

-- Position the steering so it is in the straight position.

-- Remove the seal -1- from the cover.

Fig 4: Seal And Cover From Steering Gear Housing

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-- Remove cover -2-.

-- Carefully lift seal from steering gear housing.

NOTE:

No seal remnants must enter sensor or housing when doing this.

Prevent Contact with Electrical Components -arrow- !

Fig 5: Identifying Electrical Components

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NOTE:

A locking mechanism -arrow- for the spiral spring is located on the sensor wire in the steering gear housing. When removing the sensor wire, make sure the spiral spring does not twist.

Fig 6: Steering Pinion Spiral Spring Locking Mechanism

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

Fig 7: Disconnecting Harness Connector Of Sensor Wire At Steering Pinion Using A Screwdriver

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NOTE:

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

-- Mark position of steering pinion on steering gear housing.

-- Now pull steering pinion with steering torque sensor out of steering gear housing. Secure spiral spring against twisting using for example adhesive tape.

Fig 8: Pulling Out Steering Pinion With Steering Torque Sensor Out Of Steering Gear Housing

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Installing

Fig 9: Coating Bearing And Splines Of Steering Pinion

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-- Coat the steering pinion bearing -arrow- and splines with G 052 192 A1.

NOTE:

While doing this, no grease must enter the sensor or its vicinity!

The new steering pinion with steering angle sensor as an anti-twist mechanism -arrow-. This may only be removed after locking to sensor wire.

Fig 10: Identifying New Steering Pinion With Steering Torque Sensor G269 Anti-Twist Element

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-- Insert steering pinion into steering gear housing.

-- Rotate steering pinion until spiral spring with sensor wire -arrow- can be locked. While doing this, the marking applied during removal must align with steering gear housing.

Fig 11: Lock Spiral Spring At Steering Gear Housing

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-- Pull anti-twist element off the spiral spring.

-- Place connector in spiral spring housing.

NOTE:

Connector terminal is coded and fits only in one direction.

-- Tighten the steering pinion with a new hex nut.

Fig 12: Hex Nut From Steering Pinion

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NOTE:

Steering rack moves up to stop when this is done.

-- Apply LOCTITE®5910 to the plug threads.

-- Fill the plug with grease G 052 192 A1, install it and tighten it.

-- Position the steering so it is in the straight position.

-- Coat the gasket -arrow- in the cover with grease G 052 168 A1. Only apply a thin film of it.

Fig 13: Lightly Coat Seal In Cover Using Grease

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-- Install cover with new seal.

Further installation is in the reverse sequence to removal.

-- Install and adjust thrust piece on steering pinion side. Refer to THRUST PIECE, STEERING PINION SIDE .

-- Install steering gear. Refer to STEERING GEAR .

After installing, perform a steering angle sensor -G85- basic setting with the VAS 5051B.

-- Perform the adaptation and basic setting for the steering angle sensor -G269- with the VAS 5051B.

Tightening specifications, refer to STEERING GEAR OVERVIEW, GENERATION I .

-- Perform vehicle alignment. Refer to WHEEL ALIGNMENT .