Steering column, steering column tube and steering wheel, servicing

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1 48-1 Steering column, steering column tube and steering wheel, servicing Airbag functional check and airbag On Board Diagnostic (OBD) program Repair Manual, Body-Exterior, Body- Interior, Repair Group 01. WARNING! The airbag igniter is an explosive device. Handled improperly or without adequate safeguards, it can be accidently activated and cause serious personal injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians should test, disassemble or service the airbag system. Before starting any work on the steering components of an airbag -equipped car, read the safety precautions, Repair Manual, Body-Exterior, Body- Interior, Repair Group 69.

2 48-2 WARNING! Do not re-use fasteners that are worn or deformed in normal use. Some fasteners are designed to be used only once, and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts, washers, circlips and cotter pins. Always follow recommendations in this manual-replace these fasteners with new parts where indicated, and any other time it is deemed necessary by inspection. Notes: All parts marked with an asterisk (*) can be preassembled outside of the vehicle Fig. 5. Always replace self-locking nuts and bolts. Do not attempt to repair damaged steering components by welding or straightening.

3 Hex bolt 30 Nm (22 ft lb) 2 - Protective cover 3 - Lower universal joint Different number of splines from VIN 1HN page Connecting piece 5 - Connecting sleeve 6 - Hex nut 30 Nm (22 ft lb) 7 - Upper universal joint 8 - Hex bolt 9 - Spring 10 - Lower steering column bearing Drive on using slide hammer set VW 771 and large washer Drive off downward using a tube

4 Steering column* Note: With torque overload clutch, cannot be dismantled Standard on Cabrio from m.y Can be retrofitted to all models Use corresponding steering column tube and steering column switch when retrofitting If a torque of over 100 Nm (74 ft lb) is exerted on steering wheel, then the steering column will also turn without damaging the locking pin. The straight ahead position will not be altered Lower steering column section* Remove by pulling upward out of steering column tube Checking length Fig. 3 Supplied as replacement part complete with upper section 13 - Shear bolt Tighten until head shears off Drill out to remove

5 14 - Assembly carrier

6 Steering column tube Lower bracket must lie fully on foot pedal cluster mount Steering column with torque overload clutch has a longer cut-out on underside of tube 16 - Steering column* Remove by pulling upward out of steering column tube Supplied as replacement part complete with upper section 17 - Steering wheel for airbag Removing and installing page Removing and installing airbag spiral spring -F138- page Shear bolt Before tightening, check distance between steering wheel and steering lock housing trim Drill out to remove 19 - Support ring

7 Steering column switches 21 - Spring Servicing Repair Manual, Electrical equipment, Repair Group 96 Adjusting distance between steering wheel and steering lock housing Fig. 4 For other versions of steering column with torque overload clutch parts catalog microfiche 22 - Splined adaptor sleeve Removing Fig. 1 Installing Fig Steering wheel 24 - Hex nut Install in centered position For vehicles NOT equipped with airbag 50 Nm (37 ft lb) 25 - Cover plate For vehicles NOT equipped with airbag

8 48-7 Fig. 1 Removing splined adapter sleeve Only use puller with leg clamp (e.g. Kukko 204/2 commercial type). Fig. 2 Installing splined adapter sleeve - Place sleeve on steering column and press on using hex nut up to end of thread. - Remove nut, reinstall with washer, and press sleeve on fully with nut until sleeve is firmly on its seat.

9 48-8 Fig. 3 Checking length of steering column The small sheet metal lug on the lower section must be visible in the hole in the upper section (arrow). If necessary pull both sections firmly apart onto stop. Fig. 4 Checking distance between steering wheel and steering lock housing trim - Adjust to dimension -a- by moving steering lock housing. Dimension -a- = mm ( in.) - Tighten shear-head bolt until head shears off.

10 48-9 Fig. 5 Pre-assembling steering column - Carefully clamp lower section of steering column in vice so that upper section is supported on jaws and two halves cannot slide into each other.

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