Volkswagen Passat B6 2005 - Steering column, assembly overview Стр.

1 из 20

48 - 4

Steering column, assembly overview

Note :

„ Welding and straightening operations are not

permitted on load-bearing or wheel-controlling
components.

„ Always replace self-locking nuts.

„ Always replaced corroded bolts/nuts.

„ Hex head bolt

„ Torque specifications 48-

3, Steering, torque
specifications
Steering column, assembly overview Стр. 2 из 20

„ Steering column cross member

„ Mounting bracket

„ Removing and installing

48-4, Mounting bracket,
removing and installing

„ Hex head bolt

„ Torque specifications 48-

3, Steering, torque
specifications

„ Replace each time it is

removed

„ Steering column

„ Removing and installing

48-4, Steering column,
removing and installing

„ Handle plate

„ Bolt

„ Torque specifications 48-

3, Steering, torque
specifications

„ Hex head bolt

„ Torque specifications 48-

3, Steering, torque
specifications

„ Frequency damper

„ Removing and installing

48-4, Frequency damper,
removing and installing

„ Hex head bolt

„ Torque specifications 48-

3, Steering, torque
specifications
Steering column, assembly overview Стр. 3 из 20

„ Hex head bolt

„ Torque specifications 48-

3, Steering, torque
specifications

Steering wheel, removing and installing

Special tools, testers and auxiliary items required

„ Torque wrench V.A.G 1332

Removing

- Remove driver side airbag unit

Repair Manual, Body Interior, Repair Group 69, Airbag;

Driver side airbag unit, removing and installing

.
Steering column, assembly overview Стр. 4 из 20

- Disconnect harness connector - 1 -

and - 2 - for spiral spring.

- Turn steering wheel to center position

(wheels pointing straight ahead)

- Remove bolt - 3 - and pull steering

wheel off from steering column.

Installing

- Place steering wheel on steering

column.
Steering column, assembly overview Стр. 5 из 20

- The central markings of steering wheel

and column - arrows - must align.

- Guide connector for Steering Angle

Sensor G85 into intended opening in
base of steering wheel.

- Connect connector plug - 1 - with

connection - 2 - of Steering Angle
Sensor G85 .

- Fasten steering wheel with bolt - 3 - ,

Torque specification 48-3, Steering,
torque specifications .

- Mark bolt with a punch.

The bolt may only be used 5 times.

Steering column, removing and installing

Special tools, testers and auxiliary items required

Steering column, assembly overview Стр. 6 из 20

„ Torque wrench V.A.G 1331

„ Torque wrench V.A.G 1332

Removing

The steering column is only available as a complete

replacement part. Service is not possible.

The steering lock housing can be transferred

Repair Manual, Electrical Equipment, Repair Group 94,

Ignition switch and lock cylinder

Caution!

Before starting work on the electrical system and

removing the steering wheel, the following conditions
must be met:

„ Disconnect Ground (GND) strap from the battery

Steering column, assembly overview Стр. 7 из 20

Repair Manual, Electrical Equipment, Repair Group

27, Battery; Battery, disconnecting and connecting

„ The wheels must be in the straight ahead

position.

If you do not follow these instructions, the airbag

system may fail during subsequent vehicle operation.

- Set wheels to straight ahead position.

- Pull lever below steering column down.

- Pivot steering column downward and as far outward as

possible.

- Push lever below steering column up again.

- Remove airbag from steering wheel

Repair Manual, Body Interior, Repair Group 69, Airbag;

Driver side airbag unit, removing and installing

- Remove steering wheel 48-4, Steering wheel,

removing and installing .

- Remove steering column switch trim

Repair Manual, Body Interior, Repair Group 68,

Compartments, covers and trims; Steering column trim,
removing and installing

- Remove left trim panel on driver side

Repair Manual, Body Interior, Repair Group 68,

Compartments, covers and trims; Left driver side trim,
removing and installing

.
Steering column, assembly overview Стр. 8 из 20

- Remove steering column switch

Repair Manual, Electrical Equipment, Repair Group 94,

Steering column switch; Steering column switch, removing
and installing

- Remove footwell vents from below steering column

Repair Manual, Heating Air Conditioning, Repair Group

80, Heater, servicing

- Separate all connections and ground cable on steering

column.

- Remove nuts - arrows - and remove footwell trim - 1 -

.

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

steering gear.
Steering column, assembly overview Стр. 9 из 20

- Remove cable channel - 1 - from below steering column.

To do this, lightly lift on tabs - arrows - on both sides and
pull cable channel out of guide on steering column.

- Remove plastic screws - 2 - .

- Lower steering column slightly and carefully pull it out

upward.

Caution!

Pay particular attention to the correct handling and

transport of the steering column 48-4, Steering
column, handling and transporting .

Installing

- Hook steering column into assembly aid on mounting

bracket.

- Align steering column to mounting bracket and set it in

place.
Steering column, assembly overview Стр. 10 из 20

Thereby tabs - arrows A - of mounting bracket and holes

- arrows B - of steering column must be positioned
together and be placed into one another.

This way the correct installation position of steering

column to mounting bracket is ensured.

- Fasten bolts - 2 - to steering column.

- Install cable channel - 1 - below steering column.

The tabs - arrows - must engage into guide on both sides.

- Install universal joint - 2 - on steering column pinion and

tighten bolt - 1 - .
Steering column, assembly overview Стр. 11 из 20

- Install footwell trim - 1 - and fasten nuts - arrows - .

- Connect all connections and ground cable on steering

column.

- Install footwell vents below steering column

Repair Manual, Heating Air Conditioning, Repair Group

80, Heater, servicing

- Install steering column switch

Repair Manual, Electrical Equipment, Repair Group 94,

Steering column switch; Steering column switch, removing
and installing

- Install steering column switch trim

Repair Manual, Body Interior, Repair Group 68,

Compartments, covers and trims; Steering column trim,
removing and installing

- Install left trim panel on driver side

Repair Manual, Body Interior, Repair Group 68,

Compartments, covers and trims; Left driver side trim,
removing and installing
Steering column, assembly overview Стр. 12 из 20

- Install steering wheel 48-4, Steering wheel, removing

and installing .

- Install airbag to steering wheel

Repair Manual, Body Interior, Repair Group 69, Airbag;

Driver side airbag unit, removing and installing

Torque specifications 48-3, Steering, torque

specifications .

- Perform basic setting for steering angle sensor G85

using vehicle diagnosis, testing and information system
VAS 5051 .

The basic setting for steering angle sensor G85 must be

checked after the following work:

„ If Steering Angle Sensor G85 was removed or

replaced,

„ After removing or replacing steering column;

„ After removing or replacing steering gear;

„ When steering wheel is repositioned.

Steering column, handling and transporting

Caution!

„ The correct handling of the steering column

must always be adhered to.

„ Incorrectly handling the steering column can

lead to damages to the steering column and
thereby lead to safety risks.
Steering column, assembly overview Стр. 13 из 20

Correct handling and transporting of steering column

„ Transport steering column with two hands

„ Hold steering column by upper steering column tube

and in area of upper universal joint

„ The clamping lever - 1 - must always face upward

when transporting, so that the steering shaft does
not come into contact with steering column lock - 2 -
.

Incorrect handling of steering column

Transporting steering column by the following components

can lead to damages:

„ Clamping lever
„ Weight balancing springs
„ Deformation element
Steering column, assembly overview Стр. 14 из 20

Incorrect handling of steering column with safety risks

The following handling practices will lead to damage of

steering column lock - 1 - :

„ Transporting steering column with one hand by the

steering shaft

„ Bending joints beyond 90 and coming to a stop on

steering column lock

„ Setting steering shaft down onto steering column

lock

„ Setting steering shaft down onto steering column

lock

Steering column, checking for damage

Visual check

- Check all steering column parts for damage.

Functional check

- Check that steering column turns easily without jerking.

- Check that steering column can be adjusted for height

and reach.

Mounting bracket, removing and installing

Steering column, assembly overview Стр. 15 из 20

Special tools, testers and auxiliary items required

„ Torque wrench V.A.G 1331

Removing

- Remove steering column 48-4, Steering column,

removing and installing .

- Remove instrument cluster

Repair Manual, Electrical Equipment, Repair Group 90,

Instrument cluster; Instrument cluster, removing and
installing

- Remove bolts - arrows - from under console.

Steering column, assembly overview Стр. 16 из 20

- Push connector - 1 - in direction of - arrow - and

remove it from mounting in mounting bracket.

- Remove bolt - arrow A - .

- Remove bolts - arrows B - from console on body.

Note:

„ The bolts - arrows B - are screwed in from direction

of crossmember.

- Remove bolts - 1 - and - 2 - and remove mounting

bracket from body.

Installing
Steering column, assembly overview Стр. 17 из 20

- Set mounting bracket in place and fasten bolts - 1 - and -

2- .

- Install bolts - arrows B - .

Note:

„ The bolts - arrows B - are screwed in from direction

of crossmember.

- Install bolt - arrow A - .

- Set connector - 1 - into mounting in mounting bracket

and push it in opposite direction of - arrow - up to stop.
Steering column, assembly overview Стр. 18 из 20

- Install bolts - arrows - under console.

- Install steering column 48-4, Installing .

- Install instrument cluster

Repair Manual, Electrical Equipment, Repair Group 90,

Instrument cluster; Instrument cluster, removing and
installing

Torque specifications 48-3, Steering, torque

specifications

- Perform basic setting for steering angle sensor G85

using vehicle diagnosis, testing and information system
VAS 5051 .

Frequency damper, removing and installing

Special tools, testers and auxiliary items required

„ Torque wrench V.A.G 1331

Removing

- Remove plenum chamber bulkhead

Repair Manual, Body Exterior, Repair Group 50, Plenum

chamber bulkhead - Assembly overview

.
Steering column, assembly overview Стр. 19 из 20

- Remove bolt - arrow - in plenum chamber.

- Remove steering column 48-4, Steering column,

removing and installing .

- Remove bolts - 1 - .

- Remove bolt - 2 - and remove frequency damper - 3 - .

Installing

- Fasten frequency damper to body by fastening bolt -

arrow - .
Steering column, assembly overview Стр. 20 из 20

- Install and fasten bolt - 2 - .

- Fasten bolts - 1 - for frequency damper - 3 - to 10 Nm.

- Install steering column 48-4, Installing .

- Install plenum chamber bulkhead

Repair Manual, Body Exterior, Repair Group 50, Plenum

chamber bulkhead - Assembly overview

Torque specifications 48-3, Steering, torque

specifications

- Perform basic setting for steering angle sensor G85

using vehicle diagnosis, testing and information system
VAS 5051 .