Volkswagen 2004 Golf User Manual

P
r
o
t
e
c
t
e
d
b
y
c
o
p
y
r
i
g
h
t
.
C
o
p
y
i
n
g
f
o
r
p
r
i
v
a
t
e
o
r
c
o
m
m
e
r
c
i
a
l
p
u
r
p
o
s
e
s
,
i
n
p
a
r
t
o
r
i
n
w
h
o
l
e
,
i
s
n
o
t
p
e
r
m
i
t
t
e
d
u
n
l
e
s
s
a
u
t
h
o
r
i
s
e
d
b
y
V
o
l
k
s
w
a
g
e
n
A
G
.
V
o
l
k
s
w
a
g
e
n
A
G
d
o
e
s
n
o
t
g
u
a
r
a
n
t
e
e
o
r
a
c
c
e
p
t
a
n
y
l
i
a
b
i
l
i
t
y
w
i
t
h
r
e
s
p
e
c
t
t
o
t
h
e
c
o
r
r
e
c
t
n
e
s
s
o
f
i
n
f
o
r
m
a
t
i
o
n
i
n
t
h
i
s
d
o
c
u
m
e
n
t
.
C
o
p
y
r
i
g
h
t
b
y
V
o
l
k
s
w
a
g
e
n
A
G
.
2 General repair instructions
To achieve the desired results when performing repairs on the
steering box it is important to work with the greatest possible care
and cleanliness, and to use proper tools in good condition. Also
note the basic rules on safety when performing repair procedures.
A number of general notes on the individual repair procedures,
which were otherwise repeated in the relevant sections of the
manual, are summarised here. They apply for this particular work‐
shop manual.
For a description of the design and function of the steering as‐
sembly, see ⇒ Self-study programme No. 317 ; The electrome‐
chanical power-assisted steering with double pinion .
2.1 Steering box
♦ Thoroughly clean all unions and the adjacent areas before
disconnecting.
♦ When installing the steering box, make sure that dowel
sleeves between bracket and steering box are seated correct‐
ly.
♦ Place removed parts on a clean surface and cover them to
prevent them from getting dirty. Use sheeting and paper for
this purpose. Use only lint-free cloths.
♦ Fit only clean parts; remove new parts from their packaging
only immediately prior to fitting.
♦ Use only the grease and sealants with specified part numbers.
♦ If repairs cannot be carried out immediately, carefully cover or
seal open components.
♦ Two different types of steering boxes were fitted in model year
2004. Notes on identification ⇒ page 398 .
♦ From model year 2009, a new, 3rd generation, steering box is
being used. Notes on differentiating between 2nd and 3rd
generations ⇒ page 399 .
2.2 Gaskets and seals
♦ Always renew gaskets and seals.
♦ After removing all seals, inspect the contact faces on housings
and shafts for burrs and damage and remove all which are
found.
♦ Completely remove all residue from liquid sealants from the
sealing surfaces, making sure that no residual sealant gets
into the steering box housing.
2.3 Nuts and bolts
♦ Loosen and tighten bolts and nuts securing covers and hous‐
ings diagonally.
♦ Avoid canting sensitive parts such as servo motor with control
unit. Loosen and tighten them diagonally in stages.
♦ Specified torques given are for unlubricated nuts, bolts and
screws.
♦ Always renew self-locking nuts and bolts.
Golf 2004 ➤ , Golf Plus 2005 ➤
Running gear, axles, steering - Edition 08.2009
334 Rep. Gr.48 - Steering

Volkswagen 2004 Golf Specifications

General

Brand	Volkswagen
Model	2004 Golf
Category	Automobile
Language	English