Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Sensor Wire
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
- Vehicle Diagnosis, Testing and Information System VAS 5051B
Removing
-- Remove steering gear. Refer to STEERING GEAR .
-- Clean steering gear in area of cover.
-- Clamp the steering gear as illustrated.
- VW 540/2
- 3253/6 (quantity: 2)
-- Disengage sensor wiring at steering gear housing.
-- Remove seal -1- from cover -2-.
-- Remove cover -2-.
-- Carefully lift seal from steering gear housing.
No seal remnants must enter sensor or housing when doing so.
Prevent Contact with Electrical Components -arrow- !
-- Observe general repair notes. Refer to REPAIR INFORMATION .
-- Disconnect the connector from wiring harness.
It is needed to code new sensor wiring. Connector housing is not installed on new sensor wiring.
A locking mechanism -arrow- for steering pinion spiral spring is located on sensor wire in steering gear housing. When removing the sensor wire, make sure the spiral spring does not twist.
-- Now disconnect harness connector of sensor wire at steering pinion.
To do this, press connector terminal out of spiral spring housing using a screwdriver (3 mm blade width) as depicted in the illustration.
-- Remove locking mechanism from the steering gear housing.
-- Remove sensor wiring from steering gear housing.
Installing
-- Guide sensor wiring into steering gear housing.
-- Lock spiral spring -arrow- at steering gear housing with sensor wiring.
-- Place connector in spiral spring housing.
Connector terminal is coded and fits only in one direction.
-- Disconnect old connections to control module.
-- Press the button -a- in the direction of the -arrow- and then disconnect the connector.
-- Insert new sensor wiring wires into new connector housing.
-- Use old connector as a template for coding.
-- Engage adapter -2- to connector housing -3-.
-- Engage sensor wiring to steering gear housing -1-.
Pay attention to wire routing.
-- Connect connector with control module.
-- Coat the gasket -arrow- in the cover with grease G 052 168 A1. Only apply a thin film of it.
-- Install cover with new seal.
Further installation is in the reverse sequence to removal.
Tightening specifications, refer to STEERING GEAR OVERVIEW, GENERATION I .
-- Perform vehicle alignment. Refer to WHEEL ALIGNMENT .
After installing, perform a steering angle sensor -G85- basic setting with the VAS 5051B.
NO RELATED
Use the Manual With the Right Hardware
Pair factory procedures with proven DIY tools so the instructions are easier to execute.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.