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HOMESERVICE MANUALSVOLKSWAGEN2002GOLF GLS, 2.0 K, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 10 (STEERING (A3 PLATFORM))POWER STEERING GEAR (ZF)NOTES
2002 Volkswagen Golf GLS, 2.0 K, Standard

Power steering gear (ZF): Notes

2002 Volkswagen Golf GLS, 2.0 K, StandardSECTION Notes
WARNING: This page does not describe the selected car, but rather 27 other vehicles, including the 2002 Volkswagen Cabrio, 2001 Volkswagen Cabrio, 2000 Volkswagen Cabrio, 1999 Volkswagen Jetta, and 1999 Volkswagen Golf. However, it is still accessible from the selected car via links, so may be relevant.
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.

If power steering gear is malfunctioning determine cause using pressure tests and leakage tests. If a malfunction exists, then replace the steering gear.

NOTE:
  • If reservoir fluid is low check steering system for leaks.
  • If leaks occur at line connections, tighten connections, wipe area dry and recheck for leaks.
  • To check rack seals, loosen the hose clip on the boot and push boot to one side.
  • Always replace all self-locking nuts and bolts.
  • Do not attempt to weld or straighten steering components.
  • Use only steering gear grease, Part No. AOF 063 000 04, to grease steering rack.
  • Type of oil: hydraulic oil, Part No. G 002 000
  • System oil capacity: 0.7-0.9 liter (0.74-0.95 US qt.)
  • Suction hose and pressure line routing, see POWER STEERING PUMP, RESERVOIR AND HYDRAULIC LINES, SERVICING .

The following list pertains to Fig 1.

  1. Tie rod end right 
  2. 50 N.m (37 ft lb) 
  3. Hose clamp 
  4. Boot 
    • Remove tie rod end before removing
    • Check for wear (cuts, cracks), make sure sealing surfaces and sealing lips are clean and undamaged
    • End diameters are larger than those of TRW power steering gear
    • Not interchangeable with boot for TRW steering gear
  5. Clamp 
    • Always replace
    • Tightening, see INSTALLING 
    • Not interchangeable with clamps for TRW steering gear
  6. Tie rod, left 
  7. Clamp 
    • Use pliers to remove
    • Tightening, see INSTALLING 
    • Not interchangeable with clamps for TRW steering gear
  8. Tie rod, right 
    • Removing and installing, see INSTALLING 
    • Wheel alignment, see WHEEL ALIGNMENT, CHECKING
    • Not interchangeable with tie rod for TRW steering gear

      Seat dia. of boot -4- at tie rod:

    • ZF: 15 mm (0.59 in.)
    • TRW: 12.7 mm (0.50 in.)
  9. Tie rod end left 
  10. Self-locking hex nut 
    • Always replace
    • 30 N.m (22 ft lb)
  11. Pressure balancing line 
  12. Self-locking hex nut 
    • Always replace
    • 30 N.m (22 ft lb)
  13. Clamp 
  14. Rubber mounting 

    Inside diameter:

    • ZF: 50 mm (1.97 in.)
    • TRW: 44 mm (1.73 in.)
  15. Steering gear 
    • Removing and installing, see POWER STEERING, SERVICING 
    • Check turning torque
    • Turning torque on vehicles equipped with VR6 engine is approx. 2 N.m (18 in. lb) higher
    • Adjusting, see POWER STEERING GEAR (ZF), ADJUSTING 
    • Steering gear with extra servo assistance only available on vehicles up to 66 kW (90 hp)
  16. 30 N.m (22 ft lb) 
  17. Lower universal joint 
  18. Cover disc 
  19. Sealing ring 
    • Always replace
  20. Union nut 
    • 30 N.m (22 ft lb)
  21. Data plate and company initials 
    22. Fig 1: Exploded View Of Power Steering Gear (ZF)
    G03363202Courtesy of VOLKSWAGEN OF AMERICA, INC.
RENDER: 1.0x

NO RELATED

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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.