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    2002 Volkswagen Passat 1.8L Turbo 4cyl

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    Use Code: GIFTME

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    Malibu 2001-2005

    Removal & Installation

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    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Disable the Supplemental Inflatable Restraint (SIR) system, as outlined in the Chassis Electrical Section.
      WARNING
      Secure the steering wheel utilizing a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the Supplemental Inflatable Restraint (SIR) system.

    4.  
    5. Disconnect the negative battery cable.
    6.  
    7. Raise and support the vehicle.
    8.  
    9. Remove the left front tire.
    10.  
    11. Remove the intermediate shaft to steering gear pinch bolt. Discard the bolt.
    12.  
    13. Disconnect the intermediate shaft from the steering gear.

      Click image to see an enlarged view

      Fig. Intermediate shaft at steering gear and pinch bolt

    14.  
    15. Lower the vehicle.
    16.  
    17. Remove the intermediate shaft pinch bolt at the steering column shaft. Discard the pinch bolt.

      Click image to see an enlarged view

      Fig. Intermediate shaft at steering column and pinch bolt

    18.  
    19. Slide the intermediate shaft off the steering column shaft.
    20.  
    21. To unseat the intermediate shaft seal from the dash, squeeze the 4 tabs on the seal individually, then pull towards the inside of the vehicle.
    22.  
    23. Remove the intermediate shaft and seal from the vehicle.

      Click image to see an enlarged view

      Fig. Intermediate shaft and seal removal

    24.  

    To install:

    1. Install the intermediate shaft and seal through the front of dash.
      NOTE
      To ensure seal is properly seated, inspect the 4 tabs on the seal from the engine side of the seal. Do NOT twist or squeeze the seal during installation.

    2.  
    3. Seat the intermediate shaft seal by pushing forward from the inside of the vehicle, until all four tabs of the seal are fully seated.
    4.  
    5. Connect the new intermediate shaft to the steering column shaft.
    6.  
    7. Install the new steering column pinch bolt to the intermediate shaft as follows:

      For electronic power steering, tighten the bolt to 36 ft. lbs. (49 Nm).
       
      For hydraulic power steering, tighten the bolt to 46 ft. lbs. (62 Nm).
       

    8.  
    9. Connect the intermediate shaft to the steering gear shaft.
    10.  
    11. Install the new steering gear pinch bolt to the intermediate shaft. Tighten pinch bolt to 36 ft. lbs. (49 Nm).
    12.  
    13. Install the left front wheel.
    14.  
    15. Enable SIR system.
    16.  
    17. Connect the negative battery cable.
    18.  

     
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