This procedure is from URL: http://www.vwtdirepair.com (Darell's VW TDI Maintenance Page). Go to this URL to see the photos for this procedure and content.
The A3 VW Jetta is equipped from the factory with a Supplemental Restraint System (SRS) or air bag assembly. The SRS system is designed to protect the driver and front seat passenger from death or serious bodily injury in the event of a head-on collision.
Warning
Before disassembly of the steering column, disable the air bag assembly (shown below). Accidental deployment of the air bag assembly could cause serious personal injury.
The ignition switch is located under the steering column. It is is located to the right of the steering column next to the turn signal assembly. The switch and key lock cylinder is mounted in a cast metal housing. It is secured to the wiring harness. The key lock cylinder does not have to be removed to replace the switch.
Figure 40-1 shows a typical ignition switch used on the A3 VW Jetta TDI. The switch can easily be replaced following the below steps in your driveway with a saving of over $200.00 in professional repairs. The only special tool required is a counter-hold 2-jaw gear puller (available for purchase or rental at auto parts stores). This tool is required to remove the collar on the steering column to access the ignition switch.
Figure 40-1 Typical Ignition Switch in VW A3 Jetta
After removal, the ignition switch can be checked with an digital multi-meter (DMM). One method is to backprobe the wires to the switch with a DMM. Power from the battery to feed the switch is through the two (2) red wires attached to the switch terminals. To check for switch continuity, place the leads of the DMM to the red and other color coded wires in different selected positions. With the switch "OFF" there should be no continuity in any of the wires attached to the switch terminals. With the key in the ignition, turn the switch to the "RUN" position. There should be continuity in the red/black and black wires of the switch. Switches that have to be jiggled to form a connection should be replaced.
Step 1 - Using a 1/4-inch square drive 5mm hex bit and a 1/4-inch square drive ratchet, remove the two (2) screws that secures the air bag assembly to the steering column (Figure 40-2)
Figure 40-2 Removing Screws to Air Bag
Step 2 - Remove the spiral cable (it is a snap fit) and colored "yellow" to the air bag assembly (Figure 40-3). Figure 40-4 shows the spiral cable removed to the air bag assembly.
Figure 40-3 Air Bag Spiral Cable
Figure 40-4 Spiral Cable Removed
Note
The signal from the ECM is sent through the spiral cable connected to the air bag assembly. The spiral cable is a flat ribbon that is wound with many turns of conductive wire so that it can transmit an electrical signal in any steering wheel position. Disconnecting the spiral cable disables the drivers-side air bag.
Warning
Do not use a memory keeper device to preserve the settings in the ECM's memory when working around the air bag assembly.
Step 3 - Using a 1/2-inch square drive breaker bar and a 24mm 1/2-inch square drive socket, remove the nut that secures the steering wheel to the steering column (Figure 40-5).
Figure 40-5 Removing Nut to Steering Wheel
Step 4 -Remove the screws that secures the air bag counter weight to the steering column. Figure 40-6 shows the screws being removed.
Figure 40-6 Removing Screws to Air Bag Counter Weight
Step 5 - Remove the counter weight from the steering column (Figure 40-7).
Figure 40-7 Removing Air Bag Counter Weight
Step 6 - Using 1/4-inch square drive T25 torx bit and 1/4-inch square drive ratchet, remove the screws that secures the clock spring to the steering column (Figure 40-8).
Figure 40-8 Removing Clock Spring Assembly
Step 7 - Remove the steering wheel from the steering column. Figure 40-9 shows the steering wheel being removed.
Figure 40-9 Removing Steering Wheel
Step 8 - Using a T20 torx 1/4-inch square drive bit and 1/4-inch square drive ratchet remove the assembly that houses the air bag spiral cable ( See Figure 40-10). Figure 40-11 shows the spiral cable housing removed.
Figure 40-10 Removing Spiral Cable Housing
Figure 40-11 Spiral Cable Housing Removed
Step 9 - Using a flat-blade screwdriver, remove the screws from the plate securing the turn signal, and wipers, to the steering column (See Figure 40-12).
Figure 40-12 Removing Screws to Turn Signal Assembly
Step 10 - Using a phillips screwdriver, remove the two (2) screws under the dash and remove the trim pieces attached to the steering column (See Figure 40-13).
Figure 40-13 Removing Screws to Steering Column Trim
Step 11 - Remove the turn signal and wiper assembly from the steering column (See Figure 40-14). Figure 40-15 shows the turn signal assembly removed.
Figure 40-14 Removing Turn Signal Assembly
Figure 40-15 Turn Signal Assembly Removed
Step 12 - Using Vise-Grip pliers, remove the screw securing the ignition switch assembly to the steering column (See Figure 40-16).
Figure 40-16 Removing Screw to Ignition Switch
Step 13 - Using a magic marker or scribe, indent a mark on the steering column that aligns to the mark on the collar (See Figure 40-17).
Figure 40-17 Photo Showing Alignment Mark on Collar
Note
Before going to Step 14, make sure the mark on the collar and a mark on the steering column are in alignment and visable before the collar is removed. If the collar is not aligned to the mark on the column, the steering wheel will not be straight when reinstalled.
Step 14 - Using a counter-hold two (2) jaw gear puller, position the jaws around the ridge of collar and the adjustment screw in the center of the steering column (See Figure 40-18).
Figure 40-18 Removing Steering Column Collar
Step 15 - Using a 11/16 box-end wrench, turn the adjustment screw of puller in a clock-wise direction until the collar is loose on the steering column (See Figure 40-19).
Figure 40-19 Removing Collar on Steering Column
Step 16 - Remove puller and collar from steering column.
Step 17 - Remove the ignition switch and key cylinder assembly from the steering column (See Figure 40-20).
Figure 40-20 Old Ignition Switch Removed
Step 18 - Install the new replacement switch in the cavity of the ignition switch and key cylinder assembly on the steering column (See Figure 40-21).
Figure 40-21 New Switch Installed in Housing
Step 19 - Install the replaced ignition switch and key cylinder housing on the steering column (Figure 40-22). Replace other parts reversing the steps from which they were removed.
Figure 40-22 Install Replacement Ignition Switch and Housing
Note
When installing the collar on the steering column, use the 24mm nut and breaker bar to position the collar properly on the steering column. Figure 40-23 shows the collar positioned on the steering column.
Figure 40-23 Positioning Collar on Steering Column
2-jaw gear puller
Replacement ignition switch
Digital Multi-meter
1/4-inch square drive 5mm hex bit socket
1/4-inch square drive ratchet
1/2-inch square drive breaker bar
1/2-inch square drive 24mm socket
Flat-blade screwdriver
1/4-inch square drive T-20 torx bit
1/4-inch square drive T-25 torx bit
Phillips screwdriver
Vise grip pliers
Magic marker
11/16-inch box wrench
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