Replacement of ignition switch 6N2

[jets]

A couple of weeks ago I tried starting the Polo to go to dinner. Turned the key & nothing, no lights on instruments. As we were running late I took another car. I was thinking a dead battery but when we returned home I tried the headlights & they worked fine. Next morning I checked the fuses under the cover on top of the battery & they were fine. Checking & working through the wiring diag. I decided that the ignition switch was faulty.
Going through the posts on google I worked out there is two maybe three ways to replace the switch. First way is to remove airbag/steering wheel & ignition barrel body. The second is to undo the universal joint at the bottom of the column & pull the wheel & column together. I discounted this method as many had difficulty getting it back together & in the right position. You also need to be young & smallish to get to the bolt near the pedals. I decided on the first method.
Remove the plastic cover under steering wheel in front of the steering wheel. Three screws are Torx T20, one is T30. Unclip the yellow plug & slide of the foam sleeve.
Next thing is to remove neg. terminal on battery & let the controller discharge. Some say leave for 30 mins. but I left it overnight. The first problem is how to remove the airbag. Lots of well meaning people tried to explain it but I found this to be one of the best.
VW Polo 2001 steering wheel & clock spring spiral cable - YouTube
It is important to get the screwdriver on the right side of the circlip. This involves holding the handle of the screwdriver as close as possible to the steering column or use a bent screwdriver. No one mentioned this & I spent a long time trying to release the clip. Once one side is released place a wedge under the cover so it doesn't pop back on again as you remove the other side. A dismantled clothes peg worked for me. Pull on the third spoke carefully & once released only move a short distance to disconnect the wiring connection to airbag & horn.
Undo the nut on the column [24mm socket] & note if there is marks so that the wheel goes back exactly on the same spline. The steering wheel should be horizontal with wheels in the straight ahead position before removing.
Do not disconnect the clockspring from the wheel but pull the cable with the yellow plug away with the wheel.
Pull the column down to the lowest position & lock in place. Remove plastic cover from rear of ign. switch plug & release wiring plug.
This took me around one hour because plug was very tight & hard to release. There is very little room to hold it. Remove all the other plugs.[there are 8 altogether including the yellow one. Take a note where all the wires sit as they will need to go back in place exactly.
This photo shows the wiper indicator switch still in pos. after the indicator switch is removed by removing three small screws.



This photo shows the bare shaft with the splined sleeve in place.



This pic is pulling the splined sleeve. Some say this is the most difficult part of the procedure but with this tool I found it the easiest.



This is the old shear bolt that holds the ignition barrel in place. Originally it would have had a hex. head that after installing would be broken off. Normally to remove it you can chisel or drill it. By gripping in this manner with a pair of good vice grip pliers it is possible to remove it. It's an anti theft feature to stop removal of the body & overcome the steering lock.



This is the replacement shear screw. An external torx E8 is needed to install. This design will be harder to remove once broken.



Empty ignition barrel body.



New switch installed showing the small screw that holds it in. A small Phillips head screw driver is needed. All the work so far is just to remove that screw, unplug the switch & reinstall the screw.



The ign. barrel housing is now replaced, ignition key in on position to allow it to go past column lock lug. Incidentally, the cable is not disconnected to the immobilizer ring. You will find it just goes over the end of the shaft connected. The shear screw can now be installed but not broken off. Slide spring back onto shaft followed by the splined sleeve, making sure marks line up. Sleeve is driven on with a suitable piece of tube. It doesn't need to go all the way because the steering wheel nut will pull it on later.
Install wiper switch as shown in first photo & reconnect plugs. Now install LH switch [blinkers] & screw together with the 3 small screws.
These aren't done up very tight as they screw into aluminium & could easily be stripped.
Plug in the remainder of the electrical plugs.
Slide the steering wheel back onto the column, threading the twin cable, with the yellow plug, through. Tighten nut up to 50Nm. Do not tighten against column lock. I went for a drive to make sure that steering wheel was in correct spline. This will involve clearing codes with VCDS later. If there are no scrapes from the wheel you can probably tighten the shear screw at this point.
Disconnect battery again & wait at least 30mins or more before plugging in airbag. Once again I stopped for the day & left overnight to be sure. Don't forget to also plug in the horn wire before pushing the airbag one side at a time & then the lower clips.
Slide foam sleeve back over yellow plug & reconnect.
I had a problem with the airbag light staying on & mucked around, looked on google for code 00588 Airbag Igniter. Drivers Side [N95]
33-10 Resistance Too Low- Intermittent. I finished up removing the airbag again [after disconnecting battery & waiting] to check elect. connections & reinstalling. This time after clearing the stored code the airbag light went off. Hooray
Before I connected the battery each time I turned the ignition switch to the on position. That way, if the bag goes off you are not in the car. I cannot stress enough that airbags can be dangerous & if you are not comfortable with what you are doing leave the replacement of the airbag to someone who is. Usual disclaimer, I won't be held responsible if things go pearshaped for you & the airbag goes off or something else goes wrong.
Reinstall the plastic covers in front of the steering wheel & your done.
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