check engine VOLKSWAGEN PASSAT 1996 B3, B4 / 3.G Service Repair Manual

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11 - Adjusting screw with
lock nut, 60 Nm (44 ft
lb) Before removing, mark position of adjusting
bolt and lock nut on
housing Steering gear,
adjusting Page 48-24 12 - Pressure spring
13 - Pressure piece Mark installation
position
14 - Housing Check cylinder race for scoring, if necessary
replace steering gear
complete
15 - Inverted tube nut, 30
Nm (22 ft lb)
16 - O-ring Always replace Is not included in
repair kit - see Parts
catalog Page 28 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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Power steering gear, disassembling

- Tie rods, removing - see tie rod, removing and
installing (TRW and ZF power steering), Page 48-77
- Close hose connections on power steering gear
if not already done

1 - Plastic locking screw
2 - Plastic locking screw Note:
Use jaw covers and check jaw covers for
contamination; e.g. metal chips or the like - Clean outside of power steering gear - Open hose clamp and push back boot - Clamp steering gear with toothed rod in vise and
remove tie rod - Remove tie rod - Take steering gear out of vise, screw on bracket
3315/1 and tighten bracket in vise Page 32 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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Parts, cleaning and checking - Install tool VW 771 in the puller - Pull out sealing ring - Before assembly, the housing must be checked for contamination (paint residue, chips, dirt) and
thoroughly cleaned with compressed air and
alcohol
- Clean adhesive surface for adhesive tape in area
of the slot with solvent (e.g. L160 or alcohol)
- Check cylinder race for scoring or other damage. If scoring can be felt, replace entire steering gear
- Clean toothed rod (remove old grease in the tooth
pockets) Page 39 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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Checking toothed rod for scoring If corroded areas or deep scratches are not
noticeable on the toothed rod, the toothed rod must
be replaced
An evaluation of whether the toothed rod was
damaged by force, e.g. by an accident, is not possible
with this visual inspection
If slight scoring (arrows) can be seen/felt on the
toothed rod that are only deep enough that they can
be ground off with sand paper (grain 350-600) the
toothed rod can still be used After sanding, lubricate toothed rod lightly
If the old toothed rod is used again, check the sealing
ring for scoring (visual inspection). If there is scoring
that can be seen or felt, the sealing ring and the O-
ring under it must be replaced. - Sand toothed rod with sandpaper in radial direction (this is only possible with slight scoring)
- Check chamfer on the front sides of the toothed
rod for damage, if necessary remove with a fine
grinding stone and/or sandpaper
1 - Toothed rod 2 - Sand paper (grain 350-600) 3 - Jaw covers Page 40 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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Power steering gear, assembling

Note;
All sealing rings should be lubricated with
hydraulic oil before installing. - Check whether the valve body housing -2- is
absolutely clean on the inside, otherwise clean
- Place sealing ring -1- on tool. The sealing lip -
arrow- points toward tool
- Drive sealing ring into stop 1 - Sealing ring 2 - Valve body housing - Make sure correct installation position of sealing
ring in valve body
- For better view, illustration shows valve tower in
cross section Page 43 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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Needle run-out max. 0.10 mm
If needle run-out is greater than 0.10 mm, screw
pressure piece slightly into housing
If the needle run-out is less than 0.10 mm, screw
pressure piece slightly out of housing

- Tighten lock nut
- Check needle run-out again, if necessary repeat
adjustment

- Remove gauge Close hole in adjusting screw with a stopper from
repair kit
Tie rods, installing - First install clip -2- with gasket -1- in the hole - Apply 1 drop sealing compound, Part No. AMV
188 001 02, in the hole of the clip -arrow- and
press plug -3- into the clip
- See tie rods, removing and installing (TRW and ZF steering gear), Page 48-77 Page 53 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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1 - Power steering gear Removing and
installing Page 48-15 Adjusting Page 48-59 Checking steering
moment Steering gear with
reduced steering
moment only
permissible for
vehicles up to 85 kW Steering moment on
16 V and VR 6
vehicles is approx. 2
Nm higher
2 - Hose clip Always replace- use
pliers to open Tensioning Page 48-81 Page 55 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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3 - Boot Remove ball joint
before removing Check for wear (cuts,
cracks), ensure
sealing surfaces and
sealing lips are clean
and undamaged The end diameters are larger than the boot for TRW power steering
gears Must not be installed
on TRW power
steering gear
4 - Hose clip Always replace - use
pliers to open Tensioning Page 48-81 Must not be installed
on a TRW power
steering gear Page 56 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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Repair Manual, Maintenance 7 - Lock nut, 50 Nm (37 ft
lb)
8 - Tie rod ball joint Splitting Page 48-16 Checking: 9 - Pressure balance pipe
10 - 30 Nm (22 ft lb)
11 - Clamp
12 - Rubber mounting Internal diameter ZF:
50 mm TRW: 44 mm
13 - Data plate and
company initials Page 58 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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Power steering gear, disassembling Note:
Use jaw covers, check jaw covers for contamination;
e.g. metal chips or the like - Tie rods, removing - see tie rod, removing and
installing (TRW and ZF power steering), Page 48-34 - Close hose connections on power steering gear if
not already done
1 - Plastic locking screw 2 - Plastic locking screw - Clean outside of power steering gear - Open hose clamp and push back boot - Clamp steering gear with toothed rod in vise and
remove tie rod - Remove tie rod - Take steering gear out of vise, screw on bracket
3315/1 and tighten bracket in vise
- Remove cover Page 61 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1