washer VOLKSWAGEN PASSAT 1996 B3, B4 / 3.G Service Workshop Manual

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Repair Manual, Engine
Mechanical, Repair Group 10 12 - Connecting link
mounting Conical side toward
control arm
13 - Washer Collar faces away from mounting
14 - Self-locking hex nut, 25 Nm (18 ft lb)
15 - Sub-frame Removing and
installing with
assemblies installed:
supporting assemblies
Fig. 5 Remove sub-frame
from below with VAG
1383 (with control arm
but without steering
gear). After installing
check position of
steering wheel and
align front end. Aligning engine-
transmission assembly Page 5 of 82Front Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1

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Reworking cap nut in side member
(Base and Plus suspension)
If the threads of the cap nut in the side member
are damaged, the thread must either be retapped
or the cap nut must be drilled out.
When drilling out proceed as follows.

- Support engine/transmission assembly with 10-
222 A and legs 10-222 A/1.

- Remove the sub-frame.
- Drill out the damaged side member cap nut with
a 10.2 mm diameter drill from underneath.

Note:
When drilling do not tilt the drill.

WARNING!

Wear protective goggles.

- Cut new M 12 x 1.5 thread in cap nut.
- Use a new bolt/washer assembly to secure sub-
frame Page 40-13 . Page 11 of 82Front Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1

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Bolt/washer assemblies for sub-frame Securing point
Thread
Bolt
Part No.
Front sub-frame M12 x 1.5 M12 x 1.5 x 95 10.9
N 101 612.01 1)

Rear sub-frame M12 x 1.5 M12 x 1.5 x 95 10.9 N 101 612.01
Sub-frame bracket M10 M10 x 38 10.9 N 019 541.1
Engine front cross-member to side member M10 M10 x 75 10.9
N 904 078.01 1)
1)
These bolts are not listed in the parts catalog. They must be specially ordered. Page 12 of 82Front Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1

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Note: Tightening torque remains unchanged.
1 - Bolt/washer 2 - Cap nut 3 - Side member 4 - Sub-frame 5 - Bonded rubber mounting/control arm Page 13 of 82Front Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1

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Repair Manual, Suspension, Wheels, Brakes, Steering, Repair Group 00 1 - Self-locking nut, 265
Nm (195 ft lb) Only loosen and tighten with the vehicle standing on its wheels
(danger of accident) Any paint residue
and/or corrosion on
the thread of the outer
joint must be removed
before the nut is
installed
2 - Washer
3 - Brake disc Application 4 - Brake caliper Do not loosen brake
hose when working on
front suspension Hang up with wire or
similar
5 - Hub Pressing out Fig. 3 Pressing in Fig. 8 Pulling off bearing
inner race Fig. 5 Page 15 of 82Front Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1

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15 - Self-locking
bolt/washer assembly,
125 Nm (92 ft lb) For securing brake
carrier
16 - Socket head multi-
point bolt, 45 Nm (33 ft
lb)
17 - Drive shaft To remove and install
separate ball
joint/control arm
connection Fig. 2 Repairing Page 40-46 18 - Circlip Ensure correctly
seated
19 - Self-locking hex nut, 95 Nm (70 ft lb)
20 - Hex bolt Shank diameter 11
mm Adjusting camber
Page 44-6 Mark position before
loosening Page 17 of 82Front Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1

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12 - Mounting for
connecting link Conical side towards
control arm
13 - Washer Collar faces away from mounting
14 - Self-locking hex nut, 25 Nm (18 ft lb)
15 - Hex bolt M 12 x 1.5 x 82 50 Nm (37 ft lb) and
turn 90 further 16 - 25 Nm (18 ft lb)
17 - Hex bolt, 25 Nm (18 ft
lb) To secure stabilizer
bar
18 - Hex bolt, 65 Nm (48 ft
lb)
19 - Clamp for stabilizer bar Page 29 of 82Front Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1

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11 - Circlip Ensure seated
correctly
12 - Wheel bearing Pressing out Fig. 4 Always replace, as it is destroyed during
pressing out Pressing in Fig. 5 13 - Self-locking hex nut, 35 Nm (26 ft lb)
14 - Wheel bearing housing 15 - Self-locking
bolt/washer, 125 Nm
(92 ft lb)
16 - Drive shaft Removing and
installing Page 40-43 Repairing Page 40-46 17 - Socket head multi-
point bolt, 45 Nm (33 ft
lb) Page 38 of 82Front Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1

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1 - Circlip Always replace Remove and install
with VW161 a
2 - Gasket Always replace. Pull
off protective foil and
stick onto joint. (Only
on 100 mm diameter
constant velocity joints
3 - Inner constant velocity
joint 100 mm diameter Only replace complete Pressing off Fig. 3 Pressing on Fig. 4 Greasing Notes
Page 40-46 Checking Page 40-62 4 - Dished washer Inner diameter splined Installation position:
outer diameter
(concave side)
contacts constant
velocity joint Page 47 of 82Front Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1

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10 - Dished washer Outer diameter
(concave side)
contacts thrust washer
11 - Thrust washer
12 - Circlip Always replace Insert in shaft groove 13 - Outer constant velocity joint, 90 mm diameter Only replace complete Removing Fig. 2 Installing: drive onto
shaft with plastic
hammer until
compressed circlip
seats Greasing Notes
Page 40-46 Checking Page 40-60 Page 50 of 82Front Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1