steering VOLKSWAGEN PASSAT 1995 B3, B4 / 3.G Service Workshop Manual

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Note: The boot must not be installed twisted. Page 83 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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Left-hand tie rod length, checking and
adjusting

- Check dimension "a" on left-hand tie rod and if
necessary adjust. Dimension "a" = 395 + 1 mm (all except from VR6
and 16V) Dimension "a" = 413 1 mm (VR6 and 16V)
Note: Only adjust toe on right-hand tie rod. Before installing new left-hand tie rod check
dimension "a" and if necessary adjust. Page 84 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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Assembly overview: vane pump,
reservoir and hydraulic lines (vehicles
with 4-Cyl. engines)
It is not intended that repair work be carried out
on the vane pump. If complaints are received
determine cause with the help of pressure and
leakage tests. Replace pump if faulty.

Note:
Pumps supplied as spare parts are not filled
with oil. Fill the pump with G 002 000 hydraulic
oil to rotate it by hand, otherwise the pump may
be damaged or noisy during operation.
Type of oil: hydraulic oil G 002 000 Oil system capacity: 0.7 - 0.9 Itr. (0.74 - 0.95
qt.)
Do not reuse drained hydraulic oil. Always replace O-rings. Page 85 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 - Cooling line Secured to
crossmember item
9 2 - Bracket Various versions
depending on
engine/transmission Page 48-96 3 - Pressure line
4 - Suction line Hydraulic pump -
Cooling line
5 - Hose clamp, 3 Nm (27
in lb)
6 - Hydraulic pump With V-belt pulley 7 - Hydraulic pump With ribbed belt
sprocket
8 - O-ring Always replace Page 86 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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9 - Pressure line union
10 - Banjo bolt, 35 Nm (26 ft lb)
11 - Hex bolt, 10 Nm (7 ft lb) Page 87 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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Assembly overview:
Hydraulic lines, reservoir
(vehicles with 4-Cyl.
engines)
Notes Page 48-85 1 - Power steering gear
2 - O-ring Always replace 3 - Return line, 30 Nm (22
ft lb)
4 - Pressure line, 30 Nm
(22 ft lb)
5 - Reservoir
6 - Rubber ring
7 - Hose clamp
8 - Rubber insert
9 - Captive nut
10 - Bracket Page 88 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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11 - Self-tapping screw
12 - Hose clamp
13 - Return hose
14 - Suction hose Reservoir - Cooling
line
15 - Cooling line
16 - Threaded stud
17 - Bracket Page 89 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 vane
pump, removing and
installing (vehicles with 4-
Cyl. engines)
Note: Always replace self-locking
nuts and bolts. Pumps supplied as spare
parts are not filled with
hydraulic oil. Fill the pump with G 002 000 hydraulic oil and rotate it by hand, otherwise the pump may be damaged or noisy during
operation. Do not reuse drained
hydraulic oil.
1 - Suction hose
2 - Pressure hose
3 - Hose clamp
4 - Tensioning bolt Tensioning V-belts
item 11 Page 90 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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Maintenance Manual 5 - 20 Nm(15 ft Ib)
6 - Front swivel bracket
7 - 20 Nm (15 ft lb)
8 - Adjustment bracket
9 - 20 Nm (15 ft lb)
10 - Bracket
11 - V-belts 11.5 x 685 Gas engine 11.5 x 730 Diesel
engine 11.5 x 755 Gas engine with air conditioner 11.5 x 790 Diesel
engine with air
conditioner Tensioning Page 48-93 Checking condition 12 - 25 Nm (18 ft lb) Page 91 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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13 - V-belt pulley When installing the V-
belt pulley ensure that
the crankshaft pulley
and the vane pump
pulley are aligned
14 - Shim Only installed on
vehicles with Diesel
engine
15 - 20 Nm (15 ft lb)
16 - Rear swivel bracket
17 - Vane pump Checking delivery
pressure Page 48-13 Page 92 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1