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

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Note:
Only use puller with leg clamp e.g. Kukko 204-2
(commercial type). Fig. 3 Inner race, pulling off of hub Note:
First install lower circlip. Fig. 4 Wheel bearing, pressing in Page 7 of 8Wheel bearings, servicing - disc brakes (four wheel drive vehicles)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.6

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Note:
First install backing plate on control arm.
Tightening torque: 10 Nm (7 ft lb) Fig. 5 Hub, pressing in Fig. 6 Speed sensor rotor, pressing in - Drive rotor off outer joint using a drift (rotor will be
destroyed).
- Drive new rotor carefully onto stop using a plastic
hammer. Page 8 of 8Wheel bearings, servicing - disc brakes (four wheel drive vehicles)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.6

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Vehicle alignment

Test requirements:
Measuring equipment correctly calibrated
Vehicle unladen1)

Tires inflated to correct pressure
Vehicle accurately aligned, suspension
bounced and rocked several times
Suspension, steering and steering linkage
checked for excessive play and damage.

Note:
Vehicle alignment should not be checked
before the vehicle has completed 1000 to 2000
km (600 to 1200 miles) as then the coil springs
have had time to settle.
The cause of vehicle imbalance may also be,
excessive residual imbalance and/or vertical
wheel runout.
1)
Unladened means: the weight of the vehicle
ready for the road (fuel tank completely filled,
spare wheel, vehicle tools and vehicle jack). Page 1 of 7Vehicle alignment12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.44.1

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Vehicle alignment specifications (front wheel drive vehicles) Front axle
Suspension strut axle
Engine up to 85 kW (115
hp) 110 - 128 kW
(148 - 172 hp)
Version Base suspension Plus
suspension
Total toe1)
(not pressed)
0 10' 0 10' Camber2)
(in straight- ahead position) Maximum permissible
difference between sides -1 20' 20'


max. 20' -1 10' 20'


max. 20' Toe angle difference at 20left and right lock -1 10' 30' -1 40' 30' Caster (not adjustable) Maximum permissible difference between
sides +1 40' 30'

max. 30' +3 20' 30'

max. 30' 1)
Only adjust total toe on right toe rod
2)
Camber corrections can only be made at the wheel bearing housing/suspension strut connection.
Camber adjustment Page 44-6 . Note:
After adjusting steering geometry check position of steering wheel; correct if necessary. Page 2 of 7Vehicle alignment12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.44.1

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Rear axle
Torsion beam trailing arm axle
Engine/version all
Camber1)

Maximum permissible difference between sides -1 30' 10'

max. 20' Total toe 1)
(at specified wheel camber)
Maximum permissible deviation from direction of travel +20' 10'


max. 20' 1)
not adjustable Page 3 of 7Vehicle alignment12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.44.1

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Vehicle alignment specifications (four wheel drive vehicles) Front axle
Suspension strut axle
Engine 85 kW (115 hp) 128 kW (172
hp)
Version Base
suspension Plus
suspension
Total toe1)
(not pressed)
0 10' 0 10' Camber2)
(in straight- ahead position) Maximum permissible
difference between sides -1 20' 20'


max. 30' -1 10' 20'


max. 20' Toe angle difference at 20left and right lock -1 10' 30' -1 40' 30' Caster (not adjustable) Maximum permissible difference between
sides +1 40' 30'

max. 30' +3 20' 30'

max. 30' 1)
Only adjust total toe on right toe rod
2)
Camber corrections can only be made at the wheel bearing housing/suspension strut connection.
Camber adjustment Page 44-6 . Note:
After adjusting steering geometry check position of steering wheel; correct if necessary. Page 4 of 7Vehicle alignment12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.44.1

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Rear axle
Semi-trailing arm axle
Engine 85 kW, 128 kW
(115 hp, 172 hp)
Camber1)

Maximum permissible difference between sides -1 15' 30'

max. 30' Total toe 1)
(at specified camber)
Maximum permissible deviation from direction of travel +15' 20'


max. 20' 1)
Camber and toe corrections possible using eccentric rubber mounting Repair Manual, Suspension, Wheels, Brakes, Steering, Repair Group 42 . Page 5 of 7Vehicle alignment12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.44.1

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Front wheel camber, adjusting Note: - Install special tool as shown in illustration and
slightly pre-tension.
- Loosen suspension strut/wheel bearing housing
connection.
- Adjust camber by turning the spindle to specified
setting.
- Tighten suspension strut/wheel bearing housing
connection.
- Check camber and if necessary, repeat
adjustment. Slight cant of tool is permitted. Do not move steering with tool in place! Before adjusting camber, it is essential to
examine all suspension components for damage
(visual inspection) and to replace any damaged
parts. Because bolts with a shank diameter of 11 mm
diameter have been installed as standard it is no
longer necessary to replace bolts to correct
camber. Page 6 of 7Vehicle alignment12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.44.1

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Calculating the direction of travel:

- If both toe figures have the same preceding sign
(+/+ or -/-), subtract the smaller figure from the
larger figure and divide by 2 Example.
Left rear wheel
toe
Right rear wheel
toe
+ 15' + 5'
15' - 5' =
10'
10' : 2 = 5'
Deviation from direction of travel = 5'

- Add figures with different sign (+/-) and divide by 2 Example.
Left rear wheel
toe
Right rear wheel
toe
+ 15' - 5'
15' + 5' =
20'
20' : 2 =
10'
Deviation from direction of travel = 10'
The individual result is the actual alignment
deviation from the vehicle longitudinal axis. Page 7 of 7Vehicle alignment12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.44.1

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Anti-locking Brake System
(ABS) and Anti-locking Brake
System with Electronic
Differential Lock (ABS/EDL)
Teves 04
The ABS, ABS/EDL brake system is divided
diagonally. The servo-assist is effected
pneumatically, by the vacuum brake servo unit.
Located between the brake master cylinder and
the vacuum servo unit is a mounting bracket for
the hydraulic unit with pump.
The hydraulic unit together with pump, supplies
only the anti-locking brake system (ABS) or anti-
locking brake system and traction control system
(ABS/EDL).
Malfunctions on the ABS, ABS/EDL systems do
not influence the brake system and servo. The
vehicle can be driven without the ABS, ABS/EDL
functions operating. Page 1 of 5Anti-locking Brake System (ABS) and Anti-locking Brake System with Electronic Differential Lock (A...12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.1