Engine oil VOLKSWAGEN PASSAT 1995 B3, B4 / 3.G Service User Guide

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Fig. 7 Inner wheel bearing outer race,
pressing in Fig. 8 Oil seal, driving in Page 18 of 18Wheel bearings, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.2

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17 - Coil spring Removing and
installing Page 42-13 Allocation Parts
catalog 18 - Packing
19 - Circlip
20 - Lower spring plate Installation position
Fig. 1 21 - Shock absorber Can be replaced
individually Removing and
installing Page 42-4
and Page 42-37 Check shock absorber
for leaks and noises Application see Parts
catalog Page 3 of 6Suspension strut, disassembling and assembling (four wheel drive vehicles)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.5

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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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Notes for repair work on ABS, ABS/EDL
Before doing any repair work on the anti-locking system, determine the cause of the malfunction
using On Board Diagnostic (OBD).
Repair Manual, Brake System On Board Diagnostic (OBD), Repair Group 01 Before working on the ABS, ABS/EDL system,
disconnect the battery Ground strap. On
vehicles with coded radio, obtain cooling.
When working with brake fluid, observe the
relevant safety precautions and notes Page 47-27 . After work for which the brake system had to be opened, bleed the brake system with brake filler and bleeder unit VAS 5234 Page 47-27 . During the final road test, make sure that a
controlled brake test is performed at least once
(pulsations must be felt at the brake pedal).
Absolute cleanliness is required when working
on the anti-locking brake system; it is not
permitted to use any products which contain
mineral oils, such as oils, greases etc. Page 2 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

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CAUTION!
During the final road test, make sure that at
least one controlled brake test is included
(pulsations must be felt at the brake pedal).
Absolute cleanliness is required when
working on the ABS or ABS/EDL system. DO
NOT use any products that contain mineral
oil, such as oils, greases, etc.
Thoroughly clean all connections and the
immediate vicinity before loosening. DO NOT
use aggressive cleaning agents such as
brake cleaner, gasoline or thinners.
Place removed parts on a clean surface and
cover. DO NOT use fluffy cloths.
Carefully seal or cover opened components
if a repair cannot be completed immediately.
After separating the ABS hydraulic unit and
ABS control module, always use the plastic
foam transportation protection for the valve
dome, and always use the sealing plug kit
Part No. 1 H0 693 311 A.
Only install replacement parts that were
packed in their original packaging. Only
remove them immediately before installation. When the hydraulic system is open DO NOT
work with compressed air in the vicinity and
DO NOT move the vehicle.
Take precautions to make sure that brake
fluid does not enter any wiring harness
connectors. Page 3 of 3Anti-lock Brake System (ABS) and ABS with Electronic Differential Lock (ABS/EDL), Teves 20 GI12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.2

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-
Remove Torx socket-head bolts (T25) from
ABS hydraulic unit bracket.
- Remove ABS hydraulic unit/ABS control module
assembly.

- Disconnect ABS hydraulic pump connector from
ABS control module. CAUTION! - Remove ABS control module mounting bolts
(arrows) and pull off ABS control module. Pull control module straight off. Do not tilt. Cover control unit magnetic coils with a lint-
free cloth. After separating the ABS hydraulic unit and
ABS control module, always use the plastic
foam valve dome transportation protection
Page 45-11 . Page 6 of 9ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master cylinder (Teves 20 GI), servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.3

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Removing - Press tie rods off steering arm. A - Ball joint splitter (commercial type) e.g. Kukko
No. 128/2
- Remove partition behind pedals from bulkhead
and from steering column tube to loosen the
universal joint/power steering gear. If an oil extraction unit is not available, disconnect
vane pump supply hose and drain hydraulic fluid. - Loosen nut on the universal joint (arrow). - Remove hydraulic fluid from reservoir with an oil
extraction unit, e.g. VAG 1358 A or VAG 1307 A. Page 16 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: power assisted
steering box (TRW)
Determine cause of any malfunctions using
pressure and leak testing, Page 48-13 .
Note:
Always replace self-locking nuts and bolts. Welding and straightening work on steering
components is not permitted.
To grease the rack only use steering gear
grease, Part No. AOF 063 000 04.
Type of oil: Hydraulic oil G 002 000 Oil system capacity: 0.7 - 0.9 ltr. (0.74 - 0.95
qt)
Supply and pressure line routing from Page 48-85 . Page 19 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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7 - O-ring Is assembled on
toothed rod guide
(item -6-) contained in
the repair kit
8 - Pressure
compensating tube Check for damage
(dents and kinks)
9 - Toothed rod Check for scoring After removing
lubricate immediately
with hydraulic oil
(corrosion protection) Supplied as a
replacement part, for
assignment see
replacement parts
fiche
10 - Plug Is only installed if the
toothed rod was
replaced To install, drill hole in
the adjusting bolt
Page 48-51 Supplied in repair kit Page 27 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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17 - Sealing ring Always replace 18 - Valve body Removing Page 48-32 Cannot be repaired Is not supplied as
replacement part, if
damaged replace
steering gear
19 - Support ring Eliminated starting
4/92 If present, it must be
reinstalled
20 - Adhesive film Thoroughly clean
housing in this area before sticking on, e.g. with thinner, adhesive surface must be free of oil and grease Always replace Page 29 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1