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

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Installing
Install in reverse order.

- Check position of steering wheel and, if
necessary, align front end.

Note: Tightening torques: When lifting the engine/transmission assembly
guide the lower half of the universal joint shaft -A-
into the upper half -B- at the same time (second
mechanic necessary). Coat boot with lubricant, e.g. soft soap, before
pulling onto steering gear.
Universal joint shaft 25 Nm (18 ft lb) halves
Steering gear 30 Nm (22 ft lb)
Tie rod joint 35 Nm (26 ft lb)
Subframe front and rear
70 Nm (52 ft lb) and turn 90 further Rear subframe bracket 65 Nm (48 ft lb) Page 18 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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1 - Self-locking nut 35 Nm
(26 ft lb)
2 - Self-locking 30 Nm (22
ft lb)
3 - Clamp
4 - Rubber mounting Internal diameter ZF:
50 mm TRW: 44 mm
5 - Right-hand tie rod 70 Nm (52 ft lb) Removing and
installing Page 48-77 Vehicle alignment
Page 44-1 Tie rod boot seat
diameter ZF: 15 mm
dia. TRW: 12.7 mm
dia. It must not be installed
on a ZF power
steering gear Page 20 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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6 - Left-hand tie rod 70 Nm (52 ft lb) Removing and
installing Page 48-77 Adjusting to length
Page 48-84 Tie rod boot seat
diameter ZF: 15 mm
TRW: 12.7 mm Must not be installed
on a ZF power
steering gear
7 - Hex nut 50 Nm (37 ft lb) 8 - Boot Pull on and off over tie
rod Can be replaced with
steering gear installed Must not be twisted
after adjusting toe Must not be installed
on a ZF power
steering gear Page 21 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 9 - Steering gear Removing and
installing Page 48-15 Adjusting Page 48-24 10 - Tie rod end Separating Page 48-16 Checking: 11 - Hex nut 30 Nm (22 ft lb) 12 - Universal joint Page 22 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, adjusting (TRW)

Note:
Two Mechanics are required when adjusting.
Adjust with engine switched off Adjusting steering box
By turning the steering wheel back and forth (about
30 to center axis) a knocking noise will be heard if
there is excessive play. - Raise vehicle on hoist. - Wheels in straight-ahead position. - Loosen locking nut (counter-hold with 3315/9). - Carefully turn adjustment screw (arrow) into cover
until knocking noise can no longer be heard inside
vehicle.
- Tighten locking nut. - Complete a road test ensuring that when
maneuvring or negotiating corners the steering
self-centers without binding. Page 24 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 and
reassembling (TRW)
This repair is limited to replacing the sealing
rings and, if necessary, the toothed rod. Steering
gears that are damaged by an accident must be
replaced.
For a satisfactory and successful repair, the
greatest care, safety and proper tools are
required. The special tool set 3315 that is
pictured is also a part of this.

Note:
Clean hose connections and their surroundings
thoroughly before opening.
Thoroughly clean work place (workbench, vise)
before starting work if necessary place paper
towels on the working surface.
Place parts that have been removed on a clean
surface. If the repair will not be carried out
immediately, cover parts.
Do not use cloths with lint. All the replacement parts that are needed are
contained in the repair kit.
Only take replacement parts out of the package
right before installing. Use only parts in original
packaging.
Always install all of the parts in the repair kit Page 25 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 - Tie rod For removing, see tie
rod, removing and installing (TRW and ZF power steering gear)
Page 48-77 2 - Boot Installing, see tie rod, removing and installing (TRW and ZF) power
steering), Page 48-77 3 - Hose clamp Open with nipper pliers Installation position
and tightening, see tie
rod, removing and installing (TRW and ZF power steering),
Page 48-77 Always replace 4 - Circlip Always replace 5 - Lock washer
6 - Toothed rod guide Supplied in repair kit
as assembly with
sealing ring Always replace Page 26 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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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