locking VOLKSWAGEN PASSAT 1996 B3, B4 / 3.G Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine 48-76
- Carefully slide bushing with roller bearing onto the
valve body.
- Drive bushing into the housing far enough so that
the groove for the circlip is visible.
- Install circlip. - Remove adhesive tape. - Remove installation mandrel 3315/17. - Install Torx screw into valve body and tighten to 35 Nm (26 ft lb). - Thread in locking screw, tighten to 30 Nm (22 ft lb)
and crimp at corner points.
- Grease pressure piece with AOF 063 000 04. - Install pressure piece, spring and washer in
housing.
- Install cover with adjusting screw. Adjust steering
gear after installation in vehicle. Page 76 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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Tie rods, removing and installing (power
steering gear - TRW and ZF)

Note:
Observe how tie rods are threaded into power
steering gear:

- Tie rods not secured with locking fluid
- Tie rods secured with locking fluid When exchanging secured version tie rods use
locking fluid D6 when installing.

Removing
The tie rods can only be removed/installed with
the steering gear removed. - Seal line connections on power steering gear. 1 - Plastic sealing plugs 2 - Plastic sealing plugs - Clean outside of power steering gear in vicinity of
the boot. Page 77 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

Downloaded from www.Manualslib.com manuals search engine 48-78

- Open hose clips and push boot back. Note:
Use vice clamps, check vice clamps for impurities
e.g. metal filings or similar and thoroughly remove.
Installing
Installing tie rod without locking fluid D6.
Install in reverse order. Tightening torque: 70 Nm (52
ft lb)
Installing tie rods with locking fluid D6
If parts are reused, it is essential to clean any residue
of locking fluid off the threaded studs of the inner joint
or the thread tapped hole as described below.
Otherwise there is a danger of the thread being
damaged when being reinstalled or removed. - Clamp steering gear with rack in a vice. - Remove tie rod. Page 78 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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Installing Note:
Apply one drop only in 2nd thread of rack. If too much
D6 is used the release torque when next
disassembling will be too high. No D6 must get onto
steering rack. - Adjust new tie rod to length Page 48-84 . - Coat tapped hole thread with D6 locking fluid
(arrow).
- Tighten tie rod to the specified torque, 70 Nm (52 ft lb). Always use a torque wrench. Page 80 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

Downloaded from www.Manualslib.com manuals search engine 48-90

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