warning VOLKSWAGEN PASSAT 1996 B3, B4 / 3.G Service Workshop Manual

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Reworking cap nut in side member
(Base and Plus suspension)
If the threads of the cap nut in the side member
are damaged, the thread must either be retapped
or the cap nut must be drilled out.
When drilling out proceed as follows.

- Support engine/transmission assembly with 10-
222 A and legs 10-222 A/1.

- Remove the sub-frame.
- Drill out the damaged side member cap nut with
a 10.2 mm diameter drill from underneath.

Note:
When drilling do not tilt the drill.

WARNING!

Wear protective goggles.

- Cut new M 12 x 1.5 thread in cap nut.
- Use a new bolt/washer assembly to secure sub-
frame Page 40-13 . Page 11 of 82Front Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1

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Reworking cap nut in side member
(front wheel drive vehicles)
If the threads of the cap nut in the side member
are damaged, it must either be retapped or the
cap nut must be drilled out. When drilling out
proceed as follows:

- Remove rear axle.
- Drill through damaged cap nut in the side
member using a 10.2 mm diameter drill from
underneath.

Note:
Do not tilt the drill when drilling.

WARNING!

Wear protective goggles.

- Cut new thread in the cap nut, M 12 x 1.5.
- Use new bolts, Part No. N 010.127.4 (M 12 x 1.5 x 30), and washer, Part No. N 011.531.7, to
secure the rear axle.
Tightening torque: 70 Nm (52 ft lb)

Note:
The procedure described here must only be
performed on one cap nut on each side of the
vehicle. Page 8 of 14Rear Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.1

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Reworking cap nut in side member (four
wheel drive vehicles)
If the threads of the cap nut in the side member
are damaged, it must either be retapped or the
cap nut must be drilled out.

- Remove control arm if necessary.
- Drill through damaged cap nut in the side
member using a 10.2 mm diameter drill from
underneath.

Note:
Do not tilt the drill when drilling.

WARNING!

Wear protective goggles. 1 - Cap nut 2 - Reinforcing plate 3 - Side member Page 6 of 7Rear drive shafts, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.4

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Safety precautions

WARNING!

Brake fluid is poisonous.

CAUTION!
Before working on the ABS or ABS/EDL
system, disconnect the battery Ground
(GND) strap. For anti-theft coded radios, first
make sure that the radio code is available.
Brake fluid must not contact painted parts. Brake fluid absorbs moisture from the air
and must therefore be replaced every two
years. Use only new, approved brake fluid
that complies with MVSS 116 DOT 4.
DO NOT use silicone-brake fluid (DOT 5).
Even the smallest traces can cause sever
corrosion in the brake system.
Before doing any welding repairs on the
vehicle using electric welding equipment,
disconnect the ABS control module.
After work that requires opening the brake
hydraulic system, bleed the system Page 47-29 . Page 2 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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ABS hydraulic unit and ABS control
module (Teves 20 GI), removing and
installing
Carefully read and follow all cautions and
warnings Page 45-7 before beginning work.
Location
The ABS control module is bolted to the ABS
hydraulic unit, located on the left-side of the
engine compartment.

CAUTION!
Do not bend brake lines at or near the ABS
hydraulic unit.
Switch ignition OFF when disconnecting and
reconnecting the ABS control module
connector.
Part numbers are listed here for reference
only. Always check with your Parts
department for the latest information. Sealing plug kit Part No. 1H0 698 311 A:
1 - Valve dome transportation protection (plastic
foam)
2 - Sealing plugs -M10- 3 - Sealing plugs -M12- Page 3 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