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

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Rear axle,
servicing (four
wheel drive
vehicles)
Note: When removing and
installing the rear axle, it is
recommended to remove
axle and differential
together and to separate
away from the vehicle. If
only the axle beam is to be
removed and installed, the
wishbones can remain
attached to the shock
absorber. In both cases,
disconnect vacuum lines
and wiring before lowering
the assembly. Always replace self-locking
nuts and bolts. Always replace corroded
nuts and bolts. The ABS speed sensor
wiring connections are
located under the rear seat. Page 1 of 13Rear axle, servicing (four wheel drive vehicles)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.3

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Wheel speed sensor and rotor for speed
sensor, removing and installing

Speed sensor
When installing speed sensor ensure wiring is
not twisted.
Before installing speed sensor, clean mounting
hole and coat with lubricating paste, G 000 650.
Rotors
Before installing check that rotor is clean and
undamaged.

Front axle
Vehicles with base suspension Page 40-14 . Vehicles with plus suspension Page 40-23 .
Rear axle
Vehicles with rear drum brakes Page 42-15 . Vehicles with rear disc brakes (front and four
wheel drive Page 42-24 . Page 5 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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Airbag unit, removing and installing

Removing

- Disconnect battery Ground strap.
- Center steering wheel (wheels straight-
ahead). Installing
Install in reverse order
Note:
Only use new hex socket head bolts for airbag unit.
Tightening torque: 6.5 Nm (57 in. Ib).
CAUTION!
Make sure that no one is in the vehicle when
connecting the battery Ground strap. - Remove both socket head bolts from airbag unit. - Remove airbag unit from steering wheel and
disconnect wiring connector from airbag unit.
- After installing the airbag unit, switch on ignition
then connect battery Ground strap. Page 7 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

- Install steering wheel, install nut and tighten.
Tightening torque: 50 Nm (37 ft lb).

- Connect airbag unit connector below steering
wheel.

- Install trim panel below steering column. Make
sure that the centering ring wiring connection is
located in the recess in the trim panel.

- Connect connector in steering wheel to airbag
unit connector.

- Install airbag unit Page 48-7
Note:
Use new hex socket head bolts for airbag unit.
- After installing the airbag steering wheel first
switch on ignition, then connect battery Ground
strap.

CAUTION!

Make sure that no one is in the vehicle when
connecting the battery Ground strap. Page 9 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1