Gear VOLKSWAGEN PASSAT 1997 B3, B4 / 3.G Service Owner's Manual

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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

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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

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21 - Roller bearing installation position:
inscription points up
22 - Sealing ring Always replace 23 - Circlip
24 - Ball bearing Drive from top
downward with VW
439 Grease with steering
gear grease AOF 063
000 04
25 - Self-locking hex nut, 30 Nm (22 ft lb) Always replace 26 - Locking screw, 40 Nm
(30 ft lb) Always replace Is already pre-
mounted on new
toothed rods that are
supplied as
replacement parts Page 30 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

- Tie rods, removing - see tie rod, removing and
installing (TRW and ZF power steering), Page 48-77
- Close hose connections on power steering gear
if not already done

1 - Plastic locking screw
2 - Plastic locking screw Note:
Use jaw covers and check jaw covers for
contamination; e.g. metal chips or the like - Clean outside of power steering gear - Open hose clamp and push back boot - Clamp steering gear with toothed rod in vise and
remove tie rod - Remove tie rod - Take steering gear out of vise, screw on bracket
3315/1 and tighten bracket in vise Page 32 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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Parts, cleaning and checking - Install tool VW 771 in the puller - Pull out sealing ring - Before assembly, the housing must be checked for contamination (paint residue, chips, dirt) and
thoroughly cleaned with compressed air and
alcohol
- Clean adhesive surface for adhesive tape in area
of the slot with solvent (e.g. L160 or alcohol)
- Check cylinder race for scoring or other damage. If scoring can be felt, replace entire steering gear
- Clean toothed rod (remove old grease in the tooth
pockets) Page 39 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, assembling

Note;
All sealing rings should be lubricated with
hydraulic oil before installing. - Check whether the valve body housing -2- is
absolutely clean on the inside, otherwise clean
- Place sealing ring -1- on tool. The sealing lip -
arrow- points toward tool
- Drive sealing ring into stop 1 - Sealing ring 2 - Valve body housing - Make sure correct installation position of sealing
ring in valve body
- For better view, illustration shows valve tower in
cross section Page 43 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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- Drive sealing ring in far enough sot that the groove for circlip in the housing is visible
- Install circlip - Remove adhesive tape - Remove assembly mandrel 3315/17 - Install hex nut for valve body and tighten, 30 Nm
(22 ft lb) with torque wrench SW 14 2 Note: - Install locking screw - Grease pressure piece and spring in housing in old position
- Install lock nut together with adjusting screw After tightening, the marking made during removal (arrow) on the adjusting nut and lock nut must
match If the toothed rod was replaced, before installing
the tie rods the steering gear must be readjusted Page 49 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 with new
toothed rod If a new toothed rod was used, the steering play
should be adjusted according to the following
description.
- Drill a hole 5.1 mm in diameter in the center of the
adjusting screw (on the back side center)
- Thoroughly clean adjusting screw - Place toothed rod in center position (measure
toothed rod excess right and left)
- Install pressure piece and spring in housing if not
done yet
- Screw adjusting screw and lock nut far enough into the housing so that the markings match Page 51 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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Needle run-out max. 0.10 mm
If needle run-out is greater than 0.10 mm, screw
pressure piece slightly into housing
If the needle run-out is less than 0.10 mm, screw
pressure piece slightly out of housing

- Tighten lock nut
- Check needle run-out again, if necessary repeat
adjustment

- Remove gauge Close hole in adjusting screw with a stopper from
repair kit
Tie rods, installing - First install clip -2- with gasket -1- in the hole - Apply 1 drop sealing compound, Part No. AMV
188 001 02, in the hole of the clip -arrow- and
press plug -3- into the clip
- See tie rods, removing and installing (TRW and ZF steering gear), Page 48-77 Page 53 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 steering
gear (ZF)
It is not intended that repair work be carried out
on the power steering gear. If complaints are
received determine cause with the help of
pressure tests, leakage test and troubleshooting
programs. If a malfunction exists replace the
power steering gear.

Note:
Always replace self-locking nuts and bolts. Welding and straightening work on steering
components is not permitted.
To grease the rack use only steering gear
grease, Part No. AOF 063 000 04.
Type of oil: Hydraulic oil G 002 000 Oil system capacity: 0.7 - 0.9 Itr. (0.74 - 0.95
qt)
Supply and pressure line routing Page 48-85 . Page 54 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1