VOLKSWAGEN PASSAT 1997 B3, B4 / 3.G Service Workshop Manual

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Maintenance Manual 5 - 20 Nm(15 ft Ib)
6 - Front swivel bracket
7 - 20 Nm (15 ft lb)
8 - Adjustment bracket
9 - 20 Nm (15 ft lb)
10 - Bracket
11 - V-belts 11.5 x 685 Gas engine 11.5 x 730 Diesel
engine 11.5 x 755 Gas engine with air conditioner 11.5 x 790 Diesel
engine with air
conditioner Tensioning Page 48-93 Checking condition 12 - 25 Nm (18 ft lb) Page 91 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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13 - V-belt pulley When installing the V-
belt pulley ensure that
the crankshaft pulley
and the vane pump
pulley are aligned
14 - Shim Only installed on
vehicles with Diesel
engine
15 - 20 Nm (15 ft lb)
16 - Rear swivel bracket
17 - Vane pump Checking delivery
pressure Page 48-13 Page 92 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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V-belts, tensioning (4-Cyl. engines) Specification: - Tension V-belts by turning adjustment bolt with
torque wrench -A- (VAG 1410 and VAG 1410/2). Used belts, 4 Nm (35 in. Ib) New belts, 7 Nm (62 in. Ib) Note:
Nut 4 - is only installed on gasoline engines. - Tighten adjustment clamping bolt -3- to 25 Nm (18
ft lb).
- Tighten bolt -1- to 45 Nm (33 ft lb). - Tighten bolt -2- and nut -4- to 25 Nm (18 ft lb). Page 93 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:
Pressure and cooling
lines (vehicles with VR6
engine)
Note:
Securing of pressure line
varies according to type of
transmission Fig. 1 and
Fig. 2 1 - Reservoir
2 - Suction hose Reservoir - Cooling
line
3 - Cooling line Secured to
crossmember item
8 4 - Pressure line
5 - Suction line Cooling line -
Hydraulic pump
6 - Hose clamp, 3 Nm (27
in. Ib) Page 94 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 - Hydraulic pump
8 - Seal Always replace 9 - Pressure line union
10 - Banjo bolt, 35 Nm (26 ft lb)
11 - Hex bolt, 10 Nm (7 ft lb) 12 - Hose clamp, 3 Nm (27
in. Ib)
13 - Return line Power steering gear -
Reservoir Page 95 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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Fig. 1 Pressure hose, securing (vehicles with
manual transmission) Fig. 2 Pressure hose, securing (vehicles with
automatic transmission) Page 96 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 vane
pump, removing and
installing (vehicles with
VR6 engine]
Note: Always replace seals. Do not reuse drained
hydraulic oil. Pumps supplied as spare
parts are not filled with 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.
1 - Suction hose A cooling line is installed between vane pump suction hose
and reservoir
2 - Hose clamp Page 97 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, Engine
Mechanics; Repair Group13
Repair Manual, Engine
Mechanics; Repair Group13
Repair Manual, Maintenance 3 - Pressure hose Attachment varies
according to type of
transmission Page 48-96 4 - Seal
5 - Banjo bolt, 30 Nm (22 ft lb)
6 - Vane pump Checking delivery
pressure Page 48-13 7 - Ribbed belts Removing Tensioning ensured by tensioning roller Belt routing Checking condition 8 - Belt pulley Page 98 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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9 - Hex socket head bolt,
25 Nm (18 ft lb)
10 - Hex bolt, M8 x 30, 25
Nm (18 ft lb)
11 - Hex socket head bolt,
M8 x 30, 25 Nm (18 ft
lb)
12 - Hex socket head bolt,
M8 x 20, 25 Nm (18 ft
lb)
13 - Hex socket head bolt,
M8 x 30, 25 Nm (18 ft
lb)
14 - Hex bolt, M8 x 30, 25
Nm (18 ft lb)
15 - Bracket On vehicles with air
conditioner can only
be removed having
first removed the air
conditioner bracket Page 99 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1