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

Downloaded from www.Manualslib.com manuals search engine Suspension, Wheels, Brakes, Steering

00 - General, Technical data
Suspension, Wheels, Brakes, Steering
Technical data
Steering
Brakes
Wheels, tires
40 - Front suspension
Front Wheel Suspension, Shafts and Axle
Front suspension, servicing (Base suspension)
Sub-frame, stabilizer bar and control arm (Base suspension)
Ball joint, checking (Base and Plus suspension)
Reworking cap nut in side member (Base and Plus suspension)
Wheel bearing, suspension strut and drive shaft, removing and installing (Base
running gear)
Front suspension strut, servicing (Base and Plus suspension)
Front suspension, servicing (Plus suspension)
Sub-frame, stabilizer bar and control arm, removing and installing (Plus
suspension)
Ball joint, removing and installing (Plus running gear)
Wheel bearing and suspension strut, removing and installing (Plus suspension)
Drive shaft, removing and installing (Plus running gear)
Drive shaft, repairing
Outer constant velocity joint, checking
Inner constant velocity joint, checking
Drive shaft with tripod joint, repairing
Drive axle with triple-rotor joint, removing and installing
Drive axle with triple-rotor joint, servicing
Triple-rotor joint, disassembling
Triple-rotor joint, assembling
42 - Rear suspension
Rear Wheel Suspension, Shafts and Axle
Rear axle, servicing (vehicles with front wheel drive)
Reworking cap nut in side member (front wheel drive vehicles)
Suspension strut, disassembling and assembling (front wheel drive vehicles)
Wheel bearings, servicing
Drum brakes (front wheel drive vehicles), wheel bearings, servicing
Wheel bearings, servicing - disc brakes (front wheel drive vehicles)

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Steering
Assembly overview: steering column, column tube, steering wheel and airbag
steering wheel
Airbag unit, removing and installing
Airbag steering wheel, removing and installing
Airbag Spiral Spring, removing and installing
Column tube for height adjustable steering wheel, removing and installing
Pump delivery pressure, checking
Power steering gear, removing and installing
Assembly overview: power assisted steering box (TRW)
Power steering gear, adjusting (TRW)
Power steering gear, disassembling and reassembling (TRW)
Power steering gear, disassembling
Inner sealing ring for toothed rod, pulling out
Checking toothed rod for scoring
Sealing ring on toothed rod, replacing
Sealing rings, installing on toothed rod piston
Power steering gear, assembling
Inner sealing ring for toothed rod, installing
Toothed rod, installing in housing
Adhesive tape, applying
Power steering gear, adjusting with new toothed rod
Assembly overview: power steering gear (ZF)
Power steering gear, adjusting (ZF)
Power steering gear, disassembling and reassembling (ZF)
Power steering gear, disassembling
Checking toothed rod for scoring
Sealing ring on toothed rod, replacing
Power steering gear, assembling
Tie rods, removing and installing (power steering gear - TRW and ZF)
Left-hand tie rod length, checking and adjusting
Assembly overview: vane pump, reservoir and hydraulic lines (vehicles with 4-
Cyl. engines)
Assembly overview: Hydraulic lines, reservoir (vehicles with 4-Cyl. engines)
Power steering vane pump, removing and installing (vehicles with 4-Cyl. engines)
V-belts, tensioning (4-Cyl. engines)
Assembly overview: Pressure and cooling lines (vehicles with VR6 engine)
Power steering vane pump, removing and installing (vehicles with VR6 engine]

Downloaded from www.Manualslib.com manuals search engine 00-2
Steering Model
Sedan/Wagon and syncro
Suspension version
Base Suspension
Plus Suspension
Steering gear Power assisted steering gear Power assisted steering gear
Steering wheel turns from lock to lock 3.33 3.14
Overall steering ratio 17.5:1 16.4:1
Wheel alignment specifications Page 44-2 Page 2 of 8Suspension, Wheels, Brakes, Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.00.1

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Repair Manual, Engine
Mechanical, Repair Group 10 12 - Connecting link
mounting Conical side toward
control arm
13 - Washer Collar faces away from mounting
14 - Self-locking hex nut, 25 Nm (18 ft lb)
15 - Sub-frame Removing and
installing with
assemblies installed:
supporting assemblies
Fig. 5 Remove sub-frame
from below with VAG
1383 (with control arm
but without steering
gear). After installing
check position of
steering wheel and
align front end. Aligning engine-
transmission assembly Page 5 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

Downloaded from www.Manualslib.com manuals search engine 40-14

Wheel bearing,
suspension strut and
drive shaft, removing and
installing (Base running
gear)
Note: If a vehicle has to be
moved after removing the
drive shaft, first install outer joint and tighten to 50 Nm (37 ft lb) otherwise the
wheel bearing will be
damaged. Welding and straightening
operations are not
permitted on load bearing
suspension components or
those components which
locate the wheels. Always replace self-locking
nuts. Always replace corroded
nuts/bolts. Wheel bolt tightening
torque: 110 Nm (81 ft lb). Page 14 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

Downloaded from www.Manualslib.com manuals search engine 40-30

Repair Manual, Engine
Mechanical, Repair Group 10 20 - Vibration damper Not installed on
vehicles with VR 6
engine
21 - Sub-frame Removing and
installing with
assemblies installed:
supporting assemblies
Fig. 4 Remove sub-frame from below with control arm but without
steering gear using transmission jack VAG 1383 or equivalent.
After installing check
position of steering
wheel and align front
end. Aligning
engine/transmission
assembly
22 - Stabilizer bar mounting 23 - Stabilizer bar 24 mm diameter 24 - Cap nut Reworking in side
member Page 40-11 Page 30 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

Downloaded from www.Manualslib.com manuals search engine 40-33

Ball joint, removing and installing (Plus
running gear)

Removing

- Loosen 12-point nut with vehicle standing on its
wheels.

- Disconnect drive shaft at transmission drive
flange.

- Remove bolts -arrow -A-.
- Loosen bolt -arrow -B-. - Separate connection between ball joint/control
arm. (First mark installation position). - Swing wheel and suspension strut outward and
support. Page 33 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

Downloaded from www.Manualslib.com manuals search engine 40-43

Drive shaft, removing and installing
(Plus running gear)

Removing

- Loosen 12-point nut with vehicle standing on its
wheels.

- Disconnect drive shaft from transmission drive
flange. - Remove bolts (arrow -A-). - Loosen bolt (arrow -B-). - Separate connection between ball joint/control
arm. (First mark installation position). Note:
When pressing drive shaft out ensure sufficient
clearance is available. - Press drive shaft out. Install tool as shown in
illustration. Page 43 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

Downloaded from www.Manualslib.com manuals search engine 48-14

- With engine running at idling speed. Close cut-
off valve (not longer than 5 seconds) and read
off pressure.

Specification: 85 - 95 bar (1232 - 1377
psi)

Note:
If the reading is higher or lower than specified
replace pump.
Vehicles with up to 110 kW engine Page 48-90 . Vehicles with 128 kW engine Page 48-97 . If reservoir fluid level is low then check steering
system for leaks.
For leaks at the pinion first check the lines/line
connections for leaks and if necessary tighten
and wipe dry.
If the pinion seal or the rack seals in steering
box housing are leaking then replace steering
gear.
To check the rack seals loosen the clamp on
the boot and push to one side. Page 14 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 48-15

Power steering gear, removing and
installing

When working on the power assisted steering
gear:
Absolute cleanliness is required when working
on the power steering.
Thoroughly clean connections and immediate
vicinity before loosening.
Place parts on a clean surface and cover if not
re-installing immediately.
Do not use fluffy cloths. Only unpack parts immediately prior to
installation.
Only use genuine packed parts. Vehicles with four wheel drive observe installing heat shield. Page 15 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1