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

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15 - Self-locking
bolt/washer assembly,
125 Nm (92 ft lb) For securing brake
carrier
16 - Socket head multi-
point bolt, 45 Nm (33 ft
lb)
17 - Drive shaft To remove and install
separate ball
joint/control arm
connection Fig. 2 Repairing Page 40-46 18 - Circlip Ensure correctly
seated
19 - Self-locking hex nut, 95 Nm (70 ft lb)
20 - Hex bolt Shank diameter 11
mm Adjusting camber
Page 44-6 Mark position before
loosening Page 17 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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11 - Circlip Ensure seated
correctly
12 - Wheel bearing Pressing out Fig. 4 Always replace, as it is destroyed during
pressing out Pressing in Fig. 5 13 - Self-locking hex nut, 35 Nm (26 ft lb)
14 - Wheel bearing housing 15 - Self-locking
bolt/washer, 125 Nm
(92 ft lb)
16 - Drive shaft Removing and
installing Page 40-43 Repairing Page 40-46 17 - Socket head multi-
point bolt, 45 Nm (33 ft
lb) Page 38 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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9 - Clamp For triple-rotor joint 10 - Boot
11 - Clamp For triple-rotor joint 12 - Cover Destroyed when
disassembling No longer required for
assembly; not
available as
replacement part
13 - Rectangular sealing
ring Included in repair kit;
not used in production
14 - O-ring Not required for
assembly
15 - Circlip
16 - Roller
17 - Triple-rotor star Chamfer -arrow- goes
onto axle shaft splines
first
18 - Multi-point socket-
head bolt M10 x 20 80 Nm (59 ft lb) 19 - Housing Page 74 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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2 - Cotter pin Always replace 3 - Locking ring
4 - Hex nut Adjusting wheel
bearing play Fig. 4 5 - Thrust washer
6 - Outer wheel bearing Drive out outer race
with copper drift Pressing in Fig. 6 7 - Hex socket head bolt,
10 Nm (7 ft lb)
8 - Speed sensor Only on vehicles with
ABS
9 - Stub axle Straightening
operations are not
permitted! Page 2 of 18Wheel bearings, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.2

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Wheel bearings, servicing
- disc brakes (front wheel
drive vehicles)
Note: Careful sealing, absolute
cleanliness and precise
adjustment are requirements for long wheel bearing service life.
Therefore note the
following points: Install oil seal and grease
cap as shown. Only reinstall clean
bearings. Adjust wheel bearing play
carefully.
1 - Stub axle
2 - Hex socket head bolt,
10 Nm (7 ft lb) Page 10 of 18Wheel bearings, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.2

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3 - Speed sensor Only on vehicles with
ABS Before installing
sensor, clean
mounting hole inner
surface and coat with
lubricating paste G
000 650
4 - Brake hose bracket
5 - Hex socket head bolt,
65 Nm (48 ft lb)
6 - Self-locking hex bolt,
35 Nm (26 ft lb) Always replace 7 - Guide pins
8 - Protective cap
9 - Pad retaining spring Replace when
changing pads Page 11 of 18Wheel bearings, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.2

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Wheel bearings,
servicing - disc
brakes (four wheel
drive vehicles)
Note:
If a vehicle has to be moved
after removing the drive shaft,
first install an outer joint and
tighten to 50 Nm (37 ft lb).
Otherwise the wheel bearing
will be damaged.
1 - Control arm
2 - Self locking hex socket head bolt, 60 Nm (44 ft
lb)
3 - Self locking hex bolt,
35 Nm (26 ft lb) Always replace When loosening and
tightening counter-hold on guide pins Page 1 of 8Wheel bearings, servicing - disc brakes (four wheel drive vehicles)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.6

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16 - Circlip Ensure seated
correctly
17 - Wheel bearing 72 mm diameter Pressing out Page 42-64 Pressing in page. Page 42-65 18 - Hex bolt, 10 Nm (7 ft lb) 19 - Backing plate
20 - Parking brake cable Adjusting parking
brake Page 46-36 21 - Spring clip
22 - Hex socket head bolt,
10 Nm (7 ft lb)
23 - Speed sensor Before inserting, clean
and coat with
lubricating paste G
000 650 Page 4 of 8Wheel bearings, servicing - disc brakes (four wheel drive vehicles)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.6

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Vehicle alignment specifications (front wheel drive vehicles) Front axle
Suspension strut axle
Engine up to 85 kW (115
hp) 110 - 128 kW
(148 - 172 hp)
Version Base suspension Plus
suspension
Total toe1)
(not pressed)
0 10' 0 10' Camber2)
(in straight- ahead position) Maximum permissible
difference between sides -1 20' 20'


max. 20' -1 10' 20'


max. 20' Toe angle difference at 20left and right lock -1 10' 30' -1 40' 30' Caster (not adjustable) Maximum permissible difference between
sides +1 40' 30'

max. 30' +3 20' 30'

max. 30' 1)
Only adjust total toe on right toe rod
2)
Camber corrections can only be made at the wheel bearing housing/suspension strut connection.
Camber adjustment Page 44-6 . Note:
After adjusting steering geometry check position of steering wheel; correct if necessary. Page 2 of 7Vehicle alignment12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.44.1

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Vehicle alignment specifications (four wheel drive vehicles) Front axle
Suspension strut axle
Engine 85 kW (115 hp) 128 kW (172
hp)
Version Base
suspension Plus
suspension
Total toe1)
(not pressed)
0 10' 0 10' Camber2)
(in straight- ahead position) Maximum permissible
difference between sides -1 20' 20'


max. 30' -1 10' 20'


max. 20' Toe angle difference at 20left and right lock -1 10' 30' -1 40' 30' Caster (not adjustable) Maximum permissible difference between
sides +1 40' 30'

max. 30' +3 20' 30'

max. 30' 1)
Only adjust total toe on right toe rod
2)
Camber corrections can only be made at the wheel bearing housing/suspension strut connection.
Camber adjustment Page 44-6 . Note:
After adjusting steering geometry check position of steering wheel; correct if necessary. Page 4 of 7Vehicle alignment12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.44.1