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

Downloaded from www.Manualslib.com manuals search engine 48 - Steering
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]

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4 - Boot for 94 mm
diameter constant
velocity joint Rubber version Check for tears and
chafing Installation position: At
cuff 1 to 1-1/2 grooves
visible Coat inside of cap with D3 Drive off with drift 5 - Drive axle Different drive axle
lengths - short shaft
right
6 - Hose clamp Always replace Tensioning Page 40-57 Page 3 of 7Rear drive shafts, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.4

Downloaded from www.Manualslib.com manuals search engine 45-25

Brake Pedal Position Sensor, removing
and installing

Note:
The Brake Pedal Position Sensor is only
supplied as a repair kit. Apart from the sender,
this repair kit contains a sealing ring, circlip and
four different spacer caps.

- - one white spacer cap
- - one green spacer cap
- - one blue spacer cap
- - one red spacer cap The spacer caps are of differing length. When replacing the sensor note the color of
spacer cap. The new sensor must have the
same color cap as the old sensor.
On the brake servo housing in the vicinity of the
sever location there is a colored spot, which is
identical to that of the spacer cap. Page 8 of 10Assembly overview - hydraulic unit, brake servo/brake master cylinder12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.4

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9 - Spring
10 - Steering column
switch/steering lock
housing1)
Distance between
steering
wheel/steering column
switch is not
adjustable
11 - Upper trim
12 - Support ring1)
With washer 13 - Steering column1)
Remove by pulling upwards out of column tube Checking length
Page 48-6 14 - Hex bolt, 30 Nm (22 ft
lb)
15 - Hex nut, 25 Nm (18 ft
lb)
16 - Hex nut, 30 Nm (22 ft
lb)
17 - Steering column
universal joint
18 - Spring Page 3 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 48-6
The small metal lug on the lower section must be
visible in the hole in the upper section (arrow). If
necessary pull both sections firmly apart onto stop or
press together. Fig. 3 Length of steering column, checking Fig. 4 Steering column, pre-assembling - Carefully clamp the lower section of the steering
column in a vice so that the upper part is
supported on the jaws. Page 6 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 48-21

6 - Left-hand tie rod 70 Nm (52 ft lb) Removing and
installing Page 48-77 Adjusting to length
Page 48-84 Tie rod boot seat
diameter ZF: 15 mm
TRW: 12.7 mm Must not be installed
on a ZF power
steering gear
7 - Hex nut 50 Nm (37 ft lb) 8 - Boot Pull on and off over tie
rod Can be replaced with
steering gear installed Must not be twisted
after adjusting toe Must not be installed
on a ZF power
steering gear Page 21 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 48-57

5 - Right-hand tie rod Removing and
installing Page 48-77 Vehicle alignment
Page 44-1 Tie rod boot seat
diameter ZF: 15 mm
TRW: 12.7 mm Must not be installed
on a TRW power
steering gear
6 - Left-hand tie rod Removing and
installing Page 48-77 Tie rod boot seat
diameter ZF: 15 mm
TRW: 12.7 mm Must not be installed
on a TRW power
steering gear Adjusting length
Page 48-84 Page 57 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 Note:
Apply one drop only in 2nd thread of rack. If too much
D6 is used the release torque when next
disassembling will be too high. No D6 must get onto
steering rack. - Adjust new tie rod to length Page 48-84 . - Coat tapped hole thread with D6 locking fluid
(arrow).
- Tighten tie rod to the specified torque, 70 Nm (52 ft lb). Always use a torque wrench. Page 80 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 48-84

Left-hand tie rod length, checking and
adjusting

- Check dimension "a" on left-hand tie rod and if
necessary adjust. Dimension "a" = 395 + 1 mm (all except from VR6
and 16V) Dimension "a" = 413 1 mm (VR6 and 16V)
Note: Only adjust toe on right-hand tie rod. Before installing new left-hand tie rod check
dimension "a" and if necessary adjust. Page 84 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1