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

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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

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One of the embossed arrows points toward the
recess in the control arm and the kidney shaped
opening (arrow A) faces towards center of vehicle. Fig. 3 Control arm rear mounting, installation
position Note:
If bonded rubber bushing is tight because of
corrosion, cut rubber out, saw through steel casing
and drive bushing out. Fig. 4 Control arm rear mounting, pressing
out and in Page 8 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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12 - Mounting for
connecting link Conical side towards
control arm
13 - Washer Collar faces away from mounting
14 - Self-locking hex nut, 25 Nm (18 ft lb)
15 - Hex bolt M 12 x 1.5 x 82 50 Nm (37 ft lb) and
turn 90 further 16 - 25 Nm (18 ft lb)
17 - Hex bolt, 25 Nm (18 ft
lb) To secure stabilizer
bar
18 - Hex bolt, 65 Nm (48 ft
lb)
19 - Clamp for stabilizer bar Page 29 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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Note:
Before pressing in, coat with lubricant, e.g. soft soap. Fig. 1 Control arm front mounting, pressing
out and in One of the embossed arrows points toward the
recess in the control arm and the kidney shaped
opening -arrow -A- in mounting faces towards center
of vehicle. Fig. 2 Control arm rear mounting, installation
position Page 31 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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- Disconnect drive axle from transmission drive
flange. - Mark installation position of bolts (arrows) and
remove. Installing - Swing wheel outward (if necessary, place block of
wood or equivalent between strut and wheel
housing as shown).
- Push engine/transmission assembly toward front
and remove drive axle.
- Install in reverse order of removal. Page 72 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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24 - Wheel speed sensor
rotor Insert drift through
wheel bolt holes and
drive off Drive on with suitable
sleeve
25 - Hex bolt, 60 Nm (44 ft
lb)
26 - Dished spring washer Larger seating surface
towards backing plate
27 - Backing plate
28 - Stub axle
29 - Parking brake cable Adjusting parking
brake Page 46-36 30 - Spring clip Page 6 of 10Rear wheel brakes, servicing (disc brakes)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.5

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Power steering gear, disassembling and
reassembling (TRW)
This repair is limited to replacing the sealing
rings and, if necessary, the toothed rod. Steering
gears that are damaged by an accident must be
replaced.
For a satisfactory and successful repair, the
greatest care, safety and proper tools are
required. The special tool set 3315 that is
pictured is also a part of this.

Note:
Clean hose connections and their surroundings
thoroughly before opening.
Thoroughly clean work place (workbench, vise)
before starting work if necessary place paper
towels on the working surface.
Place parts that have been removed on a clean
surface. If the repair will not be carried out
immediately, cover parts.
Do not use cloths with lint. All the replacement parts that are needed are
contained in the repair kit.
Only take replacement parts out of the package
right before installing. Use only parts in original
packaging.
Always install all of the parts in the repair kit Page 25 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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- Coat piston of toothed rod and protective tube
with hydraulic oil When sliding, make sure that the sealing ring is
pressed into the groove of the piston without
jamming - Install installation sleeve 3315/22 into the housing - Slide toothed rod into the housing - Slowly introduce the toothed rod into the housing - Pull protective tube 3315/13 off the toothed rod Align teeth of toothed rod in such a way that they
point toward the teeth of the pinion
- Screw mounting sleeve 3315/18 on toothed rod
and coat with hydraulic oil
- Carefully slide toothed rod guide 1 over the
toothed rod into the housing to stop
- Slide toothed rod completely into the housing. Page 46 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 and
reassembling (ZF)
This repair is limited to replacing the sealing
rings and, if necessary, the toothed rod. Steering
gears that are damaged by an accident must be
replaced
For a satisfactory and successful repair, the
greatest care, safety and proper tools are
required.

Note:
Clean hose connections and their surroundings
thoroughly before opening
Thoroughly clean work place (workbench, vise)
before starting work if necessary place paper
towels on the working surface
Place parts that have been removed on a clean
surface.
If the repair will not be carried out immediately,
cover parts
Do not use cloths with lint All the replacement parts that are needed are
contained in the repair kit
Only take replacement parts out of the package
right before installing. Use only parts in original
packaging
Always install all of the parts in the repair kit Page 60 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1