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Volkswagen 1995 Passat Gasoline, Repair Manual

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00-6

 

Wheels, tires 

 

Engine output (kW) 

 

Model 

 

Tire size 

1)

 

 

Wheel 

 

Offset 

 

Hole pattern 

 

55 gas  

55, 66 - Diesel  

Sedan/Wagon   185/65 R 14 86 S  

195/60 R 14 86 S  

205/50 R 15 86 S  

185/65 R 14 85 Q (M+S)  

195/60 R 14 85 Q (M+S)  

205/50 R 15 85 Q (M+S)  

6 J x 14  

6 J x 14  

6 J x 15  

6 J x 14  

6 J x 14  

6 J x 15  

38  

38  

38  

38  

38  

38  

4-hole  

55  

Sedan/Wagon   T 125/70 R 15 95 M  

(Temp. spare)  

3 

1

/

2

 J x 15 

 

40  

  

1)

 Tire pressures 

 Sticker on vehicle 

 

Page 6 of 8

Suspension, Wheels, Brakes, Steering

12/7/2004

http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.00.1

Summary of Contents for 1995 Passat Gasoline

Page 1: ......

Page 2: ......

Page 3: ...oint 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 Ou...

Page 4: ...ke System with Electronic Differential Lock ABS EDL Teves 04 Notes for repair work on ABS ABS EDL Control module removing and installing Wheel speed sensor and rotor for speed sensor removing and inst...

Page 5: ...and installing Brake Light Switch adjusting 47 Brakes Hydraulic components Assembly overview brake master cylinder brake servo Girling front brake caliper servicing Front brake caliper pistons removi...

Page 6: ...bling 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...

Page 7: ...et 3 1485 front wheel offset 35 1441 rear wheel offset 35 1489 front wheel offset 33 3 1445 rear wheel offset 33 3 Turning circle m 10 7 11 5 Steering roll radius negative mm 0 5 with offset 35 3 5 wi...

Page 8: ...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 8 Suspension Wheels...

Page 9: ...er piston diameter mm 54 Front brake disc mm dia 256 Front brake disc thickness mm 13 Pad thickness mm 14 Rear brake drum mm dia 230 Wheel cylinder mm dia 20 64 Lining thickness mm 5 Lining width mm 4...

Page 10: ...Front brake disc mm dia 256 288 Front brake thickness mm 20 13 Pad thickness mm 11 14 Rear brake caliper dia mm 38 Rear brake disc mm dia 226 Rear brake disc thickness mm 10 Pad thickness mm 12 Page 4...

Page 11: ...ront brake disc mm dia 256 288 Front brake disc thickness mm 20 25 Pad thickness mm 11 14 Rear brake caliper dia mm 38 Rear brake disc mm dia 239 Rear brake disc thickness mm 10 Pad thickness mm 12 Pa...

Page 12: ...Q M S 195 60 R 14 85 Q M S 205 50 R 15 85 Q M S 6 J x 14 6 J x 14 6 J x 15 6 J x 14 6 J x 14 6 J x 15 38 38 38 38 38 38 4 hole 55 Sedan Wagon T 125 70 R 15 95 M Temp spare 3 1 2 J x 15 40 1 Tire pres...

Page 13: ...hole 85 kW Sedan Wagon T 125 70 R 15 95 M Temp spare 3 1 2 J x 15 40 128 kW Sedan Wagon 205 50 ZR 15 86 W 195 55 R 15 85 T M S 195 55 R 15 85 T M S 205 50 R 15 85 T M S 6 J x 15 6 J x 15 6 1 2 J x 15...

Page 14: ...x 15 38 38 35 38 38 35 4 hole 85 kW Sedan Wagon syncro T 125 80 R 15 95 M Temp spare 3 1 2 J x 15 40 128 kW Sedan Wagon syncro 205 50 ZR 15 86 W 205 50 R 15 86 M S 6 J x 15 6 J x 15 35 35 5 hole 128 k...

Page 15: ...Base suspension Page 40 2 II Removing and installing wheel bearings suspension strut and drive shaft Base suspension Page 40 14 The Base suspension is installed in Passat 1995 vehicles up to 85 kW Pag...

Page 16: ...e damaged Specifications for wheel alignment Page 44 2 Welding and straightening operations are not permitted on load bearing suspension components or those components which locate the wheels Always r...

Page 17: ...ngated hole and check toe Elongated holes are not for camber adjustment Failure to observe this instruction may result in damage to drive shafts 3 Captive lock nuts 4 Air deflector plate Secured to co...

Page 18: ...5 x 65 70 Nm 52 ft lb and turn 90 further 9 Hex bolt M 12 x 1 5 x 78 70 Nm 52 ft lb and turn 90 further 10 Control arm front mounting Pressing out Fig 1 Pressing in Fig 2 11 Connecting link With rubb...

Page 19: ...nd 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 whe...

Page 20: ...bilizer bar 21 Vibration damper Note installation position large part must protrude from sub frame 22 Self locking hex nut 25 Nm 18 ft lb 23 Cap nut Repairing in side member Page 40 11 Page 6 of 82 Fr...

Page 21: ...re pressing in coat with acid free lubricant e g soft soap Fig 2 Front control arm mounting pressing in Page 7 of 82 Front Wheel Suspension Shafts and Axle 12 7 2004 http ebahn bentleypublishers com v...

Page 22: ...ear 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 ou...

Page 23: ...engine transmission assembly with 10 222 A and legs 10 222 A 1 Page 9 of 82 Front Wheel Suspension Shafts and Axle 12 7 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repai...

Page 24: ...el outward and inward There must be no perceptible or visual play during either test Observe ball joint during checks Take into account possible existing wheel bearing play or play in upper suspension...

Page 25: ...th 10 222 A and legs 10 222 A 1 Remove the sub frame Drill out the damaged side member cap nut with a 10 2 mm diameter drill from underneath Note When drilling do not tilt the drill WARNING Wear prote...

Page 26: ...10 9 N 101 612 01 Sub frame bracket M10 M10 x 38 10 9 N 019 541 1 Engine front cross member to side member M10 M10 x 75 10 9 N 904 078 01 1 1 These bolts are not listed in the parts catalog They must...

Page 27: ...1 Bolt washer 2 Cap nut 3 Side member 4 Sub frame 5 Bonded rubber mounting control arm Page 13 of 82 Front Wheel Suspension Shafts and Axle 12 7 2004 http ebahn bentleypublishers com vw servlet Displ...

Page 28: ...l 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 Alwa...

Page 29: ...of the outer joint must be removed before the nut is installed 2 Washer 3 Brake disc Application 4 Brake caliper Do not loosen brake hose when working on front suspension Hang up with wire or similar...

Page 30: ...place as it is destroyed during pressing out Pressing in Fig 7 11 Self locking hex nut 35 Nm 26 ft lb 12 Wheel bearing housing 13 Self locking hex nut 50 Nm 37 ft lb 14 Hex bolt Clamping bolt for ball...

Page 31: ...ll 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 po...

Page 32: ...moving and installing Fig 1 and Fig 2 Disassembling and assembling Page 40 23 25 Bracket 26 Hex bolt 27 Tie rod Removing and installing Page 48 77 28 Countersunk screw 29 Screw Page 18 of 82 Front Whe...

Page 33: ...mber must be adjusted each time joint is loosened Fig 2 Wheel bearing housing suspension strut joint separating Page 19 of 82 Front Wheel Suspension Shafts and Axle 12 7 2004 http ebahn bentleypublish...

Page 34: ...lation position Fig 3 Ball joint control arm connection separating Fig 4 Hub pressing out of wheel bearing housing Page 20 of 82 Front Wheel Suspension Shafts and Axle 12 7 2004 http ebahn bentleypubl...

Page 35: ...al type Fig 5 Bearing race pulling out of hub Fig 6 Wheel bearing pressing out of wheel bearing housing Page 21 of 82 Front Wheel Suspension Shafts and Axle 12 7 2004 http ebahn bentleypublishers com...

Page 36: ...g into wheel bearing housing Fig 8 Hub pressing into wheel bearing housing Page 22 of 82 Front Wheel Suspension Shafts and Axle 12 7 2004 http ebahn bentleypublishers com vw servlet Display action Got...

Page 37: ...individually Check shock absorber for leaks and noises After replacing adjust camber and toe Page 44 1 2 Buffer stop 3 Protective sleeve Page 23 of 82 Front Wheel Suspension Shafts and Axle 12 7 2004...

Page 38: ...plate 6 Axial bearing 7 Hex nut 60 Nm 44 ft lb Loosening and tightening Fig 2 8 Suspension strut mounting 9 Stop 10 Self locking hex nut 60 Nm 44 ft lb Loosening and tightening Fig 1 Page 24 of 82 Fr...

Page 39: ...loosening and tightening Fig 2 Spring removing and installing Page 25 of 82 Front Wheel Suspension Shafts and Axle 12 7 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair...

Page 40: ...llowing components are different when comparing the plus suspension with the base suspension Control arm ball joint wheel bearing housing stabilizer bar drive shaft brake disc hub wheel and tie rods T...

Page 41: ...r damage and if necessary replace ball joint Removing and installing Page 40 33 Mark installation position If replaced set to center of elongated hole and check track 3 Self locking hex nut 45 Nm 33 f...

Page 42: ...m by clip 8 Control arm front mounting Pressing out and in Fig 1 9 Hex bolt M 12 x 1 5 x 78 70 Nm 52 ft lb and turn 90 further 10 Hex bolt M 12 x 1 5 x 65 70 Nm 62 ft lb and turn 90 further 11 Connect...

Page 43: ...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 o...

Page 44: ...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 b...

Page 45: ...ws 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 82 Fro...

Page 46: ...g out and in Fig 4 Engine transmission assembly supporting with 10 222 A and 10 222 A 3 Page 32 of 82 Front Wheel Suspension Shafts and Axle 12 7 2004 http ebahn bentleypublishers com vw servlet Displ...

Page 47: ...ission 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 Pa...

Page 48: ...threads by threading nut on a few turns Install ball joint in wheel bearing housing Thread on new self locking nut and counterhold with hex key 6 mm AF 1 Hex key 6 mm AF shortened by approx 10 mm 2 Cr...

Page 49: ...ng housing 45 Nm 33 ft lb Ball joint to control arm 35 Nm 26 ft lb 1 Box insert commercial type 19 mm AF 2 Crowfoot insert commercial type 19 mm AF Page 35 of 82 Front Wheel Suspension Shafts and Axle...

Page 50: ...turn 45 further 1 8 Loosening and tightening Page 40 44 Any paint residue and or corrosion on thread of the outer joint must be removed before the nut is installed 3 Screw 4 Brake disc Repair instruc...

Page 51: ...6 Countersunk screw 7 Hub Pressing out Fig 2 Pressing in Fig 6 Pulling off inner race Fig 3 8 Speed sensor rotor Only for vehicles with ABS 9 Hex bolt 10 Nm 7 ft lb 10 Splash plate Page 37 of 82 Fron...

Page 52: ...ex 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...

Page 53: ...Nm 44 ft lb Loosening and tightening Fig 1 23 Suspension strut Disassembling and assembling Page 40 23 24 Self locking hex nut 95 Nm 70 ft lb 25 Tie rod Removing and installing Page 48 77 Page 39 of...

Page 54: ...dy loosening and tightening Fig 2 Hub pressing out of wheel bearing housing Page 40 of 82 Front Wheel Suspension Shafts and Axle 12 7 2004 http ebahn bentleypublishers com vw servlet Display action Go...

Page 55: ...cial type Fig 3 Inner race pulling off hub Fig 4 Wheel bearing pressing out of wheel bearing housing Page 41 of 82 Front Wheel Suspension Shafts and Axle 12 7 2004 http ebahn bentleypublishers com vw...

Page 56: ...g into wheel bearing housing Fig 6 Hub pressing into wheel bearing housing Page 42 of 82 Front Wheel Suspension Shafts and Axle 12 7 2004 http ebahn bentleypublishers com vw servlet Display action Got...

Page 57: ...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 o...

Page 58: ...int to control arm Install drive shaft to transmission flange shaft and secure Note Install 12 point nut to drive shaft and tighten To tighten 12 point nut we recommend the angle measuring wrench VAG...

Page 59: ...b Drive shaft to wheel bearing 90 Nm 66 ft lb and housing turn 45 further 1 8 turn Ball joint control arm 35 Nm 26 ft lb Page 45 of 82 Front Wheel Suspension Shafts and Axle 12 7 2004 http ebahn bentl...

Page 60: ...suspension Page 40 43 Note Grease quantity Outer constant velocity joint 100 g of G 6 3 grease Inner constant velocity joint 110 g of G 6 3 grease Greasing outer joint press half of the grease into th...

Page 61: ...joint 100 mm diameter Only replace complete Pressing off Fig 3 Pressing on Fig 4 Greasing Notes Page 40 46 Checking Page 40 62 4 Dished washer Inner diameter splined Installation position outer diame...

Page 62: ...llation position for right drive shaft Fig 6 Coat inside of cap with D3 Drive off with drift 6 Drive shaft Left shaft solid bar not illustrated Right shaft tube 7 Clamp Always replace Tensioning Fig 7...

Page 63: ...tensioning the small clamp Fig 7 Installation position for left shaft wheel end Fig 10 and Fig 11 Installation position for right shaft wheel end Fig 12 9 Clamp Always replace Tensioning Fig 7 and Fi...

Page 64: ...ant velocity joint 90 mm diameter Only replace complete Removing Fig 2 Installing drive onto shaft with plastic hammer until compressed circlip seats Greasing Notes Page 40 46 Checking Page 40 60 Page...

Page 65: ...age 40 46 Checking Page 40 60 15 Vibration damper Removing and installing Fig 1 Installation position Fig 1 Available as spare part Is only installed on the right drive shaft tube Exception On vehicle...

Page 66: ...locity joint Polyester elastomer version Check for tears and chafing To balance pressure briefly ventilate boot before tensioning the small clamp Fig 7 19 Protective cap 20 Hex bolt 35 Nm 26 ft lb Pag...

Page 67: ...t finish against damage To prevent axial movement apply adhesive tape or a suitable adhesive to internal diameter When installing vibration damper A note correct installation position Ensure dimension...

Page 68: ...blow from an aluminium hammer Note Fig 3 Inner constant velocity joint pressing off First drive boot off with drift Support ball hub Page 54 of 82 Front Wheel Suspension Shafts and Axle 12 7 2004 http...

Page 69: ...ore assembling boot on drive shaft mark position dimension a with for example paint or adhesive tape Under no circumstances should paint surface be damaged with a sharp tool Fig 5 Installation positio...

Page 70: ...ushed in when installing on the joint body This creates a vacuum inside the boot which draws a fold in arrow while driving After installing lift the boot at small diameter end to equalize pressure Fig...

Page 71: ...with pliers V A G 1682 Tightening torque 25 Nm 18 ft Ib Use torque wrench with 5 50 Nm range e g V A G 1331 Make sure the spindle thread is not tight If necessary lubricate with MOS 2 grease If the th...

Page 72: ...sion Fig 10 Installation position of left drive shaft wheel end joint boot shaft diameter 27 mm Cuff installation position Cuff butts against shaft shoulder arrow Fig 11 Installation position of left...

Page 73: ...er up to 1 2 a groove visible Fig 12 Installation position of right drive shaft wheel end joint boot Page 59 of 82 Front Wheel Suspension Shafts and Axle 12 7 2004 http ebahn bentleypublishers com vw...

Page 74: ...hub in relation to the ball cage and housing with an electric scriber or oil stone Swivel ball hub and ball cage Remove balls one after the other Turn cage until the two rectangular windows arrow are...

Page 75: ...of hub into rectangular cage window Tilt hub out of cage Press half of the total amount of grease Page 40 46 or Page 42 46 into the joint housing Install cage with hub in the joint housing Press in th...

Page 76: ...be interchanged Swivel ball hub and ball cage Press out ball cage in direction of arrow Press balls out of cage Tilt ball hub out of ball cage over ball track arrows Check joint housing ball hub ball...

Page 77: ...osition is acceptable Press balls into the cage Insert hub with cage and balls at right angle to the joint When inserting make sure that the wide spacing a on joint housing is aligned with the narrow...

Page 78: ...int The constant velocity joint is correctly assembled when the ball hub can be moved by hand backward and forward over its entire axial movement range Swivel in the hub with balls by applying firm pr...

Page 79: ...until circlip comes out Greasing Notes Page 40 46 Checking Page 40 62 2 Circlip Always replace Install in groove of shaft 3 Thrust ring 4 Dished washer Larger diameter concave side contacts thrust ri...

Page 80: ...briefly so pressure is equalized Fig 2 7 Clamp Always replace Tightening Fig 2 and Fig 4 8 Drive shaft left with inner tripod joint Repair of inner joint and replacement of boot not possible at this t...

Page 81: ...inner tripod joint Repair of inner joint and replacement of boot not possible at this time Replace if damaged Page 67 of 82 Front Wheel Suspension Shafts and Axle 12 7 2004 http ebahn bentleypublishe...

Page 82: ...on the joint body This creates a vacuum in the boot that makes a dent during driving arrow Briefly ventilate the boot at the small diameter after installation to provide equalize pressure Fig 2 Boot v...

Page 83: ...essary only tighten the clamp with pliers VAG 1682 Tightening torque 25 Nm 18 ft lb Use torque wrench with adjustment range 5 50 Nm e g VAG 1331 Make sure that threads of spindle on the pliers are eas...

Page 84: ...drive axle removal instructions remain unchanged from the current repair manual procedure Removing left side drive axle Set up engine support bridge Page 70 of 82 Front Wheel Suspension Shafts and Axl...

Page 85: ...ounting bolt arrow Lift engine transmission assembly Loosen drive axle nut while vehicle is standing on its wheels Page 71 of 82 Front Wheel Suspension Shafts and Axle 12 7 2004 http ebahn bentleypubl...

Page 86: ...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...

Page 87: ...reasing page 40 12 2 Circlip Always replace Insert in groove in shaft 3 Thrust ring 4 Belleville spring Larger diameter concave side contacts with thrust ring 5 Clamp Always replace Tightening page 40...

Page 88: ...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...

Page 89: ...CV joint Drive joint off axle shaft with firm blow from soft mallet Page 75 of 82 Front Wheel Suspension Shafts and Axle 12 7 2004 http ebahn bentleypublishers com vw servlet Display action Goto type...

Page 90: ...p The clamp can only be properly tightened using VAG 1682 pliers Use a torque wrench with 5 50Nm 4 37 ft lb range e g VAG 1331 or equivalent Make sure that the spindle threads of the pliers are not ti...

Page 91: ...into cover and pry open If the cover will not pry open insert screwdriver and pry from the opposite side The cover is destroyed in the removal process It does not need to be replaced Page 77 of 82 Fr...

Page 92: ...t tipped pen for marking parts Remove rubber gasket arrow from groove With triple rotor joint housing clamped in vise pull axle shaft together with triple rotor star upward out of housing Hold axle sh...

Page 93: ...lip Press triple rotor star off axle shaft Pull triple rotor joint housing off axle shaft Clean shaft and triple rotor joint housing Page 79 of 82 Front Wheel Suspension Shafts and Axle 12 7 2004 http...

Page 94: ...xle shaft splines first Place triple rotor star on axle shaft according to previously marked position Install circlip and make sure that it is correctly seated Install rollers according to previously...

Page 95: ...ar sealing ring arrow from repair kit 90 grams into joint and 90 grams behind joint Press 180 grams of axle shaft grease from repair kit into triple rotor joint Install triple rotor joint boot Install...

Page 96: ...or joint with tape so that the housing is not inadvertently pushed back when installing the axle shaft Remove tape just prior to bolting to drive flange Page 82 of 82 Front Wheel Suspension Shafts and...

Page 97: ...e 1 Wheel bolt 110 Nm 81 ft lb 2 Self locking hex nut 70 Nm 52 ft lb When tightening the nut the axle beam must be in the horizontal position unladened vehicle state 3 Hex bolt 25 Nm 18 ft lb 4 Suspen...

Page 98: ...ning nut the axle beam must be in the horizontal position unladened vehicle state 7 Hex bolt Installed from center of vehicle 8 Shouldered bolt 70 Nm 52 ft lb If threads are damaged rework captive nut...

Page 99: ...26 ft lb 11 Regulator spring bracket 12 Bonded rubber mounting Note installation position Fig 7 Pressing out Fig 5 and Fig 6 Pressing in Fig 8 Only replace as pair 13 Axle beam Stub axle contact surfa...

Page 100: ...ving and installing inertia reel cover Removing and installing inertia reel Remove and install both securing bolts arrows from interior of vehicle viewed through rear left side window Tightening torqu...

Page 101: ...ining lugs are positioned above the cut outs Fig 3 Suspension strut removing and installing Angle of inclination to axle beam 13 30 1 Fig 4 Bolting mounting bracket to axle beam Page 5 of 14 Rear Whee...

Page 102: ...e plate 3111 5 from the opposite side Note Mounting must not be driven out Otherwise the mounting seat will be widened and a tight seating of the new mounting cannot be assured Fig 6 Bonded rubber mou...

Page 103: ...stallation position Press both halves in one after the other until the mounting conical section contacts the axle beam Fig 8 Rubber bonded mounting presssing into axle beam Page 7 of 14 Rear Wheel Sus...

Page 104: ...rom underneath Note Do not tilt the drill when drilling WARNING Wear protective goggles Cut new thread in the cap nut M 12 x 1 5 Use new bolts Part No N 010 127 4 M 12 x 1 5 x 30 and washer Part No N...

Page 105: ...rewdriver Pressing on Fig 4 2 O ring 3 Self locking hex nut 25 Nm 18 ft lb 4 Dished washer 5 Upper rubber mounting 6 Gasket foam Always replace Page 9 of 14 Rear Wheel Suspension Shafts and Axle 12 7...

Page 106: ...ck absorber lower bushing Fig 3 8 Spacer tube 9 Lower rubber mounting 10 Metal cap Higher on Wagon than Sedan 11 Washer 12 Spring seat Thinner on Wagon than Sedan Installation position Fig 2 Page 10 o...

Page 107: ...ap 16 Coil spring Removing and installing Fig 1 Allocation Parts catalog Wagon has protective hose at top 17 Packing 18 Circlip 19 Lower spring plate Page 11 of 14 Rear Wheel Suspension Shafts and Axl...

Page 108: ...ed individually Removing and installing Page 42 4 Application see Parts catalog Page 12 of 14 Rear Wheel Suspension Shafts and Axle 12 7 2004 http ebahn bentleypublishers com vw servlet Display action...

Page 109: ...y be used Fig 1 Spring removing and installing Fig 2 Spring seat installation position Page 13 of 14 Rear Wheel Suspension Shafts and Axle 12 7 2004 http ebahn bentleypublishers com vw servlet Display...

Page 110: ...s B Suspension strut mounting axis a 50 C Cap axis 90 offset to shock absorber bushing axis A Fig 4 Cap in suspension strut mounting pressing in Page 14 of 14 Rear Wheel Suspension Shafts and Axle 12...

Page 111: ...el bearing service life Therefore note the following points Install oil seal and grease cap as shown Only reinstall clean bearings do not wash bearings Adjust wheel bearing play carefully 1 Grease cap...

Page 112: ...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...

Page 113: ...hed washer Larger contact surface concave side to brake backing plate 13 Hex bolt 60 Nm 44 ft lb 14 Inner wheel bearing Drive out outer race with copper drift Pressing in Fig 7 15 Speed sensor rotor P...

Page 114: ...Fig 5 When removing the brake drum make sure that the outer wheel bearing does not fall out Fill hub with multi purpose grease before installing Page 4 of 18 Wheel bearings servicing 12 7 2004 http e...

Page 115: ...by tapping lightly on the claw Fig 1 Grease cap pressing off Fig 2 Grease cap pressing off Page 5 of 18 Wheel bearings servicing 12 7 2004 http ebahn bentleypublishers com vw servlet Display action Go...

Page 116: ...use the illustrated tool Note Using a screwdriver it must be possible to move the thrust washer by finger pressure without prying Fig 4 Wheel bearing play adjusting Secure with locking ring and new co...

Page 117: ...driver through a hole in the brake drum and push the wedge upward Fig 6 Outer wheel bearing outer race pressing in Page 7 of 18 Wheel bearings servicing 12 7 2004 http ebahn bentleypublishers com vw s...

Page 118: ...Inner wheel bearing outer race pressing in Fig 8 Oil seal driving in Page 8 of 18 Wheel bearings servicing 12 7 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B...

Page 119: ...42 23 Fig 9 Rotor pressing in Page 9 of 18 Wheel bearings servicing 12 7 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 SU01 42 2...

Page 120: ...heel 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 b...

Page 121: ...0 650 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 P...

Page 122: ...e 46 33 13 Brake caliper Servicing Page 47 15 14 Outer wheel bearing Drive out outer race with copper drift Pressing in Fig 6 15 Hex nut Adjusting wheel bearing play Fig 4 16 Cotter pin Always replace...

Page 123: ...grease 22 Inner wheel bearing Drive out outer race with copper drift Pressing in Fig 7 23 Oil seal Fill between sealing lips with multi purpose grease Driving in Fig 8 24 Speed sensor rotor Only on v...

Page 124: ...eam Straightening work is not permissible Only use stub axles with 6 mounting holes 29 Parking brake cable Adjusting parking brake Page 46 36 30 Spring clip Page 14 of 18 Wheel bearings servicing 12 7...

Page 125: ...ng off Loosen grease cap by tapping lightly on the claw Fig 2 Grease cap pressing off Page 15 of 18 Wheel bearings servicing 12 7 2004 http ebahn bentleypublishers com vw servlet Display action Goto t...

Page 126: ...se the illustrated tool Note Using a screwdriver it must be possible to move the thrust washer by finger pressure without prying Fig 4 Wheel bearing play adjusting Secure with locking ring and new cot...

Page 127: ...llation position Drive on cover ring with tube VW 519 Fig 6 Outer wheel bearing outer race pressing in Page 17 of 18 Wheel bearings servicing 12 7 2004 http ebahn bentleypublishers com vw servlet Disp...

Page 128: ...Inner wheel bearing outer race pressing in Fig 8 Oil seal driving in Page 18 of 18 Wheel bearings servicing 12 7 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW...

Page 129: ...he wishbones can remain attached to the shock absorber In both cases disconnect vacuum lines and wiring before lowering the assembly Always replace self locking nuts and bolts Always replace corroded...

Page 130: ...alling Fig 2 and Fig 3 Servicing Page 42 46 3 Final drive Removing and installing from axle beam Fig 9 4 Final drive mounting bracket and carrier Removing and installing Fig 12 Replacing rubber bonded...

Page 131: ...and Fig 11 8 Rear axle mounting bracket Removing and installing at body Fig 14 9 Control arm Removing and installing Fig 5 Replacing rubber bonded mounting Fig 6 and Fig 7 Rubber bonded mounting with...

Page 132: ...bearing Servicing Page 42 59 Servicing brakes 11 Hex bolt 85 Nm 63 ft lb 12 Hex bolt for seat belt strut 25 Nm 18 ft lb Page 4 of 13 Rear axle servicing four wheel drive vehicles 12 7 2004 http ebahn...

Page 133: ...rom control arm removing and installing Before removing propshaft mark installation position If installed offset imbalance will be excessive Tightening torque A and B 45 Nm 33 ft lb Note Always suppor...

Page 134: ...corrosion on the thread of the outer joint must be removed before the nut is installed Fig 3 Drive shaft removing and installing Tightening torque A and B 25 Nm 18 ft lb Fig 4 Stabilizer bar removing...

Page 135: ...tor from axle beam Tightening torque A 120 Nm 89 ft lb Fig 5 Control arm removing and installing Fig 6 Rubber bonded mounting removing A 17 mm socket B Separating device 12 75 mm e g Kukko 17 1 Page 7...

Page 136: ...er of vehicle Note Deviations from the rear axle toe and camber specifications can be corrected by using a bonded rubber mounting with eccentric bushing Fig 8 Fig 7 Bonded rubber mounting installing P...

Page 137: ...ith this mounting the camber or toe can be altered up to 18 Fig 8 Rubber mounting to correct camber toe Installation position Alteration Eccentric upward Camber alteration negative Eccentric downward...

Page 138: ...sion 02A Repair Group 39 Tightening torque A 45 Nm 33 ft lb Fig 9 Final drive removing and installing from axle beam Page 10 of 13 Rear axle servicing four wheel drive vehicles 12 7 2004 http ebahn be...

Page 139: ...from the center of vehicle Fig 10 Installation position determining Place one half of the rubber bonded mounting in correct position and pull in with tool 3128 and 3128 1 Then place 2nd half in posit...

Page 140: ...Fig 12 Mounting bracket and final drive carrier removing and installing Tightening torque A 45 Nm 33 ft lb B 65 Nm 48 ft lb C 85 Nm 63 ft lb D 85 Nm 63 ft lb No specific installation position Insertio...

Page 141: ...n axle alignment stand after reinstalling Fig 14 Mounting bracket on body removing and installing Tightening torque A 130 Nm 96 ft lb B 60 Nm 44 ft lb C 85 Nm 63 ft lb Page 13 of 13 Rear axle servicin...

Page 142: ...joint press half of the grease into the joint and the other half evenly into the boot Greasing inner joint press half of the grease into the inner joint from both sides the other half evenly into the...

Page 143: ...age 40 54 Pressing on Page 40 55 Greasing Notes Page 42 46 Checking Page 40 62 3 Dished washer Inner diameter splined Installation position outer diameter concave side contacts constant velocity joint...

Page 144: ...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 7 Rea...

Page 145: ...isible To balance pressure briefly ventilate boot before tensioning the small clamp 8 Hose clamp Always replace Tensioning Page 40 57 9 Dished washer Outer diameter concave side contacts thrust washer...

Page 146: ...rive onto shaft with plastic hammer until compressed circlip seats Greasing Notes Page 42 46 Checking Page 40 60 13 Inner support rings Prevents boot inflating Only installed on left drive shaft trans...

Page 147: ...emove control arm if necessary Drill through damaged cap nut in the side member using a 10 2 mm diameter drill from underneath Note Do not tilt the drill when drilling WARNING Wear protective goggles...

Page 148: ...31 7 to secure the rear axle Tightening torque 65 Nm 48 ft lb Note The procedure described here must only be performed on one cap nut on each side of the vehicle Page 7 of 7 Rear drive shafts servicin...

Page 149: ...ion position Fig 5 2 Seal 3 Self locking hex nut 30 Nm 22 ft lb Always replace 4 Dished washer 5 Upper rubber mounting 6 Gasket foam Always replace Page 1 of 6 Suspension strut disassembling and assem...

Page 150: ...Spring seat 9 Spacer tube 10 Lower rubber mounting 11 Stop buffer mounting 12 Washer 13 Stop buffer 14 Ring Aluminium 15 Boot 16 Protective cap Page 2 of 6 Suspension strut disassembling and assembli...

Page 151: ...Shock absorber Can be replaced individually Removing and installing Page 42 4 and Page 42 37 Check shock absorber for leaks and noises Application see Parts catalog Page 3 of 6 Suspension strut disas...

Page 152: ...plate 1 could contact the tire Fig 1 Lower spring plate installation position 1 Lower spring plate 2 Shock absorber eye bushing Fig 2 Spring seat installation position Page 4 of 6 Suspension strut di...

Page 153: ...trut mounting to spring seat installation position Fig 4 Suspension strut mounting to shock absorber bushing aligning A Shock absorber bushing axis B Suspension strut mounting axis C Cap axis at 90 to...

Page 154: ...ng into suspension strut mounting Page 6 of 6 Suspension strut disassembling and assembling four wheel drive vehicles 12 7 2004 http ebahn bentleypublishers com vw servlet Display action Goto type rep...

Page 155: ...erwise 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 ho...

Page 156: ...ive cap 6 Pad securing springs Always replace when changing pads 7 Brake pads Repair information 8 Brake caliper Servicing 9 Pad carrier 10 Screw 11 Wheel bolt 110 Nm 81 ft lb Page 2 of 8 Wheel bearin...

Page 157: ...G 1756 or equivalent Before installing nut on outer joint remove any paint remains and or corrosion from threads 13 Shim 14 Brake disc Repair information 15 Hub Pressing out Fig 1 Pulling off inner ra...

Page 158: ...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...

Page 159: ...drive shaft Page 42 37 and Page 42 38 Removing and installing rotor Fig 6 25 Brake line Page 5 of 8 Wheel bearings servicing disc brakes four wheel drive vehicles 12 7 2004 http ebahn bentleypublishe...

Page 160: ...ing out Fig 2 Wheel bearing pressing out Page 6 of 8 Wheel bearings servicing disc brakes four wheel drive vehicles 12 7 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repai...

Page 161: ...3 Inner race pulling off of hub Note First install lower circlip Fig 4 Wheel bearing pressing in Page 7 of 8 Wheel bearings servicing disc brakes four wheel drive vehicles 12 7 2004 http ebahn bentle...

Page 162: ...r rotor pressing in Drive rotor off outer joint using a drift rotor will be destroyed Drive new rotor carefully onto stop using a plastic hammer Page 8 of 8 Wheel bearings servicing disc brakes four w...

Page 163: ...should not be checked before the vehicle has completed 1000 to 2000 km 600 to 1200 miles as then the coil springs have had time to settle The cause of vehicle imbalance may also be excessive residual...

Page 164: ...ifference at 20 left 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 c...

Page 165: ...fference between sides 1 30 10 max 20 Total toe 1 at specified wheel camber Maximum permissible deviation from direction of travel 20 10 max 20 1 not adjustable Page 3 of 7 Vehicle alignment 12 7 2004...

Page 166: ...e at 20 left 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 correctio...

Page 167: ...specified camber Maximum permissible deviation from direction of travel 15 20 max 20 1 Camber and toe corrections possible using eccentric rubber mounting Repair Manual Suspension Wheels Brakes Steer...

Page 168: ...repeat adjustment Slight cant of tool is permitted Do not move steering with tool in place Before adjusting camber it is essential to examine all suspension components for damage visual inspection an...

Page 169: ...2 5 Deviation from direction of travel 5 Add figures with different sign and divide by 2 Example Left rear wheel toe Right rear wheel toe 15 5 15 5 20 20 2 10 Deviation from direction of travel 10 Th...

Page 170: ...draulic unit with pump The hydraulic unit together with pump supplies only the anti locking brake system ABS or anti locking brake system and traction control system ABS EDL Malfunctions on the ABS AB...

Page 171: ...er work for which the brake system had to be opened bleed the brake system with brake filler and bleeder unit VAS 5234 Page 47 27 During the final road test make sure that a controlled brake test is p...

Page 172: ...allation Only use genuine packed parts When the system is open do not work with compressed air and do not move the vehicle Make sure that no brake fluid enters harness connectors During painting opera...

Page 173: ...pull connector off control module release control module locking bar Installing Install in reverse order Engage connector catch in control module slots arrow A press connector on arrow B and secure w...

Page 174: ...heck that rotor is clean and undamaged Front axle Vehicles with base suspension Page 40 14 Vehicles with plus suspension Page 40 23 Rear axle Vehicles with rear drum brakes Page 42 15 Vehicles with re...

Page 175: ...bly has been removed New ABS control units supplied as replacement parts from the Parts department are not coded and require coding after installation Repair Manual Brake System On Board Diagnostic OB...

Page 176: ...pproved brake fluid that complies with MVSS 116 DOT 4 DO NOT use silicone brake fluid DOT 5 Even the smallest traces can cause sever corrosion in the brake system Before doing any welding repairs on t...

Page 177: ...a repair cannot be completed immediately After separating the ABS hydraulic unit and ABS control module always use the plastic foam transportation protection for the valve dome and always use the sea...

Page 178: ...r 2 Brake master cylinder 3 Brake fluid reservoir 4 Cap 5 Self locking nut Always replace 25 Nm 18 ft lb 6 Torx socket head bolt T25 4 Nm 35 in lb 7 Torx socket head bolt T25 8 Nm 71 in lb Page 1 of 9...

Page 179: ...ht rear brake caliper or wheel cylinder 15 Brake line connection ABS hydraulic unit to left front brake caliper 16 Brake line Brake master cylinder secondary piston circuit to ABS hydraulic unit 17 Br...

Page 180: ...it Switch ignition OFF when disconnecting and reconnecting the ABS control module connector Part numbers are listed here for reference only Always check with your Parts department for the latest infor...

Page 181: ...was not used will not be accepted Removing CAUTION Determine correct radio anti theft coding before disconnecting the battery Disconnect battery Ground GND strap Remove coolant expansion tank and swin...

Page 182: ...from special tool VAG 1238B Close left front bleeder screw Remove heat shield from brake master cylinder Disconnect brake lines from brake master cylinder and ABS hydraulic unit Seal lines and threade...

Page 183: ...trol module Pull control module straight off Do not tilt Cover control unit magnetic coils with a lint free cloth After separating the ABS hydraulic unit and ABS control module always use the plastic...

Page 184: ...quately bled Mount ABS control module to hydraulic unit using new bolts Tightening torque 4 Nm 35 in lb Reconnect ABS hydraulic pump connector The remainder of the installation procedure is the revers...

Page 185: ...e System On Board Diagnostic OBD Repair Group 01 Tightening torques ABS control unit to ABS hydraulic unit 4 Nm 35 in lb ABS hydraulic unit to bracket Torx T25 socket head bolts 8 Nm 71 in lb Brake ma...

Page 186: ...iate the Basic Setting function of the On Board Diagnostic OBD program Repair Manual Brake System On Board Diagnostic OBD Repair Group 01 Otherwise the standard brake bleeding procedures apply Page 47...

Page 187: ...rom one another Illustration shows an exploded view of the ABS EDL unit Servicing of ABS unit is identical Distinguishing features 1 Brake Pedal Position Sensor Removing and installing Page 45 25 Chec...

Page 188: ...cylinder primary piston circuit to hydraulic unit 6 Brake servo 7 Carrier plate 8 Sealing ring 9 Pin 10 Securing clip 11 Brake fluid reservoir Page 2 of 10 Assembly overview hydraulic unit brake servo...

Page 189: ...Only on vehicles with ABS EDL Checking 15 Self locking hex nut 25 Nm 18 ft lb 16 Tandem brake master cylinder 17 Protective plate 18 Hex bolt for protective plate Page 3 of 10 Assembly overview hydra...

Page 190: ...e line connection Hydraulic unit to front right brake caliper Thread connection M10 x 1 15 Nm 11 ft lb 22 Torx bolts T 25 23 Brake line connection Hydraulic unit to rear left wheel cylinder Thread con...

Page 191: ...raulic unit to front left brake caliper Thread connection M10 x1 15 Nm 11 ft lb 26 Brake line Master brake cylinder secondary piston circuit to hydraulic unit Page 5 of 10 Assembly overview hydraulic...

Page 192: ...ve as much brake fluid as possible from brake fluid reservoir using a suction bottle Disconnect brake lines from ABS hydraulic unit and seal threaded holes with plugs from repair kit Part No 1HO 698 3...

Page 193: ...cape it is then no longer guaranteed that the unit is sufficiently filled or adequately bled Preassemble hydraulic unit and brake servo with tandem master cylinder away from vehicle Secure hydraulic u...

Page 194: ...e 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...

Page 195: ...pansion tank to side Pull connector off sensor Expand circlip with a small screwdriver in a clockwise direction and pull sensor arrow out of brake servo Page 9 of 10 Assembly overview hydraulic unit b...

Page 196: ...age Connect sensor unit connection and ensure correctly located To ensure correctly seated pull senor by hand Leaks at the sensor sealing ring result in insufficient braking vacuum and poor engine idl...

Page 197: ...mal operating position To remove brake fluid from the reservoir use a bleeder bottle which is used only for brake fluid Brake fluid is poisonous and must on not be siphoned by mouth using a hose Wheel...

Page 198: ...disc ventilated When worn always replace on both sides Brake disc diameter 256 mm Brake disc thickness 20 mm Wear limit 18 mm 3 Screw 4 Countersunk screw To secure rotor Only on vehicles with ABS Page...

Page 199: ...hickness ventilated brake disc 11 mm Checking thickness Wear limit 7 mm including backplate 6 Hub Removing and installing from Page 40 14 7 Wheel speed sensor rotor Only on vehicles with ABS 8 Hex bol...

Page 200: ...s If protective caps are damaged use repair kit Use grease packet supplied to lubricate guide pins 12 Heat shield Install in piston 13 Brake caliper housing Do not disconnect brake hose when changing...

Page 201: ...socket head bolt 10 Nm 7 ft lb 19 Speed sensor Only on vehicles with ABS Before inserting sensor clean mounting hole inner surface and coat with lubricating paste G 000 650 Page 5 of 7 Front brakes se...

Page 202: ...e caliper housing securing bolt Counter hold on guide pin Swing brake caliper housing upward Remove brake pads Page 6 of 7 Front brakes servicing Girling caliper 12 7 2004 http ebahn bentleypublishers...

Page 203: ...on back Install brake pads Swing brake caliper housing down and tighten bolt The repair kit contains two self locking bolts which must always be installed After replacing the brake pads depress brake...

Page 204: ...e disc thickness 25 mm Wear limit 23 mm 3 Brake pads Always replace on both sides Pads are different pad on piston side has retaining spring Removing and installing Page 46 12 Pad thickness 14 mm Chec...

Page 205: ...e pins If protective caps are damaged use repair kit Use grease packet supplied to lubricate guide pins 6 Brake caliper housing Do not disconnect brake hose when changing brake pads Removing and insta...

Page 206: ...2 Ribbed bolt 125 Nm 92 ft lb 13 Wheel bearing housing 14 Hex socket head bolt 10 Nm 7 ft lb 15 Speed sensor Only on vehicles with ABS Before inserting sensor clean mounting hole inner surface and coa...

Page 207: ...ed sensor rotor Only on vehicles with ABS 19 Hub Removing and installing Page 40 14 20 Countersunk bolt Page 4 of 7 Front brakes servicing Teves Ate 12 7 2004 http ebahn bentleypublishers com vw servl...

Page 208: ...ame position or uneven braking may result Remove protective caps Pry off brake pad retaining spring from brake caliper housing with a screwdriver and remove Page 5 of 7 Front brakes servicing Teves At...

Page 209: ...up fluid may overflow and cause damage Remove both guide pins from brake caliper Remove brake caliper housing and lay to one side so that weight of brake caliper does not stress or damage brake hose T...

Page 210: ...rotective caps Install retaining spring into brake caliper housing Note After replacing the brake pads depress brake pedal firmly several times with the vehicle stationary so that the brake pads are p...

Page 211: ...stalling from Page 42 19 2 Cotter pin Always replace 3 Locking ring 4 Hex nut Adjusting wheel bearing play Page 42 20 5 Thrust washer Page 1 of 4 Rear wheel brakes servicing drum brakes 12 7 2004 http...

Page 212: ...Wear limit 231 5 mm Clean thoroughly check for wear damage tolerances damaged wheel bolt threads and condition of braking surface Fill hub with multi purpose grease Check for ovality 9 Stub axle Page...

Page 213: ...12 Backing plate with brake shoes Release adjustment before removing brake drum Page 46 18 13 Dished washer Large contact surface faces back plate 14 Hex bolt 60 Nm 44 ft lb Page 3 of 4 Rear wheel br...

Page 214: ...asing Insert a screwdriver through hole in brake drum and push wedge upward Page 4 of 4 Rear wheel brakes servicing drum brakes 12 7 2004 http ebahn bentleypublishers com vw servlet Display action Got...

Page 215: ...1 Spring plate To remove push against the spring and turn through 90 2 Spring 3 Brake shoe with lever for parking brake Removing and installing Page 46 23 Adjusting parking brake Page 46 26 Page 1 of...

Page 216: ...spring 7 Brake shoe Removing and installing Page 46 23 Minimum lining thickness 2 5 mm Checking thickness 8 Cap Remove to check brake lining thickness 9 Pin 10 Wheel speed sensor Only on vehicles with...

Page 217: ...and install the brake drum push upwards through a wheel bolt hole Page 46 18 15 Push rod Lubricate contact points with G 000 650 paste 16 Locating spring Unhook with pliers Page 3 of 8 Rear wheel bra...

Page 218: ...a blunt instrument e g plastic wedge Fig 1 Wheel cylinder checking for leaks Lift dust boot If brake fluid is found in the dust boot then replace wheel cylinder Page 4 of 8 Rear wheel brakes servicing...

Page 219: ...return spring Remove brake shoes Unhook parking brake cable Clamp brake shoes in vice Remove wedge spring Remove upper return spring Unhook locating spring Page 5 of 8 Rear wheel brakes servicing 12...

Page 220: ...sh rod Connect upper return spring Connect parking brake cable to brake lever Place brake shoes on wheel cylinder pistons Connect lower return spring and lift brake shoes onto lower support Page 6 of...

Page 221: ...m and adjust wheel bearing play Adjusting wheel bearing play Page 42 20 Firmly depress brake pedal once this adjusts the rear brakes Page 7 of 8 Rear wheel brakes servicing 12 7 2004 http ebahn bentle...

Page 222: ...brake Firmly depress brake pedal once Pull parking brake lever up four notches Note The hand grip and center console must be moved to access the adjusting nuts arrow Page 46 39 Tighten adjusting nuts...

Page 223: ...9 10 11 and 12 apply for four wheel drive 1 Axle beam 2 Hex socket head bolt 10 Nm 7 ft lb 3 Wheel speed sensor Only for vehicles with ABS Insert with lubricating paste G 000 650 Page 1 of 10 Rear whe...

Page 224: ...ounter hold on guide pin 7 Guide pin 8 Protective cap 9 Pad retaining springs Always replace when changing pads 10 Backing plate ring Distance between ring collar and backing plate 9 5 mm Page 2 of 10...

Page 225: ...repair kit Use grease packet supplied to lubricate guide pins 12 Brake pads Thickness 12 mm Checking thickness Wear limit 7mm including backing plate Always replace on both sides Removing and installi...

Page 226: ...leverage Page 42 20 Secure with locking ring and new cotter pin 16 Cotter pin Always replace 17 Grease cap Removing and installing Page 42 29 18 Lock ring 19 Thrust washer 20 Wheel bolt 110 Nm 81 ft...

Page 227: ...installing Page 42 59 Brake disc thickness for both versions 10 mm Wear limit 8 mm When worn always replace on both sides Assembly sequence for run in brake discs Brake caliper Brake pads Brake carri...

Page 228: ...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 10 Rear whe...

Page 229: ...ent uneven braking Removing Remove wheels Remove parking brake cable from brake caliper arrow Remove securing bolts from brake caliper housing counter hold on guide pins Remove brake pads Page 7 of 10...

Page 230: ...brake pads Install special tool 3272 so that the collar arrow of the tool is seated against the brake caliper If the piston is difficult to move use a 13 mm open end wrench on the flats arrow A provi...

Page 231: ...e firmly depress brake pedal several times with vehicle stationary so that the brake pads are properly seated in their normal operating position After changing brake pads check brake fluid level Page...

Page 232: ...ccess to adjusting nuts arrows Page 46 39 Parking brake lever in off position Tighten adjusting nut until lever arrow lifts off the brake caliper stop A gap of max 1 5 mm from stop arrow is permissibl...

Page 233: ...2 Hand grip Pry trim up with a small screwdriver then pull forward to remove Fig 2 3 Adjusting nut Adjusting parking brake Vehicles with drum brakes Page 46 26 Vehicles with disc brakes Page 46 36 Pa...

Page 234: ...p then pull trim forward Fig 2 7 Hex nut 8 Parking brake cable Different versions for rear drum and disc brakes Allocation see Parts catalog Page 2 of 9 Parking brake lever assembly overview 12 7 2004...

Page 235: ...Fig 1 Parking brake cable installation position Fig 2 Hand grip removing Pry up parking brake cable trim with a screwdriver and pull grip and trim off forward Page 3 of 9 Parking brake lever assembly...

Page 236: ...g Remove rear ashtray center console Remove console rear securing screws arrows Page 4 of 9 Parking brake lever assembly overview 12 7 2004 http ebahn bentleypublishers com vw servlet Display action G...

Page 237: ...e all mountings before installing with G 000 602 grease 1 Securing clip Ensure securely seated 2 Pin 3 Brake servo push rod clevis 4 Self locking hex nut 20 Nm 15 ft lb 5 Brake pedal pivot pin Page 5...

Page 238: ...ing bushing 9 Brake pedal 10 Clutch pedal Removing and installing 11 Pedal cluster mounting bracket 12 Clutch pedal pivot pin 13 Clutch pedal mounting bushing 14 Over center spring mounting 15 Over ce...

Page 239: ...Ensure seated securely 17 Brake Light Switch Adjusting Page 46 45 Page 7 of 9 Parking brake lever assembly overview 12 7 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repa...

Page 240: ...al remove trim Remove brake pedal clevis pin connection securing clip Remove pin Remove brake pedal pivot pin securing clip Remove pivot pin Remove mounting sleeve return spring mounting tube with bra...

Page 241: ...rake pedal as far as possible by hand guide Brake Light Switch through the locating hole and secure by turning through 90 to left Pull brake pedal back up by hand to stop Brake Light Switch is pushed...

Page 242: ...cylinders and brake servos can be replaced independently of each other 1 Seal For brake servo 2 Self locking hex nut 20 Nm 15 ft lb 3 Mounting bracket 4 Mounting bracket For brake servo 5 Seal Page 1...

Page 243: ...foot pressure hold and start engine If the servo unit is working properly the pedal will be felt to give slightly under foot servo assistance becomes effective If faulty replace complete Check valve...

Page 244: ...der Cannot be repaired If faulty replace complete 10 Sealing plug Moisten with brake fluid and press into reservoir 11 Seal Page 3 of 4 Assembly overview brake master cylinder brake servo 12 7 2004 ht...

Page 245: ...3 Brake fluid reservoir 14 Non return valve Page 4 of 4 Assembly overview brake master cylinder brake servo 12 7 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW...

Page 246: ...tective seal 2 Bleed valve Apply thin coat of brake cylinder paste to threads before screwing in 3 Brake caliper housing 4 Self locking hex bolt 35 Nm 26 ft lb Always replace When loosening and tighte...

Page 247: ...guide pins and protective caps Brake carrier with guide pins and protective cap Supplied as replacement part assembled with sufficient grease on guide pins If protective caps or guide pins are damage...

Page 248: ...piston Force piston out of brake caliper housing using compressed air Note When removing ensure that the surface of the cylinder is not damaged Remove seal with a screwdriver Page 3 of 5 Girling fron...

Page 249: ...on Note Hold piston in front of caliper housing Using a screwdriver insert the inner sealing lip into the cylinder groove Page 4 of 5 Girling front brake caliper servicing 12 7 2004 http ebahn bentley...

Page 250: ...n locate in the piston groove Press piston into the brake caliper housing using piston resetting tool Page 5 of 5 Girling front brake caliper servicing 12 7 2004 http ebahn bentleypublishers com vw se...

Page 251: ...ective seal Push onto bleed valve 2 Bleed valve Apply thin coat of brake cylinder paste to threads before threading in 3 Cap Install in mounting bushing 4 Guide pin 25 Nm 18 ft lb 5 Mounting bushing I...

Page 252: ...Fig 2 10 Piston Force piston out of brake caliper using compressed air Fig 1 Installing Fig 3 and Fig 4 and Fig 5 First coat the piston lightly with brake cylinder paste Piston diameter 54 mm 11 Prote...

Page 253: ...maging the piston Fig 1 Piston pressing out of cylinder using compressed air Fig 2 Piston seal removing Page 3 of 5 Front brake caliper servicing Teves Ate 12 7 2004 http ebahn bentleypublishers com v...

Page 254: ...liper housing Fig 4 Protective seal installing Using a screwdriver insert inner sealing lip into cylinder groove Page 4 of 5 Front brake caliper servicing Teves Ate 12 7 2004 http ebahn bentleypublish...

Page 255: ...er sealing lip will then locate in the piston groove Fig 5 Piston installing Page 5 of 5 Front brake caliper servicing Teves Ate 12 7 2004 http ebahn bentleypublishers com vw servlet Display action Go...

Page 256: ...rake fluid and are pre bled When repairing it is essential to pre bleed the brake calipers without brake pads before installing in the vehicle Page 47 21 1 Self locking bolts 35 Nm 26 ft lb Always rep...

Page 257: ...seal Pull outer sealing lip onto piston Install inner sealing lip in brake caliper housing groove Page 47 20 5 Dust cap 6 Bleeder valve Apply thin coat of brake cylinder paste before screwing in Page...

Page 258: ...caliper housing After repairing pre bleed caliper housing Page 47 21 8 Guide pins Grease before pulling on protective cap 9 Protective cap Pull onto brake carrier and guide pin Page 3 of 8 Rear brake...

Page 259: ...h sufficient grease on guide pins If protective caps or guide pins are damaged install repair kit Use grease packet supplied to lubricate the guide pins Page 4 of 8 Rear brake caliper servicing 12 7 2...

Page 260: ...13 mm open end wrench on the flats arrow A provided for this purpose Install special tool 3272 so that the collar arrow is before the piston Note Make sure that the surface of the cylinder is not dam...

Page 261: ...Hold piston in front of brake caliper housing Insert protective seal inner sealing lip into the caliper housing groove using a screwdriver Page 6 of 8 Rear brake caliper servicing 12 7 2004 http ebahn...

Page 262: ...t to move use a 13 mm open end wrench on flats arrow A provided for this purpose If the piston is pushed back with a piston resetting tool or by operating the foot brake the automatic adjustment in th...

Page 263: ...e and using a standard bleeder bottle fill with brake fluid until bubble free brake fluid flows from the threaded hole brake hose connection Close bleeder screw Page 8 of 8 Rear brake caliper servicin...

Page 264: ...brake pedal and release quickly vehicle standing on its wheels This must cause the brake pressure regulator lever to move Checking and adjusting pressure Note The brake pressure regulator is set with...

Page 265: ...iper Bleed both gauges Lower vehicle and bounce the rear of the vehicle several times Depress brake pedal and check pressures Compare figures attained with specifications Page 47 25 and if necessary a...

Page 266: ...57 740 827 Rear axle disc Front axle 50 725 Front axle 100 1450 brakes Rear axle 35 41 508 595 Rear axle 56 62 812 899 Four wheel drive Front axle 50 725 Front axle 100 1450 Rear axle 41 47 595 682 Re...

Page 267: ...dal depressed therefore observe the following sequence Read off figures Release pedal Adjust spring Depress pedal again Read off figures and if necessary readjust Remove pressure gauges and bleed brak...

Page 268: ...di brake fluid conforms to this specification Brake fluid is poisonous Also due to its corrosive effect brake fluid must not come into contact with paintwork Brake fluid is hygroscopic which means it...

Page 269: ...leed brake calipers and wheel cylinders 1 Right rear wheel cylinder brake caliper 2 Left rear wheel cylinder brake caliper 3 Right front brake caliper 4 Left front brake caliper On vehicles with brake...

Page 270: ...by pumping the brake pedal Attach bleeder bottle hose and open bleeder screw With brake pedal held down close bleeder screw Repeat operation until no air is present Bleeding sequence Page 47 28 Changi...

Page 271: ...precautions when working on airbag Repair Manual Body Exterior Interior Repair Group 68 General body repairs Note All parts marked with a 1 can be pre assembled outside of the vehicle Pre assembling s...

Page 272: ...airbag Removing and installing Page 48 8 Removing and installing Airbag Spiral Spring Page 48 10 6 Hex socket head bolt 6 5 Nm 57 in lb Always replace 7 Connector 8 Splined adapter sleeve Removing Pa...

Page 273: ...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...

Page 274: ...washer Drive out downward with a tube 20 Washer Tighten until head shears off Drill out to remove 21 Shear bolt 22 Column tube 23 Lower trim Page 4 of 99 Steering 12 7 2004 http ebahn bentleypublisher...

Page 275: ...Splined adapter sleeve installing Place sleeve on steering column and press on with hex nut Remove nut place on washer and press sleeve fully on with nut until sleeve is firmly seated Page 5 of 99 St...

Page 276: ...nto 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 su...

Page 277: ...7 in Ib CAUTION Make sure that no one is in the vehicle when connecting the battery Ground strap Remove both socket head bolts from airbag unit Remove airbag unit from steering wheel and disconnect wi...

Page 278: ...ering wheel off turn Airbag Spiral Spring slightly so that the wire arrow faces downward Hold steering wheel in installation position The spring then locates and is prevented from turning If this step...

Page 279: ...trim panel Connect connector in steering wheel to airbag unit connector Install airbag unit Page 48 7 Note Use new hex socket head bolts for airbag unit After installing the airbag steering wheel fir...

Page 280: ...t Page 48 7 Note Remove screws 1 and remove Airbag Spiral Spring 2 from steering wheel When removing and installing the Airbag Spiral Spring ensure that it is in the center position As a new part the...

Page 281: ...50 mm 1 Operating lever 2 Packing plate 3 Column tube Square housing fits over mounting bracket 4 Rubber stop 5 Return spring Hooked into mounting bracket and column tube 6 Thrust washer 7 Packing pla...

Page 282: ...ead Tighten to 22 Nm 16 ft lb After tightening install locking plate 11 Locking plate 12 Locking plate nut 8 Nm 70 in Ib Self locking Always replace 13 Washer 14 Shear bolt Tighten until head shears o...

Page 283: ...open Start engine and if necessary add fluid to reservoir A VAG 1402 2 B VAG 1402 1 C Hose from adapter kit VAG 1402 6 D VAG 1402 V belt V belt tension OK System not leaking Hoses lines are not kinke...

Page 284: ...ge 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 pini...

Page 285: ...ediate 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...

Page 286: ...ersal joint power steering gear If an oil extraction unit is not available disconnect vane pump supply hose and drain hydraulic fluid Loosen nut on the universal joint arrow Remove hydraulic fluid fro...

Page 287: ...222A and 10 222A 3 Remove boot from seat on steering gear Remove subframe bolts Lower engine transmission assembly this will pull the two halves of the universal joint apart Disconnect hoses from ste...

Page 288: ...lf B at the same time second mechanic necessary Coat boot with lubricant e g soft soap before pulling onto steering gear Universal joint shaft 25 Nm 18 ft lb halves Steering gear 30 Nm 22 ft lb Tie ro...

Page 289: ...nd straightening work on steering components is not permitted To grease the rack only use steering gear grease Part No AOF 063 000 04 Type of oil Hydraulic oil G 002 000 Oil system capacity 0 7 0 9 lt...

Page 290: ...Right hand tie rod 70 Nm 52 ft lb Removing and installing Page 48 77 Vehicle alignment Page 44 1 Tie rod boot seat diameter ZF 15 mm dia TRW 12 7 mm dia It must not be installed on a ZF power steerin...

Page 291: ...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 i...

Page 292: ...installing Page 48 15 Adjusting Page 48 24 10 Tie rod end Separating Page 48 16 Checking 11 Hex nut 30 Nm 22 ft lb 12 Universal joint Page 22 of 99 Steering 12 7 2004 http ebahn bentleypublishers com...

Page 293: ...lb Return line 14 Sealing ring Always replace 15 Hose clamp Always replace open with pliers Tensioning Page 48 81 Page 23 of 99 Steering 12 7 2004 http ebahn bentleypublishers com vw servlet Display a...

Page 294: ...ise vehicle on hoist Wheels in straight ahead position Loosen locking nut counter hold with 3315 9 Carefully turn adjustment screw arrow into cover until knocking noise can no longer be heard inside v...

Page 295: ...efore 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...

Page 296: ...amp Open with nipper pliers Installation position and tightening see tie rod removing and installing TRW and ZF power steering Page 48 77 Always replace 4 Circlip Always replace 5 Lock washer 6 Toothe...

Page 297: ...ricate immediately with hydraulic oil corrosion protection Supplied as a replacement part for assignment see replacement parts fiche 10 Plug Is only installed if the toothed rod was replaced To instal...

Page 298: ...pring 13 Pressure piece Mark installation position 14 Housing Check cylinder race for scoring if necessary replace steering gear complete 15 Inverted tube nut 30 Nm 22 ft lb 16 O ring Always replace I...

Page 299: ...19 Support ring Eliminated starting 4 92 If present it must be reinstalled 20 Adhesive film Thoroughly clean housing in this area before sticking on e g with thinner adhesive surface must be free of...

Page 300: ...9 Grease with steering gear grease AOF 063 000 04 25 Self locking hex nut 30 Nm 22 ft lb Always replace 26 Locking screw 40 Nm 30 ft lb Always replace Is already pre mounted on new toothed rods that a...

Page 301: ...f there is scoring that can be seen or felt Already pre mounted on new toothed rods that are supplied as replacement parts 30 Sealing ring Not supplied as a replacement part 31 Sealing ring Always rep...

Page 302: ...te Use jaw covers and check jaw covers for contamination e g metal chips or the like Clean outside of power steering gear Open hose clamp and push back boot Clamp steering gear with toothed rod in vis...

Page 303: ...ew to lock nut when removing If necessary remove adjusting screw together with lock nut using tool 3115 6 Pressure piece adjusting screw are slightly stressed with slight spring pressure 1 Ratchet sta...

Page 304: ...ove 1 Spreading pliers standard commercial 2 Pressure piece Remove circlip for valve body 1 Needle nose pliers standard commercial Page 34 of 99 Steering 12 7 2004 http ebahn bentleypublishers com vw...

Page 305: ...ndard commercial Remove hex nut below valve body 1 Ratchet standard commercial 2 Open end wrench standard commercial Drive valve body upward from below with driver Remove grease from teeth of valve bo...

Page 306: ...d place toothed rod so that toothed rod piston sealing ring will not be damaged 1 Needle nose pliers standard commercial Lubricate toothed rod Drive sealing ring upward A Puller e g Kukko 21 4 B Drive...

Page 307: ...around the claws Illustration shows the housing in cross section for better view 1 Puller e g Kukko 21 4 2 Rubber band 3 Sealing ring 4 Glide bearing do not remove Page 37 of 99 Steering 12 7 2004 htt...

Page 308: ...will the claws engage behind the support ring Spread claws 2 of the tool by turning the spindle forcefully Note When introducing the tool make sure that the cylinder race is not damaged 1 Support rin...

Page 309: ...compressed air and alcohol Clean adhesive surface for adhesive tape in area of the slot with solvent e g L160 or alcohol Check cylinder race for scoring or other damage If scoring can be felt replace...

Page 310: ...used After sanding lubricate toothed rod lightly If the old toothed rod is used again check the sealing ring for scoring visual inspection If there is scoring that can be seen or felt the sealing ring...

Page 311: ...pressure on the sealing ring Pry out sealing ring and O ring A Needle nose pliers standard commercial 1 Toothed rod with piston 2 Sealing rod 3 O ring Page 41 of 99 Steering 12 7 2004 http ebahn bentl...

Page 312: ...othed rod Pull O ring over tool and install in groove of piston Lubricate sealing ring with hydraulic oil pull over tool and install in groove of piston Page 42 of 99 Steering 12 7 2004 http ebahn ben...

Page 313: ...lean 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 v...

Page 314: ...e cylinder pipe far enough so that the groove arrow on the tool matches the edge arrow A of the housing 1 Sealing ring A Edge of housing For better view illustration shows housing in cross section 1 S...

Page 315: ...ation system Grease teeth of toothed rod with AOF 063 000 04 grease Slide protective tube on to toothed rod to stop Wipe excess grease off completely Page 45 of 99 Steering 12 7 2004 http ebahn bentle...

Page 316: ...d 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...

Page 317: ...er after pulling in turn the lock washer approx 1 2 revolution further 1 Safety wire in repair kit is not formed as a ring but supplied as a straight wire 2 Pliers standard commercial Valve body insta...

Page 318: ...ll by hand into the valve body housing note position of toothed rod Tape teeth of valve body with adhesive tape to protect the sealing ring Avoid wrinkles Install upper roller bearing for valve body i...

Page 319: ...Install locking screw Grease pressure piece and spring in housing in old position Install lock nut together with adjusting screw After tightening the marking made during removal arrow on the adjusting...

Page 320: ...h sealing compound AKL 450 005 05 Tape slot with adhesive tape 1 Adhesive surface must be dry and free from grease Page 50 of 99 Steering 12 7 2004 http ebahn bentleypublishers com vw servlet Display...

Page 321: ...ng screw on the back side center Thoroughly clean adjusting screw Place toothed rod in center position measure toothed rod excess right and left Install pressure piece and spring in housing if not don...

Page 322: ...be crowned 1 3315 8 2 3315 9 3 3315 1 4 VW 387 Screw right rod onto toothed rod and tighten by hand Turn toothed rod radially from stop to stop during this process observe pointer on gauge Page 52 of...

Page 323: ...t adjustment Remove gauge Close hole in adjusting screw with a stopper from repair kit Tie rods installing First install clip 2 with gasket 1 in the hole Apply 1 drop sealing compound Part No AMV 188...

Page 324: ...ce the power steering gear Note Always replace self locking nuts and bolts Welding and straightening work on steering components is not permitted To grease the rack use only steering gear grease Part...

Page 325: ...reduced steering moment only permissible for vehicles up to 85 kW Steering moment on 16 V and VR 6 vehicles is approx 2 Nm higher 2 Hose clip Always replace use pliers to open Tensioning Page 48 81 P...

Page 326: ...ers are larger than the boot for TRW power steering gears Must not be installed on TRW power steering gear 4 Hose clip Always replace use pliers to open Tensioning Page 48 81 Must not be installed on...

Page 327: ...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 Adjust...

Page 328: ...Page 48 16 Checking 9 Pressure balance pipe 10 30 Nm 22 ft lb 11 Clamp 12 Rubber mounting Internal diameter ZF 50 mm TRW 44 mm 13 Data plate and company initials Page 58 of 99 Steering 12 7 2004 http...

Page 329: ...cking noise will be heard if there is excessive play The second mechanic carefully screws the adjustment screw arrow into the cover until the knocking noise can no longer be heard inside the vehicle C...

Page 330: ...rk 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 immediat...

Page 331: ...ing gear if not already done 1 Plastic locking screw 2 Plastic locking screw Clean outside of power steering gear Open hose clamp and push back boot Clamp steering gear with toothed rod in vise and re...

Page 332: ...g screw arrow Cover is stressed with slight spring pressure Remove pressure piece 1 Spreading pliers standard commercial Page 62 of 99 Steering 12 7 2004 http ebahn bentleypublishers com vw servlet Di...

Page 333: ...Torx screw for valve body 1 Open end wrench standard commercial SW 14 2 Torx insert standard commercial E10 3 Ratchet standard commercial 3 8 Page 63 of 99 Steering 12 7 2004 http ebahn bentleypublis...

Page 334: ...with driver Slide toothed rod all the way in the direction of the valve body Turn circlip so that the pointed end of the circlip is in the groove arrow of the housing Page 64 of 99 Steering 12 7 2004...

Page 335: ...andard commercial Lubricate toothed rod When installing the puller A make sure that the claws arrows on fig N48 0058 page 45 engage correctly under the sealing ring The puller must not be spread too w...

Page 336: ...make sure that the claws arrows on fig N48 0058 page 46 engage correctly under the sealing ring The puller must not be spread too wide because otherwise the seat for the sealing ring and the housing...

Page 337: ...removing 1 Puller e g Kukko 21 4 2 Rubber band 3 Roller bearing 4 Housing Remove sealing ring for toothed rod from the housing Disconnect hose line from valve body housing to cylinder line Clean hose...

Page 338: ...ghly with compressed air and alcohol if necessary Check cylinder race for scoring or other damage If scoring can be felt replace the complete steering gear Clean toothed rod remove old grease in tooth...

Page 339: ...n check the sealing ring for scoring visual inspection If there is scoring that can be seen or felt the sealing ring and the O ring under it must be replaced Sand toothed rod with sand paper in radial...

Page 340: ...pressure on the sealing ring Pry out sealing ring and O ring A Needle nose pliers standard commercial O ring 30 0 x 1 78 white sealing ring O ring 31 0 x 1 5 black sealing ring Slide mounting sleeve 3...

Page 341: ...hydraulic oil before installing Note correct installation position of the sealing ring Place sealing ring for valve body on the tool and drive in to stop For installation position see next illustrati...

Page 342: ...the sealing ring is properly seated Place support ring 1 and sealing ring 2 on tool Drive sealing ring for toothed rod into housing to stop Page 72 of 99 Steering 12 7 2004 http ebahn bentleypublisher...

Page 343: ...at the sealing ring is pressed into the groove of the piston without jamming Coat piston of toothed rod and protective tube with hydraulic oil Install installation sleeve 3315 21 into the housing Slid...

Page 344: ...ousing to stop Slide toothed rod completely into housing if not done yet 1 toothed rod guide Install circlip in such a way that the opening of the ring is opposite the groove in the housing Valve body...

Page 345: ...3315 17 onto valve body Lubricate valve body with hydraulic oil and carefully install by hand into the valve body housing note position of toothed rod Tape the valve body with adhesive tape Page 75 o...

Page 346: ...orx screw into valve body and tighten to 35 Nm 26 ft lb Thread in locking screw tighten to 30 Nm 22 ft lb and crimp at corner points Grease pressure piece with AOF 063 000 04 Install pressure piece sp...

Page 347: ...secured version tie rods use locking fluid D6 when installing Removing The tie rods can only be removed installed with the steering gear removed Seal line connections on power steering gear 1 Plastic...

Page 348: ...ng tie rods with locking fluid D6 If parts are reused it is essential to clean any residue of locking fluid off the threaded studs of the inner joint or the thread tapped hole as described below Other...

Page 349: ...r wire brush Check if joint stud threads are deformed replace if necessary Cover steering gear housing opening arrow with a cloth Clean threaded hole in rack with M 14 x 1 5 tap Clean thread with nitr...

Page 350: ...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...

Page 351: ...alance line Do not damage sticker A when pushing the boot on only on TRW power steering gears Make sure that the boot and the pressure balance line are installed correctly During assembly of the boot...

Page 352: ...sure compensating tube 3 Boot 4 Approx 90 Tension hose clamps with pliers VAG 1275 or equivalent Page 82 of 99 Steering 12 7 2004 http ebahn bentleypublishers com vw servlet Display action Goto type r...

Page 353: ...48 83 Note The boot must not be installed twisted Page 83 of 99 Steering 12 7 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 SU01 48 1...

Page 354: ...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 Pa...

Page 355: ...if faulty Note Pumps supplied as spare parts are not filled with oil Fill the pump with G 002 000 hydraulic oil to rotate it by hand otherwise the pump may be damaged or noisy during operation Type of...

Page 356: ...96 3 Pressure line 4 Suction line Hydraulic pump Cooling line 5 Hose clamp 3 Nm 27 in lb 6 Hydraulic pump With V belt pulley 7 Hydraulic pump With ribbed belt sprocket 8 O ring Always replace Page 86...

Page 357: ...9 Pressure line union 10 Banjo bolt 35 Nm 26 ft lb 11 Hex bolt 10 Nm 7 ft lb Page 87 of 99 Steering 12 7 2004 http ebahn bentleypublishers com vw servlet Display action Goto type repair id VW B4 SU01...

Page 358: ...teering gear 2 O ring Always replace 3 Return line 30 Nm 22 ft lb 4 Pressure line 30 Nm 22 ft lb 5 Reservoir 6 Rubber ring 7 Hose clamp 8 Rubber insert 9 Captive nut 10 Bracket Page 88 of 99 Steering...

Page 359: ...e clamp 13 Return hose 14 Suction hose Reservoir Cooling line 15 Cooling line 16 Threaded stud 17 Bracket Page 89 of 99 Steering 12 7 2004 http ebahn bentleypublishers com vw servlet Display action Go...

Page 360: ...ulic 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 Do not reuse drained hydraulic oil 1 Suction hose 2 Pressure hose...

Page 361: ...1 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 f...

Page 362: ...ne 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 99 Steering 12 7...

Page 363: ...lts 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...

Page 364: ...ransmission 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...

Page 365: ...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 99 Steering 12 7 2004 http ebahn bentleypublishers com...

Page 366: ...ing vehicles with manual transmission Fig 2 Pressure hose securing vehicles with automatic transmission Page 96 of 99 Steering 12 7 2004 http ebahn bentleypublishers com vw servlet Display action Goto...

Page 367: ...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 van...

Page 368: ...ding 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 routin...

Page 369: ...t 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...

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