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   Also See for VOLKSWAGEN PASSAT

   Summary of Contents for VOLKSWAGEN PASSAT

  • Page 3: Rear Suspension

    Suspension, Wheels, Brakes, Steering 00 - General, Technical data Suspension, Wheels, Brakes, Steering Technical data Steering Brakes Wheels, tires 40 - Front suspension Front Wheel Suspension, Shafts and Axle Front suspension, servicing (Base suspension) Sub-frame, stabilizer bar and control arm (Base suspension) Ball joint, checking (Base and Plus suspension) Reworking cap nut in side member (Base and Plus suspension) Wheel bearing, suspension strut and drive shaft, removing and installing (Base...

  • Page 4: Wheels, Tires, Wheel Alignment, Anti-lock Brake System

    Rear axle, servicing (four wheel drive vehicles) Rear drive shafts, servicing Reworking cap nut in side member (four wheel drive vehicles) Suspension strut, disassembling and assembling (four wheel drive vehicles) Wheel bearings, servicing - disc brakes (four wheel drive vehicles) 44 - Wheels, Tires, Wheel alignment Vehicle alignment Test requirements:...

  • Page 5

    Front brakes, servicing (Teves/Ate) Brake pads, removing and installing Rear wheel brakes, servicing (drum brakes) Brake shoe adjustment, releasing Rear wheel brakes, servicing Brake shoes, removing and installing Parking brake, adjusting (drum brakes) Rear wheel brakes, servicing (disc brakes) Girling rear wheel disc brakes (front and four wheel drive vehicles) Brake pads, removing and installing Parking brake, adjusting (disc brakes) Parking brake lever assembly overview...

  • Page 6

    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)

  • Page 7: Technical Data

    Suspension, Wheels, Brakes, Steering Page 1 of 8 00-1 Suspension, Wheels, Brakes, Steering Technical data Model Sedan/Wagon and syncro Base Sedan/Wagon and syncro Base Suspension Suspension Wheelbase 2625 2625 Track, unladen 1479 front, wheel offset 38 1485 front, wheel offset 35 1422 rear, wheel offset 38 1441 rear, wheel offset 35 1485 front, wheel offset 35...

  • Page 8

    Suspension, Wheels, Brakes, Steering Page 2 of 8 00-2 Steering Model Sedan/Wagon and syncro Suspension version Base Suspension Plus Suspension Steering gear Power assisted steering gear Power assisted steering gear Steering wheel turns from lock to lock 3.33 3.14 Overall steering ratio 17.5:1 16.4:1 Wheel alignment specifications...

  • Page 9

    Suspension, Wheels, Brakes, Steering Page 3 of 8 00-3 Brakes Model Sedan/Wagon Output kW (hp) 55 (75) Brake master cylinder mm dia. 22.2 (Vehicles with ABS: 23.81) Brake servo dia. in inches Front brake caliper, piston diameter Front brake disc mm dia.

  • Page 10

    Suspension, Wheels, Brakes, Steering Page 4 of 8 00-4 Model Sedan/Wagon Output kW (hp) 85 (115) 128 (172) Brake master cylinder mm dia. 23.81 Brake servo dia. in inches Front brake caliper dia. Front brake disc mm dia. Front brake thickness Pad thickness Rear brake caliper dia.

  • Page 11

    Suspension, Wheels, Brakes, Steering Page 5 of 8 00-5 Model Passat syncro Output kW (hp) 85 (115) 128 (172) Brake master cylinder mm dia. 23.81 Brake servo dia. in inches Front brake caliper dia. Front brake disc mm dia. Front brake disc thickness Pad thickness Rear brake caliper dia.

  • Page 12

    Suspension, Wheels, Brakes, Steering Page 6 of 8 00-6 Wheels, tires Engine output (kW) Model Wheel Offset Hole pattern Tire size 55 gas Sedan/Wagon 185/65 R 14 86 S 6 J x 14 4-hole 55, 66 - Diesel 195/60 R 14 86 S 6 J x 14 205/50 R 15 86 S 6 J x 15...

  • Page 13

    Suspension, Wheels, Brakes, Steering Page 7 of 8 00-7 Engine output (kW) Model Wheel Offset Hole pattern Tire size 85 kW Sedan/Wagon 185/65 R 14 86 H 6 J x 14 4-hole 195/60 R 14 86 H 6 J x 14 205/50 R 15 86 H 6 J x 15 185/65 R 14 85 Q (M+S)

  • Page 14

    Suspension, Wheels, Brakes, Steering Page 8 of 8 00-8 Engine output Model Wheel Offset Hole Tire size (kW) pattern 85 kW Sedan/Wagon 185/65 R 14 86 H 6 J x 14 4-hole syncro 195/60 R 14 86 H 6 J x 14 205/50 R 15 86 H 6 J x 15 185/65 R 14 86 Q...

  • 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. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1 12/7/2004...

  • Page 16

    Front Wheel Suspension, Shafts and Axle Page 2 of 82 40-2 Sub-frame, stabilizer bar and control arm (Base suspension) Note: If a vehicle has to be moved after removing the drive shaft, first install outer joint and tighten to 50 Nm (37 ft lb) otherwise the wheel bearing will be damaged.

  • Page 17

    Front Wheel Suspension, Shafts and Axle Page 3 of 82 40-3 1 - Hex bolt, 35 Nm (26 ft 2 - Ball joint Checking Page 40- Check rubber boot for damage and if necessary, replace ball joint Mark installation position. If replaced set to center of elongated hole and check toe...

  • Page 18

    Front Wheel Suspension, Shafts and Axle Page 4 of 82 40-4 6 - Control arm rear mounting Installation position Fig. 3 Pressing out and in Fig. 4 7 - Hex bolt M 12 x 1.5 x 82 50 Nm (37 ft lb) and turn 90 further 8 - Hex bolt M 12 x 1.5 x 65 70 Nm (52 ft lb) and...

  • Page 19

    Front Wheel Suspension, Shafts and Axle Page 5 of 82 40-5 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:...

  • Page 20

    Front Wheel Suspension, Shafts and Axle Page 6 of 82 40-6 16 - Hex bolt, 65 Nm (48 ft 17 - Stabilizer bar mounting 18 - Stabilizer bar 19 - Stabilizer bar clamp 20 - Hex bolt, 25 Nm (18 ft To secure stabilizer 21 - Vibration damper Note installation...

  • Page 21

    Front Wheel Suspension, Shafts and Axle Page 7 of 82 40-7 Fig. 1 Front control arm mounting, pressing Fig. 2 Front control arm mounting, pressing in Note: Before pressing in, coat with acid-free lubricant, e.g. soft soap. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1 12/7/2004...

  • Page 22

    Front Wheel Suspension, Shafts and Axle Page 8 of 82 40-8 Fig. 3 Control arm rear mounting, installation position 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.

  • Page 23

    Front Wheel Suspension, Shafts and Axle Page 9 of 82 40-9 Fig. 5 Supporting engine/transmission assembly with 10-222 A and legs 10-222 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1 12/7/2004...

  • Page 24

    Front Wheel Suspension, Shafts and Axle Page 10 of 82 40-10 Ball joint, checking (Base and Plus suspension) Checking axial clearance - Forcibly pull ball joint down and press up again. Checking radial play - Press lower part of wheel outward and inward. Note: There must be no perceptible or visual "play"...

  • Page 25

    Front Wheel Suspension, Shafts and Axle Page 11 of 82 40-11 Reworking cap nut in side member (Base and Plus suspension) If the threads of the cap nut in the side member are damaged, the thread must either be retapped or the cap nut must be drilled out.

  • Page 26

    Front Wheel Suspension, Shafts and Axle Page 12 of 82 40-12 Bolt/washer assemblies for sub-frame Securing point Thread Bolt Part No. Front sub-frame M12 x 1.5 M12 x 1.5 x 95 10.9 N 101 612.01 Rear sub-frame M12 x 1.5 M12 x 1.5 x 95 10.9 N 101 612.01 Sub-frame bracket M10 x 38 10.9...

  • Page 27

    Front Wheel Suspension, Shafts and Axle Page 13 of 82 40-13 Note: Tightening torque remains unchanged. 1 - Bolt/washer 2 - Cap nut 3 - Side member 4 - Sub-frame 5 - Bonded rubber mounting/control arm http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1 12/7/2004...

  • Page 28

    Front Wheel Suspension, Shafts and Axle Page 14 of 82 40-14 Wheel bearing, suspension strut and drive shaft, removing and installing (Base running gear) Note: If a vehicle has to be moved after removing the drive shaft, first install outer joint and tighten to 50 Nm (37 ft lb) otherwise the wheel bearing will be...

  • Page 29

    Front Wheel Suspension, Shafts and Axle Page 15 of 82 40-15 1 - Self-locking nut, 265 Nm (195 ft lb) Only loosen and tighten with the vehicle standing on its wheels (danger of accident) Any paint residue and/or corrosion on the thread of the outer joint must be removed before the nut is...

  • Page 30

    Front Wheel Suspension, Shafts and Axle Page 16 of 82 40-16 6 - Speed sensor rotor Only on vehicles with 7 - Hex bolt, 10 Nm (7 ft lb) 8 - Splash plate 9 - Circlip Ensure correctly seated 10 - Wheel bearing Pressing out Fig.

  • Page 31

    Front Wheel Suspension, Shafts and Axle Page 17 of 82 40-17 15 - Self-locking bolt/washer assembly, 125 Nm (92 ft lb) For securing brake carrier 16 - Socket head multi- point bolt, 45 Nm (33 ft 17 - Drive shaft To remove and install separate ball joint/control arm...

  • Page 32

    Front Wheel Suspension, Shafts and Axle Page 18 of 82 40-18 21 - Self-locking hex nut, 60 Nm (44 ft lb) Loosening and tightening Fig. 1 22 - Stop 23 - Suspension strut bearing 24 - Suspension strut Removing and installing Fig.

  • Page 33

    Front Wheel Suspension, Shafts and Axle Page 19 of 82 40-19 Fig. 1 Suspension strut to body, loosening and tightening Fig. 2 Wheel bearing housing/suspension strut joint, separating Note: Camber must be adjusted each time joint is loosened. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1 12/7/2004...

  • Page 34

    Front Wheel Suspension, Shafts and Axle Page 20 of 82 40-20 Fig. 3 Ball joint/control arm connection, separating To take drive shaft out, remove bolts (arrows). Note: First mark installation position. Fig. 4 Hub, pressing out of wheel bearing housing http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1 12/7/2004...

  • Page 35

    Front Wheel Suspension, Shafts and Axle Page 21 of 82 40-21 Fig. 5 Bearing race, pulling out of hub Only use puller with leg clamp e.g. Kukko 204-2 (commercial type). Fig. 6 Wheel bearing, pressing out of wheel bearing housing http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1 12/7/2004...

  • Page 36

    Front Wheel Suspension, Shafts and Axle Page 22 of 82 40-22 Fig. 7 Wheel bearing, pressing into wheel bearing housing Fig. 8 Hub, pressing into wheel bearing housing http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1 12/7/2004...

  • Page 37

    Front Wheel Suspension, Shafts and Axle Page 23 of 82 40-23 Front suspension strut, servicing (Base and Plus suspension) 1 - Shock absorber Can be replaced individually Check shock absorber for leaks and noises After replacing, adjust camber and toe Page 44-1 2 - Buffer stop 3 - Protective sleeve...

  • Page 38

    Front Wheel Suspension, Shafts and Axle Page 24 of 82 40-24 4 - Coil spring Removing and installing Fig. 2 Observe color coding Outer surface of spring must not be damaged Is slightly curved 5 - Spring plate 6 - Axial bearing 7 - Hex nut, 60 Nm (44 ft Loosening and tightening...

  • Page 39

    Front Wheel Suspension, Shafts and Axle Page 25 of 82 40-25 Fig. 1 Hex nut, loosening and tightening Fig. 2 Spring, removing and installing http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1 12/7/2004...

  • Page 40

    Control arm, ball joint, wheel bearing housing, stabilizer bar, drive shaft, brake disc, hub, wheel and tie rods. The Plus suspension is installed in Passat models with engine output 110 kW (148 hp) and above. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1 12/7/2004...

  • Page 41

    Front Wheel Suspension, Shafts and Axle Page 27 of 82 40-27 Sub-frame, stabilizer bar and control arm, removing and installing (Plus suspension) Notes Page 40-2 1 - Hex bolt, 35 Nm (26 ft 2 - Ball joint Checking Page 40- Check rubber boot for damage and if necessary, replace ball...

  • Page 42

    Front Wheel Suspension, Shafts and Axle Page 28 of 82 40-28 5 - Control arm rear mounting Installation position Fig. 2 Pressing out and in Fig. 3 6 - Control arm Elongated holes are not for camber adjustment! 7 - Air guide plate Secured to control arm by clip 8 - Control arm front...

  • Page 43

    Front Wheel Suspension, Shafts and Axle Page 29 of 82 40-29 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...

  • Page 44

    Front Wheel Suspension, Shafts and Axle Page 30 of 82 40-30 20 - Vibration damper Not installed on vehicles with VR 6 engine 21 - Sub-frame Removing and installing with assemblies installed: supporting assemblies Fig. 4 Remove sub-frame from below with control arm but without steering gear using transmission jack VAG...

  • Page 45

    Front Wheel Suspension, Shafts and Axle Page 31 of 82 40-31 Fig. 1 Control arm front mounting, pressing out and in Note: Before pressing in, coat with lubricant, e.g. soft soap. Fig. 2 Control arm rear mounting, installation position 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.

  • Page 46

    Front Wheel Suspension, Shafts and Axle Page 32 of 82 40-32 Fig. 3 Control arm rear mounting, pressing out and in Fig. 4 Engine/transmission assembly, supporting with 10-222 A and 10-222 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1 12/7/2004...

  • Page 47

    Front Wheel Suspension, Shafts and Axle Page 33 of 82 40-33 Ball joint, removing and installing (Plus running gear) Removing - Loosen 12-point nut with vehicle standing on its wheels. - Disconnect drive shaft at transmission drive flange. - Remove bolts -arrow -A-. - Loosen bolt -arrow -B-.

  • Page 48

    Front Wheel Suspension, Shafts and Axle Page 34 of 82 40-34 - Install ball joint splitter as shown in illustration and press out ball joint. 1 - Splitter. Matra V 176 Note: Place transmission jack VAG 1383/A, or equivalent, underneath (danger of accident through falling parts when pressing out the ball joint).

  • Page 49

    Front Wheel Suspension, Shafts and Axle Page 35 of 82 40-35 Note: Make sure that the boot is not damaged or twisted. Tightening torques Ball joint to wheel bearing housing: 45 Nm (33 ft 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) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1...

  • Page 50

    Front Wheel Suspension, Shafts and Axle Page 36 of 82 40-36 Wheel bearing and suspension strut, removing and installing (Plus suspension) Notes Page 40-14 1 - Wheel bolt, 110 Nm (81 ft lb) 2 - Self-locking 12-point 90 Nm (66 ft lb) and turn 45 further ( Loosening and tightening...

  • Page 51

    Front Wheel Suspension, Shafts and Axle Page 37 of 82 40-37 5 - Brake caliper Do not loosen brake hose when working on front suspension Hang up with wire or similar Replacing brake pads Page 46-6 6 - Countersunk screw 7 - Hub Pressing out Fig.

  • Page 52

    Front Wheel Suspension, Shafts and Axle Page 38 of 82 40-38 11 - Circlip Ensure seated correctly 12 - Wheel bearing Pressing out Fig. 4 Always replace, as it is destroyed during pressing out Pressing in Fig. 5 13 - Self-locking hex nut, 35 Nm (26 ft lb) 14 - Wheel bearing housing 15 - Self-locking...

  • Page 53

    Front Wheel Suspension, Shafts and Axle Page 39 of 82 40-39 18 - Hex bolt Camber adjustment Page 44-1 Before loosening, mark installation position 19 - Hex bolt 20 - Bracket 21 - Stop 22 - Self-locking hex nut, 60 Nm (44 ft lb) Loosening and tightening...

  • Page 54

    Front Wheel Suspension, Shafts and Axle Page 40 of 82 40-40 Fig. 1 Suspension strut to body, loosening and tightening Fig. 2 Hub, pressing out of wheel bearing housing http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1 12/7/2004...

  • Page 55

    Front Wheel Suspension, Shafts and Axle Page 41 of 82 40-41 Fig. 3 Inner race, pulling off hub Only use puller with leg clamp e.g. Kukko 204-2 (commercial type). Fig. 4 Wheel bearing, pressing out of wheel bearing housing http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1 12/7/2004...

  • Page 56

    Front Wheel Suspension, Shafts and Axle Page 42 of 82 40-42 Fig. 5 Wheel bearing, pressing into wheel bearing housing Fig. 6 Hub, pressing into wheel bearing housing http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1 12/7/2004...

  • Page 57

    Front Wheel Suspension, Shafts and Axle Page 43 of 82 40-43 Drive shaft, removing and installing (Plus running gear) Removing - Loosen 12-point nut with vehicle standing on its wheels. - Disconnect drive shaft from transmission drive flange. - Remove bolts (arrow -A-). - Loosen bolt (arrow -B-).

  • Page 58

    Front Wheel Suspension, Shafts and Axle Page 44 of 82 40-44 Installing - Remove remains of locking fluid from outer joint and hub splines. (Splines must be free of oil and grease). - Apply locking fluid D 185 400 A2 to splines as shown in illustration.

  • Page 59

    Front Wheel Suspension, Shafts and Axle Page 45 of 82 40-45 Tightening torques: Drive shaft to flange shaft/transmission 45 Nm (33 ft lb) Drive shaft to wheel bearing 90 Nm (66 ft lb) and housing turn 45 further ( turn) Ball joint/control arm 35 Nm (26 ft lb) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1 12/7/2004...

  • Page 60

    Front Wheel Suspension, Shafts and Axle Page 46 of 82 40-46 Drive shaft, repairing Drive shafts on vehicles with Plus suspension have shorter and finer splines on the outer joint. The wheel bearing is secured by a 12-point nut. The splines of the outer joint and the hub on Plus suspensions are secured with locking fluid D 185 400 A2.

  • Page 61

    Front Wheel Suspension, Shafts and Axle Page 47 of 82 40-47 1 - Circlip Always replace Remove and install with VW161 a 2 - Gasket Always replace. Pull off protective foil and stick onto joint. (Only on 100 mm diameter constant velocity joints 3 - Inner constant velocity joint 100 mm diameter...

  • Page 62

    Front Wheel Suspension, Shafts and Axle Page 48 of 82 40-48 5 - Boot for 100 mm diameter constant velocity joint Rubber version With vent hole Check for tears and chafing Installation position for left drive shaft Fig. 5 Installation position for right drive shaft Fig.

  • Page 63

    Front Wheel Suspension, Shafts and Axle Page 49 of 82 40-49 8 - Boot for 90 mm diameter constant velocity joint Polyester elastomer version Check for tears and chafing The balance pressure briefly ventilate boot before tensioning the small clamp Fig.

  • Page 64

    Front Wheel Suspension, Shafts and Axle Page 50 of 82 40-50 10 - Dished washer Outer diameter (concave side) contacts thrust washer 11 - Thrust washer 12 - Circlip Always replace Insert in shaft groove 13 - Outer constant velocity joint, 90 mm diameter Only replace complete Removing...

  • Page 65

    Front Wheel Suspension, Shafts and Axle Page 51 of 82 40-51 14 - Outer constant velocity joint, 90 mm diameter For vehicles with 16V and VR6 Wedge splines, larger diameter Only replace complete Removing Fig. 2 Installing: drive onto shaft with plastic hammer until compressed circlip seats...

  • Page 66

    Front Wheel Suspension, Shafts and Axle Page 52 of 82 40-52 16 - Clamp Always replace 17 - Support rings On rubber type boot only On transmission end only See Parts catalog 18 - Boot for 100 mm diameter constant velocity joint Polyester elastomer version...

  • Page 67

    Front Wheel Suspension, Shafts and Axle Page 53 of 82 40-53 Fig. 1 Vibration damper, removing and installing The damper consists of two halves. Both halves are joined to one another by spring pins (arrow). Installation position Fig. 1 Note: Only replace vibration damper with drive shaft removed Before driving in spring pin protect shaft paint...

  • Page 68

    Front Wheel Suspension, Shafts and Axle Page 54 of 82 40-54 Fig. 2 Outer constant velocity joint, removing - Drive joint off drive shaft with a firm blow from an aluminium hammer. Fig. 3 Inner constant velocity joint, pressing Note: First drive boot off with drift Support ball hub http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1...

  • Page 69

    Front Wheel Suspension, Shafts and Axle Page 55 of 82 40-55 Fig. 4 Inner constant velocity joint, pressing - Press on joint up to stop. - Install circlip. Note: Chamfer on inner diameter of ball hub (splines) must face the contact shoulder on the drive shaft. Fig.

  • Page 70

    Front Wheel Suspension, Shafts and Axle Page 56 of 82 40-56 Fig. 6 Installation position of right drive shaft transmission end joint boot The large diameter of vent chamber -A- must fit on the larger diameter. B - Vent hole Fig.

  • Page 71

    Front Wheel Suspension, Shafts and Axle Page 57 of 82 40-57 Fig. 8 Larger clamp, tensioning - Use pliers VAG 1682 as shown in illustration. Ensure that the jaws of the pliers seat in the -arrow -B- of the clamp. - Tension clamp by turning the spindle with a torque wrench (do not tilt pliers).

  • Page 72

    Front Wheel Suspension, Shafts and Axle Page 58 of 82 40-58 Fig. 10 Installation position of left drive shaft wheel end joint boot, shaft diameter 27 Cuff seating tolerance "a": to 1 grooves visible at end of cuff. Note: This installation position tolerance is also valid for the left drive shaft transmission end boot (polyester elastomer version).

  • Page 73

    Front Wheel Suspension, Shafts and Axle Page 59 of 82 40-59 Fig. 12 Installation position of right drive shaft, wheel end joint boot Cuff seating tolerance "a": From cuff position to chamfer up to a groove visible. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1 12/7/2004...

  • Page 74

    Front Wheel Suspension, Shafts and Axle Page 60 of 82 40-60 Outer constant velocity joint, checking The joint should be disassembled to replace dirty grease or for checking the balls and ball tracks for wear and damage. Removing - Before disassembling mark position of the ball hub in relation to the ball cage and housing with an electric scriber or oil stone.

  • Page 75

    Front Wheel Suspension, Shafts and Axle Page 61 of 82 40-61 - Swing segment of hub into rectangular cage window. - Tilt hub out of cage. Note: The 6 balls of each joint belong to one tolerance group. Check stub axle, hub, cage and balls for indentations (pitting) and signs of seizure.

  • Page 76

    Front Wheel Suspension, Shafts and Axle Page 62 of 82 40-62 Inner constant velocity joint, checking The joint should be disassembled to replace dirty grease and when checking the balls and ball tracks for wear and damage. - Swivel ball hub and ball cage. - Press out ball cage in direction of arrow.

  • Page 77

    Front Wheel Suspension, Shafts and Axle Page 63 of 82 40-63 Note: Excessive backlash in joint will be noticed as a knock during load changes. In such cases the joint must be replaced. Polished areas and ball track marks are not a reason for changing the joint.

  • Page 78

    Front Wheel Suspension, Shafts and Axle Page 64 of 82 40-64 - Swivel in ball hub, whereby the hub must be swivelled out of the cage (arrows) far enough to allow the balls to fit into the ball tracks. - Swivel in the hub with balls by applying firm pressure on the cage (arrow).

  • Page 79

    Front Wheel Suspension, Shafts and Axle Page 65 of 82 40-65 Drive shaft with tripod joint, repairing 1 - Outer constant velocity joint Replace complete Removing Fig. 1 Installing: Drive onto the shaft with plastic hammer until circlip comes out Greasing Notes Page 40-46...

  • Page 80

    Front Wheel Suspension, Shafts and Axle Page 66 of 82 40-66 5 - Clamp Always replace Tightening, Fig. 2 Fig. 3 6 - Boot for constant velocity joint, 90 mm dia. Check for cracks and abrasion Before tightening the small clamp, ventilate boot briefly so pressure is equalized, Fig.

  • Page 81

    Front Wheel Suspension, Shafts and Axle Page 67 of 82 40-67 9 - Inner splined screw, 45 Nm (33 ft lb) 10 - Drive shaft, right, with inner tripod joint Repair of inner joint and replacement of boot not possible at this time Replace if damaged http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1...

  • Page 82

    Front Wheel Suspension, Shafts and Axle Page 68 of 82 40-68 Fig. 1 Constant velocity joint, outer, removing - Drive off from drive shaft with forceful blow using an alloy hammer. Fig. 2 Boot, ventilating The boot is pressed on forcefully when installing on the joint body.

  • Page 83

    Front Wheel Suspension, Shafts and Axle Page 69 of 82 40-69 Fig. 3 Clamp, tightening on large diameter - Install pliers VAG 1682 as in illustration. Make sure that the blades of the pliers lie in the corners (arrow -B-) of the clamp. - Tighten clamp by turning the spindle with a torque wrench (do not tilt pliers during this process).

  • Page 84

    Front Wheel Suspension, Shafts and Axle Page 70 of 82 40-70 Drive axle with triple-rotor joint, removing and installing Removing right-side drive axle The right drive axle removal instructions remain unchanged from the current repair manual procedure. Removing left-side drive axle - Set up engine support bridge.

  • Page 85

    Front Wheel Suspension, Shafts and Axle Page 71 of 82 40-71 - Remove rear transmission mounting bolt (arrow). - Remove front engine mounting bolt (arrow). - Lift engine/transmission assembly - Loosen drive axle nut while vehicle is standing on its wheels. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1 12/7/2004...

  • Page 86

    Front Wheel Suspension, Shafts and Axle Page 72 of 82 40-72 - Disconnect drive axle from transmission drive flange. - Mark installation position of bolts (arrows) and remove. - Swing wheel outward (if necessary, place block of wood or equivalent between strut and wheel housing as shown).

  • Page 87

    Front Wheel Suspension, Shafts and Axle Page 73 of 82 40-73 Drive axle with triple-rotor joint, servicing 1 - Outer constant velocity (CV) joint Replace complete part only Removing Fig. 1 Installing: drive onto shaft with plastic hammer until circlip seats (springs into groove) Greasing...

  • Page 88

    Front Wheel Suspension, Shafts and Axle Page 74 of 82 40-74 9 - Clamp For triple-rotor joint 10 - Boot 11 - Clamp For triple-rotor joint 12 - Cover Destroyed when disassembling No longer required for assembly; not available as replacement part 13 - Rectangular sealing ring...

  • Page 89

    Front Wheel Suspension, Shafts and Axle Page 75 of 82 40-75 Fig. 1 Removing outer CV joint - Drive joint off axle shaft with firm blow from soft mallet. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1 12/7/2004...

  • Page 90

    Front Wheel Suspension, Shafts and Axle Page 76 of 82 40-76 Fig. 2 Tightening outer CV joint boot clamp - Position VAG 1682 pliers or equivalent (e.g. Snap- On YA 3080) as shown in illustration. Make sure plier jaws seat in grooves of clamp (arrows -B-) - Tension clamp by using torque wrench to turn spindle (keep pliers at right angle to shaft).

  • Page 91

    Front Wheel Suspension, Shafts and Axle Page 77 of 82 40-77 Triple-rotor joint, disassembling - Open hose clamp - Open clamp on shaft small end and push back boot. - Drive screwdriver or similar tool into cover and pry open. Note: If the cover will not pry open, insert screwdriver and pry from the opposite side.

  • Page 92

    Front Wheel Suspension, Shafts and Axle Page 78 of 82 40-78 - Remove O-ring -arrow- from groove. - Mark installation positions of parts -1-, -2- and -3-. 1 - Triple-rotor joint housing 2 - Triple-rotor star 3 - Axle shaft Note: Noises while driving may result if the indicated parts are not reassembled to their prior positions.

  • Page 93

    Front Wheel Suspension, Shafts and Axle Page 79 of 82 40-79 - Remove rollers and place on clean surface. - Remove circlip. -1- Pliers Commercially available - Press triple-rotor star off axle shaft. - Pull triple-rotor joint housing off axle shaft. - Clean shaft and triple-rotor joint housing.

  • Page 94

    Front Wheel Suspension, Shafts and Axle Page 80 of 82 40-80 Triple-rotor joint, assembling - Slide small diameter boot clamp onto shaft. - Slide triple-rotor joint boot onto shaft. - Slide triple-rotor joint housing onto shaft. Mounting triple-rotor star Note: The side of the star with a chamfer (arrow) goes onto the axle shaft splines first.

  • Page 95

    Front Wheel Suspension, Shafts and Axle Page 81 of 82 40-81 - Install rectangular sealing ring (arrow) from repair kit. Note: A seal is formed directly between the triple-rotor joint and the drive flange by the rectanular sealing ring. The cover is no longer required. - Press 180 grams of axle shaft grease from repair kit into triple-rotor joint .

  • Page 96

    Front Wheel Suspension, Shafts and Axle Page 82 of 82 40-82 - Tighten small diameter clamp with VAG 1275 pliers or equivalent (e.g. KD 474). CAUTION! Secure the triple-rotor joint with tape so that the housing is not inadvertently pushed back when installing the axle shaft.

  • Page 97

    Rear Wheel Suspension, Shafts and Axle Page 1 of 14 42-1 Rear Wheel Suspension, Shafts and Axle Rear axle, servicing (vehicles with front wheel drive) Note: The rear axle and wheel bearings are identical on Base and Plus suspension versions. Welding and straightening of the axle beam is not permissible.

  • Page 98

    Rear Wheel Suspension, Shafts and Axle Page 2 of 14 42-2 5 - Wheel bearing Servicing Vehicles with drum brakes Page 42-15 Vehicles with disc brakes Page 42-24 6 - 80 Nm (59 ft lb) Use only self-locking nuts with captive washers When tightening nut, the axle beam must be...

  • Page 99

    Rear Wheel Suspension, Shafts and Axle Page 3 of 14 42-3 9 - Mounting bracket with retainer for brake pressure regulator Installation position Fig. 4 Check and if necessary adjust rear axle total toe after installation If possible do not loosen when removing the rear axle 10 - Hex nut/washer, 35 Nm...

  • Page 100

    Rear Wheel Suspension, Shafts and Axle Page 4 of 14 42-4 Fig. 1 Suspension strut at body, removing and installing - Removing and installing inertia reel cover Repair Manual, Body Exterior, Interior, Repair Group 70. - Removing and installing inertia reel Repair Manual, Body Exterior, Interior, Repair Group 68.

  • Page 101

    Rear Wheel Suspension, Shafts and Axle Page 5 of 14 42-5 Fig. 3 Suspension strut, removing and installing Suspension strut is attached to the body by 4 retaining lugs in addition to the bolts. To remove, turn suspension strut until retaining lugs are positioned above the cut-outs.

  • Page 102

    Rear Wheel Suspension, Shafts and Axle Page 6 of 14 42-6 Fig. 5 Bonded rubber mounting, pressing 1st half out of axle beam Note: Before using special tool 3111 it is important to grease spindle with Molybdenum grease. Fig. 6 Bonded rubber mounting, pressing 2nd half out of axle beam Thread base plate into the pressure plate 3111/5 from...

  • Page 103

    Rear Wheel Suspension, Shafts and Axle Page 7 of 14 42-7 Fig. 7 Rubber bonded mounting, installation position Protruding segment of bonded rubber mounting faces forward on inside and rearward on outside. Fig. 8 Rubber bonded mounting, presssing into axle beam Press both halves in one after the other until the mounting conical section contacts the axle beam.

  • Page 104

    Rear Wheel Suspension, Shafts and Axle Page 8 of 14 42-8 Reworking cap nut in side member (front wheel drive vehicles) If the threads of the cap nut in the side member are damaged, it must either be retapped or the cap nut must be drilled out.

  • Page 105

    Rear Wheel Suspension, Shafts and Axle Page 9 of 14 42-9 Suspension strut, disassembling and assembling (front wheel drive vehicles) 1 - Cap Pry out with screwdriver Pressing on Fig. 4 2 - O-ring 3 - Self-locking hex nut, 25 Nm (18 ft lb) 4 - Dished washer 5 - Upper rubber mounting...

  • Page 106

    Rear Wheel Suspension, Shafts and Axle Page 10 of 14 42-10 7 - Suspension strut bearing Always replace foam gasket Welded nuts must be located in the spring seat recesses Align welded nuts and cap to shock absorber lower bushing Fig.

  • Page 107

    Rear Wheel Suspension, Shafts and Axle Page 11 of 14 42-11 13 - Stop buffer Shorter on Wagon than Sedan 14 - Protective tube Longer on Wagon than Sedan 15 - Plastic cap 16 - Coil spring Removing and installing Fig.

  • Page 108

    Rear Wheel Suspension, Shafts and Axle Page 12 of 14 42-12 20 - Shock absorber Can be replaced individually Removing and installing Page 42-4 Application see Parts catalog http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.1 12/7/2004...

  • Page 109

    Rear Wheel Suspension, Shafts and Axle Page 13 of 14 42-13 Fig. 1 Spring, removing and installing Note: Instead of VAG 1403, VAG 1752/1 may be used. Fig. 2 Spring seat, installation position http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.1 12/7/2004...

  • Page 110

    Rear Wheel Suspension, Shafts and Axle Page 14 of 14 42-14 Fig. 3 Suspension strut mounting to shock absorber bushing, aligning A - Shock absorber bushing axis B - Suspension strut mounting axis "a" 50 C - Cap axis 90 offset to shock absorber bushing axis -A-.

  • Page 111

    Wheel bearings, servicing Page 1 of 18 42-15 Wheel bearings, servicing Drum brakes (front wheel drive vehicles), wheel bearings, servicing Note: Careful sealing, absolute cleanliness and precise adjustment are requirements for long wheel bearing service life. Therefore note the following points: Install oil seal and grease cap as shown.

  • Page 112

    Wheel bearings, servicing Page 2 of 18 42-16 2 - Cotter pin Always replace 3 - Locking ring 4 - Hex nut Adjusting wheel bearing play Fig. 4 5 - Thrust washer 6 - Outer wheel bearing Drive out outer race with copper drift Pressing in Fig.

  • Page 113

    Wheel bearings, servicing Page 3 of 18 42-17 10 - Brake backing plate Bolt together with stub axle onto rear axle 11 - Oil seal Fill between sealing lips with multi-purpose grease. Driving in Fig. 8 12 - Dished washer Larger contact surface (concave side) to brake backing plate...

  • Page 114

    Wheel bearings, servicing Page 4 of 18 42-18 16 - Brake drum Before removing release brake shoe adjustment through wheel bolt hole Fig. When removing the brake drum make sure that the outer wheel bearing does not fall out. Fill hub with multi- purpose grease before installing http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.2...

  • Page 115

    Wheel bearings, servicing Page 5 of 18 42-19 Fig. 1 Grease cap, pressing off Loosen grease cap from seat by tapping lightly on the claw. Fig. 2 Grease cap, pressing off http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.2 12/7/2004...

  • Page 116

    Wheel bearings, servicing Page 6 of 18 42-20 Fig. 3 Grease cap, driving on Note: Always replace damaged (dented) grease caps. Damaged (dented) grease caps allow ingress of moisture, therefore always use the illustrated tool. Fig. 4 Wheel bearing play, adjusting Note: Using a screwdriver it must be possible to move the thrust washer by finger pressure (without prying).

  • Page 117

    Wheel bearings, servicing Page 7 of 18 42-21 Fig. 5 Brake shoe adjustment, releasing - Insert a screwdriver through a hole in the brake drum and push the wedge upward. Fig. 6 Outer wheel bearing outer race, pressing in http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.2 12/7/2004...

  • Page 118

    Wheel bearings, servicing Page 8 of 18 42-22 Fig. 7 Inner wheel bearing outer race, pressing in Fig. 8 Oil seal, driving in http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.2 12/7/2004...

  • Page 119

    Wheel bearings, servicing Page 9 of 18 42-23 Fig. 9 Rotor, pressing in http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.2 12/7/2004...

  • Page 120

    Wheel bearings, servicing Page 10 of 18 42-24 Wheel bearings, servicing - disc brakes (front wheel drive vehicles) Note: Careful sealing, absolute cleanliness and precise adjustment are requirements for long wheel bearing service life. Therefore note the following points: Install oil seal and grease cap as shown.

  • Page 121

    Wheel bearings, servicing Page 11 of 18 42-25 3 - Speed sensor Only on vehicles with Before installing sensor, clean mounting hole inner surface and coat with lubricating paste G 000 650 4 - Brake hose bracket 5 - Hex socket head bolt, 65 Nm (48 ft lb) 6 - Self-locking hex bolt, 35 Nm (26 ft lb)

  • Page 122

    Wheel bearings, servicing Page 12 of 18 42-26 10 - Cover ring Always replace Installation position Fig. 5 Drive on with tube VW 11 - Pad carrier 12 - Brake pads Removing and installing Page 46- 13 - Brake caliper Servicing Page 47- 14 - Outer wheel bearing...

  • Page 123

    Wheel bearings, servicing Page 13 of 18 42-27 17 - Grease cap Pressing off Fig. 1 Fig. 2 Driving on Fig. 3 18 - Locking ring 19 - Thrust washer 20 - Wheel bolt, 110 Nm (81 ft lb) 21 - Brake disc Before installing fill hub with multi-purpose grease...

  • Page 124

    Wheel bearings, servicing Page 14 of 18 42-28 26 - Dished washer Large contact surface (concave side) to backing plate 27 - Backing plate 28 - Axle beam Straightening work is not permissible! Only use stub axles with 6 mounting holes. 29 - Parking brake cable Adjusting parking brake...

  • Page 125

    Wheel bearings, servicing Page 15 of 18 42-29 Fig. 1 Grease cap, pressing off - Loosen grease cap by tapping lightly on the claw. Fig. 2 Grease cap, pressing off http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.2 12/7/2004...

  • Page 126

    Wheel bearings, servicing Page 16 of 18 42-30 Fig. 3 Grease cap, driving on Note: Always replace damaged (dented) grease caps. Damaged (dented) grease caps allow ingress of moisture, therefore always use the illustrated tool. Fig. 4 Wheel bearing play, adjusting Note: Using a screwdriver it must be possible to move the thrust washer by finger pressure (without prying).

  • Page 127

    Wheel bearings, servicing Page 17 of 18 42-31 Fig. 5 Cover ring, installation position Dimension "a" = 9.5 mm - Drive on cover ring with tube VW 519 Fig. 6 Outer wheel bearing outer race, pressing in http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.2 12/7/2004...

  • Page 128

    Wheel bearings, servicing Page 18 of 18 42-32 Fig. 7 Inner wheel bearing outer race, pressing in Fig. 8 Oil seal, driving in http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.2 12/7/2004...

  • Page 129

    Rear axle, servicing (four wheel drive vehicles) Page 1 of 13 42-33 Rear axle, servicing (four wheel drive vehicles) Note: When removing and installing the rear axle, it is recommended to remove axle and differential together and to separate away from the vehicle. If only the axle beam is to be removed and installed, the wishbones can remain...

  • Page 130

    Rear axle, servicing (four wheel drive vehicles) Page 2 of 13 42-34 1 - Suspension strut Removing and installing Page 42- Fig. 1 Page 42-37 Disassembling and assembling Page 42-53 Application see Parts catalog 2 - Drive shaft Removing and installing Fig.

  • Page 131

    Rear axle, servicing (four wheel drive vehicles) Page 3 of 13 42-35 5 - Propshaft Removing and installing Fig. 2 Mark installation position before removing 6 - Anti-roll bar Removing and installing Fig. 4 7 - Axle beam Replacing rubber bonded mounting Fig.

  • Page 132

    Rear axle, servicing (four wheel drive vehicles) Page 4 of 13 42-36 10 - Wheel bearing Servicing Page 42- Servicing brakes Repair Manual, Suspension, Wheels,Brakes, Steering, Repair Group 46 and47 11 - Hex bolt, 85 Nm (63 ft 12 - Hex bolt for seat belt strut, 25 Nm (18 ft lb) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.3 12/7/2004...

  • Page 133

    Rear axle, servicing (four wheel drive vehicles) Page 5 of 13 42-37 Fig. 1 Suspension strut from control arm, removing and installing Before installing, bring control arm into horizontal position (unladen state). Removing and installing suspension strut at body Page 42-4 Tightening torque -A-: 65 Nm (48 ft lb) Note: Support control arm otherwise damage may occur to...

  • Page 134

    Rear axle, servicing (four wheel drive vehicles) Page 6 of 13 42-38 Fig. 3 Drive shaft, removing and installing Loosen and tighten only when vehicle is standing on its wheels (danger of accident). Tightening torque: 90 Nm (66 ft lb) and turn 45 further ( turn) Note:...

  • Page 135

    Rear axle, servicing (four wheel drive vehicles) Page 7 of 13 42-39 Fig. 5 Control arm, removing and installing Before tightening bring control arm into horizontal position (unladen state). To remove the right-hand control arm inner bolt, remove brake pressure regulator from axle beam. Tightening torque -A-: 120 Nm (89 ft lb) Fig.

  • Page 136

    Rear axle, servicing (four wheel drive vehicles) Page 8 of 13 42-40 Fig. 7 Bonded rubber mounting, installing Before installing coat with acid free lubricant, e.g. soft soap. Installation position: Shoulder on outer mounting to outside, to inside on inner mounting (to center of vehicle).

  • Page 137

    Rear axle, servicing (four wheel drive vehicles) Page 9 of 13 42-41 Fig. 8 Rubber mounting to correct camber/toe The rubber mounting -A- is equipped with an eccentric bushing which can change the position of the control arm. This rubber mounting may only be installed in the control arm inner mounting.

  • Page 138

    Rear axle, servicing (four wheel drive vehicles) Page 10 of 13 42-42 Fig. 9 Final drive, removing and installing from axle beam Removing and installing viscous coupling Repair Manual, 5 Spd. Manual Transmission 02A; Repair Group 39 Tightening torque -A-: 45 Nm (33 ft lb) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.3 12/7/2004...

  • Page 139

    Rear axle, servicing (four wheel drive vehicles) Page 11 of 13 42-43 Fig. 10 Installation position, determining Connect segment corners of bonded rubber mounting metal core with a line. The continued line must pass through the center of hole (arrow). Note: The kidney-shaped recess must be pointing in direction of travel when viewed from the center of...

  • Page 140

    Rear axle, servicing (four wheel drive vehicles) Page 12 of 13 42-44 Fig. 12 Mounting bracket and final drive carrier, removing and installing Remove and install complete When assembling mounting bracket and final drive carrier away from the vehicle, make sure parts are correctly located relative to each other.

  • Page 141

    Rear axle, servicing (four wheel drive vehicles) Page 13 of 13 42-45 Fig. 14 Mounting bracket on body, removing and installing Mark mounting bracket installation position relative to body longitudinal member, otherwise the rear axle must be realigned on an axle alignment stand after reinstalling.

  • Page 142

    Rear drive shafts, servicing Page 1 of 7 42-46 Rear drive shafts, servicing Removing and installing drive shafts Page 42- Note: Grease quantity: - - outer constant velocity joint 80 g G-6.3 - - inner constant velocity joint 80 9 G-6.3 Greasing outer joint: press half of the grease into the joint, and the other half evenly into the boot.

  • Page 143

    Rear drive shafts, servicing Page 2 of 7 42-47 1 - Circlip Always replace Remove and install with VW161 a 2 - Inner constant velocity joint, 81 mm diameter Only replace complete Pressing off Page 40-54 Pressing on Page 40-55 Greasing Notes Page 42-46...

  • Page 144

    Rear drive shafts, servicing Page 3 of 7 42-48 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 Drive off with drift 5 - Drive axle Different drive axle...

  • Page 145

    Rear drive shafts, servicing Page 4 of 7 42-49 7 - Boot for 81 mm diameter constant velocity joint Polyester elastomer version Check for tears and chafing Installation position: At cuff 1 to 1-1/2 grooves visible To balance pressure briefly ventilate boot before tensioning the small clamp 8 - Hose clamp...

  • Page 146

    Rear drive shafts, servicing Page 5 of 7 42-50 11 - Circlip Always replace Insert in shaft groove 12 - Outer constant velocity joint: 81 mm diameter Only replace complete Removing Page 40- Installing: drive onto shaft with plastic hammer until compressed circlip seats Greasing...

  • Page 147

    Rear drive shafts, servicing Page 6 of 7 42-51 Reworking cap nut in side member (four wheel drive vehicles) If the threads of the cap nut in the side member are damaged, it must either be retapped or the cap nut must be drilled out. - Remove control arm if necessary.

  • Page 148

    Rear drive shafts, servicing Page 7 of 7 42-52 - Cut new thread in the cap nut, M 12 x 1.5. - Use new bolts, Part No. N 010 137.1 and washer, Part No. N 011 531.7 to secure the rear axle.

  • Page 149

    Suspension strut, disassembling and assembling (four wheel drive vehicles) Page 1 of 6 42-53 Suspension strut, disassembling and assembling (four wheel drive vehicles) 1 - Cap Pry out with screwdriver Pressing on Fig. 5 Installation position Fig. 5 2 - Seal 3 - Self locking hex nut, 30 Nm (22 ft lb) Always replace...

  • Page 150

    Suspension strut, disassembling and assembling (four wheel drive vehicles) Page 2 of 6 42-54 7 - Suspension strut mounting Welded nuts must be located in the spring seat recesses Installation position to spring seat Fig. 3 8 - Spring seat 9 - Spacer tube 10 - Lower rubber mounting...

  • Page 151

    Suspension strut, disassembling and assembling (four wheel drive vehicles) Page 3 of 6 42-55 17 - Coil spring Removing and installing Page 42- Allocation Parts catalog 18 - Packing 19 - Circlip 20 - Lower spring plate Installation position Fig. 1 21 - Shock absorber Can be replaced individually...

  • Page 152

    Suspension strut, disassembling and assembling (four wheel drive vehicles) Page 4 of 6 42-56 Fig. 1 Lower spring plate, installation position Lower spring plate Shock absorber eye bushing The spring plate must be installed so that the holes "a" align with the bushing -2- in the shock absorber eye.

  • Page 153

    Suspension strut, disassembling and assembling (four wheel drive vehicles) Page 5 of 6 42-57 Fig. 3 Suspension strut mounting to spring seat, installation position The upper suspension strut mounting and the spring seat (arrow A) both have markings (arrow B). These must be installed pointing forward, otherwise damage will occur to the suspension strut piston rod.

  • Page 154

    Suspension strut, disassembling and assembling (four wheel drive vehicles) Page 6 of 6 42-58 Fig. 5 Cap, pressing into suspension strut mounting http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.5 12/7/2004...

  • Page 155

    Wheel bearings, servicing - disc brakes (four wheel drive vehicles) Page 1 of 8 42-59 Wheel bearings, servicing - disc brakes (four wheel drive vehicles) Note: If a vehicle has to be moved after removing the drive shaft, first install an outer joint and tighten to 50 Nm (37 ft lb).

  • Page 156

    Wheel bearings, servicing - disc brakes (four wheel drive vehicles) Page 2 of 8 42-60 4 - Guide pins 5 - Protective cap 6 - Pad securing springs Always replace when changing pads 7 - Brake pads Repair information Repair Manual, Suspension, Wheels, Brakes, Steering, Repair Group 46 8 - Brake caliper...

  • Page 157

    Wheel bearings, servicing - disc brakes (four wheel drive vehicles) Page 3 of 8 42-61 12 - Self-locking hex nut Always Tighten to 90 Nm (66 ft lb) and turn 45 further ( turn) To tighten use recommend angle measuring wrench VAG 1756 or equivalent Before installing nut on...

  • Page 158

    Wheel bearings, servicing - disc brakes (four wheel drive vehicles) Page 4 of 8 42-62 16 - Circlip Ensure seated correctly 17 - Wheel bearing 72 mm diameter Pressing out Page 42-64 Pressing in page. Page 42-65 18 - Hex bolt, 10 Nm (7 ft lb) 19 - Backing plate 20 - Parking brake cable Adjusting parking...

  • Page 159

    Wheel bearings, servicing - disc brakes (four wheel drive vehicles) Page 5 of 8 42-63 24 - Drive shaft with speed sensor rotor Removing and installing drive shaft Page 42-37 Page 42-38 Removing and installing rotor, Fig. 25 - Brake line http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.6 12/7/2004...

  • Page 160

    Wheel bearings, servicing - disc brakes (four wheel drive vehicles) Page 6 of 8 42-64 Fig. 1 Hub, pressing out Fig. 2 Wheel bearing, pressing out http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.6 12/7/2004...

  • Page 161

    Wheel bearings, servicing - disc brakes (four wheel drive vehicles) Page 7 of 8 42-65 Fig. 3 Inner race, pulling off of hub Note: Only use puller with leg clamp e.g. Kukko 204-2 (commercial type). Fig. 4 Wheel bearing, pressing in Note: First install lower circlip.

  • Page 162

    Wheel bearings, servicing - disc brakes (four wheel drive vehicles) Page 8 of 8 42-66 Fig. 5 Hub, pressing in Note: First install backing plate on control arm. Tightening torque: 10 Nm (7 ft lb) Fig. 6 Speed sensor rotor, pressing in - Drive rotor off outer joint using a drift (rotor will be destroyed).

  • Page 163

    Vehicle alignment Page 1 of 7 44-1 Vehicle alignment Test requirements: Measuring equipment correctly calibrated Vehicle unladen Tires inflated to correct pressure Vehicle accurately aligned, suspension bounced and rocked several times Suspension, steering and steering linkage checked for excessive play and damage. Note: Vehicle alignment should not be checked before the vehicle has completed 1000 to 2000...

  • Page 164

    Vehicle alignment Page 2 of 7 44-2 Vehicle alignment specifications (front wheel drive vehicles) Front axle Suspension strut axle Engine up to 85 kW (115 110 - 128 kW (148 - 172 hp) Version Base suspension Plus suspension Total toe (not pressed) -1 20' -1 10'...

  • Page 165

    Vehicle alignment Page 3 of 7 44-3 Rear axle Torsion beam trailing arm axle Engine/version -1 30' Camber Maximum permissible difference between sides max. 20' +20' Total toe (at specified wheel camber) Maximum permissible deviation from direction of travel max. 20' not adjustable http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.44.1 12/7/2004...

  • Page 166

    Vehicle alignment Page 4 of 7 44-4 Vehicle alignment specifications (four wheel drive vehicles) Front axle Suspension strut axle Engine 85 kW (115 hp) 128 kW (172 Version Base Plus suspension suspension Total toe (not pressed) -1 20' -1 10' Camber (in straight- ahead position) Maximum permissible difference between sides...

  • Page 167

    Vehicle alignment Page 5 of 7 44-5 Rear axle Semi-trailing arm axle Engine 85 kW, 128 kW (115 hp, 172 hp) -1 15' Camber Maximum permissible difference between sides max. 30' +15' Total toe (at specified camber) Maximum permissible deviation from direction of travel max.

  • Page 168

    Vehicle alignment Page 6 of 7 44-6 Front wheel camber, adjusting - Install special tool as shown in illustration and slightly pre-tension. - Loosen suspension strut/wheel bearing housing connection. - Adjust camber by turning the spindle to specified setting. - Tighten suspension strut/wheel bearing housing connection.

  • Page 169

    Vehicle alignment Page 7 of 7 44-7 Calculating the direction of travel: - If both toe figures have the same preceding sign (+/+ or -/-), subtract the smaller figure from the larger figure and divide by 2 Example. Left rear wheel Right rear wheel + 15' + 5'...

  • Page 170

    Anti-locking Brake System (ABS) and Anti-locking Brake System with Electronic Differential Lock (A... Page 1 of 5 45-1 Anti-locking Brake System (ABS) and Anti-locking Brake System with Electronic Differential Lock (ABS/EDL) Teves 04 The ABS, ABS/EDL brake system is divided diagonally.

  • Page 171

    Anti-locking Brake System (ABS) and Anti-locking Brake System with Electronic Differential Lock (A... Page 2 of 5 45-2 Notes for repair work on ABS, ABS/EDL Before doing any repair work on the anti-locking system, determine the cause of the malfunction using On Board Diagnostic (OBD).

  • Page 172

    Anti-locking Brake System (ABS) and Anti-locking Brake System with Electronic Differential Lock (A... Page 3 of 5 45-3 Thoroughly clean all unions and the adjacent areas before loosening, do not use aggressive cleaning agents such as brake cleaner, petrol, thinners or similar. Place removed parts on a clean surface and cover.

  • Page 173

    Anti-locking Brake System (ABS) and Anti-locking Brake System with Electronic Differential Lock (A... Page 4 of 5 45-4 Control module, removing and installing Location Under the rear seat, left Note: Switch off ignition before disconnecting and connecting connectors. Removing - Fold up rear seat. - Press control module securing clips together and pull out.

  • Page 174

    Anti-locking Brake System (ABS) and Anti-locking Brake System with Electronic Differential Lock (A... Page 5 of 5 45-5 Wheel speed sensor and rotor for speed sensor, removing and installing Speed sensor When installing speed sensor ensure wiring is not twisted. Before installing speed sensor, clean mounting hole and coat with lubricating paste, G 000 650.

  • Page 175

    Anti-lock Brake System (ABS) and ABS with Electronic Differential Lock (ABS/EDL), Teves 20 GI Page 1 of 3 45-6 Anti-lock Brake System (ABS) and ABS with Electronic Differential Lock (ABS/EDL), Teves 20 GI General information The ABS or ABS/EDL braking system is divided diagonally.

  • Page 176

    Anti-lock Brake System (ABS) and ABS with Electronic Differential Lock (ABS/EDL), Teves 20 GI Page 2 of 3 45-7 Safety precautions WARNING! Brake fluid is poisonous. CAUTION! Before working on the ABS or ABS/EDL system, disconnect the battery Ground (GND) strap. For anti-theft coded radios, first make sure that the radio code is available.

  • Page 177

    Anti-lock Brake System (ABS) and ABS with Electronic Differential Lock (ABS/EDL), Teves 20 GI Page 3 of 3 45-8 CAUTION! During the final road test, make sure that at least one controlled brake test is included (pulsations must be felt at the brake pedal). Absolute cleanliness is required when working on the ABS or ABS/EDL system.

  • Page 178

    ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master cylinder (Teves 20 GI), servicing Page 1 of 9 45-9 ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master cylinder (Teves 20 GI), servicing CAUTION! DO NOT separate the ABS hydraulic pump from the valve block.

  • Page 179

    ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master cylinder (Teves 20 GI), servicing Page 2 of 9 45-10 8 - Rubber damper 9 - Retainer 10 - ABS hydraulic unit 11 - ABS control module 12 - Brake line connection ABS hydraulic unit to right-front brake caliper...

  • Page 180

    ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master cylinder (Teves 20 GI), servicing Page 3 of 9 45-11 ABS hydraulic unit and ABS control module (Teves 20 GI), removing and installing Carefully read and follow all cautions and warnings Page 45-7 before beginning work.

  • Page 181

    ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master cylinder (Teves 20 GI), servicing Page 4 of 9 45-12 After separating ABS control module from ABS hydraulic unit, always install valve dome transportation protection on hydraulic unit. Warranty claims for ABS hydraulic units on which the valve dome transportation protection was not used will not be accepted.

  • Page 182

    ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master cylinder (Teves 20 GI), servicing Page 5 of 9 45-13 - Release retainer and disconnect ABS control module connector (arrows). - Connect bleeder hose and bleeder bottle to left- front brake caliper bleeder screw, and open bleeder screw.

  • Page 183

    ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master cylinder (Teves 20 GI), servicing Page 6 of 9 45-14 - Remove Torx socket-head bolts (T25) from ABS hydraulic unit bracket. - Remove ABS hydraulic unit/ABS control module assembly. - Disconnect ABS hydraulic pump connector from ABS control module.

  • Page 184

    ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master cylinder (Teves 20 GI), servicing Page 7 of 9 45-15 Installing Note: Remove the sealing plugs from a new ABS hydraulic unit one at a time, and only when the corresponding brake line is to be connected.

  • Page 185

    ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master cylinder (Teves 20 GI), servicing Page 8 of 9 45-16 Note: For vehicles equipped with ABS/EDL, on which the brake fluid reservoir has been completely empty (e.g. leaks in brake system), it is necessary to initiate the "Basic Setting"...

  • Page 186

    ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master cylinder (Teves 20 GI), servicing Page 9 of 9 45-17 Brake hydraulic system, bleeding and filling Vehicles with ABS/EDL For vehicles with ABS/EDL, when the brake fluid reservoir has been completely emptied (e.g. due to leaks in the brake system) it is necessary to initiate the "Basic Setting"...

  • Page 187

    Assembly overview - hydraulic unit, brake servo/brake master cylinder Page 1 of 10 45-18 Assembly overview - hydraulic unit, brake servo/brake master cylinder Note: Pump and valve block must not be separated from one another. Illustration shows an exploded view of the ABS/EDL unit.

  • Page 188

    Assembly overview - hydraulic unit, brake servo/brake master cylinder Page 2 of 10 45-19 2 - Spacer cap Various versions Page 45-25 3 - Sealing ring Always replace 4 - Circlip Always replace 5 - Brake line Brake master cylinder/primary piston circuit to hydraulic unit 6 - Brake servo 7 - Carrier plate...

  • Page 189

    Assembly overview - hydraulic unit, brake servo/brake master cylinder Page 3 of 10 45-20 12 - Cap 13 - Hex socket head screw for brake fluid reservoir 14 - Series resistor Only on vehicles with ABS/EDL Checking Repair Manual, Brake System On Board Diagnostic (OBD), Repair group 01 15 - Self-locking hex nut, 25...

  • Page 190

    Assembly overview - hydraulic unit, brake servo/brake master cylinder Page 4 of 10 45-21 19 - ABS Hydraulic unit Connections (arrow) show pipe work from tandem master cylinder to ABS hydraulic unit Removing and installing Page 45- 20 - ABS/EDL Hydraulic unit Removing and installing...

  • Page 191

    Assembly overview - hydraulic unit, brake servo/brake master cylinder Page 5 of 10 45-22 24 - Brake line connection Hydraulic unit to rear right wheel cylinder Thread connection: M12 x1, 18 Nm (13 ft 25 - Brake line connection Hydraulic unit to front left brake caliper Thread connection: M10 x1, 15 Nm (11 ft...

  • Page 192

    Assembly overview - hydraulic unit, brake servo/brake master cylinder Page 6 of 10 45-23 Hydraulic unit, removing and installing Note: For easier disassembling and assembling, it is more practical to remove the hydraulic unit complete with brake servo and brake master cylinder.

  • Page 193

    Assembly overview - hydraulic unit, brake servo/brake master cylinder Page 7 of 10 45-24 - Remove nuts from brake servo/bulkhead. - Carefully remove hydraulic unit and brake servo with brake master cylinder from engine compartment. Installing Note: Hydraulic units supplied as replacement parts are already filled with hydraulic fluid and bled.

  • Page 194

    Assembly overview - hydraulic unit, brake servo/brake master cylinder Page 8 of 10 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.

  • Page 195

    Assembly overview - hydraulic unit, brake servo/brake master cylinder Page 9 of 10 45-26 Removing - Release brake servo vacuum by operating the brake pedal several times. - Remove connector from expansion tank. - Swing coolant expansion tank to side. - Pull connector off sensor.

  • Page 196

    Assembly overview - hydraulic unit, brake servo/brake master cylinder Page 10 of 10 45-27 Installing Note: When installing new circlip ensure opening is uppermost - installation position (arrow). - Install new sealing ring to sensor. (Coat sealing ring with lubricant e.g. soft soap). - Sensor notch must point downward when inserting into brake servo and be heard to engage.

  • Page 197

    Front brakes, servicing (Girling caliper) Page 1 of 7 46-1 Front brakes, servicing (Girling caliper) Note: After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the brake pads are properly seated in their normal operating position.

  • Page 198

    Front brakes, servicing (Girling caliper) Page 2 of 7 46-2 1 - Brake disc, not ventilated When worn always replace on both sides Brake disc diameter: 256 mm Brake disc thickness: 13 mm Wear limit: 11 mm 2 - Brake disc, ventilated When worn always replace on both sides Brake disc diameter:...

  • Page 199

    Front brakes, servicing (Girling caliper) Page 3 of 7 46-3 5 - Brake pad With brake pad wear indicator Always replace on both sides Removing and installing Page 46-6 Pad thickness: non- ventilated brake disc, 14 mm Pad thickness: ventilated brake disc, 11 mm Checking thickness Repair Manual, Maintenance...

  • Page 200

    Front brakes, servicing (Girling caliper) Page 4 of 7 46-4 10 - Wheel bearing housing 11 - Brake carrier with guide pins and protective caps Supplied as replacement part assembled with sufficient amount of grease on guide pins If protective caps are damaged use repair kit Use grease packet supplied to lubricate...

  • Page 201

    Front brakes, servicing (Girling caliper) Page 5 of 7 46-5 14 - Self-locking hex bolt, 35 Nm (26 ft lb) Always replace 15 - Guide pin 16 - Ribbed bolt, 125 Nm (92 ft lb) 17 - Protective cap 18 - Hex socket head bolt, 10 Nm (7 ft lb) 19 - Speed sensor Only on vehicles with...

  • Page 202

    Front brakes, servicing (Girling caliper) Page 6 of 7 46-6 Brake pads, removing and installing Removing - Remove lower brake caliper housing securing bolt. Counter-hold on guide pin. - Swing brake caliper housing upward. - Remove brake pads. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.1 12/7/2004...

  • Page 203

    Front brakes, servicing (Girling caliper) Page 7 of 7 46-7 Installing Note: Before inserting new brake pads, press piston back into the cylinder with resetting tool. Before pressing the piston back, remove some brake fluid from the reservoir with a bleeder bottle. If reservoir has been topped up, fluid may overflow and cause damage.

  • Page 204

    Front brakes, servicing (Teves/Ate) Page 1 of 7 46-8 Front brakes, servicing (Teves/Ate) 1 - Screw 2 - Brake disc When worn always replace on both sides Remove brake caliper prior to removing Ventilated brake disc diameter: 288 mm Brake disc thickness: 25 mm Wear limit: 23 mm 3 - Brake pads...

  • Page 205

    Front brakes, servicing (Teves/Ate) Page 2 of 7 46-9 4 - Retaining spring Insert in both brake caliper housing drillings 5 - Brake carrier Supplied as replacement part assembled with sufficient amount of grease on guide pins If protective caps are damaged use repair kit Use grease packet supplied to lubricate...

  • Page 206

    Front brakes, servicing (Teves/Ate) Page 3 of 7 46-10 7 - Guide pins, 25 Nm (18 ft lb) Removing and installing from Page 46-12 8 - Protective cap 9 - Seal Always replace Pry out with suitable tool 10 - Brake hose 11 - Banjo bolt, 30 Nm (22 ft 12 - Ribbed bolt, 125 Nm (92 ft lb)

  • Page 207

    Front brakes, servicing (Teves/Ate) Page 4 of 7 46-11 16 - Splash plate 17 - Hex bolt, 10 Nm (7 ft lb) 18 - Speed sensor rotor Only on vehicles with 19 - Hub Removing and installing Page 40- 20 - Countersunk bolt http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.2 12/7/2004...

  • Page 208

    Front brakes, servicing (Teves/Ate) Page 5 of 7 46-12 Brake pads, removing and installing Removing Note: If reusing brake pads mark location and install in same 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 209

    Front brakes, servicing (Teves/Ate) Page 6 of 7 46-13 - 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. - Take brake pads out of brake caliper housing or from brake carrier.

  • Page 210

    Front brakes, servicing (Teves/Ate) Page 7 of 7 46-14 - Install brake pad with retaining spring in brake caliper housing (piston). - Install outer brake pad in brake carrier. - Secure brake caliper housing with both guide pins to brake carrier. - Install both protective caps.

  • Page 211

    Rear wheel brakes, servicing (drum brakes) Page 1 of 4 46-15 Rear wheel brakes, servicing (drum brakes) Notes Page 42-15 1 - Grease cap Removing and installing from Page 42-19 2 - Cotter pin Always replace 3 - Locking ring 4 - Hex nut Adjusting wheel bearing play...

  • Page 212

    Rear wheel brakes, servicing (drum brakes) Page 2 of 4 46-16 6 - Outer wheel bearing 7 - Wheel speed sensor rotor Only on vehicles with 8 - Brake drum Vehicles with front wheel drive Brake drum diameter: 230 mm Wear limit: 231.5 mm Clean thoroughly, check for wear,...

  • Page 213

    Rear wheel brakes, servicing (drum brakes) Page 3 of 4 46-17 10 - Hex socket head bolt, 10 Nm (7 ft lb) 11 - Wheel speed sensor Only on vehicles with Insert with lubricating paste, G 000 650 12 - Backing plate with brake shoes Release adjustment before removing brake...

  • Page 214

    Rear wheel brakes, servicing (drum brakes) Page 4 of 4 46-18 Brake shoe adjustment, releasing - Insert a screwdriver through hole in brake drum and push wedge upward. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.3 12/7/2004...

  • Page 215

    Rear wheel brakes, servicing Page 1 of 8 46-19 Rear wheel brakes, servicing Note: After working on the rear wheel brakes: Release parking brake. Firmly depress the brake pedal once. 1 - Spring plate To remove, push against the spring and turn through 90 2 - Spring 3 - Brake shoe with lever...

  • Page 216

    Rear wheel brakes, servicing Page 2 of 8 46-20 4 - Upper return spring Unhook with pliers 5 - Lower return spring Lubricate contact points with G 000 650 paste 6 - Wedge spring 7 - Brake shoe Removing and installing Page 46- Minimum lining...

  • Page 217

    Rear wheel brakes, servicing Page 3 of 8 46-21 11 - Backing plate 12 - Hex socket head bolt, 10 Nm (7 ft) 13 - Wheel cylinder Checking for leaks Fig. 1 14 - Wedge To remove and install the brake drum, push upwards through a wheel bolt hole Page 46-18...

  • Page 218

    Rear wheel brakes, servicing Page 4 of 8 46-22 Fig. 1 Wheel cylinder, checking for leaks - Lift dust boot - If brake fluid is found in the dust boot then replace wheel cylinder Note: Care is to be exercised to ensure the seal is not damaged when lifting the dust boot (only use a blunt instrument, e.g.

  • Page 219

    Rear wheel brakes, servicing Page 5 of 8 46-23 Brake shoes, removing and installing Removing - Remove brake drum. - Remove spring plate. - Unhook lower return spring. - Remove brake shoes. - Unhook parking brake cable. - Clamp brake shoes in vice. - Remove wedge spring.

  • Page 220

    Rear wheel brakes, servicing Page 6 of 8 46-24 Installing - Connect locating spring and install brake shoes on the push rod. - Insert wedge. - Insert brake shoe with brake lever in push rod. - Connect upper return spring. - Connect parking brake cable to brake lever.

  • Page 221

    Rear wheel brakes, servicing Page 7 of 8 46-25 - Attach wedge spring. - Install springs and spring plates. - Install brake drum and adjust wheel bearing play. Adjusting wheel bearing play Page 42- - Firmly depress brake pedal once, this adjusts the rear brakes.

  • Page 222

    Rear wheel brakes, servicing Page 8 of 8 46-26 Parking brake, adjusting (drum brakes) Note: Due to the automatic rear wheel brake adjustment there is no requirement to adjust the parking brake. Adjustment is only necessary after replacing parking brake cables, backing plate or brake linings - Release parking brake.

  • Page 223

    Rear wheel brakes, servicing (disc brakes) Page 1 of 10 46-27 Rear wheel brakes, servicing (disc brakes) Girling rear wheel disc brakes (front and four wheel drive vehicles) Note: Only items 5, 6, 7, 8, 9, 10, 11 and 12 apply for four wheel drive.

  • Page 224

    Rear wheel brakes, servicing (disc brakes) Page 2 of 10 46-28 4 - Brake hose bracket 5 - Hex socket head bolt, 65 Nm (48 ft lb) 6 - Self-locking bolt, 35 Nm (26 ft lb) Always replace When loosening and tightening, counter- hold on guide pin 7 - Guide pin...

  • Page 225

    Rear wheel brakes, servicing (disc brakes) Page 3 of 10 46-29 11 - 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 damaged use repair kit.

  • Page 226

    Rear wheel brakes, servicing (disc brakes) Page 4 of 10 46-30 14 - Outer wheel bearing 15 - Hex nut Adjusting wheel bearing play Using a screwdriver it must be possible to move the thrust washer by finger pressure (without leverage) Page 42- Secure with locking...

  • Page 227

    Rear wheel brakes, servicing (disc brakes) Page 5 of 10 46-31 21 - Brake disc Brake disc diameter for vehicles with front wheel drive: 226 mm Removing and installing Page 42- Brake disc diameter for vehicles with four wheel drive: 239 mm Removing and installing Page 42-...

  • Page 228

    Rear wheel brakes, servicing (disc brakes) Page 6 of 10 46-32 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 26 - Dished spring washer Larger seating surface towards backing plate 27 - Backing plate...

  • Page 229

    Rear wheel brakes, servicing (disc brakes) Page 7 of 10 46-33 Brake pads, removing and installing Note: Mark brake pads when removing if they are to be reused. Re-install in their original position to prevent uneven braking! Removing - Remove wheels. - Remove parking brake cable from brake caliper (arrow).

  • Page 230

    Rear wheel brakes, servicing (disc brakes) Page 8 of 10 46-34 Installing Note: Before pressing the piston back, remove some brake fluid from the reservoir. Use a bleeder bottle or a plastic bottle which is only used for brake fluid. Brake fluid is poisonous and must not be siphoned by mouth through a hose.

  • Page 231

    Rear wheel brakes, servicing (disc brakes) Page 9 of 10 46-35 - Secure brake caliper housing with new self- locking bolts. - Attach parking brake cable (arrow) to brake caliper housing. Note: After each brake pad change firmly depress brake pedal several times with vehicle stationary, so that the brake pads are properly seated in their normal operating position.

  • Page 232

    Rear wheel brakes, servicing (disc brakes) Page 10 of 10 46-36 Parking brake, adjusting (disc brakes) Note: Due to the self-adjusting rear brakes there is no requirement to adjust the parking brake. Adjustment is only necessary after replacing parking brake cables, brake calipers, brake pads and brake discs.

  • Page 233

    Parking brake lever assembly overview Page 1 of 9 46-37 Parking brake lever assembly overview 1 - Parking brake lever Different versions for rear drum and disc brakes Before removing remove center console 2 - Hand grip Pry trim up with a small screwdriver then pull forward to remove Fig.

  • Page 234

    Parking brake lever assembly overview Page 2 of 9 46-38 4 - Lock nut 5 - Compensator 6 - Parking brake lever trim First pull off parking brake hand grip then pull trim forward Fig. 2 7 - Hex nut 8 - Parking brake cable Different versions for rear drum and disc...

  • Page 235

    Parking brake lever assembly overview Page 3 of 9 46-39 Fig. 1 Parking brake cable installation position The parking brake cable is secured by clamps to the axle beam in the center of the two colored marks (arrow). Fig. 2 Hand grip, removing - Pry up parking brake cable trim with a screwdriver and pull grip and trim off forward.

  • Page 236

    Parking brake lever assembly overview Page 4 of 9 46-40 Fig. 3 Center console, removing - Remove rear ashtray (center console). - Remove console rear securing screws (arrows). http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.6 12/7/2004...

  • Page 237

    Parking brake lever assembly overview Page 5 of 9 46-41 Brake pedal/brake servo, removing and installing CAUTION! The brake pedal travel must not be restricted by additional floor coverings. Note: Grease all mountings before installing with G 000 602 grease. 1 - Securing clip Ensure securely seated...

  • Page 238

    Parking brake lever assembly overview Page 6 of 9 46-42 6 - Brake pedal return spring 7 - Return spring mounting tube 8 - Brake pedal mounting bushing 9 - Brake pedal 10 - Clutch pedal Removing and installing Repair Manual, 5 Spd. Manual Transmission 02A, Repair Group 30 11 - Pedal cluster mounting...

  • Page 239

    Parking brake lever assembly overview Page 7 of 9 46-43 16 - Securing clip Ensure seated securely 17 - Brake Light Switch Adjusting Page 46- http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.6 12/7/2004...

  • Page 240

    Parking brake lever assembly overview Page 8 of 9 46-44 Brake pedal, removing and installing Note: Grease all mounting and contact surfaces with grease. To remove brake servo disconnect brake pedal at clevis only. Removing - Before removing brake pedal remove trim - Remove brake pedal clevis pin connection securing clip.

  • Page 241

    Parking brake lever assembly overview Page 9 of 9 46-45 Brake Light Switch, adjusting Note: The Brake Light Switch must be removed for adjusting. - Remove trim under instrument panel. - Disconnect harness connector for Brake Light Switch. - Remove Brake Light Switch by turning to right through 90 .

  • Page 242

    Assembly overview: brake master cylinder/brake servo Page 1 of 4 47-1 Assembly overview: brake master cylinder/brake servo Note: Brake master cylinders and brake servos from different manufacturers are installed. Complete master cylinders and brake servos can be replaced independently of each other. 1 - Seal For brake servo 2 - Self-locking hex nut, 20...

  • Page 243

    Assembly overview: brake master cylinder/brake servo Page 2 of 4 47-2 6 - Brake servo On gas engines the vacuum required is taken from the intake manifold. On Diesel engines an exhauster is installed to create the required vacuum. Functional check - With engine switched off, depress brake pedal...

  • Page 244

    Assembly overview: brake master cylinder/brake servo Page 3 of 4 47-3 7 - Sealing ring Always replace 8 - Self-locking hex nut, 20 Nm (15 ft lb) 9 - Brake master cylinder Cannot be repaired. If faulty, replace complete. 10 - Sealing plug Moisten with brake fluid and press into reservoir...

  • Page 245

    Assembly overview: brake master cylinder/brake servo Page 4 of 4 47-4 12 - Cap 13 - Brake fluid reservoir 14 - Non-return valve http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.1 12/7/2004...

  • Page 246

    Girling front brake caliper, servicing Page 1 of 5 47-5 Girling front brake caliper, servicing Note: When repairing install all parts supplied in repair kit. Apply thin coat of brake cylinder paste to brake cylinders, pistons and sea/s. 1 - Protective seal 2 - Bleed valve Apply thin coat of brake cylinder paste to...

  • Page 247

    Girling front brake caliper, servicing Page 2 of 5 47-6 5 - Seal Remove using a screwdriver Page 47-7 6 - Piston Removing and installing Page 47-7 Apply thin coat of brake cylinder paste before inserting 7 - Protective seal Do not damage when inserting piston 8 - Brake carrier with...

  • Page 248

    Girling front brake caliper, servicing Page 3 of 5 47-7 Front brake caliper pistons, removing and installing Removing - Force piston out of brake caliper housing using compressed air. Note: Place a piece of wood in the recess to prevent damaging the piston.

  • Page 249

    Girling front brake caliper, servicing Page 4 of 5 47-8 Installing - Place protective seal with the outer sealing lip on the piston. - Using a screwdriver, insert the inner sealing lip into the cylinder groove. Note: Hold piston in front of caliper housing. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.2 12/7/2004...

  • Page 250

    Girling front brake caliper, servicing Page 5 of 5 47-9 - Press piston into the brake caliper housing using piston resetting tool. Note: The protective seal outer sealing lip will then locate in the piston groove. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.2 12/7/2004...

  • Page 251

    Front brake caliper, servicing (Teves/Ate) Page 1 of 5 47-10 Front brake caliper, servicing (Teves/Ate) Note: When repairing install all parts supplied in repair kit. Apply thin coat of brake cylinder paste to brake cylinders, pistons and seals. 1 - Protective seal Push onto bleed valve 2 - Bleed valve Apply thin coat of...

  • Page 252

    Front brake caliper, servicing (Teves/Ate) Page 2 of 5 47-11 6 - Brake cylinder housing 7 - Brake carrier Install on brake caliper housing 8 - Retaining spring Install with both ends in the drillings in brake caliper housing 9 - Piston seal Remove using a screwdriver Fig.

  • Page 253

    Front brake caliper, servicing (Teves/Ate) Page 3 of 5 47-12 Fig. 1 Piston, pressing out of cylinder using compressed air Note: Place a piece of wood in the recess to prevent damaging the piston. Fig. 2 Piston seal, removing http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.3 12/7/2004...

  • Page 254

    Front brake caliper, servicing (Teves/Ate) Page 4 of 5 47-13 Fig. 3 Protective seal, installing Fig. 4 Protective seal, installing - Using a screwdriver, insert inner sealing lip into cylinder groove Note: Hold piston in front of caliper housing. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.3 12/7/2004...

  • Page 255

    Front brake caliper, servicing (Teves/Ate) Page 5 of 5 47-14 Fig. 5 Piston, installing Note: The protective seal outer sealing lip will then locate in the piston groove. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.3 12/7/2004...

  • Page 256

    Rear brake caliper, servicing Page 1 of 8 47-15 Rear brake caliper, servicing Note: Apply thin coat of brake cylinder paste to brake cylinder pistons and seal. When repairing install all parts supplied in repair kit. New brake calipers are filled with brake fluid and are pre-bled.

  • Page 257

    Rear brake caliper, servicing Page 2 of 8 47-16 2 - Sealing ring Remove using a screwdriver Page 47-19 3 - Piston with automatic adjustment Removing and installing Page 47- 4 - Protective seal Pull outer sealing lip onto piston Install inner sealing lip in brake caliper housing groove...

  • Page 258

    Rear brake caliper, servicing Page 3 of 8 47-17 7 - Brake caliper housing with parking brake cable lever If a leak exists at the parking brake cable lever replace brake caliper housing After repairing, pre- bleed caliper housing Page 47-21 8 - Guide pins Grease before pulling on protective cap...

  • Page 259

    Rear brake caliper, servicing Page 4 of 8 47-18 10 - Brake carrier with guide pin and protective cap Supplied as replacement part, assembled with sufficient grease on guide pins If protective caps or guide pins are damaged, install repair kit.

  • Page 260

    Rear brake caliper, servicing Page 5 of 8 47-19 Rear brake caliper piston, removing and installing Removing - Thread piston out of brake caliper housing by turning the knurled wheel counter-clockwise. Note: If piston is difficult to move, use a 13 mm open end wrench on the flats (arrow A) provided for this purpose.

  • Page 261

    Rear brake caliper, servicing Page 6 of 8 47-20 Installing - Place protective seal with the outer sealing lip on the piston. - Insert protective seal inner sealing lip into the caliper housing groove using a screwdriver. Note: Hold piston in front of brake caliper housing. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.4 12/7/2004...

  • Page 262

    Rear brake caliper, servicing Page 7 of 8 47-21 - Thread piston into housing by turning knurled wheel clockwise. Note: Install special tool 3272 so that the collar (arrow) of the tool is seated against the brake carrier. If piston is difficult to move, use a 13 mm open end wrench on flats (arrow A) provided for this purpose.

  • Page 263

    Rear brake caliper, servicing Page 8 of 8 47-22 Pre-bleeding brake caliper - Open bleeder valve 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. Note: Position brake caliper as illustrated to pre-bleed.

  • Page 264

    Brake pressure regulator, checking and adjusting Page 1 of 4 47-23 Brake pressure regulator, checking and adjusting Vehicles without ABS, vehicles with ABS, ABS/EDS, Teves 04 The brake pressure regulator is mounted on a bracket which is in turn fixed to a rear axle mounting bracket and is controlled from the rear axle by a spring.

  • Page 265

    Brake pressure regulator, checking and adjusting Page 2 of 4 47-24 - Lift vehicle and connect pressure gauges to front left brake caliper and to rear right wheel cylinder/caliper. - Bleed both gauges. Note: Bleeding brake system on vehicles with ABS Page 47-27 - Lower vehicle and bounce the rear of the vehicle...

  • Page 266

    Brake pressure regulator, checking and adjusting Page 3 of 4 47-25 Load dependent brake pressure regulator specifications Model / Version Bar (psi) Bar (psi) Rear axle drum Front axle 50 (725) Front axle 100 (1450) brakes Rear axle 30 - 36 Rear axle 51 - 57 (435 - 522)

  • Page 267

    Brake pressure regulator, checking and adjusting Page 4 of 4 47-26 Adjusting regulator Rear axle test pressure too high: - Release tension on regulator spring. Rear axle test pressures too low: - Tension regulator spring. Note: Do not adjust with brake pedal depressed, therefore observe the following sequence: - Read off figures.

  • Page 268

    Brake system, bleeding Page 1 of 3 47-27 Brake system, bleeding Brake system, bleeding (vehicles with and without ABS, ABS/EDL) Changing brake fluid Repair Manual, Maintenance Note: Bleeding the brake system on vehicles with ABS, ABS/EDL is performed as for vehicles with conventional braking systems.

  • Page 269

    Brake system, bleeding Page 2 of 3 47-28 Brake system, bleeding (with pressure bleeder VAS 5234) Opening the hydraulic unit bleed screws on vehicles with ABS, ABS/EDL is not permitted! - Connect VAS 5234 Brake filler and bleeder unit. - Open bleeder screws in the specified order and bleed brake calipers and wheel cylinders.

  • Page 270

    Brake system, bleeding Page 3 of 3 47-29 Brake system, bleeding (without pressure bleeder) Opening the hydraulic unit bleed screws on vehicles with ABS, ABS/EDL is not permitted! - Build-up brake pressure in brake system by pumping the brake pedal. - Attach bleeder bottle hose and open bleeder screw.

  • Page 271

    Steering Page 1 of 99 48-1 Steering Assembly overview: steering column, column tube, steering wheel and airbag steering wheel Airbag system functional check and interrogating Diagnostic Trouble Code (DTC) Memory. Repair Manual, Body Exterior, Interior, Repair Group 68; General body repairs Safety precautions when working on airbag Repair Manual, Body Exterior, Interior, Repair Group 68, General body repairs...

  • Page 272

    Steering Page 2 of 99 48-2 1 - Cover plate 2 - Hex nut, 50 Nm (37 ft 3 - Steering wheel Install in center position 4 - Airbag unit Removing and installing Page 48-7 5 - Steering wheel for airbag Removing and installing...

  • Page 273

    Steering Page 3 of 99 48-3 9 - Spring 10 - Steering column switch/steering lock housing Distance between steering wheel/steering column switch is not adjustable 11 - Upper trim 12 - Support ring With washer 13 - Steering column Remove by pulling upwards out of column tube Checking length...

  • Page 274

    Steering Page 4 of 99 48-4 19 - Lower steering column bearing Pull in with VW 771 and large 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 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1...

  • Page 275

    Steering Page 5 of 99 48-5 Fig. 1 Splined adapter sleeve, removing Only use puller with leg clamp (e.g. Kukko 204/2 commercial type). Fig. 2 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 276

    Steering Page 6 of 99 48-6 Fig. 3 Length of steering column, checking 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.

  • Page 277

    Steering Page 7 of 99 48-7 Airbag unit, removing and installing Removing - Disconnect battery Ground strap. - Center steering wheel (wheels straight- ahead). - Remove both socket head bolts from airbag unit. - Remove airbag unit from steering wheel and disconnect wiring connector from airbag unit.

  • Page 278

    Steering Page 8 of 99 48-8 Airbag steering wheel, removing and installing Removing - Remove airbag unit. Page 48-7 - Remove trim below steering column switch. - Separate connector (arrow). (Pull foam rubber sleeve off connector, if installed). - Remove nut and pull steering wheel off steering column.

  • Page 279

    Steering Page 9 of 99 48-9 Installing - Install steering wheel, install nut and tighten. Tightening torque: 50 Nm (37 ft lb). - Connect airbag unit connector below steering wheel. - Install trim panel below steering column. Make sure that the centering ring wiring connection is located in the recess in the trim panel.

  • Page 280

    Steering Page 10 of 99 48-10 Airbag Spiral Spring, removing and installing Remove airbag unit Page 48-7 Remove steering wheel Page 48-8 - Separate single connector for horn. - Remove screws -1- and remove Airbag Spiral Spring -2- from steering wheel. Install steering wheel Page 48-9 Install airbag unit...

  • Page 281

    Steering Page 11 of 99 48-11 Column tube for height adjustable steering wheel, removing and installing The column tube can be adjusted in height by approx. 50 mm 1 - Operating lever 2 - Packing plate 3 - Column tube Square housing fits over mounting bracket 4 - Rubber stop...

  • Page 282

    Steering Page 12 of 99 48-12 8 - Clamping sleeve 9 - Mounting bracket Before assembling, coat side sliding surfaces with MoS paste 10 - Bolt with left-hand thread Tighten to 22 Nm (16 ft lb), After tightening install locking plate 11 - Locking plate 12 - Locking plate nut, 8 Nm (70 in.

  • Page 283

    Steering Page 13 of 99 48-13 Pump delivery pressure, checking - Disconnect pump pressure line. - Install adapter and test equipment. Cut-off valve on gauge 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...

  • Page 284

    Steering Page 14 of 99 48-14 - With engine running at idling speed. Close cut- off valve (not longer than 5 seconds) and read off pressure. Specification: 85 - 95 bar (1232 - 1377 psi) Note: If the reading is higher or lower than specified replace pump.

  • Page 285

    Steering Page 15 of 99 48-15 Power steering gear, removing and installing When working on the power assisted steering gear: Absolute cleanliness is required when working on the power steering. Thoroughly clean connections and immediate vicinity before loosening. Place parts on a clean surface and cover if not re-installing immediately.

  • Page 286

    Steering Page 16 of 99 48-16 Removing - Press tie rods off steering arm. A - Ball joint splitter (commercial type) e.g. Kukko No. 128/2 - Remove partition behind pedals from bulkhead and from steering column tube to loosen the universal joint/power steering gear.

  • Page 287

    Steering Page 17 of 99 48-17 - Support engine/transmission assembly with 10- 222 A and 10-222 A/1 (support VR6 engine with 10-222A 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.

  • Page 288

    Steering Page 18 of 99 48-18 Installing Install in reverse order. - Check position of steering wheel and, if necessary, align front end. Note: When lifting the engine/transmission assembly guide the lower half of the universal joint shaft -A- into the upper half -B- at the same time (second mechanic necessary).

  • Page 289

    Steering Page 19 of 99 48-19 Assembly overview: power assisted steering box (TRW) Determine cause of any malfunctions using pressure and leak testing, Page 48-13 Note: Always replace self-locking nuts and bolts. Welding and straightening work on steering components is not permitted. To grease the rack only use steering gear grease, Part No.

  • Page 290

    Steering Page 20 of 99 48-20 1 - Self-locking nut 35 Nm (26 ft lb) 2 - Self-locking 30 Nm (22 ft lb) 3 - Clamp 4 - Rubber mounting Internal diameter ZF: 50 mm TRW: 44 mm 5 - Right-hand tie rod 70 Nm (52 ft lb) Removing and installing...

  • Page 291

    Steering Page 21 of 99 48-21 6 - Left-hand tie rod 70 Nm (52 ft lb) Removing and installing Page 48- 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)

  • Page 292

    Steering Page 22 of 99 48-22 9 - Steering gear Removing and installing Page 48- Adjusting Page 48- 10 - Tie rod end Separating Page 48-16 Checking: Repair Manual, Maintenance 11 - Hex nut 30 Nm (22 ft lb) 12 - Universal joint http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1 12/7/2004...

  • Page 293

    Steering Page 23 of 99 48-23 13 - Threaded connection 30 Nm (22 ft lb) Return line 14 - Sealing ring Always replace 15 - Hose clamp Always replace - open with pliers Tensioning Page 48-81 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1 12/7/2004...

  • Page 294

    Steering Page 24 of 99 48-24 Power steering gear, adjusting (TRW) Note: Two Mechanics are required when adjusting. Adjust with engine switched off Adjusting steering box - Raise vehicle on hoist. - Wheels in straight-ahead position. By turning the steering wheel back and forth (about 30 to center axis) a knocking noise will be heard if there is excessive play.

  • Page 295

    Steering Page 25 of 99 48-25 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.

  • Page 296

    Steering Page 26 of 99 48-26 1 - Tie rod For removing, see tie rod, removing and installing (TRW and ZF power steering gear) Page 48-77 2 - Boot Installing, see tie rod, removing and installing (TRW and ZF) power steering), Page 48- 3 - Hose clamp...

  • Page 297

    Steering Page 27 of 99 48-27 7 - O-ring Is assembled on toothed rod guide (item -6-) contained in the repair kit 8 - Pressure compensating tube Check for damage (dents and kinks) 9 - Toothed rod Check for scoring After removing lubricate immediately with hydraulic oil...

  • Page 298

    Steering Page 28 of 99 48-28 11 - Adjusting screw with lock nut, 60 Nm (44 ft Before removing, mark position of adjusting bolt and lock nut on housing Steering gear, adjusting Page 48- 12 - Pressure spring 13 - Pressure piece Mark installation position 14 - Housing...

  • Page 299

    Steering Page 29 of 99 48-29 17 - Sealing ring Always replace 18 - Valve body Removing Page 48- Cannot be repaired Is not supplied as replacement part, if damaged replace steering gear 19 - Support ring Eliminated starting 4/92 If present, it must be reinstalled 20 - Adhesive film...

  • Page 300

    Steering Page 30 of 99 48-30 21 - Roller bearing installation position: inscription points up 22 - Sealing ring Always replace 23 - Circlip 24 - Ball bearing Drive from top downward with VW Grease with steering gear grease AOF 063 000 04 25 - Self-locking hex nut, 30 Nm (22 ft lb)

  • Page 301

    Steering Page 31 of 99 48-31 27 - Pipe Do not disconnect Not supplied as replacement part Sealing ring cannot be replaced 28 - O-ring 29 - Sealing ring Replace if there is scoring that can be seen or felt Already pre-mounted on new toothed rods that are supplied as...

  • Page 302

    Steering Page 32 of 99 48-32 Power steering gear, disassembling - Tie rods, removing - see tie rod, removing and installing (TRW and ZF power steering), Page 48-77 - Close hose connections on power steering gear if not already done 1 - Plastic locking screw 2 - Plastic locking screw - Clean outside of power steering gear...

  • Page 303

    Steering Page 33 of 99 48-33 - Mark position of adjusting screw and lock nut to the housing (arrow) - Screw lock nut together with adjusting screw Note: Do not change position of adjusting screw to lock nut when removing If necessary, remove adjusting screw together with lock nut using tool 3115/6 Pressure piece/adjusting screw are slightly...

  • Page 304

    Steering Page 34 of 99 48-34 - Mark installation position of pressure piece and remove 1 - Spreading pliers (standard commercial) 2 - Pressure piece - Remove circlip for valve body 1 - Needle nose pliers (standard commercial) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1 12/7/2004...

  • Page 305

    Steering Page 35 of 99 48-35 - Remove lower locking screw for valve body 1 - Ratchet (standard commercial) If very tightly seated, loosen locking screw with a hammer and driver - 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 body...

  • Page 306

    Steering Page 36 of 99 48-36 - Pull adhesive tape out of the housing - Pull toothed rod all the way to the left - Turn lock washer so that the opening of the circlip (arrow) is in the groove of the housing - Continue to turn the lock washer (direction of rotation left or right) so that the circlip turns out of the housing...

  • Page 307

    Steering Page 37 of 99 48-37 For easier installation of the puller, it is recommended that a rubber band be placed 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 308

    Steering Page 38 of 99 48-38 Inner sealing ring for toothed rod, pulling out - Install puller for sealing ring far enough so that the marking on the tool (arrow) matches the housing edge (only then will the claws engage behind the support ring) - Spread claws -2- of the tool by turning the spindle forcefully...

  • Page 309

    Steering Page 39 of 99 48-39 - Install tool VW 771 in the puller - Pull out sealing ring Parts, cleaning and checking - Before assembly, the housing must be checked for contamination (paint residue, chips, dirt) and thoroughly cleaned with compressed air and alcohol - Clean adhesive surface for adhesive tape in area of the slot with solvent (e.g.

  • Page 310

    Steering Page 40 of 99 48-40 Checking toothed rod for scoring If corroded areas or deep scratches are not noticeable on the toothed rod, the toothed rod must be replaced An evaluation of whether the toothed rod was damaged by force, e.g. by an accident, is not possible with this visual inspection If slight scoring (arrows) can be seen/felt on the toothed rod that are only deep enough that they can...

  • Page 311

    Steering Page 41 of 99 48-41 Sealing ring on toothed rod, replacing - Press pliers together with slight 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 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1...

  • Page 312

    Steering Page 42 of 99 48-42 Sealing rings, installing on toothed rod piston - Slide mounting sleeve on toothed 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 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1 12/7/2004...

  • Page 313

    Steering Page 43 of 99 48-43 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...

  • Page 314

    Steering Page 44 of 99 48-44 Inner sealing ring for toothed rod, installing - Place sealing ring on tool - Ensure correct installation position of sealing ring for toothed rod - Drive sealing ring -1- into the cylinder pipe far enough so that the groove (arrow) on the tool matches the edge (arrow A) of the housing 1 - Sealing ring...

  • Page 315

    Steering Page 45 of 99 48-45 Toothed rod, installing in housing - 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 No grease must get into the oil circulation system! http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1 12/7/2004...

  • Page 316

    Steering Page 46 of 99 48-46 - Coat piston of toothed rod and protective tube with hydraulic oil - Install installation sleeve 3315/22 into the housing - Slide toothed rod into the housing When sliding, make sure that the sealing ring is pressed into the groove of the piston without jamming - Slowly introduce the toothed rod into the housing...

  • Page 317

    Steering Page 47 of 99 48-47 - Place lock washer in the housing and press in far enough until the groove in the lock washer in the slot of the housing is visible - Install new safety wire in the hole of the lock washer (arrow) - Pull safety wire in by turning the lock washer.

  • Page 318

    Steering Page 48 of 99 48-48 - Screw assembly mandrel 3315/17 on valve body - Lubricate valve body with hydraulic oil and carefully install by hand into the valve body housing (note position of toothed rod) Make sure that the sealing ring in the housing is not damaged by the teeth of the pinion - Tape teeth of valve body with adhesive tape to protect the sealing ring.

  • Page 319

    Steering Page 49 of 99 48-49 - Drive sealing ring in far enough sot that the groove for circlip in the housing is visible - Install circlip - Remove adhesive tape - Remove assembly mandrel 3315/17 - Install hex nut for valve body and tighten, 30 Nm (22 ft lb) with torque wrench SW 14 2 - Install locking screw - Grease pressure piece and spring in housing in old...

  • Page 320

    Steering Page 50 of 99 48-50 Adhesive tape, applying - Fill slot with sealing compound AKL 450 005 05 - Tape slot with adhesive tape 1 - Adhesive surface must be dry and free from grease http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1 12/7/2004...

  • Page 321

    Steering Page 51 of 99 48-51 Power steering gear, adjusting with new toothed rod If a new toothed rod was used, the steering play should be adjusted according to the following description. - Drill a hole 5.1 mm in diameter in the center of the adjusting screw (on the back side center) - Thoroughly clean adjusting screw - Place toothed rod in center position (measure...

  • Page 322

    Steering Page 52 of 99 48-52 - Install gauge and set to "O" with approx. 1 mm pre-load (make sure that the key does not stick, front of key must not be crowned) 1 - 3315/8 2 - 3315/9 3 - 3315/1 4 - VW 387 - Screw right rod onto toothed rod and tighten by hand...

  • Page 323

    Steering Page 53 of 99 48-53 Needle run-out max. 0.10 mm If needle run-out is greater than 0.10 mm, screw pressure piece slightly into housing If the needle run-out is less than 0.10 mm, screw pressure piece slightly out of housing - Tighten lock nut - Check needle run-out again, if necessary repeat adjustment...

  • Page 324

    Steering Page 54 of 99 48-54 Assembly overview: power steering gear (ZF) It is not intended that repair work be carried out on the power steering gear. If complaints are received determine cause with the help of pressure tests, leakage test and troubleshooting programs.

  • Page 325

    Steering Page 55 of 99 48-55 1 - Power steering gear Removing and installing Page 48- Adjusting Page 48- Checking steering moment Steering gear with reduced steering moment only permissible for vehicles up to 85 kW Steering moment on 16 V and VR 6 vehicles is approx.

  • Page 326

    Steering Page 56 of 99 48-56 3 - Boot Remove ball joint before removing Check for wear (cuts, cracks), ensure sealing surfaces and sealing lips are clean and undamaged The end diameters are larger than the boot for TRW power steering gears Must not be installed on TRW power...

  • Page 327

    Steering Page 57 of 99 48-57 5 - Right-hand tie rod Removing and installing Page 48- 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 328

    Steering Page 58 of 99 48-58 7 - Lock nut, 50 Nm (37 ft 8 - Tie rod ball joint Splitting Page 48-16 Checking: Repair Manual, Maintenance 9 - Pressure balance pipe 10 - 30 Nm (22 ft lb) 11 - Clamp 12 - Rubber mounting Internal diameter ZF: 50 mm TRW: 44 mm...

  • Page 329

    Steering Page 59 of 99 48-59 Power steering gear, adjusting (ZF) Note: Two mechanics are required when adjusting. Adjust with engine switched off. - Raise vehicle on hoist. - Wheels in straight-ahead position. - By turning the steering wheel to and fro (about 30 to center axis) a knocking noise will be heard if there is excessive play.

  • Page 330

    Steering Page 60 of 99 48-60 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.

  • Page 331

    Steering Page 61 of 99 48-61 Power steering gear, disassembling - Tie rods, removing - see tie rod, removing and installing (TRW and ZF power steering), Page 48-34 - Close hose connections on power steering gear if not already done 1 - Plastic locking screw 2 - Plastic locking screw - Clean outside of power steering gear...

  • Page 332

    Steering Page 62 of 99 48-62 Note: Do not change position of the adjusting screw (arrow) Cover is stressed with slight spring pressure - Remove pressure piece 1 - Spreading pliers (standard commercial) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1 12/7/2004...

  • Page 333

    Steering Page 63 of 99 48-63 - Remove lower locking screw for valve body 1 - Locking screw - Remove 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") http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1 12/7/2004...

  • Page 334

    Steering Page 64 of 99 48-64 - Remove circlip for valve body with needle nose pliers 1 - Drive valve body out from below 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 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1...

  • Page 335

    Steering Page 65 of 99 48-65 - First lift circlip with slotted screwdriver then pull out with pliers - Before removing toothed rod, clean housing opening with compressed air - Remove dirt and any chips that may be present - Pull toothed rod out of the housing to the right with toothed rod guide A - Screwdriver B - Pliers (standard commercial)

  • Page 336

    Steering Page 66 of 99 48-66 For easier installation of the puller, it is recommended that a rubber band be placed around the jaws. Illustration shows the housing in cross section for better view. 1 - Puller e.g. Kukko 21/4 2 - Rubber band 3 - Sealing ring 4 - Housing...

  • Page 337

    Steering Page 67 of 99 48-67 For easier installation of the puller, it is recommended that a rubber band be placed around the jaws. Illustration shows the housing in cross section for better view. 1 - Puller, e.g. Kukko 21/4 2 - Rubber band 3 - Roller bearing 4 - Housing...

  • Page 338

    Steering Page 68 of 99 48-68 Parts, cleaning and checking - Before assembly, the housing must be checked for contamination (paint residue, chips, dirt) and clean thoroughly 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

    Steering Page 69 of 99 48-69 Checking toothed rod for scoring If corroded areas or deep scratches are noticeable on the toothed rod, the toothed rod must be replaced An evaluation of whether the toothed rod was damaged by force, e.g. by an accident, is not possible with this visual inspection - Sand toothed rod with sand paper in radial direction (this is only possible with slight scoring)

  • Page 340

    Steering Page 70 of 99 48-70 Sealing ring on toothed rod, replacing When the sealing rod is replaced it must be replaced with a new one of the same color - Press pliers together with slight pressure on the sealing ring - Pry out sealing ring and O-ring A - Needle nose pliers (standard commercial) Note the matching of the O-ring to the sealing ring...

  • Page 341

    Steering Page 71 of 99 48-71 Power steering gear, assembling Note: Lubricate the sealing rings with hydraulic oil before installing - Note correct installation position of the sealing ring The sealing lip (arrow) of the sealing ring points upward toward the teeth 1 on the valve body For better viewing, the illustration shows the body housing in cross section with installed valve body.

  • Page 342

    Steering Page 72 of 99 48-72 - Place support ring -1- and sealing ring -2- on tool - Drive sealing ring for toothed rod into housing to stop When the groove -arrow- matches the edge -arrow - A- of the housing, the sealing ring is properly seated. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1 12/7/2004...

  • Page 343

    Steering Page 73 of 99 48-73 Toothed rod, installing in the housing - Grease teeth of toothed rod with AOF 063 000 04 grease - Slide protective tube over toothed rod to stop - Wipe away excess grease completely No grease must get into the oil circulation system! - Coat piston of toothed rod and protective tube with hydraulic oil - Install installation sleeve 3315/21 into the housing...

  • Page 344

    Steering Page 74 of 99 48-74 - Align teeth of toothed rod in such a way that they point toward the teeth of the pinion - Screw mounting sleeve 3315/16 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 housing if not done yet...

  • Page 345

    Steering Page 75 of 99 48-75 - Thread assembly mandrel 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). Make sure that the sealing ring in the housing is not damaged by the teeth of the pinion.

  • Page 346

    Steering Page 76 of 99 48-76 - Carefully slide bushing with roller bearing onto the valve body. - Drive bushing into the housing far enough so that the groove for the circlip is visible. - Install circlip. - Remove adhesive tape. - Remove installation mandrel 3315/17.

  • Page 347

    Steering Page 77 of 99 48-77 Tie rods, removing and installing (power steering gear - TRW and ZF) Note: Observe how tie rods are threaded into power steering gear: - Tie rods not secured with locking fluid - Tie rods secured with locking fluid When exchanging secured version tie rods use locking fluid D6 when installing.

  • Page 348

    Steering Page 78 of 99 48-78 - Open hose clips and push boot back. - Clamp steering gear with rack in a vice. Note: Use vice clamps, check vice clamps for impurities e.g. metal filings or similar and thoroughly remove. - Remove tie rod.

  • Page 349

    Steering Page 79 of 99 48-79 - Clean threaded stud or tie rod with M 14 x 1.5 tap or wire brush. - Check if joint stud threads are deformed replace if necessary. Note: Do not tilt tap when positioning. If it is difficult to turn the tap onto the thread or if metal swarf forms, this indicates the thread is deformed.

  • Page 350

    Steering Page 80 of 99 48-80 Installing - Adjust new tie rod to length Page 48-84 - Coat tapped hole thread with D6 locking fluid (arrow). 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.

  • Page 351

    Steering Page 81 of 99 48-81 Boot, installing - Check boot for wear (cuts, cracks) and ensure sealing surfaces are clean. - Install boot, but first turn the tie rod so that the tie rod ball joint shank is in the installation position. - Install pressure balance line.

  • Page 352

    Steering Page 82 of 99 48-82 1 - Hose clamp 2 - Pressure compensating tube 3 - Boot 4 - Approx. 90 - Tension hose clamps with pliers VAG 1275 or equivalent. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1 12/7/2004...

  • Page 353

    Steering Page 83 of 99 48-83 Note: The boot must not be installed twisted. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1 12/7/2004...

  • Page 354

    Steering Page 84 of 99 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.

  • Page 355

    Steering Page 85 of 99 48-85 Assembly overview: vane pump, reservoir and hydraulic lines (vehicles with 4-Cyl. engines) It is not intended that repair work be carried out on the vane pump. If complaints are received determine cause with the help of pressure and leakage tests.

  • Page 356

    Steering Page 86 of 99 48-86 1 - Cooling line Secured to crossmember item 2 - Bracket Various versions depending on engine/transmission Page 48-96 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...

  • Page 357

    Steering Page 87 of 99 48-87 9 - Pressure line union 10 - Banjo bolt, 35 Nm (26 ft 11 - Hex bolt, 10 Nm (7 ft lb) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1 12/7/2004...

  • Page 358

    Steering Page 88 of 99 48-88 Assembly overview: Hydraulic lines, reservoir (vehicles with 4-Cyl. engines) Notes Page 48-85 1 - Power steering 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...

  • Page 359

    Steering Page 89 of 99 48-89 11 - Self-tapping screw 12 - Hose clamp 13 - Return hose 14 - Suction hose Reservoir - Cooling line 15 - Cooling line 16 - Threaded stud 17 - Bracket http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1 12/7/2004...

  • Page 360

    Steering Page 90 of 99 48-90 Power steering vane pump, removing and installing (vehicles with 4- Cyl. engines) Note: Always replace self-locking nuts and bolts. Pumps supplied as spare parts are not filled with hydraulic oil. Fill the pump with G 002 000 hydraulic oil and rotate it by hand, otherwise the pump may be damaged or noisy during...

  • Page 361

    Steering Page 91 of 99 48-91 5 - 20 Nm(15 ft Ib) 6 - Front swivel bracket 7 - 20 Nm (15 ft lb) 8 - Adjustment bracket 9 - 20 Nm (15 ft lb) 10 - Bracket 11 - V-belts 11.5 x 685 Gas engine 11.5 x 730 Diesel engine...

  • Page 362

    Steering Page 92 of 99 48-92 13 - V-belt pulley When installing the V- belt pulley ensure that the crankshaft pulley and the vane 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...

  • Page 363

    Steering Page 93 of 99 48-93 V-belts, tensioning (4-Cyl. engines) - Tension V-belts by turning adjustment bolt with torque wrench -A- (VAG 1410 and VAG 1410/2). Specification: Used belts, 4 Nm (35 in. Ib) New belts, 7 Nm (62 in. Ib) - Tighten adjustment clamping bolt -3- to 25 Nm (18 ft lb).

  • Page 364

    Steering Page 94 of 99 48-94 Assembly overview: Pressure and cooling lines (vehicles with VR6 engine) Note: Securing of pressure line varies according to type of transmission Fig. 1 Fig. 2 1 - Reservoir 2 - Suction hose Reservoir - Cooling line 3 - Cooling line Secured to...

  • Page 365

    Steering Page 95 of 99 48-95 7 - Hydraulic pump 8 - Seal Always replace 9 - Pressure line union 10 - Banjo bolt, 35 Nm (26 ft 11 - Hex bolt, 10 Nm (7 ft lb) 12 - Hose clamp, 3 Nm (27 in.

  • Page 366

    Steering Page 96 of 99 48-96 Fig. 1 Pressure hose, securing (vehicles with manual transmission) Fig. 2 Pressure hose, securing (vehicles with automatic transmission) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1 12/7/2004...

  • Page 367

    Steering Page 97 of 99 48-97 Power steering vane pump, removing and installing (vehicles with VR6 engine] Note: Always replace seals. Do not reuse drained hydraulic oil. Pumps supplied as spare parts are 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...

  • Page 368

    Steering Page 98 of 99 48-98 3 - Pressure hose Attachment varies according to type of transmission Page 48-96 4 - Seal 5 - Banjo bolt, 30 Nm (22 ft 6 - Vane pump Checking delivery pressure Page 48- 7 - Ribbed belts Removing Repair Manual, Engine Mechanics;...

  • Page 369

    Steering Page 99 of 99 48-99 9 - Hex socket head bolt, 25 Nm (18 ft lb) 10 - Hex bolt, M8 x 30, 25 Nm (18 ft lb) 11 - Hex socket head bolt, M8 x 30, 25 Nm (18 ft 12 - Hex socket head bolt, M8 x 20, 25 Nm (18 ft 13 - Hex socket head bolt,...

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