1995 VOLKSWAGEN PASSAT steering

Downloaded from www.Manualslib.com manuals search engine 48-78

- Open hose clips and push boot back. Note:
Use vice clamps, check vice clamps for impurities
e.g. metal filings or similar and thoroughly remove.
Installing
Installing tie rod without locking fluid D6.
Install in reverse order. Tightening torque: 70 Nm (52
ft lb)
Installing tie rods with locking fluid D6
If parts are reused, it is essential to clean any residue
of locking fluid off the threaded studs of the inner joint
or the thread tapped hole as described below.
Otherwise there is a danger of the thread being
damaged when being reinstalled or removed. - Clamp steering gear with rack in a vice. - Remove tie rod. Page 78 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

Downloaded from www.Manualslib.com manuals search engine 48-80

Installing Note:
Apply one drop only in 2nd thread of rack. If too much
D6 is used the release torque when next
disassembling will be too high. No D6 must get onto
steering rack. - Adjust new tie rod to length Page 48-84 . - Coat tapped hole thread with D6 locking fluid
(arrow).
- Tighten tie rod to the specified torque, 70 Nm (52 ft lb). Always use a torque wrench. Page 80 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

Downloaded from www.Manualslib.com manuals search engine 48-81

Boot, installing Note: - 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. Do not damage sticker -A- when pushing the boot
on (only on TRW power steering gears). Make sure that the boot and the pressure balance
line are installed correctly. During assembly of the boot ensure that the bead -
arrows- contacts the housing. Only use genuine hose clips -B- 1 - Boot 2 - Housing Page 81 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

Downloaded from www.Manualslib.com manuals search engine 48-82
1 - Hose clamp 2 - Pressure compensating tube 3 - Boot 4 - Approx. 90 - Tension hose clamps with pliers VAG 1275 or
equivalent. Page 82 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

Downloaded from www.Manualslib.com manuals search engine 48-83

Note: The boot must not be installed twisted. Page 83 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

Downloaded from www.Manualslib.com manuals search engine 48-84

Left-hand tie rod length, checking and
adjusting

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

Downloaded from www.Manualslib.com manuals search engine 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. Replace pump if faulty.

Note:
Pumps supplied as spare parts are not filled
with oil. Fill the pump with G 002 000 hydraulic
oil to rotate it by hand, otherwise the pump may
be damaged or noisy during operation.
Type of oil: hydraulic oil G 002 000 Oil system capacity: 0.7 - 0.9 Itr. (0.74 - 0.95
qt.)
Do not reuse drained hydraulic oil. Always replace O-rings. Page 85 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

Downloaded from www.Manualslib.com manuals search engine 48-86

1 - Cooling line Secured to
crossmember item
9 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 7 - Hydraulic pump With ribbed belt
sprocket
8 - O-ring Always replace Page 86 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1