1996 VOLKSWAGEN PASSAT oil type

Downloaded from www.Manualslib.com manuals search engine 48-48
Make sure that the sealing ring in the housing is not
damaged by the teeth of the pinion - 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) - Tape teeth of valve body with adhesive tape to
protect the sealing ring. Avoid wrinkles.
- Install upper roller bearing for valve body
(inscription on roller bearing points upward)
A - Adhesive tape B - Valve body Page 48 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 48-54

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. If a malfunction exists replace the
power steering gear.

Note:
Always replace self-locking nuts and bolts. Welding and straightening work on steering
components is not permitted.
To grease the rack use only steering gear
grease, Part No. AOF 063 000 04.
Type of oil: Hydraulic oil G 002 000 Oil system capacity: 0.7 - 0.9 Itr. (0.74 - 0.95
qt)
Supply and pressure line routing Page 48-85 . Page 54 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 48-71

Power steering gear, assembling

Note: 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.
The valve body is shown slightly raised for better
viewing
Inner sealing rod for toothed rod, installing Lubricate the sealing rings with hydraulic oil
before installing
- Note correct installation position of the sealing ring - Place sealing ring for valve body on the tool and
drive in to stop. For installation position, see next
illustration
- Drive center roller bearing for valve body into stop The sealing lip (arrow) of sealing ring -3- points
toward cylinder -4-.
For better illustration, the drawing shows the housing
in cross section. 1 - Valve body 2 - Support ring 3 - Sealing ring 4 - Cylinder Page 71 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 48-73
Toothed rod, installing in the housing
No grease must get into the oil circulation system! - Grease teeth of toothed rod with AOF 063 000 04
grease
- Slide protective tube over toothed rod to stop - Wipe away excess grease completely When sliding, make sure that the sealing ring is
pressed into the groove of the piston without
jamming - Coat piston of toothed rod and protective tube with
hydraulic oil
- Install installation sleeve 3315/21 into the housing - Slide toothed rod into the housing - Slowly introduce the toothed rod into the housing - Pull protective tube 3315/5 off the toothed rod Page 73 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 48-75
Make sure that the sealing ring in the housing is not
damaged by the teeth of the pinion. - 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). - Tape the valve body with adhesive tape. Page 75 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 48-90

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
operation. Do not reuse drained
hydraulic oil.
1 - Suction hose
2 - Pressure hose
3 - Hose clamp
4 - Tensioning bolt Tensioning V-belts
item 11 Page 90 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 48-97

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
noisy during operation.
1 - Suction hose A cooling line is installed between vane pump suction hose
and reservoir
2 - Hose clamp Page 97 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1