1996 VOLKSWAGEN PASSAT hose

Downloaded from www.Manualslib.com manuals search engine 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.
Inner sealing ring for toothed rod, removing 1 - Puller, e.g. Kukko 21/4 2 - Rubber band 3 - Roller bearing 4 - Housing - Remove sealing ring for toothed rod from the
housing
- Disconnect hose line from valve body housing to
cylinder line
- Clean hose line, housing. Check threaded
connection for contamination (rubber residue,
chips) Page 67 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 48-78

- 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 48-81

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 48-86

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

Downloaded from www.Manualslib.com manuals search engine 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
7 - Hose clamp
8 - Rubber insert
9 - Captive nut
10 - Bracket Page 88 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 48-89

11 - Self-tapping screw
12 - Hose clamp
13 - Return hose
14 - Suction hose Reservoir - Cooling
line
15 - Cooling line
16 - Threaded stud
17 - Bracket Page 89 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