1997 VOLKSWAGEN PASSAT light

Downloaded from www.Manualslib.com manuals search engine 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. 2 10 - Piston Force piston out of
brake caliper using
compressed air Fig. 1 Installing Fig. 3 and
Fig. 4 and Fig. 5 First coat the piston
lightly with brake
cylinder paste. Piston diameter 54
mm
11 - Protective seal Do not damage when
installing piston Page 2 of 5Front brake caliper, servicing (Teves/Ate)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.3

Downloaded from www.Manualslib.com manuals search engine 48-8

Airbag steering wheel, removing and
installing

Removing

- Remove airbag unit. Page 48-7
- Remove trim below steering column switch. Note: - Separate connector (arrow). (Pull foam rubber
sleeve off connector, if installed).
- Remove nut and pull steering wheel off steering
column. After pulling steering wheel off, turn Airbag Spiral
Spring slightly so that the wire (arrow) faces
downward. (Hold steering wheel in installation
position). The spring then locates and is prevented
from turning.
If this step is not performed or if the spring is tufted in
an uncontrolled manner, it can lead to the spring
being overstressed at full lock, causing irreparable
damage. Page 8 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 48-33

- Mark position of adjusting screw and lock nut to
the housing (arrow) Note: - Screw lock nut together with adjusting screw 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
stressed with slight spring pressure
1 - Ratchet (standard commercial) 2 - Adjusting screw Page 33 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 48-40

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
be ground off with sand paper (grain 350-600) the
toothed rod can still be used After sanding, lubricate toothed rod lightly
If the old toothed rod is used again, check the sealing
ring for scoring (visual inspection). If there is scoring
that can be seen or felt, the sealing ring and the O-
ring under it must be replaced. - Sand toothed rod with sandpaper in radial direction (this is only possible with slight scoring)
- Check chamfer on the front sides of the toothed
rod for damage, if necessary remove with a fine
grinding stone and/or sandpaper
1 - Toothed rod 2 - Sand paper (grain 350-600) 3 - Jaw covers Page 40 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 48-41

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 Page 41 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 48-53
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

- Remove gauge Close hole in adjusting screw with a stopper from
repair kit
Tie rods, installing - First install clip -2- with gasket -1- in the hole - Apply 1 drop sealing compound, Part No. AMV
188 001 02, in the hole of the clip -arrow- and
press plug -3- into the clip
- See tie rods, removing and installing (TRW and ZF steering gear), Page 48-77 Page 53 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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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) Page 62 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 48-69

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
After sanding, lubricate toothed rod lightly
If the old toothed rod is used again, check the sealing
ring for scoring (visual inspection). If there is scoring
that can be seen or felt, the sealing ring and the O-
ring under it must be replaced. - Sand toothed rod with sand paper in radial
direction (this is only possible with slight scoring)
- Check chamfer on the front sides of the toothed
rod for damage, if necessary remove with fine
grinding stone and/or sandpaper
1 - Toothed rod 2 - Sand paper (grain 350-600) Page 69 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1