1997 VOLKSWAGEN PASSAT suspension

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Fig. 1 Front control arm mounting, pressing
out Note:
Before pressing in, coat with acid-free lubricant, e.g.
soft soap. Fig. 2 Front control arm mounting, pressing in Page 7 of 82Front Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1

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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. 3 Control arm rear mounting, installation
position Note:
If bonded rubber bushing is tight because of
corrosion, cut rubber out, saw through steel casing
and drive bushing out. Fig. 4 Control arm rear mounting, pressing
out and in Page 8 of 82Front Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1

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Fig. 5 Supporting engine/transmission
assembly with 10-222 A and legs 10-222
A/1 Page 9 of 82Front Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1

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Ball joint, checking (Base and Plus
suspension)

Checking axial clearance Checking radial play - Forcibly pull ball joint down and press up again. Note: - Press lower part of wheel outward and inward. There must be no perceptible or visual "play"
during either test. Observe ball joint during checks. Take into account possible existing wheel bearing
play or "play" in upper suspension strut mounting. Page 10 of 82Front Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1

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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.
When drilling out proceed as follows.

- Support engine/transmission assembly with 10-
222 A and legs 10-222 A/1.

- Remove the sub-frame.
- Drill out the damaged side member cap nut with
a 10.2 mm diameter drill from underneath.

Note:
When drilling do not tilt the drill.

WARNING!

Wear protective goggles.

- Cut new M 12 x 1.5 thread in cap nut.
- Use a new bolt/washer assembly to secure sub-
frame Page 40-13 . Page 11 of 82Front Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1

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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 1)

Rear sub-frame M12 x 1.5 M12 x 1.5 x 95 10.9 N 101 612.01
Sub-frame bracket M10 M10 x 38 10.9 N 019 541.1
Engine front cross-member to side member M10 M10 x 75 10.9
N 904 078.01 1)
1)
These bolts are not listed in the parts catalog. They must be specially ordered. Page 12 of 82Front Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1

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Note: Tightening torque remains unchanged.
1 - Bolt/washer 2 - Cap nut 3 - Side member 4 - Sub-frame 5 - Bonded rubber mounting/control arm Page 13 of 82Front Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1

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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
damaged. Welding and straightening
operations are not
permitted on load bearing
suspension components or
those components which
locate the wheels. Always replace self-locking
nuts. Always replace corroded
nuts/bolts. Wheel bolt tightening
torque: 110 Nm (81 ft lb). Page 14 of 82Front Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1