1997 VOLKSWAGEN PASSAT AIR

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

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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

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Sealing rings, installing on toothed rod
piston - Slide mounting sleeve on toothed rod - Pull O-ring over tool and install in groove of piston - Lubricate sealing ring with hydraulic oil, pull over
tool and install in groove of piston Page 42 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 48-43

Power steering gear, assembling

Note;
All sealing rings should be lubricated with
hydraulic oil before installing. - Check whether the valve body housing -2- is
absolutely clean on the inside, otherwise clean
- Place sealing ring -1- on tool. The sealing lip -
arrow- points toward tool
- Drive sealing ring into stop 1 - Sealing ring 2 - Valve body housing - Make sure correct installation position of sealing
ring in valve body
- For better view, illustration shows valve tower in
cross section Page 43 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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Inner sealing ring for toothed rod,
installing

- Place sealing ring on tool - Ensure correct installation position of sealing ring
for toothed rod
- Drive sealing ring -1- into the cylinder pipe far
enough so that the groove (arrow) on the tool
matches the edge (arrow A) of the housing
1 - Sealing ring A - Edge of housing For better view, illustration shows housing in cross
section
1 - Support ring 2 - Sealing ring 3 - Valve body housing Page 44 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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Toothed rod, installing in housing No grease must get into the oil circulation system! - Grease teeth of toothed rod with AOF 063 000 04
grease
- Slide protective tube on to toothed rod to stop - Wipe excess grease off completely Page 45 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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- Coat piston of toothed rod and protective tube
with hydraulic oil When sliding, make sure that the sealing ring is
pressed into the groove of the piston without
jamming - Install installation sleeve 3315/22 into the housing - Slide toothed rod into the housing - Slowly introduce the toothed rod into the housing - Pull protective tube 3315/13 off the toothed rod Align teeth of toothed rod in such a way that they
point toward the teeth of the pinion
- Screw mounting sleeve 3315/18 on toothed rod
and coat with hydraulic oil
- Carefully slide toothed rod guide 1 over the
toothed rod into the housing to stop
- Slide toothed rod completely into the housing. Page 46 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 48-47
- Place lock washer in the housing and press in far
enough until the groove in the lock washer in the
slot of the housing is visible
- Install new safety wire in the hole of the lock
washer (arrow)
- Pull safety wire in by turning the lock washer. (after pulling in, turn the lock washer approx. 1/2
revolution further)
1 - Safety wire in repair kit is not formed as a ring,
but supplied as a straight wire
2 - Pliers (standard commercial) Valve body, installing
Ball bearing must not be tipped when driving in - Carefully drive lower ball bearing for valve body
into stop Page 47 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1