1997 VOLKSWAGEN PASSAT engine

Downloaded from www.Manualslib.com manuals search engine 48-35
If very tightly seated, loosen locking screw with a
hammer and driver - Remove lower locking screw for valve body 1 - Ratchet (standard commercial) - Remove hex nut below valve body 1 - Ratchet (standard commercial) 2 - Open-end wrench (standard commercial) - Drive valve body upward from below with driver - Remove grease from teeth of valve body Page 35 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 48-36

- Pull adhesive tape out of the housing Valve body sealing ring, removing - Pull toothed rod all the way to the left - Turn lock washer so that the opening of the circlip
(arrow) is in the groove of the housing
- Continue to turn the lock washer (direction of
rotation left or right) so that the circlip turns out of
the housing
- Pull toothed rod with toothed rod guide out of the
housing, pull off toothed rod guide and place
toothed rod so that toothed rod piston sealing ring
will not be damaged
1 - Needle nose pliers (standard commercial) - Lubricate toothed rod - Drive sealing ring upward A - Puller, e.g. Kukko 21/4 B - Driver When installing the puller -A- make sure that the
claws (arrow on illustration page 13) engage
properly under the sealing ring. The puller must not
be spread too wide because otherwise the seat for
the sealing ring and housing will be damaged or the
sealing ring can jam in the housing. Page 36 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 48-37
For easier installation of the puller, it is recommended
that a rubber band be placed around the claws.
Illustration shows the housing in cross section for
better view
1 - Puller, e.g. Kukko 21/4 2 - Rubber band 3 - Sealing ring 4 - Glide bearing do not remove Page 37 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 48-38

Inner sealing ring for toothed rod,
pulling out

- Install puller for sealing ring far enough so that
the marking on the tool (arrow) matches the
housing edge (only then will the claws engage
behind the support ring)

- Spread claws -2- of the tool by turning the
spindle forcefully

Note: When introducing the tool, make sure that the
cylinder race is not damaged
1 - Support ring 2 - Claws 3 - Sealing ring 4 - Tool 3315/11 Page 38 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 48-39
Parts, cleaning and checking - Install tool VW 771 in the puller - Pull out sealing ring - Before assembly, the housing must be checked for contamination (paint residue, chips, dirt) and
thoroughly cleaned with compressed air and
alcohol
- Clean adhesive surface for adhesive tape in area
of the slot with solvent (e.g. L160 or alcohol)
- Check cylinder race for scoring or other damage. If scoring can be felt, replace entire steering gear
- Clean toothed rod (remove old grease in the tooth
pockets) Page 39 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

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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

Downloaded from www.Manualslib.com manuals search engine 48-42

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