1997 VOLKSWAGEN PASSAT AIR

Downloaded from www.Manualslib.com manuals search engine 48-48
Make sure that the sealing ring in the housing is not
damaged by the teeth of the pinion - Screw assembly mandrel 3315/17 on valve body - Lubricate valve body with hydraulic oil and
carefully install by hand into the valve body
housing (note position of toothed rod) - Tape teeth of valve body with adhesive tape to
protect the sealing ring. Avoid wrinkles.
- Install upper roller bearing for valve body
(inscription on roller bearing points upward)
A - Adhesive tape B - Valve body Page 48 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 48-49
- Drive sealing ring in far enough sot that the groove for circlip in the housing is visible
- Install circlip - Remove adhesive tape - Remove assembly mandrel 3315/17 - Install hex nut for valve body and tighten, 30 Nm
(22 ft lb) with torque wrench SW 14 2 Note: - Install locking screw - Grease pressure piece and spring in housing in old position
- Install lock nut together with adjusting screw After tightening, the marking made during removal (arrow) on the adjusting nut and lock nut must
match If the toothed rod was replaced, before installing
the tie rods the steering gear must be readjusted Page 49 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 48-50

Adhesive tape, applying - Fill slot with sealing compound AKL 450 005 05 - Tape slot with adhesive tape 1 - Adhesive surface must be dry and free from
grease Page 50 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 48-51

Power steering gear, adjusting with new
toothed rod If a new toothed rod was used, the steering play
should be adjusted according to the following
description.
- Drill a hole 5.1 mm in diameter in the center of the
adjusting screw (on the back side center)
- Thoroughly clean adjusting screw - Place toothed rod in center position (measure
toothed rod excess right and left)
- Install pressure piece and spring in housing if not
done yet
- Screw adjusting screw and lock nut far enough into the housing so that the markings match Page 51 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 48-52
- Install gauge and set to "O" with approx. 1 mm
pre-load (make sure that the key does not stick,
front of key must not be crowned)
1 - 3315/8 2 - 3315/9 3 - 3315/1 4 - VW 387 - Screw right rod onto toothed rod and tighten by
hand
- Turn toothed rod radially from stop to stop, during
this process observe pointer on gauge. Page 52 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

Downloaded from www.Manualslib.com manuals search engine 48-54

Assembly overview: power steering
gear (ZF)
It is not intended that repair work be carried out
on the power steering gear. If complaints are
received determine cause with the help of
pressure tests, leakage test and troubleshooting
programs. If a malfunction exists replace the
power steering gear.

Note:
Always replace self-locking nuts and bolts. Welding and straightening work on steering
components is not permitted.
To grease the rack use only steering gear
grease, Part No. AOF 063 000 04.
Type of oil: Hydraulic oil G 002 000 Oil system capacity: 0.7 - 0.9 Itr. (0.74 - 0.95
qt)
Supply and pressure line routing Page 48-85 . Page 54 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 48-55

1 - Power steering gear Removing and
installing Page 48-15 Adjusting Page 48-59 Checking steering
moment Steering gear with
reduced steering
moment only
permissible for
vehicles up to 85 kW Steering moment on
16 V and VR 6
vehicles is approx. 2
Nm higher
2 - Hose clip Always replace- use
pliers to open Tensioning Page 48-81 Page 55 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1