1997 VOLKSWAGEN PASSAT Gear

Downloaded from www.Manualslib.com manuals search engine 48-78

- Open hose clips and push boot back. Note:
Use vice clamps, check vice clamps for impurities
e.g. metal filings or similar and thoroughly remove.
Installing
Installing tie rod without locking fluid D6.
Install in reverse order. Tightening torque: 70 Nm (52
ft lb)
Installing tie rods with locking fluid D6
If parts are reused, it is essential to clean any residue
of locking fluid off the threaded studs of the inner joint
or the thread tapped hole as described below.
Otherwise there is a danger of the thread being
damaged when being reinstalled or removed. - Clamp steering gear with rack in a vice. - Remove tie rod. Page 78 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 48-81

Boot, installing Note: - Check boot for wear (cuts, cracks) and ensure
sealing surfaces are clean.
- Install boot, but first turn the tie rod so that the tie
rod ball joint shank is in the installation position.
- Install pressure balance line. Do not damage sticker -A- when pushing the boot
on (only on TRW power steering gears). Make sure that the boot and the pressure balance
line are installed correctly. During assembly of the boot ensure that the bead -
arrows- contacts the housing. Only use genuine hose clips -B- 1 - Boot 2 - Housing Page 81 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 48-88

Assembly overview:
Hydraulic lines, reservoir
(vehicles with 4-Cyl.
engines)
Notes Page 48-85 1 - Power steering gear
2 - O-ring Always replace 3 - Return line, 30 Nm (22
ft lb)
4 - Pressure line, 30 Nm
(22 ft lb)
5 - Reservoir
6 - Rubber ring
7 - Hose clamp
8 - Rubber insert
9 - Captive nut
10 - Bracket Page 88 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 48-95

7 - Hydraulic pump
8 - Seal Always replace 9 - Pressure line union
10 - Banjo bolt, 35 Nm (26 ft lb)
11 - Hex bolt, 10 Nm (7 ft lb) 12 - Hose clamp, 3 Nm (27
in. Ib)
13 - Return line Power steering gear -
Reservoir Page 95 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1