1997 VOLKSWAGEN PASSAT Gasket

Downloaded from www.Manualslib.com manuals search engine 40-47

1 - Circlip Always replace Remove and install
with VW161 a
2 - Gasket Always replace. Pull
off protective foil and
stick onto joint. (Only
on 100 mm diameter
constant velocity joints
3 - Inner constant velocity
joint 100 mm diameter Only replace complete Pressing off Fig. 3 Pressing on Fig. 4 Greasing Notes
Page 40-46 Checking Page 40-62 4 - Dished washer Inner diameter splined Installation position:
outer diameter
(concave side)
contacts constant
velocity joint Page 47 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

Downloaded from www.Manualslib.com manuals search engine 40-78
1 - Triple-rotor joint housing
2 - Triple-rotor star
3 - Axle shaft
Note:
CAUTION!
Do not let the rollers slide off the triple-rotor star
and fall to the floor. - Remove O-ring -arrow- from groove. - Mark installation positions of parts -1-, -2- and -3-. Noises while driving may result if the indicated
parts are not reassembled to their prior positions. Use a waterproof felt-tipped pen for marking
parts.
- Remove rubber gasket (arrow) from groove. - With triple-rotor joint housing clamped in vise, pull
axle shaft together with triple-rotor star upward out
of housing.
- Hold axle shaft in straight alignment to triple-rotor
joint and slowly push back triple-rotor joint housing
with other hand. - Mark installation position of rollers -1- on triple-
rotor star -2- using felt-tipped marker. Page 78 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

Downloaded from www.Manualslib.com manuals search engine 42-9

Suspension strut,
disassembling and
assembling (front wheel
drive vehicles)
1 - Cap Pry out with
screwdriver Pressing on Fig. 4 2 - O-ring
3 - Self-locking hex nut, 25 Nm (18 ft lb)
4 - Dished washer
5 - Upper rubber mounting 6 - Gasket (foam) Always replace Page 9 of 14Rear Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.1

Downloaded from www.Manualslib.com manuals search engine 42-10

7 - Suspension strut
bearing Always replace foam
gasket Welded nuts must be
located in the spring
seat recesses Align welded nuts and
cap to shock absorber
lower bushing Fig. 3 8 - Spacer tube
9 - Lower rubber
mounting
10 - Metal cap Higher on Wagon than
Sedan
11 - Washer
12 - Spring seat Thinner on Wagon
than Sedan Installation position
Fig. 2 Page 10 of 14Rear Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.1

Downloaded from www.Manualslib.com manuals search engine 42-53

Suspension strut,
disassembling and
assembling (four
wheel drive
vehicles)
1 - Cap Pry out with
screwdriver Pressing on Fig. 5 Installation position
Fig. 5 2 - Seal
3 - Self locking hex nut, 30 Nm (22 ft lb) Always replace 4 - Dished washer
5 - Upper rubber mounting 6 - Gasket (foam) Always replace Page 1 of 6Suspension strut, disassembling and assembling (four wheel drive vehicles)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.5

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