Volkswagen Passat Operating instructions

Suspension, Wheels, Brakes, Steering
00 - General, Technical data
Suspension, Wheels, Brakes, Steering
Technical data
Steering
Brakes
Wheels, tires
40 - Front suspension
Front Wheel Suspension, Shafts and Axle
Front suspension, servicing (Base suspension)
Sub-frame, stabilizer bar and control arm (Base suspension)
Ball joint, checking (Base and Plus suspension)
Reworking cap nut in side member (Base and Plus suspension)
Wheel bearing, suspension strut and drive shaft, removing and installing (Base
running gear)
Front suspension strut, servicing (Base and Plus suspension)
Front suspension, servicing (Plus suspension)
Sub-frame, stabilizer bar and control arm, removing and installing (Plus
suspension)
Ball joint, removing and installing (Plus running gear)
Wheel bearing and suspension strut, removing and installing (Plus suspension)
Drive shaft, removing and installing (Plus running gear)
Drive shaft, repairing
Outer constant velocityjoint, checking
Inner constant velocityjoint, checking
Drive shaft with tripod joint, repairing
Drive axle with triple-rotor joint, removing and installing
Drive axle with triple-rotor joint, servicing
Triple-rotor joint, disassembling
Triple-rotor joint, assembling
42 - Rear suspension
Rear Wheel Suspension, Shafts and Axle
Rear axle, servicing (vehicles with front wheel drive)
Reworking cap nut in side member (front wheel drive vehicles)
Suspension strut, disassembling and assembling (front wheel drive vehicles)
Wheel bearings, servicing
Drum brakes (front wheel drive vehicles), wheel bearings, servicing
Wheel bearings, servicing - disc brakes (front wheel drive vehicles)

Rear axle, servicing (four wheel drive vehicles)
Rear drive shafts, servicing
Reworking cap nut in side member (four wheel drive vehicles)
Suspension strut, disassembling and assembling (four wheel drive
vehicles)
Wheel bearings, servicing - disc brakes (four wheel drive vehicles)
44 - Wheels, Tires, Wheel alignment
Vehicle alignment
Test requirements:
Vehicle alignment specifications (front wheel drive vehicles)
Vehicle alignment specifications (four wheel drive vehicles)
Front wheel camber, adjusting
Calculating the direction oftravel:
45 - Anti-lock brake system
Anti-locking Brake System (ABS) and Anti-locking Brake System with
Electronic Differential Lock (ABS/EDL) Teves 04
Notes for repair work on ABS, ABS/EDL
Control module, removing and installing
Wheel speed sensor and rotor for speed sensor, removing and installing
Anti-lock Brake System (ABS) and ABS with Electronic Differential Lock
(ABS/EDL), Teves 20 GI
Safetyprecautions
ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master
cylinder (Teves 20 GI), servicing
ABS hydraulic unit and ABS control module (Teves 20 GI), removing and
installing
Brake hydraulic system, bleeding and filling
Assemblyoverview- hydraulic unit, brake servo/brake master cylinder
Hydraulic unit, removing and installing
Brake Pedal Position Sensor, removing and installing
46 - Brakes - Mechanical components
Front brakes, servicing (Girling caliper)
Brake pads, removing and installing

Front brakes, servicing (Teves/Ate)
Brake pads, removing and installing
Rear wheel brakes, servicing (drum brakes)
Brake shoe adjustment, releasing
Rear wheel brakes, servicing
Brake shoes, removing and installing
Parking brake, adjusting (drum brakes)
Rear wheel brakes, servicing (disc brakes)
Girling rear wheel disc brakes (front and four wheel drive vehicles)
Brake pads, removing and installing
Parking brake, adjusting (disc brakes)
Parking brake lever assemblyoverview
Brake pedal/brake servo, removing and installing
Brake pedal, removing and installing
Brake Light Switch, adjusting
47 - Brakes - Hydraulic components
Assemblyoverview: brake master cylinder/brake servo
Girling front brake caliper, servicing
Front brake caliper pistons, removing and installing
Front brake caliper, servicing (Teves/Ate)
Rear brake caliper, servicing
Rear brake caliper piston, removing and installing
Pre-bleeding brake caliper
Brake pressure regulator, checking and adjusting
Vehicles without ABS, vehicles with ABS, ABS/EDS, Teves 04
Load dependent brake pressure regulator specifications
Adjusting regulator
Brake system, bleeding
Brake system, bleeding (vehicles with and without ABS, ABS/EDL)
Brake system, bleeding (with pressure bleeder VAS 5234)
Brake system, bleeding (without pressure bleeder)

48 - Steering
Steering
Assemblyoverview: steering column, column tube, steering wheel and airbag
steering wheel
Airbag unit, removing and installing
Airbag steering wheel, removing and installing
Airbag Spiral Spring, removing and installing
Column tube for height adjustable steering wheel, removing and installing
Pump deliverypressure, checking
Power steering gear, removing and installing
Assemblyoverview: power assisted steering box(TRW)
Power steering gear, adjusting (TRW)
Power steering gear, disassembling and reassembling (TRW)
Power steering gear, disassembling
Inner sealing ring for toothed rod, pulling out
Checking toothed rod for scoring
Sealing ring on toothed rod, replacing
Sealing rings, installing on toothed rod piston
Power steering gear, assembling
Inner sealing ring for toothed rod, installing
Toothed rod, installing in housing
Adhesive tape, applying
Power steering gear, adjusting with newtoothed rod
Assemblyoverview: power steering gear (ZF)
Power steering gear, adjusting (ZF)
Power steering gear, disassembling and reassembling (ZF)
Power steering gear, disassembling
Checking toothed rod for scoring
Sealing ring on toothed rod, replacing
Power steering gear, assembling
Tie rods, removing and installing (power steering gear - TRWand ZF)
Left-hand tie rod length, checking and adjusting
Assemblyoverview: vane pump, reservoir and hydraulic lines (vehicles with 4-
Cyl. engines)
Assemblyoverview: Hydraulic lines, reservoir (vehicles with 4-Cyl. engines)
Power steering vane pump, removing and installing (vehicles with 4-Cyl. engines)
V-belts, tensioning (4-Cyl. engines)
Assemblyoverview: Pressure and cooling lines (vehicles with VR6 engine)
Power steering vane pump, removing and installing (vehicles with VR6 engine]

00-1
Suspension, Wheels, Brakes, Steering
Technical data
Model Sedan/Wagon and syncro Base
Suspension 1) Sedan/Wagon and syncro Base Suspension 2)
Wheelbase mm 2625 2625
Track, unladen mm 1479 front, wheel offset 38
1422 rear, wheel offset 38
1485 front, wheel offset 35
1428 rear, wheel offset 35
1489 front, wheel offset 33 3)
1432 rear, wheel offset 3)
1485 front, wheel offset 35
1441 rear, wheel offset 35
1489 front, wheel offset 33 3)
1445 rear, wheel offset 33 3)
Turning circle m 10.7 11.5
Steering roll radius
(negative) mm 0.5 with offset 35
3.5 with offset 38
12 with offset 35
15 with offset 38
Wheel lock angle inner
outer
42
36
3745'
3430'
1) Base Suspension, explanation Page 40-1
2) Plus Suspension, explanation Page 40-26
3) Syncro
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00-2
Steering
Model Sedan/Wagon and syncro
Suspension version Base Suspension Plus Suspension
Steering gear Power assisted steering gear Power assisted steering gear
Steering wheel turns from lock to lock 3.33 3.14
Overall steering ratio 17.5:1 16.4:1
Wheel alignment specifications Page 44-2
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00-3
Brakes
Model Sedan/Wagon
Output kW (hp) 55 (75)
Brake master cylinder mm dia. 22.2 (Vehicles with ABS: 23.81)
Brake servo dia. in inches 10
Front brake caliper, piston diameter mm 54
Front brake disc mm dia. 256
Front brake disc, thickness mm 13
Pad thickness mm 14
Rear brake drum mm dia. 230
Wheel cylinder mm dia. 20.64
Lining thickness mm 5
Lining width mm 40
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00-4
Model Sedan/Wagon
Output kW (hp) 85 (115) 128 (172)
Brake master cylinder mm dia. 23.81
Brake servo dia. in inches 10
Front brake caliper dia. mm 54
Front brake disc mm dia. 256 288
Front brake thickness mm 20 13
Pad thickness mm 11 14
Rear brake caliper dia. mm 38
Rear brake disc mm dia. 226
Rear brake disc, thickness mm 10
Pad thickness mm 12
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00-5
Model Passat syncro
Output kW (hp) 85 (115) 128 (172)
Brake master cylinder mm dia. 23.81
Brake servo dia. in inches 10
Front brake caliper dia. mm 54
Front brake disc mm dia. 256 288
Front brake disc thickness mm 20 25
Pad thickness mm 11 14
Rear brake caliper dia. mm 38
Rear brake disc mm dia. 239
Rear brake disc, thickness mm 10
Pad thickness mm 12
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00-6
Wheels, tires
Engine output (kW) Model Tire size 1) Wheel Offset Hole pattern
55 gas
55, 66 - Diesel
Sedan/Wagon 185/65 R 14 86 S
195/60 R 14 86 S
205/50 R 15 86 S
185/65 R 14 85 Q (M+S)
195/60 R 14 85 Q (M+S)
205/50 R 15 85 Q (M+S)
6 J x 14
6 J x 14
6 J x 15
6 J x 14
6 J x 14
6 J x 15
38
38
38
38
38
38
4-hole
55 Sedan/Wagon T 125/70 R 15 95 M
(Temp. spare)
3 1/2J x 15 40
1) Tire pressures Sticker on vehicle
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00-7
Engine output (kW) Model Tire size 1) Wheel Offset Hole pattern
85 kW Sedan/Wagon 185/65 R 14 86 H
195/60 R 14 86 H
205/50 R 15 86 H
185/65 R 14 85 Q (M+S)
195/60 R 14 85 Q (M+S)
205/50 R 15 85 Q (M+S)
6 J x 14
6 J x 14
6 J x 15
6 J x 14
6 J x 14
6 J x 15
38
38
35
38
38
35
4-hole
85 kW Sedan/Wagon T 125/70 R 15 95 M
(Temp. spare)
3 1/2J x 15 40
128 kW Sedan/Wagon 205/50 ZR 15 86 W
195/55 R 15 85 T (M+S)
195/55 R 15 85 T (M+S)
205/50 R 15 85 T (M+S)
6 J x 15
6 J x 15
6 1/2J x 15
6 J x 15
35
35
33
35
128 kW Sedan/Wagon T 125/70 R 16 95 M
(Temp. spare)
3 1/2J x 16 38
1) Tire pressures Sticker on vehicle
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00-8
Engine output
(kW) Model Tire size 1) Wheel Offset Hole pattern
85 kW Sedan/Wagon
syncro 185/65 R 14 86 H
195/60 R 14 86 H
205/50 R 15 86 H
185/65 R 14 86 Q
(M+S)
195/60 R 14 86 Q
(M+S)
205/50 R 15 86 Q
(M+S)
6 J x 14
6 J x 14
6 J x 15
6 J x 14
6 J x 14
6 J x 15
38
38
35
38
38
35
4-hole
85 kW Sedan/Wagon
syncro T 125/80 R 15 95 M
(Temp. spare)
3 1/2J x
15
40
128 kW Sedan/Wagon
syncro 205/50 ZR 15 86 W
205/50 R 15 86
(M+S)
6 J x 15
6 J x 15
35
35
5-hole
128 kW Sedan/Wagon
syncro T 125/70 R 16 95 M
(Temp. spare)
3 1/2J x
16
38
1) Tire pressures Sticker on vehicle
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40-1
Front Wheel
Suspension, Shafts
and Axle
Front suspension,
servicing (Base
suspension)
I- Removing and installing
subframe, stabilizer bar and
control arm (Base suspension)
Page 40-2
II - Removing and installing
wheel bearings, suspension
strut and drive shaft (Base
suspension) Page 40-14
The Base suspension is
installed in Passat 1995
vehicles up to 85 kW.
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40-2
Sub-frame, stabilizer bar
and control arm(Base
suspension)
Note:
If a vehicle has to be
moved after removing the
drive shaft, first install outer
joint and tighten to 50 Nm
(37 ft lb) otherwise the
wheel bearing will be
damaged.
Specifications for wheel
alignment Page 44-2 .
Welding and straightening
operations are not
permitted on load bearing
suspension components or
those components which
locate the wheels.
Always replace self-locking
nuts.
Always replace corroded
nuts/bolts.
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40-3
1-
Hex bolt, 35 Nm (26 ft
lb)
2- Ball joint
Checking Page 40-
10
Check rubber boot for
damage and if
necessary, replace ball
joint
Mark installation
position. If replaced
set to center of
elongated hole and
check toe
Elongated holes are
not for camber
adjustment. Failure to
observe this instruction
may result in damage
to drive shafts!
3- Captive lock nuts
4- Airdeflector plate
Secured to control arm
by clip
5- Control arm
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40-4
6-
Control arm rear
mounting
Installation position
Fig. 3
Pressing out and in
Fig. 4
7- Hex bolt M 12 x 1.5 x 82
50 Nm (37 ft lb) and
turn 90further
8- Hex bolt M 12 x 1.5 x 65
70 Nm (52 ft lb) and
turn 90further
9- Hex bolt M 12 x 1.5 x 78
70 Nm (52 ft lb) and
turn 90further
10 - Control arm front
mounting
Pressing out Fig. 1
Pressing in Fig. 2
11 - Connecting link
With rubber mounting
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40-5
Repair Manual, Engine
Mechanical, Repair Group 10
12 - Connecting link
mounting
Conical side toward
control arm
13 - Washer
Collar faces away from
mounting
14 - Self-
locking hex nut, 25
Nm (18 ft lb)
15 - Sub-frame
Removing and
installing with
assemblies installed:
supporting assemblies
Fig. 5
Remove sub-frame
from below with VAG
1383 (with control arm
but without steering
gear). After installing
check position of
steering wheel and
align front end.
Aligning engine-
transmission assembly
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40-6
16 -
Hex bolt, 65 Nm (48 ft
lb)
17 - Stabilizer bar mounting
18 - Stabilizer bar
19 - Stabilizer bar clamp
20 - Hex bolt, 25 Nm (18 ft
lb)
To secure stabilizer
bar
21 - Vibration damper
Note installation
position, large part
must protrude from
sub-frame
22 - Self-
locking hex nut, 25
Nm (18 ft lb)
23 - Cap nut
Repairing in side
member Page 40-
11
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