Volkswagen Passat (1997) manual

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Suspension, Wheels, Brakes, Steering 00 - General, Technical data Suspension, Wheels, Brakes, Steering T echnical data Steering Brakes W heels, tires 40 - Front suspension Front Wheel Suspension, Shafts and A xle Front suspension, ser v icing (Base suspension) Sub- f rame, stabili z er bar and control arm (Base suspension) Ball joint, checking (Bas[...]

Rear axle, ser v icing (four w heel dri v e v ehicles) Rear dri v e shafts, ser v icing Re w orking cap nut in side member ( f our w heel dri v e v ehicles) Suspension strut, disassembling and assembling (four w heel dri v e v ehicles) Wheel bearings, ser v icing - disc brakes (four w heel dri v e v ehicles) 44 - Wheels, Tires, Wheel alignment Vehi[...]

Front brakes, ser v icing (Te v es/ A te) Brake pads, remo v ing and installing Rear w heel brakes, ser v icing (drum brakes) Brake shoe adjustment, releasing Rear w heel brakes, ser v icing Brake shoes, remo v ing and installing Parking brake, adjusting (drum brakes) Rear w heel brakes, ser v icing (disc brakes) Girling rear w heel disc brakes ( f[...]

48 - Steering Steering Assembl y o v er v ie w : steering column, column tube, steering w heel and airbag steering w heel Airbag unit, remo v ing and installing Airbag steering w heel, remo v ing and installing Airbag Spiral Spring, remo v ing and installing Column tube f or height adjustable steering w heel, remo v ing and installing Pump deli v e[...]

0 0 -1 Suspension, Wheels, Brakes, Steering Technical data Model Sedan/Wa g on and syncro Base Suspension 1) Sedan/Wa g on 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, whee[...]

0 0 -2 Steering Model Sedan/Wa g on 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 Page 2 of 8 Suspe n s ion, Wheels, Brakes, Steering 1[...]

0 0 -3 Brakes Model Sedan/Wa g on 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 m[...]

0 0 -4 Model Sedan/Wa g on 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, thickne s s mm 10 Pad thicknes[...]

0 0 -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, thickne s s mm 10 Pad thi[...]

0 0 -6 Wheels, t i res 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 [...]

0 0 -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 / 2 J x[...]

0 0 -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. spar[...]

4 0 -1 Front Wheel Suspension, Shafts and Axl e Front suspens i on, servicing ( B ase 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 [...]

4 0 -2 Su b -frame, stabi l i z er bar and control ar m (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. Spe c ifications for wheel alignment Page 44-2 . Welding and straightening operations are not permitted on[...]

4 0 -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 -[...]

4 0 -4 6 - Control arm rear m o unting 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 9 0 further 8 - Hex bolt M 12 x 1.5 x 65 70 Nm (52 ft lb) and turn 9 0 further 9 - Hex bolt M 12 x 1.5 x 78 70 Nm (52 ft lb) and turn 9 0 further 10 - Control arm front m o unting Pressing out Fig. 1 [...]

4 0 -5 Repair Manual, Engine Mechanical, Repair Group 10 12 - Connecting link m o unting Conical side toward control arm 13 - Washer Collar faces away from mounting 14 - Self- locki n g hex nut, 25 Nm (18 ft lb) 15 - Su b -frame Removing and installing with assemblies installed: supporting assemblies Fig. 5 Remove sub-frame from below with VAG 1383[...]

4 0 -6 16 - Hex bolt, 65 Nm (48 ft lb) 17 - Stabilizer bar mo u nting 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- locki n g hex nut, 25 Nm (18 ft lb) 23 - Cap nut Repairing in side member Pa[...]

4 0 -7 Fig. 1 Front co n trol arm mounting, pressi n g out Note: Before pressing in, coat with acid-free lubricant, e.g. soft soap. Fig. 2 Front co n trol arm mounting, pressi n g in Page 7 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.40[...]

4 0 -8 One of the embossed arrows points toward the recess in the control arm and the kidney shaped opening (arrow A) faces towards center of vehicle. Fig. 3 Control arm rear mounting, installation position Note: If bonded rubber bushing is tight because of corrosion, cut rubber out, saw through steel casing and drive bushing out. Fig. 4 Control ar[...]

4 0 -9 Fig. 5 Supp o r ting engine/tra n smission assembly with 10-222 A and legs 1 0 -222 A/1 Page 9 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.40.1[...]

4 0 -10 Bal l jo i nt , check i ng (Base and P l us suspension) Checki n g axial clearance Checki n g radial play - Forcibly pull ball joint down and press up again. Note: - Press lower part of wheel outward and inward. There mu s t be no perceptible or visual "play" during either test. Observe ball joint during checks. Take into account [...]

4 0 -11 Re w ork i ng cap nut in s i de me m ber ( B ase and Plus suspens i on) If the threads of the cap nut in the side member are damaged, the thread must either be retapped or the cap nut must be drilled out. When drilling out proceed as follows. - Support engine/transmission assembl y with 10- 222 A and legs 10-222 A/1 . - Remove the sub-frame[...]

4 0 -12 Bolt/washer assemblies for su b -frame Sec u r ing point Thread Bolt Part No. Front sub-frame M12 x 1.5 M12 x 1.5 x 95 10.9 N 101 612.01 1) Rear sub-frame M12 x 1.5 M12 x 1.5 x 95 10.9 N 101 612.01 Sub-frame bra c ket M10 M10 x 38 10.9 N 019 541.1 Engine front cross-member to side member M10 M10 x 75 10.9 N 904 078.01 1) 1) These bolts are [...]

4 0 -13 Note: Tightening torque remain s unchanged. 1 - Bolt/washer 2 - Cap nut 3 - Side member 4 - Sub-frame 5 - Bonded rubber mounting/control arm Page 13 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.40.1[...]

4 0 -14 Wheel bearing , suspension strut and dr i ve shaft, remov i ng and instal l ing ( B ase runn i ng gear) 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. Welding and straightening operations are not permitted on load beari[...]

4 0 -15 Repair Manual, Suspension, Wheels, Brakes, Steering, Repair Group 00 1 - Self-locki n g n u t, 265 Nm (195 ft lb) Only loosen and tighten with the vehicle standing on its wheels (danger of accident) Any paint residue and/or corrosion on the thread of the outer joint must be removed before the nut is installed 2 - Washer 3 - Brake disc Appli[...]

4 0 -16 6 - Speed sensor rotor Only on vehicles with ABS 7 - Hex bolt, 10 Nm (7 ft l b) 8 - Splash plate 9 - Ci r clip Ensure correctly seated 10 - Wheel bearing Pressing out Fig. 6 Replace, as it is destro y ed during pressing out Pressing in Fig. 7 11 - Self- locki n g hex nut, 35 Nm (26 ft lb) 12 - Wheel bearing housing 13 - Self- locki n g hex [...]

4 0 -17 15 - Self-locki n g bolt/washer asse m b ly, 125 Nm (92 ft lb) For securing brake carrier 16 - Socket head multi- poi n t bolt, 45 Nm (33 ft lb) 17 - Drive shaft To remove and install separate ball joint/control arm connection Fig. 2 Repairing Page 40- 46 18 - Ci r clip Ensure correctly seated 19 - Self- locki n g hex nut, 95 Nm (70 ft lb) [...]

4 0 -18 21 - Self- locki n g hex nut, 60 Nm (44 ft lb) Loosening and tightening Fig. 1 22 - Stop 23 - Suspension strut bearing 24 - Suspension strut Removing and installing Fig. 1 and Fig. 2 Disassembling and assembling Page 40-23 25 - Bracket 26 - Hex bolt 27 - Tie rod Removing and installing Page 48- 77 28 - Counters u nk screw 29 - Screw Page 18[...]

4 0 -19 Fig. 1 Suspension strut t o bo d y, loosening and tightening Note: Camber must be adjusted each time joint is loosened. Fig. 2 Wheel bearing housing/suspension strut joint, separating Page 19 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.[...]

4 0 -20 To take drive shaft out, remove bolts (arrows). Note: First mark installation po s ition. Fig. 3 Ball joint/control arm connection, separating Fig. 4 Hub, p r essing out of wheel bearing housing Page 20 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair[...]

4 0 -21 Only use puller with leg clamp e.g. Kukko 204-2 (commercial type). Fig. 5 Bearing race, pulling out of hub Fig. 6 Wheel bearing, pressin g out of wheel bearing housing Page 21 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.40.1[...]

4 0 -22 Fig. 7 Wheel bearing, pressin g int o wheel bearing housing Fig. 8 Hub, p r essing into wheel bearing housing Page 22 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.40.1[...]

4 0 -23 Front suspens i on strut, servicing ( B ase and Plus suspension) 1 - Shock absorber Can be replaced individually Check shock absorber for lea k s and noi s es After replacing, adjust camber and toe Page 44-1 2 - Buffer stop 3 - Protective sleeve Page 23 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.bentleypublishers.c[...]

4 0 -24 4 - Coil spring Removing and installing Fig. 2 Observe color coding Outer surface of spring must not be damaged Is slightly curved 5 - Spring plate 6 - Axial beari ng 7 - Hex nut, 60 Nm (44 ft lb) Loosening and tightening Fig. 2 8 - Suspension strut m o unting 9 - Stop 10 - Self- locki n g hex nut, 60 Nm (44 ft lb) Loosening and tightening [...]

4 0 -25 Fig. 1 Hex nut, loosening and tightening Fig. 2 Spring, removing an d installing Page 25 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.40.1[...]

4 0 -26 Front suspens i on, servicing ( P lus suspension) I - Removing and installing subframe, stabilizer bar and control arm (plus suspension) Page 40-27 II - Removing and installing wheel bearing, suspension strut and drive shaft (plus suspension) Page 40-36 The following components are different when comparing the plus suspension with the base [...]

4 0 -27 Su b -frame, stabi l i z er bar and control ar m , re m ov i ng and i nstal l ing (P l us suspension) Notes Page 40-2 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 Removing and installing Page 40- 33 Mark installation position. If replaced set to center o[...]

4 0 -28 5 - Control arm rear m o unting Installation position Fig. 2 Pressing out and in Fig. 3 6 - Control arm Elongated holes are not for camber adjustment! 7 - Ai r guide plate Secured to control arm by clip 8 - Control arm front m o unting Pressing out and in Fig. 1 9 - Hex bolt M 12 x 1.5 x 78 70 Nm (52 ft lb) and turn 9 0 further 10 - Hex bol[...]

4 0 -29 12 - Mounting for connecting link Conical side towards control arm 13 - Washer Collar faces away from mounting 14 - Self- locki n g hex nut, 25 Nm (18 ft lb) 15 - Hex bolt M 12 x 1.5 x 82 50 Nm (37 ft lb) and turn 9 0 further 16 - 25 Nm (18 ft lb) 17 - Hex bolt, 25 Nm (18 ft lb) To secure stabilizer bar 18 - Hex bolt, 65 Nm (48 ft lb) 19 - [...]

4 0 -30 Repair Manual, Engine Mechanical, Repair Group 10 20 - Vibration damper Not installed on vehicles with VR 6 engine 21 - Su b -frame Removing and installing with assemblies installed: supporting assemblies Fig. 4 Remove sub-frame from below with control arm but without steering gear using transmission jack VAG 1383 or equivalent. After insta[...]

4 0 -31 Note: Before pressing in, coat with lubricant, e.g. soft soap. Fig. 1 Control arm front m o unting, pressing out an d in One of the embossed arrows points toward the recess in the control arm and the kidney shaped opening -arrow -A- in mounting faces towards center of vehicle. Fig. 2 Control arm rear mounting, installation position Page 31 [...]

4 0 -32 Fig. 3 Control arm rear mounting, pressing out an d in Fig. 4 Engine/transmission assembly, supporti n g with 10-222 A and 1 0 -222 A/3 Page 32 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.40.1[...]

4 0 -33 Bal l jo i nt , removing and insta l ling ( P lus runn i ng gear) Removing - Loosen 1 2 -point nut with vehicle standing on its wheels. - Disconnect drive shaft at transmission drive flange . - Remove bolts -arrow -A-. - Loosen bolt -arrow -B-. - Separate connection between ball joint/control arm. (First mark installation position) . - Swin[...]

4 0 -34 Note: Installing - Install ball joint splitter as shown in illustration and press out ball joint. 1 - Splitter. Matra V 176 Place transmission jack VAG 1383/A, or equivalent, underneath (danger of accident through falling parts when pressing out the ball joint). Protect ball joint threads by threading nut on a few turns. - Install ball join[...]

4 0 -35 Note: Make sure that the boot is not damaged or twisted. Tig h te n in g torques Ball joint to wheel bearing housing: 45 Nm (33 ft lb) Ball joint to control arm: 35 Nm (26 ft lb) 1 - Box insert (commercial type, 19 mm AF) 2 - Crowfoot insert (commercial type, 19 mm AF) Page 35 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://e[...]

4 0 -36 Wheel bearing and suspension strut , re m ov i ng and i nstal l ing (P l us suspension) Notes Page 40-14 1 - Wheel bolt, 110 N m (81 ft lb) 2 - Self-locki n g 12-poi n t nut 90 Nm (66 ft lb) and turn 4 5 further ( 1 / 8 ) Loosening and tightening Page 40- 44 Any paint residue and/or corrosion on thread of the outer joint must be removed bef[...]

4 0 -37 5 - Brake caliper Do not loosen brake hose when working on front suspension Hang up with wire or similar Replacing brake pads Page 46-6 6 - Counters u nk screw 7 - Hub Pressing out Fig. 2 Pressing in Fig. 6 Pulling off inner race Fig. 3 8 - Speed sensor rotor Only for vehicles with ABS 9 - Hex bolt, 10 Nm (7 ft l b) 10 - Splash plate Page 3[...]

4 0 -38 11 - Ci r clip Ensure seated correctl y 12 - Wheel bearing Pressing out Fig. 4 Always replace, as it is destro y ed during pressing out Pressing in Fig. 5 13 - Self- locki n g hex nut, 35 Nm (26 ft lb) 14 - Wheel bearing housing 15 - Self-locki n g bolt/washer, 125 Nm (92 ft lb) 16 - Drive shaft Removing and installing Page 40- 43 Repairing[...]

4 0 -39 18 - Hex bolt Camber adjustment Page 44-1 Before loosening, mark installation position 19 - Hex bolt 20 - Bracket 21 - Stop 22 - Self- locki n g hex nut, 60 Nm (44 ft lb) Loosening and tightening Fig. 1 23 - Suspension strut Disassembling and assembling Page 40-23 24 - Self- locki n g hex nut, 95 Nm (70 ft lb) 25 - Tie rod Removing and inst[...]

4 0 -40 Fig. 1 Suspension strut t o bo d y, loosening and tightening Fig. 2 Hub, p r essing out of wheel bearing housing Page 40 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.40.1[...]

4 0 -41 Only use puller with leg clamp e.g. Kukko 204-2 (commercial type). Fig. 3 Inner race, pulling off hub Fig. 4 Wheel bearing, pressin g out of wheel bearing housing Page 41 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.40.1[...]

4 0 -42 Fig. 5 Wheel bearing, pressin g int o wheel bearing housing Fig. 6 Hub, p r essing into wheel bearing housing Page 42 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.40.1[...]

4 0 -43 Drive shaft , removing and insta l ling (P l us running gear) Removing - Loosen 1 2 -point nut with vehicle standing on its wheels. - Disconnect drive shaft from transmission drive flange . - Remove bolts (arrow -A-). - Loosen bolt (arrow -B-). - Separate connection between ball joint/control arm. (First mark installation position) . Note: [...]

4 0 -44 Installing - Remove remains of locking fluid from outer joint and hub splines. (Splines must be free of oil and grease). - Apply locking fluid D 185 400 A2 to splines as shown in illustration. Bead cross section approx. 3 mm . - Install drive shaft. - Connect ball joint to control arm. - Install drive shaft to transmission flange shaft and [...]

4 0 -45 Tig h te n in g torques: Drive shaft to flange shaft/transmis s ion 45 Nm (33 ft lb) Drive shaft to wheel bearing 90 Nm (66 ft lb) and housing turn 4 5 further ( 1 / 8 turn) Ball joint/control arm 35 Nm (26 ft lb) Page 45 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Got[...]

4 0 -46 Drive shaft , repa i ring Drive shafts on vehicles with Plus suspension have shorter and finer splines on the outer joint. The wheel bearing is secured by a 1 2 -point nut. The splines of the outer joint and the hub on Plus suspensions are secured with locking fluid D 185 400 A2. Drive shaft, removing and installing Vehicles with Base suspe[...]

4 0 -47 1 - Ci r clip Always replace Remove and install with VW161 a 2 - Gasket Always replace. Pull off prote c tive foil and stick onto joint. (Only on 100 mm diameter constant velocity joint s 3 - Inner c o nstant velocity joint 100 mm diameter Only replace complete Pressing off Fig. 3 Pressing on Fig. 4 Greasing Notes Page 40-46 Checking Page 4[...]

4 0 -48 5 - Boot for 100 mm diameter constant velocity joi nt Rubber version With vent hole Check for tears and chafing Installation position for left drive shaft Fig. 5 Installation position for right drive shaft Fig. 6 Coat inside of cap with D3 Drive off with drift 6 - Drive shaft Left shaft, solid bar (not illustrated) Right shaft, tube 7 - Cla[...]

4 0 -49 8 - Boot for 90 mm diameter constant velocity joi nt Polyester elastomer version Check for tears and chafing The balance pressure briefly ventilate boot before tensioning the small clamp Fig. 7 Installation position for left shaft, wheel end Fig. 10 and Fig. 11 Installation position for right shaft, wheel end Fig. 12 9 - Clamp Always replac[...]

4 0 -50 10 - Dished washer Outer diameter (concave side) contacts thrust washer 11 - Thrust was h er 12 - Ci r clip Always replace Insert in shaft groove 13 - Outer constant velocity joint, 90 mm diameter Only replace complete Removing Fig. 2 Installing: drive onto shaft with plastic hammer until compressed circlip seats Greasing Notes Page 40-46 C[...]

4 0 -51 14 - Outer constant velocity joint, 90 mm diameter For vehicles with 16V and VR6 Wedge splines, larger diameter Only replace complete Removing Fig. 2 Installing: drive onto shaft with plastic hammer until compressed circlip seats Greasing Notes Page 40-46 Checking Page 40- 60 15 - Vibration damper Removing and installing Fig. 1 Installation[...]

4 0 -52 16 - Clamp Always replace 17 - Supp o r t rings On rubber type boot only On transmission end only See Parts catalog 18 - Boot for 100 mm diameter constant velocity joi nt Polyester elastomer version Check for tears and chafing To balance pressure briefly ventilate boot before tensioning the small clamp Fig. 7 19 - Protective cap 20 - Hex bo[...]

4 0 -53 The damper consists of two halves. Both halves are joined to one another by spring pins (arrow). Installation position Fig. 1 Note: Fig. 1 Vibration damper, r emoving and installing Only replace vibration damper with drive shaft removed Before driving in spring pin protect shaft paint finish against damage. To prevent axial movement apply a[...]

4 0 -54 Fig. 2 Outer constant velocity joi n t, removing - Drive joint off drive shaft with a firm blow from an aluminium hammer . Note: Fig. 3 Inner c o nstant velocity joint, pressing off First drive boot off with drift Support ball hub Page 54 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/D[...]

4 0 -55 Note: Chamfer on inner diameter of ball hub (splines) must face the contact shoulder on the drive s haft. Fig. 4 Inner c o nstant velocity joint, pressing on - Press on joint up to stop. - Install circlip. Dimension "a" = 17 mm Note: Before assembling boot on drive shaft mark position, dimension "a", with for example pai[...]

4 0 -56 The large diameter of vent chamber -A- must fit on the larger diameter. Fig. 6 Installation position of right drive s h aft transmission en d joint boot B - Vent hole Often the boot is pushed in when installing on the joint body. This creates a vacuum inside the boot which draws a fold in (arrow) while driving. After installing, lift the bo[...]

4 0 -57 Fig. 8 Larger clamp, tensioning - Use pliers VAG 1682 as shown in illustration. Ensure that the jaws of the pliers s eat in the - arrow -B- of the clamp. - Tension clamp by turning the spindle with a torque wrench (do not tilt pliers) . Note: Fig. 9 Smaller clamp, tensioning 40 The clamp can only be tensioned with pliers V.A.G 1682. Tighten[...]

4 0 -58 Cuff seating tolerance "a": 1 / 2 to 1 1 / 2 grooves visible at end of cuff. Note: This installation position tolerance is al s o valid for the left drive shaft transmission end boot (polyester elastomer version). Fig. 10 Installation position of left drive shaft wheel end joi n t boot, shaft d iameter 27 mm Cuff installation posi[...]

4 0 -59 Cuff seating tolerance "a": From cuff position to chamfer up to 1 / 2 a groove visible. Fig. 12 Installation position of right drive s h aft, wheel end joi n t boot Page 59 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.4[...]

4 0 -60 Outer constant velocity jo i nt , checking The joint should be disassembled to replace dirty grease or for checking the balls and ball tracks for wear and damage. Removing - Before disa s sembling mark position of the ball hub in relation to the ball cage and housing with an electric scriber or oil stone . - Swivel ball hub and ball cage. -[...]

4 0 -61 Note: The 6 balls of each joint belong to one tolerance group. Check stub axle, hub, cage and balls for indentations (pitting) and signs of seizure. Excessive backlash in joint will be noticed as a knock during load changes. In such cases the joint must be replaced. Polished areas and ball track marks are not a reason for changing the joint[...]

4 0 -62 Inner constant ve l ocity joint, checking The joint should be disassembled to replace dirty grease and when checking the balls and ball tracks for wear and damage. Note: The ball hub and joint are paired and must not be interchanged. - Swivel ball hub and ball cage. - Press out ball cage in direction of arrow. - Press balls out of cage. - T[...]

4 0 -63 Note: Excessive backlash in joint will be noticed as a knock during load changes. In such cases the joint must be replaced. Poli s hed areas and ball track marks are not a reason for changing the joint. Installing Note: - Insert ball hub over both c hamfers into the ball cage. Any installed position is acceptable. Press balls into the cage.[...]

4 0 -64 - Swivel in ball hub, whereby the hub must be swivelled out of the cage (arrows) far enough to allow the balls to fit into the ball tracks. Checki n g o peration of constant velocity joi n t: The constant velocity joint i s correctly assembled when the ball hub can be mo v ed by hand backward and forward over its entire axial movement range[...]

4 0 -65 Drive shaft w i th tr i pod joint, repair i ng 1 - Outer constant velocity joint Replace complete Removing Fig. 1 Installing: Drive onto the shaft with plastic hammer until circlip comes out Greasing Notes Page 40-46 Checking Page 40- 62 2 - Ci r clip Always replace Install in groove of shaft 3 - Thrust ring 4 - Dished washer Larger diamete[...]

4 0 -66 5 - Clamp Always replace Tightening, Fig. 2 and Fig. 3 6 - Boot for constant velocity joi n t, 90 mm dia. Check for cracks and abrasion Before tightening the small clamp, ventilate boot briefly so pressure is equalized, Fig. 2 7 - Clamp Always replace Tightening, Fig. 2 and Fig. 4 8 - Drive shaft, left, wit h inner tripod joint Repair of in[...]

4 0 -67 9 - Inner s p lined screw, 45 Nm (33 ft lb) 10 - Drive shaft, right, with inner tripod joint Repair of inner joint and replacement of boot not possible at this time Replace if damaged Page 67 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.[...]

4 0 -68 Fig. 1 Consta n t velocity joint, outer, removing - Drive off from drive shaft with forceful blow using an alloy hammer. The boot is pressed on forcefully when installing on the joint body. This creates a vacuum in the boot that makes a dent during driving (arrow). Briefly ventilate the boot at the small diameter after installation to provi[...]

4 0 -69 Note: Fig. 3 Clamp, tightening on large diameter - Install pliers VAG 1682 as in illustration. Make sure that the blades of the pliers lie in the corners (arrow -B-) of the clamp. - Tighten clamp by turning the spindle with a torque wrench (do not tilt pliers during this process) . Because of the hard material (compared to rubber) of the bo[...]

4 0 -70 Drive axle w i th tr i ple-rotor j oint, re m ov i ng and i nstal l ing Removing ri g ht-side d r ive axle The right drive axle removal instructions remain unchanged from the current repair manual procedure. Removing left-side d r ive axle - Set up engine support bridge. Page 70 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http:/[...]

4 0 -71 - Remove rear transmission mounting bolt (arrow). - Remove front engine mounting bolt (arrow). - Lift engine/transmission assembly - Loosen drive axle nut while vehicle is standing on its wheels. Page 71 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repai[...]

4 0 -72 - Disconnect drive axle from transmission drive flange . - Mark installation position of bolts (arrows) and remove. Installing - Swing wheel outward (if neces s ary, place bloc k of wood or equivalent between strut and wheel housing as shown). - Push engine/transmission assembly toward front and remove drive axle. - Install in reverse order[...]

4 0 -73 Drive axle w i th tr i pl e -rotor joint, servicing 1 - Outer constant velocity (CV) joi nt Replace complete part only Removing Fig. 1 Installing: drive onto shaft with plastic hammer until circlip seats (springs into groove) Greasing page 40- 12 2 - Ci r clip Always replace Insert in groove in shaft 3 - Thrust ring 4 - Belleville spri ng L[...]

4 0 -74 9 - Clamp For triple-rotor joint 10 - Boot 11 - Clamp For triple-rotor joint 12 - Cover Destroyed when disassembling No longer required for assembly; not available as replacement part 13 - Rectangula r sealing r ing Included in repair kit; not used in produ c tion 14 - O- r ing Not required for assembly 15 - Ci r clip 16 - Roller 17 - Tripl[...]

4 0 -75 Fig. 1 Removing outer CV joint - Drive joint off axle shaft with firm blow from soft mallet . Page 75 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.40.1[...]

4 0 -76 Make sure plier jaws seat in grooves of clamp (arrows -B-) Note: Fig. 2 T ightening outer CV joint boot clamp - Position VAG 1682 pliers or equivalent (e.g. Snap- On YA 3080) as shown in illustration. - Tension clamp by using torque wrench to turn spindle (keep pliers at right angle to shaft). Tightening torque: 20 Nm (15 ft lb) Due to the [...]

4 0 -77 Tr i ple-rotor j oint, d i sassembl i ng - Open hose clamp - Open clamp on shaft small end and push back boot . Note: - Drive screwdriver or similar tool into cover and pry open . If the cover will not pry open, insert screwdriver and pry from the opposite side. The cover is destroyed in the remo v al process. It does not need to be replace[...]

4 0 -78 1 - Triple- r o tor joint h ousing 2 - Triple- r o tor star 3 - Axle shaft Note: CAUTION! Do not let the rollers slide o ff the triple- r o tor star and fall to the fl o or. - Remove O-ring -arro w - from groove. - Mark installation positions of parts -1-, -2- and -3-. Noises while driving may result if the indicated parts are not reassembl[...]

4 0 -79 - Remove rollers and place on clean surface. -1- Pliers Commercially availa b le - Remove circlip. - Press triple-rotor star off axle shaft. - Pull triple-rotor joint housing off axle shaft. - Clean shaft and triple-rotor joint housing. Page 79 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.bentleypublishers.com/vw/ser[...]

4 0 -80 Tr i ple-rotor j oint, assembl i ng - Slide small diameter boot clamp onto shaft. - Slide triple-rotor joint boot onto shaft. - Slide triple-rotor joint housing onto shaft. Mounting triple- r o tor star Note: The side of the star with a chamfer (arrow) goes onto the axle shaft splines first. - Place triple-rotor star on axle shaft according[...]

4 0 -81 Note: A seal is formed directly between the triple-rotor joint and the drive flange by the rectanular sealing ring. The cover is no longer required. - Install rectangular sealing ring (arrow) from repair kit. 90 grams into joint and 90 grams behind joint - Press 180 grams of axle shaft grease from repair kit into triple-rotor joint . - Inst[...]

4 0 -82 - Tighten small diameter clamp with VAG 1275 pliers or equivalent (e.g. KD 474). CAUTION! Sec u r e the triple- r o tor joint with tape so t h at the ho u sing is not inadvertently pus h ed back when installing the axle shaft. Remove tape just prior to bolting t o drive flange. Page 82 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004[...]

4 2 -1 Rear Wheel Suspension, Shafts and Axl e Rear axle, servicing (vehicles w ith front w hee l dr i ve) Note: The rear axle and wheel bearings are identical on Base and Plus suspension versions. Welding and straightening of the axle beam is not permissible. 1 - Wheel bolt 110 Nm (81 ft lb) 2 - Self- locki n g hex nut, 70 Nm (52 ft lb) When tight[...]

4 2 -2 5 - Wheel bearing Servicing Vehicles with drum brakes Page 42-15 Vehicles with disc brakes Page 42-24 6 - 80 Nm (59 ft lb) Use only self-locking nuts with captive washers When tightening nut, the axle beam must be in the horizontal position (unladened vehicle state) 7 - Hex bolt Installed from center of vehicle 8 - Shouldered b olt, 70 N m ([...]

4 2 -3 9 - Mounting bracket with r etainer f o r brake pressure reg u lator Installation position Fig. 4 Check and if necessary adjust rear axle total toe after installation If possible do not loosen when removing the rear axle 10 - Hex nut/washer, 35 N m (26 ft lb) 11 - Reg u lator spri n g bracket 12 - Bonded ru b ber m o unting Note installation[...]

4 2 -4 Repair Manual, Body Exterior, Interior, Repair Group 70. Repair Manual, Body Exterior, Interior, Repair Group 68. Inertia reel bolt (arrow) tightening torque: 40 Nm (30 ft lb) Fig. 1 Suspension strut at body, removing and installing - Removing and installing inertia reel cover - Removing and installing inertia reel Remove and install both se[...]

4 2 -5 Suspension strut is attached to the body by 4 retaining lugs in addition to the bolts. To remove, turn suspension strut until retaining lugs are positioned above the cu t -outs. Fig. 3 Suspension strut, removing a n d installing Angle of inclination to axle beam 1 3 30' 1 . Fig. 4 Bolting mounting bracket to axle beam Page 5 of 14 Rear [...]

4 2 -6 Note: Before using special tool 3111 it is important to grease spindle with Molybdenum grease. Fig. 5 Bonded ru b ber mounting, pressing 1st half out of axle beam Thread base plate into the pressure plate 3111/5 from the opposite side. Note: Mounting must not be driven out. Otherwise the mounting seat will be widened and a tight seating of t[...]

4 2 -7 Protruding segment of bonded rubber mounting faces forward on inside and rearward on outside. Fig. 7 Rubber bo n ded mountin g , installation position Press both halves in one after the other until the mounting conical section contacts the axle beam. Fig. 8 Rubber bo n ded mountin g , presssi n g into axle beam Page 7 of 14 Rear Wheel Suspen[...]

4 2 -8 Re w ork i ng cap nut in s i de me m ber (front wheel drive vehicles) If the threads of the cap nut in the side member are damaged, it must either be retapped or the cap nut must be drilled out. When drilling out proceed as follows: - Remove rear axle. - Drill through damaged cap nut in the side member using a 10.2 mm diameter drill from und[...]

4 2 -9 Suspension strut, d i sassemb l ing and assembl i ng (front w heel dr i ve veh i cles) 1 - Cap Pry out with screwdriver Pressing on Fig. 4 2 - O- r ing 3 - Self- locki n g hex nut, 25 Nm (18 ft lb) 4 - Dished washer 5 - Uppe r rubber mounting 6 - Gasket (f o am) Always replace Page 9 of 14 Rear Wheel Suspension, Shafts and Axle 12/7/2004 htt[...]

4 2 -10 7 - Suspension strut bearing Always replace foam gasket Welded nut s 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 m o unting 10 - Metal cap Higher on Wagon than Sedan 11 - Washer 12 - Spring seat Thinner on Wagon than Sedan Installation position[...]

4 2 -11 13 - Stop b uffer Shorter on Wagon than Sedan 14 - Protective tube Longer on Wagon than Sedan 15 - Plastic cap 16 - Coil spring Removing and installing Fig. 1 Allocation Parts catalog Wagon has protective hose at top 17 - Packing 18 - Ci r clip 19 - Lower s p r ing plate Page 11 of 14 Rear Wheel Suspension, Shafts and Axle 12/7/2004 http://[...]

4 2 -12 20 - Shock absorber Can be replaced individually Removing and installing Page 42-4 Application see Parts catalog Page 12 of 14 Rear Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.42.1[...]

4 2 -13 Note: Instead of VAG 1403, VAG 1752/1 may be used. Fig. 1 Spring, removing an d installing Fig. 2 Spring seat, installati o n p osition Page 13 of 14 Rear Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.42.1[...]

4 2 -14 Fig. 3 Suspension strut mountin g to shock absorbe r bushing, aligning A - Shock absorber bushing axis B - Suspension strut mounting axis "a" 50 C - Cap axis 9 0 offset to shock absorber bushing axis -A-. Fig. 4 Cap in suspensi o n strut mo u nting, pressing in. Page 14 of 14 Rear Wheel Suspension, Shafts and Axle 12/7/2004 http:/[...]

4 2 -15 Wheel bearings, servicing Drum brakes (front w heel dr i ve veh i cles) , w hee l bearings , serv i c i ng Note: Careful sealing, absolute cleanliness and precise adjustment are requirements for long wheel bearing s ervice life. Therefore note the following points: Install oil seal and grease cap as shown. Only reinstall clean bearings, do [...]

4 2 -16 2 - Cotter pin Always replace 3 - Locking ring 4 - Hex nut Adjusting wheel bearing play Fig. 4 5 - Thrust was h er 6 - Outer wheel bearing Drive out outer race with copper drift Pressing in Fig. 6 7 - Hex socket h ead bolt, 10 Nm (7 ft lb) 8 - Speed sensor Only on vehicles with ABS 9 - Stub axle Straightening operations are not permitted! P[...]

4 2 -17 10 - Brake backing plate Bolt together with stub axle onto rear axle 11 - Oil seal Fill between sealing lips with multi-purpose grease. Driving in Fig. 8 12 - Dished washer Larger contact surface (concave side) to brake backing plate 13 - Hex bolt, 60 Nm (44 ft lb) 14 - Inner wheel bearing Drive out outer race with copper drift Pressing in [...]

4 2 -18 16 - Brake drum Before removing release brake shoe adjustment through wheel bolt hole Fig. 5 When removing the brake drum make sure that the outer wheel bearing does not fall out. Fill hub with multi- purpose grease before installing Page 4 of 18 Wheel bearings, servicing 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?actio[...]

4 2 -19 Loosen grease cap from seat by tapping lightly on the claw. Fig. 1 Grease cap, p r essing off Fig. 2 Grease cap, p r essing off Page 5 of 18 Wheel bearings, servicing 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.42.2[...]

4 2 -20 Note: Fig. 3 Grease cap, d r iving on Always replace damaged (dented) grease caps. Damaged (dented) grease caps allow ingress of moisture, therefore always use the illustrated tool. Note: Using a screwdriver it must be possible to move the thrust washer by finger pressure (without prying). Fig. 4 Wheel bearing play, adjusting - Secure with [...]

4 2 -21 Fig. 5 Brake shoe adjustment, r eleasing - Insert a screwdriver through a hole in the brake drum and push the wedge upward . Fig. 6 Outer wheel bearing outer r ace, pressing in Page 7 of 18 Wheel bearings, servicing 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.42.2[...]

4 2 -22 Fig. 7 Inner wheel bearing outer race, pressing in Fig. 8 Oil seal, driving in Page 8 of 18 Wheel bearings, servicing 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.42.2[...]

4 2 -23 Fig. 9 Rotor, pressin g in Page 9 of 18 Wheel bearings, servicing 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.42.2[...]

4 2 -24 Wheel bearings, serv i c i ng - disc brakes (front w hee l dr i ve veh i cles) Note: Careful sealing, absolute cleanliness and precise adjustment are requirements for long wheel bearing service life. Therefore note the following points: Install oil seal and grease cap as shown. Only reinstall clean bearings. Adjust wheel bearing play carefu[...]

4 2 -25 3 - Speed sensor Only on vehicles with ABS Before installing sensor, clean mounting hole inner surface and coat with lubricating pa s te G 000 650 4 - Brake hose bracket 5 - Hex socket h ead bolt, 65 Nm (48 ft lb) 6 - Self-locki n g hex bolt, 35 Nm (26 ft lb) Always replace 7 - Guide pins 8 - Protective cap 9 - Pad retaining s p r ing Repla[...]

4 2 -26 10 - Cover ring Always replace Installation position Fig. 5 Drive on with tube VW 519 11 - Pad carrier 12 - Brake pads Removing and installing Page 46- 33 13 - Brake caliper Servicing Page 47- 15 14 - Outer wheel bearing Drive out outer race with copper drift Pressing in Fig. 6 15 - Hex nut Adjusting wheel bearing play Fig. 4 16 - Cotter pi[...]

[...]

4 2 -28 26 - Dished washer Large contact surface (concave side) to backing plate 27 - Backin g plate 28 - Axle beam Straightening work is not permissible! Only use stub axles with 6 mounting holes. 29 - Parking brake cable Adjusting parking brake Page 46-36 30 - Spring clip Page 14 of 18 Wheel bearings, servicing 12/7/2004 http://ebahn.bentleypubli[...]

4 2 -29 Fig. 1 Grease cap, p r essing off - Loosen grease cap by tapping lightly on the claw. Fig. 2 Grease cap, p r essing off Page 15 of 18 Wheel bearings, servicing 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.42.2[...]

4 2 -30 Note: Fig. 3 Grease cap, d r iving on Always replace damaged (dented) grease caps. Damaged (dented) grease caps allow ingress of moisture, therefore always use the illustrated tool. Note: Using a screwdriver it must be possible to move the thrust washer by finger pressure (without prying). Fig. 4 Wheel bearing play, adjusting - Secure with [...]

4 2 -31 Dimension "a" = 9.5 mm Fig. 5 Cover ring, installation position - Drive on cover ring with tube VW 519 Fig. 6 Outer wheel bearing outer r ace, pressing in Page 17 of 18 Wheel bearings, servicing 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.42.2[...]

4 2 -32 Fig. 7 Inner wheel bearing outer race, pressing in Fig. 8 Oil seal, driving in Page 18 of 18 Wheel bearings, servicing 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.42.2[...]

4 2 -33 Rear axle, servicing (four wheel drive vehicles) Note: When removing and installing the rear axle, it is recommended to remove axle and differential together and to separate away from the vehicle. If only the axle beam is to be removed and installed, the wishbones can remain attached to the shock absorber. In both cases, disconnect vacuum l[...]

4 2 -34 1 - Suspension strut Removing and installing Page 42- 4 , Fig. 1 and Page 42-37 Disassembling and assembling Page 42-53 Application see Parts catalog 2 - Drive shaft Removing and installing Fig. 2 and Fig. 3 Servicing Page 42- 46 3 - Final drive Removing and installing from axle beam Fig. 9 4 - Final drive m o unting bracket and carrier Rem[...]

4 2 -35 5 - Propshaft Removing and installing Fig. 2 Mark installation position before removing 6 - Anti- r o ll bar Removing and installing Fig. 4 7 - Axle beam Replacing rubber bonded mounting Fig. 10 and Fig. 11 8 - Rear axle mounti n g bracket Removing and installing at body Fig. 14 9 - Control arm Removing and installing Fig. 5 Replacing rubbe[...]

4 2 -36 Repair Manual, Suspension, Wheels,Bra k es, Steering, Repair Group 46 and47 10 - Wheel bearing Servicing Page 42- 59 Servicing brakes 11 - Hex bolt, 85 Nm (63 ft lb) 12 - Hex bolt for seat belt strut, 25 N m (18 ft lb) Page 4 of 13 Rear axle, servicing (four wheel drive vehicles) 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Displ[...]

4 2 -37 Before installing, bring control arm into horizontal position (unladen state). Removing and installing suspension strut at body Page 42-4 . Tightening torque -A-: 65 Nm (48 ft lb) Note: Support control arm otherwise damage may occur to constant velocity joint as a result of over-stressing. Fig. 1 Suspension strut from control arm, r emovi n[...]

4 2 -38 Loosen and tighten only when vehicle is standing on its wheels (danger of accident). Tightening torque: 90 Nm (66 ft lb) and turn 4 5 further ( 1 / 8 turn) Note: Any paint residue and/or corrosion on the thread of the outer joint must be removed before the nut is installed. Fig. 3 Drive shaft, re m o ving and installing Tightening torque -A[...]

4 2 -39 Before tightening bring control arm into horizontal position (unladen state). To remove the right-hand control arm inner bolt, remove brake pressure regulator from axle beam. Tightening torque -A-: 120 Nm (89 ft lb) Fig. 5 Control arm, removing an d installing Fig. 6 Rubber bo n ded mountin g , removing A - 17 mm socket B - Separating devic[...]

4 2 -40 Before installing coat with acid free lubricant, e.g. soft soap. Installation position: Shoulder on outer mounting to outside, to inside on inner mounting (to center of vehicle). Note: Deviations from the rear axle toe and camber specifications can be corrected by using a bonded rubber mounting with eccentric bushing Fig. 8 Fig. 7 Bonded ru[...]

4 2 -41 The rubber mounting -A- is equipped with an eccentric bushing which can change the position of the control arm. This rubber mounting may only be installed in the control arm inner mounting. The camber and/or toe can be changed according to installation position. Note: With this mounting the camber or toe can be altered up to 18'. Fig. [...]

4 2 -42 Removing and installing viscous coupling Repair Manual, 5 Spd. Manual Transmission 02A; Repair Group 39 Tightening torque -A-: 45 Nm (33 ft lb) Fig. 9 Final drive, removing and installing from axle beam Page 10 of 13 Rear axle, servicing (four wheel drive vehicles) 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&[...]

4 2 -43 Connect segment corners of bonded rubber mounting metal core with a line. The continued line must pass through the center of hole (arrow). Note: The kidney-shaped recess must be pointing in direction of travel when viewed from the center of vehicle. Fig. 10 Installation position, determining Place one half of the rubber bonded mounting in c[...]

4 2 -44 Remove and install complete When assembling mounting bracket and final drive carrier away from the vehicle, make sure parts are correctly located relative to each other. It is essential that the bonded rubber mounting is installed stress free in the vehicle. Fig. 12 Mounting bracket an d final drive carrier, r emovi n g and installing Tig h[...]

4 2 -45 Mark mounting bracket in s tallation position relative to body longitudinal member, otherwise the rear axle must be realigned on an axle alignment stand after reinstalling. Fig. 14 Mounting bracket on body, removing and installing Tig h te n in g torque -A- 130 Nm (96 ft lb) -B- 60 Nm (44 ft lb) -C- 85 Nm (63 ft lb) Page 13 of 13 Rear axle,[...]

4 2 -46 Rear drive shafts, servicin g Removing and installing drive shafts Page 42- 37 Note: Grease quantity: - - outer constant velocity joint 80 g G -6.3 - - inner c onstant velocity joint 80 9 G-6.3 Greasing outer joint: press half of the grease into the joint, and the other half evenly into the boot. Greasing inner joint: press half of the grea[...]

4 2 -47 1 - Ci r clip Always replace Remove and install with VW161 a 2 - Inner c o nstant velocity joint, 81 mm diameter Only replace complete Pressing off Page 40-54 Pressing on Page 40-55 Greasing Notes Page 42-46 Checking Page 40- 62 3 - Dished washer Inner diameter splined Installation position: outer diameter (concave side) contacts constant v[...]

4 2 -48 4 - Boot for 94 mm diameter constant velocity joi nt Rubber version Check for tears and chafing Installation position: At cuff 1 to 1-1/2 grooves visible Coat inside of cap with D3 Drive off with drift 5 - Drive axle Different drive axle lengths - short shaft right 6 - Hose clamp Always replace Tensioning Page 40-57 Page 3 of 7 Rear drive s[...]

4 2 -49 7 - Boot for 81 mm diameter constant velocity joi nt Polyester elastomer version Check for tears and chafing Installation position: At cuff 1 to 1-1/2 grooves visible To balance pressure briefly ventilate boot before tensioning the small clamp 8 - Hose clamp Always replace Tensioning Page 40-57 9 - Dished washer Outer diameter (concave side[...]

4 2 -50 11 - Ci r clip Always replace Insert in shaft groove 12 - Outer constant velocity joint: 81 mm diameter Only replace complete Removing Page 40- 54 Installing: drive onto shaft with plastic hammer until compressed circlip seats Greasing Notes Page 42-46 Checking Page 40- 60 13 - Inner s u pport rings Prevents boot inflating Only installed on[...]

4 2 -51 Re w ork i ng cap nut in s i de me m ber (four wheel drive vehicles) If the threads of the cap nut in the side member are damaged, it must either be retapped or the cap nut must be drilled out. - Remove control arm if nece s sary. - Drill through damaged cap nut in the side member using a 10.2 mm diameter drill from underneath. Note: Do not[...]

4 2 -52 - Cut new thread in the cap nut, M 12 x 1.5. - Use new bolts, Part No. N 010 137.1 and washer, Part No. N 011 531.7 to secure the rear axle. Tightening torque: 65 Nm (48 ft lb) Note: The procedure described here must only be performed on one cap nut on each side of the vehicle. Page 7 of 7 Rear drive shafts, servicing 12/7/2004 http://ebahn[...]

4 2 -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 - Uppe r rubber mounting 6 - Gasket (f o am) Always replace Page 1 of 6 Suspe n s ion strut, disass[...]

4 2 -54 7 - Suspension strut m o unting Welded nut s must be located in the spring seat recesses Installation position to spring seat Fig. 3 8 - Spring seat 9 - Spacer tube 10 - Lower rubber m o unting 11 - Stop b uffer m o unting 12 - Washer 13 - Stop b uffer 14 - Ring (Alumini u m) 15 - Boot 16 - Protective cap Page 2 of 6 Suspe n s ion strut, di[...]

4 2 -55 17 - Coil spring Removing and installing Page 42- 13 Allocation Parts catalog 18 - Packing 19 - Ci r clip 20 - Lower s p r ing plate Installation position Fig. 1 21 - Shock absorber Can be replaced individually Removing and installing Page 42-4 and Page 42-37 Check shock absorber for lea k s and noi s es Application see Parts catalog Page 3[...]

4 2 -56 The spring plate mu s t be installed so that the holes "a" align with the bushing -2- in the shock absorber eye. Otherwise, in extreme driving situations spring plate -1- could contact the tire. Fig. 1 Lower s p r ing plate, installation position 1 - Lower spring plate 2 - Sho c k absorber e y e bushing Fig. 2 Spring seat, install[...]

4 2 -57 The upper suspension strut mounting and the spring seat (arrow A) both have markings (arrow B). These must be installed pointing forward, otherwise damage will occur to the suspension strut piston rod. Fig. 3 Suspension strut mountin g to spring seat, installation position Fig. 4 Suspension strut mountin g to shock absorbe r bushing, aligni[...]

4 2 -58 Fig. 5 Cap, pressing i n to suspension strut m o unting Page 6 of 6 Suspe n s ion strut, disassembling and assemblin g (four wheel drive vehicles) 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.42.5[...]

4 2 -59 Wheel bearings, servicing - disc brakes (four wheel drive vehicles ) Note: If a vehicle has to be moved after removing the drive shaft, first install an outer joint and tighten to 50 Nm (37 ft lb). Otherwise the wheel bearing will be damaged. 1 - Control arm 2 - Self locking hex socket head bolt, 60 Nm (44 ft lb) 3 - Self locking hex bolt, [...]

4 2 -60 Repair Manual, Suspension, Wheels, Brakes, Steering, Repair Group 46 Repair Manual, Suspension, Wheels,Bra k es, Steering, Repair Group 47 4 - Guide pins 5 - Protective cap 6 - Pad securi n g springs Always replace when changing pads 7 - Brake pads Repair information 8 - Brake caliper Servicing 9 - Pad carrier 10 - Screw 11 - Wheel bolt, 11[...]

4 2 -61 Repair Manual, Suspension, Wheels, Brakes, Steering, Repair Group 46 12 - Self-locki n g hex nut Always Tighten to 90 Nm (66 ft lb) and turn 4 5 further ( 1 / 8 turn) To tighten use recommend angle measuring wrench VAG 1756 or equivalent Before installing nut on outer joint remove any paint remains and/or corrosion from threads. 13 - Shim 1[...]

4 2 -62 16 - Ci r clip Ensure seated correctl y 17 - Wheel bearing 72 mm diameter Pressing out Page 42-64 Pressing in page. Page 42-65 18 - Hex bolt, 10 Nm (7 ft l b) 19 - Backin g plate 20 - Parking brake cable Adjusting parking brake Page 46-36 21 - Spring clip 22 - Hex socket h ead bolt, 10 Nm (7 ft lb) 23 - Speed sensor Before inserting, clean [...]

4 2 -63 24 - Drive shaft with speed sens o r rotor Removing and installing drive shaft Page 42-37 and Page 42-38 Removing and installing rotor, Fig. 6 25 - Brake line Page 5 of 8 Wheel bearings, servicing - disc brakes (four wheel drive vehicles) 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW[...]

4 2 -64 Fig. 1 Hub, p r essing out Fig. 2 Wheel bearing, pressin g out Page 6 of 8 Wheel bearings, servicing - disc brakes (four wheel drive vehicles) 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.42.6[...]

4 2 -65 Note: Only use puller with leg clamp e.g. Kukko 204-2 (commercial type). Fig. 3 Inner race, pulling off of h ub Note: First install lower circlip. Fig. 4 Wheel bearing, pressin g in Page 7 of 8 Wheel bearings, servicing - disc brakes (four wheel drive vehicles) 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&[...]

4 2 -66 Note: First install backing plate on control arm. Tightening torque: 10 Nm (7 ft lb) Fig. 5 Hub, p r essing in Fig. 6 Speed sensor rotor, pressing in - Drive rotor off outer joint using a drift (rotor will be destro y ed) . - Drive new rotor carefully onto stop using a plastic hammer . Page 8 of 8 Wheel bearings, servicing - disc brakes (fo[...]

4 4 -1 Vehicle alignmen t Test requirements: Measuring equipment correctly calibrated Vehicle unladen 1) Tires inflated to correct pressure Vehicle accurately aligned, suspension bounced and rocked several time s Suspension, steering and steering linkage checked for excessive play and damage. Note: Vehicle alignment should not be checked before the[...]

4 4 -2 Vehicle a l ignment spec i f i cations (front w heel drive veh i cles) Front axle Suspension strut axle Engine up to 85 kW (115 hp) 110 - 128 kW (148 - 172 hp) Version Base suspension Plus suspension Total toe 1) (not pressed) 0 10' 0 10' Camber 2) (in straigh t - ahead po s ition) Maximum permissible difference between sides - 1 2[...]

4 4 -3 Rear axle Torsion beam trailing arm axle Engine/version all Camber 1) Maximum permissible difference between sides - 1 30' 10' max. 20' Total toe 1) (at specified wheel camber) Maximum permissible deviation from direction of travel +20' 10' max. 20' 1) not adjustable Page 3 of 7 Vehicle alig n ment 12/7/2004 htt[...]

4 4 -4 Vehicle a l ignment spec i f i cations (four w hee l drive vehicles) Front axle Suspension strut axle Engine 85 kW (115 hp) 128 kW (172 hp) Version Base suspension Plus suspension Total toe 1) (not pressed) 0 10' 0 10' Camber 2) (in straigh t - ahead po s ition) Maximum permissible difference between sides - 1 20' 20' max[...]

4 4 -5 Rear axle Semi-trailing arm axle Engine 85 kW, 128 kW (115 hp, 172 hp) Camber 1) Maximum permissible difference between sides - 1 15' 30' max. 30' Total toe 1) (at specified camber) Maximum permissible deviation from direction of travel +15' 20' max. 20' 1) Camber and toe corrections possible using eccentric rub[...]

4 4 -6 Front w heel camber , adjust i ng Note: - Install special tool as shown in illustration and slightly pre-tension. - Loosen suspension strut/wheel bearing housing connection . - Adjust camber by turning the spindle to specified setting . - Tighten suspension strut/wheel bearing housing connection . - Check camber and if necessar y , repeat ad[...]

4 4 -7 Calculating the d i rection of trave l : - If both toe figures have the same preceding sign (+/+ or -/-), subtract the smaller figure from the larger figure and divide by 2 Example. Left rear wheel toe Right rear w h eel toe + 15' + 5' 15' - 5' = 10' 10' : 2 = 5 ' Deviation from direction of travel = 5 &apo[...]

4 5 -1 Ant i -locking Brake System ( ABS) and Anti-locking Brake System with Electronic Di f ferential Lock (ABS/EDL) Teves 04 The ABS, ABS/EDL brake system is divided diagonally. The servo-assist is effected pneumatically, by the vacuum brake servo unit. Located between the brake master cylinder and the vacuum servo unit is a mounting bracket for [...]

4 5 -2 Notes for repair w ork on A B S , A BS / E D L Before doing any repair work on the anti- locking system, determine the cause of the malfunction using On Board Diagnostic (OBD). Repair Manual, Brake System On Board Diagnostic (OBD), Repair Group 01 Before working on the ABS, ABS/EDL system, disconnect the battery Ground strap. On vehicles wit[...]

4 5 -3 Thoroughly clean all unions and the adjacent areas before loosening, do not use aggre s sive cleaning agents such as brake cleaner, petrol, thinners or similar. Place removed parts on a clean surface and cover. Do not use fluffy cloth. Carefully cover or seal open components if repairs cannot be carried out immediately. Only remove replaceme[...]

4 5 -4 Contro l m odu l e, re m ov i ng and install i ng Location Under the rear seat, left Note: Switch off ignition before disconnecting and connecting connectors. Removing - Fold up rear seat. - Press control module se c uring clips together and pull out. - To pull connector off control module, release control module locking bar . Installing - I[...]

4 5 -5 Wheel speed sensor and rotor for speed sensor, re m ov i ng and i nstal l ing Speed sensor When installing speed sensor ensure wiring is not twisted. Before installing speed sensor, clean mounting hole and coat with lubricating paste, G 000 650. Rotors Before installing check that rotor is clean and undamaged. Front axle Vehicles with base s[...]

4 5 -6 Ant i -lock Brake System (ABS) and ABS with Electronic Di f ferential Lock (ABS/EDL), Teves 20 GI General information The ABS or ABS/EDL braking s ystem is divided diagonally. Brake pedal pressure is boosted pneumatically, by the vacuum brake booster. Vehicles with Teves 20 GI ABS or ABS/EDL do not have a mechanical brake pressure regulator.[...]

4 5 -7 Safety precautions WARNING! Brake fluid is p o isonous. CAUTION! Before working on the ABS or ABS/EDL system, disconnect the battery Grou n d (GND) strap. For anti-theft coded radios, first m ake sure t h at the radi o code is available. Brake fluid must not contact painted parts. Brake fluid absorbs moisture from t h e air and must therefor[...]

4 5 -8 CAUTION! During the final road test, make sure that at least one c o ntrolled brake test is included (pulsations must be felt at the brake pedal). Abs o lute cleanli n ess is required when working on the ABS or ABS/EDL system. DO NOT use any products that contain mi n eral oil, such as oils, greases, etc. Thoroughly clean all c o nnections a[...]

4 5 -9 ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master cylinder ( Teves 20 GI), servicing CAUTION! DO NOT se p arate the ABS hydraulic pump from the valve bl o ck. 1 - Brake servo (vacuum brake booster) 2 - Brake master cylinder 3 - Brake fluid reservoir 4 - Cap 5 - Self-locki n g n ut Always replace 25 Nm (18 ft lb) 6 - Tor x so[...]

4 5 -10 8 - Rubber damper 9 - Retainer 10 - ABS h ydraulic unit 11 - ABS cont r o l module 12 - Brake line connection ABS hydraulic unit to right-front brake caliper 13 - Brake line connection ABS hydraulic unit to left-rear brake caliper or wheel cylinder 14 - Brake line connection ABS hydraulic unit to right- rear brake caliper or wheel cylinder [...]

4 5 -11 A B S hydraulic unit and A BS control module (Teves 20 GI ) , removing and instal l ing Carefully read and follow all cautions and warnings Page 45-7 before beginning work. Location The ABS control module is bolted to the ABS hydraulic unit, located on the lef t -side of the engine compartment. CAUTION! Do not bend brake lines at or n ear t[...]

4 5 -12 After separating ABS control module from ABS hydraulic unit, always install valve dome transportation protection on hydraulic unit. Warranty claims for ABS hydraulic units on which the valve dome transportation protection was not used will not be accepted. Removing CAUTION! Determine correct radio anti-theft codi n g before disconnecting th[...]

4 5 -13 - Release retainer and disconnect ABS control module connector (arrows) . - Connect bleeder hose and bleeder bottle to lef t- front brake caliper bleeder screw, and open bleeder screw . - Depress brake pedal at least 60 mm ( 2 -3/8 in.). - Install brake pedal loading device from special tool VAG 1238B. - Close left-front bleeder screw. - Re[...]

4 5 -14 - Remove Tor x socket-head bolts (T25) from ABS hydraulic unit bracket. - Remove ABS hydraulic unit/ABS control module assembly . - Disconnect ABS hydraulic pump connector from ABS control module. CAUTION! - Remove ABS control module mounting bolts (arrows) and pull off ABS control module . Pull control mod u le straight off. Do not tilt. C[...]

4 5 -15 Installing Note: Remove the sealing plug s from a new ABS hydraulic unit one at a time, and only when the corresponding brake line is to be connected. If the plugs are removed too soon, brake fluid can escape and it can no longer be certain that the unit is sufficiently filled or adequately bled. - Mount ABS control module to hydraulic unit[...]

4 5 -16 Note: For vehicles equipped with ABS/EDL, on which the brake fluid reser v oir has been completely empty (e.g. leaks in brake system), it is necessary to initiate the "Basic Setting" function of the On Board Diagnostic (OBD) program: Repair Manual, Brake System On Board Diagnostic (OBD), Repair Group 01 Otherwise the standard brak[...]

4 5 -17 Brake hydrau l ic system , bleeding and fi l l i ng Vehicles with ABS/EDL For vehicles with ABS/EDL, when the brake fluid reservoir has been completely emptied (e.g. due to leaks in the brake system) it i s necessary to initiate the "Basic Setting" function of the On Board Diagnostic (OBD) program. Repair Manual, Brake System On B[...]

4 5 -18 Assembly overview - hydraulic unit, brake servo/brake master cylinder Note: Repair Manual, Brake System On Board Diagnostic (OBD), Repair group 01 Pump and valve block must not be separated from one another. Illustration shows an exploded view of the ABS/EDL unit. Servicing of ABS unit is identical. Distinguishing features 1 - Brake Pedal P[...]

4 5 -19 2 - Spacer cap Various versions Page 45-25 3 - Sealing ring Always replace 4 - Ci r clip Always replace 5 - Brake line Brake master cylinder/primary piston circuit to hydraulic unit 6 - Brake servo 7 - Carrier plate 8 - Sealing ring 9 - Pin 10 - Sec u r ing clip 11 - Brake fluid reservoir Page 2 of 10 Assembly overview - hydraulic unit, bra[...]

4 5 -20 Repair Manual, Brake System On Board Diagnostic (OBD), Repair group 01 12 - Cap 13 - Hex socket h ead screw for brake fluid r eservoir 14 - Series resistor Only on vehicles with ABS/EDL Checking 15 - Self- locki n g hex nut, 25 Nm (18 ft lb) 16 - Tandem brake master cylin d er 17 - Protective plate 18 - Hex bolt for protective plate Page 3 [...]

4 5 -21 19 - ABS Hydraulic unit Connections (arrow) show pipe work from tandem master cylinder to ABS hydraulic unit Removing and installing Page 45- 23 20 - ABS/EDL Hydraulic unit Removing and installing Page 45- 23 21 - Brake line connection Hydraulic unit to front right brake caliper Thread connection: M10 x 1, 15 Nm (11 ft lb) 22 - Torx bolts ([...]

4 5 -22 24 - Brake line connection Hydraulic unit to rear right wheel cylinder Thread connection: M12 x1, 18 Nm (13 ft lb) 25 - Brake line connection Hydraulic unit to front left brake caliper Thread connection: M10 x1, 15 Nm (11 ft lb) 26 - Brake line Master brake cylinder/secondary piston circuit to hydraulic unit Page 5 of 10 Assembly overview -[...]

4 5 -23 Hydrau l ic un i t , removing and insta l l i ng Note: For easier disassembling and as s embling, it is more practical to remo v e the hydraulic unit complete with brake servo and brake master cylinder. Removing - Disconnect battery Ground (GND) strap. - Separate all electrical connections on ABS unit. - Remove as much brake fluid a s possi[...]

4 5 -24 - Remove nuts from brake servo/bulkhead. - Carefully remove hydraulic unit and brake servo with brake master cylinder from engine compartment. Installing Note: Hydraulic units supplied as replacement parts are already filled with hydraulic fluid and bled. Only remove sealing plugs on hydraulic unit when the relevant brake line is going to b[...]

4 5 -25 Brake Pedal P os i t i on Sensor, re m oving and insta l ling Note: The Brake Pedal Position Sensor is only supplied as a repair kit. Apart from the sender, this repair kit contains a sealing ring, circlip and four different spacer caps. - - one white spacer cap - - one green spacer cap - - one blue spacer cap - - one red spacer cap The spa[...]

4 5 -26 Removing - Release brake servo vacuum by operating the brake pedal several times . - Remove connector from expansion tank. - Swing coolant expansion tank to side. - Pull connector off sensor. - Expand circlip with a small screwdriver in a clockwise direction and pull sensor (arrow) out of brake s ervo . Page 9 of 10 Assembly overview - hydr[...]

4 5 -27 Installing Note: When installing new circlip ensure opening is uppermost - installation position (arrow). - Install new sealing ring to sensor. (Coat sealing ring with lubricant e.g. soft soap) . Note: - Sen s or notch must point downward when inserting into brake servo and be heard to engage . - Connect sensor unit connection and en s ure [...]

4 6 -1 Front brakes, servicing (Girling caliper ) Note: After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the brake pads are properly seated in their normal operating position. To remove brake fluid from the reservoir, use a bleeder bottle which is used only for brake fluid. Brake fluid is poisonou[...]

4 6 -2 1 - Brake disc, not ventilated When worn always replace on both side s Brake disc diameter: 256 mm Brake disc thickness: 13 mm Wear limit: 11 mm 2 - Brake disc, ventilated When worn always replace on both side s Brake disc diameter: 256 mm Brake disc thickness: 20 mm Wear limit: 18 mm 3 - Screw 4 - Counters u nk screw To secure rotor Only on[...]

4 6 -3 Repair Manual, Maintenance 5 - Brake pad With brake pad wear indicator Always replace on both side s Removing and installing Page 46-6 Pad thickness: non- ventilated brake disc, 14 mm Pad thickness: ventilated brake disc, 11 mm Checking thickness Wear limit: 7 mm (including backplate) 6 - Hub Removing and installing from Page 40-14 7 - Wheel[...]

4 6 -4 10 - Wheel bearing housing 11 - Brake car r ier wit h gui d e pins and protective caps Supplied as replacement part assembled with sufficient amount of grease on guide pins If protective caps are damaged use repair kit Use grease packet supplied to lubricate guide pins 12 - Heat shield Install in piston 13 - Brake caliper housing Do not disc[...]

4 6 -5 14 - Self-locki n g hex bolt, 35 Nm (26 ft lb) Always replace 15 - Guide pin 16 - Ribbed bolt, 125 Nm (92 ft lb) 17 - Protective cap 18 - Hex socket h ead bolt, 10 Nm (7 ft lb) 19 - Speed sensor Only on vehicles with ABS Before inserting sensor clean mounting hole inner surface and coat with lubricating paste, G 000 650 Page 5 of 7 Front bra[...]

4 6 -6 Brake pads , removing and insta l ling Removing - Remove lower brake caliper housing securing bolt. Counter-hold on guide pin . - Swing brake caliper housing upward. - Remove brake pads. Page 6 of 7 Front brakes, servicing (Girling caliper) 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=V[...]

4 6 -7 Installing Note: Before inserting new brake pads, press piston back into the cylinder with resetting tool. Before pressing the piston back, remove some brake fluid from the reservoir with a bleeder bottle. If reservoir has been topped up, fluid may overflow and cause damage. Note: - Press piston back. - Install brake pad s. - Swing brake cal[...]

4 6 -8 Front brakes, servicing ( Teves/Ate ) Repair Manual, Maintenance 1 - Screw 2 - Brake disc When worn always replace on both side s Remove brake caliper prior to removing Ventilated brake disc diameter: 288 mm Brake disc thickness: 25 mm Wear limit: 23 mm 3 - Brake pads Always replace on both side s Pad s are different; pad on piston side has [...]

4 6 -9 4 - Retaining spring Insert in both brake caliper housing drillings 5 - Brake car r ier Supplied as replacement part assembled with sufficient amount of grease on guide pins If protective caps are damaged use repair kit Use grease packet supplied to lubricate guide pins 6 - Brake caliper housing Do not disconnect brake hose when changing bra[...]

4 6 -10 7 - Guide pins, 25 Nm (18 ft lb) Removing and installing from Page 46-12 8 - Protective cap 9 - Seal Always replace Pry out with suitable tool 10 - Brake hose 11 - Banjo bolt, 30 Nm (22 ft lb) 12 - Ribbed bolt, 125 Nm (92 ft lb) 13 - Wheel bearing housing 14 - Hex socket h ead bolt, 10 Nm (7 ft lb) 15 - Speed sensor Only on vehicles with AB[...]

4 6 -11 16 - Splash plate 17 - Hex bolt, 10 Nm (7 ft l b) 18 - Speed sensor rotor Only on vehicles with ABS 19 - Hub Removing and installing Page 40- 14 20 - Counters u nk bolt Page 4 of 7 Front brakes, servicing (Teves/Ate) 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.46.2[...]

4 6 -12 Brake pads , removing and insta l ling Removing Note: If reusing brake pads mark location and install in same position or uneven braking may result. - Remove protective caps. - Pry off brake pad retaining s pring from brake caliper housing with a screwdriver and remove . Page 5 of 7 Front brakes, servicing (Teves/Ate) 12/7/2004 http://ebahn[...]

4 6 -13 Installing Note: Before installing new brake pads, press piston back into the cylinder with resetting tool. Before pressing the piston back, remove some brake fluid from the reservoir with a bleeder bottle. If reservoir has been topped up, fluid may overflow and cause damage. - Remove both guide pins from brake caliper. - Remove brake calip[...]

4 6 -14 - Install brake pad with retaining spring in brake caliper housing (piston). - Install outer brake pad in brake carrier. - Secure brake caliper housing with both guide pins to brake carrier. - Install both protective caps. - Install retaining spring into brake caliper housing. Note: After replacing the brake pads, depress brake pedal firmly[...]

4 6 -15 Rear wheel brakes, servicing (drum brakes ) Notes Page 42-15 1 - Grease cap Removing and installing from Page 42-19 2 - Cotter pin Always replace 3 - Locking ring 4 - Hex nut Adjusting wheel bearing play Page 42-20 5 - Thrust was h er Page 1 of 4 Rear wheel brakes, servicing (drum brakes) 12/7/2004 http://ebahn.bentleypublishers.com/vw/serv[...]

4 6 -16 6 - Outer wheel bearing 7 - Wheel s p eed sensor r o tor Only on vehicles with ABS 8 - Brake drum Vehicles with front wheel drive Brake drum diameter: 230 mm Wear limit: 231.5 mm Clean thoroughly, check for wear, damage, tolerances, damaged wheel bolt threads and condition of braking surface Fill hub with multi- purpose grease Check for ova[...]

4 6 -17 10 - Hex socket h ead bolt, 10 Nm (7 ft lb) 11 - Wheel s p eed sensor Only on vehicles with ABS Insert with lubricating paste, G 000 650 12 - Backin g plate wit h brake shoes Release adjustment before removing brake drum Page 46-18 13 - Dished washer Large contact surface faces back plate 14 - Hex bolt, 60 Nm (44 ft lb) Page 3 of 4 Rear whe[...]

4 6 -18 Brake shoe ad j ust m ent, re l eas i ng - Insert a screwdriver through hole in brake drum and push wedge upward . Page 4 of 4 Rear wheel brakes, servicing (drum brakes) 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.46.3[...]

4 6 -19 Rear wheel brakes, servicing Note: After working on the rear wheel brakes: Release parking brake. Firmly depress the bra k e pedal once. 1 - Spring plate To remove, push against the spring and turn through 9 0 2 - Spring 3 - Brake shoe with lever for parking brake Removing and installing Page 46- 23 Adjusting parking brake Page 46-26 Page 1[...]

4 6 -20 Repair Manual, Maintenance 4 - Uppe r return spring Unhook with pliers 5 - Lower return spring Lubricate contact points with G 000 650 paste 6 - Wedge spring 7 - Brake shoe Removing and installing Page 46- 23 Minimum lining thicknes s 2.5 mm Checking thickness 8 - Cap Remove to check brake lining thickness 9 - Pin 10 - Wheel s p eed sensor [...]

4 6 -21 11 - Backin g plate 12 - Hex socket h ead bolt, 10 Nm (7 ft) 13 - Wheel cylinder Checking for leaks Fig. 1 14 - Wedge To remove and install the brake drum, push upwards through a wheel bolt hole Page 46-18 15 - Push rod Lubricate contact points with G 000 650 paste 16 - Locating spring Unhook with pliers Page 3 of 8 Rear wheel brakes, servi[...]

4 6 -22 Note: Care is to be exercised to ensure the seal i s not damaged when lifting the dust boot (only use a blunt instrument, e.g. plastic wedge). Fig. 1 Wheel cylinder, checkin g for leaks - Lift dust boot - If brake fluid is found in the dust boot then replace wheel cylinder Page 4 of 8 Rear wheel brakes, servicing 12/7/2004 http://ebahn.bent[...]

4 6 -23 Brake shoes, removing and instal l ing Removing - Remove brake drum. - Remove spring plate. - Unhook lower return spring. - Remove brake shoes. - Unhook parking brake cable. - Clamp brake shoes in vice. - Remove wedge spring. - Remove upper return spring. - Unhook locating spring. Page 5 of 8 Rear wheel brakes, servicing 12/7/2004 http://eb[...]

4 6 -24 Installing - Connect locating spring and install brake shoes on the push rod. - Insert wedge. - Insert brake shoe with brake lever in push rod. - Connect upper return s pring. - Connect parking brake cable to brake lever. - Place brake shoes on wheel cylinder pistons. - Connect lower return spring and lift brake shoes onto lower support . P[...]

4 6 -25 - Attach wedge spring. - Install springs and spring plates. - Install brake drum and adjust wheel bearing play. Adjusting wheel bearing play Page 42- 20 - Firmly depress brake pedal once, this adjusts the rear brakes. Page 7 of 8 Rear wheel brakes, servicing 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty [...]

4 6 -26 Park i ng brake , adjusting (drum brakes) Note: Due to the automatic rear wheel brake adjustment there is no requirement to adjust the parking brake. Adjustment is only necessary after replacing parking brake cables, backing plate or brake linings - Release parking brake. - Firmly depress brake pedal once. - Pull parking bra k e lever up fo[...]

4 6 -27 Rear wheel brakes, servicing (disc brakes ) G i rling rear wheel disc brakes (front and four wheel drive vehicles) Note: Only items 5, 6, 7, 8, 9, 10, 11 and 12 apply for four wheel drive. 1 - Axle beam 2 - Hex socket h ead bolt, 10 Nm (7 ft lb) 3 - Wheel s p eed sensor Only for vehicles with ABS Insert with lubricating paste, G 000 650 Pag[...]

4 6 -28 4 - Brake hose bracket 5 - Hex socket h ead bolt, 65 Nm (48 ft lb) 6 - Self-locki n g b o lt, 35 Nm (26 ft lb) Always replace When loosening and tightening, counter- hold on guide pin 7 - Guide pin 8 - Protective cap 9 - Pad retaining s p r ings Always replace when changing pads 10 - Backin g plate ring Distance between ring collar and back[...]

4 6 -29 Repair Manual, Maintenance 11 - Brake car r ier wit h gui d e pins and protective cap Supplied as replacement part assembled with sufficient grease on guide pins If protective caps or guide pins are damaged use repair kit. Use grease packet supplied to lubricate guide pins. 12 - Brake pads Thickness: 12 mm Checking thickness: Wear limit: 7m[...]

4 6 -30 14 - Outer wheel bearing 15 - Hex nut Adjusting wheel bearing pla y Using a screwdriver it must be possible to move the thrust washer by finger pressure (without leverage) Page 42- 20 Secure with locking ring and new cotter pin 16 - Cotter pin Always replace 17 - Grease cap Removing and installing Page 42- 29 18 - Lock ri ng 19 - Thrust was[...]

4 6 -31 21 - Brake disc Brake disc diameter for vehicles with front wheel drive: 226 mm Removing and installing Page 42- 24 Brake disc diameter for vehicles with four wheel drive: 239 mm Removing and installing Page 42- 59 Brake disc thickness, for both v ersions: 10 mm Wear limit: 8 mm When worn, always replace on both side s Assembly sequence for[...]

4 6 -32 24 - Wheel s p eed sensor r o tor Insert drift through wheel bolt holes and drive off Drive on with suitable sleeve 25 - Hex bolt, 60 Nm (44 ft lb) 26 - Dished spring washer Larger seating surface towards backing plate 27 - Backin g plate 28 - Stub axle 29 - Parking brake cable Adjusting parking brake Page 46-36 30 - Spring clip Page 6 of 1[...]

4 6 -33 Brake pads , removing and insta l ling Note: Mark brake pads when removing if they are to be reused. Re-install in their original position to prevent uneven braking! Removing - Remove wheels. - Remove parking brake cable from brake caliper (arrow) . - Remove securing bolts from brake caliper housing; counter-hold on guide pins . - Remove br[...]

4 6 -34 Installing Note: Before pressing the piston back, remove some brake fluid from the reservoir. Use a bleeder bottle or a plastic bottle which is only u s ed for brake fluid. Brake fluid is poisonous and mu s t not be siphoned by mouth through a hose. Note: - Thread in piston by turning knurled wheel of special tool 3272 clockwise . - Install[...]

4 6 -35 - Secure brake caliper housing with new self- locking bolts . Note: - Attach parking brake cable (arrow) to brake caliper housing. After each brake pad change firmly depress brake pedal several times with vehicle stationary, so that the brake pads are properly seated in their normal operating position. After changing brake pads check brake [...]

4 6 -36 Park i ng brake , adjusting (disc brakes) Note: Due to the self-adjusting rear brakes there is no requirement to adjust the parking brake. Adjustment is only necessary after replacing parking brake cables, brake calipers, brake pads and brake discs. Remove hand grip and central console to allow access to adjusting nuts (arrows) Page 46-39 .[...]

4 6 -37 Parking brake lever assembly overvie w 1 - Parking brake lever Different versions for rear drum and disc brakes Before removing remove center console 2 - Han d grip Pry trim up with a small screwdriver then pull forward to remove Fig. 2 3 - Adjustin g n ut Adjusting parking brake: - Vehicles with drum brakes Page 46- 26 - Vehicles with disc[...]

4 6 -38 4 - Lock nut 5 - Compe n sator 6 - Parking brake leve r trim First pull off parking brake hand grip then pull trim forward Fig. 2 7 - Hex nut 8 - Parking brake cable Different versions for rear drum and disc brakes Allocation see Parts catalog Page 2 of 9 Parking brake lever assembly overview 12/7/2004 http://ebahn.bentleypublishers.com/vw/[...]

4 6 -39 The parking brake cable is secured by clamps to the axle beam in the center of the two colored marks (arrow). Fig. 1 Parking brake cable installation position Fig. 2 Han d grip, removing - Pry up parking brake cable trim with a screwdriver and pull grip and trim off forward. Page 3 of 9 Parking brake lever assembly overview 12/7/2004 http:/[...]

4 6 -40 Fig. 3 Center cons o le, removing - Remove rear ashtray (center console). - Remove console rear securing screws (arrows). Page 4 of 9 Parking brake lever assembly overview 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.46.6[...]

4 6 -41 Brake peda l /brake servo, re m ov i ng and i nstal l ing CAUTION! The brake pe d al travel must not be restricted by additional floor cove r ings. Note: Grease all mountings before installing with G 000 602 grease. 1 - Sec u r ing clip Ensure securely seated 2 - Pin 3 - Brake servo push rod clevis 4 - Self- locki n g hex nut, 20 Nm (15 ft [...]

4 6 -42 Repair Manual, 5 Spd. Manual Transmission 02A, Repair Group 30 Repair Manual, 5 Spd. Manual Transmission 02A, Repair Group 30 6 - Brake pedal return spring 7 - Return spring m o unting tube 8 - Brake pedal mou n ting bushing 9 - Brake pedal 10 - Clutch pedal Removing and installing 11 - Pedal cluster mounting bracket 12 - Clutch pedal pivot[...]

4 6 -43 16 - Sec u r ing clip Ensure seated securely 17 - Brake Light Switch Adjusting Page 46- 45 Page 7 of 9 Parking brake lever assembly overview 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.46.6[...]

4 6 -44 Brake peda l , re m ov i ng and i nstall i ng Note: Grease all mounting and contact surfaces with MoS 2 grease. To remove brake servo disconnect brake pedal at clevis only. Removing - Before removing brake pedal remove trim - Remove brake pedal clevis pin c onnection securing clip. - Remove pin. - Remove brake pedal pivot pin securing clip.[...]

4 6 -45 Brake Light S wi tch, ad j ust i ng Note: The Brake Light Switch must be removed for adjusting. - Remove trim under instrument panel. - Disconnect harness connector for Brake Light Switch. - Remove Brake Light Swit c h by turning to right through 9 0 . - Pull Brake Light Switch plunger fully out. - Depress brake pedal as far as possible by [...]

4 7 -1 Assembly overview : brake master cylinder/brake serv o Note: Brake master cylinders and brake s ervos from different manufacturers are installed. Complete master cylinders and brake s ervos can be replaced independently of each other. 1 - Seal For brake servo 2 - Self- locki n g hex nut, 20 Nm (15 ft lb) 3 - Mounting bracket 4 - Mounting bra[...]

4 7 -2 6 - Brake servo On gas engines the vacuum required is taken from the intake manifold. On Diesel engines an exhauster is installed to create the required vacuum. Functional check - With engine switched off, depress brake pedal firmly several times (to exhaust the vacuum in the unit). - Now depress brake pedal with average foot pressure, hold [...]

4 7 -3 7 - Sealing ring Always replace 8 - Self- locki n g hex nut, 20 Nm (15 ft lb) 9 - Brake master cylinder Cannot be repaired. If faulty, replace complete. 10 - Sealing plug Moisten with brake fluid and press into reservoir 11 - Seal Page 3 of 4 Assembly overview: brake master cylinder/brake ser vo 12/7/2004 http://ebahn.bentleypublishers.com/v[...]

4 7 -4 12 - Cap 13 - Brake fluid reservoir 14 - Non- r eturn valve Page 4 of 4 Assembly overview: brake master cylinder/brake ser vo 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.47.1[...]

4 7 -5 Girling f ront brake caliper, servicing Note: When repairing install all parts supplied in repair kit. Apply thin coat of brake cylinder paste to brake cylinders, pistons and sea/s. 1 - Protective seal 2 - Bleed valve Apply thin coat of brake c ylinder paste to threads before screwing in 3 - Brake caliper housing 4 - Self-locki n g hex bolt,[...]

4 7 -6 5 - Seal Remove using a screwdriver Page 47-7 6 - Piston Removing and installing Page 47-7 Apply thin coat of brake c ylinder paste before inserting 7 - Protective seal Do not damage when inserting piston 8 - Brake car r ier wit h gui d e pins and protective caps Brake carrier with guide pins and protective cap Supplied as replacement part a[...]

4 7 -7 Front brake caliper p i stons, re m oving and insta l ling Removing Note: Place a piece of wood in the recess to prevent damaging the piston. - Force piston out of brake caliper housing using compressed air . Note: When removing ensure that the surface of the cylinder is not damaged. - Remove seal with a screwdriver. Page 3 of 5 Girling fron[...]

4 7 -8 Installing - Place prote c tive seal with the outer sealing lip on the piston . Note: Hold piston in front of caliper housing. - Using a screwdriver, insert the inner sealing lip into the cylinder groove. Page 4 of 5 Girling front brake caliper, servicing 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=[...]

4 7 -9 Note: The protective seal outer sealing lip will then locate in the piston groove. - Press piston into the brake caliper housing using piston resetting tool . Page 5 of 5 Girling front brake caliper, servicing 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.47.2[...]

4 7 -10 Front brake caliper, servicing ( Teves/Ate ) Note: When repairing install all parts supplied in repair kit. Apply thin coat of brake cylinder paste to brake cylinders, pistons and seals. 1 - Protective seal Push onto bleed valve 2 - Bleed valve Apply thin coat of brake c ylinder paste to threads before threading in 3 - Cap Install in mounti[...]

4 7 -11 6 - Brake cylinder housing 7 - Brake car r ier Install on brake caliper housing 8 - Retaining spring Install with both ends in the drillings in brake caliper housing 9 - Piston seal Remove using a screwdriver Fig. 2 10 - Piston Force piston out of brake c aliper using compressed air Fig. 1 Installing Fig. 3 and Fig. 4 and Fig. 5 First coat [...]

4 7 -12 Note: Place a piece of wood in the recess to prevent damaging the piston. Fig. 1 Piston, pressin g o u t of cylinder using compressed air Fig. 2 Piston seal, removing Page 3 of 5 Front brake caliper, servicing ( T eves/Ate) 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.47.3[...]

4 7 -13 Fig. 3 Protective seal, installing Note: Hold piston in front of caliper housing. Fig. 4 Protective seal, installing - Using a screwdriver, insert inner sealing lip into cylinder groov e Page 4 of 5 Front brake caliper, servicing ( T eves/Ate) 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&[...]

4 7 -14 Note: The protective seal outer sealing lip will then locate in the piston groove. Fig. 5 Piston, i n stalling Page 5 of 5 Front brake caliper, servicing ( T eves/Ate) 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.47.3[...]

4 7 -15 Rear brake caliper, servicing Note: Apply thin coat of brake cylinder paste to brake cylinder pistons and seal. When repairing install all parts supplied in repair kit. New brake calipers are filled with brake fluid and are pre-bled. When repairing it is essential to pr e -bleed the brake c alipers (without brake pads) before installing in [...]

4 7 -16 2 - Sealing ring Remove using a screwdriver Page 47-19 3 - Piston with automatic adjustment Removing and installing Page 47- 19 4 - Protective seal Pull outer sealing lip onto piston Install inner sealing lip in brake caliper housing groove Page 47-20 5 - Dust cap 6 - Bleeder valve Apply thin coat of brake c ylinder paste before screwing in[...]

4 7 -17 7 - Brake caliper housing with parking brake cable lever If a leak exi s ts at the parking brake cable lever repla c e bra k e caliper housing After repairing, pre- bleed caliper housing Page 47-21 8 - Guide pins Grease before pulling on protective cap 9 - Protective cap Pull onto brake carrier and guide pin Page 3 of 8 Rear brake caliper, [...]

4 7 -18 10 - Brake car r ier wit h gui d e pin an d protective cap Supplied as replacement part, assembled with sufficient grease on guide pins If protective caps or guide pins are damaged, install repair kit. Use grease packet supplied to lubricate the guide pins. Page 4 of 8 Rear brake caliper, servicing 12/7/2004 http://ebahn.bentleypublishers.c[...]

4 7 -19 Rear brake ca l iper piston, re m ov i ng and instal l ing Removing Note: - Thread piston out of brake caliper housing by turning the knurled wheel counter-clockwise. If piston is difficult to move, use a 13 mm open end wrench on the flats (arrow A) provided for this purpose. Install special tool 3272 so that the collar (arrow) is before th[...]

4 7 -20 Installing - Place prote c tive seal with the outer sealing lip on the piston . Note: Hold piston in front of brake caliper housing. - Insert protective seal inner sealing lip into the caliper housing groove using a screwdriver . Page 6 of 8 Rear brake caliper, servicing 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action[...]

4 7 -21 Note: - Thread piston into housing by turning knurled wheel clockwise. Install special tool 3272 so that the collar (arrow) of the tool is seated against the brake carrier. If piston is difficult to move, use a 13 mm open end wrench on flats (arrow A) provided for this purpose. If the piston is pushed back with a piston resetting tool or by[...]

4 7 -22 Pre-b l eed i ng brake ca l iper Note: Position brake caliper as illustrated to pre-bleed. - Open bleeder valve and using a standard bleeder bottle, fill with brake fluid until bubbl e -free brake fluid flows from the threaded hole (brake hos e connection). Close bleeder screw . Page 8 of 8 Rear brake caliper, servicing 12/7/2004 http://eba[...]

4 7 -23 Brake pressure regulator, checking and adjus t ing Vehicles w ithout A B S , veh i cles w ith A B S, A B S/ E DS , Teves 04 The brake pressure regulator is mounted on a bracket which is in turn fixed to a rear axle mounting bracket and is controlled from the rear axle by a spring. Checki n g o peration Firmly depress the bra k e pedal and r[...]

4 7 -24 Note: Bleeding brake system on vehicles with ABS Page 47-27 . - Lift vehicle and connect pressure gauges to front left brake caliper and to rear right wheel cylinder/caliper. - Bleed both gauges. - Lower vehicle and bounce the rear of the vehicle several times. - Depress brake pedal and check pressures. - Compare figures attained with speci[...]

4 7 -25 Load dependent brake pressure regulator specifications Model / Versi o n Bar (psi) Bar (psi) Rear axle drum Front axle 50 (725) Front axle 100 (1450) brakes Rear axle 30 - 36 (435 - 522) Rear axle 51 - 57 (740 - 827) Rear axle disc Front axle 50 (725) Front axle 100 (1450) brakes Rear axle 35 - 41 (508 - 595) Rear axle 56 - 62 (812 - 899) F[...]

4 7 -26 Adjusting regulator Rear axle test pressure too high: - Release tension on regulator spring. Rear axle test pressures too low: - Tension regulator spring. Note: Do not adjust with brake pedal depressed, therefore observe the following sequence: - Read off figures. - Release pedal. - Adjust spring. - Depress pedal again. - Read off figures a[...]

4 7 -27 Brake system, bleeding Brake system, bleeding (vehicles w ith and w i thout A B S , A B S /E D L) Cha n gin g brake fluid Repair Manual, Maintenance Note: Bleeding the brake sy s tem on vehicle s with ABS, ABS/EDL is performed as for vehicles with conventional braking systems. Only use new brake fluid conforming to US standard FMVSS 116 DOT[...]

4 7 -28 Brake system, bleeding ( w ith pressure b l eeder VA S 5234) Opening the hydraulic unit bleed screws on vehicles with ABS, ABS/EDL is not permitted! Bleeding sequence Note: - Connect VAS 5234 Brake filler and bleeder unit. - Open bleeder screws in the specified order and bleed brake calipers and wheel cylinders . 1 - Right rear wheel cylind[...]

4 7 -29 Brake system, bleeding ( w ithout pressure bleeder) Opening the hydraulic unit bleed screws on vehicles with ABS, ABS/EDL is not permitted! - Build-up brake pressure in brake system by pumping the brake pedal. - Attach bleeder bottle hose and open bleeder screw. - With brake pedal held down, c lose bleeder screw. - Repeat operation until no[...]

4 8 -1 Steerin g Asse m bly overvie w : steering colu m n, co l umn tube, steer i ng w hee l and a i rbag steer i ng w heel Ai r b ag system functional check and interrogating Diagnostic Trouble Code (DTC) Memory. Repair Manual, Body Exterior, Interior, Repair Group 68; General body repairs Safety p r ecautions when working on airbag Repair Manual,[...]

4 8 -2 1 - Cover plate 2 - Hex nut, 50 Nm (37 ft lb) 3 - Steeri n g wheel Install in center position 4 - Ai r b ag unit Removing and installing Page 48-7 5 - Steeri n g wheel f o r airbag Removing and installing Page 48-8 Removing and installing Airbag Spiral Spring Page 48-10 6 - Hex socket h ead bolt, 6.5 N m (57 in lb) Always replace 7 - Connect[...]

4 8 -3 9 - Spring 10 - Steeri n g column switch/steerin g lock housing 1) Distance between steering wheel/steering column switch is not adjustable 11 - Uppe r t r im 12 - Supp o r t ring 1) With washer 13 - Steeri n g column 1) Remove by pulling upwards out of column tube Checking length Page 48-6 14 - Hex bolt, 30 Nm (22 ft lb) 15 - Hex nut, 25 Nm[...]

4 8 -4 19 - Lower steering column bearing Pull in with VW 771 and large washer Drive out downward with a tube 20 - Washer Tighten until head shears off Drill out to remove 21 - Shea r bolt 22 - Column tube 23 - Lower trim Page 4 of 99 Steering 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4[...]

4 8 -5 Only use puller with leg clamp (e.g. Kukko 204/2 commercial type). Fig. 1 Splined adapter sleeve, removing Fig. 2 Splined adapter sleeve, installing - Place sleeve on steering column and press on with hex nut. - Remove nut, place on washer and press sleeve fully on with nut until sleeve is firmly seated . Page 5 of 99 Steering 12/7/2004 http[...]

4 8 -6 The small metal lug on the lower section must be visible in the hole in the upper section (arrow). If necessary pull both sections firmly apart onto stop or press together. Fig. 3 Length of steering column, checking Fig. 4 Steeri n g column, pre-assembling - Carefully clamp the lower section of the steering column in a vice so that the upper[...]

4 8 -7 Airbag un i t , removing and insta l l i ng Removing - Disconnect battery Ground strap. - Center s teering wheel (wheels straight- ahead) . Installing Install in reverse order Note: Only use new hex socket head bolts for airbag unit. Tightening torque: 6.5 Nm (57 in. Ib). CAUTION! Make sure that no one is in the vehicle when connecting the b[...]

4 8 -8 Airbag steer i ng w hee l , re m oving and instal l ing Removing - Remove airbag unit. Page 48-7 - Remove trim below steering column switch. Note: - Separate connector (arrow). (Pull foam rubber sleeve off connector, if installed) . - Remove nut and pull steering wheel off steering column . After pulling steering wheel off, turn Airbag Spira[...]

4 8 -9 Installing - Install steering wheel, install nut and tighten. Tightening torque: 50 Nm (37 ft lb). - Connect airbag unit connector below steering wheel. - Install trim panel below steering column. Make sure that the centering ring wiring connection is located in the recess in the trim panel. - Connect connector in steering wheel to airbag un[...]

4 8 -10 Airbag S piral Spring, removing and instal l ing Remove airbag unit Page 48-7 Remove steering wheel Page 48- 8 - Separate single connector for horn. Install steering wheel Page 48-9 Install airbag unit Page 48-7 Note: - Remove screws -1- and remove Airbag Spiral Spring -2- from steering wheel . When removing and installing the Airbag Spiral[...]

4 8 -11 Colu m n tube for he i ght ad j ustable steer i ng wheel , removing and instal l ing The column tube can be adjusted in height by approx. 50 mm 1 - Operating lever 2 - Packing plate 3 - Column tube Square housing fits over mounting bracket 4 - Rubber stop 5 - Return spring Hooked into mounting bracket and column tube 6 - Thrust was h er 7 -[...]

4 8 -12 8 - Clamping sleeve 9 - Mounting bracket Before assembling, coat side sliding surfaces with MoS 2 paste 10 - Bolt with left-hand thread Tighten to 22 Nm (16 ft lb), After tightening install locking plate 11 - Locking plate 12 - Locking plate nut, 8 Nm (70 in. Ib) Self-locking Always replace 13 - Washer 14 - Shea r bolt Tighten until head sh[...]

4 8 -13 Pump de l ivery pressure, checking - Disconnect pump pressure line. Test re q uirements: - Install adapter and test equipment. Cut-off valve on gauge open . - Start engine and if necessary add fluid to reservoir. A - VAG 1402/2 B - VAG 1402/1 C - Hose from adapter kit VAG 1402/6 D - VAG 1402 V-belt/V-belt tension OK. System not leaking. Hos[...]

4 8 -14 - With engine running at idling speed. Close cut- off valve (not longer than 5 seconds) and read off pressure. Spe c ification: 85 - 95 bar (1232 - 1377 psi) Note: If the reading is higher or lower than specified replace pump. Vehicles with up to 110 kW engine Page 48- 90 . Vehicles with 128 kW engine Page 48-97 . If reservoir fluid level i[...]

4 8 -15 Po w er steering gear, re m oving and instal l ing When working on the p ower assisted steering gear: Absolute cleanliness i s required when working on the power steering . Thoroughly clean connections and immediate vicinity before loosening . Place parts on a clean surface and cover if not re-installing immediately . Do not use fluffy clot[...]

4 8 -16 Removing - Press tie rods off steering arm. A - Ball joint splitter (commercial type) e.g. Kukko No. 128/2 - Remove partition behind pedals from bulkhead and from steering column tube to loosen the universal joint/power steering gear. If an oil extraction unit is not available, disconnect vane pump supply hose and drain hydraulic fluid. - L[...]

4 8 -17 Instead of plastic sealing plugs a plug consisting of Part No.113 301 229 A and banjo bolt, Part No. N 904 674 01 can be used. But when using these, several 16 mm diameter sealing rings must be used so that the holes in the banjo bolt are sealed. - Support engine/transmission assembl y with 10- 222 A and 10-222 A/1 (support VR6 engine with [...]

4 8 -18 Installing Install in reverse order. - Check position of steering wheel and, if necessary, align front end . Note: Tig h te n in g torques: When lifting the engine/transmission assembly guide the lower half of the universal joint shaft -A- into the upper half -B- at the same time (second mechanic necessary). Coat boot with lubricant, e.g. s[...]

4 8 -19 Asse m bly overvie w : power assisted steer i ng box (TR W ) Determine cause of any malfunctions using pressure and leak testing, Page 48-13 . Note: Always replace self-locking nuts and bolts. Welding and straightening work on steering components is not permitted. To grease the rack only use steering gear grease, Part No. AOF 063 000 04. Ty[...]

4 8 -20 1 - Self-locki n g n u t 35 Nm (26 ft lb) 2 - Self-locki n g 30 Nm (22 ft lb) 3 - Clamp 4 - Rubber mounting Internal diameter ZF: 50 mm TRW: 44 mm 5 - Right-hand tie rod 70 Nm (52 ft lb) Removing and installing Page 48- 77 Vehicle alignment Page 44-1 Tie rod boot seat diameter Z F: 15 mm dia. TRW: 12.7 mm dia. It must not be installed on a [...]

4 8 -21 6 - Left-hand tie rod 70 Nm (52 ft lb) Removing and installing Page 48- 77 Adjusting to length Page 48-84 Tie rod boot seat diameter Z F: 15 mm TRW: 12.7 mm Must not be installed on a ZF power steering gear 7 - Hex nut 50 Nm (37 ft lb) 8 - Boot Pull on and off over tie rod Can be replaced with steering gear installed Must not be twisted aft[...]

4 8 -22 Repair Manual, Maintenance 9 - Steeri n g g ear Removing and installing Page 48- 15 Adjusting Page 48- 24 10 - Tie rod end Separating Page 48-16 Checking: 11 - Hex nut 30 Nm (22 ft lb) 12 - Universal j o int Page 22 of 99 Steering 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01[...]

4 8 -23 13 - Threaded connection 30 Nm (22 ft lb) Return line 14 - Sealing ring Always replace 15 - Hose clamp Always replace - open with pliers Tensioning Page 48-81 Page 23 of 99 Steering 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.48.1[...]

4 8 -24 Po w er steering gear, ad j ust i ng (T R W) Note: Two Mechanics are required when adjusting. Adjust with engine switched off Adjusting steering box By turning the steering wheel back and forth (about 3 0 to center axis) a knocking noise will be heard if there i s excessive play. - Raise vehicle on hoist. - Wheels in s traight-ahead positio[...]

4 8 -25 Po w er steering gear, disassemb l ing and reasse m bl i ng (T RW ) This repair is limited to replacing the sealing rings and, if necessary, the toothed rod. Steering gears that are damaged by an ac c ident must be replaced. For a satisfactory and successful repair, the greatest care, safety and proper tools are required. The special tool s[...]

4 8 -26 1 - Tie rod For removing, see tie rod, remo v ing and installing (TRW and ZF power steering gear) Page 48-77 2 - Boot Installing, see tie rod, removing and installing (TRW and ZF) power steering), Page 48- 77 3 - Hose clamp Open with nipper pliers Installation position and tightening, see tie rod, remo v ing and installing (TRW and ZF power[...]

4 8 -27 7 - O- r ing Is assembled on toothed rod guide (item -6-) contained in the repair kit 8 - Pressure compensating tube Check for damage (dents and kinks) 9 - Toothed rod Check for scoring After removing lubricate immediately with hydraulic oil (corrosion protection) Supplied as a replacement part, for assignment see replacement parts fiche 10[...]

4 8 -28 11 - Adjustin g screw with lock n ut, 60 Nm (44 ft lb) Before removing, mark position of adjusting bolt and lock nut on housing Steering gear, adjusting Page 48- 24 12 - Pressure spring 13 - Pressure p iece Mark installation position 14 - Housing Check cylinder race for scoring, if necessary replace steering gear complete 15 - Inverte d tub[...]

4 8 -29 17 - Sealing ring Always replace 18 - Valve body Removing Page 48- 32 Cannot be repaired Is not supplied as replacement part, if damaged replace steering gear 19 - Supp o r t ring Eliminated starting 4/92 If present, it must be reinstalled 20 - Adhesive film Thoroughly clean housing in this area before sticking on, e.g. with thinner, adhesi[...]

4 8 -30 21 - Roller bearing installation position: inscription points up 22 - Sealing ring Always replace 23 - Ci r clip 24 - Ball bearing Drive from top downward with VW 439 Grease with steering gear grease AOF 063 000 04 25 - Self- locki n g hex nut, 30 Nm (22 ft lb) Always replace 26 - Locking screw, 40 Nm (30 ft lb) Always replace Is already pr[...]

4 8 -31 27 - Pipe Do not disconnect Not supplied as replacement part Sealing ring cannot be replaced 28 - O- r ing 29 - Sealing ring Replace if there is scoring that can be seen or felt Already pre-mounted on new toothed rods that are s upplied as replacement parts 30 - Sealing ring Not supplied as a replacement part 31 - Sealing ring Always replac[...]

4 8 -32 Po w er steering gear, disassemb l ing - Tie rods, removing - see tie rod, removing and installing (TRW and ZF power steering), Page 48-77 - Close hose connections on power steering gear if not already done 1 - Plastic locking screw 2 - Plastic locking screw Note: Use jaw covers and check jaw covers for contamination; e.g. metal chips or th[...]

4 8 -33 - Mark position of adjusting screw and lock nut to the housing (arrow) Note: - Screw lock nut together with adjusting screw Do not change position of adjusting screw to lock nut when removing If necessary, remove adjusting screw together with lock nut using tool 3115/6 Pressure piece/adjusting screw are slightly stressed with slight spring [...]

4 8 -34 - Mark installation position of pressure piece and remov e 1 - Spreading pliers (standard commercial) 2 - Pressure piece - Remove circlip for valve body 1 - Needle nose pliers (standard commercial) Page 34 of 99 Steering 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.48.1[...]

4 8 -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[...]

4 8 -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 housin g - Pull tooth[...]

4 8 -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 99 Steering 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Di[...]

4 8 -38 Inner sea l ing r i ng for toothed rod, pu l l i ng 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 c[...]

4 8 -39 Parts, cleaning a n d 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) - C[...]

4 8 -40 Check i ng 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[...]

4 8 -41 Sea l ing r i ng on toothed rod , replacing - Press pliers together with slight pressure on the sealing rin g - 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 99 Steering 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Got[...]

4 8 -42 Sea l ing r i ngs, i nstal l ing on toothed rod p i ston - 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 99 Steering 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Got[...]

4 8 -43 Po w er steering gear, assemb l ing Note; All s ealing rings should be lubricated with hydraulic oil before installing. - Check whether the valve bod y housing -2- is absolutely clean on the inside, otherwise clean - Place sealing ring -1- on tool. The sealing lip - arrow- points toward tool - Drive sealing ring into stop 1 - Sealing ring 2[...]

4 8 -44 Inner sea l ing r i ng for toothed rod, instal l ing - Place sealing ring on tool - Ensure correct installation position of sealing ring for toothed ro d - Drive sealing ring -1- into the cylinder pipe far enough so that the groove (arrow) on the tool matches the edge (arrow A) of the housin g 1 - Sealing ring A - Edge of housing For better[...]

4 8 -45 Toothed rod, insta l ling in hous i ng No grease must get into the oil circulation system! - Grease teeth of toothed rod with AOF 063 000 04 grease - Slide protective tube on to toothed rod to stop - Wipe exce s s grease off completely Page 45 of 99 Steering 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty [...]

4 8 -46 - Coat piston of toothed rod and protective tube with hydraulic oil When sliding, make sure that the sealing ring is pressed into the groove of the piston without jamming - Install in s tallation sleeve 3315/22 into the housing - Slide toothed rod into the housing - Slowly introduce the toothed rod into the housing - Pull protective tube 33[...]

4 8 -47 - Place lock washer in the housing and press in far enough until the groove in the lock washer in the slot of the housing is visible - Install new safety wire in the hole of the lock washer (arrow) - Pull safety wire in by turning the lock washer. (after pulling in, turn the lock washer approx. 1/2 revolution further) 1 - Safety wire in rep[...]

4 8 -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. [...]

4 8 -49 - Drive sealing ring in far enough sot that the groove for circlip in the housing is visible - Install circlip - Remove adhesi v e 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 lo c king screw - Grease pressure piece and spring in housing in o[...]

4 8 -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 99 Steering 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.48.1[...]

4 8 -51 Po w er steering gear, ad j ust i ng w ith ne w 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 (me[...]

4 8 -52 - Install gauge and set to "O" with approx. 1 mm pr e -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 han d - Turn toothed rod radially from stop to stop, during this process observe pointer on gauge . Page[...]

4 8 -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 adjustmen t - Remove gauge Close hole in adjusting screw with a stoppe[...]

4 8 -54 Asse m bly overvie w : power steering gear (ZF) It is not intended that repair work be c arried 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[...]

4 8 -55 1 - Power steerin g 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 99[...]

4 8 -56 3 - Boot Remove ball joint before removing Check for wear (cuts, crack s ), ensure sealing surfaces and sealing lips are clean and undamaged The end diameters are larger than the boot for TRW power steering gears Must not be installed on TRW power steering gear 4 - Hose clip Always replace - use pliers to open Tensioning Page 48-81 Must not[...]

4 8 -57 5 - Right-hand tie rod Removing and installing Page 48- 77 Vehicle alignment Page 44-1 Tie rod boot seat diameter Z F: 15 mm TRW: 12.7 mm Must not be installed on a TRW power steering gear 6 - Left-hand tie rod Removing and installing Page 48- 77 Tie rod boot seat diameter Z F: 15 mm TRW: 12.7 mm Must not be installed on a TRW power steerin[...]

4 8 -58 Repair Manual, Maintenance 7 - Lock nut, 50 Nm (37 ft lb) 8 - Tie rod ball joi nt Splitting Page 48-16 Checking: 9 - Pressure b alance pipe 10 - 30 Nm (22 ft lb) 11 - Clamp 12 - Rubber mounting Internal diameter ZF: 50 mm TRW: 44 mm 13 - Data plate and company initials Page 58 of 99 Steering 12/7/2004 http://ebahn.bentleypublishers.com/vw/s[...]

4 8 -59 Po w er steering gear, ad j ust i ng (ZF) Note: Two mechanics are required when adjusting. Adjust with engine switched off. - Raise vehicle on hoist. - Wheels in s traight-ahead position. - By turning the steering wheel to and fro (about 3 0 to center axis) a knocking noise will be heard if there is excessive play . - The second mechanic ca[...]

4 8 -60 Po w er steering gear, disassemb l ing and reasse m bl i ng (ZF) This repair is limited to replacing the sealing rings and, if necessary, the toothed rod. Steering gears that are damaged by an ac c ident must be replaced For a satisfactory and successful repair, the greatest care, safety and proper tools are required. Note: Clean hose conne[...]

4 8 -61 Po w er steering gear, disassemb l ing Note: Use jaw covers, check jaw covers for contamination; e.g. metal chips or the like - Tie rods, removing - see tie rod, removing and installing (TRW and ZF power steering), Page 48-34 - Close hose connections on power steering gear if not already don e 1 - Plastic locking screw 2 - Plastic locking s[...]

4 8 -62 Note: Do not change position of the adjusting screw (arrow) Cover is stressed with slight spring pressure - Remove pressure piece 1 - Spreading pliers (standard commercial) Page 62 of 99 Steering 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.48.1[...]

4 8 -63 - Remove lower locking screw for valve body 1 - Locking screw - Remove Torx screw for valve body 1 - Open-end wrench (standard commercial SW 14) 2 - Torx insert (standard commercial E10) 3 - Ratchet (standard commercial 3/8") Page 63 of 99 Steering 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=r[...]

4 8 -64 - Remove circlip for valve body with needle nose pliers 1 - Drive valve body out from below with driver - Slide toothed rod all the way in the direction of the valve bod y - Turn circlip so that the pointed end of the circlip is in the groove (arrow) of the housing Page 64 of 99 Steering 12/7/2004 http://ebahn.bentleypublishers.com/vw/servl[...]

4 8 -65 Center roller bearing for valve body, removing - First lift circlip with slotted screwdriver then pull out with plier s - Before removing toothed rod, clean housing opening with compres s ed ai r - Remove dirt and any chips that may be present - Pull toothed rod out of the housing to the right with toothed rod guid e A - Screwdriver B - Pli[...]

4 8 -66 For easier installation of the puller, it is recommended that a rubber band be placed around the jaws. Illustration shows the housing in cross section for better view. Sealing ring for valve body, removin g 1 - Puller e.g. Kukko 21/4 2 - Rubber band 3 - Sealing ring 4 - Housing When installing the puller A, make sure that the claws (arrows [...]

4 8 -67 For easier installation of the puller, it is recommended that a rubber band be placed around the jaws. Illustration shows the housing in cross section for better view. Inner sealing ring for toothe d rod, removing 1 - Puller, e.g. Kukko 21/4 2 - Rubber band 3 - Roller bearing 4 - Housing - Remove sealing ring for toothed rod from the housin[...]

4 8 -68 Parts, cleaning a n d checking - Before assembly, the housing must be checked for contamination (paint residue, chips, dirt) and clean thoroughly with compressed air and alcohol if necessar y - Check cylinder race for scoring or other damage. If scoring can be felt, replace the complete steering gear - Clean toothed rod (remove old grease i[...]

4 8 -69 Check i ng toothed rod for scoring If corroded areas or deep scratches are 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 After sanding, lubricate toothed rod lightly If the old toothed rod is used[...]

4 8 -70 Sea l ing r i ng on toothed rod , replacing When the sealing rod is replaced it must be replaced with a new one of the same color Note the matching of the O-ring to the sealing ring - Press pliers together with slight pressure on the sealing rin g - Pry out sealing ring and O -ring A - Needle nose pliers (standard commercial) O-ring 30.0 x [...]

4 8 -71 Po w er steering gear, assemb l ing Note: The sealing lip (arrow) of the sealing ring points upward toward the teeth 1 on the valve body For better viewing, the illustration show s the body housing in cross section with installed valve body. The valve body is shown slightly raised for better viewing Inner sealing rod f o r toothed rod, inst[...]

4 8 -72 When the groove -arrow- matches the edge -arrow - A- of the housing, the sealing ring is properly seated. - Place support ring -1- and sealing ring -2- on tool - Drive sealing ring for toothed rod into housing to stop Page 72 of 99 Steering 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=[...]

4 8 -73 Toothed rod, installing in the housing No grease must get into the oil circulation system! - Grease teeth of toothed rod with AOF 063 000 04 grease - Slide protective tube over toothed rod to stop - Wipe away excess grease completely When sliding, make sure that the sealing ring is pressed into the groove of the piston without jamming - Coa[...]

4 8 -74 - Align teeth of toothed rod in such a way that they point toward the teeth of the pinion - Screw mounting sleeve 3315/16 on toothed rod and coat with hydraulic oil - Carefully slide toothed rod guide -1- over the toothed rod into the housing to sto p - Slide toothed rod completely into housing if not done ye t 1 - toothed rod guide - Insta[...]

4 8 -75 Make sure that the sealing ring in the housing is not damaged by the teeth of the pinion. - Thread assembly mandrel 3315/17 onto valve body . - Lubricate valve body with hydraulic oil and carefully install by hand into the valve body housing (note position of toothed rod). - Tape the valve body with adhesive tape. Page 75 of 99 Steering 12/[...]

4 8 -76 - Carefully slide bushing with roller bearing onto the valve body. - Drive bushing into the housing far enough so that the groove for the circlip is visible. - Install circlip. - Remove adhesi v e tape. - Remove installation mandrel 3315/17. - Install Torx screw into v alve body and tighten to 35 Nm (26 ft lb). - Thread in locking screw, ti[...]

4 8 -77 T i e rods, re m ov i ng and i nstall i ng (po w er steer i ng gear - TR W and ZF) Note: Observe how tie rods are threaded into power steering gear: - Tie rods not secured with locking fluid - Tie rods secured with locking fluid When exchanging secured version tie rods use locking fluid D6 when installing. Removing The tie rods can only be [...]

4 8 -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 essentia[...]

4 8 -79 Note: Do not tilt tap when positioning. If it is difficult to turn the tap onto the thread or if metal swarf forms, this indicates the thread is deformed. - Clean threaded stud or tie rod with M 14 x 1.5 tap or wire brush. - Check if joint stud threads are deformed replace if necessary . - Cover steering gear housing opening (arrow) with a [...]

4 8 -80 Installing Note: Apply one drop only in 2nd thread of rack. If too much D6 is used the release torque when next disassembling will be too high. No D6 must get onto steering rack. - Adjust new tie rod to length Page 48-84 . - Coat tapped hole thread with D6 locking fluid (arrow) . - Tighten tie rod to the specified torque, 70 Nm (52 ft lb). [...]

4 8 -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[...]

4 8 -82 1 - Hose clamp 2 - Pressure compensating tube 3 - Boot 4 - Approx. 90 - Tension hose clamps with pliers VAG 1275 or equivalent. Page 82 of 99 Steering 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.48.1[...]

4 8 -83 Note: The boot must not be installed twisted. Page 83 of 99 Steering 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.48.1[...]

4 8 -84 Left-hand t i e rod length, checking and ad j usting - Check dimension "a" on left-hand tie rod and if necessary adjust . Dimension "a" = 395 + 1 mm (all except from VR6 and 16V) Dimension "a" = 413 1 mm (VR6 and 16V) Note: Only adjust toe on right-hand tie rod. Before installing new left-hand tie rod check dim[...]

4 8 -85 Asse m bly overvie w : vane pu m p, reservoir and hydraul i c l i nes (vehicles w i th 4-Cyl . engines) It is not intended that repair work be c arried out on the vane pump. If complaints are received determine cause with the help of pressure and leakage tests. Replace pump if faulty. Note: Pumps supplied as spare parts are not filled with [...]

4 8 -86 1 - Cooli n g line Secured to crossmember item 9 2 - Bracket Various versions depending on engine/transmission Page 48-96 3 - Pressure line 4 - Suction line Hydraulic pump - Cooling line 5 - Hose clamp, 3 Nm (27 in lb) 6 - Hydraulic pump With V-belt pulley 7 - Hydraulic pump With ribbed belt sprocket 8 - O- r ing Always replace Page 86 of 9[...]

4 8 -87 9 - Pressure line union 10 - Banjo bolt, 35 Nm (26 ft lb) 11 - Hex bolt, 10 Nm (7 ft l b) Page 87 of 99 Steering 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.48.1[...]

4 8 -88 Asse m bly overvie w : Hydrau l ic l ines, reservoir (vehicles w ith 4 -Cyl . eng i nes) Notes Page 48-85 1 - Power steerin g gear 2 - O- r ing 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 99 Steerin[...]

4 8 -89 11 - Self-ta p pin g screw 12 - Hose clamp 13 - Return hose 14 - Suction hose Reservoir - Cooling line 15 - Cooli n g line 16 - Threaded stud 17 - Bracket Page 89 of 99 Steering 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.48.1[...]

4 8 -90 Po w er steering vane pu m p, re m ov i ng and instal l ing (vehicles w ith 4- Cyl . engines) Note: Always replace self-locking nuts and bolts . Pumps supplied as spare parts are not filled with hydraulic oil. Fill the pump with G 002 000 hydraulic oil and rotate it by hand, otherwise the pump may be damaged or noisy during operation. Do no[...]

4 8 -91 Maintenance Manual 5 - 20 Nm(15 ft Ib) 6 - Front swivel bracket 7 - 20 Nm (15 ft lb) 8 - Adjustment bracket 9 - 20 Nm (15 ft lb) 10 - Bracket 11 - V-belts 11.5 x 685 Gas engine 11.5 x 730 Diesel engine 11.5 x 755 Gas engine with air conditioner 11.5 x 790 Diesel engine with air conditioner Tensioning Page 48-93 Checking condition 12 - 25 Nm[...]

4 8 -92 13 - V-belt pulley When installing the V- belt pulley ensure that the crankshaft pulley and the vane pump pulley are aligned 14 - Shim Only installed on vehicles with Diesel engine 15 - 20 Nm (15 ft lb) 16 - Rear swivel bracket 17 - Vane p u mp Checking delivery pressure Page 48- 13 Page 92 of 99 Steering 12/7/2004 http://ebahn.bentleypubli[...]

4 8 -93 V-be l ts, tension i ng (4-Cyl . engines) Spe c ification: - Tension V -belts by turning adjustment bolt with torque wrench -A- (VAG 1410 and VAG 1410/2). Used belts, 4 Nm (35 in. Ib) New belts, 7 Nm (62 in. Ib) Note: Nut 4 - is only installed on gasoline engines. - Tighten adjustment clamping bolt -3- to 25 Nm (18 ft lb) . - Tighten bolt -[...]

4 8 -94 Asse m bly overvie w : Pressure and cool i ng lines (veh i cles w ith V R 6 eng i ne) Note: Securing of pressure line varies according to type of transmission Fig. 1 and Fig. 2 1 - Reservoir 2 - Suction hose Reservoir - Cooling line 3 - Cooli n g line Secured to crossmember item 8 4 - Pressure line 5 - Suction line Cooling line - Hydraulic [...]

4 8 -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 l b) 12 - Hose clamp, 3 Nm (27 in. Ib) 13 - Return line Power steering gear - Reservoir Page 95 of 99 Steering 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW[...]

4 8 -96 Fig. 1 Pressure h ose, securing (vehicles with m anual transmission) Fig. 2 Pressure h ose, securing (vehicles with automatic tra n smission) Page 96 of 99 Steering 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.48.1[...]

4 8 -97 Po w er steering vane pu m p, re m ov i ng and instal l ing (vehicles w ith VR6 eng i ne] Note: Always replace seal s. Do not reuse drained hydraulic oil. Pumps supplied as spare parts are not filled with oil. Fill the pump with G 002 000 hydraulic oil and rotate it by hand, otherwise the pump may be damaged or noisy during operation. 1 - S[...]

4 8 -98 Repair Manual, Engine Mechanics; Repair Group1 3 Repair Manual, Engine Mechanics; Repair Group1 3 Repair Manual, Maintenance 3 - Pressure h ose Attachment varies according to type of transmission Page 48-96 4 - Seal 5 - Banjo bolt, 30 Nm (22 ft lb) 6 - Vane p u mp Checking delivery pressure Page 48- 13 7 - Ribbed belts Removing Tensioning e[...]