User manual VOLKSWAGEN PASSAT

[. . . ] Suspension, Wheels, Brakes, Steering 00 - General, Technical data Suspension, Wheels, Brakes, Steering Technical data Steering Brakes Wheels, tires 40 - Front suspension Front Wheel Suspension, Shafts and Axle Front suspension, servicing (Base suspension) Sub-frame, stabilizer bar and control arm (Base suspension) Ball joint, checking (Base and Plus suspension) Reworking cap nut in side member (Base and Plus suspension) Wheel bearing, suspension strut and drive shaft, removing and installing (Base running gear) Front suspension strut, servicing (Base and Plus suspension) Front suspension, servicing (Plus suspension) Sub-frame, stabilizer bar and control arm, removing and installing (Plus suspension) Ball joint, removing and installing (Plus running gear) Wheel bearing and suspension strut, removing and installing (Plus suspension) Drive shaft, removing and installing (Plus running gear) Drive shaft, repairing Outer constant velocity joint, checking Inner constant velocity joint, checking Drive shaft with tripod joint, repairing Drive axle with triple-rotor joint, removing and installing Drive axle with triple-rotor joint, servicing Triple-rotor joint, disassembling Triple-rotor joint, assembling 42 - Rear suspension Rear Wheel Suspension, Shafts and Axle Rear axle, servicing (vehicles with front wheel drive) Reworking cap nut in side member (front wheel drive vehicles) Suspension strut, disassembling and assembling (front wheel drive vehicles) Wheel bearings, servicing Drum brakes (front wheel drive vehicles), wheel bearings, servicing Wheel bearings, servicing - disc brakes (front wheel drive vehicles) Rear axle, servicing (four wheel drive vehicles) Rear drive shafts, servicing Reworking cap nut in side member (four wheel drive vehicles) Suspension strut, disassembling and assembling (four wheel drive vehicles) Wheel bearings, servicing - disc brakes (four wheel drive vehicles) 44 - Wheels, Tires, Wheel alignment Vehicle alignment Test requirements: Vehicle alignment specifications (front wheel drive vehicles) Vehicle alignment specifications (four wheel drive vehicles) Front wheel camber, adjusting Calculating the direction of travel: 45 - Anti-lock brake system Anti-locking Brake System (ABS) and Anti-locking Brake System with Electronic Differential Lock (ABS/EDL) Teves 04 Notes for repair work on ABS, ABS/EDL Control module, removing and installing Wheel speed sensor and rotor for speed sensor, removing and installing Anti-lock Brake System (ABS) and ABS with Electronic Differential Lock (ABS/EDL), Teves 20 GI Safety precautions ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master cylinder (Teves 20 GI), servicing ABS hydraulic unit and ABS control module (Teves 20 GI), removing and installing Brake hydraulic system, bleeding and filling Assembly overview - hydraulic unit, brake servo/brake master cylinder Hydraulic unit, removing and installing Brake Pedal Position Sensor, removing and installing 46 - Brakes - Mechanical components Front brakes, servicing (Girling caliper) Brake pads, removing and installing Front brakes, servicing (Teves/Ate) Brake pads, removing and installing Rear wheel brakes, servicing (drum brakes) Brake shoe adjustment, releasing Rear wheel brakes, servicing Brake shoes, removing and installing Parking brake, adjusting (drum brakes) Rear wheel brakes, servicing (disc brakes) Girling rear wheel disc brakes (front and four wheel drive vehicles) Brake pads, removing and installing Parking brake, adjusting (disc brakes) Parking brake lever assembly overview Brake pedal/brake servo, removing and installing Brake pedal, removing and installing Brake Light Switch, adjusting 47 - Brakes - Hydraulic components Assembly overview: brake master cylinder/brake servo Girling front brake caliper, servicing Front brake caliper pistons, removing and installing Front brake caliper, servicing (Teves/Ate) Rear brake caliper, servicing Rear brake caliper piston, removing and installing Pre-bleeding brake caliper Brake pressure regulator, checking and adjusting Vehicles without ABS, vehicles with ABS, ABS/EDS, Teves 04 Load dependent brake pressure regulator specifications Adjusting regulator Brake system, bleeding Brake system, bleeding (vehicles with and without ABS, ABS/EDL) Brake system, bleeding (with pressure bleeder VAS 5234) Brake system, bleeding (without pressure bleeder) 48 - Steering Steering Assembly overview: steering column, column tube, steering wheel and airbag steering wheel Airbag unit, removing and installing Airbag steering wheel, removing and installing Airbag Spiral Spring, removing and installing Column tube for height adjustable steering wheel, removing and installing Pump delivery pressure, checking Power steering gear, removing and installing Assembly overview: power assisted steering box (TRW) Power steering gear, adjusting (TRW) Power steering gear, disassembling and reassembling (TRW) Power steering gear, disassembling Inner sealing ring for toothed rod, pulling out Checking toothed rod for scoring Sealing ring on toothed rod, replacing Sealing rings, installing on toothed rod piston Power steering gear, assembling Inner sealing ring for toothed rod, installing Toothed rod, installing in housing Adhesive tape, applying Power steering gear, adjusting with new toothed rod Assembly overview: power steering gear (ZF) Power steering gear, adjusting (ZF) Power steering gear, disassembling and reassembling (ZF) Power steering gear, disassembling Checking toothed rod for scoring Sealing ring on toothed rod, replacing Power steering gear, assembling Tie rods, removing and installing (power steering gear - TRW and ZF) Left-hand tie rod length, checking and adjusting Assembly overview: vane pump, reservoir and hydraulic lines (vehicles with 4Cyl. engines) Assembly overview: Hydraulic lines, reservoir (vehicles with 4-Cyl. engines) Power steering vane pump, removing and installing (vehicles with 4-Cyl. engines) Assembly overview: Pressure and cooling lines (vehicles with VR6 engine) Power steering vane pump, removing and installing (vehicles with VR6 engine] Suspension, Wheels, Brakes, Steering Page 1 of 8 00-1 Suspension, Wheels, Brakes, Steering Technical data Model Wheelbase Track, unladen mm mm Sedan/Wagon and syncro Base Suspension 1) 2625 1479 front, wheel offset 38 1422 rear, wheel offset 38 1485 front, wheel offset 35 1428 rear, wheel offset 35 1489 front, wheel offset 33 3) 1432 rear, wheel offset 3) Turning circle Steering roll radius (negative) Wheel lock angle m mm 10. 7 0. 5 with offset 35 3. 5 with offset 38 inner outer 1) 2) 3) Sedan/Wagon and syncro Base Suspension 2) 2625 1485 front, wheel offset 35 1441 rear, wheel offset 35 1489 front, wheel offset 33 3) 1445 rear, wheel offset 33 3) 11. 5 12 with offset 35 15 with offset 38 37 45' 34 30' 42 36 Page 40-1 Page 40-26 Base Suspension, explanation Plus Suspension, explanation Syncro http://ebahn. bentleypublishers. com/vw/servlet/Display?action=Goto&type=repair&id=VW. B4. SU01. 00. 1 12/7/2004 Suspension, Wheels, Brakes, Steering Page 2 of 8 00-2 Steering Model Suspension version Steering gear Steering wheel turns from lock to lock Overall steering ratio Sedan/Wagon and syncro Base Suspension Plus Suspension Power assisted steering gear Power assisted steering gear 3. 33 17. 5:1 Wheel alignment specifications Page 44-2 3. 14 16. 4:1 http://ebahn. bentleypublishers. com/vw/servlet/Display?action=Goto&type=repair&id=VW. B4. SU01. 00. 1 12/7/2004 Suspension, Wheels, Brakes, Steering Page 3 of 8 00-3 Brakes Model Output Brake master cylinder Brake servo Front brake caliper, piston diameter Front brake disc Front brake disc, thickness Pad thickness Rear brake drum Wheel cylinder Lining thickness Lining width kW (hp) mm dia. [. . . ] Note: After adjusting steering geometry check position of steering wheel; correct if necessary. http://ebahn. bentleypublishers. com/vw/servlet/Display?action=Goto&type=repair&id=VW. B4. SU01. 44. 1 12/7/2004 Vehicle alignment Page 5 of 7 44-5 Rear axle Engine Semi-trailing arm axle 85 kW, 128 kW (115 hp, 172 hp) Camber1) 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 rubber mounting Wheels, Brakes, Steering, Repair Group 42 . Repair Manual, Suspension, http://ebahn. bentleypublishers. com/vw/servlet/Display?action=Goto&type=repair&id=VW. B4. SU01. 44. 1 12/7/2004 Vehicle alignment Page 6 of 7 44-6 Front wheel camber, adjusting - Install special tool as shown in illustration and slightly pre-tension. Before adjusting camber, it is essential to examine all suspension components for damage (visual inspection) and to replace any damaged parts. Because bolts with a shank diameter of 11 mm diameter have been installed as standard it is no longer necessary to replace bolts to correct camber. http://ebahn. bentleypublishers. com/vw/servlet/Display?action=Goto&type=repair&id=VW. B4. SU01. 44. 1 12/7/2004 Vehicle alignment Page 7 of 7 44-7 Calculating the direction of travel: - 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 + 15' 15' - 5' = 10' 10' : 2 = 5' Deviation from direction of travel = 5' - Add figures with different sign (+/-) and divide by 2 Example. Left rear wheel toe + 15' 15' + 5' = 20' 20' : 2 = 10' Deviation from direction of travel = 10' The individual result is the actual alignment deviation from the vehicle longitudinal axis. Right rear wheel toe - 5' Right rear wheel toe + 5' http://ebahn. bentleypublishers. com/vw/servlet/Display?action=Goto&type=repair&id=VW. B4. SU01. 44. 1 12/7/2004 Anti-locking Brake System (ABS) and Anti-locking Brake System with Electronic Differential Lock (A. . . Page 1 of 5 45-1 Anti-locking Brake System (ABS) and Anti-locking Brake System with Electronic Differential 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 the hydraulic unit with pump. The hydraulic unit together with pump, supplies only the anti-locking brake system (ABS) or antilocking brake system and traction control system (ABS/EDL). Malfunctions on the ABS, ABS/EDL systems do not influence the brake system and servo. The vehicle can be driven without the ABS, ABS/EDL functions operating. http://ebahn. bentleypublishers. com/vw/servlet/Display?action=Goto&type=repair&id=VW. B4. SU01. 45. 1 12/7/2004 Anti-locking Brake System (ABS) and Anti-locking Brake System with Electronic Differential Lock (A. . . Page 2 of 5 45-2 Notes for repair work on ABS, ABS/EDL 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. When working with brake fluid, observe the relevant safety precautions and notes Page 47-27 . After work for which the brake system had to be opened, bleed the brake system with brake filler and bleeder unit VAS 5234 Page 47-27 . During the final road test, make sure that a controlled brake test is performed at least once (pulsations must be felt at the brake pedal). Absolute cleanliness is required when working on the anti-locking brake system; it is not permitted to use any products which contain mineral oils, such as oils, greases etc. http://ebahn. bentleypublishers. com/vw/servlet/Display?action=Goto&type=repair&id=VW. B4. SU01. 45. 1 12/7/2004 Anti-locking Brake System (ABS) and Anti-locking Brake System with Electronic Differential Lock (A. . . Page 3 of 5 45-3 Thoroughly clean all unions and the adjacent areas before loosening, do not use aggressive cleaning agents such as brake cleaner, petrol, thinners or similar. Carefully cover or seal open components if repairs cannot be carried out immediately. Only remove replacement parts from packaging immediately prior to installation. When the system is open do not work with compressed air and do not move the vehicle. During painting operations, the electronic control module can be exposed to a max. [. . . ] - Install boot, but first turn the tie rod so that the tie rod ball joint shank is in the installation position. Note: Do not damage sticker -A- when pushing the boot on (only on TRW power steering gears). Make sure that the boot and the pressure balance line are installed correctly. Only use genuine hose clips -B1 - Boot 2 - Housing During assembly of the boot ensure that the bead arrows- contacts the housing. http://ebahn. bentleypublishers. com/vw/servlet/Display?action=Goto&type=repair&id=VW. B4. SU01. 48. 1 12/7/2004 Steering Page 82 of 99 48-82 1 - Hose clamp 2 - Pressure compensating tube 3 - Boot 4 - Approx. [. . . ]