d3e8001bac7_116.pdf

Now tighten bolts -1- and -2-. Specification: 65 Nm. Screw on return hose and tighten banjo fitting (22 mm wrench).Specification: 50 Nm. Screw on pressure hose and tighten banjo fitting (19 mmwrench). Specification: 40 Nm. Insert boot into bulkhead.Make sure boot is not damaged while inserting. Turn steering wheel into center position, if not yet done. Insert tensioning bolt (Torx T50) and tension counterclockwise. Tighten hex nut for adjusting bolt (Torx T50). Specification: 40Nm. Now unscrew -V.A.G 1907- from steering gear.1 - Hex socket head screw2 - Threaded bore in steering gear Seal steering gear using hex socket head bolt -1-. Specification: 18 Nm. Place universal joint on steering pinion. Remove mounting device from steering column. Install storage compartment on driver side. Refer to BodyInterior; Rep. Gr. 68 ; Removal and Installation . Install wheel housing liner. Refer to Body Exterior; Rep. Gr. 66 ; Removal and Installation . After completing installation of steering gear, remove -3094- . Turn ignition key to ignition off position. Install battery. Refer to Electrical Equipment; Rep. Gr. 27 ;Removal and Installation and enter radio code if necessary. Install plenum chamber cover. Install noise insulation tray. Install wheels and tighten. Refer to 3.2 Wheel Tightening Specification, page 172 . Check power steering fluid level. Refer to 1.1 Power Steering, Checking Fluid Level, page 186 . Check steering system for leaks. Refer to 4.2 Steering System, Checking for Leaks, page 204 . Bleed steering system. Refer to 1.2 Power Steering System, Bleeding, page 186 .After installation, position of steering wheel must be checked witha road test.If steering wheel stands crooked, toe at front axle must bechecked and set if necessary! Check toe setting. Refer to 1.1 Wheel Alignment, page 153 .

5.6 Power Steering Pump, 4-CylinderSpecial tools and workshop equipment required Hose clamps -3094-

Passat 1997 Suspension, Wheels, Steering - Edition 12.2012

228 Rep. Gr.48 - Steering

Drift -3204- Torque wrench -V.A.G 1331- Water pump wrench -V.A.G 1590-Removing Remove engine noise insulation. Bring lock carrier into service position. Refer to Body Exterior; Rep. Gr. 50 ; Description and Operation .Removing Ribbed Belt on Vehicles with 4-Cylinder Gasoline Engine Move tensioner in -direction of arrow- to release tension onribbed belt. Secure using -3204- .

Remove the coolant pump ribbed belt pulley. Remove ribbed belt. Remove the power steering pump ribbed belt pulley.If necessary, -V.A.G 1590- must be filed at the corners.

Clamp off suction and return line using -3094- . Position drip tray underneath.


5. Removal and Installation 229

Remove -3094- -1- from intake line. Disconnect intake line, press out of retaining bracket and layto side. Remove the pressure hose -2-, AF 22 mm.

Remove the hex bolts -1- and hex socket head bolt -2-. Take out pump.Installing Fill hydraulic oil into power steering pump.Fill oil at pump intake connection. Turn the hub by hand until oil runs out of the pressure side.

Tighten bolts -1 - and -2- to 20 Nm.Rest of installation is the reverse of removal. Install new sealing rings onto banjo bolt.

Tighten banjo fitting for pressure hose -2-. Specification: 50Nm. Install intake line.


230 Rep. Gr.48 - Steering

Tighten hex-socket bolts for coolant/power steering pump beltpulley to 25 Nm. Install fan wheel on viscous fan clutch.

Install ribbed belt.

NoteWhen installing ribbed belt, make sure it is seated correctly onpulleys.Illustration shows procedure without lock carrier for the sake ofillustration. Top off hydraulic oil -G 002 000- . Install lock carrier and bumper. Refer to Body Exterior; Rep.Gr. 50 ; Description and Operation . Start engine and check belt running. Check power steering fluid level. Refer to 1.1 Power Steering, Checking Fluid Level, page 186 . Check steering system for leaks. Refer to 4.2 Steering System, Checking for Leaks, page 204 . Bleed steering system. Refer to 1.2 Power Steering System, Bleeding, page 186 .


5. Removal and Installation 231

5.7 Power Steering Pump, 6-CylinderNote

Always replace seals. Do not reuse fluid you have drained. Hydraulic fluid -G 002 000- Quantity of oil in system approximately 1 ltr.

1 - Pressure Line with Hose2 - Bolt

8 Nm3 - Bore on Intake Manifold4 - Power Steering Pump

Checking delivery pressure. Refer to 4.5 Power SteeringPump, Checking Delivery Pressure, 6-Cylinder, page 206 . Fill with oil before installing. Refer to 2.5 Power SteeringPump, Reservoir andHydraulic Lines Assembly Overview, 6-Cylinder, page 194 .

5 - Belt Pulley6 - Bolt

25 Nm To loosen and tighten,counterhold using -V.A.G 1590- if necessary.

7 - Bolt 25 Nm

8 - Bolt 25 Nm

9 - Bracket10 - Ignition Coil with Bracket11 - Bolt

25 Nm12 - Banjo Bolt

50 Nm13 - Seals, 16 x 22

Replace.14 - Seals, 18 x 24

Replace.


232 Rep. Gr.48 - Steering Copyright 2011 - 2013 Service Repair Solutions, Inc.

General, Technical DataGeneral InformationGeneral Information: IndexEvaluating Suspension on Vehicles Involved in AccidentsWheels, Tires and Snow Chains

SpecificationsSpecifications: IndexTechnical DataTechnical Data: IndexChassisSteering

Front SuspensionGeneral InformationGeneral Information: IndexVehicle Level Sensor in Vehicles with Dynamic Headlight Vertical Aim ControlModified Wheel Bearing Housing/Tie Rod EndModified Wheel Bearing Housing from MY 2002Modified Track Control Link from MY 2002Modified Coupling for Stabilizer

Description and OperationDescription and Operation: IndexWheel Bearing, Lifting to Curb Weight PositionLongitudinal Member Threads, RepairingElectrical and Electronic Components and Component LocationsLeft Front Level Control System Sensor Assembly OverviewLeft Rear Level Control System Sensor Assembly Overview, with FWDLeft Rear Level Control System Sensor Assembly Overview, with AWDFront Suspension Assembly OverviewSuspension Strut Assembly Overview

SpecificationsSpecifications: IndexFastener Tightening Specifications

Diagnosis and TestingDiagnosis and Testing: IndexTrack Control Link, Checking

Removal and InstallationRemoval and Installation: IndexConnection of Upper Control Arm to Wheel Bearing Housing, SeparatingSuspension StrutSpringWheel Bearing HousingFront Wheel BearingFront Wheel Bearing with Wheel Bearing Housing InstalledTrack Control ArmControl Arm BearingGuide LinkGuide Link BearingStabilizer Bar MountMounting BracketFront and Rear Upper Control Arm BearingSubframeSubframe MountDrive Axle

Disassembly and AssemblyDisassembly and Assembly: IndexDrive Axle with Constant Velocity (CV) JointDrive Axle with Triple Roller JointTriple Roller Joint

Special Tools

Rear SuspensionDescription and OperationDescription and Operation: IndexRear Axle, Lifting to Curb Weight PositionFront Wheel Drive (FWD)Front Wheel Drive (FWD): IndexRear Axle Beam Assembly OverviewShock Absorber Assembly OverviewWheel Bearing Assembly Overview

All Wheel Drive (AWD)All Wheel Drive (AWD): IndexSubframe, Aligning to VehicleSuspension Strut Assembly OverviewRear Axle Assembly OverviewSteel Wheel Bearing Housing and Control Arm Assembly OverviewAluminum Wheel Bearing Housing and Control Arm Assembly OverviewSubframe and Final Drive Assembly Overview


Removal and InstallationRemoval and Installation: IndexFront Wheel Drive (FWD)Front Wheel Drive (FWD): IndexWheel Bearing and Wheel HubRear AxleShock Absorber and Spring

All Wheel Drive (AWD)All Wheel Drive (AWD): IndexSuspension Strut, with Steel Wheel Bearing HousingSuspension Strut, with Aluminum Wheel Bearing HousingSubframeSubframe Bonded Rubber BushingCrossmember Bonded Rubber BushingTransmission Support Bonded Rubber BushingWheel Bearing, with Steel Wheel Bearing HousingWheel Bearing, with Wheel Bearing HousingSteel Wheel Bearing HousingSteel Wheel Bearing Housing Bonded Rubber BushingAluminum Wheel Bearing HousingAluminum Wheel Bearing Housing Bonded Rubber BushingUpper Control ArmUpper Control Arm Front and Rear Bonded Rubber BushingsLower Control ArmLower Control Arm Bonded Rubber BushingStabilizer Bar Coupling Rod, with Steel Wheel Bearing HousingStabilizer Bar Coupling Rod, with Aluminum Wheel Bearing HousingWheel Bearing, with Aluminum Wheel Bearing HousingDrive Axle

Disassembly and AssemblyDisassembly and Assembly: IndexDrive Axle with Constant Velocity (CV) JointSuspension Strut

Special Tools

Wheels, Tires, Wheel AlignmentGeneral InformationGeneral Information: IndexWheel AlignmentToe Constant SVehicles Pulling to One Side and Accident VehiclesWheel Repair KitTire SealantTire Sealant DisposalWheel, Changing and MountingWheel, Changing and Mounting: IntroductionWheel Mounting

Wheel Centering Seat, Protecting against CorrosionWheels and Tires, Causes for VibrationBalancingRoad Test, Performing before BalancingStationary Balancing MachineVibration Control Tire BalancerFinish BalancerWheels and Tires, Radial Lateral Run OutMatched MountingFlat Spots in Tires from Standing

Description and OperationDescription and Operation: IndexWheel Alignment Test PrerequisitesWheel Alignment Measurement PreparationsAdapters, Allocating to Suspension for AlignmentToe Constant S, Preparing for Checking/AdjustingToe Constant S, Preparing for Checking/Adjusting: IndexSuspension 1BA, 1BC, 1BE, 1BFSport Suspension 1BEHeavy Duty Suspension 1BB/1BP, 1BFRaising Vehicles with Suspension 1BA, 1BC, 1BE, 1BFRaising Vehicles with Heavy Duty Suspension 1BB/1BP, 1BF

Specifications3.1 Fastener Tightening Specifications3.2 Wheel Tightening Specification3.3 Wheel Alignment Specifications, FWD3.4 Wheel Alignment Specifications, AWD except 8-Cylinder Engine3.5 Wheel Alignment Specifications, AWD with 8-Cylinder Engine

Specifications: IndexDiagnosis and TestingDiagnosis and Testing: IndexSteering Rack, Checking Center PositionFront Axle Camber, CenteringRear Axle Camber, FWD, CheckingRear Axle Toe, FWD, CenteringRear Axle Camber, AWD, AdjustingRear Axle Toe, AWD, AdjustingToe Constant S, AdjustingFront Axle Toe, AdjustingWheel and Tire Radial and Lateral Run Out, Checking with Tire Dial GaugeDisc Wheel, Checking Radial and Lateral Run Out

Removal and InstallationRemoval and Installation: IndexTire, Sealed with SealantTire, Sealed with Sealant: IndexTires, RemovingTires, Mounting

Special Tools

SteeringGeneral InformationGeneral Information: IndexPower Steering, Checking Fluid LevelPower Steering System, Bleeding

Description and OperationDescription and Operation: IndexSteering Gear Assembly OverviewPower Steering Gear Assembly Overview, with 4-Cylinder EnginePower Steering Gear Assembly Overview, with 6 or 8-Cylinder EnginePower Steering Pump, Reservoir and Hydraulic Lines Assembly Overview, 4-CylinderPower Steering Pump, Reservoir and Hydraulic Lines Assembly Overview, 6-CylinderPower Steering Pump, Reservoir and Hydraulic Lines Assembly Overview, 5 Valve 6-Cylinder EnginePower Steering Pump, Reservoir and Hydraulic Lines Assembly Overview, with 8-Cylinder EnginePower Steering Pump Assembly Overview, 5-Valve 6-Cylinder


Diagnosis and TestingDiagnosis and Testing: IndexSteering Column, Checking for DamageSteering System, Checking for LeaksPower Steering Gear, AdjustingPower Steering Pump, Checking Delivery Pressure, 4-CylinderPower Steering Pump, Checking Delivery Pressure, 6-CylinderPower Steering Pump, Checking Delivery Pressure, 5-Valve 6-CylinderPower Steering Pump, Checking Delivery Pressure, 8-Cylinder

Removal and InstallationRemoval and Installation: IndexSteering ColumnSteering Lock HousingTie RodsPower Steering Gear, with 4 or 6-Cylinder EnginePower Steering Gear, with 8-CylinderPower Steering Pump, 4-CylinderPower Steering Pump, 6-CylinderPower Steering Pump, 5-Valve 6-CylinderPower Steering Pump, 8-Cylinder

Special Tools

d3e8001bac7_116.pdf

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