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. [. . . ] 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. Make sure that no brake fluid enters harness connectors. During painting operations, the electronic control module can be exposed to a max. temperature of 95 C (203 F) for only a short period, and to a maximum of 85 C (185 F) for longer periods (approx. 2 hours). 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 4 of 5 45-4 Control module, removing and installing Location Under the rear seat, left Note: Switch off ignition before disconnecting and connecting connectors. - Press control module securing clips together and pull out. - To pull connector off control module, release control module locking bar. - Engage connector catch in control module slots (arrow A), press connector on (arrow B) and secure with locking bar (arrow C). 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 5 of 5 45-5 Wheel speed sensor and rotor for speed sensor, removing and installing 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 suspension 14 . Rear axle Vehicles with rear drum brakes 15 . Page 42Page 40- Page 40- Vehicles with rear disc brakes (front and four wheel drive Page 42-24 . http://ebahn. bentleypublishers. com/vw/servlet/Display?action=Goto&type=repair&id=VW. B4. SU01. 45. 1 12/7/2004 Anti-lock Brake System (ABS) and ABS with Electronic Differential Lock (ABS/EDL), Teves 20 GI Page 1 of 3 45-6 Anti-lock Brake System (ABS) and ABS with Electronic Differential Lock (ABS/EDL), Teves 20 GI General information The ABS or ABS/EDL braking system 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. Specially matched software in the ABS control module regulates rear axle brake pressure. The ABS hydraulic unit -a- and ABS control module b- together make up one component. Separating them for service is only possible after the assembly has been removed. New ABS control units supplied as replacement parts from the Parts department are not coded, and require coding after installation: Repair Manual, Brake System On Board Diagnostic (OBD), Repair Group 01 Malfunctions of the ABS or ABS/EDL system do not influence the brake system or the vacuum brake booster. The conventional brake system remains functional even without ABS. Before working on the ABS or ABS/EDL system, determine the cause of the malfunction using the On Board Diagnostic (OBD) program % Repair Manual, ABS & ABS/EDL On Board Diagnostic. http://ebahn. bentleypublishers. com/vw/servlet/Display?action=Goto&type=repair&id=VW. B4. SU01. 45. 2 12/7/2004 Anti-lock Brake System (ABS) and ABS with Electronic Differential Lock (ABS/EDL), Teves 20 GI Page 2 of 3 45-7 Safety precautions WARNING!Before working on the ABS or ABS/EDL system, disconnect the battery Ground (GND) strap. [. . . ] engines) It is not intended that repair work be carried out on the vane pump. If complaints are received determine cause with the help of pressure and leakage tests. Note: Pumps supplied as spare parts are not filled with oil. Fill the pump with G 002 000 hydraulic oil to rotate it by hand, otherwise the pump may be damaged or noisy during operation. [. . . ]