Volkswagen Passat 1995 1997 User Manual

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) V-belts, tensioning (4-Cyl. engines) Assembly overview: Pressure and cooling lines (vehicles with VR6 engine) Power steering vane pump, removing and installing (vehicles with VR6 engine]

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Suspension, Wheels, Brakes, Steering

00-1

Technical data

Model

Sedan/Wagon and syncro Base

Suspension 1)

Sedan/Wagon and syncro Base

Suspension 2)

Wheelbase mm 2625 2625 Track, unladen mm 1479 front, wheel offset 38

1422 rear, wheel offset 38 1485 front, wheel offset 35 1428 rear, wheel offset 35

1485 front, wheel offset 35 1441 rear, wheel offset 35

1489 front, wheel offset 33 3)

1445 rear, wheel offset 33 3)

1489 front, wheel offset 33 3)

1432 rear, wheel offset 3) Turning circle m 10.7 11.5 Steering roll radius

mm 0.5 with offset 35

12 with offset 35

(negative)

3.5 with offset 38

15 with offset 38

Wheel lock angle inner

outer

Base Suspension, explanation Page 40-1

Plus Suspension, explanation Page 40-26

Syncro

42 36

3745'

34 30'

00-2

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Steering

Model Suspension version

Base Suspension

Sedan/Wagon and syncro

Plus Suspension

Steering gear Power assisted steering gear Power assisted steering gear Steering wheel turns from lock to lock 3.33 3.14 Overall steering ratio 17.5:1 16.4:1

Wheel alignment specifications Page 44-2

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Brakes

Model

Sedan/Wagon

Output kW (hp) 55 (75) Brake master cylinder mm dia. 22.2 (Vehicles with ABS: 23.81) Brake servo dia. in inches 10 Front brake caliper, piston diameter mm 54 Front brake disc mm dia. 256 Front brake disc, thickness mm 13 Pad thickness mm 14 Rear brake drum mm dia. 230 Wheel cylinder mm dia. 20.64 Lining thickness mm 5 Lining width mm 40

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Model

Sedan/Wagon

Output kW (hp) 85 (115) 128 (172) Brake master cylinder mm dia. 23.81 Brake servo dia. in inches 10 Front brake caliper dia. mm 54 Front brake disc mm dia. 256 288 Front brake thickness mm 20 13 Pad thickness mm 11 14 Rear brake caliper dia. mm 38 Rear brake disc mm dia. 226 Rear brake disc, thickness mm 10 Pad thickness mm 12

00-5

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Model

Passat syncro

Output kW (hp) 85 (115) 128 (172) Brake master cylinder mm dia. 23.81 Brake servo dia. in inches 10 Front brake caliper dia. mm 54 Front brake disc mm dia. 256 288 Front brake disc thickness mm 20 25 Pad thickness mm 11 14 Rear brake caliper dia. mm 38 Rear brake disc mm dia. 239 Rear brake disc, thickness mm 10 Pad thickness mm 12

00-6

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Wheels, tires

Engine output (kW) Model

55 gas 55, 66 - Diesel

Tire size 1)

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)

55 Sedan/Wagon T 125/70 R 15 95 M

(Temp. spare)

Tire pressures Sticker on vehicle

Wheel

6 J x 14 6 J x 14 6 J x 15 6 J x 14 6 J x 14 6 J x 15

3 1/2 J x 15

Offset Hole pattern

4-hole 38 38 38 38 38

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Engine output (kW)

Model

Tire size 1)

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)

85 kW Sedan/Wagon T 125/70 R 15 95 M

(Temp. spare)

128 kW Sedan/Wagon 205/50 ZR 15 86 W

195/55 R 15 85 T (M+S) 195/55 R 15 85 T (M+S)

Wheel

6 J x 14 6 J x 14 6 J x 15 6 J x 14 6 J x 14 6 J x 15

3 1/2 J x 15

6 J x 15 6 J x 15

6 1/2 J x 15

Offset Hole pattern

4-hole 38 35 38 38 35

35 35 33

205/50 R 15 85 T (M+S)

128 kW Sedan/Wagon T 125/70 R 16 95 M

(Temp. spare)

Tire pressures Sticker on vehicle

6 J x 15

3 1/2 J x 16

35 38

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Engine output (kW)

Model

85 kW Sedan/Wagon

syncro

85 kW Sedan/Wagon

syncro

128 kW Sedan/Wagon

syncro

Tire size 1)

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) T 125/80 R 15 95 M

(Temp. spare) 205/50 ZR 15 86 W

205/50 R 15 86

Wheel Offset

6 J x 14 6 J x 14 6 J x 15 6 J x 14 6 J x 14 6 J x 15

3 1/2 J x

38 38 35 38 38 35

6 J x 15 6 J x 15

35 35

Hole

pattern

4-hole

5-hole

128 kW Sedan/Wagon

syncro

Tire pressures Sticker on vehicle

(M+S) T 125/70 R 16 95 M

(Temp. spare)

3 1/2 J x

40-1

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Front Wheel Suspension, Shafts and Axle

Front suspension, servicing (Base suspension)

I - Removing and installing subframe, stabilizer bar and control arm (Base suspension)

Page 40-2

II - Removing and installing wheel bearings, suspension strut and drive shaft (Base suspension) Page 40-14

The Base suspension is installed in Passat 1995 vehicles up to 85 kW.

40-2

joint and tighten to 50 Nm

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Sub-frame, stabilizer bar and control arm (Base suspension)

Note:

If a vehicle has to be moved after removing the drive shaft, first install outer

(37 ft lb) otherwise the wheel bearing will be damaged.

Specifications for wheel alignment Page 44-2 .

Welding and straightening operations are not permitted on load bearing suspension components or those components which locate the wheels.

Always replace self-locking nuts.

Always replace corroded nuts/bolts.

40-3

necessary, replace ball

observe this instruction

Secured to control arm

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1 - Hex bolt, 35 Nm (26 ft

lb)

2 - Ball joint

Checking Page 40-

Check rubber boot for damage and if

joint Mark installation

position. If replaced set to center of elongated hole and check toe

Elongated holes are not for camber adjustment. Failure to

may result in damage to drive shafts!

3 - Captive lock nuts 4 - Air deflector plate

by clip

5 - Control arm

40-4

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6 - Control arm rear

mounting

Installation position

Fig. 3

Pressing out and in

Fig. 4

7 - Hex bolt M 12 x 1.5 x 82

50 Nm (37 ft lb) and turn 90 further

8 - Hex bolt M 12 x 1.5 x 65

70 Nm (52 ft lb) and turn 90further

9 - Hex bolt M 12 x 1.5 x 78

70 Nm (52 ft lb) and turn 90further

10 - Control arm front

mounting

Pressing out Fig. 1 Pressing in Fig. 2

11 - Connecting link

With rubber mounting

40-5

Collar faces away from

locking hex nut, 25

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12 - Connecting link

mounting

Conical side toward control arm

13 - Washer

mounting

14 - Self-

Nm (18 ft lb)

15 - Sub-frame

Removing and installing with assemblies installed: supporting assemblies

Fig. 5

Remove sub-frame from below with VAG 1383 (with control arm but without steering gear). After installing check position of steering wheel and align front end.

Aligning enginetransmission assembly

Repair Manual, Engine Mechanical, Repair Group 10

40-6

locking hex nut, 25

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16 - Hex bolt, 65 Nm (48 ft

lb) 17 - Stabilizer bar mounting 18 - Stabilizer bar 19 - Stabilizer bar clamp 20 - Hex bolt, 25 Nm (18 ft

lb)

To secure stabilizer bar

21 - Vibration damper

Note installation position, large part must protrude from sub-frame

22 - Self-

Nm (18 ft lb) 23 - Cap nut

Repairing in side member Page 40-

40-7

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Fig. 1 Front control arm mounting, pressing

out

Fig. 2 Front control arm mounting, pressing in

Note:

Before pressing in, coat with acid-free lubricant, e.g. soft soap.

40-8

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Fig. 3 Control arm rear mounting, installation

position

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. 4 Control arm rear mounting, pressing

Note:

out and in

If bonded rubber bushing is tight because of corrosion, cut rubber out, saw through steel casing and drive bushing out.

40-9

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Fig. 5 Supporting engine/transmission

assembly with 10-222 A and legs 10-222 A/1

40-10

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Ball joint, checking (Base and Plus suspension)

Checking axial clearance

- Forcibly pull ball joint down and press up again.

Checking radial play

- Press lower part of wheel outward and inward.

Note:

There must be no perceptible or visual "play" during either test.

Observe ball joint during checks. Take into account possible existing wheel bearing

play or "play" in upper suspension strut mounting.

40-11

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If the threads of the cap nut in the side member

When drilling out proceed as follows.

When drilling do not tilt the drill.

Reworking cap nut in side member (Base and Plus suspension)

are damaged, the thread must either be retapped or the cap nut must be drilled out.

- Support engine/transmission assembly with 10222 A and legs 10-222 A/1.

- Remove the sub-frame.

- Drill out the damaged side member cap nut with a 10.2 mm diameter drill from underneath.

Note:

WARNING! Wear protective goggles.

- Cut new M 12 x 1.5 thread in cap nut.

- Use a new bolt/washer assembly to secure subframe Page 40-13 .

40-12

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Bolt/washer assemblies for sub-frame

Securing point

Front sub-frame M12 x 1.5 M12 x 1.5 x 95 10.9

Thread

Bolt

Part No.

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 bracket M10 M10 x 38 10.9 N 019 541.1 Engine front cross-member to side member M10 M10 x 75 10.9

These bolts are not listed in the parts catalog. They must be specially ordered.

N 904 078.01 1)

40-13

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Note:

Tightening torque remains unchanged.

1 - Bolt/washer 2 - Cap nut 3 - Side member 4 - Sub-frame 5 - Bonded rubber mounting/control arm

40-14

joint and tighten to 50 Nm

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Wheel bearing, suspension strut and drive shaft, removing and installing (Base running gear)

Note:

If a vehicle has to be moved after removing the drive shaft, first install outer

(37 ft lb) otherwise the wheel bearing will be damaged.

Welding and straightening operations are not permitted on load bearing suspension components or those components which locate the wheels.

Always replace self-locking nuts.

Always replace corroded nuts/bolts.

Wheel bolt tightening torque: 110 Nm (81 ft lb).

40-15

tighten with the vehicle

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1 - Self-locking nut, 265

Nm (195 ft lb)

Only loosen and 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

Application

Repair Manual, Suspension,

Wheels, Brakes, Steering, Repair Group 00

4 - Brake caliper

Do not loosen brake hose when working on front suspension

Hang up with wire or similar

5 - Hub

Pressing out Fig. 3 Pressing in Fig. 8 Pulling off bearing

inner race Fig. 5

40-16

locking hex nut, 35

locking hex nut, 50

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6 - Speed sensor rotor

Only on vehicles with ABS

7 - Hex bolt, 10 Nm (7 ft lb) 8 - Splash plate 9 - Circlip

Ensure correctly seated

10 - Wheel bearing

Pressing out Fig. 6 Replace, as it is

destroyed during pressing out

Pressing in Fig. 7

11 - Self-

Nm (26 ft lb) 12 - Wheel bearing housing 13 - Self-

Nm (37 ft lb) 14 - Hex bolt

Clamping bolt for ball joint

+ 339 hidden pages