Volkswagen Passat Operating instructions

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 velocityjoint, checking

Inner constant velocityjoint, 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 oftravel:

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

Safetyprecautions

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

Assemblyoverview- 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 assemblyoverview

Brake pedal/brake servo, removing and installing

Brake pedal, removing and installing

Brake Light Switch, adjusting

47 - Brakes - Hydraulic components

Assemblyoverview: 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

Assemblyoverview: 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 deliverypressure, checking

Power steering gear, removing and installing

Assemblyoverview: 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 newtoothed rod

Assemblyoverview: 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 - TRWand ZF)

Left-hand tie rod length, checking and adjusting

Assemblyoverview: vane pump, reservoir and hydraulic lines (vehicles with 4-

Cyl. engines)

Assemblyoverview: 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)

Assemblyoverview: Pressure and cooling lines (vehicles with VR6 engine)

Power steering vane pump, removing and installing (vehicles with VR6 engine]

00-1

Suspension, Wheels, Brakes, Steering

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

1489 front, wheel offset 33 3)

1432 rear, wheel offset 3)

1485 front, wheel offset 35

1441 rear, wheel offset 35

1489 front, wheel offset 33 3)

1445 rear, wheel offset 33 3)

Turning circle m 10.7 11.5

Steering roll radius

(negative) mm 0.5 with offset 35

3.5 with offset 38

12 with offset 35

15 with offset 38

Wheel lock angle inner

outer

3745'

3430'

1) Base Suspension, explanation Page 40-1

2) Plus Suspension, explanation Page 40-26

3) Syncro

Page

Suspension, Wheels, Brakes, Steering

12/7/2004

http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.00.1

00-2

Steering

Model Sedan/Wagon 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

Suspension, Wheels, Brakes, Steering

12/7/2004

http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.00.1

00-3

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

Page

Suspension, Wheels, Brakes, Steering

12/7/2004

http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.00.1

00-4

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

Page

Suspension, Wheels, Brakes, Steering

12/7/2004

http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.00.1

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