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48 - 2

Power-assisted steering, servicing

Delivery pressure of power steering pump, checking

If pump is malfunctioning Troubleshooting suspensionno. 16 .

- Remove pressurized line from pump.

- Install adapter and test equipment. Shut-off valve onpressure gauge open.

- Start engine and top up fluid level in reservoir if

necessary.

A - V.A.G 1402/2

B - V.A.G 1402/1

C - Hose from Adapter Hose VAG1402/6

D - V.A.G 1402

Test requirements:

V-belt/V-belt tensioning OK

System sealed

Hoses/lines are not kinked or constricted

- With engine at idle speed, close shut-off valve (not morethan 5 seconds) and read pressure.

- Specified value: 85 95 bar positive pressure.

Note:

If specification is not reached or exceeded, replace

Page 1 / 20Volkswagen Passat B4 - Power-assisted steering, servicing

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pump. Vehicles with 128 kW-engine 48-4, Power

steering vane pump - vehicles with VR6 engine,removing and installing .

If power steering fluid is low in the reservoir, checkthe steering system for leaks.

In case of leaks at steering pinion, check lines/lineconnections for leaks, if necessary tighten and wipedry.

In case of leaks at the steering pinion or at steeringrack seal in steering housing, the steering gear mustbe replaced.

To test rack seal open hose clamp of boot and setboot aside.

Disposal Special information; Suspension No. 2 .

Power steering gear, removing and installing

Notes for repair work on power steering gear

All work on the power steering must be performedwith utmost cleanliness.

Thoroughly clean all connections and thesurrounding area before disconnecting.

If repairs will not be performed immediately, placeremoved parts onto a clean surface and cover.

Only use lint-free cloths.

Only unpack replacement parts immediately prior toinstallation.

Only use parts in their original packing.

Page 2 / 20Power-assisted steering, servicing

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Observe installation of heat shield for vehicles withAll-Wheel Drive .

Removing

- Press off tie rods from steering knuckle .

A - Tie rod end puller (standard), e.g. Kukko Ball J ointSeparator 128/2

- To loosen clamp connection of universal joint shaft/powersteering gear, remove partition behind pedals frombulkhead and from steering column tube.

- Loosen hex nut - arrow - from universal joint shaft.

- Drain hydraulic oil from reservoir using oil extractiondevice V.A.G 1358 A or V.A.G 1307 A .

If an oil extraction unit is not available, disconnect intakehose from vane pump and drain hydraulic oil.


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- Support engine-/transmission assembly using EngineSupport Bridge 10-222A and Bracket For Engine 10-222A/1 (VR6 engine using Engine Support Bridge 10-222A and 10-222A/3 ).

- Remove boot from seat on steering gear.

- Remove bolts for subframe.

- Lower engine/transmission assembly. Both halves of theuniversal joint shaft are pulled apart.

- Unbolt hose lines at steering gear and plug with a plasticbag and tape.

- Plug threaded bores at power steering gear with plasticscrew plugs. Instead of plastic sealing plugs, sealing plugpart no. 113 301 229 A, and banjo fitting part no. N 904674 01 can be used. To do this, additional seals of 16 mm

must be used to seal the bores in banjo fitting shaft.

- Remove steering gear nuts (bolts remain in auxiliaryframe).

- Remove steering gear toward rear.

Installing

Installation is performed in the reverse order of removal.

- check position of steering wheel, perform vehiclealignment at front, if necessary.

Note:


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When lifting the engine/transmission assembly,

guide lower half- A - of universal joint shaft intoupper half- B - of universal joint shaft at the sametime (second mechanic required).

Coat boot with lubricant, e.g. universal low-temperature grease G 052 745 A3 before pulling onto steering gear.

Tightening torques:

Universal joint shaft halves 25 Nm

Steering gear 30 Nm

Tie rod end 35 Nm

Subframe front and rear 70 Nm + 90 (1/4 turn)

Rear subframe bracket 65 Nm

Power assisted steering gear - TRW, assembly overview

If power assisted steering ismalfunctioning Troubleshootingsuspension no. 10

Note :

Always replace self-locking nuts and bolts. Welding or straightening work on any steering

components is not permissible.


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To grease the rack, only use steering gear greaseA0F 063 000 04 .

Oil type: Hydraulic fluid G 002 000 .

Oil capacity in system: 0.70.9 l. Hose routing for intake and pressure line 48-3,

Vane pump, refill tank, hydraulic lines - vehicles with4-cyl.-engine, assembly overview .

Self-locking hex nut, 35 Nm

Self-locking hex nut, 30 Nm

Clamp

Rubber bushing


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Inner diameter ZF: 50 mmTRW: 44 mm

Right tie rod

70 Nm

Removing and installing48-2, Tie rod - powersteering gear, TRW and ZF,removing and installing

Wheel Alignment 44-1,Wheel Alignment

Tie rod boot seat diameter

ZF: 15 mm TRW: 12.7mm

Must not be installed on ZF-power steering gear

Left tie rod

70 Nm

Removing and installing

48-2, Tie rod - powersteering gear, TRW and ZF,removing and installing

Adjusting to length 48-2,Length of left tie rod,checking (adjusting ifnecessary)


ZF: 15 mm TRW: 12.7

mm


Hex nut , tighten to 50 Nm

Boot

Pull on and off over tie rod

Can be replaced withsteering gear installed

Must not be twisted after toe


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is adjusted


Steering gear

Removing and installing48-2, Power steering gear,removing and installing

Adjusting 48-2, Powersteering gear - TRW,adjusting

Check steering torqueTroubleshooting; suspension

no. 16

Disposal of steering gearSpecial information,suspension No 2

Steering gear with reducedsteering torque permitted forvehicles up to 85 kW only

VR6 vehicles have asteering torque that isapprox. 2 Nm higher

Tie rod end

Pressing off Topic 48-2

Checking:

Modification: 48-2,Modified tie rod end

Hex nut , tighten to 30 Nm

Universal join t shaft

Threaded connection, 30 Nm

Return line

Sealing ring

Replace

Repair Manual, Maintenance


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Clamp

replace - open using nipperpliers

Tensioning 48-2, Boot,installing

Power steering gear - TRW, adjusting

Note:

Two technicians are required for adjustments. Adjustwith engine off.

Adjusting steering gear

- Raise vehicle on platform.

- Wheels in straight-ahead position.

Turning the steering wheel back and forth (approx. 30 offcenter axis) will produce a rattling noise if steering play is

too large.

- Loosen lock nut, counterhold using 3315/9 .

- Carefully turn adjustment screw - arrow - until rattlingnoise in vehicle interior cannot be heard anymore.

- Tighten lock nut.

- Perform a test drive, and while doing so make sure thatsteering returns to straight-ahead position on its own,without catching, after vehicle is maneuvered or driven in a

curve. Correct adjustment if necessary.

Power assisted steering gear - ZF, assembly overview


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Servicing the power steering gear is not planned. If acustomer has reported a problem, determine cause via thepressure test and leak test as well as troubleshooting. If

there is a malfunction, replace the power steering gear.

Note :

Always replace self-locking nuts and bolts. Welding or straightening work on any steering

components is not permissible. To grease the rack, only use steering gear grease

A0F 063 000 04 .

Oil type: Hydraulic fluid G 002 000 .

Oil capacity in system: 0.70.9 l. Hose routing for intake and pressure line 48-3,

Vane pump, refill tank, hydraulic lines - vehicles with4-cyl.-engine, assembly overview .


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Power steering gear

Removing and installing48-2, Power steering gear,removing and installing

Adjusting 48-2, Power-assisted steering box - ZF,adjusting

Check steering torqueTroubleshooting; suspensionno. 16

Disposal of steering gearSpecial information,suspension No 2

Steering gear with reduced

steering torque permitted forvehicles up to 85 kW only

VR6 vehicles have a


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steering torque that isapprox. 2 Nm higher

Clamp



Boot

Screw off tie rod beforedisassembling

Check for wear (slits,cracks); check sealingsurfaces and sealing lips fordirt/damage

Is larger in diameter atopenings as is at boot of

TRW power steering gear

Must not be installed onTRW-power steering gear

Clamp




Right tie rod


Wheel Alignment 44-1,Wheel Alignment

Tie rod boot seat diameterZF: 15 mm TRW: 12.7

mm


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Left tie rod



ZF: 15 mm TRW: 12.7

mm


Adjusting to length 48-2,Length of left tie rod,checking (adjusting ifnecessary)

Lock nut, 50 Nm

Tie rod end

Pressing off Topic 48-2

Checking:

Modification: 48-2,Modified tie rod end

Pressure compensating line

30 Nm

Clamp

Rubber inlay

Inner diameter ZF: 50 mmTRW: 44 mm

Type plate and companysinitials

Repair Manual, Maintenance

Power-assis ted steering box - ZF, adjust ing


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Note:

Two technicians are required for adjustments. Adjust

with engine off. - Raise vehicle on platform.

- Wheels in straight-ahead position.

- Turning the steering wheel back and forth (approx. 30off center axis) will produce a rattling noise if steering playis too large.

- Second technician turns adjustment bolt - arrow -carefully into cover during this, until the rattling noisecannot be heard in vehicle interior anymore.

- Perform a test drive, and while doing so make sure thatsteering returns to straight-ahead position on its own,without catching, after vehicle is maneuvered or driven in acurve. Correct adjustment if necessary.

Modified tie rod end

As of vehicle identification no. 3A R-099 265, a modified tierod end was introduced. Ball stud is 3 mm longer than forthe previous parts. Only modified tie rod ends are deliveredas a replacement part.

If repairs are necessary, both tie rod ends must bereplaced up to vehicle identification no. 3A R-099 264.

A mixed installation is not permissib le!

On vehicles as of vehicle identification no. 3A R-099 265,

tie rod end may be replaced individually.


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Characteristic of tie rod end, up to vehicle identification no. 3A

R-099 264

1 - Tie rod end, manufactured by TRW

- Centering arrow A in facing side of ball stud.Manufacturer code on lower side, ECO.

2 - Track rod ends manufactured by Lemfoerder metalwares

- Conical depression arrow B in facing side of ball stud.Manufacturer code on lower side, LMO or LME.

Characteristic of tie rod end, as of vehicle identification no. 3A

R-099 265

1 - Modified tie rod end, manufactured by TRW

- Cylindrical depression and centering arrow A in facingside of ball stud. Manufacturer code on lower side, ECO.

Tie rod - power steering gear, TRW and ZF, removing andinstalling

Note:

Observe threaded connection of tie rods in powersteering gear:


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Tie rods, not bonded Tie rods, bonded with locking compound If tie rods of bonded version are installed, they must

be installed with locking compound D6.

Removing

Tie rods can only be unscrewed and screwed on whensteering gear has been removed.

- Seal line connections on power steering gear if not donealready.

1 - Plastic screw plug

2 - Plastic screw plug

- Clean outside of power steering gear in area of boot.

- Open clamp and push back boot.

- Clamp steering gear together with rack into vise andremove tie rod.

Note:


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Use protective pads, check protective pads for dirt,e.g. thoroughly remove metal particles or similar.

- Remove tie rod.

Installation of tie rods without locking compound D6:

Installation is performed in the reverse order of removal.Tightening torque: 70 Nm

Installation of tie rods with lock ing compound D6:

If parts are re-used, threaded pin of inner joint or threadedbore of rack must always be cleaned from remaininglocking compound. Otherwise there is the danger ofdamage of thread if assembled/disassembled again.

- Clean threaded pin or tie rod, use tap M14 x 1.5 or wirebrush to do so.

- Check thread path of joint stub for deformation, replace ifnecessary.

Note:

Do not cant tap when attaching. If tap can only beturned onto thread with difficulty or metal particles

form, this indicates that thread is deformed.


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- Cover opening - arrow - of steering gear housing with arag.

- Clean threaded bore and rack, use tap M14 x 1.5 to do

so.

- Clean thread with nitro thinner L 160 (thread must befree of oil or grease).

- Clean using compressed air.

Installing

- If necessary, adjust tie rod to length 48-2, Length ofleft tie rod, checking (adjusting if necessary) .

- Coat thread of threaded bore with locking compound D6 -arrow - .

Note:

Apply one drop only into second turn of rack. If toomuch D6 is used, loosening torque is too high ifdisassembled. D6 must not get on to rack.

- Tighten tie rod to specified tightening torque - 70 Nm.Always use torque wrench.

Boot, installing

- Check boot for wear (slits, cracks) and check sealingsurfaces of boot for dirt.

- Install boot. Rotate tie rod beforehand so that stud of tierod end stands in installation position.

- Install pressure equalizing tube.

Note:


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Do not damage adhesive label - A - when sliding on

boot (for TRW power steering gears only).

Make sure boot and pressure equalizing tube areproperly installed. Use only original equipment clamps - B - .

- Tension clamp using Hose Clamp Pliers VAG1275 .

Note:

Take care not to twist the boot on installation (fig.shows negative example - arrows - ).


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Length of left tie rod, checking (adjusting if necessary)

- Check left tie rod for dimension "a" and adjust if

necessary.

Dimension "a" = 395 1 mm (all except VR6)

Dimension "a" = 413 1 mm (VR6)

Note:

Adjust toe on right tie rod only. Also check new tie rods for dimension "a" before

installing and adjust if necessary.


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