Gebruiksaanwijzing /service van het product Passat (1997) van de fabrikant Volkswagen
Ga naar pagina of 368
.
.
Suspension, Wheels, Brakes, Steering 00 - General, Technical data Suspension, Wheels, Brakes, Steering T echnical data Steering Brakes W heels, tires 40 - Front suspension Front Wheel Suspension, Shaf.
Rear axle, ser v icing (four w heel dri v e v ehicles) Rear dri v e shafts, ser v icing Re w orking cap nut in side member ( f our w heel dri v e v ehicles) Suspension strut, disassembling and assembl.
Front brakes, ser v icing (Te v es/ A te) Brake pads, remo v ing and installing Rear w heel brakes, ser v icing (drum brakes) Brake shoe adjustment, releasing Rear w heel brakes, ser v icing Brake sho.
48 - Steering Steering Assembl y o v er v ie w : steering column, column tube, steering w heel and airbag steering w heel Airbag unit, remo v ing and installing Airbag steering w heel, remo v ing and .
0 0 -1 Suspension, Wheels, Brakes, Steering Technical data Model Sedan/Wa g on and syncro Base Suspension 1) Sedan/Wa g on and syncro Base Suspension 2) Wheelbase mm 2625 2625 Track, unladen mm 1479 f.
0 0 -2 Steering Model Sedan/Wa g on 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.
0 0 -3 Brakes Model Sedan/Wa g on 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.
0 0 -4 Model Sedan/Wa g on 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.
0 0 -5 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.
0 0 -6 Wheels, t i res Engine output (kW) Model Tire size 1) Wheel Offset Hole pattern 55 gas 55, 66 - Diesel 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/.
0 0 -7 Engine output (kW) Model Tire size 1) Wheel Offset Hole pattern 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) 6 J x 14 6 J x 14 6 J x 15 6 J x 14 6 J x 14 6 J x 15 38 38 35 38 38 35 4-hole 85 kW Sedan/Wagon T 125/70 R 15 95 M (Temp.
0 0 -8 Engine output (kW) Model Tire size 1) Wheel Offset Hole pattern 85 kW Sedan/Wagon syncro 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) 6 J x 14 6 J x 14 6 J x 15 6 J x 14 6 J x 14 6 J x 15 38 38 35 38 38 35 4-hole 85 kW Sedan/Wagon syncro T 125/80 R 15 95 M (Temp.
4 0 -1 Front Wheel Suspension, Shafts and Axl e Front suspens i on, servicing ( B ase suspension) I - Removing and installing subframe, stabilizer bar and control arm (Base suspension) Page 40-2 II - .
4 0 -2 Su b -frame, stabi l i z er bar and control ar m (Base suspension) Note: If a vehicle has to be moved after removing the drive shaft, first install outer joint and tighten to 50 Nm (37 ft lb) otherwise the wheel bearing will be damaged. Spe c ifications for wheel alignment Page 44-2 .
4 0 -3 1 - Hex bolt, 35 Nm (26 ft lb) 2 - Ball joint Checking Page 40- 10 Check rubber boot for damage and if necessary, replace ball joint Mark installation position. If replaced set to center of elongated hole and check toe Elongated holes are not for camber adjustment.
4 0 -4 6 - Control arm rear m o unting 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 9 0 further 8 - Hex bolt M 12 x 1.5 x 65 70 Nm (52 ft lb) and turn 9 0 further 9 - Hex bolt M 12 x 1.
4 0 -5 Repair Manual, Engine Mechanical, Repair Group 10 12 - Connecting link m o unting Conical side toward control arm 13 - Washer Collar faces away from mounting 14 - Self- locki n g hex nut, 25 Nm (18 ft lb) 15 - Su b -frame Removing and installing with assemblies installed: supporting assemblies Fig.
4 0 -6 16 - Hex bolt, 65 Nm (48 ft lb) 17 - Stabilizer bar mo u nting 18 - Stabilizer bar 19 - Stabilizer bar clamp 20 - Hex bolt, 25 Nm (18 ft lb) To secure stabilizer bar 21 - Vibration damper Note .
4 0 -7 Fig. 1 Front co n trol arm mounting, pressi n g out Note: Before pressing in, coat with acid-free lubricant, e.g. soft soap. Fig. 2 Front co n trol arm mounting, pressi n g in Page 7 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.
4 0 -8 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. 3 Control arm rear mounting, installation position Note: If bonded rubber bushing is tight because of corrosion, cut rubber out, saw through steel casing and drive bushing out.
4 0 -9 Fig. 5 Supp o r ting engine/tra n smission assembly with 10-222 A and legs 1 0 -222 A/1 Page 9 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.
4 0 -10 Bal l jo i nt , check i ng (Base and P l us suspension) Checki n g axial clearance Checki n g radial play - Forcibly pull ball joint down and press up again. Note: - Press lower part of wheel outward and inward. There mu s t be no perceptible or visual "play" during either test.
4 0 -11 Re w ork i ng cap nut in s i de me m ber ( B ase and Plus suspens i on) If the threads of the cap nut in the side member are damaged, the thread must either be retapped or the cap nut must be drilled out. When drilling out proceed as follows. - Support engine/transmission assembl y with 10- 222 A and legs 10-222 A/1 .
4 0 -12 Bolt/washer assemblies for su b -frame Sec u r ing point Thread Bolt Part No. Front sub-frame M12 x 1.5 M12 x 1.5 x 95 10.9 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 bra c ket M10 M10 x 38 10.9 N 019 541.
4 0 -13 Note: Tightening torque remain s unchanged. 1 - Bolt/washer 2 - Cap nut 3 - Side member 4 - Sub-frame 5 - Bonded rubber mounting/control arm Page 13 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.
4 0 -14 Wheel bearing , suspension strut and dr i ve shaft, remov i ng and instal l ing ( B ase runn i ng gear) Note: If a vehicle has to be moved after removing the drive shaft, first install outer joint and tighten to 50 Nm (37 ft lb) otherwise the wheel bearing will be damaged.
4 0 -15 Repair Manual, Suspension, Wheels, Brakes, Steering, Repair Group 00 1 - Self-locki n g n u t, 265 Nm (195 ft lb) Only loosen and tighten with the vehicle standing on its wheels (danger of acc.
4 0 -16 6 - Speed sensor rotor Only on vehicles with ABS 7 - Hex bolt, 10 Nm (7 ft l b) 8 - Splash plate 9 - Ci r clip Ensure correctly seated 10 - Wheel bearing Pressing out Fig.
4 0 -17 15 - Self-locki n g bolt/washer asse m b ly, 125 Nm (92 ft lb) For securing brake carrier 16 - Socket head multi- poi n t bolt, 45 Nm (33 ft lb) 17 - Drive shaft To remove and install separate ball joint/control arm connection Fig.
4 0 -18 21 - Self- locki n g hex nut, 60 Nm (44 ft lb) Loosening and tightening Fig. 1 22 - Stop 23 - Suspension strut bearing 24 - Suspension strut Removing and installing Fig.
4 0 -19 Fig. 1 Suspension strut t o bo d y, loosening and tightening Note: Camber must be adjusted each time joint is loosened. Fig. 2 Wheel bearing housing/suspension strut joint, separating Page 19 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.
4 0 -20 To take drive shaft out, remove bolts (arrows). Note: First mark installation po s ition. Fig. 3 Ball joint/control arm connection, separating Fig. 4 Hub, p r essing out of wheel bearing housing Page 20 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.
4 0 -21 Only use puller with leg clamp e.g. Kukko 204-2 (commercial type). Fig. 5 Bearing race, pulling out of hub Fig. 6 Wheel bearing, pressin g out of wheel bearing housing Page 21 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.
4 0 -22 Fig. 7 Wheel bearing, pressin g int o wheel bearing housing Fig. 8 Hub, p r essing into wheel bearing housing Page 22 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.
4 0 -23 Front suspens i on strut, servicing ( B ase and Plus suspension) 1 - Shock absorber Can be replaced individually Check shock absorber for lea k s and noi s es After replacing, adjust camber and toe Page 44-1 2 - Buffer stop 3 - Protective sleeve Page 23 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.
4 0 -24 4 - Coil spring Removing and installing Fig. 2 Observe color coding Outer surface of spring must not be damaged Is slightly curved 5 - Spring plate 6 - Axial beari ng 7 - Hex nut, 60 Nm (44 ft lb) Loosening and tightening Fig.
4 0 -25 Fig. 1 Hex nut, loosening and tightening Fig. 2 Spring, removing an d installing Page 25 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.B4.SU01.
4 0 -26 Front suspens i on, servicing ( P lus suspension) I - Removing and installing subframe, stabilizer bar and control arm (plus suspension) Page 40-27 II - Removing and installing wheel bearing, .
4 0 -27 Su b -frame, stabi l i z er bar and control ar m , re m ov i ng and i nstal l ing (P l us suspension) Notes Page 40-2 1 - Hex bolt, 35 Nm (26 ft lb) 2 - Ball joint Checking Page 40- 10 Check rubber boot for damage and if necessary, replace ball joint Removing and installing Page 40- 33 Mark installation position.
4 0 -28 5 - Control arm rear m o unting Installation position Fig. 2 Pressing out and in Fig. 3 6 - Control arm Elongated holes are not for camber adjustment! 7 - Ai r guide plate Secured to control arm by clip 8 - Control arm front m o unting Pressing out and in Fig.
4 0 -29 12 - Mounting for connecting link Conical side towards control arm 13 - Washer Collar faces away from mounting 14 - Self- locki n g hex nut, 25 Nm (18 ft lb) 15 - Hex bolt M 12 x 1.
4 0 -30 Repair Manual, Engine Mechanical, Repair Group 10 20 - Vibration damper Not installed on vehicles with VR 6 engine 21 - Su b -frame Removing and installing with assemblies installed: supporting assemblies Fig. 4 Remove sub-frame from below with control arm but without steering gear using transmission jack VAG 1383 or equivalent.
4 0 -31 Note: Before pressing in, coat with lubricant, e.g. soft soap. Fig. 1 Control arm front m o unting, pressing out an d in One of the embossed arrows points toward the recess in the control arm and the kidney shaped opening -arrow -A- in mounting faces towards center of vehicle.
4 0 -32 Fig. 3 Control arm rear mounting, pressing out an d in Fig. 4 Engine/transmission assembly, supporti n g with 10-222 A and 1 0 -222 A/3 Page 32 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.
4 0 -33 Bal l jo i nt , removing and insta l ling ( P lus runn i ng gear) Removing - Loosen 1 2 -point nut with vehicle standing on its wheels. - Disconnect drive shaft at transmission drive flange . - Remove bolts -arrow -A-. - Loosen bolt -arrow -B-.
4 0 -34 Note: Installing - Install ball joint splitter as shown in illustration and press out ball joint. 1 - Splitter. Matra V 176 Place transmission jack VAG 1383/A, or equivalent, underneath (danger of accident through falling parts when pressing out the ball joint).
4 0 -35 Note: Make sure that the boot is not damaged or twisted. Tig h te n in g torques Ball joint to wheel bearing housing: 45 Nm (33 ft lb) Ball joint to control arm: 35 Nm (26 ft lb) 1 - Box inser.
4 0 -36 Wheel bearing and suspension strut , re m ov i ng and i nstal l ing (P l us suspension) Notes Page 40-14 1 - Wheel bolt, 110 N m (81 ft lb) 2 - Self-locki n g 12-poi n t nut 90 Nm (66 ft lb) a.
4 0 -37 5 - Brake caliper Do not loosen brake hose when working on front suspension Hang up with wire or similar Replacing brake pads Page 46-6 6 - Counters u nk screw 7 - Hub Pressing out Fig.
4 0 -38 11 - Ci r clip Ensure seated correctl y 12 - Wheel bearing Pressing out Fig. 4 Always replace, as it is destro y ed during pressing out Pressing in Fig.
4 0 -39 18 - Hex bolt Camber adjustment Page 44-1 Before loosening, mark installation position 19 - Hex bolt 20 - Bracket 21 - Stop 22 - Self- locki n g hex nut, 60 Nm (44 ft lb) Loosening and tightening Fig.
4 0 -40 Fig. 1 Suspension strut t o bo d y, loosening and tightening Fig. 2 Hub, p r essing out of wheel bearing housing Page 40 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.
4 0 -41 Only use puller with leg clamp e.g. Kukko 204-2 (commercial type). Fig. 3 Inner race, pulling off hub Fig. 4 Wheel bearing, pressin g out of wheel bearing housing Page 41 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.bentleypublishers.
4 0 -42 Fig. 5 Wheel bearing, pressin g int o wheel bearing housing Fig. 6 Hub, p r essing into wheel bearing housing Page 42 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.
4 0 -43 Drive shaft , removing and insta l ling (P l us running gear) Removing - Loosen 1 2 -point nut with vehicle standing on its wheels. - Disconnect drive shaft from transmission drive flange . - Remove bolts (arrow -A-). - Loosen bolt (arrow -B-).
4 0 -44 Installing - Remove remains of locking fluid from outer joint and hub splines. (Splines must be free of oil and grease). - Apply locking fluid D 185 400 A2 to splines as shown in illustration. Bead cross section approx. 3 mm . - Install drive shaft.
4 0 -45 Tig h te n in g torques: Drive shaft to flange shaft/transmis s ion 45 Nm (33 ft lb) Drive shaft to wheel bearing 90 Nm (66 ft lb) and housing turn 4 5 further ( 1 / 8 turn) Ball joint/control arm 35 Nm (26 ft lb) Page 45 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.
4 0 -46 Drive shaft , repa i ring Drive shafts on vehicles with Plus suspension have shorter and finer splines on the outer joint. The wheel bearing is secured by a 1 2 -point nut. The splines of the outer joint and the hub on Plus suspensions are secured with locking fluid D 185 400 A2.
4 0 -47 1 - Ci r clip Always replace Remove and install with VW161 a 2 - Gasket Always replace. Pull off prote c tive foil and stick onto joint. (Only on 100 mm diameter constant velocity joint s 3 - Inner c o nstant velocity joint 100 mm diameter Only replace complete Pressing off Fig.
4 0 -48 5 - Boot for 100 mm diameter constant velocity joi nt Rubber version With vent hole Check for tears and chafing Installation position for left drive shaft Fig.
4 0 -49 8 - Boot for 90 mm diameter constant velocity joi nt Polyester elastomer version Check for tears and chafing The balance pressure briefly ventilate boot before tensioning the small clamp Fig. 7 Installation position for left shaft, wheel end Fig.
4 0 -50 10 - Dished washer Outer diameter (concave side) contacts thrust washer 11 - Thrust was h er 12 - Ci r clip Always replace Insert in shaft groove 13 - Outer constant velocity joint, 90 mm diameter Only replace complete Removing Fig.
4 0 -51 14 - Outer constant velocity joint, 90 mm diameter For vehicles with 16V and VR6 Wedge splines, larger diameter Only replace complete Removing Fig. 2 Installing: drive onto shaft with plastic hammer until compressed circlip seats Greasing Notes Page 40-46 Checking Page 40- 60 15 - Vibration damper Removing and installing Fig.
4 0 -52 16 - Clamp Always replace 17 - Supp o r t rings On rubber type boot only On transmission end only See Parts catalog 18 - Boot for 100 mm diameter constant velocity joi nt Polyester elastomer version Check for tears and chafing To balance pressure briefly ventilate boot before tensioning the small clamp Fig.
4 0 -53 The damper consists of two halves. Both halves are joined to one another by spring pins (arrow). Installation position Fig. 1 Note: Fig. 1 Vibration damper, r emoving and installing Only replace vibration damper with drive shaft removed Before driving in spring pin protect shaft paint finish against damage.
4 0 -54 Fig. 2 Outer constant velocity joi n t, removing - Drive joint off drive shaft with a firm blow from an aluminium hammer . Note: Fig. 3 Inner c o nstant velocity joint, pressing off First drive boot off with drift Support ball hub Page 54 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.
4 0 -55 Note: Chamfer on inner diameter of ball hub (splines) must face the contact shoulder on the drive s haft. Fig. 4 Inner c o nstant velocity joint, pressing on - Press on joint up to stop.
4 0 -56 The large diameter of vent chamber -A- must fit on the larger diameter. Fig. 6 Installation position of right drive s h aft transmission en d joint boot B - Vent hole Often the boot is pushed in when installing on the joint body. This creates a vacuum inside the boot which draws a fold in (arrow) while driving.
4 0 -57 Fig. 8 Larger clamp, tensioning - Use pliers VAG 1682 as shown in illustration. Ensure that the jaws of the pliers s eat in the - arrow -B- of the clamp. - Tension clamp by turning the spindle with a torque wrench (do not tilt pliers) . Note: Fig.
4 0 -58 Cuff seating tolerance "a": 1 / 2 to 1 1 / 2 grooves visible at end of cuff. Note: This installation position tolerance is al s o valid for the left drive shaft transmission end boot (polyester elastomer version).
4 0 -59 Cuff seating tolerance "a": From cuff position to chamfer up to 1 / 2 a groove visible. Fig. 12 Installation position of right drive s h aft, wheel end joi n t boot Page 59 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.
4 0 -60 Outer constant velocity jo i nt , checking The joint should be disassembled to replace dirty grease or for checking the balls and ball tracks for wear and damage. Removing - Before disa s sembling mark position of the ball hub in relation to the ball cage and housing with an electric scriber or oil stone .
4 0 -61 Note: The 6 balls of each joint belong to one tolerance group. Check stub axle, hub, cage and balls for indentations (pitting) and signs of seizure. Excessive backlash in joint will be noticed as a knock during load changes. In such cases the joint must be replaced.
4 0 -62 Inner constant ve l ocity joint, checking The joint should be disassembled to replace dirty grease and when checking the balls and ball tracks for wear and damage. Note: The ball hub and joint are paired and must not be interchanged. - Swivel ball hub and ball cage.
4 0 -63 Note: Excessive backlash in joint will be noticed as a knock during load changes. In such cases the joint must be replaced. Poli s hed areas and ball track marks are not a reason for changing the joint. Installing Note: - Insert ball hub over both c hamfers into the ball cage.
4 0 -64 - Swivel in ball hub, whereby the hub must be swivelled out of the cage (arrows) far enough to allow the balls to fit into the ball tracks. Checki n g o peration of constant velocity joi n t: .
4 0 -65 Drive shaft w i th tr i pod joint, repair i ng 1 - Outer constant velocity joint Replace complete Removing Fig. 1 Installing: Drive onto the shaft with plastic hammer until circlip comes out G.
4 0 -66 5 - Clamp Always replace Tightening, Fig. 2 and Fig. 3 6 - Boot for constant velocity joi n t, 90 mm dia. Check for cracks and abrasion Before tightening the small clamp, ventilate boot briefly so pressure is equalized, Fig. 2 7 - Clamp Always replace Tightening, Fig.
4 0 -67 9 - Inner s p lined screw, 45 Nm (33 ft lb) 10 - Drive shaft, right, with inner tripod joint Repair of inner joint and replacement of boot not possible at this time Replace if damaged Page 67 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.
4 0 -68 Fig. 1 Consta n t velocity joint, outer, removing - Drive off from drive shaft with forceful blow using an alloy hammer. The boot is pressed on forcefully when installing on the joint body. This creates a vacuum in the boot that makes a dent during driving (arrow).
4 0 -69 Note: Fig. 3 Clamp, tightening on large diameter - Install pliers VAG 1682 as in illustration. Make sure that the blades of the pliers lie in the corners (arrow -B-) of the clamp. - Tighten clamp by turning the spindle with a torque wrench (do not tilt pliers during this process) .
4 0 -70 Drive axle w i th tr i ple-rotor j oint, re m ov i ng and i nstal l ing Removing ri g ht-side d r ive axle The right drive axle removal instructions remain unchanged from the current repair manual procedure. Removing left-side d r ive axle - Set up engine support bridge.
4 0 -71 - Remove rear transmission mounting bolt (arrow). - Remove front engine mounting bolt (arrow). - Lift engine/transmission assembly - Loosen drive axle nut while vehicle is standing on its wheels. Page 71 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.
4 0 -72 - Disconnect drive axle from transmission drive flange . - Mark installation position of bolts (arrows) and remove. Installing - Swing wheel outward (if neces s ary, place bloc k of wood or equivalent between strut and wheel housing as shown).
4 0 -73 Drive axle w i th tr i pl e -rotor joint, servicing 1 - Outer constant velocity (CV) joi nt Replace complete part only Removing Fig. 1 Installing: drive onto shaft with plastic hammer until ci.
4 0 -74 9 - Clamp For triple-rotor joint 10 - Boot 11 - Clamp For triple-rotor joint 12 - Cover Destroyed when disassembling No longer required for assembly; not available as replacement part 13 - Rec.
4 0 -75 Fig. 1 Removing outer CV joint - Drive joint off axle shaft with firm blow from soft mallet . Page 75 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.
4 0 -76 Make sure plier jaws seat in grooves of clamp (arrows -B-) Note: Fig. 2 T ightening outer CV joint boot clamp - Position VAG 1682 pliers or equivalent (e.g. Snap- On YA 3080) as shown in illustration. - Tension clamp by using torque wrench to turn spindle (keep pliers at right angle to shaft).
4 0 -77 Tr i ple-rotor j oint, d i sassembl i ng - Open hose clamp - Open clamp on shaft small end and push back boot . Note: - Drive screwdriver or similar tool into cover and pry open . If the cover will not pry open, insert screwdriver and pry from the opposite side.
4 0 -78 1 - Triple- r o tor joint h ousing 2 - Triple- r o tor star 3 - Axle shaft Note: CAUTION! Do not let the rollers slide o ff the triple- r o tor star and fall to the fl o or. - Remove O-ring -arro w - from groove. - Mark installation positions of parts -1-, -2- and -3-.
4 0 -79 - Remove rollers and place on clean surface. -1- Pliers Commercially availa b le - Remove circlip. - Press triple-rotor star off axle shaft. - Pull triple-rotor joint housing off axle shaft. - Clean shaft and triple-rotor joint housing. Page 79 of 82 Front Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.
4 0 -80 Tr i ple-rotor j oint, assembl i ng - Slide small diameter boot clamp onto shaft. - Slide triple-rotor joint boot onto shaft. - Slide triple-rotor joint housing onto shaft. Mounting triple- r o tor star Note: The side of the star with a chamfer (arrow) goes onto the axle shaft splines first.
4 0 -81 Note: A seal is formed directly between the triple-rotor joint and the drive flange by the rectanular sealing ring. The cover is no longer required. - Install rectangular sealing ring (arrow) from repair kit. 90 grams into joint and 90 grams behind joint - Press 180 grams of axle shaft grease from repair kit into triple-rotor joint .
4 0 -82 - Tighten small diameter clamp with VAG 1275 pliers or equivalent (e.g. KD 474). CAUTION! Sec u r e the triple- r o tor joint with tape so t h at the ho u sing is not inadvertently pus h ed back when installing the axle shaft. Remove tape just prior to bolting t o drive flange.
4 2 -1 Rear Wheel Suspension, Shafts and Axl e Rear axle, servicing (vehicles w ith front w hee l dr i ve) Note: The rear axle and wheel bearings are identical on Base and Plus suspension versions. Welding and straightening of the axle beam is not permissible.
4 2 -2 5 - Wheel bearing Servicing Vehicles with drum brakes Page 42-15 Vehicles with disc brakes Page 42-24 6 - 80 Nm (59 ft lb) Use only self-locking nuts with captive washers When tightening nut, t.
4 2 -3 9 - Mounting bracket with r etainer f o r brake pressure reg u lator Installation position Fig. 4 Check and if necessary adjust rear axle total toe after installation If possible do not loosen .
4 2 -4 Repair Manual, Body Exterior, Interior, Repair Group 70. Repair Manual, Body Exterior, Interior, Repair Group 68. Inertia reel bolt (arrow) tightening torque: 40 Nm (30 ft lb) Fig.
4 2 -5 Suspension strut is attached to the body by 4 retaining lugs in addition to the bolts. To remove, turn suspension strut until retaining lugs are positioned above the cu t -outs. Fig. 3 Suspension strut, removing a n d installing Angle of inclination to axle beam 1 3 30' 1 .
4 2 -6 Note: Before using special tool 3111 it is important to grease spindle with Molybdenum grease. Fig. 5 Bonded ru b ber mounting, pressing 1st half out of axle beam Thread base plate into the pressure plate 3111/5 from the opposite side. Note: Mounting must not be driven out.
4 2 -7 Protruding segment of bonded rubber mounting faces forward on inside and rearward on outside. Fig. 7 Rubber bo n ded mountin g , installation position Press both halves in one after the other until the mounting conical section contacts the axle beam.
4 2 -8 Re w ork i ng cap nut in s i de me m ber (front wheel drive vehicles) If the threads of the cap nut in the side member are damaged, it must either be retapped or the cap nut must be drilled out. When drilling out proceed as follows: - Remove rear axle.
4 2 -9 Suspension strut, d i sassemb l ing and assembl i ng (front w heel dr i ve veh i cles) 1 - Cap Pry out with screwdriver Pressing on Fig. 4 2 - O- r ing 3 - Self- locki n g hex nut, 25 Nm (18 ft.
4 2 -10 7 - Suspension strut bearing Always replace foam gasket Welded nut s must be located in the spring seat recesses Align welded nuts and cap to shock absorber lower bushing Fig.
4 2 -11 13 - Stop b uffer Shorter on Wagon than Sedan 14 - Protective tube Longer on Wagon than Sedan 15 - Plastic cap 16 - Coil spring Removing and installing Fig.
4 2 -12 20 - Shock absorber Can be replaced individually Removing and installing Page 42-4 Application see Parts catalog Page 12 of 14 Rear Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.
4 2 -13 Note: Instead of VAG 1403, VAG 1752/1 may be used. Fig. 1 Spring, removing an d installing Fig. 2 Spring seat, installati o n p osition Page 13 of 14 Rear Wheel Suspension, Shafts and Axle 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.
4 2 -14 Fig. 3 Suspension strut mountin g to shock absorbe r bushing, aligning A - Shock absorber bushing axis B - Suspension strut mounting axis "a" 50 C - Cap axis 9 0 offset to shock absorber bushing axis -A-. Fig. 4 Cap in suspensi o n strut mo u nting, pressing in.
4 2 -15 Wheel bearings, servicing Drum brakes (front w heel dr i ve veh i cles) , w hee l bearings , serv i c i ng Note: Careful sealing, absolute cleanliness and precise adjustment are requirements for long wheel bearing s ervice life. Therefore note the following points: Install oil seal and grease cap as shown.
4 2 -16 2 - Cotter pin Always replace 3 - Locking ring 4 - Hex nut Adjusting wheel bearing play Fig. 4 5 - Thrust was h er 6 - Outer wheel bearing Drive out outer race with copper drift Pressing in Fig.
4 2 -17 10 - Brake backing plate Bolt together with stub axle onto rear axle 11 - Oil seal Fill between sealing lips with multi-purpose grease. Driving in Fig.
4 2 -18 16 - Brake drum Before removing release brake shoe adjustment through wheel bolt hole Fig. 5 When removing the brake drum make sure that the outer wheel bearing does not fall out. Fill hub with multi- purpose grease before installing Page 4 of 18 Wheel bearings, servicing 12/7/2004 http://ebahn.
4 2 -19 Loosen grease cap from seat by tapping lightly on the claw. Fig. 1 Grease cap, p r essing off Fig. 2 Grease cap, p r essing off Page 5 of 18 Wheel bearings, servicing 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.
4 2 -20 Note: Fig. 3 Grease cap, d r iving on Always replace damaged (dented) grease caps. Damaged (dented) grease caps allow ingress of moisture, therefore always use the illustrated tool. Note: Using a screwdriver it must be possible to move the thrust washer by finger pressure (without prying).
4 2 -21 Fig. 5 Brake shoe adjustment, r eleasing - Insert a screwdriver through a hole in the brake drum and push the wedge upward . Fig. 6 Outer wheel bearing outer r ace, pressing in Page 7 of 18 Wheel bearings, servicing 12/7/2004 http://ebahn.bentleypublishers.
4 2 -22 Fig. 7 Inner wheel bearing outer race, pressing in Fig. 8 Oil seal, driving in Page 8 of 18 Wheel bearings, servicing 12/7/2004 http://ebahn.bentleypublishers.
4 2 -23 Fig. 9 Rotor, pressin g in Page 9 of 18 Wheel bearings, servicing 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.
4 2 -24 Wheel bearings, serv i c i ng - disc brakes (front w hee l dr i ve veh i cles) Note: Careful sealing, absolute cleanliness and precise adjustment are requirements for long wheel bearing service life. Therefore note the following points: Install oil seal and grease cap as shown.
4 2 -25 3 - Speed sensor Only on vehicles with ABS Before installing sensor, clean mounting hole inner surface and coat with lubricating pa s te G 000 650 4 - Brake hose bracket 5 - Hex socket h ead b.
4 2 -26 10 - Cover ring Always replace Installation position Fig. 5 Drive on with tube VW 519 11 - Pad carrier 12 - Brake pads Removing and installing Page 46- 33 13 - Brake caliper Servicing Page 47- 15 14 - Outer wheel bearing Drive out outer race with copper drift Pressing in Fig.
.
4 2 -28 26 - Dished washer Large contact surface (concave side) to backing plate 27 - Backin g plate 28 - Axle beam Straightening work is not permissible! Only use stub axles with 6 mounting holes. 29 - Parking brake cable Adjusting parking brake Page 46-36 30 - Spring clip Page 14 of 18 Wheel bearings, servicing 12/7/2004 http://ebahn.
4 2 -29 Fig. 1 Grease cap, p r essing off - Loosen grease cap by tapping lightly on the claw. Fig. 2 Grease cap, p r essing off Page 15 of 18 Wheel bearings, servicing 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.
4 2 -30 Note: Fig. 3 Grease cap, d r iving on Always replace damaged (dented) grease caps. Damaged (dented) grease caps allow ingress of moisture, therefore always use the illustrated tool. Note: Using a screwdriver it must be possible to move the thrust washer by finger pressure (without prying).
4 2 -31 Dimension "a" = 9.5 mm Fig. 5 Cover ring, installation position - Drive on cover ring with tube VW 519 Fig. 6 Outer wheel bearing outer r ace, pressing in Page 17 of 18 Wheel bearings, servicing 12/7/2004 http://ebahn.bentleypublishers.
4 2 -32 Fig. 7 Inner wheel bearing outer race, pressing in Fig. 8 Oil seal, driving in Page 18 of 18 Wheel bearings, servicing 12/7/2004 http://ebahn.bentleypublishers.
4 2 -33 Rear axle, servicing (four wheel drive vehicles) Note: When removing and installing the rear axle, it is recommended to remove axle and differential together and to separate away from the vehicle. If only the axle beam is to be removed and installed, the wishbones can remain attached to the shock absorber.
4 2 -34 1 - Suspension strut Removing and installing Page 42- 4 , Fig. 1 and Page 42-37 Disassembling and assembling Page 42-53 Application see Parts catalog 2 - Drive shaft Removing and installing Fig. 2 and Fig. 3 Servicing Page 42- 46 3 - Final drive Removing and installing from axle beam Fig.
4 2 -35 5 - Propshaft Removing and installing Fig. 2 Mark installation position before removing 6 - Anti- r o ll bar Removing and installing Fig. 4 7 - Axle beam Replacing rubber bonded mounting Fig. 10 and Fig. 11 8 - Rear axle mounti n g bracket Removing and installing at body Fig.
4 2 -36 Repair Manual, Suspension, Wheels,Bra k es, Steering, Repair Group 46 and47 10 - Wheel bearing Servicing Page 42- 59 Servicing brakes 11 - Hex bolt, 85 Nm (63 ft lb) 12 - Hex bolt for seat belt strut, 25 N m (18 ft lb) Page 4 of 13 Rear axle, servicing (four wheel drive vehicles) 12/7/2004 http://ebahn.
4 2 -37 Before installing, bring control arm into horizontal position (unladen state). Removing and installing suspension strut at body Page 42-4 . Tightening torque -A-: 65 Nm (48 ft lb) Note: Support control arm otherwise damage may occur to constant velocity joint as a result of over-stressing.
4 2 -38 Loosen and tighten only when vehicle is standing on its wheels (danger of accident). Tightening torque: 90 Nm (66 ft lb) and turn 4 5 further ( 1 / 8 turn) Note: Any paint residue and/or corrosion on the thread of the outer joint must be removed before the nut is installed.
4 2 -39 Before tightening bring control arm into horizontal position (unladen state). To remove the right-hand control arm inner bolt, remove brake pressure regulator from axle beam. Tightening torque -A-: 120 Nm (89 ft lb) Fig. 5 Control arm, removing an d installing Fig.
4 2 -40 Before installing coat with acid free lubricant, e.g. soft soap. Installation position: Shoulder on outer mounting to outside, to inside on inner mounting (to center of vehicle). Note: Deviations from the rear axle toe and camber specifications can be corrected by using a bonded rubber mounting with eccentric bushing Fig.
4 2 -41 The rubber mounting -A- is equipped with an eccentric bushing which can change the position of the control arm. This rubber mounting may only be installed in the control arm inner mounting. The camber and/or toe can be changed according to installation position.
4 2 -42 Removing and installing viscous coupling Repair Manual, 5 Spd. Manual Transmission 02A; Repair Group 39 Tightening torque -A-: 45 Nm (33 ft lb) Fig. 9 Final drive, removing and installing from axle beam Page 10 of 13 Rear axle, servicing (four wheel drive vehicles) 12/7/2004 http://ebahn.
4 2 -43 Connect segment corners of bonded rubber mounting metal core with a line. The continued line must pass through the center of hole (arrow). Note: The kidney-shaped recess must be pointing in direction of travel when viewed from the center of vehicle.
4 2 -44 Remove and install complete When assembling mounting bracket and final drive carrier away from the vehicle, make sure parts are correctly located relative to each other. It is essential that the bonded rubber mounting is installed stress free in the vehicle.
4 2 -45 Mark mounting bracket in s tallation position relative to body longitudinal member, otherwise the rear axle must be realigned on an axle alignment stand after reinstalling.
4 2 -46 Rear drive shafts, servicin g Removing and installing drive shafts Page 42- 37 Note: Grease quantity: - - outer constant velocity joint 80 g G -6.3 - - inner c onstant velocity joint 80 9 G-6.3 Greasing outer joint: press half of the grease into the joint, and the other half evenly into the boot.
4 2 -47 1 - Ci r clip Always replace Remove and install with VW161 a 2 - Inner c o nstant velocity joint, 81 mm diameter Only replace complete Pressing off Page 40-54 Pressing on Page 40-55 Greasing N.
4 2 -48 4 - Boot for 94 mm diameter constant velocity joi nt Rubber version Check for tears and chafing Installation position: At cuff 1 to 1-1/2 grooves visible Coat inside of cap with D3 Drive off w.
4 2 -49 7 - Boot for 81 mm diameter constant velocity joi nt Polyester elastomer version Check for tears and chafing Installation position: At cuff 1 to 1-1/2 grooves visible To balance pressure brief.
4 2 -50 11 - Ci r clip Always replace Insert in shaft groove 12 - Outer constant velocity joint: 81 mm diameter Only replace complete Removing Page 40- 54 Installing: drive onto shaft with plastic ham.
4 2 -51 Re w ork i ng cap nut in s i de me m ber (four wheel drive vehicles) If the threads of the cap nut in the side member are damaged, it must either be retapped or the cap nut must be drilled out. - Remove control arm if nece s sary. - Drill through damaged cap nut in the side member using a 10.
4 2 -52 - Cut new thread in the cap nut, M 12 x 1.5. - Use new bolts, Part No. N 010 137.1 and washer, Part No. N 011 531.7 to secure the rear axle. Tightening torque: 65 Nm (48 ft lb) Note: The procedure described here must only be performed on one cap nut on each side of the vehicle.
4 2 -53 Suspension strut, disassembling and assembling (four wheel drive vehicles) 1 - Cap Pry out with screwdriver Pressing on Fig. 5 Installation position Fig.
4 2 -54 7 - Suspension strut m o unting Welded nut s must be located in the spring seat recesses Installation position to spring seat Fig. 3 8 - Spring seat 9 - Spacer tube 10 - Lower rubber m o untin.
4 2 -55 17 - Coil spring Removing and installing Page 42- 13 Allocation Parts catalog 18 - Packing 19 - Ci r clip 20 - Lower s p r ing plate Installation position Fig.
4 2 -56 The spring plate mu s t be installed so that the holes "a" align with the bushing -2- in the shock absorber eye. Otherwise, in extreme driving situations spring plate -1- could contact the tire. Fig. 1 Lower s p r ing plate, installation position 1 - Lower spring plate 2 - Sho c k absorber e y e bushing Fig.
4 2 -57 The upper suspension strut mounting and the spring seat (arrow A) both have markings (arrow B). These must be installed pointing forward, otherwise damage will occur to the suspension strut piston rod. Fig. 3 Suspension strut mountin g to spring seat, installation position Fig.
4 2 -58 Fig. 5 Cap, pressing i n to suspension strut m o unting Page 6 of 6 Suspe n s ion strut, disassembling and assemblin g (four wheel drive vehicles) 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.
4 2 -59 Wheel bearings, servicing - disc brakes (four wheel drive vehicles ) Note: If a vehicle has to be moved after removing the drive shaft, first install an outer joint and tighten to 50 Nm (37 ft lb).
4 2 -60 Repair Manual, Suspension, Wheels, Brakes, Steering, Repair Group 46 Repair Manual, Suspension, Wheels,Bra k es, Steering, Repair Group 47 4 - Guide pins 5 - Protective cap 6 - Pad securi n g .
4 2 -61 Repair Manual, Suspension, Wheels, Brakes, Steering, Repair Group 46 12 - Self-locki n g hex nut Always Tighten to 90 Nm (66 ft lb) and turn 4 5 further ( 1 / 8 turn) To tighten use recommend angle measuring wrench VAG 1756 or equivalent Before installing nut on outer joint remove any paint remains and/or corrosion from threads.
4 2 -62 16 - Ci r clip Ensure seated correctl y 17 - Wheel bearing 72 mm diameter Pressing out Page 42-64 Pressing in page. Page 42-65 18 - Hex bolt, 10 Nm (7 ft l b) 19 - Backin g plate 20 - Parking .
4 2 -63 24 - Drive shaft with speed sens o r rotor Removing and installing drive shaft Page 42-37 and Page 42-38 Removing and installing rotor, Fig. 6 25 - Brake line Page 5 of 8 Wheel bearings, servicing - disc brakes (four wheel drive vehicles) 12/7/2004 http://ebahn.
4 2 -64 Fig. 1 Hub, p r essing out Fig. 2 Wheel bearing, pressin g out Page 6 of 8 Wheel bearings, servicing - disc brakes (four wheel drive vehicles) 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.
4 2 -65 Note: Only use puller with leg clamp e.g. Kukko 204-2 (commercial type). Fig. 3 Inner race, pulling off of h ub Note: First install lower circlip. Fig. 4 Wheel bearing, pressin g in Page 7 of 8 Wheel bearings, servicing - disc brakes (four wheel drive vehicles) 12/7/2004 http://ebahn.
4 2 -66 Note: First install backing plate on control arm. Tightening torque: 10 Nm (7 ft lb) Fig. 5 Hub, p r essing in Fig. 6 Speed sensor rotor, pressing in - Drive rotor off outer joint using a drift (rotor will be destro y ed) . - Drive new rotor carefully onto stop using a plastic hammer .
4 4 -1 Vehicle alignmen t Test requirements: Measuring equipment correctly calibrated Vehicle unladen 1) Tires inflated to correct pressure Vehicle accurately aligned, suspension bounced and rocked several time s Suspension, steering and steering linkage checked for excessive play and damage.
4 4 -2 Vehicle a l ignment spec i f i cations (front w heel drive veh i cles) Front axle Suspension strut axle Engine up to 85 kW (115 hp) 110 - 128 kW (148 - 172 hp) Version Base suspension Plus susp.
4 4 -3 Rear axle Torsion beam trailing arm axle Engine/version all Camber 1) Maximum permissible difference between sides - 1 30' 10' max. 20' Total toe 1) (at specified wheel camber) Maximum permissible deviation from direction of travel +20' 10' max.
4 4 -4 Vehicle a l ignment spec i f i cations (four w hee l drive vehicles) Front axle Suspension strut axle Engine 85 kW (115 hp) 128 kW (172 hp) Version Base suspension Plus suspension Total toe 1) .
4 4 -5 Rear axle Semi-trailing arm axle Engine 85 kW, 128 kW (115 hp, 172 hp) Camber 1) Maximum permissible difference between sides - 1 15' 30' max. 30' Total toe 1) (at specified camber) Maximum permissible deviation from direction of travel +15' 20' max.
4 4 -6 Front w heel camber , adjust i ng Note: - Install special tool as shown in illustration and slightly pre-tension. - Loosen suspension strut/wheel bearing housing connection . - Adjust camber by turning the spindle to specified setting . - Tighten suspension strut/wheel bearing housing connection .
4 4 -7 Calculating the d i rection of trave l : - If both toe figures have the same preceding sign (+/+ or -/-), subtract the smaller figure from the larger figure and divide by 2 Example.
4 5 -1 Ant i -locking Brake System ( ABS) and Anti-locking Brake System with Electronic Di f ferential Lock (ABS/EDL) Teves 04 The ABS, ABS/EDL brake system is divided diagonally. The servo-assist is effected pneumatically, by the vacuum brake servo unit.
4 5 -2 Notes for repair w ork on A B S , A BS / E D L Before doing any repair work on the anti- locking system, determine the cause of the malfunction using On Board Diagnostic (OBD). Repair Manual, Brake System On Board Diagnostic (OBD), Repair Group 01 Before working on the ABS, ABS/EDL system, disconnect the battery Ground strap.
4 5 -3 Thoroughly clean all unions and the adjacent areas before loosening, do not use aggre s sive cleaning agents such as brake cleaner, petrol, thinners or similar. Place removed parts on a clean surface and cover. Do not use fluffy cloth. Carefully cover or seal open components if repairs cannot be carried out immediately.
4 5 -4 Contro l m odu l e, re m ov i ng and install i ng Location Under the rear seat, left Note: Switch off ignition before disconnecting and connecting connectors. Removing - Fold up rear seat. - Press control module se c uring clips together and pull out.
4 5 -5 Wheel speed sensor and rotor for speed sensor, re m ov i ng and i nstal l ing 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.
4 5 -6 Ant i -lock Brake System (ABS) and ABS with Electronic Di f ferential Lock (ABS/EDL), Teves 20 GI General information The ABS or ABS/EDL braking s ystem is divided diagonally. Brake pedal pressure is boosted pneumatically, by the vacuum brake booster.
4 5 -7 Safety precautions WARNING! Brake fluid is p o isonous. CAUTION! Before working on the ABS or ABS/EDL system, disconnect the battery Grou n d (GND) strap. For anti-theft coded radios, first m ake sure t h at the radi o code is available. Brake fluid must not contact painted parts.
4 5 -8 CAUTION! During the final road test, make sure that at least one c o ntrolled brake test is included (pulsations must be felt at the brake pedal). Abs o lute cleanli n ess is required when working on the ABS or ABS/EDL system. DO NOT use any products that contain mi n eral oil, such as oils, greases, etc.
4 5 -9 ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master cylinder ( Teves 20 GI), servicing CAUTION! DO NOT se p arate the ABS hydraulic pump from the valve bl o ck.
4 5 -10 8 - Rubber damper 9 - Retainer 10 - ABS h ydraulic unit 11 - ABS cont r o l module 12 - Brake line connection ABS hydraulic unit to right-front brake caliper 13 - Brake line connection ABS hyd.
4 5 -11 A B S hydraulic unit and A BS control module (Teves 20 GI ) , removing and instal l ing Carefully read and follow all cautions and warnings Page 45-7 before beginning work. Location The ABS control module is bolted to the ABS hydraulic unit, located on the lef t -side of the engine compartment.
4 5 -12 After separating ABS control module from ABS hydraulic unit, always install valve dome transportation protection on hydraulic unit. Warranty claims for ABS hydraulic units on which the valve dome transportation protection was not used will not be accepted.
4 5 -13 - Release retainer and disconnect ABS control module connector (arrows) . - Connect bleeder hose and bleeder bottle to lef t- front brake caliper bleeder screw, and open bleeder screw . - Depress brake pedal at least 60 mm ( 2 -3/8 in.). - Install brake pedal loading device from special tool VAG 1238B.
4 5 -14 - Remove Tor x socket-head bolts (T25) from ABS hydraulic unit bracket. - Remove ABS hydraulic unit/ABS control module assembly . - Disconnect ABS hydraulic pump connector from ABS control module. CAUTION! - Remove ABS control module mounting bolts (arrows) and pull off ABS control module .
4 5 -15 Installing Note: Remove the sealing plug s from a new ABS hydraulic unit one at a time, and only when the corresponding brake line is to be connected. If the plugs are removed too soon, brake fluid can escape and it can no longer be certain that the unit is sufficiently filled or adequately bled.
4 5 -16 Note: For vehicles equipped with ABS/EDL, on which the brake fluid reser v oir has been completely empty (e.g. leaks in brake system), it is necessary to initiate the "Basic Setting".
4 5 -17 Brake hydrau l ic system , bleeding and fi l l i ng Vehicles with ABS/EDL For vehicles with ABS/EDL, when the brake fluid reservoir has been completely emptied (e.g. due to leaks in the brake system) it i s necessary to initiate the "Basic Setting" function of the On Board Diagnostic (OBD) program.
4 5 -18 Assembly overview - hydraulic unit, brake servo/brake master cylinder Note: Repair Manual, Brake System On Board Diagnostic (OBD), Repair group 01 Pump and valve block must not be separated from one another. Illustration shows an exploded view of the ABS/EDL unit.
4 5 -19 2 - Spacer cap Various versions Page 45-25 3 - Sealing ring Always replace 4 - Ci r clip Always replace 5 - Brake line Brake master cylinder/primary piston circuit to hydraulic unit 6 - Brake .
4 5 -20 Repair Manual, Brake System On Board Diagnostic (OBD), Repair group 01 12 - Cap 13 - Hex socket h ead screw for brake fluid r eservoir 14 - Series resistor Only on vehicles with ABS/EDL Checki.
4 5 -21 19 - ABS Hydraulic unit Connections (arrow) show pipe work from tandem master cylinder to ABS hydraulic unit Removing and installing Page 45- 23 20 - ABS/EDL Hydraulic unit Removing and instal.
4 5 -22 24 - Brake line connection Hydraulic unit to rear right wheel cylinder Thread connection: M12 x1, 18 Nm (13 ft lb) 25 - Brake line connection Hydraulic unit to front left brake caliper Thread .
4 5 -23 Hydrau l ic un i t , removing and insta l l i ng Note: For easier disassembling and as s embling, it is more practical to remo v e the hydraulic unit complete with brake servo and brake master cylinder. Removing - Disconnect battery Ground (GND) strap.
4 5 -24 - Remove nuts from brake servo/bulkhead. - Carefully remove hydraulic unit and brake servo with brake master cylinder from engine compartment. Installing Note: Hydraulic units supplied as replacement parts are already filled with hydraulic fluid and bled.
4 5 -25 Brake Pedal P os i t i on Sensor, re m oving and insta l ling Note: The Brake Pedal Position Sensor is only supplied as a repair kit. Apart from the sender, this repair kit contains a sealing ring, circlip and four different spacer caps.
4 5 -26 Removing - Release brake servo vacuum by operating the brake pedal several times . - Remove connector from expansion tank. - Swing coolant expansion tank to side. - Pull connector off sensor. - Expand circlip with a small screwdriver in a clockwise direction and pull sensor (arrow) out of brake s ervo .
4 5 -27 Installing Note: When installing new circlip ensure opening is uppermost - installation position (arrow). - Install new sealing ring to sensor. (Coat sealing ring with lubricant e.g. soft soap) . Note: - Sen s or notch must point downward when inserting into brake servo and be heard to engage .
4 6 -1 Front brakes, servicing (Girling caliper ) Note: After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the brake pads are properly seated in their normal operating position. To remove brake fluid from the reservoir, use a bleeder bottle which is used only for brake fluid.
4 6 -2 1 - Brake disc, not ventilated When worn always replace on both side s Brake disc diameter: 256 mm Brake disc thickness: 13 mm Wear limit: 11 mm 2 - Brake disc, ventilated When worn always repl.
4 6 -3 Repair Manual, Maintenance 5 - Brake pad With brake pad wear indicator Always replace on both side s Removing and installing Page 46-6 Pad thickness: non- ventilated brake disc, 14 mm Pad thick.
4 6 -4 10 - Wheel bearing housing 11 - Brake car r ier wit h gui d e pins and protective caps Supplied as replacement part assembled with sufficient amount of grease on guide pins If protective caps a.
4 6 -5 14 - Self-locki n g hex bolt, 35 Nm (26 ft lb) Always replace 15 - Guide pin 16 - Ribbed bolt, 125 Nm (92 ft lb) 17 - Protective cap 18 - Hex socket h ead bolt, 10 Nm (7 ft lb) 19 - Speed senso.
4 6 -6 Brake pads , removing and insta l ling Removing - Remove lower brake caliper housing securing bolt. Counter-hold on guide pin . - Swing brake caliper housing upward. - Remove brake pads. Page 6 of 7 Front brakes, servicing (Girling caliper) 12/7/2004 http://ebahn.
4 6 -7 Installing Note: Before inserting new brake pads, press piston back into the cylinder with resetting tool. Before pressing the piston back, remove some brake fluid from the reservoir with a bleeder bottle. If reservoir has been topped up, fluid may overflow and cause damage.
4 6 -8 Front brakes, servicing ( Teves/Ate ) Repair Manual, Maintenance 1 - Screw 2 - Brake disc When worn always replace on both side s Remove brake caliper prior to removing Ventilated brake disc di.
4 6 -9 4 - Retaining spring Insert in both brake caliper housing drillings 5 - Brake car r ier Supplied as replacement part assembled with sufficient amount of grease on guide pins If protective caps .
4 6 -10 7 - Guide pins, 25 Nm (18 ft lb) Removing and installing from Page 46-12 8 - Protective cap 9 - Seal Always replace Pry out with suitable tool 10 - Brake hose 11 - Banjo bolt, 30 Nm (22 ft lb).
4 6 -11 16 - Splash plate 17 - Hex bolt, 10 Nm (7 ft l b) 18 - Speed sensor rotor Only on vehicles with ABS 19 - Hub Removing and installing Page 40- 14 20 - Counters u nk bolt Page 4 of 7 Front brakes, servicing (Teves/Ate) 12/7/2004 http://ebahn.bentleypublishers.
4 6 -12 Brake pads , removing and insta l ling Removing Note: If reusing brake pads mark location and install in same position or uneven braking may result. - Remove protective caps. - Pry off brake pad retaining s pring from brake caliper housing with a screwdriver and remove .
4 6 -13 Installing Note: Before installing new brake pads, press piston back into the cylinder with resetting tool. Before pressing the piston back, remove some brake fluid from the reservoir with a bleeder bottle. If reservoir has been topped up, fluid may overflow and cause damage.
4 6 -14 - Install brake pad with retaining spring in brake caliper housing (piston). - Install outer brake pad in brake carrier. - Secure brake caliper housing with both guide pins to brake carrier. - Install both protective caps. - Install retaining spring into brake caliper housing.
4 6 -15 Rear wheel brakes, servicing (drum brakes ) Notes Page 42-15 1 - Grease cap Removing and installing from Page 42-19 2 - Cotter pin Always replace 3 - Locking ring 4 - Hex nut Adjusting wheel bearing play Page 42-20 5 - Thrust was h er Page 1 of 4 Rear wheel brakes, servicing (drum brakes) 12/7/2004 http://ebahn.
4 6 -16 6 - Outer wheel bearing 7 - Wheel s p eed sensor r o tor Only on vehicles with ABS 8 - Brake drum Vehicles with front wheel drive Brake drum diameter: 230 mm Wear limit: 231.
4 6 -17 10 - Hex socket h ead bolt, 10 Nm (7 ft lb) 11 - Wheel s p eed sensor Only on vehicles with ABS Insert with lubricating paste, G 000 650 12 - Backin g plate wit h brake shoes Release adjustmen.
4 6 -18 Brake shoe ad j ust m ent, re l eas i ng - Insert a screwdriver through hole in brake drum and push wedge upward . Page 4 of 4 Rear wheel brakes, servicing (drum brakes) 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.
4 6 -19 Rear wheel brakes, servicing Note: After working on the rear wheel brakes: Release parking brake. Firmly depress the bra k e pedal once. 1 - Spring plate To remove, push against the spring and.
4 6 -20 Repair Manual, Maintenance 4 - Uppe r return spring Unhook with pliers 5 - Lower return spring Lubricate contact points with G 000 650 paste 6 - Wedge spring 7 - Brake shoe Removing and installing Page 46- 23 Minimum lining thicknes s 2.
4 6 -21 11 - Backin g plate 12 - Hex socket h ead bolt, 10 Nm (7 ft) 13 - Wheel cylinder Checking for leaks Fig. 1 14 - Wedge To remove and install the brake drum, push upwards through a wheel bolt ho.
4 6 -22 Note: Care is to be exercised to ensure the seal i s not damaged when lifting the dust boot (only use a blunt instrument, e.g. plastic wedge). Fig. 1 Wheel cylinder, checkin g for leaks - Lift dust boot - If brake fluid is found in the dust boot then replace wheel cylinder Page 4 of 8 Rear wheel brakes, servicing 12/7/2004 http://ebahn.
4 6 -23 Brake shoes, removing and instal l ing Removing - Remove brake drum. - Remove spring plate. - Unhook lower return spring. - Remove brake shoes. - Unhook parking brake cable. - Clamp brake shoes in vice. - Remove wedge spring. - Remove upper return spring.
4 6 -24 Installing - Connect locating spring and install brake shoes on the push rod. - Insert wedge. - Insert brake shoe with brake lever in push rod. - Connect upper return s pring. - Connect parking brake cable to brake lever. - Place brake shoes on wheel cylinder pistons.
4 6 -25 - Attach wedge spring. - Install springs and spring plates. - Install brake drum and adjust wheel bearing play. Adjusting wheel bearing play Page 42- 20 - Firmly depress brake pedal once, this adjusts the rear brakes. Page 7 of 8 Rear wheel brakes, servicing 12/7/2004 http://ebahn.
4 6 -26 Park i ng brake , adjusting (drum brakes) Note: Due to the automatic rear wheel brake adjustment there is no requirement to adjust the parking brake. Adjustment is only necessary after replacing parking brake cables, backing plate or brake linings - Release parking brake.
4 6 -27 Rear wheel brakes, servicing (disc brakes ) G i rling rear wheel disc brakes (front and four wheel drive vehicles) Note: Only items 5, 6, 7, 8, 9, 10, 11 and 12 apply for four wheel drive.
4 6 -28 4 - Brake hose bracket 5 - Hex socket h ead bolt, 65 Nm (48 ft lb) 6 - Self-locki n g b o lt, 35 Nm (26 ft lb) Always replace When loosening and tightening, counter- hold on guide pin 7 - Guid.
4 6 -29 Repair Manual, Maintenance 11 - Brake car r ier wit h gui d e pins and protective cap Supplied as replacement part assembled with sufficient grease on guide pins If protective caps or guide pins are damaged use repair kit. Use grease packet supplied to lubricate guide pins.
4 6 -30 14 - Outer wheel bearing 15 - Hex nut Adjusting wheel bearing pla y Using a screwdriver it must be possible to move the thrust washer by finger pressure (without leverage) Page 42- 20 Secure w.
4 6 -31 21 - Brake disc Brake disc diameter for vehicles with front wheel drive: 226 mm Removing and installing Page 42- 24 Brake disc diameter for vehicles with four wheel drive: 239 mm Removing and .
4 6 -32 24 - Wheel s p eed sensor r o tor Insert drift through wheel bolt holes and drive off Drive on with suitable sleeve 25 - Hex bolt, 60 Nm (44 ft lb) 26 - Dished spring washer Larger seating sur.
4 6 -33 Brake pads , removing and insta l ling Note: Mark brake pads when removing if they are to be reused. Re-install in their original position to prevent uneven braking! Removing - Remove wheels. - Remove parking brake cable from brake caliper (arrow) .
4 6 -34 Installing Note: Before pressing the piston back, remove some brake fluid from the reservoir. Use a bleeder bottle or a plastic bottle which is only u s ed for brake fluid. Brake fluid is poisonous and mu s t not be siphoned by mouth through a hose.
4 6 -35 - Secure brake caliper housing with new self- locking bolts . Note: - Attach parking brake cable (arrow) to brake caliper housing. After each brake pad change firmly depress brake pedal several times with vehicle stationary, so that the brake pads are properly seated in their normal operating position.
4 6 -36 Park i ng brake , adjusting (disc brakes) Note: Due to the self-adjusting rear brakes there is no requirement to adjust the parking brake. Adjustment is only necessary after replacing parking brake cables, brake calipers, brake pads and brake discs.
4 6 -37 Parking brake lever assembly overvie w 1 - Parking brake lever Different versions for rear drum and disc brakes Before removing remove center console 2 - Han d grip Pry trim up with a small screwdriver then pull forward to remove Fig.
4 6 -38 4 - Lock nut 5 - Compe n sator 6 - Parking brake leve r trim First pull off parking brake hand grip then pull trim forward Fig. 2 7 - Hex nut 8 - Parking brake cable Different versions for rear drum and disc brakes Allocation see Parts catalog Page 2 of 9 Parking brake lever assembly overview 12/7/2004 http://ebahn.
4 6 -39 The parking brake cable is secured by clamps to the axle beam in the center of the two colored marks (arrow). Fig. 1 Parking brake cable installation position Fig. 2 Han d grip, removing - Pry up parking brake cable trim with a screwdriver and pull grip and trim off forward.
4 6 -40 Fig. 3 Center cons o le, removing - Remove rear ashtray (center console). - Remove console rear securing screws (arrows). Page 4 of 9 Parking brake lever assembly overview 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.
4 6 -41 Brake peda l /brake servo, re m ov i ng and i nstal l ing CAUTION! The brake pe d al travel must not be restricted by additional floor cove r ings.
4 6 -42 Repair Manual, 5 Spd. Manual Transmission 02A, Repair Group 30 Repair Manual, 5 Spd. Manual Transmission 02A, Repair Group 30 6 - Brake pedal return spring 7 - Return spring m o unting tube 8 .
4 6 -43 16 - Sec u r ing clip Ensure seated securely 17 - Brake Light Switch Adjusting Page 46- 45 Page 7 of 9 Parking brake lever assembly overview 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.
4 6 -44 Brake peda l , re m ov i ng and i nstall i ng Note: Grease all mounting and contact surfaces with MoS 2 grease. To remove brake servo disconnect brake pedal at clevis only. Removing - Before removing brake pedal remove trim - Remove brake pedal clevis pin c onnection securing clip.
4 6 -45 Brake Light S wi tch, ad j ust i ng Note: The Brake Light Switch must be removed for adjusting. - Remove trim under instrument panel. - Disconnect harness connector for Brake Light Switch. - Remove Brake Light Swit c h by turning to right through 9 0 .
4 7 -1 Assembly overview : brake master cylinder/brake serv o Note: Brake master cylinders and brake s ervos from different manufacturers are installed.
4 7 -2 6 - Brake servo On gas engines the vacuum required is taken from the intake manifold. On Diesel engines an exhauster is installed to create the required vacuum. Functional check - With engine switched off, depress brake pedal firmly several times (to exhaust the vacuum in the unit).
4 7 -3 7 - Sealing ring Always replace 8 - Self- locki n g hex nut, 20 Nm (15 ft lb) 9 - Brake master cylinder Cannot be repaired. If faulty, replace complete. 10 - Sealing plug Moisten with brake fluid and press into reservoir 11 - Seal Page 3 of 4 Assembly overview: brake master cylinder/brake ser vo 12/7/2004 http://ebahn.
4 7 -4 12 - Cap 13 - Brake fluid reservoir 14 - Non- r eturn valve Page 4 of 4 Assembly overview: brake master cylinder/brake ser vo 12/7/2004 http://ebahn.
4 7 -5 Girling f ront brake caliper, servicing Note: When repairing install all parts supplied in repair kit. Apply thin coat of brake cylinder paste to brake cylinders, pistons and sea/s.
4 7 -6 5 - Seal Remove using a screwdriver Page 47-7 6 - Piston Removing and installing Page 47-7 Apply thin coat of brake c ylinder paste before inserting 7 - Protective seal Do not damage when inser.
4 7 -7 Front brake caliper p i stons, re m oving and insta l ling Removing Note: Place a piece of wood in the recess to prevent damaging the piston. - Force piston out of brake caliper housing using compressed air . Note: When removing ensure that the surface of the cylinder is not damaged.
4 7 -8 Installing - Place prote c tive seal with the outer sealing lip on the piston . Note: Hold piston in front of caliper housing. - Using a screwdriver, insert the inner sealing lip into the cylinder groove. Page 4 of 5 Girling front brake caliper, servicing 12/7/2004 http://ebahn.
4 7 -9 Note: The protective seal outer sealing lip will then locate in the piston groove. - Press piston into the brake caliper housing using piston resetting tool . Page 5 of 5 Girling front brake caliper, servicing 12/7/2004 http://ebahn.bentleypublishers.
4 7 -10 Front brake caliper, servicing ( Teves/Ate ) Note: When repairing install all parts supplied in repair kit. Apply thin coat of brake cylinder paste to brake cylinders, pistons and seals.
4 7 -11 6 - Brake cylinder housing 7 - Brake car r ier Install on brake caliper housing 8 - Retaining spring Install with both ends in the drillings in brake caliper housing 9 - Piston seal Remove using a screwdriver Fig. 2 10 - Piston Force piston out of brake c aliper using compressed air Fig.
4 7 -12 Note: Place a piece of wood in the recess to prevent damaging the piston. Fig. 1 Piston, pressin g o u t of cylinder using compressed air Fig. 2 Piston seal, removing Page 3 of 5 Front brake caliper, servicing ( T eves/Ate) 12/7/2004 http://ebahn.
4 7 -13 Fig. 3 Protective seal, installing Note: Hold piston in front of caliper housing. Fig. 4 Protective seal, installing - Using a screwdriver, insert inner sealing lip into cylinder groov e Page 4 of 5 Front brake caliper, servicing ( T eves/Ate) 12/7/2004 http://ebahn.
4 7 -14 Note: The protective seal outer sealing lip will then locate in the piston groove. Fig. 5 Piston, i n stalling Page 5 of 5 Front brake caliper, servicing ( T eves/Ate) 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.
4 7 -15 Rear brake caliper, servicing Note: Apply thin coat of brake cylinder paste to brake cylinder pistons and seal. When repairing install all parts supplied in repair kit.
4 7 -16 2 - Sealing ring Remove using a screwdriver Page 47-19 3 - Piston with automatic adjustment Removing and installing Page 47- 19 4 - Protective seal Pull outer sealing lip onto piston Install i.
4 7 -17 7 - Brake caliper housing with parking brake cable lever If a leak exi s ts at the parking brake cable lever repla c e bra k e caliper housing After repairing, pre- bleed caliper housing Page .
4 7 -18 10 - Brake car r ier wit h gui d e pin an d protective cap Supplied as replacement part, assembled with sufficient grease on guide pins If protective caps or guide pins are damaged, install repair kit. Use grease packet supplied to lubricate the guide pins.
4 7 -19 Rear brake ca l iper piston, re m ov i ng and instal l ing Removing Note: - Thread piston out of brake caliper housing by turning the knurled wheel counter-clockwise. If piston is difficult to move, use a 13 mm open end wrench on the flats (arrow A) provided for this purpose.
4 7 -20 Installing - Place prote c tive seal with the outer sealing lip on the piston . Note: Hold piston in front of brake caliper housing. - Insert protective seal inner sealing lip into the caliper housing groove using a screwdriver . Page 6 of 8 Rear brake caliper, servicing 12/7/2004 http://ebahn.
4 7 -21 Note: - Thread piston into housing by turning knurled wheel clockwise. Install special tool 3272 so that the collar (arrow) of the tool is seated against the brake carrier. If piston is difficult to move, use a 13 mm open end wrench on flats (arrow A) provided for this purpose.
4 7 -22 Pre-b l eed i ng brake ca l iper Note: Position brake caliper as illustrated to pre-bleed. - Open bleeder valve and using a standard bleeder bottle, fill with brake fluid until bubbl e -free brake fluid flows from the threaded hole (brake hos e connection).
4 7 -23 Brake pressure regulator, checking and adjus t ing Vehicles w ithout A B S , veh i cles w ith A B S, A B S/ E DS , Teves 04 The brake pressure regulator is mounted on a bracket which is in turn fixed to a rear axle mounting bracket and is controlled from the rear axle by a spring.
4 7 -24 Note: Bleeding brake system on vehicles with ABS Page 47-27 . - Lift vehicle and connect pressure gauges to front left brake caliper and to rear right wheel cylinder/caliper. - Bleed both gauges. - Lower vehicle and bounce the rear of the vehicle several times.
4 7 -25 Load dependent brake pressure regulator specifications Model / Versi o n Bar (psi) Bar (psi) Rear axle drum Front axle 50 (725) Front axle 100 (1450) brakes Rear axle 30 - 36 (435 - 522) Rear .
4 7 -26 Adjusting regulator Rear axle test pressure too high: - Release tension on regulator spring. Rear axle test pressures too low: - Tension regulator spring. Note: Do not adjust with brake pedal depressed, therefore observe the following sequence: - Read off figures.
4 7 -27 Brake system, bleeding Brake system, bleeding (vehicles w ith and w i thout A B S , A B S /E D L) Cha n gin g brake fluid Repair Manual, Maintenance Note: Bleeding the brake sy s tem on vehicle s with ABS, ABS/EDL is performed as for vehicles with conventional braking systems.
4 7 -28 Brake system, bleeding ( w ith pressure b l eeder VA S 5234) Opening the hydraulic unit bleed screws on vehicles with ABS, ABS/EDL is not permitted! Bleeding sequence Note: - Connect VAS 5234 Brake filler and bleeder unit. - Open bleeder screws in the specified order and bleed brake calipers and wheel cylinders .
4 7 -29 Brake system, bleeding ( w ithout pressure bleeder) Opening the hydraulic unit bleed screws on vehicles with ABS, ABS/EDL is not permitted! - Build-up brake pressure in brake system by pumping the brake pedal. - Attach bleeder bottle hose and open bleeder screw.
4 8 -1 Steerin g Asse m bly overvie w : steering colu m n, co l umn tube, steer i ng w hee l and a i rbag steer i ng w heel Ai r b ag system functional check and interrogating Diagnostic Trouble Code (DTC) Memory.
4 8 -2 1 - Cover plate 2 - Hex nut, 50 Nm (37 ft lb) 3 - Steeri n g wheel Install in center position 4 - Ai r b ag unit Removing and installing Page 48-7 5 - Steeri n g wheel f o r airbag Removing and installing Page 48-8 Removing and installing Airbag Spiral Spring Page 48-10 6 - Hex socket h ead bolt, 6.
4 8 -3 9 - Spring 10 - Steeri n g column switch/steerin g lock housing 1) Distance between steering wheel/steering column switch is not adjustable 11 - Uppe r t r im 12 - Supp o r t ring 1) With washe.
4 8 -4 19 - Lower steering column bearing Pull in with VW 771 and large washer Drive out downward with a tube 20 - Washer Tighten until head shears off Drill out to remove 21 - Shea r bolt 22 - Column tube 23 - Lower trim Page 4 of 99 Steering 12/7/2004 http://ebahn.
4 8 -5 Only use puller with leg clamp (e.g. Kukko 204/2 commercial type). Fig. 1 Splined adapter sleeve, removing Fig. 2 Splined adapter sleeve, installing - Place sleeve on steering column and press on with hex nut. - Remove nut, place on washer and press sleeve fully on with nut until sleeve is firmly seated .
4 8 -6 The small metal lug on the lower section must be visible in the hole in the upper section (arrow). If necessary pull both sections firmly apart onto stop or press together.
4 8 -7 Airbag un i t , removing and insta l l i ng Removing - Disconnect battery Ground strap. - Center s teering wheel (wheels straight- ahead) . Installing Install in reverse order Note: Only use new hex socket head bolts for airbag unit. Tightening torque: 6.
4 8 -8 Airbag steer i ng w hee l , re m oving and instal l ing Removing - Remove airbag unit. Page 48-7 - Remove trim below steering column switch. Note: - Separate connector (arrow). (Pull foam rubber sleeve off connector, if installed) . - Remove nut and pull steering wheel off steering column .
4 8 -9 Installing - Install steering wheel, install nut and tighten. Tightening torque: 50 Nm (37 ft lb). - Connect airbag unit connector below steering wheel. - Install trim panel below steering column. Make sure that the centering ring wiring connection is located in the recess in the trim panel.
4 8 -10 Airbag S piral Spring, removing and instal l ing Remove airbag unit Page 48-7 Remove steering wheel Page 48- 8 - Separate single connector for horn. Install steering wheel Page 48-9 Install airbag unit Page 48-7 Note: - Remove screws -1- and remove Airbag Spiral Spring -2- from steering wheel .
4 8 -11 Colu m n tube for he i ght ad j ustable steer i ng wheel , removing and instal l ing The column tube can be adjusted in height by approx. 50 mm 1 - Operating lever 2 - Packing plate 3 - Column.
4 8 -12 8 - Clamping sleeve 9 - Mounting bracket Before assembling, coat side sliding surfaces with MoS 2 paste 10 - Bolt with left-hand thread Tighten to 22 Nm (16 ft lb), After tightening install locking plate 11 - Locking plate 12 - Locking plate nut, 8 Nm (70 in.
4 8 -13 Pump de l ivery pressure, checking - Disconnect pump pressure line. Test re q uirements: - Install adapter and test equipment. Cut-off valve on gauge open . - Start engine and if necessary add fluid to reservoir. A - VAG 1402/2 B - VAG 1402/1 C - Hose from adapter kit VAG 1402/6 D - VAG 1402 V-belt/V-belt tension OK.
4 8 -14 - With engine running at idling speed. Close cut- off valve (not longer than 5 seconds) and read off pressure. Spe c ification: 85 - 95 bar (1232 - 1377 psi) Note: If the reading is higher or lower than specified replace pump. Vehicles with up to 110 kW engine Page 48- 90 .
4 8 -15 Po w er steering gear, re m oving and instal l ing When working on the p ower assisted steering gear: Absolute cleanliness i s required when working on the power steering . Thoroughly clean connections and immediate vicinity before loosening .
4 8 -16 Removing - Press tie rods off steering arm. A - Ball joint splitter (commercial type) e.g. Kukko No. 128/2 - Remove partition behind pedals from bulkhead and from steering column tube to loosen the universal joint/power steering gear. If an oil extraction unit is not available, disconnect vane pump supply hose and drain hydraulic fluid.
4 8 -17 Instead of plastic sealing plugs a plug consisting of Part No.113 301 229 A and banjo bolt, Part No. N 904 674 01 can be used. But when using these, several 16 mm diameter sealing rings must be used so that the holes in the banjo bolt are sealed.
4 8 -18 Installing Install in reverse order. - Check position of steering wheel and, if necessary, align front end . Note: Tig h te n in g torques: When lifting the engine/transmission assembly guide the lower half of the universal joint shaft -A- into the upper half -B- at the same time (second mechanic necessary).
4 8 -19 Asse m bly overvie w : power assisted steer i ng box (TR W ) Determine cause of any malfunctions using pressure and leak testing, Page 48-13 . Note: Always replace self-locking nuts and bolts. Welding and straightening work on steering components is not permitted.
4 8 -20 1 - Self-locki n g n u t 35 Nm (26 ft lb) 2 - Self-locki n g 30 Nm (22 ft lb) 3 - Clamp 4 - Rubber mounting Internal diameter ZF: 50 mm TRW: 44 mm 5 - Right-hand tie rod 70 Nm (52 ft lb) Removing and installing Page 48- 77 Vehicle alignment Page 44-1 Tie rod boot seat diameter Z F: 15 mm dia.
4 8 -21 6 - Left-hand tie rod 70 Nm (52 ft lb) Removing and installing Page 48- 77 Adjusting to length Page 48-84 Tie rod boot seat diameter Z F: 15 mm TRW: 12.
4 8 -22 Repair Manual, Maintenance 9 - Steeri n g g ear Removing and installing Page 48- 15 Adjusting Page 48- 24 10 - Tie rod end Separating Page 48-16 Checking: 11 - Hex nut 30 Nm (22 ft lb) 12 - Universal j o int Page 22 of 99 Steering 12/7/2004 http://ebahn.
4 8 -23 13 - Threaded connection 30 Nm (22 ft lb) Return line 14 - Sealing ring Always replace 15 - Hose clamp Always replace - open with pliers Tensioning Page 48-81 Page 23 of 99 Steering 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.
4 8 -24 Po w er steering gear, ad j ust i ng (T R W) Note: Two Mechanics are required when adjusting. Adjust with engine switched off Adjusting steering box By turning the steering wheel back and forth (about 3 0 to center axis) a knocking noise will be heard if there i s excessive play.
4 8 -25 Po w er steering gear, disassemb l ing and reasse m bl i ng (T RW ) This repair is limited to replacing the sealing rings and, if necessary, the toothed rod. Steering gears that are damaged by an ac c ident must be replaced. For a satisfactory and successful repair, the greatest care, safety and proper tools are required.
4 8 -26 1 - Tie rod For removing, see tie rod, remo v ing and installing (TRW and ZF power steering gear) Page 48-77 2 - Boot Installing, see tie rod, removing and installing (TRW and ZF) power steeri.
4 8 -27 7 - O- r ing Is assembled on toothed rod guide (item -6-) contained in the repair kit 8 - Pressure compensating tube Check for damage (dents and kinks) 9 - Toothed rod Check for scoring After .
4 8 -28 11 - Adjustin g screw with lock n ut, 60 Nm (44 ft lb) Before removing, mark position of adjusting bolt and lock nut on housing Steering gear, adjusting Page 48- 24 12 - Pressure spring 13 - P.
4 8 -29 17 - Sealing ring Always replace 18 - Valve body Removing Page 48- 32 Cannot be repaired Is not supplied as replacement part, if damaged replace steering gear 19 - Supp o r t ring Eliminated starting 4/92 If present, it must be reinstalled 20 - Adhesive film Thoroughly clean housing in this area before sticking on, e.
4 8 -30 21 - Roller bearing installation position: inscription points up 22 - Sealing ring Always replace 23 - Ci r clip 24 - Ball bearing Drive from top downward with VW 439 Grease with steering gear.
4 8 -31 27 - Pipe Do not disconnect Not supplied as replacement part Sealing ring cannot be replaced 28 - O- r ing 29 - Sealing ring Replace if there is scoring that can be seen or felt Already pre-mo.
4 8 -32 Po w er steering gear, disassemb l ing - Tie rods, removing - see tie rod, removing and installing (TRW and ZF power steering), Page 48-77 - Close hose connections on power steering gear if not already done 1 - Plastic locking screw 2 - Plastic locking screw Note: Use jaw covers and check jaw covers for contamination; e.
4 8 -33 - Mark position of adjusting screw and lock nut to the housing (arrow) Note: - Screw lock nut together with adjusting screw Do not change position of adjusting screw to lock nut when removing .
4 8 -34 - Mark installation position of pressure piece and remov e 1 - Spreading pliers (standard commercial) 2 - Pressure piece - Remove circlip for valve body 1 - Needle nose pliers (standard commercial) Page 34 of 99 Steering 12/7/2004 http://ebahn.
4 8 -35 If very tightly seated, loosen locking screw with a hammer and driver - Remove lower locking screw for valve body 1 - Ratchet (standard commercial) - Remove hex nut below valve body 1 - Ratche.
4 8 -36 - Pull adhesive tape out of the housing Valve body sealing ring, removing - Pull toothed rod all the way to the left - Turn lock washer so that the opening of the circlip (arrow) is in the gro.
4 8 -37 For easier installation of the puller, it is recommended that a rubber band be placed around the claws. Illustration shows the housing in cross section for better view 1 - Puller, e.g. Kukko 21/4 2 - Rubber band 3 - Sealing ring 4 - Glide bearing do not remove Page 37 of 99 Steering 12/7/2004 http://ebahn.
4 8 -38 Inner sea l ing r i ng for toothed rod, pu l l i ng out - Install puller for sealing ring far enough so that the marking on the tool (arrow) matches the housing edge (only then will the claws .
4 8 -39 Parts, cleaning a n d checking - Install tool VW 771 in the puller - Pull out sealing ring - Before assembly, the housing must be checked for contamination (paint residue, chips, dirt) and thoroughly cleaned with compressed air and alcohol - Clean adhesive surface for adhesive tape in area of the slot with solvent (e.
4 8 -40 Check i ng toothed rod for scoring If corroded areas or deep scratches are not noticeable on the toothed rod, the toothed rod must be replaced An evaluation of whether the toothed rod was damaged by force, e.
4 8 -41 Sea l ing r i ng on toothed rod , replacing - Press pliers together with slight pressure on the sealing rin g - Pry out sealing ring and O -ring A - Needle nose pliers (standard commercial) 1 - Toothed rod with piston 2 - Sealing rod 3 - O-ring Page 41 of 99 Steering 12/7/2004 http://ebahn.
4 8 -42 Sea l ing r i ngs, i nstal l ing on toothed rod p i ston - Slide mounting sleeve on toothed rod - Pull O -ring over tool and install in groove of piston - Lubricate sealing ring with hydraulic oil, pull over tool and install in groove of piston Page 42 of 99 Steering 12/7/2004 http://ebahn.
4 8 -43 Po w er steering gear, assemb l ing Note; All s ealing rings should be lubricated with hydraulic oil before installing. - Check whether the valve bod y housing -2- is absolutely clean on the inside, otherwise clean - Place sealing ring -1- on tool.
4 8 -44 Inner sea l ing r i ng for toothed rod, instal l ing - Place sealing ring on tool - Ensure correct installation position of sealing ring for toothed ro d - Drive sealing ring -1- into the cyli.
4 8 -45 Toothed rod, insta l ling in hous i ng No grease must get into the oil circulation system! - Grease teeth of toothed rod with AOF 063 000 04 grease - Slide protective tube on to toothed rod to stop - Wipe exce s s grease off completely Page 45 of 99 Steering 12/7/2004 http://ebahn.
4 8 -46 - Coat piston of toothed rod and protective tube with hydraulic oil When sliding, make sure that the sealing ring is pressed into the groove of the piston without jamming - Install in s tallat.
4 8 -47 - Place lock washer in the housing and press in far enough until the groove in the lock washer in the slot of the housing is visible - Install new safety wire in the hole of the lock washer (arrow) - Pull safety wire in by turning the lock washer.
4 8 -48 Make sure that the sealing ring in the housing is not damaged by the teeth of the pinion - Screw assembly mandrel 3315/17 on valve body - Lubricate valve body with hydraulic oil and carefully install by hand into the valve body housing (note position of toothed rod) - Tape teeth of valve body with adhesive tape to protect the sealing ring.
4 8 -49 - Drive sealing ring in far enough sot that the groove for circlip in the housing is visible - Install circlip - Remove adhesi v e tape - Remove assembly mandrel 3315/17 - Install hex nut for .
4 8 -50 Adhesive tape, applying - Fill slot with sealing compound AKL 450 005 05 - Tape slot with adhesive tape 1 - Adhesive surface must be dry and free from grease Page 50 of 99 Steering 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.
4 8 -51 Po w er steering gear, ad j ust i ng w ith ne w toothed rod If a new toothed rod was used, the steering play should be adjusted according to the following description.
4 8 -52 - Install gauge and set to "O" with approx. 1 mm pr e -load (make sure that the key does not stick, front of key must not be crowned) 1 - 3315/8 2 - 3315/9 3 - 3315/1 4 - VW 387 - Screw right rod onto toothed rod and tighten by han d - Turn toothed rod radially from stop to stop, during this process observe pointer on gauge .
4 8 -53 Needle run-out max. 0.10 mm If needle run-out is greater than 0.10 mm, screw pressure piece slightly into housing If the needle run-out is less than 0.
4 8 -54 Asse m bly overvie w : power steering gear (ZF) It is not intended that repair work be c arried out on the power steering gear. If complaints are received determine cause with the help of pressure tests, leakage test and troubleshooting programs.
4 8 -55 1 - Power steerin g gear Removing and installing Page 48- 15 Adjusting Page 48- 59 Checking steering moment Steering gear with reduced steering moment only permissible for vehicles up to 85 kW Steering moment on 16 V and VR 6 vehicles is approx.
4 8 -56 3 - Boot Remove ball joint before removing Check for wear (cuts, crack s ), ensure sealing surfaces and sealing lips are clean and undamaged The end diameters are larger than the boot for TRW .
4 8 -57 5 - Right-hand tie rod Removing and installing Page 48- 77 Vehicle alignment Page 44-1 Tie rod boot seat diameter Z F: 15 mm TRW: 12.7 mm Must not be installed on a TRW power steering gear 6 - Left-hand tie rod Removing and installing Page 48- 77 Tie rod boot seat diameter Z F: 15 mm TRW: 12.
4 8 -58 Repair Manual, Maintenance 7 - Lock nut, 50 Nm (37 ft lb) 8 - Tie rod ball joi nt Splitting Page 48-16 Checking: 9 - Pressure b alance pipe 10 - 30 Nm (22 ft lb) 11 - Clamp 12 - Rubber mounting Internal diameter ZF: 50 mm TRW: 44 mm 13 - Data plate and company initials Page 58 of 99 Steering 12/7/2004 http://ebahn.
4 8 -59 Po w er steering gear, ad j ust i ng (ZF) Note: Two mechanics are required when adjusting. Adjust with engine switched off. - Raise vehicle on hoist. - Wheels in s traight-ahead position. - By turning the steering wheel to and fro (about 3 0 to center axis) a knocking noise will be heard if there is excessive play .
4 8 -60 Po w er steering gear, disassemb l ing and reasse m bl i ng (ZF) This repair is limited to replacing the sealing rings and, if necessary, the toothed rod. Steering gears that are damaged by an ac c ident must be replaced For a satisfactory and successful repair, the greatest care, safety and proper tools are required.
4 8 -61 Po w er steering gear, disassemb l ing Note: Use jaw covers, check jaw covers for contamination; e.g. metal chips or the like - Tie rods, removing - see tie rod, removing and installing (TRW a.
4 8 -62 Note: Do not change position of the adjusting screw (arrow) Cover is stressed with slight spring pressure - Remove pressure piece 1 - Spreading pliers (standard commercial) Page 62 of 99 Steering 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.
4 8 -63 - Remove lower locking screw for valve body 1 - Locking screw - Remove Torx screw for valve body 1 - Open-end wrench (standard commercial SW 14) 2 - Torx insert (standard commercial E10) 3 - Ratchet (standard commercial 3/8") Page 63 of 99 Steering 12/7/2004 http://ebahn.
4 8 -64 - Remove circlip for valve body with needle nose pliers 1 - Drive valve body out from below with driver - Slide toothed rod all the way in the direction of the valve bod y - Turn circlip so that the pointed end of the circlip is in the groove (arrow) of the housing Page 64 of 99 Steering 12/7/2004 http://ebahn.
4 8 -65 Center roller bearing for valve body, removing - First lift circlip with slotted screwdriver then pull out with plier s - Before removing toothed rod, clean housing opening with compres s ed a.
4 8 -66 For easier installation of the puller, it is recommended that a rubber band be placed around the jaws. Illustration shows the housing in cross section for better view.
4 8 -67 For easier installation of the puller, it is recommended that a rubber band be placed around the jaws. Illustration shows the housing in cross section for better view.
4 8 -68 Parts, cleaning a n d checking - Before assembly, the housing must be checked for contamination (paint residue, chips, dirt) and clean thoroughly with compressed air and alcohol if necessar y - Check cylinder race for scoring or other damage.
4 8 -69 Check i ng toothed rod for scoring If corroded areas or deep scratches are noticeable on the toothed rod, the toothed rod must be replaced An evaluation of whether the toothed rod was damaged by force, e.
4 8 -70 Sea l ing r i ng on toothed rod , replacing When the sealing rod is replaced it must be replaced with a new one of the same color Note the matching of the O-ring to the sealing ring - Press pliers together with slight pressure on the sealing rin g - Pry out sealing ring and O -ring A - Needle nose pliers (standard commercial) O-ring 30.
4 8 -71 Po w er steering gear, assemb l ing Note: The sealing lip (arrow) of the sealing ring points upward toward the teeth 1 on the valve body For better viewing, the illustration show s the body housing in cross section with installed valve body.
4 8 -72 When the groove -arrow- matches the edge -arrow - A- of the housing, the sealing ring is properly seated. - Place support ring -1- and sealing ring -2- on tool - Drive sealing ring for toothed rod into housing to stop Page 72 of 99 Steering 12/7/2004 http://ebahn.
4 8 -73 Toothed rod, installing in the housing No grease must get into the oil circulation system! - Grease teeth of toothed rod with AOF 063 000 04 grease - Slide protective tube over toothed rod to .
4 8 -74 - Align teeth of toothed rod in such a way that they point toward the teeth of the pinion - Screw mounting sleeve 3315/16 on toothed rod and coat with hydraulic oil - Carefully slide toothed r.
4 8 -75 Make sure that the sealing ring in the housing is not damaged by the teeth of the pinion. - Thread assembly mandrel 3315/17 onto valve body . - Lubricate valve body with hydraulic oil and carefully install by hand into the valve body housing (note position of toothed rod).
4 8 -76 - Carefully slide bushing with roller bearing onto the valve body. - Drive bushing into the housing far enough so that the groove for the circlip is visible. - Install circlip. - Remove adhesi v e tape. - Remove installation mandrel 3315/17. - Install Torx screw into v alve body and tighten to 35 Nm (26 ft lb).
4 8 -77 T i e rods, re m ov i ng and i nstall i ng (po w er steer i ng gear - TR W and ZF) Note: Observe how tie rods are threaded into power steering gear: - Tie rods not secured with locking fluid - Tie rods secured with locking fluid When exchanging secured version tie rods use locking fluid D6 when installing.
4 8 -78 - Open hose clips and push boot back. Note: Use vice clamps, check vice clamps for impurities e.g. metal filings or similar and thoroughly remove.
4 8 -79 Note: Do not tilt tap when positioning. If it is difficult to turn the tap onto the thread or if metal swarf forms, this indicates the thread is deformed. - Clean threaded stud or tie rod with M 14 x 1.5 tap or wire brush. - Check if joint stud threads are deformed replace if necessary .
4 8 -80 Installing Note: Apply one drop only in 2nd thread of rack. If too much D6 is used the release torque when next disassembling will be too high. No D6 must get onto steering rack. - Adjust new tie rod to length Page 48-84 . - Coat tapped hole thread with D6 locking fluid (arrow) .
4 8 -81 Boot, installing Note: - Check boot for wear (cuts, cracks) and ensure sealing surfaces are clean. - Install boot, but first turn the tie rod so that the tie rod ball joint shank is in the installation position . - Install pressure balance line.
4 8 -82 1 - Hose clamp 2 - Pressure compensating tube 3 - Boot 4 - Approx. 90 - Tension hose clamps with pliers VAG 1275 or equivalent. Page 82 of 99 Steering 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.
4 8 -83 Note: The boot must not be installed twisted. Page 83 of 99 Steering 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.
4 8 -84 Left-hand t i e rod length, checking and ad j usting - Check dimension "a" on left-hand tie rod and if necessary adjust . Dimension "a" = 395 + 1 mm (all except from VR6 and 16V) Dimension "a" = 413 1 mm (VR6 and 16V) Note: Only adjust toe on right-hand tie rod.
4 8 -85 Asse m bly overvie w : vane pu m p, reservoir and hydraul i c l i nes (vehicles w i th 4-Cyl . engines) It is not intended that repair work be c arried out on the vane pump. If complaints are received determine cause with the help of pressure and leakage tests.
4 8 -86 1 - Cooli n g line Secured to crossmember item 9 2 - Bracket Various versions depending on engine/transmission Page 48-96 3 - Pressure line 4 - Suction line Hydraulic pump - Cooling line 5 - H.
4 8 -87 9 - Pressure line union 10 - Banjo bolt, 35 Nm (26 ft lb) 11 - Hex bolt, 10 Nm (7 ft l b) Page 87 of 99 Steering 12/7/2004 http://ebahn.bentleypublishers.
4 8 -88 Asse m bly overvie w : Hydrau l ic l ines, reservoir (vehicles w ith 4 -Cyl . eng i nes) Notes Page 48-85 1 - Power steerin g gear 2 - O- r ing Always replace 3 - Return line, 30 Nm (22 ft lb).
4 8 -89 11 - Self-ta p pin g screw 12 - Hose clamp 13 - Return hose 14 - Suction hose Reservoir - Cooling line 15 - Cooli n g line 16 - Threaded stud 17 - Bracket Page 89 of 99 Steering 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.
4 8 -90 Po w er steering vane pu m p, re m ov i ng and instal l ing (vehicles w ith 4- Cyl . engines) Note: Always replace self-locking nuts and bolts . Pumps supplied as spare parts are not filled with hydraulic oil. Fill the pump with G 002 000 hydraulic oil and rotate it by hand, otherwise the pump may be damaged or noisy during operation.
4 8 -91 Maintenance Manual 5 - 20 Nm(15 ft Ib) 6 - Front swivel bracket 7 - 20 Nm (15 ft lb) 8 - Adjustment bracket 9 - 20 Nm (15 ft lb) 10 - Bracket 11 - V-belts 11.5 x 685 Gas engine 11.5 x 730 Diesel engine 11.5 x 755 Gas engine with air conditioner 11.
4 8 -92 13 - V-belt pulley When installing the V- belt pulley ensure that the crankshaft pulley and the vane pump pulley are aligned 14 - Shim Only installed on vehicles with Diesel engine 15 - 20 Nm (15 ft lb) 16 - Rear swivel bracket 17 - Vane p u mp Checking delivery pressure Page 48- 13 Page 92 of 99 Steering 12/7/2004 http://ebahn.
4 8 -93 V-be l ts, tension i ng (4-Cyl . engines) Spe c ification: - Tension V -belts by turning adjustment bolt with torque wrench -A- (VAG 1410 and VAG 1410/2). Used belts, 4 Nm (35 in. Ib) New belts, 7 Nm (62 in. Ib) Note: Nut 4 - is only installed on gasoline engines.
4 8 -94 Asse m bly overvie w : Pressure and cool i ng lines (veh i cles w ith V R 6 eng i ne) Note: Securing of pressure line varies according to type of transmission Fig.
4 8 -95 7 - Hydraulic pump 8 - Seal Always replace 9 - Pressure line union 10 - Banjo bolt, 35 Nm (26 ft lb) 11 - Hex bolt, 10 Nm (7 ft l b) 12 - Hose clamp, 3 Nm (27 in. Ib) 13 - Return line Power steering gear - Reservoir Page 95 of 99 Steering 12/7/2004 http://ebahn.
4 8 -96 Fig. 1 Pressure h ose, securing (vehicles with m anual transmission) Fig. 2 Pressure h ose, securing (vehicles with automatic tra n smission) Page 96 of 99 Steering 12/7/2004 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&ty p e=repair&id=VW.
4 8 -97 Po w er steering vane pu m p, re m ov i ng and instal l ing (vehicles w ith VR6 eng i ne] Note: Always replace seal s. Do not reuse drained hydraulic oil. Pumps supplied as spare parts are not filled with oil. Fill the pump with G 002 000 hydraulic oil and rotate it by hand, otherwise the pump may be damaged or noisy during operation.
4 8 -98 Repair Manual, Engine Mechanics; Repair Group1 3 Repair Manual, Engine Mechanics; Repair Group1 3 Repair Manual, Maintenance 3 - Pressure h ose Attachment varies according to type of transmiss.
Een belangrijk punt na aankoop van elk apparaat Volkswagen Passat (1997) (of zelfs voordat je het koopt) is om de handleiding te lezen. Dit moeten wij doen vanwege een paar simpele redenen:
Als u nog geen Volkswagen Passat (1997) heb gekocht dan nu is een goed moment om kennis te maken met de basisgegevens van het product. Eerst kijk dan naar de eerste pagina\'s van de handleiding, die je hierboven vindt. Je moet daar de belangrijkste technische gegevens Volkswagen Passat (1997) vinden. Op dit manier kan je controleren of het apparaat aan jouw behoeften voldoet. Op de volgende pagina's van de handleiding Volkswagen Passat (1997) leer je over alle kenmerken van het product en krijg je informatie over de werking. De informatie die je over Volkswagen Passat (1997) krijgt, zal je zeker helpen om een besluit over de aankoop te nemen.
In een situatie waarin je al een beziter van Volkswagen Passat (1997) bent, maar toch heb je de instructies niet gelezen, moet je het doen voor de hierboven beschreven redenen. Je zult dan weten of je goed de alle beschikbare functies heb gebruikt, en of je fouten heb gemaakt die het leven van de Volkswagen Passat (1997) kunnen verkorten.
Maar de belangrijkste taak van de handleiding is om de gebruiker bij het oplossen van problemen te helpen met Volkswagen Passat (1997) . Bijna altijd, zal je daar het vinden Troubleshooting met de meest voorkomende storingen en defecten #MANUAl# samen met de instructies over hun opplosinge. Zelfs als je zelf niet kan om het probleem op te lossen, zal de instructie je de weg wijzen naar verdere andere procedure, bijv. door contact met de klantenservice of het dichtstbijzijnde servicecentrum.
