Volkswagen Passat B4 - Power-assisted steering, servicing

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48 - 2

Power-assisted steering, servicing

Delivery pressure of power steering pump, checking

If pump is malfunctioning no. 16 .

Troubleshooting suspension

- Remove pressurized line from pump.

- Install adapter and test equipment. Shut-off valve on pressure gauge open. - Start engine and top up fluid level in reservoir if necessary. A - V.A.G 1402/2 B - V.A.G 1402/1 C - Hose from Adapter Hose VAG1402/6 D - V.A.G 1402 Test requirements:

V-belt/V-belt tensioning OK System sealed Hoses/lines are not kinked or constricted

- With engine at idle speed, close shut-off valve (not more than 5 seconds) and read pressure. - Specified value: 85 95 bar positive pressure. Note:

If specification is not reached or exceeded, replace

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pump.

Vehicles with 128 kW-engine 48-4, Power steering vane pump - vehicles with VR6 engine, removing and installing . If power steering fluid is low in the reservoir, check the steering system for leaks. In case of leaks at steering pinion, check lines/line connections for leaks, if necessary tighten and wipe dry. In case of leaks at the steering pinion or at steering rack seal in steering housing, the steering gear must be replaced. To test rack seal open hose clamp of boot and set boot aside. Disposal Special information; Suspension No. 2 .

Power steering gear, removing and installing

Notes for repair work on power steering gear

All work on the power steering must be performed with utmost cleanliness. Thoroughly clean all connections and the surrounding area before disconnecting. If repairs will not be performed immediately, place removed parts onto a clean surface and cover. Only use lint-free cloths. Only unpack replacement parts immediately prior to installation. Only use parts in their original packing.

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Observe installation of heat shield for vehicles with All-Wheel Drive .

Removing

- Press off tie rods from steering knuckle . A - Tie rod end puller (standard), e.g. Kukko Ball Joint Separator 128/2 - To loosen clamp connection of universal joint shaft/power steering gear, remove partition behind pedals from bulkhead and from steering column tube.

- Loosen hex nut - arrow - from universal joint shaft. - Drain hydraulic oil from reservoir using oil extraction device V.A.G 1358 A or V.A.G 1307 A . If an oil extraction unit is not available, disconnect intake hose from vane pump and drain hydraulic oil.

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- Support engine-/transmission assembly using Engine Support Bridge 10-222A and Bracket For Engine 10222A/1 (VR6 engine using Engine Support Bridge 10222A and 10-222A/3 ). - Remove boot from seat on steering gear. - Remove bolts for subframe. - Lower engine/transmission assembly. Both halves of the universal joint shaft are pulled apart. - Unbolt hose lines at steering gear and plug with a plastic bag and tape. - Plug threaded bores at power steering gear with plastic screw plugs. Instead of plastic sealing plugs, sealing plug part no. 113 301 229 A, and banjo fitting part no. N 904 674 01 can be used. To do this, additional seals of 16 mm must be used to seal the bores in banjo fitting shaft. - Remove steering gear nuts (bolts remain in auxiliary frame). - Remove steering gear toward rear.
Installing

Installation is performed in the reverse order of removal. - check position of steering wheel, perform vehicle alignment at front, if necessary. Note:

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When lifting the engine/transmission assembly, guide lower half - A - of universal joint shaft into upper half - B - of universal joint shaft at the same time (second mechanic required). Coat boot with lubricant, e.g. universal lowtemperature grease G 052 745 A3 before pulling on to steering gear.

Tightening torques: Universal joint shaft halves Steering gear Tie rod end Subframe front and rear Rear subframe bracket 25 Nm 30 Nm 35 Nm 70 Nm + 90 65 Nm (1/4 turn)

Power assisted steering gear - TRW, assembly overview

If power assisted steering is malfunctioning Troubleshooting suspension no. 10 Note :

Always replace self-locking nuts and bolts. Welding or straightening work on any steering components is not permissible.

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To grease the rack, only use steering gear grease A0F 063 000 04 . Oil type: Hydraulic fluid G 002 000 . Oil capacity in system: 0.70.9 l. Hose routing for intake and pressure line 48-3, Vane pump, refill tank, hydraulic lines - vehicles with 4-cyl.-engine, assembly overview .

Self-locking hex nut, 35 Nm Self-locking hex nut, 30 Nm Clamp Rubber bushing

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Inner diameter ZF: 50 mm TRW: 44 mm

Right tie rod

70 Nm Removing and installing 48-2, Tie rod - power steering gear, TRW and ZF, removing and installing Wheel Alignment Wheel Alignment 44-1,

Tie rod boot seat diameter ZF: 15 mm TRW: 12.7 mm Must not be installed on ZFpower steering gear

Left tie rod

70 Nm Removing and installing 48-2, Tie rod - power steering gear, TRW and ZF, removing and installing Adjusting to length 48-2, Length of left tie rod, checking (adjusting if necessary) Tie rod boot seat diameter ZF: 15 mm TRW: 12.7 mm Must not be installed on ZFpower steering gear

Hex nut, tighten to 50 Nm Boot

Pull on and off over tie rod Can be replaced with steering gear installed Must not be twisted after toe

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is adjusted

Must not be installed on ZFpower steering gear

Steering gear

Removing and installing 48-2, Power steering gear, removing and installing Adjusting 48-2, Power steering gear - TRW, adjusting Check steering torque Troubleshooting; suspension no. 16 Disposal of steering gear Special information, suspension No 2 Steering gear with reduced steering torque permitted for vehicles up to 85 kW only VR6 vehicles have a steering torque that is approx. 2 Nm higher

Tie rod end

Pressing off Checking:

Topic 48-2

Modification: 48-2, Modified tie rod end Repair Manual, Maintenance

Hex nut, tighten to 30 Nm Universal joint shaft Threaded connection, 30 Nm

Return line

Sealing ring

Replace

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Clamp

replace - open using nipper pliers Tensioning installing 48-2, Boot,

Power steering gear - TRW, adjusting

Note:

Two technicians are required for adjustments. Adjust with engine off.

Adjusting steering gear - Raise vehicle on platform. - Wheels in straight-ahead position. Turning the steering wheel back and forth (approx. 30 off center axis) will produce a rattling noise if steering play is too large. - Loosen lock nut, counterhold using 3315/9 . - Carefully turn adjustment screw - arrow - until rattling noise in vehicle interior cannot be heard anymore. - Tighten lock nut. - Perform a test drive, and while doing so make sure that steering returns to straight-ahead position on its own, without catching, after vehicle is maneuvered or driven in a curve. Correct adjustment if necessary.
Power assisted steering gear - ZF, assembly overview

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Servicing the power steering gear is not planned. If a customer has reported a problem, determine cause via the pressure test and leak test as well as troubleshooting. If there is a malfunction, replace the power steering gear. Note :

Always replace self-locking nuts and bolts. Welding or straightening work on any steering components is not permissible. To grease the rack, only use steering gear grease A0F 063 000 04 . Oil type: Hydraulic fluid G 002 000 . Oil capacity in system: 0.70.9 l. Hose routing for intake and pressure line 48-3, Vane pump, refill tank, hydraulic lines - vehicles with 4-cyl.-engine, assembly overview .

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Power steering gear

Removing and installing 48-2, Power steering gear, removing and installing Adjusting 48-2, Powerassisted steering box - ZF, adjusting Check steering torque Troubleshooting; suspension no. 16 Disposal of steering gear Special information, suspension No 2 Steering gear with reduced steering torque permitted for vehicles up to 85 kW only VR6 vehicles have a

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steering torque that is approx. 2 Nm higher

Clamp

replace - open using nipper pliers Tensioning installing 48-2, Boot,

Boot

Screw off tie rod before disassembling Check for wear (slits, cracks); check sealing surfaces and sealing lips for dirt/damage Is larger in diameter at openings as is at boot of TRW power steering gear Must not be installed on TRW-power steering gear

Clamp

replace - open using nipper pliers Tensioning installing 48-2, Boot,

Must not be installed on TRW-power steering gear

Right tie rod

Removing and installing 48-2, Tie rod - power steering gear, TRW and ZF, removing and installing Wheel Alignment Wheel Alignment 44-1,

Tie rod boot seat diameter ZF: 15 mm TRW: 12.7 mm

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Must not be installed on TRW-power steering gear

Left tie rod

Removing and installing 48-2, Tie rod - power steering gear, TRW and ZF, removing and installing Tie rod boot seat diameter ZF: 15 mm TRW: 12.7 mm Must not be installed on TRW-power steering gear Adjusting to length 48-2, Length of left tie rod, checking (adjusting if necessary)

Lock nut, 50 Nm Tie rod end

Pressing off Checking:

Topic 48-2

Modification: 48-2, Modified tie rod end Repair Manual, Maintenance

Pressure compensating line 30 Nm Clamp Rubber inlay

Inner diameter ZF: 50 mm TRW: 44 mm

Type plate and companys initials

Power-assisted steering box - ZF, adjusting

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Note:

Two technicians are required for adjustments. Adjust with engine off.

- Raise vehicle on platform. - Wheels in straight-ahead position. - Turning the steering wheel back and forth (approx. 30 off center axis) will produce a rattling noise if steering play is too large.

- Second technician turns adjustment bolt - arrow carefully into cover during this, until the rattling noise cannot be heard in vehicle interior anymore. - Perform a test drive, and while doing so make sure that steering returns to straight-ahead position on its own, without catching, after vehicle is maneuvered or driven in a curve. Correct adjustment if necessary.
Modified tie rod end

As of vehicle identification no. 3A R-099 265, a modified tie rod end was introduced. Ball stud is 3 mm longer than for the previous parts. Only modified tie rod ends are delivered as a replacement part. If repairs are necessary, both tie rod ends must be replaced up to vehicle identification no. 3A R-099 264. A mixed installation is not permissible! On vehicles as of vehicle identification no. 3A R-099 265, tie rod end may be replaced individually.

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Characteristic of tie rod end, up to vehicle identification no. 3A R-099 264

1 - Tie rod end, manufactured by TRW - Centering arrow A in facing side of ball stud. Manufacturer code on lower side, ECO. 2 - Track rod ends manufactured by Lemfoerder metal wares - Conical depression arrow B in facing side of ball stud. Manufacturer code on lower side, LMO or LME.

Characteristic of tie rod end, as of vehicle identification no. 3A R-099 265

1 - Modified tie rod end, manufactured by TRW - Cylindrical depression and centering arrow A in facing side of ball stud. Manufacturer code on lower side, ECO.
Tie rod - power steering gear, TRW and ZF, removing and installing

Note:

Observe threaded connection of tie rods in power steering gear:

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Tie rods, not bonded Tie rods, bonded with locking compound If tie rods of bonded version are installed, they must be installed with locking compound D6.

Removing

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

- Seal line connections on power steering gear if not done already. 1 - Plastic screw plug 2 - Plastic screw plug - Clean outside of power steering gear in area of boot. - Open clamp and push back boot.

- Clamp steering gear together with rack into vise and remove tie rod. Note:

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

- Remove tie rod. Installation of tie rods without locking compound D6: Installation is performed in the reverse order of removal. Tightening torque: 70 Nm Installation of tie rods with locking compound D6: If parts are re-used, threaded pin of inner joint or threaded bore of rack must always be cleaned from remaining locking compound. Otherwise there is the danger of damage of thread if assembled/disassembled again.

- Clean threaded pin or tie rod, use tap M14 x 1.5 or wire brush to do so. - Check thread path of joint stub for deformation, replace if necessary. Note:

Do not cant tap when attaching. If tap can only be turned onto thread with difficulty or metal particles form, this indicates that thread is deformed.

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- Cover opening - arrow - of steering gear housing with a rag. - Clean threaded bore and rack, use tap M14 x 1.5 to do so. - Clean thread with nitro thinner L 160 (thread must be free of oil or grease). - Clean using compressed air.
Installing

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

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

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

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

- Check boot for wear (slits, cracks) and check sealing surfaces of boot for dirt. - Install boot. Rotate tie rod beforehand so that stud of tie rod end stands in installation position. - Install pressure equalizing tube. Note:

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Do not damage adhesive label - A - when sliding on boot (for TRW power steering gears only). Make sure boot and pressure equalizing tube are properly installed. Use only original equipment clamps - B - .

- Tension clamp using Hose Clamp Pliers VAG1275 . Note:

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

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

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

Dimension "a" = 395

1 mm (all except VR6)

Dimension "a" = 413 Note:

1 mm (VR6)

Adjust toe on right tie rod only. Also check new tie rods for dimension "a" before installing and adjust if necessary.