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Passat 1997

Suspension, Wheels, Steering - Edition 12.2012


Now tighten bolts -1- and -2-. Specification: 65 Nm.
Screw on return hose and tighten banjo fitting (22 mm wrench).
Specification: 50 Nm.
Screw on pressure hose and tighten banjo fitting (19 mm
wrench). Specification: 40 Nm.
Insert boot into bulkhead.
Make sure boot is not damaged while inserting.
Turn steering wheel into center position, if not yet done.
Insert tensioning bolt (Torx T50) and tension counterclock
wise.
Tighten hex nut for adjusting bolt (Torx T50). Specification: 40
Nm.
Now unscrew -V.A.G 1907- from steering gear.
1 - Hex socket head screw
2 - Threaded bore in steering gear
Seal steering gear using hex socket head bolt -1-. Specifica
tion: 18 Nm.
Place universal joint on steering pinion.
Remove mounting device from steering column.
Install storage compartment on driver side. Refer to Body
Interior; Rep. Gr. 68 ; Removal and Installation .
Install wheel housing liner. Refer to Body Exterior; Rep. Gr.
66 ; Removal and Installation .
After completing installation of steering gear, remove -3094- .
Turn ignition key to ignition off position.
Install battery. Refer to Electrical Equipment; Rep. Gr. 27 ;
Removal and Installation and enter radio code if necessary.
Install plenum chamber cover.
Install noise insulation tray.
Install wheels and tighten. Refer to
3.2 Wheel Tightening Specification, page 172 .
Check power steering fluid level. Refer to
1.1 Power Steering, Checking Fluid Level, page 186 .
Check steering system for leaks. Refer to
4.2 Steering System, Checking for Leaks, page 204 .
Bleed steering system. Refer to
1.2 Power Steering System, Bleeding, page 186 .
After installation, position of steering wheel must be checked with
a road test.
If steering wheel stands crooked, toe at front axle must be
checked and set if necessary!
Check toe setting. Refer to
1.1 Wheel Alignment, page 153 .

5.6

Power Steering Pump, 4-Cylinder

Special tools and workshop equipment required


Hose clamps -3094-

228

Rep. Gr.48 - Steering

Passat 1997
Suspension, Wheels, Steering - Edition 12.2012
Drift -3204 Torque wrench -V.A.G 1331 Water pump wrench -V.A.G 1590Removing
Remove engine noise insulation.
Bring lock carrier into service position. Refer to Body Exte
rior; Rep. Gr. 50 ; Description and Operation .
Removing Ribbed Belt on Vehicles with 4-Cylinder Gasoline En
gine
Move tensioner in -direction of arrow- to release tension on
ribbed belt.
Secure using -3204- .

Remove the coolant pump ribbed belt pulley.


Remove ribbed belt.
Remove the power steering pump ribbed belt pulley.
If necessary, -V.A.G 1590- must be filed at the corners.

Clamp off suction and return line using -3094- .


Position drip tray underneath.

5. Removal and Installation

229

Passat 1997
Suspension, Wheels, Steering - Edition 12.2012
Remove -3094- -1- from intake line.
Disconnect intake line, press out of retaining bracket and lay
to side.
Remove the pressure hose -2-, AF 22 mm.

Remove the hex bolts -1- and hex socket head bolt -2-.
Take out pump.
Installing
Fill hydraulic oil into power steering pump.
Fill oil at pump intake connection.
Turn the hub by hand until oil runs out of the pressure side.

Tighten bolts -1 - and -2- to 20 Nm.


Rest of installation is the reverse of removal.
Install new sealing rings onto banjo bolt.

Tighten banjo fitting for pressure hose -2-. Specification: 50


Nm.
Install intake line.

230

Rep. Gr.48 - Steering

Passat 1997
Suspension, Wheels, Steering - Edition 12.2012
Tighten hex-socket bolts for coolant/power steering pump belt
pulley to 25 Nm.
Install fan wheel on viscous fan clutch.

Install ribbed belt.


Note

When installing ribbed belt, make sure it is seated correctly on


pulleys.
Illustration shows procedure without lock carrier for the sake of
illustration.
Top off hydraulic oil -G 002 000- .
Install lock carrier and bumper. Refer to Body Exterior; Rep.
Gr. 50 ; Description and Operation .
Start engine and check belt running.
Check power steering fluid level. Refer to
1.1 Power Steering, Checking Fluid Level, page 186 .
Check steering system for leaks. Refer to
4.2 Steering System, Checking for Leaks, page 204 .
Bleed steering system. Refer to
1.2 Power Steering System, Bleeding, page 186 .

5. Removal and Installation

231

Passat 1997
Suspension, Wheels, Steering - Edition 12.2012

5.7

Power Steering Pump, 6-Cylinder


Note

Always replace seals.


Do not reuse fluid you have drained.
Hydraulic fluid -G 002 000 Quantity of oil in system approximately 1 ltr.
1 - Pressure Line with Hose
2 - Bolt
8 Nm
3 - Bore on Intake Manifold
4 - Power Steering Pump
Checking delivery pres
sure. Refer to
4.5 Power Steering
Pump, Checking Deliv
ery Pressure, 6-Cylin
der, page 206 .
Fill with oil before instal
ling. Refer to
2.5 Power Steering
Pump, Reservoir and
Hydraulic Lines Assem
bly Overview, 6-Cylin
der, page 194 .
5 - Belt Pulley
6 - Bolt
25 Nm
To loosen and tighten,
counterhold using V.A.G 1590- if necessa
ry.
7 - Bolt
25 Nm
8 - Bolt
25 Nm
9 - Bracket
10 - Ignition Coil with Bracket
11 - Bolt
25 Nm
12 - Banjo Bolt
50 Nm
13 - Seals, 16 x 22
Replace.
14 - Seals, 18 x 24
Replace.

232

Rep. Gr.48 - Steering


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