Volkswagen Passat (1995, 1996, 1997) Factory Repair Manual

Gasoline,Turbo Diesel, TDI, 4-cylinder and WR6 including wagon



Suspension, Wheels, Brakes, Steering



General, Technical data

Suspension, Wheels, Brakes, Steering

Technical data

Steering

Brakes

Wheels, tires



Front suspension

Front Wheel Suspension, Shafts and Axle

Front suspension, servicing (Base suspension)

Sub-frame, stabilizer bar and control arm (Base suspension)

Ball joint, checking (Base and Plus suspension)

Reworking cap nut in side member (Base and Plus suspension)

Wheel bearing, suspension strut and drive shaft, removing and installing (Base

running gear)

Front suspension strut, servicing (Base and Plus suspension)

Front suspension, servicing (Plus suspension)

Sub-frame, stabilizer bar and control arm, removing and installing (Plus

suspension)

Ball joint, removing and installing (Plus running gear)

Wheel bearing and suspension strut, removing and installing (Plus suspension)

Drive shaft, removing and installing (Plus running gear)

Drive shaft, repairing

Outer constant velocity joint, checking

Inner constant velocity joint, checking

Drive shaft with tripod joint, repairing

Drive axle with triple-rotor joint, removing and installing

Drive axle with triple-rotor joint, servicing

Triple-rotor joint, disassembling

Triple-rotor joint, assembling



Rear suspension

Rear Wheel Suspension, Shafts and Axle

Rear axle, servicing (vehicles with front wheel drive)

Reworking cap nut in side member (front wheel drive vehicles)

Suspension strut, disassembling and assembling (front wheel drive vehicles)

Wheel bearings, servicing

Drum brakes (front wheel drive vehicles), wheel bearings, servicing

Wheel bearings, servicing - disc brakes (front wheel drive vehicles)

Rear axle, servicing (four wheel drive vehicles)

Rear drive shafts, servicing

Reworking cap nut in side member (four wheel drive vehicles)

Suspension strut, disassembling and assembling (four wheel drive

vehicles)

Wheel bearings, servicing - disc brakes (four wheel drive vehicles)



Wheels, Tires, Wheel alignment

Vehicle alignment

Test requirements:

Vehicle alignment specifications (front wheel drive vehicles)

Vehicle alignment specifications (four wheel drive vehicles)

Front wheel camber, adjusting



Anti-lock brake system

Anti-locking Brake System (ABS) and Anti-locking Brake System with

Electronic Differential Lock (ABS/EDL) Teves 04

Notes for repair work on ABS, ABS/EDL

Control module, removing and installing

Wheel speed sensor and rotor for speed sensor, removing and installing

Anti-lock Brake System (ABS) and ABS with Electronic Differential Lock

(ABS/EDL), Teves 20 GI

Safety precautions

ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master

cylinder (Teves 20 GI), servicing

ABS hydraulic unit and ABS control module (Teves 20 GI), removing and

installing

Brake hydraulic system, bleeding and filling

Assembly overview - hydraulic unit, brake servo/brake master cylinder

Hydraulic unit, removing and installing

Brake Pedal Position Sensor, removing and installing



Brakes - Mechanical components

Front brakes, servicing (Girling caliper)

Brake pads, removing and installing

Front brakes, servicing (Teves/Ate)

Brake pads, removing and installing

Rear wheel brakes, servicing (drum brakes)

Brake shoe adjustment, releasing

Rear wheel brakes, servicing

Brake shoes, removing and installing

Parking brake, adjusting (drum brakes)

Rear wheel brakes, servicing (disc brakes)

Girling rear wheel disc brakes (front and four wheel drive vehicles)

Brake pads, removing and installing

Parking brake, adjusting (disc brakes)

Parking brake lever assembly overview

Brake pedal/brake servo, removing and installing

Brake pedal, removing and installing

Brake Light Switch, adjusting



Brakes - Hydraulic components

Assembly overview: brake master cylinder/brake servo

Girling front brake caliper, servicing

Front brake caliper pistons, removing and installing

Front brake caliper, servicing (Teves/Ate)

Rear brake caliper, servicing

Rear brake caliper piston, removing and installing

Pre-bleeding brake caliper

Brake pressure regulator, checking and adjusting

Vehicles without ABS, vehicles with ABS, ABS/EDS, Teves 04

Load dependent brake pressure regulator specifications

Adjusting regulator

Brake system, bleeding

Brake system, bleeding (vehicles with and without ABS, ABS/EDL)

Brake system, bleeding (with pressure bleeder VAS 5234)

Brake system, bleeding (without pressure bleeder)



Steering

Steering

Assembly overview: steering column, column tube, steering wheel and airbag

steering wheel

Airbag unit, removing and installing

Airbag steering wheel, removing and installing

Airbag Spiral Spring, removing and installing

Column tube for height adjustable steering wheel, removing and installing

Pump delivery pressure, checking

Power steering gear, removing and installing

Assembly overview: power assisted steering box (TRW)

Power steering gear, adjusting (TRW)

Power steering gear, disassembling and reassembling (TRW)

Power steering gear, disassembling

Inner sealing ring for toothed rod, pulling out

Checking toothed rod for scoring

Sealing ring on toothed rod, replacing

Sealing rings, installing on toothed rod piston

Power steering gear, assembling

Inner sealing ring for toothed rod, installing

Toothed rod, installing in housing

Adhesive tape, applying

Power steering gear, adjusting with new toothed rod

Assembly overview: power steering gear (ZF)

Power steering gear, adjusting (ZF)

Power steering gear, disassembling and reassembling (ZF)

Power steering gear, disassembling

Checking toothed rod for scoring

Sealing ring on toothed rod, replacing

Power steering gear, assembling

Tie rods, removing and installing (power steering gear - TRW and ZF)

Left-hand tie rod length, checking and adjusting

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

Cyl. engines)

Assembly overview: Hydraulic lines, reservoir (vehicles with 4-Cyl. engines)

Power steering vane pump, removing and installing (vehicles with 4-Cyl. engines)

V-belts, tensioning (4-Cyl. engines)

Assembly overview: Pressure and cooling lines (vehicles with VR6 engine)

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





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