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  • Examplepage for repair manual Running gear, axles, steering
  • Examplepage for repair manual 2 Running gear, axles, steering
  • Examplepage for repair manual 3 Running gear, axles, steering

Running gear, axles, steering

For Passat / Passat Variant

Original Volkswagen repair manual


34,55 €7% VAT incl.

  • Deutsch
  • English

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Language: English

Digital PDF file

13.743 KB

477 Sites

Detailed technical data

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This repair manual contains: Appraisal of accident vehicles, Servicing front suspension, Assembly overview: wheel bearing, Repairing drive shaft - overview of drive shafts, Allocation of track rods to trailing arms (front- and four-wheel drive), Components of adaptive chassis control DCC and fitting locations, Position of anti-theft wheel bolts for steel wheels, Fitting wheel and tyre, Removing and fitting tyres with run-flat properties to wheel rims, Self-sealing tyres “ContiSeal”, Tyre pressure monitor display, Lane departure warning, Protecting wheel centring seat against corrosion and Electromechanical steering rack up to model year 2008. Show more
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Repair manual Passat / Passat Variant Running gear, axles, steering PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Checklist for evaluating running gear of accident vehicles
    1
  • 2 General information
    3
  • Front suspension
    4
  • 1 Appraisal of accident vehicles
    4
  • 2 Servicing front suspension
    5
  • 2.1 Overview - front axle
    5
  • 2.2 Raising wheel suspension to unladen position
    6
  • 3 Subframe, anti-roll bar, suspension links
    9
  • 3.1 Assembly overview: subframe, anti-roll bar, suspension links
    9
  • 3.2 Assembly overview: front left vehicle level sender G78
    13
  • 3.3 Removing and installing front left vehicle level sender G78
    14
  • 3.4 Repairing thread in longitudinal member
    15
  • 3.5 Fixing position of subframe
    15
  • 3.6 Lowering subframe
    17
  • 3.7 Removing and installing subframe without steering rack
    21
  • 3.8 Removing and installing subframe with steering rack
    25
  • 3.9 Repairing subframe
    30
  • 3.10 Checking swivel joint
    38
  • 3.11 Removing and installing swivel joint
    39
  • 3.12 Removing and installing suspension link with mounting bracket
    42
  • 3.14 Renewing bonded rubber bush for suspension link
    50
  • 3.15 Renewing mounting bracket with suspension link bush
    52
  • 3.16 Removing and installing anti-roll bar
    54
  • 4 Assembly overview: wheel bearing
    60
  • 4.1 Removing and installing wheel bearing unit
    62
  • 4.2 Removing and installing wheel bearing housing
    63
  • 5 Assembly overview: suspension strut
    69
  • 5.1 Removing and installing suspension strut
    71
  • 5.2 Repairing suspension strut
    77
  • 6 Removing and installing drive shafts
    80
  • 6.1 Loosening and tightening drive shaft hexagon bolt
    80
  • 6.2 Loosening and tightening twelve-point head bolt, with ribbing, securing drive shaft
    81
  • 6.4 Removing and installing drive shaft with constant velocity joint
    84
  • 6.6 Removing and installing drive shafts with triple roller joint AAR3300i (bolted on)
    92
  • 7 Repairing drive shaft - overview of drive shafts
    97
  • 7.1 Heat shields for drive shafts
    98
  • 8 Assembly overview: drive shaft with VL100 constant velocity joint
    99
  • 8.1 Dismantling and assembling drive shaft with VL100 constant velocity joint
    101
  • 8.2 Checking outer constant velocity joint
    105
  • 8.3 Checking inner constant velocity joint
    106
  • 9 Assembly overview: drive shaft with VL107 constant velocity joint
    109
  • 9.1 Dismantling and assembling drive shaft with VL107 constant velocity joint
    111
  • 10 Assembly overview: drive shaft with triple roller joint AAR2600i
    116
  • 10.1 Dismantling and assembling drive shaft with triple roller joint AAR2600i
    118
  • 11 Assembly overview: drive shaft with triple roller joint AAR3300i
    123
  • 11.1 Dismantling and assembling drive shaft with triple roller joint AAR3300i
    125
  • Rear suspension
    137
  • 1 Appraisal of accident vehicles
    137
  • 2 Repairing rear suspension (front-wheel drive)
    138
  • 2.1 Overview - rear axle
    138
  • 2.2 Rear axle in unladen position
    140
  • 3 Assembly overview: subframe (front-wheel drive)
    143
  • 3.1 Removing and installing rear axle
    143
  • 3.2 Repairing subframe
    147
  • 4 Assembly overview: transverse link, track rod (front-wheel drive)
    152
  • 4.3 Removing and installing rear left vehicle level sender G76 up to model year 2007
    156
  • 4.5 Removing and installing upper transverse link
    158
  • 4.6 Removing and installing lower transverse link
    160
  • 4.7 Removing and installing track rod
    162
  • 5 Allocation of track rods to trailing arms (front- and four-wheel drive)
    166
  • 6 Assembly overview: wheel bearing housing, trailing arm (front-wheel drive)
    168
  • 6.1 Removing and installing wheel bearing housing
    169
  • 6.2 Renewing bonded rubber bush for wheel bearing housing
    173
  • 6.3 Removing and installing wheel bearing/wheel hub unit
    176
  • 6.4 Removing and installing trailing arm with mounting bracket
    180
  • 6.5 Repairing trailing arm
    183
  • 7 Assembly overview: shock absorber, coil spring (front-wheel drive)
    186
  • 7.1 Converting to Nivomat
    187
  • 7.2 Converting to heavy-duty running gear
    187
  • 7.3 Removing and installing coil spring
    187
  • 7.4 Removing and installing shock absorbers
    188
  • 7.5 Repairing shock absorber
    190
  • 8 Assembly overview: anti-roll bar (front-wheel drive)
    193
  • 8.1 Removing and installing anti-roll bar
    193
  • 9 Repairing rear suspension (four-wheel drive)
    196
  • 9.1 Overview - rear axle
    196
  • 9.2 Rear axle in unladen position
    198
  • 10 Assembly overview: subframe, final drive (four-wheel drive)
    201
  • 10.1 Preparatory work for when installing a steel subframe
    202
  • 10.2 Removing and installing rear axle
    203
  • 10.3 Repairing aluminium subframe
    208
  • 10.4 Repairing steel subframe
    212
  • 11 Assembly overview: transverse link, track rod (four-wheel drive)
    220
  • 11.1 Rear left vehicle level sender G76 , four-wheel drive up to model year 2007
    223
  • 11.2 Rear left vehicle level sender G76 , four-wheel drive from model year 2008
    224
  • 11.5 Removing and installing upper transverse link
    226
  • 11.6 Removing and installing lower transverse link
    228
  • 11.7 Removing and installing track rod
    230
  • 12 Assembly overview: wheel bearing housing, trailing arm (four-wheel drive)
    233
  • 12.1 Removing and installing wheel bearing housing
    235
  • 12.2 Renewing bonded rubber bush for wheel bearing housing
    238
  • 12.3 Removing and installing wheel bearing/wheel hub unit
    241
  • 12.4 Removing and installing trailing arm with mounting bracket
    242
  • 12.5 Repairing trailing arm
    246
  • 13 Assembly overview: shock absorber, coil spring (four-wheel drive)
    250
  • 13.1 Converting to Nivomat
    251
  • 13.2 Converting to heavy-duty running gear
    251
  • 13.3 Removing and installing coil spring
    251
  • 13.4 Removing and installing shock absorbers
    252
  • 13.5 Repairing shock absorber
    254
  • 14 Assembly overview: anti-roll bar (four-wheel drive)
    257
  • 14.1 Removing and installing anti-roll bar
    257
  • 15 Assembly overview: drive shaft
    261
  • 15.1 Loosening and tightening drive shaft hexagon bolt
    263
  • 15.2 Loosening and tightening twelve-point head bolt, with ribbing, securing drive shaft
    264
  • 15.4 Removing and installing drive shaft
    267
  • 15.5 Dismantling and assembling drive shaft
    270
  • 15.6 Checking outer constant velocity joint
    275
  • 15.7 Checking inner constant velocity joint
    276
  • Self-levelling suspension
    278
  • 1 Appraisal of accident vehicles
    278
  • 2 Components of adaptive chassis control DCC and fitting locations
    279
  • 2.1 Shock absorber damping adjustment button E387
    280
  • 2.2 Removing and installing front left body acceleration sender G341
    280
  • 2.3 Removing and installing front right body acceleration sender G342
    281
  • 2.4 Renewing bracket for front left/right body acceleration sender G341/G342
    282
  • 2.6 Removing and installing front left/right vehicle level sender G78/G289
    285
  • 2.11 Removing and installing electronically controlled damping control unit J250
    290
  • 2.12 Basic setting of adaptive chassis control DCC
    290
  • 2.13 Cable routing left front axle
    291
  • 2.14 Cable routing right front axle
    292
  • 2.15 Cable routing rear axle
    293
  • 3 Assembly overview: suspension strut for adaptive chassis control DCC
    294
  • 3.1 Removing and installing suspension strut for adaptive chassis control DCC
    296
  • 4 Assembly overview: shock absorber for adaptive chassis control DCC (front-wheel drive)
    304
  • 4.1 Removing and installing rear body acceleration sender G343 (front-wheel drive)
    305
  • 4.3 Repairing shock absorber for adaptive chassis control DCC (front-wheel drive)
    309
  • 5 Assembly overview: shock absorber for adaptive chassis control DCC (four-wheel drive)
    311
  • 5.1 Removing and installing rear body acceleration sender G343 (four-wheel drive)
    312
  • Wheels, tyres, vehicle geometry
    318
  • 1 Appraisal of accident vehicles
    318
  • 2 Torque settings for wheels
    319
  • 3 Position of anti-theft wheel bolts for steel wheels
    320
  • 4 Fitting wheel and tyre
    321
  • 4.1 General information
    321
  • 4.2 Fittings instructions
    321
  • 5 Removing and fitting tyres (wheels with tyre pressure monitoring)
    323
  • 5.2 Wheel change
    323
  • 5.3 Pressing tyre off wheel rim
    324
  • 5.4 Removing tyre from wheel
    325
  • 5.5 Fitting tyre to wheel rim
    325
  • 6 Removing and fitting tyres with run-flat properties to wheel rims
    327
  • 6.1 Safety information
    327
  • 6.2 Fittings instructions
    327
  • 6.3 Pressing tyre off wheel rim
    328
  • 6.4 Removing tyre from wheel
    329
  • 6.5 Fitting tyre to wheel rim
    330
  • 7 Self-sealing tyres “ContiSeal”
    333
  • 7.1 Explanation for mobility tyres
    333
  • 7.2 Handling mobility tyres
    334
  • 8 Tyre pressure monitor display
    335
  • 9 Tyre pressure monitoring system (TPMS)
    337
  • 9.1 Button behaviour
    337
  • 9.2 Assembly overview: tyre pressure sensor
    338
  • 9.3 Removing and installing tyre pressure sensor
    339
  • 10 Vehicle alignment check
    341
  • 10.1 General information
    341
  • 10.2 Conditions for testing
    343
  • 10.3 Test preparations
    343
  • 10.4 Wheel alignment specifications
    344
  • 10.5 Overview - wheel alignment procedure
    347
  • 10.6 Correcting front axle camber
    348
  • 10.7 Adjusting camber on rear axle
    349
  • 10.8 Adjusting toe at rear axle
    351
  • 10.9 Adjusting front axle toe
    351
  • 10.10 Basic setting of steering angle sensor G85
    352
  • 10.11 Vehicle data sticker
    352
  • 11 Adaptive Cruise Control (ACC)
    354
  • 11.1 General information on ACC calibration
    354
  • 11.2 ACC calibration during vehicle alignment
    354
  • 11.3 ACC calibration without prior vehicle alignment
    356
  • 12 Lane departure warning
    359
  • 12.1 General information about lane departure warning
    359
  • 12.2 Calibrating the lane departure warning
    360
  • 13 Wheels, tyres
    367
  • 13.1 Models with breakdown set
    367
  • 13.2 Tyre sealant
    367
  • 13.3 Removing a tyre
    367
  • 13.4 Fitting a new tyre
    368
  • 13.5 Tyre sealant disposal
    368
  • 14 Instructions for changing or fitting wheels
    369
  • 14.1 Fitting wheels
    370
  • 15 Protecting wheel centring seat against corrosion
    371
  • 16 Vibration due to wheels/tyres - causes and rectification
    372
  • 16.1 Causes of rough running
    372
  • 16.2 Balancing wheels
    372
  • 16.3 Conducting a road test before balancing wheels
    372
  • 16.4 Balancing wheels on stationary wheel balancing machine
    373
  • 16.5 Vibration control system VAS 6230 A
    376
  • 16.6 Finish balancer
    376
  • 16.7 Radial and lateral runout of wheels and tyres
    377
  • 16.9 Checking radial and lateral run-out on wheel rim
    378
  • 16.10 Matching
    379
  • 16.11 Flat spots caused by storage or handling
    380
  • Steering
    382
  • 1 Appraisal of accident vehicles
    382
  • 2 General repair instructions
    383
  • 2.1 Steering rack
    383
  • 2.2 Gaskets and seals
    383
  • 2.3 Nuts and bolts
    383
  • 2.4 Electrical components
    384
  • 2.5 Guided Fault Finding, vehicle self-diagnosis and test instruments
    384
  • 3 Assembly overview: steering column
    385
  • 3.1 Removing and installing steering wheel
    386
  • 3.2 Removing and installing steering column
    388
  • 3.4 Handling and transporting steering column
    393
  • 3.5 Checking steering column for damage
    394
  • 3.6 Removing and installing electronic steering column lock control unit J764
    394
  • 3.7 Removing and installing mounting bracket
    396
  • 3.8 Removing and installing strut
    398
  • 4 Electromechanical steering rack up to model year 2008
    400
  • 5 Electromechanical steering rack from model year 2009
    422
  • 5.3 Removing and installing steering rack, left-hand drive vehicle (APA) from model year 2009
    425
  • 6 Differentiating between 2nd and 3rd generation steering racks
    442
  • 7.1 Removing and installing bellows
    443
  • 7.2 Removing and installing track rod
    445
  • 8.1 Assembly overview: electromechanical steering rack, left-hand drive vehicle
    449
  • 8.2 Renewing bonded rubber bushes for power-assisted steering rack
    450
  • 8.3 Removing and installing track rod
    452
  • 8.4 Removing and installing track rod ball joint
    456
  • 8.5 Removing and installing bellows
    457
  • 8.6 Checking play, security and boots of track rod ends
    460
  • 8.7 Allocation of track rod ball joints
    460
  • 9 Repairing electromechanical steering rack, right-hand drive vehicles
    461
  • 9.1 Assembly overview: electromechanical steering rack, RHD vehicle
    461
  • 9.2 Removing and installing track rod
    462
  • 9.3 Removing and installing track rod ball joint
    465
  • 9.4 Removing and installing bellows
    466
  • 9.5 Checking play, security and boots of track rod ends
    469
  • 9.6 Allocation of track rod ball joints
    469
Manufacturer's designation Running gear, axles, steering
Manufacturer Volkswagen
Suitable for Passat / Passat Variant (2005 - 2008)
Suitable car types 3C
Category Reparaturanleitung

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