Front suspension - Plus suspension, servicing. Volkswagen Passat B4 - Front suspension - Plus suspension, servicing

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Patrick Gardner
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1 Volkswagen Passat B4 - Front suspension - Plus suspension, servicing Page 1 / Front suspension - Plus suspension, servicing I - Subframe, anti-roll bar, control arm (Plus suspension), removing and installing 40-2, Subframe, anti-roll bar, control arm - Plus suspension, removing and installing. II - Wheel bearing, suspension strut, drive axle (Plus suspension), removing and installing 40-2, Wheel bearing, suspension strut - Plus suspension, removing and installing. The Plus suspension differs from the Basic suspension regarding the following components listed: Control arm, ball joint, wheel bearing housing, anti-roll bar, drive axle, brake disc, wheel hub, disc wheel, tie rod.

2 Page 2 / 22 The Plus suspension is installed in Passat vehicles as of 110 kw engine performance. Subframe, anti-roll bar, control arm - Plus suspension, removing and installing

3 Page 3 / 22 Hex bolt, 35 Nm Ball joint Checking 40-1, Control arm - Basic and Plus suspensions, checking Check rubber boot for damage, replace lower ball joint, if necessary Removing and installing 40-2, Control arm - Plus suspension, removing and installing Mark installation position, place in center of elongated hole when replacing control arm and check toe

4 Page 4 / 22 Self-locking hex nut, 45 Nm Plate with nuts Rear bearing for control arm Installation position 40-2, Installation position for rear bushing in control arm Ejecting and pressing in 40-2, Rear bearing for control arm, pressing out and pressing in Control arm Elongated holes do not serve for toe adjustment! Air deflector Mounting to control arm with clip Front bearing for control arm Ejecting and pressing in 40-1, Pressing off front bushing for control arm Hex bolt M12 x 1.5 x Nm + 90 (1/4 turn) Hex bolt M12 x 1.5 x Nm + 90 (1/4 turn) Coupling rod With rubber bushing Bearing for coupling rod Conical side faces control arm

5 Page 5 / 22 Washer Collar points away from bearing Self-locking hex nut, 20 Nm Hex bolt M12 x 1.5 x Nm + 90 (1/4 turn) Hex nut, tighten to 25 Nm Hex bolt, 25 Nm To secure anti-roll bar Hex bolt, 65 Nm Clamp for anti-roll bar Vibration damper Not present on vehicles with VR6-engine Subframe Removing and installing with installed assemblies: Supporting assemblies 40-2, Support engine- /transmission assembly using Remove subframes downward with control arms without steering gear using Engine-/Gearbox Jack VAG1383A. After installation, check position of steering wheel and perform vehicle alignment at front. Aligning engine- /transmission assembly Repair Manual, Engine Mechanical, Repair Group 10,

6 Page 6 / 22 Anti-roll bar bearing Anti-roll bar 24 mm Cap nut Rework in longitudinal member 40-1, Cap nut in longitudinal member - Basic and Plus suspensions, reworking Front bearing for control arm, pressing out and pressing in Note: Before pressing in, coat with lubricant, e.g. assembly paste G A2.

kidney-shaped recess - arrow A - in bearing points toward vehicle

7 Page 7 / 22 Installation position for rear bushing in control arm One of the arrows stamped on points to impression in control arm, kidney-shaped recess - arrow A - in bearing points toward vehicle center. Rear bearing for control arm, pressing out and pressing in

Page 8 / 22 Support engine-/transmission assembly using Engine Support Bridge 10-222A and Bracket For Engine 10-222A/1 Control arm - Plus suspension, removing and installing Removing - Loosen

8 Page 8 / 22 Support engine-/transmission assembly using Engine Support Bridge A and Bracket For Engine A/1 Control arm - Plus suspension, removing and installing Removing - Loosen 12-point nut when vehicle is standing on its wheels. - Remove drive axle from flange shaft/transmission. - Remove bolts - arrows A -. - Loosen bolt - arrow B -. - Disconnect ball joint/control arm connection. (Mark installation position beforehand.)

9 Page 9 / 22 - Swing out wheel with suspension strut and support. - Attach ejector as shown in illustration and detach ball joint. 1 - Ball joint extractor V176 Note: Place Engine-/Gearbox Jack VAG1383A or something similar underneath (danger of accident if parts fall off when ejecting ball joint). To protect ball joint thread, leave nut on a few turns. Installing - Insert ball joint into wheel bearing housing.

Page 10 / 22 - Install new self-locking nut, counterhold using hex head wrench 6 mm. 1 - Hex head wrench 6 mm, approx. 10 mm shortened. 2 - Ring insertion tool or open ring insertion tool.

10 Page 10 / 22 - Install new self-locking nut, counterhold using hex head wrench 6 mm. 1 - Hex head wrench 6 mm, approx. 10 mm shortened. 2 - Ring insertion tool or open ring insertion tool. 3 - Torque Wrench 5-50Nm VAG Bolt ball joint with control arm with new bolts to old impression. Note: Ensure that boot is not damaged or twisted. Tightening torques Ball joint to wheel bearing housing: 45 Nm Ball joint to control arm: 35 Nm 1 - Ring insertion tool (commercially available, 19 mm) 2 - Open ring insertion tool (commercially available, 19 mm) Wheel bearing, suspension strut - Plus suspension, removing and installing

11 Page 11 / 22 Wheel bolt, 110 Nm Self-locking 12-point nut 90 Nm + 45 ( 1 / 8 ) additional turn. loosening and tightening Topic 40-2 Remove any paint residue and/or corrosion in the threads of outer joint before screwing on nut. Phillips-head screw Brake disc Notes for repairing 46-1, Front brakes - brake caliper Girling, servicing

12 Page 12 / 22 Brake caliper Do not remove brake hose when working on front wheel suspension Hang with wire or similar means Replace brake pads 46-1, Brake pads, removing and installing Metal countersunk screw Wheel hub Pressing out 40-2, Pressing wheel hub out of wheel bearing housing. Pressing in 40-2, Pressing wheel hub into wheel bearing housing Remove bearing inner race 40-2, Pulling bearing inner race off of wheel hub Rotor for speed sensor Only on vehicles with ABS Hex bolt, 10 Nm Cover plate Securing ring Check for proper seating Wheel bearing Pressing out 40-2, Pressing wheel bearing out of wheel bearing housing Replace, destroyed during ejection Pressing in 40-2, Pressing wheel bearing in wheel

13 Page 13 / 22 bearing housing Self-locking hex nut, 35 Nm Wheel bearing housing Ribbed bolt, 125 Nm Drive axle Removing and installing 40-2, Drive axle with triple rotor joint, removing and installing Servicing 40-3, Drive axle, servicing Multipoint socket head bolt, 45 Nm Hex bolt Camber setting 44-1, Camber of front wheels, adjusting Mark installation position before loosening Hex bolt Bracket Stop Self-locking hex nut, 60 Nm unbolt and bolt in 40-1, Removing and installing suspension strut to body Suspension strut Disassembling and assembling 40-1, Front suspension strut - Basic/Plus suspensions, servicing Self-locking hex nut, 95 Nm Tie rod

14 Page 14 / 22 Removing and installing 48-2, Tie rod - power steering gear, TRW and ZF, removing and installing Removing and installing suspension strut to body Pressing wheel hub out of wheel bearing housing.

Page 15 / 22 Pulling bearing inner race off of

housing Pressing wheel bearing in wheel bearing

15 Page 15 / 22 Pulling bearing inner race off of wheel hub Only use puller with tension bracket, e.g. Kukko Puller 204/2 (commercially available). Pressing wheel bearing out of wheel bearing housing Pressing wheel bearing in wheel bearing housing Pressing wheel hub into wheel bearing housing

16 Page 16 / 22 Drive axle - Plus suspension, removing and installing Removing - Loosen 12-point nut when vehicle is standing on its wheels. - Remove drive axle from flange shaft/transmission. - Remove bolts - arrow A -. - Loosen bolt - arrow B -. - Disconnect ball joint/control arm connection. Mark installation position beforehand. - Press out drive axle. Use tool as shown in illustration. Note: Be sure there is sufficient room when using ejector for drive axle. Installing - Remove remaining locking compound from outer joint splines and wheel hub splines. (Splines must be free of oil

Page 17 / 22 and grease.) - Apply locking compound D 185 400 A2 onto splines as shown in illustration. Bead thickness approx. 3 mm.

- Bolt on 12-point nut to drive axle and tighten. Note: Torque wrench V.A.G 1756 is recommended for tightening 12-point nut.

17 Page 17 / 22 and grease.) - Apply locking compound D A2 onto splines as shown in illustration. Bead thickness approx. 3 mm. - Insert drive axle. - Bolt ball joint to control arm. - Bolt drive axle to flange shaft/transmission and tighten. - Bolt on 12-point nut to drive axle and tighten. Note: Torque wrench V.A.G 1756 is recommended for tightening 12-point nut. Only loosen and tighten with vehicle standing on its wheels (risk of accident) Tightening torques: Drive axle to flange shaft/transmission, 45 Nm Drive axle to wheel bearing housing, 90 Nm + 45 ( 1 / 8 ) additional turn

Page 18 / 22 Ball joint/control arm, 35 Nm Drive axle with triple rotor joint, removing and installing Drive axles with triple rotor joints are installed in vehicles with 4-cyl.

The inner joints can not be serviced at this time. The complete drive axle must be replaced when damaged (without outer joint).

18 Page 18 / 22 Ball joint/control arm, 35 Nm Drive axle with triple rotor joint, removing and installing Drive axles with triple rotor joints are installed in vehicles with 4-cyl. engine and automatic transmission. Implemented as a running-change. These joints have three rollers arranged at 120 offset in tripod star pattern, instead of six balls. The inner joints can not be serviced at this time. The complete drive axle must be replaced when damaged (without outer joint). Right drive axle, removing Removal and installation procedure is the same as for previously installed drive axles (remove air conducting part on control arm if present). Left drive axle, removing - Insert engine support bridge. - Remove bolt - arrow - for rear transmission mount.

- Loosen drive axle hex nut when vehicle is standing on its wheels.

19 Page 19 / 22 - Remove bolt - arrow - for front engine mount. - Raise engine-/transmission assembly. - Loosen drive axle hex nut when vehicle is standing on its wheels. - Remove drive axle from flange shaft/transmission. Remove bolts to remove drive axle - arrows-. Note: Mark installation position beforehand. - Swing out wheel (place a piece of wood or similar

20 Page 20 / 22 between suspension strut and wheel housing). - Press engine-/transmission assembly toward front and remove drive axle. Installing Installation is performed in the reverse order of removal. Wheel hubs with compressed splines - vehicles with Plus suspension The wheel hub splines have been modified. Points of splines - arrow - are slightly jolted (compressed). This ensures no backlash in splines between outer joint and wheel hub. This new design requires also a new method for tightening the 12-point nut. Assembly and disassembly of the drive axle is not possible without tools. In the future, only wheel hub with jolted splines are available as a replacement part. If these wheel hubs are used, no locking compound is required. Work procedure for removing and installing the drive axle has been modified. Drive axles - vehicles with compressed splines in wheel hub, removing and installing Removing If it should be necessary to move a vehicle whose drive axle has been removed, then before doing so install an outer joint in place of the drive axle and tighten it to 50 Nm, or else wheel bearing will be damaged.

Page 21 / 22 - Lift vehicle enough that the front axle is no longer burdened. - Remove 12-point nut. - Remove drive axle from flange shaft/transmission. - Mark installation position of bolts.

21 Page 21 / 22 - Lift vehicle enough that the front axle is no longer burdened. - Remove 12-point nut. - Remove drive axle from flange shaft/transmission. - Mark installation position of bolts. - Remove bolts - arrow A -. - Loosen bolt - arrow B -. - Press out drive axle. Be sure there is sufficient room when ejecting drive axle. - Remove drive axle. Installing Remove any paint and locking compound residue and/or corrosion in the threads/splines of outer joint. - Insert drive axle. - Insert outer joint as far as possible into wheel hub splines.

Page 22 / 22 - Attach 12-point nut and pull outer joint into wheel hub until outer joint arrives at stop in wheel bearing. - Bolt ball joint to control arm (35 Nm, with new bolts to old impression).

22 Page 22 / 22 - Attach 12-point nut and pull outer joint into wheel hub until outer joint arrives at stop in wheel bearing. - Bolt ball joint to control arm (35 Nm, with new bolts to old impression). - Attach inner joint and tighten bolts to 45 Nm. - Moisten contact surface of 12-point nut with oil and bolt on as far as possible. - Lower vehicle, be sure wheels do not touch floor. Otherwise, wheel bearing may be pre-damaged. - Operate brake (second mechanic required). - Tighten 12-point nut to 200 Nm and release one rotation. - Pre-tighten 12-point nut to 50 Nm. - Mark 12-point of nut with a line - arrow A -. - Draw a second line - arrow B - on the edge of the wheel hub above the next side of 12-point nut. Spacing between one 12-point to another is Turn 12-point nut until lines match up.

Wheel bearing housing, removing and installing

Page 1 of 17 40-54 Wheel bearing housing, removing and installing Removing - Remove wheel trim. On light alloy wheels use puller in vehicle tool kit to remove trim cap. - Remove bolt for drive axle. WARNING!