2021 Volkswagen Passat (US) Download Service & Repair Manual
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Repair Manual
Passat (NMS - US) 2012 ➤
Passat (NMS - US) 2016 ➤
Passat (NMS - US) 2019 ➤
Suspension, Wheels, Steering
Edition 07.2020
Service
Service Department. Technical Information
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List of Workshop Manual Repair Groups
Repair Group
00 - General, Technical Data
40 - Front Suspension
42 - Rear Suspension
43 - Self-Leveling Suspension
44 - Wheels, Tires, Wheel Alignment
48 - Steering
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness
and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as
a matter of course, be observed.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2022 Volkswagen AG, Wolfsburg D3E803A3B0C
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Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Evaluating Vehicles in Collisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Collision Vehicle Evaluation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Steering Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Seals, Sealing Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4 Bolts and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.5 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.6 Damaged Threads in Longitudinal Member, Repairing (Subframe to Body) . . . . . . . . . . . . 4
2.7 Wheel Bearing in Curb Weight, Lifting Vehicles with Coil Spring . . . . . . . . . . . . . . . . . . . . 5
3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
40 - Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1 Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.1 Overview - Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1 Overview - Subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2 Overview - Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3 Subframe, Securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4 Subframe, Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.5 Subframe without Steering Gear, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . 23
2.6 Subframe with Steering Gear, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.7 Subframe, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.8 Stabilizer Bar, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3 Suspension Strut and Upper Control Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.1 Overview - Suspension Strut and Upper Control Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.2 Suspension Strut, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.3 Suspension Strut, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4 Lower Control Arm and Ball Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.1 Overview - Lower Control Arm and Ball Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.2 Lower Control Arm, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.3 Lower Control Arm Bonded Rubber Bushing, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.4 Ball Joint, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.5 Ball Joint, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5 Wheel Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.1 Overview - Wheel Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.2 Wheel Bearing Housing, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.3 Wheel Bearing Unit, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
6 Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
6.1 Overview - Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
6.2 Overview - Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
6.3 Threaded Connection Between Drive Axle and Wheel Hub, Loosening and Tightening . . 105
6.4 Drive Axle Heat Shield, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
6.5 Drive Axle, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
6.6 Drive Axle, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
6.7 Outer CV Joint, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
6.8 Inner CV Joint, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
7 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
42 - Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1 Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Passat (NMS - US) 2012 ➤, Passat (NMS - US) 2016 ➤, Passat (NMS - US) 2019 ➤
Suspension, Wheels, Steering - Edition 07.2020
Contents i
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1.1 Overview - Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1.2 Rear Axle, Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
1.3 Rear Axle, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
2 Subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
2.1 Overview - Subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
2.2 Subframe, Securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3 Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
3.1 Overview - Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
3.2 Stabilizer Bar, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
4 Control Arm, Tie Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
4.1 Upper Transverse Link, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
4.2 Lower Transverse Link, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
4.3 Tie Rod, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
5 Suspension Strut/Shock Absorber, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
5.1 Overview - Suspension Strut, Shock Absorber and Spring . . . . . . . . . . . . . . . . . . . . . . . . 182
5.2 Shock Absorber, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
5.3 Shock Absorber, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
5.4 Spring, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
6 Wheel Bearing Housing, Wheel Bearing Unit and Trailing Arm . . . . . . . . . . . . . . . . . . . . . . 189
6.1 Overview - Wheel Bearing Housing and Wheel Bearing Unit . . . . . . . . . . . . . . . . . . . . . . 189
6.2 Wheel Bearing Housing, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
6.3 Wheel Bearing Unit, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
6.4 Wheel Bearing Housing Bonded Rubber Bushing, Replacing . . . . . . . . . . . . . . . . . . . . . . 199
6.5 Trailing Arm with Mounting Bracket, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 201
6.6 Trailing Arm, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
7 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
43 - Self-Leveling Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
1 Level Control System Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
1.1 Overview - Rear Level Control System Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
1.2 Rear Level Control System Sensor, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 216
2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
44 - Wheels, Tires, Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
1 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
1.1 Wheel Bolt Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
1.2 Tires, Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
1.3 Wheel, Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
2 Tire Pressure Monitoring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
2.1 Tire Pressure Monitoring System, System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
2.2 Basic Setting, Performing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
3 Vehicle Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
3.1 Axle Alignment Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
3.2 Evaluating Need for Axle Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
3.3 Test Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
3.4 Measure Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
3.5 Axle Alignment Specified Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
3.6 Vehicle, Preparing for Aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
3.7 Overview - Axle Alignment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
3.8 Vehicle Data Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
3.9 Front Axle Camber, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
3.10 Rear Axle Camber, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
3.11 Rear Axle Toe, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
3.12 Front Axle Toe, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Passat (NMS - US) 2012 ➤, Passat (NMS - US) 2016 ➤, Passat (NMS - US) 2019 ➤
Suspension, Wheels, Steering - Edition 07.2020
ii Contents
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3.13 Steering Angle Sensor Basic Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
4 Wheel/Tire Vibration, Causes and Solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
4.1 Flat Spots in Tires From Standing, Determining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
4.2 Vibration Causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
4.3 Road Test, Performing Before Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
4.4 Wheel, Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
4.5 Vibration Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
4.6 Tire and Wheel Radial and Lateral Run-Out, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
4.7 Tire and Wheel Radial and Lateral Run-Out, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
4.8 Rim Radial and Lateral Run-Out, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
4.9 Wheels and Tires, Matching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
5 Adaptive Cruise Control (ACC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
5.1 Adaptive Cruise Control (ACC), Calibrating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
6 Driver Assistance Systems Front Camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
6.1 Driver Assistance Systems Front Camera, Calibrating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
7 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
48 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
1 Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
1.1 Overview - Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
1.2 Steering Wheel, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
2 Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
2.1 Overview - Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
2.2 Steering Column, Checking for Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
2.3 Steering Column, Handling and Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
2.4 Steering Column, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
3 Steering Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
3.1 Overview - Steering Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
3.2 Steering Gear, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
3.3 Steering Gear, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
3.4 Tie Rod, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
3.5 Tie Rod Length, Checking and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
3.6 Tie Rod End, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
3.7 Tie Rod End, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
3.8 Boot, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
4 Power Steering Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
4.1 Overview - Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
4.2 Overview - Hydraulic Lines and Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
4.3 Power Steering Fluid Level, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
4.4 Steering, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
4.5 Power Steering Pump Delivery Pressure, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
4.6 Power Steering Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
4.7 Steering, Bleeding After Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
6 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
Passat (NMS - US) 2012 ➤, Passat (NMS - US) 2016 ➤, Passat (NMS - US) 2019 ➤
Suspension, Wheels, Steering - Edition 07.2020
Contents iii
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Passat (NMS - US) 2012 ➤, Passat (NMS - US) 2016 ➤, Passat (NMS - US) 2019 ➤
Suspension, Wheels, Steering - Edition 07.2020
iv Contents
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00 – General, Technical Data
1 Evaluating Vehicles in Collisions
(Edition 07.2020)
⇒ V1.1 ehicle Evaluation Checklist”, page 1
1.1 Collision Vehicle Evaluation Checklist
When servicing load-bearing or wheel-supporting components
on accident vehicles, damages on suspension could remain
undiscovered. These undiscovered damages may lead to heavy
damages in continued vehicle operation. Therefore, on accident
vehicles, the listed components must be checked in the descri‐
bed manner and sequence, independent of performing an axle
alignment. If no deviations from the specified values were deter‐
mined during an axle alignment, then no deformations of the
chassis are present.
Visual inspection and function check of the steering system
♦ Visual inspection for deformations and cracks
♦ Check for play in tie rod joints and steering gear
♦ Visual inspection for faulty bellows and grease boots
♦ Check electric and hydraulic lines and hoses for chafe
marks, cuts and kinks.
♦ Check of hydraulic lines, threaded connections and steering
gear for proper seal
♦ Make sure the steering gear and lines are securely fastened.
♦ Check proper function through entire steering angle by turn‐
ing steering wheel from stop to stop. Steering wheel must be
rotary without hitching at equal force
Visual and function test of the suspension
• Observe the sequence of the following test steps!
♦ Check all components shown in the overviews for deforma‐
tion, cracks and other damage.
♦ Replace the damaged components
♦ Perform a vehicle alignment on a Volkswagen AG approved
alignment rack.
Visual and function test for wheels, tires
♦ Check for run-out and imbalance.
♦ Check tires for cuts and impact damage in the tread and on
the sidewalls.
♦ Check tire inflation pressure; inflation pressure see the tire
pressure label in the fuel filler door.
Replace the tire if the wheel rim and/or the tire are damaged.
This also applies when the course of the accident and damage
on the vehicle points to possible non-visible damages.
Another criteria is the age of the tires: the tires must not be
older than 6 years.
If in doubt:
• As soon as a safety risk cannot be ruled out, the tire(s) must
be replaced.
Passat (NMS - US) 2012 ➤, Passat (NMS - US) 2016 ➤, Passat (NMS - US) 2019 ➤
Suspension, Wheels, Steering - Edition 07.2020
1. Evaluating Vehicles in Collisions 1
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Overall vehicle
Check other vehicle systems, for example:
♦ Brake system including ABS
♦ Exhaust system and passenger protection by visual and
function check
Test values, adjustment values and notes can be found in re‐
spective repair manuals/ELSA.
This test is for checking the chassis on a vehicle, that has been
in a collision. The test does not cover the entire vehicle.
Electronic vehicle systems
Safety related systems, such as: ABS/ESP; Airbag; electron‐
ically controlled suspension systems; electromechanical; elec‐
trohydraulic steering and other driver assist systems, must be
checked for possible stored fault messages using the Vehicle
Diagnostic Tester. If faults were stored in the DTC memory for
the system mentioned, then these systems must be serviced
according to the specifications in the repair manual/ELSA. After
performing repairs, check the fault stored in the DTC memory
of the affected system again, to make sure that proper function
can be ensured again.
Passat (NMS - US) 2012 ➤, Passat (NMS - US) 2016 ➤, Passat (NMS - US) 2019 ➤
Suspension, Wheels, Steering - Edition 07.2020
2 Rep. Gr.00 - General, Technical Data
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2 Repair Information
⇒ R2.1 epair Information”, page 3
⇒ G2.2 ear”, page 3
⇒ S2.3 ealing Rings”, page 4
⇒ a2.4 nd Nuts”, page 4
⇒ E2.5 lectrical Components”, page 4
⇒ T2.6 hreads in Longitudinal Member, Repairing (Subframe to
Body)”, page 4
⇒ B2.7 earing in Curb Weight, Lifting Vehicles with Coil Spring”,
page 5
2.1 General Repair Information
To perform a problem-free and successful steering gear repair,
extreme caution and cleanliness, as well as properly functioning
tools are an important requirement. The usual basic safety pre‐
cautions also, naturally apply when carrying out vehicle repairs.
A series of applicable general notes for individual repair proce‐
dures - otherwise listed several times at many points in the
repair manual - has been collected here. They apply to this
repair manual.
Refer to Self Study Program No. 317; The Electromechanical
Power Steering Design and Function for a complete description
of the structure and function of the electromechanical power
steering system.
Before performing repairs on the electromechanical steering
gear, determine the cause of the damage as closely as possible
using the Vehicle Diagnostic Tester in the “Guided Fault Find‐
ing”, “Vehicle Self-Diagnosis” and “Measurement” modes.
2.2 Steering Gear
♦ Thoroughly clean connecting points and their surrounding
areas before loosening.
♦ When installing steering gear, make sure centering sleeves
are correctly seated between console and steering gear.
♦ Place removed parts on a clean surface and cover them
so that they do not get dirty. Use foil and paper. Only use
lint-free cloths.
♦ Install only clean parts: remove the replacement parts from
their packaging just before installing them.
♦ Use greases and sealants that are identified by part num‐
bers exclusively.
Passat (NMS - US) 2012 ➤, Passat (NMS - US) 2016 ➤, Passat (NMS - US) 2019 ➤
Suspension, Wheels, Steering - Edition 07.2020
2. Repair Information 3
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♦ Carefully cover or seal opened components if the repair is
not performed immediately.
2.3 Seals, Sealing Rings
♦ Always replace the gaskets and seals.
♦ After removing seals, inspect contact surface on housings
and shafts for burrs and damage and repair if necessary.
♦ Remove all residual sealant of fluid seals from sealing surfa‐
ces, no sealant residue must enter the steering gear housing
when doing this.
2.4 Bolts and Nuts
♦ Loosen and tighten the screw and nut from the covers and
housings diagonally.
♦ Do not cant but loosen and tighten especially sensitive parts
in diagonal manner in stages, e.g. servo motor with control
module.
♦ Tightening specifications for non-lubricated bolts and nuts
are given.
♦ Always replace self-locking nuts and bolts.
2.5 Electrical Components
Surely everyone has been shocked at one time or another
when coming into contact with a metal object. The reason for
this is the build-up of static electricity in the human body. This
charge can lead to functional problems by touching the electri‐
cal components of steering gear.
– Touch a grounded object, for example, a water pipe or a
vehicle hoist, before working on electrical components. Do
not touch the connector terminals.
2.6 Damaged Threads in Longitudinal
Member, Repairing (Subframe to
Body)
Servicing weld nut threads in side rail is possible under certain
circumstances. Refer to ⇒ Body Repair; Rep. Gr. 50.
Passat (NMS - US) 2012 ➤, Passat (NMS - US) 2016 ➤, Passat (NMS - US) 2019 ➤
Suspension, Wheels, Steering - Edition 07.2020
4 Rep. Gr.00 - General, Technical Data
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What's Included?
Lifetime Access
Fast Download Speeds
Online & Offline Access
Access PDF Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$52.99
$68.99
The 2021 Volkswagen Passat (US) Download Service & Repair Manual is a comprehensive technical guide for professionals and DIYers alike. This manual covers a wide range of topics, including engine, transmission, basic maintenance, suspension, starting & charging, steering, fuel, supplemental restraint, cooling, braking, HVAC, electric, exhaust, and wiring diagrams.
- This manual provides step-by-step instructions, troubleshooting charts, exploded-view illustrations, wiring diagrams, and clear images to help you repair and maintain your vehicle.
- The manual is fully printable and compatible with most electronic devices, allowing you to access the information you need at any time and from any location.
- The manual is suitable for both professional mechanics and DIYers, providing a detailed understanding of your vehicle's inner workings and enabling you to perform complex tasks with confidence.
Included in this manual are manufacturer-sourced procedures, torque specifications, and special tools required for various repairs. Whether you're a seasoned mechanic or a DIY enthusiast, this manual has everything you need to keep your Volkswagen Passat in top condition.
