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How to change front suspension strut on VW Passat B5 Variant – replacement guide

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Important!

This replacement procedure can be used for:
VW PASSAT Variant (3B6) 1.9 TDI, VW PASSAT Variant (3B6) 1.6, VW PASSAT Variant (3B6) 2.0, VW PASSAT Variant (3B6) 2.3 VR5, VW PASSAT Variant (3B6) 1.8 T 20V, VW PASSAT Variant (3B6) 2.5 TDI, VW PASSAT Variant (3B6) 2.0, VW PASSAT Variant (3B6) 2.5 TDI, VW PASSAT Variant (3B6) 2.0 TDI, VW PASSAT Variant (3B6) 1.8 T … View more

The steps may slightly vary depending on the car design.

How to change a front shock strut on VW PASSAT 5 (B5) [TUTORIAL AUTODOC]

Alternative products

Shock absorber

Replacement: suspension strut – VW Passat B5 Variant. Tools you need:

                      Wire brush
                    
                      WD-40 spray
                    
                      Brake cleaner 
                    
                      Copper grease 
                    
                      Combination spanner #16
                    
                      Combination spanner #18
                    
                      Drive socket # 13 
                    
                      Drive socket # 15 
                    
                      Drive socket # 16 
                    
                      Drive socket # 18 
                    
                      HEX bit no.H6.
                    
                      Wheel impact socket #17
                    
                      Ratchet wrench
                    
                      Torque wrench
                    
                      Pin punch
                    
                      Hammer
                    
                      Crow bar
                    
                      Hydraulic strut spring compressor
                    
                      Hydraulic transmission jack
                    
                      Fender cover
                    
                      Wheel chock

Buy tools

Replacement: suspension strut – VW Passat B5 Variant. AUTODOC experts recommend:

Both shock struts of the front suspension should be replaced simultaneously.
The replacement procedure is identical for the left and right shock struts of the front suspension.
All work should be done with the engine stopped.

Replacement: suspension strut – VW Passat B5 Variant. Take the following steps:

Step 1

Open the hood.
Step 2

Use a fender protection cover to prevent damaging paintwork and plastic parts of the car.
Step 3

Remove the cowl grille seal.
Step 4

Raise up and remove the cowl grille.
Step 5

Clean the fasteners of the shock strut upper mount. Use a wire brush. Use WD-40 spray.
Step 6

Loosen the upper fastener of the shock strut mount. Use a drive socket #16. Use a ratchet wrench.
Step 7

Secure the wheels with chocks.
Step 8

Loosen the wheel mounting bolts. Use wheel impact socket #17.
Step 9

Raise the front of the car and secure on supports.
Step 10

Unscrew the wheel bolts.

AUTODOC recommends:
Warning! To avoid injury, hold the wheel while unscrewing the fastening bolts. VW Passat B5 Variant
Step 11

Remove the wheel.
Step 12

Clean all joints of the arm. Use a wire brush. Use WD-40 spray.
Step 13

Unscrew the upper control arm fasteners (2 pieces). Use a combination spanner #16. Use a drive socket #16.
Step 14

Remove the fastening bolt. Use a pin punch. Use a hammer.
Step 15

Detach the upper control arm from the steering knuckle (2 pieces). Use a crowbar.
Step 16

Clean the stabiliser link fasteners. Use a wire brush. Use WD-40 spray.
Step 17

Unscrew the fastener connecting the stabilizer link to the stabilizer bar. Use a combination spanner #16 (2 pieces).
Step 18

Unscrew the fastener connecting the stabilizer bar with the control arm. Use a combination spanner #16 (2 pieces).
Step 19

Remove the stabilizer rod.
Step 20

Clean the shock strut fasteners. Use a wire brush. Use WD-40 spray.
Step 21

Unscrew the lower fastener of the shock absorber strut. Use a drive socket #18. Use a combination spanner #18.
Step 22

Remove the fastening bolt.
Step 23

Detach the bottom part of the shock strut. Use a crowbar.
Step 24

Unscrew the top fastening of the shock strut mount.

Replacement: suspension strut – VW Passat B5 Variant. Tip from AUTODOC:
To avoid injuries, hold the shock strut when undoing the fastening bolts.
Step 25

Remove the suspension strut.
Step 26

Clean the fasteners of the shock strut upper mount. Use a wire brush. Use WD-40 spray.
Step 27

Loosen the upper fastener of the shock strut mount. Use a drive socket #13.
Step 28

Remove the upper shock absorber mount assembled with the control arms.
Step 29

Set the shock absorber strut on the spring compressor tool.

Replacement: suspension strut – VW Passat B5 Variant. AUTODOC experts recommend:
Note that when using a spring compressor, spring coils need to be securely gripped, compressing the spring on the opposite sides.Ensure the correct position of the spring in the retainer.Make sure that the spring coils tightly entered the lock handles.
Step 30

Compress the spring.
Step 31

Treat the shock strut rod. Use a wire brush. Use WD-40 spray.
Step 32

Remove the strut piston rod nut. Use HEX No.H6. Use a drive socket #18. Use a ratchet wrench.
Step 33

Remove the top strut mount. Use a crowbar.
Step 34

Release the coil spring.
Step 35

Remove the spring.
Step 36

Remove the shock absorber dust cap and the bump stop.

AUTODOC recommends:
Replacement: suspension strut – VW Passat B5 Variant. Carefully inspect the mount, the boot, and the bump stop of the shock absorber. Replace if necessary.
Step 37

Remove the old shock absorber from the hydraulic coil spring compressor.

Replacement: suspension strut – VW Passat B5 Variant. Professionals recommend:
Before installing a new shock absorber you should pump it manually 3-5 times.
Step 38

Install the new shock absorber on the hydraulic coil spring compressor.
Step 39

Install the spring on the shock absorber.
Step 40

Compress the spring.
Step 41

Install the dust sleeve and the bump stop on the new shock absorber.
Step 42

Install the upper strut mount and the strut mount bearing.
Step 43

Tighten the shock strut piston rod nut. Use HEX No.H6. Use a drive socket #18. Use a torque wrench. Tighten it to 50 nm torque.

Replacement: suspension strut – VW Passat B5 Variant. AUTODOC recommends:
Check to make sure the spring is positioned correctly. Avoid its misalignment.
Step 44

Decompress the spring.
Step 45

Remove the assembled shock strut.
Step 46

Treat the shock strut rod. Use copper grease.
Step 47

Install the upper shock absorber mount assembled with the control arms.
Step 48

Tighten the upper fastener of the shock absorber strut mount. Use a drive socket #13. Use a torque wrench. Tighten it to 22 nm torque.
Step 49

Install the shock strut into the wheel arch.
Step 50

Screw the top fastening of the shock strut mount. Use a drive socket #15. Use a ratchet wrench. Do not tighten it.

AUTODOC recommends:
Important! Hold the suspension strut while screwing in the fastening bolts. VW Passat B5 Variant
Step 51

Clean the mounting seats of the shock strut. Use a wire brush. Use WD-40 spray.
Step 52

Attach the suspension control arm to the shock strut.
Step 53

Install the fastening bolt.
Step 54

Screw in the lower fastener of the shock strut. Use a combination spanner #18. Use a drive socket #18.
Step 55

Clean the mounting seats and the thread of the suspension arm. Use a wire brush. Use WD-40 spray.
Step 56

Treat all joints of the arm. Use copper grease.
Step 57

Attach the upper control arm to the steering knuckle (2 pieces).
Step 58

Install the fastening bolt.
Step 59

Screw in the fasteners (2 pieces) of the upper control arm. Use a combination spanner #16. Use a drive socket #16.
Step 60

Support the arm. Use a hydraulic transmission jack.
Step 61

Tighten the lower fastening of the shock absorber. Use a combination spanner #18. Use a drive socket #18. Use a torque wrench. Tighten it to 90 Nm torque.
Step 62

Tighten the upper control arm fasteners (2 pieces). Use a combination spanner #16. Use a drive socket #16. Use a torque wrench. Tighten it to 40 Nm torque.
Step 63

Remove the support from under the arm.

Replacement: suspension strut – VW Passat B5 Variant. Tip:
Lower the hydraulic transmission jack smoothly, without jerks, to avoid damaging assemblies and mechanisms.
Step 64

Clean the mounting seats of the stabiliser link. Use a wire brush. Use WD-40 spray.
Step 65

Ιnstall the transverse stabilizer link.
Step 66

Tighten the fastener connecting the stabilizer bar with the control arm. Use a combination spanner #16. Use a drive socket #16. Use a torque wrench. Tighten it to 40 Nm torque.+90°

Replacement: suspension strut – VW Passat B5 Variant. AUTODOC experts recommend:
Important! Be sure to use new fasteners.
Step 67

Tighten the fastener connecting the stabilizer link to the stabilizer bar. Use a combination spanner #16. Use a drive socket #16. Use a torque wrench. Tighten it to 40 Nm torque.+90°

AUTODOC recommends:
Important! Be sure to use new fasteners.
Step 68

Treat all joints of the arm. Treat the shock strut fasteners. Use copper grease.
Step 69

Treat the surface where the brake disc contacts the wheel rim. Use copper grease.
Step 70

Clean the brake disk surface. Use a brake cleaner.

AUTODOC recommends:
Replacement: suspension strut – VW Passat B5 Variant. After applying the spray, wait a few minutes.
Step 71

Install the wheel.

Replacement: suspension strut – VW Passat B5 Variant. AUTODOC experts recommend:
To avoid injury, hold up the wheel when screwing in the fastening bolts.
Step 72

Screw in the wheel bolts. Use wheel impact socket #17.
Step 73

Lower the car and working in a cross order, tighten the wheel bolts. Use a torque wrench. Tighten it to 120 nm torque.
Step 74

Remove the jacks and chocks.
Step 75

Tighten the upper fastener of the shock absorber strut mount. Use a drive socket #16. Use a torque wrench. Tighten it to 65 nm torque.
Step 76

Install and secure the cowl grille.
Step 77

Install the cowl grille seal.
Step 78

Remove the fender protection cover.
Step 79

Close the hood.

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