Both coil springs of the front suspension should be replaced simultaneously.
The replacement procedure is identical for the left and right coil springs of the front suspension.
All work should be done with the engine stopped.
Replacement: coil springs – VW Passat Variant B6. Use the following procedure:
Step 1
Open the bonnet.
Step 2
Use a fender protection cover to prevent damaging paintwork and plastic parts of the car.
Step 3
Detach the windscreen washer nozzle hose. Use a clip removal tool.
Step 4
Remove the clips of the plastic cowl grille.
Step 5
Raise the wiper plastic cowl grille.
Step 6
Clean the fasteners of the shock strut upper mount. Use a wire brush. Use WD-40 spray.
Step 7
Loosen the upper fastener of the shock strut mount. Use a drive socket #13. Use a ratchet wrench.
Step 8
Secure the wheels with chocks.
Step 9
Loosen the wheel hub bolt. Use drive 12-point socket #24. Use a tap wrench.
Step 10
Loosen the wheel mounting bolts. Use wheel impact socket #17.
Step 11
Raise the front of the car and secure on supports.
Step 12
Unscrew the wheel bolts.
AUTODOC recommends:
Important! Hold the wheel while unscrewing the fastening bolts. VW Passat B6 3C Variant
Step 13
Remove the wheel.
Step 14
Clean the stabiliser link fasteners. Use a wire brush. Use WD-40 spray.
Step 15
Unscrew the fastener connecting the stabilizer link to the shock strut. Use a drive socket #18. Use a ratchet wrench.
Step 16
Remove the stabilizer rod.
Step 17
Disconnect the wiring and the brake hose from the bracket on the shock strut. Use a crowbar.
Step 18
Clean the fasteners connecting the shock strut to the steering knuckle. Use a wire brush. Use WD-40 spray.
Step 19
Unscrew the lower fastener connecting the shock strut to the steering knuckle. Use a drive socket #18. Use XZN #14. Use a tap wrench. Use a ratchet wrench.
Step 20
Remove the fastening bolt. Use drive 12-point socket #24.
Step 21
Clean all joints of the arm. Use a wire brush. Use WD-40 spray.
Step 22
Unscrew the fastener connecting the ball joint to the suspension control arm. Use a drive socket #16. Use a ratchet wrench.
Step 23
Disconnect the ball joint from the arm. Use a crowbar.
Step 24
Remove the drive shaft. Use a pin punch.
Replacement: coil springs – VW Passat 3C5. Tip:
Make sure that the drive shaft is not unloaded (when the car is jacked).
Step 25
Prop up the steering knuckle. Use a hydraulic transmission jack.
Step 26
Remove the fastening bolt.
Step 27
Release the lower fastener connecting the shock strut to the steering knuckle. Use a special drive socket to remove the shock absorber. Use a ratchet wrench.
Step 28
Clean the fasteners connecting the shock strut to the steering knuckle. Use a wire brush. Use WD-40 spray.
Step 29
Disconnect the steering knuckle from the shock absorber strut.
Step 30
Unscrew the top fastening of the shock strut mount.
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 33
Compress the spring.
Step 34
Treat the shock strut rod. Use a wire brush. Use WD-40 spray.
Step 35
Remove the strut piston rod nut. Use HEX No.H6. Use a drive socket #21. Use a ratchet wrench.
Step 36
Remove the top strut mount.
Step 37
Release the coil spring.
Step 38
Remove the spring.
Step 39
Remove the shock absorber dust cap and the bump stop.
AUTODOC recommends:
Replacement: coil springs – VW Passat B6 3C Variant. Carefully inspect the mount, the boot, and the bump stop of the shock absorber. Replace if necessary.
Step 40
Install the boot and a bump stop onto the shock absorber.
Step 41
Install the spring on the shock absorber.
Step 42
Compress the spring.
Step 43
Install the upper strut mount and the strut mount bearing.
Step 44
Tighten the shock strut piston rod nut. Use a drive socket #19. Use HEX No.H6. Use a torque wrench. Tighten it to 60 Nm torque.
Check to make sure the spring is positioned correctly. Avoid its misalignment.
Step 45
Treat the shock strut rod. Use copper grease.
Step 46
Decompress the spring.
Step 47
Remove the assembled shock strut.
Step 48
Install the shock strut into the wheel arch.
Step 49
Screw the top fastening of the shock strut mount. Do not tighten it.
AUTODOC recommends:
VW Passat Variant B6 – To avoid injury, hold the suspension strut while screwing in the fastening bolts.
Step 50
Clean the mounting seats of the shock strut. Use a wire brush. Use WD-40 spray.
Step 51
Fix the shock absorber strut on the steering knuckle.
Step 52
Install the fastening bolt.
Step 53
Screw in the fastener that connects the shock strut to the steering knuckle. Use a drive socket #18. Use XZN #14. Use a ratchet wrench.
Step 54
Clean the splines of the drive shaft CV joint. Use a wire brush. Use WD-40 spray.
Step 55
Remove the support from under the steering knuckle.
AUTODOC recommends:
Replacement: coil springs – Passat 3C5. Lower the transmission jack smoothly, without jerks, to avoid damaging components and mechanisms.
Step 56
Mount the drive shaft into the
wheel hub.
Step 57
Clean all joints of the arm. Use a wire brush. Use WD-40 spray.
Step 58
Attach the ball joint to the control arm.
Step 59
Tighten the ball joint fastener. Use a drive socket #16. Use a torque wrench. Tighten it to 60 Nm torque.
Step 60
Tighten the lower fasteners connecting the shock strut to the steering knuckle. Use XZN #14. Use a drive socket #18. Use a torque wrench. Tighten it to 70 Nm torque.+90°
AUTODOC recommends:
Important! Be sure to use new fasteners.
Step 61
Connect the fastener of the ABS sensor cable to the shock absorber strut. Fasten the brake hose on the strut. Use a crowbar.
Step 62
Ιnstall the transverse stabilizer link.
Step 63
Tighten the fastener connecting the stabilizer link to the shock strut. Use a drive socket #18. Use a torque wrench. Tighten it to 65 Nm torque.
Step 64
Install and tighten the drive shaft bolt. Use drive 12-point socket #24. Use a ratchet wrench.
Step 65
Treat all joints of the arm. Treat the shock strut fasteners. Use copper grease.
Step 66
Treat the surface where the brake disc contacts the wheel rim. Use copper grease.
Step 67
Clean the brake disk surface. Use a brake cleaner.
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