Volkswagen Passat 1997 Official Factory Repair Manual
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Volkswagen Passat 1997 Official Factory Repair Manual

Volkswagen Passat 1997 Official Factory Repair Manual

Gasoline, turbo diesel, tdi 4-cylinder and vr6, including wagon
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  • Page 3: Maintenance

    Maintenance Maintenance Engine overview Oil change service Oil change service every 10,000 miles (15,000 Km) Inspection service Inspection service every 12 months Inspection service every 20,000 miles (30,000 km) General Information Type plate Vehicle Identification Number (VIN) Engine code and engine number Vehicle, lifting Tow starting/towing Work descriptions...
  • Page 4 Spark plugs, replacing Dust and pollen filter element, replacing Toothed belt for camshaft drive: (Diesel engine code AAZ), Ccheck condition and tension Toothed belt and toothed belt tensioning roller (Diesel engine codes AFN and 1Z), replacing Toothed belt for camshaft drive (gasoline engine), check condition and tension Toothed belt, check wear (TDI engines) Fuel filter, replacing (diesel engine) Fuel filter, draining water (Diesel engine)

  • Page 5: Engine Overview

    Engine overview Page 1 of 2 Engine overview Gas engine Engines Code letters Manufactured from 10.93 Number of cylinders / valves per cylinder 6 / 2 Displacement Liters 2.8L Output kW @ RPM 128/5800 Torque Nm @ RPM 235/4200 Bore 81.0 Stroke 90.3...
  • Page 6 Engine overview Page 2 of 2 Code letters Manufactured from 10.93 10.93 Number of cylinders / valves per cylinder 4 / 2 4 / 2 Displacement Liters 1.9L 1.9L Output kW @ RPM 55/4400 66/4000 Torque Nm @ RPM 140/2200...2800 202/1900 Bore 79.5...

  • Page 7: Oil Change Service

    Oil change service Page 1 of 2 Oil change service Oil change service every 10,000 miles (15,000 Km) Vehicles with a yearly mileage performance greater than 10,000 miles (15,000 Km) sequence of individual service positions has been tested and optimized. Therefore they should be adhered to, to prevent unnecessary work interruptions.
  • Page 8 Oil change service Page 2 of 2 - Service sticker: Note date for next scheduled service (also brake fluid change) on sticker and affix sticker to door beam (B-pillar) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.ME01.01.2 12/7/2004...

  • Page 9: Inspection Service

    Inspection service Page 1 of 5 Inspection service Inspection service every 12 months Ask customer whether new wiper blades should be installed and whether they require "Windshield Clear" G 052 164 (cleaner and anti-freeze) in windshield washer system. sequence of individual service positions has been tested and optimized.
  • Page 10 Inspection service Page 2 of 5 and headlight cleaning system: Check function and setting system, checking function 01-5, Windshield - Windshield wiper blades: Check for damage; check rest wiper blades, check position; only for "juddering" wiper blades: Check pitch park position and pitch angle angle Tires...
  • Page 11 Inspection service Page 3 of 5 checking thickness - Exhaust system: Perform visual check for leaks, security and damage 01-5, Tie rod ends, - Track rod ends: Check play, security and joint boots checking 01-5, Ball joints, - Ball joints: Perform visual check of swivel joint boots for checking leaks and damage Engine compartment...
  • Page 12 Inspection service Page 4 of 5 01-5, Battery, - Battery: Checking checking 01-5, Idle speed - Idle speed: Checking (Diesel engine code AAZ): Checking (Vehicles with Diesel engine code AAZ, on which no emissions test has been performed) Final work procedures 01-5, Checking tire - Tire filling pressure at all 4 wheels and spare wheel: condition, tread wear...
  • Page 13 Inspection service Page 5 of 5 Applicable only for countries where there are no country specific mandatory exhaust emission regulations. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.ME01.01.3 12/7/2004...

  • Page 14: General Information

    General Information Page 1 of 6 General Information Type plate A - Type plate - Located on front lock carrier plate. Vehicle Identification Number (VIN) B - Vehicle Identification Number (VIN) - It is stamped on rear engine compartment bulkhead and is visible through a window in plenum chamber cover.

  • Page 15: Vehicle, Lifting

    General Information Page 2 of 6 Engine code and engine number can be found fastest on sticker - arrow - on toothed belt guard (4-cyl.-engine) or on left valve cover (6-cyl.-engine). Vehicle, lifting Caution! Vehicle may only be lifted at points indicated in illustration in order to avoid damaging vehicle floor pan and to prevent vehicle from tipping.

  • Page 16: Tow Starting/Towing

    General Information Page 3 of 6 At reinforcing plate welded to floor panel. Position support so rear edge aligns with center of sill depression. Rear: At reinforcing plate welded to floor panel. Position support so rear edge aligns with center of sill depression.
  • Page 17 General Information Page 4 of 6 wrench. - After use, unscrew towing eyelet and store with vehicle tool kit. Re-install cover. Rear towing eyelet is located at right in bumper and is covered by a flap. - To open flap, pull flap downward and let it hang freely. - To close flap, first insert at bottom and press upward until it engages.
  • Page 18 General Information Page 5 of 6 Ignition must be switched on so that steering wheel is free and turn signals, horn and if necessary windshield wiper and washer can be used. Because brake booster only works when engine is running, more pressure is required accordingly on brake pedal when engine is not running.
  • Page 19 General Information Page 6 of 6 temperature must not be tow started over a long distance, otherwise unburned fuel reaches catalytic converter and can be burned there. This may cause catalytic converter to overheat. When towing a vehicle with automatic transmission following additional points must be observed: Selector lever in "N"...
  • Page 20 Work descriptions Page 1 of 83 Work descriptions Driver's and front passenger airbags, visual check of airbag units You can see whether an airbag(s) is installed by inscription "AIRBAG" on steering wheel padded panel (driver's side) and on far side of dash panel (passenger side). - Perform visual check of pad panel - 1 - and surface of instrument panel, right side - 2 - for exterior damage.
  • Page 21 Work descriptions Page 2 of 83 5051/ 01-5, Checking DTC memory of all systems using Vehicle Diagnosis, Testing and Information System VAS 5051: Interrogating DTC memory of all systems with scan tool VAG 1551: Required special tools and equipment VAG1551 Scan Tool (ST) V.A.G 1551/ adapter cable V.A.G 1551/3 A Connecting scan tool VAG 1551: Perform following work procedure:...
  • Page 22 Work descriptions Page 3 of 83 - Unclip cover below instrument cluster. - With ignition switched off, connect Scan Tool (ST) V.A.G 1551/ using Adapter cable V.A.G 1551/3 A . Interrogating DTC memory: - Start engine and let run at idle. - Switch printer on via Print button (indicator lamp in button lights up).
  • Page 23 Work descriptions Page 4 of 83 When a control module responds with its identification, display indicates number of stored errors or indicates "no malfunction recognized" . DTCs stored in system are indicated in sequence and printed out. Then VAG1551 Scan Tool (ST) V.A.G 1551/ sends next address word.
  • Page 24 Work descriptions Page 5 of 83 Diagnostic cable, 5m without voltage supply VAS 5051/3 Connect VAS 5051 tester: - Engage parking brake. - Manual transmission: Shift gear stick in neutral. - With ignition switched off, connect Vehicle Diagnostic, Test and Information System VAS 5051/ using diagnostic cable, 5m without voltage supply VAS 5051/3 .

  • Page 25: Select Operating Mode

    Work descriptions Page 6 of 83 Indicated on display: Select operating mode: - Press button for "vehicle On Board Diagnostic (OBD)" on display - arrow - . Note: If indications shown in work procedure are not indicated on display: User manual for VAS5051 tester Indicated on display: Select vehicle system:...
  • Page 26 Work descriptions Page 7 of 83 Any system malfunctions that are stored will be displayed one after other. Next, Vehicle Diagnostic, Test and Information System VAS 5051/ sends next address word. Automatic test sequence has ended when following indication appears on display: - Press "Print"...
  • Page 27 Work descriptions Page 8 of 83 - Switch off ignition and disconnect diagnostic connector. Door check straps and securing bolts, lubricate - Lubricate side area of door arrester - arrow A - using lubricant G 000 150. - Lubricate securing bolts - arrow B - using lock cylinder grease spray G 400 01.
  • Page 28 Work descriptions Page 9 of 83 - Clean guide rail - arrows - and lubricate using lubricant G 000 450 02. Windshield wiper/washer system and headlight cleaning system, checking function Note: If during function test it is determined that wiper blades are juddering or making noises, check pitch angle of wiper blades 01-5, Windshield wiper...

  • Page 29: Mixture Ratio

    Note: Genuine Volkswagen Windshield Clear "G 052 164" protects spray nozzles, fluid reservoir and hoses from freezing. Fill with genuine Volkswagen Windshield Clear "G 052 164" in warmer season also. powerful cleanser removes wax and oil deposits from windows. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.ME01.01.5...
  • Page 30 Work descriptions Page 11 of 83 Freeze protection must be guaranteed to approx. 5 F (-15 C) (approx. -31 F (35 C) in countries with an arctic climate) in windshield washer system. Windshield washer system, check jet setting and adjust if necessary Required special tools and equipment V.A.G3125A Note:...
  • Page 31 Work descriptions Page 12 of 83 300 mm 600 mm Tolerance: 20 mm Jet setting dimension for rear window: Spray jet, center, wiper area Note: If spray jet is uneven or cannot be adjusted to specified dimensions, spray nozzle must be replaced (repair measure).
  • Page 32 Work descriptions Page 13 of 83 Windshield wiper blades, check park position and pitch angle Windshield wiper blades, check park position and adjust if necessary Required special tools and equipment Torque wrench V.A.G 1331/ (5 - 50 Nm) Perform following work procedure: - Check whether wiper blades are in park position.
  • Page 33 Work descriptions Page 14 of 83 - If necessary, adjust park position by shifting wiper arm. Tightening torque, wiper arm: 16 Nm Windshield wiper blades: Check pitch angle, adjust if necessary Note: Check pitch angle only if wiper blades are juddering or making noises.
  • Page 34 Work descriptions Page 15 of 83 screw - 3 - . - Check pitch angle. Pitch angle (specified values) for Driver's side -2.5 / -4 Passenger's side Rear wiper Tolerance Windshield wiper blade with plastic spoiler (vehicles from 05.94 on) If necessary, adjust pitch angle to specified value as follows: - Place open-end wrench 24 mm - 1 - onto adjustment...
  • Page 35 Work descriptions Page 16 of 83 - Check to make sure that windshield wiper system is not juddering. Checking tire condition, tread wear pattern , filling pressure and tread depth Note: For reasons of safety only tires of same type and tread pattern should be fitted on a vehicle! Note: Vehicle must be equipped with tires of same make.
  • Page 36 Work descriptions Page 17 of 83 Tread wear pattern on front tires is an indication of whether toe and camber settings should be checked: "Feathering" on tread indicates incorrect toe setting. . If tread is worn on one side, this is usually caused by incorrect camber.
  • Page 37 Work descriptions Page 18 of 83 Important information concerning winter tires recommended by Volkswagen is found in "Fault finding; Wheels, tires; Chapter 4; No. 2" . Tire inflation pressure table for normal tires (For all factory installed tire sizes) Filling pressure values in bar...

  • Page 38: Engine Oil Level, Checking

    Work descriptions Page 19 of 83 Wagon: 66 kW Sedan: Wagon: 81 kW Sedan: Wagon: Spare wheel: Regular wheel: Meet highest intended inflation pressure for vehicle. Engine oil level, checking After switching engine OFF, wait at least 3 minutes to allow oil to flow back into pan.
  • Page 39 Work descriptions Page 20 of 83 Oil extractor V.A.G 1307 A Oil extractor V.A.G 1358 A Torque wrench V.A.G 1331/ (5 - 50 Nm) Note: If oil is drained and not extracted using oil extractor V.A.G 1307 A or oil extractor V.A.G 1358 A , replace gasket for oil drain plug.

  • Page 40: Engine Oil, Filling

    Work descriptions Page 21 of 83 Capacities with filter change: for emissions test Tightening torque for drain plug: 4-cyl. engines: 30 Nm 6-cyl. engines: 50 Nm Oil filter, replacing 4-cyl. engine Note: Observe disposal regulations! - Loosen oil filter using tension strap (e.g. Hazet 2171-1) and remove oil filter.
  • Page 41 Work descriptions Page 22 of 83 Gasoline engine specifications: A - Multi-grade light duty oils, specification VW 500 00 or VW 502 00 B - Multi-grade oils, specification VW 501 01 - Multi-grade oils, specification API-SF or SG These oils may only be used in exceptional cases if no approved engine oil is available.
  • Page 42 Work descriptions Page 23 of 83 - As long as oil pressure warning light in instrument panel is lit, engine may run only at idle. Do not accelerate! Throttle bursts may damage turbocharger or cause it to fail completely. - Only when warning light goes out, full oil pressure is reached, and driver may accelerate.
  • Page 43 Work descriptions Page 24 of 83 Secure lubrication properties at all engine temperature and load conditions. High resistance to aging. Multi-grade light duty oils according to VW standard 500 00 exhibit beyond that following advantages: All-season usability at almost all occurring outside temperatures.
  • Page 44 Work descriptions Page 25 of 83 - Check hoses, pipes and connections of Fuel system Cooling and heating system Brake system For leaks, abrasions, porosity and brittleness. Note: Make sure that all malfunctions detected are repaired within repair measures. If fluid losses are greater than can be reasonably expected, determine cause and repair (repair measure) V-belt, checking condition and tension...
  • Page 45 Work descriptions Page 26 of 83 - Check V-belt tension by strong thumb pressure (depth of impression approx. 5 mm) and adjust if necessary. For following adjustment torque wrench V.A.G 1410/ in connection with ring- insertion tool (A/F 22 mm) V.A.G 1410/2 - A - is particularly suitable.
  • Page 46 Work descriptions Page 27 of 83 Traces of oil and grease Note: It is essential to replace ribbed belt if malfunctions are found. This will avoid possible break-downs or operating problems. replacement of a ribbed belt is a repair measure. Tensioning ribbed belt: Note: With engines with tensioning roller, stretching of...
  • Page 47 Work descriptions Page 28 of 83 - Tighten first mounting bolt - 2 - , then mounting bolt - 1 - to 25 Nm. Front manual transmission/final drive, check oil level - Remove bolt - arrow - . - Check oil level: Oil level should reach lower edge of oil filler hole.
  • Page 48 Work descriptions Page 29 of 83 - Unthread bolt for checking transmission fluid - arrow - . Oil level is correct when the rear final drive is filled up to lower edge of oil filler hole. - Screw in bolt - arrow - . When filling anew, note the following: - Unthread bolt - arrow - .
  • Page 49 Work descriptions Page 30 of 83 - If oil level is too low, top-off axle oil. Automatic transmission 096 (until December 1994): Manufacturing date see side 01-5, Transmission identification SAE 75 W 90 (synthetic) Container size 0.5 L - part number G 052 145 A1 Container size 1.0 L - part number G 052 145 A2 Note: Lubricants SAE 75 W 90 and VW ATF must not be...

  • Page 50: Transmission Identification

    Work descriptions Page 31 of 83 Automatic transmission 01M from 8/25/1996: Manufacturing date see side 01-5, Transmission identification SAE 75 W 90 (synthetic) Container size 0.5 L - part number G 052 145 A1 Container size 1.0 L - part number G 052 145 A2 Note: lubricants SAE 75 W 90 and VW ATF must not be mixed with each other.
  • Page 51 Work descriptions Page 32 of 83 Transmission code letters are also listed on vehicle data plates. Brake system, visual inspection - Master brake cylinder, brake booster (with Anti-lock Brake System -ABS-: Hydraulic unit), Check brake pressure regulator, brake caliper for leaks and damage. - Make sure that brake hoses are not twisted.
  • Page 52 Work descriptions Page 33 of 83 Required special tools and equipment Torque wrench V.A.G 1332/ (40 -200 Nm) Fashlight Perform following work procedure: - Measure outer and inner pad thickness. a - Pad thickness without backing plate - Wear limit: 2 mm With a pad thickness of 2 mm (without backing plate) brake pads have reached their wear limit and must be replaced (repair measure).
  • Page 53 Work descriptions Page 34 of 83 a - Pad thickness including backing plate - Wear limit: 2 mm With a pad thickness of 2 mm (without backing plate) brake pads have reached their wear limit and must be replaced (repair measure). Rear drum brake pads: - Check thickness of brake pads through inspection holes in brake carrier metal sheets - arrow - .
  • Page 54 Work descriptions Page 35 of 83 Malfunctions found must be repaired (repair measure). This inhibits corrosion and rusting through. Tie rod ends, checking Perform following work procedure: - With vehicle raised (wheels hanging free), check play by moving tie rods and wheels - arrow - . Play: zero play - Check mountings.
  • Page 55 Work descriptions Page 36 of 83 12 according to TL "VW 774 D" . Some vehicles are filled with coolant additive G 11 (color green). When adding coolant, use only coolant G 11 according to TL "VW 774 D" . If these vehicles were filled with G 12 for repairs, only G 12 may be refilled.
  • Page 56 Work descriptions Page 37 of 83 scale - 1 - of refractometer is designed for coolant additives -G 12- according to TL "VW 774 D" and -G 11- according to TL "VW 774 C" . scale - 2 - is designed for coolant additive -G 13-. Note: Coolant additive G 13 is currently used only in vehicles of type "L 80"...
  • Page 57 Work descriptions Page 38 of 83 0 (32) -25 (-13) -35 (-31) -5 (23) -25 (-13) -35 (-31) -10 (14) -25 (-13) -35 (-31) -15 (5) -25 (-13) -35 (-31) -20 (-4) -25 (-13) -35 (-31) -25 (-13) -35 (-31) -30 (-22) 35 (-31) -35 (-31)

  • Page 58: Spark Plugs, Replacing

    Work descriptions Page 39 of 83 -25 C (-13 F) approx. 40 % approx. 60 % -35 C (-31 F) approx. 50 % approx. 50 % -40 C (-40 F) approx. 60 % approx. 40 % Note: Coolant additives G 11 or G 12 prevent frost and corrosion damage, scaling and also raises boiling point of coolant.
  • Page 59 Work descriptions Page 40 of 83 Torque wrench V.A.G 1331/ (5 - 50 Nm) Emissions Test binder Perform following work procedure: - Disconnect spark plug connectors using assembly tool T10029 . - Remove spark plugs using spark plug removal tool VAS 3122B .
  • Page 60 Work descriptions Page 41 of 83 - Unlock spring latches - 2 - of filter element, remove filters upward. Note: Observe disposal regulations! Installing - Install new filter element. - Install rubber seal and cover. Toothed belt for camshaft drive: (Diesel engine code AAZ), Ccheck condition and tension - Performing work procedure...
  • Page 61 Work descriptions Page 42 of 83 Condition of toothed belt must be checked for: Cracks or tears - A - , cross sectional breaks Lateral scouring - B - Fraying and/or outbreaks - C - Tears in tooth base - D - Layer separation (toothed belt carcass, cord strands) Traces of oil and grease Note:...
  • Page 62 Work descriptions Page 43 of 83 Perform following work procedure: - Open clips of upper toothed belt protection. - Pull upper toothed belt protection forward or remove it if necessary. - Measure width of toothed belt using a caliper. - Wear limit: 22 mm Note: With a toothed belt width of 22 mm toothed belt has reached its wear limit and must be replaced (repair...
  • Page 63 Work descriptions Page 44 of 83 - Disconnect fuel hoses from hose connections - 1 - and - 2 - Loosen bolt - arrow - at filter mounting pull out filter upward. Installing - Install new O-ring for sealing of regulating valve. Note: flow direction of fuel is marked at connections by arrows (please do not exchange connections).
  • Page 64 Work descriptions Page 45 of 83 - Slide filter downward through filter mounting and fasten it at bolt - arrow - . - Install regulating valve with attached fuel lines. - Install retaining clamp - 5 - . - Slide fuel hoses across hose connections - 1 - and - 2 - , and secure hoses using hose clamps.
  • Page 65 Work descriptions Page 46 of 83 - Remove retaining clamp - A - and regulating valve - B - with fuel hoses attached. - Connect hose at connection sleeve of dewatering bolt - arrow - , remove bolt, and drain approx. 0.1L of fluid. - Tighten dewatering bolt - arrow - and disconnect hose.
  • Page 66 Work descriptions Page 47 of 83 VAG1551 Scan Tool (ST) V.A.G 1551/ adapter cable V.A.G 1551/3 A ATF filler tool V.A.G 1924/ http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.ME01.01.5 12/7/2004...

  • Page 67: Test Requirements

    Work descriptions Page 48 of 83 Torque wrench V.A.G 1331/ (5 - 50 Nm) Test requirements Transmission not in emergency running mode, ATF temperature not above approx. 30 Vehicle on level ground. Selector lever in "P" Perform following work procedure: - Secure container of ATF filler tool V.A.G 1924/ to vehicle.
  • Page 68 Work descriptions Page 49 of 83 Indicated on display: VAG - On Board Diagnostic (OBD) HELP 1- Rapid data transfer* VAG - On Board Diagnostic (OBD) HELP 2- Blink code output* * Two operating modes are displayed alternately - Press button -1- to select "Rapid data transfer" operating mode.
  • Page 69 Work descriptions Page 50 of 83 Press button. - Raise vehicle. - Place appropriate receptacle underneath transmission. Indicated on display: Rapid data transfer HELP Select function XX - Buttons 0 and 8 press. (Press 08 to select "Read measuring value block" function.) Indicated on display: Rapid data transfer Q 08 - Read measuring value block...
  • Page 70 Work descriptions Page 51 of 83 - For ATF test remove locking bolt - arrow - in oil pan. ATF present in overflow tube - arrow 2 - runs off. If ATF drips from hole: ATF must not be topped off. - Cut seal - arrow - of locking bolt with a side cutter and remove seal.
  • Page 71 Work descriptions Page 52 of 83 - End Output 01-5, End Output If ATF in overflow tube runs out of hole: Top off ATF - Pry off cap - arrow - with a screwdriver for protection of sealing plug. While doing so, locking mechanism of cap will be destroyed, therefore always replace cap.
  • Page 72 Work descriptions Page 53 of 83 Container size 1.0 L -part number G 052 162 A2 Note: Adding to little or too much ATF impairs functioning of transmission. - Cut seal - arrow - of locking bolt with a side cutter and remove seal.

  • Page 73: End Output

    Work descriptions Page 54 of 83 - Lock cap. Note: Cap without clip bolting device must always be replaced. cap secures sealing plug. With some transmissions a cap with a clip bolting device is installed. This cap can be reused. End Output Indicated on display: Read measuring value block 5 ->...
  • Page 74 Work descriptions Page 55 of 83 Automatic transmission, changing ATF Vehicles 12.94 with 096 transmissions Use following VW ATF (yellowish color): Container size 0.5 L -part number G 052 162 A1 Container size 1.0 L -part number G 052 162 A2 Note: Current supplies of ATF Dextron ll can be used up in transmissions until December 1994.
  • Page 75 Work descriptions Page 56 of 83 V.A.G1358A and sensor V.A.G 1358/ A2 Torque wrench V.A.G 1331/ (5 - 50 Nm) Perform following work procedure: - Extract ATF using probe V.A.G 1358/ A2 and V.A.G1358 . Note: Observe disposal regulations! Engine must not be started without ATF and vehicle must not be towed! - Remove oil pan with ATF-strainer.
  • Page 76 Work descriptions Page 57 of 83 - Install new ATF-strainer with new seal. Tightening torque for securing bolts: 8 Nm. - Install oil pan with new seal. Make sure that spacers are fastened. Tightening torque for securing bolts: 12 Nm. - Next, add 3.0L ATF (replacement capacity) using a funnel.
  • Page 77 Work descriptions Page 58 of 83 - ATF must be filled up in cold condition at least up to 20 C-marking, otherwise add ATF. - Bring ATF to a temperature of 50 ... 70 C. temperature will be measured using Scan Tool (ST) V.A.G 1551/ as follows: - Let engine run at idle.
  • Page 78 Work descriptions Page 59 of 83 Rapid data transfer Q 02 Transmission Electronics - Press Q button to confirm input. Indicated on display: 096927733BA AG3 transmission 096 2754 Coding 00000 WSC 00000 control module identification, coding, and Workshop Code (WSC) of Scan Tool (ST) V.A.G 1551/ are indicated: If displayed: Control module not responding! HELP - Press HELP button to print out an overview of all of...
  • Page 79 Work descriptions Page 60 of 83 Indicated on display: Read measuring value block Q Enter display group number 005 - Press Q button to confirm input. ATF temperature in C appears in display field 1 (exact measuring value only starting from 50 Read measuring value block 1 1 2 3 4 - Check ATF level at a temperature of 50 ...
  • Page 80 Work descriptions Page 61 of 83 Power steering fluid level, checking Fluid, when cold: Perform following work procedure: - With engine not running, bring front wheels into straight- ahead position. - Unscrew reservoir cap - arrow - with dipstick. - Clean off dipstick with a clean rag. - Tighten cap by hand and remove again.
  • Page 81 Work descriptions Page 62 of 83 - Screw cap on hand tight. Fluid, at operating temperature (from approx. 50 Perform following work procedure: - With engine not running, bring front wheels into straight- ahead position. - Unscrew reservoir cap with fitted dipstick. - Clean off dipstick with a clean rag.
  • Page 82 Work descriptions Page 63 of 83 Brake filling and bleeding tool VAS 5234 brake filling and bleeding tool V.A.G 1869/ Brake filling and bleeding tool V.A.G 1869/ with upgrade kit V.A.G 1869/4 Brake pedal depressor V.A.G 1869/2 Vehicles with manual transmission: http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.ME01.01.5 12/7/2004...
  • Page 83 Work descriptions Page 64 of 83 bleeder hose V.A.G 1238/B3 670 mm long Use only new brake fluid with part number B 000 700 A. (corresponds to US standard FMVSS 116 DOT 4) Caution! NEVER bring brake fluid into contact with fluids containing mineral oil (oil, gasoline, cleaning fluids).

  • Page 84: Vehicles With Manual Transmission

    Work descriptions Page 65 of 83 - Install brake depressor V.A.G 1869/2 between driver's seat and brake pedal, and tension. - Screw adapter VAS 5234/1 or adapter V.A.G 1869/1 onto brake fluid reservoir. - Connect filler hose of brake filling and bleeding tool VAS 5234 or brake filling and bleeding tool V.A.G 1869/ to adapter.
  • Page 85 Work descriptions Page 66 of 83 Left front 0.4 to 0.5 liters 2 Liter Total quantity with siphoned brake fluid from brake fluid reservoir and replacement capacity of hydraulic clutch mechanism - Install cover caps to brake caliper bleed screws. - Move filler lever on VAS5234 or brake filling and bleeding tool V.A.G 1869/ to position - B - (see user manual).
  • Page 86 Work descriptions Page 67 of 83 Note: To make sure that brake fluid will not overflow reservoir, max. marking must not be exceeded. Inspection service: - fluid level must always be judged in conjunction with brake pad wear. When vehicle is in use, fluid level tends to drop slightly due to brake pad wear and automatic adjustment.
  • Page 87 Work descriptions Page 68 of 83 Battery tester with printer VAS 5097/ Battery tester with printer VAS 5097/ battery tester VAS 5096/ battery tester VAS 5033 Battery fill bottle VAS 5045/ http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.ME01.01.5 12/7/2004...
  • Page 88 Work descriptions Page 69 of 83 Commercially available hydrometer Inspection service (Batteries with "magic eye" ) Perform a visual check 01-5, Performing visual check (all batteries) and check battery condition via "magic eye" 01-5, Checking batteries / batteries with magic eye and with top-sealed battery cell plugs Inspection service (Batteries without "magic eye"...
  • Page 89 Work descriptions Page 70 of 83 If battery is not securely seated, following dangers exist: Shortened service life due to damage from vibration (danger of explosion). If battery is not secured properly normal shock and vibration can damage battery plates, which results in premature battery failure.
  • Page 90 Work descriptions Page 71 of 83 Three different color indications are possible: Green battery is sufficiently charged. Black no charge or charge too low (repair measure). Colorless or yellow critical acid level reached, distilled water must be topped up 01-5, Topping off distilled water (batteries with magic eye) .
  • Page 91 Work descriptions Page 72 of 83 - load current varies depending on battery capacity, and has to be adjusted on tester. User manual for battery tester - Perform battery load test according to user manual for battery tester and compare test printout - arrow - with following table.
  • Page 92 Work descriptions Page 73 of 83 drop rapidly to below displayed minimum voltage. After test has been performed, voltage will remain at this low value for a long time, and will climb back up only very slowly. Printout from battery Inspection tester service...
  • Page 93 Work descriptions Page 74 of 83 - Screw in battery sealing plugs. Checking acid level (batteries without magic eye) Markings on battery housing - arrow - Note: Maintaining correct electrolyte level in battery is an important factor affecting length of battery's service life.
  • Page 94 Work descriptions Page 75 of 83 To avoid electrolyte impurities, which can increase self- discharge of battery, only distilled water may be added to increase acid level. - Unscrew battery sealing plugs. - Using battery fill bottle VAS 5045/ fill with distilled water up to max.-marking.
  • Page 95 Work descriptions Page 76 of 83 Observe disposal regulations! - Screw in battery sealing plugs. Checking battery / batteries with magic eye and without battery cell plugs These batteries can be recognized by "magic eye" - 1 - and a cover - 2 - (as shown in illustration). Note: "magic eye"...
  • Page 96 Work descriptions Page 77 of 83 - Colorless or yellow battery must be replaced. Idle speed (Diesel engine code AAZ): Checking Required special tools and equipment Ignition tester V.A.G 1767/ Ignition tester V.A.G 1367 Test- and adjustment requirements and specified values Emissions test Perform following work procedure: - Ignition tester V.A.G 1367 or Ignition tester V.A.G 1767/...
  • Page 97 Work descriptions Page 78 of 83 Required special tools and equipment headlight adjuster VAS 5046/ headlight adjuster VAS 5047/ headlight adjuster VAS 5208 headlight adjuster VAS 5209 Following test- and adjustment instructions are applicable to all countries. But national legislation and regulations of respective country is to be adhered to.
  • Page 98 Work descriptions Page 79 of 83 fuel gauge in lbs (kg) 100 (45) 66 (30) 33 (15) Full 0 (0) Example: If tank is filled half way, an additional weight of 66 lbs (30 kg) must be placed into luggage compartment. Note: As additional weight it is recommended to use fuel canisters filled with water (a 5-liter fuel canister...
  • Page 99 Work descriptions Page 80 of 83 - With low beam switched on, check whether horizontal light-dark border contacts hyphenated line - 1 - of test surface. - Check whether break-away point - 2 - between left horizontal part and rising part on right of light-dark border runs vertically through central point - 3 - .
  • Page 100 Work descriptions Page 81 of 83 For previous test screen with 15 -setting line, adjust as for new test screen. To avoid incorrect settings ignore 15 -setting line. Fog lights: - Check whether upper light-dark border touches setting line and runs across complete test screen width horizontally. Other auxiliary headlights: Later inserted auxiliary headlights of other systems must be checked and adjusted according to guidelines valid for...
  • Page 101 Work descriptions Page 82 of 83 Both adjustment wheels on right headlight are allocated symmetrically. Note: Also check whether reflectors in both headlights adjust themselves uniformly when operating headlight range control. Fog light (left) - Turn adjusting screw toward left (arrow) to lower beam height.
  • Page 102 Work descriptions Page 83 of 83 - Clutch: Pulling away, pedal pressure, odors - Gear selection: Ease of operation, shift lever position - Automatic transmission: Selector lever position, shift lock / ignition key removal lock, shift behavior, instrument panel cluster display - Foot-operated and hand-operated parking brake: Function, free travel and effectiveness, pulling to one side, juddering, squeal...
  • Page 103 http://listado.mercadolibre.com.mx/_CustId_67027869 rodcasti@gmail.com...

This manual is also suitable for:

Passat 1996Passat 1995

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