Page 1 Service Workshop Manual Passat 1997 ➤ Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) AUG AWM AWT Engine ID Edition 08.2011 Service Department. Technical Information...
Page 2 In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed. All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2015 Volkswagen AG, Wolfsburg K0050609620...
Page 3: Table Of Contents
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Contents 00 - Technical data ........... .
Page 4 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 19 - Cooling ............84 Removing and installing parts of cooling system .
Page 5 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Checking fuel system for leaks ..........168 21 - Turbocharging/supercharging .
Page 6 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Contents...
Page 7: Technical Data
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 00 – Technical data Engine number The engine number -arrow- („code letters“ and „serial number“) can be found to the left on the cylinder block.
Page 8: Engine Data
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Engine data Edition 02.2011 version 10.0 Engine code Manufactured 05.00 ► 10.00 11.00 ► 10.00 ► Capacity Output kW at rpm 110/5700...
Page 9: Removing And Installing Engine
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 10 – Removing and installing engine Removing and installing engine Special tools and workshop equipment required ♦ Gearbox support -3147- ♦ Hooks -10-222 A/2- ♦...
Page 10 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 ♦ Drip tray -V.A.G 1306- ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- ♦ Engine and gearbox jack - V.A.G 1383 A- ♦...
Page 11: Notes On Removing
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 ♦ Engine and gearbox sup‐ port supplement -VW 540/1B- ♦ Workshop hoist -V.A.G 1202 A- ♦ Stepladder -VAS 5085- ♦ Bracket -T10059- ♦...
Page 12 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Caution When doing any repair work, especially in the engine compart‐ ment, pay attention to the following due to the cramped condi‐...
Page 13 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Disconnect ATF line connections -arrows- and catch ATF which escapes. Vehicles with air conditioner – Observe additional information and installation work ⇒...
Page 14 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Remove crankcase breather pipe -1-. – Detach pressure pipe -2- at combination valve -arrow- and detach from cylinder head cover. – Detach combination valve with bracket -3- and lay to side.
Page 15 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Secure modified support -T10062- in centre hole on right of sump. To do this use original bolt with the 3 original washers (each 4 mm thick) -arrow- and tighten to 30 Nm.
Page 16: Notes On Installing
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Attach lifting tackle -2024 A- with lifting eye -T10059- as fol‐ lows and lift slightly with workshop crane -1202 A- : Belt pulley end: 2nd hole in hook rail at position 2.
Page 17 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Caution When doing any repair work, especially in the engine compart‐ ment, pay attention to the following due to the cramped condi‐...
Page 18: Specified Torques
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Replenish coolant ⇒ page 91 – Check headlight adjustment and correct if necessary ⇒ Main‐ tenance ; Booklet 36 Vehicles with automatic gearbox –...
Page 19: Additional Information And Assembly Work For Vehicles With Air Conditioner
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 1 - Cross tube ❑ With torque support 2 - Stop buffer 3 - Stop ❑ Allow to move onto stop buffer under its own weight and tighten se‐...
Page 20 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Secure air conditioner compressor and condenser to body so that the refrigerant lines are not under tension. Rep. gr.10 - Removing and installing engine...
Page 21: Crankshaft Group
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 13 – Crankshaft group Dismantling and assembling engine Assembly overview ⇒ page 15 Removing and installing air conditioner poly V-belt ⇒ page 19...
Page 22 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 1.1.1 Part I 1 - 10 Nm ❑ Renew. 2 - Toothed belt guard centre part 3 - Toothed belt guard upper...
Page 23 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 19 - 15 Nm 20 - Crankshaft toothed belt pulley 21 - 90 Nm + / 4 turn (90°) further ❑ Renew.
Page 24 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 1.1.2 Part II 1 - Knock sensor 1 -G61- 2 - 20 Nm ❑ The specified torque in‐ fluences the function of the knock sensor.
Page 25: Removing And Installing Air Conditioner Compressor Poly V-Belt
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 ❑ Opening begins at approx. 86 °C. ❑ Opening lift at least 7 mm. 23 - 20 Nm 24 - Support ❑ Between compact bracket and intake manifold.
Page 26: Removing And Installing Poly V-Belt
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Loosen air conditioner compressor poly V-belt tensioner se‐ curing bolts and remove poly V-belt. Installing – Fit air conditioner compressor poly V-belt.
Page 27: Removing And Installing Sealing Flanges And Flywheel Or Drive Plate
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Removing and installing sealing flanges and flywheel or drive plate Assembly overview ⇒ page 21 Renewing crankshaft oil seal - belt pulley end ⇒...
Page 28: Renewing Crankshaft Oil Seal - Pulley End
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 9 - Intermediate plate ❑ Must seat on dowel sleeves. ❑ Do not damage or bend when assembling. 10 - Sealing flange with oil seal ❑...
Page 29 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Remove stop -1- -arrows-. – Remove crankshaft toothed belt pulley. To do this, counter‐ hold pulley with counterhold -3415- . – To guide seal extractor, screw centre bolt into crankshaft to stop by hand.
Page 30: Removing And Installing Front Sealing Flange
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Remove oil residue from crankshaft journal using clean cloth. – Fit guide sleeve -T10053/1- onto crankshaft journal. – Slide oil seal over guide sleeve onto crankshaft journal.
Page 31 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Special tools and workshop equipment required ♦ Counterhold tool -3415- ♦ Assembly tool -T10053- ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- ♦...
Page 32 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Remove crankshaft toothed belt pulley. To do this, counter‐ hold pulley with counterhold -3415- . – Drain engine oil. – Remove sump ⇒...
Page 33: Removing And Installing Drive Plate
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Cut off tube nozzle at forward marking (∅ of nozzle approx. 3 mm). – Apply silicone sealing compound, as shown, to clean sealing flange sealing surface.
Page 34 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 ♦ Counterhold tool -3067- ♦ Depth gauge Loosening and tightening drive plate – To loosen and tighten bolts reverse counterhold -3067- .
Page 35 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Remove drive plate again and fit shim -2-. Tighten bolts to 30 Nm again. – Tighten bolts to 60 Nm and turn 90° (1/4 turn) further (turning further can be done in several stages).
Page 36: Removing And Installing Crankshaft
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Removing and installing crankshaft Assembly overview ⇒ page 30 Pulling needle bearing out of and driving into crankshaft ⇒ page 32 Crankshaft dimensions ⇒...
Page 37 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 8 - Needle bearing ❑ Vehicles with manual gearbox only. ❑ Pulling out and driving in ⇒ page 32 9 - Sender wheel ❑...
Page 38: Pulling Needle Roller Bearing Out Of And Driving Into Crankshaft
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Pulling needle roller bearing out of and driving into crankshaft Special tools and workshop equipment required ♦ Kukko -21/2- and Kukko -22/1- ♦...
Page 39: Crankshaft Dimensions
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Removing – Pull needle roller bearing out using puller -A-, e.g. Kukko -21/2- and Kukko -22/1- . Installing – Drive in with drift -VW 207 C- or centring mandrel -3176- .
Page 40 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Honing dimension Main journal ∅ Conrod journal ∅ (in mm) -0.037 -0.042 Rep. gr.13 - Crankshaft group...
Page 41: Dismantling And Assembling Pistons And Conrods
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Dismantling and assembling pistons and conrods Assembly overview ⇒ page 35 Piston and cylinder dimensions ⇒ page 38 Assembly overview 1 - Piston rings ❑...
Page 42 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 7 - Cylinder block ❑ Checking cylinder bores ⇒ page 38 ❑ Piston and cylinder dimensions ⇒ page 38 8 - Conrod bearing cap ❑...
Page 43 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Special tools and workshop equipment required ♦ Feeler gauges Test procedure – Clean annular groove before check. Piston ring Clearance Wear limit Compression rings 0.06…0.09...
Page 44: Piston And Cylinder Dimensions
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Checking cylinder bores Special tools and workshop equipment required ♦ Internal dial test indicator 50…100 mm Test procedure – Take measurements at 3 positions in both lateral direction -A- and longitudinal direction -B-.
Page 45: Cylinder Head, Valve Gear
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 15 – Cylinder head, valve gear Removing and installing cylinder head Assembly overview ⇒ page 39 Removing, installing and tensioning toothed belt ⇒...
Page 46 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 1 - Pipe ❑ For crankcase breather 2 - Pressure pipe ❑ For combination valve. 3 - 10 Nm 4 - Cylinder head cover 5 - Cylinder head cover gasket ❑...
Page 47: Removing, Installing And Tensioning Toothed Belt
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Checking cylinder head for distortion Max. permissible distortion: 0.1 mm. Removing, installing and tensioning toothed belt Special tools and workshop equipment required ♦...
Page 48 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Remove upper toothed belt guard. – Mark direction of rotation of toothed belt. – Turn crankshaft to TDC No. 1 cylinder.
Page 49 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – To release tension on toothed belt, loosen tensioner nut -1- and turn eccentric with pin wrench -3387- in -direction of arrow-.
Page 50 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Turn crankshaft to TDC No. 1 cylinder. – Fit toothed belt in the sequence: coolant pump, tensioning roller, camshaft pulley. – Tension toothed belt ⇒...
Page 51: Removing And Installing Cylinder Head
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Turn crankshaft two full turns and check whether camshaft and crankshaft marks align with their reference points. Tensioning roller from 08.00 (must be adjusted) –...
Page 52 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Special tools and workshop equipment required ♦ Polydrive key -3452- ♦ Drip tray -V.A.G 1306- ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- ♦...
Page 53 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Disconnect fuel supply and fuel return lines at fuel rail ⇒ page 192 – Seal lines so that fuel system is not contaminated by dirt.
Page 54: Checking Compression
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Fit new cylinder head gasket. ♦ Note position of centralising pins in cylinder block -arrows-. ♦ Note position of cylinder head gasket; part number must be readable.
Page 55 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Special tools and workshop equipment required ♦ Spark plug socket and ex‐ tension -3122 B- ♦ Torque wrench -V.A.G 1331- ♦ Compression tester -V.A.G...
Page 56 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Test procedure – Remove fuse No. 32 from fuse holder. Note Removing fuse 32 interrupts the voltage supply to the injectors. – Pull connectors off ignition coils.
Page 57: Repairing Valve Gear
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Repairing valve gear Assembly overview ⇒ page 51 Reworking valve seats ⇒ page 55 Renewing inlet camshaft oil seal ⇒ page 57 Renewing exhaust camshaft oil seal ⇒...
Page 58 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 1 - 65 Nm ❑ Use counterhold tool -3036- to loosen and tighten. 2 - Camshaft pulley ❑ Note installation posi‐ tion: the narrow web of...
Page 59 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 12 - Inlet camshaft bearing cap ❑ Installation position and installation sequence ⇒ page 63 , removing and installing camshaft. 13 - Double bearing cap ❑...
Page 60 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 27 - 25 Nm 28 - Hall sender -G40- 29 - 10 Nm Reworking cylinder head sealing surface The reworking dimension is measured through the cylinder head bolt holes.
Page 61: Reworking Valve Seats
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Wear limit: 0.2 mm Valve dimensions Caution Worn sodium filled exhaust valves must not be disposed of without first preparing the valves. They must be cut through in the centre of the stem with a hacksaw.
Page 62 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 ♦ Depth gauge ♦ Valve seat refacing tool Note When repairing engines with leaking valves, it is not sufficient ♦ to rework or renew valve seats and valves. Particularly on high...
Page 63: Renewing Inlet Camshaft Oil Seal
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Reworking inlet valve seat a = ∅ 26.2 mm b = Max. permissible reworking dimension c = 1.5…1.8 mm Z = Lower edge of cylinder head α...
Page 64 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Special tools and workshop equipment required ♦ Oil seal extractor -2085- ♦ Assembly tool -T10071- ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G...
Page 65: Renewing Exhaust Camshaft Oil Seal
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – To guide seal extractor, screw bolt -2085/1- fully into camshaft by hand. – Screw inner part of oil seal extractor -2085- two turns (approx.
Page 66 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Special tools and workshop equipment required ♦ Oil seal extractor -2085- ♦ Counterhold tool -3036- ♦ Assembly tool -T10071- ♦ Torque wrench -V.A.G 1331- ♦...
Page 67 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Set camshaft pulley to TDC No. 1 cylinder by turning crank‐ shaft. Marking on camshaft toothed belt pulley must align with mark on cylinder head cover.
Page 68: Checking Hydraulic Bucket Tappets
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Fit guide sleeve -T10071/1- onto camshaft journal. – Slide oil seal over guide sleeve onto camshaft journal. – Remove guide sleeve.
Page 69: Removing And Installing Camshafts
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Push bucket tappet down lightly with a wooden or plastic wedge. If when bucket tappet is pushed down, a 0.2 mm feeler gauge can be pushed between camshaft and bucket tappet, bucket tappet must be renewed.
Page 70 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Set camshaft pulley to TDC No. 1 cylinder by turning crank‐ shaft. Marking on camshaft toothed belt pulley must align with mark on cylinder head cover.
Page 71 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 2.6.2 Installing Note When camshafts are installed, cams for No. 1 cylinder must ♦ point upwards. When installing the bearing caps, ensure that the cap mark‐...
Page 72 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Tighten inlet and exhaust camshaft 2nd and 4th bearing caps alternately and diagonally to 10 Nm (take note of dowel sleeves).
Page 73: Checking Valve Guides
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Check position of camshafts to one another. • The two markings on the camshafts must be opposite the two arrows on the bearing caps -arrows-.
Page 74: Renewing Valve Stem Seals
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 ♦ Universal dial gauge bracket -VW 387- ♦ Dial gauge Test procedure – Insert new valve into guide. The end of the valve stem must be flush with the guide.
Page 75 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- ♦ Spark plug socket and ex‐...
Page 76 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Screw pressure hose -VW 653/3- into spark plug thread. – Secure valve spring tool -3362- to cylinder head with the tool securing bolts.
Page 77: Lubrication
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 17 – Lubrication Removing and installing parts of lu‐ brication system Note The oil level must not be above the max. mark - danger of ♦...
Page 78: Assembly Overview
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Note Engine oils conforming to VW standard 500 00, 501 01 or 502 00 can be used furthermore. The oil must then be changed every 12 months or every 15,000 km and the service interval display must be programmed accordingly.
Page 79 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 1 - Oil pump ❑ With 12 bar pressure re‐ lief valve. ❑ Before installing, check that both dowel sleeves for centring oil pump on cylinder block are fitted.
Page 80 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 20 - Oil drain plug, 30 Nm ❑ Renew plug with attached seal. 21 - Oil sump ❑ Clean sealing surface before fitting.
Page 81 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 14 - Banjo bolt, 30 Nm 15 - Gasket ❑ Renew. 16 - Oil pressure switch -F1- , 25 Nm ❑ 1.4 bar.
Page 82: Removing And Installing Oil Sump
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Removing and installing oil sump Special tools and workshop equipment required ♦ Support bracket -10-222A- with legs -10-222 A/1- ♦ Lifting tackle -2024A- ♦...
Page 83 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Unclip lower part -1- of starter cable retainer -arrows-. – Remove turbocharger oil return line from sump. Vehicles with automatic gearbox –...
Page 84 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Support subframe with workshop crane -V.A.G 1202A- . – First remove front bolts -2- and -3- on left and right-hand sides of subframe Then remove bolts -4-.
Page 85 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Loosen rear right gearbox mounting rear bolt -2- several turns, remove right gearbox mounting front bolt -1-. – Lower subframe slowly with workshop crane.
Page 86 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 1.3.2 Installing Note When installing sump with engine removed, ensure sump is ♦ flush with intermediate plate at flywheel end. This means that the sump protrudes 0.8 mm over cylinder block.
Page 87: Checking Oil Pressure And Oil Pressure Switch
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Apply silicone sealant -D 176 404 A2- as shown in figure to clean sealing surface of sump. Note Apply the sealant bead with particular care around the rear seal‐...
Page 88 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Special tools and workshop equipment required ♦ Oil pressure tester -V.A.G 1342- ♦ Diode test lamp -V.A.G 1527 B- ♦ Auxiliary measuring set - V.A.G 1594 A-...
Page 89 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 LED must not light up. – If the LED lights up, renew 1.4 bar oil pressure switch -F1- . If LED does not light up: –...
Page 90: Cooling
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 19 – Cooling Removing and installing parts of cool‐ ing system Caution When doing any repair work, especially in the engine compart‐...
Page 91 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 1 - Radiator ❑ Removing and installing ⇒ page 96 ❑ After renewing, renew entire coolant. ❑ With ATF cooler on ve‐...
Page 92: Assembly Overview - Parts Of Cooling System, Engine Side
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 15 - O-ring ❑ Renew if damaged. 16 - Plug, 10 Nm 17 - Lower coolant hose ❑ Secured to radiator and connection with a retaining clip.
Page 93 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 15 - Coolant hose ❑ Coolant hose schematic diagram ⇒ page 89 16 - Oil cooler ❑ Removing and installing ⇒ Item 22 (page 75) 17 - From heat exchanger ❑...
Page 94: Assembly Overview - Compact Bracket
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Assembly overview - compact bracket 1 - 25 Nm 2 - Tensioning element for poly V-belt ❑ Removing and installing poly V-belt ⇒...
Page 95: Coolant Hose Schematic Diagram
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Tightening sequence, compact bracket to cylinder block Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- Procedure – Fit compact bracket on cylinder block.
Page 96 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 1 - Heat exchanger for heater unit 2 - Lower coolant pipe 3 - Expansion tank 4 - Oil cooler 5 - Intake manifold...
Page 97: Draining And Filling Coolant
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Draining and filling coolant Special tools and workshop equipment required ♦ Refractometer -T10007- ♦ Drip tray -V.A.G 1306- ♦ Torque wrench -V.A.G 1331- ♦...
Page 98 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Pull off lower coolant hose retaining clip -arrow- and remove coolant hose from radiator. Note When bumper and air duct are removed in front of charge air cooler, the coolant can also be drained from radiator via the drain screw -arrow-, if necessary use auxiliary hose.
Page 99 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Note Use only coolant additive G 12 in accordance with ♦ TL VW 774 F. Identification: purple colour. G 12 and coolant additives marked „Conforming to ♦...
Page 100: Checking Cooling System For Leaks
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Screw the adapter for cooling system tester -V.A.G 1274/8- on expansion tank and extend it with adapter for cooling system tester -V.A.G 1274/10- .
Page 101 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Special tools and workshop equipment required ♦ Cooling system tester - V.A.G 1274- ♦ Adapter for cooling system tester -V.A.G 1274/8- ♦ Adapter for cooling system tester -V.A.G 1274/9-...
Page 102: Removing And Installing Radiator
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Checking pressure relief valve in filler cap – Place cooling system tester -V.A.G 1274- with adapter - V.A.G 1274/9- on filler cap.
Page 103 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Continuation for all vehicles – Remove power-assisted steering hydraulic oil cooling pipe -arrows- and lay free. Do not open hydraulic circuit. – Remove upper radiator securing pins and take out radiator forwards.
Page 104: Removing And Installing Coolant Pump
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Removing and installing coolant pump Special tools and workshop equipment required ♦ ♦ Refractometer -T10007- ♦ Drip tray -V.A.G 1306- ♦ Torque wrench -V.A.G 1331- ♦...
Page 105: Removing And Installing Viscous Fan Coupling
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Unscrew coolant pump securing bolts -1- and remove coolant pump -2-. Installing Installation is carried out in the reverse order. When installing, note the following: –...
Page 106: Removing And Installing Viscous Fan Mounting Bush
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Secure viscous coupling belt pulley with punch (5 mm ∅) -1-. – Remove viscous coupling securing bolt using an 8 mm hexa‐...
Page 107: Removing And Installing Thermostat
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Remove mounting bush circlip -arrow-. – Press mounting bush out of compact bracket using socket head bolt -3367/3- , the puller tube from assembly tool -3350- and the hexagon nut from assembly tool -3301- .
Page 108 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Remove air hose -1-. Note Disregard -item 2-. – To slacken poly V-belt, turn tensioning element in -direction of arrow-. – Remove poly V-belt from alternator pulley, release tensioning element.
Page 109: Removing And Installing Lower Coolant Pipe
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Remove coolant hose from connection -2-, release retaining clip for this. – Unscrew bolts -1-, remove connection, O-ring -3- and thermo‐...
Page 110 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Remove coolant hoses -1 and 3-. – Remove coolant expansion tank -2- -arrows-. – Separate electrical wiring on coolant shortage indicator switch -F66- at lower coolant expansion tank.
Page 111: Fuel Supply System
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 20 – Fuel supply system Removing and installing parts of fuel supply system - front wheel drive ve‐ hicles Note Hose connections must be secured with clips ⇒ Replacement ♦...
Page 112: Rules For Cleanliness
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 When removing and installing fuel gauge sender or fuel pump (fuel delivery unit) from a full or partly full fuel tank, observe the following: ♦...
Page 113 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 1 - Cap 2 - Seal ❑ Renew if damaged. 3 - Tank flap unit ❑ With rubber cup. 4 - Securing bolt 5 - Gravity valve ❑...
Page 114: Installation Position
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 13 - Union nut, 80 Nm ❑ Remove and install using union nut tool -3217- . ❑ Fit union nut tool -3217- on the three missing ribs.
Page 115: Draining Fuel Tank: Engine Code Awt
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 28 - Breather line ❑ Check for secure seating. ❑ Clipped onto fuel tank. Installation position of fuel delivery unit flange Mark -1- on flange must align with mark -2- on fuel tank.
Page 116: Removing And Installing Fuel Delivery Unit: Engine Code Awt
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 WARNING Secure fuel extractor -VAS 5190- earth wire to vehicle earth. – Remove filler cap from fuel tank filler neck. – Pull cone piece -2- off fuel extractor -VAS 5190- shaft -1-.
Page 117 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Special tools and workshop equipment required ♦ Union nut tool -3217- ♦ Fuel extractor -VAS 5091- ♦ Torque wrench -V.A.G 1332- Prerequisite •...
Page 118: Removing And Installing Fuel Gauge Sender: Engine Code Awt
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 WARNING Fuel supply lines are under pressure! Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.
Page 119: Assembly Overview - Fuel Tank With Attachments: Engine Codes Aug, Awm
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Release connector lugs on lines -3- and -4- and pull off. – Lift retaining tabs -1- and -2- using a screwdriver and pull fuel gauge sender off downwards -arrows-.
Page 120 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 11 - Breather line 12 - Supply line ❑ Black ❑ Clipped onto side of fuel tank. ❑ Check for secure seating.
Page 121 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 26 - Retaining ring ❑ Secured to body. 27 - 10 Nm 28 - Fuel filter ❑ Installation position: arrow points in direction of flow.
Page 122: Draining Fuel Tank: Engine Codes Aug, Awm
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Checking pressure retention valve From gravity valve the pressure retention valve is open in both directions of flow -arrow 1-. From changeover valve it is only open in one direction of flow -arrow 2-.
Page 123: Removing And Installing Fuel Delivery Unit: Engine Codes Aug, Awm
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Pull cone piece -2- off fuel extractor -VAS 5190- shaft -1-. – Make a mark -arrow- with insulating tape on suction hose.
Page 124 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Special tools and workshop equipment required ♦ Union nut tool -3217- ♦ Fuel extractor -VAS 5091- ♦ Torque wrench -V.A.G 1332- ♦ Fuel pump tool -3307- ♦...
Page 125 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 1.9.1 Removing – First check whether a coded radio is fitted. If so, obtain anti- theft coding. – Switch off ignition and all electrical consumers.
Page 126 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Pull off fuel gauge connector -1- on inside of flange. Note Connector -2- to fuel pump can remain connected. – Release and pull off return line -3- on inside of flange using release tool -T40020- .
Page 127 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Notch -1- now aligns with marking -3- (bayonet connection). – Connect fuel return line -2- on inside of flange. Note Always use a new O-ring for the return line.
Page 128: Removing And Installing Fuel Gauge Sender: Engine Codes Aug, Awm
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 1.10 Removing and installing fuel gauge sender: engine codes AUG, AWM Note To remove the union nut on flange the fuel tank must be max.
Page 129 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 ♦ Torque wrench -V.A.G 1331- Note Fuel tank must not be more than 1/2 full. ♦ If necessary drain fuel tank; engine code AWT: ⇒...
Page 130: Crash Fuel Shut-Off
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Pull supply hose -1- off inlet to fuel filter. – Mark return line -2- and breather line -3- and separate at con‐...
Page 131 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Special tools and workshop equipment required ♦ Pressure tester -V.A.G 1318- ♦ Adapter -V.A.G 1318/10- ♦ Adapter -V.A.G 1318/11- ♦ Adapter -V.A.G 1318/12- ♦...
Page 132 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 ♦ Auxiliary measuring set -V.A.G 1594 A- ♦ Multimeter -V.A.G 1715- Test prerequisites • Fuse 28 must be OK. • The battery voltage must be at least 11.5 V.
Page 133 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Open the threaded union -arrow- and catch escaping fuel with a cloth. Note To loosen union counterhold on fuel rail hexagon. Specified tor‐...
Page 134 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Compare quantity of fuel delivered with specification. *) Minimum delivery rate cm /30 s **) Voltage at fuel pump with engine not running and pump run‐...
Page 135 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Connect multimeter -V.A.G 1715- to 4-pin connector contact 1 -arrow- using current pick-up clamp. – Start engine and run at idling speed.
Page 136: Removing And Installing Parts Of Fuel Supply System - Four Wheel Drive Vehicles
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Removing and installing parts of fuel supply system - four wheel drive ve‐ hicles Note Hose connections must be secured with clips ⇒ Replacement ♦...
Page 137 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 1 - Cap 2 - Seal ❑ Renew if damaged. 3 - Securing bolt 4 - Tank flap unit ❑ With rubber cup.
Page 138 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 ❑ Check for secure seating. ❑ Secure with clips ⇒ Replacement Parts Department . 20 - Fuel gauge sender 3 -G237- ❑ Check ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.
Page 139: Assembly Overview - Fuel Tank With Attachments: Engine Codes Aug, Awm
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 34 - Earth connection ❑ Check for secure seating. Installation position of fuel delivery unit flange Mark -1- on flange must align with mark -2- on fuel tank.
Page 140 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 2.2.1 Fuel tank Filler neck connections ⇒ page 136 1 - Connector ❑ Black, 4-pin. ❑ For fuel gauge sender - G- and fuel pump -G6- .
Page 141 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 13 - From connecting hose ❑ ⇒ Item 18 (page 137) ❑ Check for secure seating. 14 - Breather line ❑ From activated charcoal filter to activated charcoal filter solenoid valve -N80- .
Page 142: Filler Neck
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 2.2.2 Filler neck Fuel tank connections ⇒ page 134 1 - Cap 2 - Seal ❑ Renew if damaged. 3 - Securing bolt 4 - Tank flap unit ❑...
Page 143 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 12 - 23 Nm 13 - Breather line ❑ To activated charcoal filter ⇒ Item 15 (page 167) ❑ Check for secure seating.
Page 144: Assembly Overview - Fuel Filter
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Checking pressure retention valve From gravity valve ⇒ Item 5 (page 136) pressure retention valve is open in both directions of flow -arrow 1-.
Page 145: Emptying Fuel Tank
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 1 - Banjo bolt, 30 Nm 2 - Seal ❑ Renew. 3 - Supply line ❑ Black ❑ Check for secure seat‐...
Page 146 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 ♦ Fuel extractor -VAS 5190- Procedure Observe safety precautions ⇒ page 105 Observe rules for cleanliness ⇒ page 106 – First check whether a coded radio is fitted. If so, obtain anti- theft coding.
Page 147: Removing And Installing Fuel Delivery Unit
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Screw shaft -1- of fuel extractor -VAS 5190- onto fuel tank filler neck. – Push extraction hose into fuel tank until marking on hose -arrow- coincides with shaft end.
Page 148 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Special tools and workshop equipment required ♦ Fuel tank sender unit tool -3087- ♦ Fuel pump tool -3307- ♦ Torque wrench -V.A.G 1332- ♦...
Page 149 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 WARNING Fuel supply line is pressurised. Wear eye protection and pro‐ tective clothing to avoid possible injury and skin contact. Before loosening hose connections, wrap a cloth around the connec‐...
Page 150 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Pull fuel return line -1- off junction -2-. To do this, release return line hose coupling using release tool -T40020- .
Page 151 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Turn fuel delivery unit approx. 15° clockwise onto stop with fuel pump tool -3307- . Notch -1- now aligns with marking -3- (bayonet connection).
Page 152: Removing And Installing Fuel Gauge Sender G
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Attach connectors -1- and -2- on inside of flange. ♦ White connector -1- for fuel gauge sender -G- on fuel supply side.
Page 153: Removing And Installing Fuel Gauge Sender 2 G169
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Removing and installing fuel gauge sender 2 -G169- Special tools and workshop equipment required ♦ Fuel tank sender unit tool -3087- ♦ Torque wrench -V.A.G 1332- Note The fuel tank must be max.
Page 154 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Reach into fuel tank and release retaining lugs -arrows- on bottom of suction-jet pump -2-. Note The sender is shown without the fuel tank for a clearer illustration.
Page 155: Removing And Installing Fuel Gauge Sender 3 G237
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Tighten locking ring using fuel tank sender unit tool -3087- . Specified torque: 145 Nm – Attach connector. – Read fault memories of all control units, rectify faults as nec‐...
Page 156 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Unscrew union nut with union nut tool -3218- . – Remove seal. – Remove fuel gauge sender 3 -G237- by turning anti-clockwise on its own axis -arrow-.
Page 157: Removing, Installing And Checking Suction-Jet Pumps
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Note correct installation position for fuel gauge sender 3 - G237- . Mark -2- on sender must align with mark -1- on fuel tank.
Page 158: Removing And Installing Fuel Tank
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Pull connector -6- off flange. – Pull junction piece -4- as far as possible to right. – Pull return line -7- off junction piece (press catch inwards).
Page 159 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 ♦ Torque wrench -V.A.G 1331- Note Fuel tank must not be more than 1/3 full. ♦ Empty fuel tank if necessary ⇒ page 139 ♦...
Page 160: Checking Fuel Pump
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Pull supply hose -1- off fuel filter. – Mark return line -2- and breather line -3- and separate at con‐ necting point.
Page 161 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Special tools and workshop equipment required ♦ Pressure tester -V.A.G 1318- ♦ Adapter -V.A.G 1318/10- ♦ Adapter -V.A.G 1318/11- ♦ Adapter -V.A.G 1318/12- ♦...
Page 162 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 ♦ Auxiliary measuring set -V.A.G 1594 A- ♦ Multimeter -V.A.G 1715- Test prerequisites • Fuse 28 must be OK. • The battery voltage must be at least 11.5 V.
Page 163 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Open the threaded union -arrow- and catch escaping fuel with a cloth. Note To loosen union counterhold on fuel rail hexagon. Specified tor‐...
Page 164 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Compare quantity of fuel delivered with specification. *) Minimum delivery rate cm /30 s **) Voltage at fuel pump with engine not running and pump run‐...
Page 165 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 2.11.2 Checking non-return valve for fuel pump Test prerequisites • Remote control -V.A.G 1348/3A- connected ⇒ page 156 • Pressure gauge -V.A.G 1318- connected to fuel supply line from fuel supply pipe ⇒...
Page 166: Electronic Power Control (Epc)
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Electronic power control (EPC) Function of EPC system ⇒ page 160 Assembly overview ⇒ page 160 Function of EPC system With the EPC system, the throttle valve is not operated by a cable from the accelerator There is no mechanical connection between the accelerator and the throttle valve.
Page 167 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 1 - Bearing bracket 2 - Connector ❑ Black, 6-pin. 3 - 10 Nm 4 - Accelerator position sender -G79 und G185- ❑...
Page 168: Active Charcoal Filter System: Engine Code Awt
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Active charcoal filter system: engine code AWT Note Hose connections must be secured with clips ⇒ Replacement Parts Department . Observe safety precautions ⇒...
Page 169 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 1 - Activated charcoal filter ❑ Location: in front right wheel housing. ❑ Secured to body. ❑ To remove, remove front right wheel hous‐...
Page 170: Schematic Diagram Of Activated Charcoal Filter System
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 ❑ Secured to body. Schematic diagram of activated charcoal filter system 1 - Tank flap unit 2 - Fuel tank 3 - Fuel delivery unit...
Page 171 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Pull breather line -2- from activated charcoal filter -1- off sol‐ enoid valve -3-. – Connect breather line to activated charcoal filter -2- to pres‐...
Page 172: Activated Charcoal Filter System: Engine Codes Aug, Awm
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Activated charcoal filter system: en‐ gine codes AUG, AWM Note Hose connections must be secured with clips ⇒ Replacement Parts Department .
Page 173 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 1 - Diagnostic pump bracket ❑ Bolted to body. 2 - Bolt 3 - Washer 4 - Fuel system diagnostic pump -V144- ❑...
Page 174: Schematic Diagram Of Activated Charcoal Filter System
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Schematic diagram of activated charcoal filter system 1 - Tank flap unit ❑ With rubber cup. 2 - Fuel tank ❑ When removing, sup‐...
Page 175 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Clamp off hose -A- between fuel system diagnostic pump - V144- and air filter using hose clip -3093- . – Connect K-Jetronic tester -V.A.G 1371- between activated charcoal filter system solenoid valve 1 -N80- and breather line as illustrated.
Page 176 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Open valve -A- on K-Jetronic tester -V.A.G 1371- . – Check the following lines and components for leaks by hear‐ ing, by touch, with commercially available leak detector spray or using ultrasonic tester -V.A.G 1842- .
Page 177: Turbocharging/Supercharging
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 21 – Turbocharging/supercharging Charge air system with turbocharger Note Charge air system must be free of leaks. ♦ Renew self-locking nuts. ♦...
Page 178: Rules For Cleanliness
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Rules for cleanliness When working on the turbocharger, pay careful attention to the following „5 rules“ for cleanliness: ♦ Thoroughly clean all unions and surrounding areas before dis‐...
Page 179 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 1 - Exhaust manifold 2 - Gasket ❑ Renew. ❑ Note installation posi‐ tion. 3 - Seal ❑ Renew. 4 - Union, 30 Nm...
Page 180: Removing And Installing Turbocharger
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 ❑ The charge pressure control valve and vacuum unit for charge pressure control valve are integral parts of turbocharger and cannot be replaced individually.
Page 181 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Unscrew turbocharger bracket -2-. – Unscrew oil return line -1- from turbocharger and lay to side. – Remove air hoses -4 and 5- from turbocharger.
Page 182 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Remove bolts -arrows-. – Remove air duct -1 and 2-. – Separate electrical connectors: On activated charcoal filter solenoid valve 1 -N80-...
Page 183 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Remove heat shield -3- from secondary air pipe -1- and from cylinder head cover. Note Disregard -item 2-. 1. Charge air system with turbocharger...
Page 184 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Unfasten sleeve on coolant return hose. – Clamp off coolant return hose to turbocharger using hose clips -3094- . – Remove coolant return hose -4- from turbocharger line; the line remains fitted on turbocharger.
Page 185: Assembly Overview - Parts Of Charge Air Cooling
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Specified torques Component Coolant supply line to turbocharger Bracket for coolant supply line to turbocharger 10 Turbocharger to exhaust manifold 1)2) Catalytic converter to turbocharger...
Page 186 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 1 - Intake hose 2 - From air filter. 3 - From activated charcoal fil‐ 4 - From crankcase breather 5 - To turbocharger.
Page 187: Schematic Diagram Of Turbocharging System
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Schematic diagram of turbocharging system 1 - Activated charcoal filter 2 - Breather line ❑ Engine code AWT - front-wheel drive: from...
Page 188 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 14 - Crankcase breather 15 - Secondary air inlet valve -N112- 16 - Non-return valve ❑ For activated charcoal filter system. 17 - Non-return valve ❑...
Page 189: Checking Charge Pressure System
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Checking charge pressure system Checking vacuum unit for charge pressure control valve ⇒ page 183 Checking overrun shut-off valve ⇒ page 183 Checking charge air system for leaks ⇒...
Page 190: Checking Charge Air System For Leaks
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 ♦ Hand vacuum pump with accessories -V.A.G 1390- Test prerequisite • Reduced performance or load change jolts • Vacuum hoses checked for porosity and kinks.
Page 191 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 ♦ Adapter -V.A.G 1687/1- – Remove intake hose ⇒ Item 1 (page 180) from air filter and from crankcase breather pipe. – Insert adapter -1687/1- into intake hose and seal crankcase breather connection with adapter -V.A.G 1687/4- Tighten hose...
Page 192 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Connect compressed air hose -1- (compressed air source) to charge air system tester -V.A.G 1687- . Note If there is water in the sight glass, drain at water drain screw -6-.
Page 193: Mixture Preparation - Injection
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 24 – Mixture preparation - injection Repairing injection system ⇒ „1.1 General notes on injection“, page 187 ⇒ „1.2 Safety precautions“, page 187 ⇒...
Page 194: Rules For Cleanliness
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 To prevent injuries to persons and/or damage to the injection and ignition system, the following must be observed: ♦ Do not touch or disconnect ignition cables when the engine is running or being turned at starter speed.
Page 195 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 1 - Air filter ❑ Assembly overview ⇒ page 191 2 - Lambda probe before cata‐ lytic converter -G39- , 50 Nm 3 - Lambda probe after catalyt‐...
Page 196 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 18 - Charge air pressure sender -G31- 19 - Knock sensor 2 -G66- ❑ ⇒ Item 7 (page 220) 20 - Knock sensor 1 -G61- ❑...
Page 197: Assembly Overview - Air Filter
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Assembly overview - air filter 1 - Air ducting ❑ To lock carrier. 2 - Filter element 3 - Seal 4 - Air mass meter -G70- ❑...
Page 198: Assembly Overview - Fuel Rail With Injectors
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Assembly overview - fuel rail with injectors 1 - Fuel pressure regulator ❑ Check ⇒ page 202 2 - O-ring ❑ Renew if damaged.
Page 199: Assembly Overview - Intake Manifold
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Assembly overview - intake manifold 1 - Gasket ❑ Note installation posi‐ tion. ❑ Renew. 2 - Nut ❑ 10 Nm 3 - Bolt ❑...
Page 200 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Remove engine cover -arrows-, to do this, loosen quick re‐ lease fasteners. – Drain coolant ⇒ page 91 – Remove coolant hoses -1- and -3-.
Page 201 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Disconnect electrical connector -arrow- on Hall sender -G40- . – Undo bolts for fuel rail and pull vacuum line off fuel pressure regulator -arrows-.
Page 202: Technical Data
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Remove intake manifold support -arrows-. – Disconnect hose -1- to activated charcoal filter solenoid valve 1 -N80- from intake manifold. – Pull oil dipstick out.
Page 203 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 7) Not adjustable, up-to-date figures: ⇒ Data sheets for exhaust emissions test ⇒ page 207 8) Renewing engine control unit 9) Up-to-date part number for engine control unit ⇒ Replacement Parts Department...
Page 204: Removing And Installing Air Mass Meter G70
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Removing and installing air mass me‐ ter -G70- Note Please check in the ⇒ Parts catalogue to see if an air mass ♦...
Page 205 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Note If the air filter element is very dirty or wet, dirt or water could ♦ reach the air mass meter -G70- and affect the air mass value.
Page 206: Checking Components
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Checking components Checking injectors ⇒ page 200 Checking fuel pressure regulator and holding pressure ⇒ page 202 Checking injectors Checking injectors for leaks and injection rate...
Page 207 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Test procedure – Connect test box -V.A.G 1598/31- to control unit wiring har‐ ness. The engine control unit remains disconnected. – Pull connectors off injectors.
Page 208: Checking Fuel Pressure Regulator And Holding Pressure
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Connect one contact of injector to be tested to engine earth using auxiliary cable from adapter set -V.A.G 1594 A- .
Page 209 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 ♦ Adapter set -V.A.G 1318/6 + 7- Test procedure – Remove fuse No. 28 (fuel pump) from fuse holder. WARNING Fuel supply line is pressurised. Wear eye protection and pro‐...
Page 210 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Pull vacuum hose off fuel pressure regulator -arrow-. The fuel pressure must increase to approx. 4.0 bar. If the specification is not attained: –...
Page 211: Engine Control Unit
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Engine control unit Reading and clearing engine control unit fault memory ⇒ page 205 Adapting functions and components ⇒ page 206 Renewing engine control unit ⇒...
Page 212: Adapting Functions And Components
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Connect diagnosis cable -VAS 5051/5A- or -VAS 5051/6A- to diagnosis connection. Continuation for all vehicles – Start engine and run at idling speed.
Page 213: Renewing Engine Control Unit
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Select „Function/component selection“. – Select „Drive train“. – Select „Engine code“. – Select „01 - Systems capable of self-diagnosis“. – Select „Engine management“.
Page 214: Exhaust System
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 26 – Exhaust system Removing and installing parts of ex‐ haust system Caution When doing any repair work, especially in the engine compart‐...
Page 215 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Special tools and workshop equipment required ♦ Lambda probe open ring spanner set -3337- ♦ Torque wrench -V.A.G 1331- ♦ Pneumatic sabre saw - V.A.G 1523 A-...
Page 216: Assembly Overview - Parts Of Exhaust System: Front-Wheel Drive Vehicles
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Assembly overview - parts of exhaust system: front-wheel drive vehicles 1 - 30 Nm ❑ Renew. ❑ Coat threads with high- temperature paste -G...
Page 217: Individual Parts
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Cut through connecting pipe at right angles on the separating point ⇒ Item 18 (page 211) with body saw e.g. -V.A.G 1523 A- .
Page 218: Assembly Overview - Parts Of Exhaust System: Four-Wheel Drive Vehicles
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Assembly overview - parts of exhaust system: four-wheel drive vehicles 1 - 30 Nm ❑ Renew. ❑ Coat threads with high- temperature paste -G...
Page 219 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 11 - Front exhaust pipe 12 - Washer 13 - 30 Nm ❑ Renew. ❑ Coat threads with high-temperature paste -G 052 112 A3-...
Page 220 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Installation position of double clamp The double clamp as seen from normal direction of travel – Install clamp so that ends of bolts do not protrude beyond bot‐...
Page 221: Secondary Air System
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Secondary air system Function ⇒ page 215 Assembly overview: parts of secondary air system ⇒ page 215 Checking combination valve ⇒ page 217...
Page 222 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 1 - Combination valve ❑ Check ⇒ page 217 2 - Gasket ❑ Renew. 3 - Bracket ❑ Bolted to cylinder head.
Page 223: Checking Combination Valve
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Secondary air pump relay -J299- -arrow- ♦ If tools are necessary to pull relays or control units out of the relay plate, first disconnect battery earth strap ♦...
Page 224 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Remove pressure hose -arrow- from secondary air pump mo‐ tor -V101- and blow in with slight pressure. Combination valve must be closed.
Page 225: Ignition System
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 28 – Ignition system Repairing ignition system General notes on ignition system ⇒ page 219 Safety precautions ⇒ page 219 Assembly overview - parts of ignition system ⇒...
Page 226 Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 1 - Connector ❑ Black, 4-pin. 2 - Ignition coil with output stage -N70, N127, N291, N292- ❑ Removing and installing ⇒ page 221 3 - Spark plug, 30 Nm ❑...
Page 227: Removing And Installing Ignition Coils With Output Stage
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 Removing and installing ignition coils with output stage Special tools and workshop equipment required ♦ Puller -T40039- Removing – Loosen clamping bolts -arrows- and remove engine cover up‐...
Page 228: Test Data, Spark Plugs
Passat 1997 ➤ , Passat Variant 1997 ➤ 4-cylinder injection engine (5-valve without intermediate shaft) - Edition 08.2011 – Connect 4-pin connector -2- to ignition coil -1-. – Fit engine cover and lock clamping bolts -arrows-. Test data, spark plugs...

This manual is also suitable for:

Passat variant 1997

Volkswagen Passat 1997 Workshop Manual

Quick Links

Need help?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Volkswagen Passat 1997

Summary of Contents for Volkswagen Passat 1997

This manual is also suitable for:

Table of Contents