Volkswagen Passat 1997 Manuals

Manuals and User Guides for Volkswagen Passat 1997. We have 6 Volkswagen Passat 1997 manuals available for free PDF download: Repair Manual, Official Factory Repair Manual, Workshop Manual, User Manual

VOLKSWAGEN Passat 1997 Repair Manual (370 pages)

Brand: VOLKSWAGEN | Category: Automobile | Size: 12.04 MB

Front Suspension
3
Rear Suspension
3
General, Technical Data
3
Anti-Lock Brake System
4
Brakes - Mechanical Components
4
Wheels, Tires, Wheel Alignment
4
Brakes - Hydraulic Components
5
Steering
6
Suspension, Wheels, Brakes, Steering
7
Technical Data
7
Brakes
9
Wheels, Tires
12
Front Suspension, Servicing (Base Suspension)
15
Sub-Frame, Stabilizer Bar and Control Arm (Base Suspension)
16
Hex Bolt, 35 Nm (26 Ft Lb) and Ball Joint
17
Air Deflector Plate
17
Control Arm
17
Captive Lock Nuts
17
Table of Contents
18
Connecting Link
18
Control Arm Front Mounting
18
Control Arm Rear Mounting
18
Hex Bolt M 12 X 1.5 X 82/65/78
18
Connecting Link Mounting
19
Self-Locking Hex Nut, 25 Nm (18 Ft Lb)
19
Sub-Frame
19
Washer
19
Vibration Damper/Cap Nut
20
Stabilizer Bar Mounting/Clamp
20
Self-Locking Hex Nut, 25Nm (18 Ft Lb)
20
Hex Bolt, 65 Nm (48 Ft Lb)/25 Nm (18 Ft Lb)
20
Front Control Arm Mounting, Pressing in
21
Front Control Arm Mounting, Pressingout
21
Control Arm Rear Mounting, Installation Position
22
Control Arm Rear Mounting, Pressing out and in
22
Supporting Engine/Transmission Assembly with 10-222 a and Legs 10-222 A/1
23
Ball Joint, Checking (Base and Plus Suspension)
24
Checking Axial Clearance
24
Checking Radial Play
24
Reworking Cap Nut in Side Member (Base and Plus Suspension)
25
When Drilling out Proceed as Follows
25
Bolt/Washer Assemblies for Sub-Frame
26
Wheel Bearing, Suspension Strut and Drive Shaft, Removing and Installing (Base Running Gear)
28
Self-Locking Nut, 265 Nm (195 Ft Lb)
29
Hub
29
Brake Disc/Caliper
29
Hex Bolt, 10 Nm (7 Ft Lb)
30
Speed Sensor Rotor
30
Splash Plate
30
Wheel Bearing Housing
30
Drive Shaft and Circlip
31
Self-Locking Bolt/Washer Assembly, 125 Nm (92 Ft Lb)
31
Self-Locking Hex Nut, 95Nm (70 Ft Lb)
31
Socket Head Multi-Point Bolt, 45 Nm (33 Ft Lb)
31
Bracket
32
Self-Locking Hex Nut, 60 Nm (44 Ft Lb)
32
Suspension Strut Bearing
32
Tie Rod
32
Fig. 2
32
- Suspension Strut to Body, Loosening and Tightening
  33
- Wheel Bearing Housing/Suspension Strut Joint, Separating
  33
Fig. 1
33
Nm (52 Ft Lb) and Turn 90 Further
42
Pressing out Fig
42
Connecting Link

42
- With Rubber Mounting
  42
  - Mounting Forconnecting Link
    43
  - Hex Bolt M 12 X 1.5 X 82
    43
  - Hex Bolt, 65 Nm (48 Ft Lb)
    43
  - Clamp for Stabilizer Bar
    43
- Nm (37 Ft Lb) and Turn 90 Further
  43
  - Stabilizer Bar Mounting
    44
  - Cap Nut
    44
  - Control Arm Front Mounting, Pressing out and in
    45
  - Engine/Transmission Assembly, Supporting with 10-222 a and 10-222 A/3
    46
  - Ball Joint, Removing and Installing (Plus Running Gear)
    47
  - Removing
    47
  - Installing
    48
  - Tightening Torques
    49
  - Wheel Bearing and Suspension Strut, Removing and Installing (Plus Suspension)
    50
  - Wheel Bolt, 110 Nm (81 Ft Lb) and Self-Locking 12-Point Nut
    50
  - Screw
    50
  - Brake Disc
    50
  - Brake Caliper
    51
  - Countersunk Screw
    51
  - Wheel Bearing
    52
  - Self-Locking Hex Nut, 35 Nm (26 Ft Lb)
    52
  - Self-Locking Bolt/Washer, 125 Nm (92 Ft Lb)
    52
  - Drive Shaft
    52
  - Hex Bolt
    53
  - Stop
    53
  - Self-Locking Hex Nut, 60 and 95 Nm (44 and 70 Ft Lb)
    53
  - Suspension Strut
    53
  - Inner Race, Pulling off Hub
    55
  - Drive Shaft, Removing and Installing (Plus Running Gear)
    57
  - Drive Shaft, Repairing
    60
  - Drive Shaft, Removing and Installing
    60
  - Circlip
    61
  - Gasket
    61
  - Inner Constant Velocity Joint 100 MM Diameter
    61
  - Dished Washer
    61
  - Boot for 100 MM Diameter Constant Velocity Joint
    62
  - Clamp
    62
  - Boot for 90 MM Diameter Constant Velocity Joint
    63
  - Dished/Thrust Washer
    64
  - Outer Constant Velocity Joint, 90 MM Diameter
    64
  - Vibration Damper
    65
  - Protective Cap
    66
  - Hex Bolt, 35 Nm (26 Ftlb)
    66
- Boot for 90 MM
  66
- Diameter Constant
  66
- Velocity Joint
  66
- Polyester Elastomer Version
  66
- Check for Tears and Chafing
  66
- Briefly Ventilate Boot
  66
- Before Tensioning the Small Clamp Fig
  66
  - Vibration Damper, Removing and Installing
    67
  - Vibration Damper, Installation Position
    67
- Installation Position for
  67
- Fig. 1
  67
- Clamp
  80
- Always Replace
  80
- And Fig
  80
  - Inner Splined Screw, 45 Nm (33 Ft Lb)
    81
  - Drive Shaft, Right, with Inner Tripod Joint
    81
  - Constant Velocity Joint, Outer, Removing
    82
  - Boot, Ventilating
    82
  - Clamp, Tightening on Large Diameter
    83
  - Clamp, Tightening on Small Diameter
    83
  - Drive Axle with Triple-Rotor Joint, Removing and Installing
    84
  - Removing Right-Side Drive Axle
    84
  - Removing Left-Side Drive Axle
    84
  - Drive Axle with Triple-Rotorjoint, Servicing
    87
  - Outer Constant Velocity (CV) Joint
    87
  - Belleville Spring
    87
  - Boot
    87
  - Cover
    88
  - Rectangular Sealing Ring
    88
  - O-Ring
    88
  - Triple-Rotor Star
    88
  - Removing Outer CV Joint
    89
  - Tightening Outer CV Joint Boot Clamp
    90
  - Tightening Small End Clamp
    90
  - Triple-Rotor Joint, Disassembling
    91
  - Triple-Rotor Joint, Assembling
    94
  - Rear Wheel Suspension, Shafts and Axle
    97
  - Rear Axle, Servicing (Vehicles with Front Wheel Drive)
    97
  - Wheel Bolt 110 Nm (81 Ft Lb)
    97
  - Self-Locking Hex Nut, 70Nm (52 Ft Lb)
    97
  - 80 Nm (59 Ft Lb)
    98
  - Shouldered Bolt, 70 Nm (52 Ft Lb)
    98
  - Mounting Bracket with Retainer for Brake Pressure Regulator
    99
  - Regulator Spring Bracket
    99
  - Bonded Rubber Mounting
    99
  - Axle Beam
    99
  - Suspension Strut at Body, Removing and Installing
    100
  - Suspension Strut, Removing and Installing
    101
  - Bolting Mounting Bracket to Axle Beam
    101
  - Bonded Rubber Mounting, Pressing 1St/2St Half out of Axle Beam
    102
  - Rubber Bonded Mounting, Installation Position
    103
  - Rubber Bonded Mounting, Presssing into Axle Beam
    103
  - Reworking Cap Nut in Side Member (Front Wheel Drive Vehicles)
    104
  - Suspension Strut, Disassembling and Assembling (Front Wheel Drive Vehicles)
    105
  - Upper Rubber Mounting
    105
  - Gasket (Foam)
    105
  - Spacer Tube
    106
  - Lower Rubber Mounting
    106
  - Metal Cap
    106
  - Spring Seat
    106
  - Stop Buffer
    107
  - Protective Tube
    107
  - Plastic Cap
    107
  - Coil Spring
    107
  - Spring Seat, Installation Position
    109
  - Suspension Strut Mounting to Shock Absorber Bushing, Aligning
    110
  - Cap in Suspension Strut Mounting, Pressing in
    110
  - Drum Brakes (Front Wheel Drive Vehicles), Wheel Bearings, Servicing
    111
  - Grease Cap
    111
  - Cotter Pin
    112
  - Hex Nut
    112
  - Locking Ring
    112
  - Stub Axle
    112
  - Brake Backing Plate
    113
  - Oil Seal
    113
  - Hex Bolt, 60 Nm (44 Ft Lb)
    113
  - Inner Wheel Bearing
    113
  - Brake Drum
    114
  - Grease Cap, Pressing off
    115
  - Grease Cap, Driving on
    116
  - Wheel Bearing Play, Adjusting
    116
  - Brake Shoe Adjustment, Releasing
    117
  - Outer Wheel Bearing Outer Race, Pressing in
    117
  - Inner Wheel Bearing Outer Race, Pressing in
    118
  - Oil Seal, Driving in
    118
  - Rotor, Pressing in
    119
  - Wheel Bearings, Servicing - Disc Brakes (Front Wheel Drive Vehicles)
    120
  - Hex Socket Head Bolt, 10 Nm (7 Ft Lb)
    120
  - Speed Sensor
    121
  - Brake Hose Bracket
    121
  - Guide Pins
    121
  - Pad Retaining Spring
    121
  - Cover Ring
    122
  - Pad Carrier
    122
  - Brake Pads
    122
  - Outer Wheel Bearing
    122
  - Thrust Washer
    123
  - Wheel Bolt, 110 Nm (81 Ft Lb)
    123
  - Backing Plate
    124
  - Parking Brake Cable
    124
  - Spring Clip
    124
  - Cover Ring, Installation Position
    127
  - Rear Axle, Servicing (Four Heel Drive Vehicles)
    129
  - Final Drive Mounting Bracket and Carrier
    130
  - Propshaft
    131
  - Anti-Roll Bar
    131
  - Rear Axle Mounting Bracket
    131
  - Hex Bolt, 85 Nm (63 Ft Lb)
    132
  - Hex Bolt for Seat Belt Strut, 25 Nm (18 Ft Lb)
    132
  - Suspension Strut from Control Arm, Removing and Installing
    133
  - Driveshaft and Drive Axle, Removing and Installing at Differential
    133
  - Stabilizer Bar, Removing and Installing
    134
  - Control Arm, Removing and Installing
    135
  - Rubber Bonded Mounting, Removing
    135
  - Bonded Rubber Mounting, Installing
    136
  - Rubber Mounting to Correct Camber/Toe
    137
  - Final Drive, Removing and Installing from Axle Beam
    138
  - Installation Position, Determining
    139
  - Rubber Bonded Mounting, Installing
    139
  - Mounting Bracket and Final Drive Carrier, Removing and Installing
    140
  - Remove and Install Complete
    140
  - Final Drive Bonded Rubber Bushing, Pressing in and out
    140
  - Mounting Bracket on Body, Removing and Installing
    141
  - Rear Drive Shafts, Servicing
    142
  - Inner Constant Velocity Joint, 81 MM Diameter
    143
  - Boot for 94 MM Diameter Constant Velocity Joint
    144
  - Hose Clamp
    144
  - Boot for 81 MM Diameter Constant Velocity Joint
    145
  - Outer Constant Velocity Joint: 81 MM Diameter
    146
  - Inner Support Rings
    146
  - Reworking Cap Nut in Side Member (Four Wheel Drive Vehicles)
    147
  - Suspension Strut, Disassembling and Assembling (Four Wheel Drive Vehicles)
    149
  - Seal
    149
  - Self Locking Hex Nut, 30 Nm (22 Ft Lb)
    149
  - Stop Buffer Mounting
    150
  - Ring (Aluminium)
    150
  - Packing
    151
  - Lower Spring Plate
    151
  - Lower Spring Plate, Installation Position
    152
  - Suspension Strut Mounting to Spring Seat, Installation Position
    153
  - Cap, Pressing into Suspension Strut Mounting
    154
  - Wheel Bearings, Servicing - Disc Brakes (Four-Wheel Drive Vehicles)
    155
  - Self Locking Hex Socket Head Bolt, 60 Nm (44 Ft Lb)
    155
  - Self Locking Hex Bolt, 35 Nm (26 Ft Lb)
    155
  - Pad Securing Springs
    156
  - Self-Locking Hex Nut
    157
  - Shim
    157
  - Drive Shaft with Speed Sensor Rotor
    159
  - Brake Line
    159
  - Hub, Pressing out
    160
  - Wheel Bearing, Pressing out
    160
  - Inner Race, Pulling off of Hub
    161
  - Wheel Bearing, Pressing in
    161
  - Hub, Pressing in
    162
  - Speed Sensor Rotor, Pressing in
    162
  - Vehicle Alignment
    163
  - Test Requirements
    163
  - Vehicle Alignment Specifications (Front Wheel Drive Vehicles)
    164
  - Vehicle Alignment Specifications (Four Wheel Drive Vehicles)
    166
  - Front Wheel Camber, Adjusting
    168
  - Calculating the Direction of Travel
    169
  - Anti-Locking Brake System (ABS) and Anti-Locking Brake System with Electronic Differential Lock (ABS/EDL) Teves 04
    170
  - Notes for Repair Work on ABS, ABS/EDL
    171
  - Control Module, Removing and Installing
    173
  - Location
    173
  - Wheel Speed Sensor and Rotor for Speed Sensor, Removing and Installing
    174
  - Rotors
    174
  - Rear Axle
    174
  - Anti-Lock Brake System (ABS) and ABS with Electronic Differential Lock (ABS/EDL), Teves 20 GI
    175
  - Safety Precautions
    176
  - ABS, ABS/EDL Hydraulic Unit, Vacuum Brake Booster and Brake Master Cylinder (Teves 20 GI), Servicing
    178
  - Brake Servo (Vacuum Brake Booster)
    178
  - Brake Master Cylinder
    178
  - Brake Fluid Reservoir
    178
  - Rubber Damper
    179
  - Retainer
    179
  - ABS Hydraulic Unit/Control Module
    179
  - Brake Line Connection
    179
  - ABS Hydraulic Unit and ABS Control Module (Teves 20 GI), Removing and Installing
    180
  - Sealing Plug Kit Part No. 1H0 698 311 A:
    180
  - Brake Hydraulic System, Bleeding and Filling
    186
  - Vehicles with ABS/EDL
    186
  - Assembly Overview - Hydraulic Unit, Brake Servo/Brake Master Cylinder
    187
  - Brake Pedal Position Sensor
    187
  - Sealing Ring
    188
  - Brake Servo
    188
  - Carrier Plate
    188
  - Pin
    188
  - Hex Socket Head Screw for Brake Fluid Reservoir
    189
  - Series Resistor
    189
  - Tandem Brake Master Cylinder
    189
  - Protective Plate
    189
  - ABS Hydraulic Unit
    190
  - ABS/EDL Hydraulic Unit
    190
  - Torx Bolts (T 25)
    190
  - Hydraulic Unit, Removing and Installing
    192
  - Brake Pedal Position Sensor, Removing and Installing
    194
  - Front Brakes, Servicing (Girling Caliper)
    197
  - Brake Disc, Not Ventilated
    198
  - Brake Disc, Ventilated
    198
  - Brake Pad
    199
  - Wheel Speed Sensor Rotor
    199
  - Brake Carrier with Guide Pins and Protective Caps
    200
  - Heat Shield
    200
  - Brake Caliper Housing
    200
  - Self-Locking Hex Bolt, 35 Nm (26 Ft Lb)
    201
  - Guide Pin
    201
  - Ribbed Bolt, 125 Nm (92 Ft Lb)
    201
  - Brake Pads, Removing and Installing
    202
  - Retaining Spring
    205
  - Brake Carrier
    205
  - Guide Pins, 25 Nm (18 Ft Lb)
    206
  - Banjo Bolt, 30 Nm (22 Ft Lb)
    206
  - Countersunk Bolt
    207
  - Rear Wheel Brakes, Servicing (Drum Brakes)
    211
  - Wheel Speed Sensor
    213
  - Backing Plate with Brake Shoes
    213
  - Rear Wheel Brakes, Servicing
    215
  - After Working on the Rear Wheel Brakes
    215
  - Spring Plate
    215
  - Brake Shoe with Lever for Parking Brake
    215
  - Upper Return Spring
    216
  - Lower Return Spring
    216
  - Wedge Spring
    216
  - Brake Shoe
    216
  - Wheel Cylinder
    217
  - Wedge
    217
  - Push Rod
    217
  - Locating Spring
    217
  - Wheel Cylinder, Checking for Leaks
    218
  - Brake Shoes, Removing and Installing
    219
  - Parking Brake, Adjusting (Drum Brakes)
    222
  - Rear Wheel Brakes, Servicing (Disc Brakes)
    223
  - Girling Rear Wheel Disc Brakes (Front and Four Wheel Drive Vehicles)
    223
- Hex Socket Head Bolt
  223
- Nm (7 Ft Lb)
  223
- Wheel Speed Sensor
  223
- Abs
  223
- Insert with Lubricating Paste
  223
  - Hex Socket Head Bolt, 65 Nm (48 Ft Lb)
    224
  - Self-Locking Bolt, 35 Nm (26 Ft Lb)
    224
  - Pad Retaining Springs
    224
  - Backing Plate Ring
    224
  - Brake Carrier with Guide Pins and Protective Cap
    225
  - Dished Spring Washer
    228
- Hex Bolt, 60 Nm (44 Ft Lb)
  228
  - Parking Brake, Adjusting (Disc Brakes)
    232
  - Parking Brake Lever Assembly Overview
    233
  - Hand Grip
    233
  - Adjusting Nut
    233
  - Lock Nut
    234
  - Compensator
    234
  - Parking Brake Lever Trim
    234
  - Parking Brake Cable Installation Position
    235
  - Hand Grip, Removing
    235
  - Center Console, Removing
    236
  - Brake Pedal/Brake Servo, Removing and Installing
    237
  - Brake Pedal Return Spring
    238
  - Return Spring Mounting Tube
    238
  - Brake Pedal Mounting Bushing
    238
  - Brake/Clutch Pedal
    238
  - Securing Clip
    239
  - Brake Light Switch
    239
  - Brake Pedal, Removing and Installing
    240
  - Brake Light Switch, Adjusting
    241
  - Assembly Overview: Brake Master Cylinder/Brake Servo
    242
  - Self-Locking Hex Nut, 20 Nm (15 Ft Lb)
    242
  - Mounting Bracket
    242
  - Sealing Plug
    244
  - Non-Return Valve
    245
  - Girling Front Brake Caliper, Servicing
    246
  - Protective Seal
    246
  - Bleed Valve
    246
  - Piston
    247
  - Front Brake Caliper Pistons, Removing and Installing
    248
  - Front Brake Caliper, Servicing (Teves/Ate)
    251
  - Guide Pin, 25 Nm (18 Ft Lb)
    251
  - Mounting Bushing
    251
  - Piston Seal
    252
  - Piston, Pressing out of Cylinder Using Compressed Air
    253
  - Piston Seal, Removing
    253
  - Protective Seal, Installing
    254
  - Piston, Installing
    255
  - Rear Brake Caliper, Servicing
    256
  - Self-Locking Bolts, 35 Nm (26 Ft Lb)
    256
  - Dust Cap
    257
  - Bleeder Valve
    257
  - Brake Caliper Housing with Parking Brake Cable Lever
    258
  - Brake Carrier with Guide Pin and Protective Cap
    259
  - Rear Brake Caliper Piston, Removing and Installing
    260
  - Pre-Bleeding Brake Caliper
    263
  - Brake Pressure Regulator, Checking and Adjusting
    264
  - Vehicles Without ABS, Vehicles with ABS, ABS/EDS, Teves 04
    264
  - Checking Operation
    264
  - Checking and Adjusting Pressure
    264
  - Load Dependent Brake Pressure Regulator Specifications
    266
  - Adjusting Regulator
    267
  - Brake System, Bleeding (Vehicles with and Without ABS, ABS/EDL)
    268
  - Changing Brake Fluid
    268
  - Brake System, Bleeding (with Pressure Bleeder VAS 5234)
    269
  - Bleeding Sequence
    269
  - Brake System, Bleeding (Without Pressure Bleeder)
    270
  - Assembly Overview: Steering Column, Column Tube, Steering Wheel and Airbag Steering Wheel
    271
  - Cover Plate
    272
  - Hex Nut, 50 Nm (37 Ft Lb)
    272
  - Airbag Unit
    272
  - Steering Wheel for Airbag
    272
  - Steering Column Switch/Steering Lock Housing
    273
  - Upper Trim
    273
  - Support Ring
    273
  - Steering Column
    273
  - Lower Steering Column Bearing
    274
  - Shear Bolt
    274
  - Column Tube
    274
  - Lower Trim
    274
  - Splined Adapter Sleeve, Removing
    275
  - Splined Adapter Sleeve, Installing
    275
  - Length of Steering Column, Checking
    276
  - Steering Column, Pre-Assembling
    276
  - Airbag Unit, Removing and Installing
    277
  - Airbag Steering Wheel, Removing and Installing
    278
  - Airbag Spiral Spring, Removing and Installing
    280
  - Column Tube for Height Adjustable Steering Wheel, Removing and Installing
    281
  - Operating Lever
    281
  - Packing Plate
    281
  - Rubber Stop
    281
  - Clamping Sleeve
    282
  - Bolt with Left-Hand Thread
    282
  - Locking Plate Nut, 8 Nm (70 In. Ib)
    282
  - Pump Delivery Pressure, Checking
    283
  - Power Steering Gear, Removing and Installing
    285
  - Assembly Overview: Power Assisted Steering Box (TRW)
    289
  - Self-Locking Nut 35 Nm (26 Ft Lb)
    290
  - Self-Locking 30 Nm (22 Ft Lb)
    290
  - Rubber Mounting
    290
  - Right-Hand Tie Rod
    290
  - Left-Hand Tie Rod
    291
  - Hex Nut 50 Nm (37 Ft Lb)
    291
  - Steering Gear
    292
  - Tie Rod End
    292
  - Hex Nut 30 Nm (22 Ft Lb)
    292
  - Universal Joint
    292
  - Threaded Connection 30 Nm (22 Ft Lb)
    293
  - Power Steering Gear, Adjusting (TRW)
    294
  - Adjusting Steering Box
    294
  - Power Steering Gear, Disassembling and Reassembling (TRW)
    295
  - Lock Washer
    296
  - Toothed Rod Guide
    296
  - Pressure Compensating Tube
    297
  - Toothed Rod
    297
  - Plug
    297
  - Adjusting Screw with Lock Nut, 60 Nm (44 Ft Lb)
    298
  - Pressure Spring/Piece
    298
  - Housing
    298
  - Inverted Tube Nut, 30 Nm (22 Ft Lb)
    298
  - Valve Body
    299
  - Adhesive Film
    299
  - Roller Bearing
    300
  - Ball Bearing
    300
  - Self-Locking Hex Nut, 30 Nm (22 Ft Lb)
    300
  - Locking Screw, 40 Nm (30 Ft Lb)
    300
  - Pipe
    301
  - Power Steering Gear, Disassembling
    302
  - Inner Sealing Ring for Toothed Rod, Pulling out
    308
  - Parts, Cleaning and Checking
    309
  - Checking Toothed Rod for Scoring
    310
  - Sealing Ring on Toothed Rod, Replacing
    311
  - Sealing Rings, Installing on Toothed Rod Piston
    312
  - Power Steering Gear, Assembling
    313
  - Inner Sealing Ring for Toothed Rod, Installing
    314
  - Toothed Rod, Installing in Housing
    315
  - Valve Body, Installing
    317
  - Adhesive Tape, Applying
    320
  - Power Steering Gear, Adjusting with New Toothed Rod
    321
  - Assembly Overview: Power Steering Gear (ZF)
    324
  - Power Steering Gear
    325
  - Hose Clip
    325
  - Lock Nut, 50 Nm (37 Ft Lb)
    328
  - Tie Rod Ball Joint
    328
  - Pressure Balance Pipe
    328
  - Data Plate and Company Initials
    328
  - Power Steering Gear, Adjusting (ZF)
    329
  - Power Steering Gear, Disassembling and Reassembling (ZF)
    330
  - Center Roller Bearing for Valve Body, Removing
    335
  - Sealing Ring for Valve Body, Removing
    336
  - Inner Sealing Ring for Toothed Rod, Removing
    337
  - Inner Sealing Rod for Toothed Rod, Installing
    341
  - Toothed Rod, Installing in the Housing
    343
  - Tie Rods, Removing and Installing (Power Steering Gear - TRW and ZF)
    347
  - Boot, Installing
    351
  - Tension Hose Clamps with Pliers VAG 1275 or Equivalent
    352
  - Left-Hand Tie Rod Length, Checking and Adjusting
    354
  - Assembly Overview: Vane Pump, Reservoir and Hydraulic Lines (Vehicles with 4-Cyl. Engines)
    355
  - Cooling Line
    356
  - Suction Line
    356
  - Hydraulic Pump
    356
  - Pressure Line Union
    357
  - Banjo Bolt, 35 Nm (26 Ft Lb)
    357
  - Assembly Overview: Hydraulic Lines, Reservoir (Vehicles with 4-Cyl. Engines)
    358
  - Return Line, 30 Nm (22 Ft Lb)
    358
  - Pressure Line, 30 Nm (22 Ft Lb)
    358
  - Rubber Ring
    358
  - Self-Tapping Screw
    359
  - Hose/Return/Suction Clamp
    359
  - Threaded Stud
    359
  - Power Steering Vane Pump, Removing and Installing (Vehicles with 4-Cyl. Engines)
    360
  - Suction Hose
    360
  - Tensioning Bolt
    360
  - 20 Nm (15 Ft Ib)
    361
  - Front Swivel Bracket
    361
  - Adjustment Bracket
    361
  - V-Belts
    361
  - V-Belt Pulley
    362
  - 20 Nm (15 Ft Lb)
    362
  - Rear Swivel Bracket
    362
  - Vane Pump
    362
  - V-Belts, Tensioning (4-Cyl. Engines)
    363
  - Specification
    363
  - Assembly Overview: Pressure and Coolingl Ines (Vehicles with VR6 Engine)
    364
  - Reservoir
    364
  - Hose Clamp, 3 Nm (27 In. Lb)
    364
  - Return Line
    365
  - Pressure Hose, Securing (Vehicles with Manual Transmission)
    366
  - Pressure Hose, Securing (Vehicles with Automatic Transmission)
    366
  - Power Steering Vane Pump, Removing and Installing (Vehicles with VR6 Engine)
    367
  - Ribbed Belts
    368
  - Hex Socket Head Bolt, 25 Nm (18 Ft Lb)
    369
  - Hex Bolt, M8 X 30, 25 Nm (18 Ft Lb)
    369
  - Hex Socket Head Bolt, M8 X 20, 25 Nm (18 Ft Lb)
    369
  - Hex Socket Head Bolt, M8 X 30, 25 Nm (18 Ft Lb)
    369

Volkswagen Passat 1997 Official Factory Repair Manual (307 pages)

Gasoline, Turbo Diesel, TDI,4-cylinder and VR6, including wagon

Brand: Volkswagen | Category: Automobile | Size: 8.47 MB

Electronic Component Locations

21
Table of Contents

72
- Display 1 Is
  74
- Switched off
  74
  - Repair Manual, 2.0
    76
- Switched on
  74
- 1.8 Liter Fuel Injection
  76
- Fuel Injection & Ignition
  76
- Ignition or 2.8 Liter VR6
  76
- Fuel Injection & Ignition, Repair Group
  84
  - J217
    86
  - Bring System into Basic Settings
    86
  - Input Gear
    305
    
    Adjusting
    305
  - Drive Pinion
    305
    
    Adjusting
    306
  - Differential
    307
    
    Adjusting
    307

Volkswagen Passat 1997 Workshop Manual (180 pages)

Brand: Volkswagen | Category: Automobile | Size: 1.72 MB

Volkswagen Passat 1997 User Manual (123 pages)

Construction and operation

Brand: Volkswagen | Category: Automobile | Size: 9.74 MB

Table of Contents
3
The Passat '97
4
- Dimensions and Weights
  5
- The Platform - an Advantage for Workshops
  6
- Platform
  7
- Common Parts
  7
- System Parts
  7
Environmental Protection and Recycling
8
- Solvents
  9
- Energy + Resources
  9
- The Passat in the Wind Tunnel
  10
Body
10
- Fully-Galvanised Body
  11
- Stability and Structure
  12
- High-Strength Panels
  13
- The Rear Bumpers
  13
- Body Platform
  14
Vehicle Safety
15
- Crashworthiness
  16
- Airbag Systems
  17
- The Seat Belt Tensioner
  18
- 1.6-Ltr. Engine AHL
  19
- 1.8-Ltr. 5V Engine ADR
  19
Engines and Gearboxes
19
- 1.8-Ltr. 5V Turbo Engine AEB
  20
- 2.8-Ltr. V6 Engine ACK
  20
- 2.3-Ltr. VR5 Engine AGZ
  21
- 1.9-Ltr. TDI Engine AHU
  22
- 1.9-Ltr. TDI Engine AFN
  22
- Range of Engines and Gearboxes
  23
- 5-Speed Manual Gearbox 012/01W
  24
- 5-Speed Manual Gearbox 01A
  24
- 5-Speed Automatic Gearbox 01V
  25
- 4-Speed Automatic Gearbox 01N
  25
- The Four-Link Front Suspension
  26
Running Gear
26
- The Torsion Beam Rear Suspension
  27
- The Double-Wishbone Rear Suspension
  28
- Disc Brakes, Front
  29
- Disc Brakes, Rear
  29
Brakes
29
Height and Reach Adjustment of Steering Column
30
Steering
30
Decentralised Vehicle Electrical System
31
Electrics
31
- Dash Panel Insert
  32
- Fuel Gauge
  33
- Gas Discharge Headlights
  34
- Electronic Headlight Range Control
  34
- Fan Jet Nozzle
  35
- Mode of Operation
  35
- Extended Central Locking System
  36
Extended Systems
36
- Functions of the Extended Central Locking System
  37
- The Heater
  38
- The Climatronic
  39
- The Air-Conditioning
  40
- Navigation
  41
- Navigation Computer with CD-ROM Drive
  42
- Control Unit with Control and Loudspeaker
  42
- Display Integrated in Dash Panel Insert
  42
- ABS Wheel Speed Sensor
  43
- Earth Magnetic Field Sensor
  43
- GPS Sensor
  43
- Cellular Phone Preparation
  44
- Drive Shafts
  51
- Gearbox
  51
- Overview of Topics
  51
- Abs/Edl
  52
- Mode of Operation of the Restraint Systems
  53
- Effect of the Restraint Systems During Minor Accidents
  54
- The Effect of the Restraint Systems During Serious Accidents
  55
- Side Airbag
  56
- Side Airbag Design
  57
- Crash Sensors G179/G180
  58
- Airbag Control Unit J234
  59
- Belt Tensioner
  60
- Functional Description of Front Belt Tensioner
  61
- Rear Belt Tensioner
  62
- Belt Force Limiter
  64
- The Rear Belt Tensioner
  66
- Short Intake Path
  67
- Long Intake Path
  67
- Twin Path Intake Manifold
  67
- Electric Circuit
  68
- System Overview
  69
- Function Diagram 1.8-Ltr. 5V Turbo Engine AEB
  70
- Variable Valve Timing
  73
- Performance Position
  74
- Torque Position
  74
- Variable Valve Timer
  75
- Variable Valve Timing in the V6 Engine
  76
- Idling
  76
- Function Diagram of 2.8-Ltr. 6V Engine ACK
  78
- Radiator Fan Run-On
  81
- Test Your Knowledge
  82
- Magnesium
  83
- Electrochemical Voltage Series
  84
- Excerpt from Electrochemical Voltage Series
  84
- Triple Roller Constant Velocity Joint
  87
- Torsion Beam Rear Axle
  90
- V Section of Torsion Beam Rear Axle
  91
- Hub/Wheel Bearing Unit
  92
- Double Wishbone Rear Axle
  93
- ABS/EDL Control Unit
  97
- ABS Speed Sensor
  98
- Signal Utilisation
  98
- Effect of Signal Failure
  98
- Function Diagram
  99
- Gas Discharge Lamp
  102
- Gas Discharge Headlight
  103
- Automatic Headlight Range Control
  104
- Emergency Operation
  105
- Self-Diagnosis
  105
- Headlight Position in Emergency Operation
  105
- Refrigerant Circuit
  107
- Climatronic
  108
- Sensors
  109
- Actuators
  110
- Ventilation Flap and the Fresh/Air Recirculation Flap
  111
- Fresh Air Mode
  111
- Ventilation Mode
  111
- Colour Code
  111
- Air Recirculation Mode
  112
- Central Flap
  113
- Fresh Air Blower V2
  114
- Sunshine Penetration Photosensor G107
  115
- Diagonal Sunlight Penetration
  116
- Vertical Sunlight Penetration
  116
- Effects of Signal Failure
  116
- Self-Diagnosis Fault Message
  116
- Footwell Outlet Temperature Sender G192
  117
- Central Outlet Temperature Sender G191
  117

Volkswagen Passat 1997 Repair Manual (143 pages)

Brand: Volkswagen | Category: Automobile | Size: 4.27 MB

Table of Contents

10
- Heater Core
  16
- Replacing
  16
- Always Replace Coolant
  16
- Removal/Replacement
  16
- Air Duct with Main Shut-Off Flap
  17
- Fig. 1
  20
- Installing
  31
Exterior, Interior, Repair Group

85
- Compressor
  99
- Removing
  105
- First Discharge Refrigerant Circuit
  106
- Exterior, Interior, Repair Group
  108
- Remove Front Bumper
  108
- Repair Manual, Body Exterior, Interior, Repair Group
  108

Volkswagen Passat 1997 Official Factory Repair Manual (103 pages)

Gasoline, Turbo Diesel, TDI 4-cylinder and VR6, including wagon

Brand: Volkswagen | Category: Automobile | Size: 1.67 MB

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