Engine Azx Repair Manual Eng

Service
Workshop Manual
Passat 1997 ➤
5-cylinder injection engine (4-valve), mechanics
Engine ID AZX
Edition 12.2010
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
20 - Fuel supply system
26 - Exhaust system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Passat 1997 ➤
5-cylinder injection engine (4-valve), mechanics - Edition 12.2010
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Notes on removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4 Additional information and assembly work for vehicles with air conditioner . . . . . . . . . . . . 12
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1 Part I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2 Part II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2 Removing and installing sealing flange and dual mass flywheel/drive plate . . . . . . . . . . . . 21
2.1 Renewing crankshaft oil seal, vibration damper end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.2 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.1 Fitting sender wheel to crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.1 Installing piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.2 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.1 Removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.2 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.4 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.5 Adjusting valve timing (installing timing chains) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.6 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.1 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.2 Camshaft identification, valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.3 Dismantling and assembling valve timing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.4 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.5 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.6 Checking camshaft timing control/adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.7 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.8 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1 Removing and installing parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.2 Assembly overview - sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.3 Dismantling and assembling oil filter housing/engine mounting . . . . . . . . . . . . . . . . . . . . . . 80
1.4 Dismantling and assembling oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.5 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1.6 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Contents i
Passat 1997 ➤
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.1 Parts of cooling system, body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.2 Parts of cooling system, engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1.3 Dismantling and assembling compact bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.4 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.5 Dismantling and assembling thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.6 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.7 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.8 Removing and installing viscous fan coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
1.9 Removing and installing viscous fan mounting bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.10 Checking continued coolant circulation pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
1.1 Removing and installing fuel tank with attachments and fuel filter: vehicles with front-wheel
drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
1.2 Removing and installing fuel tank with attachments and fuel filter: vehicles with four-wheel
drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1.3 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 118
1.4 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.5 Removing, installing and checking suction-jet pump: vehicles with four-wheel drive . . . . . . 119
1.6 Crash fuel shut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1.7 Removing and installing fuel delivery unit: front-wheel drive vehicles . . . . . . . . . . . . . . . . 122
1.8 Removing and installing fuel delivery unit: four-wheel drive vehicles . . . . . . . . . . . . . . . . . . 123
1.9 Removing and installing fuel gauge sender: vehicles with front-wheel drive . . . . . . . . . . . . 126
1.10 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.11 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
2 Electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
2.1 Function of EPC system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
2.2 Repairing parts of electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
2.3 Checking accelerator position sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
3 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
3.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
3.2 Repairing parts of activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
3.3 Test solenoid valve 1 for activated charcoal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3.4 Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
1.1 Exhaust manifold, front exhaust pipe and catalytic converter with attachments . . . . . . . . 151
1.2 Silencers with mountings: vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1.3 Silencers with mountings: vehicles with four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . 155
1.4 Checking catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
2 Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2.1 Removing and installing parts of secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2.2 Checking secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
2.3 Checking secondary air pump motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
2.4 Checking combination valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
ii Contents
Passat 1997 ➤
00 – Technical data
1 Engine number
The engine number („engine code“ and „serial number“) -arrow-
is located next to the vibration damper on the cylinder block.
Additionally there is a sticker on the cylinder head cover with „en‐
gine code“ and „serial number“.
The engine code is also included on the vehicle data sticker.
The engine number consists of up to nine characters (alphanu‐
meric). The first part (maximum 3 characters) makes up the
„engine code“, and the second part (6 characters), the „serial
number“. If more than 999,999 engines with the same engine
code are produced, the first of the six characters is replaced with
a letter.
1. Engine number 1
Passat 1997 ➤
2 Engine data
Issued 12.2010; Version 2.0
Engine code AZX
Manufactured 01.01 ►
Emissions fulfil EU4 standard
Cylinder arrangement VR1)
Cylinder angle 15°
Capacity l 2.3
Output kW at rpm 125/6200
Torque Nm at rpm 220/3200
Bore ∅ mm 81.0
Stroke mm 90.3
Compression ratio 10.75
RON min. 98 unleaded2)
System designation Motronic ME7.1
Self-diagnosis OBD
Knock control 2 knock sensors
Lambda control 2 probes
Catalytic converter yes
Exhaust gas recirculation no
Turbocharging/supercharging no
Secondary air system yes
Electronic power control yes
Variable intake manifold yes
Camshaft timing control yes
1) VR = V-arrangement in compact in-line design

2) In exceptional circumstances min. 95 RON, however with reduced perform‐
ance.
Volkswagen Technical Site: https://vwts.ru
2 Rep. gr.00 - Technical data

Passat 1997 ➤
10 – Removing and installing engine

1 Removing and installing engine
Special tools and workshop

equipment required
♦ Gearbox support -3147-
♦ Engine bracket -3269-
♦ Lifting tackle -2024 A-
♦ Support bracket -10 - 222
A- with rack -10 - 222 A /1-
♦ Support clamp -VW 313-
♦ Workshop hoist -
V.A.G 1202 A-
♦ Drip tray -V.A.G 1306-
1. Removing and installing engine 3

Passat 1997 ➤
♦ Torque wrench (5…50 Nm)

-V.A.G 1331-
♦ Torque wrench (40…200
Nm) -V.A.G 1332-
♦ Spring-type clip pliers -
VAS 5024-
♦ Grease -G 000 100- (vehi‐
cles with manual gearbox)
♦ Cable ties
1.1 Notes on removing

– The engine is removed forwards without gearbox.
WARNING
When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant, refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ Ensure that there is sufficient clearance to all moving or
hot components.
– All cable ties which are opened or cut through when engine is
removed must be replaced in the same position when engine
is installed.
– First check whether a coded radio is fitted. If so, obtain anti-
theft coding.
4 Rep. gr.10 - Removing and installing engine

Passat 1997 ➤
– With the ignition switched off, disconnect battery earth strap.

– Remove engine cover.
– Remove air filter ⇒ Repairing injection system; Rep. gr. 24 ;
Dismantling and assembling air filter .
– Disconnect pressure hose -arrow- from pressure pipe.
Note
To release, press buttons on hose coupling together.
– Remove pressure pipe of secondary air system.

– Pull off necessary vacuum and breather hoses from engine.
– Remove front bumper ⇒ General body repairs, exterior; Rep.
gr. 63 ; Front bumper .
– Unbolt power steering hydraulic oil cooling pipe -arrows- and

lay free. Do not open hydraulic oil circuit.
Vehicles with automatic gearbox

Passat 1997 ➤
– Disconnect ATF line connections -arrows- and catch ATF

which escapes.
Continuation for all vehicles
– Drain coolant ⇒ page 99 .
– Pull off all coolant hoses to engine using spring-type clip pliers
-VAS 5024- .
– Unbolt cooling system expansion tank and lay to side.
– Remove lock carrier with attachments ⇒ General body repairs
exterior; Rep. gr. 50 ; Body - front; Removing and installing
lock carrier with attachments .
– Remove poly V-belt ⇒ page 19 .
– Remove power-assisted steering vane pump from compact
bracket and place to one side; hoses remain connected; ⇒
Running gear, axles, steering; Front and four-wheel drive;
Rep. gr. 48 ; Vane pump, reservoir, hydraulic lines for vehicles
with 4 or 5-cylinder engines .
Vehicles with air conditioner
– Observe additional information and installation work
⇒ page 12 .
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Removing
and installing starter on vehicles with 4, 5 and 6-cylinder en‐
gines .
– Remove front exhaust pipe with catalytic converter
⇒ page 151 , Exhaust manifold, front exhaust pipe with cata‐
lytic converter and attachments.
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.

Passat 1997 ➤
– Pull fuel supply line -1- (with white marking) and fuel return line
-2- (with blue marking) off fuel rail and catch fuel that escapes
in a cloth.
– Seal lines so that fuel system is not contaminated by dirt.
– Observe rules for cleanliness ⇒ page 119 .
– Unbolt earth wire -3-.
– Separate connectors from the following components:
♦ Coolant temperature sender -G62- with sender for coolant
temperature gauge -G2-
♦ Continued coolant circulation pump -V51-
♦ Inlet camshaft control valve 1 -N205-
♦ Exhaust camshaft control valve 1 -N318-
♦ Hall sender -G40-
♦ Hall sender 2 -G163-
♦ Oil level and oil temperature sender -G266-
♦ Throttle valve module -J338-
♦ Intake manifold changeover valve -N156- and secondary air
inlet valve -N112-
Note
Before removing connectors, mark each connector and compo‐

nent to which it belongs.
Fitting locations:⇒ Repairing injection system; Rep. gr. 24 ; Fit‐

ting locations - overview .
– Also disconnect connections from following components:

1- Lambda probe after catalytic converter -G130- , 4-pin con‐
nector, brown
2- Lambda probe -G39- , 6-pin connector, black
3- Engine speed sender -G28- , grey
4- Knock sensor 1 -G61- , brown
5- Knock sensor 2 -G66- , black
6- Injectors (N30…N33, N83) 10-pin coupling station
7- Ignition coils (N70, N127, N291, N292, N323), 8-pin cou‐
pling station
– Pull off or disconnect all other electrical connections as nec‐
essary from engine and lay to side.
– Remove lower securing nuts for left and right engine mount‐
ings.
– Loosen gearbox mounting securing nuts as far as possible, do
not remove.

Passat 1997 ➤
– Fit support bracket 10-222A as shown and lift engine at rear

lifting eye until lower engine/gearbox connecting bolts can be
removed.
Note
To relieve strain on support bracket spindle, lift engine at front

lifting eye using a workshop crane -V.A.G 1202 A- and hold en‐
gine in this position using the spindle.
– Remove lower engine/gearbox securing bolts.

– Carefully lower engine again.
Note
The pin in the engine mounting -arrow- must engage in the sub-
frame when lowering the engine.
– Remove upper engine/gearbox securing bolts.

– Separate torque converter from drive plate (3 securing nuts).
Note
After removing the engine, secure the torque converter against

„falling out“.
– Attach support bracket -10 - 222 A- as shown.

– Attach gearbox support -3147- to the gearbox bell housing bolt
hole (shown in illustration with engine removed).

Passat 1997 ➤
– Attach lifting tackle -2024 A- as follows and lift slightly with

workshop crane -V.A.G 1202 A- :
Belt pulley end: 4th hole in hook rail at position 1
Flywheel end: 4th hole in hook rail at position 8
WARNING
Use locking pins -arrows- to secure hooks and locating pins.
Note
♦ The positions marked 1…4 on the bar must be towards the

pulley end.
♦ The holes in the hook rails are counted up from the hook.
– Lift engine out forwards.
Note
Guide the engine carefully when lifting out, to prevent damage to

the bodywork.
When stripping and assembling the engine it should be secured

to the engine frame with engine bracket 3269.
Modifying engine bracket -3269-
With the introduction of the VR5 engine the engine bracket -3269-
must be modified by drilling additional holes. The holes must be
handled with corrosion protection.
– If not already modified, drill three 11 mm holes according to

dimensions given. Scribe dimensions from the centre line.
1.2 Notes on installing

Installation is carried out in the reverse order. When installing,
note the following:
Procedure
– Check whether dowel sleeves for centring engine and gearbox
are in cylinder block and install if necessary.
Vehicles with manual gearbox
– Clean input shaft splines and lightly grease with G 000 100.
– Check clutch release bearing for wear and renew if necessary.

Passat 1997 ➤
– Lightly grease clutch release bearing and splines on input

shaft with G 000 100 grease (do not grease release bearing
guide sleeve).
– Rock engine to align engine mountings stress-free.
– Renew engine mounting self-locking nut -1-.
Note
♦ The pin in the engine mounting -2- must engage in the sub-
frame when lowering the engine.
♦ Specified torques for engine and gearbox mountings
⇒ page 11 .
– Tighten gearbox mounting securing nuts.

– Install engine/gearbox connecting bolts.
Note
Specified torques ⇒ page 11 .
– Install front exhaust pipe with catalytic converter

⇒ page 151 , Exhaust manifold, front exhaust pipe with cata‐
lytic converter and attachments.
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Removing and
installing starter on vehicles with 4, 5 and 6-cylinder engines .
– Install air conditioner compressor ⇒ Heating, air conditioning;
Rep. gr. 87 ; Removing and installing air conditioner com‐
pressor bracket .
– Install power-assisted steering vane pump ⇒ Running gear,
axles, steering, front and four-wheel drive; Rep. gr. 48 ; Vane
pump, reservoir, hydraulic lines for vehicles with 4 or 5-cylin‐
der engines .
– Install poly V-belt ⇒ page 19 .
– Install air filter ⇒ Repairing injection system; Rep. gr. 24 ;
Dismantling and assembling air filter .
– Install lock carrier with add-on parts ⇒ General body repairs,
exterior; Rep. gr. 50 ; Removing and installing lock carrier with
add-on parts .
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
– Check headlight adjustment and correct if necessary ⇒ Main‐
tenance ; Booklet 36
– Install coolant expansion tank.
– Replenish coolant ⇒ page 99 .

Passat 1997 ➤
– Connect ATF lines -arrows- ⇒ 5-speed automatic gearbox

01V; Rep. gr. 37 ; Dismantling and assembling gearbox; Re‐
moving and installing ATF lines .
– Check ATF and replenish if necessary: ⇒ 5-speed automatic
gearbox 01V; Rep. gr. 37 ; Checking ATF level and replen‐
ishing .
– Relearn kick-down switch point ⇒ Engine control unit; Rep.
gr. 24 ; Learning kick-down switch point .
– Perform work sequence „Procedure after open circuit in volt‐
age supply“ ⇒ Engine control unit; Rep. gr. 24 ; Procedure
after open circuit in voltage supply .
– On vehicles with an automatic gearbox the gearbox control
unit must be additionally adapted ⇒ Self-diagnosis for 5-speed
automatic gearbox 01V and four-wheel drive; Rep. gr. 01 ;
Performing self-diagnosis: Initiating basic setting .
– Carry out a road test and read fault memory ⇒ Fault memory;
Rep. gr. 01 ; Reading and erasing fault memory .
1.2.1 Specified torques

Threaded connection Specified torque
Bolts, nuts M6 10 Nm
M7 15 Nm
M8 20 Nm
M10 45 Nm
M12 60 Nm
Deviations
Starter to gearbox 65 Nm
1.3 Assembly mountings

Assembly mounting, right
A = 40 Nm B = 23 Nm3)
3) Renew securing nuts

Passat 1997 ➤
Assembly mounting, left

A = 23 Nm B = 23 Nm4)
1.4 Additional information and assembly

work for vehicles with air conditioner
WARNING
The air conditioner refrigerant circuit must not be opened.
Note
♦ The opening of the refrigerant circuit can only be carried out

in workshops, which have trained personnel and the neces‐
sary range of tools and workshop equipment.
♦ To prevent damage to condenser and also refrigerant lines/
hoses, ensure that the lines and hoses are not stretched,
kinked or bent.
♦ When installing refrigerant lines/hoses, ensure that lines and
hoses are routed/installed so that they cannot be damaged or
come into contact with rotating parts.
To facilitate removing and installing engine without opening re‐

frigerant circuit:
– Remove retaining clamp(s) for refrigerant lines.
– Remove air conditioner compressor ⇒ Heating, air condition‐
ing; Rep. gr. 87 ; Removing and installing compressor bracket.
– Secure air conditioner compressor to body so that the refrig‐
erant lines are not under tension.

Passat 1997 ➤
13 – Crankshaft group
1 Dismantling and assembling engine
Note
When carrying out assembly work, secure engine to support

clamp -3269- using engine bracket -VW 313- .
Note
If when repairing an engine, metal shavings or large quantities of

small metal particles caused, for example, by partial seizure of
crankshaft and conrod bearings are found in the engine oil, one
must apart from thoroughly cleaning oil passages, renew all oil
spray jets, the oil non-return valve, the oil cooler and oil filter el‐
ement to prevent consequential damage.
I ⇒ page 14
1. Dismantling and assembling engine 13

Passat 1997 ➤
II ⇒ page 17
1.1 Part I
1 - Valve timing housing

❑ Lightly lubricate contact
surfaces of oil seals be‐
fore installing.
❑ Removing and installing
⇒ page 63 Removing
and installing cam‐
shafts.
❑ Dismantling and assem‐
bling ⇒ page 61 ,
⇒ page 61
❑ Before installing valve
timing housing, check
strainer for soiling
⇒ page 61 .
2 - 8 Nm
❑ Renew.
3 - Camshaft timing chain
❑ Before removing, mark
direction of rotation (in‐
stallation position)
⇒ page 16 .
❑ Installing ⇒ page 48
Adjusting valve timing.
4 - Exhaust camshaft adjuster
❑ Identification: 32A.
❑ Rotate engine only with
camshaft adjuster in‐
stalled.
❑ Checking camshaft tim‐
ing control
⇒ page 69 .
5 - Intermediate shaft
6 - Thrust washer
7 - 8 Nm
❑ Insert with locking fluid -D 000 600 A2- .
8 - Tensioning plate
❑ For camshaft timing chain ⇒ Item 3 (page 14)
9 - Chain tensioner, 40 Nm
❑ For camshaft timing chain ⇒ Item 3 (page 14)
❑ Only rotate engine when chain tensioner is installed.
10 - Seal
❑ Renew if damaged or leaking.
11 - Pivot pin, 18 Nm
❑ For tensioning rail ⇒ Item 8 (page 14)
12 - Chain sprocket
❑ For timing chain ⇒ Item 17 (page 15) .
14 Rep. gr.13 - Crankshaft group

Passat 1997 ➤
❑ Installing ⇒ page 48 Adjusting valve timing.
13 - Chain sprocket
❑ For camshaft roller chain ⇒ Item 3 (page 14)
14 - 60 Nm + 1/4 turn (90°) further
❑ Renew.
❑ Use counterhold -T10069- to loosen and tighten ⇒ page 48 , adjusting valve timing
15 - Chain tensioner with tensioning plate
❑ Before installing, release locking splines in chain tensioner using a small screwdriver and press tension‐
ing plate against chain tensioner.
❑ Only rotate engine when chain tensioner is installed.
16 - Drive sprocket
❑ Built into crankshaft.
❑ Ground down tooth aligned with main bearing joint = TDC No. 1 cylinder ⇒ page 48 , Adjusting valve
timing.
17 - Timing chain
❑ Before removing, mark direction of rotation (installation position) ⇒ page 16 .
18 - Guide rail
❑ Remove and install together with roller chain ⇒ page 48 Adjusting valve timing.
19 - Locating pin without collar, 10 Nm
❑ For guide rail ⇒ Item 18 (page 15) .
20 - 18 Nm
21 - 23 Nm
22 - Inlet camshaft adjuster
❑ Identification: 24E
❑ Rotate engine only with camshaft adjuster installed.
❑ Checking camshaft timing control ⇒ page 69 .
23 - 60 Nm + 1/4 turn (90°) further
❑ Renew.
❑ Contact surface of sender wheel must be dry around bolt head when assembled.
❑ To remove and install, counterhold using 32 mm open-end spanner on camshaft ⇒ page 63 Removing
and installing camshafts.
24 - Guide rail
25 - Exhaust camshaft control valve 1 -N318-
❑ For exhaust camshaft.
❑ Before removing, mark connector belonging to component.
❑ Check activation: ⇒ Final control diagnosis; Rep. gr. 01 ; Performing final control diagnosis .
26 - Inlet camshaft control valve 1 -N205-
❑ For inlet camshaft.

Passat 1997 ➤
❑ Check activation: ⇒ Final control diagnosis; Rep. gr. 01 ; Performing final control diagnosis .
27 - Guide rail
❑ Clipped into valve timing housing.
Marking timing chains

– Mark roller chains before removing (e.g. with paint, arrow
pointing in direction of rotation).
Note
Do not mark chain by way of centre punch, notch or the like.

Passat 1997 ➤
1.2 Part II
1 - 8 Nm
❑ Secured to intake mani‐
fold.
2 - Guide tube
❑ For dipstick.
❑ Secured with bolt to in‐
take manifold.
3 - Dipstick
❑ The oil level must not be
above the max. mark!
❑ Markings ⇒ page 77 .
4 - Oil non-return valve, 6 Nm
❑ Note installation posi‐
tion.
❑ Clean if badly soiled
❑ See note ⇒ page 13 .
5 - Knock sensor 1 -G61-
❑ 3-pin.
❑ Location: on right of cyl.
2.
❑ Checking ⇒ Fault mem‐
ory; Rep. gr. 01 ; Read‐
ing and erasing fault
memory .
6 - 20 Nm
❑ The torque setting influ‐
ences the function of the
knock sensor.
7 - 10 Nm
8 - Oil pump drive cover
9 - O-ring
❑ Renew. Volkswagen Technical Site: https://vwts.ru
❑ Lubricate before installing.
10 - Oil pump drive
11 - Cylinder block
❑ Removing and installing sealing flange and dual-mass flywheel ⇒ page 21 .
❑ Removing and installing crankshaft ⇒ page 27 .
❑ Dismantling and assembling pistons and conrods ⇒ page 29 .
13 - Thrust washer
14 - 8 Nm
15 - Drive shaft
❑ For oil pump drive.
16 - Engine speed sender -G28-
❑ Checking ⇒ Fault memory; Rep. gr. 01 ; Reading and erasing fault memory .

Passat 1997 ➤
17 - Oil pump
❑ Dismantling and assembling ⇒ page 81 .
❑ Coat oil pressure pipe with sealant -AMV 188 001 02- at cylinder block and oil pump housing.
18 - 23 Nm
19 - 40 Nm
20 - 8 Nm
21 - Oil drain plug, 30 Nm
❑ If seal is leaking, nip open and renew.
22 - Oil sump
❑ Clean sealing surface before fitting.
❑ Install with silicone sealant -D 176 404 A2- .
❑ Removing and installing ⇒ page 82 .
23 - Oil level and oil temperature sender -G266-
❑ Black connector, 3-pin.
❑ Checking: ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.
24 - Seal
❑ Renew.
25 - 12 Nm
26 - Seal
❑ Renew.
27 - Oil filter bracket/engine mounting
❑ Coolant hose schematic diagram ⇒ page 96 .
28 - 23 Nm
29 - Torque reaction support
30 - Fitting bolt, 25 Nm
❑ Observe tightening sequence ⇒ page 96 .
31 - 25 Nm
32 - Compact bracket
❑ For tensioner, viscous fan coupling, alternator, coolant pump and power-assisted steering vane pump.
33 - Coolant pipe
❑ To thermostat housing ⇒ Item 10 (page 37)
❑ Removing and installing ⇒ page 93 , Parts of cooling system - engine side.
34 - Knock sensor 2 -G66-
❑ 3-pin.
❑ Fitting location: between cylinder 3 and cylinder 5.
❑ Checking ⇒ Fault memory; Rep. gr. 01 ; Reading and erasing fault memory
35 - Vibration damper
❑ Removing and installing poly V-belt ⇒ page 19 .

Passat 1997 ➤
36 - 100 Nm + 1/4 turn (90°) further

❑ Renew.
❑ To loosen and tighten, use counterhold -T10069- ⇒ page 19
❑ Tighten using torque wrench -V.A.G 1601- .
To loosen and tighten securing bolt, secure vibration damper us‐

ing counterhold -T10069-
Note
♦ Renew securing bolt for vibration damper.

♦ Tighten securing bolt using torque wrench -V.A.G 1601- .
1.3 Removing and installing poly V-belt
Note
Before removing the poly V-belt mark the direction of rotation.

When installing belt ensure it is correctly seated in pulleys.

– Bring lock carrier into service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Lock carrier - service position .
– Mark direction of rotation of poly V-belt.
– Remove radiator fan from viscous fan coupling.
– Turn tensioning roller anticlockwise with a socket wrench
-arrow- until poly V-belt tension is relieved.
– Remove poly V-belt.
Installing poly V-belt
– Install in reverse order.
Note
♦ Specified torque for poly V-belt idler roller: 23 Nm

♦ Before installing poly V-belt, ensure that all ancillaries (alter‐
nator, air conditioner compressor, power-assisted steering
vane pump) are secured tightly.
♦ When installing poly V-belt, check direction of belt rotation and
proper seating of belt in pulleys.

Passat 1997 ➤
– Fit poly V-belt.

After completing repairs always:
– Start engine and check that belt runs properly.
– Install lock carrier with attachments ⇒ General body repairs,
exterior; Rep. gr. 50 ; Lock carrier service position .
– Fit engine cover.

Passat 1997 ➤
2 Removing and installing sealing

flange and dual mass flywheel/drive
plate
Note
♦ When carrying out assembly work, secure engine to support

♦ Repairing clutch ⇒ 5-speed manual gearbox 012/01W; Rep.
gr. 30 ; Repairing clutch .
1 - 100 Nm + 1/4 turn (90°) fur‐

ther
❑ Renew.
❑ Use counterhold tool -
T10069- to loosen and
tighten.
2 - Vibration damper
poly V-belt ⇒ page 19 .
3 - 8 Nm
4 - Seal
❑ PTFE oil seal:
❑ Identification: Without
inner coil spring.
❑ Do not additionally oil or
grease the oil seal seal‐
ing lip.
❑ Before installing, re‐
move oil residue from
crankshaft journal using
a clean cloth.
❑ Renewing ⇒ page 23 .
5 - Sealing flange
❑ Coat sealing surfaces
with sealant -AMV 188
001 02- .
6 - Cylinder block
crankshaft
⇒ page 27 .
bling pistons and con‐
rods ⇒ page 29 .
7 - Sealing flange
❑ Coat sealing surfaces with sealant -AMV 188 001 02- .
8 - Seal
❑ PTFE oil seal:
❑ Identification: Without inner coil spring.
❑ Do not additionally oil or grease the oil seal sealing lip.
❑ Before installing, remove oil residue from crankshaft journal using a clean cloth.
2. Removing and installing sealing flange and dual mass flywheel/drive plate 21
Passat 1997 ➤
❑ Remove using extractor hook -2086- .
❑ When installing: position using sleeve -2003/2A- .
❑ Pull onto to stop using fitting sleeve -2003/1- .
9 - Intermediate plate
❑ For gearbox attachment
❑ When installing, bolt to cylinder block first and only then fit sump
10 - 60 Nm + 1/2 turn (180°) further
❑ Renew.
❑ Use counterhold tool -T10069- to loosen and tighten.
11 - Dual mass flywheel/drive plate
❑ Removing and installing drive plate ⇒ page 25 .
12 - M10 - 45Nm M12 - 65Nm
13 - 23 Nm
14 - Spacer

Passat 1997 ➤
2.1 Renewing crankshaft oil seal, vibration damper end

equipment required
♦ Oil seal extractor -3203-
♦ Fitting sleeves -3266-
♦ Counterhold tool -T10069-
♦ Torque wrench -V.A.G
1332-
1601-
♦ Guide sleeve -T10053/1-
Removing
Passat 1997 ➤
– Remove vibration damper. To do this, lock vibration damper

using counterhold -T10069- .
– Screw inner part of oil seal extractor -3203- three turns (ap‐
prox. 4 mm) out of outer part and lock using knurled screw.
– Lubricate threaded head of oil seal extractor -3203- , place it

in position and while exerting firm pressure, screw it into oil
seal as far as possible.
– Loosen knurled screw and turn inner part against crankshaft
until the oil seal is pulled out.
Note
In place of oil seal with internal circular spring -1-, a PTFE oil seal
is being gradually introduced (Teflon) -2-. This has a wider sealing
lip. PTFE oil seals are installed free of oil and grease. When a
PTFE oil seal is installed as original equipment, then only a PTFE
oil seal may be installed as a replacement.
– Remove oil residue from crankshaft journal using clean cloth.
– Position guide sleeve -T10053/1- on front of crankshaft journal

and carefully slide oil seal as far as possible onto crankshaft
journal over guide sleeve.
– Remove guide sleeve -T10053/1- .

Passat 1997 ➤
– Press oil seal in to stop with installing sleeve from 3266. To do

this, use an old vibration damper securing bolt.
– Install vibration damper and lock with counterhold -T10069- .

– Tighten new securing bolt to 100 Nm and then turn 90° (1/4
turn) further (turning further can be done in several stages).
Note
♦ Renew securing bolt for vibration damper.

♦ Tighten securing bolt using torque wrench -V.A.G 1601- .
– Install poly V-belt ⇒ page 19 .
2.2 Removing and installing drive plate

Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1332-
♦ Depth gauge
♦ Straight edge
Passat 1997 ➤
– Remove drive plate. To do this, lock vibration damper using

counterhold -T10069- .
– Loosen drive plate securing bolts diagonally and remove.
Note
A 15 mm spacer is installed between drive plate and crankshaft.
– Remove drive plate.

Installing
– Position drive plate and spacer on crankshaft.
– Insert at least 3 old securing bolts and tighten to 30 Nm.
– Check dimension -a- to intermediate plate through 3 holes for

torque converter attachment using a straight edge and depth
gauge, and calculate average.
– Compare average with specification (measured distance +
thickness of straight edge). Specification: 18.1…19.7 mm
If specification is not attained:
– Remove drive plate again and fit appropriate shim -1-.
Note
Only one shim of the appropriate thickness may be used.
When specification is attained:

– Insert new securing bolts and tighten by hand.
– Tighten securing bolts to 60 Nm and turn 180° (1/2 turn) further
(turning further can be done in several stages).

Passat 1997 ➤
3 Removing and installing crankshaft
Note
♦ When carrying out assembly work, secure engine to support

♦ Before removing crankshaft, ensure that a suitable surface for
storing crankshaft is prepared to ensure that sender wheel
(item ⇒ Item 6 (page 28) ) is not damaged or lies against any
other item.
♦ When changing bearing shells, use only bearing shells of
same colour code.
1 - Bearing cap
❑ Bearing cap 1: vibration
damper end
❑ Bearing cap 4 with re‐
cesses for thrust wash‐
ers.
❑ Bearing shell retaining
lugs in cylinder block
and bearing caps must
align.
2 - 30 Nm + 1/2 turn (180°) fur‐
ther
❑ Renew.
❑ 2 x 90° further is permit‐
ted.
3 - Bearing shells 1…6
❑ Before removing, see
notes ⇒ page 27 .
❑ For bearing cap without
oil groove.
❑ For cylinder block with
oil groove.
❑ Do not interchange
used bearing shells
(mark).
4 - Thrust washer
❑ For bearing cap 4.
❑ Note fixing arrange‐
ment.
5 - Crankshaft
❑ Before removing, see
notes ⇒ page 27 .
❑ Axial clearance new:
0.07…0.24 mm , wear limit: 0.30 mm.
❑ Check radial clearance using Plastigage new: 0.02…0.06 mm, wear limit: 0.10 mm.
❑ Do not rotate crankshaft when checking radial clearance.
❑ Crankshaft dimensions, main bearing: 59.958…59.978 mm, conrod bearing: 53.958…53.978 mm. Re‐
working is not permitted.
❑ Oil bearing surfaces before installing
3. Removing and installing crankshaft 27

Passat 1997 ➤
6 - Sender wheel
❑ For engine speed sender -G28- .
❑ Renew.
❑ Installing ⇒ page 28 .
7 - 10 Nm + 1/4 turn (90°) further
❑ Renew.
❑ Note correct sequence when tightening ⇒ page 28 .
8 - Oil spray jet
❑ For crankshaft bearings 2…6
❑ For piston cooling.
❑ Opening pressure: 2.0 bar
3.1 Fitting sender wheel to crankshaft

♦ Locking fluid -D 000 600 A2-
Procedure
Ensure that contact surfaces of crankshaft and sender wheel are
free of oil and grease.
– For additional hold apply a thin coat of locking fluid „D 000 600
A2“ to crankshaft/sender wheel contact surfaces.
– Ensure when installing that marking -VR5- -arrow- is at single
threaded hole.
– First tighten all new securing bolts lightly by hand.
– First tighten securing bolt -1- to 10 Nm + 90° (1/4 turn) further.
– Then tighten securing bolts -2- to 10 Nm + 90° (1/4 turn) fur‐
ther.

Passat 1997 ➤
4 Dismantling and assembling pistons and conrods
1 - Piston rings
❑ Offset gaps by 120°.
❑ Use piston ring pliers to
remove and install.
❑ „TOP“ faces towards
piston crown.
❑ Checking ring gap
⇒ page 30 .
❑ Checking ring-to-groove
clearance ⇒ page 30 .
2 - Piston
❑ Check ⇒ page 31 .
❑ Mark cylinder number
and installation position
relative to conrod.
❑ Low point of piston
crown faces to centre of
cylinder block.
❑ Install with piston fitting
tool -3278-
⇒ page 31 .
3 - Circlip
4 - Conrod
❑ Renew as set only.
❑ Mark cylinder number
-B-.
❑ Installation position:
marks -A- must be
above one another.
❑ Oil bearing surfaces be‐
fore installing
5 - Bearing shell
tion.
❑ Do not interchange used bearing shells.
❑ The lugs on bearing shells must fit tightly in the recesses.
❑ Axial clearance new: 0.05…0.35 mm, wear limit: 0.40 mm
❑ Check radial clearance with Plastigage: new: 0.02…0.07 mm, wear limit: 0.10 mm. Do not rotate crank‐
shaft when checking radial clearance.
6 - Conrod bearing cap
❑ Mark cylinder number -B-.
❑ Installation position: marks -A- must be above one another.
7 - 30 Nm + 1/4 turn (90°) further
❑ Renew.
❑ Oil threads and contact surface.
❑ To measure radial clearance, tighten to 30 Nm but not further.
8 - Cylinder block
❑ Checking cylinder bores ⇒ page 31 .
❑ Removing and installing crankshaft ⇒ page 27 .
❑ Piston and cylinder dimensions ⇒ page 32 .
4. Dismantling and assembling pistons and conrods 29

Passat 1997 ➤
9 - Piston pin
❑ If difficult to remove, heat piston to 60 °C.
❑ Remove and install with drift -VW 222- a
Checking piston ring gap

♦ Feeler gauges
Test procedure
– Push ring at right angles from above down to approx. 15 mm
from bottom end of cylinder. Push in using a piston without
rings.
Piston ring Ring gap
New Wear limit
Rectangular-section ring mm 0.20…0.40 1.0
Tapered stepped ring mm 0.20…0.40 1.0
Oil scraper ring mm 0.25…0.50 1.0
Checking ring-to-groove clearance

♦ Feeler gauges
Test procedure
– Clean ring groove before checking.
Piston ring Clearance
New Wear limit
Rectangular-section ring mm 0.04…0.08 0.15
Tapered stepped ring mm 0.02…0.06 0.15
Oil scraper ring mm 0.03…0.06 0.15

Passat 1997 ➤
Checking piston

♦ External micrometer 75…100 mm
Test procedure
– Measure pistons approx. 6 mm from lower edge of skirt and
90° to piston pin axis.
• Difference between actual and nominal diameter max. 0.04
mm.
Checking cylinder bores

♦ Cylinder gauge 50…100 mm
Test procedure
– Take measurements at 3 positions in both lateral direction
-A- and longitudinal direction -B-.
• Difference between actual and nominal diameter max. 0.08
mm.
Note
Cylinder bores must not be measured when cylinder block is

mounted on a repair stand with engine support bracket -3269- ,
as measurements may then be incorrect.
4.1 Installing piston

♦ Piston fitting tool -3278-
4. Dismantling and assembling pistons and conrods 31

Passat 1997 ➤
Note
If a new piston fitting tool is used to install the pistons, first pass
piston with oiled piston rings twice through the tool and remove
any resulting metal shavings, if necessary. Only then install piston
with piston rings.
Procedure
– Push piston into oiled funnel by hand. Flat side of piston crown
must face lug on piston fitting tool -arrow-.
– Hold tool (with piston inserted) on upper edge and press piston
in with both thumbs.
– Push piston in until it protrudes approx. 15 mm from the lower
edge of the piston fitting tool.
– Place piston in respective cylinder bore. Lug on fitting tool
-arrow- must face centre of cylinder block.
– Hold fitting tool tightly against cylinder block and push piston
in.
4.2 Piston and cylinder dimensions

Honing dimen‐ Piston ∅ Cylinder bore ∅
sion
Basic dimension mm 80.965 81.010
Stage I mm 81.465 81.510
Stage II mm 81.965 82.010

Passat 1997 ➤
15 – Cylinder head, valve gear

1 Cylinder head
Note
♦ If an exchange cylinder head is installed, all the contact sur‐

faces between the support elements, roller rocker fingers and
the running surfaces of the cam shafts must be oiled before
the cylinder head cover is installed.
♦ The plastic protectors fitted to protect the open valves must be
removed only immediately before the cylinder head is fitted.
♦ When replacing the cylinder head the complete coolant must
be renewed.
♦ Removing and installing intake manifold ⇒ page 39 .
♦ Dismantling and assembling engine: ⇒ Repairing injection
system; Rep. gr. 24 ; Dismantling and assembling intake
manifold .
♦ Removing and installing cover ⇒ page 36 .
♦ Checking compression ⇒ page 53 .
1. Cylinder head 33
Passat 1997 ➤
1 - 8 Nm
2 - Cable guide
❑ For ignition coil wiring.
3 - 8 Nm
❑ With spacer sleeve and
seal.
❑ Renew seal if damaged.
4 - Cap
❑ Renew seal if damaged.
5 - Boot
❑ Renew if damaged.
6 - 8 Nm
7 - Earth wire
8 - Cylinder head cover
⇒ page 39 .
9 - Lifting eye
10 - 23 Nm
direction of rotation (in‐
stallation position)
⇒ page 16 .
12 - Combination valve
and installing parts of
secondary air system.
13 - Inlet camshaft control valve 1 -N205-
❑ Checking activation: ⇒ Final control diagnosis; Rep. gr. 01 ; Performing final control diagnosis .
14 - Exhaust camshaft control valve 1 -N318-
❑ Checking activation: ⇒ Final control diagnosis; Rep. gr. 01 ; Performing final control diagnosis .
15 - 60 Nm + 1/4 turn (90°) further
❑ Renew.
34 Rep. gr.15 - Cylinder head, valve gear

Passat 1997 ➤
17 - Guide rail
❑ Clipped into valve timing housing.
19 - Cylinder head gasket
❑ Metal gasket.
❑ Renew.
❑ Preparing cylinder head gasket for assembly ⇒ page 36 .
❑ After renewing, renew entire coolant.
20 - Cylinder head
❑ Check for distortion ⇒ page 35 .
21 - Cylinder head bolt
❑ Renew.
❑ Refer to assembly instructions and sequence when loosening and tightening ⇒ page 41 Removing and
installing cylinder head.
22 - Cylinder head cover gasket
❑ Note installation position.
Checking cylinder head for distortion

♦ Straight edge
♦ Feeler gauges
1. Cylinder head 35
Passat 1997 ➤
Max. permissible distortion: 0.05 mm.

Preparing cylinder head gasket for assembly

♦ Sealant -AMV 176 501 02-
♦ Sealant -AMV 174 004 01-
Procedure
– Remove old sealant from 3 mm holes in cylinder head gasket
-arrows-.
Note
With the cylinder head installed, the holes in the cylinder head
gasket are only half visible.
– Fill 3 mm drillings in cylinder head gasket with sealant -AMV

174 004 01- and apply a raised drop of sealant at each of these
points.
Note
Sealant -AMV 174 004 01- hardens quickly.
– Then coat cover and sealing flange with sealant -AMV 176 501
02- and immediately install.
1.1 Removing and installing

Passat 1997 ➤
1 - Bracket
❑ For coolant pipe and
wiring harness
❑ Coolant hose schematic
diagram ⇒ page 96 .
2 - 8 Nm
3 - Hall sender 2 -G163-
connector belonging to
component.
❑ Checking: ⇒ Fault
memory; Rep. gr. 01 ;
Reading and erasing
fault memory
4 - Chain tensioner, 40 Nm
❑ For camshaft timing
chain
⇒ Item 11 (page 34)
❑ Only rotate engine when
chain tensioner is instal‐
led.
5 - Seal
❑ Renew if damaged or
leaking.
6 - Bracket
❑ For continued coolant
circulation pump
7 - Continued coolant circula‐
tion pump -V51-
8 - Seal
❑ For valve -1- for inlet camshaft control -N205- , ⇒ Item 13 (page 34) and valve -1- for exhaust camshaft
control -N318- , ⇒ Item 14 (page 34) .
❑ Installing ⇒ page 38 .
9 - 23 Nm
10 - Thermostat housing
11 - Retaining clamp
12 - Seal
❑ Renew.
13 - Cover
❑ Can be removed and installed with cylinder head fitted.
❑ Sealant for sealing surfaces ⇒ ETKA (Electronic parts catalogue) .
❑ If only cover has been removed, prepare cylinder head gasket for assembly ⇒ page 36 .
❑ With O-ring for sealing oil channel ⇒ Item 15 (page 38)
1. Cylinder head 37
Passat 1997 ➤
14 - Hall sender -G40-

❑ Checking: ⇒ Fault memory; Rep. gr. 01 ; Reading and erasing fault memory
15 - O-ring
❑ For sealing oil channel.
❑ Renew.
Installing cover seals

♦ Fitting sleeve -3378-
♦ Fitting sleeve -3253/6-
– Do not lubricate seals.

Passat 1997 ➤
– Install oil seal with fitting sleeve -3378- in cover -1- and pull in
flush using fitting sleeve -3253/6- from assembly tool -3253- .
1.2 Removing and installing cylinder head

cover
♦ Hose clip pliers -VAS 6340-

Removing
WARNING

tions:
sitions.
hot components.

theft coding.
– With ignition switched off, disconnect earth strap from battery.
1. Cylinder head 39
Passat 1997 ➤
– All cable ties which are opened or cut open when engine is
is installed.
– Disconnect crankcase breather connection hose -1- from cyl‐
inder head cover.
Note
Press buttons on hose couplings to do this.
– Pull 6-pin connector -2- off throttle valve control module.

– Now pull vacuum lines -arrows- off intake manifold.
– Remove intake hose -3- between air mass meter and throttle
valve control module.
– Open and close expansion tank cap to release pressure in
cooling system.
WARNING
Hot steam may escape when expansion tank is opened. Place

cloth over cap and open with caution.
– Pull coolant hoses off throttle valve module and seal hose
ends e.g. using hose clamps 3094.
– Unbolt coolant expansion tank and lay to side.
Note
Coolant hoses on expansion tank can remain connected.

Passat 1997 ➤
– Unbolt earth wire -3-.

– Separate connectors -arrows-.
– Unclip connector from retainer.
– Pull vacuum hose off intake manifold change-over vacuum
actuator.
– Unscrew dipstick guide tube from intake manifold.
– Now remove the two bolts for the intake manifold support.
– Unscrew securing bolts of intake manifold/cylinder head and
remove intake manifold together with throttle valve module.
– Remove intake manifold and place it on a suitable surface so
that the vacuum unit will not be damaged.
Note
Seal intake ports in intake manifold and in cylinder head with a

clean cloth.
– Unclip wiring harness of ignition coils from cable guide.

– Remove ignition coils with output stages ⇒ Repairing ignition
system; Rep. gr. 28 ; Removing and installing parts of ignition
system .
– Remove cylinder head cover.
Installing
note the following:
Note
♦ Bolt intake manifold first to cylinder head. Then tighten the two
bolts of intake manifold support.
♦ Ensure that fuel hose connections are tight.
– If necessary fill with coolant ⇒ page 99 .

– Read fault memory ⇒ Fault memory; Rep. gr. 01 ; Reading
and erasing fault memory .
– Adapt engine control unit to throttle valve module ⇒ Engine
control unit; Rep. gr. 24 ; Adapting engine control unit to throt‐
tle valve module .
– Perform work sequence „Procedure after open circuit in volt‐
age supply“ ⇒ Engine control unit; Rep. gr. 24 ; Procedure
after open circuit in voltage supply .
Threaded connection Specified torque
Cylinder head cover to cylinder head 8 Nm
Intake manifold to cylinder head 13 Nm
Intake manifold to support 23 Nm
Dip stick guide tube to intake manifold 8 Nm
1.3 Removing and installing cylinder head

Prerequisite
• The engine must be no more than warm to touch.
1. Cylinder head 41
Passat 1997 ➤

equipment required
♦ Camshaft bar -T10068 A-
♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-
♦ Spring-type clip pliers -VAS
5024A-
♦ Puller -T10095 A-
1.3.1 Removing
WARNING

tions:
sitions.
hot components.

theft coding.
is installed.

Passat 1997 ➤
– Pull fuel supply line -1- (with white marking) and fuel return line
-2- (with blue marking) off fuel rail and catch fuel that escapes
in a cloth.
WARNING
Fuel system is under pressure! Before opening the system

place a cloth around the connection. Then release pressure by
carefully loosening the connection.
– Seal lines so that fuel system is not contaminated by dirt.

– Remove intake manifold ⇒ page 39 Removing and installing
cylinder head cover.
– Remove coolant pipe bracket and/or wiring harness from cov‐
er.
– Pull 4-pin connector off coolant temperature sender -G62- with
coolant temperature gauge sender -G2- ⇒ page 97 , Dis‐
mantling and assembling thermostat housing.
– Now remove thermostat housing ⇒ page 93 Parts of cooling
system - engine side.
– Set crankshaft to TDC No. 1 cylinder marks -arrow- by turning

crankshaft on the vibration damper securing bolt in direction
of engine rotation:
– Remove cylinder head cover ⇒ page 39 .
– Remove chain tensioner for camshaft timing chain -arrow-.
1. Cylinder head 43
Passat 1997 ➤
– Mark timing chain before removing (e.g. with paint, arrow

Note
– Disconnect connectors from the following components of cov‐

er:
♦ Continued coolant circulation pump -V51- ,
♦ Valve -1- for inlet camshaft control -N205- ,
♦ Valve -1- for exhaust camshaft control -N318- ,
♦ Hall sender -G40- ,
♦ Hall sender 2 -G163- .
Note

– Move wiring harness clear.

– Remove camshaft cover ⇒ page 36 .
– Unbolt front exhaust pipe with catalytic converter from exhaust
manifold ⇒ page 151 , Exhaust manifold, front exhaust pipe
with catalytic converter and attachments.
– Now check timing: if the TDC No. 1 Cyl. setting is correct it is

possible to see a notch on the intermediate shaft chain sprock‐
ets -arrow-.
Note
This condition is only achieved every 2nd complete rotation of

crankshaft.
If the groove cannot be seen:

– Turn crankshaft one full turn further in direction of engine ro‐
tation.
Note
When the crankshaft is turned, the tensioner plate must be press‐

ed against the camshaft roller chain by hand instead of with chain
tensioner.

Passat 1997 ➤
– Camshaft bar -T10068- must engage in grooves in both shafts.
Note
If camshaft bar cannot be fitted, turn crankshaft in direction of

engine rotation up to approx. 5 mm past TDC setting for No. 1
cylinder (dependent on drive chain tolerances).
Check setting marks of camshaft adjusters against marks on con‐

trol housing:
– Arrows -A and B- on camshaft adjusters must align with notch‐

es -arrows- in timing housing -C-.
– First remove exhaust camshaft adjuster and then remove inlet
camshaft adjuster.
Note
Counterhold only with 32 mm open-end spanner on camshaft

-arrows-. The camshaft bar -T10068- must not be in place when
tightening or loosening the camshaft adjusters.
– Remove securing bolts -arrows- and remove guide rail -1-.

– Lay camshaft timing chain aside.
1. Cylinder head 45
Passat 1997 ➤
– Loosen cylinder head bolts in sequence given and then re‐

move completely.
Note
Use tool 3452 for polydrive cylinder head bolts.
– Carefully remove cylinder head.
1.3.2 Installing
– Place clean cloths in cylinders so that no dirt or emery cloth
particles can get in between cylinder wall and piston.
– Also prevent dirt and emery cloth particles from getting into
coolant.
– Now carefully clean sealing surfaces of cylinder head and cyl‐
inder block. Ensure that surfaces are not scored or scratched
(if abrasive paper is used, grade must not be less than 100).
– Carefully remove metal particles, emery residue and cloths.
If the piston for No. 1 cylinder is not at TDC:
of engine rotation:
Note
♦ Do not remove new cylinder head gasket from its packing until
immediately before installing.
♦ Handle new gasket with extreme care. Damage will cause
leakage.
– Fit new cylinder head gasket. Inscription (Part No.) must be

readable.
– Ensure that dowel sleeves are inserted into cylinder block

holes 15 and 16, and the cylinder head gasket is located.
Camshaft bar has been removed:
– Position camshafts in cylinder head to TDC No. 1 cylinder.

Passat 1997 ➤
Note
If the camshaft bar cannot be engaged in the camshafts, turn

camshafts in direction of rotation past TDC No. 1 Cyl. and then
back to TDC No. 1 Cyl.
– Fit cylinder head, screw in new cylinder head bolts and tighten
hand tight.
– Tighten cylinder head bolts in tightening sequence as follows:
Note
The longer cylinder head bolts must be inserted in the centre

holes of cylinder head.
– Pre-tighten all bolts to 30 Nm.

– Then tighten all bolts to 50 Nm.
– Then tighten all bolts 1/4 turn (90°) further using a rigid wrench.
– Then tighten all bolts again 1/4 turn (90°) further.
Adjusting valve timing ⇒ page 48 .

Preparing cylinder head gasket and cover for assembly
⇒ page 36 .
– Lubricate O-ring for oil channel seal and insert into cover.
– Install cover part immediately, fit all securing bolts and lightly
tighten.
– First tighten M8 securing bolts to 23 Nm and then tighten M6
securing bolts to 8 Nm.
– Install chain tensioner for camshaft roller chain and tighten to
40 Nm.
– Install cylinder head cover and intake manifold ⇒ page 39 ,
Removing and installing cylinder head cover.
– Check camshaft timing control ⇒ page 69 .
Note
It is not necessary to retighten cylinder head bolts after repairs.
1. Cylinder head 47
Passat 1997 ➤
1.4 Checking valve timing

Test procedure
– Remove intake manifold and cylinder head cover ⇒ page 39
– Set crankshaft to TDC No. 1 cylinder marking -arrow- by turn‐
ing crankshaft on the vibration damper securing bolt in direc‐
tion of engine rotation.

If camshaft bar cannot be engaged:
– Turn crankshaft one full turn further in direction of engine ro‐
tation.
Note
If camshaft bar cannot be fitted, turn crankshaft in direction of

engine rotation up to approx. 5 mm past TDC setting for No. 1
cylinder (dependent on drive chain tolerances).
Check setting marks of camshaft adjusters against marks on con‐

trol housing:

Note
Figure shows view with cover removed.
If the markings do not align:

– Adjust valve timing ⇒ page 48 .
If the markings align:
1.5 Adjusting valve timing (installing timing chains)

Passat 1997 ➤

equipment required
1331-
1332-
♦ Sealant -AMV 176 501-
♦ Sealant -174 004 01-
Procedure
WARNING

tions:
sitions.
hot components.
Note
The following procedure is described with engine removed. You

can start with adjustments at the relevant point, depending on
how far the engine has been dismantled.
1. Cylinder head 49
Passat 1997 ➤
Install roller chain and chain tensioner with tensioning plate for
intermediate shaft drive:
– Adjust position of crankshaft relative to intermediate shaft. The
ground down tooth of drive sprocket -B- must be flush with
bearing joint (TDC No. 1 cylinder).
– Install both pins without collar for guide rail -2- and tighten to
10 Nm.
Note
If roller chain has already been used, note direction of rotation

marking ⇒ page 16 .
– Install guide rail -2- with roller chain -1- and both chain sprock‐
ets -3- and -4-. Marking on roller chain sprocket -4- must align
with notch -C- or -D- on thrust washer of intermediate shaft.
When installing, ensure that roller chain runs completely straight
in guide plate from crankshaft to intermediate shaft.
– Tighten bolts for chain sprockets -3- and -4- on intermediate

shaft by hand.
Note
Note that all sprocket securing bolts must be renewed.
– Now install chain tensioner on opposite side.

– To do this, release locking teeth of chain tensioner -A- with a
small screwdriver and press tensioning plate against chain
tensioner.
– Install chain tensioner in this position and tighten to 8 Nm.
– Lock vibration damper with counterhold -T10069- .

Passat 1997 ➤
– Tighten new intermediate shaft chain sprocket securing bolts

-3- and -4- to 60 Nm + 90° (1/4 turn further), turning further can
be done in several steps.
– Remove counterhold -T10069- .
– Check again position of crankshaft -B- relative to intermediate
shaft -C- or -D-.
– Set engine to TDC No. 1 cylinder again.
Install camshaft drive roller chain:
– Now position camshafts in cylinder head at TDC No. 1 cylin‐
der.
Note
If necessary, turn camshafts -arrow- to correct position using 32

mm open-end spanner. The camshaft bar -T10068- must not be
installed while this is done.
– It must now be possible to insert the camshaft bar -T10068- in

both shaft grooves.
Note
♦ If cylinder head is removed:

♦ Installing cylinder head ⇒ page 41 , Removing and installing
cylinder head.
– Lay camshaft roller chain over intermediate shaft sprocket.

– Route chain between tensioning bar and guide rail in direction
of valve timing housing.
– First install camshaft adjuster of inlet side with camshaft roller
chain fitted.
1. Cylinder head 51
Passat 1997 ➤
– Position both camshaft adjusters (identification: 24E on inlet

side and 32A on exhaust side) at mounting of camshafts
-arrows-.
Note
The camshaft adjusters -1- can be turned in two directions. En‐

sure when installing, that sender wheel for Hall sender is turned
in direction of -arrow- onto stop. The distance between both ar‐
rows on the camshaft adjuster gear is exactly 16 rollers on the
camshaft roller chain.
– Install exhaust camshaft adjuster with camshaft roller chain

fitted.

– Tighten new securing bolts for camshaft adjusters hand-tight.
Note
The distance between both arrows on the camshaft adjuster gear

is 16 rollers on the camshaft roller chain.
– Remove camshaft bar -T10068- .

– Turn crankshaft two full turns in direction of engine rotation
and check valve timing ⇒ page 48 .
Note
When the crankshaft is turned, the tensioner plate must be press‐

ed against the camshaft roller chain by hand instead of with chain
tensioner.
If the markings do not align:

– Repeat valve timing adjustment.
If the markings align:

Passat 1997 ➤
– Hold camshaft which is to be tightened using a 32 mm open-

end spanner -arrow-.
Note
The camshaft bar -T10068- must not be installed while this is

done.
– Tighten new securing bolts -3- for inlet and exhaust camshaft
adjusters -4 and 2- to 60 Nm + 90° (1/4 turn further). Turning
further can be done in several steps.
– Coat sealing surface of sealing flange with sealant -AMV 188
001 02- and install. Tighten securing bolts to 8 Nm.
– Renew oil seal in sealing flange ⇒ Item 8 (page 21) .
⇒ page 36 .
tighten.
40 Nm.
– Turn crankshaft two full turns in direction of engine rotation
and check valve timing again ⇒ page 48 .
1.6 Checking compression
1. Cylinder head 53
Passat 1997 ➤

equipment required
♦ Spark plug socket and ex‐
tension -3122 B-
♦ Compression tester -V.A.G
1763-
1331-
Test prerequisite
• Engine oil temperature must be at least 30 °C.
• The battery voltage must be at least 11.5 V.
• All electrical consumers, e.g. lights and rear window heating,
must be switched off.
• If the vehicle is equipped with an air conditioner, it must be
switched off.
– Remove fuse No. 32 from fuse holder.
Note
Removing fuse 32 interrupts the voltage supply to the injectors.

Passat 1997 ➤
– Disconnect crankcase breather connection hose -1- from cyl‐

inder head cover.
Note
Press buttons on hose couplings to do this.
– Pull 6-pin connector -2- off throttle valve control module.

– Remove intake hose -3- between air mass meter and throttle
valve control module: ⇒ Repair group 24; Repairing injection
system .
– Now pull vacuum lines -arrows- off intake manifold.
– Open and close expansion tank cap to release pressure in
cooling system.
WARNING

– Pull coolant hoses off throttle valve module and seal hose
ends e.g. using hose clamps 3094.
1. Cylinder head 55
Passat 1997 ➤
– Turn hexagon key anti-clockwise until tension is relieved on

intake manifold.
– Now remove the two bolts for the intake manifold support.
– Remove upper part of intake manifold.
Note
The gasket between upper part of intake manifold and lower part
of intake manifold must always be renewed when installing.
– Remove ignition coils with output stages: ⇒ Repair group 28;

Repairing ignition system; Removing and installing parts of ig‐
nition system .
– Remove spark plugs with spark plug socket and extension
3122 B.
– Check compression pressure with compression tester -
V.A.G 1763- .
Note
Using compression tester ⇒ Operating instructions.
– Operate starter until tester shows no further pressure in‐

crease.
Compression pressures:
New: 10…31 bar, wear limit: 7.5 bar
Maximum permissible difference between all cylinders: 3 bar
– Insert spark plugs using spark plug socket and extension
-3122 B- and tighten to 30 Nm.
– Read fault memory and erase: ⇒ Rep. Gr. 01; Fault memory;
Reading and erasing fault memory .

Passat 1997 ➤
2 Valve gear
1 - 5 Nm + 1/8 turn (45°) further

2 - Exhaust camshaft bearing
cap
❑ Lightly coat contact sur‐
face of bearing cap 8
with grease -G 052 723
A2- before installing
⇒ page 59 .
❑ Installation position
⇒ page 60 .
❑ Installation sequence
and installing camshaft.
3 - Seal
❑ Renew if leaking.
❑ When installing valve
timing housing, lightly
lubricate contact surfa‐
ces of seal.
❑ When replacing seals,
do not spread too wide‐
ly.
❑ Offset gaps by 120°.
4 - Valve timing housing
❑ Lightly lubricate contact
surfaces of oil seals be‐
fore installing.
bling ⇒ page 61 .
❑ Before installing valve
timing housing, check
strainer for soiling
⇒ page 61 .
5 - 8 Nm
❑ Renew.
❑ Before removing, mark direction of rotation (installation position) ⇒ page 16 .
8 - 60 Nm + 1/4 turn (90°) further
❑ Renew.
2. Valve gear 57
Passat 1997 ➤
10 - Cylinder head height
❑ Minimum height: a = 139.9 mm.
11 - Valves
❑ Do not rework, only lapping-in is permitted.
❑ Valve dimensions ⇒ page 60 .
12 - Cylinder head
❑ Check for distortion ⇒ page 35 .
❑ Reworking valve seats ⇒ page 61 .
13 - Support element
❑ Before installing, check camshaft axial clearance ⇒ page 59 .
❑ Do not interchange.
❑ With hydraulic valve clearance compensation.
14 - Valve stem seal
❑ Renewing ⇒ page 74 .
15 - Securing clip
❑ Check for secure seating.
16 - Roller rocker finger
❑ Before installing, check camshaft axial clearance ⇒ page 59 .
❑ Do not interchange.
❑ Check roller bearing for ease of movement.
❑ Oil contact surface.
❑ When installing, secure to supporting element using securing clip.
17 - Valve spring
❑ Removing and installing ⇒ page 74 , Renewing valve stem seals.
18 - Valve spring plate
19 - Valve cotters
20 - Inlet camshaft bearing cap
❑ Lightly coat contact surface of bearing cap 7 with grease -G 052 723 A2- before installing ⇒ page 59 .
❑ Installation position ⇒ page 60 .
❑ Installation sequence ⇒ page 63 Removing and installing camshaft.
21 - Inlet camshaft
❑ Check radial clearance with Plastigage, wear limit: 0.1 mm.
❑ Runout: max. 0.01 mm.
❑ Checking axial clearance ⇒ page 59 .
❑ Identification and valve timing ⇒ page 61

Passat 1997 ➤
22 - Exhaust camshaft
❑ Check radial clearance with Plastigage, wear limit: 0.1 mm.
❑ Runout: max. 0.01 mm.
❑ Checking axial clearance ⇒ page 59 .
❑ Identification and valve timing ⇒ page 61
Camshafts, checking axial clearance

♦ Universal dial gauge bracket -VW 387-
♦ Dial gauge
Perform measurements with support elements and roller rocker
fingers removed.
Inlet camshaft
– Install bearing cap 7 and tighten to 5 Nm and turn 1/8 (45°)
further.
Wear limit: max. 0.10 mm
Exhaust camshaft
– Install bearing cap 8 and tighten to 5 Nm and turn 1/8 (45°)
further.
Wear limit: max. 0.10 mm
Lightly coat contact surfaces of bearing caps 7 and 8 with grease
-G 052 723 A2- before installing.
Procedure
– Lightly coat contact surfaces (hatched area in figure) of bear‐
ing caps 7 and 8 with grease -G 052 723 A2- before installing.
2. Valve gear 59
Passat 1997 ➤
Fitting position of camshaft bearing caps

Point of bearing cap -arrow A- of inlet and outlet camshafts face
outwards.
Identification on bearing caps is right side up when viewed from
exhaust side.
2.1 Valve dimensions
Note
Valves must not be reworked. Only lapping-in is permitted.
Dimensions of inlet valves

Dimension Short inlet valve long
inlet valve
∅a mm 31.00 31.00
∅b mm 5.96 5.96
c mm 102.20 136.10
α ∠° 45 45
Dimensions of exhaust valves
Dimension Short exhaust valve Long exhaust
valve
∅a mm 27.00 27.00
∅b mm 5.94 5.94
c mm 102.50 136.40
α ∠° 45 45

Passat 1997 ➤
2.2 Camshaft identification, valve timing

Camshaft identification
Identification between cam pair for cylinders 3 and 4 of respective
camshaft.
Camshaft Identification
A - Exhaust camshaft 066 101 index
B - Inlet camshaft 066 102 index
Valve timing at 1 mm valve lift
Valve Inlet valve Exhaust valve
Opens BTDC --- 210.0 °
Closes BTDC --- 5.0 °
Opens ATDC 30.0 ° ---
Closes ATDC 240.0 ° ---
2.3 Dismantling and assembling valve tim‐

ing housing
1 - Guide rail: clipped into control housing
2 - Valve timing housing:
- Only renew complete with valve -1- for inlet camshaft control -
N205- and valve -1- for exhaust camshaft control -N318- .
3 - Inlet camshaft control valve -1- -N205-
4 - Exhaust camshaft control valve -1- -N318-
5 - 8 Nm: renew (4 securing bolts)
Checking valve timing housing strainer for soiling.

– Unclip strainer -2- from back of valve timing housing -1- and
remove any dirt.
2.4 Reworking valve seats

♦ Depth gauge
♦ Valve seat refacing tool
2. Valve gear 61
Passat 1997 ➤
Procedure
Note
♦ When repairing engines with leaking valves, it is not sufficient

to rework or renew valve seats and valves. Particularly on high
mileage engines, it is necessary also to check valve guides for
wear ⇒ page 74 .
♦ Valve seats are only to be reworked to the extent required to
yield a proper surface appearance. Before beginning to rework
valve seats, calculate the maximum permissible reworking di‐
mensions. If the reworking dimension is exceeded, the hy‐
draulic valve clearance compensation can no longer be
guaranteed and the cylinder head must be renewed.
– Remove camshafts ⇒ page 63 .

The max. permissible reworking dimension is calculated as fol‐
lows:
– Insert valve and press firmly against seat.
Note
If the valve is to be renewed as part of a repair, use a new valve

for the calculation.
– Measure distance -a- between end of valve stem and upper

edge of cylinder head.
– Calculate maximum permissible reworking dimension from
measured distance -a- and minimum dimension.
Minimum dimension:
Short inlet valve mm 31.8
Long inlet valve mm 10.2
Short exhaust valve mm 31.8
Long exhaust valve mm 10.2
Measured distance -a- minus minimum dimension = maximum
permissible reworking dimension.
Example:
Measured distance 10.6 mm
— Minimum dimension 10.2 mm
= Max. permissible reworking dimension 0.4 mm

Passat 1997 ➤
Reworking inlet valve seat

a - = ∅ 30.6 mm
b - = max. permissible reworking dimension
c - = 0.9…1.5 mm
d - = max. ∅ 35.0 mm
r2 - = radius 2.0 mm
Z - = bottom surface of cylinder head
α - 45° valve seat angle
β - 30° upper correction angle
γ - 60° lower correction angle
Reworking exhaust valve seat

a - = ∅ 26.7 mm
b - = max. permissible reworking dimension
c - = 1.2…1.7 mm
d - = max. ∅ 29.0 mm
r2 - = radius 2.0 mm
Z - = bottom surface of cylinder head
α - 45° valve seat angle
β - 30° upper correction angle
γ - 60° lower correction angle
2.5 Removing and installing camshafts

(With cylinder head installed)
2. Valve gear 63
Passat 1997 ➤

equipment required
1331-
1332-
♦ Grease -G 052 723 A2-
2.5.1 Removing
WARNING

tions:
sitions.
hot components.

theft coding.
is installed.

Passat 1997 ➤
– Remove intake manifold ⇒ page 39 Removing and installing

cylinder head cover.
– Pull 4-pin connector off coolant temperature sender -G62- with
coolant temperature gauge sender -G2- ⇒ page 97 , Dis‐
mantling and assembling thermostat housing.
– Now remove thermostat housing ⇒ page 93 Parts of cooling
system - engine side.
of engine rotation:
– Remove cylinder head cover ⇒ page 39 .
– Remove chain tensioner for camshaft timing chain -arrow-.
2. Valve gear 65
Passat 1997 ➤
– Mark timing chain before removing (e.g. with paint, arrow

Note
– Disconnect connectors from the following components of cov‐

er:
♦ Continued coolant circulation pump -V51- ,
♦ Inlet camshaft control valve 1 -N205- ,
♦ Exhaust camshaft control valve 1 -N318- ,
♦ Hall sender -G40- ,
♦ Hall sender 2 -G163- .
Note

– Move wiring harness clear.

– Remove camshaft cover ⇒ page 36 .
– First remove exhaust camshaft adjuster and then remove inlet

camshaft adjuster.
Note
Counterhold only with 32 mm open-end spanner on camshaft

-arrows-. The camshaft bar -T10068- must not be in place when
tightening or loosening the camshaft adjusters.
– Lay camshaft timing chain aside.
– Unbolt control housing from cylinder head -arrows-.

– Pull valve timing housing carefully off camshaft seals.

Passat 1997 ➤
A - Inlet camshaft
– First remove bearing caps 1 and 11.
– Remove bearing caps 3 and 9.
– Loosen bearing caps 5 and 7 alternately and diagonally.
B - Exhaust camshaft
– First remove bearing caps 2 and 12.
– Remove bearing caps 4 and 10.
– Loosen bearing caps 6 and 8 alternately and diagonally.
– Carefully remove camshafts and lay aside on clean surface.
– Remove roller rocker fingers together with support elements
and lay aside on a clean surface.
– Ensure that roller rocker fingers and support elements are not
interchanged.
2.5.2 Installing
Prerequisites
• When camshafts are installed, cams for No. 1 cylinder must
point upwards.
• The pistons must not be positioned at TDC.
– Install supporting elements in cylinder head and fit respective
roller rocker finger onto respective valve stem end or support‐
ing element.
– Ensure that all roller rocker fingers -1- seat properly on valve
stem ends and are clipped into their respective support ele‐
ments -2-.
– Oil running surfaces of camshafts.
– Carefully place each camshaft in its respective bearing in the
cylinder head. When doing this, note camshaft identification
⇒ page 61
2. Valve gear 67
Passat 1997 ➤
Note
♦ Observe fitting position of bearing caps:

♦ Point of bearing cap -arrow A- of inlet and outlet camshafts
face outwards.
♦ Identification on bearing caps is right side up when viewed
from exhaust side.
A - Inlet camshaft
ing cap 7 with grease -G 052 723 A2- before installing
⇒ page 59 .
– Tighten bearing caps 5 and 7 alternately and diagonally to
5 Nm + 1/8 turn (45°).
– Install bearing caps 3 and 9 and tighten to 5 Nm + 1/8 turn
(45°).
– Install bearing caps 1 and 11 and also tighten to 5 Nm + 1/8
turn (45°).
B - Exhaust camshaft

ing cap 8 with grease -G 052 723 A2- before installing.
– Tighten bearing caps 6 and 8 alternately and diagonally to
5 Nm + 1/8 turn (45°).
– Install bearing caps 4 and 10 and tighten to 5 Nm + 1/8 turn
(45°).
– Install bearing caps 2 and 12 and also tighten to 5 Nm + 1/8
turn (45°).
– Position camshafts in cylinder head to TDC No. 1 cylinder.

Passat 1997 ➤
Note
If the camshaft bar cannot be engaged in the camshafts, turn

camshafts in direction of rotation past TDC No. 1 Cyl. and then
back to TDC No. 1 Cyl.
– Before installing, check valve timing housing strainer for soil‐

ing ⇒ page 61 .
– Before installing valve timing housing, lightly lubricate valve
timing housing surfaces contacting camshaft seals.
– Lightly lubricate contact surfaces of camshaft seals and slowly
push valve timing housing over camshaft seals.
– Install control housing, renew securing bolts -arrows- and

tighten to 8 Nm.
Adjusting valve timing ⇒ page 48 .
⇒ page 36 .
tighten.
40 Nm.
2.6 Checking camshaft timing control/ad‐

justment
Function
Camshaft adjustment is dependent upon load and revolutions.
The electric camshaft control valves switches oil pressure to the
camshaft adjusters (mechanical adjusters), which then adjusts
the camshafts.
♦ Fault reader -V.A.G 1551-
2. Valve gear 69
Passat 1997 ➤
♦ Diagnostic cable -V.A.G 1551/3-
Note
Instead of fault reader -V.A.G 1551- , vehicle system tester -

V.A.G 1552- can also be used, though a print-out is not possible.
Test prerequisites
• Fuses must be OK.
• Engine oil level OK, checking ⇒ page 77 , ⇒ page 77 .
• No fault may be stored in fault memory ⇒ Fault memory; Rep.
gr. 01 ; Reading and erasing fault memory .
• Coolant temperature must be 80…95 °C, ⇒ display group 01,
display zone 2
Checking activation
– First check activation of valve -1- of inlet camshaft control -
N205- and valve -1- of exhaust camshaft control -N318- via
final control diagnosis ⇒ Final control diagnosis; Rep. gr. 01 ;
Performing final control diagnosis .
If activation is OK:
– Check position of camshafts to crankshaft ⇒ page 70 .
2.6.1 Checking position of camshafts to

crankshaft
First check coolant temperature.
– Connect fault reader -V.A.G 1551- (V.A.G 1552). Start engine
and select „Address word“ 01 of engine control unit. Connect
fault reader and select engine control unit ⇒ General notes for
self-diagnosis; Rep. gr. 01 ; Connecting fault reader .
Indicated on display: Rapid data transfer HELP
Select function XX
– Press keys 0 and 4 for function „Initiate basic settings“ and

confirm entry with Q key.
Indicated on display: Basic setting
Input display group number XXX
– Press buttons 0 0 and 1 for „display group number 1“ and

confirm entry with Q button.

Passat 1997 ➤
Indicated on display: (1…4 = display zones) System in basic setting 1 ->

1 2 3 4
• Continue with test when coolant temperature is 80…95°C, -

display zone 2-
Change to display group 208 as follows:
– Press the C button.
Indicated on display: Basic setting

Indicated on display: (1…4 = display zones) System in basic setting 208 -
>
1 2 3 4
Display zones
1 2 3 4
Display group 208: Position of inlet camshaft to crankshaft
Readout xxxx rpm xxx (° CA) xxx° CA xxxxxxxx
Display Engine speed Detected 1st phase Adapted offset Status
shows flank
Specifi‐ Idling speed 111…131 (° CA) -10.0…10.0° CA xxxxx100
cation
If the specifications are not obtained

– Press → button.
If no fault is stored in the fault memory:
– Press buttons 0 and 6 for function „End output“ and confirm
entry with Q button.
– Switch off ignition.
– Check valve timing ⇒ page 48
If the specifications are attained:
– Change to display group 209 as follows: -V.A.G 1551- : Press
key 3 -V.A.G 1552- : Press key ↑ .
>
1 2 3 4
Display zones
1 2 3 4
Display group 209: Position of exhaust camshaft to crankshaft
Readout xxxx rpm xxx (° CA) xxx° CA xxxxxxxx
Display Engine speed Detected 1st phase Adapted offset Status
shows flank
Specifi‐ Idling speed 111…131 (° CA) -10.0…10.0° CA xxxxx100
cation
Volkswagen Technical Site: https://vwts.ru 2. Valve gear 71

Passat 1997 ➤
– Check valve timing ⇒ page 48
2.6.2 Checking camshaft timing control/ad‐

justment
Indicated on display: (1…4 = display zones). System in basic setting 210 -
>
1 2 3 4
– Depress brake pedal and hold.

– Depress accelerator to full throttle position.
Engine revolutions are raised by engine control unit to approx.
2300 rpm.
Display zones
1 2 3 4
Display group 210: Adjustment of inlet camshaft
Readout xxxx rpm xxx.x° CA xxx.x° CA xxxxxxxx
Display Engine speed Specified angle Actual angle Status
shows
Specifi‐ approx. 2300 rpm 0.0…50.0° KW approx. specified angle xxxxx100
cation
Note
The display values increase to approx. 50.0° CA and then drop

back to 0.0° CA.
Note
Specified value „xxxxx100“ in display zone 4 is only displayed

after several seconds. Continue with test until specified angle 0.0°
CA is shown in display zone 2.
– Release brake pedal and accelerator.


Passat 1997 ➤

– Check Hall senders ( -G40- and -G163- ) (connectors may be
interchanged): ⇒ Repairing ignition system; Rep. gr. 28 ;
Checking Hall sender .
– Check oil pressure ⇒ page 87 , checking oil pressure and oil
pressure switch.
If no fault is detected:
– Renew inlet camshaft adjuster ⇒ page 63 , Removing and in‐
stalling camshafts.
>
1 2 3 4

2300 rpm.
Display zones
1 2 3 4
Display group 211: Adjustment of exhaust camshaft
Readout xxxx rpm xxx.x° CA xxx.x° CA xxxxxxxx
Display Engine speed Specified angle Actual angle Status
shows
Specifi‐ approx. 2300 rpm 0.0…22.0° CA approx. specified angle xxxxx100
cation
Note
The display values increase to approx. 22.0° CA and then drop

back to 0.0° CA.
Note
The actual angle jumps to approx. 22.0° CA and then drops back
to the specified value. The upper and lower stops for the actual
angle must equate to the specified angle in display zone 2.
Note
Specified value „xxxxx100“ in display zone 4 is only displayed

after several seconds. Continue with test until specified angle 0.0°
CA is shown in display zone 2.

2. Valve gear 73
Passat 1997 ➤
– Check Hall senders ( -G40- and -G163- ) (connectors may be
interchanged): ⇒ Repairing ignition system; Rep. gr. 28 ;
Checking Hall sender .
– Check oil pressure ⇒ page 87 , checking oil pressure and oil
pressure switch.
If no fault is detected:
– Renew exhaust camshaft adjuster ⇒ page 63 , Removing and
installing camshafts.
2.7 Checking valve guides

♦ 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. Due to slight differences in stem di‐
ameters, use only an inlet valve in inlet guide and an exhaust
valve in exhaust guide.
– Determine rock. Wear limit: 0.8 mm
If rock tolerance is exceeded:
– Renew cylinder head.
2.8 Renewing valve stem seals

(With cylinder head installed)

Passat 1997 ➤

equipment required
♦ Valve lever -VW 541/1 A-
with press tool -VW 541/6-
♦ Valve assembly device
-2036- with adapter plates
-2036/1-
♦ Spark plug socket and ex‐
tension -3122 B-
♦ Valve stem seal puller
-3364-
♦ Valve stem seal fitting tool
-3365-
♦ Adapter -T40012-
1331-
Removing
– Remove camshafts ⇒ page 63 .
– Remove roller rocker fingers together with support elements
and lay aside on a clean surface.
– Ensure that roller rocker fingers and support elements are not
interchanged.
– Remove spark plugs using spark plug socket and extension
-3122 B- .
– Set piston of respective cylinder to „bottom dead centre“.
2. Valve gear 75
Passat 1997 ➤
– Set-up valve assembly device -2036- with adapter plates

-2036/1- and adjust mounting.
– Screw adapter -T40012- into spark plug thread and apply a
continuous pressure of min. 6 bar.
– Remove valve springs using valve lever -VW 541/1 A- and
press tool -VW 541/6- .
Note
Tight cotters can be loosened by tapping lightly on lever.
– Pull off valve stem seals using valve stem seal puller -3364- .
Installing
– To prevent damage to new valve stem seals, place plastic

sleeve -A- on valve stem.
– Lubricate sealing lip of valve stem seal -B-, place it in the valve
stem oil seal fitting tool -3365- and push carefully onto valve
guide.
– Install camshafts ⇒ page 63 .

Passat 1997 ➤
17 – Lubrication
1 Removing and installing parts of lu‐
brication system
Note
♦ If when repairing an engine, metal shavings or large quantities

of small metal particles caused, for example, by partial seizure
of crankshaft and conrod bearings are found in the engine oil,
one must apart from thoroughly cleaning oil passages, renew
all oil spray jets, the oil non-return valve, the oil cooler and oil
filter element to prevent consequential damage.
♦ The oil level must not be above the max. mark - danger of
damage to catalytic converter! Markings ⇒ page 77 ,
⇒ page 77 .
1.1 Engine oil

Oil capacities
With oil filter 4.7 l
5) Current values: ⇒ Exhaust emissions test
Engine oil specifications with long-life service

New VW standard (specially developed, ageing resistant) initial
filling: VW standard 503 00 (VW TL 52 173).
Note
♦ The engine is filled at the factory with engine oil conforming to

VW standard 503 00. This engine oil is designed for long
maintenance intervals. However, the engine oils listed below
can also be used.
♦ 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 15000 km and the service interval
display must be programmed accordingly. Procedure: ⇒ Main‐
Markings on oil dipstick

1 - Max. mark
2 - Min. mark
a - Area above hatched field up to max. mark: Do not top up with
engine oil!
b - Oil level within hatched field: can be topped-up with engine oil.
c - Area from min. mark up to hatched field: Must be topped up,
max. 0.5 l of engine oil!
1.2 Assembly overview - sump
1. Removing and installing parts of lubrication system 77

Passat 1997 ➤
1 - 8 Nm
❑ Secured to intake mani‐
fold.
2 - Dipstick
❑ The oil level must not be
above the max. mark!
❑ Markings ⇒ page 77 .
3 - Guide tube
❑ For dipstick.
❑ Secured with bolt to in‐
take manifold.
4 - Oil non-return valve, 6 Nm
tion.
❑ Clean if badly soiled
5 - 10 Nm
6 - Oil pump drive cover
7 - O-ring
❑ Renew.
❑ Lubricate before instal‐
ling.
8 - Oil pump drive
9 - Cylinder block
sealing flange and dual-
mass flywheel
⇒ page 21 .
crankshaft ⇒ page 27 .
bling pistons and conrods ⇒ page 29 .
11 - Thrust washer
12 - 8 Nm
13 - Oil spray jet
❑ For crankshaft bearings 2…6
❑ For piston cooling.
❑ Opening pressure: 2.0 bar
14 - Drive shaft
15 - Oil pump
❑ Coat oil pressure pipe with sealant -AMV 188 001 02- at cylinder block and oil pump housing.
78 Rep. gr.17 - Lubrication

Passat 1997 ➤
16 - 23 Nm
17 - 8 Nm
18 - 40 Nm
19 - Torque reaction support
20 - 8 Nm
21 - Sump cover
❑ Must not be removed.
❑ If cover has been removed, use silicone sealant -D 176 404 A2- when installing.
❑ Renew plug with attached seal.
23 - Oil sump
❑ Clean sealing surface before fitting.
❑ Install with silicone sealant -D 176 404 A2- .
24 - Seal
❑ Renew.
25 - Oil level and oil temperature sender -G266-
❑ Black connector, 3-pin.
26 - Bracket
❑ For ATF lines.
❑ Only on vehicles with automatic gearbox.
27 - 12 Nm
28 - Baffle plate
29 - Oil filter bracket/engine mounting
30 - 23 Nm
31 - Gasket
❑ Renew.
1.2.1 Removing and installing oil spray jet

♦ 4 mm ∅ drift
♦ 6 mm ∅ drift
Note
Oil spray jets are installed in main crankshaft bearings 2…6.

Passat 1997 ➤
Prerequisite
• Crankshaft removed
Removing
– Press oil spray jet out towards bearing using a 4 mm ∅ drift.
Installing
– To install, press oil spray jet in by hand using a 6 mm ∅ drift
-arrow-.
1.3 Dismantling and assembling oil filter housing/engine mounting
1 - Oil filter bracket/engine

mounting
❑ With oil return valve.
2 - Gasket
❑ Renew.
tion.
❑ Lubricate before instal‐
ling.
3 - Oil cooler
❑ Ensure clearance to ad‐
jacent components.
❑ Coat contact surfaces
outside the seal, with
sealant -
AMV 188 001 02- .
4 - Oil cooler cover, 25 Nm
5 - 23 Nm
7 - Oil filter lower part, 25 Nm
❑ Drain before removing.
❑ With by-pass valve,
opening pressure: 2.50
bar
8 - Oil filter element
❑ Observe change inter‐
vals.
9 - Oil pressure switch -F1- 1.4 bar, 20 Nm
❑ Identification: black

Passat 1997 ➤
10 - Plug, 25 Nm
❑ For oil return valve.
11 - Seal
❑ Renew.
12 - Gasket
❑ Renew.
1.4 Dismantling and assembling oil pump
1 - Drive shaft
2 - Oil pump housing
3 - 23 Nm
4 - Gears
❑ Checking backlash
⇒ page 82 .
❑ Checking axial clear‐
ance ⇒ page 82 .
5 - Oil pump cover with pres‐
sure relief valve
❑ Opening pressure:
5.3…5.7 bar.
❑ Clean strainer if soiled.
6 - 8 Nm
❑ Insert with locking fluid -
D 000 600 A2- .
7 - Oil pressure pipe
❑ Coat with sealant -AMV
188 001 02- at cylinder
block and oil pump
housing.
8 - 8 Nm
9 - Seal

Passat 1997 ➤
Checking oil pump backlash

♦ Feeler gauges
Wear limit: 0.20 mm
Checking oil pump axial clearance

♦ Straight edge
♦ Feeler gauges
Wear limit: 0.10 mm
1.5 Removing and installing oil sump

Passat 1997 ➤

equipment required
♦ Support bracket -10 - 222
A- with rack -10 - 222 A /1-
♦ Workshop hoist -V.A.G
1202 A-
1331-
♦ Silicone sealant -D 176 404
A2-
♦ Hand drill with plastic brush
attachment
♦ Flat scraper
♦ Cable ties
♦ Eye protection
Removing
– Drain engine oil.
Note
Observe environmental regulations for disposal.
– Pull 3-pin connector off oil level and oil temperature sender -
G266- .
– Unbolt retainers for ATF lines on torque reaction support and
sump.
– Unbolt torque reaction support from sump.

Passat 1997 ➤
– Unclip lower part -1- of starter cable retainer -arrows-.
– Mark the fitting position of threaded connections -1- and lo‐

cating sleeves -2- below on the left and right engine mounts.
– Unbolt both engine mountings from below.
– Attach support bracket 10-222A as shown.

– Support engine at rear lifting eye with support bracket.
– Tension engine slightly with spindle of support bracket.
– Support assembly carrier with workshop crane 1202 A.
Note
To avoid having to perform wheel alignment, the subframe must

only be loosened or lowered at the front end.

Passat 1997 ➤
– First remove front bolts -2- and -3- on left and right-hand sides
of subframe Then remove bolts -4-.
– Loosen rear right gearbox mounting rear bolt -2- several turns,
remove right gearbox mounting front bolt -1-.
Vehicles with manual gearbox
– Loosen left gearbox mounting nut -arrow- until it is flush with

end of bolt (turned approx. 4 threads).
– Loosen rear left gearbox mounting rear bolt -2- several turns,
remove left gearbox mounting front bolt -1-.

Passat 1997 ➤
– Lower subframe slowly with workshop crane.

– Remove workshop crane, swivel anti-roll bar down.
– Unbolt sump. If necessary, push assembly carrier downwards
by hand slightly to be ease the loosening of the bolts on the
intermediate plate.
– Now remove sump.
– Loosen sump with light blows of a rubber headed hammer if
necessary.
– Remove sealant residue from cylinder block with a flat scraper.
– Remove sealant residue on sump using a rotating brush, e.g.

an electric drill with a plastic brush attachment (wear safety
goggles).
– Clean sealing surfaces. They must be free of oil and grease.
Installing
Prerequisite
• Intermediate plate must be bolted firmly to cylinder block
⇒ Item 9 (page 22) .
Note
♦ Observe expiry date of sealing compound.

♦ The oil sump must be installed within 5 minutes of applying
silicone sealing compound.
– Cut off tube nozzle at forward marking (∅ of nozzle approx. 3

mm).
– Apply silicone sealing compound, as shown, to clean sealing
surface on sump. Sealing compound bead must be:
♦ 2…3 mm thick.
♦ Run bead along inner side of bolt holes -arrows-.
Note
The sealant bead must not be thicker, otherwise excess sealing

compound will enter the oil sump and may block the oil suction
line strainer.

Passat 1997 ➤
– Apply silicone sealing compound bead as shown to the clean

sealing surface of the sump.
– Install sump immediately and tighten all sump bolts lightly.
– Tighten sump bolts slightly.
– Tighten M10 bolts of sump/intermediate plate by hand.
– Tighten oil sump bolts to 12 Nm.
– Tighten M10 bolts of sump/intermediate plate to 45 Nm.
Note
Let sealing compound dry for approx. 30 minutes after installing

sump. Only then fill with engine oil.
– Install subframe ⇒ Running gear, front-wheel drive and four-

wheel drive; Rep. gr. 40 ; Removing and installing subframe .
Specified torques
Component Nm
Engine mounting to subframe 6)
23
Torque reaction support to sump 40
Gearbox support to gearbox mounting M10 40
Gearbox mounting to subframe M8 25
ATF lines on sump and torque reaction 10
support
Further assembly is basically the reverse of the dismantling se‐

quence.
– Install lock carrier with attachments ⇒ General body repairs,
exterior; Rep. gr. 50 ; Lock carrier service position .
1.6 Checking oil pressure and oil pressure switch

Passat 1997 ➤

equipment required
♦ Oil pressure tester -V.A.G
1342-
♦ Adapter -V.A.G 1342/14-
♦ Voltage tester -V.A.G
1527B-
♦ Auxiliary measuring set -
V.A.G 1594C-
Test prerequisites
• Engine oil level OK, checking ⇒ page 77 .
• Engine oil temperature at least 80 °C (radiator fan must have
run once)
Note
Functional check and repair of the optical and acoustic oil pres‐
sure warning: ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations

Passat 1997 ➤
Checking oil pressure switch

– Remove oil pressure switch -F1- and screw into tester.
– Screw oil pressure tester -V.A.G 1342- with adapter -V.A.G
1342/14- into oil filter housing in place of oil pressure switch.
Note
Observe installation position of adapter: the conical connecting

piece of the adapter must be screwed into the pressure hose of
the tester.
– Connect brown wire of tester to earth (-).

– Connect voltage tester -V.A.G 1527B- using test cables from
-V.A.G 1594 A- to battery positive (+) and oil pressure switch.
LED must not light up.
If the LED lights up:
– Renew oil pressure switch -F1- ⇒ Item 9 (page 80) .
If LED does not light up:
– Start engine and run at idling speed, at 1.2…1.6 bar the LED
must light up, otherwise renew oil pressure switch -F1-
⇒ Item 9 (page 80) .
Checking oil pressure
– Check oil pressure at different speeds: Idling: minimum 2.0
bar, 2,000 rpm: 3.0…5.5 bar. above 2,000 rpm: maximum 7.0
bar.
– Rectify mechanical damage, e.g. bearing damage.
At higher engine speeds, the oil pressure must not exceed 7.0
bar.
If the specification is exceeded:
– Check the oil passages.
– Renew oil pump if necessary ⇒ page 81 , Dismantling and as‐
sembling oil pump.

Passat 1997 ➤
19 – Cooling
1 Removing and installing parts of cool‐
ing system
WARNING

tions:
sitions.
hot components.
Note
♦ When the engine is warm, the cooling system is under pres‐

sure. If necessary, release pressure before beginning repair
work.
♦ Hoses are secured with spring-type clips. In case of repair,
only use spring-type clips.
♦ Spring-type clip pliers -VAS 5024- or hose clip pliers -
V.A.G 1921- are recommended for fitting spring-type clips.
♦ When installing coolant hoses, route stress-free so that they
do not come into contact with other components (observe
markings on coolant connection and hose).
Perform cooling system leakage test with cooling system tester -

V.A.G 1274- and adapters -V.A.G 1274/8- and -V.A.G 1274/9- .
Parts of cooling system - body side ⇒ page 90 .
Parts of cooling system - engine side ⇒ page 93 .
Coolant hose schematic diagram ⇒ page 96 .
Dismantling and assembling thermostat housing ⇒ page 97 .
Draining and filling with coolant ⇒ page 99 .
Coolant mixture ratios ⇒ page 99 , draining and filling with cool‐
ant.
1.1 Parts of cooling system, body side
90 Rep. gr.19 - Cooling

Passat 1997 ➤
1 - Sealing strip
❑ Pushed onto top and
bottom of radiator.
2 - Securing clip
3 - Rubber mounting
4 - Radiator
⇒ page 103 .
❑ After renewing, renew
entire coolant.
❑ With ATF cooler on ve‐
hicles with an automatic
gearbox and front-
wheel drive: ⇒ 5-speed
automatic gearbox 01V;
Repair group 37; Dis‐
mantling and assem‐
bling gearbox; Remov‐
ing and installing ATF
lines .
❑ With ATF cooler on ve‐
hicles with an automatic
gearbox and four-wheel
drive: ⇒ 5-speed auto‐
matic gearbox 01V,
four-wheel drive; Repair
group 37; Dismantling
and assembling gear‐
box; Removing and in‐
stalling ATF lines .
❑ Cleaning ATF cooler on
vehicles with front-
wheel drive: ⇒ 5-speed
automatic gearbox 01V;
Repair group 37; Dis‐
mantling and assem‐
bling gearbox; Cleaning
ATF lines and ATF cooler .
❑ Cleaning ATF cooler on vehicles with four-wheel drive: ⇒ 5-speed automatic gearbox 01V, four-wheel
drive; Repair group 37; Dismantling and assembling gearbox; Cleaning ATF lines and ATF cooler .
5 - Connection for ATF lines
❑ Only on vehicles with automatic gearbox.
6 - Rubber bush
7 - Radiator fan -V7-
❑ Vehicles with optional equipment only.
8 - Fan ring
❑ Clipped into air shroud and secured with locking bolt ⇒ Item 9 (page 91) .
9 - Locking bolt
10 - 10 Nm
11 - Connector
❑ For radiator fan -V7- .
12 - Connector
❑ Black, 4-pin.
❑ For thermal switch for radiator fan.
1. Removing and installing parts of cooling system 91

Passat 1997 ➤
13 - Radiator fan thermal switch -F18-

❑ For electric fan.
❑ Vehicles with optional equipment only.
❑ Switching temperatures:
1st stage on 92…97 °C, off 84…91 °C
2nd stage on 99…105 °C, off 91…98 °C

❑ Secured with securing clip
14 - O-ring
15 - Lower coolant hose
❑ Secured to radiator with quick-release coupling.
16 - Retaining clip
17 - Plug, 10 Nm
18 - Drain plug, 10 Nm
19 - Upper coolant hose

Passat 1997 ➤
1.2 Parts of cooling system, engine side
1 - 10 Nm
2 - Fan wheel
3 - Coolant hose
❑ From union for combi‐
nation valve.
4 - Throttle valve module
❑ Heated by coolant.
5 - 8 Nm
6 - Seal
❑ Renew.
7 - Bracket
❑ For coolant pipe and
wiring harness
8 - To heat exchanger
9 - 8 Nm
bling ⇒ page 97 .
tion pump -V51-
12 - O-ring
❑ Renew.
13 - From heat exchanger
14 - 10 Nm
15 - Expansion tank
❑ Carry out leak test of cooling system using cooling system tester -V.A.G 1274- and adapter -
V.A.G 1274/8- .
16 - Seal
17 - Cap
❑ Check with cooling system tester -V.A.G 1274- and adapter -V.A.G 1274/9-
❑ Test pressure: 1.4…1.6 bar.

Passat 1997 ➤

20 - Gasket
❑ Renew.
21 - Oil cooler
❑ Dismantling and assembling ⇒ page 80 , Dismantling and assembling oil filter housing/engine mounting.
22 - 25 Nm
23 - Compact bracket
❑ For tensioner, viscous fan coupling, alternator, coolant pump and power-assisted steering vane pump.
24 - Coolant pipe
25 - 8 Nm
1.3 Dismantling and assembling compact

bracket
Note
Specified torque for poly V-belt idler roller: 23 Nm

Passat 1997 ➤
1 - Viscous fan coupling

⇒ page 105 .
2 - Belt pulley
❑ For viscous fan cou‐
pling.
⇒ page 105 , removing
and installing viscous
fan coupling.
3 - 30 Nm
4 - Compact bracket
❑ For tensioner, viscous
fan coupling, alternator,
coolant pump and pow‐
er-assisted steering
vane pump.
5 - 25 Nm
❑ Observe tightening se‐
quence ⇒ page 96 .
6 - Mounting
7 - Circlip
8 - 45 Nm
❑ For viscous fan cou‐
pling.
9 - Cover
❑ For coolant pump.
10 - Gasket
❑ Renew.
11 - 25 Nm
12 - O-ring
❑ Renew.
13 - Coolant pump
❑ Check for ease of movement.
14 - Belt pulley
❑ For coolant pump.
15 - 25 Nm
16 - 8 Nm
17 - Tensioning element for poly V-belt
❑ Removing and installing poly V-belt ⇒ page 19 .
18 - Bearing bush
❑ For viscous fan coupling.

Passat 1997 ➤
Tightening sequence, compact bracket to cylinder block

Procedure
– Position compact bracket on cylinder block and tighten secur‐
ing bolts by hand.
– Tighten compact bracket in sequence as follows to 25 Nm:
1 - Tighten fitting bolts -A-
2 - Tighten bolts -B-
1.4 Coolant hose schematic diagram

Passat 1997 ➤
1 - Throttle valve module

2 - Coolant pipe
3 - Heat exchanger for heater
unit
4 - Quick-release coupling
5 - Expansion tank
tion pump -V51-
9 - Radiator
11 - Oil cooler
12 - Coolant pump
13 - Cylinder block
14 - Coolant pipe
15 - Cylinder head
1.5 Dismantling and assembling thermostat

housing
Note
Routing of coolant hoses on thermostat housing ⇒ page 93 , parts

of cooling system - engine side.
Volkswagen Technical Site: https://vwts.ru

Passat 1997 ➤
1 - O-ring
2 - Retaining clip
❑ Check for secure seat‐
ing.
4 - 8 Nm
5 - Thermostat
tion.
❑ Checking: heat thermo‐
stat in water.
❑ Opening begins at ap‐
prox. 80 °C.
❑ Ends at approx. 105 °C.
❑ Opening lift at least 7
mm.
6 - Connection
7 - Seal
❑ Renew.
8 - Coolant temperature send‐
er -G62-
❑ With coolant tempera‐
ture display sender -
G2- .
❑ For engine control unit.
❑ Before removing, re‐
lease pressure in cool‐
ing system if necessary.
❑ Checking: ⇒ Fault
memory; Rep. gr. 01 ;
Reading and erasing
fault memory
9 - Plug
❑ Before removing, release pressure in cooling system if necessary.

Passat 1997 ➤
1.6 Draining and filling coolant

equipment required
♦ Hose clamps up to 25 mm
-3094-
♦ Refractometer -T10007-
♦ Adapter for cooling system
tester -V.A.G 1274/8-
♦ Pipe for cooling system
tester -V.A.G 1274/10-
1331-
♦ Cooling system charge unit
-VAS 6096-
Draining
– Open cap on coolant expansion tank.

Passat 1997 ➤
WARNING

– Remove noise insulation ⇒ General body repairs, exterior;

Rep. gr. 50 ; Assembly overview - noise insulation .
– Remove drain plug -arrow-.
– Pull out retaining clip -arrow- for coolant hose and remove
coolant hose from quick-release coupling of radiator.
Note
Observe environmental regulations for disposal.
Filling

Passat 1997 ➤
Note
♦ Use only coolant additive G 12 in accordance with TL -

VW 774 F- . Identification: purple colour.
♦ G 12 and coolant additives marked "In accordance with TL -
VW 774- F" prevent frost and corrosion damage and scaling
and also raise the boiling point of coolant. Therefore, the sys‐
tem must be filled all year round with frost and corrosion
protection additives.
♦ G 12 purple (in accordance with -VW 774 F- ) can be mixed
with existing coolant additives G 11 and G 12 red!
♦ Because of its higher boiling point, the coolant improves en‐
gine reliability under heavy loads, particularly in countries with
tropical climates.
♦ Frost protection is required down to about -25 °C (in countries
with arctic climates: down to about -35 °C).
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. The anti-
freeze must be at least 40% of mixture.
♦ If for climatic reasons greater frost protection is required, the
amount of G 12 can be increased, but only up to 60% (frost
protection to about -40 °C). Otherwise frost protection and
cooling effectiveness are reduced again.
♦ The refractometer -T10007- is recommended for determining
the current anti-freeze concentration.
♦ If radiator, heat exchanger, cylinder head or cylinder head
gasket is renewed, do not reuse old coolant.
Recommended mixture ratios:

Frost protection Anti-freeze G 127) Water7)
to quantity
-25°C 40 % 3.6 l 5.4 l
-35°C 50 % 4.5 l 4.5 l
7) The quantity of coolant can vary depending upon vehicle equipment.
Procedure
– Install lower coolant hose and secure with retaining clip.
– Install drain plug in radiator.
With cooling system charge unit -VAS 6096-
– Screw adapter -V.A.G 1274/8- onto expansion tank.
– Fill coolant circuit using cooling system charge unit -
VAS 6096- . ⇒ Operating instructions for cooling system
charge unit VAS 6096
Without cooling system charge unit -VAS 6096-

Passat 1997 ➤
– Screw adapter -V.A.G 1274/8- and adapter -V.A.G 1274/10-

onto expansion tank.
– Loosen coolant hose on heat exchanger and pull back hose

sufficiently so that the bleeder hole -arrow- is no longer hidden
by the connection.
– Fill with coolant until it flows out of the bleeder hole in coolant
hose.
– Push coolant hose onto connection and tighten using hose
clip.
– Fit expansion tank cap.
– Switch off heater and air conditioner.
– Start engine and maintain an engine speed of about 1300 rpm
for about 4 minutes.
– Then run engine at idling speed until electric radiator fan cuts
in.
– To relieve pressure, carefully open cap on coolant expansion
tank.
– Now screw adapter -V.A.G 1274/8- with adapter -

V.A.G 1274/10- onto expansion tank again.

Passat 1997 ➤
– Loosen coolant hose on heat exchanger and pull back hose

sufficiently so that the bleeder hole -arrow- is no longer hidden
by the connection.
– Fill up with coolant until it flows out at bleeder hole free of
bubbles again.
– Push coolant hose onto connection and tighten using hose
clip.
– Remove both adapters from expansion tank and remove/fill
with coolant so that fluid is at max. mark.
– Fit expansion tank cap.
– Clamp breather hose off from upper coolant hose using hose
clamps 3093 or 3094.
– Start engine and maintain an engine speed of about 3000 rpm
for approx. 4 minutes then maintain an engine speed of about
1300 rpm for approx. 3 minutes.
– Remove hose clamp from breather hose on upper coolant
hose.
– Allow engine to run at idling speed for approx. 15 minutes.
– Allow engine to cool.
– Check coolant level and top up if necessary. When the engine
is at normal operating temperature, the coolant level must be
on the max. mark; when the engine is cold, between the min.
and max. marks.
1.7 Removing and installing radiator

Passat 1997 ➤

equipment required
♦ Refractometer -T10007-
1331-
♦ Spring-type clip pliers
-5024-
Removing
– Remove front bumper ⇒ General body repairs, exterior; Rep.
gr. 63 ; Front bumper .
– Pull coolant hoses off radiator.
– Remove ATF lines from radiator ⇒ 5-speed automatic gear‐
box 01V; Rep. gr. 37 ; Removing and installing ATF lines .

Passat 1997 ➤

– Unbolt power steering hydraulic oil cooling pipe -arrows- and
lay free. Do not open hydraulic oil circuit.
– Remove upper radiator securing clips and take radiator out
forwards.
Vehicles with air conditioner
– Observe additional information and installation work
⇒ page 105 .
Installing
note the following:
– Check ATF level ⇒ 5-speed automatic gearbox 01V; Rep. gr.
37 ; Checking ATF level and topping-up .
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
– Install front bumper ⇒ General body repairs, exterior; Rep. gr.
63 ; Front bumper .
– Check headlight adjustment and correct if necessary ⇒ Main‐
Additional information and assembly work for vehicles with air
conditioner
WARNING
The air conditioner refrigerant circuit must not be opened.
Note
To prevent damage to condenser and also to refrigerant lines/

hoses, ensure that the lines and hoses are not stretched, kinked
or bent.
– Remove retaining clamp(s) for refrigerant lines.

– Remove condenser from radiator and pull forward as far as is
possible.
– Secure condenser to body so that refrigerant pipes/hoses are
not stressed.
– Pull radiator out between condenser and lock carrier.
1.8 Removing and installing viscous fan

coupling

Passat 1997 ➤
♦ 2-hole pin wrench -3212-
Removing
– Move lock carrier to service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Service position .
– Remove fan wheel from viscous fan coupling.
– Counterhold belt pulley for viscous fan coupling using pin
wrench -3212- .
– Remove viscous fan coupling securing bolts (using 8 mm allen

key -1-) and remove viscous fan coupling with belt pulley.
– Remove belt pulley from viscous fan coupling.
1.9 Removing and installing viscous fan mounting bush

Passat 1997 ➤

equipment required
♦ Hexagon bolt from assem‐
bly tool -3290-
♦ Hexagon nut from assem‐
bly tool -3301-
♦ Thrust piece -3349/1-
♦ Thrust piece -3367/2-
♦ Multi-purpose tool -VW
771- with adapter -
VW 771/15-
♦ Pins -VW 771/43-

Passat 1997 ➤

1331-
♦ Spring-type clip pliers -
VAS 5024-
♦ 5 mm ∅ drift
Removing
– Removing radiator ⇒ page 103 .
– Remove viscous fan coupling (with belt pulley) ⇒ page 105 .
– Unscrew dipstick guide tube securing bolt from intake mani‐
fold.
– Pull dipstick guide tube out of cylinder block.
– Remove bearing bush securing clips -arrows-.

Passat 1997 ➤
– Pull out bearing bush with front bush with aid of multi-purpose
tool -VW 771- , adapter -VW 771/15- and pin -VW 771/43- .
– Carefully drive rear bush out using a drift (∅ 5 mm).
– Press front bush out of bearing bush using press plate -

VW 401- .
– Press new bushes into bearing bush using press plate -

VW 401- . Dimension -a- = 11 mm
Note
♦ Do not cant bush when pressing.

♦ Note different sizes of bushes.
Installing
– Fit bearing bush with bushes onto compact bracket using hex‐
agon nut from assembly tool -3301- , press piece -3367/2- ,
press piece -3349/1- and hexagon nut from assembly tool
-3290- as shown.
– Tighten hexagon nut from assembly tool -3301- by hand as far
as possible.
Note
Do not cant bush when pulling.

Passat 1997 ➤
– Press bearing bush with bushes into compact bracket to stop.

– Secure bearing bush with securing clips after installing.
– Install viscous fan coupling ⇒ page 105 .
– Install dip stick guide tube, specified torque: 8 Nm.
– Install radiator ⇒ page 103 .
1.10 Checking continued coolant circulation

pump
♦ Voltage tester -V.A.G 1527B-
♦ Auxiliary measuring set -V.A.G 1594C-
♦ Current flow diagram

Test prerequisite
• All fuses must be OK.
Test procedure
– Pull 2-pin connector off continued coolant circulation pump -
V51- .
Checking function

Passat 1997 ➤
– Connect contacts of continued coolant circulation pump -V51-

to battery using adapter cables from auxiliary set -V.A.G
1594C- . Continued coolant circulation pump -V51- must run.
If the continued coolant circulation pump -V51- does not run:
– Renew continued coolant circulation pump -V51- .
If the continued coolant circulation pump -V51- runs:
Checking activation
– Switch ignition on and off again.
– Connect voltage tester -V.A.G 1527B- to connector detached

from continued coolant circulation pump -V51- using auxiliary
cables from adapter set -V.A.G 1594C- . LED must light up.
Note
This check must be performed within 10 minutes of switching ig‐

nition off.

– Locate and eliminate open circuit referring to current flow di‐
agram: ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.

Passat 1997 ➤
20 – Fuel supply system

1 Removing and installing parts of fuel
supply system
Note
♦ Hose connections are secured with either spring-type or

clamp-type clips.
♦ Always renew clamp-type clips with spring-type clips.
♦ Fuel hoses on engine must be secured with spring-type clips
only. The use of clamp or screw-type clips is not permissible.
♦ The fuel extractor -VAS 5190- is recommended to empty the
fuel tank.
♦ Hose clip pliers -VAS 5024- or hose clip pliers -V.A.G 1921-
are recommended for installation of spring-type clips.
Removing and installing fuel tank with attachments and fuel filter:
vehicles with front-wheel drive ⇒ page 112 .
Removing and installing fuel tank with attachments and fuel filter:
vehicles with four-wheel drive ⇒ page 115 .
Observe safety precautions ⇒ page 118 .
Observe rules for cleanliness ⇒ page 119 .
Removing, installing and checking suction-jet pump: vehicles with
four-wheel drive ⇒ page 119 .
Observe crash fuel shut-off ⇒ page 121 .
Electronic power control (EPC) ⇒ page 137 .
Activated charcoal filter system ⇒ page 143 .
1.1 Removing and installing fuel tank with

attachments and fuel filter: vehicles with
front-wheel drive
Note
Ensure, on completion of all work on the fuel delivery unit and fuel
gauge that the fuel supply and fuel return hoses do not touch the
fuel tank (transfer of pumping noises).
112 Rep. gr.20 - Fuel supply system

Passat 1997 ➤
1 - Cap
❑ With securing clip.
2 - Seal
3 - Tank flap unit
❑ With rubber cup.
4 - Securing bolt
5 - Gravity valve
❑ To remove valve unclip
upwards out of support.
❑ Check valve for
through-flow; valve ver‐
tical: open, valve tilted
45°: closed.
6 - O-ring
7 - Breather line
❑ Black
❑ Clipped onto side of fuel
tank.
❑ Check for secure seat‐
ing.
❑ Secure with spring-type
clips.
❑ To activated charcoal fil‐
ter
⇒ Item 1 (page 144) .
8 - Breather valve
sideways out of support.
❑ Before installing remove
cap ⇒ Item 1 (page 113) .
9 - Earth connection
10 - Supply line
❑ Black
❑ Clipped onto side of fuel tank.
❑ To release lower securing clip, press together circlip on face side of angled connection.
❑ Between flange ⇒ Item 14 (page 114) and fuel filter -item ⇒ Item 26 (page 114) -
11 - Return line
❑ Blue or with blue marking.
❑ To release lower securing clip, press together circlip on face side of angled connection.
❑ From fuel return pipe on fuel rail: ⇒ Repairing injection system; Rep. gr. 24 ; Dismantling and assembling
fuel rail and injectors .
12 - Connector
❑ Black, 4-pin.
❑ For fuel gauge sender -G- and fuel pump -G6- .
1. Removing and installing parts of fuel supply system 113

Passat 1997 ➤
13 - Union nut, 80 Nm
❑ Remove and install using union nut tool -3217- .
14 - Flange
❑ Only renew complete with fuel supply unit.
❑ Note installation position on fuel tank ⇒ page 115 .
15 - Fuel gauge sender -G-
❑ Clipped onto fuel delivery unit reservoir.
16 - Return line
❑ Between flange ⇒ Item 14 (page 114) and fuel delivery unit reservoir.
17 - Supply line
❑ Between flange ⇒ Item 14 (page 114) and fuel delivery unit -item ⇒ Item 18 (page 114) -.
18 - Fuel delivery unit
❑ Can only be renewed complete with flange.
❑ Checking fuel pump ⇒ page 128 .
19 - Seal
❑ When installing, fit dry in fuel tank opening.
❑ Moisten with fuel only when installing flange.
20 - 25 Nm
21 - Fuel tank
❑ When removing, support using engine and gearbox jack -V.A.G 1383 A- .
22 - Bracket
❑ For securing straps.
23 - Securing strap
❑ Note different lengths.
❑ Installation position: Fixing point (holes) face in direction of travel.
24 - Retaining ring
❑ Secured to body.
25 - 10 Nm
26 - Fuel filter
❑ Installation position: arrow points in direction of flow.
27 - Supply line
❑ Black
❑ Secure with spring-type clips.
❑ To fuel supply pipe on fuel rail ⇒ Repairing injection system; Rep. gr. 24 ; Dismantling and assembling
fuel rail and injectors
28 - Breather line
❑ Clipped onto top of fuel tank.

Passat 1997 ➤
Installation position of fuel delivery unit flange

Mark on flange -1- must align with mark on fuel tank -2-.
Note
After installing fuel delivery unit flange, check that supply, return
and breather lines are still clipped onto fuel tank.
Checking breather valve

Lever in rest position: closed.
Lever pushed in direction of arrow: open.
Note
Before installing breather valve remove fuel tank cap.
1.2 Removing and installing fuel tank with

attachments and fuel filter: vehicles with
four-wheel drive
Note
Ensure, on completion of all work on the fuel delivery unit and fuel
gauge that the fuel supply and fuel return hoses do not touch the
fuel tank (transfer of pumping noises).

Passat 1997 ➤
1 - Cap
2 - Seal
3 - Securing bolt
4 - Tank flap unit
❑ With rubber cup.
5 - O-ring
6 - Breather valve
sideways out of support.
❑ Before installing remove
cap
⇒ Item 1 (page 113) .
7 - Connecting hose
8 - Gravity valve
upwards out of support.
❑ Check valve for
through-flow; valve ver‐
tical: open, valve tilted
45°: closed.
9 - 10 Nm
10 - Fuel filler neck
11 - Non-return valve
tion: white side of valve
points in direction of
sealing cap
⇒ Item 1 (page 113) .
12 - Connecting hose
13 - Heat shield
❑ For fuel filler neck ⇒ Item 10 (page 116) .
14 - Union nut, 60 Nm
❑ Remove and install using union nut tool -3218- .
15 - Connector
❑ Black
❑ For fuel gauge sender -G-
16 - Flange
❑ Note installation position on fuel tank ⇒ page 115 .
17 - Seal
❑ When installing, fit dry in fuel tank opening.
❑ Moisten with fuel only when installing flange ⇒ Item 14 (page 114) .
18 - Breather line
❑ To prevent damage to the fuel tank connection always route the breather line stress-free.
❑ Black

Passat 1997 ➤
19 - Heat shield
❑ For fuel tank.
20 - Securing clip
21 - Fuel gauge sender 3 -G237-
22 - 25 Nm
23 - Securing strap
24 - Fuel gauge sender 2 -G169-
25 - Locking ring, 145 Nm
❑ Remove and install using fuel tank sender unit tool -3087- .
26 - Fuel tank
❑ When removing, support using engine and gearbox jack -V.A.G 1383 A- .
27 - Return line
❑ Blue or with blue marking.
❑ From fuel return pipe on fuel rail: ⇒ Repairing injection system; Rep. gr. 24 ; Dismantling and assembling
fuel rail and injectors .
28 - Connector
❑ Black, 4-pin.
❑ For fuel gauge sender -G- and fuel pump -G6- .
29 - Supply line
❑ Black
30 - Fuel gauge sender -G-
❑ Clipped on reservoir housing in fuel tank.
31 - Fuel delivery unit
❑ Checking fuel pump ⇒ page 128 .
32 - Supply line
❑ Black
❑ To fuel supply pipe on fuel rail ⇒ Repairing injection system; Rep. gr. 24 ; Dismantling and assembling
fuel rail and injectors
33 - Fuel filter
❑ Installation position: arrow points in direction of flow.
34 - Breather line
❑ Black

Passat 1997 ➤
❑ To activated charcoal filter ⇒ Item 1 (page 144) .
35 - Earth connection
Installation position of fuel delivery unit flange

Mark on flange -1- must align with mark on fuel tank -2-.
Note
After installing fuel delivery unit flange, check that supply, return
and breather lines are still clipped onto fuel tank.
Checking breather valve

Lever in rest position: closed.
Lever pushed in direction of arrow: open.
Note
Before installing breather valve remove fuel tank cap.
1.3 Safety precautions when working on

fuel supply system
WARNING

tions:
sitions.
hot components.
When removing and installing fuel gauge sender or fuel pump

(fuel delivery unit) from a full or partly full fuel tank, observe the
following:

Passat 1997 ➤
WARNING

♦ Before beginning work, place an extraction hose close to

sender opening in fuel tank to extract escaping fuel fumes and
switch on exhaust extraction system. If no exhaust gas ex‐
traction system is available, a radial fan with a displacement
greater than 15 m3/h can be used providing that motor is not
in air flow.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
♦ For safety reasons, fuse No. 28 must be removed from the
fuse holder before opening the fuel system. Otherwise, the fuel
pump could be activated by the driver's door contact switch.
1.4 Rules for cleanliness

When working on the fuel supply and injection system, pay careful
attention to the following „5 rules“ for cleanliness:
♦ Thoroughly clean all unions and surrounding areas before dis‐
connecting.
♦ Place removed parts on a clean surface and cover. Use only
lint-free cloths.
♦ Carefully cover opened components or seal if repairs cannot
be carried out immediately.
♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have not been stored in their packing (e.g. in
tool boxes etc.).
♦ When system is open: do not work with compressed air if this
can be avoided. Do not move vehicle unless absolutely nec‐
essary.
1.5 Removing, installing and checking suc‐

tion-jet pump: vehicles with four-wheel
drive
On vehicles with four-wheel drive the shape of the fuel tank dic‐
tates that a suction-jet pump is required to pump fuel from vicinity
of fuel gauge sender 2 - ⇒ Item 24 (page 117) - to the fuel delivery
unit. A second suction-jet pump ensures that the delivery unit in
the reservoir housing is supplied with fuel. The suction-jet pump
function according to a principle of physics using the return flow
of fuel via a junction with pressure limiting valve.
Note
♦ A check is only necessary when:

♦ the engine stops due to lack of fuel
♦ fault codes (V.A.G codes) „17536, 17538, 17544 and 17546“
are stored in the fault memory even though the fuel gauge
shows that the fuel tank is 1/4 full.

Passat 1997 ➤
– Read and erase fault memory ⇒ Fault memory; Rep. gr. 01 ;

♦ Fuel tank sender unit tool -3087-
Test prerequisites
• Fuel tank must have been drained
• The three fuel gauge senders (G, G169 and G237) must have
been checked using the fault finding programme and are
OK.:⇒ Current flow diagrams, Electrical fault finding and Fitting
locations
Procedure
– Note safety precautions before beginning work ⇒ page 118 .
WARNING


theft coding.
– Pull 4-pin connector and fuel hoses off fuel delivery unit (right
side of vehicle) and remove the fuel delivery unit
⇒ page 123 , removing and installing fuel delivery unit.
– Now pull 2-pin connector off fuel gauge sender 2 -G169- (left
side of vehicle), open the sealing ring with fuel tank sender unit
tool -3087- and carefully lift the sender.

Passat 1997 ➤
– Now pull off connector -1- under the cover on fuel gauge send‐
er 2 -2-.
– Lift fuel gauge sender 2 -G169- -2- and pull suction-jet pump
-3- out of locking device of sender.
– Take out fuel gauge sender 2 -G169- .
– Now, on right side of vehicle (fuel delivery unit), pull line to

suction-jet pump -2- off junction -1- and pull connector -3- off
fuel gauge sender -G- to fuel gauge sender 2 -G169- .
– Now the suction-jet pump can be pulled out of the side of fuel
gauge sender 2 (left side of vehicle).
– Check that the fuel lines on suction-jet pump are fitted securely
and are not damaged.
– Additionally check suction-jet pump for possible soiling.
If no fault is found:
– Install suction-jet pump and fuel gauge sender 2 -G169- again
in reverse order.
Note
In other work sequences the return supply line must be pulled off
junction. When doing this observe that all O-rings must be re‐
newed.
Now check junction piece with pressure relief valve as follows:
– Pull off connections for return supply -2-, connections -3- and
-4- for suction-jet pump on junction with pressure relief valve
-1-.
– Unclip the junction which is secured on the reservoir housing.
– Use a test hose and blow into connection, from direction of fuel
return -2-, there must be through flow in directions -3- and
-4-.
– Hold connections -3- and -4- closed, the pressure relief valve
must open under slight opposing pressure.
– If no opposing pressure can be determined or the pressure
relief valve does not open, renew junction with pressure relief
valve.
1.6 Crash fuel shut-off

Function
Vehicles with an airbag are fitted with a crash fuel shut-off. It re‐
duces the danger of a fire in a crash as the fuel pump is switched
off via the fuel pump relay. The system also improves the starting
characteristics of the engine. When door is opened, the fuel pump
is activated for 2 seconds to build up pressure in the fuel system.
When opening fuel system:

Passat 1997 ➤
– Check activation of fuel pump relay referring to current flow

diagram and with -V.A.G 1466 A- , checking: ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations.
1.7 Removing and installing fuel delivery

unit: front-wheel drive vehicles
♦ Union nut tool -3217-
Removing
• The fuel tank must not be more than 1/2 full.
Note
♦ If necessary, empty fuel tank using fuel extractor -VAS 5190- .

♦ Note safety precautions before beginning work ⇒ page 118 .

theft coding.
– Remove cover in luggage compartment floor.
WARNING


Passat 1997 ➤
– Pull 4-pin connector and supply and return pipes -arrows- off
flange.
Note
To release fuel lines press together circlip on face side of angled

connection at bottom.
– Unscrew union nut with union nut tool -3217- .

– Pull fuel delivery unit with seal out of opening in fuel tank.
Note
If delivery unit is to be renewed, drain old delivery unit before dis‐

posal.
Installing
– Installation of fuel delivery unit is carried out in reverse order.
Note
♦ Do not bend fuel gauge sender when installing.

♦ Insert seal for flange or fuel delivery unit dry into opening of
fuel tank.
♦ Moisten seal with fuel only when installing flange or fuel de‐
livery unit.
♦ Ensure that fuel lines are tight.
♦ Do not interchange supply and return lines.
♦ Note Installation position of fuel delivery unit flange: Mark on
flange -1- must align with mark on fuel tank -2-.
♦ After installing fuel delivery unit, check that supply, return and
breather lines are still clipped onto fuel tank.
1.8 Removing and installing fuel delivery

unit: four-wheel drive vehicles

Passat 1997 ➤
♦ Fuel tank sender unit tool -3087-
♦ Fuel pump tool -3307-

Removing
• The fuel tank must not be more than 1/2 full.
Note
♦ If necessary, empty fuel tank using fuel extractor -VAS 5190- .

♦ Note safety precautions before beginning work ⇒ page 118 .

theft coding.
– Remove rear seat bench.
– Remove cover in floor.
WARNING


Passat 1997 ➤
– Pull 4-pin connector and supply and return pipes -arrows- off
flange.
– Unscrew locking ring with fuel tank sender unit tool -3087- .
– Pull flange and seal out of opening in fuel tank.
– Unclip fuel gauge sender -G- from reservoir housing and re‐
move.
– Turn fuel delivery unit approx. 15° anti-clockwise onto stop

with fuel pump tool -3307- and remove.
Note
If delivery unit is to be renewed, drain old delivery unit before dis‐

posal.
Installing
– Installation of fuel delivery unit is carried out in reverse order.

Passat 1997 ➤
Note
♦ Do not bend fuel gauge sender when installing.

♦ Insert seal for flange or fuel delivery unit dry into opening of
fuel tank.
♦ Moisten seal with fuel only when installing flange or fuel de‐
livery unit.
♦ Do not interchange supply and return hoses (return hose -
blue-).
♦ Ensure that fuel lines are tight.
♦ Secure fuel hoses with spring-type clips.
♦ Note Installation position of fuel delivery unit flange: Mark on
flange -1- must align with mark on fuel tank -2-.
♦ After installing fuel delivery unit flange, check that the supply,
return and breather pipes are still clipped onto fuel tank.
1.9 Removing and installing fuel gauge

sender: vehicles with front-wheel drive
Note
How to remove and install fuel delivery unit ⇒ page 122
Removing
– 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-.
Installing
– Insert fuel gauge sender into guides on fuel delivery unit and
press upwards until it engages.
1.10 Removing and installing fuel tank


Passat 1997 ➤
♦ Engine and gearbox jack -V.A.G 1383 A-
Removing
– Note safety precautions before beginning work ⇒ page 118 .
theft coding.
Vehicles with four-wheel drive
– Remove centre and rear silencer of exhaust system
⇒ page 155 , Silencer with fixtures.
– Remove rear axle ⇒ Running gear front and four wheel drive;
Rep. gr. 42 ; Repairing rear axle; Removing and installing rear
axle .
– Open fuel tank filler flap.
– Remove rear right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Removing and installing wheel
housing liner.
– Remove protective plate for filler neck.
– Drain fuel tank and clean fuel filler neck and surrounding area.
– Unscrew securing bolt and remove tank flap unit with rubber
cup.
– Remove filler neck securing bolts.
Front-wheel drive vehicles
WARNING


Passat 1997 ➤
– Pull supply line -1- off inlet to fuel filter.

– Mark return line -2- and breather line -3- and separate at con‐
necting point.
WARNING

– Pull supply hose -1- off fuel filter.

– Mark return line -2- and breather line -3- and separate at con‐
necting point.
– Remove left and right protective plates on fuel tank and floor.
– Remove cover from fuel delivery unit.
– Remove securing straps. When doing this, support fuel tank
with engine and gearbox jack -V.A.G 1383 A- .
– Lower with engine and gearbox jack -V.A.G 1383 A- just

enough to allow connector to be pulled off flange -arrow-.
– Lower fuel tank.
Installing
note the following:
Caution
To prevent damage to the fuel tank connections always route

the breather lines stress-free.
♦ Install breather and fuel hoses free of kinks.

♦ Ensure that fuel hose connections are tight.
♦ Secure fuel hoses with spring-type clips.
♦ Do not interchange supply and return hose (return hose blue
or blue markings, supply hose black).
Note
After installing fuel tank, check that the supply, return and breath‐
er lines are still clipped onto the fuel tank.
1.11 Checking fuel pump

Passat 1997 ➤

equipment required
♦ K-Jetronic pressure tester -
V.A.G 1318-
♦ Adapter set -V.A.G
1318/10-12-
♦ Hose adapter -V.A.G
1318/16-
♦ Remote control for V.A.G
1348 -V.A.G 1348/3A-
♦ Adapter cable -V.A.G
1348/3-2-

Passat 1997 ➤
♦ Fuel tank sender unit tool

-3087- (vehicles with four-
wheel drive)
♦ Union nut tool -3217- (vehi‐
cles with four-wheel drive)
1332-
♦ Tester -1466 A-
♦ Voltage tester -V.A.G
1527B-
V.A.G 1594A-
♦ Multimeter -V.A.G 1715-
♦ -VAS 5024- Spring-type
clip pliers

Passat 1997 ➤
Test prerequisites
• Fuse 28 must be OK.
switched off.
Note
Observe the functional description of the crash fuel shut-off

⇒ page 121 .
1.11.1 Checking function and voltage supply
Note
Before carrying out further work, battery earth strap may have to
be disconnected. First check whether a coded radio is fitted. Ob‐
tain anti-theft coding first if necessary.

– Briefly operate starter. Fuel pump must be heard to run.
If the fuel pump does not start:
– Remove fuse holder cover.
– Pull fuse No. 28 out of fuse holder.
– Connect remote control -V.A.G 1348/3A- with adapter cable -
V.A.G 1348/3-2- to contact 28a to fuel pump and battery
positive (+).
– Operate remote control.
If fuel pump runs:
– Check activation of fuel pump relay referring to current flow
diagram and with -V.A.G 1466 A- , checking: ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations.
If fuel pump does not run:

Passat 1997 ➤
– Pull 4-pin connector off fuel tank flange -arrow-.
– Connect voltage tester -V.A.G 1527B- to outer contacts of

connector using cables from -V.A.G 1594 A- .
– Operate remote control. LED must light up
– Locate and eliminate open circuit referring to current flow di‐
agram: ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
If LED lights up (voltage supply OK):
– Unscrew union nut with union nut tool -3217- .

– Unscrew locking ring with fuel tank sender unit tool -3087- .
– Check that electrical wires between flange and fuel pump are
connected.
If no open circuit can be found:
– Fuel pump is defective. Renew fuel delivery unit:
♦ Vehicles with front-wheel drive ⇒ page 122 ,
♦ Vehicles with four-wheel drive ⇒ page 123 .
1.11.2 Checking delivery rate

Test prerequisites
• Voltage supply OK.
• Remote control -V.A.G 1348/3A- connected.
Test procedure
– Remove filler cap from fuel tank filler neck.

Passat 1997 ➤
– Remove intake manifold cover.
WARNING

– Connect pressure gauge -V.A.G 1318- to fuel supply line

(white marking) using adapter -V.A.G 1318/10- .
Note
Secure all hose connections with hose clips.
– Push hose adapter - V.A.G 1318/16- onto adapter -

V.A.G 1318/11- of pressure tester -V.A.G 1318- and hold it in
the measuring beaker.
– Open shut-off tap of pressure tester -V.A.G 1318- . The lever
then points in the direction of flow -A-.
– Operate remote control -V.A.G 1348/3A- . Then slowly close
shut-off tap until a pressure of 3 bar is displayed on pressure
gauge. From this point on do not move position of shut-off tap.
– Empty measuring container.
– Delivery rate of fuel pump depends on battery voltage. There‐
fore connect multimeter with auxiliary cables from -
V.A.G 1594 A- to vehicle battery.
– Operate remote control for 30 seconds while measuring bat‐
tery voltage.
– Compare quantity of fuel delivered with specification.

8) Minimum delivery cm3/30 seconds
9) Voltage at fuel pump with engine not running and pump running (approx. 2
volts less than battery voltage).
Example:
During the test a voltage of 12.2 volts is measured at the battery.
As the voltage at the pump is approx. 2 volts less than the battery
voltage, this will equate to a minimum delivery rate of 550 cm3/30
s.
If minimum delivery rate is not attained:
– Check the fuel pipes for possible restrictions (kinks) or block‐
ages.

Passat 1997 ➤


– Connect pressure tester -V.A.G 1318- to hose using adapter
-1318/10- .
– Repeat delivery rate check.
If the minimum delivery rate is now attained:
– Renew fuel filter.
If the minimum delivery rate is again not attained:
– Remove fuel delivery unit and check for dirt in filter strainer.
Only if still no fault has been detected:
If delivery rate has been attained, but nevertheless you suspect
a fuel supply system fault (e.g. intermittent failure of fuel supply
system):
– Check current draw of fuel pump as follows:
– Reconnect all disconnected fuel lines.

Passat 1997 ➤
– Connect multimeter - V.A.G 1715- with pick-up clamp to the

green/yellow wire (chamber 1 in 4-pin connector) in wiring
harness.
– Connect multimeter - V.A.G 1715- with pick-up clamp to the

green/yellow wire (chamber 1 in 4-pin connector) in wiring
harness.
– Start engine and run at idling speed.
– Measure current draw of fuel pump. Specification: max. 8
amps.
Note
If the fuel system malfunction is intermittent, you can perform the

check during a road test, but a 2nd person is necessary.
If the current draw is exceeded:

1.11.3 Checking non-return valve for fuel pump

Test prerequisites
• Remote control -V.A.G 1348/3A- connected.
• Pressure gauge -V.A.G 1318- connected to fuel supply line
from fuel supply pipe.
Note
This test checks for leaks in the fuel supply line connections from
the fuel delivery unit to the point at which the pressure gauge -
V.A.G 1318- is connected.

Passat 1997 ➤
Test procedure
– Close shut-off tap of pressure tester -V.A.G 1318- (lever at
right angles to direction of flow position -B-).
– Operate remote control at short intervals until a pressure of
approx. 3 bar has built up.
– If pressure builds up too high, relieve excess pressure by
carefully opening shut-off tap.
WARNING
Danger of spray when opening shut-off tap. Hold container

over free connection of pressure tester.
– Watch pressure drop on pressure gauge. After 10 minutes,

pressure must not drop below 2.5 bar.
If the pressure drops further:
– Check line connections for leaks.
If no fault in lines is detected:
♦ Front-wheel drive vehicles ⇒ page 122 .
♦ Four-wheel drive vehicles ⇒ page 123 .

Passat 1997 ➤
2 Electronic power control (EPC)
2.1 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.
The position of the accelerator is transmitted to the engine control
unit by two accelerator position senders (variable resistors to‐
gether in one housing) connected to the accelerator.
The position of the accelerator (driver's requirement) is a main
input value for the engine control unit.
The throttle valve is operated over the complete engine speed
and load range by an electric motor (throttle valve positioner) in
the throttle valve module.
The throttle valve is operated by the throttle valve positioner which
is controlled by the engine control unit.
When the engine is not running and the ignition is switched on,
the engine control unit moves the throttle valve exactly as pre‐
scribed by the accelerator position sender. That is, when the
accelerator is depressed halfway, the throttle valve positioner
opens the throttle valve by the same amount. The throttle is then
approximately half open.
When the engine is running (under load), the engine control unit
can open or close the throttle valve independently of the accel‐
erator position sender.
This means that the throttle valve can already be completely open
even though the accelerator is depressed half way. This has the
advantage of preventing throttling losses at the throttle valve.
After evaluating the torque requirements of various components
(e.g. air conditioning system, automatic gearbox, ABS/ESP and
so on), the engine control unit calculates the optimal throttle valve
opening angle for the respective situation.
This also results in significantly improved consumption and ex‐
haust emission values under certain load conditions.
It is incorrect to believe that the „EPC“ is comprised of one or two
components only. E-Gas is a system containing all components
which have an influence, or control or monitor the position of the
throttle valve, such as the accelerator position sensor, the throttle
valve control unit, the EPC warning lamp, the engine control unit.
– EPC warning lamp function test: ⇒ Repair group 01; General
notes for self-diagnosis; Significance of EPC warning lamp
(electronic power control fault lamp) in dash panel insert .
2.2 Repairing parts of electronic power control (EPC)
2. Electronic power control (EPC) 137

Passat 1997 ➤
1 - Bearing bracket
❑ Removing and instal‐
ling: ⇒ Running gear;
Rep. gr. 46 ; Brakes -
mechanism; Assembly
overview - brake pedal/
mounting bracket .
2 - Connector
❑ Black, 6-pin.
3 - 10 Nm
4 - Accelerator position sender
-G79-
❑ Not adjustable.
❑ The accelerator position
sender passes the posi‐
tion of the accelerator
on to the engine control
unit.
❑ Remove footwell cover
to remove sender.
❑ If renewed on vehicles
with an automatic gear‐
box, relearn kick-down
switch point: ⇒ Engine
control unit; Rep. gr.
24 ; Learning kick-down
switch point .

Passat 1997 ➤
2.3 Checking accelerator position sender

equipment required
♦ Hand-held multimeter -
V.A.G 1526 A-
V.A.G 1594 A-
♦ Adapter cable, 121-pin -
V.A.G 1598/31-
or vehicle system tester -
V.A.G 1552- with cable -
V.A.G 1551/3-
♦ Current flow diagram
Function
Both accelerator position senders -G79- and -G185- are located
on the accelerator and pass the driver's requirements on to the
engine control unit independently of one another. Both senders
are installed together in a housing.

Passat 1997 ➤
Test prerequisites
switched off.
Test procedure
– Connect fault reader -V.A.G 1551- (V.A.G 1552) and select
engine control unit with „address word“ 01. The ignition must
be switched on for this purpose: ⇒ Repair group 01; General
notes for self-diagnosis; Connecting fault reader .
Indicated on display:
Rapid data transfer HELP
Select function XX
– Press keys 0 and 8 for „Read measured value block“ function

and confirm with Q key.
Read measured value block

Indicated on display: (1…4 = display zones)
Read measured value block 62 ->
1 2 3 4
– Check specifications of sender 1 -G79- at idling speed stop in

display zone 3.
Specification: 12…97 %
– Check specifications of sender 2 -G185- at idling speed stop
in display zone 4.
Specification: 4…49 %
Note
The engine control unit calculates the angle sender voltage value
as a percent of 5 Volts and displays this percentage. (5 volt supply
voltage equals 100 %).
– Slowly depress accelerator down to full throttle position and

observe the percentage display in display zones 3 and 4:
The percent figures in display zone 3 must rise evenly. The
tolerance range of 12…97% is not covered completely.
The percent figures in display zone 4 must rise evenly. The
tolerance range of 4…49% is not covered completely.
Note
The figure displayed in display zone 3 must always be approxi‐

mately double that displayed in display zone 4.

Passat 1997 ➤
If the display does not indicate as described:
– Test voltage supply and wiring to control unit
Checking voltage supply and wiring to control unit
– Remove cover in footwell (driver side).
– Pull 3-pin connector off accelerator position sender.
– Switch on ignition.
– Connect multimeter to measure voltage using auxiliary cables

from -V.A.G 1594 A- to the following connector contacts.
Contact 1 + earth
Contact 1 + 5
Contact 2 + earth
Contact 2 + 3
• Specification: at least 4.5 V
– Connect adapter cable -V.A.G 1598/31- to control unit wiring

harness. The engine control unit remains disconnected.

Passat 1997 ➤
– Check cables between test box and 6-pin connector for open
circuit using current flow diagram.
Contact 1 and test box socket 72
• Cable resistance: max. 1.5 Ω.
– Additionally check wires for short to one another, to vehicle
earth and to battery positive.
• Specification: ∞ Ω.
If no fault in lines is detected:
– Renew accelerator position sender ⇒ Item 4 (page 138) .
– Read and erase fault memory ⇒ Fault memory; Rep. gr. 01 ;
– If the accelerator position sender has been renewed in a ve‐
hicle with an automatic gearbox, the engine control unit must
also re-learn the kickdown switch point ⇒ Engine control unit;
Rep. gr. 24 ; Re-learning kickdown switch point .
– On vehicles with an automatic gearbox the gearbox control
unit must be additionally adapted ⇒ Self-diagnosis for 5-speed
automatic gearbox 01V and four-wheel drive; Rep. gr. 01 ;
Performing self-diagnosis: Initiating basic setting .

Passat 1997 ➤
3 Activated charcoal filter system
3.1 Function
Depending upon the air pressure and ambient temperature, fuel
vapour will form above the level of fuel in the tank.
The activated charcoal filter system prevents these HC emissions
escaping to the atmosphere.
Fuel vapours get into the activated charcoal filter from the highest
point in fuel tank via the gravity valve (closed at an angle of 45°).
The activated charcoal stores these vapours like a sponge.
When the car is being driven and Lambda control is active (engine
warm), active charcoal filter system solenoid valve 1 -N80- , also
known as regeneration valve, is activated (pulsed) by the engine
control unit depending upon load and engine speed. The opening
period depends on the input signals.
During the purging procedure (regeneration of the activated char‐
coal), the intake manifold vacuum draws in fresh air through the
vent opening on the underside of the activated charcoal filter. The
fuel vapours stored in the activated charcoal and fresh air are fed
to combustion in metered quantities.
The pressure retention valve ( ⇒ Item 10 (page 144) ) prevents
fuel vapours from being drawn from the fuel tank when activated
charcoal filter system solenoid valve 1 -N80- is open and intake
manifold vacuum is present. It thus ensures that the purging of
the activated charcoal filter has priority.
Active charcoal filter system solenoid valve 1 -N80- is closed
when it is not supplied with current (e.g. open circuit). The acti‐
vated charcoal filter will not be purged.
Note
♦ Hose connections are secured with either spring-type or

clamp-type clips.
♦ Always renew clamp-type clips with spring-type clips.
♦ Spring-type clip pliers -VAS 5024- or hose clip pliers -
V.A.G 1921- are recommended for fitting spring-type clips.

Checking fuel tank breather ⇒ page 147 .
3.2 Repairing parts of activated charcoal filter system
3. Activated charcoal filter system 143

Passat 1997 ➤
1 - Activated charcoal filter

❑ Location: in front right
wheel housing.
❑ To remove, remove
front right wheel hous‐
ing liner ⇒ General body
repairs, exterior; Rep.
gr. 66 ; Removing and
installing wheel housing
liner
2 - 10 Nm
3 - Air filter housing
4 - Retaining ring
❑ For activated charcoal
filter system solenoid
valve 1 -N80- .
5 - Activated charcoal filter sol‐
enoid valve 1 -N80-
❑ When engine is warm,
valve will be activated
(pulsed) by engine con‐
trol unit.
❑ Installation position: ar‐
row points in direction of
flow.
❑ Check activation: ⇒ Fi‐
nal control diagnosis;
Rep. gr. 01 ; Performing
final control diagnosis .
6 - Connector
❑ Black, 2-pin
❑ For activated charcoal
filter system solenoid valve 1 -N80- . Volkswagen Technical Site: https://vwts.ru
7 - Breather line
❑ To crankcase breather connecting hose between cylinder head cover and intake air hose: ⇒ Repairing
injection system; Rep. gr. 24 ; Removing and installing parts of the injection system .
❑ Press together at front to release.
8 - Junction
9 - To intake manifold.
10 - Pressure retention valve
❑ For fuel tank breather.
❑ Shuts-off the tank venting when the solenoid valve -N80- is open and intake manifold pressure is present
11 - Breather line
❑ Black
❑ From gravity valve on fuel tank: vehicles with front-wheel drive ⇒ Item 5 (page 113) .
❑ From breather valve on fuel tank: vehicles with four-wheel drive ⇒ Item 6 (page 116) .

Passat 1997 ➤
12 - Securing bolt
13 - Breather hose
❑ To atmosphere.
14 - O-ring
Checking pressure retention valve

From gravity valve, the pressure retention valve is open in both
directions of flow - arrow -1-.
From activated charcoal filter/activated charcoal filter system sol‐
enoid valve 1, it is only open in one direction of flow -arrow 2-.
3.3 Test solenoid valve 1 for activated char‐

coal filter
♦ Line -V.A.G 1551/3-
Note
Vehicle system tester -V.A.G 1551- can be used instead of fault

reader -V.A.G 1552- , however a print-out is not possible.

Passat 1997 ➤
Test prerequisites
• No fault may be stored in fault memory: ⇒ Rep. Gr. 01; Fault
memory; Reading and erasing fault memory .
• Coolant temperature must be at least 80°C, ⇒ display group
01, display zone 2.
Checking activation
– First check activation of activated charcoal filter solenoid 1
(tank breather valve) using final control diagnosis: ⇒ Repair
group 01; Final control diagnosis; Performing final control di‐
agnosis .
If activation is OK:
– Perform check of functions.
Functional check
fault reader and select engine control unit: ⇒ Repair group 01;
General notes for self-diagnosis; Connecting fault reader .
Select function XX

Basic setting

System in basic setting 1 ->
1 2 3 4
Only continue with the test when:

• Coolant temperature is above 80°C, -display zone 2-.
– Change to display group 70 as follows:
Basic setting


Passat 1997 ➤
Note
No engine loading may be created during this diagnosis, other‐

wise the test will be terminated and can only be reinitiated by a
bust of the throttle.

1 2 3 4
When the diagnosis of the engine control unit has been initiated
the display in display zone 4 will jump from „Test OFF“ to „Test
ON“.
– Leave engine running at idle until the specification „TBV OK“
is displayed in display zone 4.
Note
TBV is the abbreviation for: tank breather valve (activated char‐

coal filter system solenoid valve 1).
If display zone 4 displays „TBV n.OK“:
– Check breather lines to activated charcoal filter are not kinked.
– Check fuel tank venting ⇒ page 147 .
3.4 Checking fuel tank breather

♦ Vacuum tester -V.A.G 1368-

Passat 1997 ➤
♦ Hand vacuum pump -V.A.G 1390-
Test procedure
– Remove front right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Removing and installing wheel
housing liner .
– Pull breather line -2- from activated charcoal filter -1- off sol‐
enoid valve -3-.
– Connect vacuum tester -V.A.G 1368- connection -A- to breath‐
er line -2- to activated charcoal filter.
– Connect hand vacuum pump -V.A.G 1390- to connection -B-.
– Set vacuum tester -V.A.G 1368- to -A/B- position.
– Operate hand vacuum pump -V.A.G 1390- several times. Vac‐
uum must not build up.
If vacuum builds up:
– Check breather hose -5- on activated charcoal filter -1- for
soiling and clean if necessary.
If vacuum does not build up:
– Plug lines -5- and -6-.
– Operate hand vacuum pump -V.A.G 1390- several times. A
vacuum must build up.
– Renew activated charcoal filter -1- with pressure retention
valve -4-.
Checking breather line
– Remove fuel filler cap.
– Connect hand vacuum pump -V.A.G 1390- to vacuum tester -

V.A.G 1368- -connection B-.
– Set vacuum tester -V.A.G 1368- to -A/B- position.
– Check gravity valve ⇒ Item 5 (page 113) .
– Check gravity valve ⇒ Item 8 (page 116) .

Passat 1997 ➤
– Check line -1- from fuel tank for blockage.

– Refit fuel filler cap.
Note
If the fuel level in the tank is low the hand vacuum must be oper‐
ated at least 20 to 30 times.

– Renew fuel tank cap.

Passat 1997 ➤
26 – Exhaust system
1 Removing and installing parts of ex‐
haust system
WARNING

tions:
sitions.
hot components.
Note
♦ After working on the exhaust system ensure that the system

is not under stress, and that there is sufficient clearance to the
bodywork. If necessary, loosen double clamps and align si‐
lencer and exhaust pipe so that sufficient clearance is main‐
tained to the bodywork and the support rings are evenly
loaded.
♦ Align mountings so that they have a 7 … 9 mm preloading
when the exhaust system is cold. The arrows point in direction
of travel.
♦ Renew self-locking nuts.

♦ Lambda probe open ring spanner set -3337-
150 Rep. gr.26 - Exhaust system

Passat 1997 ➤
1.1 Exhaust manifold, front exhaust pipe

and catalytic converter with attachments
Note
♦ Components marked with an * are checked by self-diagnosis:

⇒ Fault memory; Rep. gr. 01 ; Reading and erasing fault
memory .
♦ Renew self-locking nuts.
1. Removing and installing parts of exhaust system 151

Passat 1997 ➤
1 - 25 Nm
❑ Renew.
2 - Washer
3 - Heat shield
4 - Lambda probe -G39- *
50 Nm
❑ Remove and install with
Lambda probe open
ring spanner set -3337- .
❑ Grease only the threads
with G 052 112 A3 ;
G 052 112 A3 must not
get into the slots on the
probe body.
❑ If seal is leaking, nip
open and renew.
❑ If renewed, erase learnt
values and adapt en‐
gine control unit anew:
⇒ Engine control unit;
Rep. gr. 24 ; Erasing
learnt values of control
unit for engine electron‐
ics .
❑ Checking Lambda con‐
trol: ⇒ Checking func‐
tions; Rep. gr. 24 ;
Checking Lambda
probe and Lambda con‐
trol before catalytic con‐
verter .
5 - Connector
❑ Black, 6-pin.
❑ For Lambda probe -
G39- and Lambda
probe heating -Z19- .
❑ Secured on left of bulkhead below expansion tank (looking forwards).
6 - Exhaust manifold
❑ With cut-out for secondary air system.
7 - Gasket
❑ Renew.
8 - Catalytic converter
❑ To remove, remove air filter and pressure pipe for secondary air system.
❑ If renewed, erase learnt values and adapt engine control unit anew: ⇒ Engine control unit; Rep. gr. 24 ;
Erasing learnt values of control unit for engine electronics .
❑ Checking catalytic converter ⇒ page 156
9 - Connector
❑ Brown, 4-pin.
❑ For Lambda probe after catalytic converter -G130- and Lambda probe heating 1 after catalytic converter
-Z29- .
❑ Secured on left of bulkhead below expansion tank (looking forwards).
10 - Lambda probe after catalytic converter -G130- * 50 Nm
❑ Remove and install with Lambda probe open ring spanner set -3337- .
❑ Grease only the threads with G 052 112 A3 ; G 052 112 A3 must not get into the slots on the probe body.

Passat 1997 ➤
❑ If renewed, erase learnt values and adapt engine control unit anew: ⇒ Engine control unit; Rep. gr. 24 ;
Erasing learnt values of control unit for engine electronics .
❑ Checking Lambda control: ⇒ Checking functions; Rep. gr. 24 ; Checking Lambda probe and Lambda
control after catalytic converter .
11 - 40 Nm
❑ Renew.
12 - Coach bolt
13 - To centre silencer
14 - Double clamp
❑ Slide double clamp onto front exhaust pipe up to stop.
15 - 40 Nm
16 - Front exhaust pipe
17 - Mounting
❑ Individual components for vehicles with a manual gearbox ⇒ page 153 .
❑ Individual components for vehicles with an automatic gearbox ⇒ page 153 .
18 - 25 Nm
❑ Renew.
Individual components of mountings (vehicles with manual gear‐

box)
1 - Buffer
2 - Spacer sleeve
3 - Washer
4 - Right plate
5 - Washer
6 - Hexagon bolt
7 - Spacer sleeve
8 - Left plate
9 - Spring
10 - Hexagon bolt
11 - Self-locking nut, 25 Nm
Individual components of mountings (vehicles with automatic

gearbox)
1 - Washer
2 - Bracket with buffer
3 - Spacer sleeve
4 - Front exhaust pipe
5 - Hexagon bolt, 25 Nm
6 - Hexagon bolt
7 - Spring
8 - Self-locking nut, 25 Nm

Passat 1997 ➤
1.2 Silencers with mountings: vehicles with front-wheel drive
1 - From front exhaust pipe

2 - 25 Nm
3 - Mounting
❑ With retaining ring.
4 - Centre silencer
5 - Bracket
6 - Mounting
7 - Rear silencer
8 - Repair double clamp
9 - 40 Nm
10 - Coach bolt
11 - Separating point
❑ Centre and rear silenc‐
ers are installed as a
single component dur‐
ing production. In cases
of repair, the centre and
rear silencer are sup‐
plied separately, with a
double clamp for con‐
necting.
❑ Cut through exhaust
pipe at right angles on
separating point using
body saw e.g. -
V.A.G 1523-
⇒ page 154 .
Separating point between centre silencer and rear silencer

♦ e.g. pneumatic sabre saw -V.A.G 1523A-
Procedure
– Separate connecting pipe between centre silencer and rear
silencer at the point marked with a groove: measurement -a-
approx. 160 mm.

Passat 1997 ➤
1.3 Silencers with mountings: vehicles with four-wheel drive
1 - From front exhaust pipe

2 - 25 Nm
3 - Mounting
❑ With retaining ring.
4 - 40 Nm
5 - Coach bolt
6 - Repair double clamp
7 - Separating point
❑ Centre and rear silenc‐
ers are installed as a
single component dur‐
ing production. In cases
of repair, the centre and
rear silencer are sup‐
plied separately, with a
double clamp for con‐
necting.
❑ Cut through exhaust
pipe at right angles on
separating point using
body saw e.g. -
V.A.G 1523-
⇒ page 154 .
8 - Rear right silencer
9 - Mounting
10 - Bracket
11 - Rear left silencer
12 - Centre silencer
Separating point between centre silencer and rear silencer

♦ e.g. pneumatic sabre saw -V.A.G 1523A-
Procedure
– Separate connecting pipe between centre silencer and rear
silencer at the point marked with a groove: measurement -a-
approx. 244 mm.

Passat 1997 ➤
1.4 Checking catalytic converter

♦ Line -V.A.G 1551/3-
Note


Passat 1997 ➤
Test prerequisites
• Dipped headlights and heated rear window must be switched
on.
• Exhaust system between catalytic converter and cylinder head
must be free of leaks.
• No fault may be stored in fault memory: ⇒ Fault memory; Rep.
01, display zone 2.
• Catalytic converter temperature must be at least 350°C, ⇒ dis‐
play group 46, display zone 2.
• Lambda probe ageing before catalytic converter OK., Check‐
ing: ⇒ Checking function; Rep. gr. 24 ; Checking Lambda
probe ageing before catalytic converter .
• Lambda probe ageing after catalytic converter OK., Checking:
⇒ Checking function; Rep. gr. 24 ; Checking Lambda probe
ageing after catalytic converter (trim regulation) .
Note
This diagnosis is only completed when the diagnosis for Lambda

probe ageing before and after catalytic converter has been per‐
formed successfully.
Test procedure
fault reader and select engine control unit: ⇒ General notes
for self-diagnosis; Rep. gr. 01 ; Connecting fault reader .
Select function XX

Basic setting

1 2 3 4


Passat 1997 ➤
Basic setting

1 2 3 4
– Switch on dipped beam and heated rear window.

2300 rpm.
– Depress brake pedal and accelerator until the display in dis‐
play zone 4 jumps from „Test OFF“ to „Test ON“.
The catalytic converter temperature in display zone 2 must be
at least 350 °C.
– Continue to depress brake pedal and accelerator until the
specification „Cat B1 OK“ is displayed in display zone 4.
– Switch off dipped beam and heated rear window.
If display zone 4 displays „Cat B1n.OK“:
– Read fault memory: ⇒ Fault memory; Rep. gr. 01 ; Reading
– Carry out a road test to free Lambda probe of any deposits,
then repeat the test.
If specification „Cat B1 OK“ is again not attained:
– Renew catalytic converter.
– Erase learnt values and adapt engine control unit anew: ⇒
Engine control unit; Rep. gr. 24 ; Erasing learnt values of con‐
trol unit for engine electronics .

Passat 1997 ➤
2 Secondary air system
WARNING

tions:
sitions.
hot components.
Function
During a cold start, air is blown in behind the exhaust valve by the
secondary air system. This produces an oxygen rich exhaust gas,
causing afterburning and reducing the heat-up phase of the cat‐
alytic converter. Activation is initiated by the Motronic control unit
-J220- via the secondary air pump relay -J299- to combination
valve.
Checking secondary air system ⇒ page 161 .
2.1 Removing and installing parts of secon‐

dary air system
Note
♦ Components marked with an * are checked by self-diagnosis:

⇒ Fault memory; Rep. gr. 01 ; Reading and erasing fault
memory .
♦ Components marked with ** are checked by the final control
diagnosis: ⇒ Final control diagnosis; Rep. gr. 01 ; Performing
♦ Secondary air pump relay -J299- ** ⇒ page 161 .
2. Secondary air system 159

Passat 1997 ➤
1 - Gasket
❑ Renew.
tion.
2 - Combination valve
3 - 8 Nm
4 - Connection
❑ For combination valve
and coolant hose
5 - Air duct
❑ In cylinder head
6 - Intake manifold
7 - Vacuum actuator
❑ For intake manifold
change-over.
8 - O-ring
9 - To intake manifold.
10 - To fuel pressure regulator.
11 - Non-return valve
tion.
❑ White connection faces
to secondary air inlet
valve -N112- / variable
intake manifold change‐
over valve -N156-
12 - Connector
❑ Black, 2-pin
❑ Before pulling off, mark allocation of connector to component
13 - From vacuum reservoir
❑ Location: in front left wheel housing.
❑ To remove, remove front left wheel housing liner: ⇒ General body repairs, exterior; Rep. gr. 66 ; Re‐
moving and installing wheel housing liner. .
14 - Variable intake manifold change-over valve -N156- */**
❑ The valve will be activated from the engine control unit (pulsed).
15 - Secondary air inlet valve -N112- */**
❑ The valve will be activated from the engine control unit (pulsed).
16 - Bracket
❑ For intake manifold changeover valve -N156- and secondary air inlet valve -N112- .
17 - 13 Nm
18 - Retaining clamp
19 - 10 Nm
20 - Connector
❑ Black, 2-pin

Passat 1997 ➤
❑ For secondary air pump motor.
21 - Pressure hose
22 - Intake hose
❑ From air filter.
23 - Secondary air pump motor -V101- **
24 - Bracket
❑ For secondary air pump motor -V101-
25 - Pressure pipe
Secondary air pump relay -J299- -arrow-
Note
♦ If tools are necessary to pull relays or control units out of the

relay plate, first disconnect battery earth strap
♦ Before disconnecting battery earth strap obtain code for radios
with anti-theft coding.
2.2 Checking secondary air system


Passat 1997 ➤
♦ Line -V.A.G 1551/3-
Note


Passat 1997 ➤
Test prerequisites
• Vacuum pipes and hose connections free of leaks.
• Vacuum pipes not blocked or kinked.
01, display zone 2.
• Lambda probe ageing before catalytic converter OK., Check‐
ing: ⇒ Checking function; Rep. gr. 24 ; Checking Lambda
probe ageing before catalytic converter .
Note
This diagnosis is only completed when the diagnosis for Lambda

probe ageing before catalytic converter has been performed suc‐
cessfully.
Test procedure
fault reader and select engine control unit: ⇒ General notes
for self-diagnosis; Rep. gr. 01 ; Connecting fault reader .
Select function XX

Basic setting

1 2 3 4

Basic setting


Passat 1997 ➤
Note
No engine loading may be created during this diagnosis, other‐

wise the test will be terminated and can only be reinitiated after
switching the ignition off and on again and performing a road test.

1 2 3 4
When the diagnosis of the engine control unit has been initiated
the display in display zone 4 will jump from „Test OFF“ to „Test
ON“.
– Leave engine running at idle until the specification „Syst. OK“
is displayed in display zone 4.
If display zone 4 displays „Syst. n. OK“:
– Initiate final control diagnosis and select secondary air inlet
valve -N112- and secondary air pump relay -J299- : ⇒ Final
control diagnosis; Rep. gr. 01 ; Performing final control diag‐
nosis .
– Check secondary air pump motor ⇒ page 164 .
– Check combination valve ⇒ page 166 .
2.3 Checking secondary air pump motor


Passat 1997 ➤
♦ Line -V.A.G 1551/3-
Note

Test prerequisites

• Fuse S130 for secondary air pump relay -J299- -arrow- in pro‐
tective housing is OK.
• Secondary air pump intake hose not blocked or kinked.
Test procedure

Passat 1997 ➤
– Disconnect pressure hose -arrow- from pressure pipe.
Note
To release, press buttons on hose coupling together.
– Activate secondary air pump relay -J299- via final control di‐
agnosis: ⇒ Final control diagnosis; Rep. gr. 01 ; Performing
The secondary air pump motor should run at intervals and air
should escape from the outlet point.
If the motor runs but no or little air is delivered:
– Proceed with final control diagnosis until completed.
– Renew secondary air pump motor -V101-
⇒ Item 23 (page 161) .
If secondary air pump motor does not run at intervals:
– Check activation of secondary air pump motor -V101- : ⇒ Final
control diagnosis; Rep. gr. 01 ; Performing final control diag‐
nosis .
2.4 Checking combination valve

♦ Hand vacuum pump -V.A.G 1390-
Test prerequisites
• Final control diagnosis carried out: ⇒ Final control diagnosis;
Rep. gr. 01 ; Performing final control diagnosis .
• Vacuum pipes and hose connections free of leaks.
• Vacuum pipes not blocked or kinked.
Test procedure
Note
Do not use compressed air during the following check!

Passat 1997 ➤
– Remove intake hose between air mass meter and throttle

valve module: ⇒ Injection system; Rep. gr. 24 ; Repairing
injection system .
– Pull vacuum hose from secondary air inlet valve -N112- off
combination valve -arrow-.
– Connect hand vacuum pump -V.A.G 1390- to vacuum con‐

nection on combination valve -arrow-.
– Remove insulation tray: ⇒ General body repairs, exterior;
Rep. gr. 50 ; Body - front; Assembly overview - noise insulation
– Remove pressure hose -arrow- from secondary air pump mo‐

tor and blow in with slight pressure. Combination valve must
be closed.
– Operate hand vacuum pump -V.A.G 1390- . Valve must open.
If the combination valve does not open, or is constantly open:
– Renew combination valve ⇒ Item 2 (page 160) .

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Service

Service Department. Technical Information

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

1) VR = V-arrangement in compact in-line design

Volkswagen Technical Site: https://vwts.ru

2 Rep. gr.00 - Technical data

10 – Removing and installing engine

Special tools and workshop

1. Removing and installing engine 3

♦ Torque wrench (5…50 Nm)

1.1 Notes on removing

When doing any repair work, especially in the engine compart‐

4 Rep. gr.10 - Removing and installing engine

– With the ignition switched off, disconnect battery earth strap.

To release, press buttons on hose coupling together.

– Remove pressure pipe of secondary air system.

– Unbolt power steering hydraulic oil cooling pipe -arrows- and

1. Removing and installing engine 5

– Disconnect ATF line connections -arrows- and catch ATF

Fuel supply lines are under pressure! Before loosening hose

6 Rep. gr.10 - Removing and installing engine

Before removing connectors, mark each connector and compo‐

Fitting locations:⇒ Repairing injection system; Rep. gr. 24 ; Fit‐

– Also disconnect connections from following components:

1. Removing and installing engine 7

– Fit support bracket 10-222A as shown and lift engine at rear

To relieve strain on support bracket spindle, lift engine at front

– Remove lower engine/gearbox securing bolts.

– Remove upper engine/gearbox securing bolts.

– Separate torque converter from drive plate (3 securing nuts).

After removing the engine, secure the torque converter against

Continuation for all vehicles

– Attach support bracket -10 - 222 A- as shown.

8 Rep. gr.10 - Removing and installing engine

– Attach lifting tackle -2024 A- as follows and lift slightly with

Use locking pins -arrows- to secure hooks and locating pins.

♦ The positions marked 1…4 on the bar must be towards the

– Lift engine out forwards.

Guide the engine carefully when lifting out, to prevent damage to

When stripping and assembling the engine it should be secured

– If not already modified, drill three 11 mm holes according to

1.2 Notes on installing

1. Removing and installing engine 9

– Lightly grease clutch release bearing and splines on input

– Tighten gearbox mounting securing nuts.

Specified torques ⇒ page 11 .

– Install front exhaust pipe with catalytic converter

10 Rep. gr.10 - Removing and installing engine

– Connect ATF lines -arrows- ⇒ 5-speed automatic gearbox

1.2.1 Specified torques

1.3 Assembly mountings

1. Removing and installing engine 11

Assembly mounting, left

1.4 Additional information and assembly

The air conditioner refrigerant circuit must not be opened.

♦ The opening of the refrigerant circuit can only be carried out

To facilitate removing and installing engine without opening re‐

12 Rep. gr.10 - Removing and installing engine

When carrying out assembly work, secure engine to support

If when repairing an engine, metal shavings or large quantities of

1. Dismantling and assembling engine 13