D3E8034F002-5-Cylinder Injection Engine (4-Valve) Mechanics

Service
Workshop Manual
Passat 1997 ➤
5-cylinder injection engine (4-valve),
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Service Department. Technical Information

Service
List of Workshop Manual Repair
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00 - Technical data
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10 - Removing and installing engine
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13 - Crankshaft group
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15 - Cylinder head, valve gear
17 - Lubrication
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19 - Cooling
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20 - Fuel supply system

26 - Exhaust system
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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.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2015 Volkswagen AG, Wolfsburg D3E8034F002

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 . . . . . . . . . . .G.. V.ol.ks.w.ag.e.n . . . . . . . . . . . . . . . . . . . . . . . . 33

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1 Cylinder head . . . . . . . . . . . . .V.ol.ks.w.a. . . . . . . . . . . . . . . . o. e.s.no. t.g. . . . . . . . . . . . . . . . . . . . . . 33
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1.1 Removing and installing .is.ed. b. . . . . . . . . . . . . . . . . . . . . . . . . . . . a.ra. n.t . . . . . . . . . . . . . . . . . . 36
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1.2 Removing and installing aut cylinder head cover . . . . . . . . . . . . . . . . . . . o. r .a . . . . . . . . . . . . . . .
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1.3 Removing and installing ss cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . c. . . . . . . . . . . . . . . 41
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1.4 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

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1.5 Adjusting valve timing (installing timing chains) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

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1.6 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

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2 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
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2.1 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

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2.2 Camshaft identification, valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

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2.3 Dismantling and assembling valve timing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

2.4 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.5 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
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2.6 Checking camshaft timing control/adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

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2.7 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

2.8 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
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17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
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1 Removing and installing parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

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1.1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

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1.2 Assembly overview - sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

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1.3 Dismantling and assembling oil filter housing/engine mounting . . . . . . . . . . . . . . . . . . . . . . 80

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1.4 Dismantling and assembling oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

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1.5 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
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1.6 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
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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 . V.o.lk.s.w.ag. e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
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1.7 Removing and installing agen radiator . . . A. G. d. o.es. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
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1.8 Removing and d by installing viscous fan coupling .gu.a.r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
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1.9 Removing utho and installing viscous fan mounting bush e. o.r . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
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1.10 Checking
ss continued coolant circulation pump . . . . . . . .c . . . . . . . . . . . . . . . . . . . . . . . . . . 110
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20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
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1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
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drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
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1.2 Removing and installing fuel tank with attachments and fuel filter: vehicles with four-wheel
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drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
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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
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1.6 Crash fuel shut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
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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 . . . . . . . . . . . . . . . . . . nform
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1.9 Removing and installing fuel gauge sender: vehicles with front-wheel drive . . . . . . . . . . . . 126
1.10 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
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1.11 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

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2 Electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

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2.1 Function of EPC system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

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2.2 Repairing parts of electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

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2.3 Checking accelerator position sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
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3 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
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3.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
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3.2 Repairing parts of activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
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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.
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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)
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Torque Nm at rpm 220/3200
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Bore ∅ mm 81.0
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Compression ratio 10.75
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RON min. 98 unleaded2)
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System designation Motronic ME7.1
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Knock control 2 knock sensors
Lambda control 2 probes
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Catalytic converter yes
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Exhaust gas recirculation no

Turbocharging/supercharging no
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Secondary air system yes

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Electronic power control yes

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Variable intake manifold yes

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Camshaft timing control yes

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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- agen
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♦ Support bracket -10 - 222 ed b y gu
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♦ Support clamp -VWs 313-
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♦ Workshop hoist -
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♦ Drip tray -V.A.G 1306-
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1. Removing and installing engine 3

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♦ Torque wrench (5…50 Nm)
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♦ Torque wrench (40…200
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♦ Spring-type clip pliers -
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♦ Grease -G 000 100- (vehi‐
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♦ Cable ties
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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.
AG. Volkswagen
– Remove air filter ⇒ Repairing injection
wage system; Rep. gr.
n AG do
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not ;
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Dismantling and assembling
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– Disconnect pressureuthose
ho -arrow- from pressure pipe. or
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To release, press buttons on hose coupling together.
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– Remove pressure pipe of secondary air system.
hole
spec
– Pull off necessary vacuum and breather hoses from engine.
es, in part or in w
t to the co
– Remove front bumper ⇒ General body repairs, exterior; Rep.
gr. 63 ; Front bumper .
rrectness of i
– Unbolt power steering hydraulic oil cooling pipe -arrows- and
l purpos
lay free. Do not open hydraulic oil circuit.

Vehicles with automatic gearbox
nform
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or
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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 AG. Volkswagen AG d
bracket and place to one side; hoses remain connected; agen⇒ oes
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Running gear, axles, steering; Front and four-wheel
ed by drive; gu
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Rep. gr. 48 ; Vane pump, reservoir, hydraulic
horis lines for vehicles nte
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with 4 or 5-cylinder engines . s aut ra
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s
Vehicles with air conditioner
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– Observe additional information and installation work
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⇒ page 12 .
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– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Removing
spec
and installing starter on vehicles with 4, 5 and 6-cylinder en‐
t to the co
gines .
– Remove front exhaust pipe with catalytic converter
⇒ page 151 , Exhaust manifold, front exhaust pipe with cata‐
rrectne
lytic converter and attachments.
ss
WARNING
o
cial p
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mer
Fuel supply lines are under pressure! Before loosening hose

atio
connections, wrap a cloth around the connection. Then release
om
n
pressure by carefully pulling hose off connection.
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Passat 1997 ➤
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gu engine (4-valve), mechanics - Edition 12.2010
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– Pull fuelaut supply line -1- (with white marking) and fuel return
ho e o line
ra
-2- (with
ss blue marking) off fuel rail and catch fuel that escapes c
in a cloth.
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– Seal lines so that fuel system is not contaminated by dirt.
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– Observe rules for cleanliness ⇒ page 119 .
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– Unbolt earth wire -3-.
h re
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spec
– Separate connectors from the following components:
t to the co
♦ Coolant temperature sender -G62- with sender for coolant
temperature gauge -G2-
♦ Continued coolant circulation pump -V51-
rrectne
♦ Inlet camshaft control valve 1 -N205-
ss o
♦ Exhaust camshaft control valve 1 -N318-
cial p
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♦ Hall sender -G40-
mer
atio
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♦ Hall sender 2 -G163-

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♦ Oil level and oil temperature sender -G266-
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♦ Throttle valve module -J338-
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♦ Intake manifold changeover valve -N156- and secondary air

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Note
agen
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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.

lkswage es n
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– Separate torque converter
d byV from drive plate (3 securing unuts).
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After removing the engine, secure the torque converter against

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

rrectness of i
– Attach gearbox support -3147- to the gearbox bell housing bolt

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hole (shown in illustration with engine removed).

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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
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Use locking pins -arrows- to secure hooks and locating pins.
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♦ The positions marked 1…4 on the bar must be towards the
es, in part or in w
pulley end.
t to the co
♦ The holes in the hook rails are counted up from the hook.
rrectness of i
– Lift engine out forwards.
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Guide the engine carefully when lifting out, to prevent damage to
atio
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the bodywork.
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When stripping and assembling the engine it should be secured

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to the engine frame with engine bracket 3269.
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Modifying engine bracket -3269-
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– 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 . n AG. Volkswagen A ge G do
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– Install power-assisted steering vane pump ⇒ Running yV
olk gear, ot g
ua
axles, steering, front and four-wheel drive; Rep. ed b 48 ; Vane
gr. ran
is tee
or
pump, reservoir, hydraulic lines for vehiclesuthwith 4 or 5-cylin‐ or
der engines . ss
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un
– Install poly V-belt ⇒ page 19 .

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– Install air filter ⇒ Repairing injection system; Rep. gr. 24 ;

rm
ab
pe
Dismantling and assembling air filter .

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– Install lock carrier with add-on parts ⇒ General body repairs,

h re
exterior; Rep. gr. 50 ; Removing and installing lock carrier with

hole
spec
add-on parts .
es, in part or in w
t to the co
– Electrical connections and routing ⇒ Current flow diagrams,

Electrical fault finding and Fitting locations.
rrectness of i
– Check headlight adjustment and correct if necessary ⇒ Main‐

tenance ; Booklet 36
l purpos
– Install coolant expansion tank.

nform
ercia
– Replenish coolant ⇒ page 99 .

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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 .
Vehicles with automatic gearbox AG. Volkswagen AG d
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– On vehicles with an automatic gearbox the gearboxd bcontrolyV
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unit must be additionally adapted ⇒ Self-diagnosis orisfor 5-speed
e nte
automatic gearbox 01V and four-wheel drive;auRep.th gr. 01 ; eo
ra
Performing self-diagnosis: Initiating basic setting
ss . c
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– Carry out a road test and read fault memory ⇒ Fault memory;
rm
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Rep. gr. 01 ; Reading and erasing fault memory .
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1.2.1 Specified torques
hole
spec
es, in part or in w
t to the co
Threaded connection Specified torque
Bolts, nuts M6 10 Nm
rrectness of i
M7 15 Nm
M8 20 Nm
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M10 45 Nm
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ercia
M12 60 Nm
m
Deviations
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Starter to gearbox 65 Nm
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1.3 Assembly mountings

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Assembly mounting, right

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A = 40 Nm B = 23 Nm3)
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Prote AG.

Passat 1997 ➤
Assembly mounting, left

A = 23 Nm B = 23 Nm4)
4) Renew securing nuts
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 agen
AG. Volkswagen AG d
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in workshops, which have trained personnel and the neces‐ by
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sary range of tools and workshop equipment. rised ara
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♦ To prevent damage to condenser ut lines/
and also refrigerant
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hoses, ensure that the lines and hoses are not stretched,
s
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kinked or bent.
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♦ When installing refrigerant lines/hoses, ensure that lines and
erm
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hoses are routed/installed so that they cannot be damaged or
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come into contact with rotating parts.
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To facilitate removing and installing engine without opening re‐
es, in part or in w
frigerant circuit:
t to the co
– Remove retaining clamp(s) for refrigerant lines.
– Remove air conditioner compressor ⇒ Heating, air condition‐
ing; Rep. gr. 87 ; Removing and installing compressor bracket. rrectness of i
l purpos
– Secure air conditioner compressor to body so that the refrig‐

erant lines are not under tension.
nform
mercia
at
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ion
c
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or
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ate
do
priv
cum
for
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t.
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Prote AG.

Passat 1997 ➤
AG. Volkswagen AG d
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Note
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When carrying out assembly work, secure engine to support
h re
hole
clamp -3269- using engine bracket -VW 313- .
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
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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 . n AG. Volkswagen AG do
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3 - Camshaft timing chain
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❑ Before removing, mark
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direction of rotation (in‐

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⇒ page 16 . wit
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❑ Installing ⇒ page 48
h re
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Adjusting valve timing.

spec
es, in part or in w
4 - Exhaust camshaft adjuster

t to the co
❑ Identification: 32A.
❑ Rotate engine only with
rrectness of i
camshaft adjuster in‐

stalled.
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❑ Checking camshaft tim‐

rm
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ing control
atio
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⇒ page 69 .
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5 - Intermediate shaft
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6 - Thrust washer
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7 - 8 Nm
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❑ Insert with locking fluid -D 000 600 A2- .
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8 - Tensioning plate
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❑ 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
❑ For guide rail ⇒wItem
agen 24 (page 15)A.G doe
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21 - 23 Nm ed by ara
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❑ Forutguide
ho rail ⇒ Item 24 (page 15) . eo
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22 - Inlet
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camshaft adjuster
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❑ Identification: 24E
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23 - 60 Nm + 1/4 turn (90°) further

es, in part or in w
t to the co
❑ Renew.
❑ Contact surface of sender wheel must be dry around bolt head when assembled.
rrectness of i
❑ To remove and install, counterhold using 32 mm open-end spanner on camshaft ⇒ page 63 Removing
and installing camshafts.
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24 - Guide rail
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25 - Exhaust camshaft control valve 1 -N318-

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❑ For exhaust camshaft.

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❑ Before removing, mark connector belonging to component.

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❑ Check activation: ⇒ Final control diagnosis; Rep. gr. 01 ; Performing final control diagnosis .
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26 - Inlet camshaft control valve 1 -N205- t. C rig
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Passat 1997 ➤
❑ Check activation: ⇒ Final control diagnosis; Rep. gr. 01 ; Performing final control diagnosis .
27 - Guide rail
❑ Clipped into valve timing housing.
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– Mark roller chains before removing (e.g.riswith
ed paint, arrow ara
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at
om
ion
c
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or
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ate
do
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for
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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 AG. Volkswagen AG d
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❑ See note ⇒ page 13 . olksw not
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5 - Knock sensor 1 -G61- horis nte
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❑ 3-pin. ss a c
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le
❑ Location: on right of cyl.

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❑ Checking ⇒ Fault mem‐
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ility
ory; Rep. gr. 01 ; Read‐
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spec
6 - 20 Nm
t to the co
❑ The torque setting influ‐
ences the function of the
knock sensor.
rrectne
7 - 10 Nm
ss
8 - Oil pump drive cover
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9 - O-ring
form
mer
❑ Renew.
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❑ Lubricate before installing.

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10 - Oil pump drive

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11 - Cylinder block
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❑ Removing and installing sealing flange and dual-mass flywheel ⇒ page 21 .
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❑ Removing and installing crankshaft ⇒ page 27 . ht. rig
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❑ Dismantling and assembling pistons and conrods ⇒ page 29 .
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12 - Intermediate shaft
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.
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24 - Seal Vol
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❑ Renew. ris
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25 - 12 Nm ce
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26 - Seal y li
erm
ab
❑ Renew. ility
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hole
27 - Oil filter bracket/engine mounting

spec
es, in part or in w

t to the co
❑ Coolant hose schematic diagram ⇒ page 96 .

28 - 23 Nm
rrectness of i
29 - Torque reaction support

l purpos
30 - Fitting bolt, 25 Nm
❑ Observe tightening sequence ⇒ page 96 .
nf
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orm
31 - 25 Nm
m
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32 - Compact bracket
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❑ For tensioner, viscous fan coupling, alternator, coolant pump and power-assisted steering vane pump.
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Cop py
33 - Coolant pipe
t. rig
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pyri by
❑ To thermostat housing ⇒ Item 10 (page 37)
co Vo
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❑ Removing and installing ⇒ page 93 , Parts of cooling system - engine side.
AG.
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 .

AG. Volkswagen AG d
agen oes
Volksw not
gu
Passat 1997 ➤
y
rise
d b
5-cylinder injection engine (4-valve), ara mechanics
nte - Edition 12.2010
tho eo
au ra
36 - 100 Nm + 1/4 turn (90°)
ss further c
ce
e
nl
pt
❑ Renew.
du
an
itte
y li
❑ To loosen and tighten, use counterhold -T10069- ⇒ page 19
erm
ab
ility
❑ Tighten using torque wrench -V.A.G 1601- .
ot p
wit
, is n
h re
hole
spec
To loosen and tighten securing bolt, secure vibration damper us‐
es, in part or in w
t to the co
ing counterhold -T10069-
rrectness of i
Note
l purpos
♦ Renew securing bolt for vibration damper.

♦ Tighten securing bolt using torque wrench -V.A.G 1601- .
nf
ercia
orm
m
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n in
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1.3 Removing and installing poly V-belt
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Cop py
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by lksw
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Prote AG.
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 .
. Volkswage n AG n AG d
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– Fit engine cover. y Volks not
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nl
pt
du
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itte
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ab
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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m
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n in
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Cop py
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by
cted agen
Prote AG.

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 AG. Volkswagen AG d
agen oes
ksw
❑ Removing and installing by Vol not
gu
poly V-belt ⇒ page 19 . rise
d ara
nte
tho eo
3 - 8 Nm s au ra
c
s
ce
le
4 - Seal
un
pt
an
d
❑ PTFE oil seal:

itte
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rm
ab
❑ Identification: Without
pe
ility
inner coil spring.
ot
wit
, is n
h re
❑ Do not additionally oil or
hole
grease the oil seal seal‐
spec
ing lip.
es, in part or in w
t to the co
❑ Before installing, re‐
move oil residue from
crankshaft journal using
rrectness of i
a clean cloth.
l purpos
❑ Renewing ⇒ page 23 .
5 - Sealing flange
nform
ercia
❑ Coat sealing surfaces

m
with sealant -AMV 188

a
com
tio
001 02- .
n in
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te o
thi
6 - Cylinder block
s
iva
do

r
rp
cum
fo
crankshaft
en
ng
t.
⇒ page 27 .
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rods ⇒ page 29 . cted agen
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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
AG. Volkswagen AG d
agen oes
olksw not
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au ra
ss c
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
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t.
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Cop py
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

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-
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
tho eo
au ra
ss c
ce
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
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.
lkswage es n
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byV ua
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or
Note ss
au ac
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nl
pt
In place of oil seal with internal circular spring -1-, a PTFE oil seal
du
an
itte
is being gradually introduced (Teflon) -2-. This has a wider sealing

y li
erm
lip. PTFE oil seals are installed free of oil and grease. When a ab
ility
ot p
PTFE oil seal is installed as original equipment, then only a PTFE wit
, is n
oil seal may be installed as a replacement. h re

hole
spec
– Remove oil residue from crankshaft journal using clean cloth.

es, in part or in w
t to the co
rrectness of i
– Position guide sleeve -T10053/1- on front of crankshaft journal

l purpos
and carefully slide oil seal as far as possible onto crankshaft

journal over guide sleeve.
nform
ercia
– Remove guide sleeve -T10053/1- .

m
at
om
ion
c
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or
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ate
do
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cum
for
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t.
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Cop py
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

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

this, use an old vibration damper securing bolt.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
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un
– Install vibration damper and lock with counterhold -T10069- .
pt
an
d
itte
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– Tighten new securing bolt to 100 Nm and then turn 90° (1/4
erm
ab
turn) further (turning further can be done in several stages).
ility
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wit
is n
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ole,
Note
spec
t to the co
♦ Renew securing bolt for vibration damper.
♦ Tighten securing bolt using torque wrench -V.A.G 1601- .
rrectne
– Install poly V-belt ⇒ page 19 .
ss o
cial p
f i
2.2 Removing and installing drive plate
nform
mer
atio
Special tools and workshop equipment required
om
n
c
i
or
n
thi
te
sd
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cum
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fo
en
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t.
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Cop py
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by
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Prote AG.
♦ 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. . Volkswagen AG
gen AG does
swa
– Insert at least 3 old securing bolts and tighten to 30 Nm.
by
Vol
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– Check dimension -a- to intermediate plate through
auth
3 holes for ra
torque converter attachment using a straights edge and depth
s c
ce
e
gauge, and calculate average.

nl
pt
du
an
itte
– Compare average with specification (measured distance +
y li
erm
ab
thickness of straight edge). Specification: 18.1…19.7 mm
ility
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wit
If specification is not attained:
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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– Remove drive plate again and fit appropriate shim -1-.
nform
ercia
Note
m
at
om
io
Only one shim of the appropriate thickness may be used.
n
c
in t
or
his
ate
When specification is attained: do

priv
cum
for
– Insert new securing bolts and tighten by hand.

en
ng
t.
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op
– Tighten securing bolts to 60 Nm and turn 180° (1/2 turn) further
C py
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(turning further can be done in several stages).
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

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 AG. Volkswagen AG d
agen oes
ksw
and bearing bcaps
yV
ol
must not
gu
ara
align. ris ed
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2 - 30 Nm s+s a1/2
u
turn (180°) fur‐ ra
c
ther
ce
le
un
pt
❑ Renew.
an
d
itte
y li
❑ 2 x 90° further is permit‐

rm
ab
pe
ility
ted.
ot
wit
, is n
3 - Bearing shells 1…6

h re
hole
❑ Before removing, see

spec
es, in part or in w
notes ⇒ page 27 .
t to the co
❑ For bearing cap without

oil groove.
rrectness of i
❑ For cylinder block with

oil groove.
l purpos
❑ Do not interchange
used bearing shells
nform
ercia
(mark).
m
4 - Thrust washer
a
com
tion in
❑ For bearing cap 4.

r
te o
thi
❑ Note fixing arrange‐

s
iva
do
ment.
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rp
cum
fo
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5 - Crankshaft
n
t.
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❑ Before removing, see
C py
ht. rig
notes ⇒ page 27 . rig ht
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lksw
❑ Axial clearance new:
by
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Prote
0.07…0.24 mm , wear limit: 0.30 mm.
AG.
❑ 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
❑ See note ⇒ page 13 .
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.
. Volkswag
– For additional hold apply a thin coat wof
aglocking
en AG fluid „D 000d600
en AG
oes
A2“ to crankshaft/sender wheel Volks
contact surfaces. not
gu
by a d ran
ise
– Ensure when installing that
ho marking -VR5- -arrow- is at single
r tee
ut or
threaded hole. ss
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ce
le
– First tighten all new securing bolts lightly by hand.

un
pt
an
d
itte
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– First tighten securing bolt -1- to 10 Nm + 90° (1/4 turn) further.

rm
ab
pe
ility
– Then tighten securing bolts -2- to 10 Nm + 90° (1/4 turn) fur‐

ot
wit
, is n
ther.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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en
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t.
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Cop py
t. rig
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by
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Prote AG.

Passat 1997 ➤
4 Dismantling and assembling pistons and conrods

lkswage es n
1 - Piston rings d byV
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ua
ran
❑ Offset gaps by 120°. ir se tee
tho
u or
❑ Use piston ring pliers to ss
a ac
remove and install.
ce
le
un
pt
an
❑ „TOP“ faces towards
d
itte
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piston crown.
rm
ab
pe
ility
❑ Checking ring gap
ot
wit
⇒ page 30 . , is n
h re
hole
❑ Checking ring-to-groove
spec
clearance ⇒ page 30 .
es, in part or in w
t to the co
2 - Piston
❑ Check ⇒ page 31 .
rrectness of i
❑ Mark cylinder number
and installation position
l purpos
relative to conrod.
❑ Low point of piston
nform
ercia
crown faces to centre of

cylinder block.
m
a
com
tio
❑ Install with piston fitting
n in
r
tool -3278-
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thi
⇒ page 31 .
s
iva
do
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cum
3 - Circlip
fo
en
ng
t.
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4 - Conrod t. Cop py
rig
❑ Renew as set only.
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co
❑ Mark cylinder number
by lksw
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Prote
-B-.
AG.
❑ 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
Special tools and workshop equipment required AG. Volkswagen AG d

agen oes
olksw not
V gu
♦ Feeler gauges d by ara
ise nte
or eo
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Test procedure s aut ra
c
s
– Push ring at right angles from above down to approx. 15 mm
ce
le
un
pt
from bottom end of cylinder. Push in using a piston without
an
d
itte
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rings.
erm
ab
ility
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Piston ring Ring gap
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is n
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New Wear limit
ole,
spec
Rectangular-section ring mm 0.20…0.40 1.0
t to the co
Tapered stepped ring mm 0.20…0.40 1.0
Oil scraper ring mm 0.25…0.50 1.0
rrectne
Checking ring-to-groove clearance
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
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fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c
lksw
cted agen
Prote AG.
♦ 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
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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h
aut ra
ss c
ce
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un
pt
an
d
itte
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erm
ab
ility
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is n
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♦ Cylinder gauge 50…100 mm

ole,
spec
Test procedure
t to the co
– Take measurements at 3 positions in both lateral direction

-A- and longitudinal direction -B-.
rrectne
• Difference between actual and nominal diameter max. 0.08

mm.
ss o
cial p
f in
Note
form
mer
atio
Cylinder bores must not be measured when cylinder block is

om
mounted on a repair stand with engine support bracket -3269- ,

c
i
or
n thi
as measurements may then be incorrect.

te
sd
iva
o
pr
cum
r
fo
4.1 Installing piston

en
ng
t.
yi Co
op py
Special tools and workshop equipment required t. C rig
gh ht
pyri by
♦ Piston fitting tool -3278-
o Vo
by c lksw
cted agen
Prote AG.
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.
AG. Volkswagen AG d
agen oes
olksw not
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4.2 Piston and cylinder dimensions d b ara
rise nte
tho eo
au ra
Honing dimen‐ ss Piston ∅ Cylinder bore ∅ c ce
sion
le
un
pt
an
d
itte
Basic dimension mm 80.965 81.010

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rm
ab
Stage I mm 81.465 81.510

pe
ility
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wit
Stage II mm 81.965 82.010

, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤
15 – Cylinder head, valve gear

1 Cylinder
ksw head
A G. Volkswagen AG d
agen oes
not
Vol gu
by ara
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th
Noteau ra
c
ss
ce
le
un
pt
♦ If an exchange cylinder head is installed, all the contact sur‐
an
d
itte
faces between the support elements, roller rocker fingers and
y li
rm
ab
the running surfaces of the cam shafts must be oiled before
pe
ility
the cylinder head cover is installed.
ot
wit
, is n
h re
♦ The plastic protectors fitted to protect the open valves must be
hole
removed only immediately before the cylinder head is fitted.
spec
es, in part or in w
t to the co
♦ When replacing the cylinder head the complete coolant must
be renewed.
♦ Removing and installing intake manifold ⇒ page 39 .
rrectness of i
♦ Dismantling and assembling engine: ⇒ Repairing injection
l purpos
system; Rep. gr. 24 ; Dismantling and assembling intake

manifold .
nform
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♦ Removing and installing cover ⇒ page 36 .

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♦ Checking compression ⇒ page 53 .
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1. Cylinder head 33
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1-8 Nm ss c
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2 - Cable guide
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3 - 8 Nm
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4 - Cap
❑ Renew seal if damaged.
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5 - Boot
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❑ Renew if damaged.
6 - 8 Nm
nform
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7 - Earth wire
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8 - Cylinder head cover
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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-
❑ For inlet camshaft.
❑ 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.
18 - Inlet camshaft adjuster
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19 - Cylinder head gasket au ac
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❑ Metal gasket.
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❑ Preparing cylinder head gasket for assembly ⇒ page 36 .
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20 - Cylinder head
hole
spec
❑ Check for distortion ⇒ page 35 .
es, in part or in w
t to the co
rrectness of i
21 - Cylinder head bolt
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❑ Renew.
❑ Refer to assembly instructions and sequence when loosening and tightening ⇒ page 41 Removing and
installing cylinder head.
nform
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22 - Cylinder head cover gasket

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♦ 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
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1.1 Removing and installing

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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
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❑ For continued coolant hor eo
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7 - Continued coolant circula‐

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8 - Seal spec
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❑ For valve -1- for inlet camshaft control -N205- , ⇒ Item 13 (page 34) and valve -1- for exhaust camshaft
control -N318- , ⇒ Item 14 (page 34) .
rrectness of i
❑ Installing ⇒ page 38 .
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9 - 23 Nm
10 - Thermostat housing
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❑ Sealant for sealing surfaces ⇒ ETKA (Electronic parts catalogue) .
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❑ 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-

❑ For inlet camshaft.
❑ 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-
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38
Prote AG.
Rep. gr.15 - Cylinder head, valve gear
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- .
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cover
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♦ Hose clip pliers -VAS 6340-
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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.
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Coolant hoses on expansion tank can remain connected. hor is tee
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Passat 1997 ➤
– Unbolt earth wire -3-.

– Separate connectors -arrows-.
Volkswa AG. gen AG
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– Unclip connector
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– Pull vacuum
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actuator.
aut ra
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– Unscrew dipstick guide tube from intake manifold.
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– Now remove the two bolts for the intake manifold support.
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– Unscrew securing bolts of intake manifold/cylinder head and
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– Remove intake manifold and place it on a suitable surface so
spec
that the vacuum unit will not be damaged.
es, in part or in w
t to the co
Note
rrectness of i
Seal intake ports in intake manifold and in cylinder head with a
l purpos
clean cloth.
nf
ercia
– Unclip wiring harness of ignition coils from cable guide.
orm
m
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– Remove ignition coils with output stages ⇒ Repairing ignition
om
system; Rep. gr. 28 ; Removing and installing parts of ignition

n in
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– Remove cylinder head cover.

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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-
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♦ Puller -T10095 A-
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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 .
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– Remove chain tensioner for camshaft timing chain -arrow-.

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1. Cylinder head 43
Passat 1997 ➤
– Mark timing chain before removing (e.g. with paint, arrow

pointing in direction of rotation).
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. agen

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– Remove camshaft cover ⇒ page 36 . d by V gu
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– Unbolt front exhaust pipe with catalytic
ut converter from exhaust
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manifold ⇒ page 151 , Exhaust manifold,
ss a
front exhaust pipe c
with catalytic converter and attachments.
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– Now check timing: if the TDC No. 1 Cyl. setting is correct it is
erm
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possible to see a notch on the intermediate shaft chain sprock‐
ility
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Note
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This condition is only achieved every 2nd complete rotation of

crankshaft.
rrectne
If the groove cannot be seen:

ss o
– Turn crankshaft one full turn further in direction of engine ro‐

cial p
f in
tation.
form
mer
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Note
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When the crankshaft is turned, the tensioner plate must be press‐

i
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ed against the camshaft roller chain by hand instead of with chain

fo
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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). agen
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Check setting marks of camshaft adjusters against marksorion
s con‐
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– Arrows -A and B- on camshaft adjusters must align with notch‐
erm
ab
es -arrows- in timing housing -C-.
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– First remove exhaust camshaft adjuster and then remove inlet
h re
camshaft adjuster.
hole
spec
es, in part or in w
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Note
n
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Counterhold only with 32 mm open-end spanner on camshaft
do
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-arrows-. The camshaft bar -T10068- must not be in place when
um
for
tightening or loosening the camshaft adjusters.
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– 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, gradeAG
must
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– Carefully remove metal
by
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If the piston for No.
tho1 cylinder is not at TDC:
ri e or
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– Set crankshaft
ss to TDC No. 1 cylinder marks -arrow- by turning
ce
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crankshaft on the vibration damper securing bolt in direction

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of engine rotation:
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♦ Do not remove new cylinder head gasket from its packing until
es, in part or in w
immediately before installing.

t to the co
♦ Handle new gasket with extreme care. Damage will cause

leakage.
rrectness of i
– Fit new cylinder head gasket. Inscription (Part No.) must be

l purpos
readable.
nform
ercia
– Ensure that dowel sleeves are inserted into cylinder block

holes 15 and 16, and the cylinder head gasket is located.
m
at
om
ion
Camshaft bar has been removed:

c
in t
or
his
te
– Position camshafts in cylinder head to TDC No. 1 cylinder.

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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.

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Adjusting valve timing ⇒ page b48
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Preparing cylinder headugasket
tho
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and cover for assembly tee
or
⇒ page 36 . ss
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– Lubricate O-ring for oil channel seal and insert into cover.
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– Install cover part immediately, fit all securing bolts and lightly
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tighten.
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– First tighten M8 securing bolts to 23 Nm and then tighten M6

h re
securing bolts to 8 Nm.

hole
spec
es, in part or in w
– Install chain tensioner for camshaft roller chain and tighten to

t to the co
40 Nm.
– Install cylinder head cover and intake manifold ⇒ page 39 ,
Removing and installing cylinder head cover.
rrectness of i

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– Check camshaft timing control ⇒ page 69 .

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It is not necessary to retighten cylinder head bolts after repairs.

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1. Cylinder head 47
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Passat 1997 ➤ thor eo
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5-cylinder injection engine
ss a (4-valve), mechanics - Edition 12.2010 c
ce
le
un
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1.4 Checking valve timing
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Test procedure
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t to the co
– Remove intake manifold and cylinder head cover ⇒ page 39
– Set crankshaft to TDC No. 1 cylinder marking -arrow- by turn‐
rrectness of i
ing crankshaft on the vibration damper securing bolt in direc‐
l purpos
tion of engine rotation.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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– Camshaft bar -T10068- must engage in grooves in both shafts. cop Vo
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If camshaft bar cannot be engaged:
AG.
– 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-
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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.
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– Tighten bolts for chain sprockets -3- and -4- on intermediate ed b y gu
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shaft by hand. horis nte
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Note that all sprocket securing bolts must be renewed.
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– Now install chain tensioner on opposite side.
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– To do this, release locking teeth of chain tensioner -A- with a
es, in part or in w
small screwdriver and press tensioning plate against chain
t to the co
tensioner.
– Install chain tensioner in this position and tighten to 8 Nm.
rrectness of i
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– Lock vibration damper with counterhold -T10069- .
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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.
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– It must now be possible to insert the camshaft bar -T10068- in

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both shaft grooves.

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♦ If cylinder head is removed:

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

– Route chain between tensioning bar and guide rail in direction
nform
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of valve timing housing.

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– First install camshaft adjuster of inlet side with camshaft roller

ion
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chain fitted.
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1. Cylinder head 51
Passat 1997 ➤
5-cylinder injection engine (4-valve), mechanics - nEdition
wage
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– Position both camshaft adjusters (identification:
ris
ed 24E on inlet nte
side and 32A on exhaust side) at mounting tho of camshafts eo
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-arrows-. ss c
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Note
The camshaft adjusters -1- can be turned in two directions. En‐
nf
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sure when installing, that sender wheel for Hall sender is turned
rm
m
in direction of -arrow- onto stop. The distance between both ar‐
atio
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rows on the camshaft adjuster gear is exactly 16 rollers on the

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– Install exhaust camshaft adjuster with camshaft roller chain
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– 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-. wage
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The camshaft bar -T10068- must not be installed while this is
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– 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.
rrectness of i
– Coat sealing surface of sealing flange with sealant -AMV 188
l purpos
001 02- and install. Tighten securing bolts to 8 Nm.

– Renew oil seal in sealing flange ⇒ Item 8 (page 21) .
nform
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Preparing cylinder head gasket and cover for assembly

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⇒ page 36 .
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– Install chain tensioner for camshaft roller chain and tighten to
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40 Nm.
AG.
– 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
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Passat 1997 ➤tho r eo
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5-cylinder injection
ss a engine (4-valve), mechanics - Edition 12.2010 c
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equipment required
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♦ Spark plug socket and ex‐
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tension -3122 B-
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♦ Compression tester -V.A.G
spec
1763-
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1331-
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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
Hot steam may escape when expansion tank is opened. Place

cloth over cap and open with caution.
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– Pull coolant hoses off throttle valve module
Voland seal hose
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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. n AG. Volkswagen AG do
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– Check compression pressure with compression tester - d byV ua
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V.A.G 1763- . ir se tee
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Using compression tester ⇒ Operating instructions.
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– Operate starter until tester shows no further pressure in‐
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crease.
spec
es, in part or in w
Compression pressures:
t to the co
New: 10…31 bar, wear limit: 7.5 bar
Maximum permissible difference between all cylinders: 3 bar
rrectness of i
– Insert spark plugs using spark plug socket and extension
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-3122 B- and tighten to 30 Nm.
nform
– Read fault memory and erase: ⇒ Rep. Gr. 01; Fault memory;
ercia
Reading and erasing fault memory .

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

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2 - Exhaust camshaft bearing ed by
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❑ Lightly coat contact sur‐ ss a c
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with grease -G 052 723
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A2- before installing
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⇒ page 59 .
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⇒ page 60 .
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❑ Installation sequence
es, in part or in w
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and installing camshaft.
3 - Seal
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❑ Renew if leaking.
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❑ When installing valve

timing housing, lightly
lubricate contact surfa‐
nf
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ces of seal.
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❑ When replacing seals,
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do not spread too wide‐

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❑ Offset gaps by 120°.

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❑ Dismantling and assem‐ Prote AG.
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 ➤
9 - Inlet camshaft adjuster
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 agen
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❑ Before installing, check camshaft axial clearance ⇒ page d by 59
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❑ Do not interchange. hor eo
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❑ With hydraulic valve clearance compensation. s s c
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14 - Valve stem seal
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❑ Renewing ⇒ page 74 .
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15 - Securing clip
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❑ Check for secure seating.
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16 - Roller rocker finger
es, in part or in w
t to the co
❑ Before installing, check camshaft axial clearance ⇒ page 59 .
❑ Do not interchange.
❑ Check roller bearing for ease of movement.
rrectness of i
❑ Oil contact surface.
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❑ When installing, secure to supporting element using securing clip.

17 - Valve spring
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❑ Removing and installing ⇒ page 74 , Renewing valve stem seals.

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18 - Valve spring plate

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19 - Valve cotters
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20 - Inlet camshaft bearing cap
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❑ Lightly coat contact surface of bearing cap 7 with grease -G 052 723 A2- before installing ⇒ page 59 .
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❑ Installation position ⇒ page 60 .
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❑ Installation sequence ⇒ page 63 Removing and installing camshaft.
AG.
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
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Special tools and workshop equipment required ised b ara
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♦ Universal dial gauge bracket -VW 387- s aut ra
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♦ Dial gauge
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Perform measurements with support elements and roller rocker
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fingers removed.
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Inlet camshaft
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– Install bearing cap 7 and tighten to 5 Nm and turn 1/8 (45°)
spec
further.
es, in part or in w
t to the co
Wear limit: max. 0.10 mm
Exhaust camshaft
rrectness of i
– Install bearing cap 8 and tighten to 5 Nm and turn 1/8 (45°)
l purpos
further.
Wear limit: max. 0.10 mm
nf
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Lightly coat contact surfaces of bearing caps 7 and 8 with grease
rm
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Procedure
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– Lightly coat contact surfaces (hatched area in figure) of bear‐

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ing caps 7 and 8 with grease -G 052 723 A2- before installing.
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2. Valve gear 59
Passat 1997 ➤
en(4-valve),
AG. Volkswamechanics
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Fitting position of camshaft ed
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Point of bearing cap au -arrow A- of inlet and
t outlet camshafts face or ac
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Identification on bearing caps is right side up when viewed from
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2.1 Valve dimensions

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Valves must not be reworked. Only lapping-in is permitted.
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Dimensions of inlet valves
AG.
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 en AG. Volkswagen AG
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Valve timing at 1 mm valve lift byV gu
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Valve Inlet valve auExhaust valve
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Opens BTDC --- 210.0 °
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Closes BTDC --- 5.0 °
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Opens ATDC 30.0 ° ---
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2.3 Dismantling and assembling valve tim‐
es, in part or in w
t to the co
ing housing
1 - Guide rail: clipped into control housing
rrectness of i
2 - Valve timing housing:
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- Only renew complete with valve -1- for inlet camshaft control -
N205- and valve -1- for exhaust camshaft control -N318- .
nf
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3 - Inlet camshaft control valve -1- -N205-
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4 - Exhaust camshaft control valve -1- -N318-

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5 - 8 Nm: renew (4 securing bolts)

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Checking valve timing housing strainer for soiling.
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– Unclip strainer -2- from back of valve timing housing -1- and C py
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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.
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Minimum dimension: by Vol ot g
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Short inlet valve tho mm 31.8 or
au ac
Long inlet valve ss mm 10.2
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Short exhaust valve mm 31.8

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Long exhaust valve mm 10.2

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Example:
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Measured distance 10.6 mm

— Minimum dimension 10.2 mm
rrectne
= Max. permissible reworking dimension 0.4 mm

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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 AG. Volkswagen AG d
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d - = max. ∅ 29.0 mm ss
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r2 - = radius 2.0 mm
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Z - = bottom surface of cylinder head
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β - 30° upper correction angle
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γ - 60° lower correction angle
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2.5 Removing and installing camshafts
rrectness of i
(With cylinder head installed)
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2. Valve gear 63
Passat 1997 ➤

equipment required
1331-
1332-
♦ Grease -G 052 723 A2-
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pyri by
Vo
co lksw
by
cted agen
ment, pay attention to the following due to the cramped condi‐ Prote AG.
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
olks
wage of cooling es n
ot g
system - engine side. d byV ua
ran
ir se tee
– Set crankshaft to TDC No. 1 cylinder
uth marks -arrow- by turning
o
or
crankshaft on the vibration damper
ss
a
securing bolt in direction ac
of engine rotation:
ce
le
un
pt
an
d
– Remove cylinder head cover ⇒ page 39 .

itte
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erm
ab
ility
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is n
h re
ole,
spec
t to the co
rrectne
– Remove chain tensioner for camshaft timing chain -arrow-.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Valve gear 65
Passat 1997 ➤
wage
e ks s no
Vol t gu
by ara
– Mark timing chain before removing (e.g. with paint, arrow ris
ed
nte
pointing in direction of rotation). autho eo
ra
ss c
ce
e
nl
pt
du
Note
an
itte
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erm
ab
ility
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h re
– Disconnect connectors from the following components of cov‐
hole
spec
er:
es, in part or in w
t to the co
♦ Continued coolant circulation pump -V51- ,
♦ Inlet camshaft control valve 1 -N205- ,
rrectness of i
♦ Exhaust camshaft control valve 1 -N318- , l purpos
♦ Hall sender -G40- ,

♦ Hall sender 2 -G163- .
nform
mercia
at
om
io
Note
n
c
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or
his
ate
do
riv

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for
en
ng
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op
– Move wiring harness clear. C py
t. rig
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yri
– Remove camshaft cover ⇒ page 36 .
p by
co Vo
by lksw
cted agen
Prote AG.
– 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. AG. Volkswagen AG d
swagen oes
k n ol ot g
yV
– Ensure that all roller rocker ed fingers -1- seat properly on valve
b ua
ran
ris
stem ends and are clippedtho into their respective support ele‐ tee
or
ments -2-. ss au ac
ce
e
– Oil running surfaces of camshafts.

nl
pt
du
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itte
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– Carefully place each camshaft in its respective bearing in the

erm
ab
cylinder head. When doing this, note camshaft identification

ility
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⇒ page 61
wit
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h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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orm
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op Vo
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Prote
cted AG.
agen 2. Valve gear
Passat 1997 ➤
Note
AG. Volkswagen AG d
agen oes
lksw not
♦ Observe fitting position ofd bbearing
yV
o
caps: gu
ara
ise nte
r
♦ Point of bearing caput-arrow
ho A- of inlet and outlet camshafts eo
ra
face outwards. ss a c
ce
le
♦ Identification on bearing caps is right side up when viewed

un
pt
an
d
from exhaust side.

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ility
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spec
t to the co
rrectness o
cial p
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A - Inlet camshaft
inform
mer
atio
ing cap 7 with grease -G 052 723 A2- before installing
om
n
⇒ page 59 .
c
i
or
n thi
te
– Tighten bearing caps 5 and 7 alternately and diagonally to

sd
iva
5 Nm + 1/8 turn (45°). o

pr
cum
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fo
en
ng
– Install bearing caps 3 and 9 and tighten to 5 Nm + 1/8 turn

t.
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op
(45°). C py
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by
– Install bearing caps 1 and 11 and also tighten to 5 Nm + 1/8 copy Vo
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turn (45°). cted agen
Prote AG.
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 AG. Volkswagen AG d

agen oes
olksw not
If the camshaft bar cannoted b be engaged in the camshafts, turn
y V gu
ara
camshafts in direction
horisof rotation past TDC No. 1 Cyl. and then nte
eo
back to TDC No. s1a Cyl.
ut ra
c
s
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pt
– Before installing, check valve timing housing strainer for soil‐
du
an
itte
ing ⇒ page 61 .
y li
erm
ab
ility
– Before installing valve timing housing, lightly lubricate valve
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timing housing surfaces contacting camshaft seals.
, is n
h re
hole
– Lightly lubricate contact surfaces of camshaft seals and slowly
spec
push valve timing housing over camshaft seals.
es, in part or in w
t to the co
– Install control housing, renew securing bolts -arrows- and
tighten to 8 Nm.
rrectness of i
Adjusting valve timing ⇒ page 48 .
l purpos
Preparing cylinder head gasket and cover for assembly

⇒ page 36 .
nf
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tighten.
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– First tighten M8 securing bolts to 23 Nm and then tighten M6 o

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– Install chain tensioner for camshaft roller chain and tighten to Cop py
40 Nm.
t. rig
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pyri by
Vo
co
by lksw
cted agen
Prote AG.
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 groupw01,
gen AG
. Volkswagen AG
does
s a
display zone 2 yV
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gu b ara
ed nte
Checking activation thoris e or
au ac
– First check activation of valve -1- of inlet camshaft
ss control -
ce
le
N205- and valve -1- of exhaust camshaft control -N318- via

un
pt
final control diagnosis ⇒ Final control diagnosis; Rep. gr. 01 ;

an
d
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Performing final control diagnosis .

rm
ab
pe
ility
If activation is OK:
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wit
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h re
– Check position of camshafts to crankshaft ⇒ page 70 .

hole
spec
es, in part or in w
2.6.1 Checking position of camshafts to

t to the co
crankshaft
rrectness of i
First check coolant temperature.

l purpos
– 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
nform
ercia
self-diagnosis; Rep. gr. 01 ; Connecting fault reader .

m
a
com
Indicated on display:
ion in
Rapid data transfer HELP

r
Select function XX
te o
thi
s
iva
– Press keys 0 and 4 for function „Initiate basic settings“ and

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confirm entry with Q key.

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Indicated on display: t. Cop
Basic setting
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rig
gh Input display group number XXX ht
pyri by
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– Press buttons 0 0 and 1 for „display group number 1“ and Prote
cted AG.
agen
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
Input display group number XXX
– Press buttons 2 0 and 8 for „display group number 208“ and

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 nxxx
AG. V(°olCA)
kswagen AG xxx° CA xxxxxxxx
lkswage does
not
Display Engine speed by Vo Detected 1st phase Adapted
gu
ara offset Status
shows oris
ed flank nte
th eo
Specifi‐ Idling speed
au 111…131 (° CA) -10.0…10.0° r a CA
c xxxxx100
ss
cation
ce
le
un
pt
an
d
itte
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erm
ab
ility
If the specifications are not obtained
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– Press → button. h re
ole,
spec

t to the co
If no fault is stored in the fault memory:

rrectne
– Press buttons 0 and 6 for function „End output“ and confirm

entry with Q button.
ss
– Switch off ignition.

o
cial p
f in
– Check valve timing ⇒ page 48

form
mer
atio
If the specifications are attained:

om
n
c
– Change to display group 209 as follows: -V.A.G 1551- : Press

or
n thi
e
key 3 -V.A.G 1552- : Press key ↑ .

t
sd
iva
o
pr
cum
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Indicated on display: (1…4 = display zones)

fo
System in basic setting 209 -

en
ng
t.
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Cop py 1 2 3 4
t. rig
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Display zones
cop Vo
by lksw
cted agen
1 2 3 Prote
4
AG.
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
2. Valve gear 71
Passat 1997 ➤
– Press → button.
AG. Volkswagen AG d
agen oes
– Check valve timing ⇒ page 48 olksw not
V gu
d by ara
e
If the specifications are attained: horis nte
eo
aut ra
– Check camshaft timing control ⇒ page 72s.
s c
ce
le
un
pt
2.6.2 Checking camshaft timing control/ad‐
an
d
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justment
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ab
pe
ility
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hole
spec
Indicated on display: (1…4 = display zones).
es, in part or in w
System in basic setting 210 -
t to the co
>
1 2 3 4
– Depress brake pedal and hold.
rrectness of i
– Depress accelerator to full throttle position.
l purpos
Engine revolutions are raised by engine control unit to approx.

2300 rpm.
nform
ercia
Display zones
m
a
com
tio
1 2 3 4
n in
r
te o
thi
Display group 210: Adjustment of inlet camshaft
s
iva
do
r
Readout xxxx rpm xxx.x° CA xxx.x° CA xxxxxxxx

rp
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en
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Display Engine speed Specified angle Actual angle Status

n
t.
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shows C py
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Specifi‐ approx. 2300 rpm 0.0…50.0° KW approx. specified angle xxxxx100
p by
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by c
cation
lksw
cted agen
Prote AG.
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.
If the specifications are attained:
Indicated on display: (1…4 = display zones) System in basic setting 211 -
>
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
AG. Volkswagen AG d
Display group 211: Adjustment of exhaust camshaft swagen oes
olk not
yV gu
Readout xxxx rpm xxx.x°
ised b CA xxx.x° CA ara
nte xxxxxxxx
or eo
Display Engine speed aSpecified
uth
angle Actual angle ra Status
shows ss c
ce
e
nl
Specifi‐ approx. 2300 rpm 0.0…22.0° CA approx. specified angle xxxxx100

pt
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itte
cation
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erm
ab
ility
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hole
spec
Note
es, in part or in w
t to the co
The display values increase to approx. 22.0° CA and then drop

back to 0.0° CA.
rrectness of i
l purpos
Note
nf
ercia
The actual angle jumps to approx. 22.0° CA and then drops back
rm
m
to the specified value. The upper and lower stops for the actual
atio
m
angle must equate to the specified angle in display zone 2.

o
n in
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thi
te
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Note
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ng
t.
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op py
Specified value „xxxxx100“ in display zone 4 is only displayed t. C rig
gh ht
after several seconds. Continue with test until specified angle 0.0° yri
p by
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CA is shown in display zone 2.
by c lksw
cted agen
Prote AG.

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.
If the specifications are attained: AG. Volkswagen AG d
agen oes
olksw not
yV gu
– Press buttons 0 and 6 for isedfunction
b „End output“ and confirm ara
nte
entry with Q button. uthor eo
ra
s a c
– Switch off ignition. s
ce
e
nl
pt
du
an
2.7 Checking valve guides
itte
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erm
ab
ility
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♦ Universal dial gauge bracket -VW 387- h re

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
te
♦ Dial gauge
a
do
priv
cum
or
Test procedure
f
en
ng
t.
yi Co
– Insert new valve into guide. The end of the valve stem must Cop py
t. rig
be flush with the guide. Due to slight differences in stem di‐ yri
gh by
ht
ameters, use only an inlet valve in inlet guide and an exhaust op Vo
by c lksw
valve in exhaust guide. cted agen
Prote AG.
– 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 AG. Volkswagen AG d
agen oes
ksw
-3365- byV
ol not
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ara
ed
is nte
♦ Adapter -T40012- hor eo
aut ra
c
♦ Torque wrench -V.A.G ss
ce
e
1331-
nl
pt
du
an
itte
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erm
ab
ility
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, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
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 .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

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 gen AG. Volkswagen AG d
of crankshaft and conrod bearings are found in the engine Vol
koil,
swa oes
not
one must apart from thoroughly cleaning oil passages, ed byrenew gu
ara
all oil spray jets, the oil non-return valve, the oil cooler
horis and oil nte
eo
filter element to prevent consequential damage. s aut ra
c s
♦ The oil level must not be above the max. mark - danger of
ce
e
nl
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du
damage to catalytic converter! Markings ⇒ page 77 ,
an
itte
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⇒ page 77 .
erm
ab
ility
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1.1 Engine oil
, is n
h re
hole
spec
Oil capacities
es, in part or in w
t to the co
With oil filter 4.7 l
5) Current values: ⇒ Exhaust emissions test
rrectness of i
Engine oil specifications with long-life service
l purpos
New VW standard (specially developed, ageing resistant) initial

filling: VW standard 503 00 (VW TL 52 173).
nf
ercia
orm
m
Note
atio
om
n in
or c
♦ The engine is filled at the factory with engine oil conforming to
thi
te
sd
a
VW standard 503 00. This engine oil is designed for long

iv
o
r
maintenance intervals. However, the engine oils listed below

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can also be used.

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ng
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♦ Engine oils conforming to VW standard 500 00, 501 01 or
C py
t. rig
gh
502 00 can be used furthermore. The oil must then be changed
ht
pyri by
Vo
o
every 12 months or every 15000 km and the service interval by c lksw
cted agen
display must be programmed accordingly. Procedure: ⇒ Main‐ Prote AG.
tenance ; Booklet 36
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. agen
AG. Volkswagen AG d
oes
olksw not
❑ Secured with bolt to in‐ d by V gu
ara
take manifold. orise nte
eo
th
u ra
4 - Oil non-return valve, 6 Nm ss a c
ce
le

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pt
an
tion.
d
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ab
❑ Clean if badly soiled
ility
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5 - 10 Nm
ole,
spec
6 - Oil pump drive cover
t to the co
7 - O-ring
❑ Renew.
rrectne
❑ Lubricate before instal‐
ling.
ss o
8 - Oil pump drive
cial p
f inform
9 - Cylinder block
mer
atio
om
n
sealing flange and dual-
c
i
or
n
mass flywheel
thi
te
sd
a
⇒ page 21 .
iv
o
pr
cum
r

fo
en
ng
crankshaft ⇒ page 27 .
t.
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op py
t. C rig
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bling pistons and conrods ⇒ page 29 . p by
co Vo
by lksw
cted agen
10 - Intermediate shaft Prote AG.
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. AG. Volkswagen AG d
agen oes
❑ Lubricate
Vobefore
lksw installing. not
g
by ua
ed ra
25 - Oil hlevel
ris and oil temperature sender -G266- ntee
ut o or
❑ss a Black connector, 3-pin. ac
ce
e
nl
pt
du
an
itte
26 - Bracket
y li
erm
ab
❑ For ATF lines.

ility
ot p
wit
❑ Only on vehicles with automatic gearbox.

, is n
h re
hole
27 - 12 Nm
spec
es, in part or in w
28 - Baffle plate
t to the co
29 - Oil filter bracket/engine mounting

rrectness of i

l purpos
30 - 23 Nm
nform
ercia
31 - Gasket
m
❑ Renew.
at
om
io

n
c
in t
or
his
e

at
do
priv
cum
for
en
ng
t.
yi
1.2.1 Removing and installing oil spray jet
Co
Cop py
t. rig
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yri by
cop Vo
by lksw
cted agen
Prote
♦ 4 mm ∅ drift
AG.
♦ 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.
AG. Volkswagen AG d
❑ Coat contact surfaces agen oes
olksw not
outside the seal, with d by V gu
ara
sealant - rise nte
ho eo
AMV 188 001 02- . s aut ra
c
s
ce
e
nl
pt
du

an
itte
y li
erm
ab
ility
ot p
4 - Oil cooler cover, 25 Nm

wit
, is n
h re
5 - 23 Nm
hole
spec

es, in part or in w
t to the co
7 - Oil filter lower part, 25 Nm

❑ Drain before removing.
rrectness of i
❑ With by-pass valve,

opening pressure: 2.50
l purpos
bar
8 - Oil filter element
nform
ercia
❑ Observe change inter‐

m
at
vals.
om
ion
c
in t

or
his
ate
9 - Oil pressure switch -F1- 1.4 bar, 20 Nm

do
priv
cum
or
❑ Identification: black
f
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
80
Prote AG.
Rep. gr.17 - Lubrication
Passat 1997 ➤
❑ Check ⇒ page 87 . agen
AG. Volkswagen AG d
oes
olksw not
V
10 - Plug, 25 Nm d by gu
ara
rise nte
❑ For oil return valve. utho eo
ra
s a c
11 - Seal s
ce
le
un
pt
❑ Renew.
an
d
itte
y li
rm
12 - Gasket
ab
pe
ility
❑ Renew.
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1.4 Dismantling and assembling oil pump
rrectness of i
1 - Drive shaft
l purpos

2 - Oil pump housing
nform
ercia
3 - 23 Nm
m
a
com
tion in
4 - Gears
r
te o
thi
❑ Checking backlash
s
iva
do
⇒ page 82 .
r
rp
cum
fo
❑ Checking axial clear‐
en
ng
t.
yi
ance ⇒ page 82 .
Co
Cop py
t. rig
gh
5 - Oil pump cover with pres‐
ht
pyri by
Vo
o
sure relief valve
c by lksw
cted agen
Prote AG.
❑ 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 lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
♦ Feeler gauges
Wear limit: 0.20 mm
ss o
cial p
f
Checking oil pump axial clearance
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ 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-
olkswagen AG
en AG. V
♦ Hand drill with oplastic
ksw
ag brush does
not
V l
attachment
ed
by gu
ara
ris nte
♦ Flat ascraper
ut
ho eo
ra
ss c
♦ Cable ties
ce
e
nl
pt
du
an
♦ Eye protection
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
op py
Removing
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– 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-.
AG. Volkswagen AG d
– Mark the fitting position of threaded connections -1- and lo‐ lksw
agen oes
not
cating sleeves -2- below on the left and right engine mounts. d by Vo gu
ara
rise nte
– Unbolt both engine mountings from below. utho eo
ra
s a c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Attach support bracket 10-222A as shown.
rrectness of i
– Support engine at rear lifting eye with support bracket.
l purpos
– Tension engine slightly with spindle of support bracket.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
– Support assembly carrier with workshop crane 1202 A.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
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
lkswage es n
Vo ot g
– Loosen left ed gearbox mounting nut -arrow- until ritanis flush
by ua with
end of horbolt (turned approx. 4 threads).
is tee
aut or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Loosen rear left gearbox mounting rear bolt -2- several turns,
remove left gearbox mounting front bolt -1-.
l purpos

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

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.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
– Remove sealant residue ison e sump using a rotating brush, e.g.
d b ara
nte
an electric drill with a uplastic
thor
brush attachment (wear safety eo
goggles). ss a ra
c
ce
e
– Clean sealing surfaces. They must be free of oil and grease.

nl
pt
du
an
itte
y li
Installing
erm
ab
ility
ot p
Prerequisite
wit
, is n
h re
• Intermediate plate must be bolted firmly to cylinder block
hole
⇒ Item 9 (page 22) .
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ Observe expiry date of sealing compound.
l purpos
♦ The oil sump must be installed within 5 minutes of applying

silicone sealing compound. nform
mercia
at
– Cut off tube nozzle at forward marking (∅ of nozzle approx. 3

om
io
mm).
n
c
in t
or
his
e
– Apply silicone sealing compound, as shown, to clean sealing

at
do
riv
surface on sump. Sealing compound bead must be:

p
cum
for
en
g
♦ 2…3 mm thick.
n
t.
yi Co
Cop py
♦ Run bead along inner side of bolt holes -arrows-.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
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
en AG. V
o.lkswagen AG
ag does
ksw not
Specified torques y Vol gu
b ara
ed nte
ris
Component tho
Nm eo
au ra
c
ss
Engine mounting to subframe 6) 23
ce
le
un
pt
Torque reaction support to sump 40
an
d
itte
y li
erm
Gearbox support to gearbox mounting M10 40
ab
ility
ot p
Gearbox mounting to subframe M8 25
wit
is n
h re
ATF lines on sump and torque reaction 10
ole,
support
spec
t to the co
6) Renew securing nuts
Further assembly is basically the reverse of the dismantling se‐

quence.
rrectne
– Install lock carrier with attachments ⇒ General body repairs,
exterior; Rep. gr. 50 ; Lock carrier service position .
ss o
cial p
f inform
1.6 Checking oil pressure and oil pressure switch
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤

equipment required n AG. Volkswagen AG do
lkswage es n
o ot g
♦ Oil pressure tester -V.A.G d byV ua
ran
1342- o
ir se tee
th or
u
♦ Adapter -V.A.G 1342/14- ss
a ac
ce
le
un
♦ Voltage tester -V.A.G
pt
an
d
1527B-
itte
y li
rm
ab
pe
♦ Auxiliary measuring set -
ility
ot
V.A.G 1594C-
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
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:G. Idling:
Volkswaminimum
gen AG 2.0
gen A
bar, 2,000 rpm: 3.0…5.5 bar.lkabove 2,000 rpm: maximum does 7.0
swa not
bar. db
yV
o gu
a
e ran
ris tee
If the specifications are
ut not obtained
ho or
sa ac
– Rectify mechanical
s
damage, e.g. bearing damage.
ce
e
nl
pt
du
At higher engine speeds, the oil pressure must not exceed 7.0
an
itte
y li
bar.
erm
ab
ility
ot p
If the specification is exceeded:

wit
, is n
h re
– Check the oil passages.

hole
spec
– Renew oil pump if necessary ⇒ page 81 , Dismantling and as‐

es, in part or in w
t to the co
sembling oil pump.

rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Passat 1997 ➤
19 – Cooling
1 Removing and installing parts of cool‐
ing system
AG. Volkswagen AG d
agen
WARNING Volksw
oes
not
by gu
d ara
ise nte
When doing any repair work, uespecially
thor
in the engine compart‐ eo
a ra
ss c
tions:
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
sitions.
wit
is n
h re
ole,
spec
hot components.
t to the co
rrectne
Note
s
♦ When the engine is warm, the cooling system is under pres‐
s o
cial p
f
sure. If necessary, release pressure before beginning repair
in
work.
form
mer
atio
♦ Hoses are secured with spring-type clips. In case of repair,
om
n
only use spring-type clips.
c
i
or
n thi
e
♦ Spring-type clip pliers -VAS 5024- or hose clip pliers -

t
sd
iva
V.A.G 1921- are recommended for fitting spring-type clips.

pr
cum
r
fo
en
ng
♦ When installing coolant hoses, route stress-free so that they

t.
yi Co
op
do not come into contact with other components (observe C py
t. rig
markings on coolant connection and hose).
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
Perform cooling system leakage test with cooling system tester -
AG.
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. agen
AG. Volkswagen AG d
oes
olksw not
2 - Securing clip d by V gu
ara
rise nte
3 - Rubber mounting autho eo
ra
ss c
4 - Radiator
ce
le
un
pt
an
d
itte
y li
⇒ page 103 . rm
ab
pe
ility
❑ After renewing, renew
ot
wit
entire coolant.
, is n
h re
❑ With ATF cooler on ve‐
hole
spec
hicles with an automatic
es, in part or in w
gearbox and front-
t to the co
wheel drive: ⇒ 5-speed
automatic gearbox 01V;
Repair group 37; Dis‐
rrectness of i
mantling and assem‐
bling gearbox; Remov‐
l purpos
ing and installing ATF

lines .
nform
ercia
❑ With ATF cooler on ve‐

m
hicles with an automatic
a
com
ti
gearbox and four-wheel
on in
drive: ⇒ 5-speed auto‐
r
te o
thi
matic gearbox 01V,
s
iva
do
four-wheel drive; Repair
r
rp
cum
group 37; Dismantling
fo
en
ng
and assembling gear‐

t.
yi Co
op
box; Removing and in‐
C py
t. rig
gh
stalling ATF lines .
ht
pyri by
Vo
co lksw
❑ Cleaning ATF cooler on
by
cted agen
Prote
vehicles with front-
AG.
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
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen APassat 1997 ➤
agen G do
5-cylinder injection engine (4-valve),
Volksw mechanics - Edition
es n12.2010
ot y gu
db ara
ise nte
1.2 Parts of cooling system, engine side
r
tho eo
au ra
c
ss
ce
e
nl
pt
du
1 - 10 Nm
an
itte
y li
erm
ab
2 - Fan wheel
ility
ot p
wit
3 - Coolant hose
, is n
h re
❑ From union for combi‐
hole
spec
nation valve.
es, in part or in w
t to the co
4 - Throttle valve module
rrectness of i
❑ Heated by coolant.
5 - 8 Nm l purpos
nf
ercia
6 - Seal
orm
❑ Renew.
m
atio
om
n in
7 - Bracket
or c
thi
e
❑ For coolant pipe and

t
sd
iva
wiring harness
o
r
rp
cu
o
m
f
en
ng
t.
yi
Co
Cop py
t. rig
gh
8 - To heat exchanger
ht
pyri by
Vo
o
by c lksw
❑ Coolant hose schematic Prote
cted AG.
agen
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
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
1.3 Dismantling and assembling compact
ed
ris nte
ho eo
ut
bracket ss a ra
c
ce
le
un
pt
an
d
itte
y li
Note
erm
ab
ility
ot p
Specified torque for poly V-belt idler roller: 23 Nm

wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

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 lkswage es n
o ot g
yV ua
❑ For coolant pump. ir se
d b ran
o tee
h
10 - Gasket aut or
ac
ss
❑ Renew.
ce
e
nl
pt
du
an
11 - 25 Nm
itte
y li
erm
ab
12 - O-ring
ility
ot p
wit
❑ Renew.
, is n
h re
hole
13 - Coolant pump
spec
es, in part or in w
❑ Check for ease of movement.

t to the co
14 - Belt pulley
❑ For coolant pump.
rrectness of i
15 - 25 Nm
l purpos
16 - 8 Nm
nform
ercia
17 - Tensioning element for poly V-belt

m
❑ Removing and installing poly V-belt ⇒ page 19 .

at
om
ion
c
18 - Bearing bush
in t
or
his
e
❑ For viscous fan coupling.

at
do
priv

um
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤
Tightening sequence, compact bracket to cylinder block
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
Procedure
t to the co
– Position compact bracket on cylinder block and tighten secur‐
ing bolts by hand.
rrectness of i
– Tighten compact bracket in sequence as follows to 25 Nm:
l purpos
1 - Tighten fitting bolts -A-

nform
ercia
2 - Tighten bolts -B-

m
1.4 Coolant hose schematic diagram

a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

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 agen
AG. Volkswagen AG d
oes
olksw not
12 - Coolant pump ed byV gu
ara
ris nte
13 - Cylinder block aut
ho eo
ra
ss c
14 - Coolant pipe
ce
e
nl
pt
du
an
15 - Cylinder head
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
io
1.5 Dismantling and assembling thermostat

n
c
in t
or
housing
his
ate
do
priv
cum
for
en
ng
t.
yi
Note
Co
Cop py
ht. rig
rig ht
Routing of coolant hoses on thermostat housing ⇒ page 93 , parts
py by
co Vo
by lksw
of cooling system - engine side. Prote
cted AG.
agen

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.
AG. Volkswagen AG d
❑ Before removing, re‐ agen oes
olksw not
lease pressure in cool‐ ed byV gu
ara
ing system if necessary. horis nte
eo
ut
❑ Checking: ⇒ Fault ss a ra
c
memory; Rep. gr. 01 ;
ce
e
nl
Reading and erasing

pt
du
an
itte
fault memory
y li
erm
ab
9 - Plug
ility
ot p
wit
, is n
❑ Before removing, release pressure in cooling system if necessary.

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

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-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
Draining
rm
m
atio
m
– Open cap on coolant expansion tank.

o
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
99
cted agen
Prote AG.
1. Removing and installing parts of cooling system
Passat 1997 ➤
lkswage es n
WARNING d byV
o ot g
ua
ran
ir se tee
ho
Hot steam may escape when expansion tank is opened.
aut
Place or
ac
cloth over cap and open with caution. ss
ce
le
un
pt
an
d
itte
y li
erm
– Remove noise insulation ⇒ General body repairs, exterior;
ab
ility
Rep. gr. 50 ; Assembly overview - noise insulation .
ot p
wit
is n
– Remove drain plug -arrow-.
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e
– Pull out retaining clip -arrow- for coolant hose and remove
t
sd
va
coolant hose from quick-release coupling of radiator.

i
o
pr
cum
r
fo
en
ng
t.
yi Co
op
Note
C py
t. rig
gh ht
pyri by
Vo
co
Observe environmental regulations for disposal.
by lksw
cted agen
Prote AG.
Filling

Passat 1997 ➤
Note
. Volkswagen AG
gen AG
♦ Use only coolant additive G 12 in accordanceVwith
olks TL -
wa does
not
VW 774 F- . Identification: purple colour. ed b y gu
ara
ris nte
o
♦ G 12 and coolant additives marked "In aut accordance with TL -
h eo
ra
VW 774- F" prevent frost and corrosion
ss damage and scaling c
and also raise the boiling point of coolant. Therefore, the sys‐
ce
e
nl
pt
du
tem must be filled all year round with frost and corrosion
an
itte
y li
protection additives.
erm
ab
ility
ot p
♦ G 12 purple (in accordance with -VW 774 F- ) can be mixed
wit
, is n
with existing coolant additives G 11 and G 12 red!
h re
hole
♦ Because of its higher boiling point, the coolant improves en‐
spec
gine reliability under heavy loads, particularly in countries with
es, in part or in w
t to the co
tropical climates.
♦ Frost protection is required down to about -25 °C (in countries
with arctic climates: down to about -35 °C).
rrectness of i
♦ The coolant concentration must not be reduced by adding wa‐
l purpos
ter even in warmer seasons and in warmer countries. The anti-

freeze must be at least 40% of mixture.
nf
ercia
o
♦ If for climatic reasons greater frost protection is required, the
rm
m
atio
amount of G 12 can be increased, but only up to 60% (frost
om
protection to about -40 °C). Otherwise frost protection and
n in
or c
cooling effectiveness are reduced again.
thi
te
sd
iva
♦ The refractometer -T10007- is recommended for determining
o
r
rp
cu
the current anti-freeze concentration.
o
m
f
en
ng
t.
yi Co
♦ If radiator, heat exchanger, cylinder head or cylinder head Cop py
t. rig
gasket is renewed, do not reuse old coolant. opyri
gh by
Vo
ht
by c lksw
cted agen
Recommended mixture ratios: Prote AG.
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 holeo-arrow- is no longer hidden
. V lkswagen AG
by the connection. swagen AG does
k not
Vol g
– Fill with coolant suntil
ed
by it flows out of the bleeder hole inucoolant
ara
nte
hose. thori eo
au ra
c
– Push coolant
ss hose onto connection and tighten using hose
ce
le
clip.
un
pt
an
d
itte
y li
– Fit expansion tank cap.
rm
ab
pe
ility
– Switch off heater and air conditioner.
ot
wit
, is n
– Start engine and maintain an engine speed of about 1300 rpm h re

hole
for about 4 minutes. spec

es, in part or in w
– Then run engine at idling speed until electric radiator fan cuts
t to the co
in.
rrectness of i
– To relieve pressure, carefully open cap on coolant expansion

l purpos
tank.
nform
ercia
– Now screw adapter -V.A.G 1274/8- with adapter -

V.A.G 1274/10- onto expansion tank again.
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

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
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
103
cted agen
Prote AG.
1. Removing and installing parts of cooling system
Passat 1997 ➤

equipment required
♦ Refractometer -T10007-
1331-
♦ Spring-type clip pliers
-5024-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
Removing
ce
le
un
pt
an

d
itte
y li
rm
ab
– Remove front bumper ⇒ General body repairs, exterior; Rep.

pe
ility
gr. 63 ; Front bumper .

ot
wit
, is n
h re
– Pull coolant hoses off radiator.

hole
spec

es, in part or in w
t to the co
– Remove ATF lines from radiator ⇒ 5-speed automatic gear‐

box 01V; Rep. gr. 37 ; Removing and installing ATF lines .
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

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 .
n AG. Volkswagen A
– Check headlight adjustment and correct
olks
waifgenecessary ⇒ Main‐
G do
es n
ot g
tenance ; Booklet 36 db
y V ua
r e an
ris tee
Additional information and assembly
tho work for vehicles with air or
au
conditioner ss ac
ce
le
un
pt
an
d
WARNING
itte
y li
rm
ab
pe
ility
The air conditioner refrigerant circuit must not be opened.

ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
To prevent damage to condenser and also to refrigerant lines/

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

nform
ercia
– Remove condenser from radiator and pull forward as far as is

m
possible.
com
tion in
r
– Secure condenser to body so that refrigerant pipes/hoses are

te o
thi
s
not stressed.
iva
do
r
rp
cum
– Pull radiator out between condenser and lock carrier.

fo
en
ng
t.
yi Co
Cop py
1.8 Removing and installing viscous fan
t. rig
gh ht
pyri by
coupling
o Vo
by c lksw
cted agen
Prote AG.

Passat 1997 ➤
♦ 2-hole pin wrench -3212-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
Removing
t to the co
– Move lock carrier to service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Service position .
rrectne
– Remove fan wheel from viscous fan coupling.
ss
– Counterhold belt pulley for viscous fan coupling using pin
o
cial p
f
wrench -3212- .
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– 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 wage
e ks s no
Vol t gu
♦ Hexagon bolt efrom
db
y assem‐ ara
bly tool -3290-
ho
ris nte
eo
t
au ra
♦ Hexagon ss nut from assem‐ c
bly tool -3301-
ce
le
un
pt
an
d
itte
♦ Thrust piece -3349/1-
y li
rm
ab
pe
ility
♦ Thrust piece -3367/2-
ot
wit
, is n
♦ Multi-purpose tool -VW
h re
hole
771- with adapter -
spec
VW 771/15-
es, in part or in w
t to the co
♦ Pins -VW 771/43-
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Passat 1997 ➤

1331-
♦ Spring-type clip pliers -
VAS 5024-
♦ 5 mm ∅ drift
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
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- .
AG. Volkswagen AG d
agen oes
ksw not
– Press new bushes into by V bearing bush using press plate
ol
gu-
ara
VW 401- . Dimension
rise
d -a- = 11 mm nte
tho eo
au ra
ss c
Note
ce
le
un
pt
an
d
itte
y li
♦ Do not cant bush when pressing.

rm
ab
pe
ility
♦ Note different sizes of bushes.

ot
wit
, is n
h re
hole
Installing
spec
es, in part or in w
t to the co
– Fit bearing bush with bushes onto compact bracket using hex‐
rrectness of i
agon nut from assembly tool -3301- , press piece -3367/2- ,

press piece -3349/1- and hexagon nut from assembly tool
l purpos
-3290- as shown.
– Tighten hexagon nut from assembly tool -3301- by hand as far
nform
ercia
as possible.
m
a
com
tion in
r
te o
Note
thi
s
iva
do
r
rp
Do not cant bush when pulling.

um
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤
olkswagen AG
en AG. V
– Press bearing bush with bushes into compact bracket
olks
wag to stop. does
not
y V gu
db ara
– Secure bearing bush with securing clips after rise installing. nte
ho eo
ut
– Install viscous fan coupling ⇒ page 105
ss a . ra
c
ce
le
– Install dip stick guide tube, specified torque: 8 Nm.
un
pt
an
d
itte
y li
– Install radiator ⇒ page 103 .
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
1.10 Checking continued coolant circulation
rrectne
pump
s
s o
cial p
f i
♦ Voltage tester -V.A.G 1527B-
nform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ 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 agen open circuit referring
AG. Volkswagen AG d
oes to current flow di‐
agram: ⇒ Currentolksw flow diagrams, Electricalnot fault finding and
y V gu
Fitting ilocations.
sedb ara
n
r tee
ho
aut or
ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
nte
autho
ra
ss c
ce
le
un
pt
20 – Fuel supply system
an
d
itte
y li
rm
ab
pe
ility
ot
1 Removing and installing parts of fuel
wit
, is n
h re
supply system
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ Hose connections are secured with either spring-type or
clamp-type clips. l purpos
♦ Always renew clamp-type clips with spring-type clips.
nform
ercia
♦ Fuel hoses on engine must be secured with spring-type clips

only. The use of clamp or screw-type clips is not permissible.
m
a
com
tion in
♦ The fuel extractor -VAS 5190- is recommended to empty the
r
te o
thi
fuel tank.
s
iva
do
r
♦ Hose clip pliers -VAS 5024- or hose clip pliers -V.A.G 1921-
rp
cum
fo
are recommended for installation of spring-type clips.
en
ng
t.
yi Co
Cop py
t. rig
Removing and installing fuel tank with attachments and fuel filter:
gh ht
yri by
vehicles with front-wheel drive ⇒ page 112 .
cop Vo
by lksw
cted agen
Prote AG.
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. wage
es n
lks
❑ To activated charcoal fil‐ d byV
o ot g
ua
ter o
ir se
ran
tee
⇒ Item 1 (page 144) . auth or
ac
ss
8 - Breather valve ce
le
un
pt
❑ To remove valve unclip an
d
itte
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sideways out of support.
rm
ab
pe
ility
❑ Before installing remove
ot
wit
cap ⇒ Item 1 (page 113) .
, is n
h re

hole
spec
es, in part or in w
9 - Earth connection
t to the co

10 - Supply line
rrectness of i
❑ Black
l purpos

❑ Clipped onto side of fuel tank.
nform
ercia
❑ To release lower securing clip, press together circlip on face side of angled connection.
m
❑ Between flange ⇒ Item 14 (page 114) and fuel filter -item ⇒ Item 26 (page 114) -
com
tion in
r
11 - Return line
te o
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❑ Blue or with blue marking.

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❑ To release lower securing clip, press together circlip on face side of angled connection.
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❑ From fuel return pipe on fuel rail: ⇒ Repairing injection system; Rep. gr. 24 ; Dismantling and assembling
c by lksw
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fuel rail and injectors .
Prote AG.
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.
AG. Volkswagen AG d
20 - 25 Nm agen oes
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21 - Fuel tank rised
nte
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❑ When removing, support using
s aut engine and gearbox jack -V.A.G 1383 A- . or ac
s
ce
le
un
pt
an
d
22 - Bracket
itte
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ab
❑ For securing straps.

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23 - Securing strap
spec
❑ Note different lengths.

t to the co
❑ Installation position: Fixing point (holes) face in direction of travel.

24 - Retaining ring
rrectne
❑ Secured to body.
25 - 10 Nm
ss o
cial p
26 - Fuel filter
inform
mer
❑ Installation position: arrow points in direction of flow.

atio
m
27 - Supply line
o
n
c
i
or
❑ Black
thi
te
sd
va

i
o
pr
cum
r
fo
❑ Secure with spring-type clips.

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ng
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❑ To fuel supply pipe on fuel rail ⇒ Repairing injection system; Rep. gr. 24 ; Dismantling and assembling Cop py
. rig
fuel rail and injectors
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28 - Breather line
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❑ 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.

AG. Volkswagen AG d
agen oes
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1.2 Removing and installing fuel tank with
ss c
ce
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nl
pt
attachments and fuel filter: vehicles with

du
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four-wheel drive
erm
ab
ility
ot p
wit
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Note
hole
spec
es, in part or in w
Ensure, on completion of all work on the fuel delivery unit and fuel
t to the co
gauge that the fuel supply and fuel return hoses do not touch the
fuel tank (transfer of pumping noises).
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
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t.
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Cop py
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cted agen
Prote AG.

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) . wage
es n
olks ot g
❑ Check ⇒ page 115 . d byV ua
ran
ir se tee
7 - Connecting hose utho
or
a ac
ss
8 - Gravity valve
ce
e
nl
pt
du
an
itte
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upwards out of support.
erm
ab
❑ Check valve for
ility
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through-flow; valve ver‐
wit
, is n
h re
tical: open, valve tilted
hole
45°: closed.
spec
es, in part or in w
9 - 10 Nm
t to the co
10 - Fuel filler neck
rrectness of i
11 - Non-return valve
l purpos
tion: white side of valve

points in direction of
nform
ercia
sealing cap
⇒ Item 1 (page 113) .
m
at
om
12 - Connecting hose ion

c
in t
or
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13 - Heat shield
at
do
priv
❑ For fuel filler neck ⇒ Item 10 (page 116) .

um
for
en
ng
t.
14 - Union nut, 60 Nm
yi Co
Cop py
❑ Remove and install using union nut tool -3218- .
t. rig
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15 - Connector
c by lksw
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Prote AG.
❑ 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. agen AG. Volkswagen AG do
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❑ For fuel Vol
by gauge sender -G- and fuel pump
ot g -G6- .
d ua
ran
ise
29 - Supply
ut
ho
r
line tee
or
a ac
❑s Black
s
ce
e
nl

pt
du
an
itte

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erm
ab
ility
30 - Fuel gauge sender -G-

ot p
wit
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❑ Clipped on reservoir housing in fuel tank.

h re
hole
spec
31 - Fuel delivery unit

es, in part or in w

t to the co
❑ Checking fuel pump ⇒ page 128 .

rrectness of i
32 - Supply line
l purpos
❑ Black
nf
ercia
or

m
m
atio
m
❑ To fuel supply pipe on fuel rail ⇒ Repairing injection system; Rep. gr. 24 ; Dismantling and assembling
o
n in
c
fuel rail and injectors

or
thi
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sd
a
33 - Fuel filter
iv
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cu
❑ Installation position: arrow points in direction of flow.

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f
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34 - Breather line Cop py
t. rig
gh
❑ Black
ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

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.
AG. Volkswagen AG d
agen oes
lksw not
1.3 Safety precautions when working on Vo gu
d by ara
ise nte
fuel supply system or eo
h
aut ra
ss c
ce
le
un
pt
WARNING
an
d
itte
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rm
ab

pe
ility

ot
wit
, is n
tions:
h re
hole
spec
es, in part or in w

t to the co

sitions.
rrectness of i

hot components.
l purpos
nform
When removing and installing fuel gauge sender or fuel pump

ercia
(fuel delivery unit) from a full or partly full fuel tank, observe the
m
following:
com
tion in
r
te o
thi
s
iva
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fo
en
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Cop py
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118
cted agen
Prote
Rep. gr.20 - Fuel supply system
AG.
Passat 1997 ➤
AG. Volkswagen AG d
agen oes
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WARNING rise d b ara
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tho eo
u ra
Fuel s a under pressure! Before loosening hose
supply lines sare c
ce
e
nl
pt
pressure by carefully pulling hose off connection. du
an
itte
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erm
ab
ility
ot p
♦ Before beginning work, place an extraction hose close to
wit
, is n
sender opening in fuel tank to extract escaping fuel fumes and
h re
hole
switch on exhaust extraction system. If no exhaust gas ex‐
spec
traction system is available, a radial fan with a displacement
es, in part or in w
t to the co
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!
rrectness of i
♦ For safety reasons, fuse No. 28 must be removed from the
l purpos
fuse holder before opening the fuel system. Otherwise, the fuel
pump could be activated by the driver's door contact switch.
nf
ercia
orm
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om
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c
1.4 Rules for cleanliness

or
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When working on the fuel supply and injection system, pay careful
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attention to the following „5 rules“ for cleanliness:
f
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ng
t.
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op
♦ Thoroughly clean all unions and surrounding areas before dis‐ C py
t. rig
connecting. gh ht
pyri by
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♦ Place removed parts on a clean surface and cover. Use only Prote
cted AG.
agen
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
AG. Volkswagen A
agen
– Note safety precautions beforeolbeginning work ⇒ page 118
G do
es n .
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yV
db ara
rise nte
WARNING tho eo
au ra
c
ss
ce
e
nl
pt
du

an
itte
y li

erm
ab
ility
ot p
wit
, is n

h re
hole
theft coding.
spec
es, in part or in w
– With the ignition switched off, disconnect battery earth strap.

t to the co
– Pull 4-pin connector and fuel hoses off fuel delivery unit (right
side of vehicle) and remove the fuel delivery unit
rrectness of i
⇒ page 123 , removing and installing fuel delivery unit.

l purpos
– 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.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
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cted agen
Prote AG.

Passat 1997 ➤
gen AG. engine
V (4-valve),
olkswagen AG d
mechanics - Edition 12.2010
wa oes
olks not
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– Now pull off connector -1- under the edcover on fuel gauge send‐
b ara
nte
ris
er 2 -2-. tho eo
au ra
c
ss
– Lift fuel gauge sender 2 -G169- -2- and pull suction-jet pump
ce
e
-3- out of locking device of sender.
nl
pt
du
an
itte
y li
– Take out fuel gauge sender 2 -G169- .
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Now, on right side of vehicle (fuel delivery unit), pull line to
suction-jet pump -2- off junction -1- and pull connector -3- off
l purpos
fuel gauge sender -G- to fuel gauge sender 2 -G169- .

– Now the suction-jet pump can be pulled out of the side of fuel
nf
ercia
o
gauge sender 2 (left side of vehicle).
rm
m
atio
m
– Check that the fuel lines on suction-jet pump are fitted securely
o
n in
c
and are not damaged.

or
thi
te
sd
a
– Additionally check suction-jet pump for possible soiling.

iv
o
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rp
cu
o
m
If no fault is found:
f
en
ng
t.
yi Co
op
– Install suction-jet pump and fuel gauge sender 2 -G169- again C py
t. rig
in reverse order. gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
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 G. Volkswage
nA n AG d
wage oes
yV
olks not
gu
b ara
ed
♦ Union nut tool -3217- oris nte
eo
th
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
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- .

AG. Volkswagen
– Pull fuel delivery unitlkswith
wageseal out of opening
n AG do
ein
s n fuel tank. o ot g
yV ua
edb ran
ris tee
Note tho or
au ac
ss
ce
e
If delivery unit is to be renewed, drain old delivery unit before dis‐

nl
pt
du
an
posal.
itte
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erm
ab
ility
ot p
Installing
wit
, is n
h re
– Installation of fuel delivery unit is carried out in reverse order.
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ Do not bend fuel gauge sender when installing.

l purpos
♦ Insert seal for flange or fuel delivery unit dry into opening of
fuel tank.
nf
ercia
♦ Moisten seal with fuel only when installing flange or fuel de‐
rm
m
livery unit.
atio
om
n in
c
♦ Ensure that fuel lines are tight.

or
thi
te
sd
a
♦ Do not interchange supply and return lines.

iv
o
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rp
cu
o
♦ Note Installation position of fuel delivery unit flange: Mark on

f
en
ng
t.
flange -1- must align with mark on fuel tank -2-.
yi Co
Cop py
t. rig
♦ After installing fuel delivery unit, check that supply, return and
gh ht
yri by
breather lines are still clipped onto fuel tank.
op Vo
by c lksw
cted agen
Prote AG.
1.8 Removing and installing fuel delivery

unit: four-wheel drive vehicles

Passat 1997 ➤
♦ Fuel tank sender unit tool -3087-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
♦ Fuel pump tool -3307-
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
Removing
c
i
or
n thi
te
• The fuel tank must not be more than 1/2 full.
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi
Note
Co
Cop py
t. rig
gh ht
yri by
♦ If necessary, empty fuel tank using fuel extractor -VAS 5190- . cop Vo
by lksw
cted agen
Prote
♦ Note safety precautions before beginning work ⇒ page 118 .
AG.

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.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Turn fuel delivery unit approx. 15° anti-clockwise onto stop
ility
ot p
with fuel pump tool -3307- and remove.
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
If delivery unit is to be renewed, drain old delivery unit before dis‐
posal.
rrectness of i
Installing
l purpos
– Installation of fuel delivery unit is carried out in reverse order.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
nte
autho
ra
ss c
ce
le
un
pt
an
d
Note
itte
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rm
ab
pe
ility
♦ Do not bend fuel gauge sender when installing.
ot
wit
, is n
h re
♦ Insert seal for flange or fuel delivery unit dry into opening of
hole
spec
fuel tank.
es, in part or in w
t to the co
♦ Moisten seal with fuel only when installing flange or fuel de‐
livery unit.
♦ Do not interchange supply and return hoses (return hose -
rrectness of i
blue-).
l purpos
♦ Ensure that fuel lines are tight.

♦ Secure fuel hoses with spring-type clips.
nform
ercia
♦ Note Installation position of fuel delivery unit flange: Mark on

m
a
com
t
flange -1- must align with mark on fuel tank -2-.
ion in
r
te o
♦ After installing fuel delivery unit flange, check that the supply,
thi
s
iva
return and breather pipes are still clipped onto fuel tank.
do
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rp
cum
fo
en
ng
t.
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1.9 Removing and installing fuel gauge Cop py
t. rig
gh ht
sender: vehicles with front-wheel drive pyri by
Vo
co lksw
by
cted agen
Prote AG.
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 . gen AG. Volkswagen AG d
wa oes
olks not
– First check whether a coded radio is fitted. If so, obtain
d b anti-
yV gu
ara
theft coding. orise nte
eo
h
ut ra
– With the ignition switched off, disconnect battery
ss
a
earth strap. c
ce
e
nl
Vehicles with four-wheel drive
pt
du
an
itte
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– Remove centre and rear silencer of exhaust system
erm
ab
⇒ page 155 , Silencer with fixtures.
ility
ot p
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– Remove rear axle ⇒ Running gear front and four wheel drive;
h re
Rep. gr. 42 ; Repairing rear axle; Removing and installing rear
hole
spec
axle .
es, in part or in w
t to the co
– Open fuel tank filler flap.
rrectness of i
– Remove rear right wheel housing liner ⇒ General body re‐
l purpos
pairs, exterior; Rep. gr. 66 ; Removing and installing wheel

housing liner.
nform
ercia

m
– Remove protective plate for filler neck.
at
om
ion
c
in t
or
his
ate
– Drain fuel tank and clean fuel filler neck and surrounding area.
do
priv
cum
or
– Unscrew securing bolt and remove tank flap unit with rubber
f
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ng
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cup.
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– Remove filler neck securing bolts.
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Front-wheel drive vehicles cted agen
Prote AG.
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:
lkswage es n
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Caution ir se
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th or
u
To prevent damage to the fuel tank connections
ss
a
always route ac
the breather lines stress-free.
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nl
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♦ Install breather and fuel hoses free of kinks.

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♦ Ensure that fuel hose connections are tight.

h re
hole
♦ Secure fuel hoses with spring-type clips.

spec
es, in part or in w
t to the co
♦ Do not interchange supply and return hose (return hose blue

or blue markings, supply hose black).
rrectness of i
Note
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After installing fuel tank, check that the supply, return and breath‐
er lines are still clipped onto the fuel tank.
nf
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1.11 Checking fuel pump

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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-
lkswage es n
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es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
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ate
do
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Prote AG.

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
AG. Volkswagen AG d
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nform
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Prote AG.

Passat 1997 ➤
agen AGengine
. Volkswa(4-valve),
gen AG
do mechanics - Edition 12.2010
w es n
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Test prerequisites ris
ed
b ran
tee
tho or
• Fuse 28 must be OK. au ac
ss
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ility
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switched off.
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spec
es, in part or in w
t to the co
Note
Observe the functional description of the crash fuel shut-off
rrectness of i
⇒ page 121 .
l purpos
1.11.1 Checking function and voltage supply
nf
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Note
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Before carrying out further work, battery earth strap may have to
iv
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be disconnected. First check whether a coded radio is fitted. Ob‐
o
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f
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tain anti-theft coding first if necessary.

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Front-wheel drive vehicles
rig ht
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agen
Prote AG.

– 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):
Front-wheel drive vehicles AG. Volkswagen AG d
agen oes
olksw not
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– Unscrew union nut with unionthonut tool -3217- .
r eo
au ra
c
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un
pt
an
d
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erm
ab
ility
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ole,
spec
t to the co
rrectne
– Unscrew locking ring with fuel tank sender unit tool -3087- .
ss

o
cial p
f in
– Check that electrical wires between flange and fuel pump are
form
mer
connected.
atio
om
If no open circuit can be found:

n
c
i
or
n thi
e
– Fuel pump is defective. Renew fuel delivery unit:

t
sd
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pr
♦ Vehicles with front-wheel drive ⇒ page 122 ,

um
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fo
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♦ Vehicles with four-wheel drive ⇒ page 123 .
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1.11.2 Checking delivery rate
Prote AG.
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. . Volkswage AG n AG d
agen oes
olksw not
V
– Compare quantity of fueleddelivered by with specification. gu
ara
ris nte
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8) Minimum delivery cm3/30auseconds
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9) Voltage at fuel pump with engine not running and pump running (approx. 2
ce
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nl
volts less than battery voltage).

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Example:
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ility
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During the test a voltage of 12.2 volts is measured at the battery.

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As the voltage at the pump is approx. 2 volts less than the battery
h re
voltage, this will equate to a minimum delivery rate of 550 cm3/30

hole
spec
s.
es, in part or in w
t to the co
If minimum delivery rate is not attained:

– Check the fuel pipes for possible restrictions (kinks) or block‐
rrectness of i
ages.
l purpos

nf
ercia
orm
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Prote AG.

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

AG. Volkswagen AG d
agen oes
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– Pull supply line
aut -1- off inlet to fuel filter. ra
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itte
– Connect pressure tester -V.A.G 1318- to hose using adapter
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-1318/10- .
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– Repeat delivery rate check.
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If the minimum delivery rate is now attained:
spec
es, in part or in w
– Renew fuel filter.
t to the co
If the minimum delivery rate is again not attained:
– Remove fuel delivery unit and check for dirt in filter strainer.
rrectness of i
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nf
ercia
Only if still no fault has been detected:

rm
m
atio
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If delivery rate has been attained, but nevertheless you suspect

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a fuel supply system fault (e.g. intermittent failure of fuel supply C py
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– Check current draw of fuel pump as follows: Prote
cted AG.
agen
– 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.
AG. Volkswagen AG d
agen oes
olksw not
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rise nte
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– Connect multimeter - V.A.G 1715- with pick-up clamp to the

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green/yellow wire (chamber 1 in 4-pin connector) in wiring
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harness.
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ility
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– Start engine and run at idling speed.
hole
spec
– Measure current draw of fuel pump. Specification: max. 8
es, in part or in w
t to the co
amps.
rrectness of i
Note
l purpos
If the fuel system malfunction is intermittent, you can perform the

check during a road test, but a 2nd person is necessary.
nf
ercia
orm
If the current draw is exceeded:
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atio
om
n in
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♦ Vehicles with four-wheel drive ⇒ page 123 . cu

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1.11.3 Checking non-return valve for fuel pump
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Test prerequisites cted agen
Prote AG.
• 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.
olkswagen AG
en AG. V
– Watch pressure drop on pressure ogauge.
ksw
ag After 10 minutes,does
not
V l
pressure must not drop belowed2.5
b bar.
y gu
ara
is nte
or
If the pressure drops further:
au
th eo
ra
ss c
– Check line connections for leaks.
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le
un
pt
an
d
If no fault in lines is detected:

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ab
pe
ility
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♦ Front-wheel drive vehicles ⇒ page 122 .
h re
hole
spec
♦ Four-wheel drive vehicles ⇒ page 123 .
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cted agen
Prote AG.

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.
wage
This means that the throttle valve can already be completely open olks es n
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yV
even though the accelerator is depressed half way. This has d the
b ua
ran
ir se
advantage of preventing throttling losses at the throttle tvalve.
ho tee
or
au ac
After evaluating the torque requirements of various components
ss
ce
e
(e.g. air conditioning system, automatic gearbox, ABS/ESP and

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so on), the engine control unit calculates the optimal throttle valve
itte
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opening angle for the respective situation.
erm
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This also results in significantly improved consumption and ex‐
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haust emission values under certain load conditions.
h re
hole
spec
It is incorrect to believe that the „EPC“ is comprised of one or two
es, in part or in w
components only. E-Gas is a system containing all components
t to the co
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. rrectness of i

l purpos
– EPC warning lamp function test: ⇒ Repair group 01; General

notes for self-diagnosis; Significance of EPC warning lamp
nform
ercia
(electronic power control fault lamp) in dash panel insert .

m
at
2.2 Repairing parts of electronic power control (EPC)

om
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Prote AG.
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. agen
AG. Volkswagen AG d
oes
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❑ The accelerator position by
Vo gu
ara
sender passes the posi‐ rised
nte
tion of the accelerator aut
ho eo
ra
on to the engine control ss c
unit.
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❑ Remove footwell cover

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to remove sender.
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❑ If renewed on vehicles
h re
ole,
with an automatic gear‐
spec
box, relearn kick-down
t to the co
switch point: ⇒ Engine
control unit; Rep. gr.
24 ; Learning kick-down
switch point .
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
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cted agen
Prote AG.

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- agen
AG. Volkswagen AG d
o w es n
olks ot g
♦ Fault reader -V.A.G db
y V 1551- ua
ran
or vehicle system
rise tester - tee
ho
V.A.G 1552-aut with cable - or
ac
V.A.G 1551/3-
ss
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le
un
pt
♦ Current flow diagram
an
d
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pe
ility
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h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
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t.
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Cop py
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pyri by
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Prote AG.
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 ➤
AG. Volkswagen AG d
lksw
agen oes
n o ot g
yV ua
edb ran
Test prerequisites ris tee
tho or
au ac
• Fuses must be OK. ss
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ility
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switched off.
spec
es, in part or in w
Test procedure
t to the co
– Connect fault reader -V.A.G 1551- (V.A.G 1552) and select
engine control unit with „address word“ 01. The ignition must
rrectness of i
be switched on for this purpose: ⇒ Repair group 01; General
notes for self-diagnosis; Connecting fault reader . l purpos
nform
ercia

Select function XX
m
at
om
ion
– Press keys 0 and 8 for „Read measured value block“ function
c
in t
or
and confirm with Q key.
his
ate
do
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en
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Read measured value block op py
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Input display group number XXX gh ht
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– Press buttons 0 6 and 2 for „display group number 62“ and cted agen
Prote AG.
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
G. Volkswage nA n AG d
wage oe
Checking voltage
y V supply and wiring to control tunit
olks s no
gu
b ara
ed
– Remove
tho
ris cover in footwell (driver side). nte
e or
au ac
– Pull
ss 3-pin connector off accelerator position sender.
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nl
pt
– Switch on ignition.
du
an
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erm
ab
– Connect multimeter to measure voltage using auxiliary cables
ility
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from -V.A.G 1594 A- to the following connector contacts.
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Contact 1 + earth
hole
spec
es, in part or in w
Contact 1 + 5
t to the co
Contact 2 + earth
Contact 2 + 3
rrectness of i
• Specification: at least 4.5 V
l purpos

nf
ercia

orm
m
atio
om
– Connect adapter cable -V.A.G 1598/31- to control unit wiring

n in
or c
harness. The engine control unit remains disconnected.

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by
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Prote AG.

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 gbasic
en AG. setting
Volkswag.en AG
d wa oes
olks not
byV gu
ara
ed nte
ris
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c
ss
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un
pt
an
d
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

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 AG. Volkswagen AG d

agen oes
olksw not
V gu
d by ara
♦ Hose connections are securedoris with either spring-type or
e nte
eo
clamp-type clips. aut
h
ra
ss c
♦ Always renew clamp-type clips with spring-type clips.
ce
e
nl
pt
du
an
♦ Spring-type clip pliers -VAS 5024- or hose clip pliers -

itte
y li
erm
V.A.G 1921- are recommended for fitting spring-type clips.

ab
ility
ot p
wit
, is n

h re
hole
spec

es, in part or in w
t to the co
Checking fuel tank breather ⇒ page 147 .
3.2 Repairing parts of activated charcoal filter system

rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
143
agen
Prote AG.
3. Activated charcoal filter system
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 wagen AG. Volkswagen AG doe
final control diagnosisy V.olks s no
t gu
b ara
ed
6 - Connector ho
ris nte
e
ut or
❑ Black, 2-pinss a ac
ce
e
❑ For activated charcoal

nl
pt
du
filter system solenoid valve 1 -N80- .

an
itte
y li
erm
ab
7 - Breather line
ility
ot p
❑ To crankcase breather connecting hose between cylinder head cover and intake air hose: ⇒ Repairing
wit
, is n
injection system; Rep. gr. 24 ; Removing and installing parts of the injection system .
h re
hole
spec

es, in part or in w
❑ Press together at front to release.

t to the co
8 - Junction
rrectness of i
9 - To intake manifold.
l purpos
10 - Pressure retention valve

❑ For fuel tank breather.
nform
ercia
❑ Shuts-off the tank venting when the solenoid valve -N80- is open and intake manifold pressure is present
m

at
om
ion
c
11 - Breather line
in t
or
his
te
❑ Black
a
do
priv

um
for
en
ng
❑ From gravity valve on fuel tank: vehicles with front-wheel drive ⇒ Item 5 (page 113) .
t.
yi Co
Cop py
❑ From breather valve on fuel tank: vehicles with four-wheel drive ⇒ Item 6 (page 116) .
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Passat 1997 ➤
12 - Securing bolt
13 - Breather hose
❑ To atmosphere.
agen
AG. Volkswagen AG d
o w es n
olks ot g
14 - O-ring ed by V ua
ran
ris
❑ Renewut
ho if damaged. tee
or
a ac
ss
ce
e
nl
pt
du
an
Checking pressure retention valve
itte
y li
erm
ab
From gravity valve, the pressure retention valve is open in both
ility
ot p
directions of flow - arrow -1-.
wit
, is n
h re
From activated charcoal filter/activated charcoal filter system sol‐
hole
spec
enoid valve 1, it is only open in one direction of flow -arrow 2-.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
3.3 Test solenoid valve 1 for activated char‐

m
at
coal filter
om
ion
c
in t
or

his
ate
do
riv

p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ 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.
3. Activated charcoal filter system 145

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
AG. Volkswagen AG d
– Connect fault reader -V.A.G 1551- (V.A.G 1552). Start engine lkswagen oes
not
and select „Address word“ 01 of engine control unit. Connect db
yV
o gu
ara
fault reader and select engine control unit: ⇒ Repair group ris01;
e nte
General notes for self-diagnosis; Connecting fault reader tho
au .
eo
ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
Select function XX
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Basic setting
rrectne
ss o
cial p
f inform
mer
System in basic setting 1 -> atio

1 2 3 4
om
n
c
Only continue with the test when:

or
n thi
te
sd
a
• Coolant temperature is above 80°C, -display zone 2-.

iv
o
pr
cum
r
fo
– Change to display group 70 as follows:

en
ng
t.
yi Co
op
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
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.

System in basic setting 70 ->
1 2 3 4
When the diagnosis of the nengine

AG. Volkscontrol unit
wagen AG has been initiated
the display in display lkswage 4 will jump from d„Test
zone
oes
notOFF“ to „Test
Vo gu
ON“. se
d by ara
n
i tee
or
– Leaveauengine
th running at idle until the specification „TBV
or OK“
ac
is displayed in display zone 4.
ss
ce
le
un
pt
an
d
itte
y li
Note
rm
ab
pe
ility
ot
wit
TBV is the abbreviation for: tank breather valve (activated char‐
, is n
h re
coal filter system solenoid valve 1).
hole
spec
es, in part or in w
t to the co
entry with Q button. rrectness of i

l purpos
If display zone 4 displays „TBV n.OK“:

nform
ercia
– Check breather lines to activated charcoal filter are not kinked.

m
– Check fuel tank venting ⇒ page 147 .

com
tion in
r
te o
thi
3.4 Checking fuel tank breather

s
iva
do
r
rp
cum
fo

en
ng
t.
yi Co
op
♦ Vacuum tester -V.A.G 1368- C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
Passat 1997 ➤ autho eo
ra
5-cylinder injection engine (4-valve), mechanics - Edition 12.2010 ss c
ce
e
nl
pt
du
an
♦ Hand vacuum pump -V.A.G 1390-
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Test procedure
m
at
om
io
– Remove front right wheel housing liner ⇒ General body re‐
n
c
in t
r
pairs, exterior; Rep. gr. 66 ; Removing and installing wheel

o
his
e
housing liner .
at
do
priv
cum
or
– Pull breather line -2- from activated charcoal filter -1- off sol‐
f
en
g
enoid valve -3-.

n
t.
yi Co
Cop py
– Connect vacuum tester -V.A.G 1368- connection -A- to breath‐
t. rig
gh ht
yri by
er line -2- to activated charcoal filter. cop Vo
by lksw
cted agen
Prote
– Connect hand vacuum pump -V.A.G 1390- to connection -B-.
AG.
– 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.
If vacuum builds up:
– 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
AG. Volkswagen AG d
If the fuel level in the tank is low the hand vacuum must
olks
wage be oper‐
n oes
not
ated at least 20 to 30 times. db
y V gu
ara
e nte
ris
tho eo
If vacuum builds up: ss
au ra
c
ce
e
– Renew fuel tank cap.

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

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

ment, pay attention to the following Adue to the cramped condi‐
G. Volkswagen AG d
tions: lkswagen oes
n o ot g
yV u
♦ Route all the various
ise lines (e.g. for fuel, hydraulics, acti‐ ante
db ar
vated charcoaluthfilter
or system, coolant, refrigerant, brake eo
a ra
ss c
sitions.
ce
le
un
pt
an
d

itte
y li
hot components.
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
♦ After working on the exhaust system ensure that the system
is not under stress, and that there is sufficient clearance to the
rrectness of i
bodywork. If necessary, loosen double clamps and align si‐
lencer and exhaust pipe so that sufficient clearance is main‐
l purpos
tained to the bodywork and the support rings are evenly

loaded.
nform
ercia
♦ Align mountings so that they have a 7 … 9 mm preloading

when the exhaust system is cold. The arrows point in direction
m
a
com
of travel.
ion in
r
te o
♦ Renew self-locking nuts.

thi
s
iva
do
r
rp
cum
fo
en

ng
t.
yi Co
op py
♦ Lambda probe open ring spanner set -3337- t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
150 Rep. gr.26 - Exhaust system

Passat 1997 ➤
AG. Vo(4-valve),
lkswagen mechanics - Edition 12.2010
n AG do
wage es n
olks ot g
♦ Torque wrench -V.A.G 1332- ed
by
V ua
ran
oris tee
th or
au ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
1.1 Exhaust manifold, front exhaust pipe
and catalytic converter with attachments
ss o
cial p
f inform
mer
Note
atio
om
n
c
♦ Components marked with an * are checked by self-diagnosis:
i
or
n thi
e
⇒ Fault memory; Rep. gr. 01 ; Reading and erasing fault

t
sd
va
memory .
i
o
pr
cum
r
fo
en
♦ Renew self-locking nuts.
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Removing and installing parts of exhaust system 151

Passat 1997 ➤
1 - 25 Nm
❑ Renew.
2 - Washer
AG. Volkswagen AG d
3 - Heat shield ksw
agen oes
not
Vol
y gu
4 - Lambda probe -G39- d *
b ara
rise nte
50 Nm utho eo
ra
a
❑ Remove ands install with
s c
ce
le
Lambda probe open

un
pt
ring spanner set -3337- .
an
d
itte
y li
rm
❑ Grease only the threads
ab
pe
ility
with G 052 112 A3 ;
ot
wit
G 052 112 A3 must not
, is n
h re
get into the slots on the
hole
spec
probe body.
es, in part or in w
❑ If seal is leaking, nip
t to the co
open and renew.
❑ If renewed, erase learnt
rrectness of i
values and adapt en‐
gine control unit anew:
l purpos
⇒ Engine control unit;

Rep. gr. 24 ; Erasing
learnt values of control
nform
ercia
unit for engine electron‐

m
ics .
a
com
tion in
❑ Checking Lambda con‐
r
te o
thi
trol: ⇒ Checking func‐
s
iva
tions; Rep. gr. 24 ;

do
r
rp
Checking Lambda
um
fo
en
probe and Lambda con‐

ng
t.
yi Co
trol before catalytic con‐ Cop py
verter .
t. rig
gh ht
pyri by
Vo
co
5 - Connector
by lksw
cted agen
Prote AG.
❑ 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 ➤
AG (4-valve),
. Volkswage mechanics
nA - Edition 12.2010
n G do
wage es n
olks
❑ If renewed, erase learnt values and adapt d bengine
y V control unit anew: ⇒ Engine
ot g
ua control unit; Rep. gr. 24 ;
Erasing learnt values of control unit fororis engine electronics .
e ran
tee
th o
❑ Checking Lambda control: ⇒ Checking au functions; Rep. gr. 24 ; Checking Lambda rprobe ac and Lambda
ss
control after catalytic converter .
ce
e
nl
pt
du
11 - 40 Nm
an
itte
y li
erm
❑ Renew.
ab
ility
ot p
12 - Coach bolt
wit
, is n
h re
13 - To centre silencer
hole
spec
es, in part or in w
14 - Double clamp
t to the co
❑ Slide double clamp onto front exhaust pipe up to stop.
15 - 40 Nm
rrectness of i
16 - Front exhaust pipe
l purpos
17 - Mounting
❑ Individual components for vehicles with a manual gearbox ⇒ page 153 .
nf
ercia
orm
❑ Individual components for vehicles with an automatic gearbox ⇒ page 153 .
m
atio
om
18 - 25 Nm
n in
or c
thi
e
❑ Renew.
t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi
Individual components of mountings (vehicles with manual gear‐
Co
Cop py
box) ht. rig
rig ht
py by
o Vo
1 - Buffer by c lksw
cted agen
Prote AG.
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 AG. Volkswagen AG d
agen oes
olksw not
yV gu
7 - Rear silencer ed b ara
nte
ris
ho eo
8 - Repair double clamp aut ra
c
ss
9 - 40 Nm
ce
le
un
pt
an
d
itte
10 - Coach bolt
y li
rm
ab
pe
11 - Separating point
ility
ot
wit
, is n
❑ Centre and rear silenc‐
h re
ers are installed as a
hole
spec
single component dur‐
es, in part or in w
ing production. In cases
t to the co
of repair, the centre and
rear silencer are sup‐
plied separately, with a
rrectness of i
double clamp for con‐
necting.
l purpos
❑ Cut through exhaust

pipe at right angles on
nform
ercia
separating point using

body saw e.g. -
m
a
com
ti
V.A.G 1523-
on in
⇒ page 154 .
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
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 AG. Volkswagen AG d
agen oes
ksw
❑ With retaining ring. by
Vol not
gu
ara
ed
is nte
4 - 40 Nm hor eo
aut ra
c
5 - Coach bolt ss
ce
e
nl
pt
du
6 - Repair double clamp
an
itte
y li
erm
ab
7 - Separating point
ility
ot p
❑ Centre and rear silenc‐
wit
, is n
ers are installed as a
h re
hole
single component dur‐
spec
ing production. In cases
es, in part or in w
of repair, the centre and
t to the co
rear silencer are sup‐
plied separately, with a
double clamp for con‐
rrectness of i
necting.
l purpos
❑ Cut through exhaust

pipe at right angles on
separating point using
nform
ercia
body saw e.g. -

m
V.A.G 1523-
at
om
io
⇒ page 154 .
n
c
in t
or
his
e
8 - Rear right silencer

at
do
priv
9 - Mounting
um
for
en
ng
t.
yi
10 - Bracket
Co
Cop py
t. rig
gh
11 - Rear left silencer
ht
pyri by
Vo
o
by c lksw
12 - Centre silencer
cted agen
Prote AG.
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

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
♦ Line -V.A.G 1551/3-
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
r
Note
p
cum
r
fo
en
ng
t.
yi Co
Instead of fault reader -V.A.G 1551- , vehicle system tester - . Cop py
ht rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

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.
• Coolant temperature must be at least 80°C, ⇒ display group
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
. Volkswagen AG
probe ageing before catalytic converter
sw.
a gen AG does
k not
y Vol gu
• Lambda probe ageing after catalytic d b converter OK., Checking: ara
ise nte
⇒ Checking function; Rep. thgr. 24 ; Checking Lambda probe
or eo
ageing after catalytic converter
ss
au (trim regulation) . ra
c
ce
le
un
pt
an
d
itte
Note
y li
rm
ab
pe
ility
This diagnosis is only completed when the diagnosis for Lambda
ot
wit
, is n
probe ageing before and after catalytic converter has been per‐
h re
formed successfully.
hole
spec
es, in part or in w
t to the co
Test procedure
fault reader and select engine control unit: ⇒ General notes rrectness of i
l purpos
for self-diagnosis; Rep. gr. 01 ; Connecting fault reader .

nform
ercia

m
Select function XX
com
tion in

r
te o
thi

s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op py
Basic setting t. C rig
Input display group number XXX gh ht
pyri by
Vo
co lksw
by
– Press buttons 0 0 and 1 for „display group number 1“ and cted agen
Prote AG.
1 2 3 4


Passat 1997 ➤
Basic setting

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

– Depress brake pedal and hold. agen
AG. Volkswagen AG d
oes
olksw not
V
– Depress accelerator to full throttle position.d by gu
ara
rise nte
o eo
Engine revolutions are raised by engine
auth control unit to approx. ra
2300 rpm. ss c
ce
e
nl
pt
– Depress brake pedal and accelerator until the display in dis‐
du
an
itte
play zone 4 jumps from „Test OFF“ to „Test ON“.
y li
erm
ab
ility
The catalytic converter temperature in display zone 2 must be
ot p
wit
at least 350 °C.
, is n
h re
hole
– Continue to depress brake pedal and accelerator until the
spec
specification „Cat B1 OK“ is displayed in display zone 4.
es, in part or in w
t to the co
rrectness of i
l purpos

– Switch off dipped beam and heated rear window.
nf
ercia
orm
m
atio
om
n in
If display zone 4 displays „Cat B1n.OK“:
or c
thi
te
– Read fault memory: ⇒ Fault memory; Rep. gr. 01 ; Reading

sd
iva

r
rp
cu
o
m
f
en
ng
– Carry out a road test to free Lambda probe of any deposits,

t.
yi Co
op
then repeat the test. C py
t. rig
gh ht
yri by
If specification „Cat B1 OK“ is again not attained: cop Vo
by lksw
cted agen
Prote
– Renew catalytic converter.
AG.
– 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.
♦ Ensure that there iswsufficient
agen
AG. Voclearance
lkswagen AG
to
doeall moving or
hot components.
yV
olks s no
t gu
b ara
ed nte
oris e
th or
au ac
Function ss
ce
le
un
During a cold start, air is blown in behind the exhaust valve by the
pt
an
d
itte
secondary air system. This produces an oxygen rich exhaust gas,
y li
rm
ab
causing afterburning and reducing the heat-up phase of the cat‐
pe
ility
alytic converter. Activation is initiated by the Motronic control unit
ot
wit
-J220- via the secondary air pump relay -J299- to combination
, is n
h re
valve.
hole
spec
Checking secondary air system ⇒ page 161 .
es, in part or in w
t to the co
2.1 Removing and installing parts of secon‐
dary air system rrectness of i
l purpos
Note
nform
ercia
♦ Components marked with an * are checked by self-diagnosis:

m
⇒ Fault memory; Rep. gr. 01 ; Reading and erasing fault

com
tio
memory .
n in
r
te o
thi
♦ Components marked with ** are checked by the final control

s
iva
do
diagnosis: ⇒ Final control diagnosis; Rep. gr. 01 ; Performing

r
rp
cum
fo
final control diagnosis .

en
ng
t.
yi Co
op
♦ Secondary air pump relay -J299- ** ⇒ page 161 . C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Secondary air system 159

Passat 1997 ➤
1 - Gasket
❑ Renew.
tion.
2 - Combination valve
3 - 8 Nm
4 - Connection AG. Volkswagen AG d
agen
❑ For combination valve Volksw
oes
not
gu
and coolant hose d by ara
rise nte
❑ Coolant hose schematic ut ho eo
ra
diagram ⇒ page 96 . ss a c
ce
le
un
5 - Air duct
pt
an
d
itte
y li
❑ In cylinder head
rm
ab
pe
ility
6 - Intake manifold
ot
wit
, is n
h re
7 - Vacuum actuator
hole
spec
❑ For intake manifold
es, in part or in w
change-over.
t to the co
8 - O-ring
rrectness of i
9 - To intake manifold.
l purpos
10 - To fuel pressure regulator.
nform
ercia
11 - Non-return valve
m

a
com
tion. tion in
r
te o
❑ White connection faces

thi
s
iva
to secondary air inlet

do
r
rp
valve -N112- / variable

um
fo
intake manifold change‐

en
ng
t.
yi Co
over valve -N156- t. Cop py
rig
gh ht
12 - Connector yri
p by
co Vo
by lksw
❑ Black, 2-pin cted agen
Prote AG.
❑ 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

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o eo
aut
h
ra Passat 1997 ➤
s c
s 5-cylinder injection engine (4-valve), mechanics - Edition 12.2010
ce
e
nl
pt
du
an
❑ For secondary air pump motor. itte
y li
erm
ab
21 - Pressure hose
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
22 - Intake hose
t to the co
❑ From air filter.
rrectness of i
l purpos
23 - Secondary air pump motor -V101- **

nform
ercia
24 - Bracket
m
at
om
❑ For secondary air pump motor -V101-
ion
c
in t
or
25 - Pressure pipe
his
ate
do
priv
cum
for
en
ng
t.
Secondary air pump relay -J299- -arrow-
yi Co
Cop py
ht. rig
rig ht
py by
o Vo
Note
by c lksw
cted agen
Prote AG.
♦ 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-

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Passat 1997 ➤
Test prerequisites
• Vacuum pipes and hose connections free of leaks.
• Vacuum pipes not blocked
gen AG
. Voor
lkskinked.
wagen AG
a does
lksw n
• No fault may db
ybe
Vo stored in fault memory: ⇒ Fault
ot g
uamemory; Rep.
gr. 01 o;riReading
se and erasing fault memory . ran
te
h eo
ut r
• Coolant
ss
a temperature must be at least 80°C, ⇒ displayacgroup
01, display zone 2.
ce
e
nl
pt
du
an
• Lambda probe ageing before catalytic converter OK., Check‐
itte
y li
ing: ⇒ Checking function; Rep. gr. 24 ; Checking Lambda
erm
ab
ility
probe ageing before catalytic converter .
ot p
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
This diagnosis is only completed when the diagnosis for Lambda
probe ageing before catalytic converter has been performed suc‐
cessfully.
rrectness of i
l purpos
Test procedure
nform
ercia

fault reader and select engine control unit: ⇒ General notes
m
at
om
for self-diagnosis; Rep. gr. 01 ; Connecting fault reader .

ion
c
in t
or
his
ate
do
priv
cum

for
Select function XX
en
ng
t.
yi Co
op
C py
t. rig
gh
ht
pyri by
Vo
o
by c lksw
cted
agen
Prote AG.
Basic setting

1 2 3 4

Basic setting


Passat 1997 ➤
Note
No engine loading may be created during

wage
n AG. Vothis
lkswadiagnosis,
gen AG
does other‐
wise the test will be terminatedy Volksand can only be reinitiated
notafter
gu
switching the ignition offiseand on again and performing a road test.
d b ara
nt
r ee
ho
aut or
ac
ss (1…4 = display zones)
ce
le
un
pt
an
d

itte
y li
1 2 3 4
erm
ab
ility
When the diagnosis of the engine control unit has been initiated
ot p
wit
the display in display zone 4 will jump from „Test OFF“ to „Test
is n
h re
ON“.
ole,
spec
– Leave engine running at idle until the specification „Syst. OK“
t to the co
is displayed in display zone 4.
rrectne
ss o
cial p
f inform
If display zone 4 displays „Syst. n. OK“:
mer
atio
m
– Initiate final control diagnosis and select secondary air inlet

o
n
c
valve -N112- and secondary air pump relay -J299- : ⇒ Final

i
or
n thi
e
control diagnosis; Rep. gr. 01 ; Performing final control diag‐

t
sd
va
nosis .
i
o
pr
cum
r
fo
en
ng
– Check secondary air pump motor ⇒ page 164 . yi

t.
Co
op py
– Check combination valve ⇒ page 166 . t. C rig
gh ht
pyri by
Vo
co lksw
by
2.3 Checking secondary air pump motor
cted agen
Prote AG.


Passat 1997 ➤
♦ Line -V.A.G 1551/3-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
l purpos
Test prerequisites
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

• 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 ➤
. Volkswagen AG
a gen AG does
– Disconnect pressure hose -arrow-
Volfrom pressure pipe.
ksw not
gu
by ara
ed nte
oris eo
th
Note ss
au ra
c
ce
e
nl
pt
To release, press buttons on hose coupling together. du
an
itte
y li
erm
ab
– Activate secondary air pump relay -J299- via final control di‐
ility
ot p
agnosis: ⇒ Final control diagnosis; Rep. gr. 01 ; Performing
wit
, is n
final control diagnosis .
h re
hole
spec
The secondary air pump motor should run at intervals and air
es, in part or in w
should escape from the outlet point.
t to the co
If the motor runs but no or little air is delivered:
rrectness of i
– Proceed with final control diagnosis until completed.
l purpos

nf
ercia
orm
m
atio
– Renew secondary air pump motor -V101-
om
n in
⇒ Item 23 (page 161) .
or c
thi
e
If secondary air pump motor does not run at intervals:

t
sd
iva
o
r
rp
cu
– Check activation of secondary air pump motor -V101- : ⇒ Final
o
m
f
en
ng
control diagnosis; Rep. gr. 01 ; Performing final control diag‐

t.
yi Co
op
nosis . C py
t. rig
gh ht
pyri by
Vo
co
2.4 Checking combination valve
by lksw
cted agen
Prote AG.

♦ 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
G. Volkswagen
– Remove pressure hose -arrow-lkfrom swa secondary air pump
gen A AG do
esmo‐
not
tor and blow in with slight dpressure.
by Vo Combination valve must gu
ara
be closed. orise nte
h eo
ut ra
– Operate hand vacuum
ss
a pump -V.A.G 1390- . Valve must open. c
ce
e
nl
If the combination valve does not open, or is constantly open:

pt
du
an
itte
y li
– Renew combination valve ⇒ Item 2 (page 160) .

erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

D3E8034F002-5-Cylinder Injection Engine (4-Valve) Mechanics

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Service

Service Department. Technical Information

10 - Removing and installing engine

20 - Fuel supply system

All rights reserved.

Copyright © 2015 Volkswagen AG, Wolfsburg D3E8034F002

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

15 - Cylinder head, valve gear . . . . . . . . . . .G.. V.ol.ks.w.ag.e.n . . . . . . . . . . . . . . . . . . . . . . . . 33

1.4 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

1.5 Adjusting valve timing (installing timing chains) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

1.6 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

2.1 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

2.2 Camshaft identification, valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

2.3 Dismantling and assembling valve timing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

2.6 Checking camshaft timing control/adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

2.7 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

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

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

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

3.3 Test solenoid valve 1 for activated charcoal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

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

RON min. 98 unleaded2)

System designation Motronic ME7.1

Exhaust gas recirculation no

Secondary air system yes

Electronic power control yes

Variable intake manifold yes

Camshaft timing control yes

2 Rep. gr.00 - Technical data

10 – Removing and installing engine

Special tools and workshop

1. Removing and installing engine 3

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.

lay free. Do not open hydraulic oil circuit.

1. Removing and installing engine 5

– Disconnect ATF line connections -arrows- and catch ATF

– Observe additional information and installation work

– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Removing

and installing starter on vehicles with 4, 5 and 6-cylinder en‐

Fuel supply lines are under pressure! Before loosening hose

6 Rep. gr.10 - Removing and installing engine

– Seal lines so that fuel system is not contaminated by dirt.

– Unbolt earth wire -3-.

♦ Hall sender 2 -G163-

♦ Intake manifold changeover valve -N156- and secondary air

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.

After removing the engine, secure the torque converter against