K0450732920-6-Cylinder Diesel Engine

Service
Workshop Manual
Passat 1997 ➤
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
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10 - Removing and installing enginew oes
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13 - Crankshaft group horise nte
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15 - Cylinder head, valve
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17 - Lubrication
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19 - Cooling
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20 - Fuel supply system
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21 - Turbocharging/supercharging
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23 - Mixture preparation - injection
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26 - Exhaust system
28 - Glow plug 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 K0450732920

Passat 1997 ➤
6-cylinder diesel engine - Edition 11.2003
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.5 Front engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.6 Electrohydraulic engine mounting, left and right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.7 Pneumatic engine mounting, left and right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.8 Additional information and removal instructions for vehicles with air conditioner . . . . . . . . 16
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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1.2 Removing and installing poly-V-belt . . . . . . . . . . s.w.a.ge. n. A.G. . . . . . . .ge. n. A. G. d. o.e.s . . . . . . . . . . . . 24
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1.3 Removing and installing bracket for vane pump d by and oil cooler . . . . . . . . . . . . g. u.a.r . . . . . . .
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2 Removing and installing sealing flangesthand or flywheel or drive plate . . . . . . . . . . . . te. e.o. . . . 29
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2.1 Renewing crankshaft oil seal - belt pulley ss
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2.2 Removing and installing front sealing flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.3 Removing and installing dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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2.4 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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3 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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3.1 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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3.2 Removing and installing chain sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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4 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.1 Checking piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.2 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
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15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

1.1 Removing and installing front intake manifold, engine codes AFB, AKN, BAU and BDH . . 50
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1.2 Removing and installing front intake manifold, engine code BDG . . . . . . . . . . . . . . . . . . . . 51
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1.3 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

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1.4 Removing, installing and tensioning toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

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1.5 Removing toothed belt from camshaft pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

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1.6 Removing and installing left intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

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1.7 Removing and installing right intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

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1.8 Removing and installing left cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
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1.9 Removing and installing right cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
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1.10 Removing left cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cted 75
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1.11 Removing right cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.12 Installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1.13 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2 Repairing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.1 Checking axial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.2 Renewing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.3 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Contents i
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2.4 Checking hydraulic valve compensation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
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2.5 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
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2.6 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
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17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
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1 Removing and installing parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
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1.1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
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1.2 Removing and installing oil filter bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.3 Removing and installing lower part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
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1.5 Removing and installing upper part of sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.6 Renewing oil check valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
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1.7 Removing and installing oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
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1.8 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
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19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
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1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
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1.1 Parts of cooling system - body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

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1.2 Coolant pump and thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
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1.3 Overview - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

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1.4 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
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1.5 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
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1.6 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
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1.7 Removing and installing front coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
1.8 Removing and installing left upper and lower coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . 132
1.9 Removing and installing right coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.10 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
1.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 137
1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
1.3 Removing and installing fuel tank with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
1.4 Repairing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.5 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.6 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
1.7 Checking low fuel level sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
1.8 Removing and installing fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1.9 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1.10 Removing and installing suction-jet pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.11 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.12 Bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
2 Accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
2.1 Repairing accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
2.2 Adjusting pedal position sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
2.3 Function of EPC system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
1 Charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
1.2 Removing and installing turbocharger with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . 169
1.3 Removing and installing turbocharger with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . 171
1.4 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
1.5 Removing and installing compensator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1.6 Removing and installing parts of charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
1.7 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
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Passat 1997 ➤
1.8 Charge pressure control hose routing diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

1.9 Charge pressure control hose routing diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

1 Repairing diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
1.3 Repairing injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
1.4 Removing and installing injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
1.5 Dynamically checking and adjusting commencement of injection . . . . . . . . . . . . . . . . . . . . 186
1.6 Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
1.7 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
1.8 Repairing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
1.9 Adapting idling speed . . . . . . . . . . . . . . . . . . . . . . . . .. V. o.lk.s.w.a.g . . . . . . . . . . . . . . . . . . . . . . . 192
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1.10 Identification of injection pump . . . . . . . . .o.lk.sw. a.g.e . . . . . . . . . . . . G . .do. e.s.no. . . . . . . . . . . . . . . 194
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1.11 Removing and installing intake manifold d flap . . . . . . . . . . . . . . . . . . . . . . . u.a.ra. . . . . . . . . . .
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2 Engine control unit . . . . . . . . . . .u.th.o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . e.o.r . . . . . . . 196
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2.1 Reading and erasing engine control ss unit fault memory . . . . . . . . . . . . . . . . . . . . . .c . . . . . . 196
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2.2 Adapting functions and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

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2.3 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
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26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
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1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
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1.1 Front exhaust pipe with catalytic converter, middle silencer, rear silencer and attachments
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1.2 Front exhaust pipe with catalytic converter and attachments . . . . . . . . . . . . . . . . . . . . . . . . 202
1.3 Silencer with mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
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1.4 Removing and installing left exhaust manifold with front exhaust pipe . . . . . . . . . . . . . . . . 206
1.5 Removing and installing right exhaust manifold with front exhaust pipe . . . . . . . . . . . . . . 208
l purpos
2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

2.1 Vacuum hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
nform
ercia
2.2 Checking exhaust gas recirculation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

m
a
2.3 Removing and installing exhaust gas recirculation valve . . . . . . . . . . . . . . . . . . . . . . . . . . 212
com
tion in
r
te o
thi
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 s
iva
do
r
1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

rp
cum
fo
en
1.1 Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

ng
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1.2 Checking glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
C py
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Prote AG.
Contents iii
Passat 1997 ➤
AG. Volkswagen AG d
agen oes
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or eo
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aut ra
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un
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pe
ility
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wit
, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
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a
com
tion in
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iv Contents
Passat 1997 ➤
00 – Technical data
1 Technical data
1.1 Engine number n AG. Volkswagen AG do

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The engine number (“engine code”dand by “serial number”) can be
Vo ot g
ua
found on the flat surface of the cylinder
o
ir se block, on front of right ran
tee
cylinder bank. auth or
ac
ss
In addition, there is a sticker on the toothed belt guard with “engine
ce
le
un
pt
code” and “serial number”.
an
d
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The engine code is also included on the vehicle data plate.
rm
ab
pe
ility
ot
The engine number consists of up to nine characters (alphanu‐
wit
, is n
meric). The first part (maximum 3 characters) makes up the
h re
hole
“engine code”, and the second part (6 characters), the “serial
spec
number”. If more than 999,999 engines with the same engine
es, in part or in w
t to the co
code are produced, the first of the six characters is replaced with
a letter.
rrectness of i
1.2 Engine data
l purpos
Engine code AFB AKN BAU BDH BDG
nform
ercia
Manufactured 08.98 ▸ 09.99 ▸ 12.02 ▸ 12.02 ▸ 03.03▸

Emissions fulfil MVEG II EU3 standard EU3/D4 EU4 standard EU4 standard
m
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standard standards
ion in
r
Capacity l 2.5 2.5 2.5 2.5 2.5

te o
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s
iva
Output kW at rpm 110/4000 110/4000 132/4000 132/4000

do 120/4000
r
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Torque Nm at rpm 310/1500 ... 310/1500 ... 370/1500 ... 370/1500 ... 350/1500 ...
fo
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3200 3200 2500 2500 2500

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Bore ∅ mm 78.3 78.3 78.3 78.3 78.3
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Stroke mm 86.4 86.4 86.4 86.4 86.4
cop Vo
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Compression ratio 19.5 19.5 18.5 18.5 18.5
Prote AG.
CN min. 49 49 49 49 49
Firing order 1-4-3-6-2-5 1-4-3-6-2-5 1-4-3-6-2-5 1-4-3-6-2-5 1-4-3-6-2-5
Catalytic converter yes yes yes yes yes
Exhaust gas recirculation yes yes yes yes yes
Turbocharging/supercharg‐ yes yes yes yes yes
ing
Charge air cooling yes yes yes yes yes
1. Technical data 1
Passat 1997 ➤
10 – Removing and installing engine

1 Removing and installing engine
1.1 Removing engine
Special tools and workshop

equipment required
♦ Support clamp -VW 313-
♦ Engine and gearbox sup‐
port -VW 540-
♦ Engine and gearbox sup‐
port supplement -VW
540/1B-
♦ Support bracket -V.A.G
10-222A-
♦ Lifting tackle -VAS 2024A-
♦ Gearbox support -VAS
3147-
AG. Volkswagen AG d
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spec
es, in part or in w
t to the co
rrectness of i
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Rep. Gr.10 - Removing and installing engine
agen
Prote AG.
Passat 1997 ➤
♦ Retainer -T10062-
♦ Drip tray -V.A.G 1306/-
♦ Torque wrench -V.A.G
1331/- (5...50 Nm)
1332/- (40...200 Nm)
♦ Engine and gearbox jack -
V.A.G 1383/A-
♦ Spring-type clip pliers -VAS
5024/-
♦ Grease -G 000 100- (vehi‐
cles with manual gearbox)
♦ Cable ties
♦ Matra V175 Socket 15 mm
♦ Pin wrench -VAS 3212-
♦ Hose clips up to 40 mm Ø - AG. Volkswagen
VAS 3093- lksw
agen AG do
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es, in part or in w
t to the co
rrectness of i
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1. Removing and installing engine 3

Passat 1997 ➤
Note
♦ Before carrying out further work, disconnect battery earth

strap. First check whether a coded radio is fitted. Obtain radio
code first if necessary.
♦ The engine is removed forwards without gearbox.
♦ All cable ties which are opened or cut through when engine is
removed must be replaced in the same position when engine
is installed.
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‐ AG. Volkswagen AG d
sitions. agen oes
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♦ Ensure that there is sufficient clearance to all movingrisor
ed
nte
hot components. autho eo
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1.2 Procedure
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– With ignition switched off, disconnect earth strap at battery.
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– Install lock carrier with attachments. ⇒ General body repairs,
h re
hole
exterior; Rep. Gr. 50 ; Body - front .
spec
es, in part or in w
– Detach ATF lines from gearbox. ⇒ 5-speed automatic gearbox
t to the co
01V; Rep. Gr. 37 ; Dismantling and assembling gearbox; Re‐
moving and installing ATF lines on vehicles with a V6 TDI
engine .
rrectness of i
– Drain coolant ⇒ page 122 .
l purpos
– Remove engine cover first.
nf
ercia
– Remove air intake duct -1- and cover -2-.

orm
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– Remove intake manifold cover.
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4 Rep. Gr.10 - Removing and installing engine

Passat 1997 ➤
– Remove air duct in front of charge air cooler -arrows-.

– Clamp off fuel supply and return lines on fuel filter.
WARNING n AG. Volkswagen AG do

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♦ The fuel and the fuel lines in the fuel system can dbecome
b ua
ran
ir se
very hot (danger of scalding)! tho tee
or
au ac
♦ The fuel system is also under pressure! Before opening ss
ce
le
the system, place cloths around the connections. Then
un
pt
carefully loosen connection to release the pressure!
an
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♦ Wear eye and hand protection when performing any type
ility
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of repair work on the fuel system!
wit
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spec
– Disconnect inter-connecting, coolant, vacuum and intake ho‐
t to the co
ses on engine.
– Remove cover -arrow- at power steering fluid reservoir.
rrectne
– Pull off/disconnect all electrical connections as necessary
from engine and lay to one side.
ss o
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– Remove heat shield over turbocharger.
f inform
mer
– Remove front exhaust pipe with catalytic converter or starter
atio
catalytic converter. ⇒ Item 16 (page 172)
om
n
c
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n
– Remove viscous fan. ⇒ page 20
thi
te
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– Remove poly-V-belt. ⇒ page 24

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– Observe additional information and installation work
AG.
⇒ page 16 .
1.2.2 Continuation for all vehicles

– Unbolt power assisted steering vane pump from bracket and
lay to side, hoses remain connected. ⇒ Running gear, axles,
steering - front and four-wheel drive; Rep. Gr. 48 ; Assembly
overview - vane pump, reservoir, hydraulic lines .
– Remove starter. ⇒ Electrical system; Rep. Gr. 27 ; Starter;
Removing and installing starter .

Passat 1997 ➤
1.2.3 Vehicles with automatic gearbox

– Unbolt torque converter by removing bolts -arrow- through the
starter motor opening with 15 mm socket Matra V175 (crank‐
shaft must be turned 1/3 revolution in direction of operation
each time).
Note
♦ To loosen torque converter bolts, counterhold on centre bolt

of vibration damper.
♦ When removing engine, a second mechanic must hold the
torque converter in the gearbox through the starter motor
opening.
♦ After removing the engine, secure the torque converter
against “falling out”. AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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1.2.4 Continuation for all vehicles or eo
h
aut ra
ss c
– Unbolt torque reaction support at sump and secure it to sup‐
ce
e
nl
pt
port -T10062- with two bolts.
du
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itte
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– To be able to remove lower engine/gearbox securing bolts, lift
erm
ab
ility
engine and gearbox slightly with support -T10062- and engine
ot p
and gearbox jack -V.A.G 1383 A- .
wit
, is n
h re
hole
– Remove lower engine to gearbox connecting bolts.

spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
– Unclip the electrical connectors and wires on left and right en‐
atio
m
gine mountings -arrows-.

o
n in
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– Remove rear bolts -1- and -2- on the left and right engine sup‐
te
sd
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ports.
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Prote AG.

Passat 1997 ➤
– Mark the installation position of the threaded connections -1- . Volkswagen AG

and the locating sleeves -2- on underside of the leftlkandgen AG
swa right does
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engine mountings. db
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Note ss
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un
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Different mounting holes are provided for the different engine ver‐
itte
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sions.
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– Remove bottom nut -1- at engine mountings (left and right).
h re
hole
spec
– Remove upper engine to gearbox connecting bolts. Leave one
es, in part or in w
bolt in place (finger-tight).
t to the co
– Loosen securing bolt -A- (on back of turbocharger) a few turns
and turn brace -B- aside in direction of arrow. Tighten bolt
rrectness of i
-A- hand tight again.
l purpos
Note
nform
mercia
The engine is shown in the illustration from the rear, with gearbox
a
com
tio
removed.
n in
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– Fit support bracket -10-222A- with hooks -10-222A/2- as
t. rig
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shown. op Vo
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– Fit gearbox support -3147- in gearbox bell housing bolt hole
AG.
(shown in illustration with engine removed).

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

workshop crane -V.A.G 1202 A- :
Belt pulley end: 2nd hole in hook rail at position 2.
Flywheel end: 3rd hole in hook rail at position 8
WARNING
AG. Volkswagen AG d
agen oes
olksw not
The hooks and locating pins must be secured with lockingd pins.
by
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Note
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♦ The positions marked 1...4 on the bar must be towards the
ility
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pulley end.
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♦ The holes in the hooks are counted up from the hook.
ole,
spec
t to the co
– Unscrew remaining engine/gearbox bolt.
– Remove the front securing bolts on both engine supports and
remove engine supports together with engine mountings.
rrectne
– Lift engine out forwards.
ss o
cial p
f in
Note
form
mer
atio
m
Guide the engine carefully when lifting out, to prevent damage to

o
n
c
the bodywork.
i
or
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sd
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– Secure torque converter against “falling out” after separating

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When working on engine, secure engine to repair stand -VW 313- C py
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using engine and gearbox support -VW 540- and engine and
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gearbox support supplementary set -VW 540/1 B- .
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– Drill out the hole in the engine bracket -VW 540- to13 mm.
1.3 Notes on installing

Installation is carried out in the reverse order. When installing,
note the following:
WARNING

tions:
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ Ensure that there is sufficient clearance to all moving or
hot components.
– On assembly, renew oil seals and gaskets as well as self-

locking nuts and bolts that are tightened by turning through to
a specified angle.

Passat 1997 ➤
– Before installing engine, check that brace -B- is still swung to

the side -direction of arrow-. After engine is installed, the brace
will be swung down.
– Check whether dowel sleeves for centring wagengine
en AG. Vand gearbox
olkswagen AG
does
s
are in cylinder block and install if necessary.
yV
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ed nte
– Only use nuts approved in parts
tho
ris programme to secure torque e or
converter to drive plate. s au ac
s
ce
le
Checking torque converter installation dimension un
pt
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ility
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spec
t to the co
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cial p
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mer
atio
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Prote AG.

Passat 1997 ➤
If the converter is correctly positioned, the distance between the

contact surfaces below at the tapped holes in the converter and
the contact surface of the converter bell of automatic gearbox 01V
is about 23 mm.
WARNING
If the torque converter is not installed correctly, the drive lugs

of the torque converter and the ATF pump will be seriously
damaged when the gearbox is joined to the engine.
– Secure ATF lines to ATF cooler. ⇒ 5-speed automatic gearbox

01V; Rep. Gr. 37 ; Dismantling and assembling gearbox; Re‐
moving and installing ATF lines on vehicles with a V6 TDI
engine .
– Check ATF level. ⇒ 5-speed automatic gearbox 01V; Rep.
Gr. 37 ; Checking ATF level and topping-up; Checking ATF
level .
– Allow torque reaction support to move under own weight onto
torque reaction support buffer and tighten to 25 Nm.
– Install power steering vane pump. ⇒ Running gear, axles,
steering - front and four-wheel drive; Rep. Gr. 48 ; Assembly
overview - vane pump, reservoir, hydraulic lines .
– Align engine mountings free of tension by rocking engine.
– Install air conditioner compressor. ⇒ Heating, air conditioning;
Rep. Gr. 87 ; Manually controlled air conditioning system; Air
conditioner compressor bracket .
– Install poly-V-belt. ⇒ page 24
– Install lock carrier with attachments. ⇒ General body repairs,
exterior; Rep. Gr. 50 ; Body - front .
– Electrical connections and routing ⇒olkElectrical
n AG. V swagen AG system; Rep.
Gr. 97 . wage does
olks not
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– Fill coolant system
or
ise with coolant ⇒ page 125 . . nte
th eo
s au ra
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s
ce
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Note
un
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Do not reuse dirty coolant.

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– Bleed fuel system ⇒ page 162 .

h re
ole,
spec
WARNING
t to the co
Attempts to start engine before fuel system is bled could lead

to injection pump damage.
rrectnes
– Carry out road test and read fault memory. ⇒ page 196
s o
cial p
f in
– Check headlight adjustment and correct if necessary ⇒ Main‐

form
mer
tenance ; Booklet .
atio
om
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1.4 Torque settings

or
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Threaded connection Torque setting

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Bolts, nuts M6 10 Nm
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10
AG.
Rep. Gr.10 - Removing and installing engine
Passat 1997 ➤

M8 20 Nm . Volkswagen AG
gen AG does
M10 45
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M12 ed b 60 Nm ara
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Except for the following: au
t ra
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ss
Air filter housing on body 10 Nm
ce
le
un
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an
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Engine support to cylinder block 45 Nm
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Air conditioning compressor poly-V-belt ten‐ 22 Nm
pe
ility
sioner on bracket
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Alternator to engine M8 22 Nm
h re
hole
spec
Front exhaust pipe or starter catalytic convert‐ 25 Nm
es, in part or in w
er to turbocharger
t to the co
Heat shield to turbocharger 10 Nm
Compensator brace to compensator 22 Nm
rrectness of i
Coolant drain plug to coolant drain pipe 10 Nm
l purpos
Torque reaction support to lock carrier 25 Nm

Torque converter drive plate to torque con‐ 85 Nm
nform
ercia
verter M10×1
m
a
Air conditioner compressor to bracket 22 Nm
com
tion in
Power assisted steering vane pump to bracket 22 Nm
r
te o
thi
for vane pump and oil cooler
s
iva
do
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Belt pulley for power steering vane pump 22 Nm

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Viscous fan to mounting 70 Nm

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1.5 Front engine mounting
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Passat 1997 ➤
1 - Cross tube
2 - Torque reaction stop
❑ Allow to move onto stop
buffer under its own
weight and tighten se‐
curing bolts.
3 - Washer
4 - 30 Nm
5 - Stop buffer
6 - 25 Nm
7 - Torque reaction support
AG. Volkswagen AG d
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es, in part or in w
t to the co
rrectness of i
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Prote AG.

Passat 1997 ➤
1.6 Electrohydraulic engine mounting, left

and right
1.6.1 Left electrohydraulic engine mounting
1 - Cylinder block
2 - 20 Nm
3 - Engine support
4 - 45 Nm
5 - Washer
6 - Protective cap AG. Volkswagen AG d
agen oes
olksw not
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7 - Engine mounting d b ara
rise nte
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8 - Connection on left electro‐ aut ra
c
hydraulic engine mounting sol‐ ss
ce
e
enoid valve -N144-

nl
pt
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9 - Engine mounting console
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spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
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or
his
ate
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Prote AG.

Passat 1997 ➤
1.6.2 Right electrohydraulic engine mounting
1 - Cylinder block
2 - Engine support
3 - 45 Nm . Volkswagen AG
gen AG does
swa
4 - Engine mounting y Volk not
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5 - Connection on right
thoris
electro‐ eo
hydraulic engines mounting
au sol‐ ra
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enoid valve -N145-
s
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nl
pt
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ab
7 - 20 Nm
ility
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8 - Protective cap
, is n
h re
hole
9 - Washer
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
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Prote AG.

Passat 1997 ➤
1.7 Pneumatic engine mounting, left and

right
1.7.1 Left pneumatic engine mounting
1 - Cylinder block
2 - 20 Nm
3 - Engine support
4 - 45 Nm
5 - Washer
6 - Engine mounting
7 - Engine mounting console AG. Volkswagen AG d
agen oes
ksw
8 - 20 Nm by Vol not
gu
ara
d
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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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
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤
1.7.2 Right pneumatic engine mounting
1 - Cylinder block
2 - Engine support
3 - 45 Nm
4 - Engine mounting
6 - 20 Nm
7 - Washer
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
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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.
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op py
1.8 Additional information and removal in‐
. C rig
ht ht
rig by
py
structions for vehicles with air condition‐
co Vo
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cted agen
Prote
er
AG.
WARNING
The air conditioner refrigerant circuit must not be opened.
Note
To prevent damage to condenser and also to refrigerant lines/

hoses, ensure that the lines and hoses are not stretched, kinked
or bent.
To facilitate removing and installing engine without opening re‐

frigerant circuit:
– Remove retaining clamp(s) for refrigerant lines.

Passat 1997 ➤
– Remove poly-V-belt. ⇒ page 24 .

– Secure air conditioner compressor to body so that the refrig‐
erant lines are not under tension.
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.

Passat 1997 ➤
AG. Volkswagen AG d
agen
13 – Crankshaft group
oes
olksw not
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ara
ed
ris nte
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ut ra
1 Dismantling and assembling engine s a c
s
ce
e
nl
pt
du
Repairing injectors ⇒ page 192 .
an
itte
y li
erm
ab
1.1 Overview
ility
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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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
I ⇒ page 19
II ⇒ page 21
III ⇒ page 22
IV ⇒ page 23
18 Rep. Gr.13 - Crankshaft group

Passat 1997 ➤
1.1.1 Part I
1 - Poly-V-belt
❑ Mark direction of rota‐
tion before removing
❑ Check for wear
❑ Do not kink
❑ Removing and installing
⇒ page 24
2 - Spacer sleeve
n AG. Volkswagen AG do
3 - 22 Nm lkswage es n
o ot g
yV ua
4 - Alternator ir se
d b ran
tee
tho
or
5 - 45 Nm au ac
ss
ce
e
6 - 22 Nm
nl
pt
du
an
itte
7 - Bracket
y li
erm
ab
❑ For alternator
ility
ot p
wit
, is n
8 - 10 Nm
h re
hole
spec
9 - 22 Nm
es, in part or in w
t to the co
10 - Cover
❑ For idler roller
rrectness of i
11 - 22 Nm
l purpos
12 - Idler roller
❑ For poly-V-belt
nf
ercia
o
13 - Idler roller
rm
m
atio
❑ For poly-V-belt
om
n in
or c
14 - Cover cap thi

te
sd
iva
15 - 45 Nm
o
r
rp
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o
m
f
16 - 10 Nm
en
ng
t.
yi Co
op py
17 - Bracket t. C rig
gh ht
yri by
❑ For viscous fan cop Vo
by lksw
cted agen
❑ Viscous fan mounting not separately replaceable Prote AG.
❑ Set engine to TDC before removing

18 - 22 Nm
19 - Belt pulley
❑ For viscous fan
❑ Removing and installing viscous fan ⇒ page 20
20 - Gasket
❑ Renew
21 - Bracket
❑ For vane pump and oil cooler
❑ Removing and installing ⇒ page 26
22 - 22 Nm
23 - Power steering pump
❑ For power assisted steering
1. Dismantling and assembling engine 19

Passat 1997 ➤
❑ Removing and installing: ⇒ Running gear, axles, steering - front and four-wheel drive; Rep. Gr. 48 ;
Assembly overview - vane pump, reservoir, hydraulic lines .
24 - 22 Nm
25 - Belt pulley
❑ For vane pump
. Volkswage
n AG n AG d
wage oes
26 - 22 Nm Volks not
gu
by ara
ed
27 - Vibration damperoris nte
eo
th
au
❑ With poly-V-belt pulley
ra
c
ss
ce
le
❑ When installing note fixing arrangement

un
pt
an
d
itte
28 - 22 Nm
y li
rm
ab
pe
ility
ot
wit
, is n
h re
Removing and installing viscous fan
hole
spec
– Remove viscous fan using two open jaw spanners.
es, in part or in w
t to the co
– When installing viscous fan, tighten to 70 Nm.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
Removing and installing power steering pump pulley.

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.
Special tools and workshop equipment required

♦ Pin wrench -3212-
– Use 2-hole pin wrench -3212- to counterhold when slackening
and tightening bolts -arrows-.
♦ Torque setting: 22 Nm.

Passat 1997 ➤
1.1.2 Part II
1 - Lever
❑ For tensioning assem‐
bly
2 - Fitting bolt, 22 Nm
3 - Cover
❑ For tensioning roller
4 - Tensioning roller
❑ For poly-V-belt
5 - 22 Nm
6 - Tensioning element
7 - Sleeve
8 - Gasket
❑ Renew
9 - Bracket
❑ For vane pump and oil
cooler
⇒ page 26
10 - Securing pins
11 - Seal
❑ Renew
12 - Bush
13 - Washer
❑ Note installation posi‐ AG. Volkswagen AG d
tion lksw
agen oes
n o ot g
yV u
14 - Power steeringrisepump
db ara
nte
o eo
❑ For power aut assisted
h
ra
steeringss c
ce
e
nl
❑ Removing and installing: ⇒ Running gear, axles, steering - front and four-wheel drive; Rep. Gr. 48 ;
pt
du
an
Assembly overview - vane pump, reservoir, hydraulic lines .

itte
y li
erm
ab
15 - Bracket
ility
ot p
wit
, is n
16 - Seal
h re
hole
❑ Renew
spec
es, in part or in w
❑ Fit into lugs on oil cooler

t to the co
17 - 25 Nm
18 - Gasket
rrectness of i
❑ Renew
l purpos
19 - Oil cooler
nf
ercia
❑ See note ⇒ page 97

orm

m
atio
om
n in
20 - Belt pulley
or c
thi
e
❑ For vane pump

t
sd
iva
o
r
❑ Installation position: shoulder in direction of travel

rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
21
agen
Prote AG.
1. Dismantling and assembling engine
Passat 1997 ➤
1.1.3 Part III
1 - Crankshaft sprocket
❑ Contact surface be‐
tween sprocket and
crankshaft must be free
of oil
❑ Can only be installed in
one position
2 - Toothed belt tensioner
3 - 10 Nm
4 - 42 Nm
5 - Tensioning lever
6 - 42 Nm
7 - Washer
AG. Volkswagen AG d
8 - Tensioning roller agen oes
olksw not
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d by ara
9 - 75 Nm orise nte
h eo
ut ra
10 - Camshaft pulley
ss a c
ce
le
❑ Removing toothed belt

un
pt
from camshaft pulleys

an
d
itte
y li
⇒ page 59
erm
ab
ility
❑ Pull off using two arm

ot p
wit
puller -T40001-
is n
h re
ole,
11 - Toothed belt
spec

t to the co

❑ Do not kink
rrectne
❑ Check for wear

❑ Removing, installing
s
and tensioning
s o
⇒ page 52
cial p
f inform
12 - 10 Nm
mer
atio
m
13 - Coolant pump
o
n
c
i
or

thi
te
sd
iva
14 - 10 Nm
pr
cum
r
fo
en
ng
15 - Rear right toothed belt guard

t.
yi Co
Cop py
16 - Rear centre toothed belt guard
t. rig
gh ht
pyri by
Vo
o
17 - Rear left toothed belt guard
by c lksw
cted agen
Prote AG.
18 - Gasket
❑ Renew
❑ Removing toothed belt from camshaft pulleys ⇒ page 59
❑ Pull off using two arm puller -T40001-

lkswage es n
o ot g
byV ua
d ran
ir se tee
o
auth or
ac Passat 1997 ➤
ss 6-cylinder diesel engine - Edition 11.2003
ce
e
nl
pt
du
an
20 - Washer
itte
y li
erm
ab
21 - 75 Nm
ility
ot p
wit
, is n
22 - Idler roller
h re
hole
spec
23 - Lower toothed belt guard es, in part or in w
❑ Removal involves unscrewing vibration damper
t to the co
24 - 10 Nm
rrectness of i
25 - 45 Nm
l purpos
26 - Spacer sleeve
27 - 200 Nm + 1/2 turn (180°) further
nf
ercia
o
❑ Renew
rm
m
atio
m
❑ Do not lubricate with oil

o
n in
c
❑ To loosen and tighten, use clamping bolt -3242-

or
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
1.1.4 Part IV
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
1 - Bracket
c by lksw
cted agen
Prote AG.
❑ For viscous fan
2 - 35 Nm
3 - 22 Nm
4 - Vibration damper
❑ For injection pump pul‐
ley
5 - Toothed belt
❑ Do not kink
❑ Check for wear
⇒ page 52
6 - Injection pump
⇒ page 183
7 - Injection pump belt pulley
❑ When installing, posi‐
tion in middle of elonga‐
ted holes
❑ Dynamically checking
and adjusting com‐
mencement of injection
⇒ page 186
8 - Washer
9 - 22 Nm
10 - Tensioning roller

Passat 1997 ➤
1.2 Removing and installing poly-V-belt

♦ Torque wrench -V.A.G 1331-
♦ Torque wrench -V.A.G 1332- AG. Volkswagen AG d

agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au 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
Before removing the poly-V-belt mark the direction of rotation.

When installing belt ensure it is correctly seated in pulleys. nf
ercia
or
1.2.1 Removing
m
m
atio
om
n in
c
– Bring lock carrier into service position. ⇒ General body re‐

or
thi
pairs, exterior; Rep. Gr. 50 ; Body - front .

te
sd
iva
o
r

rp
cu
o
m
f
en
ng
t.
– Remove viscous fan.
yi Co
Cop py
t. rig
– Remove poly-V-belt cover. gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Pay attention to the poly-V-belt cover spacer sleeves.

Passat 1997 ➤
1.2.2 Vehicles with air conditioner

– Remove cap and loosen tensioning roller bolt -arrow-, and
then remove poly-V-belt.
Note
Before removing the poly-V-belt mark the direction of rotation.

When installing belt ensure it is correctly seated in pulleys.
lkswage es n
Vo ot g
– Turn hexagon key in direction of arrow and d byinsert a ∅ 4 mm ua
ran
drift -1-. o
ir se tee
th or
u
– Remove poly-V-belt. ss
a ac
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
1.2.3 Installing
rrectness of i
l purpos

note the following:
nf
ercia
– Fit poly-V-belt first over crankshaft belt pulley, idler rollers and
orm
finally tensioning roller.
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
co lksw
by
cted agen
Prote AG.
– Remove drift -1- while turning hexagon key in direction of ar‐

row.

Passat 1997 ➤

– Fit air conditioning compressor poly-V-belt -arrow-.
– Fit torque wrench -V.A.G 1331- -C- with 8 mm hexagon socket

head key, as shown and tension poly-V-belt by turning in di‐
rection of arrow to 7 Nm.
– At the same time, tighten bolt -A- to 22 Nm.
– Start engine and check how belt runs.
AG. Volkswagen
1.3 Removing and Vinstalling
olks
wage
n
bracket Afor
G do
es n
ot g
vane pumprisand
ed
by
oil cooler ua
ran
te
tho eo
sa
u equipment required ra
c
s
ce
le
♦ Drip tray -V.A.G 1306-

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.

Passat 1997 ➤
1.3.1 Removing
– Drain coolant. ⇒ page 122
– Unbolt poly-V-belt pulley at vane pump -arrows-, using 2-hole
pin wrench -3212- as a counterhold.
– Unbolt vane pump from bracket and place on longitudinal
member.
Note
The vane pump hoses remain connected.

– Remove cover -arrow- at power steering fluid reservoir.
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
– Separate connector for air conditioning compressor magnetic

rm
ab
clutch -arrow- and place wiring to side.

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 AG d
agen oes
olksw not
byV gu
ara
ed
Passatho1997 ➤
ris nte
eo
t
6-cylinder
s au diesel engine - Edition 11.2003 ra
c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Loosen hose clamps -arrows- and push clamps back on ho‐
ility
ot p
ses.
wit
, is n
h re
– Place drip tray -V.A.G 1306- under engine.
hole
spec
– Pull rear hose off oil cooler.
es, in part or in w
t to the co
– Slacken mountings -1 ... 4- and remove bracket together with
oil cooler.
rrectness of i
l purpos
nf
ercia
orm
m
atio
m
1.3.4 Installing
o
n in
or c
thi
e

t
sd
iva
note the following:
o
r
rp
cu
o
m
f
– Fill coolant system with coolant ⇒ page 125 . .
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Passat 1997 ➤
swage es n
2 Removing and installing sealing olk ot g
byV ua
d ran
ir se
flanges and flywheel or drive plate autho tee
or
ac
ss
ce
le
un
pt
Note
an
d
itte
y li
erm
ab
For repairs to the clutch: ⇒ 5 or 6-Speed manual gearbox 01E/
ility
ot p
0A1; Rep. Gr. 30 ; Repairing clutch .
wit
is n
h re
ole,
spec
1 - 10 Nm
t to the co
2 - 30 Nm
❑ Renew
rrectne
3 - Seal
ss
❑ Renew ⇒ page 31
o
cial p
f in
4 - O-ring
form
mer
❑ For oil drilling
atio
om
❑ Renew
n
c
i
or
n thi
e
5 - Timing chain tensioning el‐

t
sd
iva
o
ement
pr
cum
r
fo
❑ Tighten to 35 Nm
en
ng
t.
yi Co
op py
6 - 10 Nm t. C rig
gh ht
pyri by
7 - Guide tube
co Vo
by lksw
cted agen
Prote AG.
8 - O-ring
❑ Renew
9 - Oil sump, upper part
⇒ page 108
10 - 45 Nm
11 - Counterbalance shaft
housing
❑ With counterbalance
shaft
⇒ page 111
12 - 22 Nm
13 - Bolt
❑ Torque setting on cylin‐
der block 13 Nm
❑ Torque setting on sealing flange 10 Nm
14 - 45 Nm
15 - Dual-mass flywheel or drive plate
❑ Removing and installing dual-mass flywheel ⇒ page 35
❑ Removing and installing drive plate ⇒ page 36
16 - For flywheel: 60 Nm + 1/2 turn (180 °) further. For drive plate: 60 Nm + 1/4 turn (90 °) further
❑ Renew
❑ Lock with locking pin -VAS 3242- when loosening and tightening crankshaft ⇒ page 55
17 - Needle roller bearing
❑ Remove with inside puller Kukko 21/1 and counter support Kukko 22/1
2. Removing and installing sealing flanges and flywheel or drive plate 29

Passat 1997 ➤
❑ Install with punch - 3264-
18 - Gasket
❑ Gasket discontinued
❑ Install with D 176 404 A2 Silicone sealant
19 - Dowel pin
❑ Check that pin is firmly seated in crankshaft
20 - Sealing flange with oil seal
❑ Remove sump in order to remove and install ⇒ page 108
❑ Lightly oil sealing lip
❑ To install, push guide sleeve from installation kit onto crankshaft
21 - Gasket
❑ Renew
22 - Cylinder block
❑ Removing and installing crankshaft ⇒ page 38
❑ Dismantling and assembling pistons and conrods ⇒ page 42
AG. Volkswagen
agen AG do
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23 - Gasket y Vol ot g
ua
b
ed ran
❑ Renew oris tee
th or
au
24 - Front sealingsflange
s ac
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
o
by c lksw
cted agen
Prote AG.

Passat 1997 ➤
2.1 Renewing crankshaft oil seal - belt pulley end

equipment required
♦ Fitting sleeve -3202/1-
♦ Oil seal extractor -3203-
♦ Fitting sleeve -3265-
1331-
1332-
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
2.1.1 Removing
spec
es, in part or in w
t to the co
– Remove toothed belt. ⇒ page 52

– Remove central bolt -3- for crankshaft belt pulley -1-.
rrectness of i
– Remove spacer sleeve -2- and toothed belt -1-.

l purpos
– Screw inner part of oil seal extractor -3203- six (approx. 3 mm)
out of outer part and lock with knurled screw.
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 ➤
– Lubricate threaded head of oil seal extractor -3203- , place it

in position and forcefully screw it as far as possible into oil seal.
– Loosen knurled screw and turn inner part against crankshaft
until the oil seal is pulled out.
2.1.2 Installing
– Do not lubricate sealing lip or outer edge of new oil seal.
– Fit oil seal using fitting sleeve -3202/1- .
– Press in seal until flush using fitting
wagsleeve
en AG. V-3265- and central
olkswagen AG
does
bolt. yV
o lks not
gu b ara
ed nte
oris e
th or
au
Note ss
ac
ce
le
un
pt
Place the spacer sleeve under centre bolt.
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
– Install crankshaft toothed belt pulley -1- with spacer sleeve

-2- using new central bolt -3-.
rrectness of i
– Tighten new securing bolt to 200 Nm and then turn 1/2 turn
l purpos
(180°) further.
nform
ercia
Note
m
a
com
tion in
♦ The contact surfaces between pulley and crankshaft must be

r
te o
oil-free.
thi
s
iva
do
♦ Do not lubricate bolt for crankshaft toothed belt pulley.

r
rp
cum
fo
en
ng
t.
yi Co
– Installing and tightening toothed belt: ⇒ page 57 . t. Cop py
rig
gh ht
pyri by
Vo
2.2 Removing and installing front sealing flange
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤

equipment required
♦ Fitting sleeve -3202/1-
♦ Fitting sleeve -3265-
1331-
1332-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
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ility
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2.2.1 Removing
wit
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ole,
spec
– Remove toothed belt. ⇒ page 52

t to the co
– Remove central bolt -3- and spacer sleeve -2- for crankshaft
belt pulley -1-.
– Remove upper part of sump ⇒ page 108 .
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
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fo
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Passat 1997 ➤
– Remove idler roller -4-, tensioning roller -3-, tensioning lever

-2- and tensioning element -1-.
– Unbolt front sealing flange.
– Remove sealing flange; if necessary, loosen using light blows
with a rubber headed hammer.
AG. Volkswagen AG d
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2.2.2 Installing ut ra
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s
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nl
pt
du
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note the following:
itte
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ility
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Note
, is n
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hole
spec
♦ Before fitting the sealing flange, check the position of the oil
es, in part or in w
pump drive chain. The chain must lie on the guide rail of the
t to the co
chain tensioner -arrow-.
♦ If the sealing flange is installed with the oil seal already fitted,
rrectness of i
place fitting sleeve -3202/1- on end of crankshaft before in‐
stalling sealing flange.
l purpos
– Clean sealing surfaces. They must be free of oil and grease.
nf
ercia
orm
m
atio
m
– Insert bolt -2- with locking fluid.

o
n in
or c
– Tighten bolts -1- to 10 Nm and bolt -2- to 30 Nm.

thi
te
sd
iva
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– Do not lubricate sealing lip and outer circumference of oil seal

rp
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o
before pressing in.

f
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t.
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Cop py
t. rig
gh ht
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Note p by
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by lksw
cted agen
Prote AG.
Place the spacer sleeve under centre bolt.
– Install idler roller.

♦ Installation position: groove in securing drilling (for bolt head)
faces forward.
– Note washers under tensioning roller and tensioning lever.
– Install crankshaft toothed belt pulley -1- with spacer sleeve

-2- using new central bolt -3-.
Note
♦ The contact surfaces between pulley and crankshaft must be

oil-free.
♦ Do not lubricate bolt for crankshaft toothed belt pulley.
– Install upper part of sump ⇒ page 108 .

Installing toothed belt and adjusting valve timing ⇒ page 57 .

Passat 1997 ➤
2.3 Removing and installing dual-mass fly‐

wheel
♦ Clamping bolt -3242- AG. Volkswagen AG d
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olksw not
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ility
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wit
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hole
spec
es, in part or in w
t to the co
♦ Torque wrench -V.A.G 1332- (40...200 Nm)
rrectness of i
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nf
ercia
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m
atio
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n in
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Cop py
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2.3.1 Removing
ht ht
rig by
copy Vo
by lksw
cted
– Remove noise insulation -arrows-.
agen
Prote AG.
– Remove gearbox ⇒ Manual gearbox; Rep. Gr. 34 ; Removing

and installing gearbox .
– Open oil filler cap and turn engine over in direction of rotation
until -OT- (TDC) is visible on camshaft.
– Remove sealing plug from cylinder block. The TDC drilling in
the crankshaft must be visible (or able to be felt) in the sealing
plug hole.

Passat 1997 ➤
– Screw locking pin -3242- into hole. This stops the crankshaft
turning.
– Mark position of flywheel relative to crankcase housing.
– Unbolt flywheel.
2.3.2 Installing AG. Volkswagen AG d

agen oes
lksw not
Installation is carried out in the reverse sequence
d by Vo
of removal. gu
ara
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Note ss c
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nl
pt
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♦ The needle bearing is located in the flywheel and must be
itte
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pressed in if a new flywheel is installed ⇒ Item 17 (page 29) .
erm
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ility
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♦ Always renew flywheel securing bolts.
wit
, is n
h re
hole
spec
2.4 Removing and installing drive plate
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
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t.
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Cop py
t. rig
gh ht
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♦ Depth gauge cop Vo
by lksw
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Prote
2.4.1 Removing
AG.
– Remove gearbox ⇒ Automatic gearbox; Rep. Gr. 37 ; Re‐

moving and installing gearbox .
– Mark position of drive plate relative to engine and remove drive
plate.
Note
To loosen drive plate bolts, counterhold centre bolt of vibration

damper.

Passat 1997 ➤
2.4.2 Installing
– Fit drive plate with washer -2- and 3.0 or 4.0 mm shim -1-.
– Fit at least 3 old bolts and tighten to 30 Nm.
– Check dimension -a- at three points and calculate average.

Specification: approx. 18.1 ... 19.7 mm.
If the specification is not obtained:
– Remove drive plate again and refit with other shim -1-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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– Tightenut securing bolts again to 30 Nm.
ho eo
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s
– Repeat measurements.
ce
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un
pt
an
d
If the specification is obtained

itte
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rm
ab
– Tighten securing bolts to 60 Nm and turn 90° (1/4) further (the

pe
ility
ot
additional 1/4 turn can be done in several stages).

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
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

Passat 1997 ➤
3 Removing and installing crankshaft
Note
Before carrying out repair work, secure engine on assembly stand

with engine and gearbox support -VW 540- .
AG. Volkswagen AG d
agen oes
olksw not
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1 - Dowel sleeve horis nte
eo
ut
❑ Insert in cylinder block ss a ra
c
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2 - Chain sprocket
nl
pt
du
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itte
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ab
⇒ page 40
ility
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3 - Crankshaft
, is n
h re
❑ Axial clearance new:
hole
spec
0.090...0.251 mm, wear
es, in part or in w
limit: 0.30 mm
t to the co
❑ Check radial clearance
with Plastigage new:
rrectness of i
0.018...00.045 mm,
wear limit: 0.10 mm
l purpos
❑ Do not rotate crankshaft

when checking radial
nform
ercia
clearance
❑ Crankshaft dimensions
m
at
om
⇒ page 40
ion
c
in t
or
4 - Dowel pin his

ate
do
riv
5 - Support
p
cum
for
en
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❑ Note installation posi‐

n
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tion ⇒ page 40 ht. Cop py
rig
rig ht
6 - 22 Nm py by
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by lksw
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7 - Bolts Prote AG.
❑ For bearing cap

❑ Renew
❑ Torque setting
⇒ page 39
❑ Tightening sequence
⇒ page 39
8 - Bearing cap
❑ Note marking
⇒ page 39
❑ Installing ⇒ page 39
9 - 22 Nm
10 - Support
❑ Note installation position ⇒ page 40
11 - Thrust washer
❑ Only fitted on 4th crankshaft bearing
❑ Oil grooves face outwards
❑ Note fixing arrangement
12 - Bearing shell
❑ For bearing cap without oil groove

Passat 1997 ➤
❑ Do not interchange used bearing shells (mark) AG. Volkswagen AG d
agen oes
olksw not
❑ Bearing shells worn down to nickel layer
ed
by V must be renewed gu
ara
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13 - Dowel pin aut
ho eo
ra
ss c
14 - Thrust washer
ce
e
nl
pt
du
❑ Only fitted on 4th crankshaft bearing
an
itte
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❑ Oil grooves face outwards
erm
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15 - Bearing shell
wit
, is n
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❑ For cylinder block with oil groove
hole
spec
❑ Do not interchange used bearing shells (mark)
es, in part or in w
t to the co
16 - Bolts
❑ Torque setting ⇒ page 39
rrectness of i
❑ Tightening sequence ⇒ page 39
l purpos
Crankshaft bearing cap identification
nform
ercia
♦ Bearing 1 is located at belt pulley end

m
at
om
io
♦ Bearing 4 is located at the flywheel end
n
c
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ate
do
priv
cum
for
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.
Installing crankshaft bearing caps

– Renew bolts -1-...-16-.
– Insert fitting sleeves in bearing caps.
– Oil tapped holes in bearing caps and tighten in the following
order:
1- Tighten bolts -1-...-8- to 60 Nm.
2- Tighten bolts -1-...-8- 90° (1/ 4 turn further) with ridged
wrench.
3- Tighten bolts -9-...-16- to 60 Nm.
4- Tighten bolts -9-...-16- 90° (1/ 4 turn further) with ridged
wrench.
5- Tighten bolts -A- to 28 Nm.
3. Removing and installing crankshaft 39

Passat 1997 ➤
Installation positions of braces

♦ Arrow points forwards
♦ Brace with mark -1- to belt pulley end
♦ Brace with mark -4- to flywheel end
3.1 Crankshaft dimensions

Honing dimen‐ Crankshaft main Conrod
sion bearing journal ∅ journal ∅
Basic dimension 65.00 -0.022 58.00 -0.022
-0.042 -0.042
1st oversize 64.75 -0.022 57.75 -0.022
-0.042 -0.042
3.2 Removing and

lksw
ainstalling
gen AG chain dsprocket
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oes
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b
equipment required ran
tee
tho or
♦ Fitting sleeve -30-100-
sa
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s
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nl
pt
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spec
es, in part or in w
t to the co
rrectness of i
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♦ Two arm puller (commercially available)
3.2.1 Removing
nform
mercia
at
– Remove upper part of sump. ⇒ page 108

om
ion
c
in t
r
– Remove front sealing flange. ⇒ page 32

o
his
ate
do
riv
– Remove chain tensioner and chain.

p
cum
for
en
– Pull chain sprocket: off crankshaft using a two-arm puller -2-,

ng
t.
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protect end of crankshaft by placing a suitable washer -1- un‐ Cop py
der threaded spindle of puller. ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Passat 1997 ➤
3.2.2 Installing
WARNING
Wear protective gloves!
– Heat chain sprocket in an oven for approx. 15 minutes to 220

°C.
– Fit heated chain sprocket onto end of crankshaft using pliers olkswagen AG
and press onto final position on crankshaft using drift sleeveswagen AG. V does
-30-100- . by Volk not
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th or
au ac
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nl
pt
du
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itte
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erm
ab
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
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3. Removing and installing crankshaft 41

Passat 1997 ➤
4 Dismantling and assembling pistons and conrods
1 - Conrod bolt, 30 Nm + 1/4

turn (90°) further
❑ Renew
❑ Oil threads and contact
surface
❑ To measure radial clear‐
ance, tighten to 30 Nm
but not further
2 - Conrod bearing cap
❑ Do not interchange
❑ Mark cylinder number
-B-
❑ Installation position:
note cast marks -A-
⇒ page 45
3 - Bearing shell
tion
❑ Do not interchange
used bearing shells
❑ Axial play for each con‐
rod pair, new:
0.20...0.44 mm. Wear
limit: 0.60 mm
AG. Volkswagen AG d
with Plastigage: new: lksw
agen oes
not
0.015...0.062 mm, wear by
Vo gu
ara
limit: 0.120 mm. Do not orised
nte
rotate crankshaft when aut
h eo
ra
checking radial clear‐ ss c
ance
ce
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4 - Conrod
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❑ Renew as set only

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❑ Mark cylinder number

is n
h re
-B-
ole,
spec
❑ Installation position: note cast marks -A- ⇒ page 45

t to the co
5 - Circlip
6 - Piston pin
rrectne
❑ Remove and install with drift -VW 222 A-

7 - Piston
ss o
❑ With combustion chamber

cial p
f inform
❑ Mark installation position and cylinder number

mer
atio
❑ Installation position and allocation of piston to cylinder ⇒ page 44

om
n
c
❑ Arrow on piston crown points to centre of engine

i
or
n thi
te
❑ Install using piston ring clamp

sd
iva
o
pr
❑ If cracks in piston skirt, renew piston

um
r
fo
en
ng
❑ Checking piston projection at TDC ⇒ page 45

t.
yi Co
op py
❑ Piston and cylinder dimensions ⇒ page 46
t. C rig
gh ht
pyri by
Vo
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8 - Piston rings by c lksw
cted agen
Prote AG.
❑ Offset gaps by 120°

Passat 1997 ➤
❑ Remove and install using piston ring pliers
❑ “TOP” faces towards piston crown
❑ Checking ring gap ⇒ page 43
❑ Checking ring-to-groove clearance ⇒ page 43
9 - 10 Nm
10 - Oil spray jet
❑ For piston cooling
Checking piston ring gap
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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aut ra
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nl
pt
du
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erm
ab

ility
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♦ Feeler gauges
wit
, is n
h re
hole
– Push ring squarely from above down to approx. 15 mm from

spec
bottom end of cylinder.

es, in part or in w
t to the co
Piston ring New Wear limit

dimensions in mm
rrectness of i
1st compression ring 0.20...0.40 0.8

l purpos
2nd compression ring 0.80...1.00 1.4

Oil scraper ring 0.25...0.50 0.8
nform
ercia
Checking ring-to-groove clearance

m
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.

♦ Feeler gauges
– Clean groove in piston before checking clearance.
Piston ring New Wear limit
dimensions in mm
1st compression ring 0.100...0.135 0.150
2nd compression ring 0.045...0.085 0.110
Oil scraper ring 0.025...0.065 0.090
4. Dismantling and assembling pistons and conrods 43

Passat 1997 ➤
Checking cylinder bores
AG. Volkswagen AG d
agen oes
olksw not
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rise nte
tho eo
au ra
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nl
pt
du
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itte
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erm
ab
♦ Internal dial gauge 50...100 mm
ility
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– Take measurements at 3 positions in both transverse -A- and
h re
hole
longitudinal -B- directions, as illustrated. Difference between
spec
actual and nominal diameter: not more than 0.08 mm.
es, in part or in w
t to the co
Note
rrectness of i
Measuring the cylinder bores must not be done when the cylinder
l purpos
block is mounted on a repair stand with adapter bracket -

VW 540- , as incorrect measurements would then be possible.
nf
ercia
or
Piston installation position and allocation of piston to cylinder
m
m
atio
om
The pistons in banks with cylinders -1-...-3- and with cylinders
n in
or c
-4-...-6- are different.
thi
te
sd
iva
♦ Installation position: the arrows on the piston crowns must
o
r
rp
cu
point towards the middle of the engine.
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
Note yri
p by
co Vo
by lksw
cted agen
Prote
Do not use centre punch because later damage (cracks) could
AG.
develop.
The cylinder allocation of new pistons is painted or engraved on

the crowns.
♦ Piston for cylinders 1, 2 and 3: marking 1/2/3
♦ Piston for cylinders 4, 5 and 6: marking 4/5/6
Note
Piston classification ⇒ page 46 .

Passat 1997 ➤
Marking conrods
Note
♦ Only renew conrods as a complete set.

AG. Volkswagen AG d
agen
♦ Do not interchange conrod bearings. olksw
oes
not
byV gu
ara
ed
ris nte
– Before removing, mark mating positions
ut
ho of conrods and con‐ eo
ra
rod bearing caps with coloured pen
ss a
-arrow-. c
ce
e
nl
pt
du
an
itte
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erm
ab
Conrod installation position
ility
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Marks on castings -arrows- ⇒ page 42 are located as shown in
h re
illustration.
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
Illustration shows front pair of conrods.
l purpos
nf
ercia
orm
m
atio
m
4.1 Checking piston projection at TDC

o
n in
or c
thi
e

t
sd
iva
o
r
rp
cu
♦ Measuring bridge -VW 382/7-
o
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f
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ End dimension plate -VW 385/17-
♦ Dial gauge
4. Dismantling and assembling pistons and conrods 45

Passat 1997 ➤
4.1.1 Test procedure

Piston projection at TDC must be measured when installing new
pistons or a short engine. Install the appropriate cylinder head
gasket depending upon piston projection, according to following
table:
Piston projection Identification
Holes/notches
0.39 mm ... 0.49 mm 1
0.49 mm ... 0.54 mm 2
0.54 mm ... 0.65 mm 3
4.1.2 Cylinder head gasket identification

♦ Holes = arrow 1
♦ Part No. = arrow 2
♦ Production control code = arrow 3 (can be disregarded)
Note
♦ If different values are determined during the projection meas‐

urement, use the largest dimension for selecting the gasket.
♦ The cylinder head gasket must be determined separately for
each cylinder bank.
4.2 Piston and cylinder dimensions

olksw AG. V agen AG
agen does
olksw Piston ∅ Cylinder nobore
t gu ∅
y V
e db ara
Basic dimen‐ horisI 2) 78.253 ... 78.306 ... nte
eo
sion aut 78.261 1)
78.310 ra
ss c
II 2) 78.259 ... 78.310 ...
ce
le
un
pt
78.267 1) 78.314
an
d
itte
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Intermediate I 2) 78.293 ... 78.346 ...

erm
ab
size 78.301 1) 78.350

ility
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is n
II 2) 78.299 ... 78.350 ...

h re
78.307 1) 78.354
ole,
spec
1) Dimensions without graphite coat (thickness 0.02 mm) The graphite coat on
t to the co
piston skirt wears off.

2) The piston classification is stamped into the piston crown -arrow-.
rrectne
Piston classification
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.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Passat 1997 ➤
15 – Cylinder head, valve gear

1 Removing and installing cylinder
head
Note
♦ When installing an exchange cylinder head with fitted cam‐

shaft, oil the contact surfaces between the rocker fingers and
the cam surfaces before installing the cylinder head cover.
♦ Reworking diesel cylinder heads is not permissible.
♦ If the cylinder head is replaced, the entire coolant must also
be renewed.
♦ The plastic packing pieces for protecting the open valves must
not be removed until immediately before fitting cylinder head.
♦ Do not place cylinder head on its underside, as this will dam‐
age the injectors and glow plugs.
♦ A valve limiting pressure to 2.7 bar (for lubricating points in
cylinder head) is screwed into each cylinder head. Torque set‐
ting: 25 Nm.
Checking compression ⇒ page 84
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
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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
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.
1. Removing and installing cylinder head 47

Passat 1997 ➤
1 - Cylinder head
❑ Removing left cylinder
head ⇒ page 75
❑ Removing right cylinder
head ⇒ page 77
❑ Check for distortion
⇒ page 49
❑ Installing ⇒ page 80
❑ After renewing, renew
entire coolant
2 - Cylinder head cover gasket
❑ Renew if damaged
❑ Before fitting, seal trans‐
fer points with sealant -
D 454 300 A2-
⇒ page 50
3 - Cylinder head bolt
❑ Renew
❑ Note sequence when
loosening ⇒ page 75
❑ Note correct sequence
when tightening
⇒ page 80 agen
AG. Volkswagen AG d
oes
olksw not
4 - Cylinder head cover ed byV gu
ara
is nte
❑ Removing and installing ut
hor eo
cylinder head cover ss a ra
c
(left-side) ⇒ page 70
ce
le
un
pt
an
d
itte
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cylinder head cover
erm
ab
(right-side) ⇒ page 72
ility
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❑ If injector seals are dam‐
is n
h re
aged, replace cylinder
ole,
head cover
spec
t to the co
5 - Deflector ring
rrectne
6 - Gasket
ss
7 - Cap
o
cial p
f inform
8 - Injector pipes
mer
atio
om
❑ Remove with ring spanner -3035-

c
i
or
n thi
e
❑ Always remove pipework complete

t
sd
iva
o
pr
❑ Do not alter shape

um
r
fo
en
ng
t.
9 - Return line
yi Co
Cop py
ht. rig
10 - Seal rig ht
py by
o Vo
❑ Renew
by c lksw
cted agen
Prote AG.
11 - Banjo bolt, 5 Nm
12 - Intake manifold
❑ Removing and installing front intake manifold ⇒ page 50
❑ Removing and installing left intake manifold ⇒ page 67
❑ Removing and installing right intake manifold ⇒ page 69
48 Rep. Gr.15 - Cylinder head, valve gear

Passat 1997 ➤
13 - 10 Nm
❑ Tighten in stages and in diagonal sequence
14 - Gasket
❑ Renew
15 - Dowel sleeve
❑ Qty. 2
❑ Be careful that no fitting sleeve falls into the intake ports
16 - 10 Nm
❑ Tighten in stages and in diagonal sequence
17 - Heat shield
❑ For vacuum pump
18 - 10 Nm
19 - Exhauster pump
❑ For brake servo AG. Volkswagen AG d
agen oes
❑ Removing and installing ⇒ page 50 Volksw not
gu
by ara
d
20 - O-rings rise nte
tho eo
u
❑ For vacuum pump ss a ra
c
❑ Renew
ce
e
nl
pt
du
an
itte
21 - Cylinder head gasket
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erm
ab
❑ Note marking ⇒ page 49
ility
ot p
wit
❑ Renew
, is n
h re
hole
spec
es, in part or in w
t to the co
Checking cylinder head for distortion
Max. permissible distortion: 0.1 mm
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
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o
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f
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ng
Cylinder head gasket identification

t.
yi Co
Cop py
♦ Holes = arrow 1
t. rig
gh ht
pyri by
Vo
o
♦ Part No. = arrow 2
c by lksw
cted agen
Prote AG.
♦ Production control code = arrow 3 (can be disregarded)
Note
Different thicknesses of cylinder head gasket are fitted depending

on the piston projection. When fitting a new cylinder head gasket,
install a new gasket with same identification.

Passat 1997 ➤
Removing and installing exhauster pump

– Remove vacuum hose to vacuum pump.
– Remove bolts -1- for vacuum pump with heat shield on left
cylinder head and turn pump in direction of arrow.
– Renew O-rings
Sealing points for bearing caps on cylinder head

– Apply a small quantity of sealant -D 454 300 A2- to transition
sealing surfaces of cylinder head -arrows-.
1.1 Removing agand

en AG. installing
Volkswagen AGfront intake
does
ksw
manifold, engine codes AFB, AKN,ara BAU
ol not
y V gu
d b
ise
and BDH
r nte
ho eo
ut r ac
sa
Removings and installing front intake manifold, engine code BDG
ce
e
nl
⇒ page 51
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
r
1.1.1 Removing
o
his
ate
do
riv

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

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
rised
nte Passat 1997 ➤
o eo
r a6-cylinder diesel engine - Edition 11.2003
h
aut
ss c
ce
e
– Pull vacuum hose from shut off valve support -arrow-.
nl
pt
du
an
itte
y li
– Pull left air intake hose off shut off valve support.
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
– Remove front intake manifold -arrow-.
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.
1.1.2 Installing
Installation is carried out in the reverse sequence of removal.
Note
Always renew self-locking nuts, gaskets and seals.
1.1.3 Torque settings

Threaded connection Torque set‐
ting
Front intake manifold to left or right manifold 10 Nm
Exhaust gas recirculation pipe to front intake 10 Nm
manifold
1.2 Removing and installing front intake

manifold, engine code BDG

Passat 1997 ➤
1.2.1 Removing
– Remove bolts -arrows- from intake manifold flap motor -
V157- .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
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ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Loosen exhaust gas recirculation cooler.
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
– Remove front intake manifold -arrow-.

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1.2.2 Installing
Note
1.3 Torque settings

ting
Front intake manifold to left or right manifold 10 Nm
Exhaust gas recirculation cooler to front intake 10 Nm
manifold
1.4 Removing, installing and tensioning toothed belt

Passat 1997 ➤

equipment required
♦ Counterhold -VAS 3036- agen
AG. Volkswagen AG d
oes
olksw not
V gu
♦ Socket attachment (22 mm) ed by ara
nte
-VAS 3078- horis
eo
aut ra
♦ Clamping bolt -VAS 3242- ss c
ce
le
un
pt
♦ Locking pin for diesel injec‐
an
d
itte
tion pump -VAS 3359-
y li
rm
ab
pe
ility
♦ Camshaft holder -VAS
ot
wit
3458-
, is n
h re
hole
♦ Locking pin -T40011-
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.

Passat 1997 ➤
♦ Two-arm puller -T40001-

1331- (5...50 Nm)
1332- (40...200 Nm)
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
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
1.4.1 Removing
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.
Note
If a piston is at TDC, the valves could strike the piston when the
camshafts turn.

plug hole.

Passat 1997 ➤
– Screw locking pin -3242- into hole. This stops the crankshaft
turning.
– Remove the coolant expansion tank (coolant hoses remain
attached).
– Remove vacuum hose to vacuum pump -arrows-. n AG. Volkswagen AG do

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
– Remove exhauster pump.
– Remove air filter housing.
ss o
cial p
f
– Remove air pipe between turbocharger and right charge air
inform
cooler.
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
op
– Use screwdriver to lever off cover -arrow- on right cylinder C py
t. rig
head.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
♦ Cover is destroyed during removal.

♦ Do not damage sealing flange.

Passat 1997 ➤
– Insert camshaft holders -3458- in both cylinder heads and se‐

cure them against falling with chains.
Note
Camshaft holders -3458- must not be used as counterholds.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
– Remove vibration damper for injection pump pulley (bolts ise
d b ara
nte
-1-). uthor eo
a ra
ss c
ce
le
un
pt
Note
an
d
itte
y li
rm
ab
On no account must the nut -2- for the injection pump pulley be
pe
ility
loosened. Otherwise the injection pump basic setting may be al‐
ot
wit
, is n
tered and this cannot be reset with normal workshop equipment
h re
hole
spec
es, in part or in w
– Mark direction of rotation of toothed belt.
t to the co
rrectness of i
– Loosen toothed belt tensioner and remove injection pump
toothed belt from camshaft pulley.
l purpos
– Remove the vibration damper. Loosening the centre bolt is not

necessary.
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
– Unbolt bottom section of toothed belt guard -4-.
c by lksw
cted agen
Prote AG.
– Remove drive pulley for viscous fan.
– Remove viscous fan bracket with idler roller (bolts -1-, -2- and
-3-).
– Remove drive pulley on camshaft for injection pump.

Passat 1997 ➤
– Loosen bolts of both camshaft pulleys, counterhold pulley with

counterhold -3036- for this.
Note
gen A n AG G. Volkswage
♦ Camshaft holders -3458- must not be
Volkused
swa as counterholds. does no
t y gu
db ara
♦ Bolts remain loosely screwedorin.
ise nte
th eo
s au ra
c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
– Turn toothed belt tensioning roller in direction of arrow with 8
wit
mm hexagon key until the tensioning lever of the tensioning
is n
h re
element is so compressed that the locking pin -T40011- fits in
ole,
spec
the hole and in the plunger.
t to the co
Note
rrectne
The toothed belt tensioning element is oil dampened. It can there‐
fore only be pushed back slowly.
ss o
cial p
f inform
mer
atio
om
– Pull left and right camshaft pulleys off their tapers using two-
n
c
i
or
n
arm puller -T40001- .
thi
te
sd
va
– Remove bolt for left camshaft pulley and remove camshaft

i
o
pr
cum
r
pulley.
fo
en
ng
t.
yi Co
– Mark direction of rotation of toothed belt. Cop py
t. rig
gh ht
yri
– Remove toothed belt. p by
co Vo
by lksw
cted agen
Prote AG.
1.4.2 Installing
• Camshaft locked with camshaft holder -3458- .
• Crankshaft locked in position with locking pin -3242- .
• Camshaft sprockets are able to turn.
Note
The crankshaft must not be at TDC at any cylinder when the

camshaft is turned. Danger of damage to valves and piston
crowns.

Passat 1997 ➤
6-cylinder diesel engine -ksEdition
wage 11.2003 es n
ol ot g
yV ua
db ran
– Fit toothed belt first overoris crankshaft toothed belt pulley, then
e
tee
the right camshaft pulley
auth
followed by the tensioning roller, the or
ac
idler roller and thesscoolant pump.
ce
le
un
pt
– Finally fit belt over the left camshaft toothed belt pulley and
an
d
itte
bolt pulley to camshaft.
y li
rm
ab
pe
ility
– Secure both camshaft pulleys only lightly.
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Release tension -arrow- on toothed belt tensioning roller with
l purpos
8 mm hexagon key and pull out locking pin -T40011- for hy‐
draulic tensioner.
nform
mercia
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
– Tension toothed belt by turning belt in direction of arrow with cted agen
Prote AG.
torque wrench -V.A.G 1331- to 15 Nm.
– Tighten bolts on camshaft pulleys. Use counterhold -3036- for
this, tightening torque 75 Nm.
Note
– Secure viscous fan bracket:

1- 45 Nm
2- 10 Nm
3- 22 Nm
4- 10 Nm
– Lock injection pump pulley in position with locking pin -3359- .

Passat 1997 ➤
– Align drive pulley for injection pump -1- so that it is aligned

centrally in elongated holes.
– Tighten bolts -arrows- by hand (it should be possible to turn
drive pulley on camshaft pulley).
– Fit injection pump toothed belt. Pay attention to marked direc‐
tion of rotation.
– Tension toothed belt. Turn hexagon key anti-clockwise en AG. Volkswagen AG

-arrow- until marks -1- align over one another. Then ag
kswtighten
does
not
Vol
the securing nut to 36 Nm using 22 mm socketed by-3078- . gu
ara
is nte
or
– Tighten camshaft pulley bolts to 22 Nm.auth eo
ra
ss c
– Remove locking pin -3359- , camshaft holders -3458- and
ce
le
un
pt
locking pin -3242- .
an
d
itte
y li
– Turn crankshaft two rotations in engine direction of rotation
erm
ab
ility
and set again to TDC.
ot p
wit
is n
– Repeat check.
h re
ole,
spec
– Remove camshaft holders -3458- and locking pin -3242- .
t to the co
– Install vibration damper and tighten injection pump pulley bolts
to 22 Nm.
rrectne
– Install TDC marking cover with new seal on cylinder block.
– Install vacuum pump.
ss o
– Install new cap on right cylinder head.
cial p
f inform
– Install crankshaft vibration damper. Pay attention to locking
mer
lug on toothed belt pulley.
atio
om
n
c
Further assembly is basically the reverse of the dismantling pro‐
i
or
n thi
e
cedure.
t
sd
iva
o
pr

um
r
fo
en
ng
t.
yi
– Checking commencement of injection of injection pump
Co
op py
⇒ page 186 . t. C rig
gh ht
pyri by
Vo
co lksw
by
1.5 Removing toothed belt from camshaft pulleys
cted agen
Prote AG.

Passat 1997 ➤

equipment required
♦ Counterhold -VAS 3036-
♦ Socket attachment (22 mm)
-VAS 3078-
♦ Clamping bolt -VAS 3242-
♦ Locking pin for diesel injec‐
tion pump -VAS 3359-
♦ Camshaft holder -VAS
3458-
AG. Volkswagen AG d
♦ Locking pin -T40011- 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.

Passat 1997 ➤
♦ Two-arm puller -T40001-

1331- (5...50 Nm)
1332- (40...200 Nm)
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
rrectness of i
l purpos
1.5.1 Removing
nform
ercia

m
at
om
ion
c
– Remove engine cover.

in t
or
his
te
– Remove viscous fan.

a
do
priv
cum
or
– Remove front left and right toothed belt guards.

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

Passat 1997 ➤
– Remove poly-V-belt cover -arrows-.
Note
Pay attention to the poly-V-belt cover spacer sleeves.
– Remove sealing plugs from cylinder block. The TDC drilling in
plug hole. wage
e ks s no
Vol t gu
d by ara
e nte
ris
utho eo
ra
a c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
– Screw locking pin -3242- into hole. This stops the crankshaft h re
turning.
hole
spec
es, in part or in w

t to the co
attached).
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
– Remove vacuum hose to vacuum pump -arrows-.

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 ➤
– Remove exhauster pump.
– Remove air filter housing.
– Release fuel lines from retainer and set aside fuel filter with
attached lines.

cooler -arrow-.
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
– Use screwdriver to lever off cover -arrow- on right cylinder
hole
spec
head.
es, in part or in w
t to the co
Note
rrectness of i
♦ Cover is destroyed during removal.
l purpos
♦ Do not damage sealing flange.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
– Insert camshaft holders -3458- in both cylinder heads and se‐

do
r
rp
cure them against falling with chains.

um
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 ➤

toothed belt from camshaft pulley.
– Unbolt drive pulley -1- for injection pump from camshaft pulley
-arrows-.
Note
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
– Loosen bolts of both camshaft pulleys, counterhold pulley with
ce
le
un
pt
counterhold -3036- for this.
an
d
itte
y li
erm
ab
ility
ot p
Note
wit
is n
h re
ole,
Bolts remain loosely screwed in.
spec
t to the co
– Remove right cover cap, located under viscous fan bracket.
rrectness o
– Turn toothed belt tensioning roller in direction of arrow with 8

cial p
f in
mm hexagon key until the tensioning lever of the tensioning

form
mer
element is so compressed that the locking pin -T40011- fits in

atio
the hole and in the plunger.

om
n
c
i
or
n thi
te
sd
a
Note
iv
o
pr
cum
r
fo
en
ng
The toothed belt tensioning element is oil dampened. It can there‐

t.
yi Co
op
fore only be pushed back slowly. C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤
– Pull left and right camshaft pulleys off their tapers using two-
arm puller -T40001- .
– Detach both camshaft pulleys.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
ut ra
1.5.2 Installing ss a c
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
wit
The crankshaft must not be at TDC at any cylinder when the
, is n
h re
camshaft is turned. Danger of damage to valves and piston
hole
spec
crowns.
es, in part or in w
t to the co
• Camshaft locked with camshaft holder -3458- .
rrectness of i
• Camshaft sprockets are able to turn.
l purpos
1.5.3 Procedure
nf
ercia
o
– Fit toothed belt onto one of the camshaft toothed belt pulleys.
rm
m
atio
m
– Then fit belt over the second camshaft toothed belt pulley and
o
n in
c
bolt pulley to camshaft.

or
thi
te
sd
a
– Secure both camshaft pulleys only lightly.

iv
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.
– Release tension -arrow- on toothed belt tensioning roller with

8 mm hexagon key and pull out locking pin -T40011- for hy‐
draulic tensioner.

Passat 1997 ➤
– Tension toothed belt by turning belt in direction of arrow with

torque wrench -V.A.G 1331- to 15 Nm.
– Tighten bolts on camshaft pulleys. Use counterhold -3036- for
this, tightening torque 75 Nm.
Note
– Lock injection pump pulley in position with locking pinw-3359-

agen
AG..Volkswagen AG d
oe
ks s no
Vol t gu
d by ara
e nte
ris
utho eo
ra
a 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
– Fit injection pump toothed belt. Pay attention to marked direc‐
tion of rotation.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
– Tension toothed belt. Turn hexagon key anti-clockwise

o
r
rp
cu
-arrow- until marks -1- align over one another. Then tighten
o
m
f
en
ng
the securing nut with 22 mm socket -3078- .

t.
yi Co
Cop py
.
♦ Torque setting: 36 Nm.
t rig
gh ht
pyri by
Vo
co
– Tighten camshaft pulley bolts to 22 Nm.
by lksw
cted agen
Prote AG.
– Remove locking pin -3359- .
– Remove camshaft holders -3458- from both cylinder heads.
until crankshaft is set to OT (TDC) again.
– Repeat check.
– Check tension of injection pump toothed belt.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
thor eo Passat 1997 ➤
u ra
ss a 6-cylinder
c diesel engine - Edition 11.2003
ce
e
nl
pt
du
– The marks -1- and -2- must align.
an
itte
y li
erm
ab
– Screw TDC-mark sealing plug with new O-ring in cylinder
ility
ot p
block.
wit
, is n
h re
– Install vacuum pump.
hole
spec
– Install new cap on right cylinder head.
es, in part or in w
t to the co
cedure.
rrectness of i
– Check commencement of injection of injection pump
⇒ page 186 .
l purpos
nf
ercia
1.6 Removing and installing left intake
orm
m
manifold
atio
om
n in
or c
thi
te
sd
iva
♦ Ring spanner -3035-
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.6.1 Removing
– Remove front intake manifold ⇒ page 50 .

Passat 1997 ➤
– Remove heat shield over turbocharger -arrows-.
– Pull vacuum hose -arrow- off mechanical exhaust recirculation

valve.
– Unbolt injection lines with ring
swa
gspanner
en AG. V -3035- . does
olkswagen AG
k not
Vol g
– Release wiring harnessd b in the area of left intake manifold uand
y ara
ise nte
place to side. thor 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
– Remove left intake manifold -arrows-. spec

es, in part or in w
t to the co
Note
rrectness of i
♦ When removing intake manifold, be careful of the two fitting

l purpos
sleeves.
♦ Block off intake ports in cylinder head with clean cloths.
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
t. rig
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pyri by
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cted agen
Prote AG.
1.6.2 Installing
Note
♦ Always renew self-locking nuts, gaskets and seals.

♦ When installing intake manifold, check the two fitting sleeves.

Left intake manifold to cylinder head 10 Nm

Passat 1997 ➤

Mechanical exhaust gas recirculation valve to 22 Nm
intake manifold
Injection lines to injectors or injection pump 30 Nm
1.7 Removing and installing right intake

manifold

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
1.7.1 Removing
– Remove engine cover first. t to the co
rrectness of i
l purpos
– Pull hose -arrow- off turbocharger.

– Unbolt injection lines with ring spanner -3035- .
nform
ercia
– Release wiring harness in the area of right intake manifold and

m
a
com
place to side.
ion in
r
te o
– Pull air pipe from turbocharger and push aside (do not re‐
thi
s
iva
move).
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Passat 1997 ➤
– Remove right intake manifold -arrows-.
Note
♦ When removing intake manifold, be careful of the two fitting

sleeves.
♦ Block off intake ports in cylinder head with clean cloths.
1.7.2 Installing
en AG. V
of
olkremoval.
swagen AG
wag does
olks not
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ara
ed
Note tho
ris nte
eo
au ra
c
ss
♦ Always renew self-locking nuts, gaskets and seals.
ce
le
un
pt
an
d
♦ When installing intake manifold, check the two fitting sleeves.

itte
y li
erm
ab
ility
ot p

wit
is n
h re
ole,

spec
Right intake manifold to cylinder head 10 Nm

t to the co
Oil line to intake manifold 22 Nm

rrectne
1.8 Removing and installing left cylinder

ss
head cover
o
cial p
f inform

mer
atio
m

o
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
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤
1.8.1 Removing
attached). olkswage es n
o
V t gu
by a
– Pull off
ris wiring to coolant shortage indicator switch
ed ran -F66- and
tee
set
au
tcoolant
ho
expansion tank to side. or
a
ss c
– Pull vacuum hose -arrow- off mechanical exhaust recirculation
ce
e
nl
valve.
pt
du
an
itte
y li

erm
ab
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
Do not attempt to reshape injector pipes

t to the co
rrectness of i
l purpos
– Pull connector off intake manifold pressure sender -G71-

-arrow-.
nf
ercia
orm
– Release cable retainer on left cylinder head cover and place

m
atio
m
wiring harness to side.

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
o
by c lksw
cted agen
Prote AG.

Passat 1997 ➤
– Unbolt return line from injectors -1-.

– Remove cylinder head cover nuts -arrows- and remove cylin‐
der head cover.
1.8.2 Installing
. Volkswage
ksw
agen of removal. AG does
AG n
n
Vol ot g
by ua
ed ran
oris tee
Note au
th or
ac
ss
ce
e
♦ Renew return line seals.

nl
pt
du
an
itte
y li
♦ Renew cylinder head cover gaskets if damaged.
erm
ab
ility
ot p
♦ If injector seals are damaged, cylinder head cover must be
wit
, is n
replaced.
h re
hole
spec
es, in part or in w
t to the co
– Tighten cylinder head cover nuts using diagonal sequence.
rrectness of i
– Install front intake manifold ⇒ page 50 .
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu

o
m
f
en
ng
t.
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op py
t. C rig
gh ht
pyri by
Cylinder head cover to cylinder head 10 Nm
co Vo
by lksw
cted agen
Prote
Return line to injectors 5 Nm
AG.
1.9 Removing and installing right cylinder

head cover

Passat 1997 ➤
1.9.1 Removing
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
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rm
ab
pe
ility
ot
wit
, is n
– Release hose clamp -3-.

h re
hole
spec
– Detach connector -4-.

es, in part or in w
t to the co
– Pull hose -2- off air filter housing.

– Unscrew bolt -1- and take off air filter housing.
rrectness of i

cooler.
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
t. rig
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pyri by
Vo
co
73
by lksw
cted agen
Prote 1. Removing and installing cylinder head
AG.
Passat 1997 ➤
– Pull hoses -arrows- off turbocharger and mechanical exhaust

gas recirculation valve.
Note
– Release wiring harness on cylinder head cover and place to

side.
– Remove dip stick guide tube.
Note
The guide tube for the engine oil dipstick must not be pulled out
upwards, as otherwise the O-ring at the base of the guide tube
will have to be renewed.

der head cover.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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1.9.2 Installing
ce
e
nl
pt
du
an
itte
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erm
ab
note the following:
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
t to the co
♦ Renew return line seals.
♦ Renew cylinder head cover gaskets if damaged. rrectness of i
♦ If injector seals are damaged, cylinder head cover must be

replaced.
l purpos

nf
ercia

orm
m
atio
– Tighten cylinder head cover nuts using diagonal sequence.

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
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤

Return line to injectors 5 Nm
Guide tube for dipstick to cylinder head 10 Nm
1.10 Removing left cylinder head

Installing cylinder head ⇒ page 80 .
G. Volkswage
Special tools and lkworkshop
swa
gen A equipment required
n AG d
oes
no ot g
yV ua
♦ Ring spanner
ise
db -3035- ran
r tee
ho
aut or
ac
ss
ce
e
nl
pt
du
an
itte
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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
Note
nform
ercia

m
at

om
ion
c
in t
r
♦ Secure all hose connections with hose clamps comparable to

o
his
te
production standard.
a
do
priv
cum
or
♦ All cable ties which are opened or cut through when cylinder
f
en
g
head is removed must be replaced in the same position when

n
t.
yi Co
op
cylinder head is installed.
C py
t. rig
gh ht
pyri by
Vo
co
1.10.1 Removing
by lksw
cted agen
Prote AG.

– Remove left exhaust manifold with exhaust pipe.
⇒ page 206
– Remove toothed belt from camshaft pulleys. ⇒ page 59

Passat 1997 ➤
ks wage es
– Pull hoses -arrows- off turbocharger
Vol and mechanical exhaust
not
gu
by
ris
ed ara
nt ee
tho or
– Unbolt injection lines
sa
u with ring spanner -3035- . ac
s
ce
e
nl
pt
du
an
Note
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Pull off rear middle toothed belt guard -2- upwards.
rrectness of i
– Remove bolts -arrows- and take off rear left -3- and right -1-
l purpos
toothed belt guards.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
– Pull off both coolant hoses -arrows-. pyri by
Vo
co lksw
by
cted agen
– Remove bolts -1- and -2-. Prote AG.
– Pull off coolant pipe to front.

– Pull connectors off injector pump and glow plugs.

-arrow-.
– Release cable retainer on left cylinder head cover and place

Passat 1997 ➤
– Remove mechanical exhaust gas recirculation valve from left

intake manifold -arrow-.
– Pull coolant hoses -1- and -2- off coolant pipe.

– Remove bolts -3-.
Note
The coolant pipe is shown in figure with enginegeremoved.

n AG. Volkswagen AG d
wa oes
olks not
yV gu
– Remove left coolant pipe from cylinder
ris
ed
b
block to the rear. ara
nte
tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
der head cover.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Loosen socket head bolts in sequence given and then remove

m
a
com
completely.
ion in
r
te o
– Remove cylinder head and place it on a soft pad (foam rubber).

thi
s
iva
do
r
rp
cum
fo
en
Note
ng
t.
yi Co
Cop py
ht. rig
Do not place cylinder head on the workbench because injectors rig ht
py by
and glow plugs could be damaged.
co Vo
by lksw
cted agen
Prote AG.
1.11 Removing right cylinder head

Installing cylinder head ⇒ page 80 .

Passat 1997 ➤
Note

♦ Secure all hose connections with hose clamps comparable to
production standard.
♦ All cable ties which are opened or cut through when cylinder
head is removed must be replaced in the same position when
cylinder head is installed.
1.11.1 Removing
AG. Volkswagen AG d
– Drain coolant ⇒ page 122 . ksw
agen oes
not
ol
yV gu
– Remove right exhaust manifold
ised b with exhaust pipe ara
nte
⇒ page 208 . ut
hor eo
a ra
s c
– Remove toothed belts from camshaft pulleys. ⇒ page 59
ce
le
un
pt

an
d
itte
y li
erm
ab
– Pull hoses -arrows- off turbocharger and mechanical exhaust

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.

Passat 1997 ➤
– Remove heat shield over turbocharger -arrows-.

Note
– Remove intake hose from air filter to turbocharger.
– Pull off connectors -1-, -2- and -3-.

– Pull connector -4- off injection pump.
– Pull connector -5- off coolant temperature sender.
– Pull connectors off glow plugs and place wiring harness to
side.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
– Pull connector -arrow- off right engine mounting and place
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
– Pull off connector -arrow- and place wire for needle lift sender
to side.
nform
ercia
– Remove oil line from turbocharger and intake manifold.

m
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 ➤
– Remove bolts -2- and -3-.

. Volkswagen AG
gen AG does
– Push coolant pipe -1- to rear and leave
Vol
itksw
there.
a
not
y gu
db ara
rise nte
tho eo
Note au ra
c
ss
ce
le
un
pt
The coolant pipe is shown in figure with oil filter bracket removed.
an
d
itte
y li
rm
ab
– Remove rear right toothed belt guard.
pe
ility
ot
wit
, is n
– Unbolt oil dipstick guide tube from cylinder head arrows and
h re
pull it off upwards.
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
Renew O-ring on oil dipstick guide tube.
l purpos
nform
ercia

der head cover.
m
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.
– Loosen socket head bolts in sequence given and then remove

completely.
– Remove cylinder head and place it on a soft pad (foam rubber).
Note
Do not place cylinder head on the workbench because injectors

and glow plugs could be damaged.
1.12 Installing cylinder head

Passat 1997 ➤

equipment required
♦ Camshaft holder -3458-
♦ Clamping bolt -3242-
1331-
1332-
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
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
WARNING
do
priv
cum
for
en
g

n
t.
yi Co
Cop py
t.
tions:
rig
gh ht
pyri by
Vo
o
by c
lksw
cted agen
Prote
AG.

sitions.
hot components.

Passat 1997 ➤
Note
AG. Volkswagen AG d
♦ Always renew cylinder head bolts. lksw
agen oes
not
Vo gu
by
♦ When working on engine, replace self-locking nuts andisbolts ed ara
nte
tightened to a specified angle as well as gaskets and ut
hoseals.
r eo
ra
s a c
♦ If repairing, carefully remove any remaining gasket
s material
ce
le
from the cylinder head and cylinder block. Ensure that no long
un
pt
an
d
scores or scratches are created. When using abrasive paper
itte
y li
do not use a grade less than 100.
erm
ab
ility
ot p
♦ Carefully remove emery and abrasive remains.
wit
is n
h re
♦ Remove new cylinder head gasket from packaging, just before ole,
spec
installation.
t to the co
♦ Handle gasket very carefully. Damaging the silicone layer or
the indented area will lead to leaks.
♦ Place cylinder head gasket over fitting sleeves. The word -
rrectne
oben- (top) or the Part No. must face towards cylinder head.
s
♦ If the cylinder head is replaced, the entire coolant must also
s o
be renewed.
cial p
f inform
mer
1.12.1 Procedure
atio
om
n
c
i
or
n
– Turn crankshaft and camshaft to TDC marking before fitting
thi
te
cylinder head. Camshaft holder -3458- must be fitted in cam‐
sd
iva
o
r
shaft and locking pin -3242- must be screwed in.

p
cum
r
fo
en
ng
– Fit new cylinder head gasket. Lettering (Part No.) must be

t.
yi Co
op
readable. C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Note Prote AG.
♦ If the cylinder head gasket or cylinder head is replaced, the

new and old gaskets must have the same number of holes.
♦ If parts of the crankshaft assembly have been renewed, the
new cylinder head gasket must be selected by measuring the
piston projection at TDC ⇒ page 45 .
– Renew coolant pipe O-rings before installing cylinder head.

– Fit the cylinder head.
– Insert new cylinder head bolts and tighten hand-tight.

Passat 1997 ➤
– Tighten cylinder head in four stages in sequence shown as

follows:
1- Tighten initially with torque wrench:
Stage I = 35 Nm
Stage II = 60 Nm
2- Turn further with rigid spanner:
Stage III = 1/4 turn (90°)
Stage IV = 1/4 turn (90°)

– When installing right cylinder head, replace O-ring below on
dip stick guide tube. To do this, remove poly-V-belt, loosen
alternator and swing aside.swagen AG. Volkswagen AG does
k not
Vol g
Further assembly is basically
ed
by the reverse of the dismantlingupro‐
ara
nte
cedure. oris eo
th
au ra
– Fit toothed belt
ss onto camshaft pulleys ⇒ page 57 . c
ce
le
un
pt
– Fill coolant system with coolant. ⇒ page 125
an
d
itte
y li
erm
– Bleed fuel system ⇒ page 162 .
ab
ility
ot p
wit
is n
WARNING
h re
ole,
spec
Attempts to start engine before fuel system is bled could lead
t to the co
to injection pump damage.
– After reconnecting battery, enter radio anti-theft code: ⇒ Ra‐ rrectne

dio operating instructions .
ss o
cial p
f in
Note
form
mer
atio
m
Faults will have been stored because the connector to injection

o
n
c
pump has been separated. Therefore read and erase fault mem‐
i
or
n thi
e
ory.
t
sd
iva
o
pr
cum
r
fo
– Reading and erasing fault memory ⇒ page 196 .

en
ng
t.
yi Co
Cop py
ht. rig
1.12.2 Torque settings rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Guide tube for dipstick to cylinder head 10 Nm
Toothed belt guard to cylinder head or 10 Nm
injection pump

Front coolant pipe to M6 10 Nm
cylinder head or cylinder block M8 22 Nm
Oil line to turbocharger 15 Nm
Oil line to intake manifold 22 Nm
Coolant pipe (left-side) to cylinder head 10 Nm
Coolant pipe to compensator 22 Nm

Passat 1997 ➤

Mechanical exhaust gas recirculation valve to 22 Nm
intake manifold
1.13 Checking compression

equipment required
♦ U/J extension and socket,
10 mm -3220-
♦ Compression tester -
V.A.G 1763- with adapter -
V.A.G 1763/5-
♦ Torque wrench -
V.A.G 1331- (5...50 Nm)
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
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
1.13.1 Test prerequisite

ss o
cial p
• Engine oil temperature must be at least 30 °C.

inform
mer

atio
om
n
c

i
or
n thi
te
sd
– Separate connector to injection pump.

iva
o
pr
cum
r
fo
– Remove all glow plugs using jointed spanner -3220- .

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

Passat 1997 ➤
– Screw in adapter -V.A.G 1763/5- in place of glow plugs.

– Check compression using compression tester -V.A.G 1763- .
Note
Using compression tester ⇒ Operating instructions.
– Operate starter until tester shows no further pressure in‐

crease.
Compression pressures: agen
AG. Volkswagen AG d
oes
olksw not
New: 27...33 bar, wear limit: 24 bar ed byV gu
ara
ris nte
o
Maximum permissible difference between all cylinders:
aut
h 5 bar eo
ra
ss c
– Install glow plugs using jointed extension and socket -3220- .
ce
le
un
pt
an
d
Torque setting: 15 Nm.

itte
y li
rm
ab
– Carry out road test and interrogate fault memory
pe
ility
⇒ page 196 .
ot
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
Faults will have been stored because the connector to injection
pump has been separated. Therefore read and erase fault mem‐
rrectness of i
ory.
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Passat 1997 ➤
2 Repairing valve gear
Note
♦ Wait about 30 minutes after installing the camshafts before

starting the engine. Hydraulic valve compensation elements
have to settle (otherwise valves will strike pistons).
♦ After working on valve gear, carefully turn engine over by hand
at least 2 complete revolutions to ensure that no valve strikes
piston when engine is started.
♦ Always renew gaskets and seals.
1 - Inlet camshaft bearing cap

❑ Installation position
⇒ page 88
❑ Lightly coat sealing sur‐
faces of front and rear
bearing caps with seal‐ Volkswagen AG
ant -D 454 300 A2- be‐ swagen AG. does
fore installing byV
olk not
gu
ara
⇒ page 88 rised
nte
ho eo
❑ Installation sequence
aut ra
c
s
⇒ page 90 Removing
s
ce
e
and installing camshaft

nl
pt
du
an
itte
y li
2 - 15 Nm
erm
ab
ility
ot p
3 - 10 Nm
wit
, is n
h re
4 - Exhaust camshaft bearing

hole
cap
spec
es, in part or in w
t to the co
⇒ page 88
❑ Installation sequence
⇒ page 90 Removing
rrectness of i
and installing camshaft

l purpos
5 - Inlet camshaft
nform
ercia
⇒ page 90
m
at
❑ Checking axial clear‐

om
io
ance ⇒ page 88
n
c
in t
or
his
e

at
do
riv
with Plastigage new:

p
cum
or
0.035...0.085 mm, wear

f
en
g
limit: 0.10 mm
n
t.
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op py
❑ Runout: max. 0.04 mm
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6 - Exhaust camshaft
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AG.
⇒ page 90
❑ Checking axial clearance ⇒ page 88
❑ Check radial clearance with Plastigage new: 0.035...0.085 mm, wear limit: 0.10 mm
❑ Runout: max. 0.04 mm
7 - Exhauster pump
❑ For brake servo

Passat 1997 ➤
8 - Axial bearing washer

❑ Qty. 2
9 - Cylinder head
❑ Removing left cylinder head ⇒ page 75
❑ Removing right cylinder head ⇒ page 77 agen AG. Volkswagen AG do
ksw es n
❑ Installing cylinder head ⇒ page 80 by Vol ot g
ua
ed ran
❑ Valve seats are not to be reworked
horis tee
t or
au ac
10 - Hydraulic valve compensation
ss element
ce
e
❑ Checking ⇒ page 94 nl
pt
du
an
itte
❑ Oil contact surfaces
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ab
ility
11 - Exhaust valves
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wit
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❑ Do not rework, only lapping-in is permitted
h re
hole
❑ Valve dimensions ⇒ page 87
spec
es, in part or in w
12 - Inlet valves
t to the co
❑ Do not rework, only lapping-in is permitted
❑ Valve dimensions ⇒ page 87
rrectness of i
13 - Seal
l purpos
nf
ercia
orm
m
15 - 75 Nm
atio
om
n in
c
16 - Valve stem seal

or
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17 - Valve spring
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18 - Valve spring plate t. Cop py
rig
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19 - Valve cotters p by
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by lksw
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20 - Hydraulic valve compensation element Prote AG.
❑ Checking ⇒ page 94
❑ Oil contact surfaces
21 - Rocker finger guide
22 - Rocker finger
Valve dimensions
Note
Valves must not be reworked. Only lapping-in is permitted.
Dimension Inlet valve Exhaust valve

∅a mm 27.00 ... 27.20 24.00 ... 24.20
∅b mm 5.968 ... 5.982 5.958 ... 5.972
c mm 100.35 ... 100.75 100.35 ... 100.75
α ∠° 45 45
2. Repairing valve gear 87

Passat 1997 ➤
Applying sealant to bearing cap

– Lightly coat hatched surfaces of front and rear bearing caps of
inlet camshaft with sealant -D 454 300 A2- and install bearing
caps.
– Do not coat inner surfaces -arrows- with sealant.
Fitting position of camshaft bearing caps

– Note numbering of bearing caps 0 ... 6.
AG. Volkswagen AG d
agen oes
ksw
– Note that bearing caps are not symmetrical. Before installing by V ol not
gu
camshaft, fit bearing caps and determine installation positions.rised ara
nte
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pt
an
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pe
ility
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spec
es, in part or in w
t to the co
rrectness of i
2.1 Checking axial clearance of camshafts
l purpos

♦ Universal dial gauge bracket -VW 387-
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
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.
♦ Dial gauge
Perform check with rocker fingers removed and first and last
bearing caps fitted.

Passat 1997 ➤
– Bolt universal dial gauge bracket -VW 387- with dial gauge to
cylinder head:
Inlet camshaft
Exhaust camshaft
Wear limit: max. 0.30 mm. agen
AG. Volkswagen AG d
oes
olksw not
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pt
du
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itte
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ab
ility
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wit
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h re
hole
spec
es, in part or in w
2.2 Renewing camshaft oil seal
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
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pyri by
Vo
co lksw
by
cted
♦ Fitting sleeves -3241-
agen
Prote AG.

Passat 1997 ➤
2.2.1 Removing
Note
Oil seals should be renewed on both cylinder heads if one oil seal
is leaking.
– Adjust inner part of oil seal extractor -2085- so that it is level

with the outer part and lock in position with knurled screw.
– Lubricate threaded head of oil seal extractor -2085- , place it
in position and exerting firm pressure, screw it as far as pos‐
sible into oil seal.
– Loosen knurled screw and turn inner part of extractor against
camshaft until oil seal has been extracted.
olks
wage es n
o V t gu
by ara
– Clamp flats of oil seal extractor
ris
ed -2085- in vice. Remove oil seal nte
with pliers. utho eo
ra
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ss
ce
le
un
pt
an
d
itte
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ab
pe
ility
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2.2.2 Installing
hole
spec
es, in part or in w
– Lightly oil sealing lip of oil seal.

– Push oil seal onto camshaft taper. t to the co
– Place 3 washers between bolt -3241/7- and fitting sleeve

rrectness of i
-3241/1- .
l purpos
– Press in oil seal flush using fitting sleeve -3241/1- and bolt
-3241/7- .
nform
ercia
– Fit toothed belt onto camshaft pulleys. ⇒ page 65

m
a
com
tion in
r
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thi
s
iva
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cum
fo
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t.
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Cop py
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rig ht
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co Vo
by lksw
cted agen
Prote AG.
2.3 Removing and installing camshafts

Passat 1997 ➤

equipment required
1331- (5...50 Nm)
♦ Camshaft holder -3458-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
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ss
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e
nl
pt
du
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itte
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erm
ab
ility
ot p
wit
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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
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ate
do
priv
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for
en
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op
2.3.1 Removing
C py
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Vo
co
by lksw
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Prote AG.
– Remove cylinder head cover left ⇒ page 70 and right
⇒ page 72 .
– Pull off rear middle toothed belt guard -2- upwards.

Passat 1997 ➤
– Remove retainers of concerned injectors and pull out injectors

upwards.
– Mark installation position of rocker fingers with coloured pen.
– Unbolt camshaft bearing caps and remove camshafts.
Note
When removing camshaft, pay attention to rocker fingers and

guides.
2.3.2 Installing
– Remove threaded stud -arrow- in front of locking slot of ex‐
haust camshaft. agen
AG. Volkswagen AG d
o w es n
olks ot g
– Insert axial bearing washers. byV ua
ed ran
ris tee
– Insert rocker finger guidesaand
utho rocker fingers. or
ac
ss
ce
le
un
pt
Note
an
d
itte
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erm
ab
♦ Note the marked installation position of rocker fingers.
ility
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wit
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♦ If needed, use a little grease to help fit rocker fingers.
h re
ole,
spec
t to the co
– Install inlet camshaft so that the camshaft holder -3458- can
be inserted.
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.
– Note that bearing caps are not symmetrical. Before installing
yi Co
op
camshaft, fit bearing caps and determine installation positions.
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Passat 1997 ➤
– Tighten bearing caps 1 and 5 to 10 Nm.
Note
Note the numbering on the bearing caps.
– Install outlet camshaft so that the camshaft holder -3458- can

be inserted.
– Tighten bearing caps 0 and 4 to 10 Nm.
– Check adjustment again using camshaft holder -3458- .
– Check fitting position of rocker fingers and guides.
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
– Lightly coat hatched surfaces of front and rear bearing caps of
rm
ab
inlet camshaft with sealant -D 454 300 A2- and tighten bearing
pe
ility
ot
caps to 15 Nm.
wit
, is n
– Do not coat inner surfaces -arrows- with sealant. h re

hole
spec
es, in part or in w
– Tighten remaining bearing caps to 10 Nm.

t to the co
– Install threaded stud.

rrectness of i
cedure.
l purpos
Note
nform
mercia
Always renew copper seals and O-rings between cylinder head

a
com
tio
and injectors.
n in
r
te o
thi
s
iva
– Make sure that injectors are properly seated.

do
r
rp
cum
fo
– Install retainers and tighten to 10 Nm.

en
ng
t.
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op
– Fit toothed belt onto camshaft pulleys ⇒ page 65 .
C py
t. rig
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– Install cylinder head covers left ⇒ page 70 and right
op Vo
by c lksw
⇒ page 72 . cted agen
Prote AG.
Note


Passat 1997 ➤
2.4 Checking hydraulic valve compensation

elements
♦ Feeler gauges
♦ Wood or plastic wedge
Note
♦ Hydraulic valve compensation elements cannot be serviced.

♦ Irregular valve noises when starting engine are normal.

– Start engine and run until radiator fan has switched on once.
– Increase engine speed to about 2500 rpm for approx. 2 mi‐
nutes.
Note
If irregular valve noises disappear during starting but recur during

short trips, the oil check valve must be replaced. The oil check
valve is located in the oil filter bracket ⇒ page 112 .
If the hydraulic compensation elements are still noisy, determine

the defective element as follows:
– Remove cylinder head cover left ⇒ page 70 and right AG. Volkswagen AG d
agen
⇒ page 72 . olksw
oes
not
byV gu
ara
d
– Turn crankshaft clockwise until cams of bucket tappets to orisbe
e nte
eo
checked are pointing upwards. aut
h
ra
ss c
– Determine clearance between cam and roller rocker finger.
ce
e
nl
pt
du
an
– Push bucket tappet down lightly with a wooden or plastic
itte
y li
erm
wedge. If play develops between cam and rocker finger, the
ab
ility
hydraulic compensation element needs to be replaced.
ot p
wit
, is n
h re
hole
Note spec
es, in part or in w
t to the co

rrectness of i

l purpos

nform
ercia
2.5 Renewing valve stem seals

m
at
om
ion
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in t
or
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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.

Passat 1997 ➤

equipment required
♦ Valve lever -VW 541/1A-
with press tool -VW 541/6-
♦ Valve assembly appliance
-2036- with adapter plates
-2036/1-
♦ U/J extension and socket,
10 mm -3220-
♦ Puller -3364-
♦ Fitting tool -3365-
♦
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
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aut ra
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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
2.5.1 Removing
nform
ercia
– Remove all glow plugs using jointed spanner -3220- .

m
at
om
ion
– Remove cylinder head left ⇒ page 75 and right ⇒ page 77 .

c
in t
or
his
te
– Remove camshafts. ⇒ page 90

a
do
priv
cum
or
– Insert valve assembly device -2036- with adapter plates

f
en
ng
-2036/1- and adjust mounting to height of studs.

t.
yi Co
Cop py
t.
– Remove valve springs using valve lever -VW 541/1A- and
rig
gh ht
yri by
press tool -VW 541/6- . op Vo
by c lksw
cted agen
Prote
– Pull off valve stem seals using puller -3364- .
AG.

AG. Volkswagen AG d
agen oes
olksw not
V
Passat 1997 ➤ d by gu
ara
ise nte
6-cylinder dieselthoengine - Edition 11.2003
r eo
au ra
ss c
2.5.2 Installing
ce
e
nl
pt
du
an
itte
y li
– Place the plastic sleeve -A- supplied on the respective valve erm
ab
stem. This will prevent the new valve stem seal -B- being
ility
ot p
damaged.
wit
, is n
h re
– Place new valve stem seal in fitting tool -3365- .
hole
spec
– Lubricate sealing lip of valve stem seal and carefully push onto
es, in part or in w
t to the co
valve guide.
– Install cylinder head covers left ⇒ page 70 and right
⇒ page 72 .
rrectness of i
l purpos
cedure.
nf
ercia
orm
2.6 Checking valve guides
m
atio
om
n in
c

or
thi
te
sd
a
♦ Universal dial gauge bracket -VW 387-

iv
o
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rp
cu
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m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Dial gauge
– Insert new valve into guide. The end of the valve stem must
be flush with the guide. Due to differences in stem diameters,
use only an inlet valve in inlet guide and an exhaust valve in
exhaust guide.
– Determine rock. Wear limit: inlet valve guide = 1.0 mm; ex‐
haust valve guide = 1.3 mm

Passat 1997 ➤
17 – Lubrication
1 Removing and installing parts of lu‐
brication system
Note
♦ If large quantities of swarf as well as fine metal particles

(caused, for example, by partial seizure of the crankshaft or
conrod bearings) are found in the engine oil when performing
repairs, clean the oil passages thoroughly and renew the oil
cooler in order to prevent subsequent damage.
♦ The oil level must not be above the max. mark - danger of
damage to catalytic converter! G. Volkswagen
nA AG do
wage es n
Volks ot g
Checking oil pressure ed ⇒ page 115
by ua
ran
oris tee
1.1 Engine oil
ss
au
th or
ac
ce
e
nl
pt
du
an
itte
1.1.1 Oil capacities:

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erm
ab
ility
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Engine codes AFB and AKN with oil filter 5.4l3)

wit
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Engine codes BAU, BDH and BDG with oil filter 5.0l3) h re
hole
spec
3) Up-to-date figures: ⇒ Data sheets for exhaust emission test
es, in part or in w
t to the co
1.1.2 Engine oil specification: vehicles with no

long-life service
rrectness of i
Use engine oils conforming to VW standard 505 00 or 505 01.

l purpos
1.1.3 Engine oil specifications: vehicles 06.99

nform
ercia
▸ with long-life service

m
at
om
Use engine oils conforming to VW standard 506 00 or 503 00.

ion
c
in t
or
his
ate
do
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Note
p
cum
for
en
ng
t.
Engine oils conforming to VW standard 505 00 or 505 01 can
yi Co
op
continue to be used. The oil must then be changed every 12
C py
ht. rig
months or every 15,000 km and the service interval display must
rig ht
py by
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be programmed accordingly. Procedure: ⇒ Maintenance ; Book‐ by c lksw
cted agen
let . Prote AG.
1.1.4 Part I
Part II Dismantling oil filter bracket ⇒ page 100
1. Removing and installing parts of lubrication system 97

Passat 1997 ➤
1 - 10 Nm
❑ Tighten in stages and in
diagonal sequence
2 - Oil sump, lower part
❑ Engine codes AKN,
BAU, BDH and BDG:
with oil level/oil temper‐
ature sender -G266-
⇒ page 103
3 - Chain guard
4 - Gasket
❑ Moulded gasket to ap‐
prox. 11.98
❑ Renew
❑ Gasket discontinued as
off approx. 12.98
❑ Install with silicone seal‐
ant -D 176 404 A2-
5 - 10 Nm
6 - 22 Nm
7 - Oil pump
❑ With pressure control
valve 3.8 bar
❑ With 11-bar pressure re‐
lief valve
❑ Removing and instal‐
ling, ⇒ page 105
8 - Chain
⇒ page 29 AG. Volkswagen AG d
agen oes
lksw not
9 - Oil pump chain sprocket by Vo gu
ara
d
ise nte
10 - 25 Nm uthor eo
a ra
s c
11 - 10 Nm s
ce
e
nl
pt
du
an
itte
y li
erm
ab
13 - Oil distribution line

ility
ot p
❑ From oil pump to counterbalance shaft housing

wit
, is n
h re
14 - Bolt
hole
spec
❑ Torque setting on cylinder block 13 Nm

es, in part or in w
t to the co
❑ Torque setting on sealing flange 10 Nm

15 - 45 Nm
rrectness of i
16 - Torque reaction support

l purpos
17 - O-ring
❑ Renew
nf
ercia
or
18 - Guide tube
m
m
atio
m
o
n in
or c
thi
19 - Gasket
te
sd
iva
❑ Gasket discontinued
r
rp
cu
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m
f
❑ Install with silicone sealant -D176404A2-

en
ng
t.
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Cop py
t. rig
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98
cop Vo
by lksw
Rep. Gr.17 - Lubrication Prote
cted AG.
agen
Passat 1997 ➤
20 - Oil sump, upper part

21 - 45 Nm
23 - Oil pressure line
24 - 45 Nm
25 - Counterbalance shaft housing
❑ With counterbalance shaft
26 - Idler sprocket
27 - 10 Nm
28 - Baffle
29 - 10 Nm
30 - Oil drain plug, 25 Nm
31 - Seal
❑ Renew
32 - 10 Nm
33 - Oil level/oil temperature sender -G266-
❑ Only installed on engines with code AKN, BAU, BDH or BDG
34 - Seal
❑ Renew
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au 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
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
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤
1.1.5 Part II
1 - Gasket
❑ Renew
2 - Oil supply line
❑ To turbocharger
3 - O-ring
❑ Renew
4 - 10 Nm
5 - Oil seals
❑ Renew
6 - Oil temperature sender -
G8- , 15 Nm
7 - Oil temperature sender , 15
Nm
❑ Function only in con‐ agen
AG. Volkswagen AG d
oes
junction with optional olksw not
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equipment d by ara
ise nte
or eo
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8 - Oil pressure switch -F1- s aut ra
c
s
❑ 1.9 bar switch: grey
ce
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nl
pt
du
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itte
y li
erm
ab
ility
ot p
9 - 22 Nm
wit
, is n
h re
hole
spec
es, in part or in w
11 - Oil filter element
t to the co
12 - O-ring
❑ Renew
rrectness of i
13 - Cap
l purpos
14 - 10 Nm nf
ercia
orm
m
15 - Heat shield
atio
om
n in
c
16 - Retaining ring
or
thi
te
sd
a
17 - Connection
iv
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r
rp
cu
❑ For crankcase breather

o
m
f
en
ng
t.
yi
❑ Clean strainer if soiled
Co
Cop py
t. rig
18 - Seal
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pyri by
Vo
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by c
❑ Renew
lksw
cted agen
Prote AG.
19 - 10 Nm
20 - Cover
❑ For pressure regulation valve
21 - Diaphragm
22 - Pressure plate
23 - Spring
100 Rep. Gr.17 - Lubrication

Passat 1997 ➤
24 - 10 Nm
❑ Tighten bolts in diagonal sequence
25 - Oil filter bracket
❑ With crankcase breather
❑ With pressure regulation valve for crankcase breather
❑ With filter bypass valve, 2.5 bar
❑ Ensure secure seating of oil filter element guide tube
1.2 Removing and installing oil filter bracket

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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au ra
ss c
ce
le
un
pt
an
d
itte
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ab
ility
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spec
t to the co
1.2.1 Removing
– Remove injection pump ⇒ page 183 .
rrectne
– Remove turbocharger ⇒ page 169 .
s
Vehicles with no coolant cooled exhaust gas recirculation:
s o
cial p
f i
– Remove left bolt on mechanical exhaust recirculation valve
nform
-2-.
mer
atio
m
– Unscrew nuts -1-.

o
n
c
i
or
n thi
– Remove exhaust recirculation pipe -3-.
te
sd
iva
o
r
Vehicles with coolant cooled exhaust gas recirculation:

p
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 ➤
– Remove left bolt on mechanical exhaust recirculation valve

-3-.
– Detach coolant hose -4- from cooler for exhaust gas recircu‐
lation.
– Remove cooler -1- for exhaust recirculation.
Continuation for all vehicles
– Loosen coolant pipe securing bolt -arrow-.
– Remove bolt -2- for oil line -1-.

– Pull off oil line -1-. n AG. Volkswagen AG do
lkswage es n
– Unscrew securing d b bolts
yV
o
-arrows-. ot g
ua
ran
ir se tee
– Press coolant
uth pipe aside and remove oil filter bracket.
o
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
1.2.2 Installing
nform
mercia

at
om
ion
c
in t
or
his
ate
Note
do
priv
cum
for
en

ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
102
co Vo
by lksw
Rep. Gr.17 - Lubrication cted agen
Prote AG.
Passat 1997 ➤
– Install injection pump ⇒ page 25 .

– Install turbocharger ⇒ page 172 .

ting
Oil filter bracket to cylinder block 10 Nm
Mechanical exhaust gas recirculation valve to in‐ 22 Nm
take manifold
Exhaust gas recirculation pipe to compensator 22 Nm
Exhaust gas recirculation pipe to front intake 10 Nm
manifold
1.3 Removing and installing lower part of

sump
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au 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
♦ Silicone sealant -D 176 404 A2-
1.3.1 Removing
rrectness of i
l purpos
– Remove noise insulation tray. ⇒ General body repairs, exte‐

rior; Rep. Gr. 50 ; Body - front; noise insulation .
nf
ercia
– Drain engine oil.

orm
m
atio
om
n in
c
– Remove bracket for ATF pipes on right of sump -2-.

or
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
cted agen
Prote AG.

Passat 1997 ➤

– Remove both refrigerant line brackets -1- and -3- from sump.

– Remove air hose between right charge air cooler and lock
carrier -arrow-.
– Unbolt anti-roll bar from subframe -2- and swivel downwards n AG. Volkswagen AG do
around mounting points -1-. olks
wage es n
o
yV t gu
db ara
rise nte
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
spec
es, in part or in w
t to the co
– Unbolt sump - lower part -1- and carefully remove downwards.

rrectness of i
Note
l purpos
♦ Be careful of chain guard in sump when removing sump - lower

part.
nform
ercia
♦ Pull connector off oil level/oil temperature sender -G266- .

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
op
1.3.4 Installing C py
t. rig
gh ht
pyri by
o Vo
by c lksw
cted agen
Prote AG.

Passat 1997 ➤
Note
– Clean sealing surfaces.

gen AG
They
. Volkswmust
agen Abe
G dfree of oil and grease.
a oes
lksw n
– Use a new db
gasket
yV
o
or silicone sealant -D 176ot g
404
ua A2- when
installing
o
ir se the lower part of the sump. If a gasket awas
r n
tee installed
originally
auth then a gasket must be installed again. or
a
ss c
– Position lower part of sump and fit bolts, then tighten all bolts
ce
le
un
pt
hand-tight to 10 Nm using diagonal sequence.
an
d
itte
y li
– Reconnect connector for oil level/oil temperature sender -
erm
ab
ility
G266- .
ot p
wit
is n
– Fill coolant system with coolant ⇒ page 125 .
h re
ole,
spec
– Fill up with engine oil and check oil level.
t to the co
1.4 Removing and installing oil pump
rrectne
equipment required
ss o
♦ Locking pin -3204-
cial p
♦ Clamping bolt -3242- f inform

mer
atio
m

o
n
c
i
or

thi
te
sd
a
1331- (5...50 Nm)

iv
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.
1.4.1 Removing

Passat 1997 ➤

– Open oil filler cap.
– Turn engine over by hand in direction of rotation until “- OT
-” (TDC) is visible on camshaft.
Note
Use crankshaft centre bolt to turn engine over by hand.
– Remove sealing plug from left cylinder block. The TDC drilling
in the crankshaft must be visible (or able to be felt) in the seal‐
ing plug hole. AG. Volkswagen A gen G do
swa es
– Screw locking pin -3242-
by
Vol into hole. This stops the crankshaft
k not
gu
turning. ris
ed ara
nte
tho eo
– Remove bottom
ss
au section of sump ⇒ page 103 . ra
c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Remove bolts -1- and remove baffle.

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
– Lock counterbalance shaft with locking pin -3204- .

um
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 oil pump sprocket bolt -1- but do not remove bolt.
– Loosen counterbalance shaft sprocket bolt -3-.
– Remove banjo bolt -4- and hexagon bolt -2- and remove oil
line to counterbalance shaft.
wage es n
– Remove oil pressure line -arrows-. yV
olks ot g
ua
d b ran
ir se tee
tho
u or
Note ss
a ac
ce
le
un
pt
Caution, oil will flow out of pump.
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Use a screwdriver to push drive chain upwards.
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
– Remove drive chain idler sprocket bolts -arrows-. pyri by
Vo
co lksw
by
cted
– Remove idler wheel and chain sprocket for oil pump.
agen
Prote AG.
– Remove oil pump.

Passat 1997 ➤
1.4.2 Installing
Note
– Check that locking pin -3242- is screwed in. AG. Volkswagen AG d

agen oes
ksw
– Lock counterbalance shaft with locking pin -3204-by. Vol not
gu
ara
d
rise nte
tho eo
au 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
– Now first tighten chain sprocket bolt -3-.
rrectness of i
– Install lower part of sump ⇒ page 103 .
l purpos
– Install poly-V-belt ⇒ page 24 .
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.
1.5 Removing and installing upper part of sump

Passat 1997 ➤

equipment required
♦ Support bracket -10-222A-AG. Volkswagen AG d
agen
with adaptersVo-10-222A/1- oes
lksw not
y gu
db ara
♦ Lifting otackle
ris
e -2024 A- nte
h eo
ut ra
♦ Drip
ss tray -V.A.G 1306-
a c
ce
e
nl
pt
du
an
1331-
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
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 agen
Prote AG.
Note
Before carrying out further work, disconnect battery earth strap.

First check whether a coded radio is fitted. Obtain radio code first
if necessary.
1.5.1 Removing
– Open cap on coolant expansion tank.
– Remove dip stick guide tube.

– Remove power assisted steering reservoir cover.

Passat 1997 ➤
lkswage es n
Vo ot g
– Separate connector for air conditioningedcompressor
by magnetic ua
ran
horis tee
ut 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
– Remove both refrigerant line brackets -1- and -3- from sump.
rrectne
– Remove bracket for ATF pipes -2- on right of sump.
ss o
cial p
f i
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
yri by
cop Vo
by lksw
cted agen
Prote AG.
– Remove alternator. ⇒ Electrical system; Rep. Gr. 27 ; Alter‐
nator .
– Remove starter. ⇒ Electrical system; Rep. Gr. 27 ; Starter;
Removing and installing starter .
– Drain engine oil.
– Unbolt lower part of sump -1- and carefully remove forwards
⇒ page 103 .
Note
Be careful of chain guard in sump when removing sump - lower

part.
– Loosen both left and right engine mounting nuts -1- until they
are flush with lower edge of threaded stud (about 4 threads).
– Set up support bracket -10-222A- with legs -10-222A/1- on
wing panel flanges.

Passat 1997 ➤
– Remove lifting eye from lifting tackle -2024 A- .

– Re-insert pin -1- in centre hole of lifting tackle -2024 A- and
secure with split pin.
– Hang the pin of lifting tackle -2024 A- onto the spindle of sup‐
port bracket -10-222A- .
– Engage lifting tackle -2024 A- in front and rear lifting eyes on
engine.
WARNING
The hooks and locating pins must be secured with locking pins.
– Raise engine as far as possible with spindles of support brack‐

et -10-222A- .
Note
Raise engine only so far that no pipes or coolant hoses will be

damaged or stretched.
wage es n
– Remove oil pump ⇒ page 105 yV
.olks ot g
d b ua
e ran
– Remove engine/gearbox horissecuring bolts in the region of sump tee
- upper part. aut or
ac
ss
– Remove dip stick guide tube. ce
e
nl
pt
du
an
itte
– Remove bolts -1- and -2- for sump - upper part. y li

erm
ab
ility
ot p
– Press sump - upper part from cylinder block spring pins. wit
, is n
h re
– Push sump - upper part towards left of vehicle and remove it.
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
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
Note
by lksw
cted agen
Prote AG.
♦ The counterbalance shaft housing can be removed from the

upper part of the sump -arrows-.
♦ To renew sump - upper part, remove torque reaction support

Passat 1997 ➤
1.5.4 Installing
Note
– Clean sealing surfaces before installing sump - upper part.

– Install sump with silicone sealant -D 176 404 A2- .
– Put sump - upper part in place and diagonally hand-tighten all
sump - upper part/cylinder block bolts.
– Diagonally tighten sump - upper part/cylinder block bolts:
1- 10 Nm
2- 13 Nm
– Tighten upper part of sump to gearbox bolts to 45 Nm.
– Install oil pump ⇒ page 105 .
– Install lower part of sump ⇒ page 103 .
– Remove support bracket -10-222A- .
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
– Tighten both left and right engine mounting nuts -1- to 20 Nm.
ility
ot
wit
, is n
h re
hole
spec
– Allow torque reaction support to move under own weight onto
es, in part or in w
torque reaction support buffer and tighten to 25 Nm.
t to the co
– Fill coolant system with coolant ⇒ page 125 .
rrectness of i
l purpos
nform
mercia
a
com
ti
1.6 Renewing oil check valve

on in
r
te o
thi
s
iva
do
r
rp
Note
um
fo
en
ng
t.
yi Co
op
If irregular valve noises disappear during longer trips but recur C py
t. rig
during short trips, the oil check valve must be replaced.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤
– Remove oil filter bracket ⇒ page 101 .

1- O-ring, renew.
2- O-ring, renew.
AG. Volkswagen AG d
3- Left cylinder head oil check valve, 20 Nm. agen oes
olksw not
y V gu
b ara
4- Banjo bolt, 15 Nm rise
d
nte
tho eo
u
5- Piston cooling spray jet, 20 Nm. ss a ra
c
ce
le
6- Oil line.
un
pt
an
d
itte
y li
7- O-ring, renew.
erm
ab
ility
ot p
8- Right cylinder head oil check valve, 20 Nm.
wit
is n
h re
9- O-ring, renew.
ole,
spec
1.7 Removing and installing oil cooler
t to the co
rrectne
equipment required
s
s o
cial p
f in
form
mer
atio
m
1331- (5...50 Nm)

o
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.
1.7.1 Removing

Passat 1997 ➤

– Unbolt poly-V-belt pulley at vane pump -arrows-, using 2-hole
pin wrench -3212- as a counterhold.
– Unbolt vane pump from bracket and place vane pump on lon‐
gitudinal member.
Note
The vane pump hoses remain connected.

– Remove power assisted steering reservoir cover.
– Separate connector for air conditioning compressor magnetic

– Loosen hose clamps -arrows- and push clamps back on ho‐
ses. G. Volkswagen nA AG do
wage es n
yV
olks ot g
ua
b
ed ran
– Pull rear hose off oil cooler. horis tee
ut or
ac
– Remove bolted connection s a and remove
s-1- oil cooler.
ce
le
un
pt
an
d
itte
WARNING
y li
erm
ab
ility
ot p
Oil and coolant will flow out.

wit
is n
h re
ole,
spec
1.7.4 Installing
t to the co

rrectne

ss o
cial p

inform
mer
atio

om
ting
c
i
or
n thi
e
Power assisted steering vane pump to bracket for 22 Nm

t
sd
iva
vane pump and oil cooler

pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
114
by lksw
cted agen
Rep. Gr.17 - Lubrication Prote AG.
Passat 1997 ➤

ting
Air conditioning compressor bracket to bracket 22 Nm
for vane pump and oil cooler or to sump - upper
part.
Belt pulley for power steering vane pump 22 Nm
Oil cooler to bracket for vane pump and oil cooler 25 Nm
1.8 Checking oil pressure and oil pressure

switch
1.8.1 Function of dynamic oil pressure warn‐

ing system
Checking warning lamp
After the ignition is switched on (“Terminal 15 on”) and engine is
not running, the oil pressure warning lamp lights up (not in vehi‐
cles with auto-check system).
Criteria for warning
• Engine is not running and oil pressure switch is closed.
• Coolant temperature below 60 °C, engine speed above 300
rpm and oil pressure switch open.
• Coolant temperature above 60 °C, engine speed above 1,500
rpm and oil pressure switch open. gen AG
. Volkswagen AG
d a oes
lksw not
• At engine speeds above 5,000 rpm, an active oil warning
db
yV
o
will gu
ara
not be cancelled regardless of state of oil pressure
oris switch.
e nte
eo
h
ut ra
• If the oil pressure switch is open for longerssthan
a 0.5 seconds c
at engine speeds above 1,500 rpm, the incident will be stored.
ce
le
un
pt
If this situation occurs three times during one trip, the warning
an
d
itte
remains or will remain active at engine speeds below 1,300
y li
rm
ab
rpm.
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.

Passat 1997 ➤

equipment required
♦ Oil pressure tester -
V.A.G 1342-
♦ Diode test lamp -
V.A.G 1527 B-
♦ Auxiliary measuring set -
V.A.G 1594 A-
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
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n
Note
thi
te
sd
iva
o
r
♦ Oil level OK.

p
cum
r
fo
en
ng
t.
♦ Oil warning lamp -K3- must light up when ignition is turned on.
yi Co
Cop py
ht. rig
♦ In vehicles with auto-check system, the “OK” display must light rig ht
py by
up (select symbol). co Vo
by lksw
cted agen
Prote AG.
♦ Engine oil temperature approx. 80 °C.

Passat 1997 ➤

– Remove oil pressure switch -F1- and screw into oil pressure
tester -V.A.G 1342- .
– Screw tester into oil filter bracket in place of the oil pressure
switch. agen
AG. Volkswagen AG d
oes n w
ot g olks
– Connect brown wire of tester eto
d bearth (-).
yV ua
ran
ir s tee
– Connect voltage tester -V.A.G
autho
1527 B- to battery positive (+) or
ac
and oil pressure switchssusing cables from auxiliary test set -
V.A.G 1594 A- . LED must not light up.
ce
le
un
pt
an
d
itte
– Start engine.
y li
erm
ab
♦ At 0.75 ... 1.6 bar the LED must light up; otherwise renew oil
ility
ot p
pressure switch.
wit
is n
h re
ole,
– If the LED does not light up, renew oil pressure switch.
spec
t to the co
Note
rrectne
Observe tester and LED while starting, as switching point of oil
pressure switch may already be exceeded when starting.
ss o
♦ Oil pressure at idling speed: at least 0.8 bar
cial p
f inform
♦ Oil pressure 2,000 rpm: min. 2.0 bar
mer
atio
m
♦ Oil pressure at higher engine speeds: max. 7.0 bar

o
n
c
i
or
n thi
If the specifications are not attained
te
sd
iva
o
pr
c
– Renew oil pump ⇒ page 105 .
um
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 ➤
19 – Cooling
1 Removing and installing parts of cool‐
ing system
WARNING

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

sure. If necessary, release pressure before beginning repair
work.
♦ Hoses are secured with spring-type clips. In case of repair,
only use spring-type clips.
♦ Spring-type clip pliers -VAS 5024- or hose clip pliers -
V.A.G 1921- are recommended for fitting spring-type clips.
♦ When installing coolant hoses, route stress-free so that they
do not come into contact with other componentsAG. V(observe
olkswagen AG
markings on coolant connection and ohose).
lksw
agen does
no
V t gu
by
♦ Always renew gaskets and seals.
ris
ed
ara
nte
tho eo
au ra
c
Perform cooling system using cooling system tester leakage
ss
test
ce
e
-V.A.G 1274- , adapter -V.A.G 1274/8- and adapter -

nl
pt
du
an
V.A.G 1274/9- .
itte
y li
erm
ab
Parts of cooling system - body side ⇒ page 118 .

ility
ot p
wit
Removing and installing viscous fan ⇒ page 20

, is n
h re
hole
1.1 Parts of cooling system - body side

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
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 agen
Prote
118
AG.
Rep. Gr.19 - Cooling
Passat 1997 ➤
1 - Cooler
⇒ page 134
❑ After renewing, renew
entire coolant
❑ With AFT cooler on ve‐
hicles with automatic
gearbox: ⇒ 5-speed au‐
tomatic gearbox 01V;
Rep. Gr. 37 ; Disman‐
tling and assembling
gearbox; Removing and
installing ATF lines on
vehicles with a V6 TDI
engine .
❑ Cleaning ATF cooler: ⇒
5-speed automatic
gearbox 01V; Rep. Gr.
37 ; Dismantling and as‐
sembling gearbox;
Cleaning ATF lines and
ATF cooler
2 - Securing clip
3 - Rubber mounting
4 - Rubber washer
5 - O-ring
6 - Connector
❑ For radiator fan thermal
switch
7 - Radiator fan thermal switch
-F18- , 35 Nm AG. Volkswagen AG d
agen oes
olksw not
❑ For electric fan ed by V gu
ara
is nte
❑ Switching tempera‐
ut
hor eo
tures: ss a ra
c
❑ 1st stage on 92...97 °C, off 84...91 °C
ce
e
nl
pt
du
an
❑ 2nd stage on 99...105 °C, off 91...98 °C

itte
y li
erm
ab
8 - Bottom coolant hose

ility
ot p
wit
❑ Secured to radiator with retaining clip

, is n
h re
❑ Check for secure seating

hole
spec
es, in part or in w
9 - Seal
t to the co
❑ Renew
10 - Locking bolt
rrectness of i
11 - 10 Nm
l purpos
12 - Fan ring
❑ Clipped into air shroud and secured with locking bolt ⇒ Item 10 (page 119)
nform
mercia
13 - 2-pin connector
at
om
ion
c
14 - Radiator fan -V7-

in t
or
his
ate
15 - Drain plug, 10 Nm
do
priv
cum
or
16 - Top coolant hose

f
en
ng
t.
yi Co
❑ Secured to radiator with retaining clip t. Cop py
rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Removing and installing parts of cooling system 119

wage es n
Passat 1997 ➤y Vo lks ot g
b ua
6-cylinder diesel
ir se
d engine - Edition 11.2003 ran
tee
tho
u or
a ac
1.2 ss Coolant pump and thermostat
ce
e
nl
pt
du
an
itte
y li
1 - 10 Nm
erm
ab
ility
ot p
❑ Insert with locking fluid -
wit
, is n
D 000 600 A2-
h re
hole
spec
2 - 10 Nm
es, in part or in w
t to the co
3 - 25 Nm
4 - Seal
rrectness of i
❑ Renew
l purpos
5 - Thermostat housing
6 - O-ring
nf
ercia
❑ Renew
orm
m
atio
7 - Thermostat
om
n in
c

or
thi
e
⇒ page 126
t
sd
iva
o
r
rp
cu
o
m
f
⇒ page 120
en
ng
t.
yi Co
op
❑ Checking: Heat thermo‐ C py
t. rig
stat in water
gh ht
pyri by
Vo
o
❑ Opening begins at ap‐
c by lksw
cted agen
prox. 87 °C
Prote AG.
❑ Ends at approx. 102 °C

❑ Opening lift min. 8 mm
8 - Gasket
❑ Renew
9 - Coolant pump
⇒ page 125
❑ Check for ease of move‐
ment
10 - 10 Nm
Installation position of thermostat

♦ Bleed valve -arrow- facing upwards
♦ Housing seal
120 Rep. Gr.19 - Cooling

Passat 1997 ➤
1.3 Overview - coolant pipes
1 - 10 Nm
2 - 22 Nm
3 - O-ring
❑ Renew
4 - Coolant temperature send‐
er -G62-
❑ With coolant tempera‐
ture sender -G2-
5 - Retaining clip
6 - Right coolant pipe
⇒ page 134
7 - Bracket
8 - Left upper coolant pipe
❑ Removing and installing lkswage es n
o ot g
⇒ page 132 byV ua
d ran
ir se tee
o
9 - Lower left coolant pipe auth or
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ss
ce
le
⇒ page 132
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10 - Hose
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ab
pe
ility
11 - Front coolant pipe
ot
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hole
⇒ page 131
spec
es, in part or in w
t to the co
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AG. Volkswagen AG d
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Passat 1997 ➤ by
Vo l not
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6-cylinder diesel engine - Edition
orise 11.2003 nte
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1.4 Draining and filling coolant s
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nl
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equipment required
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♦ Refractometer -T10007-
hole
spec
es, in part or in w
t to the co
♦ Spring-type clip pliers -
VAS 5024 A-
rrectness of i
♦ Cooling system charge unit
-VAS 6096-
l purpos
♦ Adapter -V.A.G 1274/8-
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1.4.1 Draining
Note
Follow disposal regulations for coolant!
WARNING
Hot steam may escape when expansion tank is opened. Place

cloth over cap and open with caution.
– Open cap on coolant expansion tank.


Passat 1997 ➤
– Drain coolant from engine using drain plug -arrow-.
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– Pull off bottom coolant hose retaining clip -arrow- and remove
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ab
coolant hose from radiator.
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cial p
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1.4.2 Vehicles with no air conditioner
mer
atio
om
– Pull oil cooler hose -arrow- off left side of engine. n

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– Unbolt coolant expansion tank -arrows 1-.
– Pull off wiring to coolant shortage indicator switch -F66- and
set coolant expansion tank to side.
Note
Coolant hoses -2- remain connected.

Passat 1997 ➤
– Pull off coolant hose -arrow- and press it down to drain coolant.
AG. Volkswagen AG d
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Prote AG.

Passat 1997 ➤
1.4.4 Filling
Note
♦ Only use coolant additive G 12 in accordance with

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

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-35 °C
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an
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– Fit the lower coolant hose.

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– Fit coolant hose to oil cooler or to upper coolant pipe.

wit
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– Install noise insulation tray. ⇒ General body repairs, exterior;

hole
spec
Rep. Gr. 50 ; Body - front; noise insulation .

es, in part or in w
t to the co
– Screw adapter -V.A.G 1274/8- onto expansion tank.

– Fill coolant circuit using cooling system charge unit -
rrectness of i
VAS 6096- . ⇒ Operating instructions for cooling system

charge unit VAS 6096.
l purpos
1.5 Removing and installing coolant pump

nf
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1. Removing and installing parts of cooling system
AG. Volkswagen AG d
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Passat o1997
ris
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6-cylinder
s aut
diesel engine - Edition 11.2003 ra
c
s
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♦ Torque wrench -V.A.G 1331- nl
pt
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1.5.1 Removing
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– Remove toothed belt ⇒ page 52 .
f
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op
– Remove front intake manifold. ⇒ page 50
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– Pull off rear middle toothed belt guard -2- upwards. cop Vo
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AG.
– Remove securing bolts -arrows- from coolant pump and re‐

move coolant pump.
1.5.2 Installing
note the following:
– Fit coolant pump with a new gasket to cylinder block and tight‐
en all securing bolts to 10 Nm.
– Install toothed belt. ⇒ page 52
1.6 Removing and installing thermostat

Passat 1997 ➤

equipment required
♦ Socket, 22 mm -3078-
♦ Locking pin -T40011-
1331-
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1.6.1 Removing spec

es, in part or in w
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Note
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Use crankshaft centre bolt to turn engine over by hand.

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the crankshaft must be visible (or able to be felt) in the sealing . C rig
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plug hole.
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Passat 1997 ➤ wage
n AG does
olks not
6-cylinder diesel engine -d Edition
by
V 11.2003 gu
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– Screw locking pin -3242-s auinto hole.
t
This stops the crankshaft ra
c
turning. s
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nl
pt
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ab
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove vibration damper for injection pump pulley (bolts

-1-).
nf
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Note
atio
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n in
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op
– Mark direction of rotation of toothed belt. C py
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toothed belt. Prote
cted AG.
agen
– Remove the 8 securing bolts -1- and remove crankshaft vi‐

bration damper.
Note
Loosening centre bolt is not required to remove vibration damper.
– Unbolt bottom section of toothed belt guard -4-.

– Unbolt viscous fan drive pulley.
– Remove viscous fan bracket with idler roller (bolts -1-, -2- and
-3-).

Passat 1997 ➤
– Unbolt drive pulley -1- for injection pump from camshaft pulley
-arrows-.
wage
– Turn toothed belt tensioning roller in direction
olks of arrow with 8 es n
ot g
yV
mm hexagon key until the tensioning d lever of the tensioning
b ua
ran
ir se
element is so compressed thatth the locking pin -T40011- fits in
o tee
or
the hole and in the plunger.ss au ac
ce
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nl
pt
du
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Note
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ab
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The toothed belt tensioner is oil-damped and can therefore only
wit
, is n
be compressed slowly by applying constant pressure.
h re
hole
spec
es, in part or in w
t to the co
– Pull toothed belt slightly forward from tensioning roller
rrectness of i
-arrow-.
l purpos
– Remove coolant hose from thermostat housing.

– Remove thermostat housing (bolts -1-, -2- and -3-).
nf
ercia
o
– Remove thermostat.
rm
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1.6.2 Installing
ht
pyri by
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cted agen
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AG.
note the following:

– Moisten new O-ring with coolant.
– Insert thermostat into engine block.
Note
The thermostat bleeder valve -arrow- must be on top.
– Install thermostat housing.

Passat 1997 ➤
– Insert bolts -2- and -3- with locking fluid -D 000 600 A2- .
– Push toothed belt back.
– Release tension on toothed belt tensioning roller with 8 mm
hexagon key and pull out locking pin for hydraulic tensioner.
– Tension toothed belt by turning belt in direction of arrow with

torque wrench to 15 Nm.
AG. Volkswagen AG d
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nl
pt
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ab
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– Tighten viscous fan bracket:
wit
, is n
h re
-1- - 45 Nm
hole
spec
-2- - 10 Nm
es, in part or in w
t to the co
-3- - 22 Nm
-4- - 10 Nm
rrectness of i
l purpos
nform
mercia
at
om
ion

c
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or

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ate
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or

f
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t.
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– Fit injection pump toothed belt. Pay attention to marked direc‐ C py
t. rig
tion of rotation.
gh ht
pyri by
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Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e nte
horis Passat 1997 ➤e o
ut
ss a 6-cylinder diesel engine - Edition 11.2003 ra
c
ce
e
nl
pt
– Tension toothed belt. Turn hexagon key anti-clockwise
du
an
itte
-arrow- until marks -1- align over one another. Then tighten
y li
erm
ab
the securing nut ( Socket, 22 mm -3078- ) to 36 Nm.
ility
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wit
– Tighten camshaft pulley bolts to 22 Nm.
, is n
h re
hole
– Remove locking pin -3359- and locking pin -3242- .
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Check tension of injection pump toothed belt.
♦ The marks -1- and -2- must align. m
at
om
ion
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or
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ate
do
priv
cum
for
en
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
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Prote AG.
– Install vibration damper for injection pump pulley (bolts -1-).

– Install crankshaft vibration damper. Pay attention to locking
lug on toothed belt pulley.
– Install toothed belt guard.
– Check commencement of injection of injection pump.
⇒ page 186
tenance ; Booklet .
1.7 Removing and installing front coolant

pipe
1.7.1 Removing
– Remove toothed belt ⇒ page 52 .
– Remove right camshaft pulley.
– Remove front intake manifold. ⇒ page 50

olkswagen AG
Passat 1997 ➤ wage
n AG. V does
olks not
db
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ara
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ris
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– Pull off rear middle toothed belt guard -2-
au upwards.
t ra
c
ss
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le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Pull off both coolant hoses -arrows-.

– Remove bolts -1- and -2-.
nform
ercia
– Pull off coolant pipe to front.

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tion in
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1.7.2 Installing
note the following:
Note

– Slide front coolant pipe into right coolant pipe and hole on cyl‐
inder head.
– Install toothed belt. ⇒ page 52
– Check commencement of injection of injection pump.
⇒ page 186
tenance ; Booklet .
1.8 Removing and installing left upper and

lower coolant pipes
1.8.1 Removing
– Remove oil filter bracket. ⇒ page 101

Passat 1997 ➤
n AG. Volkswagen AG do 6-cylinder diesel engine - Edition 11.2003
lkswage es n
Vo ot g
– Remove coolant by hoses -2-. ua
ed ran
oris tee
h
– Unboltaucoolant expansion tank -arrows 1-.
t or
ac
ss
– Pull off wiring to coolant shortage indicator switch -F66- and
ce
e
nl
pt
du
set coolant expansion tank to side.
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
– Pull coolant hoses -1- and -2- off coolant pipe.
l purpos
nform
ercia
Note
m
at
om
io
The coolant pipe is shown in figure with engine removed.
n
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– Open cable tie -2- at rear on heat shield and place wiring to
c by lksw
cted agen
side.
Prote AG.
– Unbolt heat shield -3- from compensator -arrows- and remove

it.
– Pull coolant hoses -1- and -4- off coolant pipes.
– Pull coolant pipe to rear out of cylinder block.
– Turn coolant pipe on rear edge to the right and upwards and
remove it.
– Disconnect coolant hose -arrow-.

– Remove lower left coolant pipe.
1.8.2 Installing
note the following:
Note

Passat 1997 ➤

– Slide upper coolant pipe into hole on cylinder head.
– Install oil filter bracket. ⇒ page 101
tenance ; Booklet .
1.9 Removing and installing right coolant

pipe
1.9.1 Removing
– Drain coolant. ⇒ page 122 AG. Volkswagen AG d
agen oes
olksw not
yV gu
– Remove oil filter bracket. ⇒ page 101 ed b ara
nte
ris
ho eo
– Remove bolts -2- and -3-. aut ra
c
ss
– Push coolant pipe -1- to rear and remove it.
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
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es, in part or in w
t to the co
rrectness of i
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1.9.2 Installing
nform
ercia
note the following:

m
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tion in
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um
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ng
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– Moisten new O-ring with coolant. C py
ht. rig
rig ht
by
– Install oil filter bracket ⇒ page 101 . copy Vo
by lksw
cted agen
Prote
AG.
1.10 Removing and installing radiator


Passat 1997 ➤
1.10.1 Removing
– Remove front bumper. ⇒ General body repairs, exterior; Rep.
Gr. 50 ; Body - front .
– Remove air pipe from charge air cooler.
– Unbolt power steering hydraulic oil cooling pipe -arrows-.
– Pull coolant hoses off radiator, release retaining clip on union
for this.
– Remove ATF lines from radiator. ⇒ 5-speed automatic gear‐
box 01V; Rep. Gr. 37 ; Dismantling and assembling gearbox;
Removing and installing ATF lines on vehicles with a V6 TDI
engine .
1.10.2 Vehicles with air conditioning

– Observe additional information and installation work
⇒ page 135 .

– Remove upper radiator securing clips and take radiator out
forwards. . Volkswage
gen AG n AG d
swa oes
1.10.4 Installing
db
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Installation is carried
tho out in the reverse order. When installing, e or
au
note the following:
ss ac
ce
e
nl

pt
du
an
itte
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– Install front bumper. ⇒ General body repairs, exterior; Rep.

erm
ab
Gr. 50 ; Body - front .

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wit
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tenance ; Booklet .
hole
spec
es, in part or in w
1.10.5 Additional information and removal in‐

t to the co
structions for vehicles with air condition‐

er
rrectness of i
l purpos
WARNING
nform
ercia
The air conditioner refrigerant circuit must not be opened.

m
at
om
ion
c
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or
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ate
Note
do
priv
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en
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To prevent damage to condenser and also to refrigerant lines/

n
t.
yi Co
hoses, ensure that the lines and hoses are not stretched, kinked Cop py
ht. rig
or bent. rig ht
py by
co Vo
by lksw
cted agen
– Remove retaining clamp(s) for refrigerant lines.
Prote AG.
– Unbolt condenser from radiator and pull it as far as possible

forwards.
– Pull radiator out between condenser and lock carrier.

Passat 1997 ➤
– Secure condenser to body so that the refrigerant lines are not

under tension.
1.10.6 Torque settings wage

es n
olks ot g
yV
Threaded connection ir se
d b Torque setting ua
ran
o tee
Condenser to radiator auth
10 Nm or
ac
ss
Cooling pipe to radiator 10 Nm
ce
le
un
pt
an
d
itte
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ab
pe
ility
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, is n
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hole
spec
es, in part or in w
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nform
mercia
a
com
tion in
r
te o
thi
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Cop py
t. rig
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pyri by
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by
cted agen
Prote AG.

Passat 1997 ➤
20 – Fuel supply system

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

clamp-type clips.
♦ Always replace clamp-type clips with spring-type clips.
♦ Spring-type clip pliers -VAS 5024- or hose clip pliers -V.A.G
1921- are recommended for installation of spring-type clips.
Repairing fuel filter ⇒ page 147 .

Observe safety precautions ⇒ page 137 .
Observe rules for cleanliness ⇒ page 138 .
Bleeding fuel system ⇒ page 162 .
1.1 Safety precautions when working on

fuel supply system
WARNING

tions:
AG. Volkswagen AG d
sitions. lksw
agen oes
n o ot g
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♦ Ensure that there is sufficient clearance
ris
edto all moving or
b ran
hot components. o tee
h
ut or
ac
sa
♦ The fuel and the fuel lines in the sfuel system can become
ce
le
very hot (danger of scalding)!

un
pt
an
d
itte
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♦ The fuel system is also under pressure! Before opening

rm
ab
the system, place cloths around the connections. Then

pe
ility
carefully loosen connection to release the pressure!

ot
wit
, is n
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♦ Wear eye and hand protection when performing any type

hole
spec
of repair work on the fuel system!

es, in part or in w
t to the co
When removing and installing fuel gauge sender or fuel pump

(fuel delivery unit) from a full or partly full fuel tank, observe the
rrectness of i
following:
l purpos
♦ Before beginning work, place an extraction hose close to

sender opening in fuel tank to extract escaping fuel fumes and
nform
ercia
switch on exhaust extraction system. If no exhaust extraction

system is available, a radial fan with a displacement greater
m
than 15 m3/h can be used providing that motor is not in air flow.
com
tion in
r
te o
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!

thi
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iva
do
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rp
cum
fo
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t.
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Cop py
t. rig
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137
co Vo
by lksw
cted 1. Removing and installing parts of fuel supply system
agen
Prote AG.
Passat 1997 ➤
1.2 Rules for cleanliness

When working on the fuel supply and injection systems, pay care‐
ful attention to the following “6 rules” for cleanliness:
♦ Thoroughly clean all unions and adjacent areas before dis‐
connecting.
♦ Place removed parts on a clean surface and cover. Do not use
fluffy 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.
♦ Also ensure that no diesel Afuel
G. Voruns
lkswaon
gen to the coolant hoses.
AG do
If necessary, the hoses agen
olksw must be cleaned immediately.
es n
ot g
Dam‐
aged hoses must
d by Vbe renewed. uar e an
ris tee
1.3 auRemoving and installing fuel tank with
tho or
ac
ss
attachments
ce
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nl
pt
du
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itte
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erm
ab
1.3.1 Four-wheel drive vehicles, part I

ility
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wit
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Front-wheel drive vehicles, part I ⇒ page 143

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.
138 Rep. Gr.20 - Fuel supply system

Passat 1997 ➤
1 - Cap
2 - Seal
3 - Securing bolt
4 - Tank flap unit
❑ With rubber cup
5 - O-ring
6 - Breather valve
❑ To remove valve unclip
sideways out of support
❑ Before installing remove
sealing cap
⇒ Item 1 (page 139)
7 - Connecting hose
8 - Gravity valve
❑ To remove valve unclip wage
es n
upwards out of support y V olks ot g
ua
d b
❑ Check valve for oris
e ran
tee
through-flow valve au verti‐
th or
ac
cal: open, valvesstilted
45°: closed ce
e
nl
pt
du
an
itte
9 - 25 Nm y li
erm
ab
10 - Fuel tank filler neck ility
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11 - Non-return valve
h re
hole
spec

es, in part or in w
tion: white side of valve

t to the co
points in direction of
sealing cap
rrectness of i
12 - Connecting hose
l purpos
13 - Heat shield
❑ For fuel filler neck
nf
ercia
14 - 10 Nm
orm
m
atio
15 - Union nut, 60 Nm
om
n in
c
❑ Remove and install using union nut tool -3218-

or
thi
te
sd
a
16 - Connector
iv
o
r
rp
cu
❑ Black
o
m
f
en
ng
t.
yi
❑ For fuel gauge sender 2 -G169-
Co
Cop py
ht. rig
17 - Flange
rig ht
py by
co Vo
by lksw
❑ Note installation position on fuel tank ⇒ page 140 Prote
cted AG.
agen
18 - Seal
❑ Renew
❑ Moisten with fuel when installing
19 - Breather line
❑ Secure with spring-type clips
1. Removing and installing parts of fuel supply system 139

Passat 1997 ➤
20 - Fuel gauge sender 3 -G237-

❑ Checking: ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
21 - Heat shield
❑ For fuel tank
22 - Securing clip
23 - Securing strap
❑ Note installation position
24 - Fuel gauge sender 2 -G169-
❑ Checking: ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
25 - Locking ring, 120 Nm
❑ Remove and install using fuel tank sender wrench -3087-
26 - Fuel tank
❑ When removing, support using engine and gearbox jack -V.A.G 1383/A-
❑ Emptying fuel tank ⇒ page 147
27 - Return line
28 - Supply line
29 - Fuel gauge sender -G-
❑ Clipped onto reservoir housing in fuel tank
30 - Fuel delivery unit
AG. Volkswagen AG d
❑ With low fuel level sender -G210- agen
ksw , checking ⇒ page 150
oes
ol not
y V gu
❑ Renew complete only sed b ara
nte
ri
❑ Removing and installingautho
⇒ page 154 eo
ra
s c
❑ Checking fuel pump s ⇒ page 160
ce
e
nl
pt
❑ Clean strainer if soiled

du
an
itte
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31 - Earth connection
erm
ab
ility
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wit
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❑ Installation position ⇒ page 144

h re
hole
spec
es, in part or in w
t to the co
Installation position of fuel delivery unit flange

Mark on flange -1- must align with mark on fuel tank -2-.
rrectness of i
l purpos
Note
nform
ercia
After installing fuel delivery unit flange, check that supply, return
and breather lines are still clipped onto fuel tank.
m
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
140
cted agen
Prote AG.
Rep. Gr.20 - Fuel supply system
Passat 1997 ➤
Checking breather valve wage

es n
olks ot g
Lever in rest position: closed byV ua
d ran
ir se tee
o
Lever pushed in direction of arrow: openauth or
ac
ss
ce
e
nl
pt
du
Note
an
itte
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erm
ab
ility
Before installing breather valve remove fuel tank cap.
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1.3.2 Four-wheel drive vehicles, part II
rrectness of i
1 - Fuel gauge sender -G-
l purpos

⇒ page 152
nf
ercia
orm
2 - Fuel delivery unit
m
atio
m
❑ With low fuel level send‐

o
n in
or c
er -G210- , checking
thi
te
⇒ page 150
sd
iva
o
r
rp
cu
❑ Renew complete only
o
m
f
en
ng

t.
yi Co
op
⇒ page 154
C py
t. rig
gh ht
yri
❑ Checking fuel pump p by
co Vo
lksw
⇒ page 160
by
cted agen
Prote AG.
3 - Return line
❑ To remove fuel delivery
unit, pull off inner part of
reservoir housing up‐
wards
4 - Sealing flange
❑ Cannot be renewed
separately
tion
5 - Return line
❑ From fuel filter
❑ Clipped to sealing
flange
❑ Press release button to
remove
6 - Supply line
❑ To fuel filter
7 - Connector
❑ For low fuel level sender
-G210-
8 - Connector
❑ For fuel pump and fuel gauge senders -G-
9 - Union nut, 60 Nm
❑ Remove and install using union nut tool -3217-

Passat 1997 ➤
10 - Seal
❑ Renew
❑ Moisten with fuel when installing
11 - Fuel line
❑ Fuel pump/reservoir housing or fuel pump/suction-jet pump
❑ To remove fuel delivery unit, separate connection
12 - Reservoir housing, outer part
❑ With suction-jet pump
1.3.3 Description of function . Volkswagen AG

gen AG does
swa
In order to empty the fuel tank as much as possible, a two-partyV
olk not
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reservoir housing with electric fuel pump is located rin isedthe tank.
b ara
nte
tho eo
The electric fuel pump delivers fuel from the outer
s au part of the res‐ ra
c
ervoir housing to a closed container (reservoir chamber) in the
s
ce
le
inner part of the reservoir housing. The injection pump of the die‐
un
pt
an
d
sel direct injection system draws fuel from this chamber.

itte
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erm
ab
In addition, the electric fuel pump forces fuel via a Y-junction into
ility
ot p
a suction-jet pump located on the bottom of the reservoir housing.
wit
is n
The suction-jet pump ensures that the outer part of the reservoir
h re
ole,
housing is always filled with fuel.
spec
In order to guarantee reliable engine operation, the chamber in
t to the co
the inner part of the reservoir housing must always be filled with
fuel. If the fuel level threatens to sink due to an empty tank, the
low fuel level sender -G210- gives a signal to shut off the injection
rrectne
system.
Installation position of low fuel level sender -G210- : In inner part
ss o
of reservoir housing
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 ➤
1.3.4 Front-wheel drive vehicles, part I
1 - Return line
❑ Line is double galong
en AG. Vun‐ agen AG doe
olksw
dersidey Vof swa and
olkfloor s no
t gu
endsise
d front and rear in a
b ara
nte
Y-junction
ut
hor eo
a ra
❑s Removing and installing
s c
⇒ page 144
ce
e
nl
pt
du
an
itte
2 - Supply line
y li
erm
ab
❑ To fuel filter
ility
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wit
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3 - 25 Nm
h re
hole
spec
4 - Tank flap unit
es, in part or in w
❑ With rubber cup
t to the co
5 - Seal
rrectness of i
6 - Cap
l purpos
7 - Securing bolt
nf
ercia
8 - O-ring
orm
m
atio
❑ Renew
om
n in
c
9 - Gravity valve
or
thi
te
sd
a
iv
o
r
rp
cu
⇒ page 144
o
m
f
en
ng
❑ To remove valve unclip

t.
yi Co
op
upwards out of filler C py
t. rig
neck
gh ht
pyri by
Vo
o
❑ Examine valve for
by c lksw
cted agen
through-flow valve verti‐
Prote AG.
cal: open, valve tilted

45°: closed
10 - Earth connection
⇒ page 144
❑ After fitting, use Ohmmeter to check electrical connection of metal ring on fuel filler neck to an unpainted
place on body - Specification: about 10 Ω
11 - Breather valve
❑ Installation position ⇒ page 144
❑ Removing and installing, checking ⇒ page 144
12 - Breather line
13 - Fuel tank
❑ Emptying fuel tank ⇒ page 147
14 - 25 Nm
15 - Securing strap
❑ Note differing lengths

Passat 1997 ➤
❑ Drillings in direction of travel (forwards)
Installation position of gravity valve, breather valve and earth

connection
1- Earth connection
2- Gravity valve
3- Metal ring on fuel filler neck
4- Breather valve
– Route earth connection as shown in illustration.
– Ensure that plug connector for earth connection is properly
seated on metal ring on fuel filler neck.
– Secure contact plate of earth wire to fuel filler neck with shoul‐
dered screw.
– After fitting, use Ohmmeter to check electrical connection of
metal ring on fuel filler neck to an unpainted place on body.
♦ Specification: about 10 Ω
Removing, installing and checking breather valve

– To remove valve, unclip from support to the side.
Note
Before installing breather valve remove fuel tank cap.
– Install O-ring with a lubricant. . Volkswagen AG

gen AG does
swa
– Check breather valve: byV
olk not
gu
d ara
ise nte
Lever in rest position: closedthor eo
au ra
Lever pushed in direction sof arrow: open
s c
ce
le
un
pt
an
d
Removing and installing fuel return line Y-junction

itte
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rm
ab
pe
♦ Only on vehicles up to 01.02

ility
ot
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♦ The return line is double along the underside of vehicles with

h re
6-cylinder engines for better fuel cooling.

hole
spec
es, in part or in w
♦ Tighten connections -arrows- to 15 Nm.

t to the co
rrectness of i
l purpos
nform
ercia
1.3.5 Removing and installing fuel cooler (on‐

m
a
com
ly vehicles from 01.02)

ion 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 ➤
♦ Torque wrench -V.A.G 1331/- (5...50 Nm)
1.3.6 Removing
Note
The fuel cooler is located in the return line to tank. It is locatedwon

agen
AG. Volkswagen AG d
oes
the vehicle underbody. yV
olks not
gu b ara
ed nte
oris
– Remove retaining clips -C- and securing bolt a-B-
ut then
h remove e or
ac
cover -A-. ss
ce
le
un
pt
– Separate fuel lines at fuel cooler.
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
– Remove securing nuts -arrows-.
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.
1.3.7 Installing
Note the following:
♦ Tighten fuel cooler securing nuts to 15 Nm.
1.3.8 Front-wheel drive vehicles, part II

AG. Volkswagen AG d
agen oes
ksw
Passat 1997by➤ Vol not
gu
d ara
6-cylinderoris diesel engine - Edition 11.2003
e nte
h eo
aut ra
c
1 - Fuel gauge
s sender -G-
s
ce
e
nl
pt
du
an
itte
y li
2 - Flange
erm
ab
ility
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❑ Cannot be renewed
wit
, is n
separately
h re
hole
spec
tion
es, in part or in w
t to the co
3 - Seal
❑ Renew
rrectness of i
❑ Moisten with fuel when
installing
l purpos
4 - Supply line
nform
ercia
❑ To fuel filter
m
5 - Return line
at
om
ion
c
6 - Connector
in t
or
his
te
❑ For low fuel level sender

a
do
riv
-G210-
p
cum
for
en
ng
7 - Connector
t.
yi Co
Cop py
❑ For fuel pump and fuel
t. rig
gh ht
yri
gauge senders -G- p by
o Vo
by c lksw
cted agen
8 - Union nut Prote AG.
❑ Remove and install us‐

ing union nut tool -VAS
3217- .

Passat 1997 ➤
1.4 Repairing fuel filter
1 - 10 Nm
2 - Bracket
❑ For fuel filter
3 - Retaining clip
4 - Return line
❑ From injection pump
5 - Regulating valve
❑ Installation position: ar‐
row points towards fuel
tank
❑ When changing filter,
remove retaining clip
and take control valve
off complete with fuel
lines.
olkswagen AG
❑ Below + 15 °C: en AG. V
agPassa‐ does
ksw
geway to y Vfilter open
o l not
gu
edb ara
❑ Over horis + 31 °C: Passage‐ nte
eo
way
au
t to filter closed ra
c
ss
6 - Return line
ce
le
un
pt
an
d
❑ To fuel tank
itte
y li
erm
ab
7 - Supply line
ility
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wit
❑ From fuel tank

is n
h re
ole,
8 - Water drain screw, 4 Nm

spec
9 - Seal
t to the co
❑ Renew
10 - Fuel filter
rrectne
❑ Flow direction is marked

by arrows
ss o
❑ Do not interchange con‐

cial p
f in
nections
form
mer
❑ Observe change intervals

atio
om
11 - Supply line
c
i
or
n thi
e
❑ To injection pump
t
sd
iva
o
pr
12 - Plastic element
um
r
fo
en
ng
t.
❑ Push onto fuel filter
yi Co
Cop py
t. rig
13 - 10 Nm
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1.5 Emptying fuel tank


Passat 1997 ➤
♦ Fuel extractor -VAS 5190-
lkswage es n
Vo ot g
– Remove sealing flange ed ⇒ page 154 , Removing and installing
by ua
ran
fuel delivery unit.thoris tee
u or
a ac
– Extract fuel from
ss fuel tank with fuel extractor -VAS 5190- .
ce
e
nl
pt
1.5.1 Vehicles with four-wheel drive
du
an
itte
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erm
ab
– Additionally extract fuel through opening for fuel tank sender
ility
ot p
2 ⇒ Item 24 (page 140) using fuel extractor -VAS 5190- .
wit
, is n
h re
1.6 Removing and installing fuel tank
hole
spec
es, in part or in w
t to the co
Special tools and workshop equipment required rrectness of i
l purpos
♦ Engine and gearbox jack -V.A.G 1383/A-

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 ➤
1.6.1 Removing
Note
Before carrying out further work, disconnect battery earth strap.

First check whether a coded radio is fitted. Obtain radio code first
if necessary.
lkswage es n
Vo ot g
– If necessary, empty fuel tank usingd fuel by extractor -VAS 5190- ua
ran
⇒ page 147 . orise
tee
th or
u
– With ignition switched off, disconnect
ss
a
earth strap at battery. ac
ce
e
nl
– Remove luggage compartment trim.
pt
du
an
itte
y li
– Unbolt cover for fuel gauge sender under luggage compart‐
erm
ab
ment trim.
ility
ot p
wit
, is n
– Separate connectors arrows.
h re
hole
spec
es, in part or in w
t to the co
– Remove rear seat bench.
– Remove right floor cover.
rrectness of i
– Detach connectors -1- and -2-.
l purpos
– Remove left and right middle and rear silencers of exhaust

system ⇒ page 205 .
nform
ercia
– Remove rear axle: ⇒ Running gear, axles, steering - front and

m
at
four-wheel drive; Rep. Gr. 42 ; Repairing rear axle (vehicles
om
io
with four-wheel drive) .
n
c
in t
or
his
ate
do
priv
Note cum
for
en
ng
t.
yi Co
op
Remove complete propshaft, to prevent damage to joints of prop‐ C py
t. rig
shaft.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Remove rear right wheel housing liner: ⇒ General body re‐
pairs, exterior; Rep. Gr. 66 ; Exterior equipment; Rear wheel
housing liner .

– Remove protective plate for filler neck.

– Open fuel tank filler flap.
– Remove securing bolt and remove fuel tank flap unit with rub‐
ber cup.
– Remove filler neck securing bolts .
– If fitted, remove cd trim in front of rear axle.

Passat 1997 ➤
– Disconnect fuel supply and return lines at connection points

-arrows- (marking them, if necessary).
Note
The figure shows a front-wheel drive vehicle, the connections on

a four-wheel drive vehicle are identical.

– Remove left and right protective plates on fuel tank and floor.

– Remove securing straps. When doing this, support fuel tank
with engine and gearbox jack -V.A.G 1383/A- .
– Slowly lower fuel tank.
1.6.8 Installing
note the following:
AG. Volkswagen AG d
♦ Route breather hose without kinking. agen oes
olksw not
y V gu
b ara
♦ Route fuel hoses without kinking. rise
d
nte
tho eo
u
♦ Secure fuel hoses with spring-type clips. ss a ra
c
ce
le
– Secure contact plate of earth wire to fuel filler neck with shoul‐
un
pt
an
d
dered screw.
itte
y li
rm
ab
pe
ility
WARNING
ot
wit
, is n
h re
hole
It is essential to ensure that the earth connection is screwed
spec
on and that the connector is securely attached to fuel filler neck.
es, in part or in w
t to the co
Installation position ⇒ page 144
rrectness of i
– Reconnect connectors for fuel pump and fuel gauge sender.
l purpos
Note
nform
ercia
After installing fuel tank, check that the supply, return and breath‐
m
a
com
er pipes are still clipped onto the fuel tank.

tion in
r
te o
thi
1.7 Checking low fuel level sender

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 AG d
agen oes
Volksw not
gu
Passat 1997 ➤
y
rise
d b
6-cylinder
ara
nte diesel engine - Edition 11.2003
tho eo
au ra
♦ Hand multimeterss-V.A.G 1526 B- c
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
co lksw
by
cted agen
Prote AG.
Note
Sender for low fuel level -G210- cannot be renewed separately.
1.7.1 Procedure
ment trim.


– Pull off 2-pin connector.
– Measure resistance at both contacts -1- and -2- on sealing
flange.

Passat 1997 ➤

AG. Volkswagen n AG do
wage es n
olksand -2- on sealing
– Measure resistance at both contactsy V-1- ot g
ua
flange. ris
edb ran
tee
tho or
s au ac
s
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
♦ Fuel level in reservoir housing OK: Specification about 430 Ω
ss o
♦ Fuel level in reservoir housing too low: Specification about 100
cial p
f i
Ω
nform
mer
– If you measure 0 Ω∼ or ∞ Ω, there is an open circuit in the tank
atio
m
or a short circuit.
o
n
c
i
or
n thi
te
sd
iva
o
Note
pr
cum
r
fo
en
ng
t.
yi
To check the two resistance values, remove fuel delivery unit
Co
op py
⇒ page 154 . Measure resistance values with fuel delivery unit in
. C rig
ht ht
rig
normal position and turned upside down. py by
co Vo
by lksw
cted agen
Prote AG.
1.8 Removing and installing fuel gauge

sender

1.8.2 Removing
– If necessary, empty fuel tank using fuel extractor -VAS 5190-
⇒ page 147 .
– Remove sealing flange ⇒ page 154 , Removing and installing
fuel delivery unit.
– Carefully pull out sealing flange and lay it aside with hoses
connected.
– Pull return line angled connector up off inner part of reservoir
housing -arrow-.
– Mark fuel gauge connections on inside of sealing flange and
pull off connectors.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
c
Passat 1997 ➤
s
s 6-cylinder diesel engine - Edition 11.2003
ce
e
nl
pt
du
an
itte
– Remove sender by simultaneously pressing locking lug and
y li
erm
ab
pulling it out of reservoir housing in fuel tank -arrows-.
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
For the ease of illustration, the reservoir housing is shown without
t to the co
tank.
rrectness of i
l purpos
nform
ercia
1.8.3 Installing
m
at
om
ion
c
in t
or
note the following:
his
ate
do
riv
– Insert fuel gauge sender into guide on outer section of reser‐

p
cum
or
voir housing and press down until it clicks into place.

f
en
ng
t.
yi Co
op
– Push return line angled connector onto inner part of reservoir C py
t. rig
housing until it engages -arrow-.
gh ht
pyri by
Vo
o
by c lksw
– Install sealing flange ⇒ page 154 , Removing and installing
cted agen
Prote AG.
fuel delivery unit.
1.8.4 Front-wheel drive vehicles

1.8.5 Removing
⇒ page 147 .
– Remove fuel delivery unit.
– Pull lines -3- and -4- off fuel gauge sender -G- .
– Raise retaining tabs -1- and -2- using a screwdriver and slide
fuel gauge sender -G- in -direction of arrow-.
1.8.6 Installing
note the following:
– Insert fuel gauge sender -G- into guide on fuel delivery unit
and press upwards until sender clicks into place.

Passat 1997 ➤
– Connector on fuel gauge sender -G- must engage correctly.
1.9 Removing and installing fuel delivery

unit

equipment required
♦ Union nut tool -3217-
♦ Fuel tank sender wrench
-3087-
♦ Fuel pump tool -3307-
♦ Hose clip pliers -
V.A.G 1275-
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
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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
ercia

m
a
com
tio

n in
r
te o
thi
1.9.2 Removing
s
iva
do
r
rp
cum
fo

en
ng
t.
⇒ page 147 .
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
– Unbolt cover for fuel gauge sender under luggage compart‐ Prote
cted AG.
agen
ment trim.
– Pull off connector.

Passat 1997 ➤
– Press the release button and pull return line -1- off sealing
flange -arrows-.
– Pull supply line -2- off sealing flange.
– Remove union nut using union nut tool -3217- .

– Detach connectors -1- and -2-.
– Press the release button -arrow- and pull return line -3- off
sealing flange.
– Pull supply line -4- off sealing flange.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
– Remove sealing ring using union nut tool -3217- .
ce
e
nl
pt
du
an
– Pull flange and seal out of opening in fuel tank.
itte
y li
erm
ab
– Unclip fuel gauge sender -G- from reservoir housing in fuel

ility
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tank and remove it.

wit
, is n
h re
– Mark fuel gauge connections on inside of sealing flange and

hole
spec
pull off connectors.

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
155
co Vo
by lksw
1. Removing and installing parts of fuel supply system
cted agen
Prote AG.
AG. Volkswagen AG d
Passat 1997 ➤ agen oes
olksw not
V
6-cylinder diesel engine - Edition 11.2003 d by gu
ara
rise nte
tho eo
– Pull return line angled connector up off inner part of reservoir
ss au ra
c
housing -arrow-.
ce
le
un
pt
an
– Unclip fuel gauge sender -G- from reservoir housing in fuel
d
itte
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tank and remove it.
erm
ab
ility
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wit
is n
h re
Note
ole,
spec
t to the co
tank.
rrectne
– Press release tabs -arrows- and disconnect fuel hose at Y-
ss
junction.
o
cial p
f inform
– Place fuel hose to suction-jet pump in fuel tank.
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
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Turn fuel delivery unit approx. 15° anti-clockwise onto stop
with fuel pump tool -3307- and remove delivery unit.
Note
If delivery unit is to be renewed, drain old delivery unit before dis‐

posal.
1.9.3 Installing
note the following:
Note
♦ Do not bend fuel sender when installing.

♦ Renew flange seal and coat with fuel when fitting.
♦ Secure fuel hoses with spring-type clips.
– Insert inner part of the reservoir housing with sealing flange

into fuel tank.

Passat 1997 ➤
– Insert inner part of reservoir housing in fuel tank so that notch

-1- on inner part of reservoir housing aligns with marking -2-
on outer part of reservoir housing.
– Turn inner part of reservoir housing with pump approx. 15°
clockwise onto stop with fuel pump tool -3307- . Notch -1- now
aligns with marking -3- (bayonet connection).
Note

tank.
– Push fuel hose onto Y-junction until engaging lug engages.

– Put Y-junction with fuel hoses to the side in fuel tank.
Note
Carefully route fuel hoses and electrical wiring inside fuel tank.
– Tighten union nut to 60 Nm using union nut tool -3217- .

– Tighten sealing ring to 120 Nm using fuel tank sender unit tool
-3087- .
– Note installation position of fuel delivery unit flange
⇒ page 140
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise
r nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
♦ Union nut tool -VAS 3217-

itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
or
1.9.5 Removing
m
m
atio
om
n in

or c
⇒ page 147 .
thi
te
sd
iva
o
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rp
cu
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f
en
ng

t.
yi Co
op
ment trim. C py
t. rig
gh ht
yri by
– Pull off connector. cop Vo
by lksw
cted agen
Prote AG.

Passat 1997 ➤
– Press the release button and pull return line and supply line
off sealing flange.
– Remove union nut using union nut tool -3217- .
– Pull fuel delivery unit and sealgeout of. Vopening
n AG olkswagenin
AGfuel
d
tank.
a oes
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Vol gu
d by ara
e nte
ris
tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
is n
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ole,
spec
1.9.6 Installing
t to the co
note the following:
rrectnes
Note
s o
cial p
f inform
♦ Do not bend fuel sender when installing.
mer
atio
m
♦ Renew flange seal and coat with fuel when fitting.

o
n
c
i
or
n thi
e
1.10
t
Removing and installing suction-jet

sd
iva
o
pr
pump
um
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fo
en
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t.
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op
On vehicles with four-wheel drive the shape of the fuel tank dic‐ C py
t. rig
tates that a suction-jet pump is required to pump fuel to the fuel
gh ht
yri by
delivery unit from area of sender 2 ⇒ Item 24 (page 140) . A sec‐
op Vo
by c lksw
cted
ond suction-jet pump ensures that the delivery unit in the reservoir
agen
Prote AG.
housing is supplied with fuel. The suction-jet pump function ac‐
cording 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 00561 is stored in fault memory
♦ even though the fuel gauge shows the fuel tank is 1/4 full.

• The 3 senders must be checked using fault finding programme
and be OK. ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations.
• Fuel tank must be empty ⇒ page 147 .

Passat 1997 ➤
♦ Fuel tank sender wrench -3087-
1.10.2 Procedure
– Note safety precautions before beginning work ⇒ page 137 .
– Pull 4-pin connector and fuel hoses off fuel delivery unit (right-
hand side of vehicle) and remove the fuel delivery unit
⇒ page 154 , removing and installing fuel delivery unit.
– Now pull 2-pin connector off fuel gauge sender 2 -G169- (left-
hand side of vehicle), open the sealing ring with fuel tank
sender unit tool -3087- and carefully lift the sender.
– Now pull off connector -1- under sender 2 cover -2-.

AG. Volkswagen A
– Lift sender 2 -2- and pull suction-jet
olks
wage
n
pump-3- outGofdolocking
es n
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device of sender. d by V ua
r e an
ris tee
– Take out senderut2.
ho or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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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
o
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rp
cu
o
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f
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
159
by lksw
cted agen
Prote AG.
1. Removing and installing parts of fuel supply system
Passat 1997 ➤
– Now, on right-hand side of vehicle (fuel delivery unit), pull line

to suction-jet pump -2- off junction -1- and pull connector -3-
off fuel gauge sender -G- , fuel gauge sender 2 -G169- .
– Now the suction-jet pump can be pull out from sender 2 side
(left-hand side of vehicle).
– Check that the fuel lines on suction-jet pump are fitted securely
and are not damaged.
– Additionally check suction-jet pump for possible soiling.
If no fault is found:
– Install suction-jet pump and sender 2 again in reverse order.
Note
In the subsequent work procedure the return line must be pulled

off junction. When doing this observe thatgeall
n AGO-rings
. Volkswamust
gen AGbe re‐
newed. Volkswa does
not
by gu
ara
ed nte
ris
Now check junction piece uwith
tho pressure relief valve as follows: eo
ra
a c
ss
ce
e
– Pull off connections for return supply line -2-, connections -1-
nl
pt
du
and -4- for suction-jet pump on junction with pressure relief
an
itte
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valve -3-.
erm
ab
ility
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– Unclip the junction which is secured on the reservoir housing.
wit
, is n
h re
– Use a test hose and blow into connection, from direction of fuel
hole
spec
return -2-, there must be through flow in directions -1- and
es, in part or in w
-4-.
t to the co
– Hold connections -1- and -4- closed, the pressure limiting
valve must open under slight opposing pressure.
rrectness of i
– If no opposing pressure is noticed or the pressure limiting

l purpos
valve does not open, renew junction piece with pressure relief
valve.
nf
ercia
1.11 Checking fuel pump

rm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
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f
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤

equipment required
♦ Remote control -
V.A.G 1348/3A- AG. Volkswagen AG d
agen oes
olksw not
yV gu
♦ Adapter lead - ed b ara
nte
is
V.A.G 1348/3-2- thor eo
au ra
c
♦ Hand multimeter -V.A.G
ss
ce
e
1526 B-
nl
pt
du
an
itte
y li
♦ Auxiliary measuring set -
erm
ab
V.A.G 1594 C-
ility
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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
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
♦ Battery charge at least 12 V

♦ Fuse No. 28 OK
♦ Fuel pump relay “214” position No. -5- on 13-position relay
carrier above relay plate
♦ Fuel filter OK
♦ Ignition switched off

– Remove cover in front of fuse holder.

Passat 1997 ➤
– Pull fuse No. 28 out of fuse holder.

– Connect remote control -V.A.G 1348/3A- to contact 28a for
fuel pump and battery positive (+) using adapter cables -
V.A.G 1348/3-2-
– Operate remote control.
♦ Pump should start running audibly.
Note
The fuel pump runs very quietly. Where possible, avoid noisy sur‐
roundings for this test.
Fuel pump does not run:

ment trim.


– Pull 4-pin connector off flange on fuel tank.
– Check voltage between contacts 1 and 4 on connector with
multimeter -V.A.G 1526 B- , press switch continuously on re‐
mote control for this. n AG. Volkswagen A ge G do
swa es n
♦ Specification: approx. battery
by voltage
Vol
k ot g
ua
d ran
ise
If the specification is not tobtained:
ho
r tee
or
au ac
ss open circuit using current flow diagram
– Locate and eliminate
ce
le
⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐

un
pt
an
cations.
d
itte
y li
erm
ab
– If the wiring connections are OK, replace fuel delivery unit.

ility
ot p
wit
is n
h re
ole,
spec
1.12 Bleeding fuel system

t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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en
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t.
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Cop py
ht. rig
rig ht
py by
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by lksw
cted agen
Prote AG.

Passat 1997 ➤

equipment required
♦ Hose clamps -3093- or
hose clamps -3094-
♦ Remote control -
V.A.G 1348/3A-
♦ Adapter lead -
V.A.G 1348/3-2-
♦ Hand vacuum pump with
accessories -V.A.G 1390-
and water drainage reser‐
voir -V.A.G 1390/1-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au 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
rrectness of i
l purpos
Note
nf
ercia
orm
m
♦ To bleed the fuel system, you must ensure that the inner part
atio
m
of the reservoir housing is always filled with fuel (capacity

o
n in
or c
about 0.5 litre).

thi
te
sd
iva
♦ When the engine is not running (because the electric fuel

o
r
rp
cu
pump does not run then), you can only be sure that the inner
o
m
f
en
ng
part of the reservoir housing is reliably filled when the fuel tank
t.
yi Co
op
contains more than 40 litres. Therefore, fill the tank to more C py
t. rig
than 40 litres, if necessary, before bleeding.
gh ht
pyri by
Vo
co lksw
by
♦ If the fuel tank should not be filled due to subsequent test work, cted agen
Prote AG.
fill the inner part of the reservoir housing during bleeding as
follows:

– Remove cover in front of fuse holder.

Passat 1997 ➤
– Pull fuse No. 28 out of fuse holder.

– Connect remote control -V.A.G 1348/3A- to contact 28a for
fuel pump and battery positive (+) using adapter cables -
V.A.G 1348/3-2-
– Connect crocodile clamp to positive (+) terminal of battery.
– Press remote control switch during bleeding. The sound of the
fuel pump must be clearly audible.
– Clamp off the fuel return line between injection pump and fuel
filter and between fuel filter and fuel tank with hose clamps
-3094- .
– Pull return line from injectors of right cylinder bank off injection
pump.
– Insert appropriate reducing piece -2- from water drainage res‐
ervoir -V.A.G 1390/1- in hose.
– Connect reducing piece to hose -1- and water drainage res‐
ervoir -V.A.G 1390/1- .
– Operate hand vacuum pump and fill the container three times
in this manner.
AG. Volkswagen AG d
agen oes
olksw not
yV gu
Note ised b ara
nte
or eo
h
ut ra
♦ Air bubbles may still be visible in the line even after filling
s the
s a c
bleeder container three times.
ce
le
un
pt
an
d
♦ Drain bleeder container in good time. No fluid may enter the

itte
y li
erm
hand vacuum pump.
ab
ility
ot p
wit
is n
– Reconnect return line to injection pump.
h re
ole,
spec
– Remove the hose clamp -3094- from return line.
t to the co
– Insert fuse No. 28, if it has been removed.
– Start engine and perform visual check of fuel system for leaks.
rrectne
WARNING
ss o
cial p
f
Do not prolong attempted starting for longer than 15 seconds.
inform
If engine does not start, repeat bleeding procedure.
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 ➤
2 Accelerator mechanism
2.1 Repairing accelerator mechanism
2.1.1 Vehicles ▸ 04.99

Vehicles 05.99 ▸ ⇒ page 166 wage
es n
olks ot g
byV ua
d ran
ir se
1 - 6-pin connector utho tee
or
a ac
❑ For accelerator pedalss
position sender -G79-
ce
le
un
pt
an
d
itte
2 - 10 Nm
y li
erm
ab
ility
3 - Accelerator position sender
ot p
wit
-G79-
is n
h re
ole,
❑ Adjusting ⇒ page 166
spec
❑ When removing and in‐
t to the co
stalling accelerator ped‐
al position sender,
mounting bracket
rrectne
⇒ Item 9 (page 165)
must be removed
s
4 - Cable cam
s o
cial p
f in
5 - 10 Nm
form
mer
6 - Operating rod
atio
om
n
❑ With adjustment screw
c
i
or
n thi
te
7 - Accelerator pedal stop

sd
iva
o
pr
❑ On vehicles with manual

um
r
fo
en
ng
gearbox “HS” is visible yi

t.
Co
op
❑ On vehicles with auto‐
C py
t. rig
gh
matic gearbox “AG” is
ht
pyri by
Vo
visible
co lksw
by
cted agen
Prote AG.
8 - Accelerator pedal
9 - Mounting bracket
⇒ Brake systems; Rep.
Gr. 46 ; Assembly over‐
view - brake pedal
(LHD)
2. Accelerator mechanism 165

Passat 1997 ➤
2.1.2 Vehicles 05.99 ▸
1 - Mounting bracket
⇒ Brake systems; Rep.
Gr. 46 ; Assembly over‐
view - brake pedal
(LHD)
2 - Connector
❑ Black, 6-pin.
3 - 10 Nm
4 - Accelerator pedal position
sender -G79- and accelerator
position pedal sender 2 -G185-
AG. Volkswagen AG d
❑ To remove, remove agen oes
olksw not
dash panel cover and d by V gu
ara
pedal cluster cover. rise nte
tho eo
u
❑ If renewed adapt control ss a ra
c
unit for automatic gear‐
ce
e
nl
box: Function ⇒ Vehicle
pt
du
an
itte
diagnosis, testing and
y li
erm
ab
information system VAS
ility
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5051
wit
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5 - Bracket
hole
spec
❑ For footwell cover
es, in part or in w
t to the co
❑ Clipped on accelerator
pedal position sender -
G79- and accelerator
position pedal sender 2
rrectness of i
-G185-
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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f
en
2.2 Adjusting pedal position sender

ng
t.
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Cop py
t. rig
Vehicles ▸ 04.99 gh ht
pyri by
Vo
co lksw
by
(Accelerator pedal position sender removed) Prote
cted AG.
agen
2.2.1 Procedure
Adjusting cable cam:

Passat 1997 ➤
– The cable cam is to be set so that in the rest position the ex‐
tended edge of the spanner surface passes through the centre
of the hole -arrow-.
– Then secure accelerator position sender with preassembled
cable cam to mounting block.
– Install bearing bracket: ⇒ Braking system; Rep. Gr. 46 ; As‐
sembly overview - Brake pedal (LHD)
– Reconnect sender 6-pin connector.
AG. Volkswagen AG d
agen oes
Fine adjustment with sender installed: olksw not
byV gu
ara
ed
– Turn accelerator pedal stop tohoposition “HS” for manual gear‐
ris nte
eo
box (also vehicles with automatic
aut gearbox), “HS” is visible. ra
c
ss
– Depress accelerator pedal by hand until accelerator pedal lies
ce
le
un
pt
against accelerator pedal stop.
an
d
itte
y li
rm
ab
pe
ility
Note
ot
wit
, is n
h re
hole
On vehicles with automatic gearbox, the kick-down switch pres‐
spec
sure point must be distinctly noticeable before the full throttle stop.
es, in part or in w
t to the co
If accelerator pedal stop is not reached or pressure point of kick‐
down switch cannot be felt: adjust accelerator pedal stop by
rrectness of i
turning adjustment screw on actuator rod.
l purpos
2.2.2 Vehicles with automatic gearbox
nform
ercia
– Turn accelerator pedal stop by 180° so that lettering “AG” is

m
visible ⇒ Item 7 (page 165) .
a
com
tion in
r
te o
thi
s
iva
– Check function after adjusting accelerator position sender: do

r
rp
c
Function ⇒ Vehicle diagnosis, testing and information system
um
fo
VAS 5051
en
ng
t.
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op py
2.3 Function of EPC system
. C rig
ht ht
rig by
copy Vo
lksw
With the EPC system, the throttle valve is not operated by a cable.
by
cted agen
Prote
There is no mechanical connection between the accelerator pedal
AG.
and the throttle valve.

The position of the accelerator pedal is transmitted to the engine
control unit by two accelerator pedal position senders (variable
resistors together in one housing) connected to the accelerator
pedal.
The position of the accelerator pedal (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 control 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 pedal 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 pedal position sender.
2. Accelerator mechanism 167

Passat 1997 ➤
This means that the throttle valve can already be completely open
even though the accelerator pedal is depressed half way. This
has the advantage of preventing throttling losses at the throttle
valve.
After evaluating the torque requirements of various components
(e.g. air conditioning system, automatic gearbox, ABS/ESP and
so on), the engine control unit calculates the optimal throttle valve
opening angle for the respective situation.
This also results in significantly improved fuel consumption and
exhaust emissions under certain load conditions.
Volkswa AG. gen AG
agen do
“EPC” is a system comprising olks
w
all components which es n
contribute
ot g to
yV
determining, controlling d b or monitoring the position of the ua
rthrottle
an
ir se
valve, e.g. accelerator
ho position sender, throttle valve controltemod‐
eo
ut
ule, EPC warning
ss
a lamp, engine control unit and so on. ra
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
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
cted agen
Prote AG.

Passat 1997 ➤
21 – Turbocharging/supercharging
1 Charge air system with turbocharger

When working on the turbocharger, pay careful attention to the
following rules of cleanliness:
connecting.
fluffy cloths!
tool boxes etc.).
essary.
1.2 Removing and installing turbocharger

with attachments agen
AG. Volkswagen AG d
w oes
olks not
byV gu
ara
ed nte
ris
1.2.1 Engine codes: AFB and AKN au
tho eo
ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
Note
pe
ility
ot
wit
, is n
♦ All hose connections are secured by clips.

h re
hole
spec
♦ Charge air system must be free of leaks.

es, in part or in w
t to the co
♦ Renew self-locking nuts.

♦ Before attaching oil supply line, fill turbocharger at connection
rrectness of i
with engine oil.

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.
1. Charge air system with turbocharger 169

Passat 1997 ➤
1 - O-ring
❑ Renew
2 - Oil return line
❑ To cylinder block
3 - Gasket
❑ Renew
4 - O-ring
❑ Renew
5 - 10 Nm
6 - Hose
❑ To charge air control
vacuum unit
7 - 22 Nm
8 - Oil supply line
❑ Before installing, fill tur‐
bocharger with engine
oil through oil supply line
connection
9 - 15 Nm
10 - Seal
❑ Renew
11 - 10 Nm
12 - Heat shield
13 - Turbocharger
⇒ page 172
14 - 25 Nm
AG. Volkswagen AG d
❑ Renew agen oes
olksw not
byV gu
ara
15 - 25 Nm rised
nte
ho eo
❑ Renew s aut ra
c
s
16 - Intermediate piece
ce
le
un
pt
an
d
itte
17 - 25 Nm
y li
rm
ab
❑ Renew
pe
ility
ot
wit
, is n
18 - Gasket
h re
hole
❑ Renew
spec
es, in part or in w
19 - Front exhaust pipe

t to the co
20 - 22 Nm
rrectness of i
21 - Support
❑ For compensator
l purpos
22 - Compensator
nform
ercia

m
23 - 25 Nm
com
tion in
24 - 10 Nm
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
170
by lksw
cted agen
Rep. Gr.21 - Turbocharging/supercharging Prote AG.
Passat 1997 ➤

with attachments
1.3.1 Engine codes BAU, BDH and BDG

Note

♦ Renew self-locking nuts.
♦ Before attaching oil supply line, fill turbocharger at connection
with engine oil.
1 - O-ring
❑ Renew
2 - Oil return line
❑ To cylinder block
3 - Gasket
❑ Renew
4 - O-ring
❑ Renew
5 - 10 Nm AG. Volkswagen AG d
agen oes
6 - Hose olksw not
byV gu
ara
d
❑ To charge air control orise nte
eo
vacuum unit aut
h
ra
ss c
7 - 22 Nm
ce
e
nl
pt
du
an
8 - Oil supply line

itte
y li
erm
ab
❑ Before installing, fill tur‐

ility
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bocharger with engine

wit
, is n
oil through oil supply line

h re
connection
hole
spec
es, in part or in w
9 - 15 Nm
t to the co
10 - Seal
❑ Renew
rrectness of i
11 - 10 Nm
l purpos
12 - Heat shield
nf
ercia
13 - Turbocharger
orm
m

atio
m
⇒ page 172
o
n in
or c
thi
14 - 25 Nm
te
sd
iva
❑ Renew
r
rp
cu
o
m
f
en
ng
15 - 25 Nm
t.
yi Co
op py
❑ Renew
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

Passat 1997 ➤
16 - Starter catalytic converter

17 - 25 Nm
❑ Renew
19 - Gasket
❑ Renew
20 - 22 Nm
21 - Support
❑ For compensator
22 - Compensator
23 - 25 Nm
24 - 10 Nm

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
1.4.1 Removing
is n
h re
ole,
spec
– Remove front exhaust pipe with catalytic converter or starter

catalytic converter.
t to the co
– Remove air intake duct and air filter cover.

– Release hose clamp -3-.
rrectne
– Detach connector -4-.

ss
– Pull hose -2- off air filter housing.

o
cial p
f inform
– Unscrew bolt -1- and take off air filter housing.

mer
atio
– Pull hose off charge air control vacuum unit.

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.
172 Rep. Gr.21 - Turbocharging/supercharging

Passat 1997 ➤
– Remove intake hose from air filter to turbocharger -arrows-.
– Loosen hose clamps -1- and push hose in direction of arrow.

– Unclip fuel line from retainer on oil line.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
– Remove oil line -1- from turbocharger.
ce
le
un
pt
an
d
– Unbolt oil line from intake manifold -2-.

itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
– Unbolt turbocharger from compensator -arrow - (4 nuts).
cial p
f inform
– Remove turbocharger upwards.
mer
atio
om
n
c
i
or
Note
thi
te
sd
iva
o
r
Close off oil channels in cylinder block with clean cloths.

p
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.
1.4.2 Installing

Passat 1997 ➤
Note
♦ Renew seals and O-rings.

♦ When installing turbocharger, be careful not to damage O-ring
-arrow- for oil return.
Volkswa
♦ Fill turbocharger with engine oil through oilssupply
wage
n AGconnecting
. gen AG
does
line. yV
olk not
gu
db ara
ise nte
♦ After installing turbocharger, runthoengine for about 1 minute at
r eo
idling and do not rev up immediately,
ss
au this ensures that the tur‐ ra
c
bocharger is fully primed with oil
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
1.5 Removing and installing compensator
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
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f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1.5.1 Removing
– Remove turbocharger ⇒ page 172 .
– Open cable tie -1- at rear on heat shield and place wiring to
side.
– Remove left exhaust manifold with exhaust pipe
⇒ page 206 .
– Remove right exhaust manifold with exhaust pipe
⇒ page 208 .
– Unbolt heat shield -2- from support -arrows- and remove it.
Vehicles with no coolant cooled exhaust gas recirculation

Passat 1997 ➤
– Remove bolt on left of mechanical exhaust gas return valve

-3-.
Note
Leave exhaust gas recirculation pipe -4- in installation position.
Vehicles with coolant cooled exhaust gas recirculation
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
– Remove bolt on left of mechanical exhaust gas return valve
du
an
itte
-3-.
y li
erm
ab
ility
ot p
wit
, is n
– Coolant hose -4- remains connected.

h re
hole
spec
es, in part or in w
t to the co
Note
Leave exhaust gas recirculation pipe -1- in installation position.

rrectness of i

l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
– Remove securing bolt at top left of engine/gearbox flange
yi Co
op py
-arrow 1-. t. C rig
gh ht
pyri by
– Remove bolts -arrows 2-.
o Vo
by c lksw
cted agen
Prote AG.
– Remove compensator to right rear.
1.5.2 Installing
– Install turbocharger ⇒ page 172 .
– Install left exhaust manifold with exhaust pipe ⇒ page 208 .
– Install right exhaust manifold with exhaust pipe ⇒ page 209 .

Passat 1997 ➤
Note
Renew gaskets and seals.
1.6 Removing and installing parts of charge

air cooling Volkswag AG. en AG
agen does
olksw not
yV gu
db ara
Note rise nte
tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
♦ Illustration shows left-side charge air cooler.
ility
ot p
wit
is n
h re
ole,
1 - Air duct
spec
2 - Hose
t to the co
❑ Between charge air
cooler and air intake
rrectne
pipe in scoop
3 - O-ring
ss
❑ Renew o
cial p
f inform
4 - Intake manifold pressure
mer
sender -G71-
atio
om
n
c
5 - 10 Nm
i
or
n thi
te
sd
6 - Hose
iva
o
pr
cum
❑ Between shut-off flap

r
fo
en
ng
housing and charge air

t.
yi Co
cooler Cop py
t. rig
gh ht
yri
7 - Bracket p by
co Vo
by lksw
cted agen
8 - Rubber grommet Prote AG.
9 - Charge air cooler

⇒ page 177
10 - Rubber grommet

Passat 1997 ➤
1.7 Removing and installing charge air cool‐

er
1.7.1 Removing
– Pull air hose off top of charge air cooler.
Note
Illustration shows left-side charge air cooler.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
-arrow-.
nl
pt
du
an
itte
y li
– Detach charge air cooler and remove downwards.
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
1.7.2 Installing
nf
ercia
o
rm
m
atio
m
1.8 Charge pressure control hose routing di‐

o
n in
or c
agram
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
1.8.1 Engine codes: AFB and AKN
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
Passat 1997 ➤ d by
V gu
ara
e nte
6-cylinder diesel engine - Editionhori11.2003
s
eo
aut ra
ss c
1 - Vacuum line
ce
e
nl
pt
du
❑ From charge pressure
an
itte
y li
control solenoid valve -
erm
ab
N75- to charge pressure
ility
ot p
control vacuum unit
wit
, is n
h re
2 - To air filter
hole
spec
es, in part or in w
3 - Charge pressure control
t to the co
solenoid valve -N75-
rrectness of i
(light/dark sides): as
l purpos
shown in figure
5 - Brake servo
nform
ercia
6 - To vacuum pump
m
at
om
io
7 - To exhaust gas recircula‐
n
c
in t
or
tion valve -N18-
his
ate
do
riv
❑ Connecting
p
cum
⇒ page 210
for
en
ng
t.
yi Co
8 - To exhaust gas recircula‐ Cop py
tion valve -N18-
t. rig
gh ht
pyri by
❑ Connecting
o Vo
by c lksw
cted
⇒ page 210
agen
Prote AG.
9 - Vacuum unit for charge

pressure control

Passat 1997 ➤
1.9 Charge pressure control hose routing di‐

agram
1 - Vacuum line
❑ From charge pressure
control solenoid valve -
N75- to charge pressure
control vacuum unit
2 - To air filter
3 - Charge pressure control
solenoid valve -N75-
4 - To non-return valve
shown in figure
6 - Brake servo
7 - To vacuum pump
8 - To exhaust gas recircula‐
tion valve -N18-
❑ Connecting
⇒ page 210 n AG. Volkswagen AG do
lkswage es n
o ot g
9 - Vacuum unit for charge d byV ua
ran
pressure control ir se tee
tho
u or
a ac
10 - Air filter 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
cted agen
Prote AG.

Passat 1997 ➤
23 – Mixture preparation - injection

agen
AG. Volkswagen AG d
o w es n
olks ot g
byV ua
1 Repairing diesel direct injection sys‐ tho
ris
ed ran
tee
tem
or
au ac
ss
ce
e
nl
The diesel direct injection system control unit is equipped with a
pt
du
an
itte
fault memory. Read fault memory before and after making repairs
y li
erm
ab
or adjustments. ⇒ page 196
ility
ot p
1.1 Safety precautions
wit
, is n
h re
hole
spec
es, in part or in w
WARNING
t to the co
rrectness of i
tions:
l purpos
nform
ercia
sitions.
m
at
om
i
on
c
hot components.
in t
or
his
ate
do
priv
cum
or
Observe following if test and measuring instruments are required

f
en
ng
t.
during a road test:
yi Co
Cop py
t. rig
♦ Test and measuring instruments must be secured to rear seat
gh ht
pyri by
and operated by a second person from this location.
co Vo
by lksw
cted agen
Prote AG.
If test and measuring instruments are operated from front pas‐
senger's seat and the vehicle is involved in an accident, the
person sitting in this seat could be seriously injured when the air‐
bag is triggered.
To prevent injuries to persons and/or damage to the injection and
glow plug system, the following must be noted:
♦ The ignition must be switched off before connecting or dis‐
connecting injection or glow plug system wiring or tester ca‐
bles.
♦ If the engine is to be turned at starter speed, without starting,
e.g. when checking compressions, pull connector off injection
pump.
♦ Before disconnecting battery, obtain radio code for radios fit‐
ted with anti-theft coding.
♦ Disconnecting and reconnecting the battery must only be un‐
dertaken when the ignition is switched off otherwise the diesel
direct injection system control unit may be damaged.

When working on fuel supply and injection system, pay careful
attention to the following rules for cleanliness:
connecting.
fluffy cloths!
180 Rep. Gr.23 - Mixture preparation - injection

Passat 1997 ➤

tool boxes etc.).
essary.
♦ Also ensure that no diesel fuel runs on to the coolant hoses.
If necessary, the hoses must be cleaned immediately. Dam‐
aged hoses must be renewed.
1.3 Repairing injection pump

♦ Observe rules for cleanliness ⇒ page 180
♦ Removing and installing injection pump ⇒ page 183
♦ Dynamically checking and adjusting commencement of injec‐
tion ⇒ page 186
1 - Injector pipes
❑ Remove with ring span‐
ner -3035- n AG. Volkswagen AG do
swage es n
❑ Do not alter shape byV
olk ot g
ua
d ran
❑ To remove, remove in‐ ir se tee
ho
jection pump aut or
ac
⇒ page 183 ss
ce
e
nl
pt
du
2 - 9-pin connector
an
itte
y li
❑ Only disconnect or con‐
erm
ab
nect with ignition switch‐
ility
ot p
ed off
wit
, is n
h re
❑ Release to pull off
hole
spec
es, in part or in w
3 - Seal
t to the co
❑ Renew
4 - Connection, 45 Nm
❑ With pressure valve rrectness of i
l purpos
5 - 10 Nm
6 - Injection pump
nform
ercia
❑ With injection pump

m
at
control unit -J399-

om
ion
c
❑ With metering solenoid

in t
or
his
e
valve
at
do
riv
❑ With injection pump

p
cum
or
speed sender
f
en
ng
t.
yi Co
❑ With commencement of Cop py
. rig
injection valve
t
gh ht
pyri by
Vo
o
❑ With fuel temperature
c by lksw
cted agen
sender -G81- Prote AG.
❑ Checking identification
⇒ page 194
7 - Dowel sleeve
8 - 20 Nm
9 - Securing nut
❑ For injection pump pulley
1. Repairing diesel direct injection system 181

Passat 1997 ➤
❑ Do not loosen. Otherwise the injection pump basic setting may be altered and this cannot be reset with
normal workshop equipment
. Volkswagen AG
wa gen AG does
10 - Toothed belt olks not
byV gu
ara
❑ Mark direction of rotation
ris
ed before removing nte
ho eo
❑ Check for wear au t ra
c
ss
11 - Vibration damper
ce
le
un
pt
an
d
itte
12 - O-ring
y li
rm
ab
pe
ility
ot
wit
, is n
13 - Injector
h re
hole
❑ For 3rd cylinder with needle lift sender -G80-
spec
es, in part or in w
t to the co
❑ Repairing ⇒ page 192
rrectness of i
14 - Sleeve
l purpos
15 - Retainer
nform
ercia
17 - Supply line
m
a
com
tio
n in
r
te o
thi
18 - Return line
s
iva
do
r
rp
c
❑ To regulating valve/fuel filter
um
fo
en
ng
t.
yi Co
Cop py
t. rig
20 - Connection
gh ht
pyri by
Vo
o
❑ For spill line
c by lksw
cted agen
Prote AG.

Passat 1997 ➤
1.4 Removing and installing injection pump

equipment required
♦ Ring insert -T10023-
1331-
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
1.4.1 Removing
erm
ab
ility
ot p
wit
, is n
h re
hole
– Remove front intake pipe. ⇒ page 50

spec
es, in part or in w
– Open oil filler cap.

t to the co
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
183
agen
Prote AG.
1. Repairing diesel direct injection system
Passat 1997 ➤
– Turn crankshaft in engine direction of rotation, until -OT- (TDC)

is visible on the camshaft.
– Remove TDC marking plug on cylinder block.
Note
♦ Vehicles with air conditioning, remove sound insulation on

gearbox.
♦ There is a TDC drilling in the crankshaft directly behind the
sealing plug.
– Screw locking pin -3242- into the hole of the removed sealing
plug.
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
– Remove vibration damper for injection pump pulley (bolts

t to the co
-1-).
rrectness of i
Note
l purpos
nf
ercia

orm
m
atio
m

o
n in
or c
thi
e
– Loosen the toothed belt tensioner securing nut and take the
t
sd
iva
toothed belt off.

o
r
rp
cu
o
m
f
– Pull connector off injection pump.

en
ng
t.
yi Co
op py
– Unbolt all fuel supply and return lines at fuel pump. t. C rig
gh ht
pyri by
– Cover openings with a clean cloth.
co Vo
by lksw
cted agen
Prote AG.
– Undo injection lines at injector using ring spanner -3035- .
– Remove injection pump securing nuts/bolts.

– Lift out injection pump complete with injector lines.
– Undo injection lines at injection pump using ring spanner
-3035- .

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
orise nte
eo
Passat 1997 ➤
h
s aut ra
c 6-cylinder diesel engine - Edition 11.2003
s
ce
e
nl
1.4.2 Installing
pt
du
an
itte
y li
erm
ab
– Position injection pump horizontally on a flat surface (for ex‐
ility
ot p
ample using 2 equal height wooden blocks).
wit
, is n
h re
– Screw injector lines onto injection pump so that distance -C-
hole
is 70 mm for all lines.
spec
es, in part or in w
t to the co
rrectness of i
Note
l purpos
♦ Do not rework as the torque presses on the taper (danger of

leaks).
nf
ercia
o
♦ Ensure that the injection lines are not interchanged or twisted.
rm
m
atio
om
– When measuring, slide the union nut back slightly to ensure
n in
or c
the measurement is undertaken on top of the taper of the line.
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
– Distance -C- is calculated as follows: distance -A- minus dis‐

t.
yi Co
op
tance -B- (support) provides distance -C- = 70 mm.
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted
Note
agen
Prote AG.
Check that both fitting sleeves are fitted to centralize the injection
pump in the cylinder block or fit if necessary.
– Fit injection pump on cylinder block and secure.

Bolt torque setting to cylinder block: 20 Nm
Bolt torque setting to toothed belt guard: 10 Nm

– Screw injector lines onto injectors and tighten to 30 Nm.
Note
♦ Do not rework as the torque presses on the taper (danger of

leaks).
♦ Ensure that the injection lines are not interchanged or twisted.

Passat 1997 ➤
– Loosen securing bolts -1- for camshaft toothed belt pulley.

– Align camshaft toothed belt pulley at centre of elongated
holes.
– Fit toothed belt (note direction of rotation).
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
– Tension toothed belt. Turn hexagon key uanti-clockwise
tho until eo
ra
the marks -arrow- align over one another.
ss a c
ce
le
– Tighten securing nut with ring insert -T10023- .

un
pt
an
d
itte
y li
rm
ab
pe
ility
– Tighten camshaft pulley securing bolts to 20 Nm.
ot
wit
, is n
h re
– Remove locking pin -3359- from injection pump pulley.
hole
spec
es, in part or in w
t to the co
until crankshaft is set to OT (TDC) again.
rrectness of i
– Check the toothed belt tensioner marks again.
l purpos
– Install vibration damper and tighten the securing bolts -1- to

20 Nm.
nform
ercia
– Install TDC mark sealing plug on cylinder block.

m
a
com
tio
– Install front intake manifold ⇒ page 50 .
n in
r
te o
thi
– Reconnect connector to injection pump.
s
iva
do
r
rp
c
– Reconnect fuel lines.
um
fo
en
ng
t.
yi
– Fill injection pump, through return line union, with clean diesel
Co
Cop py
⇒ page 162 .
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.4.3 Vehicles from model year 2002

– Adapt new injection pump to immobilizer: Function ⇒ Vehicle
diagnosis, testing and information system VAS 5051.

– Dynamically check commencement of injection and adjust if
necessary ⇒ page 186 .
1.5 Dynamically checking and adjusting

commencement of injection

Passat 1997 ➤
♦ Ring insert -T10023-
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
♦ Vehicle diagnosis, testing and information system -VAS 5051-
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
♦ Diagnostic cable, 3 m with voltage supply -VAS 5051/1- or di‐
or c
agnostic cable, 5 m with no voltage supply -VAS 5051/3-
thi
te
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Note
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♦ Dynamically checking and correcting commencement of in‐ cted agen
Prote AG.
jection is only possible in diagnosis function “04 - Basic set‐
ting”.
♦ Commencement of injection must always be checked, and if
necessary adjusted, after renewing the toothed belt or loos‐
ening the injection pump bolts or toothed belt pulleys.
1.5.1 Procedure
– Connect vehicle diagnosis, testing and information system -
VAS 5051- and read fault memory of engine control unit
⇒ page 196 .
Engine running at idling speed
– Press key “08 - Read measured value block” on display.
– Press key 7 for “Display group number 7” and confirm entry
with Q key.
Display Display Appears on display

group zone
07 1 XX.X°C
2 XX.X°C
3 XX.X°C
4 80.4°C
– Check value for coolant temperature in display zone 4.

Passat 1997 ➤
Specification: at least 80 °C
– Press key ← twice.
– Press key “04 - Basic settings” on display.
– Press key 4 for “Display group number 4” and confirm entry
AG. Volkswagen AG d
with Q key. swagen oes
olk no
V t gu
by ara
After approx. 10 seconds theoritiming
se
d
device is moved to the retar‐ nte
ded (late) position. au
th eo
ra
ss c
ce
le
un
pt
group zone
an
d
itte
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rm
04 1 861 rpm
ab
pe
ility
2 Late
ot
wit
, is n
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3 2.2° ATDC
hole
spec
4 100 %
es, in part or in w
t to the co
Specification in display zone 3: 2° ATDC ± 1.5°
If the specifications are not attained
rrectness of i
l purpos
– Press function “06-End output”.
nform
– Switch off ignition.
mercia
a
com
tion in
– Check tension of injection pump toothed belt. The marks
r
te o
-arrow- must align thi

s
iva
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rp
If the marks do not align:

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fo
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t.
– Loosen toothed belt tensioner.
yi Co
Cop py
t. rig
– Tension toothed belt. Turn hexagon key anti-clockwise until
gh ht
pyri by
the marks -arrow- align over one another.
o Vo
by c lksw
cted agen
Prote AG.
– Tighten securing nut with ring insert -T10023- .
If the marks on toothed belt tensioner align:
– Loosen securing bolts -1- for camshaft toothed belt pulley.

– Turn injection pump shaft slightly by turning securing nut -2-
in:
Direction A to retarded commencement of injection
Direction B to advance commencement of injection
Note
– Tighten camshaft pulley securing bolts to 20 Nm.

– Check commencement of injection again.

Passat 1997 ➤
1.6 Checking injectors


1.6.1 Procedure
VAS 5051- and readsfault AG. Volkswagen AG d control unit
wagenmemory of engine oes
⇒ page 196 . by Volk not
gu
d ara
se nte
Engine running
tho at idling speed
ri e or
au ac
– Press key
ss “08 - Read measured value block” on display.
ce
le
un
pt
– Press keys 1 and 3 for “Display group number 13” and con‐
an
d
itte
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firm entry with Q key.

rm
ab
pe
ility
Indicated on display: Display zone: 1 = Cyl. 3; 2 = Cyl. 1

ot
wit
, is n
h re

hole
spec
group zone
es, in part or in w
t to the co
13 1 0.82 mg/H
2 0.64 mg/H
rrectness of i
3
4
l purpos
Specification: -2...2 mg/H

nform
ercia
– Change to display group 14 as follows: Press key ↑ .

m
a
com
Indicated on display: Display zone: 2 = Cyl. 6; 3 = Cyl. 4; 4 = Cyl.

ion in
5
r
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do

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group zone
fo
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t.
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14 1
Co
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2 gh
1.04 mg/H
ht
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0.86 mg/H
lksw
cted agen
Prote AG.
4 0.64 mg/H
Specification: -2...2 mg/H
– If one or more results lie outside the tolerances, exchange in‐
jectors with one another (except injector for No. 3 cylinder).
– If the fault wanders with the injector, renew the injector
⇒ page 190 .
– If the fault remains on the same cylinder, check the compres‐
sion ⇒ page 84 .

Passat 1997 ➤
1.7 Removing and installing injectors

AG. Volkswagen AG d
agen oes
olksw not
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un
pt
an
Note
d
itte
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erm
ab
ility
♦ Defective injectors cause the following faults:

ot p
wit
is n
♦ Misfiring
h re
ole,
spec
♦ Knocking in one or more cylinders

t to the co
♦ Engine over-heating
♦ Loss of power
rrectne
♦ Excessive black exhaust smoke

s
♦ Higher fuel consumption

s o
cial p
♦ Excessive blue smoke when starting from cold

inform
mer
atio
m
1.7.1 Removing
o
n
c
i
or
n thi
e
– Remove cylinder head cover of respective cylinder bank.

t
sd
va
⇒ page 70
i
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 ➤
– Remove securing nuts and take off retainer.

– Pull out injector.
Note
If a cam lob hinders the removal of an injector, turn crankshaft in

engine direction of rotation further.
1.7.2 Installing
– Check O-ring on injector for damage, renew if necessary.
– Insert injector complete with sleeve -2- and new copper seal
-1-.
Note
When installing the injector, ensure that the fitted pin -3- is guided
into the groove in the cylinder head.
1.7.3 Injector with needle lift sender

– Guide injector cable through retainer.
– Fit retainer.
– Tighten retainer securing nuts to 10 Nm. wage
es n
lks ot g
Vo
– Route cable in the plate guide provider d on the camshaft bear‐
by ua
ran
ing -arrow-. ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
is n
h re
ole,
1.7.4 Injectors with no needle lift sender

spec
t to the co
– Fit retainer.
– Tighten retainer securing nuts to 10 Nm.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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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
co
191
by lksw
cted agen
Prote 1. Repairing diesel direct injection system
AG.
Passat 1997 ➤
1.7.5 Continuation for all injectors

– Install cylinder head cover ⇒ page 70 .
1.8 Repairing injectors

These engines are equipped with dual spring injectors. The fuel
injected therefore occurs in 2 stages. If faults occur with these
injectors then they are to be exchanged as neither repairs nor
pressure setting is possible.
♦ Injector tester -V.A.G 1322-
♦ Pressure line -V.A.G 1322/2-

• Pressure gauge on
1.8.2 Checking injection pressure
WARNING
AG. Volkswagen AG d
agen oes
ksw
When testing injectors ensure that the jet of fuel does not con‐ by Vol not
gu
tact the hands as the high pressure will cause the fuel ristoe d ara
nte
penetrate the skin and may cause severe injuries. utho eo
ra
s a c
s ce
le
un
pt
– Connect injector to injector test unit.
an
d
itte
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erm
ab
– Press pump lever down slowly. When spray begins, read off
ility
ot p
opening pressure. For deviations from specification renew in‐

wit
is n
jector.
h re
ole,
spec
Specifications:
t to the co
New injectors: 200...230 bar.

Wear limit: 170 bar.
rrectness o
cial p
f inform
1.8.3 Checking for leaks

mer
atio
m
– Move pump lever down slowly and maintain a pressure of ap‐

o
n
c
prox. 150 bar for 10 seconds. No fuel should leak from the
or
n thi
e
nozzle tip.
t
sd
iva
o
pr
– If injector leaks, replace.

um
r
fo
en
ng
t.
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1.9 Adapting idling speed
Co
Cop py
t. rig
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Special tools and workshop equipment required cop Vo
by lksw
cted agen
Prote AG.

Passat 1997 ➤

Note
The idling speed can be adjusted within preset tolerances.
1.9.1 Procedure
⇒ page 196 .
Engine running at idling speed
– Press key “10 - Adaption” on display.
– Press key 2 for “Channel 2” and confirm entry with Q key.
AG. Volkswagen AG d
Ensure the specifications for the idling speed are
lksw kept whilst per‐
agen oes
not
forming the adaption. db
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a
e ran
ris tee
Specification: 700...840 rpm utho or
a ac
ss
There are two possibilities for changing the adaption values:
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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hole
spec
es, in part or in w
t to the co
1.9.2 Progressive adaption

Moving the regulator in stages increases or decreases the idling
rrectness of i
speed adaption value.

l purpos
Increase idling speed: move regulator to right.

Decrease idling speed: move regulator to left.
nform
ercia
– Press key Store .

m
at
om
io
– Press key Accept .

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c
in t
or
his
e

at
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priv

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

Passat 1997 ➤
1.9.3 Direct adaption

The idling speed adaption value can be selected directly using
the keypad.
– Press key Keypad .
– Enter new adaption value and confirm entry with Q key.
– Press key Store .
– Press key Accept .
– Press the ← key.
1.10 Identification of injection pump

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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aut ra
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un
pt
an
d

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erm
ab
1.10.1 Procedure
ility
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wit
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h re
ole,

spec
⇒ page 196 . t to the co

Ignition switched on.
– Press key “08 - Read measured value block” on display.
rrectne
– Press keys 2 and 5 for “Display group number 25” and con‐
firm entry with Q key.
ss o
cial p
Injection pump identification is displayed on display e.g.:

inform
mer
00008059 130 106DC062 2.V70420220868

atio
om
♦ 00008 = Data status

c
i
or
n thi
te
♦ 059 130 106D = Part number of injection pump (see parts

sd
iva
o
r
catalogue for current version of injection pump)

p
cum
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fo
en
ng
♦ C062 2.V70 = Injection pump software version

t.
yi Co
Cop py
.
♦ 420220 = Injection pump serial number
ht rig
rig ht
py by
co Vo
♦ 868 = Date of manufacture of injection pump
by lksw
cted agen
Prote AG.

Passat 1997 ➤
1.11 Removing and installing intake manifold

flap
1.11.1 olkswage Removing

es n
ot g
byV ua
– Pull connector off intake
ir se
d manifold flap motor -V157- . ran
tee
tho
or
– Remove intakes amanifold
u flap securing bolts -arrows-. ac
s
ce
e
– Release securing clips on connecting hose and pull off intake

nl
pt
du
manifold flap to side.
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
1.11.2 Installing
nf
ercia

or
note the following:

m
m
atio
m
– Install intake manifold flap to intake manifold with a new O-ring

o
n in
or c
and tighten securing bolts to 10 Nm.

thi
te
sd
iva
o
r
rp
cu
o
m
f
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 ➤
agen
AG. Volkswagen AG d
o w es n
olks ot g
byV ua
ed ran
ris
2 Engine control unit
tee
tho or
au ac
ss
ce
e
nl
pt
du
an
2.1 Reading and erasing engine control unit
itte
y li
erm
ab
fault memory
ility
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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
or

f
en
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n
t.
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Cop py
. rig
2.1.1 Procedure
ht ht
rig by
copy Vo
by lksw
cted
agen
Prote AG.
VAS 5051- as follows:
Vehicles ▸ 09.00
– Pull cover off in direction of arrow.
– Connect connector of the 3 m diagnostic cable with voltage
supply -VAS 5051/1- or 5 m diagnostic cable with no voltage
supply -VAS 5051/3- to diagnostic socket.
Vehicles 10.00 ▸

Passat 1997 ➤
– Fit connector of diagnosis lead, 3m with power supply -VAS

5051/1- or diagnosis lead, 5m without power supply -VAS
5051/3- to diagnosis connection -arrow-.
– Start engine and run at idling speed.
Only when engine does not start:
– Switch on ignition.
2.1.2 Select operating mode:

– Press key on display for “Vehicle self-diagnosis”.
2.1.3 Select vehicle system:

– Press button “01 - Engine electronics” on display.. Volkswage
n AG n AG d
wage oes
The control unit identification and codingy Vare
olksindicated on the dis‐ not
gu
play. ise
d b ara
nte
r
ho eo
ut
2.1.4 Select diagnostic function: ss
a ra
c
ce
e
nl
– Press key “02 - Read fault memory” on display.
pt
du
an
itte
y li
– If no fault is stored in engine control unit “0 fault detected” is
erm
ab
displayed.
ility
ot p
wit
, is n
– If faults are stored in the engine control unit, these are shown
h re
one below the other on the display.
hole
spec
es, in part or in w
– Press the ← key.
t to the co
– Press key “05 - Erase fault memory” on display.
rrectness of i
2.2 Adapting functions and components
l purpos

nf
ercia
or

m
m
atio
om
n in
or c
thi
te
sd
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f
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Select “guided fault finding” in vehicle diagnosis, testing and in‐
formation system -VAS 5051- .
After all control units have been read:
– Press “GoTo” key.
– Select “Function/component selection”.
2. Engine control unit 197

Passat 1997 ➤
– Select “Drive train”.

– Select “Engine code”.
– Select “01-Systems capable of self-diagnosis”.
– Select “Engine management”.
– Select “Functions”.
– Select “Function or component”.
2.3 Removing and installing engine control

unit
– Before removing engine control unit, first read control unit
identification and thereby the coding of the engine control unit
currently installed ⇒ page 196 ; Reading and erasing engine
control unit fault memory.
2.3.1 Removing
– Switch off ignition.
– Remove E-box cover.
– Unclip the engine control unit retainer.
. Volkswagen AG
wa gen AG does
– Release connector on engine control unit and pullVoff
olksconnec‐ not
gu
tor. ed
by ara
nte
is
or eo
– Remove the old control unit and insert the
au new control
th unit. ra
ss c
– Check the previous coding and code the new control unit
ce
le
un
pt
⇒ page 197 ; Adapting functions and components.
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Passat 1997 ➤
26 – Exhaust system
1 Removing and installing parts of ex‐
haust system
Note
♦ After working on the exhaust system ensure that the system

is not under stress, and that there is sufficient clearance to the
bodywork. If necessary, loosen double and single clamps and
align silencer and exhaust pipe so that sufficient clearance is
maintained to the bodywork and the support rings are evenly
loaded.
G. Volkswage
♦ Renew self-locking nuts. lkswagen A n AG d
oes
not
Vo gu
y
♦ The flexible pipe connection
ise
d b
(de-coupling element) on the front
ara
n
exhaust pipe must
ut
honot be bent more than 10° - otherwise it can e o
r te
be damaged. ss a ra
c
ce
e
♦ The left or right exhaust manifold and front exhaust pipe and
nl
pt
du
an
only be removed together.
itte
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erm
ab
ility
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1.1 Front exhaust pipe with catalytic con‐
wit
, is n
verter, middle silencer, rear silencer and
h re
hole
spec
attachments
es, in part or in w
t to the co
rrectness of i
Four-wheel drive vehicles ⇒ page 202

l purpos

nform
ercia
Engine codes BAU, BDH and BDG ⇒ page 201

m
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
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co lksw
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cted agen
Prote AG.
1. Removing and installing parts of exhaust system 199

Passat 1997 ➤
1 - 25 Nm
2 - Mounting
3 - Turbocharger
4 - Gasket
❑ Renew
❑ With catalytic converter
❑ Components of exhaust
pipe mountings for vehi‐
cles with manual gear‐
box ⇒ page 202
❑ Individual components
of exhaust pipe mount‐
ings for vehicles with au‐
tomatic gearbox
⇒ page 202
6 - Double clamp
7 - 40 Nm
8 - Mounting
9 - Rear silencer
❑ Middle and rear silenc‐
ers are installed as a
single component dur‐
ing production. In cases
of repair, the centre and
rear silencer are sup‐
plied separately, includ‐
ing a double clamp for
purposes of connection
❑ Cut through connecting
pipe with e.g. body saw
-V.A.G 1523 A- at right agen
AG. Volkswagen AG d
oes
angles at separating olksw not
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point ⇒ page 201 rise
d b ara
nte
tho eo
10 - Repair double clamp s a u ra
c
s
ce
le
un
pt
an
d
11 - Middle silencer
itte
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erm
ab
❑ Cut through connecting pipe with e.g. body saw -V.A.G 1523 A- at right angles at separating point
ility
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⇒ page 201
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.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
200
cted agen
Prote AG.
Rep. Gr.26 - Exhaust system
Passat 1997 ➤
1 - 25 Nm
2 - Mounting AG. Volkswagen AG d
agen oes
lksw not
3 - Starter catalytic converter
d by
Vo gu
ara
ise nte
r
4 - Gasket ut
ho eo
ra
a
❑ Renew s s c
ce
e
nl
pt
du
an
itte
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❑ With catalytic converter
erm
ab
ility
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, is n
h re
hole
spec
box ⇒ page 202
es, in part or in w
t to the co
tomatic gearbox
rrectness of i
⇒ page 202
l purpos
6 - Double clamp
7 - 40 Nm
nf
ercia
orm
8 - Mounting
m
atio
om
n in
9 - Rear silencer
or c
thi
e

t
sd
iva

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cu

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f
en
ng

t.
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op
C py
t. rig
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ht
pyri by
Vo
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by c lksw
cted agen
ing a double clamp for Prote AG.
-V.A.G 1523 A- at right
angles at separating
point ⇒ page 201
10 - Repair double clamp
11 - Middle silencer
❑ Cut through connecting pipe with e.g. body saw -V.A.G 1523 A- at right angles at separating point
⇒ page 201
Separating point between middle silencer and rear silencer

AG. Volkswagen AG d
agen oes
olksw not
y V gu
Passat 1997 ➤ rise
d b ara
nte
6-cylinder diesel engine - Edition 11.2003 autho eo
ra
ss c
ce
le
Installation position of repair double clamp
un
pt
an
d
itte
– Installation position of repair double clamp -1- horizontal, bol‐
y li
erm
ab
ted connections pointing left.
ility
ot p
wit
– Evenly tighten bolted connections of repair double clamp to 40
is n
h re
Nm
ole,
spec
t to the co
rrectness o
cial p
f
Individual components of exhaust pipe mountings for vehicles
inform
with manual gearbox
mer
atio
1- Bolt, 25 Nm
om
n
c
i
or
n
2- Bracket
thi
te
sd
va
3- Nut, self-locking -25 Nm-

i
o
pr
cum
r
fo
en
4- Bolt, 25 Nm
ng
t.
yi Co
op py
5- Spacer tube t. C rig
gh ht
pyri by
Vo
6- Bolt, 25 Nm
co lksw
by
cted agen
Prote AG.
7- Washer
8- Spring
9- Buffer
10 - Bracket
11 - Spacer sleeve

with automatic gearbox
1- Bolt, 25 Nm
2- Washer
3- Bracket
4- Bolt, 25 Nm
5- Spacer tube
6- Buffer
7- Bracket
9- Bolt, 25 Nm
10 - Washer
11 - Spring
12 - Spacer sleeve
1.2 Front exhaust pipe with catalytic con‐

verter and attachments

Front-wheel drive vehicles ⇒ page 199
202 Rep. Gr.26 - Exhaust system

Passat 1997 ➤

Engine codes BAU, BDH and BDG ⇒ page 204
1 - 25 Nm
2 - Turbocharger
3 - Gasket
❑ Renew
❑ With catalytic convert‐
ers
5 - Double clamp
6 - 40 Nm
7 - To middle silencer
8 - Mounting
box ⇒ page 204
tomatic gearbox
⇒ page 205
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au 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
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
cted agen
Prote AG.

Passat 1997 ➤

AG. Volkswagen AG d
agen oes
1 - Starter catalytic converter Volksw not
gu
by ara
d
2 - Gasket rise nte
tho eo
u
❑ Renew ss a ra
c
ce
e
3 - 25 Nm
nl
pt
du
an
itte
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erm
ab
ility
❑ With catalytic convert‐
ot p
wit
ers
, is n
h re
hole
5 - Double clamp
spec
es, in part or in w
6 - 40 Nm
t to the co
7 - To middle silencer
rrectness of i
8 - Mounting
l purpos

nf
ercia
box ⇒ page 204
orm
m
atio
m

o
n in
c

or
thi
e
tomatic gearbox
t
sd
iva
⇒ page 205
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

with manual gearbox
1- Bolt, 25 Nm
2- Bolt, 25 Nm
3- Bracket
4- Bolt, 25 Nm
6- Spacer tube
7- Spacer sleeve
8- Buffer
9- Bracket
10 - Spring
11 - Washer

Passat 1997 ➤

with automatic gearbox
1- Bolt, 25 Nm
3- Bracket
4- Bolt, 25 Nm
5- Bolt, 25 Nm
6- Spacer tube
7- Spacer sleeve
8- Buffer
9- Bracket
10 - Spring
11 - Washer
1.3 Silencer with mountings
1 - 40 Nm
2 - From catalytic converter
3 - Coach bolt
4 - Double clamp agen
AG. Volkswagen AG d
oes
olksw not
V gu
5- 25 Nm ed by ara
nte
ris
o eo
6- Mounting auth
ra
ss c
❑ With retaining ring
ce
le
un
pt
an
7 - Middle silencer
d
itte
y li
erm
ab
8 - Repair double clamp

ility
ot p
wit
9 - Separating point
is n
h re
ole,

spec

t to the co

rrectne

ing a double clamp for
ss
o
cial p
f i

nform

mer
-V.A.G 1523 A- at right

atio
m
angles at separating
o
n
c
i
or
point ⇒ page 206

thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

Passat 1997 ➤
10 - Rear right silencer

11 - Mounting
12 - Rear left silencer
Separating point between middle silencer and rear silencer
lkswage es n
o ot g
Special tools and workshop equipment d by V required ua
ran
ir se tee
♦ Pneumatic sabre saw -V.A.Gutho 1523 A- 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
t to the co
rrectness of i
l purpos
1.3.2 Procedure
– Separate connecting pipe between middle silencer and rear
nform
ercia
silencer at the point marked with a groove: Measurement -a-

m
approx. 244 mm.

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.
1.4 Removing and installing left exhaust

manifold with front exhaust pipe

Passat 1997 ➤
1.4.1 Removing

– Removing air conditioner compressor: Observe additional
notes and repair work ⇒ page 16 . wage
e
olks s no
yV t gu
ris
ed
b ara
nte
tho eo
– Remove heat shield over turbocharger
ss
au -arrows-. ra
c
ce
e
– Remove complete front exhaust pipe with catalytic converter

nl
pt
du
an
or starter catalytic converter.
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
– Remove exhaust manifold nuts -arrows- (accessible from be‐

low).
nform
ercia

attached).
m
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 ➤
– Unbolt exhaust pipe from turbocharger -arrows- (accessible

from above).
– Take out exhaust manifold with exhaust pipe upwards.
– Separate exhaust manifold from exhaust pipe if necessary.
1.4.4 Installing
– Note installation position of exhaust manifold gasket:
Aluminium side facing cylinder head

ting
Exhaust manifold to cylinder head agen AG. Volkswagen A22
G dNm
oes
lksw not
Exhaust pipe to exhaust manifold
d by Vo
22 Nm gu
ara
ise nte
Exhaust pipe to compensator
thor 22 Nm eo
u ra
sa
Front exhaust pipe swith catalytic converter or 25 Nm c
starter catalytic converter to turbocharger
ce
e
nl
pt
du
an
Front exhaust pipe to gearbox mounting 25 Nm

itte
y li
erm
ab

ility
ot p
wit
Exhaust pipe clamping sleeve 40 Nm

, is n
h re
Air conditioner compressor to bracket 22 Nm

hole
spec
Floor cross member to body 20 Nm

es, in part or in w
t to the co
1.5 Removing and installing right exhaust

manifold with front exhaust pipe
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
cted agen
Prote AG.
1.5.1 Removing

Passat 1997 ➤

cooler -arrow-.
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
– First remove exhaust manifold and exhaust pipe nuts acces‐

pt
an
d
itte
sible from below and those accessible from above -arrows-.

y li
erm
ab
– Take out exhaust manifold with exhaust pipe upwards.

ility
ot p
wit
is n
– Separate exhaust manifold from exhaust pipe if necessary.

h re
ole,
spec
t to the co
rrectness o
cial p
f i
1.5.2 Installing
nform
mer
atio

om
n
c
i
or
– Note installation position of exhaust manifold gasket:

thi
te
sd
va
Aluminium side facing cylinder head

i
o
pr
cum
r
fo
en
ng

t.
yi Co
Cop py
t. rig
gh
ht
pyri by
Vo
ting
o
by c lksw
cted agen
Prote AG.
Exhaust manifold to cylinder head 22 Nm
Exhaust pipe to exhaust manifold 22 Nm
Exhaust pipe to compensator 22 Nm

Passat 1997 ➤
2 Exhaust gas recirculation system
Note
♦ The exhaust gas recirculation system is actuated by the diesel

direct injection system control unit -J248- via the exhaust gas
recirculation valve -N18- to the mechanical exhaust gas recir‐
culation valve.
♦ The cone-shaped plunger in the mechanical exhaust gas re‐
circulation valve ensures that various cross sectional openings
are possible at different plunger lifts.
AG. Volkswagen AG d
agen
♦ Pulsed control enables every conceivable valve Vposition.
olks
w oes
not
gu
by ara
ed
♦ Renew self-locking nuts. oris nte
eo
th
au ra
c
ss
ce
le
WARNING
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
tions:
h re
ole,
spec
t to the co
sitions.
rrectne
hot components.
ss o
cial p
f i
2.1 Vacuum hose schematic diagram
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Passat 1997 ➤
1 - Vacuum line
❑ From mechanical ex‐
haust gas recirculation
valve to exhaust gas re‐
circulation valve -N18-
2 - Exhaust gas recirculation
valve
3 - To charge pressure control agen
AG. Volkswagen AG d
oes
solenoid valve -N75- . olksw not
yV g b ua
ed ran
4 - To air filter ho
ris tee
ut or
❑ Only installed with
ss
a en‐ ac
gine codes AFB, AKN,
ce
le
un
BAU and BDH
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
shown in figure
hole
spec
es, in part or in w
6 - Brake servo
t to the co
7 - Exhauster pump
8 - Exhaust gas recirculation
rrectness of i
valve -N18-
l purpos
9 - To vacuum reservoir
❑ In wheel housing
nform
ercia
10 - Electrohydraulic engine
m
a
mounting solenoid valve -
com
N398- tion in
r
te o
thi
11 - To engine mountings
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted
2.2 Checking exhaust gas recirculation
agen
Prote AG.
valve
♦ Hand vacuum pump -V.A.G 1390-
– Pull vacuum hose off exhaust gas recirculation valve.
2. Exhaust gas recirculation system 211

Passat 1997 ➤
– Connect hand vacuum pump -V.A.G 1390- to valve.

– Operate hand vacuum pump -V.A.G 1390- .
– Pull hand vacuum pump hose off exhaust gas recirculation
valve.
♦ The closing of the valve should be clearly audible.
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
rm
ab
pe
ility
2.3 Removing and installing exhaust gas re‐
ot
wit
, is n
circulation valve
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
op
♦ Torque wrench -V.A.G 1331- (5...50 Nm) C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2.3.1 Removal for vehicles with no coolant

cooled exhaust gas recirculation
– Remove exhaust gas supports ⇒ Item 16 (page 170) .
– Pull vacuum hose off exhaust gas recirculation valve.

Passat 1997 ➤
– Remove nuts -1- and bolt -2-.

– Remove mechanical exhaust gas recirculation valve.
2.3.2 Removal for vehicles with coolant

cooled exhaust gas recirculation
– Remove starter catalytic converter ⇒ Item 16 (page 172) .
olkswagen AG
– Remove front intake manifold ⇒ page
swa
g51
en A.G. V does
k not
Vol gu
– Pull vacuum hose off exhaust
se
d b gas recirculation valve.
y ara
nte
i
or eo
– Unbolt injection lines with
au ring spanner -3035- .
th ra
ss c
– Remove nuts -2- and bolt -3-.
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
2.3.3 Installing
en
ng
t.
yi Co
Cop py
Installation is carried out in the reverse order. When installing, ht. rig
rig ht
by
note the following: copy Vo
by lksw
cted agen
Prote
AG.

ting
Mechanical exhaust gas recirculation valve to in‐ 22 Nm
take manifold
Exhaust gas recirculation pipe to compensator 22 Nm
2. Exhaust gas recirculation system 213

Passat 1997 ➤
AG. Volkswagen AG d
agen oes
olksw not
Threaded connection Torque ed byset‐
V gu
ara
risting nte
ho eo
ut ra
Injection lines to injectors or injection pump ss a
30 Nm 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.

Passat 1997 ➤
28 – Glow plug system

1 Glow plug system
1.1 Checking glow plug system

♦ Hand multimeter -V.A.G 1526 B-
♦ Auxiliary measuring set -V.A.G 1594 C-
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
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1.1.1 Test prerequisites
rrectness of i
• Battery voltage at least 11.5 V
l purpos
• Ignition switched off
nform
ercia
• Diesel direct injection system control unit -J248- is OK.

m
at
om
• Glow plug strip fuses ( fuse -S125- and fuse -S189- ) OK.
ion
c
in t
or

his
ate
do
priv
c
– Pull glow plug connectors off glow plugs.
um
for
en
ng
t.
yi
– Connect multimeter to measure voltage between a glow plug
Co
op py
connector and vehicle earth. t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
VAS 5051- , switch ignition on and read fault memory of engine Prote AG.
control unit ⇒ page 196 .
– Initiate final control diagnosis and activate glow plug relay -
J52- .
Display on multimeter must swing between 0 V and approx. bat‐
tery voltage.
– If no voltage is present: ⇒ Current flow diagrams, Electrical
fault finding and Fitting locations
1.2 Checking glow plugs

♦ Auxiliary measuring set -V.A.G 1594 C-
♦ Diode test lamp -V.A.G 1527 B-
1. Glow plug system 215

Passat 1997 ➤
♦ U/J extension and socket, 10 mm -3220-
1.2.1 Test prerequisites

• Battery voltage at least 11.5 V olkswage es n
ot g
V
by ua
• Ignition switched off ris
ed ran
tee
tho or
au
1.2.2 Test procedure ss ac
ce
e
nl
pt
– Pull glow plug connectors off glow plugs.
du
an
itte
y li
erm
– Connect diode test lamp wire using auxiliary clips from auxili‐
ab
ility
ary cable set to battery positive (+).
ot p
wit
, is n
– Place test probe of diode test lamp on each glow plug in turn.
h re
hole
spec
Diode lights up: Glow plug OK.
es, in part or in w
t to the co
If diode does not light up: fit a new glow plug
– Remove and install glow plugs with jointed spanner -3220- . 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 agen
Prote AG.
216 Rep. Gr.28 - Glow plug system

K0450732920-6-Cylinder Diesel Engine

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Service

Service Department. Technical Information

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Copyright © 2015 Volkswagen AG, Wolfsburg K0450732920

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2.4 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

3 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

1.3 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

1.4 Removing, installing and tensioning toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

1.5 Removing toothed belt from camshaft pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

1.6 Removing and installing left intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

1.7 Removing and installing right intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

1.1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

1.1 Parts of cooling system - body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

1.3 Overview - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

1.8 Charge pressure control hose routing diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

2.2 Adapting functions and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

2.3 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

2.2 Checking exhaust gas recirculation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

1.1 Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

1.1 Engine number n AG. Volkswagen AG do

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

Engine code AFB AKN BAU BDH BDG

Manufactured 08.98 ▸ 09.99 ▸ 12.02 ▸ 12.02 ▸ 03.03▸

Capacity l 2.5 2.5 2.5 2.5 2.5

Output kW at rpm 110/4000 110/4000 132/4000 132/4000

3200 3200 2500 2500 2500

10 – Removing and installing engine

1.1 Removing engine

Special tools and workshop

1. Removing and installing engine 3

♦ Before carrying out further work, disconnect battery earth

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

– Install lock carrier with attachments. ⇒ General body repairs,

exterior; Rep. Gr. 50 ; Body - front .

– Detach ATF lines from gearbox. ⇒ 5-speed automatic gearbox

– Remove engine cover first.

– Remove air intake duct -1- and cover -2-.

4 Rep. Gr.10 - Removing and installing engine

– Remove air duct in front of charge air cooler -arrows-.

WARNING n AG. Volkswagen AG do

– Disconnect inter-connecting, coolant, vacuum and intake ho‐

– Remove cover -arrow- at power steering fluid reservoir.

– Remove heat shield over turbocharger.

– Remove front exhaust pipe with catalytic converter or starter

– Remove poly-V-belt. ⇒ page 24

1.2.2 Continuation for all vehicles

1. Removing and installing engine 5

1.2.3 Vehicles with automatic gearbox

♦ To loosen torque converter bolts, counterhold on centre bolt

and gearbox jack -V.A.G 1383 A- .

– Remove lower engine to gearbox connecting bolts.

gine mountings -arrows-.

6 Rep. Gr.10 - Removing and installing engine

– Mark the installation position of the threaded connections -1- . Volkswagen AG