K0050606020-5-Speed Automatic Gearbox 01V

n AG.
Volkswagen AG do
Service lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Workshop Manual
l purpos
Passat 1997 ➤
nform
ercia
5-speed automatic gearbox 01V

m
at
om
ion
c
Edition 08.2007
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.
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
32 - Torque converter
37 - Controls, housing
38 - Gears, control
39 - Final drive - differential
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
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
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 K0050606020

Passat 1997 ➤
5-speed automatic gearbox 01V - Edition 08.2007
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Gearbox identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Notes on 5-speed automatic gearbox 01V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Notes on 5-speed automatic gearbox 01V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Identification codes, engine allocation, ratios, equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.1 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.2 “Vorsprung durch Technik” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
32 - Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1 Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.1 Identification of torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 Checking torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3 Draining torque converter a. g.e.n .AG . .. V.o.lk.sw
. a. g.e.n.A.G.d.o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ksw es
1.4 Removing and installing by
Vol torque converter oil seal .n.ot.g.u . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
d a
1.5 Installing torqueorconverter
ise . . . . . . . . . . . . . . . . . . . . . . .ra.n.te. . . . . . . . . . . . . . . . . . . . . . . . . 15
th eo
au ra
37 - Controls, housing
ss
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
c
ce
e
nl
pt
1 Electrical and electronic components and their locations . . . . . . . . . . . . . . . . . . . . . . . . . . 17
du
an
itte
y li
2 Repairing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
erm
ab
ility
2.1 Checking selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ot p
wit
, is n
2.2 Checking and adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . h re 26

2.3 Checking operation of the ignition key withdrawal lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
hole
spec
2.4 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

es, in part or in w
t to the co
2.5 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

2.6 Dismantling and assembling selector mechanism (assembly overview) . . . . . . . . . . . . . . 33
2.7 Dismantling and assembling selector mechanism (assembly sequence) . . . . . . . . . . . . . . 38
rrectness of i
2.8 Removing and installing selector lever lock solenoid N110 . . . . . . . . . . . . . . . . . . . . . . . . 44

l purpos
2.9 Removing and installing selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

2.10 Removing and installing locking cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
nf
ercia
2.11 Adjusting locking cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

orm
m
atio
3 Dismantling and assembling the selector mechanism cover . . . . . . . . . . . . . . . . . . . . . . . . 53

om
n in
3.1 Selector mechanism cover - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

or c
thi
3.2 Removing and installing the selector mechanism cover . . . . . . . . . . . . . . . . . . . . . . . . . . 53

te
sd
iva
3.3 Dismantling and assembling selector mechanism cover . . . . . . . . . . . . . . . . . . . . . . . . . . 55

o
r
rp
cu
o
m
f
4 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

en
ng
t.
yi Co
op
4.1 Removing and installing the gearbox for vehicles with 4-cylinder TDI engine with pump/nozzle
C py
t. rig
unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
gh
57
ht
pyri by
Vo
4.2 Removing and installing gearbox for vehicles with 4-cylinder petrol engines . . . . . . . . . . 71
co lksw
by
cted agen
Prote
4.3 Removing and installing gearbox for vehicles with 5-cylinder engines . . . . . . . . . . . . . . . . 82
AG.
4.4 Installing and removing the gearbox for vehicles with V6 TDI engines . . . . . . . . . . . . . . . . 95
4.5 Removing and installing the gearbox for vehicles with V6 petrol engines . . . . . . . . . . . . . . 111
4.6 Transporting automatic gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4.7 Securing gearbox to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.8 Installing and removing the gearbox mountings and gearbox support on the left and right
........................................................................ 129
5 Checking ATF level and topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
5.1 Checking ATF level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
5.2 Topping up ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Contents i
Passat 1997 ➤
5.3 Replacing ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

6 Overview - power transmission, front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
6.1 Position of the selector elements with hydraulic control E17 . . . . . . . . . . . . . . . . . . . . . . . . 141
6.2 Position of the selector elements with hydraulic control E18/2 . . . . . . . . . . . . . . . . . . . . . . 142
7 Dismantling and assembling gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
7.1 Removing and installing ATF lines in vehicles with 4-cylinder engines . . . . . . . . . . . . . . . . 143
7.2 Removing and installing ATF lines in vehicles with 5-cylinder 110 kW engine . . . . . . . . . . 144
7.3 Removing and installing ATF lines in vehicles with 5-cylinder 125 kW engine . . . . . . . . . . 145
7.4 Removing and installing ATF lines in vehicles with V6 TDI engines . . . . . . . . . . . . . . . . . . 146
7.5 Removing and installing ATF lines in vehicles with V6 petrol engines . . . . . . . . . . . . . . . . 147
7.6 Cleaning ATF lines and ATF cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
38 - Gears, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

1 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.1 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
2 Removing and installing ATF strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
2.1 Removing and installing ATF strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
3 Removing and installing valve body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
3.1 Assembly overview of valve body for gearbox with hydraulic control E17 . . . . . . . . . . . . . . 152
3.2 Assembly sequence of valve body for gearbox with hydraulic control E17 . . . . . . . . . . . . 154
3.3 Assembly overview of valve body for gearbox with hydraulic control E18/2 . . . . . . . . . . . . 159
3.4 Assembly sequence of valve body for gearbox with hydraulic control E18/2 . . . . . . . . . . . . 161
3.5 Removing and installing internal oil pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3.6 Replacing gearbox speed sender G38 gen AorG. gearbox
Volkswagen output
AG do speed sender G195 ........ 167
swa es n
3.7 Replacing gearbox input speed yV
olksender G182 . . . . . . . . . .
o t .
gu. . . . . . . . . . . . . . ......... 168
db ara
3.8 Removing and installing riswiring
e harness in gearbox . . . . . . . . . .n.
tee. . . . . . . . . . . ........ 170
ho
3.9 Replacing gearbox oila temperature sender (ATF) G93 . . . . . . . . . . .ac. . . . . . . . . . . . . . . . .
ut o r 172
ss
4 Replacing sealing ring for selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
ce
e
nl
pt
du
4.1 Renewing oil seal for selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

an
itte
y li
erm
5 Replacing multi-function switch F125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

ab
ility
ot p
5.1 Replacing multi-function switch F125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

wit
, is n
6 Replacing speedometer sender G22 or vehicle speed sender G68 . . . . . . . . . . . . . . . . . . 177

h re
hole
spec
6.1 Replacing sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

es, in part or in w
t to the co
39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

1 Checking oil in front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
rrectness of i
1.1 Checking oil in front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

l purpos
2 Repairing front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

2.1 Replacing sealing ring for right flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
2.2 Replacing sealing ring for left flange shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
nform
ercia
2.3 Replacing front final drive/gearbox housing sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . 190

m
at
om
2.4 Replacing O-ring on cover for front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

ion
c
in t
2.5 Renewing O-ring on cover for front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

or
his
te
2.6 Replacing the front final drive seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

a
do
priv
3 Definitions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
um
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ii Contents
Passat 1997 ➤
00 – Technical data
1 Gearbox identification
The 5-speed automatic gearbox 01V is installed in the Passat
1997 ▸ in combination with 4, 5 and 6-cylinder engines. Allocation
⇒ page 3 .
1.1 Gearbox identification
1.1.1 Location of code letters on gearboxn AG. Volkswagen A

ge G do
swa es n
The gearbox code letters are given on the type plate
by
Voat
lk the bottom ot g
ua
of the gearbox -arrow-. ris
ed ran
tee
ho
aut or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Gearbox code letters and gearbox serial number.
rrectness of i
Gearbox Serial No. -arrow 1-, Gearbox identification -arrow 2-
l purpos
Code letters -arrow 3-

The gearbox code also appears on the vehicle identification
nf
ercia
plates.
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
co lksw
by
cted agen
Prote AG.
1. Gearbox identification 1
Passat 1997 ➤
2 Notes on 5-speed automatic gearbox

01V
⇒ Self-study programme No. 180 ; 5-speed automatic gearbox
01V provides extensive information about the operation of this
gearbox.
2.1 Notes on 5-speed automatic gearbox

01V
2.1.1 Torque converter

The torque converter is equipped with a lock-up clutch. The clos‐
ing of the lock-up clutch is determined by the engine load and
speed and produces very little vibration. The lock-up clutch drives
all forwards gears mechanically without slip.
2.1.2 Gearbox
. Volkswagen AG
wa gen AG does
The 5-speed automatic gearbox 01V has five hydraulically
olks acti‐ not
yV
vated forward gears. When the lock-up clutch is eclosed, these
gu
db ara
nte
forward gears become mechanically driven gearsho
ris by eliminating eo
torque converter slip. aut ra
s s c
ce
e
2.1.3 Automatic gearbox control unit -J217-

nl
pt
du
an
itte
with driving situation gearshifts (fuzzy
y li
erm
ab
logic)
ility
ot p
wit
, is n
h re
The gear change point, which is dependent on the driving situa‐
hole
tion and driving resistance, is determined automatically.
spec
es, in part or in w
Advantages:
t to the co
• Gear changes will be fuel-consumption orientated.
rrectness of i
• Maximum engine output is always available.
l purpos
• Individual adaptation of gear change points in all driving sit‐

uations. nf
ercia
• Gear change points are infinitely variable.

orm
m
atio
2.1.4 Gear change point variations for grades

om
n in
or c
An additional gear change map automatically selects gear

thi
te
sd
a
changes for gradients dependent upon accelerator pedal position

iv
o
r
rp
cu
and driving speed.

o
m
f
en
ng
t.
yi
• Gear change map for extreme uphill stretches is matched to
Co
op py
engine output. t. C rig
gh ht
pyri by
• Gear change map for extreme downhill stretches is matched
o Vo
by c lksw
cted
to the braking effect of the engine.
agen
Prote AG.
2.1.5 Guided fault finding, vehicle self-diag‐

nosis and testing
Before performing repairs on the automatic gearbox, determine
the cause of the fault as accurately as possible using vehicle di‐
agnosis, testing and information system -VAS 5051- in modes of
operation “guided fault finding”, “vehicle self-diagnosis” and “test
instruments”.
2 Rep. Gr.00 - Technical data

Passat 1997 ➤
AG. Volkswagen AG d
agen oes
lksw not
3 Identification codes, engine allocation, ratios, equipment Vo gu
by ara
d
rise nte
tho eo
Automatic gearbox ss au
01V ra
c
ce
Gearbox Identification CJQ CJW DDT
le
un
pt
code
an
d
itte
y li
rm
Manufactured from 03.97 01.97 04.97
ab
pe
ility
to 01.99 04.97 08.95
ot
wit
, is n
Allocation Model Passat 1997 ▸ Passat 1997 ▸ Passat 1997 ▸
h re
hole
Engine 1.8 l - 110 kW 2.8 l - 142 kW 1.8 l - 110 kW
spec
es, in part or in w
Data bus no no no
t to the co
Hydraulic control E17 E17 E17
For information about this, refer to
rrectness of i
⇒ page 20
l purpos
nform
Automatic gearbox 01V
ercia
Gearbox Identification DEP DSJ

m
a
com
t
code
ion in
r
te o
Manufactured from 08.99 08.99
thi
s
to 08.00
iva
do
r
rp
cum
Allocation Model Passat 1997 ▸ Passat 1997 ▸
fo
en
ng
t.
yi
Engine 2.3 l - 110 kW 2.3 l - 110 kW
Co
Cop py
t. rig
Data bus gh
yes yes
ht
pyri by
Vo
o
Hydraulic control E18/2 E18/2
c by lksw
cted agen
Prote AG.
⇒ page 20

Gearbox Identification DRD DSS DUL
code
to 05.97 08.00
2.8 l - 137 kW
Data bus yes yes no
Hydraulic control E17 E17 E17
⇒ page 20

Gearbox Identification DUM EBU EBW
code
to 08.00 08.00 08.00
2.8 l - 140 kW
Data bus no no yes
3. Identification codes, engine allocation, ratios, equipment 3

AG. Volkswagen AG d
agen
Passat 1997 ➤ Volksw
oes
not
by gu
5-speed automatic gearbox 01V - Edition 08.2007 ised ara
nte
or eo
h
aut ra
Hydraulic control E17 ss E18/2 E18/2 c
ce
e
nl
pt
du
⇒ page 20
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Gearbox Identification EDC EFP EFR
es, in part or in w
code
t to the co
to 08.99 08.00 11.99
rrectness of i
l purpos
diesel diesel
nf
ercia
Data bus yes no yes
orm
Hydraulic control E18/2 E18/2 E17
m
atio
m
o
n in
c
⇒ page 20
or
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng

t.
yi Co
Cop py
Gearbox Identification EKC EMA EMK
t. rig
gh ht
yri
code
p by
o Vo
by c lksw
cted agen
Manufactured from 08.99 Prote 01.00 AG.
08.99
to 08.00 08.00 11.99
diesel diesel
Data bus no yes yes
Hydraulic control E18/2 E18/2 E18/2
⇒ page 20

Gearbox Identification ERY ETU ETZ
code
to 08.00 08.00 08.00
diesel diesel diesel
Data bus no yes yes
Hydraulic control E18/2 E17 E18/2
⇒ page 20

Gearbox Identification EYF EZR EZS
code
to 08.00 08.99

Passat 1997 ➤

1.9 l - 96 kW 1.8 l - 125 kW
diesel
Data bus yes yes yes
⇒ page 20

Gearbox Identification EZT EZU EZV
code
to 08.00 08.00 05.01
diesel
⇒ page 20
AG. Volkswagen AG d
agen oes
olksw not
V gu
by ara
Automatic gearbox orised
nte 01V
h eo
Gearbox aut
Identification EZW ra EZY EZZ
s c
s
code
ce
le
un
pt

an
d
itte
y li
to 05.01
erm
ab
ility

ot p
wit
is n

h re
ole,
diesel 2.8 l - 140 kW

spec

t to the co

⇒ page 20
rrectness o
cial p

inform
Gearbox Identification FEV FHV FNL

mer
atio
code
om
n
c

i
or
n thi
to 05.03
te
sd
iva
o
r

p
cum
r
fo
en
ng

t.
yi Co
diesel
Cop py
t. rig
gh ht
Data bus yri
yes yes yes
p by
o Vo
by c lksw
Hydraulic control cted
E18/2 E18/2 E18/2
agen
Prote AG.
⇒ page 20

Gearbox Identification FAD GMR
code
3. Identification codes, engine allocation, ratios, equipment 5

Passat 1997 ➤
Manufactured from 05.03 11.03

to
Allocation Model Passat 1997 ▸ Passat 1997 ▸
Engine 2.5 l - n120
AG. VkW
olkswagen2.0 l - 100 kW
AG do
ksw diesel diesel
age es n
ol ot g
yV
Data bus ed b yes yes ua
ran
oris tee
Hydraulic control au
th E18/2 E18/2 or
a
For information about this, refer to ss c
ce
⇒ page 20
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Passat 1997 ➤
AG. Volkswagen AG d
agen oes
olksw not
4 Capacities yV
b gu
d ara
ise nte
or eo
h
aut ra
ss c
ce
4.1 Capacities e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
4.1.1 Planetary gear
wit
, is n
h re
hole
Capacities Planetary gear Automatic
spec
gearbox
es, in part or in w
t to the co
Initial filling 9.0 l 01V
Change about 2.6 - 3.0 l1)
rrectness of i
Lubricant VW ATF
l purpos
1) Change required only following repair work or removal of oil pan up to 3 litres.
VW ATF is available as a part.
nform
ercia
Container size 0.5 l - part number ⇒ Electronic parts catalogue

m
at
om
“ETKA” .
ion
c
in t
or
his
ate
“ETKA” .
do
priv
cum
or
Only replacement part VW ATF may be used for the planetary

f
en
ng
t.
gears in automatic gearbox 01V.
yi Co
Cop py
ht. rig
4.1.2 Front final drive
rig ht
py by
co Vo
by lksw
cted agen
Prote
Capacities Front final drive Automatic
AG.
gearbox
Initial filling approx. 0.75 l 01V
Change Filled for life, no change
Lubricant Gear oil
SAE 75 W 90
(synthetic oil)
Gear oil SAE 75 W 90 (synthetic oil) is available as a part.
“ETKA” .
“ETKA” .
Checking gear oil in front final drive ⇒ page 178 .
4. Capacities 7
Passat 1997 ➤
5 General repair notes

To ensure perfect and successful gearbox repairs, the greatest
care and cleanliness as well as the use of good and proper tools
are essential. Of course, the basic rules for safety also apply dur‐
ing repair work.
A number of generally valid instructions applicable for the various
repair procedures - which were formerly repeated a number of
times at numerous places in the workshop manual - are summar‐
ised here. They apply to this workshop manual.
5.1 General repair notes
n AG. Volkswagen AG do
5.1.1 Special tools yV
olkswage es n
ot g
ua
b
ed ran
A summary of the special toolshoand
ris workshop equipment used in tee
the workshop manual precedess au each repair procedure and can
t or
ac
be found in “Special tools/Workshop equipment” binder.
s
ce
le
un
pt
The catalogue is also available on CD-ROM and can be ordered
an
d
itte
y li
the usual way from Bertelsmann.
rm
ab
pe
ility
5.1.2 Gearbox
ot
wit
, is n
h re
♦ If the automatic gearbox has been exchanged, the following
hole
spec
fluid levels are to be checked:
es, in part or in w
t to the co
– ATF in planetary gearbox ⇒ page 135 .
– Gear oil in front final drive ⇒ page 178 .
rrectness of i
– Capacities and specifications ⇒ page 7 .
l purpos
♦ Do not run engine or tow vehicle with pan removed or when

there is no ATF in gearbox.
nform
ercia
♦ With gearbox removed, secure torque converter against falling

m
out.
a
com
tion in
♦ Thoroughly clean connecting points and surrounding areas

r
te o
thi
and then loosen bolts.

s
iva
do
r
rp
♦ Before installing gearbox, check installation dimension for tor‐

um
fo
en
g
que converter ⇒ page 15 .

n
t.
yi Co
op py
♦ When installing the gearbox, ensure that dowel sleeves be‐
t. C rig
gh ht
yri
tween the engine and gearbox are correctly located. p by
co Vo
by lksw
cted agen
♦ Place removed parts on a clean surface. Cover parts to pre‐ Prote AG.
vent soiling. Use plastic sheeting and paper. Use lint-free
cloths only!
♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing.
♦ If repair work cannot be performed immediately, cover new
parts which have been removed from their packing.
♦ When installing mounting brackets or waxed components,
clean the contact surfaces. Contact surfaces must be free of
wax and grease.

Passat 1997 ➤
5.1.3 Valve body

♦ Renew gearbox if the selector elements are scorched or burnt.
♦ Allocate valve body according to gearbox code ⇒ Electronic
parts catalogue “ETKA” .
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
5.1.4 Seals and sealing rings
du
an
itte
y li
erm
ab
♦ Always renew O-rings, seals and gaskets.
ility
ot p
wit
, is n
♦ When seals have been removed, check contact surface on
h re
housings or shafts for burrs and damage and rectify as nec‐
hole
spec
essary.
es, in part or in w
t to the co
♦ Thoroughly clean housing connecting surfaces and apply
sealant -AMV 188 200 03- .
♦ Before installing a radial oil seal, half fill space between sealing
rrectness of i
lips with grease -G 052 128 A1- -arrow- and then install.
l purpos
♦ Open side of oil seal faces oil.

♦ Before installing oil seals, moisten outer circumference of seal
nf
ercia
o
and sealing lip with ATF or gear oil depending on installation
rm
m
location.
atio
om
n in
c
♦ Moisten O-rings with ATF to prevent damage to the rings dur‐

or
thi
e
ing assembly.
t
sd
iva
o
r
rp
cu
♦ Only use ATF for automatic transmission components. Other
o
m
f
en
ng
lubricants cause faults to occur in the gearbox hydraulics.

t.
yi Co
op py
♦ After installing, check ATF level in planetary gearbox or gear
t. C rig
gh ht
yri
oil in final drive and correct level if necessary. p by
co Vo
by lksw
cted agen
– ATF in planetary gearbox ⇒ page 135 . Prote AG.
– Gear oil in front final drive ⇒ page 178 .

– Capacities and specifications ⇒ page 7 .
5.1.5 Locking devices

♦ Do not overstretch retaining rings. Renew as necessary.
♦ Retaining rings must locate properly in grooves.
♦ Renew spring pins. Installation position: slot longitudinal to line
of force.
5. General repair notes 9

Passat 1997 ➤
5.1.6 Nuts and bolts

♦ Loosen and tighten securing bolts and nuts for covers and
housings diagonally.
♦ Do not cant particularly sensitive parts such as the valve body.
Loosen and tighten nuts and bolts gradually and in diagonal
sequence.
♦ Torque settings are specified for unoiled bolts and nuts.
♦ Threads of bolts secured with locking fluid must be cleaned
with a wire brush. Then insert bolts with locking fluid -
AMV 185 100 A1- .
♦ Use a thread chaser to clear residual locking fluid from all
threaded holes into which self-locking bolts are to be screwed.
Otherwise there is a danger of bolts shearing when subse‐
quently being removed.
♦ Always renew self-locking bolts and nuts.
♦ For threaded connections, ensure that contact surfaces as
well as nuts and bolts are rewaxed only after assembly, if nec‐
essary.
5.1.7 Bearings
. Volkswagen AG
gen AG does
♦ Tapered roller bearings are allocated in ⇒ Electronic parts olks
wa not
catalogue “ETKA” according to gearbox date of manufacture byV gu
ara
ed
and codes. ho
ris nte
eo
t
au ra
♦ All tapered roller bearings fitted to the same shaft must
ss be re‐ c
newed as a set. Use same make of bearings.
ce
le
un
pt
an
d
itte
♦ Install needle bearings with lettered side (thicker metal) to‐
y li
rm
ab
wards fitting tool.
pe
ility
ot
wit
♦ Heat tapered roller bearing inner races to approx. 100 ±C be‐
, is n
h re
fore installing.
hole
spec
♦ Do not interchange outer or inner races of bearings of the
es, in part or in w
t to the co
same size. The bearings are matched in pairs.
♦ Depending on location, apply gear oil or ATF to bearings be‐
fore installing.
rrectness of i
l purpos
5.1.8 Shims
♦ Measure shims at several points with a micrometer. The var‐ nform
ercia
ious thicknesses make it possible to achieve the exact shim

m
thickness required.
a
com
tion in
♦ Check for burrs and damage.

r
te o
thi
s
iva
♦ Install only flawless shims.

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 ➤
5.1.9 Guided fault finding, vehicle self-diag‐

nosis and testing
♦ Before performing repairs on the automatic gearbox, deter‐
mine the cause of the fault as accurately as possible using
vehicle diagnosis, testing and information system -VAS 5051-
in modes of operation “guided fault finding”, “vehicle self-
diagnosis” and “test instruments”.
5.2 “Vorsprung durch Technik”

The gearbox “01V” can be repaired.
n AGThe
. Volksinstructions
wagen AG
doesfor repair
wage
were written by Audi andVare
olks being used by Volkswagen. not
g y ua
db ra
♦ “General” datahoand
ris information for fault finding can be found
e nte
in ⇒ Automatic ut gearbox 01V, Front-wheel drive and four- e or
a ac
wheel drive;ss Rep. Gr. 00
ce
le
un
pt
♦ Instructions for the torque converter ⇒ Automatic gearbox
an
d
itte
y li
01V, Front-wheel drive and four-wheel drive; Rep. Gr. 32
erm
ab
ility
ot p
♦ Planetary gearbox ⇒ Automatic gearbox 01V, Front-wheel

wit
drive and four-wheel drive; Rep. Gr. 37
is n
h re
ole,
♦ “Gears, control” ⇒ Automatic gearbox 01V, Front-wheel drive

spec
and four-wheel drive; Rep. Gr. 38

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.
5. General repair notes 11

Passat 1997 ➤
32 – Torque converter
1 Torque converter
wage es n
1 - Torque converter Vol
ks ot g
d by ua
❑ Secure in place when ris
e ran
tee
tho
gearbox is removed or
au ac
⇒ page 12 ss
ce
e
nl
❑ Identification
pt
du
an
⇒ page 13
itte
y li
erm
ab
❑ Installing ⇒ page 15
ility
ot p
wit
2 - Seal
, is n
h re
❑ Renewing ⇒ page 14
hole
spec
es, in part or in w
3 - Stop ring
t to the co
❑ Behind sealing ring
❑ Renew if damaged
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.
Secure torque converter to prevent it from falling out
12 Rep. Gr.32 - Torque converter

Passat 1997 ➤
1.1 Identification of torque converter

There are various torque converters. They are identified by codes
-arrow-.
1.2 Checking torque converter

– Check torque converter hub for scoring -arrow-.
The torque converter is welded and must be renewed if damaged.
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
1.3 Draining torque converter

y li
erm
ab
ility
ot p
Special tools and workshop equipment required

wit
, is n
h re
♦ Oil extraction unit -V.A.G 1358 A-

hole
spec
♦ Oil extraction probe -V.A.G 1358 A/1-

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
If ATF has become fouled by abraded material or if a major over‐

en
ng
t.
yi
haul of gearbox is being performed, drain torque converter as
Co
Cop py
follows: ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Torque converter 13
Passat 1997 ➤
– Extract ATF from torque converter using oil extractor -

V.A.G 1358 A- and oil extraction probe -V.A.G 1358 A/1-
1.4 Removing and installing torque convert‐

er oil seal
1.4.1 Removing
♦ Oil seal extractor lever -VW 681-
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
♦ Thrust piece -3295-
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Remove gearbox ⇒ page 57 .

m
at
om
io
– Secure gearbox to assembly stand ⇒ page 127 .

n
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 ➤
– Apply oil seal extractor lever -VW 681- directly behind sealing
lip of oil seal to avoid damaging stop ring.
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
1.4.2 Installing
wit
is n
h re
ole,
– Insert stop ring.
spec
– Apply ATF to circumference and sealing lips of oil seal.
t to the co
Installation position:
Open side of oil seal faces gearbox.
rrectne
– Using thrust piece -3295- , drive in torque converter oil seal to
s
stop of thrust piece.
s o
cial p
f in
– Install gearbox ⇒ page 57 .
form
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.
1.5 Installing torque converter
♦ Depth gauge
– Push on torque converter hub through seal to first stop.
– Turn torque converter inwards using light pressure until notch
in hub engages in follower of pump gear and torque converter
can be felt to slip in place.
1. Torque converter 15
AG. Volkswagen AG d
agen oes
ksw
Passat 1997 ➤ by
Vol not
gu
d ara
5-speed automatic gearbox 01V oris- Edition 08.2007
e nte
h eo
aut ra
c
The torque converter is correctly installed
ss
when the distance be‐
ce
le
tween the contact surfaces underneath at the threaded holes for
un
pt
an
the torque converter and the contact surface of the torque con‐
d
itte
y li
verter housing of the automatic gearbox 01V is approx. 23 mm.
erm
ab
ility
ot p
If the torque converter is not installed correctly the distance is
wit
is n
approx. 11 mm.
h re
ole,
spec
Caution
t to the co
If the torque converter is improperly installed, the follower of
the converter or ATF pump will be destroyed when the gearbox
rrectne
is bolted onto the engine.
ss o
cial p
f
During subsequent installation, observe in particular the following
inform
points:
mer
atio
When tightening bolts on engine/gearbox flange, check repeat‐
om
n
edly that the torque converter can still be turned behind the drive
c
i
or
n thi
plate.
te
sd
iva
o
r
If the torque converter cannot be turned, it can be assumed that

p
cum
r
fo
it is not properly installed and that the follower of the torque con‐
en
ng
t.
yi
verter or the ATF pump will be destroyed during the final tighten‐
Co
op py
ing of the screw connections. t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Passat 1997 ➤
37 – Controls, housing
1 Electrical and electronic components and their locations
1 - Control unit for automatic

gearbox -J217-
❑ Location ⇒ page 18
❑ Removing ⇒ page 19
❑ Installing ⇒ page 19
❑ Can be checked using
“guided fault finding” of - AG. Volkswagen AG d
VAS 5051- lksw
agen oes
not
Vo gu
by
2 - Engine control unit rised ara
nte
o eo
❑ Location and removingauth
ra
and installing ss c
ce
le
⇒ page 19
un
pt
an
d
itte
3 - Diagnostic connection
y li
rm
ab
pe
❑ Location in vehicles be‐
ility
ot
fore 09.00 ⇒ page 19 .
wit
, is n
h re
❑ Location in vehicles af‐
hole
spec
ter 10.00 ⇒ page 20 .
es, in part or in w
t to the co
4 - Wiring harness with gear‐
box oil temperature sender
(ATF) -G93-
rrectness of i
l purpos
❑ Can be checked using

“guided fault finding” of -
VAS 5051-
nform
ercia
5 - Valve body
m
a
com
ti
on in
r
te o
❑ With hydraulic control

thi
s
iva
type E17 or E18/2

do
r
rp
cum
❑ Components can be
fo
en
g
checked using “guided

n
t.
yi Co
op
fault finding” of - C py
t. rig
VAS 5051-
gh ht
pyri by
Vo
o
by c lksw
6 - Multifunction switch -F125- Prote
cted AG.
agen
❑ Removing and installing ⇒ page 175
❑ Can be checked using “guided fault finding” of -VAS 5051-
7 - Gearbox input speed sender -G182-
❑ Measures gearbox input shaft speed
8 - Gearbox speed sender -G38- or gearbox output speed sender -G195-
❑ Measures gearbox output shaft speed
9 - Tiptronic switch -F189-
1. Electrical and electronic components and their locations 17

Passat 1997 ➤
❑ If the switch is faulty, the symbol panel with printed circuit board must be replaced
⇒ Item 7 (page 34)
10 - Selector lever lock solenoid -N110-
11 - Throttle valve potentiometer -G69- or accelerator pedal position senders -G79- and -G185-
❑ More information ⇒ page 23
12 - Cruise control system switch -E45- Volkswa
n AG. gen AG
❑ Location ⇒ page 22 wage does
V olks not
gu
y
❑ Can be checked using ise
d b “guided fault finding” of -VAS 5051-ara
n
r tee
ho
13 - Starter inhibitors arelay
ut -J207- or
ac
s
ce
le
un
pt
an
d
14 - Selector lever position display -Y6-

itte
y li
rm
ab
pe
ility
ot
❑ If all segments of selector lever position indicator light up together or
wit
, is n
h re
❑ If no selector lever position is displayed, this indicates gearbox emergency running mode
hole
spec
15 - Kickdown switch -F8-
es, in part or in w
❑ Location in vehicles without EPC ⇒ page 22 t to the co

❑ Location in vehicles with EPC ⇒ page 22
rrectness of i

l purpos
16 - Brake light switch -F- or brake pedal switch -F47-

❑ Location and removing and installing ⇒ page 23
nform
ercia

m
a
com
tion in
r
te o
Location of control unit for automatic gearbox -J217-

thi
s
iva
do
The control unit is located in front of the right-hand seat under the
r
rp
cum
fo
carpet in footwell.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
18 Rep. Gr.37 - Controls, housing

Passat 1997 ➤
Removing automatic gearbox control unit -J217-

– Remove the trim from the right A pillar at the bottom and the
right door sill strip. ⇒ General body repairs, interior; Rep. Gr.
70 ; Pillar and side trims; Removing and installing A pillar trim
at bottom .
– Loosen and raise carpet. AG. Volkswagen AG d
agen oes
lksw not
– Unclip control unit from box -arrows-. d byV
o gu
ara
ise nte
r
– Switch off ignition and then wait 30 seconds
ut
ho before removing eo
ra
multi-pin connector. ss a c
ce
e
nl
– Release multi-pin connector and then pull connector off con‐
pt
du
an
trol unit. itte
y li
erm
ab
ility
ot p
Installing automatic gearbox control unit -J217-
wit
, is n
h re
– Place multi-pin connector on gearbox control unit connector
hole
spec
housing -1-, swing in -2- and lock -3-.
es, in part or in w
t to the co
If the control unit has been replaced, it must be coded. To do this:
– Connect -VAS 5051- and continue to advance until “Function/
component selection” is displayed.
rrectness of i
– Then press “Drive (Repair group 01; 10...26; 28...39)”.
l purpos
– Then “5-speed automatic gearbox 01V”.
nf
ercia
– Press “01 - Self-diagnosis”.
orm
m
atio
– Press “Electrical components”.
om
n in
or c
– Press “J217 - Automatic gearbox control unit”.
thi
te
sd
iva
– Press “Code control unit”.
o
r
rp
cu
o
m
f
en
ng
t.
yi
Engine control unit
Co
Cop py
ht. rig
Location: the control unit is located in left plenum chamber. rig ht
py by
co Vo
by lksw
Removing and installing control unit:
cted agen
Prote AG.
⇒ Rep. Gr. 23 ; of the corresponding engine code letters

⇒ Rep. Gr. 24 ; of the corresponding engine code letters
If engine control unit or gearbox control unit is renewed, the sys‐
tem must be restored to basic setting.
– Perform the basic setting in “Vehicle self-diagnosis” with the -
VAS 5051- .
Diagnostic connection in vehicles before 09.00

Location: diagnostic connection is located in centre console.
– Remove cover above diagnostic connection next to handbrake
lever.

Passat 1997 ➤
Diagnostic connection in vehicles after 10.00

Location: diagnostic connection -arrow- is located below driver
storage compartment.
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
Valve body
h re
hole
spec
Location: valve body is bolted to underside of gearbox housing
es, in part or in w
and covered by pan.
t to the co
Solenoid valves -N88- , -N89- , -N90- , -N91- , -N92- , -N93- , -
N94- are secured to the valve body of hydraulic control E17.
rrectness of i
On the valve body of hydraulic control E18/2, solenoid valves -
l purpos
N91- , -N92- , -N93- , -N94- are designated pressure control

valves 1 -N215- , 2 -N216- , 3 -N217- and 4 -N218- .
nf
ercia
There are two different types of hydraulic control:
orm
m
♦ Gearbox with hydraulic control E17, in which the gearbox input
atio
om
speed sender (inductive sender) is secured to the underside
n in
or c
of the valve body.
thi
te
sd
iva
Removing and installing valve body ⇒ page 154 . o

r
rp
cu
o
m
f
en
ng
Information about which control is installed ⇒ page 3 .

t.
yi Co
op py
♦ Gearbox with hydraulic control E18/2, in which the gearbox
t. C rig
gh ht
yri
input speed sender (Hall sender) is secured to the gearbox p by
o Vo
by c
housing behind the valve body.
lksw
cted agen
Prote AG.
Removing and installing valve body ⇒ page 161 .
Wiring harness with integral gearbox oil temperature sender

(ATF) -G93-
Location: Gearbox oil temperature sender -arrow- is located in
wiring harness on valve body.
Valve body must be removed to replace cable loom. It is not nec‐
essary to remove gearbox.
Removing and installing wiring harness ⇒ page 170 .

Passat 1997 ➤
Gearbox speed sender -G38- or gearbox output speed sender -

G195-
Location: Gearbox speed sender is located on rear right of gear‐
box.
Removing and installing gearbox speed sender ⇒ page 167 .
Multi-function switch -F125-

Location: Multi-function switch -1- is located on left of gearbox;
multi-pin connector for multi-function switch -2-.
Vehicles before 09.00
Multi-pin connector for multi-function switch 8-pin.
Vehicles after 10.00
Multi-pin connector for multi-function switch 10-pin.
Removing and installing multi-function switch ⇒ page 175 .
Gearbox input speed sender -G182-

Location:
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
The gearbox input speed sender is located on the underside of

h re
hole
the valve body on gearboxes with hydraulic control E17 (see il‐
spec
lustration). In these gearboxes, this sender is an inductive sender.

es, in part or in w
t to the co
In gearboxes with hydraulic control E18/2, gearbox input speed

sender -A- is secured to the gearbox housing behind the valve
body. In these gearboxes, this sender is a Hall sender.
rrectness of i

l purpos
Removing and installing gearbox input speed sender

⇒ page 168 .
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 ➤
Selector lever lock solenoid -N110-

Location: The selector lever lock solenoid is located in the selec‐
tor lever housing -arrow-.
Removing and installing selector lever lock solenoid
⇒ page 44 .
AG. Volkswagen AG d
agen oes
Cruise control system switch -E45- y Volksw not
gu
db ara
Location: cruise control switch iselocated
ris on steering column nte
tho eo
switch. au ra
c
ss
Removing and installing cruise control system switch ⇒ Electrical
ce
le
un
pt
system; Rep. Gr. 94 ; Steering column switch; Removing and
an
d
itte
y li
installing steering column switch .
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Kickdown switch -F8- in vehicles without EPC
rrectness of i
Location: Kickdown switch -arrow- is integrated into accelerator
l purpos
cable and is located on bulkhead in engine compartment.

Removing and installing kickdown switch ⇒ Rep. Gr. 20 ; Re‐ nform
ercia
moving and installing parts of the fuel supply; Setting the accel‐
erator cable .
m
a
com
tio
– When removing and installing kickdown switch, remove and

n in
r
install the accelerator cable, then adjust afterwards.

te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
Kickdown switch -F8- in vehicles with EPC rig ht
py by
co Vo
by lksw
Location: kickdown switch -arrow- is integrated in accelerator
cted agen
Prote AG.
pedal position sender.
Removing and installing kickdown switch ⇒ Rep. Gr. 20 ; Re‐
moving and installing parts of the fuel supply; Setting the accel‐
erator cable .

Passat 1997 ➤
Brake light switch -F- or brake pedal switch -F47-

AG. VolkswagenAG do n
es n wage
olks on the pedal cluster.
Location: switch is located ot g
yV
b ua
ed ran
Removing and tinstalling
ho
ris the brake light switch or brake pedal tee
switch ⇒ Brakeau systems; Rep. Gr. 46 ; Brake pedal (RHD) - or a
ss c
Assembly overview; Setting brake light switch and brake pedal
ce
le
switch F47 .
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
Relay for starter interlock -J207-
Location: relay is located on the relay plate on left behind dash
rrectness of i
panel.
l purpos
Relay is marked with number “204”.

Relay positions
nform
ercia
Removing and installing the dash panel ⇒ General body repairs,

m
a
interior; Rep. Gr. 70 ; Dash panel; Removing and installing dash
com
tio
panel .
n in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi
Selector lever position display -Y6-
Co
Cop py
t. rig
gh
Vehicles before 09.00
ht
pyri by
Vo
o
by c lksw
Location: In dash panel insert cted agen
Prote AG.
Vehicles after 10.00

Location: in dash panel insert with data bus diagnostic interface
-J533-
Removing and installing selector lever position display ⇒ Elec‐
trical system; Rep. Gr. 90 ; Dash panel insert; Removing and
installing dash panel insert .
Throttle valve potentiometer -G69- or accelerator pedal position

senders -G79- and -G185-
In vehicles with a data bus, the signal comes from the bus. In
addition, the data bus interface is checked in these vehicles.
If the electrical signals in the “vehicle self-diagnosis” for gearbox
ECU are displayed as faults, then the “self-diagnosis” for engine
ECU must always be performed.
The “basic setting” of the engine control unit must also be per‐
formed after the throttle valve potentiometer or accelerator pedal
position sender has been replaced or its setting changed.
Locations:
The potentiometer is a component part of the throttle valve mod‐
ule -J338- . It is located on the throttle valve housing/induction
manifold of the engine.
Checking and adjusting or removing and installing throttle valve
potentiometer ⇒ Rep. Gr. 23 ; of the corresponding engine code
letters .

Passat 1997 ➤
The accelerator pedal position sender -G79- , component of the

electronic power control (EPC), is located on the pedal cluster.
Checking or removing and installing the accelerator pedal posi‐
tion sender ⇒ Rep. Gr. 20 ; Removing and installing parts of the
fuel supply; Checking accelerator position sender .
n AG. Volkswagen A G do
wage es n
olks ot g
byV ua
ed ran
ris tee
tho or
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
Tiptronic switch -F189-
wit
, is n
h re
Location: The Tiptronic switch -F189- is integrated in the printed
hole
spec
circuit board of the symbol panel, which is located in the selector
es, in part or in w
mechanism cover.
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
It consists of 3 Hall sensors -A-, -B- and -C- that are activated by
r
te o
thi
a magnet on the transverse roller blind of the cover strip.
s
iva
do
r
rp
-A- Sensor for back button

um
fo
en
ng
t.
yi
-B- Sensor for Tiptronic detection
Co
Cop py
t. rig
gh
-C- Sensor for up button
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤
2 Repairing selector mechanism
WARNING
Before working on engine when it is running, move selector

lever into position “P” and apply handbrake.
2.1 Checking selector mechanism

The starter must not operate in the selector lever positions “2”,
“3”, “4”, “D” and “R”.
On right-hand drive vehicles the starter must only operate in se‐
lector lever positions “P” and “N” when the locking button in the
selector lever handle is not pressed.
When travelling at speeds above 5 km/h and shifting into selector
lever position “N”, solenoid for selector lever lock must not engage
and block selector lever. Selector lever can be shifted into a driv‐
ing gear.
When travelling at speeds below 5 km/h (almost stationary) and
shifting into selector lever position “N”, solenoid for selector lever
lock should only engage after about 1 second. Selector lever can‐
not be shifted out of “N” position until brake pedal is depressed.
olkswagen AG
en AG. V
– Check and adjust selector
olks
wag lever cable ⇒ page 26
does
not.
yV gu
db ara
– Check ignition
or
isekey withdrawal lock ⇒ page 28 . nte
th eo
au ra
2.1.1 ssSelector lever in “P” position and ignition c
ce
le
switched on
un
pt
an
d
itte
y li
• Brake pedal not depressed:

rm
ab
pe
ility
ot
Selector lever is locked and cannot be shifted out of “P” position

wit
, is n
when the button is pressed. Solenoid for selector lever lock blocks
h re
hole
selector lever.
spec
es, in part or in w
• Brake pedal depressed:

t to the co
Solenoid for selector lever lock releases selector lever. It is pos‐

sible to shift into a driving gear. Slowly shift selector lever from
rrectness of i
“P” through to “2”, checking whether selector lever position in

dash panel insert corresponds to selector lever position.
l purpos
2.1.2 Selector lever in “N” position and ignition

nform
ercia
switched on
m
a
com
• Brake pedal not depressed:

ion in
r
te o
Selector lever is locked and cannot be shifted out of “N” position

thi
s
iva
when the button is pressed. Solenoid for selector lever lock blocks
do
r
rp
selector lever.
cum
fo
en
ng
t.
• Brake pedal depressed:
yi Co
Cop py
t. rig
Solenoid for selector lever lock releases selector lever. It is pos‐
gh ht
yri by
sible to shift into a driving gear.
op Vo
by c lksw
cted agen
Prote AG.
2.1.3 Selector lever in position “D”, ignition
and lights switched on
• Shift selector lever into Tiptronic gate:
The illuminated “D” symbol in the selector lever position display
must go out and the “+” and “-” symbols must light up.
2. Repairing selector mechanism 25

Passat 1997 ➤
When selector lever is shifted into Tiptronic gate, selector lever

position display in dash panel insert must change from “P R N D
4 3 2” to “5 4 3 2 1”.
2.1.4 Selector lever position display

Simultaneous illumination of all selector lever position display
segments indicates gearbox emergency running mode.
– Check and adjust selector lever cable ⇒ page 26 .
– Check ignition key withdrawal lock ⇒ page 28 .
2.2 Checking and adjusting selector lever

cable
2.2.1 Checking
. Volkswagen AG
a gen AG does
♦ Removal lever -80-200-
Vol
ksw not
gu
by ara
ed nte
oris eo
th
au ra
c
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
♦ Torque wrench -V.A.G 1331-

rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
Vo
2.2.2 Checking
co lksw
by
cted agen
Prote AG.
Additional information required

♦ Workshop manual Passat 1997 ▸ Engine, mechanics
– Move selector lever to “P” position.
– Raise vehicle.

Passat 1997 ➤
– In vehicles with an auxiliary heater, unscrew and remove bolts

-arrows- from the exhaust pipe on the noise
gen AG
.insulation.
Volkswagen AG
a does
ksw not
y Vol gu
b ara
ed nte
oris eo
th
au ra
c
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 noise insulation -arrows A- and -arrows B-.
– In vehicles with noise insulation -D-, unscrew and remove
bolts -arrows C-.
rrectne
Vehicles with V6 engines
ss
– Remove front exhaust system with catalytic converter ⇒ Rep.
o
cial p
f
Gr. 26 ; Removing and installing parts of exhaust system .
inform
mer
– Remove selector lever cable guard plate.
atio
om
n
Continuation for all vehicles
c
i
or
n thi
e
– Remove left-hand gearbox support ⇒ page 129 .

t
sd
iva
o
pr
cum
r
fo
en
ng
– Remove selector lever cable from selector shaft lever

t.
yi Co
-arrow-. Cop py
t. rig
gh ht
yri
– Move selector lever from “P” to “2”. p by
co Vo
by lksw
cted agen
• Selector lever mechanism and selector lever cable must move Prote AG.
freely. If necessary replace selector lever cable or service se‐
lector lever mechanism.
– Move selector shaft lever on gearbox to position “P”. Locking
lever must engage in park lock wheel so that both front wheels
are blocked (cannot be turned together in same direction).
• It must be possible to press the selector lever cable onto the
selector shaft lever. Adjust the selector lever cable if this is not
possible.
– Carefully press selector lever cable onto selector shaft lever
using pliers, taking care not to bend selector shaft lever, be‐
cause otherwise it will not be possible to precisely adjust
selector mechanism.
2.2.3 Adjusting
• Selector lever cable is disconnected from selector shaft lever.

Passat 1997 ➤
– Loosen bolts -arrows 1- securing support bracket to gearbox.

– If necessary, undo the selector lever cable from support brack‐
et -arrow 2-. When doing this, counter hold on hexagon flats
-arrow 3-.
– Grease the ball socket of the selector lever cable using poly‐
carbamide grease -G 052 142 A2- .
– Using a pair of pliers, carefully pushwathe
gen Aselector
G. Volkswlever cable
agen AG
does
s
onto selector shaft lever -2-. y Volk not
gu b ara
ed nte
Take care not to bend selector
tho
ris shaft lever, because otherwise it e or
will not be possible to precisely
sa
u adjust selector mechanism. ac
s
ce
le
– Align selector lever cable, free of stress, on the support brack‐

un
pt
et using the oblong holes.
an
d
itte
y li
erm
ab
ility
– Tighten support bracket/gearbox -arrows 1- to specified torque
ot p
wit
⇒ page 48 .
is n
h re
ole,
– Tighten selector lever cable/support bracket -arrow 2- to
spec
specified torque ⇒ page 48 . When doing this, counter hold
t to the co
on hexagon flats -arrow 3-.
– Check selector mechanism ⇒ page 25 .
rrectne
– Install left-hand gearbox support ⇒ page 129 .
ss o
cial p
f
– Install selector lever cable guard plate ⇒ page 48 .
inform
mer
– Install front exhaust system with catalytic converter ⇒ Rep.
atio
Gr. 26 ; Removing and installing parts of the exhaust system .
om
n
c
i
or
n
thi
te
sd
iva
o
pr
– Install noise insulation element(s).

um
r
fo
en
ng
t.
yi
– In vehicles with an auxiliary heater, screw the exhaust pipe
Co
op py
firmly onto the noise insulation.
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.3 Checking operation of the ignition key withdrawal lock
Start
↓ ← ← ← ← ← ← ← ← ← ← ← ← ←
↓ ↑
– Move selector lever to “P”. – Replace the faulty selector mechanism or
steering lock.
– Switch off the ignition, remove the ignition key.
↓ ↑
↓ no → → → ↑
↓ ↑
Can the selector lever be shifted → yes → Is the locking ca‐ → yes → – Correct adjust‐
out of “P” when the button is ble incorrectly ment
pressed? set? ⇒ page 52
↓ ↑

Passat 1997 ➤
no ↑ ← ← ←
↓ ↑
Function OK. ↑
↓ ↑
– Depress brake pedal. ↑
– Insert the ignition key and switch on the ignition.
– Move selector lever to “P”.

↓ ↑
Can the selector lever be shifted out of “P” → no → → ↑
when the button is pressed?
↓ ↑
yes ↑
↓ ↑
It must be possible to move selector lever into “R, N, D, ↑
4, 3, 2”.
↓ ↑
– Switch off ignition. ↑
– Release the brake pedal.

↓ ↑
Can ignition key be withdrawn? → → yes →
no ↑ ←
↓ ↑
no → – Press the brake pedal and shift the → The ignition key can be removed and the but‐
selector lever into “P”. ton on the selector lever is blocked in “P”.
↓
yes
↓
AG. Volkswagen AG d Ignition key withdrawal lock OK.
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
2.4 Removing and installing selector lever
ce
le
un
pt
an
d
handle
itte
y li
rm
ab
pe
ility
ot
wit
, is n
2.4.1 There are various handles which are re‐

h re
hole
spec
moved and installed in different ways.

es, in part or in w
t to the co
– Before each installation job, push the sleeve on the selector

lever down somewhat.
rrectness of i
– Please look to see what is the colour of the plastic part in the
handle.
l purpos
Colour is black: removing and installing ⇒ page 30 .

nform
ercia
Colour is red-brown: This handle can replace the handle with the
black plastic part.
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
29
Prote AG.
2. Repairing selector mechanism
Passat 1997 ➤
2.4.2 Removing and installing the handle with

the red/brown plastic part
– Simply pull the handle only. Do not press the button as you do
so.
If you inadvertently press the button into the handle, you can ei‐
ther pull it out again or carefully blow it out with compressed air.
– Before installing, it is essential to make sure the pushbutton is
pulled out past the pressure point and that it projects by at least
10 millimetres -a-.
Do this by pulling the button out by hand past the pressure point
that can be felt. In this way, it will not drop back again.
– For installing, move the selector lever to “D” and press the
handle onto the selector lever.
2.4.3 Removing the handle with the black

plastic part
olks
wage
es n
o
V t gu
by ara
– Set selector rlever
ise
d
in position “3”. nte
ho eo
ut
– Slide sleeve
ss
a -1- downwards. ra
c
ce
le
– Pull the button -2- out of handle -3- just enough that the pull
un
pt
an
d
lever -arrow- hangs downwards.

itte
y li
erm
ab
– Now pull handle off selector lever.

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
2.4.4 Installing the handle with the black plas‐

pr
cum
r
fo
en
tic part
ng
t.
yi Co
Cop py
t. rig
– Set selector lever in position “3”. gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Passat 1997 ➤
– Pull the button -2- out of handle -3-agjust enough

en AG. Volkswathat
gen Athe
G dopull
lever -arrow- hangs downwards.V olksw es n
ot g
by ua
ed ran
Installation position: Button
ho
rifaces
s driver. tee
t or
au ac
– Now press the handle
ss on selector lever onto stop.
ce
le
un
– Pull the pushbutton out further and guide the pull lever
pt
an
d
itte
-arrow- into the handle.
y li
rm
ab
pe
– Press the pushbutton so that the pull lever engages in the pull
ility
ot
rod -4-. The button must now spring back onto stop.
wit
, is n
h re
hole
– Slide the sleeve -1- upwards.
spec
es, in part or in w
– Set selector lever in position “P”.
t to the co
rrectness of i
l purpos
nform
mercia
2.5 Removing and installing selector mech‐
a
com
tion in
anism
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op
♦ Workshop manual Passat 1997 ▸ General body repairs, inte‐
C py
t. rig
gh
rior
ht
pyri by
Vo
co lksw
by
cted
2.5.1 Removing
agen
Prote AG.
– First check whether a coded radio is fitted. In this case, obtain

anti-theft code.
– With ignition switched off, disconnect battery earth strap ⇒
Electrical system; Rep. Gr. 27 ; Battery; Disconnecting and
connecting battery .
– Remove selector lever handle ⇒ page 29 .
– Remove centre console and extension ⇒ General body re‐
pairs, interior; Rep. Gr. 70 ; Compartments, covers and trims;
Removing and installing centre console .
– Remove cover ⇒ page 53 .
– Unplug electrical connectors ⇒ page 37 .
– Unclip locking cable from locking lever and unclip securing
spring on mounting bracket. To do this, lift securing spring
slightly.
– Raise vehicle.
– Remove front exhaust system with catalytic converter if it was
removed ⇒ Rep. Gr. 26 ; Removing and installing parts of
exhaust system .

Passat 1997 ➤
– Remove cover from mounting bracket -arrows-.
– Press together ends of securing clip -B- and remove.

– Pull down locking plate -A- (for securing selector lever cable
to mounting bracket) and remove.
– Pull selector lever cable off selector lever.
– Remove nuts (Qty. 4) from above.
– Remove mounting bracket from below.
– At the same time pull selector lever cable out of mounting
bracket. When doing this, do not kink the cable. AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
2.5.2 Installing ss c
ce
le
un
pt
an
d
• Selector lever and selector shaft lever to position “P” (parking

itte
y li
lock must engage).
erm
ab
ility
ot p
– Raise vehicle.
wit
is n
h re
ole,
spec
t to the co
– Slide selector lever cable boot and mounting bracket cover
onto selector lever cable.
rrectne
– Do not bend or kink selector lever cable.
s
– Insert selector lever cable in mounting bracket.
s o
cial p
f i
– Install mounting bracket on body.
nform
mer
– Tighten nuts (Qty. 4) from above ⇒ Item 21 (page 35) .

atio
om
n
c
– Connect electrical connections ⇒ page 37 .

i
or
n thi
te
sd
a
– Install and adjust locking cable ⇒ page 50 .

iv
o
pr
cum
r
fo
– Install cover ⇒ page 53 .

en
ng
t.
yi Co
op
– Move the selector lever into position “3”. C py
ht. rig
rig ht
– Install selector lever handle ⇒ page 30 .
py by
co Vo
by lksw
cted agen
– Connect selector lever cable to selector lever.
Prote AG.

Passat 1997 ➤
The angled end of the locking plate -A- must point towards the
end of the selector lever cable.
– Fit locking plate -A- for selector lever cable onto mounting
bracket.
– Press together ends of securing clip -B- and slide onto end of
selector lever cable.
– Install cover. When doing this check position of seal.
– Tighten nuts -arrows- (Qty. 4) ⇒ Item 28 (page 36) .

– Check selector lever cable adjustment and adjust if necessary
⇒ page 26 .
– Install front exhaust system with catalytic converter if it was
removed ⇒ Rep. Gr. 26 ; Removing and installing parts of the
exhaust system .
– Install centre console and extension ⇒ General body repairs,
interior; Rep. Gr. 70 ; Compartments, covers and trims; Re‐
moving and installing centre console .
– Connect the battery earth strap ⇒ Electrical system; Rep. Gr.
27 ; Battery; Disconnecting and connecting battery .
– Check selector mechanism ⇒ page 25 .
– Code radio ⇒ Radio, telephone, navigation; Rep. Gr. 91 ;
Radio, telephone, navigation .
– Initialise electric windows and set clock ⇒ Maintenance ; Book‐
olks
wage es n
ot g
let 36 . d byV ua
ran
e
ris tee
utho or
2.6 Dismantling and assembling selector ss
a ac
ce
le
mechanism (assembly overview)

un
pt
an
d
itte
Assembly procedure ⇒ page 38 y li

erm
ab
ility
ot p
Special tools and workshop equipment required wit

is n
h re
♦ Polycarbamide grease -G 052 142 A2-

ole,
spec
Lubricate bearing positions and sliding surfaces with polycarba‐

t to the co
mide grease -G 052 142 A2- .

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.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
Passat 1997 ➤ orise nte
eo
h
5-speed automatic
s a gearbox 01V - Edition 08.2007
ut ra
c
s
ce
le
un
1 - Selector lever handle
pt
an
d
itte
y li
❑ Removing and installing
erm
ab
⇒ page 29
ility
ot p
wit
2 - Sleeve
is n
h re
ole,
❑ Locates in the selector
spec
lever handle
t to the co
❑ Prevents the selector
lever handle from being
pulled off
rrectne
❑ Installation position: an‐
gled surface faces to‐
s
wards back.
s o
cial p
f i
3 - Cover
nform
mer
❑ With trim piece
atio
m
⇒ Item 6 (page 34) ,

o
n
c
symbol panel
i
or
n thi
⇒ Item 7 (page 34) ,
te
sd
va
cover strip
i
o
pr
c
um
r
fo
en
ng
and guide
t.
yi Co
⇒ Item 9 (page 34) Cop py
t. rig
gh
❑ Removing upwards
ht
pyri by
Vo
co lksw
by
❑ Removing connector for Prote
cted AG.
agen
gearshift positions, se‐
lector lever lock and Tip‐
tronic ⇒ page 37
⇒ page 53
❑ Dismantling and assem‐
bling ⇒ page 55
4 - Guide sleeve
❑ Sliding onto selector
lever
❑ Installation position: En‐
gage foot to rear
5 - Cover moulding
❑ With trim piece ⇒ Item 6 (page 34) and symbol panel ⇒ Item 7 (page 34)
❑ Cannot be replaced individually
6 - Trim piece
❑ Integrated with symbol panel ⇒ Item 7 (page 34) in cover moulding ⇒ Item 5 (page 34)
7 - Symbol panel
❑ With printed circuit board
❑ With Tiptronic switch -F189- integrated in the printed circuit board
❑ Integrated with trim piece ⇒ Item 6 (page 34) in cover moulding ⇒ Item 5 (page 34)
8 - Cover strip
❑ With 2 magnets for Tiptronic switch -F189- and gear indicator
❑ Magnets must be firmly connected to the cover strip
9 - Guide
❑ Guides the cover strip

AG. Volkswagen AG d
ksw
agen oes
not
Passat 1997 ➤
ol
by5-speed
V automatic gearbox 01V g-uEdition 08.2007
a
d ran
ise tee
or
❑ Unclip from cover moulding ⇒ Item 5au (page 34) ⇒ page 53
th or
ac
ss
10 - Bearing bush
ce
le
un
pt
❑ Securing in mounting bracket ⇒ Item 22 (page 35) with locking plate ⇒ Item 11 (page 35)
an
d
itte
y li
erm
ab
ility
ot p
11 - Locking plate
wit
is n
h re
❑ Secures mounting bush ⇒ Item 10 (page 35) in mounting bracket ⇒ Item 22 (page 35)
ole,
spec
❑ Install with angled ends pointing towards inside of mounting bracket
t to the co
❑ Always replace
12 - Pull rod
rrectne
13 - Spring
ss o
cial p
f inform
14 - Selector lever
mer
atio
❑ With pull rod, coil spring, selector gate and Tiptronic spring mechanism
om
n
c
i
or
n thi
te
sd
❑ Dismantling and assembling ⇒ page 42
iva
o
pr
cum
r
15 - Buffer stop
fo
en
ng
t.
yi
❑ Clipping into cable lever ⇒ Item 17 (page 35)
Co
Cop py
ht. rig
❑ Install with large contact surface towards selector lever rig ht
py by
co Vo
by lksw
16 - Detent Prote
cted AG.
agen
❑ Clipping into cable lever ⇒ Item 17 (page 35)

17 - Cable lever
❑ Secured in mounting bracket ⇒ Item 22 (page 35) with fulcrum pin ⇒ Item 23 (page 35)
18 - Locating spring with roller
❑ For gearshift positions
19 - Locating spring with roller
❑ For Tiptronic position
20 - Frame
❑ Clipping onto mounting bracket ⇒ Item 22 (page 35)
❑ Installation position: Ribbed side upwards
21 - Nut, 10 Nm
22 - Mounting bracket
23 - Fulcrum pin
❑ Secures cable lever ⇒ Item 17 (page 35) in mounting bracket ⇒ Item 22 (page 35)
24 - Locking pawl
❑ For selector lever lock
25 - Selector lever lock solenoid -N110-
❑ Removing and installing cable for selector lever lock ⇒ page 37

AG. Volkswagen AG d
agen oes
ksw
Passat 1997 ➤ by
Vol not
gu
d ara
5-speed automatic oris gearbox 01V - Edition 08.2007
e nte
h eo
aut ra
c
26 - Fulcrum pin ss
ce
e
nl
❑ For locking pawl ⇒ Item 24 (page 35)
pt
du
an
itte
y li
erm
ab
ility
ot p
27 - Cover
wit
, is n
❑ With seal for mounting bracket ⇒ Item 22 (page 35)
h re
hole
spec
es, in part or in w
t to the co
28 - Nut, 10 Nm
29 - Securing clip
rrectness of i
❑ For selector lever cable ⇒ Item 31 (page 36) to cable lever ⇒ Item 17 (page 35)
❑ Installation position: Angled end forwards and upwards
l purpos
30 - Locking plate
nf
ercia
❑ For securing selector lever cable ⇒ Item 31 (page 36) to mounting bracket ⇒ Item 22 (page 35)
orm
m
❑ Installation position: Angled end points to end of selector lever cable
atio
om
❑ Always replace
n in
or c
thi
e
31 - Selector lever cable

t
sd
iva
o
r
rp
cu
❑ Do not bend or kink; lightly grease cable eye and ball socket before installing
o
m
f
en
ng

t.
yi Co
op py
❑ Adjusting ⇒ page 26
t. C rig
gh ht
yri by
❑ Selector lever cable must be replaced if rubber sleeves are damaged
op Vo
by c lksw
cted agen
❑ When installing, make sure that rubber sleeve on gearbox side is not twisted Prote AG.
32 - Hexagon bolt, 23 Nm
33 - Support bracket
❑ For selector lever cable to gearbox
34 - Bracket
❑ For locking cable
35 - Cable clip
36 - Ignition/starter switch
37 - Locking cable
❑ For ignition key removal lock
❑ Must not be kinked
❑ Adjusting ⇒ page 52
38 - Lever for locking cable
❑ For ignition key removal lock
39 - Securing spring
40 - Mounting
❑ For selector lever in Tiptronic position

Passat 1997 ➤
2.6.1 Removing and installing cable for selec‐

tor lever lock, selector lever illumination
and Tiptronic
AG. Volkswagen AG d
agen oes
olksw not
2.6.2 Removing ise
d by V gu
ara
nte
or eo
h
Additional information required s aut ra
c
s
ce
e
nl
pt
du
rior
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
– Unplug connector -1- for selector lever lock magnet -2- (con‐
spec
cealed).
es, in part or in w
t to the co
– Unclip cover -3- and lift up.
– Pull out connector -4- for gearshift positions and Tiptronic in
rrectness of i
direction of arrow.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
2.6.3 Installing
p
cum
for
en
ng
t.
Install in reverse order of removal.
yi Co
Cop py
t. rig
gh ht
yri by
interior; Rep. Gr. 70 ; Compartments, covers and trims; Re‐ cop Vo
by lksw
cted
agen
Prote AG.
2.6.4 Removing and installing securing spring

for locking cable
Removing
rior

Passat 1997 ➤
– Lift up top spring -arrow B- slightly and pull the locking cable
out of the mounting bracket.
– Disengage spring -arrow A- from retainer lug -arrow C- and lift
out.
Installing
– Insert spring from above -arrow B- and engage under retainer

lug -arrow C-.
– Align spring so that it lies level in groove -arrow A-.
n AG. Volkswagen AG ge does
swa
– Lift up top spring -arrow B- slightly
by
Vol and push the locking cableot gu
k n
ara
into the mounting bracket.ris
ed
nte
tho eo
– Install centre console
ss
aand
u
extension ⇒ General body repairs, ra
c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
2.7 Dismantling and assembling selector

spec
es, in part or in w
mechanism (assembly sequence)

t to the co
rrectness of i
2.7.1 Dismantling
l purpos

♦ Tube -VW 421-
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.
♦ Tube -VW 423-

Passat 1997 ➤
♦ Polycarbamide grease -G 052 142 A2-

Lubricate bearing positions and sliding surfaces with polycarba‐
mide grease -G 052 142 A2- .
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
– Remove selector mechanism ⇒ page 31 .

hole
spec
es, in part or in w
– First remove stop buffer ⇒ Item 15 (page 35) from cable lever
t to the co
⇒ Item 17 (page 35) .

– Shift selector lever ⇒ Item 14 (page 35) into Tiptronic position,
then remove frame ⇒ Item 20 (page 35) .
rrectness of i
– Move the selector lever into position “2”.

l purpos
– Lift lever for locking cable ⇒ Item 38 (page 36) , detach from
mounting and remove from mounting bracket
nf
ercia
⇒ Item 22 (page 35) .

rm
m
atio
m
– Shift selector lever to position “D”.

o
n in
or c
thi
– Carefully lever spring clip for Tiptronic position

te
sd
a
⇒ Item 19 (page 35) out of mounting bracket

iv
o
r
rp
cu
⇒ Item 22 (page 35) from the outside.

o
m
f
en
ng
t.
yi
– Pull out locking clips ⇒ Item 11 (page 35) for selector lever
Co
Cop py
⇒ Item 14 (page 35) mounting bushes ⇒ Item 10 (page 35) .
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

lkswage es n
o ot g
Passat 1997 ➤ byV ua
d ran
ir se
5-speed automatic gearbox 01V - Edition
th 08.2007
o tee
or
au ac
ss
– Push out selector lever ⇒ Item 14 (page 35) mounting bushes
ce
e
nl
pt
⇒ Item 10 (page 35) with a screwdriver.
du
an
itte
y li
erm
– Remove selector lever ⇒ Item 14 (page 35) as a complete unit.
ab
ility
ot p
Dismantle selector lever ⇒ page 42 .
wit
, is n
h re
– To remove mounting ⇒ Item 40 (page 36) for selector lever
hole
spec
⇒ Item 14 (page 35) Tiptronic position, release retaining lugs
es, in part or in w
(Qty. 3) on outside of mounting bracket ⇒ Item 22 (page 35)
t to the co
and take mounting ⇒ Item 40 (page 36) out from the inside.
– Press out pin ⇒ Item 26 (page 36) for locking pawl
rrectness of i
⇒ Item 24 (page 35) using a drift. Support mounting bracket
⇒ Item 22 (page 35) with tube -VW 423- when doing this.
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
co lksw
by
cted agen
Prote AG.
– Lift out selector lever lock solenoid ⇒ Item 25 (page 35) to‐
gether with locking pawl ⇒ Item 24 (page 35) .
– Carefully lever spring clip ⇒ Item 18 (page 35) for selector lever
positions out of mounting bracket ⇒ Item 22 (page 35) from
the outside.
– Move cable lever ⇒ Item 17 (page 35) to park position.
– Press out the left bearing pin ⇒ Item 23 (page 35) first and then
the right pin using a drift from inside.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
orise nte
e
Passat 1997 ➤
h
s aut
5-speed oautomatic
ra
c gearbox 01V - Edition 08.2007
s
ce
e
nl
– Pull cable lever ⇒ Item 17 (page 35) and detent
pt
du
an
⇒ Item 16 (page 35) (in park position) out of mounting bracket
itte
y li
erm
⇒ Item 22 (page 35) upwards.
ab
ility
ot p
– Disengage detent ⇒ Item 16 (page 35) from cable lever
wit
, is n
⇒ Item 17 (page 35) .
h re
hole
spec
2.7.2 Assembling
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.
– Engage detent ⇒ Item 16 (page 35) in cable lever

⇒ Item 17 (page 35) .
– Insert cable lever ⇒ Item 17 (page 35) and detent
⇒ Item 16 (page 35) into mounting bracket
⇒ Item 22 (page 35) from above (opening -arrow- of detent is
inserted first).
– Drive both mounting pins ⇒ Item 23 (page 35) for the cable
lever ⇒ Item 17 (page 35) with detent ⇒ Item 16 (page 35) into
the mounting bracket ⇒ Item 22 (page 35) as far as they will
go. Support mounting bracket on inside when doing this.
– Press spring clip with roller ⇒ Item 18 (page 35) for selector
lever position into mounting on mounting bracket
⇒ Item 22 (page 35) as far as it will go.

Passat 1997 ➤
– Insert selector lever lock solenoid ⇒ Item 25 (page 35) in

mounting bracket ⇒ Item 22 (page 35) from above together
with locking pawl ⇒ Item 24 (page 35) .
– Carefully drive in pin ⇒ Item 26 (page 36) for locking pawl
⇒ Item 24 (page 35) . Support mounting bracket
⇒ Item 22 (page 35) with tube -VW 423- when doing this.
– Press mounting for Tiptronic position ⇒ Item 40 (page 36) into
mounting bracket ⇒ Item 22 (page 35) from inside. Locking
lugs (Qty. 3) must engage.
– Insert selector lever ⇒ Item 14 (page 35) in mounting bracket
⇒ Item 22 (page 35) as a complete unit.
– Engage selector lever ⇒ Item 14 (page 35) in cable lever
ksw
age es n
⇒ Item 17 (page 35) at top and bottom. y Vol ot g
ua
db e ran
ris tee
– Slide the two selector lever ⇒ Item 14 (pageut35)
ho mounting or
bushes ⇒ Item 10 (page 35) into the mounting
ss a
bracket ac
⇒ Item 22 (page 35) , one from the front and one from the rear.
ce
e
nl
pt
du
an
– Fit locking clips ⇒ Item 11 (page 35) to secure mounting bush‐
itte
y li
erm
es ⇒ Item 10 (page 35) in mounting bracket
ab
ility
⇒ Item 22 (page 35) . The angled ends of the clips must point
ot p
wit
inwards.
, is n
h re
hole
– Press spring clip for Tiptronic position ⇒ Item 19 (page 35) into
spec
mounting on mounting bracket ⇒ Item 22 (page 35) as far as
es, in part or in w
t to the co
it will go.
rrectness of i
– Place lever for locking cable ⇒ Item 38 (page 36) in mounting
bracket ⇒ Item 22 (page 35) and make sure that it engages
l purpos
properly at both mountings.

– Check the locking function of the lever for locking cable
nf
ercia
o
⇒ Item 38 (page 36) . With the selector lever
rm
m
⇒ Item 14 (page 35) in position “P”, the locking lever should
atio
m
engage the detent ⇒ Item 16 (page 35) and make it impossible

o
n in
or c
to change gear.
thi
te
sd
iva
– Move selector lever ⇒ Item 14 (page 35) into Tiptronic position. o

r
rp
cu
o
m
f
– Place frame ⇒ Item 20 (page 35) on mounting bracket

en
ng
t.
yi Co
⇒ Item 22 (page 35) (ribbed side upwards) and insert stop Cop py
buffer ⇒ Item 15 (page 35) in cable lever
t. rig
gh ht
yri
⇒ Item 17 (page 35) .
p by
co Vo
by lksw
cted agen
– Install selector mechanism ⇒ page 32 .
Prote AG.
2.7.3 Dismantling and assembling selector

lever
– Remove the selector lever ⇒ page 38 .

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 5-speed automatic gearbox 01V - Edition 08.2007
ce
le
un
pt
an
d
itte
Dismantling
y li
erm
ab
– Drive out the selector lever mounting pin using a drift as shown
ility
ot p
in the illustration.
wit
is n
h re
ole,
– Lift pull rod and slide selector gate out of selector lever to‐
spec
gether with Tiptronic spring mechanism.
t to the co
– Release coil spring, then remove pull rod and coil spring from
selector lever.
rrectne
– Lever gate cover out on both sides.
ss o
cial p
f inform
mer
atio
m
– Carefully lever out springs -1- and -2- and thrust pieces (Qty.
o
n
c
i
3) for Tiptronic spring mechanism with a screwdriver -arrow-.
or
n thi
te
sd
a
Assembling
iv
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.
– Fit guides -C- onto stop so that the narrower part points to‐
wards the pull rod.
– Place coil spring -B- onto pull rod -A-.
– Insert pull rod and coil spring in selector lever.
Rounded corner -arrow- points in direction of travel.
– Check that pull rod slides freely on the two guides -C- on the
selector lever.
Assemble Tiptronic spring mechanism as follows:
– Press in a gate cover.
– Insert a short spring -1- and two long springs -2- with thrust
pieces (Qty. 3) into the gate by hand.
– Spray the Tiptronic spring mechanism thinly with polycarbon‐
ate grease -G 052 142 A2- and insert.
– Press in second gate cover.

Passat 1997 ➤
– Lift pull rod -D- and slide selector gate -B- with Tiptronic spring
mechanism into selector lever .-A-.
Volkswage n AG n AG d
wage oe
– Drive in selector lever
yV
olks mounting pin -C- with a sdrift
not
gu
⇒ page 43 . ise d b ara
n r tee
ho
– To secure aupin, make two new punch marks -arrows- at 90°r ato
t o
c
ss
the existing ones.
ce
e
nl
pt
du
The mounting pin may only have a maximum of 4 punch marks.
an
itte
y li
erm
ab
– Install selector lever ⇒ page 41 .
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
lock solenoid -N110-
m
atio
om
n in
or c
thi
te
sd
a
2.8.1 Removing
iv
o
r
rp
cu
o
m
f
en
ng

t.
yi Co
Cop py
– Remove stop buffer -2- from cable lever.
t. rig
gh ht
pyri by
Vo
o
– Shift selector lever -1- into Tiptronic position, then remove
c by lksw
cted agen
frame -3-.
Prote AG.

– Lift lever for locking cable -4-, detach from mounting and re‐
move from mounting bracket -5-.
– Press out pin for locking pawl -6- using a drift.
– Lift out selector lever lock solenoid -7- together with locking
pawl -6-.
2.8.2 Installing
– Insert selector lever lock solenoid -7- in mounting bracket -5-
from above together with locking pawl.
– Carefully drive in pin for locking pawl -6-.
– Place lever for locking cable -4- in mounting bracket -5- and
make sure that it engages properly at both mountings.
– Place frame -3- on mounting bracket (ribbed side upwards)
and insert stop buffer -2- in cable lever.

Passat 1997 ➤

cable
2.9.1 Removing agen

AG. Volkswagen AG d
oes
olksw not
Special tools and workshop equipment
d by V required gu
ara
ise nte
r
♦ Removal lever -80-200- uth o eo
ra
s a c
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
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Raise vehicle.
-arrows- from the exhaust pipe on the noise insulation.

Passat 1997 ➤

bolts -arrows C-.
– Remove front exhaust system with catalytic converter ⇒ Rep.
– Remove cover from mounting bracket -arrows-.

AG. Volkswagen AG d
Disconnect selector lever cable from mounting bracket: lksw
agen oes
not
Vo gu
by 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
– Press together ends of securing clip -B- and remove.
– Pull down locking plate -A- (for securing selector lever cable
to mounting bracket) and remove.
rrectness of i
– Pull selector lever cable off selector lever.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
g

n
t.
yi Co
-arrow-. Cop py
t. rig
gh ht
yri
– Remove support bracket from gearbox. p by
co Vo
by lksw
cted agen
– Release selector lever cable from support bracket. Prote AG.
– Pull selector lever cable out from mounting bracket, when do‐
ing this do not kink selector lever cable.
2.9.2 Installing
– Do not bend or kink selector lever cable. Lightly grease cable
eye and ball socket before installing.
– Press selector lever cable -1- fully forwards -arrow-.

AG. Volkswagen AG d
ksw
agen Passat
oes
no
1997 ➤
ol
5-speedd bautomatic
yV gearbox 01V - Edition t08.2007
gu
ara
rise nte
ho eo
– Move selector shaft lever -2- on the gearbox in s aut ra
c
-direction of arrow- to position “2”. s
ce
e
nl
pt
du
– Grease the ball socket of the selector lever cable using poly‐
an
itte
y li
carbamide grease -G 052 142 A2- .
erm
ab
ility
ot p
– Carefully press the ball head of selector lever cable -1- onto
wit
, is n
the selector shaft lever.
h re
hole
Take care not to bend selector shaft lever -2-, because otherwise
spec
es, in part or in w
it will not be possible to precisely adjust selector mechanism.
t to the co
– Move selector shaft lever -2- on gearbox to position “P”. Lock‐
ing lever must engage in park lock wheel so that both front
wheels are blocked (cannot be turned together in same direc‐
rrectness of i
tion).
– Do not bend or kink selector lever cable. Lightly grease cable l purpos
eye and ball socket before installing.
nform
ercia
– Using a pair of pliers, carefully push the selector lever cable

m
at
onto selector shaft lever -2-.
om
ion
c
in t
Take care not to bend selector shaft lever, because otherwise it
or
his
e
will not be possible to precisely adjust selector mechanism.

at
do
priv
c
– Insert selector lever cable in mounting bracket.
um
for
en
ng
t.
yi
– Connect selector lever cable to selector lever.
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
The angled end of the locking plate -A- must point towards the
end of the selector lever cable.
– Fit locking plate -A- for selector lever cable onto mounting
bracket.
– Press together ends of securing clip -B- and slide onto end of
selector lever cable.
– Connect selector lever cable to support bracket hand-tight.
– Bolt support bracket to gearbox (hand-tight).
– Align selector lever cable in support bracket.
– Tighten support bracket/gearbox -arrows 1- to specified torque

⇒ page 48 .
– Tighten selector lever cable/support bracket -arrow 2- to
specified torque ⇒ page 48 . When doing this, counter hold
on hexagon flats -arrow 3-.

Passat 1997 ➤
– Tighten nuts -arrows- ⇒ Item 28 (page 36) .

⇒ page 26 .

2.9.3 Torque settings

olkswagen AG
en AG. V
Components Torque setting
olks
wag does
not
V gu
by ara
Selector lever cable -5- on support bracket -B- 12
ris Nm
ed nte
tho eo
Support bracket -B-, -2- and -3- on gearbox au 23 Nm ra
c
ss
Guard plate -A-, -1- and -4- on gearbox 23 Nm
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
2.10 Removing and installing locking cable

t to the co
rrectness of i
2.10.1 Removing
l purpos

♦ Setting gauge for locking cable -3352 A-
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.

Passat 1997 ➤

AG. Volkswagen
agen AG do
ksw es n
y Vol ot g
ua
b
ed ran
oris tee
th or
au 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
rior
l purpos
♦ Workshop manual Passat 1997 ▸ Electrical system
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.

– Vehicles with coded radio unit, note or obtain code.

Passat 1997 ➤

AG. Volkswagen AG d
– Remove selector lever handle ⇒ page 29 . agen oes
olksw not
V gu
d by ara
– Remove centre console and extension ⇒ or is General body re‐
e nte
pairs, interior; Rep. Gr. 70 ; Compartments,
aut
h covers and trims; eo
ra
Removing and installing centre console
ss . c
ce
e
nl
pt
– Remove the steering wheel with airbag ⇒ General body re‐
du
an
pairs, interior; Rep. Gr. 69 ; Airbag; Removing and installing itte
y li
erm
ab
steering wheel or ⇒ General body repairs, interior; Rep. Gr.
ility
ot p
69 ; Airbag; Removing and installing driver's side airbag unit .
wit
, is n
h re
– Remove the steering column switch ⇒ Electrical system; Rep.
hole
Gr. 94 ; Steering column switch; Removing and installing
spec
es, in part or in w
steering column switch .
t to the co
– Turn ignition key to ignition on position.
rrectness of i
– Release locking clip -1- and pull locking cable out from ignition/
l purpos
starter switch.
nform
ercia
– Unclip locking cable from securing spring on mounting brack‐

m
at
om
et. To do this, lift securing spring slightly ⇒ page 37 .
ion
c
in t
or
– Release locking cable from cable clip -2- and take out.
his
ate
do
riv
2.10.2 Installing
p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Passat 1997 ➤
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
– Route locking cable free of kinks.

l purpos
– Turn ignition key to ignition on position.

nf
ercia
– Fit locking cable to ignition/starter switch.

orm
m
atio
m
– Check that locking device -1- engages.

o
n in
or c
– Secure locking cable to airbag sensor with cable clip -2-.

thi
te
sd
iva
– Turn ignition/starter switch to locked position (ignition off).

o
r
rp
cu
o
m
f
en
ng

t.
yi Co
Cop py
– Hook locking cable into locking lever and clip locking cable ht. rig
rig ht
support bracket -3- into securing spring of mounting bracket py by
co Vo
by lksw
⇒ page 37 . Prote
cted AG.
agen

Passat 1997 ➤
2.11 Adjusting locking cable

– Loosen bolt -6-.
– It must be possible to move support bracket -3- by hand in
direction of arrow -5-.
– Move steering column down and to rear.
– Push setting gauge for locking cable -3352 A- -4- on between
locking lever and the locking cable eye.
– To compensate for play, pull support bracket in direction of
arrow -5- onto stop and tighten bolt -6- to 10 Nm.
– Remove setting bar.
– Check ignition key withdrawal lock after each adjustment of
locking cable ⇒ page 28 .
– Install the steering column switch ⇒ Electrical system; Rep.
Gr. 94 ; Steering column switch; Removing and installing
steering column switch .
– Install the steering wheel with airbag ⇒ General body repairs,
interior; Rep. Gr. 69 ; Airbag; Removing and installing steering
wheel or ⇒ General body repairs, interior; Rep. Gr. 69 ; Air‐
bag; Removing and installing driver's side airbag unit .
moving and installing centre console . AG. Volkswagen AG d
agen oes
ksw
– Install cover ⇒ page 53 . by
Vol not
gu
ara
ed
is nte
– Install selector lever handle ⇒ page 30 . hor eo
aut ra
c
– Connect the battery earth strap ⇒ Electrical system; Rep. Gr. ss
ce
le

un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
let 36 .
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 ➤
3 Dismantling and assembling

lksw
agen
AG. the se‐ does no
Volkswagen AG
lector mechanism dcover

Vo t gu
by ara
se nt
ri ee
tho or
s au ac
s
3.1 Selector mechanism cover - Assembly overview
ce
e
nl
pt
du
an
itte
y li
Removing and installing the selector mechanism cover erm
ab
⇒ page 53 .
ility
ot p
wit
, is n
Dismantling and assembling the selector mechanism cover
h re
⇒ page 55 .
hole
spec
es, in part or in w
t to the co
1 - Cover moulding
❑ With trim piece and
symbol panel
rrectness of i
❑ Can only be replaced as
l purpos
a complete item
2 - Cover strip
nform
ercia
❑ With 2 magnets
m
at
-arrows- for Tiptronic
om
io
switch -F189- and gear
n
c
in t
or
indicator
his
ate
do
riv
❑ Magnets must be firmly

p
cum
connected to the cover
for
en
g
strip
n
t.
yi Co
Cop py
3 - Guide
t. rig
gh ht
pyri by
❑ Guides the cover strip
co Vo
by lksw
cted agen
Prote AG.
3.2 Removing and installing the selector

mechanism cover
3.2.1 Removing
rior
3. Dismantling and assembling the selector mechanism cover 53

Passat 1997 ➤
– Remove selector lever handle ⇒ page 29 .

– Pull the pull rod up and move the selector lever to position “P”
with the pull rod pulled up.
– Switch off ignition.
– Remove centre console ⇒ General body repairs, interior; Rep.
Gr. 70 ; Compartments, covers and trims; Removing and in‐
stalling centre console .
– Carefully lever retaining tabs -arrows A- (Qty. 4) off from
above.
You are not allowed to lever off the four retaining tabs
-arrows B- of the printed circuit board that are visible from above.
Otherwise, the printed circuit board will be damaged.
The complete cover must be replaced if retaining tabs
-arrows A- or -arrows B- are damaged.
– Lift off the complete cover of the selector mechanism.
– Press release -arrow A- on plug -1- and pull it out of cover

-2- in direction of arrow -B-.
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
3.2.2 Installing wit

, is n
h re
hole
Install in reverse order of removal. During this step, observe the

spec
following:
es, in part or in w
t to the co
– Connect plug -1- opposite to direction of arrow -B- into cover

-2- before it is clipped into the selector mechanism.
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 ➤
– Carefully place the cover onto the selector mechanism and

lock using retaining tabs -arrows A- (Qty. 4).
The complete cover must be replaced if retaining tabs
-arrows A- or -arrows B- are damaged.
n AG. Volkswagen A
– Install centreoconsole
ksw
age ⇒ General bodyG do
erepairs,
s no interior; Rep.
y V l
Gr. 70 ; dCompartments, covers and trims; tRemoving
gu and in‐
b ara
stalling
oriscentre
e
console . nte
e
h
ut or
– Install
ss
a
selector lever handle ⇒ page 29 . ac
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
3.3 Dismantling and assembling selector
, is n
h re
hole
mechanism cover
spec
es, in part or in w
t to the co
3.3.1 Dismantling
rrectness of i
l purpos
You are not allowed to lever off the four retaining tabs
-arrows B- of the printed circuit board. Otherwise, the printed cir‐
nf
cuit board will be damaged.
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
co lksw
by
cted agen
Prote AG.
– Carefully lever off retaining tabs -arrows-.
3. Dismantling and assembling the selector mechanism cover 55

Passat 1997 ➤
– Remove cover strip -2- out of guide -3-.
3.3.2 Assembling
– Check whether magnets -arrows- are attached to cover strip
-2-.
If this is not the case, replace the cover strip. agen
AG. Volkswagen AG d
oes
olksw not
V
– Insert cover strip -2- into guide -3-. ed by gu
ara
ris nte
ho eo
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
– Place the guide with the cover strip onto the cover moulding
and carefully lock together -arrows-.
nform
mercia
Replace the entire cover if retaining tabs -arrows- are damaged.

a
com
tion in
– Install cover ⇒ page 54 .

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 ➤
4 Removing and installing gearbox

Vehicles with 4-cylinder petrol engine ⇒ page 71
Vehicles with 4-cylinder TDI engine with pump/nozzle unit
⇒ page 57 .
Vehicles with 5-cylinder engines ⇒ page 82 .
Vehicles with V6 TDI engines ⇒ page 95 .
Vehicles with V6 petrol engines ⇒ page 111 .
Transporting the automatic gearbox ⇒ page 126 .
Secure gearbox to assembly stand ⇒ page 127 .
Removing and installing left and right gearbox support
⇒ page 129 .
4.1 Removing and installing the gearbox for vehicles with 4-cylinder TDI engine
with pump/nozzle unit
agen
AG. Volkswagen AG d
o
w es n
olks ot g
byV ua
ed ran
Special tools and workshopthoris tee
or
equipment required au ac
ss
ce
e
♦ Support bracket -10-222A-

nl
pt
du
an
itte
♦ Rack -10-222A/1-
y li
erm
ab
ility
ot p
wit
, is n
♦ Lifting tackle -2024 A-
h re
hole
spec
♦ Gearbox support -3282-
es, in part or in w
t to the co
♦ Adjustment plate -3282/19-
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4. Removing and installing gearbox 57

Passat 1997 ➤
♦ Locating pins -3393-

♦ Lifting aid -3457-
♦ Drip tray -V.A.G 1306-
♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-
♦ Engine and gearbox jack -
V.A.G 1383 A-
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
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
va
♦ Support bridge -30-211 A-

i
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 ➤
♦ Step ladder -VAS 5085-

♦ Workshop manual Passat 1997 ▸ 4-cylinder diesel engine,
mechanics (without intermediate shaft)
AG. Volkswagen A
♦ Workshop manual Passat ksw 1997 ▸ Running gear,
agen G do
es naxles, steer‐
y Vol
ing - front and four-wheel drive
ot g
ua
db r e an
ris t
♦ Workshop manual
ut
ho Passat 1997 ▸ Electrical system ee
or
a ac
ss
♦ Workshop manual Passat 1997 ▸ General body repairs, ex‐
ce
e
nl
terior
pt
du
an
itte
y li
4.1.1 Removing
erm
ab
ility
ot p

wit
, is n
anti-theft code. h re
hole
spec
es, in part or in w

t to the co
– Pull dipstick -1- out of the guide tube.
rrectness of i
– Unclip the covers for the nuts.

l purpos
– Unscrew and remove nuts -arrows- and remove the engine

cover.
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
yri
– Unclip the covers for the nuts. p by
co Vo
by lksw
cted agen
– Unscrew and remove nuts -arrows- and remove the air filter Prote AG.
cover.
– Take intake hose off induction manifold.

Passat 1997 ➤
– Unclip connectors -1- and -2- under the coolant tank out of the
bracket.
– Remove the suction connecting piece with intake manifold flap
and exhaust gas recirculation valve ⇒ 4-cylinder diesel en‐
gine, mechanics (without intermediate shaft); Rep. Gr. 26 ;
Exhaust gas recirculation system; Removing and installing
parts of the exhaust gas recirculation system .
– Remove eye of support device -2024 A- .
– Insert pin into centre hole of support device -2024 A- and se‐
cure with a split pin.
– Fit support bar -10-222A- together with supports -10-222A/1- .
– Hook lifting tackle -2024 A- onto the spindle of support bracket

-10-222A- .
– Take up weight of engine/gearbox assembly on spindles.
– Loosen wheel bolts.
– Raise vehicle.
– Remove front wheels.
– Unclip the retaining clip for coupling rod -1- of vehicle level
. Volkswagen AG
sender -G78- from track control link -2-.
swa
gen AG does
k not
Vol 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
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 ➤

bolts -arrows C-.
– Remove left and right drive shaft noise insulation from wheel
housing -arrows-.
– Remove front exhaust system with catalytic converter ⇒ 4-
cylinder diesel engine, mechanics (without intermediate
shaft); Rep. Gr. 26 ; Removing and installing parts of exhaust
system .
– Remove left drive shaft guard plate -arrows-. The third bolt is
not visible in the figure.
– Disconnect left and right-hand drive shafts -1- from flanges
and tie them up.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
– Remove noise insulation retainer -1-.
ce
le
un
pt
an
d
– Pull connector -2- off wire for multi-function switch.

itte
y li
erm
ab
– Turn locking lever -3- and unplug connector for gearbox wiring
ility
ot p
harness.
wit
is n
h re
ole,
– Cut through cable tie -4-.

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
61
by lksw
cted agen
Prote 4. Removing and installing gearbox
AG.
Passat 1997 ➤
– Pull the plug off speedometer sender -G22- -arrow A-.

– Place drip tray -V.A.G 1306- underneath.
– Thoroughly clean area around connection between ATF line
and gearbox.
– Remove ATF lines from engine/gearbox assembly -arrows-

and tie-up.
– Seal off ATF lines and gearbox with clean plugs.
– Remove starter ⇒ Electrical system; Rep. Gr. 27 ; Starter;
Removing and installing starter .
– Unbolt torque converter from drive plate (3 securing bolts).
Turn crankshaft 13 turn for each bolt.
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
– Mark position of selector lever cable support bracket on gear‐

an
d
itte
box housing in order to reinstall it in same position. Unbolt

y li
erm
ab
support bracket -arrows-.

ility
ot p
wit
– Remove side and lower connecting bolts for engine/gearbox.

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
62
Prote AG.
Rep. Gr.37 - Controls, housing
AG. Volkswagen AG d Passat 1997 ➤
agen oes
o lksw not 5-speed automatic gearbox 01V - Edition 08.2007
y V gu
d b ara
rise nte
– Set upugearbox
tho support -3282- . eo
ra
s a c
Set up gearbox support -3282- for automatic gearbox 01V with
s
ce
le
adjusting plate -3282/19- .

un
pt
an
d
itte
y li
The symbols on the adjusting plate indicate the mounts required;
rm
ab
the arrow points forward.
pe
ility
ot
wit
, is n
– Position engine/gearbox jack -V.A.G 1383 A- with gearbox
h re
support -3282- under the gearbox, align adjusting plate paral‐
hole
spec
lel to gearbox and support gearbox.
es, in part or in w
t to the co
rrectness of i
To prevent damage to the ATF pan when the support bracket
l purpos
-A- is bolted on:

– Lay two washers between support area of support bracket and
nform
ercia
gearbox.
m
a
com
t
– Secure gearbox with bolt -A-.
ion 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
– Before unbolting engine mounting from subframe, mark loca‐
Prote AG.
tion of threaded connections -1- and locating sleeves -2-.
– Remove nuts -1- below at left and right on engine mounting.

– Remove gearbox mounting/subframe securing bolts -2-.
– Before separating subframe, always use locating pins -3393-
on both sides of vehicle to check that at least holes -1- and
-2- align.

Passat 1997 ➤
There is no need to take account of hole -3-.

If this is not the case, perform wheel alignment after tightening
the subframe.
G. Volkswagen AG d
– Unscrew bolts -1- and -2- at rear of subframe on both sides of lkswagen A oes
not
vehicle. by
Vo gu
ara
d
ise nte
– Remove bolts -3- at front of subframe on both sides ofutvehicle.
ho
r eo
ra
sa c
– Unscrew and remove bolts -4- (two on each side ofs vehicle).
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
– Unhook the power steering hose from bracket -arrow-.
rrectness of i
When lowering the gearbox, please take care not to damage any
components.
l purpos
– Now step onto step ladder -VAS 5085- to lower the engine/
gearbox unit using the spindles.
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
op py
– Lower the engine/gearbox unit by turning the spindles through t. C rig
gh ht
approx 8 turns. pyri by
Vo
co lksw
by
cted
– At the same time, lower engine/gearbox assembly using en‐
agen
Prote AG.
gine and gearbox jack -V.A.G 1383 A- (2nd mechanic).

Passat 1997 ➤

-arrow-.
– Remove upper engine/gearbox securing bolts.
– Press gearbox off engine while simultaneously pressing tor‐
que converter out of drive plate.
– Press torque converter

agen against
AG. VolkswageATF
n AG dpump -arrow-.
o w es n
olks ot g
– Lower gearbox.
ed
by
V ua
ran
ris tee
utho 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
– Secure the torque converter with support bridge -30-211 A- to

prevent it from falling down.
rrectness of i
Use workshop hoist -V.A.G 1202 A- and transportation tool -3457-

l purpos
to transport the automatic gearbox ⇒ page 126 .

When working on gearbox, secure it to repair stand with transport
nf
ercia
device -3457- and retaining plate -VW 309- ⇒ page 127 .

orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op
4.1.2 Installing
C py
t. rig
gh ht
pyri by
Vo
o
– Clean ATF cooler and ATF lines before installing an exchange
c by lksw
cted agen
gearbox ⇒ page 148 . Prote AG.
– Before installing gearbox, ensure that torque converter seats

correctly in gearbox ⇒ page 15 .
– Ensure that the dowel sleeves and the intermediate plate are
correctly positioned on engine.
– Set up gearbox support -3282- .
– Place gearbox on gearbox jack.

Passat 1997 ➤
– Secure gearbox to gearbox support -3282- using bolt -A-.

– Place gearbox jack under vehicle.
– Guide gearbox in between lowered subframe and underbody.
– Align gearbox to engine.
– Screw in one engine/gearbox connecting bolt hand-tight on
each side. AG. Volkswagen n AG do
wage es n
olks
– Bolt torque converter and drive plate together. ot g
yV b ua
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
To do this, screw in the bolts by hand and tighten to 85 Nm.
an
itte
y li
erm
ab
– Additionally bolt on a bracket or an earth connection at many
ility
ot p
connecting bolts ⇒ page 71 .
wit
, is n
h re
– Screw in upper engine/gearbox connecting bolts and tighten
hole
to specified torque ⇒ page 71 .
spec
es, in part or in w
t to the co
– Now step onto step ladder -VAS 5085- to lift the engine/gear‐
box unit using the spindles.
rrectness of i
l purpos
nform
ercia
– Lift up the engine/gearbox unit by turning the spindles through

approx. 8 turns.
m
at
om
io
– At the same time, lift the engine/gearbox unit using engine and
n
c
in t
r
gearbox jack -V.A.G 1383 A- (2nd mechanic).

o
his
ate
do
riv
1. Installing subframe with wheel alignment

p
cum
for
en
g
2. Installing subframe without wheel alignment

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Wheels must be aligned if holes -1- and -2- did not align
⇒ page 63 before the subframe was removed.
– Install subframe using bolts originally removed. These bolts
must be replaced following wheel alignment.
– Tighten old bolts to specified torque without additional part-
turn ⇒ Running gear, axles, steering - front and four-wheel
drive; Rep. Gr. 40 ; Repairing front suspension; Removing
and installing subframe .
WARNING
The vehicle must not be driven in this state.
2. No wheel alignment is required if holes -1- and -2- were aligned

before subframe was separated ⇒ page 63 .
– Install subframe with new bolts, observing the tightening se‐
quence ⇒ Running gear, axles, steering - front and four-wheel

Passat 1997 ➤
AG. Volkswagen
swagengearbox 01V -AG
5-speed automatic Edition
does 08.2007
olk no t gu
yV
db ara
– ise
Bolt engine bearings onto subframe according to markings
r nte
tho eo
made for threaded connections -1- and locating ssleeves
au -2-. ra
c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Screw on nuts -1- below on left and right engine mountings ⇒
Running gear, axles, steering - front and four-wheel drive; l purpos
Rep. Gr. 40 ; Repairing front suspension; Removing and in‐
stalling subframe .
nform
ercia
– Screw in new gearbox mounting/subframe bolts -2-

m
at
om
⇒ page 134 .
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
– After subframe has been bolted to body, and engine/gearbox cted agen
Prote AG.
unit to subframe, remove bolt -A-.
– Remove engine and gearbox jack -V.A.G 1383 A- .
– Apply anti-corrosion agent to point of contact between bolt
-A- and oil pan.
– Screw in engine/gearbox connecting bolts at the sides and the
bottom and tighten to specified torque ⇒ page 71 .
– Fit the retaining clip for the coupling rod of vehicle level sender
-G78- to front left track control link ⇒ Running gear, axles,
steering - front and four-wheel drive; Rep. Gr. 40 ; Electrical
and electronic components and their locations; Vehicle level
sender -G78- on the front axle .
– Do not bend or kink selector lever cable. Grease cable eye
and ball socket with polycarbonate grease -G 052 142 A2-
before installing.
– Move selector shaft lever -2- on gearbox in

-direction of arrow- to position “2” and carefully use a pair of
pliers to press the ball head of selector lever cable -1- onto the
lever of the selector shaft.
– Press selector lever cable -1- fully forwards -arrow- to engage
selector shaft lever -2- in position “2”.

Passat 1997 ➤
– Bolt support bracket of selector lever cable to gearbox

-arrows- at marked location ⇒ Item 32 (page 36) .
– Install starter ⇒ Electrical system; Rep. Gr. 27 ; Starter; Re‐
moving and installing starter .
– Always replace O rings -1-.

– Moisten new O-rings with ATF and insert.
– Ensure that O-rings are seated correctly so that they do not
slip when ATF lines are inserted.
– Insert ATF lines completely to stop in gearbox by hand.
– Do not tighten bolt -2- until all the ATF lines have been con‐
nected ⇒ Item 1 (page 143) .
– Plug connector into multi-function switch -2-.

– Fit connector for gearbox wiring harness and secure with lock‐
ing lever -3-.
– Install noise insulation bracket -1- ⇒ General body repairs,
exterior; Rep. Gr. 50 ; Body front; Assembly overview - noise
insulation .
– Replace cable tie -4-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
– Push the plug onto speedometer sender -G22- -arrow A-.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
68
c by lksw
cted agen
Rep. Gr.37 - Controls, housing Prote AG.
Passat 1997 ➤
– Install drive shafts -1- onto flange shafts ⇒ Running gear,

axles, steering - front and four-wheel drive; Rep. Gr. 40 ; Re‐
pairing drive shafts; Removing and installing drive shafts .
– Install right drive shaft guard plate -arrows-. The third bolt is
not visible in the figure. ⇒ Running gear, axles, steering - front
and four-wheel drive; Rep. Gr. 40 ; Repairing drive shafts;
Removing and installing drive shafts .
AG. Volkswagen
– Install front exhaust systemlkwith catalytic
wage
n
converter ⇒esRep.
AG do
o s not
Gr. 26 ; Removing anddinstalling
by
V parts of the exhaust systemgu .
a
e ran
ris tee
utho or
a ac
ss
ce
le
un
pt
an
d
– Fit left and right drive shaft noise insulation to wheel housing.
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
ercia

m
a
com
t
firmly onto the noise insulation. ion in
r
te o
thi
s
iva
– Install front wheels ⇒ Running gear, axles, steering - front and

do
r
rp
four-wheel drive; Rep. Gr. 44 ; Torque settings for wheel bolts .

um
fo
en
ng
t.
yi
– Remove support device -10-222A- .
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Hook the power steering hose into bracket -arrow-.

– Install the suction connecting piece with intake manifold flap
and exhaust gas recirculation valve ⇒ 4-cylinder diesel en‐
gine, mechanics (without intermediate shaft); Rep. Gr. 26 ;
Exhaust gas recirculation system; Removing and installing
parts of the exhaust gas recirculation system .

Passat 1997 ➤
– Plug connectors -1- and -2- into the bracket under the coolant
tank.
– Fit the intake hose onto the induction manifold.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
– Put on the air filter cover a screw nuts -arrows- on tight rise 4-
⇒ nte
tho eo
s au ra
c
shaft); Rep. Gr. 10 ; Removing and installing engine;
s Tight‐
ce
e
ening torques . nl
pt
du
an
itte
y li
– Clip in covers for nuts.
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
– Put on the engine cover and screw the nuts on tightly ⇒ 4-
l purpos

shaft); Rep. Gr. 10 ; Removing and installing engine; Tight‐
ening torques .
nf
ercia
orm
– Clip in covers for nuts.
m
atio
om
– Insert dipstick -1- into the guide tube.
n in
or c
thi
e

t
sd
iva
o
r
rp
cu
o
m
f
en
ng

t.
yi Co
op
let 36 . C py
t. rig
gh ht
yri
p by
co Vo
by lksw
Radio, telephone, navigation . Prote
cted AG.
agen

⇒ page 26 .
– With gearbox installed, check gear oil level in final drive
⇒ page 178 .
– Finally, check ATF level and top up ⇒ page 135 .
– When checking ATF level, check ATF line connections -A- and
-B- for leaks.

Passat 1997 ➤

Gearbox to engine
Item Bolt Quantity Nm
1 M12 x 67 3 65
23) M12 x 110 1 65
3 M12 x 90 1 65
42) M12 x 60 1 45
5 M10 x 45 4 45
64) M12 x 67 1 65
2) With nut
3) With bracket for wiring harness
4) With wire retainer
Item A = dowel sleeves
4.2 Removing and installing gearboxlksfor

wagevehicles with 4-cylinder
es n petrol engines
o ot g
yV ua
edb ran
ris tee
ho
ut or
♦ Locating pins -3393- ss
a ac
ce
e

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
♦ Torque wrench -
wit
, is n
V.A.G 1331-
h re
hole
♦ Torque wrench -
spec
V.A.G 1332-
es, in part or in w
t to the co
V.A.G 1383 A-
rrectness of i
♦ Without illustration:
l purpos

♦ Rack -10-222A/1-
nform
ercia

m
at
om
io

n
c
in t
or
his
e

at
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
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
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
op
♦ Workshop manual Passat 1997 ▸ 4-cylinder injection engine,
C py
ht. rig
5 valves (without intermediate shaft)
rig ht
py by
co Vo
by lksw
cted
♦ Workshop manual Passat 1997 ▸ Running gear, axles, steer‐
agen
Prote AG.
terior
4.2.1 Removing
– First check whether a coded radio is fitted. If so, obtain anti-
theft code.
– Remove cover from engine.
– Remove air filter housing.
– Fit support bracket -10-222A- together with racks -10-222A/
1- .

Passat 1997 ➤
– Hook engine on both liftingn Aeyes.

G. Volkswagen A ge Gd
wa oes
olks
– Take up weight bofy Vengine/gearbox assembly. not gua
d ran
se
Leave rear spindle
ho
ri slightly loose to enable the lowering of the
tee rear
ut or
later. ss
a ac
ce
le

un
pt
an
d
itte
y li
– Raise vehicle.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Unclip retaining clip for coupling rod -1- of vehicle level sender
-G78- from track control link -2-.
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
– In vehicles with an auxiliary heater, remove bolts -arrows- from Cop py
exhaust pipe to the insulation.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– In vehicles with noise insulation -D-, remove bolts
-arrows C-.

Passat 1997 ➤
housing -arrows-.
– Remove front exhaust system with catalytic converter.
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
– Disconnect left and right drive shafts -1- from flanges and tie
erm
ab
ility
up.
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– If noise insulation retainer -1- is present, remove it.
nf
ercia
o
– Pull connector -2- off wire for multifunction switch.
rm
m
atio
m
o
n in
c
harness.
or
thi
te
sd
a

iv
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.
– Pull connector off speedometer sender -G22- -arrow A-.

and gearbox.

Passat 1997 ➤

and tie up.
– Seal ATF lines and gearbox with clean plugs.

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or

f
en
ng
t.
yi Co
op
Set up gearbox support -3282- for automatic gearbox 01V with C py
t. rig
gh ht
pyri by
Vo
co lksw
by
The symbols on the adjusting plate indicate the mounts required; Prote
cted AG.
agen
support -3282- under gearbox and align adjusting plate paral‐

Passat 1997 ➤

-A- is bolted on:
gearbox.


-2- align.
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
Hole -3- may be disregarded.

itte
y li
erm
ab

ility
ot p
subframe!
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 ➤
– Unscrew bolts -1- and -2- at rear of subframe on both sides of

vehicle.
– Remove bolts -3- at front of subframe on both sides of vehicle.
– Unscrew and remove bolts -4- (two on each side of vehicle).
– Unhook power steering hose from bracket -arrow-.

components.
AG. Volkswagen AG d
– Now step onto stepladder -VAS 5085- tolklower
wage the engine/
n oes
o s not
gearbox unit using the spindles. db
y V gu
ara
ise nte
r
– At the same time, lower engine/gearbox
ut
ho assembly using en‐ eo
ra
gine and gearbox jack -V.A.G
ss a1383 A- (2nd mechanic). c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
-arrow-.
spec
es, in part or in w
t to the co
– Remove upper engine/gearbox connecting bolts.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
e
– Press torque converter against ATF pump -arrow-.

at
do
priv
– Lower gearbox.
um
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Passat 1997 ➤

device -3457- and retaining plate -VW 309- ⇒apage
gen AG127 .
. Volkswagen AG
do
ksw es n
Vol ot g
d by ua
ran
e
ris tee
utho or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
4.2.2 Installing
ility
ot p
wit
, is n
h re
hole
gearbox ⇒ page 148 .
spec
es, in part or in w
t to the co
– Ensure that the dowel sleeves and the intermediate plate are
rrectness of i
correctly positioned on engine.
l purpos

nform
ercia

m
at
om
io
n
c
in t
or
his
e

at
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.
each side.
– Bolt torque converter and drive plate together.

– A bracket or an earth connection is bolted onto some con‐
necting bolts ⇒ page 82 .
– Raise engine and gearbox assembly by turning spindles.

Passat 1997 ➤
must be renewed following wheel alignment.
and installing subframe . agen
AG. Volkswagen AG d
oes
olksw not
y V gu
d b ara
WARNING horise nte
eo
ut ra
s a c
The vehicle must not be driven in this state. s
ce
le
un
pt
an
d
itte
y li
erm
ab
2. No wheel alignment is required if holes -1- and -2- were aligned
ility
before subframe was separated ⇒ page 63 . ot p
wit
is n
h re
ole,
spec
t to the co
– Bolt engine bearings onto subframe according to markings
rrectne
made for threaded connections -1- and locating sleeves -2-.
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
yri
– Screw on nuts -1- below on left and right engine mountings ⇒ p by
co Vo
by lksw
Running gear, axles, steering - front and four-wheel drive; Prote
cted AG.
agen
stalling subframe .
⇒ page 134 .

Passat 1997 ➤
– After subframe has been bolted to body, and engine/gearbox

-A- and oil pan.
– Install retaining clip for coupling rod of vehicle level sender -
G78- on front left track control link ⇒ Running gear, axles,
steering - front and four-wheel drive; Rep. Gr. 40 ; Electric and
electronic components and locations; Vehicle level sender -
G78- on front axle .
before installing.

AG. Volkswagen AG d
-direction of arrow- to position “2” and, using pliers,
ksw
agencarefully oes
not
l
press ball head of selector lever cable -1-byonto
Vo selector shaft gu
ara
lever. ris
ed
nte
ho eo
ut
Take care not to bend selector shaftsslever
a -2- because otherwise ra
c
it will not be possible to adjust selector mechanism precisely.
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
– Always renew O-rings -1-.
Co
Cop py
t. rig
gh
ht
pyri by
Vo
o
by c lksw
– Ensure that O-rings are seated correctly so that they do not cted agen
Prote AG.
slip from their seats when ATF lines are inserted.
– Do not tighten bolt -2- until ATF lines have been completely
inserted ⇒ Item 1 (page 143) .

Passat 1997 ➤
– Plug connector into multifunction switch -2-.

ing lever -3-.
insulation .
– Push plug onto speedometer sender -G22- -arrow A-.
– Attach drive shafts -1- to flange shafts ⇒ Running gear, axles,

steering - front and four-wheel drive; Rep. Gr. 40 ; Repairing
drive shafts; Removing and installing drive shafts .
olkswagen AG
– Install right drive shaft guard plate -arrows-. The third bolt
agen is
AG. V does
ksw
not visible in the figure. ⇒ Running gear, axles, steering
yV
ol - front not
gu
and four-wheel drive; Rep. Gr. 40 ; Repairing db
ise drive shafts;
ara
r nte
Removing and installing drive shafts . utho eo
ra
sa c
– Install front exhaust system with catalytic
s
converter ⇒ Rep.
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.

Passat 1997 ➤

– In vehicles with an auxiliary heater, bolt exhaust pipe firmly to
noise insulation.
– Install air filter housing.
– Connect battery ⇒ Electrical system; Rep. Gr. 27 ; Battery;
Disconnecting and connecting battery .
let 36 .
⇒ page 26 .
⇒ page 178 .
– When checking ATF level, check ATF pipe connections -A-

and -B- for leaks.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
Gearbox to engine
un
pt
an
d
itte
y li
Item Bolt Nm
rm
ab
pe
ility
1, 8, 9, 10 M10 x 45 45
ot
wit
, is n
h re
2, 3 5), 4, 11 M12 x 67 65
hole
spec
5 5) M12 x 110 65
es, in part or in w
t to the co
6 M12 x 90 65
7 6) M10 x 60 45
rrectness of i
A Dowel sleeve for centring

l purpos
5) With wire retainer

6) With nut
nform
ercia
4.3 Removing and installing gearbox for vehicles with 5-cylinder engines
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.

Passat 1997 ➤
Special tools and workshop

equipment required
♦ Rack -10-222A/1-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
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
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤

♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-
V.A.G 1383 A-
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
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 ➤

♦ Workshop manual Passat 1997 ▸ 5-cylinder fuel injection en‐
gine, mechanics
terior
4.3.1 Removing
anti-theft code.
– With ignition switched off, disconnect battery
olks
wagearth
e
strap ⇒ es n
ot g
Electrical system; Rep. Gr. 27 ; Battery;
d by V Disconnecting and ua
ran
connecting battery . or
ise tee
h
ut or
– Take intake hose off induction
ss manifold.
a ac ce
e
nl
– Remove eye of support device -2024 A- .

pt
du
an
itte
y li
– Insert pin into centre hole of support device -2024 A- and se‐
erm
ab
cure with a split pin.

ility
ot p
wit
, is n
– Fit support bar -10-222A- together with supports -10-222A/1- .

h re
hole
spec
– Hook lifting tackle -2024 A- onto the spindle of support bracket

es, in part or in w
-10-222A- .
t to the co

rrectness of i
– Raise vehicle.
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
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤

-arrows- from the exhaust pipe Gon. Vothe
lkswnoise
agen insulation. nA AG do
wage es n
Volks ot g
by ua
ed ran
oris tee
th or
au 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

bolts -arrows C-.
rrectness of i

l purpos
cylinder fuel injection engine, mechanics; Rep. Gr. 26 ; Re‐

moving and installing parts of exhaust system .
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
f
en
ng
t.
yi
Co
Cop py
t. rig
gh
ht
pyri by
Vo
and tie them up.
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤

harness.

and gearbox.

and tie-up.
– Seal off ATF lines with clean plugs.
– Unbolt torque converter from drive plate (3 securing
olks
wagebolts). es n
ot g
yV ua
db ran
rise tee
tho or
au ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab

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

Passat 1997 ➤

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
ot
wit
, is n
Set up gearbox support -3282- for “automatic gearbox 01V” with
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
t
ion in
-A- is bolted on:
r
te o
thi
s
iva
do
r
rp
c
gearbox.
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 ➤

-2- align.

the subframe.

vehicle.
– Unscrew and remove bolts
AG. V-4-
olks(two
wagenon
A
each side of vehicle).
gen G do
swa es
When lowering bthe
y V gearbox, please take care nott gto
olk no
uadamage any
components.rised ran
te
tho eo
– Nows step
au onto step ladder -VAS 5085- to lower the engine/
ra
c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
– Lower the engine/gearbox unit by turning the spindles through

is n
h re
approx 8 turns.
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 ➤

-arrow-.

– Lower gearbox.

prevent it from falling down. AG. Volkswagen
n AG do
s no wage e
Use workshop hoist -V.A.G
yV
olks 1202 A- and transportation t tool
gu -3457-
to transport the automatic
ris
edb gearbox ⇒ page 126 . ara
nt ee
tho o
When working au on gearbox, secure it to repair stand with transport
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
4.3.2 Installing
t to the co

rrectness of i

l purpos

– Before installing, ensure that dowel sleeves are correctly lo‐
nform
ercia
cated.
m
at
om

ion
c
in t
or

his
ate

do
priv
cum
or

f
en
ng
t.
yi
Co
Cop py
ht. rig
– Position engine/gearbox jack -V.A.G 1383 A- with gearbox rig ht
py by
co Vo
by lksw
cted agen
lel to gearbox and support gearbox. Prote AG.

Passat 1997 ➤

– Guide gearbox in between lowered subframe
en AG. V
olkswagen Aand
G
underbody.
ag does
ksw not
Vol
– Align gearbox to engine. gu
by d ara
ise n
– Screw in one engine/gearbox
ut
ho
r
connecting bolt hand-tight ontee o
each side. ss a 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
te

a
do
riv
approx. 8 turns.
p
cum
for
en
g
n
t.
yi Co
op
gearbox jack -V.A.G 1383 A- (2nd mechanic). C py
t. rig
gh ht
yri by
1. Installing subframe with wheel alignment op Vo
by c lksw
cted agen
Prote
AG.
must be renewed following wheel alignment.
WARNING
2. No wheel alignment is required if holes -1- and -2- have been

lined up ⇒ page 89 .

Passat 1997 ➤

made for threaded connections -1- and nlocating sleeves
AG. Volkswagen A -2-. G do
wage es n
Volks ot g
by ua
ed ran
oris tee
th or
au 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
Running gear, axles, steering - front and four-wheel drive;
stalling subframe .
rrectness of i
l purpos
⇒ page 134 .
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
– After subframe has been bolted to body, and engine/gearbox en

ng
t.
yi Co
unit to subframe, remove bolt -A-. . Cop py
rig
ht ht
rig by
copy Vo
by lksw
cted
agen
Prote AG.
-A- and oil pan.
before installing.


Passat 1997 ➤


n AG. Volkswagen AG
– Insert ATF lines completelyoto
lkswstop in gearbox by hand.
age does
no
yV t gu
b ara
– Do not tighten bolt -2-
ris until all the ATF lines have been con‐ ntee
ed
nected ⇒ Item 8 (page
utho
144) . 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
ing lever -3-.
– Install noise insulation bracket -1- ⇒ General body repairs, t to the co

insulation .
rrectne

ss o
cial p
f inform
mer
atio
om

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 ➤

– Install guard plates for left and right drive shafts -arrows-. The
third bolt is not visible in the figure. ⇒ Running gear, axles,
– Install noise insulation.

let 36 .
⇒ page 26 .
⇒ page 178 .
AG. Volkswagen AG d
agen
– Finally, check ATF level and top up ⇒ page 135 . Volksw
oes
not
by gu
d ara
rise nte
– When checking ATF level, check ATF line connections uth-A-
o and eo
ra
-B- for leaks. ss a 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
94
AG.
Passat 1997 ➤

Gearbox to engine
1 M12 x 75 2 65
28) M12 x 130 1 65
37) M12 x 130 1 65
4 M10 x 60 3 45
5 M10 x 70 1 45
69) M12 x 130 1 65
7) With nut
9) With heat shield AG. Volkswagen AG d
agen oes
olksw not
Item A = dowel sleeves ed byV gu
ara
ris nte
ho eo
ut ra
4.4 Installing and removing the gearbox for vehicles with V6 TDI engines s a c
s
ce
le
un
pt
an
d
itte
y li
rm
ab
equipment required
pe
ility
ot
wit
, is n
h re
hole
spec
♦ Rack -10-222A/1-
es, in part or in w
t to the co
♦ Adapter -10-222 A/3-
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.

AG. Volkswagen AG d
agen oes
olksw not
V
Passat 1997 ➤ d by gu
ara
ise nte
5-speed automatic gearbox 01V - Edition 08.2007thor eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
♦ Torque wrench -
hole
spec
V.A.G 1331-
es, in part or in w
t to the co
♦ Torque wrench -
V.A.G 1332-
rrectness of i
V.A.G 1383 A-
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
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤
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
♦ Workshop manual Passat 1997 ▸ 6-cylinder diesel engine,
h re
hole
mechanics
spec
es, in part or in w
t to the co
rrectness of i
l purpos
terior
4.4.1 Removing
nform
ercia

m
at
om
anti-theft code.
ion
c
in t
or
his
ate
do
priv
c
um
for
en
ng
t.
yi
– Unclip the covers for the nuts.
Co
Cop py
t. rig
– Unscrew and remove nuts -arrows- and remove the engine
gh ht
pyri by
cover.
o Vo
by c lksw
cted agen
Prote AG.
– Remove heat shield above turbocharger -arrows-.

Passat 1997 ➤
– Unscrew securing nuts -arrows- for the exhaust pipe on the

turbocharger manifold.
– Assemble support bracket -10-222A- in conjunction with racks

-10-222A/1- and adapters -10-222 A/3- .
– Raise vehicle.
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

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.

Passat 1997 ➤

wage
es ks not
Vol gu
– In vehicles with noise insulation -D-, unscrew ed and remove
by ara
nte
bolts -arrows C-. thoris 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
housing -arrows-.
rrectness of i
l purpos
cylinder diesel engine, mechanics; Rep. Gr. 26 ; Removing

and installing parts of exhaust system .
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
op
– Remove left drive shaft protective plate -arrows-. The third bolt
C py
ht. rig
is not visible in the figure.
rig ht
py by
co Vo
by lksw
cted
agen
Prote AG.
and tie them up.

harness.

Passat 1997 ➤

– Unscrew engine speed sender -G28- -arrow B- from gearbox.
– Remove bracket for ATF line from engine oil sump.

and gearbox.
– Separate ATF lines -1- to ATF cooler.

wage
– Do not remove bracket -3- for ATF lines. olks es n
ot g
byV ua
ed ran
– Remove gearbox side starter motor boltho-2-.
ris tee
ut or
a ac
– Remove starter ⇒ Electrical system;ss Rep. Gr. 27 ; Starter;
ce
e
nl
pt
du
an
itte

y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec

es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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 ➤
– Mark position of selector lever cable support bracket on

wage
gear‐
n AG. Volkswagen AG
does
box housing in order to reinstall it in same position.
yV
olks Unbolt not
gu
support bracket -arrows-. ise
d b ara
n r tee
ho
– Remove side and lower connectingsbolts
au
t
for engine/gearbox. or
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
s
s o
cial p
f inform
mer
– Move engine and gearbox jack -V.A.G 1383 A- with gearbox
atio
support -3282- under vehicle, align adjusting plate parallel to
om
gearbox and support gearbox.
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
op
C py
t. rig
gh
-A- is bolted on:
ht
pyri by
Vo
co lksw
by
cted
agen
Prote AG.
gearbox.


Passat 1997 ➤
– Pull off the vacuum lines on the engine mountings.

-2- align.

the subframe.

vehicle.
. Volkswagen AG
gen AG does
When lowering the gearbox, please take careVnot
olks to damage any
wa not
components. ed
by gu
ara
is nte
or eo
– Now step onto step ladder -VAS a5085-
ut
h
to lower the engine/ ra
gearbox unit using the spindles.ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p

wit
, is n
approx. 8 turns.
h re
hole
spec
– When doing this, lower the engine/gearbox unit on the spin‐

es, in part or in w
dles, working alternately 2 turns at a time.

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
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤
– Remove bolts -1- and -4- and selector lever cable guard plate
-A-.

-arrow-.
– Remove upper engine/gearbox securing bolts -arrows-.

en AG. V
olkswagen AG
ag does
lksw not
– Loosen bolt -A- (on rear of turbocharger) a few db
y Vturns and pivot
o gu
ara
strut -B- to side in direction of arrow. Tighten
or
ise bolt -A- slightly. nte
th 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
The engine is shown from the rear with the gearbox removed.
rrectness of i

l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Passat 1997 ➤

– Lower gearbox.
– Secure the torque converter with support bridge -30-211 A- to n AG. Volkswagen AG do
wage
prevent it from falling down. yV
olks es n
ot g
b ua
ed ran
horis tee
to transport the automatic gearbox ⇒ page 126 . s aut or
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
4.4.2 Installing
rrectne
ss
Only when ATF lines on gearbox have been removed:
o
cial p
f in
form
mer
atio
om
n
c
i
or
n
thi
e

t
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
– Do not tighten bolt -2- until all the ATF lines have been con‐ Cop py
t. rig
gh ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.

cated.


Passat 1997 ➤

– Place gearbox jack under
wage
nvehicle.
AG. Volkswagen AG d
oe
ks s no
Vol t
– Guide gearboxedin
by between lowered subframe and underbody.
gu
ara
is nte
or
– Align gearbox
au
th to engine. eo
ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Before installing gearbox, check whether strut -B- is still pivo‐
t to the co
ted to side in -direction of arrow-. The strut is pivoted down‐
wards after the gearbox has been installed.
rrectne
each side.
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
op
C py
t. rig
gh
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Screw the bolt of the turbocharger/gearbox strut tightly ⇒ 6-
cylinder diesel engine, mechanics; Rep. Gr. 10 ; Installing and
removing engine; Tightening torques .
– Now step onto step ladder -VAS 5085- to lift the engine/gear‐
box unit using the spindles.

Passat 1997 ➤

approx. 8 turns.
– When doing this, lift the engine/gearbox unit on the spindles,
working alternately 2 turns at a time.
must be replaced following wheel alignment.
– Tighten the old bolts only to specified torque ⇒ Running gear,
pairing front suspension; Removing and installing subframe .
WARNING

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
d
2. No wheel alignment is required if holes -1- and -2- have orisbeen
e nte
lined up ⇒ page 102 . aut
h eo
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
g
stalling subframe .
n
t.
yi Co
Cop py
– Connect vacuum lines to engine mountings. ht. rig
rig ht
py by
o Vo
– Screw in new gearbox mounting/subframe bolts -2- by c lksw
cted agen
⇒ page 134 . Prote AG.

Passat 1997 ➤

AG. Volkswagen AG d
unit to subframe, remove bolt -A-. ksw
agen oes
n ol ot g
yV ua
– Remove engine and gearbox jack
ise
-V.A.G
db 1383 A- . ran
r tee
ho
– Apply anti-corrosion agent tos aupoint
t
of contact between bolt or
ac
-A- and oil pan. s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
before installing.
l purpos

nform
ercia
m
at
om
io
n
c
in t
or
his
ate
do
riv

p
cum
or

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

-arrows- at marked location ⇒ page 111 .
– Install selector lever cable guard plate -A- and tighten bolts
-1- and -4- ⇒ page 111 .

Passat 1997 ➤
– Fit ATF lines -1- to engine/gearbox unit and screw tight

⇒ Item 13 (page 146) .
– Screw the bracket for the ATF line onto the engine oil sump
⇒ Item 11 (page 146) .
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
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
ing lever -3-.
rrectness of i
l purpos
insulation .
nform
ercia

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo

en
ng
t.
yi Co
op
– Screw engine speed sender -G28- -arrow B- onto gearbox. C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Passat 1997 ➤

– Install left drive shaft guard plate -arrows-. Third bolt cannot
be seen in figure ⇒ Running gear, axles, steering - front and
four-wheel drive; Rep. Gr. 40 ; Repairing drive shafts; Re‐
moving and installing drive shafts .
– Install front exhaust system with catalytic converter⇒ 6-cylin‐
der diesel engine, mechanics; Rep. Gr. 26 ; Removing and
installing parts of the exhaust system .
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
– Install noise insulation elements -arrows-.
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
– Screw on the securing nuts for the exhaust pipe on the turbo‐
nf
ercia
charger manifold ⇒ 6-cylinder diesel engine, mechanics; Rep.

rm
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.

Passat 1997 ➤
– Install the heat shield above the turbocharger -arrows- ⇒ 6-

cylinder diesel engine, mechanics; Rep. Gr. 26 ; Installing and
removing parts of exhaust system .
– Put on the engine cover and tighten the nuts ⇒ 6-cylinder die‐
sel engine, mechanics; Rep. Gr. 10 ; Installing and removing
engine; Tightening torques . AG. Volkswagen AG d
agen oes
ksw ol not
yV gu
– Clip in covers for the nuts. edb ara
nte
ris
ho eo
– Connect the battery earth strap ⇒ Electrical system;
aut Rep. Gr. ra
c
ss
ce
le
un
pt
an
d
itte
y li
let 36 .
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
⇒ page 26 .
t to the co
⇒ page 178 .
rrectne
ss
o
cial p
f
-B- for leaks.
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.
– Check connections -1- of the ATF lines for leaks when check‐
ing ATF level.
There is no need to take account of bolts -2- and -3- in this case.

Passat 1997 ➤

Gearbox to engine
Item Bolt Quantity Nm AG. Volkswagen AG d
agen oes
ksw
112)
M12 x 80 1 65 by
Vol not
gu
d ara
e
213) M12 x 90 1 65 horis nte
eo
ut ra
3 M12 x 75 1 65 ss a c
ce
le
410) M10 x 60 1 45
un
pt
an
d
itte
5 M10 x 45 3 45
y li
rm
ab
6 M10 x 80 1 65
pe
ility
ot
wit
711) M12 x 110 1 65
, is n
h re
hole
8 M12 x 67 2 65
spec
es, in part or in w
t to the co
10) With nut
11) With bracket for ATF lines
12) With bracket for turbocharger
rrectness of i
l purpos
Item A = dowel sleeves
nform
ercia

m
a
com
tio
Selector lever cable -5- on support bracket -B- 12 Nm
n in
r
te o
thi
Support bracket -B-, -2- and -3- on gearbox 23 Nm
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.
4.5 Removing and installing the gearbox for vehicles with V6 petrol engines

Passat 1997 ➤
. Volkswage AG n AG d
agen oes
olksw not
Special tools and workshop db
yV gu
ara
equipment required rise nte
tho eo
au ra
♦ Support bracket -10-222A- ss c
ce
le
un
♦ Rack -10-222A/1-
pt
an
d
itte
y li
♦ Adapter -10-222 A/3-
rm
ab
pe
ility
♦ Shackle -10-222A/12-
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 ➤

♦ Torque wrench - n AG. Volkswagen AG do
wage
V.A.G 1331- olks es n
ot g
byV ua
ed ran
♦ Torque wrench h-oris tee
V.A.G 1332- aut or
ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤

V.A.G 1383 A-
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
do
priv
cum
for
en
ng
t.
yi Co
op py
♦ Workshop manual Passat 1997 ▸ 6-cylinder fuel injection en‐ t. C rig
gh ht
gine, mechanics pyri by
Vo
o
by c lksw
cted agen
♦ Workshop manual Passat 1997 ▸ Running gear, axles, steer‐ Prote AG.
terior
4.5.1 Removing
anti-theft code.

Passat 1997 ➤
– Unscrew and remove bolts -arrows- and remove the engine

cover.
– Assemble support bracket -10-222A- in conjunction with racks

-10-222A/1- and adapters -10-222 A/3- .
– Secure the spindles onto the engine. To do this, additionally
use a shackle -10-222A/12- on the front of the engine, in order
to avoid damage.
– Raise vehicle. agen
AG. Volkswagen AG d
oes
olksw not
V gu
– Remove front wheels. d by 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
or

f
en
ng
t.
-arrows- from the exhaust pipe on the noise insulation. Cop
yi Co
py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤

bolts -arrows C-.
cylinder fuel injection engine, mechanics; Rep. Gr. 26 ; Re‐
moving and installing parts of exhaust system .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
– Remove left and right drive shaft guard plates -arrows-. The
un
pt
an
d
third bolt is not visible in the figure.

itte
y li
erm
ab
ility
ot p
and tie them up.
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
harness. thi
te
sd
va

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.

– Unscrew engine speed sender -G28- -arrow B- from gearbox.

agen 5-speedoeautomatic gearbox 01V - Edition 08.2007
olksw s no
t gu
byV ara
ed
ris nte
– Remove bracket for ATF ho line from engine oil sump. eo
aut ra
c
– Place drip tray -V.A.G
ss
1306- underneath.
ce
e
nl
pt
du
an
itte
y li
and gearbox. 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
– Separate ATF lines -1- to ATF cooler.
l purpos
nform
ercia
– Do not remove bracket -3- for ATF lines.

m
– Remove gearbox side starter motor bolt -2-.
at
om
ion
c
in t
or
his
e

at
do
priv
c
um
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted
agen
Prote AG.
-A-.

Passat 1997 ➤

support bracket.

support -3282- under vehicle, align adjusting plateswaparallel
gen AG to
. Volkswagen AG
does
gearbox and support gearbox. by
Volk not
gu
ara
ed nte
ris
tho e or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
-A- is bolted on:
ab
ility
ot p
wit
, is n
gearbox.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia

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
cted agen
Prote AG.

Passat 1997 ➤

-2- align.

the subframe.
lkswage es n
o ot g
byV ua
d ran
ir se tee
– Unscrew bolts -1- and
uth -2- at rear of subframe on both sides of
o
or
vehicle. ss
a ac
ce
le

un
pt
an
d
itte
y li

erm
ab
ility
ot p
wit
is n
components.
h re
ole,
spec

t to the co
rrectne

approx. 8 turns.
ss o
cial p
– When doing this, lower the engine/gearbox unit on the spin‐

inform
dles, working alternately 2 turns at a time.

mer
atio
m

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.

Passat 1997 ➤

-arrow-.
AG. Volkswagen AG d
agen oes
ksw
– Press torque converter against by V ATF pump -arrow-.
ol not
gu
ara
ed
is nte
– Lower gearbox. hor 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

nform
ercia

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
ht
4.5.2 Installing
rig by
copy Vo
by lksw
cted agen
Prote
AG.

Only when ATF lines on gearbox have been removed:
– Do not tighten bolt -2- until all the ATF lines have been con‐
cated.

Passat 1997 ➤

gearbox and support gearbox. Volkswa AG. gen AG
agen does
olksw not
yV gu
db ara
rise nte
tho eo
au ra
c
ss
ce
le
un
pt
an
d

itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
each side.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia

m
a
com
tion in
r
te o

thi
s
iva
do
r
rp
cum
fo

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

approx. 8 turns.
– When doing this, lift the engine/gearbox unit on the spindles,
working alternately 2 turns at a time.

Passat 1997 ➤
Volkswagen AG
– Install subframe using bolts originally removed. These bolts agen
AG. does
ksw
must be renewed following wheel alignment. by
Vol not
gu
ara
d
se nte
– Tighten old bolts to specified torque without additional
ho
ri part- eo
ut
turn ⇒ Running gear, axles, steering - front sand
s a four-wheel ra
c
ce
le
un
pt
an
d
itte
y li
erm
ab
WARNING
ility
ot p
wit
is n
h re
ole,
spec
t to the co
2. No wheel alignment is required if holes -1- and -2- have been
lined up ⇒ page 119 .
rrectne
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
co lksw
by
cted agen
Prote AG.

stalling subframe .
⇒ page 134 .

Passat 1997 ➤

-A- and oil pan.
– Install retaining clip for coupling rod of vehicle level sender -
G78- on front left track control link ⇒ Running gear, axles,
steering - front and four-wheel drive; Rep. Gr. 40 ; Electric and
electronic components and locations; Vehicle level sender -
G78- on front axle .
before installing.

AG. Volkswagen AG d
agen oes
ksw
– Bolt support bracket of selector lever cable to gearbox atby V ol not
gu
marked location ⇒ page 126 . rised ara
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
– Install selector lever cable guard plate -A- and tighten bolts
rrectness of i
-1- and -4- ⇒ page 126 .

l purpos

nf
ercia
– Fit heat shield -A- to vehicle underbody.

orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Passat 1997 ➤
– Fit ATF lines -1- to engine/gearbox unit and screw tight

⇒ Item 8 (page 147) .
– Screw the bracket for the ATF line onto the engine oil sump
⇒ Item 12 (page 147) .

– Fit connector for gearbox wiring harness and secure with lock‐ AG. Volkswagen AG d
ing lever -3-. lksw
agen oes
not
o
yV gu
– Install noise insulation bracket -1- ⇒ General body repairs,rised b ara
nte
exterior; Rep. Gr. 50 ; Body front; Assembly overview u-thnoise
o eo
ra
insulation . ss a 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
– Screw engine speed sender -G28- -arrow B- onto gearbox.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Passat 1997 ➤

– Install guard plates for left and right drive shafts -arrows-. The
third bolt is not visible in the figure. ⇒ Running gear, axles,
– Install front exhaust system with catalytic converter⇒ 6-cylin‐
der injection engine, mechanics; Rep. Gr. 26 ; Removing and
installing parts of the exhaust system .
– Install noise insulation elements -arrows-.

– Put on the engine cover and engage bolts -arrows-.

. Volkswagen AG
– Connect the battery earth strap ⇒ Electrical system;ksRep.
wage Gr.
n AG does
not
27 ; Battery; Disconnecting and connecting battery
by
V .
ol
gu
ara
d
ise nte
– Initialise electric windows and set clock ⇒ Maintenance
ho
r
; Book‐ eo
ut
let 36 . ss a ra
c
ce
le

un
pt
an
d

itte
y li
rm
ab
pe
ility
⇒ page 26 .
ot
wit
, is n
h re
hole
⇒ page 178 . spec

es, in part or in w
t to the co
rrectness of i
-B- for leaks.

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 ➤
– Check connections -1- of the ATF lines for leaks when check‐
ing ATF level.
There is no need to take account of bolts -2- and -3- in this case.

Gearbox to engine
1 M12 x 67 3 65
2 M12 x 90 1 65
3 M12 x 75 1 65
4 M10 x 60 1 45
5 M10 x 45 3 45
6 M10 x 80 1 65
7 M12 x 110 1 65
14) With nut AG. Volkswagen AG d
agen oes
olksw not
15) With bracket for ATF lines by
V gu
ara
ed
ris nte
ho eo
Item A = dowel sleeves s aut ra
c
s
ce
e

nl
pt
du
an
itte
Selector lever cable -5- on support bracket -B- 12 Nm

y li
erm
ab
ility
Support bracket -B-, -2- and -3- on gearbox 23 Nm

ot p
wit
, is n

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
4.6 Transporting automatic gearbox

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.

Passat 1997 ➤
♦ Workshop hoist -V.A.G 1202 A-

to transport automatic gearbox 01V and for setting up gearbox
support -3282- .
When performing installation work, secure the gearbox to the re‐
pair stand with workshop hoist -V.A.G 1202 A- , transport tool
-3457- and retaining plate -VW 309- ⇒ page 127 .
– Remove ATF lines from the gearbox (only for vehicles with 6-
cylinder engine).
– Seal ATF holes with clean plugs.
– Unscrew the gearbox supports on the left and right.
– Fit transportation tool device -3457- to mountings on gearbox
housing and secure.
– Hook transportation tool -3457- with the gearbox onto work‐
shop hoist -V.A.G 1202 A- .
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
4.7 Securing gearbox to assembly stand

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 ➤

equipment required
♦ Support plate -VW 309-
♦ Support clamp -VW 313-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
♦ Workshop hoist -V.A.G 1202 A-

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 ➤
– Fit transportation tool device -3457- to mountings on gearbox

housing and secure.
– Bolt support plate -VW 309- to transportation aid -3457- .
– Using workshop hoist -VW 309- , attach gearbox with support

plate -V.A.G 1202 A- to support clamp -VW 313- .
If the gearbox is to be turned upwards on the repair stand without
the oil being drained, the breather holes for the gearbox
n AG. Volkshousing
wagen AG
and the final drive must be sealed and drip lkswage -V.A.G 1306-
tray
does
not
Vo
placed underneath the assembly. ed by gu
ara
is nte
or eo
The aid of a second mechanic ais
ut required to turn the gearbox.
h
ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
4.8 Installing and removing the gearbox mountings and gearbox support on the
hole
spec
left and right
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
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤

equipment required
♦ Torque wrench -
V.A.G 1331-
V.A.G 1383 A-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
4.8.1 Removing gearbox mountings on the
p by
co Vo
by lksw
cted
left and right
agen
Prote AG.


Passat 1997 ➤
– Remove noise insulation -arrows A- and -B-.

bolts -arrows C-.
The gearbox must be supported as described if a gearbox mount‐
ing is removed.


gearbox and support gearbox.
– Fill the space between the gearbox support and the oil pan
with washers. en AG. V
olkswagen AG
ag does
ksw not
Dismantle the gearbox support on the right and
by left:
Vol gu
ara
ed nte
ris
tho eo
au ra
Note ss c
ce
le
un
pt
an
d
For vehicles with hydraulic gearbox mounting

itte
y li
rm
ab
pe
ility
ot
Items -C- and -B- are not used with hydraulic gearbox mounting
wit
, is n
h re
-H-, because bolt -G- is directly screwed into the gearbox mount‐
hole
ing.
spec
es, in part or in w
t to the co
– Unscrew and remove bolt -G-.

– Unscrew bolts -A-.
rrectness of i
– Use engine/gearbox jack -V.A.G 1383 A- and gearbox support

-3282- to lift the gearbox slightly and remove hydraulic gear‐
l purpos
box mounting -H-.

– Remove gearbox support -E-.
nform
mercia
a
com
tio
Note
n in
r
te o
thi
s
iva
For vehicles with bonded rubber gearbox mounting

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 ➤
– Unscrew bolts -A-.

– Unscrew nut -B- and remove with stop -C-.
– Remove bolt -F-.
– Use engine and gearbox jack -V.A.G 1383 A- with gearbox
support -3282- to lift gearbox slightly and remove bonded rub‐
ber gearbox mounting -D-.
– Remove gearbox support -E-.
4.8.2 Removing right-hand gearbox support

– Removing gearbox mountings ⇒ page 130 .
– Remove the front right exhaust system (except for vehicles
with V6 TDI engines) ⇒ Engine, mechanics; Rep. Gr. 26 ;
Installing and removing parts of exhaust system .
– Unscrew bolts -B-.
– Remove heat shield -C- (except for vehicles with V6 TDI en‐
gines).
– Remove gearbox support -D- by unscrewing and removing
bolts -A- from the gearbox.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
4.8.3 Removing left-hand gearbox support

un
pt
an
d
itte
y li
– Removing gearbox mountings ⇒ page 130 .

rm
ab
pe
ility
ot
– Remove the front left exhaust system (except for vehicles with
wit
, is n
4 and 5-cylinder engines) ⇒ Engine, mechanics; Rep. Gr. 26 ;

h re
hole

spec
es, in part or in w
t to the co
-A-.
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
132
c by lksw
cted agen
Prote AG.
lkswage es n
o ot g
byV ua Passat 1997 ➤
d ran
ir se
tho 5-speed automatic
tee
or gearbox 01V - Edition 08.2007
au ac
ss
– Unscrew bolts -B-.
ce
le
un
pt
an
d
– Remove heat shield -C- (except for vehicles with 4 and 5-cyl‐
itte
y li
erm
inder engines).
ab
ility
ot p
– Remove gearbox support -D- by unscrewing and removing
wit
is n
bolts -A- from the gearbox.
h re
ole,
spec
t to the co
rrectness o
4.8.4 Installing the gearbox support and gear‐
cial p
f inform
box mountings
mer
atio
m

o
n
c
i
following:
or
n thi
te
sd
va
– Install the gearbox support on the gearbox ⇒ page 134 .

i
o
pr
cum
r
fo
– Clean residual locking fluid out of the threaded holes in gear‐
en
ng
t.
yi
box mounting -D- or -H-. A thread chaser is suitable for clean‐
Co
Cop py
ing.
t. rig
gh ht
pyri by
Vo
o
– Screw bolt -F- or -G- tight ⇒ page 134 .
c by lksw
cted agen
Prote AG.
– Screw in new bolts -A- ⇒ page 134 .
– Install the front right exhaust system (except for vehicles with
V6 TDI engines) ⇒ Engine, mechanics; Rep. Gr. 26 ; Installing
and removing parts of exhaust system .
– Install the front left exhaust system (except for vehicles with 4
and 5-cylinder engines) ⇒ Engine, mechanics; Rep. Gr. 26 ;

Passat 1997 ➤

Gearbox mountings left and right
Item Nm
A 23 agen
AG. Volkswagen AG d
oes
Inserted with locking fluid Volksw not
gu
Always replace d by ara
ise nte
or eo
B with F 50 aut
h
ra
ss c
G 50
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
Right-hand gearbox support

Item Nm
nf
ercia
orm
A 40
m
atio
om
B 10
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.
Left-hand gearbox support
Item Nm
A 40
B 10

Passat 1997 ➤
5 Checking ATF level and topping up
5.1 Checking ATF level
Caution
Wear eye protection.

equipment required
♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-
♦ ATF filling unit -
V.A.G 1924-
♦ Vehicle diagnosis, testing
and information system -
VAS 5051-
♦ Diagnosis lead, 3 m with
voltage supply -
VAS 5051/1- or diagnosis
lead, 5 m without voltage
supply -VAS 5051/3-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
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
co lksw
by
cted agen
Prote AG.
5. Checking ATF level and topping up 135

Passat 1997 ➤
Brief description
The check of the level is based on the overflow principle depend‐
ing on the ATF temperature.
The ATF level is affected by the ATF temperature.
Checking the ATF level when the ATF temperature is too low
leads to overfilling. AG. Volkswagen AG d
agen oes
lksw not
Checking the ATF level when the ATF temperature is too high d by
Vo gu
ara
leads to under filling. orise nte
h eo
ut ra
Both an excessive and an insufficient level hinders the
ss a function c
of the gearbox.
ce
e
nl
pt
du
an
Test preconditions
itte
y li
erm
ab
• The reservoir of the ATF filling unit -V.A.G 1924- is to be filled
ility
ot p
only with the ATF authorised for the automatic gearbox 01V.
wit
, is n
The ATF has not been mixed with other oils.
h re
hole
spec
• Gearbox is not in emergency running mode and ATF temper‐
es, in part or in w
ature is not above approx. 30 °C.
t to the co
• Vehicle level.
rrectness of i
• Selector lever at “P”, engine running at idling speed.
l purpos
• All electrical consumers and air conditioner must be switched

off.
nf
ercia
o
– The drain plug with sealing ring -1- must always be replaced.
rm
m
atio
m
– The O-ring -arrow- on ATF inspection plug -2- must always be

o
n in
c
replaced.
or
thi
te
sd
a
– The ATF fill level -3- is affected by the ATF temperature.

iv
o
r
rp
cu
o
m
– Deflector cap -4- with opening for ATF filling unit -V.A.G 1924- .
f
en
ng
t.
yi
If the reservoir is inserted in one of the openings, the deflector
Co
op py
cap must not be knocked upwards into the oil pan. t. C rig
gh ht
pyri by
VW ATF is obtainable as a spare part. Specifications ⇒ page 7 .
o Vo
by c lksw
cted agen
Prote AG.
Checking ATF level
– Secure reservoir of ATF filling unit -V.A.G 1924- to vehicle.

Passat 1997 ➤


bolts -arrows C-.
– Connect vehicle diagnosis, testing and information system -
VAS 5051- .
– With ignition switched off, connect tester -VAS 5051- using
diagnostic cable -VAS 5051/1- or -VAS 5051/3- to diagnostic
connection and advance through program until “Function/
component selection” is displayed.
– Then press “Drive (Repair group 01; 10...26; 28...39)”.
– Then press “5-speed automatic gearbox 01V”.
– Press “Functions”.
– Press “Check ATF level”.
– Press → key.
The ATF temperature should not be warmer than approx. 30 °C
at the start of the test. n AG. Volkswagen AG
wage does
– Start engine. Volks not
gu
by ara
ed nte
– Raise vehicle. oris eo
th
s au ra
c
s
ce
le
un
pt
– Press → key.
an
d
itte
y li
rm
ab
pe
ility
– Bring ATF to test temperature.

ot
wit
, is n
Test temperature 35 °C to 45 °C.

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 ➤
– Remove ATF inspection plug from oil pan.

If ATF drips out of inspection hole:
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
ATF level is OK.
erm
ab
ility
ot p
Only a small amount of ATF should come out of the inspection
wit
is n
hole when the engine is running.
h re
ole,
spec
– Fit new O-ring on ATF inspection plug and tighten to 80 Nm.
t to the co
This completes the ATF check.
– Switch off engine.
rrectne
If no ATF drips out of inspection hole: replenish ATF
ss o
⇒ page 138 .
cial p
f inform
mer
5.2 Topping up ATF

atio
om
n
c
i
or
– Guide ATF filling unit -V.A.G 1924- in through an opening

thi
e
-arrow- in deflector cap, taking care not to push deflector cap

t
sd
iva
upwards out of position.

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.
– Fill with ATF using ATF filling unit -V.A.G 1924- until ATF flows
out of inspection hole.
Caution
An ATF level which is too low or too high will impair the function
of the gearbox.

Passat 1997 ➤
– Fit new O-ring on ATF inspection plug -arrow- and tighten to

80 Nm.
– Switch off engine.
5.3 Replacing ATF

Prerequisites
• Engine is switched off.
• All electrical consumers and air conditioner must be switched
off.
• Gearbox is not in emergency running mode, ATF temperature
is not above approx. 30 °C.
• Vehicle level.
• Selector lever in “P”.
The drain plug with sealing ring must be replaced.
– Secure reservoir of ATF filling unit -V.A.G 1924- to vehicle.
AG. Volkswagen AG d
agen oes
– Raise vehicle. 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
nf
ercia

rm
m
atio

om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Passat 1997 ➤
AG. Volkswagen AG d
agen oes
lksw not
– Remove noise insulation byV
o -arrows A- and -arrows B-. gu
ara
ed
is nte
– In vehicles with
ut
h noise insulation -D-, unscrew and remove e o
or
bolts -arrows
ss C-.
a ra
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
– Remove drain plug -arrow 1-.
rrectne
– Drain ATF.
ss
– Tighten new drain plug -arrow 1- ⇒ Item 1 (page 152) .
o
cial p
f in
– Remove ATF inspection plug -arrow 2-.
form
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
ht
– Guide ATF filling unit -V.A.G 1924- in through an opening
rig by
opy Vo
-arrow- in deflector cap, taking care not to push deflector cap
by c lksw
cted agen
upwards out of position.
Prote AG.
– Fill with ATF until ATF comes out of inspection hole.

– Screw ATF level plug in hand-tight.
– Start engine.
– Press brake pedal.
– Shift through all selector lever positions with vehicle station‐
ary, leaving selector lever in each position for about 10 sec‐
onds.

Passat 1997 ➤
6 Overview - power transmission, front-wheel drive
A - Clutch A
B - Clutch B
E - Clutch E
F - Clutch F
C - Brake C
D - Brake D
G - Brake G
F1 - Freewheel
Arrows indicate direction of
travel.
1 - Engine
2 - Torque converter with lock-
up clutch
3 - Differential
4 - Automatic gearbox
5 - Pinion shaft
Z1, Z2 and Z3 = Spur gears of
the intermediate drive
Z4, Z5 = Crown wheel and pin‐ AG. Volkswagen AG d

ion (final drive) agen oes
olksw not
V gu
d by ara
-Arrows- point forwards orise nte
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
6.1 Position of the selector elements with

t to the co
hydraulic control E17

rrectness of i
The following table shows which selector elements are operated

in the individual gears to help you deal with complaints regarding
l purpos
poor acceleration and speed performance or generally with drive

train faults. The table makes it possible to determine which se‐
lector elements are not operating properly.
nform
mercia
Solenoid valves Clutches

at
om
ion
c
Solenoid valves Clutch Brakes Free‐

in t
or
wheel
his
ate
do
riv
Position / gear N88 N89 N90 N91 N92 N93 N94 A B E F C D G 1st gea
p
cum
or
r
f
en
ng
t.
yi Co
R = Reverse x x x x x x
Cop py
t. rig
gh
N = Neutral x x x x x- x-
ht
pyri by
Vo
o
by c lksw
D, 1st gear x x x cted x x x x
agen
Prote AG.
D, 2nd gear x x x x x x x x
D, 3rd gear x x-x x x x x x
6. Overview - power transmission, front-wheel drive 141

Passat 1997 ➤

D, 4th gear x-x x x x x
D, 5th gear x x-x x x x x x
2nd, 1st gear x x x x x x x
D, 5th to 4th x x x x x -x- x x -x-
gear
AG. Volkswagen AG d
agen oes
olksw not
V gu
x = Component is actuated ed by ara
nte
ris
o eo
- = Component is not actuated aut
h
ra
ss c
(x) = Component is actuated according to situation (driving con‐
ce
e
nl
pt
dition)
du
an
itte
y li
erm
6.2 Position of the selector elements with
ab
ility
ot p
hydraulic control E18/2
wit
, is n
h re
hole
The following table shows which selector elements are operated
spec
in the individual gears to help you deal with complaints regarding
es, in part or in w
t to the co
poor acceleration and speed performance or generally with drive
train faults. The table makes it possible to determine which se‐
lector elements are not operating properly.
rrectness of i
l purpos
Solenoid Pressure regulating Clutch Brakes Free‐

valves valves wheel
nform
ercia
Position / gear N88 N89 N90 N21 N21 N21 N21 A B E F C D G 1st gea
m
5 6 7 8 r
at
om
ion
R = Reverse x x x x x x
c
in t
or
his
e
N = Neutral x x x x x- x-
at
do
priv
c
D, 1st gear x x x x x x x
um
for
en
ng
D, 2nd gear x x x x x x x x
t.
yi Co
Cop py
D, 3rd gear x x-x x x x x x
t. rig
gh ht
pyri by
D, 4th gear x-x x x x x
o Vo
by c lksw
cted agen
Prote
D, 5th gear x x-x x x x x x
AG.
2nd, 1st gear x x x x x x x

D, 5th to 4th x x x x x -x- x x -x-
gear
x = Component is actuated
- = Component is not actuated
(x) = Component is actuated according to situation (driving con‐
dition)

Passat 1997 ➤
7 Dismantling and assembling gearbox

Removing and installing ATF lines in vehicles with 4-cylinder en‐
gines ⇒ page 143 .
Removing and installing ATF lines in vehicles with 5-cylinder 110
kW engine ⇒ page 144 .
Removing and installing ATF lines in vehicles with 5-cylinder 125
kW engine ⇒ page 145 .
Removing and installing ATF lines in vehicles with V6 TDI engine
⇒ page 146 .
Removing and installing ATF lines in vehicles with V6 petrol en‐
gine ⇒ page 147 . en AG. V
olkswagen AG
ag does
ksw not
Cleaning ATF lines and ATF cooler ⇒ page Vol
by 148 . gu
ara
ed nte
ris
7.1 Removing and installing ATF lines in vehicles with 4-cylinder engines
au
tho eo
ra
ss c
ce
le
un
pt
an
d
itte
y li
❑ Before tightening bolt,
rm
ab
pe
ility
push in line to stop by
ot
wit
hand
, is n
h re
hole
2 - ATF line
spec
es, in part or in w
❑ To cooler
t to the co
❑ Note inscription on
gearbox housing
rrectness of i
3 - ATF line
l purpos
❑ From cooler
gearbox housing
nform
ercia
4 - O-ring
m
a
com
❑ Inserting with ATF tion in

r
te o
thi
❑ Always replace
s
iva
do
r
rp
5 - O-ring
um
fo
en
g
❑ Inserting with ATF

n
t.
yi Co
op py
❑ Always replace t. C rig
gh ht
pyri by
co Vo
by lksw
cted agen
Prote
AG.

hand
7 - O-ring
❑ Always replace
hand
9 - Union nut, 30 Nm
10 - Bracket
11 - Hexagon bolt
❑ Need not be unscrewed to remove and install ATF lines.
7. Dismantling and assembling gearbox 143

Passat 1997 ➤
12 - Hexagon nut, 5 Nm
13 - Clamp
14 - Bracket
❑ On engine/gearbox support
7.2 Removing and installing ATF lines in vehicles with 5-cylinder 110 kW engine
hand
2 - O-ring
❑ Always replace
3 - ATF line
❑ From cooler lkswage es n
o ot g
byV ua
❑ Note inscription on ir se
d ran
tee
gearbox housing utho
or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
hand
ility
ot p
wit
5 - ATF line
, is n
h re
hole
❑ To cooler
spec
es, in part or in w
t to the co
gearbox housing
6 - O-ring
rrectness of i

l purpos
❑ Always replace
7 - O-ring
nf
ercia

orm
m
❑ Always replace
atio
om
n in
c
or
thi
te
sd

iva
o
r

rp
cu
o
hand
f
en
ng
t.
yi Co
op
9 - Hexagon socket head bolt,
C py
t. rig
gh
5 Nm
ht
pyri by
Vo
co lksw
by
10 - Clamp
cted agen
Prote AG.
11 - Bracket
12 - Hexagon socket head bolt, 25 Nm

Passat 1997 ➤
7.3 Removing and installing ATF lines in vehicles with 5-cylinder 125 kW engine
hand
2 - O-ring
❑ Always replace
3 - ATF line
❑ From cooler
gearbox housing
hand
5 - ATF line
❑ To cooler
gearbox housing
6 - O-ring
❑ Always replace
7 - O-ring
❑ Always replace
. Volkswagen AG
gen AG does
Vol
ksw
a
not
by gu
❑ Before tightening
ris
ed bolt, ara
nte
pushutin
ho line to stop by eo
ra
hand
ss
a c
ce
le
9 - Hexagon socket head bolt,

un
pt
an
d
5 Nm
itte
y li
erm
ab
10 - Clamp
ility
ot p
wit
is n
11 - Torque rod
h re
ole,
spec
t to the co
14 - Clamp
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 ➤
7.4 Removing and installing ATF lines in vehicles with V6 TDI engines
hand
2 - ATF line
❑ To cooler
AG. Volkswagen AG d
❑ Note coloured markings agen oes
olksw not
-arrow- ed byV gu
ara
is nte
❑ Note inscription on ut
hor eo
gearbox housing ss a ra
c
ce
e
3 - ATF line
nl
pt
du
an
itte
❑ From cooler
y li
erm
ab
❑ Note coloured markings
ility
ot p
-arrow-
wit
, is n
h re
hole
spec
gearbox housing
es, in part or in w
t to the co
4 - O-ring
❑ Always replace
rrectness of i
5 - O-ring
l purpos

❑ Always replace
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
a
hand
iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
❑ Before tightening bolt, Cop py
push in line to stop by ht. rig
rig ht
hand
py by
co Vo
by lksw
cted agen
8 - O-ring
Prote AG.

❑ Always replace
9 - Bracket
11 - Hexagon nut, 5 Nm
❑ Self-locking
❑ Always replace
12 - Clamp
16 - Bracket

Passat 1997 ➤
7.5 Removing and installing ATF lines in vehicles with V6 petrol engines
1 - Hexagon bolt, 20 Nm agen

AG. Volkswagen AG d
oes
lksw not
❑ Before tightening bolt,d by
Vo gu
ara
push in line to stop
oris by
e nte
hand au
th eo
ra
ss c
2 - ATF line
ce
e
nl
pt
du
❑ To cooler
an
itte
y li
erm
ab
ility
-arrow-
ot p
wit
, is n
h re
gearbox housing
hole
spec
es, in part or in w
3 - ATF line
t to the co
❑ From cooler
rrectness of i
-arrow-
l purpos
gearbox housing
4 - O-ring
nf
ercia
orm
m
atio
m
❑ Always replace
o
n in
or c
thi
e
t
sd
iva
o
r
rp
6 - Hexagon bolt, 10 Nm cu
o
m
f
en
ng
t.
yi
7 - Bracket
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
9 - ATF line cted agen
Prote AG.
❑ To cooler
-arrow-
gearbox housing
10 - ATF line
❑ From cooler
❑ Note coloured markings -arrow-
❑ Note inscription on gearbox housing
11 - Clamp
13 - ATF line
❑ To cooler
14 - ATF line
❑ From cooler
❑ Before tightening bolt, push in line to stop by hand

Passat 1997 ➤
7.6 Cleaning ATF lines and ATF cooler

If there is dirt in the ATF, blow through ATF cooler and ATF lines
with compressed air (not more than 10 bar) before installing gear‐
box.
Caution
Wear eye protection!
– Release bracket for rigid ATF lines on gearbox ⇒ page 143 .

– Unscrew bolt -2-.
– Pull ATF lines off gearbox.
– Connect a hose to ATF line -A- and secure with a hose clamp.
Hang other end of hose in a suitable container.
Blow through ATF line -B- with a compressed air gun.
Change hose from ATF line -A- overGto ATF line -B- and repeat
A . Volkswagen AG d
procedure. lkswagen oes
n o ot g
yV ua
Replace O-rings -1-.rised b ran
tee
tho or
Moisten O-ringss with
au ATF. ac
s
ce
le
Insert ATF lines completely to stop in gearbox by hand.

un
pt
an
d
itte
Do not tighten bolt -2- until all the ATF lines have been connected
y li
erm
ab
⇒ page 143 .
ility
ot p
wit
Finally, check ATF level and top up ⇒ page 135 .

is n
h re
ole,
When checking ATF level, check ATF line connections -A- and
spec
-B- for leaks.

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 ➤
38 – Gears, control
1 Removing and installing oil pankswagen AG. Volkswagen AG does
ol not
yV gu
edb ara
ris nte
ho eo
1.1 Removing and installing oil pan ss
aut ra
c
ce
e
nl
pt
du
an
itte
1.1.1 Removing
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
co lksw
by
cted agen
Prote AG.
– Observe general repair instructions ⇒ page 8 .

1. Removing and installing oil pan 149

Passat 1997 ➤

bolts -arrows C-.

– Drain ATF.
– Unscrew bolts on oil pan in diagonal sequence and remove oil
pan.
1.1.2 Installing
following:
The drain plug with sealing ring must be replaced. agen
AG. Volkswagen AG d
oes
olksw not
V gu
– Clean all four magnets in recesses of oil pan. Ensureed by that ara
nte
magnets are seated correctly in oil pan. horis
eo
aut ra
– Install oil pan with new gasket. ss c
ce
le
un
pt
– Tighten oil pan bolts in several stages and in diagonal se‐

an
d
itte
quence ⇒ Item 2 (page 152) .

y li
erm
ab
ility
– Tighten new drain plug ⇒ Item 1 (page 152) .

ot p
wit
is n

h re
ole,
spec


t to the co
– Fill with ATF; check ATF level and top up ⇒ page 135 .
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
150 Rep. Gr.38 - Gears, control

Passat 1997 ➤
2 Removing and installing

lksw
agen ATF strainer
AG. Volkswagen AG d
oes
n o ot g
yV ua
edb ran
ris tee
tho
2.1 Removingssand installing ATF strainer
or
au ac
ce
e
nl
pt
du
an
itte
y li
2.1.1 Removing
erm
ab
ility
ot p
wit
, is n
h re
– Remove oil pan ⇒ page 149 .
hole
spec
es, in part or in w
– Unscrew the bolts of the ATF strainer.
t to the co
– Pull ATF strainer off valve body.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
2.1.2 Installing
f
en
ng
t.
yi Co
op py
– Moisten seal on intake neck of strainer with ATF. t. C rig
gh ht
pyri by
– Carefully push intake neck into opening of valve body to stop.
o Vo
by c lksw
cted agen
Prote AG.
– Tighten bolts ⇒ Item 37 (page 154) .
– Install oil pan ⇒ page 149 .
2. Removing and installing ATF strainer 151

Passat 1997 ➤
3 Removing and installing valve body

Information about which control is installed: ⇒ page 3 .
Differentiating criteria ⇒ page 20 .
Assembly overview of valve body for gearbox with hydraulic con‐
trol E17 ⇒ page 152 .
Assembly overview of valve body for gearbox with hydraulic con‐
trol E18/2 ⇒ page 159 .
3.1 Assembly overview of valve body for gearbox with hydraulic control E17
Assembly procedure ⇒ page 154
Caution
Do not run engine or tow vehicle

AG. Vwith
olkswoil
agepan
n AGremoved or when
agen does
Volksw not
y gu
db ara
rise nte
tho eo
s au ra
c
s
1 - Drain plug, 40 Nm
ce
le
un
pt
❑ With sealing ring

an
d
itte
y li
rm
ab
❑ Always replace
pe
ility
❑ Remove to drain ATF

ot
wit
, is n
⇒ page 154
h re
hole
spec
2 - Bolt, 10 Nm
es, in part or in w
t to the co
❑ Tightening oil pan bolts

in several stages and in
diagonal sequence
rrectness of i
3 - Oil pan
l purpos

⇒ page 149
nform
ercia
4 - Seal
m
❑ Always replace
a
com
tion in
5 - Magnet
r
te o
thi
❑ Qty. 4 in depressions in
s
iva
do
r
oil pan
rp
cum
fo
en
❑ Always clean when oil

ng
t.
yi Co
pan is removed t. Cop py
rig
gh
❑ Ensuring that magnets
ht
pyri by
Vo
are correctly seated in
co lksw
by
cted agen
oil pan Prote AG.
6 - ATF strainer
⇒ page 151
7 - Seal
❑ Pulling off from ATF
strainer with separating
device -Kukko 18/0-
❑ Pressing onto suction
collar on ATF strainer
8 - Bolt, 8 Nm
❑ Bolts securing valve body: 1 bolt M6×30; 16 bolts M6×60

Passat 1997 ➤
❑ Observing tightening sequence ⇒ page 158
9 - Valve body
❑ Allocation according to gearbox code ⇒ Electronic parts catalogue (ETKA)
10 - Bracket
❑ For wiring harness
❑ Hooking wiring harness into bracket
❑ Secured with bolts for valve body
11 - Bolt, 6 Nm
❑ Replacing ⇒ page 167
13 - Spacer sleeve
❑ Length: 8 mm
14 - Internal oil pipe
❑ Always replace
15 - O-ring
❑ Always replace
AG. Volkswagen AG d
❑ Moistening with ATF and inserting agen oes
olksw not
V gu
by ara
16 - Speedometer sender -G22- rised
nte
ho eo
❑ Replacing ⇒ page 177 s aut ra
c
s
17 - O-ring
ce
e
nl
pt
du
an
❑ Always replace
itte
y li
erm
ab
❑ Moistening with gear oil and inserting
ility
ot p
wit
18 - Multi-function switch -F125-
, is n
h re
hole
spec
❑ Replacing selector shaft sealing ring ⇒ page 173
es, in part or in w
19 - Bolt, 8 Nm t to the co
20 - O-ring
rrectness of i
❑ Always replace
l purpos
❑ Moistening with ATF and inserting

21 - Securing clip
nform
ercia
❑ Always replace
m
at
om
io
22 - Wiring harness
n
c
in t
or

his
ate
do
riv
❑ Gearbox oil (ATF) temperature sender -G93- integrated in wiring harness

p
cum
or
❑ To replace, remove and install valve body ⇒ page 154

f
en
ng
t.
yi Co
❑ Unhooking wiring harness from bracket ⇒ Item 10 (page 153) Cop py
t. rig
gh
❑ Position of connector on harness: flat part of rear collar faces towards oil pan; lugs on collar are horizontal
ht
pyri by
Vo
o
by c lksw
cted
23 - Bolt, 6 Nm
agen
Prote AG.

25 - Spacer sleeve
❑ Length: 20 mm
3. Removing and installing valve body 153

Passat 1997 ➤
26 - Bolt, 6 Nm
27 - Bracket
❑ For solenoid valve
28 - Solenoid valve 4 -N91-
❑ With O-ring
❑ Moistening O-ring with ATF and inserting
❑ Without O-ring
❑ Without O-ring AG. Volkswagen AG d
agen oes
olksw not
31 - Bolt, 6 Nm d by
V gu
ara
ise nte
r
32 - Bracket ut
ho eo
ra
a c
❑ For solenoid valves ss
ce
e
nl
pt
du
an
itte
y li
❑ With O-ring
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
❑ With O-ring
es, in part or in w
t to the co
rrectness of i
❑ With O-ring
l purpos
nf
ercia
❑ Without O-ring
orm
m
❑ To replace, remove and install oil pan ⇒ page 149 and remove guide plate for parking lock mechanism
atio
om
❑ When installing, do not tighten bolts for guide plate (23 Nm) with selector lever in “P”
n in
or c
thi
e
37 - Bolt, 6 Nm
t
sd
iva
o
r
rp
cu
38 - Sealing ring
o
m
f
en
ng
t.
yi
❑ Always replace
Co
Cop py
t. rig
39 - ATF inspection plug
gh ht
pyri by
Vo
o
by c
❑ Tightening ⇒ page 138
lksw
cted agen
Prote AG.
3.2 Assembly sequence of valve body for

gearbox with hydraulic control E17
3.2.1 Removing

AG. Volkswagen AG d
agen oes
olksw not
yV gu
ed b ara
nte
Passat 1997 ➤
ris
ut
ho 5-speed automaticeo
ra
gearbox 01V - Edition 08.2007
s a c
s
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Replace soiled or defective valve body.

bolts -arrows C-.

Passat 1997 ➤

– Drain ATF.
pan.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
– Unscrew the two bolts on ATF strainer -arrows-.
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
– Lever securing clip off connector on wiring harness. 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.
– Unplug connector from gearbox speed sender -G38- .

– Only remove the bolts from the valve body which are marked
with an arrow.

Passat 1997 ➤
The bolt identified by -arrow A- is shorter than the other bolts.

– Do not loosen any other bolts. This would impair the function
of the valve body.
– Detach valve body from gearbox and guide out connector from
wiring harness.
– Do not place the valve body on gearbox input speed sender -
G182- on the rear.
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
3.2.2 Installing
ab
ility
ot p
wit
– Lubricate new O-rings for connector on wiring harness with
, is n
h re
ATF.
hole
spec
– Fit connector in gearbox housing with flat part -arrow A- facing
es, in part or in w
t to the co
towards oil pan.
– Align valve body with dowel pin -arrow B- to hole in gearbox
housing -arrow C-. rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
– Place valve body in position so that pin of detent plate -1- en‐
o
m
f
en
ng
gages in slot of selector slide -2-.

t.
yi Co
Cop py
t. rig
– Tighten bolts (hand-tight) securing valve body -arrows-. pyri
gh by
Vo
ht
o
by c lksw
cted agen
Prote AG.

Passat 1997 ➤
The bolt identified by -arrow A- is shorter than the other bolts.

– Tighten bolts to specified torque, working from centre out‐
wards
⇒ Item 8 (page 152) .
– Plug connector onto gearbox speed sender -G38- .
– Press in securing clip for connector on wiring harness until re‐

taining tab engages.
AG. Volkswagen AG d
agen oes
– Lubricate seal on intake neck of ATF strainer with ATF. y Volksw not
gu
d b ara
– Carefully push intake neck of strainer into opening of valverise nte
ho eo
body to stop. s aut ra
c
s
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
– Bolt on ATF strainer and tighten bolts -arrows-

t to the co
⇒ Item 37 (page 154) .

– Install oil pan with new gasket.
rrectness of i

l purpos

nform
ercia
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
158
c by lksw
cted agen
Rep. Gr.38 - Gears, control Prote AG.
Passat 1997 ➤
kswage es n
3.3 Assembly overview of valve body for gearbox with hydraulic control E18/2 ol ot g
byV ua
d ran
ir se tee
o
Assembly procedure ⇒ page 161 auth or
ac
ss
ce
le
un
pt
Caution
an
d
itte
y li
erm
ab
Do not run engine or tow vehicle with oil pan removed or when
ility
ot p
wit
is n
h re
ole,
spec
t to the co
1 - Drain plug, 40 Nm
rrectne
❑ Always replace
❑ Remove to drain ATF
⇒ page 161
ss o
cial p
f
2 - Bolt, 10 Nm
inform
mer
❑ Tightening oil pan bolts
atio
in several stages and in
om
n
diagonal sequence
c
i
or
n thi
te
3 - Oil pan
sd
iva
o
pr
c
um
r
fo
en
⇒ page 149
ng
t.
yi Co
op py
4 - Seal t. C rig
gh ht
yri by
❑ Always replace cop Vo
by lksw
cted agen
Prote
5 - ATF strainer
AG.

⇒ page 151
6 - Bolt, 8 Nm
❑ For securing valve body
16 bolts M6×60
⇒ page 161
❑ Observing tightening
sequence ⇒ page 165
7 - Valve body
⇒ page 161
❑ Allocation according to
gearbox code ⇒ Elec‐
tronic parts catalogue
(ETKA)
8 - Bolt, 8 Nm
9 - Bracket
❑ For wiring harness
❑ Hooking wiring harness into bracket
❑ Secured with bolts for valve body
10 - Bolt, 6 Nm
12 - Spacer sleeve
❑ Length: 8 mm

lkswage es n
o ot g
byV ua
d ran
ir se
Passat 1997 th ➤
o tee
or
u
5-speedss automatic gearbox 01V - Edition 08.2007
a ac
ce
e
nl
pt
du
13 - Internal oil pipe
an
itte
y li
❑ Always replace
erm
ab
ility
ot p
wit
, is n
h re
14 - O-ring
hole
spec
❑ Always replace
es, in part or in w
t to the co
15 - Speedometer sender -G22- or vehicle speed sender -G68-
rrectness of i
l purpos
16 - O-ring
❑ Always replace
nf
ercia
❑ Moistening with gear oil and inserting
orm
m
atio
17 - Multi-function switch -F125-
om
n in
c

or
thi
te
❑ Replacing selector shaft sealing ring ⇒ page 173
sd
iva
o
r
rp
cu
18 - Bolt, 8 Nm
o
m
f
en
ng
t.
yi Co
19 - O-ring t. Cop py
rig
gh
❑ Always replace
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
20 - Securing clip
❑ Always replace
21 - Wiring harness
❑ Gearbox oil (ATF) temperature sender -G93- integrated in wiring harness
❑ Unhooking wiring harness from bracket ⇒ Item 9 (page 159)
❑ Position of connector on harness: flat part of rear collar faces towards oil pan; lugs on collar are horizontal
22 - Bolt, 9 Nm
24 - Connector
❑ Is pulled off wiring harness in gearbox
❑ Must be pulled off before removing valve body
25 - Bolt, 6 Nm
26 - Bracket
❑ For solenoid valve
27 - Automatic gearbox pressure control valve 1 -N215-
❑ With O-ring
❑ Without O-ring
❑ Without O-ring
30 - Bolt, 6 Nm
31 - Bracket
❑ For solenoid valves

Passat 1997 ➤

❑ With O-ring
❑ With O-ring
❑ With O-ring
❑ Without O-ring
❑ To replace, remove and install oil pan ⇒ page 149 and remove guide plate for parking lock mechanism
❑ When installing, do not tighten bolts for guide plate (23 Nm) with selector lever in “P”
36 - Bolt, 6 Nm
37 - Magnet
❑ Qty. 4 in depressions in oil pan
❑ Always clean when oil pan is removed
❑ Ensuring that magnets are correctly seated in oil pan
AG. Volkswagen AG d
38 - Sealing ring lksw
agen oes
not
Vo gu
❑ Always replace ed by ara
nte
ris
o eo
39 - ATF inspection plug aut
h
ra
ss c
❑ Tightening ⇒ page 138
ce
le
un
pt
an
d
itte
y li
rm
ab
3.4 Assembly sequence of valve body for

pe
ility
ot
wit
, is n
gearbox with hydraulic control E18/2

h re
hole
spec
es, in part or in w
t to the co
3.4.1 Removing
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 oes
♦ Torque wrench -V.A.G
Vol 1331-
ksw not
gu
by ara
ed nte
oris eo
th
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Replace soiled or defective valve body.
l purpos

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

bolts -arrows C-.
– Remove the drain plug.

– Drain ATF.
pan.

agen
AG. Volkswagen AG d
oes
Passat 1997 ➤
olksw 5-speed
not automatic gearbox 01V - Edition 08.2007
byV gu
ara
ed
ris nte
– Unscrew athe
ut two bolts on ATF strainer -arrows-.
ho eo
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
– Lever securing clip off connector on wiring harness.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
– Unplug connector -A- from gearbox speed sender -G38- .
Prote AG.
– Pull off connector -B- to gearbox speed sender -G182- .

– Only remove the bolts from the valve body which are marked
with an arrow.
Bolt -arrow A- is not fitted and therefore does not have to be con‐
sidered.
– Do not loosen any other bolts. This would impair the function
of the valve body.
– Detach valve body from gearbox and guide out connector from
wiring harness.

lkswage es n
o ot g
byV ua
d ran
ir se tee
o
Passat
au 1997 ➤
th or
ac
ss
ce
le
un
pt
an
d
3.4.2 Installing
itte
y li
erm
ab
ility
ot p
– To prevent wire from being pinched when valve body is instal‐
wit
led, route wire with connector -C- as in figure.
is n
h re
ole,
– Lubricate new O-rings for connector on wiring harness with
spec
ATF.
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
– Fit connector in gearbox housing with flat part -arrow A- facing
co Vo
by lksw
cted
towards oil pan.
agen
Prote AG.
– Align valve body with dowel pin -arrow B- to hole in gearbox

housing -arrow C-.
– Place valve body in position so that pin of detent plate -1- en‐
gages in slot of selector slide -2-.
– Tighten valve body securing bolts -arrows- hand-tight from
centre outwards.

Passat 1997 ➤
Bolt -arrow A- is not fitted and therefore does not have to be con‐
sidered.
– Tighten bolts to specified torque, working from centre out‐
wards
⇒ Item 6 (page 159) .
– Plug connector -A- to gearbox speed sender -G38- .

– Pull wire to gearbox input speed sender upwards
en AG. V
olkswbetween
agen AG
valve body and wiring harness. olkswag does
no
V t gu
by ara
– Join connector -B- to gearbox
ris
ed speed sender -G182- . nte
tho eo
s au ra
c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Press in securing clip for connector on wiring harness until re‐

t to the co
taining tab engages.

– Lubricate seal on intake neck of ATF strainer with ATF.
rrectne
– Carefully push intake neck of strainer into opening of valve

body to stop.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
– Bolt on ATF strainer and tighten bolts -arrows-

r
fo
en
ng
⇒ Item 36 (page 161) .

t.
yi Co
Cop py
– Install oil pan with new gasket.
t. rig
gh ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.


Passat 1997 ➤
3.5 Removing and installing internal oil pipe

♦ Fitting tool -3381-
Defective O-rings on the internal oil pipe allow ATF to enter dif‐
ferential, which then becomes overfilled and oil will seep out of
breather holes of differential.
If an oil pipe is removed, it should generally be replaced.
The oil pipe must be installed only using fitting tool -3381- . Oth‐
erwise, the oil pipe may be bent and will leak.
3.5.1 Removing
– Remove the valve body with hydraulic control E17
⇒ page 154 . AG. Volkswagen A gen G do
swa es n
– Remove the valve body with hydraulic bcontrol
yV
olk E18/2 ot g
ua
⇒ page 161 . ris
ed ran
tee
tho or
– Lever internal oil pipe off gearbox
s a housing using a screwdriver.
u ac
s
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
3.5.2 Installing
– Replace O-rings.
nform
ercia
– Insert internal oil pipe into fitting tool -3381- .

m
a
com
tion in
Open side of fitting tool -3381- faces towards outer wall of gear‐
r
te o
thi
box.
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 ➤
– Knock oil pipe into gearbox housing until tool stops against
gearbox housing. Use a plastic hammer to do this.
Do not cant oil pipe. Drive in both ends of oil pipe equally.
– Install the valve body with hydraulic control E17 ⇒ page 157 .
– Install the valve body with hydraulic control E18/2
⇒ page 164 .
3.6 Replacing gearbox speed sender -G38-

or gearbox output speed sender -G195-
3.6.1 Removing
– Remove oil pan ⇒ page 149 .
– Unplug connector from gearbox speed sender.
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
– Remove gearbox speed sender -2-.
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
c
3.6.2 Installing
or
thi
te
sd
iva
– Install gearbox speed sender -2- together with spacer sleeve

o
r
rp
cu
-1- (length: 8 mm) and tighten to specified torque

o
m
f
en
ng
⇒ Item 10 (page 159) .

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

Passat 1997 ➤
– Plug connector onto gearbox speed sender.

– Install oil pan ⇒ page 149 .
3.7 Replacing gearbox input speed sender -

G182-
Information about which control is installed: ⇒ page 3 .
Differentiating criteria ⇒ page 20 .
3.7.1 Removing (gearbox with hydraulic con‐

trol E17)
⇒ page 154 .
– Turn valve body over, and unplug connector from gearbox in‐
put speed sender -1-.
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
– Unscrew gearbox input speed sender -1- from valve body

du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
3.7.2 Installing (gearbox with hydraulic control

orm
E17)
m
atio
om
n in
c
or
thi
te
sd
iva
The side of the sender with the plug contacts faces towards the
o
r
rp
cu
centre of the valve body.

o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
168
agen
Prote AG.
Rep. Gr.38 - Gears, control
Passat 1997 ➤
– Bolt on gearbox input speed sender -1- using spacer sleeves

-2- (length: 20 mm) ⇒ Item 23 (page 153) .
– Push the connector onto gearbox input speed sender -1-.


trol E18/2) lksw
agen
AG. Volkswagen AG d
oes
n o ot g
yV
– Remove the valve body withishydraulic
ed
b control E18/2 ua
ran
⇒ page 161 . thor tee
or
u ac
sa
– Unbolt sender for gearbox
s input signal -A- from gearbox.
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.

Passat 1997 ➤

E18/2)
– Bolt gearbox speed sender -A- with bolt -B- to gearbox
⇒ Item 22 (page 160) .
– To prevent wire from being pinched when valve body is instal‐
led, route wire with connector -C- as in figure.
⇒ page 164 .
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
3.8 Removing and installing wiring harness

du
an
itte
y li
in gearbox
erm
ab
ility
ot p
Removing and installing wiring harness, gearbox with hydraulic

wit
, is n
h re
control E18/2 ⇒ page 171 .

hole
spec

es, in part or in w
t to the co
trol E17)
rrectness of i
⇒ page 154 .
l purpos
– Using a small screwdriver, lever out retaining tabs on solenoid

valve connectors and pull off connectors -A- one after the oth‐
er.
nf
ercia
orm
– Unhook wiring harness from retaining tabs -B- on side of valve

m
atio
m
body.
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 ➤
– Turn valve body over, and unplug connector from gearbox in‐
put speed sender -1-.
– Remove retaining clip -arrow A- and unclip wiring harness
from retaining clip -arrow B-.
– Pull connector -2- off solenoid valve 4 -N91- .
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
E17)
y li
erm
ab
ility
ot p
wit
, is n
following:
h re
hole
spec
– When installing, plug connectors onto respective solenoid
es, in part or in w
valves.
t to the co
– Clip harness into intended retaining clips. If not installed cor‐
rectly, harness can be pinched when valve body is installed.
rrectness of i
l purpos
nf
ercia
orm
trol E18/2)
m
atio
om
n in
c
– Remove the valve body with hydraulic control E18/2

or
thi
e
⇒ page 161 .
t
sd
iva
o
r
rp
– Using a small screwdriver, lever out retaining tabs on solenoid cu

o
m
f
en
ng
valve connectors and pull off connectors -A- one after the oth‐
t.
yi Co
er. Cop py
ht. rig
rig ht
– Unhook wiring harness from retaining tabs -B- on side of valve py by
co Vo
body.
by lksw
cted agen
Prote AG.

Passat 1997 ➤
– Turn valve body onto back and remove connector -1-

n Afrom
G. Volkswagen AG d
pressure control valve 1 -N215- . lkswage oes
no
o V t gu
by ara
– Remove retaining clip -arrow A- and unclip
ise
d
wiring harness nte
or
from retaining clip -arrow B-. auth eo
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
E18/2)
rrectness of i
l purpos
following:
– When installing, plug connectors onto respective solenoid
nf
ercia
o
valves.
rm
m
atio
m
– Clip harness into intended retaining clips. If not installed cor‐

o
n in
c
rectly, harness can be pinched when valve body is installed.

or
thi
te
sd
a

iv
o
r
rp
cu
⇒ page 164 .
o
m
f
en
ng
t.
yi
Co
Cop py
t. rig
gh
3.9 Replacing gearbox oil temperature
ht
pyri by
Vo
co lksw
by
sender (ATF) -G93- cted agen
Prote AG.

trol E17)
The gearbox oil temperature sender -G93- is integrated into the
gearbox wiring harness.
– Remove wiring harness in gearbox ⇒ page 170 .

E17)
– Replace wiring harness.
– Install new wiring harness in gearbox ⇒ page 171 .

trol E18/2)
The gearbox oil temperature sender -G93- is integrated into the
gearbox wiring harness.
– Remove wiring harness in gearbox ⇒ page 171 .

E18/2)
– Replace wiring harness.
– Install new wiring harness in gearbox ⇒ page 172 .

Passat 1997 ➤
4 Replacing sealing ring for selector

shaft
4.1 Renewing oil seal for selector shaft
4.1.1 Removing
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
– Remove multi-function switch -F125- ⇒ page 175 .

es, in part or in w
t to the co

– Remove front left exhaust system ⇒ Engine, mechanics; Rep.
rrectness of i

l purpos

nf
ercia

rm
m
-arrow-.
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.
4. Replacing sealing ring for selector shaft 173

Passat 1997 ➤
– Drive spring pin -1- out of gearbox selector lever -2- -arrow-
until gearbox selector lever can be removed from selector
shaft.
– Lever out sealing ring using a screwdriver.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
4.1.2 Installing ss
a ac
ce
le
un
pt
– Apply ATF to circumference and space between sealing lips.
an
d
itte
y li
rm
ab
pe
ility
ot
Open side of sealing ring faces gearbox.
wit
, is n
h re
– Drive in new sealing ring to stop of thrust piece -3385- , taking
hole
spec
care not to cant sealing ring.
es, in part or in w
t to the co
– Push gearbox selector lever onto selector shaft and drive in
spring pin.
rrectness of i
– Using a pair of pliers, carefully push the selector lever cable
onto selector shaft lever -2-.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
Take care not to bend selector shaft lever, because otherwise it

do
r
rp
will not be possible to precisely adjust selector mechanism.

um
fo
en
ng
t.
yi
– Install multi-function switch ⇒ page 175 .
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
– Install front left exhaust system ⇒ Engine, mechanics; Rep. cted agen
Prote AG.

Passat 1997 ➤
5 Replacing multi-function switch -

F125-
5.1 Replacing multi-function switch -F125-

Additional information required AG. Volkswagen AG d
agen oes
olksw not
♦ Workshop manual Passat 1997 d by▸ Running gear, axles, steer‐
V gu
ara
orise nte
eo
h
ut ra
5.1.1 Removing s a c
s
ce
e
nl
pt
du
– Remove left wheel.
an
itte
y li
erm
ab
Vehicles with TDI engines
ility
ot p
wit
– Remove left drive shaft noise insulation from wheel housing
, is n
h re
-arrows-.
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
e

at
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.

bolts -arrows C-.
– Unbolt multi-function switch -F125- from gearbox and pull
switch off selector shaft.
5.1.2 Installing
Centre multi-function switch -F125- on selector shaft. Do not cant
or use force when installing. Otherwise, the switch contacts will
be damaged.
5. Replacing multi-function switch F125 175

Passat 1997 ➤
– Place multi-function switch -F125- on selector shaft. Flat sec‐

tion in splines in switch -3- must coincide with flat section on
selector shaft -1-.
– Turn switch so that dowel hole -4- in switch housing can be
fitted on locating pin -2- on gearbox housing.
– Bolt multi-function switch -F125- to gearbox
⇒ Item 18 (page 160) .
lkswage es n
Vo ot g
– Fit noise insulation for drive shaft at the left d wheel housing.
by ua
ran
ir se tee
o
Continuation for all vehicles auth or
ac
ss
– Install left wheel ⇒ Running gear, axles, steering - front and
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.

agen
Volksw 5-speed
oes
notautomatic gearbox 01V - Edition 08.2007
by gu
d ara
ise nte
or eo
h
ut
6 Replacing speedometer sender -
ss a ra
c
G22- or vehicle speed sender -G68-
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
6.1 Replacing sender
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
6.1.1 Removing
rrectness of i
– Remove left wheel.
l purpos
nf
ercia
– Remove left drive shaft noise insulation from wheel housing
orm
-arrows-.
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.
– Pull connector -arrow A- off sender.

– Press the retaining clip of the sender downwards and turn to
outside front -arrow-.
– Pull out sender.
6.1.2 Installing
following:
– Replace O-rings -arrows-.
– Insert new O-rings with gearbox oil.
– Insert sender.
– Engage retaining catch on bearing bracket for flange shaft.
– Install left wheel ⇒ Running gear, axles, steering - front and
6. Replacing speedometer sender G22 or vehicle speed sender G68 177

Passat 1997 ➤
39 – Final drive - differential

1 Checking oil in front final drive
1.1 Checking oil in front final drive

♦ Hexagon key extension, 8 mm -3247-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
u ra
Oil level is checked with gearbox installed.
ss a c
ce
le
– Drive vehicle a short distance to warm up gear oil.

un
pt
an
d
itte
y li
– Position vehicle over pit or on 4-pillar hoist so that it stands

rm
ab
level.
pe
ility
ot
wit
, is n
– Switch off engine and allow oil to settle for approx. 5 minutes.
h re
hole
spec

es, in part or in w
t to the co
– Remove right drive shaft noise insulation from wheel housing

-arrows-.
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
178
Prote AG.
Rep. Gr.39 - Final drive - differential
Passat 1997 ➤
– Remove oil plug.

The oil level is correct when the front final drive is filled to the lower
edge of the filler hole.
– Allow excess gear oil to pour out or top up as necessary.
Specification ⇒ page 7
– If gear oil needs to be replenished following repair work, fill
front final drive slowly and evenly over a period of at least 5
minutes until gear oil drips out over lower edge of oil filler hole.
A filling time of at least 5 minutes is necessary so thatAoil can
G. Volkswagen AG d
spread evenly throughout gearbox. lkswagen oes
n o ot g
yV ua
edb ran
– Screw in old plug. ho
ris tee
aut or
ac
– Drive vehicle a short distance to
ss warm up gear oil.
ce
le
un
pt
– Check oil level in final drive again.
an
d
itte
y li
rm
– When oil level is correct, renew oil plug for front final drive
ab
pe
ility
⇒ Item 4 (page 180) .
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Fit noise insulation for drive shaft at the right wheel housing.
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. Checking oil in front final drive 179

Passat 1997 ➤
2 Repairing front final drive

(Gearbox installed)
n AG . Volkswagen AG
1 - Sealing ring wage does
Volks not
❑ Between final drive and ed by gu
ara
gearbox housing ris nte
utho eo
ra
❑ Replacing ⇒ page 190ss
a c
ce
le
2 - Shim
un
pt
an
d
itte
❑ Behind taper roller bear‐
y li
rm
ab
ing outer race
pe
ility
ot
wit
3 - Taper roller bearing outer
, is n
h re
race
hole
spec
4 - Plug, 30 Nm
es, in part or in w
t to the co
❑ Always replace
rrectness of i
5 - Bolt, 23 Nm
l purpos
6 - Right flange shaft

7 - Sealing ring for right flange
nform
ercia
shaft
m
a
com
tion in
8 - Bolt, 23 Nm
r
te o
thi
s
iva
❑ Observing tightening do
r
rp
c
sequence ⇒ page 195
um
fo
en
ng
t.
9 - Cover for front final drive
yi Co
Cop py
t. rig
10 - Shim
gh ht
pyri by
Vo
o
❑ Behind taper roller bear‐
c by lksw
cted agen
ing outer race
Prote AG.
11 - Taper roller bearing outer

race
12 - O-ring
❑ Always replace
13 - Differential
14 - Bolt, 23 Nm
❑ Observing tightening sequence ⇒ page 201
15 - Housing cover for front final drive
16 - Dowel sleeve
17 - Seal
18 - Spring pin
19 - Lever
❑ For selector shaft
20 - Sealing ring
❑ For selector shaft
180 Rep. Gr.39 - Final drive - differential

Passat 1997 ➤
21 - Bolt, 23 Nm
22 - Sealing ring for left flange shaft
23 - Input gear
❑ For speedometer sender -G22-
❑ Installation position ⇒ page 188
24 - Left flange shaft
25 - Bearing bracket for flange shaft
26 - Deep groove ball bearing for flange shaft
27 - Retaining ring
28 - O-ring
❑ Square cross section
❑ To replace, remove and install left flange shaft ⇒ page 184
2.1 Replacing sealing ring for right flange shaftVolkswa

AG. gen AG
agen does
olksw not
yV gu
Special tools and workshop rise
db ara
nte
equipment required tho eo
au ra
c
ss
♦
ce
le
un
pt
♦ Sealing ring extractor lever
an
d
itte
y li
-VW 681-
erm
ab
ility
ot p
wit
is n
h re
♦ Torque wrench -
ole,
spec
V.A.G 1331-
t to the co
♦ Torque wrench -
V.A.G 1332-
♦ Grease -G 052 128 A1-
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.
2. Repairing front final drive 181

Passat 1997 ➤

♦ Workshop manual Passat 1997 ▸, Running gear - front and
four-wheel-drive
2.1.1 Removing swage

es n
lk ot g
Vo
– Observe general repair instructions ⇒ page 8 . d by ua
ran
ir se tee
o
– Only loosen drive shaft/wheel hub bolt and wheel
au bolts when
th or
ac
vehicle is standing on its wheels. ss
ce
le
un
pt
– Remove wheel.
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
-arrows-.
h re
ole,
spec
All vehicles except for V6 TDI
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e

t
sd
iva
o
pr
c
um
r
fo
en
ng
t.
yi
– Remove right drive shaft -1- ⇒ Running gear, axles, steering
Co
op py
- front and four-wheel drive; Rep. Gr. 40 ; Repairing drive t. C rig
gh ht
shafts; Removing and installing drive shafts . pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove flange shaft bolt using mandrel to prevent flange from

turning.
– Pull out right flange shaft.

agen
AG. Volkswagen AG d
oes Passat 1997 ➤
ksw not
by Vol
5-speed automatic ggearbox
ua 01V - Edition 08.2007
d ran
rise te
– Remove flange shaft sealingtho ring. eo
s au ra
c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
2.1.2 Installing
– Apply gear oil to circumference and sealing lips of sealing ring.
nform
ercia
– Half-fill space between sealing lip and dust lip with grease -
m
at
om
G 052 128 A1- .
ion
c
in t
or
his
ate
do
riv
Open side of sealing ring faces gearbox.

p
cum
for
en
g
– Drive in new sealing ring to stop, being careful not to cant

n
t.
yi Co
sealing ring. Cop py
t. rig
gh ht
yri
– Install right flange shaft.
p by
co Vo
by lksw
cted agen
Prote AG.
– Install flange shaft bolt -arrow- using mandrel to prevent flange

from turning ⇒ Item 5 (page 180) .
– Install right drive shaft -1- ⇒ Running gear, axles, steering -

front and four-wheel drive; Rep. Gr. 40 ; Repairing drive
shafts; Removing and installing drive shafts .
– Install right drive shaft guard plate -arrows-. Third bolt cannot

Passat 1997 ➤
– Install wheel ⇒ Running gear, axles, steering - front and four-
wheel drive; Rep. Gr. 44 ; Torque settings for wheel bolts .
– With gearbox installed, check gear oil level in front final drive
⇒ page 178 .
2.2 Replacing sealing ring for left flange shaft

equipment required
♦
♦ Pressure plate -VW 401-
♦ Pressure plate -VW 402-
♦ Press tool -VW 407-
♦ Press tool -VW 412-
AG. Volkswagen AG d
agen oes
♦ Sealing ring extractor lever Volksw not
gu
-VW 681- ed by ara
nte
ris
o eo
♦ Tube -32-109- aut
h
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 ➤
♦ Tube -2040-
♦ Drift -3384-
♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-
♦ Oil extraction unit -
V.A.G 1358 A-
♦ Grease -G 052 128 A1-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
s c
Additional information required s ce
e
nl
pt
du

an
itte
y li
four-wheel-drive
erm
ab
ility
ot p
2.2.1 Removing left flange shaft

wit
, is n
h re
hole

spec
es, in part or in w
– Only loosen left drive shaft/wheel hub bolt and left and right
t to the co
wheel bolts when vehicle is standing on its wheels.

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.

Passat 1997 ➤

housing -arrows-.
Vehicles with V6 engines 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
– Remove left drive shaft protective plate -arrows-. The third bolt
t to the co
is not visible in the figure.
rrectne
– Remove left drive shaft -1- ⇒ Running gear, axles, steering -
s
s o
cial p
f in
form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
– Unscrew gear oil inspection plug -arrow- and draw off at least
en
ng
t.
yi
0.5 litre gear oil from front final drive using oil extraction device
Co
op py
-V.A.G 1358 A- . t. C rig
gh ht
pyri by
It is essential that the gear oil is extracted from the front final drive;
co Vo
by lksw
cted
otherwise the gear oil will mix with the ATF.
agen
Prote AG.
– Remove speedometer sender ⇒ page 177 .

– Detach bracket for connector from flange shaft bearing brack‐
et.
– Unbolt flange shaft bearing bracket -arrows-.

– Pull out flange shaft.

Passat 1997 ➤
2.2.2 Removing sealing ring

– Remove circlip -arrow A- for deep groove ball bearing.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
– Press oflange
ris
ed
shaft out of flange shaft bearing bracket.nte
h eo
ut ra
– Pull
ss a out flange shaft sealing ring using sealing ring extractor
c -
VW 681- .
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
2.2.3 Removing deep groove ball bearing

thi
te
sd
iva
o
pr
– Press deep groove ball bearing out of bearing bracket.

um
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 ➤
2.2.4 Installing deep groove ball bearing

– Press new deep groove ball bearing into bearing bracket.
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
2.2.5 Installing sealing ring

nf
ercia
orm
– Half-fill space between sealing lip and dust lip with grease -
m
atio
m
G 052 128 A1- .

o
n in
or c
– Drive in new sealing ring to stop of thrust piece, taking care

thi
te
sd
a
not to cant sealing ring.

iv
o
r
rp
cu
o
f
en
ng
t.
yi Co
op
Lugs on drive gear must engage in slots on flange shaft. C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Place the speedometer drive gear onto the flange shaft.

Passat 1997 ➤
– Press bearing bracket with deep groove ball bearing onto

flange shaft.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
– Insert circlip -arrow A-.
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
2.2.6 Installing left flange shaft
en
ng
t.
yi Co
Cop py
.
– Replace O-ring -arrow B- in flange shaft bearing bracket.
t rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Check that there are no sharp edges on gearbox end of flange

shaft; deburr edges if necessary.
– Install flange shaft.

Passat 1997 ➤
– Bolt on flange shaft bearing bracket -arrows-

⇒ Item 21 (page 181) .
– Attach connector bracket to flange shaft bearing bracket.
– Install speedometer sender ⇒ page 177 .
– Install left drive shaft -1- ⇒ Running gear, axles, steering - front
and four-wheel drive; Rep. Gr. 40 ; Repairing drive shafts;
Removing and installing drive shafts .
⇒ page 178 .
– Install left drive shaft guard plate -arrows-. Third bolt cannot
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
2.3 Replacing front final drive/gearbox housing sealing ring

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
♦ Sealing ring extractor lever
-VW 681-
♦ Torque wrench -
V.A.G 1332-
V.A.G 1383 A- with univer‐
sal gearbox mounting -
V.A.G 1359/2-
♦ Oil extraction unit -
V.A.G 1358 A-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
u ra
Additional information required ss a c
ce
le

un
pt
an
d
four-wheel-drive
itte
y li
erm
ab

ility
ot p
wit
is n
A defective sealing ring will allow ATF or axle oil to escape into
h re
ole,
the torque converter bell housing via the central breather in the
spec
sealing ring (between the two sealing lips).

t to the co
In addition, a defective sealing ring can allow ATF to enter the

differential. This will become overfilled and ATF will escape from
the front final drive breather.
rrectne
2.3.1 Removing
ss

o
cial p
f inform
– Raise vehicle.
mer
atio
m
– Remove wheel.
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
191
Prote AG.
2. Repairing front final drive
Passat 1997 ➤
5-speed automatic gearbox 01V - Edition 08.2007 lkswage es n
o ot g
byV ua
d ran
Vehicles with TDI engines ir se tee
tho
u or
a ac
ss
ce
e
-arrows-.
nl
pt
du
an
itte
y li
erm
ab
ility
– Remove front right exhaust pipe ⇒ Engine, mechanics; Rep.
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
or
m
m
atio
m

o
n in
or c
- front and four-wheel drive; Rep. Gr. 40 ; Repairing drive
thi
e

t
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.
– Unscrew gear oil inspection plug -arrow- and draw off at least
0.5 litre gear oil from front final drive using oil extraction device
-V.A.G 1358 A- .
It is essential that the gear oil is extracted from the front final drive;

turning.
– Remove right-hand gearbox support ⇒ page 129 .
– Unscrew bolts securing cover for front final drive and remove
cover.
– Pull out differential and remove.

Passat 1997 ➤
– Remove taper roller bearing outer race -1- for differential and
shim -2- behind outer race from gearbox housing by hand.
Thickness of shim -2- is measured; the shim must not be replaced
with another shim of different thickness.
– Removing left flange shaft ⇒ page 185 .
– Pull out sealing ring.

The sealing ring extractor lever must be applied behind the two
sealing lips of the sealing ring. Do not apply lever to outer cir‐
cumference of sealing ring, because this would damage sealing
surface in gearbox. Guide lever carefully when removing sealing
ring.
2.3.2 Installing yV
olkswage es n
ot g
ua
b
ed ran
– Examine sealing ring seat hinor gearbox for damage; reface sur‐
is tee
face if necessary. aut or
ac
ss
ce
e
nl
pt
du
an
itte
– Push sealing ring onto thrust piece -3383- with protruding

y li
erm
ab
sealing lip of sealing ring facing towards tool.

ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Drive in new sealing ring to stop.

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
cted agen
Prote AG.

Passat 1997 ➤
ks wage es
– Insert shim -2- and taper Vol roller bearing outer race -1-otfor
n
gu dif‐
by
ferential to stop inrisegearbox housing by hand.
d ara
nt ee
tho or
– Install differential
sa
u in gearbox housing. ac
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Replace O-ring.
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
– Install cover for front final drive. yri
p by
co Vo
by lksw
cted
Tightening sequence:
agen
Prote AG.
♦ Stage 1: tighten bolts -1-,-2- and -3- hand-tight.

♦ Stage 2: tighten bolts -1- to-12- to specified torques in se‐
quence indicated ⇒ Item 8 (page 180) .
– Install right-hand gearbox support ⇒ page 129 .
– Install left flange shaft ⇒ page 185 .
– Install flange shaft bolt using drift to prevent flange from turning
⇒ Item 5 (page 180) .
⇒ page 178 .

Passat 1997 ➤

and four-wheel drive; Repair group 40; Servicing drive shafts;
Removing and installing drive shafts
– Install front right exhaust system ⇒ Engine, mechanics; Rep.
wage es n
olks
– Fit noise insulation for drive shaft at the right
y V wheel housing.
ot g
b ua
ed ran
Continuation for all vehicles thoris tee
or
au ac
– Install wheel ⇒ Running gear, - front and four- axles,
ss steering
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
2.4 Replacing O-ring on cover for front final
rrectness of i
drive
l purpos
nform
ercia

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
cted agen
Prote AG.
Additional required information

four-wheel-drive
2.4.1 Removing
– Raise vehicle.
– Remove wheel.

Passat 1997 ➤

-arrows-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Remove front right exhaust pipe ⇒ Engine, mechanics; Rep.
t to the co
rrectne
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n
turning.
thi
te
sd
iva
o
r
– Draw gear oil out of final drive using oil extractor -

p
cum
r
fo
V.A.G 1358 A- .
en
ng
t.
yi Co
op
It is essential that the gear oil is extracted from the front final drive; C py
t. rig
gh ht
pyri by
Vo
co lksw
by
– Place drip tray -V.A.G 1306- underneath. cted agen
Prote AG.

cover.
2.4.2 Installing
following:
– Replace O-ring.

Passat 1997 ➤
– Install cover for front final drive.

– Install flange shaft bolt using drift to prevent flange from turning
⇒ Item 5 (page 180) .
⇒ page 178 . agen
AG. Volkswagen AG d
o
ksw es n
Vol ot g
d by ua
ran
e
ris tee
tho or
au 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
and four-wheel drive; Repair group 40; Servicing drive shafts;

Removing and installing drive shafts
nf
ercia
– Install front right exhaust system ⇒ Engine, mechanics; Rep.

Gr. 26 ; Removing and installing parts of exhaust system . orm
m
atio
om

n in
or c
thi
te
sd
a
iv
o
r
rp
cu
o
m
f

en
ng
t.
yi Co
op
C py
t. rig
gh
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2.5 Renewing O-ring on cover for front final

drive

Passat 1997 ➤
AG. Volkswagen AG d
Additional required information agen oes
olksw not
byV gu
ara
d
♦ Workshop manual Passat 1997ori▸,
s Running gear - front and
e nte
four-wheel-drive aut
h eo
ra
ss c
ce
le
un
pt
an
d
2.5.1 Removing
itte
y li
erm
ab
ility
ot p
wit
is n
h re
– Raise vehicle.
ole,
spec
– Remove wheel.
t to the co
rrectne
-arrows-.
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
ht. rig
– Remove left drive shaft guard plate -arrows-. The third bolt is rig ht
py by
Vo
co lksw
by
cted agen
Prote AG.
– Remove front right exhaust pipe ⇒ Rep. Gr. 26 ; Removing
and installing parts of exhaust system .

Passat 1997 ➤
– Remove flange shaft bolt -arrow- using mandrel to prevent

flange from turning.
– Draw gear oil out of final drive using oil extractor - lkswage es n
o ot g
V.A.G 1358 A- . byV ua
d ran
ir se tee
o
– Place drip tray -V.A.G 1306- underneath. auth or
ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
cover.
wit
, is n
h re
hole
spec
es, in part or in w
– Replace O-ring -arrow-.
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
2.5.2 Installing
en
ng
t.
yi Co
op py
Install in reverse order of removal. During this step, observe the t. C rig
gh ht
following: pyri by
Vo
co lksw
by
cted agen
– Install cover for front final drive. Prote AG.
– Install flange shaft bolt -arrow- using mandrel to prevent flange

from turning ⇒ Item 5 (page 180) .
⇒ page 178 .

Passat 1997 ➤
– Install right drive shaft -1- ⇒ Running gear,

gen AG
. Voaxles,
lkswagesteering
n AG d -
front and four-wheel drive; Rep. VolkGr.
swa 40 ; Repairing drive oes
not
shafts; Removing and installing
ed
by drive shafts . gu
ara
is nte
or
All vehicles except for V6
au TDI
th eo
ra
ss c
– Install right drive shaft guard plate -arrows-. Third bolt cannot
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
– Install front right exhaust pipe ⇒ Rep. Gr. 26 ; Removing and
is n
h re
installing parts of exhaust system .
ole,
spec
t to the co
rrectne
s
s 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
op py
2.6 Replacing the front final drive seal
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
♦ Engine and gearbox jack -V.A.G 1383 A- with universal gear‐
box mounting -V.A.G 1359/2-
2.6.1 Removing

agen
ksw 5-speed automatic gearbox 01V - Edition 08.2007
oes
ol not
yV gu
edb ara
ris nte
– Remove front exhaust system withut
ho catalytic converter ⇒ Rep. eo
Gr. 26 ; Removing and installing
ss a parts of exhaust system . ra
c
ce
e
– Support the gearbox from below using engine/gearbox jack -
nl
pt
du
an
V.A.G 1383 A- and universal gearbox support -V.A.G 1359/2- .
itte
y li
erm
ab
– Remove gearbox mountings ⇒ page 129 . The gearbox sup‐
ility
ot p
ports remain on the gearbox.
wit
, is n
h re
– Place drip tray -V.A.G 1306- underneath. hole
spec
es, in part or in w
– Unscrew bolts -1- to -14- on housing cover for front final drive.
t to the co
Note
rrectness of i
♦ Slowly and carefully remove housing cover for front final drive
l purpos
off gearbox housing. Otherwise spur gears can drop out of

gearbox.
nf
ercia
o
♦ Spur gears which have been dropped on the floor must not be
rm
m
atio
reinstalled. If this happens, gearbox must be replaced.
om
n in
or c
thi
– Lift off housing cover for front final drive.
te
sd
iva
o
r
rp
cu
– Do not remove the spur gears for the front final drive. Secure
o
m
f
spur gears against falling out.
en
ng
t.
yi Co
op
If the spur gears for the front final drive have been removed, they
C py
t. rig
gh
must be reinstalled with markings on gears facing outwards (away
ht
pyri by
Vo
o
from gearbox). by c lksw
cted agen
Prote AG.
2.6.2 Installing
following:
– Ensure that dowel sleeve -arrow A- is seated correctly before
installing.
– Fit gasket.
– Install housing cover for front final drive.
– Install the left and right gearbox support ⇒ page 129 .
– Fill with ATF and check ATF level ⇒ page 135 .

AG. Volkswagen AG d
agen oes
olksw not
y V gu
Passat 1997 ➤ rise
d b ara
nte
autho eo
ra
ss c
ce
e
nl
pt
du
3 Definitions:
an
itte
y li
erm
ab
These explanations refer only to this assembly group: Automatic
ility
ot p
gearbox 01V, 5-speed, four-wheel drive. These definitions are not
wit
, is n
necessarily generally valid.
h re
hole
spec
ATF (Automatic Transmission Fluid)
es, in part or in w
t to the co
Gear oil for automatic gearbox
ATF pump
rrectness of i
Supplies the automatic changing of gears, all lubrication points
l purpos
(except front final drive and transfer gearbox) and torque con‐
verter with ATF. For more information, refer to ⇒ Self-study pro‐
gramme No. 180 ; 5-speed automatic gearbox 01V .
nf
ercia
or
ATF level
m
m
atio
m
The level of ATF in gearbox when “full”. The function and smooth‐
o
n in
or c
ness of gear changes require conscientious checking and main‐
thi
e
tenance of the ATF level. For more information, refer to ⇒ Self-

t
sd
iva
o
study programme No. 180 ; 5-speed automatic gearbox 01V .
r
rp
cu
o
m
When measuring ATF level, refer to specifications in workshop
f
en
ng
t.
manual.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
It is characterised by an upgraded dynamic shift program (DSP) Prote
cted AG.
agen
and has two planetary gear sets. For more information, refer to
01V .
Brakes
Together with the clutches, they shift between the individual for‐
ward gears and reverse gear of the planetary gearbox and enable
the various forward gear ratios. Unlike the clutches, the brakes
are supported on the gearbox housing. Further information can
be found in ⇒ Self-study programme No. 180 ; 5-speed automatic
gearbox 01V .
Data bus
Transportation of data. To do this, the electrical signals are
brought into a certain format (bus). For more information, refer to
01V and ⇒ Self-study programme No. 186 ; The CAN data bus .
Torque converter
Transfers the engine torque to the automatic gearbox and acts as
a drive-away clutch. The torque converter also includes the lock-
up clutch. For more information, refer to ⇒ Self-study programme
No. 180 ; 5-speed automatic gearbox 01V .
DSP (Dynamic shift program)
For more information, refer to ⇒ Self-study programme No. 180 ;
5-speed automatic gearbox 01V .
Self-diagnosis
The capability of the control unit
to detect faults,
to react to faults,
to store faults,
to register values and make them available in measured value
block. For more information, refer to ⇒ Self-study programme No.
180 ; 5-speed automatic gearbox 01V and the test unit instruction
manual.

Passat 1997 ➤
“▸” button
Button on VAS 5051 tester display, also referred to as “continue”
button.
Performing electrical check
A targeted check of the electronic components by performing
measurements.
Performing vehicle self-diagnosis
Connect vehicle diagnosis, testing and information system -
VAS 5051- and then select, amongst other items, Read fault
memory, Perform final control diagnosis or Read measured value
block.
Vehicle diagnosis, testing and information system -VAS 5051-
The -VAS 5051- replaces and expands all functions of the previ‐
ous Fault reader -V.A.G 1551- or Vehicle system tester -
V.A.G 1552- .
The operating modes “Vehicle self-diagnosis”, “Measuring tech‐
nology” and “Guided fault finding” provide the latest comprehen‐
sive technical information
Further information can be found in ⇒ Self-study programme No.
202 ; Vehicle Diagnosis, Testing and Information system
VAS 5051 .
Freewheel/stator
Ensures the torque is increased in the torque converter when
driving off.
Freewheel/gearbox AG. Volkswagen AG d
agen oes
olksw not
yV gu
Technically simplifies
ed b the gear changes without interrupting
ara
n the
is
power andthensures
or a constant gear change quality. tee o
au ra
c
Gearboxss speed sender -G38- or gearbox output speed sender -
ce
le
G195-
un
pt
an
d
itte
y li
The sender records the gearbox output speed and transmits it to

rm
ab
the automatic gearbox control unit. For more information, refer to

pe
ility

ot
wit
, is n
01V .
h re
hole
spec
Gearbox oil temperature sender -G93-

es, in part or in w
t to the co
Monitors the temperature of the ATF to prevent the gearbox from

overheating. It is located on the valve body within the wiring har‐
ness to the solenoid valves. For more information, refer to ⇒ Self-
rrectness of i

l purpos
Gearbox input speed sender -G182-

The sender records the speed of the planetary carrier of the Rav‐
nform
ercia
igneaux planetary gear set and transmits it to the automatic

gearbox control unit. For more information, refer to ⇒ Self-study
m
programme No. 180 ; 5-speed automatic gearbox 01V .

com
tion in
r
Guided fault finding

te o
thi
s
iva
do
An operating mode of the vehicle diagnosis, testing and informa‐

r
rp
cum
tion system -VAS 5051- .

fo
en
ng
t.
yi Co
Existing faults can be detected (and rectified) using a computer
t. Cop py
and “guided fault finding” in a dynamic fault-finding program, “ve‐
rig
gh ht
yri by
hicle self-diagnosis” and “testing”.
op Vo
by c lksw
cted agen
Prote
Initialising
AG.
Activate a defined setting using a specific program sequence.
3. Definitions: 203
Passat 1997 ➤
Kickdown switch -F8-

The kickdown switch is integrated in the accelerator pedal cable
or in accelerator position sender -G79- . When the accelerator
pedal is depressed fully onto its stop the gearbox changes down
for acceleration. For more information, refer to ⇒ Self-study pro‐
Clutches
Together with the brakes, they shift between the individual for‐
ward gears and reverse gear of the planetary gearbox and enable
the various forward gear ratios. For more information, refer to
01V .
Wiring
Routing of electrical wiring and components in vehicle.
Lepelletier design
Pierre Lepelletier further developed the Ravigneaux planetary
gear set and added a further planetary gear set. This enabled
more gears while reducing the number of components when com‐
pared with other planetary gear set combinations.
Selector lever lock solenoid -N110-
Located in the selector mechanism close to the selector lever.
Prevents (unintentional) movement of the selector lever from po‐
sitions “P” and “N” when the brake pedal is not depressed. For
more information, refer to ⇒ Self-study programme No. w180agen; 5-
AG. Volkswagen AG d
oes
s
speed automatic gearbox 01V . yV
olk not
gu b ara
ed nte
Solenoid valves -N88- to -N90- horis e
ut or
ac
Opens and closes the oil channels to the brakes sa
sclutches and
ce
le
according to signals from the control unit. For more information,

un
pt
refer to ⇒ Self-study programme No. 180 ; 5-speed automatic
an
d
itte
y li
gearbox 01V .
erm
ab
ility
ot p
Solenoid valve -N91- or pressure control valve 1 -N215-

wit
is n
As a modulation valve, continuously regulates the quantity of ATF h re

ole,
spec
delivered. For more information, refer to ⇒ Self-study programme
No. 180 ; 5-speed automatic gearbox 01V .

t to the co
Solenoid valves -N92- and -N93- or pressure control valve 2 -

N216- and pressure control valve 3 -N217-
rrectne
These modulation valves continuously regulate the hydraulic

pressure during gear changes to enable the clutches and brakes
s
to open and close smoothly. For more information, refer to ⇒ Self-

s o
cial p

f inform
mer
Solenoid valve -N94- or pressure control valve 4 -N218-

atio
m
As a modulation valve, regulates the opening and closing of the

o
n
c
i
or
lock-up clutch. For more information, refer to ⇒ Self-study pro‐

thi
e

t
sd
iva
o
pr
cum
Multi-function switch -F125-

r
fo
en
ng
t.
yi Co
Its function is to pass on the selector lever positions to automatic Cop py
gearbox control unit -J217- in automatic mode. Multi-function
t. rig
gh ht
yri
switch is connected to the selector shaft and the selector lever
p by
co Vo
by lksw
cable. For more information, refer to ⇒ Self-study programme No. Prote
cted AG.
agen
180 ; 5-speed automatic gearbox 01V .
Emergency running
If a sensor fails, the control unit selects substitute signals and
initiates substitute functions. If this is not possible, emergency
running is initiated.

Passat 1997 ➤
Emergency running is a “mode of the control unit” which ensures

continued driving safety and protects the gearbox against dam‐
age when faults are detected while impairing the driving charac‐
teristics as little as possible. For more information, refer to ⇒ Self-
Parking lock
The selector lever controls the parking lock wheel when the ve‐
hicle is stationary and prevents the vehicle from unintentional
rolling.
Planetary gear
Is a mechanical component of the automatic gearbox and is
switched via the clutches and brakes without interrupting power
transmission.
Planetary gear set
Automatic gearbox 01V has two planetary gear sets (a Rav‐
igneaux set and a simple planetary gear set), which enables the
selection of five forward gears and a reverse gear. For more in‐
formation, refer to ⇒ Self-study programme No. 180 ; 5-speed
automatic gearbox 01V .
Ravigneaux planetary gear set
The planetary gear set is named after the inventor. Further infor‐
mation on Ravigneaux planetary gear set can be found in ⇒ Self-
study programme No. 180 ; 5-speed automatic gearbox 01V and
⇒ Self-study programme No. 172 ; Automatic gearbox, model
year 1995 .
AG. Volkswagen AG d
Relay for starter interlock -J207- lksw
agen oes
not
Vo gu
y
The relay switches on the reversing lights when rise the selector lever
d b ara
nte
is in the “R” position. The signal for this comes
utho from multi-function eo
ra
switch -F125- . ss a c
ce
le
The relay “enables” the starter in selector lever positions “P” and
un
pt
an
d
“N”.
itte
y li
erm
ab
Valve body
ility
ot p
wit
is n
Located on the bottom of the gearbox and is inside the ATF pan.
h re
ole,
Its valves regulate and distribute hydraulic pressure via the oil spec
channels to the shift elements (clutches and brakes).
t to the co
Control unit for automatic gearbox -J217-

The electronic control unit determines the shift points with the dy‐
rrectne
namic shift program (DSP). “Self-diagnosis” monitors the function

of the gearbox. If components or sensors fail, an emergency run‐
ning program ensures that the vehicle can still be driven. For more
ss
information, refer to ⇒ Self-study programme No. 180 ; 5-speed

o
cial p

inform
mer
AF
atio
om
Abbreviation for across flats.

n
c
i
or
n thi
e
Tiptronic
t
sd
iva
o
pr
cum
With an additional selector gate on the right of the normal selector

r
fo
en
ng
gate, it is now possible to manually shift up a gear by moving the

t.
yi Co
op
selector lever to plus (+) and manually shift down a gear by mov‐ C py
t. rig
ing the selector lever to negative (-).
gh ht
pyri by
Vo
co lksw
by
There are automatic gearboxes 01V without Tiptronic also and Prote
cted AG.
agen
therefore only one selector gate for the selector lever as before.
For more information, refer to ⇒ Self-study programme No. 180 ;
5-speed automatic gearbox 01V .
3. Definitions: 205
Passat 1997 ➤
Overlapping gear changes

The actuation of the appropriate shift elements by the control unit
ensures smooth gear changes. For more information, refer to
01V .
TCC (Torque converter lock-up clutch)
It transmits engine torque mechanically to the gearbox. For more
information, refer to ⇒ Self-study programme No. 180 ; 5-speed
Selector lever position display -Y6-
Shows the position of the selector lever and the gear selected with
Tiptronic in a display in the dash panel insert. For more informa‐
tion, refer to ⇒ Self-study programme No. 180 ; 5-speed auto‐
matic gearbox 01V .
Selector lever lock
Prevents (unintentional) movement of the selector lever from po‐
sitions “P” and “N” when the brake pedal is not depressed. For
more information, refer to ⇒ Self-study programme No. 180 ; 5-
speed automatic gearbox 01V .
Ignition key withdrawal lock
It ensures that the ignition key can only be withdrawn when park
position is selected and in addition mechanically locks the selec‐
tor lever in this position.
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
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.

K0050606020-5-Speed Automatic Gearbox 01V

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

K0050606020-5-Speed Automatic Gearbox 01V

Uploaded by

Copyright:

Available Formats

n AG.

5-speed automatic gearbox 01V

Service Department. Technical Information

All rights reserved.

Copyright © 2015 Volkswagen AG, Wolfsburg K0050606020

2.2 Checking and adjusting selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . h re 26

2.4 Removing and installing selector lever handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2.5 Removing and installing selector mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

2.8 Removing and installing selector lever lock solenoid N110 . . . . . . . . . . . . . . . . . . . . . . . . 44

2.9 Removing and installing selector lever cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

2.11 Adjusting locking cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

3 Dismantling and assembling the selector mechanism cover . . . . . . . . . . . . . . . . . . . . . . . . 53

3.1 Selector mechanism cover - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

3.2 Removing and installing the selector mechanism cover . . . . . . . . . . . . . . . . . . . . . . . . . . 53

3.3 Dismantling and assembling selector mechanism cover . . . . . . . . . . . . . . . . . . . . . . . . . . 55

4 Removing and installing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

5.3 Replacing ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

38 - Gears, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

4.1 Renewing oil seal for selector shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

5 Replacing multi-function switch F125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

5.1 Replacing multi-function switch F125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

6 Replacing speedometer sender G22 or vehicle speed sender G68 . . . . . . . . . . . . . . . . . . 177

6.1 Replacing sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

39 - Final drive - differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

1.1 Checking oil in front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

2 Repairing front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

2.3 Replacing front final drive/gearbox housing sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . 190

2.4 Replacing O-ring on cover for front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

2.5 Renewing O-ring on cover for front final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

2.6 Replacing the front final drive seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

1.1 Gearbox identification

1.1.1 Location of code letters on gearboxn AG. Volkswagen A

Code letters -arrow 3-

2 Notes on 5-speed automatic gearbox

2.1 Notes on 5-speed automatic gearbox

2.1.1 Torque converter

2.1.3 Automatic gearbox control unit -J217-

with driving situation gearshifts (fuzzy

tion and driving resistance, is determined automatically.

• Individual adaptation of gear change points in all driving sit‐

• Gear change points are infinitely variable.

2.1.4 Gear change point variations for grades

An additional gear change map automatically selects gear

changes for gradients dependent upon accelerator pedal position

and driving speed.

2.1.5 Guided fault finding, vehicle self-diag‐

2 Rep. Gr.00 - Technical data

Gearbox Identification DEP DSJ

Manufactured from 08.99 08.99

Automatic gearbox 01V

Automatic gearbox 01V

3. Identification codes, engine allocation, ratios, equipment 3

Automatic gearbox 01V

Automatic gearbox 01V

Automatic gearbox 01V

4 Rep. Gr.00 - Technical data

Engine 1.9 l - 85 kW 2.0 l - 96 kW 1.8 l - 110 kW

Automatic gearbox 01V

Manufactured from 08.00 08.00 06.00

Allocation Model Passat 1997 ▸ Passat 1997 ▸ Passat 1997 ▸

Engine 2.5 l - 110 kW 2.8 l - 142 kW 2.8 l - 142 kW

diesel 2.8 l - 140 kW

Data bus yes yes yes