Volkswagen Passat 1997 Operating instructions

Maintenance
Maintenance
Engine overview
Oil change service
Oil change service every10,000 miles (15,000 Km)
Inspection service
Inspection service every12 months
Inspection service every20,000 miles (30,000 km)
General Information
Type plate
Vehicle Identification Number (VIN)
Engine code and engine number
Vehicle, lifting
Towstarting/towing
Work descriptions
Driver's and front passenger airbags, visual check ofairbag units
On Board Diagnostic (OBD), checking DTC memoryofall systems
Door check straps and securing bolts, lubricate
Sunroof, checking function, cleaning and lubricating guide rails
Windshield wiper/washer system and headlight cleaning system, checking
function
Windshield wiper blades, check park position and pitch angle
Checking tire condition, tread wear pattern , filling pressure and tread depth
Engine oil level, checking
Engine oil, changing and replacing oil filter
Engine and components in engine compartment (from above and below), check
for leaks and damage
V-belt, checking condition and tension
Ribbed belt, Check condition and tension (engines without automatic tensioning
roller)
Front manual transmission/final drive, check oil level
Rear final drive (Syncro): Check oil level
Automatic transmission, check final drive oil level
Brake system, visual inspection
Brake pads front and rear, checking thickness
Underbodysealant, checking
Tie rod ends, checking
Ball joints, checking
Cooling system anti-freeze protection and coolant level, checking

Spark plugs, replacing
Dust and pollen filter element, replacing
Toothed belt for camshaft drive: (Diesel engine code AAZ), Ccheck condition and
tension
Toothed belt and toothed belt tensioning roller (Diesel engine codes AFN and
1Z), replacing
Toothed belt for camshaft drive (gasoline engine), check condition and tension
Toothed belt, check wear (TDI engines)
Fuel filter, replacing (diesel engine)
Fuel filter, draining water (Diesel engine)
Automatic transmission, Checking ATF level
Automatic transmission, changing ATF
Power steering fluid level, checking
Brake fluid, changing
Brake fluid level, checking
Battery, checking
Idle speed (Diesel engine code AAZ): Checking
Headlight setting, checking
Road test, performing

1
Engine overview
Engines Gas engine
Code lettersAAA
Manufacturedfrom10.93
Number of cylinders / valves per cylinder6 / 2
DisplacementLiters2.8L
OutputkW @ RPM128/5800
TorqueNm @ RPM 235/4200 1)
Bore
mm
81.0
Strokemm90.3
Compression ratio10.0
Fuel injection / ignition systemMotronic M 2.9
RONat least95 unleaded
On Board Diagnostic (OBD)Yes
Catalytic converterYes
Oxygen sensor controlYes
Exhaust Gas Recirculation (EGR)No
Exhaust turbocharging systemNo
1) 240 Nm when using Super plus unleaded RON 98
)with catalytic converter, unleaded
Engines Gas engine
Code lettersABA
Manufacturedfrom03.95
Number of cylinders / valves per cylinder4/2
DisplacementLiters2.0L
Output
kW @ RPM
85@5400
TorqueNm @ RPM165@3200
Bore
mm
82.5
Strokemm92.8
Compression ratio9.4:1
Fuel injection / ignition systemMotronic MFI
RONat least 91 unleaded 1)
On Board Diagnostic (OBD)Yes
Catalytic converterYes *)
Oxygen sensor controlYes
Exhaust Gas Recirculation (EGR)Yes
Exhaust turbocharging systemNo
1) In exceptional cases, fuel with a RON of at least 91 may
be used, although engine performance will be diminished
Engines Diesel engineDiesel engine
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Code lettersAAZ1Z
Manufacturedfrom10.9310.93
Number of cylinders / valves per cylinder4 / 24 / 2
DisplacementLiters1.9L1.9L
OutputkW @ RPM55/440066/4000
TorqueNm @ RPM140/2200...2800202/1900
Bore
mm
79.579.5
Strokemm95.595.5
Compression ratio22.5:119.5:1
Fuel injection / ignition systemTurbo-DieselTDI
CNat least4949
On Board Diagnostic (OBD)NoYes
Catalytic converterYesYes
Oxygen sensor controlNoNo
Exhaust Gas Recirculation (EGR)YesYes
Exhaust turbocharging systemYesYes
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2
Oil change service
Oil change service every 10,000 miles
(15,000 Km)
Vehicles with a yearly mileage performance
greater than 10,000 miles (15,000 Km)
nsequence of individual service positions has been
tested and optimized. Therefore they should be
adhered to, to prevent unnecessary work
interruptions.
nWhen malfunctions are found within framework of an
oil change service, which require repair measures,
inform customer.
nAsk customer whether new wiper blades should be
fitted and whether theyrequire "Windshield Clear" G
052 164 (cleaner and anti-freeze) in windshield
washer system.
Work to be performed:page
- Dust and pollen filter: Replace filter element
01-5, Dust
and pollen filter
element,
replacing
(only TDI engines)
- Toothed belt: Check wear
01-5,
Toothed belt,
check wear
(TDI engines)
(Vehicles with Diesel engine, which use bio diesel conforming to specification
DIN E 51 606 - or use diesel, which does not conform to specification EN 590)
- Fuel filter: Drain water
01-5, Fuel
filter, draining
water (Diesel
engine)
- Engine oil: Drain, replace oil filter
01-
5, Engine
oil, changing
and replacing
oil filter
- Disc brake pads front and rear: Check thickness
01-5, Brake
pads front and
rear, checking
thickness
- Engine oil: Filling
01-
5, Engine
oil, changing
and replacing
oil filter
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-
Service sticker: Note date for next scheduled service (also
brake fluid change) on sticker and affix sticker to door beam
(B-pillar)
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3
Inspection service
Inspectionservice every 12 months
nAsk customer whether new wiper blades should be
installed and whether they require "Windshield Clear"
G 052 164 (cleaner and anti-freeze) in windshield
washer system.
nsequence of individual service positions has been
tested and optimized. Therefore they should be
adhered to, to prevent unnecessary work
interruptions.
nwork description sequence corresponds with
Inspection service work procedure, which is most
commonly performed service.
nWhen malfunctions are found within framework of an
inspection service, which require repair measures,
inform customer.
Work to be performedpage
Electronics
- Front lights - check function: Parking light, low beam, high
beam, fog lights, turn signals, emergency flashers
- Rear lights - check function: Brake light (also 3rd brake
light), tail light, back-up lights, fog light, license plate lights,
luggage compartment light, turn signals, emergency
flashers
- Interior and glove compartment lighting, cigarette lighter,
horn and warning lamps: Checking function
-
Airbag for driver and passenger: Perform a visual check of
airbag units for outer damage
01-
5, Driver's
and front passenger
airbags, visual check
of airbag units
- On Board Diagnostic (OBD): Check DTC memory of all
systems
01-5, On Board
Diagnostic (OBD),
checking DTC memory
of all systems
Vehicle exterior
- Door arrester and securing bolts: Lubricate
01-5, Door check
straps and securing
bolts, lubricate
- Windshield wiper/washer system and headlight cleaning 01-5, Windshield
wiper/washer system
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system: Check function and setting
and headlight cleaning
system, checking
function
- Windshield wiper blades: Check for damage; check rest
position; only for "juddering" wiper blades: Check pitch
angle
01-5, Windshield
wiper blades, check
park position and pitch
angle
Tires
- Spare wheel: Check condition, wear pattern, tread depth
_______ mm
01-5, Checking tire
condition, tread wear
pattern , filling
pressure and tread
depth
- Front left tire: Check condition, wear pattern, tread depth
_______ mm
01-5, Checking tire
condition, tread wear
pattern , filling
pressure and tread
depth
- Rear left tire: Check condition, wear pattern, tread depth
_______ mm
01-5, Checking tire
condition, tread wear
pattern , filling
pressure and tread
depth
- Rear right tire: Check condition, wear pattern, tread depth
_______ mm
01-5, Checking tire
condition, tread wear
pattern , filling
pressure and tread
depth
- Front right tire: Check condition, wear pattern, tread depth
_______ mm
01-5, Checking tire
condition, tread wear
pattern , filling
pressure and tread
depth
Vehicle from below
- Engine oil: Drain or extract; replace oil filter
01-5, Engine oil,
changing and
replacing oil filter
- Engine and components in engine compartment (from
below): Visual check for leaks and damage
01-5, Engine and
components in engine
compartment (from
above and below),
check for leaks and
damage
- Transmission, final drive and joint protective
bellows/boots: Visual check for leaks and damage
- Brake system: Visual check for leaks and damage
01-
5, Brake system,
visual inspection
- Brake pads front and rear: Checking thickness
01-5, Brake pads
front and rear,
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