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
Page
1
of
2
Engine overview
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.ME01.01.1

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
Page
2
of
2
Engine overview
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.ME01.01.1

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
Page
1
of
2
Oil change service
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.ME01.01.2

-
Service sticker: Note date for next scheduled service (also
brake fluid change) on sticker and affix sticker to door beam
(B-pillar)
Page
2
of
2
Oil change service
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.ME01.01.2

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
Page
1
of
5
Inspection service
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.ME01.01.3

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,
Page
2
of
5
Inspection service
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.ME01.01.3

checking thickness
- Exhaust system: Perform visual check for leaks, security
and damage
- Track rod ends: Check play, security and joint boots
01-5, Tie rod ends,
checking
- Ball joints: Perform visual check of swivel joint boots for
leaks and damage
01-5, Ball joints,
checking
Engine compartment
- Engine oil: Filling
01-5, Engine oil,
changing and
replacing oil filter
- Engine and components in engine compartment (from
above): Visual check for leaks and damage
01-5, Engine and
components in engine
compartment (from
above and below),
check for leaks and
damage
- Windshield wipe-/wash system: Top-up with fluid G 052
164
01-5, Check freeze
protection protection
content of windshield
wiper/washer system,
top off if necessary
Specification 13 F (-25 C) (in countries with arctic climate -31 F
(-35 C)) / actual value(measuredvalue): ____ F ( C)
- Cooling system: Checking freeze protection and coolant
level
01-5, Cooling
system anti-freeze
protection and coolant
level, checking
- 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)
(every 2 years or every 60,000 km - whichever occurs first)
- Air cleaner: Clean housing and replace filter element
(Diesel engine)
- Fuel filter: Drain water
01-5, Fuel filter,
draining water (Diesel
engine)
(every 2 years)
- Change brake fluid / additional work as a separate charge!
01-5, Brake fluid,
changing
- Brake fluid level (depending on brake pad wear):
Checking
01-5, Brake fluid
level, checking
Page
3
of
5
Inspection service
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.ME01.01.3

- Battery: Checking
01-5, Battery,
checking
(Vehicles with Diesel engine code AAZ, on which no emissions test has
been performed)
- Idle speed: Checking
01-5, Idle speed
(Diesel engine code
AAZ): Checking
Final work procedures
- Tire filling pressure at all 4 wheels and spare wheel:
Checking
01-5, Checking tire
condition, tread wear
pattern , filling
pressure and tread
depth
- Headlight setting: Checking
01-5, Headlight
setting, checking
-
Service sticker: Note date for next scheduled service (also
brake fluid change) and affix sticker to driver's-side door
beam (B-pillar)
- Road test vehicle
01-5, Road test,
performing
)Applicable only for countries where there are no country
specific mandatory exhaust emission regulations.
Inspectionservice every 20,000 miles
(30,000 km)
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.
nCheck First aid box storage life date has not been
exceeded. If this is case, ask customer whether First
Aid box should be replaced.
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.
Page
4
of
5
Inspection service
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.ME01.01.3

)Applicable only for countries where there are no country
specific mandatory exhaust emission regulations.
Page
5
of
5
Inspection service
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.ME01.01.3

4
GeneralInformation
Type plate
A
- Type plate
- Located on front lock carrier plate.
Vehicle IdentificationNumber (VIN)
B - Vehicle Identification Number (VIN)
-
It is stamped on rear engine compartment bulkhead and is
visible through a window in plenum chamber cover.
Meaning of Vehicle Identification Number (VIN):
WVWZZZ3AZRE or B000
001
Manufacturer's
mark
Filler
characters ModelFiller characters Model year 1994 Production location Serial
number
Engine codeandengine number
Page
1
of
6
General Information
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.ME01.01.4

Engine code and engine number can be found fastest on
sticker - arrow - on toothed belt guard (4-cyl.-engine) or on
left valve cover (6
-
cyl.
-
engine).
Vehicle, lifting
Caution!
nVehicle may only be lifted at points indicated in
illustration in order to avoid damaging vehicle
floor pan and to prevent vehicle from tipping.
nNever start engine and engage a gear with vehicle
lifted so long as evenone wheel has contact with
floor. There is a risk of an accident if this is not
observed!
n
If work is to be performed under vehicle it must be
supported by suitable stands.
Floor jack:
In order to prevent damage to vehicle underbody, a suitable
rubber or wood liner must be used.
Vehicle must never be lifted on engine oil pan,
transmission, rear axle, front axle or bottom sill. Serious
damage can occur.
Workshop hoist:
Before driving onto hoist, make sure weight of vehicle does
not exceed permissible hoist capacity.
Lift points for workshop hoists and floor jacks:
Front:
Page
2
of
6
General Information
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.ME01.01.4

At reinforcing plate welded to floor panel.
Position support so rear edge aligns with center of sill
depression.
Rear:
At reinforcing plate welded to floor panel.
Position support so rear edge aligns with center of sill
depression.
Caution!
Do not lift vehicle on vertical sill reinforcement or
damage to vehicle could result.
Tow starting/towing
A towing eyelet must be screwed into front right bumper
beforehand in order to be able to tow vehicle. towing eyelet
is supplied with vehicle tool kit.
- Using a screwdriver, pry out cover toward front and
remove.
- Screw in towing eyelet to stop and tighten using lug
Page
3
of
6
General Information
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.ME01.01.4

wrench.
- After use, unscrew towing eyelet and store with vehicle
tool kit. Re-install cover.
Rear towing eyelet is located at right in bumper and is
covered by a flap.
- To open flap, pull flap downward and let it hang freely.
- To close flap, first insert at bottom and press upward until
it engages.
Note
:
nTow-ropes or bars should be attached at above
mentioned points only.
nTow-rope should be able to stretch to reduce risk of
damage to both vehicles. It is advisable to use
synthetic fiber ropes or ropes of similar elastic
material only. However, it is safer to use a tow-bar!
nAvoid excessive towing effort and do not jerk. During
towing operationson unsurfaced roads there is
always a danger that attachment points will be
overstressed and damaged.
nBattery from another vehicle should be used for
starting if possible before trying to start an engine by
towing.
If vehicle has to be tow started or towed once
Note following:
nRegulations concerning towing must be observed.
nBoth drivers must be familiar with specifics of towing
procedures. Inexperienced drivers should not attempt
to tow start or tow.
nWhen using a tow rope driver of towing vehicle must
engage clutch very gently when driving off and
changing gear.
n
Driver of vehicle being towed must make sure that tow
rope is always tight.
nEmergency lights must be switched on both vehicles -
unless local regulations differ.
Page
4
of
6
General Information
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.ME01.01.4

nIgnition must be switched on so that steering wheel is
free and turn signals, horn and if necessary
windshield wiper and washer can be used.
nBecause brake booster only works when engine is
running, more pressure is required accordingly on
brake pedal when engine is not running.
nIn vehicles with Power Assisted Steering (PAS), more
force must be used to steer when engine is not
running.
nWhen there is no lubricant in a manual transmission
or automatic transmission, vehicle may only be towed
with driving wheels lifted.
Important notes concerning tow starting a vehicle:
It is generally recommended not to tow start vehicle.
Instead jump leads should be used.
Other reasons against tow starting a vehicle:
nDuring tow starting, riskof an accident occurring is
high, e.g. driving into vehicle towing.
nVehicles with gasoline engines can be damaged by
unburned fuel entering catalytic converter.
nTow starting vehicles with an automatic transmission
is for technical reasonsnot possible.
When tow starting vehicles withmanual transmission,
always note following:
Caution!
During tow starting, vehicles upto and including1.6L
displacement, risk of an accident occurringis high, e.g.
driving into towing vehicle . For this reason, a jump
lead should be used for these vehicles.
- Before tow starting, engage 2nd or 3rd gear.
- Switch ignition on .
- As soon as engine starts, depress clutch and shift into
neutral to avoid running into towing vehicle.
Note
:
n
For vehicles with catalytic converter (gasoline engines
only), engine with catalytic converter at operating
Page
5
of
6
General Information
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.ME01.01.4

temperature must not be tow started over a long
distance, otherwise unburned fuel reaches catalytic
converter and can be burned there. This may cause
catalytic converter to overheat.
When towing a vehicle with automatic transmission
following additional points must be observed:
nSelector lever in "N" position.
nDo not tow vehicle faster than 30 mph (50 km/h).
nDo not tow further than 30 miles (50 km).
nIf towing over greater distances, vehicle must be
suspended at front.
Reason: When engine is not running transmission oil pump
is not working and transmission is not adequately lubricated
for high speeds or long distances.
Using a breakdown vehicle, vehicle may only be towed
suspended at front.
Reason: If given a rear suspended tow, drive shafts turn
backward. planetary gears in automatic transmission then
turn at such high speeds that transmission will be severely
damaged in a short time.
Page
6
of
6
General Information
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.ME01.01.4

5
Work descriptions
Driver's and front passenger airbags, visual
checkof airbag units
You can see whether an airbag(s) is installed by inscription
"AIRBAG" on steering wheel padded panel (driver's side)
and on far side of dash panel (passenger side).
- Perform visual check of pad panel - 1 - and surface of
instrument panel, right side
-
2
-
for exterior damage.
Caution!
nSteering wheel padded panel surface must not
have stickers attached or be covered or be
otherwise modified. This ensures that future
function of airbag is guaranteed. Make sure
customer is aware of these instructions.
nSteering wheel padded panel must only be
cleaned with a dry cloth or a cloth moistened with
water.
On Board Diagnostic(OBD), checkingDTC
memoryof all systems
Interrogating DTC memory can be performed using one of
two methods:
nusing Scan Tool (ST) V.A.G 1551/ 01-5,
Interrogating DTC memory of all systems with scan
tool VAG 1551:
or the
nVehicle Diagnostic, Test and Information System
VAS
Page
1
of
83
Work descriptions
12/7/2004
http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.ME01.01.5