Engine Agz Repair Manual Eng

Service
Workshop Manual
Passat 1997 ➤
5-cylinder injection engine, mechanics
Engine ID AGZ
Edition 10.2012
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
20 - Fuel supply system
26 - Exhaust system
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.
Passat 1997 ➤
5-cylinder injection engine, mechanics - Edition 10.2012
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Notes on removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4 Additional information and assembly work for vehicles with air conditioner . . . . . . . . . . . . 10
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.1 Part I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3 Adjusting valve timing (installing timing chains) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4 Part II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.5 Part III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.6 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2 Removing and installing sealing flange and dual mass flywheel/drive plate . . . . . . . . . . . . 28
2.1 Renewing crankshaft oil seal, vibration damper end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.2 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.3 Removing and installing seal, flywheel end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.1 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.1 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.3 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2 Repairing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.1 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.2 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.3 Checking hydraulic bucket tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.4 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.5 Renewing valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.6 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1 Removing and installing parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1.1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.2 Dismantling and assembling oil filter housing/assembly mountings . . . . . . . . . . . . . . . . . . 67
1.3 Dismantling and assembling oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.4 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.5 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1.1 Parts of cooling system - body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Contents i
Passat 1997 ➤
1.2 Parts of cooling system - engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

1.3 Removing and installing compact bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.4 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.5 Dismantling and assembling thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1.6 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1.7 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.8 Removing and installing viscous fan coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.9 Removing and installing viscous fan bearing bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.10 Checking continued coolant circulation pump V51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.11 Checking radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.1 Removing and installing fuel tank with attachments and fuel filter, vehicles with four-wheel
drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.2 Removing and installing suction-jet pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.3 Removing and installing fuel tank with attachments and fuel filter, vehicles with front-wheel
drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.4 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.5 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.6 Crash fuel shut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.7 Removing and installing fuel delivery unit, vehicles with four-wheel drive . . . . . . . . . . . . . . 104
1.8 Removing and installing fuel delivery unit, vehicles with front-wheel drive . . . . . . . . . . . . 106
1.9 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.10 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.11 Repairing accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.12 Adjusting accelerator cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
1.13 Repairing parts of activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.14 Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1.1 Exhaust manifold, front exhaust pipe and catalytic converter with attachments, vehicles with
four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1.2 Exhaust manifold, front exhaust pipe and catalytic converter with attachments, vehicles with
front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
1.3 Silencers with mountings, vehicles with four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . 125
1.4 Silencers with mountings, vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2 Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
2.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
2.2 Removing and installing components of secondary air system . . . . . . . . . . . . . . . . . . . . . . 129
2.3 Checking combination valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
2.4 Removing and installing combination valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
ii Contents
Passat 1997 ➤
00 – Technical data
1 Technical data
(VRL005198; Edition 10.2012)
⇒ “1.1 Engine number”, page 1
⇒ “1.2 Engine data”, page 1
1.1 Engine number

The engine number (“engine code” (three characters) and “serial
number” (max. six characters)) is located next to the cylinder head
on the cylinder block. You can see it if you look down in between
the heater element for crankcase breather N79 and the throttle
valve module.
Additionally there is a sticker on the cylinder head cover with “en‐
gine code” and “serial number”.
The engine code is also included on the vehicle data sticker.
In vehicle models as of 2000 ►, the engine number (“engine code”

and “serial number”) -arrow- is located next to the vibration damp‐
er on the cylinder block. If more than 999,999 engines with the
same engine code are produced, the first of the six characters is
replaced with a letter.
Additionally, a sticker with “engine code” and “serial number” is
attached to the intake manifold.
1.2 Engine data

Engine codes AGZ
Manufactured 10.96 ►
Emissions fulfil D3 standard
Cylinder arrangement VR1)
Cylinder angle 15°
Capacity l 2.3
Output kW at rpm 110/6000
Torque Nm at rpm 205/3200
Bore ∅ mm 81.0
Stroke mm 90.2
Compression ratio 10.0
Volkswagen Technical Site: https://vwts.ru
1. Technical data 1
Passat 1997 ➤
1) VR = V-arrangement in compact in-line design
Engine codes AGZ

RON min. 95 unleaded2)
Injection system Motronic M3.8.3
Ignition system Motronic M3.8.3
Firing order 1-2-4-5-3
Knock control yes
Self-diagnosis yes
Lambda control yes
Catalytic converter yes
Exhaust gas recirculation no
Secondary air system yes
Turbocharging/supercharging no
2) In exceptional circumstances min. 91 RON, however with reduced perform‐

ance.
2 Rep. gr.00 - Technical data

Passat 1997 ➤
10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Notes on removing”, page 3
⇒ “1.2 Notes on installing”, page 8
⇒ “1.3 Assembly mountings”, page 10
⇒ “1.4 Additional information and assembly work for vehicles with
air conditioner”, page 10
1.1 Notes on removing
Special tools and workshop

equipment required
♦ Gearbox support 3147
♦ Engine bracket 3269
♦ Lifting tackle 2024 A
♦ Support bracket 10 - 222 A
with rack 10 - 222 A /1
♦ Support clamp -VW 313-
♦ Workshop hoist -
V.A.G 1202 A-
♦ Drip tray -V.A.G 1306-
1. Removing and installing engine 3

Passat 1997 ➤
♦ -V.A.G 1331- Torque

wrench (5…50 Nm)
wrench (40…200 Nm)
♦ Hose clip pliers -
V.A.G 1921-
♦ G 000 100 grease (vehicles
with manual gearbox)
♦ Cable ties
Procedure
– First check whether a coded radio is fitted. If so, obtain anti-
theft coding.
– The engine is removed forwards without gearbox.
– With ignition switched off, disconnect earth strap from battery.
– All cable ties which are opened or cut through when engine is
removed must be replaced in the same position when engine
is installed.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation; Assembly overview - noise in‐
sulation .
– Remove front bumper ⇒ General body repairs, exterior; Rep.
gr. 63 ; Front bumper .
– Pull connectors off horns.
4 Rep. gr.10 - Removing and installing engine

Passat 1997 ➤
– Disconnect connectors for headlights and headlight height ad‐

justment mechanism -arrows- on left and right.
– Disconnect connectors ahead of ABS unit -arrows-.
– Unbolt hydraulic oil cooling pipe of power-assisted steering

-arrows- and place to one side. Do not open hydraulic oil cir‐
cuit.
– Drain coolant ⇒ page 82 .
– Unbolt cooling system expansion tank and lay to side.
– Remove lock carrier with attachments ⇒ General body re‐
pairs, exterior; Rep. gr. 50 ; Lock carrier .
– Remove air filter ⇒ Rep. gr. 24 ; Repairing injection; Disman‐
tling and assembling air filter .
– Remove poly V-belt ⇒ page 26 .
– Remove power-assisted steering vane pump from compact
bracket and place to one side; hoses remain connected ⇒
Running gear, axles, steering; Front and four-wheel drive;
Rep. gr. 48 ; Vane pump, reservoir, hydraulic lines for vehicles
with 4 or 5-cylinder engines; Removing and installing vane
pump, vehicles with 4 or 5-cylinder engines .
Vehicles with air conditioner
– Observe additional information and installation work
⇒ page 10 .
Continuation for all vehicles
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter -B-;
Removing and installing starter on vehicles with 4, 5 and 6-
cylinder engines .
– Unbolt front exhaust pipe from exhaust manifold.

Passat 1997 ➤
– Detach accelerator cable from cable disc of throttle valve con‐

trol module and from cable support bracket -arrows- (do not
remove locating clip on cable support bracket).
WARNING
Fuel supply lines are under pressure! Before loosening hose

connections, wrap a cloth around the connection. Then release
pressure by carefully pulling hose off connection.
– Disconnect fuel supply and fuel return lines at fuel rail.

– Remove inter-connecting, coolant, vacuum and intake hoses
on engine.
– Disconnect connectors on following components: air mass
meter -G70- , solenoid valve -N80- for activated charcoal filter
system, variable intake manifold changeover valve -N156- ,
Hall sender -G40- , throttle valve module -J338- , injectors ( -
N30- ... N33, N83), output stage for ignition coils -N122- ,
coolant temperature sender -G62- , intake manifold tempera‐
ture sender -G72- . For information on fitting locations, refer to
⇒ Rep. gr. 24 ; Repairing injection system; Overview of fitting
locations .
– Disconnect following connectors: 1 - Lambda probe 1 -G39- ,

black; 2 - knock sensor 1 -G61- , green; 3 - knock sensor 2 -
G66- , blue; 4 - engine speed sender -G28- , grey.
– Pull off or disconnect all other electrical connections as nec‐
essary from engine and lay to side.
– Remove lower securing nuts for left and right engine mount‐
ings.
– Loosen gearbox mounting securing nuts as far as possible, do
not remove.
– Fit support bracket 10-222A as shown and lift engine until low‐
er engine/gearbox connecting bolts can be removed.
– Remove lower engine/gearbox securing bolts.
– Carefully lower engine again.

Passat 1997 ➤
Note
The pin in the engine mounting -arrow- must engage in the sub-
frame when lowering the engine.
– Remove upper engine/gearbox securing bolts.

Vehicles with automatic gearbox
– Separate torque converter from drive plate (3 securing nuts).
Note
After removing the engine, secure the torque converter against

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

– Attach gearbox support 3147 to bolt hole in gearbox housing
(shown in illustration with engine removed).

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

workshop hoist -V.A.G 1202 A- :
Belt pulley end: 4th hole in hook rail at position 1
Flywheel end: 4th hole in hook rail at position 8
WARNING
Use locking pins -arrows- to secure hooks and locating pins.
Note
♦ The positions marked 1…4 on the bar must be towards the

pulley end.
♦ The holes in the hook rails are counted up from the hook.
– Lift engine out forwards.
Note
Guide the engine carefully when lifting out, to prevent damage to

the bodywork.
When carrying out repair work, the engine must be secured to the
assembly stand with engine bracket 3269.
1.2 Notes on installing

Procedure
Install in reverse order. In the process, note the following:
Vehicles with manual gearbox
– Check clutch release bearing for wear and renew if necessary.
– Lightly grease clutch release bearing and splines on input
shaft with G 000 100 grease (do not grease release bearing
guide sleeve).
– Check whether dowel sleeves for centring engine and gearbox
are in cylinder block and install if necessary.
– Rock engine to align engine mountings stress-free.

Passat 1997 ➤
– Renew engine mounting self-locking nut -1-.
Note
♦ The pin in the engine mounting -2- must engage in the sub-
frame when lowering the engine.
♦ Specified torques for engine and gearbox mountings
⇒ page 10 .
– Install engine/gearbox connecting bolts.

– Tighten gearbox mounting securing nuts. Specified torque
40 Nm.
– Install front exhaust pipe.
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter -B-;
Removing and installing starter on vehicles with 4, 5 and 6-
cylinder engines .
– Install air conditioner compressor ⇒ Heating, air conditioning;
Rep. gr. 87 ; Bracket for air conditioner compressor; Remov‐
ing and installing bracket for air conditioner compressor, en‐
gine codes AGZ and AZX .
– Install power-assisted steering vane pump ⇒ Running gear,
axles, steering; Front and four-wheel drive; Rep. gr. 48 ; Vane
pump, reservoir, hydraulic lines for vehicles with 4 or 5-cylin‐
der engines; Removing and installing vane pump, vehicles
with 4- or 5-cylinder engines .
– Install poly V-belt ⇒ page 26 .
– Install air filter ⇒ Rep. gr. 24 ; Repairing injection system;
Dismantling and assembling air filter .
– Install lock carrier with attachments ⇒ General body repairs,
exterior; Rep. gr. 50 ; Lock carrier .
– Adjust throttle cable ⇒ page 116 , Repairing accelerator
mechanism.
– Install coolant expansion tank.
– Replenish coolant ⇒ page 82 .
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
– Check headlight adjustment and correct if necessary ⇒ Main‐
tenance ; Booklet .
– Carry out road test and read all fault memory ⇒ Motronic in‐
jection and ignition system (5-cyl. engine); Rep. gr. 01 ; Self-
diagnosis; Reading and clearing fault memory .
– Adapt engine control unit to throttle valve module ⇒ Rep. gr.
24 ; Renewing, coding and adapting engine control unit;
Adapting engine control unit to throttle valve module .

Passat 1997 ➤
Specified torques
Threaded connection Specified torque
Bolts, nuts M6 10 Nm
M8 20 Nm
M10 45 Nm
M12 60 Nm
Deviations
Starter to gearbox 65 Nm
1.3 Assembly mountings

Specified torques
Front assembly mountings
A = 60 Nm
B = 25 Nm
Rear right assembly mountings

A = 25 Nm
1.4 Additional information and assembly

work for vehicles with air conditioner
WARNING
The air conditioner refrigerant circuit must not be opened.
Note
To prevent damage to condenser and also to refrigerant lines/

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

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

Passat 1997 ➤
– Remove air conditioner compressor ⇒ Heating, air condition‐

ing; Rep. gr. 87 ; Bracket for air conditioner compressor;
Removing and installing bracket for air conditioner compres‐
sor, engine codes AGZ and AZX .
– Secure air conditioner compressor to body so that the refrig‐
erant lines are not under tension.

Passat 1997 ➤
13 – Crankshaft group
1 Dismantling and assembling engine
Note
12 Rep. gr.13 - Crankshaft group

Passat 1997 ➤
Note
♦ Use the assembly tool -T10029- only, to pull off and push on
the spark plug connectors.
♦ If when repairing an engine, metal shavings or large quantities
of small metal particles caused, for example, by partial seizure
of crankshaft and conrod bearings are found in the engine oil,
one must apart from thoroughly cleaning oil passages, renew
all oil spray jets, the oil non-return valve, and the oil cooler to
prevent consequential damage.
I ⇒ page 13
II ⇒ page 22
III ⇒ page 24
1.1 Part I
1 - Camshaft chain sprocket

❑ For roller chain
⇒ Item 9 (page 14)
❑ Removing and installing
⇒ page 57 Removing
and installing cam‐
shafts.
2 - Sender wheel
❑ For Hall sender -G40- .
shafts.
3 - 100 Nm
❑ Lubricate contact sur‐
face of bolt head when
fitting
❑ To remove and install,
counterhold using 24
mm open-end spanner
on camshaft
⇒ page 57 , Removing
shafts.
4 - Pivot pin, 18 Nm
❑ For tensioning plate
⇒ Item 7 (page 14)
5 - Seal
❑ Renew if damaged or
leaking.
6 - Chain tensioner, 40 Nm
❑ For camshaft drive
chain, item Volkswagen Technical Site: https://vwts.ru
1. Dismantling and assembling engine 13

Passat 1997 ➤
⇒ Item 9 (page 14) .

❑ Only rotate engine when chain tensioner is installed.
7 - Tensioning plate
❑ For camshaft drive chain, item ⇒ Item 9 (page 14) .
8 - Chain sprocket
❑ For roller chain ⇒ Item 15 (page 14)
❑ Installing ⇒ page 16 Adjusting valve timing.
9 - Camshaft timing chain
❑ Before removing, mark direction of rotation (installation position) ⇒ page 22 .
10 - 100 Nm
❑ Use counter-hold tool 3406 to loosen and tighten ⇒ page 16 , Adjusting valve timing.
11 - Chain sprocket
12 - 10 Nm
13 - Chain tensioner with tensioning plate
❑ Before installing, release locking splines in chain tensioner using a small screwdriver and press tension‐
ing plate against chain tensioner.
14 - Drive sprocket
❑ Built into crankshaft.
❑ Ground down tooth aligned with main bearing joint = TDC No. 1 cylinder ⇒ page 16 , Adjusting valve
timing.
15 - Roller chain
❑ Before removing, mark direction of rotation (installation position) ⇒ page 22 .
16 - Guide rail
❑ Remove together with roller chain ⇒ page 16 , Adjusting valve timing.
17 - Locating pin without collar, 10 Nm
❑ For guide rail ⇒ Item 16 (page 14)
18 - Locating pin with collar, 10 Nm
❑ For guide rail ⇒ Item 21 (page 14)
19 - 20 Nm
❑ Insert with locking fluid “D6”.
20 - 20 Nm
21 - Guide rail
22 - 10 Nm
❑ Insert with locking fluid “D6”.
23 - Thrust washer
24 - Intermediate shaft

Passat 1997 ➤
1.2 Checking valve timing

Special tools and workshop equipment required
♦ Camshaft bar 3268
♦ Assembly tool -T10029-
Test procedure
sulation .
– Remove cylinder head cover ⇒ page 44 .
– Set crankshaft to TDC No. 1 cylinder marking -arrow- by turn‐
ing crankshaft on the vibration damper securing bolt in direc‐
tion of engine rotation.

Passat 1997 ➤
If the TDC No. 1 Cyl. setting is correct it is possible to see a notch

on the intermediate shaft chain sprockets -arrow-.
Note
This condition is only achieved every 2nd complete rotation of

crankshaft.
If the groove cannot be seen:

– Turn crankshaft one full turn further in direction of engine ro‐
tation.
– It must be possible to insert camshaft bar 3268 into the groove

in the long camshaft and the camshaft bar must be flush with
the shoulder on the short camshaft.
1.3 Adjusting valve timing (installing timing chains)

Passat 1997 ➤

equipment required
♦ Counter-hold tool 3406
wrench (5…50 Nm)
⇒ “1.3.1 Engine removed”, page 17

⇒ “1.3.2 Engine installed, cylinder head removed”, page 20
1.3.1 Engine removed

Installing roller chain and chain tensioner with tensioning plate:

Passat 1997 ➤
– Check or adjust the crankshaft position relative to the inter‐

mediate shaft. The ground down tooth of drive sprocket -B-
must be flush with bearing joint (no. 1 cylinder at TDC
position).
– Install pin without collar for guide rail -2- and tighten it to 10
Nm.
– Install guide rail -2- with roller chain -1- and both chain sprock‐
ets -3- and -4-. Observe direction of rotation of roller chain
⇒ page 22 . Marking on roller chain sprocket -4- must align
with notch -C- or -D- on thrust washer.
– Disengage locking teeth in chain tensioner using a small
screwdriver -A-.
– Push guide rail against chain tensioner and tighten chain ten‐
sioner to 10 Nm.
– Lock vibration damper in place using counter-hold tool 3406.

Passat 1997 ➤
– Tighten chain sprockets 3 and 4 for intermediate shaft to 100

Nm.
– Remove counter-hold tool 3406.
– Check position of crankshaft relative to intermediate shaft. The
ground down tooth of drive sprocket -B- must be flush with
bearing joint (no. 1 cylinder at TDC position).
Installing camshaft timing chain and chain tensioner with tension‐
ing plate:
– Set both camshafts to TDC position for no. 1 cylinder.

– Install pivot pin for tensioning plate and tighten it to 18 Nm.
– Install tensioning plate for chain tensioner (camshaft timing
chain).
– Install pivot pin with collar for guide rail and tighten it to 10 Nm.
Note
♦ With cylinder head removed:

♦ Install cylinder head ⇒ page 46 , Removing and installing
cylinder head.
– Fit guide rail onto pivot pin. Insert short securing bolt with lock‐
ing fluid “D6” and tighten both bolts to 20 Nm.
– Fit camshaft timing chain onto intermediate shaft (observe di‐

rection of rotation).
– Install camshaft chain sprocket and roller chain to camshaft
for cylinders 1, 3 and 5 (long camshaft) and tighten by hand.
– Install camshaft chain sprocket (with sender wheel for Hall
sender) and camshaft timing chain to camshaft for cylinders 2
and 4 and tighten by hand.
Note
Lubricate contact surfaces of bolt heads when fitting.
– Remove camshaft bar 3268.

– Tighten securing bolts for camshaft chain sprockets to 100
Nm.

Passat 1997 ➤
Note
Only counterhold at camshaft with 24 mm open-end spanner

-arrow-. The camshaft bar 3268 must not be fitted when sprockets
are being loosened or tightened.
– Coat sealing surface of sealing flange with AMV 188 001 02

and install it. Tighten securing bolt to 10 Nm.
– Renew seal for sealing flange ⇒ page 28 ; Removing and
installing sealing flanges and dual mass flywheel/drive plate.
– Prepare cylinder head gasket for assembly ⇒ page 44 .
– Coat sealing surface of cover with AMV 188 001 02.
– Lubricate O-ring for oil channel seal and insert it into cover.
– Install cover, insert all securing bolts and tighten gently.
– First tighten M8 securing bolts to 25 Nm and then tighten M6
securing bolts to 10 Nm.
– Install chain tensioner for camshaft timing chain and tighten to
40 Nm.
Note
Only rotate engine when chain tensioner is installed. Otherwise

the camshaft timing chain will jump.
– Turn crankshaft two full turns in direction of engine rotation

and check valve timing ⇒ page 15 .
1.3.2 Engine installed, cylinder head removed

– Set crankshaft to TDC No. 1 cylinder marks -arrow- by turning
crankshaft on the vibration damper securing bolt in direction
of engine rotation:
If the TDC No. 1 Cyl. setting is correct it is possible to see a notch

on the intermediate shaft chain sprockets -arrow-.
If the groove cannot be seen:
– Turn crankshaft once in direction of engine rotation.
Note
If the crankshaft is rotated with cylinder head removed, a second

mechanic must guide the camshaft timing chain by hand to pre‐
vent it from being trapped.
– Set both camshafts to TDC position for no. 1 cylinder.

Passat 1997 ➤

– Prepare cylinder head gasket for assembly ⇒ page 44 .
– Installing cylinder head ⇒ page 46 .
– Fit guide rail onto pivot pin. Insert short securing bolt with lock‐
ing fluid “D6” and tighten both bolts to 20 Nm.
– Install camshaft chain sprocket with camshaft timing chain to
camshaft for cylinders 1, 3 and 5 (long camshaft) and tighten
by hand.
– Install camshaft chain sprocket (with sender wheel for Hall
sender) and camshaft timing chain to camshaft for cylinders 2
and 4 and tighten by hand.
Note
Lubricate contact surfaces of bolt heads when fitting.
– Remove camshaft bar 3268.

– Tighten securing bolts for camshaft chain sprockets to 100
Nm.
Note

– Coat sealing surface of cover with AMV 188 001 02.

– Lubricate O-ring for oil channel seal and insert it into cover.
– Install cover, insert all securing bolts and tighten gently.
40 Nm.
Note
Only rotate engine when chain tensioner is installed. Otherwise

the camshaft timing chain will jump.
– Turn crankshaft two full turns in direction of engine rotation

and check valve timing ⇒ page 15 .

Passat 1997 ➤
Marking timing chains

– Mark roller chains before removing (e.g. with paint, arrow
pointing in direction of rotation).
Note
Do not mark chain by way of centre punch, notch or the like.
1.4 Part II
1 - Upper part of intake mani‐

fold
❑ Dismantling and assem‐
bling ⇒ Rep. gr. 24 ;
Repairing injection sys‐
tem; Dismantling and
assembling upper part
and lower part of intake
manifold .
bling, plastic variable in‐
take manifold ⇒ Rep.
gr. 24 ; Repairing injec‐
tion system; Disman‐
tling and assembling up‐
per part and lower part
of intake manifold, plas‐
tic variable intake mani‐
fold .
2 - Throttle valve module -
J338-
❑ Heated by coolant.
⇒ Rep. gr. 24 ; Repair‐
ing injection system;
Dismantling and assem‐
bling upper part and
lower part of intake
manifold .
❑ Removing and instal‐
ling, plastic variable in‐

Passat 1997 ➤
fold .
3 - 10 Nm
4 - Cap
5 - Cylinder head cover
❑ Removing and installing ⇒ page 44 .
❑ Renew if damaged or leaking.
6 - Bracket
7 - Cylinder head bolt
❑ Renew.
❑ Follow installation instructions and sequence when loosening and tightening ⇒ page 46 .
8 - Cylinder head
❑ After renewing, renew entire coolant.
9 - Cover
❑ Can be removed and installed with cylinder head fitted.
❑ Coat sealing surfaces with AMV 188 001 02.
❑ If only cover has been removed, prepare cylinder head gasket for assembly ⇒ page 44 ,
⇒ page 44 .
❑ For camshaft timing chain
11 - Continued coolant circulation pump -V51-
❑ Checking ⇒ page 92 .
12 - Seal
❑ Renew.
13 - Ignition coil N, N128, N158, N163, N164
❑ Checking: ⇒ Rep. gr. 28 ; Repairing ignition system; Checking ignition coils with output stage .
14 - 25 Nm
15 - Thermostat housing
❑ Dismantling and assembling ⇒ page 80 .
16 - Cylinder head gasket
❑ Renew.
17 - Lower part of intake manifold
18 - Gasket for lower part of intake manifold
❑ Renew.
❑ Plastic variable intake manifold has individual seals. Renew these only if damaged.
19 - Variable intake manifold changeover valve -N156-
❑ Checking: ⇒ Motronic injection and ignition system (5-cyl. engine); Rep. gr. 01 ; Self-diagnosis; Reading
and clearing fault memory .
20 - Vacuum actuator
❑ For variable intake manifold changeover valve.

Passat 1997 ➤
1.5 Part III
1 - 10 Nm
2 - Oil pump drive cover
3 - O-ring
❑ Renew.
❑ Lubricate before instal‐
ling.
4 - Oil pump drive
5 - Cylinder block
sealing flanges and fly‐
wheel/drive plate
⇒ page 28 .
crankshaft
⇒ page 35 .
bling pistons and con‐
rods ⇒ page 37 .
7 - Thrust washer
8 - 10 Nm
❑ Insert with locking fluid
“D6”.
9 - Knock sensor 2 -G66-
❑ Checking: ⇒ Motronic
injection and ignition
system (5-cyl. engine);
Rep. gr. 01 ; Self-diag‐
nosis; Reading and

Passat 1997 ➤
clearing fault memory .

10 - 20 Nm
❑ The torque setting influ‐
ences the function of the knock sensor.
11 - Engine speed sender -G28-
12 - Coolant pipe
❑ To thermostat housing ⇒ Item 15 (page 23) .
13 - Drive shaft
❑ For oil pump drive.
14 - Oil pump
❑ Coat oil pressure pipe on cylinder block and oil pump housing with AMV 188 001 02
15 - 25 Nm
16 - 20 Nm + 1/4 turn (90°) further
❑ Renew.
17 - Torque reaction support
18 - Oil pan
19 - Oil drain plug, 20 Nm
20 - Seal
❑ Renew.
21 - 12 Nm
22 - Oil filter housing/assembly carrier
23 - Oil cooler
❑ Coat contact area outside the seal with AMV 188 001 02.
❑ Ensure clearance to adjacent components.
❑ See note ⇒ page 12 .
24 - Fitting bolt, 25 Nm
25 - Compact bracket
❑ For coolant pump, thermostat, poly V-belt tensioning roller, alternator and and power-assisted steering
vane pump.
26 - Vibration damper
❑ Removing and installing poly V-belt ⇒ page 26 .
27 - 100 Nm + 1/4 turn (90°) further
❑ Renew.
❑ Use counter-hold tool 3406 to loosen and tighten ⇒ page 26 .
28 - Guide tube
❑ For dipstick.
❑ Secured with bolt to intake manifold.
29 - Dipstick
❑ The oil level must not be above the max. mark!
30 - Oil non-return valve, 5 Nm
❑ Note installation position.

Passat 1997 ➤
❑ Clean if badly soiled
To loosen and tighten securing bolt, secure vibration damper us‐

ing counter-hold tool.
Note
♦ Renew securing bolt for vibration damper.

♦ With the introduction of the VR5 engine the counterhold -3406-
must be modified. The hole must be handled with corrosion
protection. The counter-hold tool -T10069- can also be used.
♦ If not already modified, drill an 18 mm hole parallel to the ex‐
isting hole.

♦ Counterhold 3406
♦ Torque wrench -V.A.G 1601- (150…800 Nm)
♦ Socket AF 27, 3/4” drive (commercially available)
1.6 Removing and installing poly V-belt

♦ Socket AF 15, 1/2” drive (commercially available)
Removing poly V-belt
– Move lock carrier to service position ⇒ General body repairs,
– Mark direction of rotation of poly V-belt.
– Remove radiator fan from viscous fan coupling.

Passat 1997 ➤
– Turn tensioning roller anticlockwise with a socket wrench

-arrow- until poly V-belt tension is relieved.
– Remove poly V-belt.
Installing poly V-belt
– Install in reverse order.
Note
♦ Before installing the poly V-belt, ensure that all ancillaries (al‐
ternator, air conditioner compressor, vane pump, coolant
pump) are securely mounted.
♦ When installing belt ensure it is correctly seated in pulleys.
– Fit poly V-belt.

After completing repairs always:
– Start engine and check that belt runs properly.

Passat 1997 ➤
2 Removing and installing sealing

flange and dual mass flywheel/drive
plate
Note
♦ Repairing clutch ⇒ Rep. gr. 30 ; Repairing clutch .

♦ When carrying out repair work, the engine must be secured to
the assembly stand with engine bracket 3269.
1 - 100 Nm + 1/4 turn (90°) fur‐

ther
❑ Renew.
❑ To loosen or tighten,
use counter-hold tool
⇒ page 29 , Renewing
crankshaft oil seal, vi‐
bration damper end.
2 - Vibration damper
3 - 10 Nm
4 - Seal
❑ Renew. ⇒ page 29 .
5 - Sealing flange
❑ Coat sealing surface
with AMV 188 001 02.
6 - Cylinder block
crankshaft
⇒ page 35 .
bling pistons and con‐
rods ⇒ page 37 .
7 - Sealing flange
❑ Coat sealing surfaces
with AMV 188 001 02.
8 - Seal
❑ Remove using extractor
hook -T20143/2- .
❑ Only for seals with gar‐
ter spring: lubricate

Passat 1997 ➤
sealing lip.
❑ PTFE oil seal:
❑ Removing and installing seal ⇒ page 32 .
❑ Identification: Without inner coil spring.
❑ Do not additionally oil or grease the oil seal sealing lip.
❑ Before installing, remove oil residue from crankshaft journal using a clean cloth.
9 - Intermediate plate
❑ For mounting gearbox
❑ When installing, first bolt to cylinder block, and only fit oil pan afterwards.
10 - 60 Nm + 1/2 turn (180°) further
❑ Renew.
11 - Dual mass flywheel/drive plate
❑ Removing and installing drive plate ⇒ page 31 .
12 - M10 - 45 Nm, M12 - 65 Nm
13 - 25 Nm
2.1 Renewing crankshaft oil seal, vibration damper end

equipment required
♦ Puller hooks -T20143/1-
♦ Counter-hold tool -T10069-
or counter-hold tool -3406-
♦ Socket -T10215-
♦ Torque wrench -V.A.G
1601-
♦ Torque wrench -V.A.G
1332-
2. Removing and installing sealing flange and dual mass flywheel/drive plate 29
Passat 1997 ➤
Note

isting hole.
Removing
– Remove vibration damper. To do this, lock vibration damper

in place using counter-hold tool 3406.
– Fit puller hooks -T20143/1- behind sealing lip of oil seal as
shown in illustration.
– Support puller hook -T20143/1- on sealing flange and lever

seal out in direction of -arrow-.
Installing
– Remove oil residue from crankshaft journal using clean cloth.
– Push guide sleeve -T10215/1- -1- at front onto crankshaft jour‐
nal.
– Now slide oil seal -2- carefully over guide sleeve as far as it
will go.
– Press oil seal in as far as stop with fitting sleeve -T10215/2-

-3-. To do this, use an old vibration damper securing bolt -4-.

Passat 1997 ➤
– Install vibration damper and lock it in place with counter-hold

tool 3406.
– Tighten new securing bolt to 100 Nm and turn 90° (1/4 turn)
further.
2.2 Removing and installing drive plate

equipment required
♦ Counterhold -3406-
♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-
♦ Depth gauge
♦ Straight edge
Passat 1997 ➤
Note

isting hole.
Removing
– Lock vibration damper in place using counter-hold tool 3406.

– Loosen drive plate securing bolts diagonally and remove.
Note
A 15 mm spacer is installed between drive plate and crankshaft.
– Remove drive plate.

Installing
– Position drive plate and spacer on crankshaft.
– Insert at least 3 old securing bolts and tighten to 30 Nm.
– Check dimension -a- to intermediate plate through 3 holes for

torque converter attachment using a straight edge and depth
gauge, and calculate average.
– Compare average with specification (measured distance +
thickness of straight edge). Specification: 18.1 ... 19.7 mm
If specification is not attained:
– Remove drive plate again and fit appropriate shim -1-.
Note
Only one shim of the appropriate thickness may be used.
When specification is attained:

– Insert new securing bolts and tighten by hand.
– Tighten securing bolts to 60 Nm and turn 180° (1/2 turn) further
(turning further can be done in several stages).
2.3 Removing and installing seal, flywheel

end

Passat 1997 ➤
♦ Fitting tool -T10122-
♦ Puller hooks -T20143-
Removing oil seal at flywheel end

– Fit puller hooks -T20143/2- behind sealing lip of oil seal as
– Support puller hook -T20143/2- on sealing flange and lever
seal out in direction of -arrow-.
Installing oil seal at flywheel end
Passat 1997 ➤
– Pull oil seal -A- by the outside over the sleeve -T10122/1- onto
pulling sleeve -T10122/2- .
– Separate the two fitting sleeves.
– Then set pulling sleeve -T10122/2- with dry oil seal onto crank‐
shaft journal.
– Now drive it into sealing flange to stop using thrust piece -

T10122/3- .

Passat 1997 ➤
3 Removing and installing crankshaft
Note
♦ Before removing crankshaft, ensure that a suitable surface for

storing crankshaft is prepared to ensure that sender wheel
(item ⇒ Item 6 (page 36) ) is not damaged or lies against any
other item.
♦ When carrying out repair work, the engine must be secured to
the assembly stand with engine bracket 3269.
1 - Bearing cap
❑ Bearing cap 1: vibration
damper end
❑ Bearing cap 4 with re‐
cesses for thrust wash‐
ers.
❑ Bearing shell retaining
lugs in cylinder block
and bearing caps must
align.
2 - 30 Nm + 1/2 turn (180°) fur‐
ther
❑ Renew.
❑ 2 x 90° further is permit‐
ted.
3 - Bearing shells 1… 6
❑ For bearing cap without
oil groove.
❑ For cylinder block with
oil groove.
❑ Do not interchange
used bearing shells
(mark).
4 - Thrust washer
❑ For bearing cap 4.
❑ Note fixing arrange‐
ment.
5 - Crankshaft
❑ Axial clearance new:
0.07…0.23 mm, wear
limit: 0.30 mm
❑ Check radial clearance
with Plastigage new:
3. Removing and installing crankshaft 35

Passat 1997 ➤
0.02…0.06 mm, wear

limit: 0.10 mm
❑ Do not rotate crankshaft when checking radial clearance.
❑ Crankshaft dimensions: crankshaft bearing: 59.958 ... 59.978 mm, conrod bearing 53.958 ... 53.978 mm,
reworking is not permitted.
❑ If renewed, use bearing shell marked yellow.
6 - Sender wheel
❑ For engine speed sender -G28- .
❑ Renew.
❑ Installing ⇒ page 36 .
7 - 10 Nm + 1/4 turn (90°) further
❑ Renew.
8 - Oil spray jet
❑ For crankshaft bearings 2…6
❑ For piston cooling.
❑ Opening pressure: 2.0 bar
Fitting sender wheel to crankshaft

Ensure that contact surfaces of crankshaft and sender wheel are
free of oil and grease.
– For additional hold apply a thin coat of locking fluid D 000 600
to backside of sender wheel.
– Ensure during installation that -VR5- marking -arrow- is
aligned with correct threaded hole.
– Initially, tighten all securing bolts slightly by hand. Then, pro‐
ceed as described under ⇒ Item 7 (page 36) and

Passat 1997 ➤
4 Dismantling and assembling pistons

and conrods
Note
1 - Piston rings
❑ Offset gaps by 120°.
❑ Use piston ring pliers to
remove and install.
❑ “TOP” faces towards
piston crown.
❑ Checking ring gap
⇒ page 38 .
❑ Checking ring-to-groove
clearance ⇒ page 39 .
2 - Piston
❑ Mark cylinder number
and installation position
relative to conrod.
❑ High point of piston
crown faces to centre of
cylinder block.
❑ Install with funnel 3278
⇒ page 40 .
3 - Conrod
❑ Renew as set only.
❑ Mark cylinder number
-B-.
❑ Installation position:
marks -A- must be
above one another.
4 - Conrod bearing cap
❑ Note installation posi‐
4. Dismantling and assembling pistons and conrods 37

Passat 1997 ➤
tion.
5 - 30 Nm + 1/4 turn (90°) further
❑ Renew.
❑ Oil threads and contact surface.
❑ To measure radial clearance, tighten to 30 Nm but not further.
6 - Bearing shell
❑ Do not interchange used bearing shells.
❑ The lugs on bearing shells must fit tightly in the recesses.
❑ Axial clearance new: 0.05…0.31 mm, wear limit: 0.40 mm
❑ Check radial clearance with Plastigage: new: 0.02…0.07 mm, wear limit: 0.10 mm. Do not rotate crank‐
shaft when checking radial clearance.
7 - Cylinder block
❑ Checking cylinder bores ⇒ page 40 .
❑ Piston and cylinder dimensions ⇒ page 41 .
8 - Piston pin
❑ If difficult to remove, heat piston to 60 °C.
❑ Remove and install using drift -VW 222 A- .
9 - Circlip
Checking piston ring gap

♦ Feeler gauges
Test procedure
– Push ring at right angles from above down to approx. 15 mm
from bottom end of cylinder. Push in using a piston without
rings.
Piston ring Ring gap
New Wear limit
Rectangular-section ring mm 0.20...0.40 1.0
Tapered stepped ring mm 0.20...0.40 1.0
Oil scraper ring mm 0.25...0.50 1.0

Passat 1997 ➤
Checking ring-to-groove clearance

♦ Feeler gauges
Clean annular groove before check.
Piston ring Clearance
New Wear limit
Rectangular-section ring mm 0.04...0.09 0.15
Tapered stepped ring mm 0.03...0.06 0.15
Oil scraper ring mm 0.02...0.06 0.15
Checking piston

♦ External micrometer 75…100 mm
Measure approx. 6 mm from lower edge of skirt, at 90° to piston
pin axis.

Passat 1997 ➤
Deviation from nominal dimension max. 0.04 mm

Checking cylinder bores

♦ Cylinder gauge 50…100 mm
Test procedure
– Take measurements at 3 positions in both lateral direction
-A- and longitudinal direction -B-.
– Deviation from nominal dimension max. 0.08 mm
Note
Measuring the cylinder bores must not be done when the cylinder
block is secured to the assembly stand with engine bracket 3269,
as incorrect measurements would then be possible.
Installing piston with funnel 3278

♦ Funnel 3278
Note
If a new funnel is used to install the pistons, first pass piston with
oiled piston rings twice through the funnel and remove any re‐
sulting metal shavings, if necessary. Only then install piston with
piston rings.
– Push piston into oiled funnel by hand. High point of piston

crown must face the lug on the funnel -arrow-.
– Hold funnel (with piston inserted) on upper edge and press
piston in with both thumbs.
– Push piston in until it protrudes approx. 15 mm from the lower
edge of the funnel.
– Place piston in respective cylinder bore. Lug on funnel
-arrow- must face centre of cylinder block.

Passat 1997 ➤
– Hold funnel tightly against cylinder block and push piston in.
4.1 Piston and cylinder dimensions

Honing dimen‐ Piston ∅ Cylinder bore ∅
sion
Basic dimension mm 80.985 81.01
Stage I mm 81.485 81.51
Stage II mm 81.985 82.01

Passat 1997 ➤
15 – Cylinder head, valve gear

1 Removing and installing cylinder
head
Checking compression ⇒ page 50 .
Note
♦ Use the assembly tool -T10029- only, to pull off and push on
the spark plug connectors.
♦ When installing an exchange cylinder head with camshafts in‐
stalled, the contact surfaces between bucket tappets and
cams must be oiled after installation.
♦ The plastic protectors fitted to protect the open valves must be
removed only immediately before the cylinder head is fitted.
♦ When replacing the cylinder head the complete coolant must
be renewed.
1 - Upper part of intake mani‐

fold
⇒ page 44 ; Removing
and installing cylinder
head cover.
❑ Initially, bolt it together
with lower part of intake
manifold to cylinder
head. Then bolt it to both
supports.
manifold .
❑ Removing and instal‐
ling, plastic variable in‐
fold .
2 - Throttle valve module -
J338-
42 Rep. gr.15 - Cylinder head, valve gear

Passat 1997 ➤
manifold .
❑ Removing and installing, plastic variable intake manifold ⇒ Rep. gr. 24 ; Repairing injection system;
Dismantling and assembling upper part and lower part of intake manifold, plastic variable intake manifold .
3 - 10 Nm
4 - Cap
5 - Cylinder head cover
❑ Renew if damaged or leaking.
❑ Before fitting, coat transitions between cover and cylinder head and the half-moon-shaped recess with
D 454 300 A3.
6 - Bracket
7 - Cylinder head bolt
❑ Renew.
❑ Follow installation instructions and sequence when loosening and tightening ⇒ page 46 .
8 - Cylinder head
❑ Check for distortion ⇒ page 44 .
9 - O-ring
❑ Renew.
❑ Lubricate before installing.
10 - O-ring
11 - Hall sender -G40-
❑ For camshaft timing chain
13 - Continued coolant circulation pump -V51-
14 - Seal
❑ Renew if leaking.
15 - Ignition coil N, N128, N158, N163, N164
❑ Checking: ⇒ Rep. gr. 28 ; Repairing ignition system; Checking ignition coils with output stage .
16 - 25 Nm
17 - Cover
❑ Can be removed and installed with cylinder head fitted.
❑ Coat sealing surfaces with AMV 188 001 02.
❑ If only cover has been removed, prepare cylinder head gasket for assembly ⇒ page 44 .
19 - Cylinder head gasket
❑ Renew.
20 - Lower part of intake manifold
1. Removing and installing cylinder head 43

Passat 1997 ➤
21 - Gasket for lower part of intake manifold

❑ Renew.
❑ Plastic variable intake manifold has individual seals. Renew these only if damaged.
22 - Variable intake manifold changeover valve -N156-
23 - Vacuum actuator
❑ For variable intake manifold changeover valve.
Checking cylinder head for distortion

♦ Feeler gauges
Max. permissible distortion: 0.1 mm.
Preparing cylinder head gasket for assembly

♦ Sealant AMV 188 001 02
– Remove old sealant from 3 mm holes in cylinder head gasket
as well as from cover and sealing flange -arrows-.
– Fill 3 mm holes in the cylinder head gasket with sealant AMV
188 001 02 and coat sealing surfaces on cover and sealing
flange with sealant.
Note
With the cylinder head installed, the holes in the cylinder head
gasket are only half visible.
1.1 Removing and installing cylinder head

cover

Passat 1997 ➤
♦ -V.A.G 1331- Torque wrench (5…50 Nm)

♦ Hose clip pliers -V.A.G 1921-
Removing
Note
Before carrying out further work, disconnect battery earth strap.

First check whether a coded radio is fitted. Obtain anti-theft cod‐
ing first if necessary.
– With ignition switched off, disconnect battery earth strap.

– All cable ties which are opened or cut open when engine is
removed must be replaced in the same position when engine
is installed.
– Unclip ignition cables and use assembly tool -T10029- to re‐
move spark plug connectors.
– Remove intake hose between air mass meter -G70- and throt‐
tle valve module -J338- and pull off hose connection for air
circulation around injectors ⇒ Rep. gr. 24 .
– Pull connector -1- off throttle valve module -2-.
– Carefully open cap of coolant expansion tank in order to re‐
lease any pressure from cooling system and close cap again.
– Detach accelerator cable from cable support bracket and
throttle valve module (do not remove locating clip).

Passat 1997 ➤
– Pull coolant hoses 1 and 2 off throttle valve module and seal
hose ends.
– Now, pull off vacuum connections 3, 4 and 5 as well as the
connector for intake manifold temperature sender 6.
– Unbolt dipstick guide tube from upper part of intake manifold.
– Detach vacuum hose from intake manifold change-over vac‐
uum actuator.
– Now, unscrew the two bolts for the intake manifold support.
– Then, unbolt upper part of intake manifold from lower part of
intake manifold.
– Remove upper part of intake manifold and place it on a suitable
surface so that the vacuum unit will not be damaged.
Note
Seal intake ports in lower part of intake manifold and in cylinder

head with a clean cloth.
– Remove cylinder head cover.

Installing
Install in reverse order.
Note
♦ Renew cylinder head cover if damaged or leaking.

♦ Initially, bolt upper part of intake manifold together with lower
part of intake manifold to cylinder head. Then tighten the two
bolts on the intake manifold support.
♦ Ensure that fuel hose connections are tight.
– If necessary fill with coolant ⇒ page 82 .

– Adjust throttle cable ⇒ page 116 , Repairing accelerator
mechanism.
– Read fault memory ⇒ Motronic injection and ignition system
(5-cyl. engine); Rep. gr. 01 ; Self-diagnosis; Reading and
Specified torques
Threaded connection Specified torque
Cylinder head cover to cylinder head 10 Nm
Upper part of intake manifold with lower part 25 Nm
of intake manifold to cylinder head
Upper part of intake manifold to support on left 10 Nm
and right
Support for upper part of intake manifold to 25 Nm
cylinder head
1.2 Removing and installing cylinder head

Passat 1997 ➤

equipment required
wrench (5…50 Nm)
V.A.G 1921-
Prerequisites
• The engine must be no more than warm to touch.
Procedure
theft coding.
– Loosen or separate the following components:
♦ accelerator cable
♦ high-voltage cables terminal 4 from ignition coils
♦ hose leading to activated charcoal filter solenoid valve 1
♦ vacuum hose to brake servo from intake manifold
♦ earth strap on ignition coils.
– With the ignition switched off, disconnect battery earth strap.

Passat 1997 ➤

– Remove cylinder head cover.
WARNING

– Using hose clip pliers -V.A.G 1921- , remove fuel return line
-1- (blue or blue marking) and fuel supply line -2- (black or
black marking) from fuel pressure regulator.
– Seal lines so that fuel system is not contaminated by dirt.
– Disconnect connector for wires leading to injectors and pull

vacuum hose off fuel pressure regulator.
– Now, unbolt dipstick guide tube from lower part of intake mani‐
fold.
– Unbolt lower part of intake manifold with output stage bracket
from cylinder head and remove lower part of intake manifold.
– Loosen hose clips and pull coolant hoses off coolant thermo‐
stat housing.
– Now, remove thermostat housing.
– Then, detach electric coolant pump -V51- from its bracket.
Coolant hoses can remain connected.
– Pull 3-pin connector off Hall sender -G40- ; sender remains
installed.
– Now, remove ignition coils.
– Now, unbolt the brackets and the camshaft chain sprocket
cover.
– Loosen camshaft chain sprockets. Counterhold camshafts us‐

ing an open-end wrench AF 24 while doing so.
– Remove heat shield from exhaust manifold.
– Remove front exhaust pipe from exhaust manifold.
– Now, remove exhaust manifold.

Passat 1997 ➤
– Loosen cylinder head bolts in sequence given and then re‐

move completely.
– Carefully remove cylinder head.
Installing
– Place clean cloths in cylinders so that no dirt or emery cloth
particles can get in between cylinder wall and piston.
– Also prevent dirt and emery cloth particles from getting into
coolant.
– Now carefully clean sealing surfaces of cylinder head and cyl‐
inder block. Ensure that surfaces are not scored or scratched
(if abrasive paper is used, grade must not be less than 100).
– Carefully remove metal particles, emery residue and cloths.
If the piston for no. 1 cylinder is not at TDC position:

Note
♦ Do not remove new cylinder head gasket from its packing until
immediately before installing.
♦ Handle new gasket with extreme care. Damage will cause
leakage.
– Fit new cylinder head gasket. Inscription (Part No.) must be

readable.
Ensure that dowel sleeves are inserted into cylinder block holes
15 and 16, and that the cylinder head gasket is located.
– Position camshafts in cylinder head to TDC for no. 1 cylinder.

– Now prepare cylinder head gasket for assembly ⇒ page 44
and ⇒ page 44 .
– Fit cylinder head, install cylinder head bolts and tighten hand
tight.

Passat 1997 ➤
– Tighten cylinder head bolts in tightening sequence as follows:

– Pre-tighten all bolts to 30 Nm.
– Then tighten all bolts to 50 Nm.
– Then tighten all bolts 1/4 turn (90°) further using a rigid wrench.
– Then tighten all bolts again 1/4 turn (90°) further.
Further assembly is basically the reverse of the dismantling se‐

quence.
Note
Ensure that the O-ring for sealing the oil channel is fitted in the
camshaft sprocket cover.
Adjusting valve timing ⇒ page 16 .

Filling with new coolant ⇒ page 82 .
Note
It is not necessary to retighten cylinder head bolts after repairs.
1.3 Checking compression

Passat 1997 ➤

equipment required
♦ Spark plug socket and ex‐
tension 3122 B
wrench (5…50 Nm)
♦ Compression tester -
V.A.G 1763-
Test prerequisite
• Engine oil temperature at least 30 °C
Test procedure
– Pull connector off heater element for crankcase breather and
remove intake hose between upper part of air filter and throttle
valve module -J338- together with crankcase breather valve.
– Unclip ignition cables and use assembly tool -T10029- to re‐
move spark plug connectors.
– Remove spark plugs using spark plug socket and extension
3122 B.

Passat 1997 ➤
– Pull 6-pin connector -arrow- off output stage.

– Fully open throttle valve.
– Check compression using compression tester -V.A.G 1381- or
-V.A.G 1763- .
Note
Using compression tester ⇒ Operating instructions.
– Operate starter until tester shows no further pressure in‐

crease.
Compression pressures:
New: 10…13 bar, wear limit: 7.5 bar
Maximum permissible difference between all cylinders: 3 bar

Passat 1997 ➤
2 Repairing valve gear
Note
Cylinder heads which have cracks between the valve seats or

between valve seat inserts and the spark plug thread can be used
further without reducing service life, providing the cracks do not
exceed a maximum of 0.5 mm in width.
1 - Bearing cap
❑ Installation position
⇒ page 55 .
❑ Installation sequence
and installing camshaft.
2 - 20 Nm
3 - Camshafts
❑ Checking axial clear‐
ance ⇒ page 55 .
⇒ page 57 .
❑ Check radial clearance
with Plastigage, wear
limit: 0.10 mm.
❑ Runout: max. 0.01 mm.
4 - Camshaft chain sprocket
shafts.
5 - Sender wheel
❑ For Hall sender -G40- .
❑ Contact surface of cam‐
shaft timing chain
sprocket and sender
wheel must be dry when
assembled.
2. Repairing valve gear 53

Passat 1997 ➤
shafts.
6 - 100 Nm
❑ To remove and install,
counterhold using 24 mm open-end spanner on camshaft ⇒ page 57 , Removing and installing cam‐
shafts.
❑ Lubricate contact surface of bolt head when fitting
7 - Cylinder head height
❑ Minimum height: a = 139.5
8 - Cylinder head
❑ Reworking valve seats ⇒ page 56 .
9 - Valves
❑ Do not rework, only lapping-in is permitted.
❑ Valve dimensions ⇒ page 55
10 - Valve guide
❑ Repair guide with collar.
11 - Valve stem seal
12 - Valve springs
❑ Removing and installing ⇒ page 62 , Renewing valve stem seals.
13 - Valve spring plate
14 - Valve cotters
15 - Bucket tappet
❑ Do not interchange.
❑ With hydraulic valve clearance compensation.
❑ Set down with contact surface facing downwards.
❑ Before installing, check camshaft axial clearance ⇒ page 55 .
❑ Oil contact surface.

Passat 1997 ➤
Camshafts, checking axial clearance

Special tools and work‐
shop equipment re‐
quired
♦ Universal dial gauge
bracket -VW 387-
♦ Dial gauge
Camshafts, checking ax‐
ial clearance
Test procedure
Wear limit: max.
0.15 mm
Check with bucket tap‐
pets removed and first
and last bearing caps fit‐
ted on the respective
camshaft.
Installation position of camshaft bearing caps

The markings -arrows- on the bearing caps must face towards
vibration damper end.
Valve dimensions
Note
Valves must not be reworked. Only lapping-in is permitted.
Dimension Inlet valve Exhaust valve

∅a mm 39.0 34.20
∅b mm 6.967 6.96
c mm 105.95 106.95
α ∠° 45 45

Passat 1997 ➤
2.1 Reworking valve seats

♦ Depth gauge
♦ Valve seat refacing tool
Note
♦ When repairing engines with leaking valves, it is not sufficient

to rework or renew valve seats and valves. There is also a
requirement to check the valve guides for wear. This is par‐
ticularly important on high mileage engines.
♦ Valve seats should be reworked only enough to produce a
perfect seating pattern. Before beginning to rework valve
seats, calculate the maximum permissible reworking dimen‐
sions. If the reworking dimension is exceeded, the hydraulic
valve clearance compensation can no longer be guaranteed
and the cylinder head must be renewed.
Procedure
Calculate maximum permissible reworking dimension.
– Insert valve and press firmly against seat.
Note
If the valve is to be renewed as part of a repair, use a new valve

for the calculation.
– Measure distance -a- between end of valve stem and upper

edge of cylinder head.
– Calculate maximum permissible reworking dimension from
measured distance -a- and minimum dimension.
Minimum dimension: inlet valve 33.9 mm, exhaust valve 34.1 mm
Measured distance -a- minus minimum dimension = maximum
permissible reworking dimension.
Example:
Measured dis‐ 34.8 mm
tance -a-
- Minimum di‐ 34.1 mm
mension
= Max. permissi‐ 0.7 mm
ble reworking
dimension

Passat 1997 ➤
Reworking inlet valve seat

a = ∅ 38.3 mm
b = max. permissible reworking dimension 1)
c = 1.4 mm ... 2.0 mm, if necessary rework valve seat in‐
sert using a 75° correction cutter.
Z = lower edge of cylinder head
α = 45° valve seat angle
β = 30° upper correction angle
γ = 60° lower correction angle
Reworking exhaust valve seat

a = ∅ 33.5 mm
b = max. permissible reworking dimension 1)
c = 2.0 mm ... 2.5 mm, if necessary rework valve seat in‐
sert using a 75° correction cutter.
Z = lower edge of cylinder head
α = 45° valve seat angle
β = 30° upper correction angle
γ = 73° lower correction angle
2.2 Removing and installing camshafts


Passat 1997 ➤
Removing
– Remove chain tensioner for camshaft timing chain.
– Remove cover ⇒ Item 17 (page 43) and
⇒ Item 17 (page 43) .
– Loosen securing bolts on camshaft chain sprockets.
Note

– Removing camshaft chain sprockets.
Removing bearing caps of camshaft for cylinders 1, 3 and 5 and

for camshaft of cylinders 2 and 4
For the long camshaft observe the following:
– First, remove bearing cap 1.
– Loosen bearing caps 3 and 5 alternately and diagonally.
For the short camshaft observe the following:
– First, remove bearing cap 4.
– Slowly loosen bearing caps 2 and 6.
Installing
– Oil running surfaces of camshafts.
Note
♦ When installing the camshafts, the recesses for the camshaft

chain sprockets -arrows- must face upwards.
♦ When installing the bearing caps, ensure that the cap mark‐
ings can be read from the exhaust side of the cylinder head
and that the arrows are facing towards the vibration damper
end.

Passat 1997 ➤
Installing camshaft for cylinders 1, 3 and 5 and camshaft for cyl‐

inders 2 and 4
For the long camshaft observe the following:
– Tighten bearing caps 3 and 5 alternately and diagonally to
20 Nm.
– Tighten bearing cap 1 also to 20 Nm.
For the short camshaft observe the following:
– Tighten bearing caps 4 and 6 alternately and diagonally to
20 Nm.
– Install bearing cap 2 and tighten it also to 20 Nm.
– Clean sealing surfaces on cylinder head and on camshaft
sprocket cover.
– Remove old sealant from 3 mm holes in cylinder head gasket

-arrows-.
Note
With the cylinder head installed, the holes in the cylinder head
gasket are only half visible.
– Install camshaft chain sprocket with camshaft timing chain

⇒ page 16 , Adjusting valve timing.
– Fill 3 mm holes in cylinder head gasket with sealant AMV 188
001 02.
– Coat sealing surface of camshaft sprocket cover with AMV 188
001 02.
Note
Ensure that the O-ring for sealing the oil channel is fitted in the
camshaft sprocket cover.
– Install camshaft sprocket cover, start all securing bolts and

tighten them gently.
40 Nm.
Note
When new bucket tappets have been installed the engine must
not be started for about 30 minutes. Hydraulic compensation el‐
ements must settle (otherwise valves will strike pistons).
2.3 Checking hydraulic bucket tappets

♦ Feeler gauges
♦ Wooden/plastic wedge

Passat 1997 ➤
Test procedure
Note
♦ Renew defective bucket tappets complete (cannot be adjusted

or repaired).
♦ Irregular valve noise during starting is normal.
– Start engine and run it until the radiator fan has switched on
once.
– Increase speed for 2 minutes to approx. 2500 rpm.
If the hydraulic bucket tappets are still noisy, determine defective
tappet as follows:
– Rotate crankshaft clockwise using securing bolt for vibration
damper until cam of tappet to be checked is in top position.
– Determine clearance between cam and bucket tappet.
– If play exceeds 0.2 mm, renew bucket tappet. If play is less
than 0.1 mm or there is no play, continue with check as follows:
– Push tappet down with a wooden or plastic wedge. If you no‐
tice a free travel of more than 0.2 mm before the valve opens,
renew the tappet.
Note
When new bucket tappets have been installed the engine must
not be started for about 30 minutes. Hydraulic compensation el‐
ements must settle (otherwise valves will strike pistons).
2.4 Checking valve guides

♦ Universal dial gauge bracket -VW 387-
♦ Dial gauge

Passat 1997 ➤
Test procedure
– Insert new valve in guide. Valve stem end must be flush with
guide. Due to slight differences in stem diameters, use only an
inlet valve in inlet guide and an exhaust valve in exhaust guide.
– Determine rock. Wear limit: inlet valve guide = 1.0 mm, ex‐
haust valve guide = 1.3 mm.
2.5 Renewing valve guides

♦ Reamer, 7 mm 3120 and cutting fluid
♦ Drift 3121
Removing
– Clean and check cylinder head. Cylinder heads in which the
valve seats can no longer be reworked or cylinder heads which
have already been machined to the minimum dimension
(height) ⇒ Item 7 (page 54) or which already have AS valve
guides installed are unsuitable for having their valve guides
renewed.

Passat 1997 ➤
– Drive out worn valve guides with drift 3121 working from cam‐
shaft end.
Installing
– Moisten new valve guides with oil and press them in with drift
3121 working from camshaft end (cylinder head cold) until
shoulder makes contact. The cylinder head must rest flat in its
seat.
Note
When the shoulder on the guide makes contact, the fitting pres‐
sure must not exceed 1.0 t otherwise the shoulder may break off.
– Ream valve guide with reamer 3120. Use plenty of cutting flu‐
id.
– Reworking valve seats ⇒ page 56 .
2.6 Renewing valve stem seals

Passat 1997 ➤

equipment required
♦ Valve assembly device
2036
♦ Puller 3047 A
♦ Spark plug socket and ex‐
tension 3122 B
♦ 3129 Fitting tool
♦ Valve lever -VW 541/1A-
♦ -VW 541/5- Thrust piece
♦ -VW 653/3- Pressure hose
(With cylinder head installed)

Removing
– Remove camshafts ⇒ page 57 .
– Remove bucket tappets (do not interchange) and place with
cam contact surface downwards.
– Remove spark plugs using spark plug socket and extension
3122 B.
– Set piston of respective cylinder to “bottom dead centre”.

Passat 1997 ➤
– Insert valve assembly device 2036 and adjust mountings to

height of studs.
– Screw pressure hose -VW 653/3- into spark plug thread and
apply a continuous pressure of at least 6 bar.
– Remove valve springs with lever -VW 541/1A- and press piece
-VW 541/5- .
Note
Tight valve cotters can be loosened by tapping lightly on assem‐

bly lever.
– Pull off valve stem seals using puller 3047 A.

Installing
– To prevent damage to new valve stem seals, place plastic

sleeve -A- on valve stem.
– Oil valve stem seal -B-, insert it in fitting tool 3129 and push it
carefully onto valve guide.

Passat 1997 ➤
17 – Lubrication
1 Removing and installing parts of lu‐
brication system
Note
♦ If when repairing an engine, metal shavings or large quantities

of small metal particles caused, for example, by partial seizure
of crankshaft and conrod bearings are found in the engine oil,
one must apart from thoroughly cleaning oil passages, renew
all oil spray jets, the oil non-return valve, and the oil cooler to
prevent consequential damage.
♦ The oil level must not be above the max. mark - danger of
damage to catalytic converter!
Checking oil pressure and oil pressure switch ⇒ page 73
1 - 10 Nm
2 - Oil pump drive cover
3 - O-ring
❑ Renew.
ling.
4 - Oil pump drive
5 - Cylinder block
7 - Thrust washer
8 - 10 Nm
“D6”.
9 - Oil spray jet
❑ For crankshaft bearings
2…6
❑ For piston cooling.
⇒ page 67 .
❑ Opening pressure: 2.0
bar
10 - Drive shaft
11 - Oil pump
bling ⇒ page 69 .
❑ Coat oil pressure pipe
on cylinder block and oil
1. Removing and installing parts of lubrication system 65

Passat 1997 ➤
pump housing with AMV

188 001 02
12 - 25 Nm
13 - 20 Nm + 1/4 turn (90°) further
❑ Renew.
14 - 8 Nm
15 - Baffle plate
16 - Oil pan
❑ Renew plug with attached seal.
18 - 10 Nm
19 - Torque reaction support
20 - Gasket
❑ Renew.
21 - Oil filter housing/assembly carrier
22 - Oil filter lower part, 30 Nm
23 - Oil cooler cover, 25 Nm
24 - Guide tube
❑ For dipstick.
❑ Secured with bolt to intake manifold.
25 - Dipstick
❑ The oil level must not be above the max. mark!
26 - Oil non-return valve, 5 Nm
❑ Clean if badly soiled
Oil level and oil temperature sender -G266-

Check only vehicles 05.99 ►: ⇒ Current flow diagrams, Electrical
fault finding and Fitting locations.
1 - Oil level and oil temperature sender -G266-
2 - 10 Nm
3 - Renew seal.
4 - 3-pin connector.
66 Rep. gr.17 - Lubrication

Passat 1997 ➤
Removing and installing oil spray jet
Note
Oil spray jets are installed in crankshaft bearings 2…6.
• Crankshaft removed
Removing
– Press oil spray jet out towards bearing using a 4 mm ∅ drift.
Installing
– To install, press oil spray jet in by hand using a 6 mm ∅ drift
-arrow-.
1.1 Engine oil

Oil capacities
Without oil filter 3.0 l with oil filter 3.7 l.
Engine oil specification: Vehicles ► 05.99
Engine oil conforming to VW standard 500 00, 501 01 or 502 00
can be used. In exceptional cases only: multi-grade or single-
grade oil conforming to ACEA A2/A3.
Engine oil specification: Vehicles 05.99 ► with long-life service
Use engine oils conforming to VW standard 503 00.
Note
♦ The engine is filled at the factory with engine oil conforming to

VW standard 503 00. This engine oil is designed for long serv‐
ice intervals.
♦ Engine oils conforming to VW standard 500 00, 501 01 or
502 00 can be used furthermore. The oil must then be changed
every 12 months or every 15,000 km and the service interval
display must be programmed accordingly. Procedure: ⇒ Main‐
tenance ; Booklet .
1.2 Dismantling and assembling oil filter housing/assembly mountings

Passat 1997 ➤
1 - Oil filter housing/assembly

mounting
❑ With oil return valve.
2 - Gasket
❑ Renew.
tion.
ling.
3 - Oil cooler
❑ Ensure clearance to ad‐
jacent components.
4 - Oil cooler cover, 25 Nm
5 - 25 Nm
7 - Oil filter lower part, 30 Nm
❑ Drain before removing.
❑ With by-pass valve,
opening pressure: 2.50
bar
8 - Oil filter element
❑ Observe change inter‐
vals.
9 - 1.4 bar oil pressure switch -
F1- , 20 Nm
❑ Black
❑ If seal is leaking, nip
open and renew.
10 - Plug, 25 Nm
❑ For oil return valve.
11 - Seal
❑ Renew.
12 - Gasket
❑ Renew.

Passat 1997 ➤
1.3 Dismantling and assembling oil pump
1 - Drive shaft
2 - Oil pump housing
3 - 25 Nm
4 - Gears
❑ Checking backlash
⇒ page 69 .
❑ Checking axial clear‐
ance ⇒ page 70 .
5 - Oil pump cover with pres‐
sure relief valve
❑ Opening pressure: 5.3
bar ... 5.7 bar.
❑ Clean strainer if soiled.
6 - 10 Nm
❑ Renew.
“D6”.
7 - Oil pressure pipe
❑ Coat with AMV 188 001
02 on cylinder block and
on oil pump housing.
8 - 10 Nm
9 - O-ring
❑ Renew if damaged.
Checking oil pump backlash

♦ Feeler gauges

Passat 1997 ➤
Wear limit: 0.20 mm

Checking oil pump axial clearance

♦ Feeler gauges
Wear limit: 0.10 mm
1.4 Removing and installing oil pan

♦ Support bracket 10 - 222 A with rack 10 - 222 A /1
♦ Workshop hoist -V.A.G 1202 A-
♦ Hand drill with plastic brush attachment
♦ Silicone sealant D 176 404 A2
♦ Cable ties
Removing
– Drain engine oil.
– Unbolt torque reaction support on right from oil pan.
– Cut cable tie -arrows-, open bracket for start cable, remove
cable.
– Mark the fitting position of threaded connections -1- and lo‐

cating sleeves -2- below on the left and right engine mounts.
– Unbolt both engine mountings from below.

Passat 1997 ➤
– Attach support bracket 10-222A as shown.

– Support engine at rear lifting eye with support bracket.
– Tension engine slightly with spindle of support bracket.
– Support assembly carrier with workshop crane 1202 A.
Note
To avoid having to perform wheel alignment, the subframe must

only be loosened or lowered at the front end.
– First remove front bolts -2- and -3- on left and right-hand sides
of subframe Then remove bolts -4-.
– Loosen rear right gearbox mounting rear bolt -2- several turns,
remove right gearbox mounting front bolt -1-.

Passat 1997 ➤
– Loosen left gearbox mounting nut -arrow- until it is flush with

end of bolt (turned approx. 4 threads).
– Lower subframe slowly with workshop crane.

– Remove workshop crane, swivel anti-roll bar down.
– Unbolt oil pan. If necessary, push assembly carrier down‐
wards by hand slightly to be ease the loosening of the bolts on
the intermediate plate.
– Now remove oil pan.
– Loosen oil pan with light blows of a rubber headed hammer if
necessary.
– Remove sealant residue from cylinder block with a flat scraper.
– Remove sealant residue on oil pan using a rotating brush, e.g.

an electric drill with a plastic brush attachment (wear safety
goggles).
– Clean sealing surfaces. They must be free of oil and grease.
Installing
• The intermediate plate must be firmly bolted to cylinder block
Note
♦ Observe expiry date of sealing compound.

♦ The oil pan must be installed within 5 minutes of applying sil‐
icone sealing compound.
– Cut off tube nozzle at forward marking (∅ of nozzle approx. 3

mm).
– Apply silicone sealing compound, as shown, to clean sealing
surface on oil pan. Sealing compound bead must be:
♦ 2…3 mm thick.
♦ Run bead along inner side of bolt holes -arrows-.
Note
The sealant bead must not be thicker, otherwise excess sealing

compound will enter the oil pan and may block the oil suction line
strainer.

Passat 1997 ➤
– Apply silicone sealing compound bead as shown to the clean

sealing surface of the oil pan.
– Install oil pan immediately and tighten all oil pan bolts lightly.
– Tighten oil pan bolts slightly.
– Tighten M10 bolts of oil pan/intermediate plate by hand.
– Tighten oil pan bolts to 15 Nm.
– Tighten M10 bolts of oil pan/intermediate plate to 45 Nm.
Note
Let sealing compound dry for approx. 30 minutes after installing

oil pan. Only then fill with engine oil.
Further assembly is basically the reverse of the dismantling se‐

quence.
1.5 Checking oil pressure and oil pressure

switch
Note
Functional check and repair of the optical and acoustic oil pres‐
sure warning: ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.

♦ Oil pressure tester -V.A.G 1342-
♦ Voltage tester -V.A.G 1527-
♦ Auxiliary measuring set -V.A.G 1594-
Test procedure
– Remove 1.4 bar oil pressure switch -F1- (black insulation) and
screw it into the tester.
– Screw tester into oil filter housing in place of oil pressure
switch.
– Connect brown wire of tester to earth (-).
– Connect diode test lamp -V.A.G 1527- using auxiliary cables
from -V.A.G 1594- to battery positive (+) and oil pressure
switch. LED should not light up.
– If the LED lights up, renew 1.4 bar oil pressure switch -F1- .
If LED does not light up:
– Start engine and run at idling speed. At 1.2…1.6 bar the LED
must light up; otherwise renew the 1.4 bar oil pressure switch
-F1- .
– Increase engine speed further. At 2,000 rpm and an oil tem‐
perature of 80°C the oil pressure should be at least 2.0 bar.
At higher engine speed, oil pressure must not exceed 7.0 bar.
– Renew oil pump if necessary ⇒ page 69 , Dismantling and as‐
sembling oil pump.

Passat 1997 ➤
19 – Cooling
1 Removing and installing parts of cool‐
ing system
WARNING
When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant, refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ Ensure that there is sufficient clearance to all moving or
hot components.
Note
♦ When the engine is warm, the cooling system is under pres‐

sure. If necessary, release pressure before beginning repair
work.
♦ Hoses are secured with spring-type clips. In case of repair,
only use spring-type clips.
♦ Spring-type clip pliers -VAS 5024- or hose clip pliers -
V.A.G 1921- are recommended for fitting spring-type clips.
♦ When installing coolant hoses, route stress-free so that they
do not come into contact with other components (observe
markings on coolant connection and hose).
Perform leakage test of cooling system using cooling system test‐

er -V.A.G 1274- and adapter -V.A.G 1274/8- .
Parts of cooling system - body side ⇒ page 74 .
Parts of cooling system - engine side ⇒ page 76 .
Dismantling and assembling thermostat housing ⇒ page 80 .
Coolant hose schematic diagram ⇒ page 79 .
Draining and filling with coolant ⇒ page 82 .
Coolant mixture ratios ⇒ page 82 , draining and filling with cool‐
ant.
1.1 Parts of cooling system - body side
74 Rep. gr.19 - Cooling

Passat 1997 ➤
1 - Radiator/cooler
⇒ page 86 .
❑ After renewing, renew
entire coolant.
❑ With ATF cooler on ve‐
hicles with automatic
gearbox ⇒ Rep. gr. 37 ;
bling gearbox; Remov‐
ing and installing ATF
lines on vehicles with 5-
cylinder engine and 110
kW .
❑ Cleaning ATF cooler ⇒
Rep. gr. 37 ; Disman‐
tling and assembling
gearbox; Cleaning ATF
lines and ATF cooler .
2 - Securing clip
3 - Rubber mounting
4 - Upper coolant hose
❑ Secured to radiator with
retaining clip.
❑ Check for secure seat‐
ing.
❑ Coolant hose schematic
diagram ⇒ page 79 .
5 - Rubber washer
6 - Radiator fan -V7-
7 - Fan ring
❑ Clipped into air shroud
and secured with lock‐
ing bolt
8 - Locking bolt
9 - 10 Nm
10 - 2-pin connector
11 - Lower coolant hose
❑ Secured to radiator with retaining clip.
❑ Check for secure seating.
❑ Coolant hose schematic diagram ⇒ page 79 .
12 - O-ring
13 - Connector
❑ Black, 3-pin.
❑ For radiator fan thermal switch
14 - Radiator fan thermal switch -F18- , 35 Nm
❑ Switching temperatures: stage 1 on: 84...89 °C, off: 76...83 °C, stage 2 on: 90…95 °C, off: 82…89 °C.
15 - Seal
❑ Renew.
16 - Drain plug, 10 Nm
1. Removing and installing parts of cooling system 75

Passat 1997 ➤
1.2 Parts of cooling system - engine side
1 - 10 Nm
2 - Fan wheel
3 - O-ring
❑ Renew.
4 - Coolant hose
❑ Secured to cylinder
head with retaining clip.
ing.
5 - Throttle valve control mod‐
ule
6 - 10 Nm
7 - To heat exchanger
8 - Gasket
❑ Renew.
bling ⇒ page 80 .
10 - Continued coolant circula‐
tion pump -V51-
11 - From heat exchanger

Passat 1997 ➤
12 - Cap
❑ Check using cooling system tester -V.A.G 1274- and adapter -V.A.G 1274/9- .
❑ Test pressure: 1.4…1.6 bar.
13 - O-ring
14 - Expansion tank
❑ Perform leakage test of cooling system using cooling system tester -V.A.G 1274- and adapter -
V.A.G 1274/8- .
17 - Oil cooler
❑ Removing and installing ⇒ Item 3 (page 68) , ⇒ Item 3 (page 68) .
18 - 25 Nm
❑ Observe tightening sequence ⇒ page 79 .
19 - Compact bracket
❑ For tensioning device, viscous fan coupling, alternator, coolant pump and power-assisted steering vane
pump.
20 - Coolant pipe

Passat 1997 ➤
1.3 Removing and installing compact bracket
1 - Viscous fan coupling

⇒ page 87 .
2 - Belt pulley
❑ For viscous fan cou‐
pling.
⇒ page 87 , Removing
and installing viscous
fan coupling.
3 - 30 Nm
4 - Compact bracket
❑ For tensioning device,
viscous fan coupling, al‐
ternator, coolant pump
and power-assisted
steering vane pump.
5 - 25 Nm
❑ Observe tightening se‐
quence ⇒ page 79 .
6 - Mounting
7 - Circlip
8 - 45 Nm
❑ For viscous fan cou‐
pling.
9 - Cover
❑ For coolant pump.
10 - Gasket
❑ Renew.
11 - 25 Nm
12 - O-ring
❑ Renew.
13 - Coolant pump
❑ Check for ease of movement.
14 - Belt pulley
❑ For coolant pump.
15 - 25 Nm
16 - 8 Nm
17 - Tensioning element for poly V-belt
❑ Removing and installing poly V-belt ⇒ page 26 .
18 - Bearing bush
❑ For viscous fan coupling.

Passat 1997 ➤
Tightening sequence, compact bracket to cylinder block

Procedure
– Position compact bracket on cylinder block and tighten secur‐
ing bolts by hand.
– Tighten compact bracket in sequence as follows to 25 Nm:
1 - Tighten fitting bolts -A-
2 - Tighten bolts -B-
1.4 Coolant hose schematic diagram

Passat 1997 ➤
1 - Heat exchanger for heater

unit
2 - Expansion tank
4 - Radiator/cooler
6 - Coolant pump
7 - Coolant pipe
8 - Oil cooler
10 - Cylinder head/cylinder
block
11 - Intake manifold
ule
13 - Continued coolant circula‐
tion pump
1.5 Dismantling and assembling thermostat

housing
Note
Routing of coolant hoses on thermostat housing ⇒ page 76 , Parts

of cooling system - engine side.

Passat 1997 ➤
2 - 10 Nm
3 - Thermostat
❑ Installation position:
Breather notch or valve
faces upwards.
❑ Checking: heat thermo‐
stat in water.
❑ Opening begins at ap‐
prox. 80 °C.
❑ Ends at approx. 105 °C.
❑ Opening lift at least 7
mm.
4 - Seal
❑ Renew.
5 - Connection
6 - Bush
7 - 10 Nm
8 - O-ring
❑ Renew.
9 - Connection
10 - Coolant temperature
sender -G62-
❑ With coolant tempera‐
ture display sender -
G2- .
❑ Blue, 2-pin
❑ For Motronic.
Rep. gr. 01 ; Self-diagnosis; Reading and clearing fault memory .
11 - Coolant temperature sender -G62-
❑ For air conditioning system
12 - Retaining clip

Passat 1997 ➤
1.6 Draining and filling coolant

equipment required
♦ Hose clamps, up to Ø 25
mm 3094
♦ Adapter -V.A.G 1274/8-
wrench (5…50 Nm)
♦ Not shown: cooling system
charge unit -VAS 6096-
Draining
WARNING
Hot steam may escape when expansion tank is opened. Place

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

sulation .

Passat 1997 ➤
– Remove drain plug -arrow-.
– Pull off lower coolant hose retaining clip -arrow- and remove
coolant hose from radiator.
Note
Follow disposal regulations for coolant!
Filling

Passat 1997 ➤
Note
♦ Only use coolant additive G12 in accordance with TL -

VW 774 F- . Identification: purple colour.
♦ G 12 and coolant additives marked "In accordance with TL -
VW 774- F" prevent frost and corrosion damage and scaling
and also raise the boiling point of coolant. Therefore, the sys‐
tem must be filled all year round with frost and corrosion
protection additives.
♦ G 12 purple (in accordance with -VW 774 F- ) can be mixed
with existing coolant additives G 11 and G 12 red!
♦ Frost protection is required down to about -25 °C (in countries
with arctic climates: down to about -35 °C).
♦ The refractometer -T10007- is recommended for determining
the current anti-freeze concentration.
♦ Because of its higher boiling point, the coolant improves en‐
gine reliability under heavy loads, particularly in countries with
tropical climates.
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. The anti-
freeze must be at least 40% of mixture.
♦ If for climatic reasons greater frost protection is required, the
amount of G 12 can be increased, but only up to 60% (frost
protection to about -40 °C). Otherwise frost protection and
cooling effectiveness are reduced again.
♦ If radiator, heat exchanger, cylinder head or cylinder head
gasket is renewed, do not reuse old coolant.
♦ The use of the cooling system charge unit -VAS 6096- is rec‐
ommended for filling the coolant circuit.
Recommended mixture ratios:

Frost protection Anti-freeze G 123) Water3)
to quantity
-25 °C 40 % 3.6 l 5.4 l
-35 °C 50 % 4.5 l 4.5 l
3) The quantity of coolant can vary depending upon vehicle equipment.
Procedure
– Install lower coolant hose and secure.
– Install drain plug in radiator.
With cooling system charge unit -VAS 6096-
– Screw adapter -V.A.G 1274/8- onto coolant expansion tank.
– Fill coolant circuit using cooling system charge unit -
VAS 6096- . ⇒ Operating instructions for cooling system
charge unit VAS 6096
Without cooling system charge unit -VAS 6096-

Passat 1997 ➤
– Screw adapter -V.A.G 1274/8- and adapter -V.A.G 1274/10-

onto expansion tank.
– Loosen coolant hose on heat exchanger and pull back hose

sufficiently so that the bleeder hole -arrow- is no longer hidden
by the connection.
– Fill with coolant until it flows out of the bleeder hole in coolant
hose.
– Push coolant hose onto connection and tighten using hose
clip.
– Fit expansion tank cap.
– Switch off heater and air conditioner.
– Start engine and maintain an engine speed of about 1300 rpm
for about 4 minutes.
– Then run engine at idling speed until radiator fan cuts in.
– Switch off ignition.
– To relieve pressure, carefully open cap on coolant expansion
tank.
– Now screw adapter -V.A.G 1274/8- with adapter -

V.A.G 1274/10- onto expansion tank again.

Passat 1997 ➤
– Loosen coolant hose on heat exchanger and pull back hose

sufficiently so that the bleeder hole -arrow- is no longer hidden
by the connection.
– Fill up with coolant until it flows out at bleeder hole free of
bubbles again.
– Push coolant hose onto connection and tighten using hose
clip.
– Remove both adapters from expansion tank and remove/fill
with coolant so that fluid is at max. mark.
– Fit expansion tank cap.
– Clamp breather hose off from upper coolant hose using hose
clamps 3093 or 3094.
– Start engine and maintain an engine speed of about 3000 rpm
for approx. 4 minutes then maintain an engine speed of about
1300 rpm for approx. 3 minutes.
– Remove hose clamp from breather hose on upper coolant
hose.
– Allow engine to run at idling speed for approx. 15 minutes.
– Allow engine to cool.
– Check coolant level and top up if necessary. When the engine
is at normal operating temperature, the coolant level must be
on the max. mark; when the engine is cold, between the min.
and max. marks.
1.7 Removing and installing radiator

Removing
– Pull coolant hoses off radiator.
– Pull connector off thermal switch.
– Remove ATF lines from radiator ⇒ Rep. gr. 37 ; Dismantling
and assembling gearbox; Removing and installing ATF lines
on vehicles with 5-cylinder engine and 110 kW .

Passat 1997 ➤

– Unbolt hydraulic oil cooling pipe of power-assisted steering
-arrows- and place to one side. Do not open hydraulic oil cir‐
cuit.
– Remove upper radiator securing clips and take radiator out
forwards.
Vehicles with air conditioner
– Observe additional information and installation work
⇒ page 87 .
Installing
Installation is carried out in the reverse order. When installing,
note the following:
– Check ATF level ⇒ Rep. gr. 37 ; Checking and topping up
ATF level; Checking ATF level .
– Replenish coolant ⇒ page 82 .
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
– Install front bumper ⇒ General body repairs, exterior; Rep. gr.
63 ; Front bumper .
– Check headlight adjustment and correct if necessary ⇒ Main‐
tenance ; Booklet .
Additional information and assembly work for vehicles with air
conditioner
WARNING
The air conditioner refrigerant circuit must not be opened.
Note
To prevent damage to condenser and also to refrigerant lines/

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

– Remove condenser from radiator and pull forward as far as is
possible.
– Secure condenser to body so that refrigerant pipes/hoses are
not stressed.
– Pull out radiator towards front.
1.8 Removing and installing viscous fan

coupling

Passat 1997 ➤
♦ Pin wrench 3212
Removing
– Remove viscous fan coupling fan wheel.
– Counterhold belt pulley for viscous fan coupling using pin
wrench 3212.
– Remove viscous fan coupling securing bolts (using 8 mm hex‐

agon key -1-) and remove viscous fan coupling with belt pulley.
– Remove belt pulley from viscous fan coupling.
Installing
note the following:
– Bolt belt pulley to viscous fan coupling and tighten it to 10 Nm.
– Tighten viscous fan coupling on compact bracket to 45 Nm.
– Bolt fan wheel to viscous fan coupling, tightening to 10 Nm.

Passat 1997 ➤
1.9 Removing and installing viscous fan bearing bush

equipment required
♦ Hexagon bolt from assem‐
bly tool 3290
♦ Hexagon nut from assem‐
bly tool 3301
♦ Thrust piece 3349/1
♦ Thrust piece 3367/2
♦ -VW 771- Multi-purpose
tool with adapter -
VW 771/15-
♦ Pins -VW 771/43-
♦ Thrust plate -VW 401-

Passat 1997 ➤

wrench (5…50 Nm)
V.A.G 1921-
♦ 5 mm ∅ drift
Removing
– Removing radiator ⇒ page 86 .
– Remove viscous fan coupling (with belt pulley) ⇒ page 87 .
– Unscrew securing bolt of dipstick guide tube from intake con‐
necting pipe.
– Pull dipstick guide tube out of cylinder block.
– Remove bearing bush securing clips -arrows-.

Passat 1997 ➤
– Pull out bearing bush with front bush using multi-purpose tool
-VW 771- , adapter -VW 771/15- and pin -VW 771/43- .
– Carefully drive rear bush out using a drift (∅ 5 mm).
– Press front bush off bearing bush using thrust plate -VW 401- .
– Press new bush onto bearing bush using thrust plate -

VW 401- . Dimension -a- = 11 mm
Note
♦ Do not cant bush when pressing.

♦ Note different sizes of bushes.
Installing
– Fit bearing bush with bushes onto compact bracket using hex‐
agon nut from assembly tool 3301, thrust piece 3367/2, thrust
piece 3349/1 and hexagon bolt from assembly tool 3290 as
– Tighten hexagon nut from assembly tool 3301 by hand as far
as possible.
Note
Do not cant bush when pulling.

Passat 1997 ➤
– Press bearing bush with bushes into compact bracket to stop.

– Secure bearing bush with securing clips after installing.
– Install viscous fan coupling ⇒ page 87 .
– Install dip stick guide tube, specified torque = 10 Nm.
– Install radiator ⇒ page 86 .
– Install front bumper ⇒ General body repairs, exterior; Rep. gr.
63 ; Front bumper .
1.10 Checking continued coolant circulation

pump -V51-
♦ Hand-held multimeter -V.A.G 1526- or multimeter -
V.A.G 1715-
♦ Current flow diagram
Note
The continued coolant circulation pump is still actuated by the

coolant pump control unit -J155- for 12 minutes after the ignition
has been switched off.
Test prerequisite
• Fuse 34 must be OK.
Test procedure
– Pull the 2-pin connector off continued coolant circulation pump
-V51- .
– Connect contacts 1 and 2 of continued coolant circulation

pump -V51- to battery using auxiliary cables from auxiliary
measuring set -V.A.G 1594- . Continued coolant circulation
pump must start up.
If the continued coolant circulation pump does not run:
– Renew pump.
If the continued coolant circulation pump runs:
– Locate and eliminate open circuit referring to current flow di‐
agram: ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
If no wiring fault is detected:
– Renew coolant pump control unit J155.

Passat 1997 ➤
1.11 Checking radiator fan -V7-

♦ Hand-held multimeter -V.A.G 1526- or multimeter -
V.A.G 1715-
Test prerequisite
• Fuse 34 must be OK.
• Radiator fan thermal switch -F18- OK.
Test procedure
– Pull 3-pin connector off radiator fan thermal switch -F18- .
– Switch on ignition.
– Bridge contact -1- and contact -2- of connector with auxiliary

cables from auxiliary measuring set -V.A.G 1594- . Radiator
fan -V7- must start up at speed 1.
– Bridge contact -1- and contact -3- of connector with auxiliary
cables from auxiliary measuring set -V.A.G 1594- . Radiator
fan -V7- must start up at speed 2.
If fan speeds 1 or 2 do not run:
Fitting locations.
If no open circuit is found:
– Renew radiator fan -V7- .

Passat 1997 ➤
20 – Fuel supply system

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

clamp-type clips.
♦ Always renew clamp-type clips with spring-type clips.
♦ Fuel hoses on engine must be secured with spring-type clips
only. The use of clamp or screw-type clips is not permissible.
♦ The use of hose clip pliers -V.A.G 1921- is recommended for
installing spring-type clips.
Observe safety precautions ⇒ page 103 .

Observe rules for cleanliness ⇒ page 103 .
Observe crash fuel shut-off ⇒ page 103 .
Removing and installing fuel tank with its attachments and fuel
filter ⇒ page 94 .
Repairing accelerator mechanism ⇒ page 116 .
Adjusting throttle cable ⇒ page 118 .
Repairing parts of activated charcoal filter system ⇒ page 119 .
1.1 Removing and installing fuel tank with

attachments and fuel filter, vehicles with
four-wheel drive
Front-wheel drive vehicles ⇒ page 99 .
94 Rep. gr.20 - Fuel supply system

Passat 1997 ➤
1 - Cap
2 - Seal
3 - Securing bolt
4 - Tank flap unit
❑ With rubber cup.
5 - O-ring
6 - Breather valve
❑ To remove valve unclip
sideways out of support.
❑ Before installing remove
cap ⇒ Item 1 (page 95) .
7 - Connecting hose
8 - Gravity valve
upwards out of support.
❑ Check valve for
through-flow; valve ver‐
tical: open, valve tilted
45°: closed.
9 - 25 Nm
10 - Fuel filler neck
11 - Non-return valve
tion: valve end faces to‐
1. Removing and installing parts of fuel supply system 95

Passat 1997 ➤
wards cap.
12 - Connecting hose
13 - Heat shield
❑ For fuel filler neck
14 - 10 Nm
15 - Union nut, 60 Nm
❑ Remove and install with spanner 3218
16 - Connector
❑ Black
❑ For fuel gauge sender
17 - Flange
❑ Note installation position on fuel tank ⇒ page 97 .
18 - Seal
❑ When installing, fit dry in fuel tank opening.
❑ Moisten with fuel only when installing flange.
19 - Breather line
❑ Black
❑ Secure with spring-type clips.
20 - Fuel gauge sender 3 -G237-
❑ Checking: ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.
21 - Heat shield
❑ For fuel tank.
22 - Securing clip
23 - Securing strap
24 - Fuel gauge sender 2 -G169-
❑ Checking: ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.
25 - Locking ring
26 - Fuel tank
❑ When removing, support it using engine and gearbox jack -V.A.G 1383 A- .
27 - Return line
❑ Blue or with blue marking.
❑ From fuel return pipe on fuel rail ⇒ Rep. gr. 24 ; Repairing injection system; Dismantling and assembling
fuel rail .
28 - Supply line
❑ Black

Passat 1997 ➤
29 - Fuel gauge sender -G-

❑ Clipped on reservoir housing in fuel tank.
30 - Fuel delivery unit
❑ Checking fuel pump ⇒ page 110 .
31 - Supply line
❑ Black
❑ To fuel supply pipe on fuel rail ⇒ Rep. gr. 24 ; Repairing injection system; Dismantling and assembling
fuel rail .
32 - Fuel filter
❑ Installation position: arrow points in direction of flow.
33 - Breather line
❑ Black
❑ Clipped onto side of fuel tank.
❑ To activated charcoal filter ⇒ Item 1 (page 120) , ⇒ Item 1 (page 120) .
34 - Earth connection
Installation position of fuel delivery unit flange

Mark on flange -1- must align with mark on fuel tank -2-.
Note
After installing fuel delivery unit flange, check that supply, return
and breather lines are still clipped onto fuel tank.
Checking breather valve

Lever in rest position: closed.
Lever pushed in direction of arrow: open.
Note
Before installing breather valve remove fuel tank cap.
1.2 Removing and installing suction-jet

pumps
On vehicles with four-wheel drive, fuel has to be pumped from the
area of sender 2 ⇒ Item 24 (page 96) and ⇒ Item 24 (page 96) to
the fuel delivery unit by means of a suction-jet pump due to the

Passat 1997 ➤
shape of the fuel tank. A second suction-jet pump ensures that

the delivery unit in the reservoir housing is supplied with fuel. The
suction-jet pump function according to a principle of physics using
the return flow of fuel via a junction with pressure limiting valve.
Note
♦ A check must only be performed, if:

♦ the engine switches off due to insufficient fuel.
♦ fault 00561 is stored in the fault memory although the fuel
gauge indicates that the tank is still 1/4 filled.
Test prerequisite
• The three fuel gauge senders have been checked using fault-
finding program and are OK ⇒ Current flow diagrams, Electri‐
cal fault finding and Fitting locations.
• Fuel tank must be drained.
♦ Fuel tank sender unit tool 3087
Procedure
– Note safety precautions before beginning work ⇒ page 103 .
WARNING

– Pull 4-pin connector and fuel hoses off fuel delivery unit (right
side of vehicle) and remove fuel delivery unit ⇒ page 104 ,
Removing and installing fuel delivery unit.
– Now, pull 2-pin connector off fuel gauge sender 2 -G169- (left
side of vehicle), open locking ring with Fuel tank sender unit
tool 3087 and carefully lift the sender.

Passat 1997 ➤
– Now, pull off connector -1- under the cover on sender 2 -2-.
– Lift sender -2- and pull suction-jet pump -3- off locking device
of sender.
– Remove sender 2.
– Now, on right side of vehicle (fuel delivery unit), pull line to

suction-jet pump -2- off junction -1- and pull off connector -3-
for connection of fuel gauge sender -G- and sender 2 -G169- .
– Now the suction-jet pump can be pulled out from side of sender
2 (left side of vehicle).
– Check that the fuel lines on suction-jet pump are fitted securely
and are not damaged.
– Additionally check suction-jet pump for possible soiling.
If no fault is found:
– Install suction-jet pump and sender 2 again in reverse order.
Note
In other work sequences the return supply line must be pulled off
junction. When doing this observe that all O-rings must be re‐
newed.
Now check junction piece with pressure relief valve as follows:
– Pull off connections for return supply -2-, connections -3- and
-4- for suction-jet pump on junction with pressure relief valve
-1-.
– Unclip the junction which is secured on the reservoir housing.
– Use a test hose and blow into connection, from direction of fuel
return -2-, there must be through flow in directions -3- and
-4-.
– Hold connections -3- and -4- closed, the pressure relief valve
must open under slight opposing pressure.
– If no opposing pressure can be determined or the pressure
relief valve does not open, renew junction with pressure relief
valve.
1.3 Removing and installing fuel tank with attachments and fuel filter, vehicles
with front-wheel drive

Passat 1997 ➤
1 - Cap
2 - Seal
3 - Tank flap unit
❑ With rubber cup.
4 - Securing bolt
5 - Gravity valve
upwards out of support.
❑ Check valve for
through-flow; valve ver‐
tical: open, valve tilted
45°: closed.
6 - O-ring
7 - Breather line
❑ Black
❑ Clipped onto side of fuel
tank.
ing.
❑ Secure with spring-type
clips.
❑ To activated charcoal fil‐
ter
⇒ Item 1 (page 120) ,
⇒ Item 1 (page 120) .
8 - Breather valve
sideways out of support.
❑ Before installing remove

Passat 1997 ➤
cap ⇒ Item 1 (page 95) .

9 - Earth connection
10 - Supply line
❑ Black
❑ Between flange ⇒ Item 14 (page 101) and fuel filter -item ⇒ Item 25 (page 102) -
11 - Return line
❑ Blue or with blue marking.
❑ From fuel return pipe on fuel rail ⇒ Rep. gr. 24 ; Repairing injection system; Dismantling and assembling
fuel rail .
12 - Connector
❑ Black, 4-pin.
❑ For fuel gauge sender -G- and fuel pump -G6- .
13 - Union nut, 60 Nm
14 - Flange
❑ Note installation position on fuel tank ⇒ page 97 .
❑ Only renew complete with fuel delivery unit.
15 - Fuel gauge sender -G-
❑ Clipped on reservoir housing in fuel tank.
16 - Supply line
❑ Between flange ⇒ Item 14 (page 101) and fuel delivery unit -item ⇒ Item 17 (page 101) -.
17 - Fuel delivery unit
❑ Can only be renewed complete with flange.
❑ Checking fuel pump ⇒ page 110 .
18 - Seal
❑ When installing, fit dry in fuel tank opening.
❑ Moisten with fuel only when installing flange.
19 - 25 Nm
20 - Fuel tank
❑ When removing, support it using engine and gearbox jack -V.A.G 1383 A- .
21 - Bracket
❑ For securing straps.

Passat 1997 ➤
22 - Securing strap
❑ Note different lengths.
❑ Installation position: Fixing point (holes) face in direction of travel.
23 - Retaining ring
❑ Secured to body.
24 - 10 Nm
25 - Fuel filter
❑ Installation position: arrow points in direction of flow.
26 - Supply line
❑ Black
❑ To fuel supply pipe on fuel rail ⇒ Rep. gr. 24 ; Repairing injection system; Dismantling and assembling
fuel rail .
27 - Return line
❑ Between flange, item ⇒ Item 14 (page 101) , and baffle housing in fuel tank.
28 - Breather line
❑ Clipped onto top of fuel tank.
Installation position of fuel delivery unit flange

Mark on flange -1- must align with mark on fuel tank -2-.
Note
After installing fuel delivery unit flange, check that supply, return
and breather lines are still clipped onto fuel tank.
Checking breather valve

Lever in rest position: closed.
Lever pushed in direction of arrow: open.
Note
Before installing breather valve remove fuel tank cap.

Passat 1997 ➤
1.4 Safety precautions when working on

fuel supply system
WARNING

When removing and installing fuel gauge sender or fuel pump

(fuel delivery unit) from a full or partly full fuel tank, observe the
following:
♦ Before beginning work, place an extraction hose close to
sender opening in fuel tank to extract escaping fuel fumes and
switch on exhaust extraction system. If no exhaust gas ex‐
traction system is available, a radial fan with a displacement
greater than 15 m3/h can be used providing that motor is not
in air flow.
♦ For safety reasons, fuse No. 28 must be removed from the
fuse holder before opening the fuel system. Otherwise, the fuel
pump could be activated by the driver's door contact switch.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
1.5 Rules for cleanliness

When working on the fuel supply and injection system, observe
the following “5 rules” for cleanliness:
♦ Thoroughly clean all unions and surrounding areas before dis‐
connecting.
♦ Place removed parts on a clean surface and cover. Use only
lint-free cloths.
♦ Carefully cover opened components or seal if repairs cannot
be carried out immediately.
♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have not been stored in their packing (e.g. in
tool boxes etc.).
♦ When system is open: do not work with compressed air if this
can be avoided. Do not move vehicle unless absolutely nec‐
essary.
1.6 Crash fuel shut-off

Function
Vehicles with an airbag are fitted with a crash fuel shut-off. It re‐
duces the danger of a fire in a crash as the fuel pump is switched
off via the fuel pump relay.
The system also improves the starting characteristics of the en‐
gine. When door is opened, the fuel pump is activated for 2
seconds to build up pressure in the fuel system.
These vehicles with an airbag are also fitted with a crash fuel shut-
off. However, in these vehicles diagnosis and deployment are
realised via the CAN bus.
When opening fuel system:
Observe safety precautions ⇒ page 103 .

Passat 1997 ➤
– Check fuel pump relay ⇒ Current flow diagrams, Electrical fault

finding and Fitting locations.
1.7 Removing and installing fuel delivery

unit, vehicles with four-wheel drive
♦ Fuel pump tool 3307
♦ Fuel tank sender unit tool 3087
Removing
theft coding.
– Remove rear bench seat.
– Remove cover in floor.

Passat 1997 ➤
– Pull 4-pin connector and supply and return lines -arrows- off
flange.
WARNING

– Unscrew locking ring using fuel tank sender unit tool 3087.
– Pull flange and seal out of opening in fuel tank.
– Unclip fuel gauge sender -G- from baffle housing in fuel tank
and remove it.
– Turn fuel delivery unit towards left by approx. 15° as far as stop
using fuel pump tool 3307 and remove it.
Note
If delivery unit is to be renewed, drain old delivery unit before dis‐

posal.
Installing
– Installation of fuel delivery unit is carried out in reverse order.

Passat 1997 ➤
Note
♦ Do not bend fuel gauge sender when installing.

♦ Coat flange seal with fuel when fitting.
♦ Do not interchange supply and return hoses (return line -
blue-).
♦ Secure fuel hoses with spring-type clips.
♦ Note Installation position of fuel delivery unit flange: Mark on
flange -1- must align with mark on fuel tank -2-.
♦ After installing fuel delivery unit flange, check that the supply,
return and breather pipes are still clipped onto fuel tank.
1.8 Removing and installing fuel delivery

unit, vehicles with front-wheel drive
♦ Fuel pump tool 3307
♦ 3217 Union nut spanner

Passat 1997 ➤
Removing
theft coding.
– Remove cover in luggage compartment floor.
– Pull 4-pin connector and supply and return lines -arrows- off
flange.
WARNING

– Remove union nut with spanner 3217.

– Pull flange and seal out of opening in fuel tank.
– Unclip fuel gauge sender -G- from baffle housing in fuel tank
and remove it.
– Turn fuel delivery unit towards left by approx. 15° as far as stop
using fuel pump tool 3307 and remove it.
Note
If delivery unit is to be renewed, drain old delivery unit before dis‐

posal.
Installing
– Installation of fuel delivery unit is carried out in reverse order.

Passat 1997 ➤
Note
♦ Do not bend fuel gauge sender when installing.

♦ Coat flange seal with fuel when fitting.
♦ Do not interchange supply and return hoses (return line -
blue-).
♦ Note Installation position of fuel delivery unit flange: Mark on
flange -1- must align with mark on fuel tank -2-.
♦ After installing fuel delivery unit flange, check that the supply,
return and breather pipes are still clipped onto fuel tank.
1.9 Removing and installing fuel tank

♦ Engine and gearbox jack -V.A.G 1383 A-

Removing
theft coding.
Vehicles with all-wheel drive
– Remove centre and rear silencers of exhaust system
⇒ page 125 .
– Remove rear axle ⇒ Running gear, axles, steering; Rep. gr.
42 ; Repairing rear axle, vehicles with four-wheel drive; Re‐
moving and installing subframe .
– Open fuel tank filler flap.
– Remove rear right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liner; Assembly
overview - rear wheel housing liner .
– Remove shield for filler neck.

Passat 1997 ➤

– Drain fuel tank and clean fuel filler neck and surrounding area.
– Unscrew securing bolt and remove tank flap unit with rubber
cup.
– Remove filler neck securing bolt.
– Pull supply hose -1- off fuel filter.
WARNING

– Mark return line -2- and breather line -3- and separate at con‐
necting point.
– Remove left and right heat shields on fuel tank and underbody.
Front-wheel drive vehicles
– Pull supply line -1- off inlet to fuel filter.
WARNING

– Mark return line -2- and breather line -3- and separate at con‐
necting point.
– Remove securing straps. When doing this, support fuel tank
with engine and gearbox jack -V.A.G 1383 A- .
– Lower with engine and gearbox jack -V.A.G 1383 A- just

enough to allow connector on flange -arrow- to be pulled off.
– Lower fuel tank.
Installing
note the following:
♦ Install breather and fuel hoses free of kinks.
♦ Do not interchange supply and return hose (return hose blue
or blue markings, supply hose black).
Note
After installing fuel tank, check that the supply, return and breath‐
er lines are still clipped onto the fuel tank.

Passat 1997 ➤
1.10 Checking fuel pump

equipment required
♦ K-Jetronic pressure tester -
V.A.G 1318-
♦ Remote control -
V.A.G 1348-
♦ Tester -V.A.G 1466 A-
♦ Voltage tester -V.A.G 1527-

Passat 1997 ➤
♦ Auxiliary measuring set -

V.A.G 1594-
♦ Multimeter -V.A.G 1715-
♦ Measuring container
♦ Vehicles with four-wheel
drive: fuel tank sender unit
tool 3087
♦ Vehicles with front-wheel
drive: union nut tool 3217
Test prerequisites
• Battery voltage at least 11.5 V
• Fuse No. 28 OK
1.10.1 Checking function and voltage supply


Passat 1997 ➤

– Briefly operate starter. Fuel pump must be heard to run.
If the fuel pump does not start:
– Remove fuse holder cover.
– Pull fuse No. 28 out of fuse holder.
– Connect remote control -V.A.G 1348/3A- with adapter cable -
V.A.G 1348/3-2- to contact 28a to fuel pump and battery
positive (+).
– Operate remote control.
If fuel pump runs:
– Check activation of fuel pump relay: ⇒ Fault finding with tester
V.A.G 1466 .
If fuel pump does not run:
– Pull 4-pin connector off flange on fuel tank -arrow-.
– Connect diode test lamp -V.A.G 1527- with adapter cables

from -V.A.G 1594- to the outer contacts of the connector.
– Operate remote control. LED must light up.
If LED does not light up:
Fitting locations.
If LED lights up (voltage supply OK):
– Unscrew locking ring using fuel tank sender unit tool 3087.

Passat 1997 ➤
– Remove union nut with spanner 3217.

– Check that electrical wires between flange and fuel pump are
connected.
If no open circuit can be found:
– Fuel pump defective. Renew fuel delivery unit ⇒ page 104 ,
removing and installing fuel delivery unit.
1.10.2 Checking delivery rate

Test prerequisites
• Voltage supply OK.
• Remote control -V.A.G 1348/3A- connected
Test procedure
– Remove filler cap from fuel tank filler neck.
– Connect K-Jetronic pressure tester -V.A.G 1318- with adapter
-V.A.G 1318/10- to fuel supply line (white arrow).
WARNING

Note
Secure all hose connections with hose clips.
– Push a commercially available hose onto adapter -

V.A.G 1318/11- K-Jetronic pressure tester and hold hose in a
measuring container.
– Open the pressure tester shut-off tap. The lever then points in
the direction of flow -A-.
– Operate remote control -V.A.G 1348/3A- . Then slowly close
shut-off tap until a pressure of 3 bar is displayed on pressure
gauge. From this point on do not move position of shut-off tap.
– Empty measuring container.
– Delivery rate of fuel pump depends on battery voltage. There‐
fore connect multimeter with auxiliary cables from -
V.A.G 1594- to vehicle battery.
– Operate remote control for 30 seconds while measuring bat‐
tery voltage.

Passat 1997 ➤
– Compare quantity of fuel delivered with specification.

4) Minimum delivery cm3/30 seconds
5) Voltage at fuel pump with engine not running and pump running (approx. 2
volts less than battery voltage).
Example:
During the test a voltage of 12.2 volts is measured at the battery.
As the voltage at the pump is approx. 2 volts less than the battery
voltage, this will equate to a minimum delivery rate of 550 cm3/30
s.
If minimum delivery rate is not attained:
– Check the fuel pipes for possible restrictions (kinks) or block‐
ages.


Passat 1997 ➤

– Connect K-Jetronic pressure tester -V.A.G 1318- to hose with
adapter 1318/10.
– Repeat delivery rate check.
If the minimum delivery rate is now attained:
– Renew fuel filter.
If the minimum delivery rate is again not attained:
– Remove fuel delivery unit ( ⇒ page 104 ) and check fuel strain‐
er for soiling.
Only if still no fault has been detected:
If delivery rate has been attained, but nevertheless you suspect
a fuel supply system fault (e.g. intermittent failure of fuel supply
system):
– Check current draw of fuel pump as follows:
– Reconnect all disconnected fuel lines.
– Connect multimeter -V.A.G 1715- with pick-up clamp to green/

yellow wire in wiring harness.
– Start engine and run at idling speed.
– Measure current draw of fuel pump. Specification: max. 8
amps.
Note
If the fuel system malfunction is intermittent, you can perform the

check during a road test, but a 2nd person is necessary.
If the current draw is exceeded:

1.10.3 Checking non-return valve for fuel pump

Test prerequisites
• Remote control -V.A.G 1348/3A- connected
• K-Jetronic pressure tester -V.A.G 1318- is connected to fuel
supply line from fuel supply pipe.

Passat 1997 ➤
Test procedure
Note
With this check, the fuel supply line connections from the fuel de‐
livery unit to the point at which the pressure gauge -V.A.G 1318-
is connected will be checked for leaks at the same time.
– Close pressure gauge shut-off tap (lever at right angles to

throughflow direction - position -B-).
– Operate remote control at short intervals until a pressure of
approx. 3 bar has built up.
– If pressure builds up too high, relieve excess pressure by
carefully opening shut-off tap.
WARNING
Danger of spray when opening shut-off tap. Hold container

over free connection of pressure tester.
– Watch pressure drop on pressure gauge. After 10 minutes,

pressure must not drop below 2.5 bar.
If the pressure drops further:
– Check line connections for leaks.
If no fault in lines is detected:
1.11 Repairing accelerator mechanism

Passat 1997 ➤
1 - Accelerator cable retainer

❑ On plenum chamber
bulkhead.
⇒ page 118 .
2 - Accelerator cable retainer
❑ To plenum chamber
bulkhead
❑ Only vehicles with man‐
ual gearbox.
3 - Retaining clip
❑ Only vehicles with man‐
ual gearbox.
ing.
❑ Secured behind plenum
chamber bulkhead.
4 - Retaining clip
❑ Only on vehicles with
automatic gearbox.
ing.
❑ Secured in front of ple‐
num chamber bulkhead.
5 - Kick-down switch -F8-
❑ To plenum chamber
bulkhead
❑ Checking ⇒ page 118 ,
Adjusting throttle cable
on vehicles with auto‐
matic gearbox.
6 - Connector
❑ Black, 2-pin.
7 - Accelerator cable
❑ Adjusting ⇒ page 118 .
❑ Do not reuse damaged accelerator cable, renew.
8 - Cable cam
❑ On throttle valve module.
9 - Support bracket
❑ For accelerator cable.
10 - 10 Nm
11 - Retainer
❑ Adjusting accelerator cable ⇒ page 118 .
12 - Accelerator
13 - Mounting bracket
14 - Accelerator pedal stop
❑ Installation position of accelerator pedal stop on mounting bracket ⇒ page 118 .

Passat 1997 ➤
Removing and installing accelerator cable retainer

Removing
– Turn accelerator cable retainer anti-clockwise by approx. 90°
and remove it from plenum chamber bulkhead.
Installing
– Insert accelerator cable through plenum chamber bulkhead
-arrow 1-.
– Fit accelerator cable retainer into plenum chamber bulkhead
and turn it clockwise by approx. 90° -arrow 2-.
Installation position of accelerator pedal stop on mounting bracket

♦ On vehicles with manual gearbox, the lettering “HS” -1- is visi‐
ble in installed condition.
♦ On vehicles with automatic gearbox, the lettering “AG” -2- is
visible in installed condition.
1.12 Adjusting accelerator cable

♦ Hand-held multimeter -V.A.G 1526A-

Passat 1997 ➤
♦ Auxiliary measuring set -V.A.G 1594A-
Procedure
– Adjust accelerator cable by moving locating clip -arrow- at
support bracket, so that full throttle position is attained at cable
cam of throttle valve module.
– Release accelerator pedal
– Pull 2-pin connector off kick-down switch -F8- located in en‐
gine compartment at front (on plenum chamber bulkhead).
– Connect hand-held multimeter -V.A.G 1526- with auxiliary ca‐

bles from auxiliary measuring set -V.A.G 1594- to kick-down
switch.
– Check resistance at switch. Specification: ∞∼Ω
– Slowly move accelerator in direction of full throttle.
Shortly after the kick-down pressure point the resistance must
drop to 0 Ω. At this point the accelerator pedal must be just off the
stop.
Vehicles with manual gearbox

– Adjust accelerator cable by moving locating clip -arrow- at
support bracket, so that full throttle position is attained at cable
cam of throttle valve module.
1.13 Repairing parts of activated charcoal filter system

Passat 1997 ➤
1 - Activated charcoal filter

❑ Location: in front right
wheel housing.
❑ To remove, remove
front right wheel hous‐
ing liner ⇒ General body
repairs, exterior; Rep.
gr. 66 ; Wheel housing
liner; Assembly over‐
view - front wheel hous‐
ing liner .
2 - 10 Nm
3 - Air filter housing
4 - Retaining ring
❑ For solenoid valve 1.
5 - Solenoid valve 1 -N80-
❑ When engine is warm,
valve will be activated
(pulsed) by engine con‐
trol unit.
❑ Installation position: ar‐
row points in direction of
flow.
Rep. gr. 01 ; Final con‐
trol diagnosis .
6 - Connector
❑ Black, 2-pin.
❑ For solenoid valve 1.
ule
8 - O-ring
9 - Breather line
❑ Black
❑ From gravity valve on fuel tank
10 - Securing bolt
11 - Breather hose
❑ To atmosphere.
1.14 Checking fuel tank breather


Passat 1997 ➤
♦ Vacuum tester -V.A.G 1368-
♦ Hand vacuum pump -V.A.G 1390-
Test procedure
– Remove front right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liner; Assembly
overview - front wheel housing liner .
– Pull breather line -2- from activated charcoal filter -1- off sol‐
enoid valve -3-.
– Connect hand vacuum pump -V.A.G 1390- to line -2-.
– Pull off breather line -5- between fuel tank and activated char‐
coal filter and connect it to connection A of vacuum tester -
V.A.G 1368- .
– Connect connection B of vacuum tester -V.A.G 1368- with
breather line -4- leading to activated charcoal filter.
– Set vacuum tester to position -B-.
– Operate hand vacuum pump -V.A.G 1390- several times. Vac‐
uum must not build up.
If vacuum builds up:
– Check breather hose -6- on activated charcoal filter -1- for
soiling and clean if necessary.
If vacuum does not build up:
– Remove fuel filler cap.

Passat 1997 ➤
– Connect hand vacuum pump -V.A.G 1390- to connection B of

vacuum tester -V.A.G 1368- .
– Set vacuum tester to -A/B- position.
– Check gravity valve.
– Check line -1- from fuel tank for blockage.
If vacuum does not build up:
– Refit fuel filler cap.
Note
If the fuel level in the tank is low, the hand vacuum pump must be
operated at least 20-30 times.

– Renew fuel tank cap.

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

is not under stress, and that there is sufficient clearance to the
bodywork. If necessary, loosen double clamps and align si‐
lencer and exhaust pipe so that sufficient clearance is main‐
tained to the bodywork and the support rings are evenly
loaded.
♦ Renew self-locking nuts.
⇒ “1.1 Exhaust manifold, front exhaust pipe and catalytic con‐

verter with attachments, vehicles with four-wheel drive”,
page 123
⇒ “1.2 Exhaust manifold, front exhaust pipe and catalytic con‐
verter with attachments, vehicles with front-wheel drive”,
page 125
⇒ “1.3 Silencers with mountings, vehicles with four-wheel drive”,
page 125
⇒ “1.4 Silencers with mountings, vehicles with front-wheel drive”,
page 127
1.1 Exhaust manifold, front exhaust pipe

and catalytic converter with attach‐
ments, vehicles with four-wheel drive
1. Removing and installing parts of exhaust system 123

Passat 1997 ➤
1 - Heat shield
2 - 25 Nm
3 - Exhaust manifold
4 - Gasket
❑ Renew.
5 - Lambda probe -G39- , 50
Nm
❑ Grease only the thread
with “G5”; “G5” must not
get into slots in probe
body.
nosis; Reading and
❑ Checking lambda probe
and lambda control ⇒
Rep. gr. 24 ; Checking
components and func‐
tions; Checking lambda
probe and lambda con‐
trol .
heater ⇒ Rep. gr. 24 ;
Checking components
and functions; Checking
lambda probe heater .
6 - To centre silencer
7 - Catalytic converter
8 - Bolt
9 - Spacer sleeve
10 - Spring
11 - Washer
12 - Rubber bush
13 - Bracket
14 - Front exhaust pipe
15 - 30 Nm
124 Rep. gr.26 - Exhaust system

Passat 1997 ➤
1.2 Exhaust manifold, front exhaust pipe and catalytic converter with attach‐
ments, vehicles with front-wheel drive
1 - Heat shield
2 - 25 Nm
3 - Gasket
❑ Renew.
4 - Double clamp
5 - Coach bolt
6 - To centre silencer
7 - Washer
8 - 40 Nm
9 - Lambda probe -G39- , 50
Nm
❑ Grease only the thread
with “G5”; “G5” must not
get into slots in probe
body.
nosis; Reading and
and lambda control ⇒
Rep. gr. 24 ; Checking
components and func‐
tions; Checking lambda
probe and lambda con‐
trol .
heater ⇒ Rep. gr. 24 ;
Checking components
and functions; Checking
lambda probe heater .
10 - 4-pin connector
❑ Black
❑ Secured on left of bulkhead below expansion tank (looking forwards).
❑ For lambda probe and lambda probe heater.
11 - Front exhaust pipe with catalytic converter
12 - Exhaust manifold
1.3 Silencers with mountings, vehicles with

four-wheel drive

Passat 1997 ➤
1 - 40 Nm
2 - From catalytic converter
3 - Coach bolt
4 - Double clamp
5 - 25 Nm
6 - Mounting
❑ With retaining ring.
7 - Middle silencer
8 - Repair double clamp
9 - Separating point
❑ Middle and rear silenc‐
ers are installed as a
single component dur‐
ing production. In cases
of repair, the centre and
rear silencer are sup‐
plied separately, with a
double clamp for con‐
necting.
❑ Cut through exhaust
pipe at right angles on
separating point using
body saw e.g. -
V.A.G 1523-
⇒ page 126 .
10 - Rear right silencer
11 - Mounting
12 - Bracket
13 - Rear left silencer
Separating point between centre silencer and rear silencer

Passat 1997 ➤
♦ Pneumatic sabre saw -V.A.G 1523 A-
Procedure
– Separate connecting pipe between centre silencer and rear
silencer at the point marked with a groove: measurement -a-
approx. 244 mm.
1.4 Silencers with mountings, vehicles with front-wheel drive
1 - From catalytic converter

2 - 25 Nm
3 - Mounting
❑ With retaining ring.
4 - Middle silencer
5 - Bracket
6 - Mounting
7 - Rear silencer
8 - Repair double clamp
9 - 40 Nm
10 - Coach bolt
11 - Separating point
❑ Middle and rear silenc‐
ers are installed as a
single component dur‐
ing production. In cases
of repair, the centre and
rear silencer are sup‐
plied separately, with a
double clamp for con‐
necting.
❑ Cut through exhaust
pipe at right angles on
separating point using
body saw e.g. -
V.A.G 1523-
⇒ page 126 .

Passat 1997 ➤
Separating point between centre silencer and rear silencer

♦ Pneumatic sabre saw -V.A.G 1523 A-
Procedure
– Separate connecting pipe between centre silencer and rear
silencer at the point marked with a groove: dimension -a- ap‐
prox. 160...170 mm.

Passat 1997 ➤
2 Secondary air system

⇒ “2.1 Function”, page 129
⇒ “2.2 Removing and installing components of secondary air sys‐
tem”, page 129
⇒ “2.3 Checking combination valve”, page 131
⇒ “2.4 Removing and installing combination valve”, page 133
2.1 Function
The secondary air system blows air in behind the exhaust valves
for 65 seconds during a cold start (+15°C to +35°C coolant tem‐
perature). This produces an oxygen rich exhaust gas, causing
afterburning and reducing the heat-up phase of the catalytic con‐
verter. The Motronic control unit -J220- activates the system via
the secondary air pump relay -J299- to the secondary air inlet
valve ( -N112- , changeover valve) and combination valve. Addi‐
tionally, after each subsequent engine start (up to max. 85 C
engine temperature), the secondary air system will, after a 20
second delay, switch in for 5 seconds during idling and will be
checked by the self-diagnosis.
2.2 Removing and installing components of

secondary air system
Note
♦ The components marked with are checked via self-diagnosis

⇒ Motronic injection and ignition system (5-cyl. engine); Rep.
gr. 01 ; Self-diagnosis; Reading and clearing fault memory .
♦ The components marked with are checked via final control di‐
agnosis ⇒ Motronic injection and ignition system (5-cyl. en‐
gine); Rep. gr. 01 ; Final control diagnosis .
♦ Secondary air pump relay -J299- with fuse S130
⇒ page 131 .
2. Secondary air system 129

Passat 1997 ➤
1 - Combination valve
⇒ page 133 .
2 - 5 Nm
3 - O-ring
❑ Renew.
4 - Air duct
❑ In cylinder head
5 - Bracket
❑ For secondary air inlet
valve -N112- and intake
manifold changeover
valve -N156- .
6 - To fuel pressure regulator.
7 - To upper part of intake
manifold
8 - Intake manifold changeover
valve -N156- /
9 - Connector
❑ Black, 2-pin.
10 - Non-return valve
❑ Black side of valve faces

Passat 1997 ➤
intake manifold.
11 - To intake manifold changeover vacuum actuator.
12 - To vacuum reservoir
13 - To upper part of air filter.
14 - Intake hose
15 - Secondary air pump motor -V101- /
16 - Connector
❑ Black, 2-pin.
❑ For secondary air pump motor.
17 - Bracket
❑ For secondary air pump motor.
18 - Rubber bush
19 - Housing
20 - 10 Nm
21 - Secondary air inlet valve -N112- /
22 - Connector
❑ Green, 2-pin.
❑ For secondary air inlet valve.
23 - Connection
24 - Pressure hose
25 - Gasket
❑ Renew.
26 - Connection
❑ For combination valve.
Secondary air pump relay -J299- -1-

♦ With fuse S130, -2-.
2.3 Checking combination valve


Passat 1997 ➤
♦ -V.A.G 1390- Hand vacuum pump
Test prerequisites
• No fault in fault memory: ⇒ Motronic injection and ignition
system (5-cyl. engine); Rep. gr. 01 ; Self-diagnosis; Reading
• Final control diagnosis completed ⇒ Motronic injection and
ignition system (5-cyl. engine); Rep. gr. 01 ; Final control di‐
agnosis .
• Vacuum pipes and hose connections free of leaks.
• Vacuum pipes not blocked or kinked.
Test procedure
– Pull vacuum hose from combination valve off secondary air
inlet valve -N112- .
– Connect hand vacuum pump -V.A.G 1390- to vacuum hose
leading to combination valve.
Note
Do not use compressed air during the following check!

Passat 1997 ➤
– Separate pressure hose -arrow-, connect auxiliary hose and

blow into auxiliary hose in direction of combination valve. En‐
sure to build up only a slight pressure. Combination valve must
be closed.
– Operate hand vacuum pump. Combination valve must open.
If combination valve does not open:
– Renew combination valve ⇒ page 133 , Removing and instal‐
ling combination valve.
2.4 Removing and installing combination

valve
Removing
Perform the following steps to remove the combination valve:
♦ Unbolt coolant expansion tank. The coolant hoses remain
connected.
♦ Pull off connector located below coolant expansion tank.
♦ Carefully move coolant expansion tank clear to one side.
♦ Pull pressure hose and vacuum hose off combination valve.
♦ Unbolt combination valve from lower part of intake manifold
and pull it out of air duct together with connecting piece.
Installing
Installation is performed in the reverse sequence. In the process,
note the following:
♦ O-rings must be renewed.
♦ Pressure hose and vacuum hose must be secured firmly on
combination valve.

Engine Agz Repair Manual Eng

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Service

Service Department. Technical Information

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

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

1.2 Parts of cooling system - engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

1.1 Engine number

In vehicle models as of 2000 ►, the engine number (“engine code”

1.2 Engine data

1) VR = V-arrangement in compact in-line design

Engine codes AGZ

2) In exceptional circumstances min. 91 RON, however with reduced perform‐

2 Rep. gr.00 - Technical data

10 – Removing and installing engine

1.1 Notes on removing

Special tools and workshop

1. Removing and installing engine 3

♦ -V.A.G 1331- Torque

4 Rep. gr.10 - Removing and installing engine

– Disconnect connectors for headlights and headlight height ad‐

– Disconnect connectors ahead of ABS unit -arrows-.

– Unbolt hydraulic oil cooling pipe of power-assisted steering

1. Removing and installing engine 5

– Detach accelerator cable from cable disc of throttle valve con‐

Fuel supply lines are under pressure! Before loosening hose

– Disconnect fuel supply and fuel return lines at fuel rail.

– Disconnect following connectors: 1 - Lambda probe 1 -G39- ,

6 Rep. gr.10 - Removing and installing engine

– Remove upper engine/gearbox securing bolts.

– Separate torque converter from drive plate (3 securing nuts).

After removing the engine, secure the torque converter against

Continuation for all vehicles

– Attach support bracket 10-222A as shown.

1. Removing and installing engine 7

– Attach lifting tackle 2024 A as follows and lift slightly with

Use locking pins -arrows- to secure hooks and locating pins.

♦ The positions marked 1…4 on the bar must be towards the

– Lift engine out forwards.

Guide the engine carefully when lifting out, to prevent damage to

1.2 Notes on installing

8 Rep. gr.10 - Removing and installing engine

– Renew engine mounting self-locking nut -1-.

– Install engine/gearbox connecting bolts.

1. Removing and installing engine 9

1.3 Assembly mountings

Rear right assembly mountings

1.4 Additional information and assembly

The air conditioner refrigerant circuit must not be opened.

To prevent damage to condenser and also to refrigerant lines/

To facilitate removing and installing engine without opening re‐

10 Rep. gr.10 - Removing and installing engine

– Remove air conditioner compressor ⇒ Heating, air condition‐

1. Removing and installing engine 11

12 Rep. gr.13 - Crankshaft group

1 - Camshaft chain sprocket

1. Dismantling and assembling engine 13

⇒ Item 9 (page 14) .

14 Rep. gr.13 - Crankshaft group

1.2 Checking valve timing

♦ Assembly tool -T10029-

1. Dismantling and assembling engine 15

If the TDC No. 1 Cyl. setting is correct it is possible to see a notch

This condition is only achieved every 2nd complete rotation of