Volkswagen Passat B4 Factory Workshop Manual / Repair Manual

VOLKSWAGEN PASSAT B4 - FACTORY SERVICE MANUAL

- English Workshop Manual, in PDF format, to vehicles Volkswagen Passat B4.


FACTORY SERVICE MANUAL:


001 - (WIRING SCHEMATICS) 1995
- Cover
- How to read Wiring Schematics
- Index - 1995 - Passat (2.8L-Engine - Motronic Multiport Fuel Injection (MFI)/128kW), code AAA, from August 1994
- Index - 1995 - Passat (1.9L-Engine - Turbo Diesel Fuel Injection (DFI)/55kW), code AAZ, from August 1994
- Index - 1995 - Passat (2.0L-Engine - Motronic Multiport Fuel Injection (MFI)/85kW), code ABA, from February 1995
- Index - 1995 - Common Systems
- Num 1 - Passat --- Standard Equipment
- Num 2 - 2.8L-Engine --- Motronic Mutiport Fuel Injection (MFI)/128kW, code AAA
- Num 3 - Coolant fan, two speeds, 250W,code AAA
- Num 4 - Coolant fan, two speeds, 250W,code AAZ
- Num 5 - Air conditioning, D 1.9l-Engine --- Turbo Diesel Fuel Injection (DFI)/55 kW, code AAZ
- Num 6 - Air conditioning, D 2.8l-Engine --- Motronic Multiport Fuel Injection (MFI)/ 128 kW, code AAA
- Num 7 - Front and rear power windows
- Num 8 - Heated seats
- Num 9 - Interior light with delay switch, rear reading lights, make-up mirror lights
- Num 10 - Heated power mirrors
- Num 11 - Heated washer nozzles
- Num 12 - Trunk lid release, sedan only
- Num 13 - Anti-lock brake system (ABS) with electronic differential lock (EDL)
- Num 14 - Cruise control
- Num 15 - Central locking system and anti-theft alarm system
- Num 16 - Power sunroof
- Num 17 - 1.9L-Engine --- Turbo Diesel Fuel Injection (DFI)/55kW, code AAZ
- Num 18 - Airbag
- Num 19 - Automatic transmission, D 2.8L-Engine --- Motronic Multiport Fuel Injection (MFI)/128kW, code AAA
- Num 20 - Stereo radio with CD-changer and eight speakers
- Num 21 - Coolant fan, three speeds, 450W, code AAA
- Num 22 - Coolant fan, three speeds, 450W, code AAZ
- Num 23 - Daytime running lights, only Canada
- Num 24 - 2.0L-Engine --- Motronic Mutiport Fuel Injection (MFI)/85kW, code ABA
- Num 25 - Airbag
- Num 26 - Air conditioning, D 2.0l-Engine --- Motronic Multiport Fuel Injection (MFI)/85kW, code ABA
- Num 27 - Automatic transmission, D 2.8L-Engine --- Motronic Multiport Fuel Injection (MFI)/128kW, code AAA, D 2.0L-Engine --- Motronic Multiport Fuel Injection (MFI)/85kW, code ABA

002 - (WIRING SCHEMATICS) 1996
- Cover
- How to read Wiring Schematics
- Index - 1996 - Passat (2.8L-Engine - Motronic Multiport Fuel Injection (MFI)/128kW), code AAA, from August 1995
- Index - 1996 - Passat (2.0L-Engine - Motronic Multiport Fuel Injection (MFI)/85kW), code ABA, from August 1995
- Index - 1996 - Passat (1.9L-Engine - Turbo Diesel Fuel Injection (DFI)/55kW), code 1Z, from August 1995
- Index - 1996 - Common Systems
- Num 3 - Coolant fan, two speeds, 250W,code AAA
- Num 4 - Coolant fan, two speeds, 250W,code AAZ
- Num 5 - Air conditioning, D 1.9l-Engine --- Turbo Diesel Fuel Injection (DFI)/55 kW, code AAZ
- Num 6 - Air conditioning, D 2.8l-Engine --- Motronic Multiport Fuel Injection (MFI)/ 128 kW, code AAA
- Num 7 - Front and rear power windows
- Num 8 - Heated seats
- Num 9 - Interior light with delay switch, rear reading lights, make-up mirror lights
- Num 10 - Heated power mirrors
- Num 11 - Heated washer nozzles

- Num 12 - Trunk lid release, sedan only
- Num 14 - Cruise control
- Num 15 - Central locking system and anti-theft alarm system
- Num 16 - Power sunroof
- Num 18 - Airbag
- Num 20 - Stereo radio with CD-changer and eight speakers
- Num 21 - Coolant fan, three speeds, 450W, code AAA
- Num 22 - Coolant fan, three speeds, 450W, code AAZ
- Num 23 - Daytime running lights, only Canada
- Num 26 - Air conditioning, D 2.0l-Engine --- Motronic Multiport Fuel Injection (MFI)/85kW, code ABA
- Num 28 - Automatic transmission, D 1.9L-Engine --- Turbo Diesel Fuel Injection (DFI), 66kW, code 1Z
- Num 29 - 1.9L-Engine --- Turbo Diesel Fuel Injection (DFI), 66kW, code 1Z
- Num 30 - 2.0L-Engine --- Motronic Mutiport Fuel Injection (MFI)/85kW, code ABA
- Num 31 - 2.8L-Engine --- Motronic Mutiport Fuel Injection (MFI)/128kW, code AAA
- Num 32 - Automatic transmission, D 2.8L-Engine --- Motronic Multiport Fuel Injection (MFI)/128kW, code AAA, D 2.0L-Engine --- Motronic Multiport Fuel Injection (MFI)/85kW, code ABA
- Num 33 - Anti-lock brake system (ABS) with electronic differential lock (EDL)
- Num 34 - Passat --- Standard Equipment
- Num 35 - Air-Conditioning - 1,9 L-Engine-Turbo Diesel Fuel Injection (DFI) / 66 kW, code 1Z

003 - (2.0 LITER 4-CYL. 2V ENGINE MECHANICAL).
- Cover
- Index - 2.0 Liter 4-Cyl. 2V Engine Mechanical, Engine Code(s): ABA m.y. 1995
- Technical data
- Engine, removing and installing
- Engine disassembling and assembling
- Sealing flange and flywheel or drive plate, removing and installing
- Crankshaft, removing and installing
- Pistons and connecting rods, disassembling and assembling
- Cylinder head removal and installation
- Cylinder head, disassembling and assembling
- Lubrication system, general information
- Cooling system
- Fuel supply system
- Evaporative Emissions (EVAP) system
- Exhaust system removal and installation
- Exhaust Gas Recirculation (EGR) system
- Secondary Air Injection (AIR) system

004 - (2.8 LITER VR6 2V ENGINE MECHANICAL).
- Cover
- Index - 2.8 Liter VR6 2V Engine Mechanical, Engine Code(s): AAA
- Technical data
- Engine, removing and installing
- Engine, disassembly and assembly
- Cylinder head, removing and installing
- Compression testing
- Valve train, servicing
- Lubrication system, component removal and installation
- Oil filter housing, disassembling and assembling
- Cooling system, component removal and installation
- Radiator and radiator fan, removing and installing
- Fuel supply system components, removing and installing
- Exhaust system components, removing and installing
- Secondary Air Injection system, function

005 - (2.0 LITER 4-CYL.).
- Cover
- Index - 2.0 Liter 4-Cyl. 2V Fuel Injection & Ignition, Engine Code(s): ABA m.y. 1995
- On Board Diagnostic
- Motronic fuel injection and ignition system
- Motronic fuel injection system, servicing
- Motronic fuel injection and ignition system
- Motronic ignition system, servicing

006 - (2.0 LITER 4-CYL. 2V FUEL INJECTION & IGNITION).
- Cover
- Index - 2.0 Liter 4-Cyl. 2V Fuel Injection & Ignition
- On Board Diagnostic (OBD)
- VAG 1551 Scan Tool (ST), connecting and selecting "Engine Electronics" address word 01
- VAG 1551 Scan Tool (ST), connecting and selecting "CARB/OBD II" address word 33
- Multiport fuel injection and ignition system
- Multiport fuel injection and ignition system

007 - (2.0 LITER 4-CYL. 2V GENERIC SCAN TOOL FUEL INJECTION & IGNITION).
- Cover
- Index - 2.0 Liter 4-Cyl. 2V Generic Scan Tool Fuel Injection & Ignition, Engine Code(s): ABA m.y. 1996-1997
- Fuel supply system components, removing and installing
- EVAP canister system
- Accelerator Pedal (AP) cable, adjusting
- Motronic fuel injection and ignition system
- Components of engine, checking
- Function tests
- Engine Control Module (ECM)
- Additional signals, Checking
- Exhaust system components, removing and installing
- Secondary Air Injection (AIR) system

- Ignition, servicing
- Selector lever mechanism, servicing
- Electrical components of transmission control, removing and installing, checking
- Transmission Control Module (TCM)
- General information for On Board Diagnostic (OBD)
- Diagnostic mode, selecting
- Readiness code
- Diagnostic Trouble Code (DTC) tables

008 - (2.8 LITER VR6 2V FUEL INJECTION & IGNITION).
- Cover
- Index - 2.8 Liter VR6 2V Fuel Injection & Ignition, Engine Code(s): AAA m.y. 1995
- On Board Diagnostic (OBD)
- On Board Diagnostic, technical data
- VAG 1551 Scan Tool, connecting
- Check DTC Memory (function 02)
- Diagnostic Trouble Code (DTC) table
- Erase DTC Memory (function 05)
- Output Diagnostic Test Mode (DTM), initiating
- Electrical wiring and component checks
- Motronic Fuel Injection and Ignition system, component layout
- Motronic Fuel Injection and Ignition system

009 - (2.8.LITER.VR6.2V.FUEL.INJECTION.&.IGNITION).
- Cover
- Index - 2.8 Liter VR6 2V Fuel Injection & Ignition, Engine Code(s): AAA m.y. 1996-1997
- On Board Diagnostic (OBD II)
- VAG 1551 Scan Tool (ST), connecting and selecting "Engine Electronics" address word 01
- VAG 1551 Scan Tool (ST), connecting and selecting "CARB/OBD II" address word 33

- Multiport fuel injection and ignition system
- Multiport fuel injection and ignition system

010 - (2.8.LITER.VR6.2V.GENERIC.SCAN.TOOL.FUEL.INJECT).
- Cover
- Index - 2.8 Liter VR6 2V Generic Scan Tool Fuel Injection & Ignition, Engine Code(s): AAA m.y. 1996-1997
- Fuel supply system components, removing and installing
- EVAP canister system
- Accelerator Pedal (AP) cable, adjusting
- Motronic fuel injection and ignition system
- Engine components,checking
- Function tests
- Engine Control Module (ECM)
- Additional signals, checking
- Exhaust system components, removing and installing
- Secondary Air Injection (AIR) system
- Ignition, servicing
- Transmission control electrical components, removing and installing, checking
- Transmission Control Module (TCM)
- General information for On Board Diagnostic (OBD)
- Diagnostic function, selecting
- Readiness code
- DTC tables

011 - (5.SPD..MANUAL.TRANSMISSION.02A).
- Cover
- Index - 5 Spd. Manual Transmission 02A
- Transmission identification
- Transmission layout
- Calculating overall ratio (i)
- General repair instructions
- Clutch actuating mechanism
- Servicing clutch release mechanism
- Clutch, servicing
- Gear selector mechanism, servicing
- Transmission disassembly and assembly, overview
- Transmission housing and clutch housing, servicing
- Selector shaft, disassembling and assembling
- Shift forks, disassembling and assembling
- Input shaft, disassembling and assembling
- Input shaft, adjusting
- Output shaft, disassembling/ assembling
- Output shaft, adjusting
- Reverse idler shaft, disassembling and assembling
- Axle flange oil seal, replacing
- Differential, assembly
- Adjustment overview
- Differential, adjusting

012 - (4.SPD..AUTOMATIC.TRANSMISSION.01M).
- Cover
- Index - 4 Spd. Automatic Transmission 01M
- Transmission, identification
- Automatic transmission 01M, general information
- Code letters, transmission allocation, ratios, equipment
- On Board Diagnostic (OBD), function
- Electrical component locations
- On Board Diagnostic program
- Diagnostic Trouble Code (DTC) table
- Diagnostic Trouble Code (DTC) Memory, erasing
- Test table
- Electrical check
- Test table
- Torque converter
- Torque converter
- Selector mechanism, servicing
- Shift mechanism, disassembling and assembling
- Selector lever, disassembling and assembling
- Locking cable, removing and installing
- Transmission, checking
- Shift points in km/in (mph)
- Stall Speed Chart
- Transmission, removing and installing
- Transmission with selector elements
- ATF cooler and ATF filler tube, removing and installing
- Planetary transmission, disassembling and assembling -Overview-
- Planetary transmission, disassembling and assembling
- Transmission, removing and installing
- Planetary transmissionadjustments, overview
- Planet carrier, adjusting
- Reverse gear brake - B1-, adjusting
- Clutch play between -K1- and -K2-, adjusting
- 2nd and 4th gear brake -B2-, adjusting
- ATF pump, disassembling and assembling
- Free wheel with -B1- piston, disassembling and assembling
- 1st to 3rd gear clutch -K1-, disassembling and assembling
- Reverse gear clutch -K2-, disassembling and assembling
- 4th gear clutch -K3- with turbine shaft, disassembling and assembling
- Valve body, removing and installing
- Parking lock, disassembling and assembling
- Final drive oil level, checking
- Final drive, disassembling and assembling
- Input gear, removing and installing
- Drive pinion, removing and installing
- Differential, removing and installing
- Differential, disassembling and assembling
- Final drive, adjusting

013 - (4 SPD. AUTOMATIC TRANSMISSION 096).
- Cover
- Index - 4 Spd. Automatic Transmission 096
- Transmission identification
- Code letters, model/engine applications, ratios, equipment
- Capacities
- Repair instructions
- On Board Diagnostic (OBD), general information
- On Board Diagnostic (OBD) program
- Transmission electrical testing
- Torque converter
- Shift mechanism, servicing
- Transmission, checking
- Transmission, removing and installing
- ATF level
- Gear selector elements
- Transmission, disassembling and assembling
- ATF pump, disassembling and assembling
- Free wheel with -B1- piston, disassembling and assembling
- 1st to 3rd gear clutch -K1- with turbine shaft, disassembling and assembling
- Reverse gear clutch -K2-, disassembling and assembling
- 4th gear clutch -K3- with pump shaft, disassembling and assembling
- Valve body, removing and installing
- Parking lock, disassembling and assembling
- Oil in final drive, checking
- Drive flange oil seal, removing and installing
- Final drive, disassembling and assembling
- Final drive, adjusting

014 - (BRAKE.SYSTEM.ON.BOARD.DIAGNOSTIC).
- Cover
- Index - Brake System On Board Diagnostic (OBD)
- Teves 04 Anti-lock Brakes (ABS) and Anti-lock Brakes with Electronic Differential Lock (ABS/EDL), On Board Diagnostic (OBD)
- Teves 04 ABS and ABS/EDL electrical/electronic component locations
- Teves 04 ABS and ABS/EDL On Board Diagnostic (OBD)
- Teves 04 ABS and ABS/EDL electrical test
- Teves 20 GI Anti-lock Brakes (ABS) and Anti-lock Brakes with Electronic Differential Lock (ABS/EDL), On Board Diagnostic (OBD)
- Teves 20 GI ABS and ABS/EDL electrical/electronic component locations
- Teves 20 GI ABS and ABS/EDL warning lights, malfunctions displayed
- Teves 20 GI ABS and ABS/EDL On Board Diagnostic (OBD)
- Teves 20 GI ABS and ABS/EDL electrical test

015 - (SUSPENSION, WHEELS, BRAKES, STEERING).
- Cover
- Index - Suspension, Wheels, Brakes, Steering
- Suspension, Wheels, Brakes, Steering
- Front Wheel Suspension, Shafts and Axle
- Rear Wheel Suspension, Shafts and Axle
- Wheel bearings, servicing
- Rear axle, servicing (four wheel drive vehicles)
- Rear drive shafts, servicing
- Suspension strut, disassembling and assembling (four wheel drive vehicles)
- Wheel bearings, servicing - disc brakes (four wheel drive vehicles)
- Vehicle alignment
- Anti-locking Brake System (ABS) and Anti-locking Brake System with Electronic Differential Lock (ABS/EDL) Teves 04
- Anti-lock Brake System (ABS) and ABS with Electronic Differential Lock (ABS/EDL), Teves 20 GI
- ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master cylinder (Teves 20 GI), servicing
- Assembly overview - hydraulic unit, brake servo/brake master cylinder
- Front brakes, servicing (Girling caliper)
- Front brakes, servicing (Teves/Ate)
- Rear wheel brakes, servicing (drum brakes)
- Rear wheel brakes, servicing
- Rear wheel brakes, servicing (disc brakes)
- Parking brake lever assembly overview
- Assembly overview: brake master cylinder/brake servo
- Girling front brake caliper, servicing
- Front brake caliper, servicing (Teves/Ate)
- Rear brake caliper, servicing
- Brake pressure regulator, checking and adjusting
- Brake system, bleeding
- Steering

016 - (BODY.EXTERIOR,.INTERIOR).
- Cover
- Index - Body Exterior, Interior
- Airbag System, On Board Diagnostic (OBD), vehicles up to 09.94
- Airbag system, On Board Diagnostic (OBD), vehicles from 10.94
- Body, front
- Hood
- Rear lid
- Front door assembly
- Central locking, repairing (Sedan)
- Rear door assembly
- Sliding/tilting roof
- Sliding/tilting roof with glass panel
- Bumpers
- Rear bumper, removing and installing
- Flush-bonded windows
- Bolted windows
- Roof moldings
- Roof railing, removing and installing
- Radiator grille, removing and installing
- Wheel housing liner
- Exterior mirror
- Protective moldings
- Inside mirror
- Luggage compartment cover, removing and installing
- Screen separator wall, retrofitting
- Safety restraint system
- Seatbelts
- Seat belts, inspecting
- Airbag
- Instrument panel, removing and installing
- Door trim
- Trim
- Headliner
- Front seat
- Rear seats

- Seat upholstery

018 VOLKSWAGEN PASSAT OFFICIAL FACTORY REPAIR MANUAL (HEATING & AIR CONDITIONING)
- Cover
- Index - Heating & Air Conditioning
- Heating and ventilation system
- A/C refrigerant system, notes
- Manual A/C
- Compressor bracket, removing and installing
- A/C refrigerant system
- A/C refrigerant system, servicing
- A/C refrigerant system, troubleshooting
- A/C refrigerant system, capacities

020 - (MAINTENANCE).
- Cover
- Index - Maintenance
- Engine overview
- Oil change service
- Inspection service
- General Information
- Work descriptions



UNIFORM INSPECTION GUIDELINES:


- A/c-heater system uniform inspection guidelines *
- anti-lock brakes uniform inspection guideline *
- auto trans diagnosis menu - volkswagen
- brake system uniform inspection guidelines *
- electrical system uniform inspection guidelines *
- engine systems uniform inspection guidelines *
- exhaust system uniform inspection guidelines *
- steering uniform inspection guidelines *
- suspension uniform inspection guidelines *
- symptom check list *
- 1.8l 4-cyl 8-valve & 2.0l 4-cyl 8-valve & 16-valve
- 2.8l in-line v6 (vr6)
- A - engine/vin id
- A/c compressor oil checking
- A/c compressor servicing
- A/c system general diagnostic procedures
- A/c system general servicing
- A/c-heater system - manual
- Aa - using this section (general help information)
- Abbreviations
- Alternator & regulator
- Anti-lock brake safety precautions
- Anti-lock brake system
- Anti-theft system
- Axle shafts
- B - emission application
- Brake system
- C - specifications
- Clutch
- Computer relearn procedures
- Cruise control system
- D - adjustments - 4-cyl
- D - adjustments - vr6
- Defogger - rear window
- Door locks - power
- E - theory/operation - 4-cyl
- E - theory/operation - vr6
- Electrical component locator
- Electrostatic discharge warning - basic information
- Emission control visual inspection procedures
- Engine overhaul procedures - general information
- F - basic testing
- Faulty radiator fan motor could overheat & stall eng
- Fuel leakage could cause fire:new fuel hose & clamps
- Fuses & circuit breakers
- G - tests w/codes
- Gear tooth contact patterns
- General cooling system servicing
- H - tests w/o codes
- How to use system wiring diagrams
- I - system/component tests - 4-cyl
- I - system/component tests - vr6
- Instrument panel
- Instrument panel
- Interference verification check for ohc engine
- J - pin voltage charts - 4-cyl
- J - pin voltage charts - vr6
- L - wiring diagrams
- M - vacuum diagrams
- Maintenance information
- Maintenance reminder light reset procedures
- Metric conversions
- Mirrors - power
- N - remove/install/overhaul - 4-cyl
- N - remove/install/overhaul - vr6
- P - egr function testing
- Pre-alignment checks
- Riding height adjustment
- Scheduled services
- Separation of axle: new front axle lock nuts
- Specifications & electric cooling fans
- Starter
- Steering column
- Steering column switches
- Steering gear - power rack & pinion
- Sun roof - power
- Suspension - front
- Suspension - rear
- System wiring diagrams
- Transmission removal & installation - a/t
- Transmission removal & installation - m/t
- Transmission servicing - a/t
- Transmission servicing - m/t
- Trouble shooting - basic procedures
- Waveforms - injector pattern tutorial
- Wheel alignment specifications & procedures
- Wheel alignment theory/operation
- Wiper/washer system
- Wiring diagram symbols
- Wiring diagrams