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- Passat 1995
- Official Factory Repair Manual
Volkswagen Passat 1995 Official Factory Repair Manual
Summary of Passat 1995
Page 3
Maintenance maintenance engine overview oil change service oil change service every 10,000 miles (15,000 km) inspection service inspection service every 12 months inspection service every 20,000 miles (30,000 km) general information type plate vehicle identification number (vin) engine code and engi...
Page 4
Spark plugs, replacing dust and pollen filter element, replacing toothed belt for camshaft drive: (diesel engine code aaz), ccheck condition and tension toothed belt and toothed belt tensioning roller (diesel engine codes afn and 1z), replacing toothed belt for camshaft drive (gasoline engine), chec...
Page 5: Engine Overview
1 engine overview engines gas engine code letters aaa manufactured from 10.93 number of cylinders / valves per cylinder 6 / 2 displacement liters 2.8l output kw @ rpm 128/5800 torque nm @ rpm 235/4200 1) bore mm 81.0 stroke mm 90.3 compression ratio 10.0 fuel injection / ignition system motronic m 2...
Page 6
Code letters aaz 1z manufactured from 10.93 10.93 number of cylinders / valves per cylinder 4 / 2 4 / 2 displacement liters 1.9l 1.9l output kw @ rpm 55/4400 66/4000 torque nm @ rpm 140/2200...2800 202/1900 bore mm 79.5 79.5 stroke mm 95.5 95.5 compression ratio 22.5:1 19.5:1 fuel injection / igniti...
Page 7: Oil Change Service
2 oil change service oil change service every 10,000 miles (15,000 km) vehicles with a yearly mileage performance greater than 10,000 miles (15,000 km) n sequence of individual service positions has been tested and optimized. Therefore they should be adhered to, to prevent unnecessary work interrupt...
Page 8
- service sticker: note date for next scheduled service (also brake fluid change) on sticker and affix sticker to door beam (b-pillar) page 2 of 2 oil change service 12/7/2004 http://ebahn.Bentleypublishers.Com/vw/servlet/display?Action=goto&type=repair&id=vw.B4.Me01.01.2.
Page 9: Inspection Service
3 inspection service inspection service every 12 months n ask customer whether new wiper blades should be installed and whether they require "windshield clear" g 052 164 (cleaner and anti-freeze) in windshield washer system. N sequence of individual service positions has been tested and optimized. T...
Page 10
System: check function and setting and headlight cleaning system, checking function - windshield wiper blades: check for damage; check rest position; only for "juddering" wiper blades: check pitch angle 01-5, windshield wiper blades, check park position and pitch angle tires - spare wheel: check con...
Page 11
Checking thickness - exhaust system: perform visual check for leaks, security and damage - track rod ends: check play, security and joint boots 01-5, tie rod ends, checking - ball joints: perform visual check of swivel joint boots for leaks and damage 01-5, ball joints, checking engine compartment -...
Page 12: (30,000 Km)
- battery: checking 01-5, battery, checking (vehicles with diesel engine code aaz, on which no emissions test has been performed) - idle speed: checking 01-5, idle speed (diesel engine code aaz): checking final work procedures - tire filling pressure at all 4 wheels and spare wheel: checking 01-5, c...
Page 13
) applicable only for countries where there are no country specific mandatory exhaust emission regulations. Page 5 of 5 inspection service 12/7/2004 http://ebahn.Bentleypublishers.Com/vw/servlet/display?Action=goto&type=repair&id=vw.B4.Me01.01.3.
Page 14: General Information
4 general information type plate a - type plate - located on front lock carrier plate. Vehicle identification number (vin) b - vehicle identification number (vin) - it is stamped on rear engine compartment bulkhead and is visible through a window in plenum chamber cover. Meaning of vehicle identific...
Page 15: Vehicle, Lifting
Engine code and engine number can be found fastest on sticker - arrow - on toothed belt guard (4-cyl.-engine) or on left valve cover (6-cyl.-engine). Vehicle, lifting caution! N vehicle may only be lifted at points indicated in illustration in order to avoid damaging vehicle floor pan and to prevent...
Page 16: Tow Starting/towing
At reinforcing plate welded to floor panel. Position support so rear edge aligns with center of sill depression. Rear: at reinforcing plate welded to floor panel. Position support so rear edge aligns with center of sill depression. Caution! Do not lift vehicle on vertical sill reinforcement or damag...
Page 17
Wrench. - after use, unscrew towing eyelet and store with vehicle tool kit. Re-install cover. Rear towing eyelet is located at right in bumper and is covered by a flap. - to open flap, pull flap downward and let it hang freely. - to close flap, first insert at bottom and press upward until it engage...
Page 18
N ignition must be switched on so that steering wheel is free and turn signals, horn and if necessary windshield wiper and washer can be used. N because brake booster only works when engine is running, more pressure is required accordingly on brake pedal when engine is not running. N in vehicles wit...
Page 19
Temperature must not be tow started over a long distance, otherwise unburned fuel reaches catalytic converter and can be burned there. This may cause catalytic converter to overheat. When towing a vehicle with automatic transmission following additional points must be observed: n selector lever in "...
Page 20: Work Descriptions
5 work descriptions driver's and front passenger airbags, visual check of airbag units you can see whether an airbag(s) is installed by inscription "airbag" on steering wheel padded panel (driver's side) and on far side of dash panel (passenger side). - perform visual check of pad panel - 1 - and su...
Page 21
5051/ 01-5, checking dtc memory of all systems using vehicle diagnosis, testing and information system vas 5051: . Interrogating dtc memory of all systems with scan tool vag 1551: required special tools and equipment n vag1551 scan tool (st) v.A.G 1551/ n adapter cable v.A.G 1551/3 a connecting scan...
Page 22
- unclip cover below instrument cluster. - with ignition switched off, connect scan tool (st) v.A.G 1551/ using adapter cable v.A.G 1551/3 a . Interrogating dtc memory: - start engine and let run at idle. - switch printer on via print button (indicator lamp in button lights up). Indicated on display...
Page 23
When a control module responds with its identification, display indicates number of stored errors or indicates "no malfunction recognized" . Dtcs stored in system are indicated in sequence and printed out. Then vag1551 scan tool (st) v.A.G 1551/ sends next address word. Automatic test sequence has e...
Page 24
N diagnostic cable, 5m without voltage supply vas 5051/3 connect vas 5051 tester: - engage parking brake. - manual transmission: shift gear stick in neutral. - with ignition switched off, connect vehicle diagnostic, test and information system vas 5051/ using diagnostic cable, 5m without voltage sup...
Page 25
Indicated on display: select operating mode: - press button for "vehicle on board diagnostic (obd)" on display - arrow - . Note: n if indications shown in work procedure are not indicated on display: user manual for vas5051 tester indicated on display: select vehicle system: - press "00 - check dtc ...
Page 26
Any system malfunctions that are stored will be displayed one after other. Next, vehicle diagnostic, test and information system vas 5051/ sends next address word. Automatic test sequence has ended when following indication appears on display: - press "print" button - 1 - on display and then press "...
Page 27: Lubricate
- switch off ignition and disconnect diagnostic connector. Door check straps and securing bolts, lubricate - lubricate side area of door arrester - arrow a - using lubricant g 000 150. - lubricate securing bolts - arrow b - using lock cylinder grease spray g 400 01. Sunroof, checking function, clean...
Page 28: Function
- clean guide rail - arrows - and lubricate using lubricant g 000 450 02. Windshield wiper/washer system and headlight cleaning system, checking function note: n if during function test it is determined that wiper blades are juddering or making noises, check pitch angle of wiper blades 01-5, windshi...
Page 29
Following tests. Place a drop of water on glass to improve readability of bright/dark boundary. Bright/dark boundary can be clearly recognized on "waterline" . - check concentration of anti-freeze additive using refractometer t10007 (follow user manual). Scale - 1 - of refractometer is designed spec...
Page 30
N freeze protection must be guaranteed to approx. 5 f (-15 c) (approx. -31 f (35 c) in countries with an arctic climate) in windshield washer system. Windshield washer system, check jet setting and adjust if necessary required special tools and equipment n v.A.G3125a note: n never use a needle or a ...
Page 31
B 300 mm d 600 mm tolerance: 20 mm jet setting dimension for rear window: spray jet, center, wiper area note: n if spray jet is uneven or cannot be adjusted to specified dimensions, spray nozzle must be replaced (repair measure). Headlight cleaning system, check jet setting and adjust if necessary r...
Page 32: Position And Pitch Angle
Windshield wiper blades, check park position and pitch angle windshield wiper blades, check park position and adjust if necessary required special tools and equipment n torque wrench v.A.G 1331/ (5 - 50 nm) perform following work procedure: - check whether wiper blades are in park position. Windshie...
Page 33
- if necessary, adjust park position by shifting wiper arm. Tightening torque, wiper arm: 16 nm windshield wiper blades: check pitch angle, adjust if necessary note: n check pitch angle only if wiper blades are juddering or making noises. Required special tools and equipment n windshield wiper adjus...
Page 34
Screw - 3 - . - check pitch angle. Pitch angle (specified values) for driver's side -2.5 / -4 1) passenger's side 0 rear wiper 0 tolerance 2 1) windshield wiper blade with plastic spoiler (vehicles from 05.94 on) if necessary, adjust pitch angle to specified value as follows: - place open-end wrench...
Page 35
- check to make sure that windshield wiper system is not juddering. Checking tire condition, tread wear pattern , filling pressure and tread depth note: n for reasons of safety only tires of same type and tread pattern should be fitted on a vehicle! Note: n vehicle must be equipped with tires of sam...
Page 36
Tread wear pattern on front tires is an indication of whether toe and camber settings should be checked: n "feathering" on tread indicates incorrect toe setting. . N if tread is worn on one side, this is usually caused by incorrect camber. . When wear of this nature is noticed, determine cause by pe...
Page 37
N important information concerning winter tires recommended by volkswagen is found in "fault finding; wheels, tires; chapter 4; no. 2" . Tire inflation pressure table for normal tires (for all factory installed tire sizes) filling pressure values in bar half load front rear full load front rear vehi...
Page 38: Engine Oil Level, Checking
Wagon: 2.0 2.0 2.2 2.8 66 kw sedan: 2.2 2.2 2.4 2.7 wagon: 2.2 2.2 2.4 3.0 81 kw sedan: 2.4 2.4 2.6 2.9 wagon: 2.4 2.4 2.6 3.2 spare wheel: regular wheel: 4.2 meet highest intended inflation pressure for vehicle. Engine oil level, checking after switching engine off, wait at least 3 minutes to allow...
Page 39
N oil extractor v.A.G 1307 a or n oil extractor v.A.G 1358 a n torque wrench v.A.G 1331/ (5 - 50 nm) note: n if oil is drained and not extracted using oil extractor v.A.G 1307 a or oil extractor v.A.G 1358 a , replace gasket for oil drain plug. N observe disposal regulations! Page 20 of 83 work desc...
Page 40
Capacities with filter change: for emissions test tightening torque for drain plug: n 4-cyl. Engines: 30 nm n 6-cyl. Engines: 50 nm oil filter, replacing 4-cyl. Engine note: n observe disposal regulations! - loosen oil filter using tension strap (e.G. Hazet 2171-1) and remove oil filter. - clean eng...
Page 41
Gasoline engine specifications: a - multi-grade light duty oils, specification vw 500 00 or vw 502 00 b - multi-grade oils, specification vw 501 01 - multi-grade oils, specification api-sf or sg ) these oils may only be used in exceptional cases if no approved engine oil is available. Specification ...
Page 42
- as long as oil pressure warning light in instrument panel is lit, engine may run only at idle. Do not accelerate! Throttle bursts may damage turbocharger or cause it to fail completely. - only when warning light goes out, full oil pressure is reached, and driver may accelerate. - after topping off...
Page 43: For Leaks And Damage
N secure lubrication properties at all engine temperature and load conditions. N high resistance to aging. Multi-grade light duty oils according to vw standard 500 00 exhibit beyond that following advantages: n all-season usability at almost all occurring outside temperatures. N smaller friction los...
Page 44
- check hoses, pipes and connections of n fuel system n cooling and heating system n brake system for leaks, abrasions, porosity and brittleness. Note: n make sure that all malfunctions detected are repaired within repair measures. N if fluid losses are greater than can be reasonably expected, deter...
Page 45: Roller)
- check v-belt tension by strong thumb pressure (depth of impression approx. 5 mm) and adjust if necessary. For following adjustment torque wrench v.A.G 1410/ in connection with ring- insertion tool (a/f 22 mm) v.A.G 1410/2 - a - is particularly suitable. - loosen bolts - 1 - and - 2 - , clamping sc...
Page 46
N traces of oil and grease note: n it is essential to replace ribbed belt if malfunctions are found. This will avoid possible break-downs or operating problems. Replacement of a ribbed belt is a repair measure. Tensioning ribbed belt: note: n with engines with tensioning roller, stretching of ribbed...
Page 47: Oil Level
- tighten first mounting bolt - 2 - , then mounting bolt - 1 - to 25 nm. Front manual transmission/final drive, check oil level - remove bolt - arrow - . - check oil level: oil level should reach lower edge of oil filler hole. - if necessary, top-up transmission fluid "specification g 50 sae 75w90 (...
Page 48: Level
- unthread bolt for checking transmission fluid - arrow - . Oil level is correct when the rear final drive is filled up to lower edge of oil filler hole. - screw in bolt - arrow - . When filling anew, note the following: - unthread bolt - arrow - . - top up transmission fluid to lower edge of oil fi...
Page 49
- if oil level is too low, top-off axle oil. Automatic transmission 096 (until december 1994): manufacturing date see side 01-5, transmission identification sae 75 w 90 (synthetic) n container size 0.5 l - part number g 052 145 a1 n container size 1.0 l - part number g 052 145 a2 note: n lubricants ...
Page 50
Automatic transmission 01m from 8/25/1996: manufacturing date see side 01-5, transmission identification sae 75 w 90 (synthetic) n container size 0.5 l - part number g 052 145 a1 n container size 1.0 l - part number g 052 145 a2 note: n lubricants sae 75 w 90 and vw atf must not be mixed with each o...
Page 51: Thickness
Transmission code letters are also listed on vehicle data plates. Brake system, visual inspection - master brake cylinder, brake booster (with anti-lock brake system -abs-: hydraulic unit), check brake pressure regulator, brake caliper for leaks and damage. - make sure that brake hoses are not twist...
Page 52
Required special tools and equipment n torque wrench v.A.G 1332/ (40 -200 nm) n fashlight perform following work procedure: - measure outer and inner pad thickness. A - pad thickness without backing plate - wear limit: 2 mm with a pad thickness of 2 mm (without backing plate) brake pads have reached...
Page 53: Underbody Sealant, Checking
A - pad thickness including backing plate - wear limit: 2 mm with a pad thickness of 2 mm (without backing plate) brake pads have reached their wear limit and must be replaced (repair measure). Rear drum brake pads: - check thickness of brake pads through inspection holes in brake carrier metal shee...
Page 54: Tie Rod Ends, Checking
N malfunctions found must be repaired (repair measure). This inhibits corrosion and rusting through. Tie rod ends, checking perform following work procedure: - with vehicle raised (wheels hanging free), check play by moving tie rods and wheels - arrow - . Play: zero play - check mountings. - check j...
Page 55
12 according to tl "vw 774 d" . Some vehicles are filled with coolant additive g 11 (color green). When adding coolant, use only coolant g 11 according to tl "vw 774 d" . If these vehicles were filled with g 12 for repairs, only g 12 may be refilled. Caution! N coolant additives g 11 and g 12 must n...
Page 56
Scale - 1 - of refractometer is designed for coolant additives -g 12- according to tl "vw 774 d" and -g 11- according to tl "vw 774 c" . Scale - 2 - is designed for coolant additive -g 13-. Note: n coolant additive g 13 is currently used only in vehicles of type "l 80" . N freeze protection additive...
Page 57
0 (32) -25 (-13) 3.5 5.0 -35 (-31) 4.0 6.0 -5 (23) -25 (-13) 3.0 4.5 -35 (-31) 3.5 5.5 -10 (14) -25 (-13) 2.0 3.5 -35 (-31) 3.0 4.5 -15 (5) -25 (-13) 1.5 2.5 -35 (-31) 2.0 3.5 -20 (-4) -25 (-13) 1.0 1.5 -35 (-31) 1.5 2.5 -25 (-13) -35 (-31) 1.0 1.5 -30 (-22) 35 (-31) 0.5 1.0 -35 (-31) -40 (-40) 0.5 ...
Page 58: Spark Plugs, Replacing
-25 c (-13 f) approx. 40 % approx. 60 % -35 c (-31 f) approx. 50 % approx. 50 % -40 c (-40 f) approx. 60 % approx. 40 % note: n coolant additives g 11 or g 12 prevent frost and corrosion damage, scaling and also raises boiling point of coolant. Therefore, cooling system must be filled year round wit...
Page 59
N torque wrench v.A.G 1331/ (5 - 50 nm) n emissions test binder perform following work procedure: - disconnect spark plug connectors using assembly tool t10029 . - remove spark plugs using spark plug removal tool vas 3122b . Note: n spark plug identification and tightening torque emissions test n ob...
Page 60: Tension
- unlock spring latches - 2 - of filter element, remove filters upward. Note: n observe disposal regulations! Installing - install new filter element. - install rubber seal and cover. Toothed belt for camshaft drive: (diesel engine code aaz), ccheck condition and tension - performing work procedure ...
Page 61
Condition of toothed belt must be checked for: n cracks or tears - a - , cross sectional breaks n lateral scouring - b - n fraying and/or outbreaks - c - n tears in tooth base - d - n layer separation (toothed belt carcass, cord strands) n traces of oil and grease note: n it is essential to replace ...
Page 62
Perform following work procedure: - open clips of upper toothed belt protection. - pull upper toothed belt protection forward or remove it if necessary. - measure width of toothed belt using a caliper. - wear limit: 22 mm note: n with a toothed belt width of 22 mm toothed belt has reached its wear l...
Page 63
- disconnect fuel hoses from hose connections - 1 - and - 2 - . - loosen bolt - arrow - at filter mounting pull out filter upward. Installing - install new o-ring for sealing of regulating valve. Note: n flow direction of fuel is marked at connections by arrows (please do not exchange connections). ...
Page 64
- slide filter downward through filter mounting and fasten it at bolt - arrow - . - install regulating valve with attached fuel lines. - install retaining clamp - 5 - . - slide fuel hoses across hose connections - 1 - and - 2 - , and secure hoses using hose clamps. - check fuel system for proper sea...
Page 65
- remove retaining clamp - a - and regulating valve - b - with fuel hoses attached. - connect hose at connection sleeve of dewatering bolt - arrow - , remove bolt, and drain approx. 0.1l of fluid. - tighten dewatering bolt - arrow - and disconnect hose. - install new o-ring for sealing of regulating...
Page 66
N vag1551 scan tool (st) v.A.G 1551/ n adapter cable v.A.G 1551/3 a n atf filler tool v.A.G 1924/ page 47 of 83 work descriptions 12/7/2004 http://ebahn.Bentleypublishers.Com/vw/servlet/display?Action=goto&type=repair&id=vw.B4.Me01.01.5.
Page 67
N torque wrench v.A.G 1331/ (5 - 50 nm) test requirements n transmission not in emergency running mode, atf temperature not above approx. 30 c n vehicle on level ground. N selector lever in "p" perform following work procedure: - secure container of atf filler tool v.A.G 1924/ to vehicle. Connect sc...
Page 68
Indicated on display: vag - on board diagnostic (obd) help 1- rapid data transfer* or vag - on board diagnostic (obd) help 2- blink code output* * two operating modes are displayed alternately - press button -1- to select "rapid data transfer" operating mode. Indicated on display: rapid data transfe...
Page 69
- press button. - raise vehicle. - place appropriate receptacle underneath transmission. Indicated on display: rapid data transfer help select function xx - buttons 0 and 8 press. (press 08 to select "read measuring value block" function.) indicated on display: rapid data transfer q 08 - read measur...
Page 70
- for atf test remove locking bolt - arrow - in oil pan. Atf present in overflow tube - arrow 2 - runs off. If atf drips from hole: atf must not be topped off. - cut seal - arrow - of locking bolt with a side cutter and remove seal. - install locking bolt with new seal and screw in hand-tight. - tig...
Page 71
- end output 01-5, end output . If atf in overflow tube runs out of hole: top off atf - pry off cap - arrow - with a screwdriver for protection of sealing plug. While doing so, locking mechanism of cap will be destroyed, therefore always replace cap. Note: n with some transmissions a cap with a clip...
Page 72
Container size 1.0 l -part number g 052 162 a2 note: n adding to little or too much atf impairs functioning of transmission. - cut seal - arrow - of locking bolt with a side cutter and remove seal. - install locking bolt with new seal and screw in hand-tight. - tighten locking bolt - arrow 1 - with ...
Page 73
- lock cap. Note: n cap without clip bolting device must always be replaced. Cap secures sealing plug. N with some transmissions a cap with a clip bolting device is installed. This cap can be reused. End output indicated on display: read measuring value block 5 -> 40 c 0011011 0 900 rpm - press butt...
Page 74
Automatic transmission, changing atf vehicles 12.94 with 096 transmissions use following vw atf (yellowish color): n container size 0.5 l -part number g 052 162 a1 n container size 1.0 l -part number g 052 162 a2 note: n current supplies of atf dextron ll can be used up in transmissions until decemb...
Page 75
N v.A.G1358a and sensor v.A.G 1358/ a2 n torque wrench v.A.G 1331/ (5 - 50 nm) perform following work procedure: - extract atf using probe v.A.G 1358/ a2 and v.A.G1358 . Note: n observe disposal regulations! N engine must not be started without atf and vehicle must not be towed! - remove oil pan wit...
Page 76
- install new atf-strainer with new seal. Tightening torque for securing bolts: 8 nm. - install oil pan with new seal. Make sure that spacers are fastened. Tightening torque for securing bolts: 12 nm. - next, add 3.0l atf (replacement capacity) using a funnel. Note: n to wipe dipstick off a lint-fre...
Page 77
- atf must be filled up in cold condition at least up to 20 c-marking, otherwise add atf. - bring atf to a temperature of 50 ... 70 c. Temperature will be measured using scan tool (st) v.A.G 1551/ as follows: - let engine run at idle. Connect scan tool (st) v.A.G 1551/ using adapter cable v.A.G 1551...
Page 78
Rapid data transfer q 02 transmission electronics - press q button to confirm input. Indicated on display: 096927733ba ag3 transmission 096 2754 coding 00000 wsc 00000 control module identification, coding, and workshop code (wsc) of scan tool (st) v.A.G 1551/ are indicated: if displayed: control mo...
Page 79
Indicated on display: read measuring value block q enter display group number 005 - press q button to confirm input. Atf temperature in c appears in display field 1 (exact measuring value only starting from 50 c). Read measuring value block 1 1 2 3 4 - check atf level at a temperature of 50 ... 70 c...
Page 80
Power steering fluid level, checking fluid, when cold: perform following work procedure: - with engine not running, bring front wheels into straight- ahead position. - unscrew reservoir cap - arrow - with dipstick. - clean off dipstick with a clean rag. - tighten cap by hand and remove again. Note: ...
Page 81: Brake Fluid, Changing
- screw cap on hand tight. Fluid, at operating temperature (from approx. 50 ): perform following work procedure: - with engine not running, bring front wheels into straight- ahead position. - unscrew reservoir cap with fitted dipstick. - clean off dipstick with a clean rag. - tighten cap by hand and...
Page 82
N brake filling and bleeding tool vas 5234 or n brake filling and bleeding tool v.A.G 1869/ or n brake filling and bleeding tool v.A.G 1869/ with upgrade kit v.A.G 1869/4 n brake pedal depressor v.A.G 1869/2 vehicles with manual transmission: page 63 of 83 work descriptions 12/7/2004 http://ebahn.Be...
Page 83
N bleeder hose v.A.G 1238/b3 670 mm long use only new brake fluid with part number b 000 700 a. (corresponds to us standard fmvss 116 dot 4) caution! N never bring brake fluid into contact with fluids containing mineral oil (oil, gasoline, cleaning fluids). Oils containing minerals damage seals and ...
Page 84
- install brake depressor v.A.G 1869/2 between driver's seat and brake pedal, and tension. - screw adapter vas 5234/1 or adapter v.A.G 1869/1 onto brake fluid reservoir. - connect filler hose of brake filling and bleeding tool vas 5234 or brake filling and bleeding tool v.A.G 1869/ to adapter. Vehic...
Page 85: Brake Fluid Level, Checking
Left front 0.4 to 0.5 liters total quantity 1) 2 liter 1) with siphoned brake fluid from brake fluid reservoir and replacement capacity of hydraulic clutch mechanism - install cover caps to brake caliper bleed screws. - move filler lever on vas5234 or brake filling and bleeding tool v.A.G 1869/ to p...
Page 86: Battery, Checking
Note: n to make sure that brake fluid will not overflow reservoir, max. Marking must not be exceeded. Inspection service: - fluid level must always be judged in conjunction with brake pad wear. When vehicle is in use, fluid level tends to drop slightly due to brake pad wear and automatic adjustment....
Page 87
N battery tester with printer vas 5097/ or n battery tester with printer vas 5097/ or n battery tester vas 5096/ or n battery tester vas 5033 n battery fill bottle vas 5045/ page 68 of 83 work descriptions 12/7/2004 http://ebahn.Bentleypublishers.Com/vw/servlet/display?Action=goto&type=repair&id=vw....
Page 88
N commercially available hydrometer inspection service (batteries with "magic eye" ) perform a visual check 01-5, performing visual check (all batteries) and check battery condition via "magic eye" 01-5, checking batteries / batteries with magic eye and with top-sealed battery cell plugs . Inspectio...
Page 89
If battery is not securely seated, following dangers exist: n shortened service life due to damage from vibration (danger of explosion). N if battery is not secured properly normal shock and vibration can damage battery plates, which results in premature battery failure. N battery casing can be dama...
Page 90
N three different color indications are possible: green battery is sufficiently charged. Black no charge or charge too low (repair measure). Colorless or yellow critical acid level reached, distilled water must be topped up 01-5, topping off distilled water (batteries with magic eye) . Then, perform...
Page 91
- load current varies depending on battery capacity, and has to be adjusted on tester. User manual for battery tester - perform battery load test according to user manual for battery tester and compare test printout - arrow - with following table. Remarks concerning test printout: 1 - measuring rang...
Page 92
Drop rapidly to below displayed minimum voltage. After test has been performed, voltage will remain at this low value for a long time, and will climb back up only very slowly. Printout from battery tester inspection service starting output very good battery ok starting output good battery ok startin...
Page 93
- screw in battery sealing plugs. Checking acid level (batteries without magic eye) markings on battery housing - arrow - note: n maintaining correct electrolyte level in battery is an important factor affecting length of battery's service life. Electrolyte level too low note: n too low an electroly...
Page 94
To avoid electrolyte impurities, which can increase self- discharge of battery, only distilled water may be added to increase acid level. - unscrew battery sealing plugs. - using battery fill bottle vas 5045/ fill with distilled water up to max.-marking. Note: n construction of filler tube of batter...
Page 95
N observe disposal regulations! - screw in battery sealing plugs. Checking battery / batteries with magic eye and without battery cell plugs these batteries can be recognized by "magic eye" - 1 - and a cover - 2 - (as shown in illustration). Note: n "magic eye" can be located at various positions on...
Page 96: Checking
- colorless or yellow battery must be replaced. Idle speed (diesel engine code aaz): checking required special tools and equipment n ignition tester v.A.G 1767/ or n ignition tester v.A.G 1367 test- and adjustment requirements and specified values emissions test perform following work procedure: - i...
Page 97
Required special tools and equipment n headlight adjuster vas 5046/ or n headlight adjuster vas 5047/ or n headlight adjuster vas 5208 or n headlight adjuster vas 5209 following test- and adjustment instructions are applicable to all countries. But national legislation and regulations of respective ...
Page 98
Fuel gauge in lbs (kg) 1/4 100 (45) 1/2 66 (30) 3/4 33 (15) full 0 (0) example: if tank is filled half way, an additional weight of 66 lbs (30 kg) must be placed into luggage compartment. Note: n as additional weight it is recommended to use fuel canisters filled with water (a 5-liter fuel canister ...
Page 99
- with low beam switched on, check whether horizontal light-dark border contacts hyphenated line - 1 - of test surface. - check whether break-away point - 2 - between left horizontal part and rising part on right of light-dark border runs vertically through central point - 3 - . Bright core of light...
Page 100
N for previous test screen with 15 -setting line, adjust as for new test screen. To avoid incorrect settings ignore 15 -setting line. Fog lights: - check whether upper light-dark border touches setting line and runs across complete test screen width horizontally. Other auxiliary headlights: later in...
Page 101: Road Test, Performing
Both adjustment wheels on right headlight are allocated symmetrically. Note: n also check whether reflectors in both headlights adjust themselves uniformly when operating headlight range control. Fog light (left) - turn adjusting screw toward left (arrow) to lower beam height. Horizontal adjustment ...
Page 102
- clutch: pulling away, pedal pressure, odors - gear selection: ease of operation, shift lever position - automatic transmission: selector lever position, shift lock / ignition key removal lock, shift behavior, instrument panel cluster display - foot-operated and hand-operated parking brake: functio...
Page 103: Rodcasti@gmail.Com
Http://listado.Mercadolibre.Com.Mx/_custid_67027869 rodcasti@gmail.Com.