Maintenance Procedures: Maintenance Volkswagen Passat B5 рестайлинг

Service intervals

Refer to Maintenance Service Circular for appropriate Model and Year.

Final drive rear, check transmission fluid level

1. Passat 4Motion

Transmission fluid in rear final drive, checking -->

1. «39 - FINAL DRIVE, DIFFERENTIAL»(ref-255343-S36022790642007053000000) for 5 AND 6 SPD. MANUAL TRANSMISSION 01E/0A1 FRONT WHEEL DRIVE
2. «39 FINAL DRIVE, DIFFERENTIAL»(ref-255345-S24252671802007053000000) for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT WHEEL DRIVE
3. «39F - FINAL DRIVE, FRONT DIFFERENTIAL»(ref-255347-S41602061872007053000000) or «39R - FINAL DRIVE, REAR DIFFERENTIAL»(ref-255347-S22131259552007053000000) for 5 SPD. AUTOMATIC TRANSMISSION 01VA FRONT AND ALL WHEEL DRIVE - EXTERNAL COMPONENTS, SERVICING
4. «39 - FINAL DRIVE, DIFFERENTIAL»(ref-255348-S25191222792007053000000) for 5 SPD. AUTOMATIC TRANSMISSION 01VA FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING
5. «39 - FINAL DRIVE, DIFFERENTIAL»(ref-255340-S38619606902007053000000) for 5 SPD. MANUAL TRANSMISSION 012 / 01W
6. «39F - FINAL DRIVE, DIFFERENTIAL (FRONT)»(ref-255342-S28440189092007053000000) or «39R - FINAL DRIVE, DIFFERENTIAL (REAR)»(ref-255342-S39196065542007053000000) for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE
7. «39F - FINAL DRIVE, DIFFERENTIAL (FRONT)»(ref-255341-S20458665932007053000000) or «39R - FINAL DRIVE, DIFFERENTIAL (REAR)»(ref-255341-S38753407542007053000000) for 6 SPEED MANUAL TRANSMISSION 01E ALL WHEEL DRIVE

Scheme 11

1. Check ball joint boots - arrows - for leaks and damage.

Automatic transmission, front final drive, checking fluid level

1. Work procedure, --> «39 - FINAL DRIVE, DIFFERENTIAL»(ref-255343-S36022790642007053000000) for 5 AND 6 SPD. MANUAL TRANSMISSION 01E/0A1 FRONT WHEEL DRIVE «39 FINAL DRIVE, DIFFERENTIAL»(ref-255345-S24252671802007053000000) for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT WHEEL DRIVE «39F - FINAL DRIVE, FRONT DIFFERENTIAL»(ref-255347-S41602061872007053000000) or «39R - FINAL DRIVE, REAR DIFFERENTIAL»(ref-255347-S22131259552007053000000) for 5 SPD. AUTOMATIC TRANSMISSION 01VA FRONT AND ALL WHEEL DRIVE - EXTERNAL COMPONENTS, SERVICING «39 - FINAL DRIVE, DIFFERENTIAL»(ref-255348-S25191222792007053000000) for 5 SPD. AUTOMATIC TRANSMISSION 01VA FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING .

Brake fluid, changing

Notes on application and safety --> Notes On Application And Safety Precaution .

Brake fluid specification --> Specification Of Brake Fluid .

Work procedure, change brake fluid --> Work Procedure, Changing Brake Fluid .

Work Procedure, Changing Brake Fluid

Special tools, testers and auxiliary items required

Scheme 12

1. Brake pedal depressor V.A.G 1869/2

Scheme 13

1. Brake filling and bleeding tool VAS 5234

Vehicles --> 1999 ( --> X)

Observe operating instructions for brake charger/bleeder unit VAS 5234 !

Scheme 14

1. Remove cap from brake fluid reservoir - 1 -.

Scheme 15

1. Extract as much brake fluid as possible from brake fluid reservoir using suction hose of brake charger/bleeder unit VAS 5234 - 1 -.
2. Alternatively, extract as much brake fluid as possible using a suction bottle with built-in strainer.

Note. After extracting, observe that no further brake fluid runs into the reservoir (the brake fluid level in the reservoir must align with the lower edge of the strainer).

Vehicles 2000 --> (Y --> )

Observe operating instructions for brake charger/bleeder unit VAS 5234 !

Scheme 16

1. Remove cap from brake fluid reservoir - 1 -.

Scheme 17

1. Remove locking bolt - arrow - of brake fluid reservoir.

Scheme 18

1. Connect suction hose of brake charger/bleeder unit VAS 5234 to tube - 1 - of brake fluid reservoir.
2. Extract as much brake fluid as possible from brake fluid reservoir using suction hose of brake charger/bleeder unit VAS 5234.
3. Disconnect suction hose.

1. Connect suction hose of brake charger/bleeder unit VAS 5234 to tube - 2 - of brake fluid reservoir.
2. Extract as much brake fluid as possible from brake fluid reservoir using suction hose of brake charger/bleeder unit VAS 5234.
3. Disconnect suction hose.
4. Screw locking bolt onto brake fluid reservoir.

Continued for all vehicles

1. Install brake pedal depressor V.A.G 1869/2 between drivers seat and brake pedal and apply tension.

Scheme 19

1. Screw adapter - 1 - onto brake fluid reservoir.

Scheme 20

1. Connect filler hose - 1 - of brake charger/bleeder unit VAS 5234 to the adapter.

Vehicles with manual transmission

1. Pull cover cap off clutch slave cylinder bleed screw.

Scheme 21

1. Connect bleeder hose - A - of collector bottle on bleeder screw of the clutch slave cylinder - arrow - , open the bleeder screw, and allow approx. 0.1 liters to flow out. Close bleeder screw and install cover cap.
2. Operate clutch pedal several times.

Continued for all vehicles

1. Pull cover caps off bleeder screws of brake calipers.

Scheme 22

1. Connect bleeder hose - 1 - of collector bottle to a rear bleeder screw * See footnote , open bleeder screw and allow the corresponding brake fluid quantity to flow out (see table below). Close bleeder screw.

*Bleed right rear first.

Repeat work sequence on other side of vehicle at rear.

Scheme 23

1. Connect bleeder hose - 1 - of collector bottle to a front bleeder screw * See footnote , open bleeder screw and allow the corresponding brake fluid quantity to flow out (see table below). Close bleeder screw.

* Bleed right front first.

Repeat work sequence on other side of vehicle at front.

Table - Sequence / quantity of brake fluid

* Including brake fluid extracted from brake fluid reservoir and quantity from clutch slave cylinder.

1. Fit cover caps to brake caliper bleed screws.
2. Move filler lever on brake charger/bleeder unit VAS 5234 to position - B - (see operating instructions).
3. Take filler hose off adapter.
4. Unscrew adapter from brake fluid reservoir.

1. Check brake fluid level and correct if necessary.

1. Screw in cap - 1 - of brake fluid reservoir.
2. Remove brake pedal depressor.
3. Check pedal pressure and brake pedal free play. Free play: Max. 1 / 3 of pedal travel

Brake fluid level, checking

Notes on application and safety --> Notes On Application And Safety Precaution .

Brake fluid specification --> Specification Of Brake Fluid .

Work procedure, brake fluid level (depending on brake pad wear): Checking --> Work procedure, brake fluid level (depending on brake pad wear), check .

Work procedure, brake fluid level (depending on brake pad wear), check

Brake fluid level at delivery inspection

1. On vehicles 10.00 --> , push battery cover toward left - arrows - and remove cover upward.

Scheme 24

The brake fluid level on the reservoir can be checked through a hole in the battery cover, using a flashlight. For delivery inspection, the fluid level must be at the max.-marking.

Note. To prevent the brake fluid from overflowing from the reservoir, the level must not be over the MAX mark.

Brake fluid level at Inspection Service

The fluid level must always be judged in conjunction with brake pad wear.

When vehicle is in use, the fluid level tends to drop slightly due to brake pad wear and automatic adjustment.

1. Recommended brake fluid level when brake pad wear limit has almost been reached

"At MIN-marking and slightly above it" , "NO TOPPING OFF REQUIRED".

1. Recommended brake fluid level when brake pads are new or are far removed from the brake pad wear limit

"Between MIN- and MAX-Marking".

Engine oil, draining or extracting and filling; replacing oil filter

Engine oil: Draining or extracting and filling --> Engine oil, draining or extracting .

Oil filter, replacing --> Oil filter, replacing .

Engine oil, filling --> Filling engine oil .

Engine oil, draining or extracting

Special tools, testers and auxiliary items required

Scheme 25

1. Oil extractor V.A.G 1782
2. Oil absorbent towel VAS 6204/1

Engine oil, draining or extracting

Perform the following work procedure

Note. In engines with standing oil filter module, oil filter should be changed before changing engine oil --> Engine oil, draining or extracting and filling; replacing oil filter . Removing the filter element will open a valve and oil in the filter housing will flow automatically into the crankshaft housing. If engine oil is drained and not extracted using old oil extraction unit, replace oil drain plug. This prevents leaks. Observe waste disposal regulations!

1. Extract engine oil using old oil collecting and extracting unit V.A.G 1782.

or

1. Remove oil drain plug
2. Drain engine oil.

Note. The oil drain plug is equipped with a permanent seal, therefore the oil drain plug must always be replaced. Observe waste disposal regulations!

1. Screw in new oil drain plug with sealing ring hand-tight.
2. Fill up with engine oil, specification --> «Service tables»(ref-255362-S11456457172007053000000) .

Engine oil capacity --> Fluid Capacity Chart for appropriate Model and Year.

Torque specifications for oil drain plug

1. 4-cyl. Engines: Sheet metal oil pan 50 Nm, aluminum oil pan 30 Nm
2. 6-cyl. gasoline engines 30 Nm
3. 8-cyl. gasoline engines 30 Nm

Front manual transmission/final drive, fluid level, checking

>

1. «34 - MANUAL TRANSMISSION - CONTROLS, HOUSING»(ref-255343-S24639746102007053000000) for 5 AND 6 SPD. MANUAL TRANSMISSION 01E/0A1 FRONT WHEEL DRIVE
2. «34 - MANUAL TRANSMISSION - CONTROLS, HOUSING»(ref-255340-S13525181902007053000000) for 5 SPD. MANUAL TRANSMISSION 012 / 01W
3. «34 - MANUAL TRANSMISSION - CONTROLS, HOUSING»(ref-255342-S04131633372007053000000) for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE
4. «34 - MANUAL TRANSMISSION - CONTROLS, HOUSING»(ref-255341-S04939003272007053000000) for 6 SPEED MANUAL TRANSMISSION 01E ALL WHEEL DRIVE

Checking windshield wash/wipe system freeze protection concentration, add fluid if necessary

Special tools, testers and auxiliary items required

1. Refractometer T10007

Note. Read the bright/dark boundary to obtain an accurate reading for the following tests. Place a drop of water on the glass to improve the readability of the bright/dark boundary. The bright/dark boundary can be clearly recognized on the "WATERLINE".

1. Check the concentration of the anti-freeze additive using refractometer T10007 (operating instructions).

Scheme 26

The scale - 1 - of the refractometer is designed specifically for genuine Volkswagen Windshield Cleaner G 052 164 .

The scale - 2 - is designed for commercially available windshield cleaner as well as a mixture of commercially available windshield cleaner and windshield cleanser concentrate G 052 164 .

Filling-up with fluid

The windshield wash/wipe system fluid reservoir must be filled up fully.

Use only windshield cleanser concentrate G 052 164 all-year-round when topping-off the windshield wash/wipe system.

Mixture ratio

Note. Windshield cleaner G 052 164 protects spray nozzles, fluid reservoir and hoses from freezing. All vehicles with fan type spray nozzles must always be filled with Windshield Cleaner G 052 164 as this fluid has a low viscosity at minus temperatures. The complicated spray jet system could otherwise become blocked due to crystallized washer fluid and adversely affect the fan pattern of the spray jet. Windshield cleanser concentrate G 052 164 assures that the fan type spray jets remain functional even at low temperatures. Fill also with Windshield Clear G 052 164 in the warmer season. The powerful cleanser removes wax and oil deposits from the windows. Freeze protection (anti-freeze) must be guaranteed to approx.-13 F (-25 ° C) (approx -31 ° F (-35 ° C) in countries with an arctic climate) in the washer system.

Sunroof, checking function, cleaning and lubricating guide rails

Perform the following work procedure

1. Check function of sunroof.

Scheme 27

1. Clean guide rails - arrows - and lubricate with special grease G 000 450 02 .

Note. Part numbers are for reference only. Always check with your Parts Department for the latest part number information

Fluid, when cold

Perform the following work procedure

1. With engine not running, move front wheels in straight-ahead position.

Scheme 28

1. Unscrew reservoir cap - arrow - with fitted dipstick.
2. Clean dipstick with clean cloth.
3. Screw cap on hand-tight and remove again.

Note. Screw cap fully in to get an accurate fluid level reading.

Scheme 29

1. Check fluid level: Fluid level must be in area of MIN mark (up to 2 mm above or below mark).

Note. If fluid level is above specified range, fluid must be extracted off. If the fluid level is below the specified level, check the hydraulic system for leaks (repair measure). It is not enough to simply top off with fluid. If power steering system is properly sealed, fill with fluid G 002 000 . Part numbers are for reference only. Always check with your Parts Department for the latest part number information

1. Screw in cap hand tight.

Warm fluid (at approx. 122 ° F (50 ° C))

Perform the following work procedure

1. With engine not running, move front wheels in straight-ahead position.

1. Unscrew reservoir cap - arrow - with fitted dipstick.
2. Clean dipstick with clean cloth.
3. Screw cap on hand-tight and remove again.

Note. Screw cap in fully to get an accurate fluid level reading.

1. Check fluid level: Check fluid level. It must be between MIN and MAX markings.

Note. If the fluid level is above the MAX mark, extract fluid. If the fluid level is below the MIN mark, check the power steering system for leaks (repair procedure). It is not enough to simply top off with fluid. If power steering system is properly sealed, fill with fluid G 002 000 .

1. Screw in cap hand tight.

Door arrester, lubricate

Perform the following work procedure

Scheme 30

1. Lubricate door arrester at points shown - arrows -.

Use lubricant G000150 .

Note. Part numbers are for reference only. Always check with your Parts Department for the latest part number information

Rear lid, lubricate left and right multi-joint hinge

Note. This maintenance point only applies to the sedan and not the wagon. Lubricant specification: G 000 115 A2 (200 ml spray can) Part numbers are for reference only. Always check with your Parts Department for the latest part number information

Corrosion protection measures

1. Open rear lid.
2. Remove left/right lid hinge cover if present.

Scheme 31

1. Spray each of the four hinge joints on both rear lid hinges - arrows -.

Note. Included spray tube must be inserted in sprayer head to aim spray. Shake spray can about five times. Spray must not be shaken too long or hard because otherwise spray oil will foam up and its lubricating ability is reduced.

1. Completely open and close rear lid several times.
2. Reassemble vehicle.
3. Clean excess oil from body and joints.

Additional steps for stiff hinges

Note. These additional steps do not belong to the service scope and should be handled as repair measures. In order to make hinges move more easily again and to protect them from corrosion, perform the following procedure

1. Open rear lid.
2. Remove left/right lid hinge cover if present.

Scheme 32

1. Remove gas-filled strut - 2 - --> «55 HOOD, LIDS»(ref-255352-S28818425092007053000000)

1. Spray each of the four hinge joints on both rear lid hinges - arrows -.

Note. Included spray tube must be inserted in sprayer head to aim spray. Shake spray can about five times. Spray must not be shaken too long or hard because otherwise spray oil will foam up and its lubricating ability is reduced.

In order for the universal oil to move into the hinge joints, the hinges in the joint area must have a temperature at least 86 ° F (30 ° C).

In cold exterior temperatures, the hinges must be warmed up in the joint area with a hot air gun to approximately 86 - 104 ° F (30 - 40 ° C) before spraying.

1. Completely open and close rear lid about 15 times.

Note. This entire hinge treatment procedure must be performed at least 3 times in order to keep the hinges moving easily and to protect against further corrosion.

1. Clean excess oil from body and joints.
2. Reassemble vehicle.