Volkswagen Passat / Santana 1980 thru 1987, service e-manual (in Russian)

Contents Foreword Operating instructions Maintenance Overall dimensions, weights and capacities Identification numbers Maintenance Recommended lubricants and fluids Engine Specifications Part A - 4-cylinder engines General description Maintenance Basic actions possible with the engine in the car Basic actions possible only after removing the engine from the car Engine removal method Engine - removal and installation Disassembly of the engine - general description Optional components - removal and installation Cylinder head and camshaft removal Camshaft and tappets - removal Valves - removal and reconstruction Cylinder head - research and reconstruction Camshaft and bearings - research and reconstruction Valves - installation Camshaft and tappets - installation Cylinder head and camshaft - installation Valve clearances - check and adjust Toothed belt and sprockets - removal and installation Flywheel / drive disc - removal and installation Intermediate shaft - removal and installation Pallet - removal and installation Crankshaft oil seals - replacement Oil pump - removal, research and installation Pistons and connecting rods - removal and disassembly Pistons and cylinder bores - study Pistons and connecting rods - assembly and installation Crankshaft - removal, research and installation Oil filter and casing - removal and installation Engine mounting bracket - removing and installing Part B - 5 cylinder engines General description Maintenance Basic actions possible with the engine in the car Basic actions possible only after removing the engine from the car Engine removal method Engine - removal and installation Dismantling the engine Optional components - removal and installation Camshaft and tappets - removal Cylinder head removal Valves - removal and reconstruction Cylinder head - research and reconstruction Camshaft and bearings - research and reconstruction Valves - installation Cylinder head - installation Camshaft and tappets - installation Valve clearances - check and adjust Toothed belt and sprockets - removal and installation Flywheel / drive disc - removal and installation Pallet - removal Crankshaft oil seals - replacement Oil pump - removal, check and installation Pistons and connecting rods - removal and disassembly Pistons and cylinder bores - check Pistons and connecting rods - assembly and installation Crankshaft - removal, inspection and installation Oil filter - removal and installation Engine mounting brackets - removal and installation Troubleshooting - engine Cooling system Specifications General description and service Cooling system - draining fluid Cooling system - flushing Cooling system - filling Antifreeze mixture Radiator - removal, inspection, cleaning and installation Thermostat - removal, testing and installation Water pump - removal and installation Cooling fan thermal switch - test, removal and installation Cooling temperature sensor liquids - removal and installation Heater valve - removal and installation Troubleshooting - cooling system Fuel and exhaust systems Specifications Part A: Carburetor and related fuel system components General description Maintenance Air filter element - replacement and cleaning Air filter - removal and installation Automatic air temperature control - general description Mechanical fuel pump - test, removal and installation Fuel line filter - replacement Fuel tank - removal and installation Fuel tank - removal, service and installation Fuel level sensor and gravity valve - removed tie and installation Accelerator cable - removal, installation and adjustment Carburetor - removal and installation Carburetor - disassembly, maintenance and assembly Carburetor adjustment Intake and exhaust manifolds - removal and installation Exhaust system - removal and installation Part B: Fuel injection system Fuel injection system - general description Service, adjustment and precautions - fuel injection system Air filter element (injection system) - removing, cleaning / replacing and installing Air filter (injection system) - removal and installation Thermostat of the air intake of the air filter (injection system) - removal, testing and installation Intake manifold (injection system) - removal and installation Fuel pump (injection system) - removal, testing and installation Idling speed (injection system) - adjustment Idle mixture (injection system) - adjustment Fuel filter (injection system) - removal and installation Fuel accumulator (injection system) - removal and installation Fuel rail - removal and installation Air flow meter - removal and installation Unloader valve - removal, service and installation Start fuel switch - check Cold start valve - check Warm-up control - check Airflow sensor lever and control plunger - check Auxiliary air valve - check Part C: Troubleshooting Troubleshooting - fuel system (carburetor models) Troubleshooting - fuel system (fuel injection models) Ignition system Specifications General description Maintenance Distributor - removal and installation Distributor - disassembly, inspection and assembly Thermo-pneumoclanan and control valve - check Transistor ignition system - precautions Transistor ignition system - test Ignition timing - basic setting Ignition timing - dynamic setting Ignition coil - test Spark plugs and high voltage wires - general description Troubleshooting - ignition system Clutch Specifications General description Clutch - adjustment Clutch cable - replacement Clutch pedal - removal and installation Coupling - removal, inspection and installation Release bearing and mechanism - removal and installation Troubleshooting - clutch Mechanical transmission and final drive Specifications General description Maintenance Gearbox - removal and installation Gearbox (014) - disassembly into main blocks Input shaft (014) - bulkhead Output shaft (014) - bulkhead Gearbox / final drive cover (014) - service Bearing housing / gears (014) - service Switch cover (014) - service Gearbox (014) - assembly Gear lever (014) - removal, installation and adjustment Gear shift rod (014) - bulkhead Gearbox (013 and 093) - disassembly into main blocks Input shaft (013 and 093) - bulkhead Output shaft (013 and 093) bulkhead Gearbox / final drive cover (013 and 093) - service Bearing / gear carrier (013 and 093) - service Switch cover (013 and 093) - service 5th gear components (013 and 093) - service Gearbox (013 and 093) - assembly Gear lever (013 and 093) - removal, installation and adjustment Troubleshooting - manual transmission and final drive Automatic transmission and final drive Specifications General description Automatic transmission - precautions and maintenance Transmission fluid - draining and filling Automatic transmission 089 - removal and installation Automatic transmission 087 - removal and installation Torque converter - check and drain fluid Automatic transmission - disassembly and assembly Final drive cover - service Regulator - removal, configuration and installation Accelerator pedal and traction - adjustment Lever and cable selection - removal, installation and adjustment Inhibitor switch - removal, installation and adjustment Drive shafts Specifications General description and service Drive shafts - removal and installation Drive shafts - bulkhead Troubleshooting - drive shafts Braking system Specifications General description Maintenance Brake disc pads - inspection and replacement Disc support - removal and installation Disc support - bulkhead Brake disc - inspection, removal and installation Rear brake shoes - inspect and replace Rear working brake cylinder - removal, bulkhead and installation Brake drum - inspection and restoration Master cylinder - removal and installation Master cylinder - bulkhead Brake pressure regulator - test and adjustment Brake pipes and hoses - removal and installation Hydraulic system - pumping Brake pedal - removal and installation Hand brake lever - removal and installation Handbrake - adjustment Vacuum booster - description and test Vacuum booster - removal and installation Troubleshooting - brake system Electrical equipment Specifications General description Maintenance Battery - removal and installation Battery - service Battery - electrolyte replenishment Battery - charging Generator - maintenance and special precautions Generator - removal and installation Alternator drive belt - replacement and adjustment Generator - service Starter - test in the car Starter - removal and installation Starter - bulkhead Automatic stop / start system (ASS) - general information Parts of the automatic stop / start system (models up to 1983) - removal and installation Parts of the automatic stop / start system (models since 1983) - removal and installation Fuses and relays - general description Ignition socket / steering column lock - removal and installation Dashboard block - removal and installation Dashboard unit - removal, testing and assembly Steering column switches - removal and installation Valve switches - removal and installation Door and trunk lighting switches - removal and installation Lighter - removal and installation Speedometer cable - removal and installation Headlights and headlights - removal and installation Headlights - adjustment Incandescent bulbs - replacement Sound signal - removal and installation Wiper blades - replacing Wiper motor - removal and installation Wiper holders and rod - removal and installation Rear window wiper blade - replace Rear window wiper motor - removing and installing Rear wiper holder and rod - removing and installing Washer system for windshield, rear window and headlights Speed control system - description and action Speed control system - removal and installation Heater motor block - removal and installation Heater control switch - removal and installation Heated rear window - care and repair Wiring diagrams - description Troubleshooting - electrical equipment Suspension and steering Specifications General description Maintenance Front suspension strut - removal and installation Front suspension strut - bulkhead Front hub and bearing - removal and installation Anti-roll bar - removing and installing Front wishbone - removal, repair and installation Rear axle - removal and installation Rear suspension strut / shock absorber - removal and installation Rear wheel bearings - removal, installation and adjustment Rear stub axle - removal and installation Steeringe wheel - removal and installation Steering column - removal, bulkhead and installation Tie rod - removal and installation Steering gear unit - removal and installation Steering damper - test, removal and installation Steering covers - replacement Direct acting steering gear - adjustment Power steering - filter change Power steering - draining and filling fluid Power steering - check leaks Power steering pump - removal, installation and adjustment Installing wheels - checking and adjusting Wheels and tires Troubleshooting - suspension and steering Body General description Body and subframe - service Upholstery and rugs - service Repair of minor damage to the body Body repair - serious damage Door bounce - find and repair Front door trim panel - removal and installation Front and rear door locks - removal and installation External door handles - removal and installation Front door - removal and disassembly Rear door trim panel - removing and installing Back door - removal and repair Doors - removal and installation Door strike plate - adjustment Front grill - removal and installation Hood - removal, installation and adjustment Bonnet release cable - removal and installation Trunk lid - removal, installation and adjustment Trunk lid lock - removal, installation and adjustment Rear door (Hatchback) - removal, installation and adjustment Rear door lock (Hatchback) - removal and installation Rear door (Station wagon) - removal and installation Rear door lock (Universal) - removal and installation Rear door support pillars - removal and installation Exterior mirror - removal and installation Bumpers - removal and installation Windshield and rear window glass - removal and installation Dashboard - removal and installation Center console - removal and installation Seats - removal and installation Roof hatch - general information Roof hatch - adjustment only Roof hatch - removal, installation and adjustment Central locking - general information Electric windows - general information Heater - removal and installation Heater control cables - adjustment Air conditioner Appendix: Changes and information on later models Introduction Specifications Engine Cooling system Fuel and exhaust systems Ignition system Clutch Mechanical transmission and final drive Automatic transmission and final drive Electrical system Suspension and steering Appendix: Diesel models Part A. Diesel engine Specifications General description Basic actions possible with the engine in the car Basic actions possible only after removing the engine from the car Engine removal method Engine - removal and installation Engine / gearbox - decoupling and assembly Disassembly of the engine - general description Ancillary engine components - removal Toothed belt and sprockets - removal Camshaft - removal, inspection and installation Cylinder head removal Cylinder head disassembly Sump and oil pump - removal and installation Pistons and connecting rods - removal Crankshaft and main bearings - removal Intermediate shaft - removal Oil filter - change Oil cooler - removal and installation Oil filter bracket - removing and installing Oil seals - replacement Inspection and maintenance - general description Crankshaft and bearings - inspection and maintenance Cylinder block / crankcase - inspection and maintenance Pistons and connecting rods - inspection and maintenance Oil pump - inspection and service Intermediate shaft - inspection and service Flywheel / drive disc - inspection and service Toothed belt and sprockets - inspection and service Engine - general description Crankshaft and main bearings - installation Intermediate Shaft - Installation Pistons and connecting rods - installation Valve clearances - check and adjust (models produced in August 1985) Cylinder head - installation Timing belt and sprockets - installation Ancillary engine components - installation Engine - installation Part B. Fuel system for diesel models Fuel system - general description Hydraulic pushers - check free run (models from august 1985) Winter operation Engine - adjustment after complete bulkhead Fuel injection system repair Removing water / replacing fuel filter Throttle draft adjustment Checking and adjusting the maximum engine speed Cold start actuator adjustment Checking and adjusting idle speed Cleaning / replacing replacement air filter element Glow plugs Checking the preheating plugs Removing and installing injectors Checking the start of fuel delivery by the pump Checking / adjusting motor control Removing and installing fuel level indicator sensor with gravity valve Removing and installing fuel tank Exhaust system Turbocharger Wiring diagrams