VOLKSWAGEN PASSAT GASOLINE TURBO DIESEL TDI 4 CYLINDER VR6 WAGON 1995 1996 1997 FACTORY SERVICE REPAIR MANUAL

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VOLKSWAGEN PASSAT GASOLINE TURBO DIESEL TDI 4 CYLINDER VR6 WAGON 1995 1996 1997 FACTORY SERVICE REPAIR MANUAL

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VOLKSWAGEN PASSAT GASOLINE TURBO DIESEL TDI 4 CYLINDER VR6 WAGON 1995 1996 1997 FACTORY SERVICE REPAIR MANUAL

369 PAGES

Loaded with illustrations, instructions, photos, and diagrams, complete to service and repair your vehicle.

1995-1997

MANUALS COVER:

General, Technical data:

Suspension, Wheels, Brakes, Steering

Technical data

Steering

Brakes

Wheels, tires

Front suspension:

Front Wheel Suspension, Shafts and Axle

Front suspension, servicing (Base suspension)

Sub-frame, stabilizer bar and control arm (Base suspension)

Ball joint, checking (Base and Plus suspension)

Reworking cap nut in side member (Base and Plus suspension)

Wheel bearing, suspension strut and drive shaft, removing and installing (Base

running gear)

Front suspension strut, servicing (Base and Plus suspension)

Front suspension, servicing (Plus suspension)

Sub-frame, stabilizer bar and control arm, removing and installing (Plus

suspension)

Ball joint, removing and installing (Plus running gear)

Wheel bearing and suspension strut, removing and installing (Plus suspension)

Drive shaft, removing and installing (Plus running gear)

Drive shaft, repairing

Outer constant velocity joint, checking

Inner constant velocity joint, checking

Drive shaft with tripod joint, repairing

Drive axle with triple-rotor joint, removing and installing

Drive axle with triple-rotor joint, servicing

Triple-rotor joint, disassembling

Triple-rotor joint, assembling

Rear suspension:

Rear Wheel Suspension, Shafts and Axle

Rear axle, servicing (vehicles with front wheel drive)

Reworking cap nut in side member (front wheel drive vehicles)

Suspension strut, disassembling and assembling (front wheel drive vehicles)

Wheel bearings, servicing

Drum brakes (front wheel drive vehicles), wheel bearings, servicing

Wheel bearings, servicing – disc brakes (front wheel drive vehicles)

Rear axle, servicing (four wheel drive vehicles)

Rear drive shafts, servicing

Reworking cap nut in side member (four wheel drive vehicles)

Suspension strut, disassembling and assembling (four wheel drive

vehicles)

Wheel bearings, servicing – disc brakes (four wheel drive vehicles)

Wheels, Tires, Wheel alignment:

Vehicle alignment

Test requirements:

Vehicle alignment specifications (front wheel drive vehicles)

Vehicle alignment specifications (four wheel drive vehicles)

Front wheel camber, adjusting

Calculating the direction of travel:

Anti-lock brake system:

Anti-locking Brake System (ABS) and Anti-locking Brake System with

Electronic Differential Lock (ABS/EDL) Teves 04

Notes for repair work on ABS, ABS/EDL

Control module, removing and installing

Wheel speed sensor and rotor for speed sensor, removing and installing

Anti-lock Brake System (ABS) and ABS with Electronic Differential Lock

(ABS/EDL), Teves 20 GI

Safety precautions

ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master

cylinder (Teves 20 GI), servicing

ABS hydraulic unit and ABS control module (Teves 20 GI), removing and

installing

Brake hydraulic system, bleeding and filling

Assembly overview – hydraulic unit, brake servo/brake master cylinder

Hydraulic unit, removing and installing

Brake Pedal Position Sensor, removing and installing

Brakes – Mechanical components:

Front brakes, servicing (Girling caliper)

Brake pads, removing and installing

Front brakes, servicing (Teves/Ate)

Brake pads, removing and installing

Rear wheel brakes, servicing (drum brakes)

Brake shoe adjustment, releasing

Rear wheel brakes, servicing

Brake shoes, removing and installing

Parking brake, adjusting (drum brakes)

Rear wheel brakes, servicing (disc brakes)

Girling rear wheel disc brakes (front and four wheel drive vehicles)

Brake pads, removing and installing

Parking brake, adjusting (disc brakes)

Parking brake lever assembly overview

Brake pedal/brake servo, removing and installing

Brake pedal, removing and installing

Brake Light Switch, adjusting

Brakes – Hydraulic components:

Assembly overview: brake master cylinder/brake servo

Girling front brake caliper, servicing

Front brake caliper pistons, removing and installing

Front brake caliper, servicing (Teves/Ate)

Rear brake caliper, servicing

Rear brake caliper piston, removing and installing

Pre-bleeding brake caliper

Brake pressure regulator, checking and adjusting

Vehicles without ABS, vehicles with ABS, ABS/EDS, Teves 04

Load dependent brake pressure regulator specifications

Adjusting regulator

Brake system, bleeding

Brake system, bleeding (vehicles with and without ABS, ABS/EDL)

Brake system, bleeding (with pressure bleeder VAS 5234)

Brake system, bleeding (without pressure bleeder)

Steering:

Steering

Assembly overview: steering column, column tube, steering wheel and airbag

steering wheel

Airbag unit, removing and installing

Airbag steering wheel, removing and installing

Airbag Spiral Spring, removing and installing

Column tube for height adjustable steering wheel, removing and installing

Pump delivery pressure, checking

Power steering gear, removing and installing

Assembly overview: power assisted steering box (TRW)

Power steering gear, adjusting (TRW)

Power steering gear, disassembling and reassembling (TRW)

Power steering gear, disassembling

Inner sealing ring for toothed rod, pulling out

Checking toothed rod for scoring

Sealing ring on toothed rod, replacing

Sealing rings, installing on toothed rod piston

Power steering gear, assembling

Inner sealing ring for toothed rod, installing

Toothed rod, installing in housing

Adhesive tape, applying

Power steering gear, adjusting with new toothed rod

Assembly overview: power steering gear (ZF)

Power steering gear, adjusting (ZF)

Power steering gear, disassembling and reassembling (ZF)

Power steering gear, disassembling

Checking toothed rod for scoring

Sealing ring on toothed rod, replacing

Power steering gear, assembling

Tie rods, removing and installing (power steering gear – TRW and ZF)

Left-hand tie rod length, checking and adjusting

Assembly overview: vane pump, reservoir and hydraulic lines (vehicles with 4-

Cyl. engines)

Assembly overview: Hydraulic lines, reservoir (vehicles with 4-Cyl. engines)

Power steering vane pump, removing and installing (vehicles with 4-Cyl. engines)

V-belts, tensioning (4-Cyl. engines)

Assembly overview: Pressure and cooling lines (vehicles with VR6 engine)

Power steering vane pump, removing and installing (vehicles with VR6 engine]

This manual is the same as the manual used by workshops. Service Manual contains detailed instructions and step by step diagrams for all workshop procedures.

Language: English
Format: PDF – Indexed and Searchable

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The Volkswagen Passat B4 wagon, produced from 1995 to 1997 in the U.S. market, was offered with three distinct engine options to cater to different performance and efficiency needs. These included a standard 4-cylinder gasoline engine, an economical Turbo Diesel (TDI) option, and a powerful VR6 gasoline engine for the top-end model.

Passat wagon engine and trim comparison (1995–1997)

Engine Type	Trim Level	Horsepower (HP)	Transmission	Key Feature
4-Cylinder Gasoline	GLS	115 HP @ 5400 RPM (2.0-liter)	5-speed manual or 4-speed automatic	Good for a balance of power and economy. The GLS trim was discontinued for the 1997 model year in the U.S..
Turbo Diesel (TDI)	TDI	90 HP @ 3750 RPM (1.9-liter)	5-speed manual	Very fuel-efficient, with some drivers reporting high mileage. The TDI wagon had fewer than 1,000 sales in the U.S. during its 1996–1997 run.
VR6 Gasoline	GLX	172 HP @ 5800 RPM (2.8-liter)	5-speed manual or 4-speed automatic	Offers superior performance, with a 0–60 mph time of around 8 seconds. The GLX was the top-tier, luxury-oriented model.

Features across the B4 wagon

Despite differences in trim and engine, all B4 Passat models shared these general characteristics:

Wagon body style: The wagon provided a spacious cargo area, offering 14.4 to 34.2 cubic feet of volume, depending on whether the rear seats were folded.
Heavy facelift: The B4 was a heavily updated version of the previous B3 model, not an entirely new car. It was distinguishable by its grille, which was reintroduced to match other VW models of the time.
Safety features: The B4 came with dual front airbags and seatbelt pretensioners. The GLX trim added anti-lock brakes (ABS).
Standard equipment: Standard features included air conditioning, power steering, power windows, power locks, and an audio system.

Ownership considerations for used models

When considering a used 1995–1997 Passat wagon, keep the following in mind:

Maintenance: These older models may require more frequent maintenance compared to newer vehicles. Owners have noted potential issues with electrical components like windows and door locks, as well as the cooling system.
TDI availability: The TDI wagon is relatively rare in the U.S. market, so finding one in good condition may be a challenge.
Parts: Some specialized parts may be harder to find, but many components are shared with other contemporary VW models like the Jetta and Golf.
GLS discontinuation: Be aware that the 4-cylinder GLS wagon was not sold in the 1997 model year in the U.S., which ended with the GLX and TDI versions only.