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

Volkswagen Passat / Santana 1980 thru 1987, repair e-manual (in Russian)
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Only original manuals
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9 10 1
Publisher: © "Gusi-Lebedi"
ISBN: 985-4550-10-9
Number of pages: 304
Format: file PDF

About the manual

Engine type: petrol / diesel

Engine capacity: 1.6 / 1.8 / 1.9 / 2.0 / 1.6D l.

In the manual you will find

  • Instructions for repair of various vehicle components
  • Information on self-service car
  • Information on the design of the car and how to prevent failure
  • The information for the trip to the service station, if the self-repair is impossible
Publisher: Gusi-Lebedi
Categories: Volkswagen
Only original manuals
Available immediately after payment
Full compliance with the paper edition
100% protection of your payments
Publisher: © "Gusi-Lebedi"
ISBN: 985-4550-10-9
Number of pages: 304
Format: file PDF

About the manual

Engine type: petrol / diesel

Engine capacity: 1.6 / 1.8 / 1.9 / 2.0 / 1.6D l.

In the manual you will find

  • Instructions for repair of various vehicle components
  • Information on self-service car
  • Information on the design of the car and how to prevent failure
  • The information for the trip to the service station, if the self-repair is impossible

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

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Машина старая, нужна была инструкция как чинить. Информация в книге пригодилась, но хотелось бы цветных картинок. А так вроде ничего.