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1991 Volkswagen Passat CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Volkswagen REPAIR SHOPS DON'T WANT YOU TO KNOW
Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!Select Section
- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
A/C & HEATER SERVICE PROCEDURES FOR 1991 Volkswagen Passat AUTOMOBILES
Volkswagen -> Component Replacement & Adjustment -> BLOWER MOTOR, REPLACE -> CABRIOLET -> CORRADO, GOLF, GTI, JETTA & PASSAT -> FOX -> VANAGON
Vehicle: 1991 Volkswagen Passat 1.8 L4 GAS
CABRIOLET
- Disconnect battery ground cable.
- If equipped with A/C, remove screws securing air distribution flap housing to cowl and partially remove cover.
- Remove screws securing heater cover to cowl and remove cover.
- Remove resistor retaining bolts and lay resistor aside.
- Remove clamp and screws securing motor, then remove fan and motor assembly, Fig. .
- Reverse procedure to install.
CORRADO, GOLF, GTI, JETTA & PASSAT
It may be necessary to remove glove box assembly to gain access to blower motor.
- Disconnect bat...
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BRAKE SERVICE PROCEDURES FOR 1991 Volkswagen Passat AUTOMOBILES
DISC BRAKES -> Girling Single Piston w/Dual Mounting Bolts, Rear -> BRAKE CALIPER PRE-BLEEDING
Vehicle: 1991 Volkswagen Passat 2.0 L4 GAS
- Place caliper so that piston bore is facing down.
- Open bleeder valve, then connect a ...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1991 Volkswagen Passat AUTOMOBILES
Volkswagen -> Fuel Filter Scheduled Maintenance -> 1990-06 Models w/Gasoline Engines -> Normal Service -> Severe Service
Vehicle: 1991 Volkswagen Passat GL 2.0 L4 GAS
Normal Service
Se...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1991 Volkswagen Passat AUTOMOBILES
CV AXLE SHAFT, Replace
Vehicle: 1991 Volkswagen Passat GL 2.0 L4 GAS
- With vehicle on ground, remove drive axle retaining nut from wheel assembly.
- Raise and support vehicle.
- Remove drive axle to transmission drive flange attaching bolts.
- Separate ball joint from whe...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 1991 Volkswagen Passat AUTOMOBILES
Starter, Replace
Vehicle: 1991 Volkswagen Passat GL 2.0 L4 GAS
- Obtain audio coded anti-theft code, then disconnect battery ground cable, then support engine/transmission assembly using suitable engine support tool.
- Cut and discard cable ties used to secure wiring from starter/alternator.
- Unclip and pull off white and black har...
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MAINTENANCE LAMP RESET PROCEDURES FOR 1991 Volkswagen Passat AUTOMOBILES
Volkswagen -> Air Bag Warning Lamp ->
Vehicle: 1991 Volkswagen Passat 2.0 L4 GAS
If the Air Bag warning lamp lights and stays on, diagnosis and ...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1991 Volkswagen Passat AUTOMOBILES
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 1991 Volkswagen Passat GL 2.0 L4 GAS
Inlet
- Drain coolant into a suitable container.
- Reposition hose clamp at heater core and remove hose.
- Reposition hose clamp at coolant connection and remove hose.
- Remove hose from vehicle.
- Reverse procedure t...
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SERPENTINE BELT SERVICE PROCEDURES FOR 1991 Volkswagen Passat AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 1991 Volkswagen Passat GL 2.0 L4 GAS
- Rotate or lift the belt tensioner arm, using a suitable tool to relieve tension from dr...
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COMPONENT LOCATION DIAGRAMS FOR 1991 Volkswagen Passat AUTOMOBILES
Component location diagrams for most 1991 Volkswagen Passat cars and light trucks sold in the U.S. from 1990+.
Engine Compartment Component Locations Diagram for 1991 Volkswagen Passat GL 2.0 L4 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 1991 Volkswagen Passat AUTOMOBILES
OEM drawn wiring diagrams for most 1991 Volkswagen Passat cars and light trucks sold in the U.S.
1991 Volkswagen Passat GL 2.0 L4 GAS Wiring Diagram Components on diagram: |
1991 Volkswagen Passat GL 2.0 L4 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1991 Volkswagen Passat AUTOMOBILES
OEM TSB listings for most 1991 Volkswagen Passat cars and light trucks sold in the U.S. from 1985+.
Document: BATTERY, DISCHARGED, DIAGNOSIS FOR EXCESSIVE STATIC CURRENT DRAW - REVISED Vehicle: 1991 Volkswagen Passat GL 2.0 L4 GAS Symptoms: |
Document: EXHAUST HEAT SHIELD, REPLACEMENT GUIDELINES - REVISED Vehicle: 1991 Volkswagen Passat GL 2.0 L4 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 1991 Volkswagen Passat AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1991 Volkswagen Passat cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 1991 Volkswagen Passat cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 1991 Volkswagen Passat cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 1991 Volkswagen Passat cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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