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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!

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Get Full Access Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 1991 Volkswagen Passat car and truck repair procedures including Volkswagen engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up & drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix your Volkswagen Passat automobile. Try the Automotix DIY solution today!
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Using the Automotix DIY repair procedures will save you hundreds and even thousands of dollars! In addition, it will save you hours of touring the city searching for Volkswagen mechanics you can trust. The Automotix DIY solution is particularly affordable. A full access to the entire DIY repair procedures and diagrams for your 1991 Volkswagen Passat vehicle will cost less than a single gallon of gas. Here are some of the DIY repair tips and procedures you will find here:

A/C & HEATER SERVICE PROCEDURES FOR 1991 Volkswagen Passat AUTOMOBILES

Volkswagen -> Diagnosis & Testing -> A/C COMPONENT DIAGNOSIS & TESTING -> A/C Microswitch -> A/C Thermostat -> CABRIOLET -> Cooling Fan Thermoswitch -> GOLF, GTI & JETTA -> High Pressure Switch -> Low Pressure Switch
Vehicle: 1991 Volkswagen Passat GL 2.0 L4 GAS

CABRIOLET

A/C Microswitch

Microswitch is operated by fan control lever.

  • Disconnect electrical connector from switch, connect ohmmeter to switch terminals and operate fan switch in all positions.
  • Meter should indicate no continuity with fan switch in off position. Meter should indicate continuity when fan lever is moved between off and low speed position, and should indicate continuity in all fan speed positions.
  • If switch fails to operate as outlined, loosen retaining screw and adjust switch position.
  • If A/C switch...

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BRAKE SERVICE PROCEDURES FOR 1991 Volkswagen Passat AUTOMOBILES

HYDRAULIC BRAKE SYSTEM -> ADJUSTMENTS -> BRAKE PRESSURE REGULATOR -> Cabriolet -> Corrado, Fox & Passat -> MODELS LESS ANTI-LOCK BRAKES -> Vanagon
Vehicle: 1991 Volkswagen Passat GL 2.0 L4 GAS

BRAKE PRESSURE REGULATOR

MODELS LESS ANTI-LOCK BRAKES
Cabriolet

Brake pressure regulator is mounted on body, and operated by a spring attached to the rear axle.

  • Remove bleeder screw on right front caliper and connect gauge US 1016 or equivalent.
  • Remove bleeder screw on left rear wheel cylinder/caliper and connect gauge US 1016 or equivalent.
  • Bleed both hoses and gauges with bleeding screws on gauges, then depress brake pedal firmly several times.
  • Depress brake pedal until gauge of right front caliper reads 797 psi. Gauge of left rear wheel cylinder/caliper must read 565-623 psi.
  • Increase p...

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FUEL FILTER REPLACEMENT PROCEDURES FOR 1991 Volkswagen Passat AUTOMOBILES

Volkswagen -> Fuel Filter Replacement -> Gasoline Engines -> Models w/Fitting Or Union Bolt Connection -> Models w/Fuel Hose Connection
Vehicle: 1991 Volkswagen Passat Syncro 1.8 L4 GAS

Models w/Fuel Hose Connection

Do not smoke or allow an open flame of any type when working on or near any fuel system related components. The highly flammable vapor mixtures may ignite, resulting in serious personal injury.

After the battery has been disconnected and reconnected, some abnormal driveabilty symptoms may occur. The vehicle may need to be driven while the vehicle relearns its adaptive strategy.

  • Obtain the vehicle owners radio theft protection code prior to disconnecting the battery ground cable.
  • Disconnect the battery ground cable.
  • On models equipped with underbody moun...

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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 -> Malfunction Indicator Lamp -> -> Digifant & Digifant II -> Digifant I -> OBD ll
Vehicle: 1991 Volkswagen Passat GL 2.0 L4 GAS

OBD ll

If faults are recognized and verified by the engine control module, they will be indicated by switching on the MIL. Perform the functional inspection as follows: Turn the ignition switch to the ON position. The MIL must light up if the MIL does not light with the ignition switch on, inspect the bulb and/or locate and eliminate short or open in wiring circuit from the engine control module to MIL using a proper wiring diagram. If no fault can be detected in the wiring the ECM may be faulty. If the MIL lights with the ignition switch on, start engine and run at idle speed the MIL must go o...

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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 GASEngine Compartment Component Locations Diagram for 1991 Volkswagen Passat GL 2.0 L4 GAS

Components on diagram:
  • Ignition Coil
  • CIS-E Motronic Control Unit
  • ignition Distributor w/Hall Sender
  • EGR Valve
  • Fuel Distributor
  • CLICK HERE TO GET FULL ACCESS TO 1991 Volkswagen Passat PARTS/COMPONENTS LOCATION DIAGRAMS!

    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 Diagram1991 Volkswagen Passat GL 2.0 L4 GAS Wiring Diagram

    Components on diagram:
  • Fuel Pump
  • Radio
  • Instrument Cluster
  • Oxygen Sensor
  • Cigarette Lighter
  • 1991 Volkswagen Passat GL 2.0 L4 GAS Wiring Diagram1991 Volkswagen Passat GL 2.0 L4 GAS Wiring Diagram

    Components on diagram:
  • Automatic Transmission Control Unit
  • Back-Up Light- Right
  • Back-Up Light- Left
  • Starter Interlock and Back-Up Light Relay
  • CLICK HERE TO GET FULL ACCESS TO 1991 Volkswagen Passat WIRING DIAGRAMS!

    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: EXHAUST HEAT SHIELD, REPLACEMENT GUIDELINES - REVISED
    Vehicle: 1991 Volkswagen Passat GL 2.0 L4 GAS

    Auto Systems:
  • Exhaust System
  • Document: BATTERY, DISCHARGED, DIAGNOSIS FOR EXCESSIVE STATIC CURRENT DRAW - REVISED
    Vehicle: 1991 Volkswagen Passat GL 2.0 L4 GAS

    Symptoms:
  • Low, Dead Battery
  • Auto Systems:
  • Chassis Electrical, Wiring, Fuses & Breakers, Wipers, Motors
  • CLICK HERE TO GET FULL ACCESS TO 1991 Volkswagen Passat TECHNICAL SERVICE BULLETINS!

    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

    CLICK HERE TO GET FULL ACCESS TO 1991 Volkswagen Passat SPECIFICATIONS DATA!

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