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Turbocharging Components, System Overview NOTE: – Boost pressure control is switched off during partial throttle operation by the EGR part throttle switch -Fl66- and the two-way valve for EGR -N161- – Check and adjust EGR part throttle switch – Check two-way valve for EGR 1 – Exhaust manifold 2 – 25 Nm (18 ft lb) 3 – Hose – To Diesel injection pump 4 – Gasket – Replace – Coated side toward intake manifold 5 – Intake manifold 6 – 45 Nm (33 ft lb) – Replace – Coat threads and bolt head sealing surfaces with high temperature (2000 °F) anti-sieze compound 7 – Gasket – Replace – Note installation position 8 – To Positive Crankcase Ventilation valve 9 – From Air Cleaner 10 – Turbocharger – Boost pressure checking, refer to “Turbocharger, Checking”. See: Testing and Inspection 11 – Wastegate – Integral part of turbocharger cannot be replaced – Hose/pipe connections, refer to “Turbocharger Hoses and Lines, Connecting”. See: Vacuum and Vapor Hose Diagrams 12 – Oil return line – To cylinder block 13 – Sealing rings Page 3 1996 Volkswagen Passat Sedan L4-1.9L DSL Turbo (AAZ) Copyright © 2008, ALLDATA 9.70 Page 2 – Replace 14 – Banjo bolt – 30 Nm (22 ft lb) 15 – 30 Nm (22 ft Ib) 16 – Front exhaust pipe 17 – Oil supply pipe – From oil filter bracket 18 – Air hose 19 – Mounting bracket – Between exhaust pipe and exhaust manifold

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1. Install cylinder head. A. Place cylinder head on cylinder block. (a) Place a new cylinder head gasket on the cylinder block. CAUTION: Be careful of the installation direction. (b) Place the cylinder head on the cylinder head gasket. B. Install cylinder head bolts. NOTE: The cylinder head bolts are tightened in 2 progressive steps (steps (b) and (d)). If any cylinder head bolt is broken or deformed, replace it. (a) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts. Cylinder Head Installation Install and uniformly tighten the 10 cylinder head bolts and plate washers in several passes, in the sequence shown. Torque: 49 Nm (36 ft. lbs.) If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt. (c) Mark the front of the cylinder head bolt head with paint. (d) Retighten the cylinder head bolts 90° in the numerical order shown. (e) Check that the painted mark is now at a 90° angle to the front. Install the 2 bolts holding the water bypass pipe to the cylinder head. Torque to 19 Nm (14 ft. lbs.) (g) Connect the camshaft position sensor connector. 2. Install spark plug tubes. (a) Clean the cylinder head tube holes of any residual adhesive, oil or foreign particles. Remove any oil with kerosene or gasoline. (b) Screw the threads of the spark plug tube coated with adhesive into the cylinder head.

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2. Jack-up vehicle, support it with safety stands, and remove front wheels. 3. Unlock axle nut. See Fig. 9 . CAUTION: Be sure to loose and retighten axle nut after removing wheel from vehicle. Failure to follow this rule may damage wheel bearings. 4. Remove axle nut while depressing brake pedal to prevent front drive shaft from turning. 5. Remove stabilizer link. See Fig. 10 . 6. Remove disc brake caliper from housing, and suspend it from strut using a wire. 7. Remove disc rotor from hub. See Fig. 11 . If disc rotor seizes up within hub, drive disc rotor out by installing an 8-mm bolt in screw hole on the rotor. 8. Remove cotter pin and castle nut which secure tie-rod end to housing knuckle arm. See Fig. 12 . 9. Using a puller, remove tie-rod ball joint from knuckle arm. See Fig. 13 . 10. Remove ABS sensor assembly and harness. See Fig. 14 . 11. Remove bolt which secures sensor harness to strut. See Fig. 15 . 12. Remove transverse link ball joint from housing. See Fig. 16 . CAUTION: DO NOT pull inner joint when removing axle shaft. 13. Remove inner joint from transmission spindle. 14. Remove front axle shaft assembly from hub. See Fig. 17 . 15. After scribing an alignment mark on camber adjusting bolt head, remove bolts which connect housing and strut, and disconnect housing from strut. See Fig. 18 .

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ADJUSTMENTS & INSPECTION WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES NOTE: See WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article in the WHEEL ALIGNMENT section. WHEEL BEARING No adjustment is required. RIDING HEIGHT Measure the distance between bolt head of upper shock absorber mounting and center of bolt head of lower shock absorber mounting. If distance measured is not 10.3-10.4″ (263-265 mm) turn torsion bar adjustment bolt until correct riding height is obtained. BALL JOINT CHECKING Raise and support vehicle. Inspect ball joints for excessive play and damaged rubber boots. There should be no vertical or horizontal ball joint play. Replace ball joint if any play is present. REMOVAL & INSTALLATION BALL JOINTS

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In step 17 of the ’01 Civic A/C installation instruction (AII 21888-22262), you must remove the A/C compressor bracket to install the heat insulator. Three of the A/C compressor bolts are 10 x 45 mm and one is 10 x 35 mm. When you reinstall the compressor bracket, make sure you reinstall the 10 x 35 mm bolt in the lower right bolt hole in the bracket. If you install one of the longer 10 x 45 mm bolts in that hole, the bolt head will damage the compressor