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Caution: Refer to Gasoline/Gasoline Vapors Caution in the Preface section. Important: There are several types of Plastic Collar Fuel and Evaporative Emission Quick Connect Fittings used on this vehicle. • Bartholomew (1) • Q Release (2) • Squeeze to Release (3) • Sliding Retainer (4) • Push Down TI (5) The following instructions apply to all of these types of Plastic Collar Quick Connect Fittings except where indicated. 1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to the Fuel Pressure Relief . Caution: Refer to Safety Glasses Caution in the Preface section. Notice: Refer to Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Notice in the Preface section. 2. Using compressed air, blow any dirt out of the quick-connect fitting. 3. This step applies to Bartholomew style connectors ONLY. Squeeze the plastic quick connect fitting release tabs. 4. This step applies to Q Release style connectors ONLY. Release the fitting by Pushing the tab toward the other side of the slot in the fitting. 5. This step applies to Squeeze to Release style connectors ONLY. Squeeze where indicated by arrows on both sides of the plastic ring surrounding the quick connect fitting. 6. This step applies to Sliding Retainer style connectors ONLY. Release the fitting by pressing on one side of the release tab causing it to push in slightly. If the tab does not move, try pressing the tab in from the opposite side. The tab will only move in one direction. 7. This step applies to the Push Down TI style connectors ONLY. Release the fitting by pressing on the tab indicated by arrow. Caution: Refer to Relieving Fuel Pressure Caution in the Preface section.

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cooler Hose replacement Procedure 1) Place vehicle on lift. 2) Remove the engine under cover. Hose clamp location 3) Squeeze the hose clamps and reposition to remove the hose. Confirm the direction and angle of the original hose clamps before removal. It is important to reinstall clamps in their original position. 4) Place a drain pan under the hose to collect any CVTF which may leak out. caution: if the cVtF has spilled onto the exhaust pipe or body frame, wipe it off with a rag to avoid dripping fluid. 5) Remove the inlet cooler hose. Note: Be extremely careful not to damage the pipe. 6) Make sure the cooler hose pipe ends are clean prior to installing a new hose. 7) Install a new hose reusing the original hose clamps. Note: Do not permit the end of the hose to extend past the raised lip section of the pipe. Be sure to place the hose clamps in their original position. If the original hose clamps are damaged or deformed, replace as necessary. note: Neither replenishment of transmission fluid nor inspection of fluid level will be neces- sary during replacement of the hose unless the original hose was found to be leaking fluid. Approx. 50cc through 70cc of fluid may be lost during hose replacement. The amount of fluid remaining will still keep the necessary level with sufficient reserve margin. check and add cVtF cAution: • CVTF level changes along with CVTF temperature. When inspecting CVTF level, observe the specified CVTF temperature. • Always use specified CVTF or equivalent. Using other fluid except for specified or equivalent will cause malfunction.

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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