Volkswagen Passat 2005 and earlier

OK.

So, i'm no mechanic, and it seems it's hard to find info online (vehicle manuals/diagrams) that would help me become one.

First:
Does anyone out there know where i could get a bootleg FREE copy of the 1999 Volkswagen Passat 1.8 turbo REPAIR MANUAL?

Second:
While i was driving my Passat there was a blow-out of my exahust intake manifold (where the exhaust attaches to the engine). So, naturally, of course my car sounds very loud because of the disconnection. Does anyone know what the exhaust (the part under the hood, near the engine - not under the car near the Cat) is made out of - cast iron ??
I have thought of welding it back, but am leaning towards a replacement of the part.

Any feedback/knowledge sharing is appreciated!! Thanks for your time!

Replies to this message:

altair4 (Sep 29, 2009 12:21 pm)

#8240 of 8275 Re: 1999 Passat - Exhaust Intake snapped [divinity] by altair4

Sep 29, 2009 (12:21 pm)

Replying to: divinity (Sep 29, 2009 9:49 am)

Wait...what? The "exhaust intake manifold?" Which one - exhaust or intake? They're mutually exclusive. Need more info to help you.

If you were to google "Passat Etka" you might find something that woudl help you.

#8241 of 8275 One page maintenance chart? by passatstuck

Oct 11, 2009 (8:14 pm)

I've got a 2003 Passat 4 motion wagon. v6.
There isn't any handy dandy one page chart available. I must have spent two hours w. the manual and on-line also. I called the VW dept. that's responsible for manuals, and they don't have any such thing.

Two Questions:
1. Has anyone compiled a chart?
2. Has anyone found maintenance info on severe conditions?

Exasperated and stuck w. my Passat.

Replies to this message:

altair4 (Oct 12, 2009 6:54 am)
- passatstuck (Oct 12, 2009 7:05 pm)

#8242 of 8275 Re: One page maintenance chart? [passatstuck] by altair4

Oct 12, 2009 (6:54 am)

Replying to: passatstuck (Oct 11, 2009 8:14 pm)

VWoA's website has a feature where you can plug in your veicle info and it will generate the next maintenance required for your mileage. Once there, you can click on "View Complete Schedule" and it will show the entire schedule. It is not a severe serviceschedule, however.

Start here:
http://www.vw.com/myvw/yourcar/maintenance/findschedules/en/us/index.html

Replies to this message:

passatstuck (Oct 12, 2009 7:05 pm)

#8243 of 8275 Re: One page maintenance chart? [altair4] by passatstuck

Oct 12, 2009 (7:05 pm)

Replying to: altair4 (Oct 12, 2009 6:54 am)

Thank you so much. I've printed the chart for the first 100k miles services and checked all my service records against it. I hope I can figure out what the severe service sched. is. All the manual says is call the dealer.

Can't thank you enough! Gotta save this site... http://www.vw.com/myvw/yourcar/maintenance/findschedules/en/us/index.html

P.

#8244 of 8275 Speaking of maintenance......... by tomj2

Oct 14, 2009 (10:17 am)

On my 2003, 1.8T, Passat, dealer says timing belt replacement should be done at 60K. Manual says only to check at 40K and 80K. Anybody know how essential this is? Dealer wants $1000! No wonder they recommend it...

Replies to this message:

whitey9 (Oct 30, 2009 11:32 am)
- altair4 (Oct 30, 2009 6:29 pm)

#8245 of 8275 Re: Speaking of maintenance......... [tomj2] by whitey9

Oct 30, 2009 (11:32 am)

Replying to: tomj2 (Oct 14, 2009 10:17 am)

ACTUALLY, VW, not the dealer, wants the cam ( timing ) belt inspected priodically.
Remove the cover at the top/front of the engine and check the sides of the belt for cracks. ( My cover has a water hose clipped to it. ) I replaced my belt at 105,000mi. It was quite an ordeal and I do not recommend anyone w/o "heavy line" experience even attempting to do it. The valve timing must be right, and the cam belt must not be too tight, or too loose. The whole front of the car must be removed. ( Bumper, headlights, AC condensor and radiator. ) The AC system must be drained of refrigerant and later refilled. I replaced the camshaft belt tensioner, the water pump, and thermostat during the cam belt replacement. The repair manual cost of $100. NOT for an amateur.

Replies to this message:

altair4 (Oct 30, 2009 6:29 pm)

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