REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Volkswagen Passat B5 (from 1996 to 2004, the year of issue)

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Volkswagen
	Passat B5
		Instructions
		Maintenance
		Engines
			Specifications
			general information
			The bottom mudguard of a motor compartment
			The four-cylinder petrol engine
			Diesel engine 1,9-TDI-I
				Removing and installing toothed belt
				Removing and installing cylinder head (diesel engine of 1.9 liters)
			Timing
			Engine 2,8-I-V6
		Cooling
		Fuel system
		Motor Control
		An exhaust system
		Transmission
		Chassis
		Steering
		Brakes
		Body
		Heating, ventilation
		Electrical

printable version

Diesel engine 1,9-TDI-I

The drive timing of the diesel engine

1 - the mounting clip;
2 - the top casing of a gear belt;
3 - a gear belt. Before removing the toothed belt must be put on it the arrow indicating the direction of the toothed belt;
4 - a nut, 20 Nm;
5 - eccentric;
6 - a tension roller of a gear belt;
7 - a bolt, 45 Nm;
8 - a pulley of a camshaft;
9 - a bolt, 25 Nm;
10 - the guide roller;
11 - a bolt, 10 Nm;
12 - a back casing of a gear belt;
13 - the fuel Naso ;,
14 - an arm;

15 - the console;
16 - pulley of the fuel pump;
17 - a nut, 55 Nm;
18 - pulley of the fuel pump of two sections;
19 - a pulley of an intermediate shaft;
20 - a pulley of a gear belt of a cranked shaft;
21 - bolt crankshaft pulley 90 Nm + tighten on a corner 90 ?�;
22 - bolts of fastening of a pulley of a composite high pressure fuel pump, 20 Nm + tighten on a corner 90 ?�. When installing it is necessary to use new bolts;
23 - the bottom casing of a gear belt;
24 - damper / pulley auxiliary drive a belt. Setting of the pulley is only possible in one position after the alignment holes.

All operations on removal and installation of a gear belt on the diesel engine similar to operations on removal and installation of a gear belt on the four-cylinder petrol engines. The rest of this section sets out the operations that are typical only for engines 1,9-I-TDI.

The device required for fixing the diesel engine camshaft

PERFORMANCE ORDER

	1. Using a wrench, turn the V-belt tension roller all the way counterclockwise, and in this position the roller remove the top casing of a gear belt.
2. Turn the crankshaft in the engine mounting position of the piston of the first cylinder in the top dead center.
3. To lock the camshaft and a pulley of the injection pump piston at TDC of the first cylinder in the compression stroke is necessary to use special locking tools, see. Fig. Adaptations necessary for fixing the camshaft diesel engines.
	4. Set the instrument to lock into the recess in the end of the camshaft.
5. With the blocking tool installed in the camshaft, turn camshaft (turning the crankshaft clockwise) so that the tool blocking one side pressed against the surface of the cylinder head. Using the blade of the probe, measure the gap between the second end of the tool block and the cylinder head. Turn camshaft slightly back and on both sides between the tool block and the cylinder head, set two probe thickness equal to half of the previously measured gap.
	6. Through a hole in the clutch housing check that the TDC mark on the flywheel is aligned with the pointer.

Engines with monoblock pulley of the fuel pump

PERFORMANCE ORDER

	1. Insert the pin block through the insertion hole of the pulley of the fuel pump into the hole in the bracket for the fuel pump pulley.
2. The pin block can be made independently in accordance with the dimensions in Fig. Adaptations necessary for fixing the camshaft diesel engines.

Engines with a two-pulley of the fuel pump

PERFORMANCE ORDER

1. Lock the fuel pump pulley locking pin.
	2. From the pulley of the fuel pump unscrew the screws (1), and in their place screw new bolts, having tightened their moment of 20 Nm. They do not unscrew the central nut of a pulley of the fuel pump, as this pulley can be displaced.
3. Loosen the toothed belt tension by unscrewing the nut of the pulley tensioner.
4. Remove the bolt and remove directing roller of a gear belt. To reinstall the toothed belt check the direction of rotation.
	5. Loosen the bolt of a pulley of a camshaft on half of turn. Remove a pulley of a gear belt of a camshaft with a camshaft assembly cone using a drift through a hole in a back casing of a gear belt.
6. Set the guide roller of a gear belt and fix its bolt, having tightened its moment of 25 Nm.
7. Install the timing belt on the crankshaft pulley, the pulley of the fuel pump and camshaft pulley.
8. Install the timing belt on the pulley with the flat side of the intermediate shaft and the roller mechanism of a tension.
9. Remove the pin blocking high pressure fuel pump.
10. Check that the front part of the toothed belt taut and slack in the belt has to be from the roller mechanism of a tension.
	11. Using a wrench, turn the mechanism of a tension of a gear belt clockwise before combination of labels on a pulley and hub of the tensioner.
12. Check the tension of the toothed belt by turning it in the center between the intermediate and camshaft. This belt has to turn only 90 ?�.
13. After adjusting the tension of the timing belt tensioner tighten the lock nut to 45 Nm.
14. Tighten the pulley bolt camshaft torque.
15. Remove camshaft blocking tool.
16. Rotate the crankshaft two full turns in the normal direction of rotation and re-establish the piston of the first cylinder is at TDC on the compression stroke. Check that the pin of blokirova can be installed in the hole FITTING tion pulley of the fuel pump. Check and, if necessary, re-adjust the tension of the toothed belt.
17. Install the timing belt covers, shock absorber / AUX pulley of the drive belt and the cylinder head cover.
18. Install ribbed accessory belt.
19. Check the installation of the moment of injection of high pressure fuel pump. A warning At the fuel pump gear consisting of two sections after the installation of the moment of injection of the fuel pump, tighten the three screws gear to 20 Nm and then tighten them to the angle of 90 ?�.

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Removing and installing toothed belt