add to favorites contacts sitemap
REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Volkswagen Passat B6 (from the year 2004)

general info. full specifications. diagnostics. hints. tips. tricks
Volkswagen Passat B6
Home
 
Volkswagen
Passat B6
Operation and maintenance of car
Engine
Overview
Mechanical (engine capacity of 1.6 liters)
Lubrication system
Cooling system
Fuel Injection System
The mechanical part (petrol engines of 2.0 liters)
Compression Test
Removing Engine
Installation of the timing belt
Valve Actuator
Removal and installation of camshafts
Replacing the valve stem seals (if installed cylinder head)
Replacement exhaust camshaft oil seal
Removal and installation of the phase shifter
Removing and installing valve 1 control valve timing
Removing and installing V-ribbed belt
Replacing crankshaft oil seal on the side of the pulley
Removing and installing sealing flange on the side of the pulley
Removal and installation of the flange on the side of the crankshaft flywheel
Removal and installation of a flywheel
Removing and installing drive plate
Crankshaft
The pistons and connecting rods
Checking the pistons, piston rings and cylinder bore
Removing and installing cylinder head cover
Removing the cylinder head
Installing the cylinder head
Lubrication system
System ohlazhdeiya
Fuel system
Injection system
System of release of gases otrabotavschih
Ignition system
The mechanical part (diesel engines of 2.0 liters)
Lubrication system
Cooling system
Fuel system
Turbocharging turbo running on exhaust
The direct injection diesel
Exhaust
Tables
Transmission
Chassis
Steering Gear
Brakes
Onboard electric
Body
diagrams
 


Hit Counter by Digits


print page printable version

Removing Engine



NOTE
During subsequent operations the ground cable must be disconnected from the battery. Therefore, you must first check whether the car radio with coding.
The engine is removed together with the gearbox down.
After the installation of the engine must be in the same places again set all cable clamps, remove or cut for its dismantling.

ATTENTION
In any assembly work, particularly in the engine compartment due to the compact layout, consider the following.
Motorways of all kinds (such as fuel, hydraulic absorber, activated carbon, cooling systems, circuit conditioning systems, brake lines, vacuum hoses) and electrical wiring must be routed as they were originally laid.
To avoid damage, ensure sufficient clearance to all moving or hot components.

Disconnect the ground cable from the battery when the ignition is off.

Engine cover
Fig. 2.82. Engine cover


Remove, if present, the engine cover (Fig. 2.82).
Disconnect the hose 1 and connector plug on the intake air temperature sensor 2 on the air filter housing.

Air filter with air hose
Fig. 2.83. Air filter with air hose


3 Remove the bolt and remove the air filter housing with air hose 4 (Fig. 2.83).
Remove the battery and battery holder frame.
Remove the wiper arms, plenum chamber casing and plenum chamber on the front side.
Disconnect the engine wiring harness connector to the engine control unit.
Remove wiper arms and plenum chamber cover.
Disconnect the engine wiring harness connector to the engine control unit.

Holder entry to the engine wiring harness
Fig. 2.84. Holder entry to the engine wiring harness


Unlock input for engine wiring harness and pull up (Fig. 2.84).

Fixing the cable generator to the fuse holder
Fig. 2.85. Fixing the cable generator to the fuse holder


Remove the cable from the generator fuse holder (Fig. 2.85).

Securing workpiece
Fig. 2.86. Securing workpiece


Remove the earth cable from the spar (Fig. 2.86).
Open cable clamps on the side member.
Disconnect the wiring harness connectors of the engine to the body and put the harness on the engine.

Pipeline and Fuel
Fig. 2.87. Pipeline and Fuel


Disconnect the vent line 1 and fuel 2. When you click on the clips (Fig. 2.87).
Remove the soundproofing screen.
Result a radiator framework in service position.
Drain the coolant.
Remove the front left wheel arch liner.

Holder exhaust system
Fig. 2.88. Holder exhaust system


Remove the holder of the exhaust system (Fig. 2.88).

NOTE
On vehicles with Engine code BLX and BVX Bracket exhaust system removed together with cable duct of oxygen sensors for the catalyst.

Vehicles with front-wheel drive

Fastening heat shield
Fig. 2.89. Fastening heat shield


Remove heat shield for right drive shaft (Fig. 2.89).

Continuation of the assembly operations for all vehicles
Remove the right drive shaft and remove the left drive shaft from the transmission.

Attaching Front Pipe
Fig. 2.90. Attaching Front Pipe


Unscrew the nuts of a reception pipe to a final collector and disconnect it from the exhaust manifold (Fig. 2.90).

NOTE
Releasable pipe receiving elements can not be bent more than 10 ?�.

Vehicles with Engine code BLX, BVX
Remove the catalyst memory NO.
Remove front propeller shaft tube.

Continuation of the assembly operations for all vehicles

Aligning bearing bracket
Fig. 2.91. Aligning bearing bracket


Remove the screws 1-3 and remove the rocker support (Fig. 2.91).

Duct Hose
Fig. 2.92. Duct Hose


Disconnect the hose at the bottom of the duct on the expansion tank and remove it (Fig. 2.92).
Remove the terminals, disconnect and release the rest of the available power wire from the engine / transmission.
Disconnect all connectors from the engine, vacuum and intake hoses and hoses and coolant.

NOTE
To avoid damage to the capacitor, and the pipes and hoses circuit conditioning systems, you must make sure that the lines and hoses have been laid without tension, bends and kinks.
To be able to remove and install the engine and without opening the refrigerant circuit.

Remove ribbed belt.
Unscrew air conditioner compressor from bracket.
Secure air conditioner compressor bracket on the castle so that there is no load on the highway / coolant hoses.

Vehicles with manual transmission
Remove the drive gear from the gearbox.

Stretching and clutch slave cylinder
Fig. 2.93. Stretching and clutch slave cylinder


1 Remove the stretch (Fig. 2.93).
Remove the clutch slave cylinder and set it aside, do not open the trunk.

ATTENTION
On the clutch slave cylinder after dismantling do not press. The working cylinder may be damaged.

Cars with automatic transmission
Remove the drive cable from gearbox selector.

Continuation of the assembly operations for all vehicles

Coupling plug
Fig. 2.94. Coupling plug


Remove the connector plug 1 of the attachment (Fig. 2.94).
Unscrew bolts 2-4.
Set the rack to lock the engine in the engine and gearbox.

Rack Installation
Fig. 2.95. Rack Installation


Place the rack for the engine, as shown in Figure 2.95, to the engine and tighten it with a torque of 20 Nm to the engine block.
Screw the rack to support the engine through the intake manifold mounting bolt M10h25 to 20 N ?� m to the cylinder block.
Slightly lift the engine and transmission with the rack for the engine and gearbox.

Fixing the upper engine mount bracket
Fig. 2.96. Fixing the upper engine mount bracket


Remove the suspension of the power unit from the upper engine support (Fig. 2.96).

Mounting bracket gearbox support
Fig. 2.97. Mounting bracket gearbox support


Remove the power train from the gearbox support (Fig. 2.97).

NOTE
To loosen the securing bolts use ladder.
Lower the engine and transmission to be careful to avoid damage to the body.
Carefully opustitedvigatel and transmission down.

Mounting engine on assembly stand
For assembly work the engine must be mounted on a retainer for the engine and gearbox.
Remove the transmission from the engine.

Device for hanging
Fig. 2.98. Device for hanging


Hang the device for hanging follows and lift up the crane from the rack for engine and gearbox (Fig. 2.98).
From the pulley 4 th hole of the guide in position 1
Flywheel side third guide hole at position 7

ATTENTION
To prevent damage to the engine and the vehicle, use the hook and locking pin special belay pins.

Holes 1-4 carrier strips pointing in the direction of belt pulleys.
Countdown holes in the rails is carried out by a hook.
Fix the engine on the retainer engine and gearbox.

Engine installation
Install in reverse order, with the following should be considered.
Insert new mounting sleeves for centering engine and gearbox to the engine block.

The intermediate plate
Fig. 2.99. The intermediate plate


Suspend the intermediate plate on sealing flange and slide it into the sleeve-fitting (Fig. 2.99).

Vehicles with manual transmission
Lightly grease the teeth of the input shaft.
Check and install the clutch and clutch.

Continuation of the assembly operations for all vehicles
When installing the power unit (engine and gearbox) must have sufficient space to subframe and radiator.
Align the motor support as follows:

The distance between the support and the engine and the right side member
Fig. 2.100. The distance between the support and the engine and the right side member


Between the engine support and the right side member and the distance should be at least 10 mm (Fig. 2.100).
Cast edge in the engine support 2 should be located parallel to the arm 1.

Checking the parallelism of the edges of the bracket and the gearbox console
Fig. 2.101. Checking the parallelism of the edges of the bracket and the gearbox console


Pay attention to the side of the gearbox on the parallel edges of the bracket 2 and the console gearbox 1 (Fig. 2.101).
Install the rocker support.
Install the right drive shaft and screw the left drive shaft to the gearbox.

Vehicles with four-wheel drive
Install the front propeller shaft tube.

Vehicles with a letter designation BLR, BVY
Fasten the exhaust pipe catalyst.

Vehicles with Engine code BLX, BVX
Install a catalyst memory NOx.

Vehicles with Engine code BLY, BVZ
Fasten the exhaust pipe catalyst.

Vehicles with manual transmission
Install the actuator switch, if necessary - adjust.
Install hydraulic clutch slave cylinder.

Cars with automatic transmission
Install the selector cable and adjust it if necessary.

Continuation of the assembly operations for all vehicles
Install the air conditioning compressor.
Install poly V-belt.
Install screen proofing.
Connect the connector to the engine control unit.
Install the battery and battery holder frame.
Fill the coolant.
Perform a test drive.
Then perform testing of vehicle systems and eliminate possible interferences.

NOTE
After clearing the fault memory is necessary to create a code of OBD.

Tightening torques




« previos page
Compression Test
next page »
Installation of the timing belt

Copyright © 2010 AutoManuals.biz. Trademarks belong to their respective owners. All rights reserved.