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  • Examplepage for repair manual 4-cyl. injection engine (1.6 ltr. with roller rocker finger)
  • Examplepage for repair manual 2 4-cyl. injection engine (1.6 ltr. with roller rocker finger)
  • Examplepage for repair manual 3 4-cyl. injection engine (1.6 ltr. with roller rocker finger)
  • Examplepage for repair manual 4-cyl. injection engine (1.6 ltr. with roller rocker finger)
  • Examplepage for repair manual 2 4-cyl. injection engine (1.6 ltr. with roller rocker finger)
  • Examplepage for repair manual 3 4-cyl. injection engine (1.6 ltr. with roller rocker finger)

4-cyl. injection engine (1.6 ltr. with roller rocker finger)

For Passat / Passat Variant

Original Volkswagen repair manual


16,70 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

3.756 KB

201 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Electronic power control (EPC), Activated charcoal filter system and Checking components. Show more
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Repair manual Passat / Passat Variant 4-cyl. injection engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Technical data
    1
  • 1.1 Technical data
    1
  • 1.2 Engine number
    1
  • 1.3 Engine data
    1
  • Removing and installing engine
    3
  • 1 Removing and installing engine
    3
  • 1.1 Removing and installing engine
    3
  • 1.2 Notes on removing
    5
  • 1.3 Notes on installing
    8
  • 1.4 Tightening torques
    9
  • 1.5 Front engine mounting
    10
  • 1.6 Additional information and removal instructions for vehicles with air conditioner
    10
  • Crankshaft group
    12
  • 1 Dismantling and assembling engine
    12
  • 1.1 Dismantling and assembling engine
    12
  • 1.2 Removing and installing ribbed belt for air conditioner compressor
    19
  • 1.3 Removing and installing ribbed belt
    20
  • 2 Removing and installing sealing flanges and flywheel
    21
  • 2.1 Removing and installing sealing flanges and flywheel
    21
  • 2.2 Renewing crankshaft oil seal -belt pulley end
    24
  • 2.3 Removing and installing front sealing flange
    27
  • 3 Removing and installing crankshaft
    30
  • 3.1 Removing and installing crankshaft
    30
  • 3.2 Colour markings
    34
  • 3.3 Pulling needle bearing out of crankshaft and driving in
    35
  • 3.4 Crankshaft dimensions
    37
  • 4 Dismantling and assembling pistons and conrods
    38
  • 4.1 Dismantling and assembling pistons and conrods
    38
  • 4.2 Piston and cylinder dimensions
    43
  • Cylinder head, Valve gear
    44
  • 1 Removing and installing cylinder head
    44
  • 1.1 Removing and installing cylinder head
    44
  • 1.2 Removing and installing cylinder head
    50
  • 1.3 Removing and installing toothed belt
    54
  • 1.4 Checking semi-automatic toothed belt tensioning roller
    57
  • 1.5 Checking compression pressure
    58
  • 2 Servicing valve gear
    60
  • 2.1 Servicing valve gear
    60
  • 2.2 Reworking valve seats
    65
  • 2.3 Replacing camshaft oil seal
    67
  • 2.4 Removing and installing camshaft
    70
  • 2.5 Checking valve guides
    74
  • 2.6 Renewing valve stem seals
    75
  • Lubrication
    78
  • 1 Removing and installing parts of the lubrication system
    78
  • 1.1 Removing and installing parts of the lubrication system
    78
  • 1.2 Removing and installing sump
    87
  • 1.3 Checking oil pressure and oil pressure switch
    93
  • Cooling system
    95
  • 1 Removing and installing parts of cooling system
    95
  • 1.1 Removing and installing parts of cooling system
    95
  • 1.2 Parts of cooling system body side
    96
  • 1.3 Parts of cooling system engine side
    99
  • 1.4 Removing and installing compact bracket
    103
  • 1.5 Coolant hose connection diagram
    106
  • 1.6 Draining and filling cooling system
    107
  • 1.7 Removing and installing radiator
    110
  • 1.8 Removing and installing coolant pump
    112
  • 1.9 Removing and installing viscous fan coupling
    113
  • 1.10 Removing and installing viscous fan coupling bearing bush
    115
  • Fuel supply system
    117
  • 1 Removing and installing parts of fuel supply system
    117
  • 1.1 Removing and installing parts of fuel supply system
    117
  • 1.2 Removing and installing fuel tank with its attachments and fuel filter
    118
  • 1.3 Safety precautions when working on the fuel supply system
    125
  • 1.4 Rules for cleanliness
    126
  • 1.5 Removing and installing fuel delivery unit
    126
  • 1.6 Removing and installing fuel gauge sender
    128
  • 1.7 Removing and installing fuel tank
    129
  • 1.8 Crash fuel shut-off
    130
  • 1.9 Checking fuel pump
    131
  • 2 Electronic power control (EPC)
    138
  • 2.1 Electronic power control (EPC)
    138
  • 2.2 Function of EPC system
    138
  • 2.3 Servicing parts of electronic power control (EPC)
    139
  • 3 Activated charcoal filter system
    140
  • 3.1 Activated charcoal filter system
    140
  • 3.2 Function
    140
  • 3.3 Servicing parts of the activated charcoal filter system
    141
  • 3.4 Checking fuel tank breather
    143
  • Mixture preparation, Injection
    146
  • 1 Servicing injection system
    146
  • 1.1 Servicing injection system
    146
  • 1.2 Fitting locations overview
    146
  • 1.3 General notes on injection
    153
  • 1.4 Dismantling and assembling intake manifold
    154
  • 1.5 Dismantling and assembling air cleaner
    158
  • 1.6 Dismantling and assembling intake hose
    160
  • 1.7 Dismantling and assembling fuel rail with injectors
    162
  • 1.8 Safety precautions
    163
  • 1.9 Rules for cleanliness
    164
  • 1.10 Technical data
    164
  • 2 Checking components
    165
  • 2.1 Checking components
    165
  • 2.2 Checking spray pattern and checking for leaks
    165
  • 2.3 Checking fuel pressure regulator and holding pressure
    167
  • 2.4 Checking intake manifold change-over
    169
  • 3 Engine control unit
    170
  • 3.1 Engine control unit
    170
  • 3.2 Replacing engine control unit
    170
  • 3.3 Adapting functions and components
    171
  • 3.4 Interrogating and erasing engine control unit fault memory
    172
  • Exhaust system
    174
  • 1 Removing and installing parts of exhaust system
    174
  • 1.1 Removing and installing parts of exhaust system
    174
  • 1.2 Exhaust manifold, front exhaust pipe and catalyst with attachments
    175
  • 1.3 Silencer with mountings
    179
  • 2 Secondary air system
    181
  • 2.1 Secondary air system
    181
  • 2.2 Function
    182
  • 2.3 Removing and installing parts of the secondary air system
    182
  • 2.4 Checking combi-valve
    185
  • 3 Exhaust gas recirculation system
    187
  • 3.1 Exhaust gas recirculation system
    187
  • 3.2 Servicing parts of exhaust gas recirculation system
    187
  • Ignition system
    189
  • 1 Servicing ignition system
    189
  • 1.1 Servicing ignition system
    189
  • 1.2 General notes on ignition system
    189
  • 1.3 Removing and installing parts of the ignition system
    190
  • 1.4 Safety precautions
    193
  • 1.5 Test data, spark plugs
    194
Manufacturer's designation 4-cyl. injection engine (1.6 ltr. with roller rocker finger)
Manufacturer Volkswagen
Suitable for Passat / Passat Variant (1997 - 2005)
Suitable car types 3B
Engine code ALZ
Category Reparaturanleitung

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