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  • Examplepage for repair manual 4-cylinder diesel engine with unit injector
  • Examplepage for repair manual 2 4-cylinder diesel engine with unit injector
  • Examplepage for repair manual 3 4-cylinder diesel engine with unit injector

4-cylinder diesel engine with unit injector

For Passat / Passat Variant

Original Volkswagen repair manual


14,58 €7% VAT incl.

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  • English

Immediately available for download

Language: English

Digital PDF file

5.811 KB

172 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Sealing flange and flywheel or drive plate, Crankshaft, Pistons and conrods, Cylinder head, Parts of fuel supply system and Charge air system with turbocharger. Show more
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Repair manual Passat / Passat Variant 4-cylinder diesel engine with unit injector PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Technical data
    1
  • 1.1 Engine number
    1
  • 1.2 Engine data
    1
  • Removing and installing engine
    3
  • 1 Removing and installing engine
    3
  • 1.1 Notes on removing
    4
  • 1.2 Notes on installing
    8
  • 1.3 Specified torques
    9
  • 1.4 Front engine mounting
    10
  • 1.5 Additional information and assembly work for vehicles with air conditioner
    10
  • Crankshaft group
    12
  • 1 Dismantling and assembling engine
    12
  • 1.1 Assembly overview
    12
  • 1.2 Removing and installing poly V-belt
    18
  • 2 Sealing flange and flywheel or drive plate
    19
  • 2.1 Assembly overview
    19
  • 2.2 Renewing crankshaft oil seal - pulley end
    20
  • 2.3 Removing and installing drive plate
    21
  • 2.4 Removing and installing sealing flange - pulley end
    23
  • 3 Crankshaft
    26
  • 3.1 Assembly overview
    26
  • 3.2 Pulling needle roller bearing out of and driving into crankshaft
    28
  • 3.3 Crankshaft dimensions
    29
  • 4 Pistons and conrods
    30
  • 4.1 Assembly overview
    30
  • 4.2 Separating new conrods
    31
  • 4.3 Pistons and cylinders
    32
  • 4.4 Checking piston projection at TDC
    33
  • 4.5 Piston and cylinder dimensions
    34
  • Cylinder head, valve gear
    35
  • 1 Cylinder head
    35
  • 1.1 Assembly overview
    35
  • 1.2 Removing, installing and tensioning toothed belt
    37
  • 1.3 Removing and installing cylinder head
    48
  • 1.4 Checking compression
    51
  • 2 Repairing valve gear
    54
  • 2.1 Assembly overview - valve gear
    54
  • 2.2 Reworking valve seats
    57
  • 2.3 Checking valve guides
    58
  • 2.4 Renewing valve stem seals
    59
  • 2.5 Removing and installing camshaft
    60
  • 2.6 Removing and installing camshaft oil seal
    63
  • Lubrication
    66
  • 1 Parts of lubrication system
    66
  • 1.1 Engine oil
    66
  • 1.2 Assembly overview - parts of lubrication system
    67
  • 1.3 Assembly overview - oil filter bracket
    69
  • 1.4 Removing and installing oil sump
    70
  • 1.5 Checking oil pressure and oil pressure switch
    75
  • Cooling
    78
  • 1 Parts of cooling system
    78
  • 1.1 Assembly overview - parts of cooling system, body side
    78
  • 1.2 Assembly overview - parts of cooling system, engine side
    82
  • 1.3 Draining and filling coolant
    87
  • 1.4 Removing and installing radiator
    90
  • 1.5 Removing and installing coolant pump
    92
  • 1.6 Removing and installing thermostat
    94
  • 1.7 Removing and installing viscous fan coupling
    96
  • 1.8 Check fuel cooling pump V166
    97
  • 1.9 Check radiator fan V7
    98
  • Fuel supply system
    101
  • 1 Parts of fuel supply system
    101
  • 1.1 Safety precautions when working on fuel supply system
    101
  • 1.2 Rules for cleanliness
    101
  • 1.4 Assembly overview - fuel filter
    106
  • 1.5 Fuel and coolant hose schematic diagram
    109
  • 1.6 Removing and installing fuel cooler
    110
  • 1.7 Removing and installing fuel tank
    111
  • 1.8 Removing and installing fuel pump
    112
  • 1.9 Removing and installing suction-jet pump
    115
  • 1.10 Checking fuel pump
    117
  • 1.11 Removing and installing fuel delivery unit
    117
  • 1.12 Removing and installing fuel gauge sender
    122
  • 1.13 Assembly overview - accelerator mechanism
    122
  • 1.14 Adjust accelerator position sender
    124
  • 1.15 Removing and installing tandem pump
    125
  • 1.16 Checking tandem pump
    128
  • Turbocharging/supercharging
    132
  • 1 Charge air system with turbocharger
    132
  • 1.1 Assembly overview - turbocharger with attachments
    132
  • 1.2 Removing and installing parts of charge air cooling
    134
  • 1.3 Vacuum hose schematic diagram
    138
  • 1.4 Rules for cleanliness
    138
  • Mixture preparation - injection
    140
  • 1 Repairing diesel direct injection system
    140
  • 1.1 Safety precautions
    140
  • 1.2 Rules for cleanliness
    140
  • 1.3 Overview of fitting locations
    141
  • 1.4 Assembly overview - intake manifold flap
    143
  • 1.5 Assembly overview - unit injector
    143
  • 1.6 Removing and installing O-rings for unit injector
    144
  • 1.7 Removing and installing unit injector
    146
  • 2 Engine control unit
    151
  • 2.1 Reading and clearing engine control unit event memory
    151
  • 2.2 Adapting functions and components
    152
  • 2.3 Removing and installing engine control unit
    153
  • Exhaust system
    155
  • 1 Parts of the exhaust system
    155
  • 1.1 Assembly overview - four-wheel drive vehicles
    155
  • 1.2 Assembly overview - front-wheel drive vehicles
    157
  • 2 Exhaust gas recirculation system
    159
  • 2.1 Assembly overview - parts of exhaust gas recirculation
    159
  • 2.2 Checking exhaust gas recirculation valve (mechanical)
    163
  • Glow plug system
    165
  • 1 Checking glow plug system
    165
  • 1.1 Checking glow plugs
    165
Manufacturer's designation 4-cylinder diesel engine with unit injector
Manufacturer Volkswagen
Suitable for Passat / Passat Variant (1997 - 2005)
Suitable car types 3B
Engine code ATJ, AVB, AVF, AWX
Category Reparaturanleitung

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