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  • Examplepage for repair manual 4-cylinder injection engine
  • Examplepage for repair manual 2 4-cylinder injection engine
  • Examplepage for repair manual 3 4-cylinder injection engine
  • Examplepage for repair manual 4-cylinder injection engine
  • Examplepage for repair manual 2 4-cylinder injection engine
  • Examplepage for repair manual 3 4-cylinder injection engine

4-cylinder injection engine

For Passat / Passat Variant

Original Volkswagen repair manual


13,41 €7% VAT incl.

Immediately available for download

Language: English

Digital PDF file

4.330 KB

156 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Repairing parts of electronic power control (EPC), Activated charcoal filter system, Checking components and Engine control unit. Show more
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Repair manual Passat / Passat Variant 4-cylinder injection engine 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
    2
  • 1 Removing and installing engine
    2
  • 1.1 Notes on removing
    3
  • 1.2 Notes on installing
    7
  • 1.3 Front engine mounting
    9
  • 1.4 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 air conditioner compressor poly V-belt
    16
  • 1.3 Removing and installing poly V-belt
    16
  • 2 Removing and installing sealing flanges and flywheel or drive plate
    18
  • 2.1 Renewing crankshaft oil seal on belt pulley end
    19
  • 2.2 Removing and installing front sealing flange
    22
  • 2.3 Removing and installing drive plate
    25
  • 3 Removing and installing crankshaft
    28
  • 3.1 Crankshaft dimensions
    29
  • 3.2 Pulling needle roller bearing out of and driving into crankshaft
    30
  • 4 Dismantling and assembling pistons and conrods
    32
  • 4.1 Piston and cylinder dimensions
    34
  • Cylinder head, valve gear
    35
  • 1 Removing and installing cylinder head
    35
  • 1.1 Removing, installing and tensioning toothed belt
    37
  • 1.2 Removing and installing cylinder head
    41
  • 1.3 Checking compression
    44
  • 2 Repairing valve gear
    47
  • 2.1 Reworking valve seats
    49
  • 2.2 Renewing camshaft oil seals
    51
  • 2.3 Checking hydraulic bucket tappets
    55
  • 2.4 Removing and installing camshaft
    56
  • 2.5 Checking valve guides
    65
  • 2.6 Renewing valve stem seals
    66
  • Lubrication
    71
  • 1 Removing and installing parts of lubrication system
    71
  • 1.1 Dismantling and assembling oil filter housing
    74
  • 1.2 Dismantling and assembling oil pump with balancer shaft gear assembly
    75
  • 1.3 Removing and installing oil pump with balancer shaft gear assembly
    76
  • 1.4 Removing and installing oil sump
    79
  • 1.5 Checking oil pressure and oil pressure switch
    84
  • Cooling
    87
  • 1 Removing and installing parts of cooling system
    87
  • 1.1 Parts of cooling system, body side
    87
  • 1.2 Parts of cooling system, engine side
    89
  • 1.3 Coolant hose schematic diagram
    91
  • 1.4 Removing and installing compact bracket
    92
  • 1.5 Draining and filling coolant
    93
  • 1.6 Removing and installing radiator
    96
  • 1.7 Removing and installing coolant pump
    98
  • 1.8 Removing and installing viscous fan coupling
    100
  • 1.9 Removing and installing viscous fan mounting bush
    101
  • 1.10 Dismantling and assembling coolant distribution housing
    102
  • 1.11 Electronically regulated cooling system
    103
  • 1.12 Checking map-controlled engine cooling thermostat
    104
  • Fuel supply system
    105
  • 1 Removing and installing parts of fuel supply system
    105
  • 1.1 Removing and installing fuel tank with attachments and fuel filter
    105
  • 1.2 Safety precautions when working on fuel supply system
    108
  • 1.3 Rules for cleanliness
    109
  • 1.4 Removing and installing fuel delivery unit
    109
  • 1.5 Removing and installing fuel gauge sender
    111
  • 1.6 Removing and installing fuel tank
    112
  • 1.7 Crash fuel shut-off
    113
  • 1.8 Checking fuel pump
    113
  • 2 Repairing parts of electronic power control (EPC)
    120
  • 2.1 Function of EPC system
    120
  • 3 Activated charcoal filter system
    122
  • 3.1 Function
    122
  • 3.2 Repairing parts of activated charcoal filter system
    122
  • 3.3 Checking fuel tank breather
    123
  • Mixture preparation - injection
    126
  • 1 Repairing injection system
    126
  • 1.1 General notes on injection
    126
  • 1.2 Removing and installing parts of the injection system
    126
  • 1.3 Dismantling and assembling intake manifold
    129
  • 1.4 Dismantling and assembling air filter
    130
  • 1.5 Dismantling and assembling intake hose
    131
  • 1.6 Dismantling and assembling fuel rail with injectors
    132
  • 1.7 Safety precautions
    132
  • 1.8 Rules for cleanliness
    133
  • 1.9 Technical data
    134
  • 2 Checking components
    135
  • 2.1 Checking injectors for leaks and injection rate
    135
  • 2.2 Checking fuel pressure regulator and holding pressure
    137
  • 2.3 Checking intake manifold change-over
    139
  • 3 Engine control unit
    141
  • 3.1 Renewing engine control unit
    141
  • 3.2 Adapting components
    141
  • 3.3 Reading and erasing engine control unit fault memory
    142
  • Exhaust system
    144
  • 1 Removing and installing parts of exhaust system
    144
  • 1.2 Silencer with mountings
    146
  • Ignition system
    148
  • 1 Repairing ignition system
    148
  • 1.1 General notes on ignition system
    148
  • 1.2 Removing and installing parts of ignition system
    148
  • 1.3 Safety precautions
    149
  • 1.4 Test data, spark plugs
    150
Manufacturer's designation 4-cylinder injection engine
Manufacturer Volkswagen
Suitable for Passat / Passat Variant (1997 - 2005)
Suitable car types 3B
Engine code ALT
Category Reparaturanleitung

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