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  • Examplepage for repair manual 4-cylinder injection engine (1.6 l engine, direct injection)
  • Examplepage for repair manual 2 4-cylinder injection engine (1.6 l engine, direct injection)
  • Examplepage for repair manual 3 4-cylinder injection engine (1.6 l engine, direct injection)

4-cylinder injection engine (1.6 l engine, direct injection)

For Passat / Passat Variant

Original Volkswagen repair manual


13,20 €7% VAT incl.

Immediately available for download

Language: English

Digital PDF file

6.486 KB

153 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Cylinder head, Fuel tank, Repairing fuel supply system, Repairing electronic power control (EPC) and Checking components. 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 Removing engine
    3
  • 1.2 Securing engine to engine stand
    7
  • 1.3 Installing engine
    7
  • 1.4 Tightening torques
    8
  • 1.5 Assembly mountings
    9
  • 1.6 Notes on repairs to air conditioning system
    9
  • Crankshaft group
    11
  • 1 Dismantling and assembling engine
    11
  • 1.1 Part I: Assembly overview - belt drive
    12
  • 1.2 Part II: Assembly overview - cylinder block
    13
  • 1.3 Removing and installing poly V-belt
    15
  • 1.4 Removing and installing valve timing housing
    16
  • 2 Removing and installing sealing flanges and flywheel/drive plate
    19
  • 2.1 Assembly overview
    19
  • 2.2 Renewing crankshaft oil seal - pulley end
    21
  • 2.3 Poly V-belt pulley securing bolt tightening procedure
    22
  • 2.4 Renewing crankshaft sealing flange - flywheel end, vehicles with manual gearbox
    26
  • 2.6 Crankshaft dimensions
    39
  • 3 Dismantling and assembling pistons and conrods
    41
  • 3.1 Assembly overview
    41
  • 3.2 Checking piston
    42
  • 3.3 Piston and cylinder dimensions
    43
  • Cylinder head, valve gear
    44
  • 1 Cylinder head
    44
  • 1.1 Assembly overview
    45
  • 1.2 Checking valve timing
    47
  • 1.3 Adjusting valve timing
    49
  • 1.4 Removing and installing camshaft housing
    53
  • 1.5 Removing and installing cylinder head
    56
  • 1.6 Checking compression
    59
  • 2 Repairing valve gear
    61
  • 2.1 Assembly overview
    61
  • 2.2 Checking camshaft axial clearance
    63
  • 2.3 Reworking valve seats
    63
  • 2.4 Checking valve guides
    65
  • 2.5 Renewing valve shaft seals
    66
  • Lubrication
    68
  • 1 Removing and installing parts of lubrication system
    68
  • 1.1 Engine oil
    68
  • 1.2 Assembly overview
    69
  • 1.3 Removing and installing sump
    70
  • 1.4 Removing and installing oil pump
    72
  • 1.5 Checking oil pressure and oil pressure switch
    75
  • Cooling
    77
  • 1 Removing and installing parts of cooling system
    77
  • 1.1 Assembly overview - parts of cooling system - body side
    78
  • 1.2 Assembly overview - parts of cooling system - engine side
    79
  • 1.3 Coolant hose schematic diagram
    81
  • 1.4 Draining and filling cooling system
    82
  • 1.5 Removing and installing radiator
    84
  • 1.6 Removing and installing coolant pump
    86
  • Fuel supply system
    88
  • 1 Fuel tank
    88
  • 1.1 Safety precautions when working on fuel supply system
    88
  • 1.2 Rules for cleanliness
    88
  • 1.3 Assembly overview - fuel tank
    89
  • 1.4 Emptying fuel tank
    90
  • 1.5 Removing and installing fuel tank
    92
  • 2 Repairing fuel supply system
    95
  • 2.1 Safety precautions when working on fuel supply system
    95
  • 2.2 Rules for cleanliness
    95
  • 2.3 Removing and installing fuel delivery unit
    96
  • 2.4 Removing and installing fuel gauge sender G
    99
  • 2.5 Checking fuel pump
    99
  • 2.6 Removing and installing high pressure pump
    105
  • 3 Repairing electronic power control (EPC)
    110
  • 3.1 Function of EPC system
    110
  • 3.2 Assembly overview
    111
  • 3.3 Removing and installing accelerator module
    111
  • 4 Activated charcoal filter system
    113
  • 4.1 Function
    113
  • 4.2 Assembly overview
    114
  • 4.3 Checking fuel tank breather system
    114
  • Mixture preparation - injection
    116
  • 1 Repairing injection system
    116
  • 1.1 Assembly overview - intake manifold
    117
  • 1.2 Assembly overview - fuel rail with injectors
    119
  • 1.3 Checking vacuum reservoir in intake manifold for leaks
    120
  • 1.4 Assembly overview - air filter
    121
  • 1.5 Removing and installing air filter
    122
  • 1.6 Cleaning throttle valve module J338
    123
  • 1.7 Removing and installing injectors
    124
  • 1.8 Safety precautions
    127
  • 1.9 Rules for cleanliness
    129
  • 1.10 Technical data
    129
  • 2 Checking components
    130
  • 2.1 Checking intake air preheating
    130
  • 3 Engine control unit
    131
  • 3.1 Removing and installing engine control unit
    131
  • 3.2 Removing and installing anti-theft engine control unit
    132
  • Exhaust system
    136
  • 1 Removing and installing parts of exhaust system
    136
  • 1.1 Assembly overview - catalytic converters and attachments
    136
  • 1.2 Assembly overview - silencer with mountings
    138
  • 2 Exhaust gas recirculation system
    140
  • 2.1 Exhaust gas recirculation system - exploded view
    140
  • 2.2 Removing and installing exhaust gas recirculation valve N18
    141
  • Ignition system
    143
  • 1 Repairing ignition system
    143
  • 1.1 Assembly overview - ignition system
    144
  • 1.2 Removing and installing ignition coils with output stages
    144
  • 1.3 Safety precautions
    145
  • 1.4 Test data, spark plugs
    146
Manufacturer's designation 4-cylinder injection engine (1.6 l engine, direct injection)
Manufacturer Volkswagen
Suitable for Passat / Passat Variant (2005 - 2008)
Suitable car types 3C
Engine code BLF
Category Reparaturanleitung

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