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  • Examplepage for repair manual 4-cylinder injection engine (1.6 l roller rocker finger)
  • Examplepage for repair manual 2 4-cylinder injection engine (1.6 l roller rocker finger)
  • Examplepage for repair manual 3 4-cylinder injection engine (1.6 l roller rocker finger)

4-cylinder injection engine (1.6 l roller rocker finger)

For Passat / Passat Variant

Original Volkswagen repair manual


14,21 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

4.912 KB

167 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Sealing flanges and flywheel, Cylinder head, Parts of lubrication system, Fuel tank, Electronic power control (EPC), Activated charcoal filter system 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 Installing engine
    8
  • Crankshaft group
    11
  • 1 Dismantling and assembling engine
    11
  • 1.1 Assembly overview
    11
  • 1.2 Removing and installing poly V-belt
    17
  • 2 Sealing flanges and flywheel
    19
  • 2.1 Assembly overview - sealing flange
    19
  • 2.2 Renewing crankshaft oil seal - pulley end
    20
  • 2.3 Removing and installing sealing flange - pulley end
    22
  • 2.4 Removing and installing crankshaft sealing flange - flywheel end
    25
  • 3 Removing and installing crankshaft
    30
  • 3.1 Assembly overview - crankshaft
    30
  • 3.2 Crankshaft dimensions
    32
  • 4 Dismantling and assembling pistons and conrods
    33
  • 4.1 Assembly overview - pistons and conrods
    33
  • 4.2 Separating new conrod
    34
  • 4.3 Checking pistons, piston rings and cylinder bores
    34
  • 4.4 Piston and cylinder dimensions
    36
  • Cylinder head, valve gear
    37
  • 1 Cylinder head
    37
  • 1.1 Assembly overview - cylinder head
    37
  • 1.2 Removing and installing cylinder head
    40
  • 1.3 Removing, installing and tensioning toothed belt
    44
  • 1.4 Checking semi-automatic toothed belt tensioning roller
    50
  • 1.5 Checking compression
    51
  • 2 Valve gear
    53
  • 2.1 Assembly overview - valve gear
    53
  • 2.2 Valve dimensions
    55
  • 2.3 Reworking valve seats
    55
  • 2.4 Checking valve guides
    57
  • 2.5 Renewing camshaft oil seal
    57
  • 2.6 Removing and installing camshaft
    60
  • 2.7 Renewing valve stem seals
    64
  • Lubrication
    67
  • 1 Parts of lubrication system
    67
  • 1.1 Engine oil
    67
  • 1.2 Assembly overview - parts of lubrication system
    67
  • 1.3 Removing and installing sump
    70
  • 1.4 Removing and installing oil pump
    71
  • 1.5 Checking oil pressure and oil pressure switch
    72
  • Cooling
    74
  • 1 Removing and installing parts of cooling system
    74
  • 1.1 Assembly overview - parts of cooling system, engine side
    74
  • 1.2 Assembly overview - parts of cooling system, body side (radiator with two radiator fans)
    76
  • 1.4 Coolant hose schematic diagram
    78
  • 1.5 Draining and filling coolant
    79
  • 1.6 Removing and installing radiator
    82
  • 1.7 Removing and installing coolant pump
    85
  • 1.8 Removing and installing thermostat
    87
  • 1.9 Removing and installing radiator fan V7 and radiator fan 2 V177
    89
  • 1.10 Checking cooling system for leaks
    90
  • Fuel supply system
    93
  • 1 Fuel tank
    93
  • 1.1 Safety precautions when working on fuel supply system
    93
  • 1.2 Rules for cleanliness
    93
  • 1.3 Assembly overview - fuel tank
    94
  • 1.4 Emptying fuel tank
    95
  • 1.5 Removing and installing fuel tank
    99
  • 2 Repairing fuel supply system
    103
  • 2.1 Safety precautions when working on fuel supply system
    103
  • 2.2 Rules for cleanliness
    104
  • 2.3 Removing and installing fuel delivery unit
    104
  • 2.4 Removing and installing fuel gauge sender G
    107
  • 2.5 Checking fuel pump
    108
  • 2.6 Bleeding fuel system
    116
  • 3 Electronic power control (EPC)
    120
  • 3.1 Function of EPC system
    120
  • 3.2 Assembly overview - accelerator module
    120
  • 3.3 Removing and installing accelerator module
    121
  • 4 Activated charcoal filter system
    124
  • 4.1 Function
    124
  • 4.2 Assembly overview - activated charcoal filter system
    124
  • 4.3 Checking fuel tank breather
    125
  • Mixture preparation - injection
    127
  • 1 Repairing injection system
    127
  • 1.1 General notes on injection
    127
  • 1.2 Safety precautions
    128
  • 1.3 Rules for cleanliness
    128
  • 1.4 Technical data
    129
  • 1.5 Assembly overview - intake manifold with attachments
    129
  • 1.6 Assembly overview - fuel rail with injectors
    131
  • 1.7 Assembly overview - air filter with attachments
    132
  • 1.8 Removing and installing lower part of intake manifold
    132
  • 1.9 Removing and installing complete intake manifold
    134
  • 1.10 Removing and installing injectors
    137
  • 2 Checking components
    139
  • 2.1 Checking injectors for leaks and quantity injected
    139
  • 2.2 Checking intake manifold change-over
    143
  • 3 Engine control unit
    145
  • 3.1 Removing and installing engine control unit
    145
  • 3.2 Removing and installing anti-theft engine control unit
    146
  • Exhaust system
    150
  • 1 Removing and installing parts of exhaust system
    150
  • 1.1 Assembly overview - exhaust system
    150
  • 1.2 Separating centre and rear silencers
    152
  • 1.3 Removing and installing front exhaust pipe with catalytic converter
    153
  • 1.4 Removing and installing exhaust manifold
    155
  • 2 Secondary air system
    156
  • 2.1 Function
    156
  • 2.2 Assembly overview - secondary air system, engine code BSE
    156
  • 2.3 Checking combination valve
    157
  • Ignition system
    159
  • 1 Repairing ignition system
    159
  • 1.1 General notes on ignition system
    159
  • 1.2 Safety precautions
    159
  • 1.3 Assembly overview - ignition system
    159
  • 1.4 Test data, spark plugs
    160
Manufacturer's designation 4-cylinder injection engine (1.6 l roller rocker finger)
Manufacturer Volkswagen
Suitable for Passat / Passat Variant (2005 - 2008)
Suitable car types 3C
Engine code BSF
Category Reparaturanleitung

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