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  • Examplepage for repair manual 4-cylinder injection engine (5-valve)
  • Examplepage for repair manual 2 4-cylinder injection engine (5-valve)
  • Examplepage for repair manual 3 4-cylinder injection engine (5-valve)

4-cylinder injection engine (5-valve)

For Passat / Passat Variant

Original Volkswagen repair manual


15,68 €7% VAT incl.

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  • English

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Language: English

Digital PDF file

4.908 KB

187 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Cylinder head, Parts of lubrication system, Activated charcoal filter system, Assembly overview - electronic power control (EPC), Accelerator mechanism (throttle cable), 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
    3
  • 1 Removing and installing engine
    3
  • 1.1 Notes on removing
    5
  • 1.2 Notes on installing
    8
  • 1.3 Specified torques
    10
  • Crankshaft group
    12
  • 1 Dismantling and assembling engine
    12
  • 1.1 Part I - Assembly overview
    14
  • 1.2 Part II - Assembly overview
    15
  • 1.3 Part lll: assembly overview - old toothed belt tensioner
    16
  • 1.4 Part lV: assembly overview - new toothed belt tensioner
    18
  • 1.5 Removing and installing air conditioner compressor poly V-belt
    19
  • 1.6 Removing and installing poly V-belt
    20
  • 2 Removing and installing sealing flanges and flywheel or drive plate
    21
  • 2.1 Assembly overview - sealing flanges and flywheel
    21
  • 2.2 Renewing crankshaft oil seal - pulley end
    22
  • 2.3 Removing and installing drive plate
    24
  • 3 Removing and installing crankshaft
    26
  • 3.1 Assembly overview - crankshaft
    26
  • 3.2 Pulling needle roller bearing out of and driving into crankshaft
    28
  • 3.3 Crankshaft dimensions
    29
  • 4 Dismantling and assembling pistons and conrods
    30
  • 4.1 Assembly overview - pistons and conrods
    30
  • 4.2 Checking pistons, piston rings and cylinder bores
    31
  • Cylinder head, valve gear
    33
  • 1 Cylinder head
    33
  • 1.1 Assembly overview - cylinder head
    33
  • 1.2 Removing and installing cylinder head
    35
  • 1.3 Removing, installing and tensioning toothed belt
    38
  • 1.4 Checking compression
    46
  • 2 Repairing valve gear
    48
  • 2.1 Assembly overview - valve gear
    48
  • 2.2 Checking camshaft axial clearance
    50
  • 2.3 Reworking valve seats
    51
  • 2.4 Renewing camshaft oil seals
    52
  • 2.5 Checking hydraulic bucket tappets
    57
  • 2.6 Removing and installing camshafts
    58
  • 2.7 Checking valve guides
    62
  • 2.8 Renewing valve stem seals
    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 Removing and installing oil sump
    71
  • 1.4 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
    80
  • 1.3 Assembly overview - coolant pump and compact bracket
    82
  • 1.4 Assembly overview - coolant pump
    84
  • 1.5 Coolant hose schematic diagram
    84
  • 1.6 Draining and filling coolant
    87
  • 1.7 Removing and installing radiator
    90
  • 1.8 Removing and installing viscous fan coupling
    92
  • 1.9 Removing and installing viscous fan mounting bush
    92
  • 1.10 Removing and installing coolant pump V-belt
    94
  • Fuel supply system
    96
  • 1 Removing and installing parts of fuel supply system
    96
  • 1.1 Assembly overview - fuel tank with attachments
    96
  • 1.2 Safety precautions when working on fuel supply system
    102
  • 1.3 Rules for cleanliness
    102
  • 1.4 Removing and installing fuel delivery unit, front-wheel drive vehicles
    103
  • 1.5 Removing and installing fuel delivery unit, four-wheel drive vehicles
    105
  • 1.6 Removing and installing fuel tank
    107
  • 1.7 Checking fuel pump
    110
  • 2 Activated charcoal filter system
    117
  • 2.1 Function
    117
  • 2.2 Assembly overview - activated charcoal filter system
    117
  • 2.3 Checking fuel tank breather
    118
  • 3 Assembly overview - electronic power control (EPC)
    121
  • 4 Accelerator mechanism (throttle cable)
    122
  • 4.1 Assembly overview - accelerator mechanism
    122
  • 4.2 Adjusting accelerator cable
    123
  • Turbocharging/supercharging
    126
  • 1.1 Rules for cleanliness
    126
  • 1.2 Safety precautions
    126
  • 1.3 Assembly overview - turbocharger with attachments
    127
  • 1.4 Assembly overview - charge air cooling
    130
  • 1.5 Schematic diagram of turbocharging system
    130
  • 2 Checking charge pressure system
    134
  • 2.1 Checking charge pressure control, vehicles without EPC system
    134
  • 2.2 Checking vacuum unit for charge pressure control valve
    135
  • 2.3 Checking overrun shut-off valve
    136
  • 2.4 Checking charge air system for leaks
    137
  • Mixture preparation - injection
    139
  • 1 Repairing injection system
    139
  • 1.1 General notes on injection
    139
  • 1.2 Overview of fitting locations
    139
  • 1.3 Assembly overview - parts of injection system
    143
  • 1.4 Assembly overview - air filter
    147
  • 1.5 Assembly overview - fuel rail with injectors
    149
  • 1.6 Assembly overview - intake manifold change-over
    149
  • 1.7 Assembly overview - throttle valve control module
    151
  • 1.8 Safety precautions
    152
  • 1.9 Rules for cleanliness
    154
  • 1.10 Technical data
    154
  • 2 Checking components
    156
  • 2.2 Checking intake manifold change-over
    156
  • 2.3 Checking injectors for leaks and quantity injected
    156
  • 2.4 Checking fuel pressure regulator and holding pressure
    159
  • 3 Engine control unit
    162
  • 3.1 Renewing engine control unit
    162
  • 3.2 Adapting functions and components
    162
  • 3.3 Reading and erasing engine control unit fault memory
    163
  • Exhaust system
    165
  • 1 Parts of exhaust system
    165
  • 1.1 Assembly overview - front-wheel drive vehicles
    165
  • 1.2 Assembly overview - four-wheel drive vehicles
    169
  • 2 Secondary air system
    171
  • 2.1 Function
    171
  • 2.2 Assembly overview - secondary air system
    171
  • 2.3 Checking combination valve
    172
  • 2.4 Checking secondary air inlet valve
    173
  • Ignition system
    174
  • 1 Repairing ignition system
    174
  • 1.1 General notes on ignition system
    174
  • 1.2 Assembly overview - ignition system
    174
  • 1.3 Safety precautions
    179
  • 1.4 Test data, spark plugs
    180
Manufacturer's designation 4-cylinder injection engine (5-valve)
Manufacturer Volkswagen
Suitable for Passat / Passat Variant (1997 - 2005)
Suitable car types 3B
Engine code AEB, AFY, ANB, APT, APU, ARG, ATW
Category Reparaturanleitung

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