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  • Examplepage for repair manual 4-cylinder injection engine (5-valve without intermediate shaft)
  • Examplepage for repair manual 2 4-cylinder injection engine (5-valve without intermediate shaft)
  • Examplepage for repair manual 3 4-cylinder injection engine (5-valve without intermediate shaft)

4-cylinder injection engine (5-valve without intermediate shaft)

For Passat / Passat Variant

Original Volkswagen repair manual


18,65 €7% VAT incl.

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  • English

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Language: English

Digital PDF file

5.858 KB

228 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Electronic power control (EPC), Active charcoal filter system: engine code AWT 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 Engine number
    1
  • 2 Engine data
    2
  • Removing and installing engine
    3
  • 1 Removing and installing engine
    3
  • 1.1 Notes on removing
    5
  • 1.2 Notes on installing
    10
  • 1.3 Specified torques
    12
  • 1.4 Assembly overview - front engine mounting
    12
  • 1.5 Additional information and assembly work for vehicles with air conditioner
    13
  • Crankshaft group
    15
  • 1 Dismantling and assembling engine
    15
  • 1.1 Assembly overview
    15
  • 1.2 Removing and installing air conditioner compressor poly V-belt
    19
  • 1.3 Removing and installing poly V-belt
    20
  • 2 Removing and installing sealing flanges and flywheel or drive plate
    21
  • 2.1 Assembly overview
    21
  • 2.2 Renewing crankshaft oil seal - pulley end
    22
  • 2.3 Removing and installing front sealing flange
    24
  • 2.4 Removing and installing drive plate
    27
  • 3 Removing and installing crankshaft
    30
  • 3.1 Assembly overview
    30
  • 3.2 Pulling needle roller bearing out of and driving into crankshaft
    32
  • 3.3 Crankshaft dimensions
    33
  • 4 Dismantling and assembling pistons and conrods
    35
  • 4.1 Assembly overview
    35
  • 4.2 Piston and cylinder dimensions
    38
  • Cylinder head, valve gear
    39
  • 1 Removing and installing cylinder head
    39
  • 1.1 Assembly overview
    39
  • 1.2 Removing, installing and tensioning toothed belt
    41
  • 1.3 Removing and installing cylinder head
    45
  • 1.4 Checking compression
    48
  • 2 Repairing valve gear
    51
  • 2.1 Assembly overview
    51
  • 2.2 Reworking valve seats
    55
  • 2.3 Renewing inlet camshaft oil seal
    57
  • 2.4 Renewing exhaust camshaft oil seal
    59
  • 2.5 Checking hydraulic bucket tappets
    62
  • 2.6 Removing and installing camshafts
    63
  • 2.7 Checking valve guides
    67
  • 2.8 Renewing valve stem seals
    68
  • Lubrication
    71
  • 1 Removing and installing parts of lubrication system
    71
  • 1.1 Engine oil
    71
  • 1.2 Assembly overview
    72
  • 1.3 Removing and installing oil sump
    76
  • 1.4 Checking oil pressure and oil pressure switch
    81
  • Cooling
    84
  • 1 Removing and installing parts of cooling system
    84
  • 1.1 Assembly overview - parts of cooling system, body side
    84
  • 1.2 Assembly overview - parts of cooling system, engine side
    86
  • 1.3 Assembly overview - compact bracket
    88
  • 1.4 Coolant hose schematic diagram
    89
  • 1.5 Draining and filling coolant
    91
  • 1.6 Checking cooling system for leaks
    94
  • 1.7 Removing and installing radiator
    96
  • 1.8 Removing and installing coolant pump
    98
  • 1.9 Removing and installing viscous fan coupling
    99
  • 1.10 Removing and installing viscous fan mounting bush
    100
  • 1.11 Removing and installing thermostat
    101
  • 1.12 Removing and installing lower coolant pipe
    103
  • Fuel supply system
    105
  • 1 Removing and installing parts of fuel supply system - front wheel drive vehicles
    105
  • 1.1 Safety precautions when working on fuel supply system
    105
  • 1.2 Rules for cleanliness
    106
  • 1.3 Assembly overview - fuel tank with attachments: engine code AWT
    106
  • 1.4 Draining fuel tank: engine code AWT
    109
  • 1.5 Removing and installing fuel delivery unit: engine code AWT
    110
  • 1.6 Removing and installing fuel gauge sender: engine code AWT
    112
  • 1.7 Assembly overview - fuel tank with attachments: engine codes AUG, AWM
    113
  • 1.8 Draining fuel tank: engine codes AUG, AWM
    116
  • 1.9 Removing and installing fuel delivery unit: engine codes AUG, AWM
    117
  • 1.10 Removing and installing fuel gauge sender: engine codes AUG, AWM
    122
  • 1.11 Removing and installing fuel tank
    122
  • 1.12 Crash fuel shut-off
    124
  • 1.13 Checking fuel pump
    124
  • 2 Removing and installing parts of fuel supply system - four wheel drive vehicles
    130
  • 2.1 Assembly overview - fuel tank with attachments: engine code AWT
    130
  • 2.2 Assembly overview - fuel tank with attachments: engine codes AUG, AWM
    133
  • 2.3 Assembly overview - fuel filter
    138
  • 2.4 Emptying fuel tank
    139
  • 2.5 Removing and installing fuel delivery unit
    141
  • 2.6 Removing and installing fuel gauge sender G
    146
  • 2.7 Removing and installing fuel gauge sender 2 G169
    147
  • 2.8 Removing and installing fuel gauge sender 3 G237
    149
  • 2.9 Removing, installing and checking suction-jet pumps
    151
  • 2.10 Removing and installing fuel tank
    152
  • 2.11 Checking fuel pump
    154
  • 3 Electronic power control (EPC)
    160
  • 3.1 Function of EPC system
    160
  • 3.2 Assembly overview
    160
  • 4 Active charcoal filter system: engine code AWT
    162
  • 4.1 Function
    162
  • 4.2 Assembly overview - parts of activated charcoal filter system
    162
  • 4.3 Schematic diagram of activated charcoal filter system
    164
  • 4.4 Checking fuel tank breather
    164
  • 5 Activated charcoal filter system: engine codes AUG, AWM
    166
  • 5.1 Description of leakage diagnosis
    166
  • 5.2 Assembly overview - parts of activated charcoal filter system
    166
  • 5.3 Schematic diagram of activated charcoal filter system
    168
  • 5.4 Checking fuel system for leaks
    168
  • Turbocharging/supercharging
    171
  • 1 Charge air system with turbocharger
    171
  • 1.1 Safety precautions
    171
  • 1.2 Rules for cleanliness
    172
  • 1.3 Assembly overview - turbocharger with attachments
    172
  • 1.4 Removing and installing turbocharger
    174
  • 1.5 Assembly overview - parts of charge air cooling
    179
  • 1.6 Schematic diagram of turbocharging system
    181
  • 2 Checking charge pressure system
    183
  • 2.1 Checking vacuum unit for charge pressure control valve
    183
  • 2.2 Checking overrun shut-off valve
    183
  • 2.3 Checking charge air system for leaks
    184
  • Mixture preparation - injection
    187
  • 1 Repairing injection system
    187
  • 1.1 General notes on injection
    187
  • 1.2 Safety precautions
    187
  • 1.3 Rules for cleanliness
    188
  • 1.4 Overview of fitting locations
    188
  • 1.5 Assembly overview - air filter
    191
  • 1.6 Assembly overview - fuel rail with injectors
    192
  • 1.7 Assembly overview - intake manifold
    193
  • 1.8 Removing and installing intake manifold
    193
  • 1.9 Technical data
    196
  • 2 Removing and installing air mass meter G70
    198
  • 2.1 Removing air mass meter G70 (with no housing)
    198
  • 2.2 Removing air mass meter G70 (with housing)
    198
  • 2.3 Installing air mass meter G70
    198
  • 3 Checking components
    200
  • 3.1 Checking injectors
    200
  • 3.2 Checking fuel pressure regulator and holding pressure
    202
  • 4 Engine control unit
    205
  • 4.1 Reading and erasing engine control unit fault memory
    205
  • 4.2 Adapting functions and components
    206
  • 4.3 Renewing engine control unit
    207
  • Exhaust system
    208
  • 1 Removing and installing parts of exhaust system
    208
  • 1.1 Assembly overview - parts of exhaust system: front-wheel drive vehicles
    210
  • 1.2 Assembly overview - parts of exhaust system: four-wheel drive vehicles
    212
  • 2 Secondary air system
    215
  • 2.1 Function
    215
  • 2.2 Assembly overview: parts of secondary air system
    215
  • 2.3 Checking combination valve
    217
  • Ignition system
    219
  • 1 Repairing ignition system
    219
  • 1.1 General notes on ignition system
    219
  • 1.2 Safety precautions
    219
  • 1.3 Assembly overview - parts of ignition system
    219
  • 1.4 Removing and installing ignition coils with output stage
    221
  • 1.5 Test data, spark plugs
    222
Manufacturer's designation 4-cylinder injection engine (5-valve without intermediate shaft)
Manufacturer Volkswagen
Suitable for Passat / Passat Variant (1997 - 2005)
Suitable car types 3B
Engine code AWM, AWT
Category Reparaturanleitung

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