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  • Examplepage for repair manual 6-cyl. Diesel engine, Mechanics
  • Examplepage for repair manual 2 6-cyl. Diesel engine, Mechanics
  • Examplepage for repair manual 3 6-cyl. Diesel engine, Mechanics

6-cyl. Diesel engine, Mechanics

For Passat / Passat Variant

Original Volkswagen repair manual


21,70 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

5.699 KB

271 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Servicing valve mechanism and Charge air system with turbocharger. Show more
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Repair manual Passat / Passat Variant 6-cyl. Diesel engine, Mechanics PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Technical data
    1
  • 1.1 Technical data
    1
  • 1.2 Engine number
    1
  • 1.3 Engine data
    1
  • Removing and installing engine
    3
  • 1 Removing and installing engine
    3
  • 1.1 Removing and installing engine
    3
  • 1.2 Notes on removing
    5
  • 1.3 Notes on installing
    9
  • 1.4 Tightening torques
    11
  • 1.5 Front engine mounting
    13
  • 1.6 Electro/hydraulic engine mounting, left and right
    14
  • 1.7 Additional information and removal instructions for vehicles with air conditioner
    16
  • Crankshaft group
    17
  • 1 Dismantling and assembling engine
    17
  • 1.1 Dismantling and assembling engine
    17
  • 1.2 Removing and installing ribbed belt
    32
  • 1.3 Removing and installing bracket for vane pump and oil cooler
    35
  • 1.4 Removing, installing and tensioning toothed belts
    37
  • 1.5 Removing toothed belt from camshaft sprockets
    45
  • 2 Removing and installing sealing flanges and flywheel/drive plate
    53
  • 2.1 Removing and installing sealing flanges and flywheel/drive plate
    53
  • 2.2 Renewing crankshaft oil seal -belt pulley end
    57
  • 2.3 Removing and installing front sealing flange
    59
  • 2.4 Removing and installing dual mass flywheel
    62
  • 2.5 Removing and installing drive plate
    63
  • 3 Removing and installing crankshaft
    65
  • 3.1 Removing and installing crankshaft
    65
  • 3.2 Crankshaft dimensions
    70
  • 3.3 Removing and installing sprocket
    70
  • 4 Dismantling and assembling pistons and conrods
    72
  • 4.1 Dismantling and assembling pistons and conrods
    72
  • 4.2 Checking piston projection at TDC
    79
  • 4.3 Piston and cylinder dimensions
    80
  • Cylinder head, Valve gear
    82
  • 1 Removing and installing cylinder head
    82
  • 1.1 Removing and installing cylinder head
    82
  • 1.2 Removing and installing front intake manifold
    87
  • 1.3 Removing and installing left intake manifold
    88
  • 1.4 Removing and installing right intake manifold
    90
  • 1.5 Removing and installing left cylinder head cover
    92
  • 1.6 Removing and installing cylinder head cover
    94
  • 1.7 Removing left cylinder head
    97
  • 1.8 Removing right cylinder head
    100
  • 1.9 Installing cylinder head
    104
  • 1.10 Checking compression pressures
    107
  • 2 Servicing valve mechanism
    108
  • 2.1 Servicing valve mechanism
    108
  • 2.2 Check axial clearance of camshafts
    115
  • 2.3 Replacing camshaft oil seal
    116
  • 2.4 Removing and installing camshafts
    118
  • 2.5 Checking hydraulic compensation elements
    122
  • 2.6 Renewing valve stem seals
    123
  • 2.7 Checking valve guides
    125
  • Lubrication
    126
  • 1 Removing and installing parts of the lubrication system
    126
  • 1.1 Removing and installing parts of the lubrication system
    126
  • 1.2 Removing and installing oil filter bracket
    135
  • 1.3 Removing and installing oil sump - lower part
    137
  • 1.4 Removing and installing oil pump
    139
  • 1.5 Removing and installing oil sump - upper part
    143
  • 1.6 Renewing oil check valve
    147
  • 1.7 Removing and installing oil cooler
    148
  • 1.8 Checking oil pressure and oil pressure switch
    150
  • Cooling system
    153
  • 1 Removing and installing parts of cooling system
    153
  • 1.1 Removing and installing parts of cooling system
    153
  • 1.2 Parts of cooling system body side
    154
  • 1.3 Coolant pump and thermostat
    157
  • 1.4 Coolant pipes - overview
    159
  • 1.5 Draining and filling coolant
    161
  • 1.6 Removing and installing coolant pump
    165
  • 1.7 Removing and installing thermostat
    167
  • 1.8 Removing and replacing front coolant pipe
    173
  • 1.9 Removing and replacing left upper and lower coolant pipe
    174
  • 1.10 Removing and replacing right coolant pipe
    176
  • 1.11 Removing and installing radiator
    176
  • Fuel supply system
    178
  • 1 Removing and installing parts of fuel supply system
    178
  • 1.1 Removing and installing parts of fuel supply system
    178
  • 1.2 Removing and installing fuel tank with its attachments
    179
  • 1.3 Servicing fuel filter
    193
  • 1.4 Safety precautions when working on the fuel supply system
    195
  • 1.5 Rules for cleanliness
    195
  • 1.6 Emptying fuel tank
    195
  • 1.7 Removing and installing fuel tank
    196
  • 1.8 Checking low fuel level sender
    198
  • 1.9 Removing and installing fuel gauge sender
    200
  • 1.10 Removing and installing fuel delivery unit
    201
  • 1.11 Removing and installing suction jet pump
    205
  • 1.12 Checking fuel pump
    208
  • 1.13 Bleeding fuel system
    211
  • 2 Accelerator mechanism
    213
  • 2.1 Accelerator mechanism
    213
  • 2.2 Servicing accelerator mechanism
    213
  • 2.3 Checking accelerator pedal position sender
    216
  • 2.4 Adjusting pedal position sender (vehicles >05.99)
    222
  • Charging
    223
  • 1 Charge air system with turbocharger
    223
  • 1.1 Charge air system with turbocharger
    223
  • 1.2 Removing and installing turbocharger with attachments
    223
  • 1.3 Removing and installing turbocharger
    226
  • 1.4 Removing and installing compensator
    228
  • 1.5 Removing and installing parts of charge air cooling system
    230
  • 1.6 Removing and installing charge air cooler
    232
  • 1.7 Charge pressure control hose routing diagram
    233
  • 1.8 Rules for cleanliness
    234
  • 2 Checking charge pressure system
    235
  • 2.1 Checking charge pressure system
    235
  • 2.2 Checking turbocharger and charge pressure control
    235
  • 2.3 Checking pressure unit for charge pressure regulating valve
    240
  • 2.4 Checking charge pressure control solenoid valve
    242
  • Exhaust system
    246
  • 1 Removing and installing parts of exhaust system
    246
  • 1.1 Removing and installing parts of exhaust system
    246
  • 1.3 Front exhaust pipe and catalyst with attachments
    250
  • 1.4 Silencer with mountings
    252
  • 1.5 Removing and installing left exhaust manifold with front exhaust pipe
    254
  • 1.6 Removing and installing right exhaust manifold with front exhaust pipe
    256
  • 2 Exhaust gas recirculation system
    258
  • 2.1 Exhaust gas recirculation system
    258
  • 2.2 Vacuum hose connection diagram
    258
  • 2.3 Checking exhaust gas recirculation valve (mechanical)
    259
  • 2.4 Removing and installing exhaust gas recirculation valve
    260
  • 2.5 Checking exhaust gas recirculation
    261
Manufacturer's designation 6-cyl. Diesel engine, Mechanics
Manufacturer Volkswagen
Suitable for Passat / Passat Variant (1997 - 2005)
Suitable car types 3B
Engine code AKN
Category Reparaturanleitung

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