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  • Examplepage for repair manual 6-cylinder injection engine
  • Examplepage for repair manual 2 6-cylinder injection engine
  • Examplepage for repair manual 3 6-cylinder injection engine

6-cylinder injection engine

For Passat / Passat Variant

Original Volkswagen repair manual


19,73 €7% VAT incl.

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Language: English

Digital PDF file

6.459 KB

243 Sites

Detailed technical data

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This repair manual contains: Removing and installing engine, Crankshaft, Cylinder head, Parts of lubrication system, Parts of fuel supply system - vehicles with front-wheel drive, Accelerator mechanism: engine codes ACK, AGE, AHA, ALG, Checking components and Engine control unit. Show more
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Repair manual Passat / Passat Variant 6-cylinder injection engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Technical data
    1
  • 1.1 Engine data
    1
  • Removing and installing engine
    3
  • 1 Removing and installing engine
    3
  • 1.1 Notes on removing
    5
  • 1.2 Securing engine to assembly stand
    9
  • 1.3 Notes on installing
    10
  • 1.4 Specified torques
    13
  • 1.5 Additional information for vehicles with air conditioner
    13
  • 1.6 Assembly overview - front engine mounting
    14
  • Crankshaft group
    15
  • 1 Dismantling and assembling engine
    15
  • 1.1 Assembly overview - engine, belt pulley end
    15
  • 1.2 Assembly overview - toothed belt drive
    17
  • 1.3 Assembly overview - poly V-belt drive
    18
  • 1.4 Removing and installing belt pulley or vibration damper
    19
  • 1.5 Removing and installing poly V-belt
    20
  • 1.6 Assembly overview - crankcase breather
    22
  • 2 Removing and installing sealing flanges and flywheel or drive plate
    23
  • 2.1 Assembly overview - sealing flange
    23
  • 2.2 Renewing crankshaft oil seal - pulley end
    25
  • 2.3 Removing and installing sealing flange - pulley end
    26
  • 2.4 Removing and installing crankshaft sealing flange - flywheel end
    32
  • 2.5 Removing and installing dual-mass flywheel
    33
  • 2.6 Pulling needle bearing out of and driving into crankshaft
    35
  • 2.7 Removing and installing drive plate
    35
  • 3 Crankshaft
    38
  • 3.1 Assembly overview - crankshaft
    38
  • 3.2 Crankshaft dimensions
    40
  • 3.3 Measuring axial clearance of crankshaft
    40
  • 3.4 Measuring radial clearance of crankshaft
    41
  • 3.5 Removing and installing drive chain sprocket for oil pump
    42
  • 4 Dismantling and assembling pistons and conrods
    44
  • 4.1 Checking pistons, piston rings and cylinder bores
    44
  • 4.2 Assembly overview - pistons and conrods
    46
  • 4.3 Piston and cylinder dimensions
    48
  • Cylinder head, valve gear
    49
  • 1 Cylinder head
    49
  • 1.1 Assembly overview - cylinder head
    49
  • 1.2 Removing, installing and tensioning toothed belt
    51
  • 1.3 Removing and installing cylinder head
    55
  • 1.4 Compression test
    61
  • 2 Valve gear
    64
  • 2.1 Assembly overview
    64
  • 2.2 Reworking valve seats
    69
  • 2.3 Renewing camshaft oil seals
    70
  • 2.4 Checking hydraulic bucket tappets
    73
  • 2.5 Removing and installing camshafts and variable camshaft timing adjusters
    74
  • 2.6 Driving sealing cap (core plug) into replacement cylinder head
    81
  • 2.7 Checking valve guides
    81
  • 2.8 Renewing valve stem seals
    82
  • Lubrication
    84
  • 1 Parts of lubrication system
    84
  • 1.1 Engine oil
    84
  • 1.2 Assembly overview - oil pump with chain drive
    85
  • 1.3 Removing and installing lower part of sump
    87
  • 1.4 Checking chain tensioner for oil pump and removing and installing oil pump
    91
  • 1.5 Removing and installing chain and chain tensioner for oil pump
    93
  • 1.6 Removing and installing upper part of sump
    93
  • 1.7 Renewing oil retention valves
    99
  • 1.8 Checking oil pressure and oil pressure switch
    100
  • Cooling
    103
  • 1 Parts of cooling system
    103
  • 1.1 Assembly overview - parts of cooling system, body side
    103
  • 1.2 Assembly overview - parts of cooling system, engine side
    105
  • 1.3 Checking continued coolant circulation pump
    107
  • 1.4 Coolant hose schematic diagram
    108
  • 1.5 Draining and filling coolant
    110
  • 1.6 Removing and installing radiator
    114
  • 1.7 Removing and installing coolant pump
    116
  • 1.8 Removing and installing thermostat
    118
  • 1.9 Removing and installing viscous fan coupling
    120
  • Fuel supply system
    122
  • 1 Parts of fuel supply system - vehicles with front-wheel drive
    122
  • 1.1 Safety precautions when working on fuel supply system
    122
  • 1.2 Rules for cleanliness
    123
  • 1.11 Assembly overview - fuel tank with attachments: engine codes AHA, ATQ
    139
  • 1.12 Removing and installing fuel tank
    142
  • 1.13 Crash fuel shut-off
    144
  • 1.14 Checking fuel pump
    144
  • 2 Parts of fuel supply system - vehicles with four-wheel drive
    150
  • 2.2 Assembly overview - fuel tank with attachments: engine codes AHA, ATQ
    153
  • 2.3 Assembly overview - fuel filter
    158
  • 2.4 Emptying fuel tank
    159
  • 2.5 Removing and installing fuel delivery unit
    161
  • 2.6 Removing and installing fuel gauge sender G
    166
  • 2.7 Removing and installing fuel gauge sender 2 G169
    167
  • 2.8 Removing and installing fuel gauge sender 3 G237
    169
  • 2.9 Removing, installing and checking suction-jet pumps
    172
  • 2.10 Removing and installing fuel tank
    173
  • 2.11 Checking fuel pump
    176
  • 3 Accelerator mechanism: engine codes ACK, AGE, AHA, ALG
    182
  • 3.1 Assembly overview
    182
  • 3.2 Adjusting accelerator cable
    183
  • 4.1 Function of the electronic throttle
    185
  • 4.2 Assembly overview
    185
  • 5.1 Activated charcoal filter system function description
    187
  • 5.2 Assembly overview
    187
  • 5.3 Checking fuel tank breather
    189
  • 6 Activated charcoal filter system: engine codes AHA, ATQ
    193
  • 6.1 Activated charcoal filter system function description
    193
  • 6.2 Assembly overview
    194
  • 6.3 Overview of activated charcoal filter system
    195
  • Mixture preparation - injection
    196
  • 1 Repairing injection system
    196
  • 1.1 Safety precautions
    196
  • 1.2 Rules for cleanliness
    197
  • 1.3 Assembly overview - air filter
    197
  • 1.4 Assembly overview - fuel rail with injectors
    199
  • 1.7 Technical data
    204
  • 2 Checking components
    205
  • 2.1 Checking injectors for leaks and injection rate
    205
  • 2.2 Checking fuel pressure regulator and holding pressure
    207
  • 3 Engine control unit
    211
  • 3.1 Renewing engine control unit
    211
  • 3.2 Adapting functions and components
    212
  • 3.3 Reading and erasing engine control unit fault memory
    214
  • Exhaust system
    216
  • 1 Removing and installing parts of exhaust system
    216
  • 1.3 Assembly overview - silencer with mountings: vehicles with front-wheel drive
    221
  • 1.4 Assembly overview - silencer with mountings: vehicles with four-wheel drive
    222
  • 1.5 Removing and installing front exhaust pipe with catalytic converter
    223
  • 2.1 Assembly overview
    229
  • 2.2 Checking combination valve
    232
  • 2.3 Removing and installing combination valve
    233
  • Ignition system
    235
  • 1 Ignition system
    235
  • 1.1 Safety precautions
    235
  • 1.2 Assembly overview
    235
  • 1.3 Test data, spark plugs
    237
Manufacturer's designation 6-cylinder injection engine
Manufacturer Volkswagen
Suitable for Passat / Passat Variant (1997 - 2005)
Suitable car types 3B
Engine code AGE, AHA, ALG, AMX, APR, AQD, ATQ, ATX, BBG
Category Reparaturanleitung

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