6-cylinder injection engine (direct injection)

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 Removing engine
  4
• 1.2 Securing engine on engine and gearbox support VAS 6095
  11
• 1.3 Installing engine
  12
• 1.4 Specified torques for assembly mounting
  14
• Crankshaft group
  16
• 1.1 Part I
  18
• 1.2 Part II
  21
• 1.3 Removing and installing vibration damper (engine codes BWS, CDVA)
  22
• 1.4 Removing and installing vibration damper (engine code BLV)
  23
• 1.5 Removing and installing bracket for ancillaries
  25
• 1.6 Assembly overview - poly V-belt drive
  25
• 1.7 Removing and installing poly-V belt
  27
• 1.8 Removing and installing tensioner for poly V-belt
  28
• 2.1 Part I
  31
• 2.2 Part II
  33
• 2.3 Removing and installing vibration damper
  35
• 2.4 Removing and installing bracket for ancillaries
  35
• 2.5 Assembly overview - poly V-belt drive
  36
• 2.6 Removing and installing poly-V belt
  37
• 2.7 Removing and installing tensioner for poly V-belt
  38
• 3 Sealing flange and flywheel or drive plate
  40
• 3.1 Assembly overview - sealing flanges and flywheel
  40
• 3.2 Assembly overview - sealing flanges and drive plate
  42
• 3.3 Assembly overview - timing chain covers
  43
• 3.4 Removing and installing crankshaft seal on gearbox side
  43
• 3.5 Removing and installing sealing flange on gearbox side
  45
• 3.6 Removing and installing flywheel
  48
• 3.7 Removing and installing drive plate
  49
• 3.8 Renewing crankshaft sealing flange -vibration damper end- (engine code BLV)
  50
• 4 Assembly overview - crankshaft
  55
• 4.1 Fitting sender wheel to crankshaft
  56
• 4.2 Pulling needle bearing out of and driving into crankshaft
  57
• 4.3 Allocation of main bearing shells
  59
• 5 Pistons and conrods
  64
• 5.1 Assembly overview - pistons and conrods
  64
• 5.2 Checking pistons, piston rings and cylinder bores
  65
• 5.3 Piston and cylinder dimensions
  69
• Cylinder head, valve gear
  70
• 1 Cylinder head
  70
• 1.1 Assembly overview - cylinder head
  70
• 1.2 Removing and installing cylinder head
  73
• 1.3 Checking valve timing
  81
• 1.4 Removing and installing camshaft adjuster
  86
• 1.5 Removing and installing chain drive for oil pump
  98
• 1.6 Removing and installing camshaft drive timing chain
  109
• 1.7 Removing and installing chain drive sprocket for high-pressure pump
  112
• 1.8 Removing and installing cylinder head cover
  113
• 1.9 Assembly overview - mechanical vacuum pump
  116
• 1.10 Removing and installing mechanical vacuum pump
  117
• 1.11 Installing cover oil seals
  119
• 1.12 Checking compression
  120
• 2 Valve gear
  123
• 2.1 Assembly overview - valve gear
  123
• 2.2 Camshafts, checking axial clearance
  125
• 2.5 Removing and installing camshaft control valves
  128
• 2.6 Removing and installing camshafts
  132
• 2.7 Camshaft identification
  139
• 2.8 Renewing valve stem seals
  139
• 2.9 Valve dimensions
  142
• 2.10 Checking valve guides
  142
• 2.11 Reworking valve seats
  143
• Lubrication
  145
• 1 Parts of lubrication system
  145
• 1.1 Engine oil:
  145
• 1.4 Removing and installing oil spray jet
  149
• 1.5 Removing and installing sump
  150
• 1.6 Removing and installing oil pump
  152
• 1.9 Assembly overview - oil filter housing (engine code BLV)
  164
• 1.11 Checking oil pressure and oil pressure switch (engine code CNNA, BWS from 01.2011)
  168
• Cooling
  172
• 1 Parts of cooling system
  172
• 1.1 Assembly overview - parts of cooling system, body side
  173
• 1.2 Assembly overview - cooling system, engine side
  174
• 1.3 Coolant hose connection diagram
  176
• 1.4 Draining and adding coolant
  177
• 1.5 Removing and installing fan mounting with fans
  180
• 1.6 Removing and installing radiator
  182
• 1.7 Removing and installing coolant pump
  184
• 1.8 Removing and installing thermostat
  187
• 1.9 Checking cooling system for leaks
  189
• Fuel supply system
  191
• 1 Safety precautions and rules for cleanliness
  191
• 1.1 Safety measures when working on fuel supply
  191
• 1.2 Releasing pressure in high-pressure area
  192
• 1.3 Rules for cleanliness
  193
• 2 Fuel tank (Passat CC with front-wheel drive)
  194
• 2.1 Assembly overview - fuel tank
  194
• 2.2 Emptying fuel tank
  196
• 2.3 Removing and installing fuel tank
  200
• 2.4 Removing and installing fuel gauge sender G
  203
• 3 Fuel tank (Passat CC with four-wheel drive)
  205
• 3.1 Assembly overview - fuel tank (engine code BWS)
  205
• 3.2 Assembly overview - fuel tank (engine code BLV, CNNA)
  208
• 3.3 Emptying fuel tank
  209
• 3.4 Removing and installing fuel tank
  215
• 3.5 Removing and installing fuel gauge sender 2 G169
  220
• 3.6 Removing and installing suction-jet pump
  223
• 4 Repairing fuel supply (Passat CC)
  225
• 4.1 Removing and installing fuel delivery unit
  225
• 4.2 Removing and installing fuel gauge sender G
  230
• 4.3 Checking fuel pump
  231
• 5 Activated charcoal filter system (Passat CC with engine code BLV, CNNA)
  242
• 5.1 Function
  242
• 5.2 Assembly overview - activated charcoal filter system
  242
• 5.3 Checking fuel system for leaks
  243
• 6 Activated charcoal filter system (Passat CC with engine code BWS)
  251
• 6.1 Function
  251
• 6.2 Assembly overview - activated charcoal filter system
  251
• 6.3 Checking fuel tank breather
  252
• 7 Fuel tank (Eos)
  254
• 7.1 Assembly overview - fuel tank
  254
• 7.2 Emptying fuel tank
  256
• 7.3 Removing and installing fuel tank
  260
• 8 Repairing fuel supply (Eos)
  264
• 8.1 Removing and installing fuel delivery unit
  264
• 8.2 Removing and installing fuel gauge sender G
  267
• 8.3 Checking fuel pump G6
  268
• 9 Activated charcoal filter system (Eos)
  280
• 9.1 Assembly overview - activated charcoal filter system
  280
• 9.2 Checking fuel tank breather
  280
• 10 Electronic power control (EPC)
  283
• 10.1 Assembly overview - accelerator module
  283
• 10.2 Removing and installing accelerator pedal module
  283
• Mixture preparation - injection
  286
• 1 Injection system
  286
• 1.1 General notes on the injection system
  287
• 1.2 Rules for cleanliness
  287
• 1.3 Technical data
  287
• 1.4 Assembly overview - intake manifold
  288
• 1.5 Assembly overview - fuel rail with high-pressure pump and injectors
  289
• 1.6 Assembly overview - air filter
  292
• 1.7 Checking intake air preheating
  293
• 1.8 Removing and installing intake manifold upper part
  293
• 1.9 Removing and installing lower part of intake manifold with fuel rail
  296
• 1.10 Removing and installing high-pressure pump
  300
• 1.11 Checking fuel pressure sender G247
  303
• 1.12 Removing and installing injectors
  306
• 1.13 Renewing seals on injectors
  310
• 2 Engine control unit J623 (Passat)
  314
• 2.1 Removing and installing engine (motor) control unit J623
  314
• 2.2 Removing and installing anti-theft engine control unit J623
  315
• 3 Engine control unit J623 (Eos)
  318
• 3.1 Removing and installing engine control unit
  318
• 3.2 Removing and installing anti-theft engine control unit
  319
• Exhaust system
  323
• 1.2 Removing and installing exhaust manifold
  326
• 1.3 Removing and installing Lambda probe G39 and Lambda probe 2 G108
  327
• 1.4 Removing and installing front exhaust pipes with catalytic converters and front silencers
  329
• 2.2 Removing and installing exhaust manifold
  335
• 2.3 Removing and installing Lambda probe G39 and Lambda probe 2 G108
  336
• 3 Silencers with mountings (vehicles with four-wheel drive)
  343
• 3.1 Assembly overview - silencers with mountings
  343
• 4 Silencers with mountings (Passat CC with front-wheel drive)
  347
• 4.1 Assembly overview - silencers with mountings
  347
• 5 Silencer with mountings (Eos)
  350
• 5.1 Assembly overview - silencers with mountings
  350
• 5.2 Clamps
  351
• 5.3 Separating centre and rear silencers
  351
• 5.4 Aligning exhaust system free of stress
  352
• Ignition system
  354
• 1 Ignition system
  354
• 1.1 General notes on ignition system
  354
• 1.2 Assembly overview - ignition system
  354
• 1.3 Test data, spark plugs
  356
• 1.4 Removing and installing ignition coils with output stage
  356