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  • Examplepage for repair manual 6-cylinder injection engine (direct injection)
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  • Examplepage for repair manual 3 6-cylinder injection engine (direct injection)

6-cylinder injection engine (direct injection)

For Passat / Passat Variant

Original Volkswagen repair manual


27,33 €7% VAT incl.

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Language: English

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11.112 KB

355 Sites

Detailed technical data

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This repair manual contains: Removing and installing engine, Sealing flange and flywheel or drive plate, Assembly overview - crankshaft, Pistons and conrods, Cylinder head, Repairing fuel supply, Activated charcoal filter system (engine code AXZ), Engine control unit J623 and Ignition system. 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 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
    10
  • 1.3 Installing engine
    11
  • 1.4 Specified torques for assembly mounting
    13
  • Crankshaft group
    15
  • 1 Dismantling and assembling engine
    15
  • 1.1 Part I
    16
  • 1.2 Part II
    19
  • 1.3 Removing and installing vibration damper
    20
  • 1.4 Removing and installing ancillary bracket
    22
  • 1.5 Assembly overview - poly V-belt drive
    22
  • 1.6 Removing and installing poly V-belt
    24
  • 1.7 Removing and installing tensioner for poly V-belt
    25
  • 2 Sealing flange and flywheel or drive plate
    26
  • 2.1 Assembly overview - sealing flanges and flywheel
    26
  • 2.2 Assembly overview - sealing flanges and drive plate
    27
  • 2.3 Assembly overview - timing chain covers
    28
  • 2.4 Removing and installing crankshaft seal on gearbox side
    29
  • 2.5 Removing and installing sealing flange on gearbox side
    30
  • 2.6 Removing and installing flywheel
    33
  • 2.7 Removing and installing drive plate
    34
  • 2.8 Renewing crankshaft sealing flange -vibration damper side-
    35
  • 3 Assembly overview - crankshaft
    38
  • 3.1 Fitting sender wheel to crankshaft
    39
  • 3.2 Pulling needle bearing out of and driving into crankshaft
    40
  • 3.3 Allocation of main bearing shells
    42
  • 4 Pistons and conrods
    47
  • 4.1 Checking piston and cylinder
    48
  • 4.2 Piston and cylinder dimensions
    52
  • Cylinder head, valve gear
    53
  • 1 Cylinder head
    53
  • 1.1 Assembly overview - cylinder head
    53
  • 1.2 Removing and installing cylinder head
    56
  • 1.3 Checking valve timing
    64
  • 1.4 Removing and installing camshaft adjuster
    70
  • 1.5 Removing and installing chain drive for oil pump
    83
  • 1.6 Removing and installing camshaft drive timing chain, vehicles with vacuum pump
    92
  • 1.8 Removing and installing cylinder head cover
    100
  • 1.9 Assembly overview - mechanical vacuum pump
    102
  • 1.10 Removing and installing mechanical vacuum pump
    103
  • 1.11 Installing cover oil seals
    105
  • 1.12 Checking compression
    106
  • 2 Valve gear
    110
  • 2.1 Assembly overview - valve gear
    110
  • 2.2 Camshafts, checking axial clearance
    112
  • 2.3 Assembly overview - control housing
    113
  • 2.4 Removing and installing camshaft control valves
    114
  • 2.5 Removing and installing camshafts
    118
  • 2.6 Camshaft identification
    125
  • 2.7 Renewing valve stem seals
    125
  • 2.8 Valve dimensions
    128
  • 2.9 Checking valve guides
    128
  • 2.10 Reworking valve seats
    129
  • Lubrication
    131
  • 1 Parts of lubrication system
    131
  • 1.1 Engine oil
    131
  • 1.2 Assembly overview - sump, oil pump and oil filter bracket
    132
  • 1.3 Removing and installing oil sump
    134
  • 1.4 Removing and installing oil pump
    137
  • 1.5 Assembly overview - oil filter housing
    145
  • 1.6 Checking oil pressure and oil pressure switch
    147
  • Cooling
    150
  • 1 Parts of cooling system
    150
  • 1.1 Assembly overview - parts of cooling system, body side
    151
  • 1.2 Assembly overview - additional cooler
    153
  • 1.3 Assembly overview - cooling system, engine side
    153
  • 1.4 Coolant hose schematic diagram
    156
  • 1.5 Draining and filling coolant
    157
  • 1.6 Removing and installing fan support with fans
    160
  • 1.7 Removing and installing radiator
    162
  • 1.8 Removing and installing coolant pump
    164
  • 1.9 Removing and installing thermostat
    167
  • 1.10 Checking cooling system for leaks
    168
  • Fuel supply system
    171
  • 1 Safety precautions and rules for cleanliness
    171
  • 1.1 Safety precautions when working on fuel supply system
    171
  • 1.2 Releasing pressure in high-pressure area
    172
  • 1.3 Rules for cleanliness
    173
  • 2 Fuel tank, vehicles with front-wheel drive
    174
  • 2.1 Assembly overview - fuel tank
    174
  • 2.2 Emptying fuel tank
    176
  • 2.3 Removing and installing fuel tank
    180
  • 2.4 Removing and installing fuel gauge sender G
    183
  • 3 Fuel tank, vehicles with four-wheel drive
    185
  • 3.1 Rules for cleanliness
    185
  • 3.2 Assembly overview - fuel tank (engine code AXZ)
    185
  • 3.3 Assembly overview - fuel tank (engine code BLV)
    188
  • 3.4 Emptying fuel tank
    189
  • 3.5 Removing and installing fuel tank (vehicles to 06/2007)
    195
  • 3.6 Removing and installing fuel tank (vehicles from 06/2007)
    201
  • 3.7 Removing and installing fuel gauge sender 2 G169
    206
  • 3.8 Removing and installing suction-jet pump
    209
  • 4 Repairing fuel supply
    211
  • 4.1 Rules for cleanliness
    211
  • 4.2 Removing and installing fuel delivery unit
    211
  • 4.3 Removing and installing fuel gauge sender G
    216
  • 4.4 Checking fuel pump
    217
  • 5 Electronic power control (EPC)
    234
  • 5.1 Assembly overview - accelerator module
    234
  • 5.2 Removing and installing accelerator module
    234
  • 6 Assembly overview - activated charcoal filter system (engine code BLV)
    237
  • 6.1 Function
    237
  • 6.2 Assembly overview - activated charcoal filter system
    237
  • 6.3 Checking fuel system for leaks
    238
  • 7 Activated charcoal filter system (engine code AXZ)
    246
  • 7.1 Function
    246
  • 7.2 Assembly overview - activated charcoal filter system
    246
  • 7.3 Checking fuel tank breather
    247
  • Mixture preparation - injection
    249
  • 1 Injection system (vehicles with one-piece manifold)
    249
  • 1.1 General notes on the injection system
    250
  • 1.2 Rules for cleanliness
    250
  • 1.3 Technical data
    251
  • 1.4 Assembly overview - intake manifold
    251
  • 1.5 Checking vacuum reservoir in intake manifold for leaks
    252
  • 1.6 Checking vacuum unit for intake manifold flaps
    253
  • 1.7 Assembly overview - fuel rail with high-pressure pump (vehicles up to 07.2007)
    255
  • 1.8 Assembly overview - fuel rail with high-pressure pump (vehicles from 07.2007)
    257
  • 1.9 Assembly overview - air filter
    260
  • 1.10 Checking intake air preheating
    261
  • 1.11 Assembly overview - suction-jet pump
    261
  • 1.12 Removing and installing intake manifold
    262
  • 1.13 Removing and installing high-pressure pump
    268
  • 1.14 Checking fuel pressure sender G247
    271
  • 1.15 Removing and installing injectors
    274
  • 2 Injection system (vehicles with two-piece manifold)
    282
  • 2.1 General notes on the injection system
    283
  • 2.2 Rules for cleanliness
    283
  • 2.3 Technical data
    284
  • 2.4 Assembly overview - intake manifold
    284
  • 2.5 Assembly overview - fuel rail with high-pressure pump and injectors
    285
  • 2.6 Assembly overview - air filter
    288
  • 2.7 Checking intake air preheating
    289
  • 2.8 Removing and installing intake manifold upper part
    289
  • 2.9 Removing and installing intake manifold lower part with fuel rail
    292
  • 2.10 Removing and installing high-pressure pump
    295
  • 2.11 Checking fuel pressure sender G247
    297
  • 2.12 Removing and installing injectors
    300
  • 3 Engine control unit J623
    308
  • 3.1 Removing and installing engine control unit J623
    308
  • 3.3 Removing and installing anti-theft engine control unit J623 (with locking clip)
    313
  • Exhaust system
    315
  • 1 Exhaust system (engine code AXZ)
    315
  • 1.2 Removing and installing exhaust manifold
    318
  • 1.3 Removing and installing Lambda probe G39 and Lambda probe 2 G108
    319
  • 1.4 Removing and installing front exhaust pipes with catalytic converters and front silencers
    321
  • 1.5 Assembly overview - silencers with mountings
    323
  • 2 Exhaust system (engine code BLV)
    327
  • 2.2 Removing and installing exhaust manifold
    331
  • 2.3 Removing and installing Lambda probe G39 and Lambda probe 2 G108
    332
  • 2.6 Assembly overview - silencer with mountings (front-wheel drive)
    338
  • 2.7 Assembly overview - silencer with mountings (four-wheel drive)
    340
  • Ignition system
    345
  • 1 Ignition system
    345
  • 1.1 General notes on ignition system
    345
  • 1.2 Assembly overview - ignition system
    345
  • 1.3 Test data, spark plugs
    347
  • 1.4 Removing and installing ignition coils with output stage
    347
Manufacturer's designation 6-cylinder injection engine (direct injection)
Manufacturer Volkswagen
Suitable for Passat / Passat Variant (2005 - 2008)
Suitable car types 3C
Engine code AXZ
Category Reparaturanleitung

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