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

6-cylinder injection engine Volkswagen R GmbH

For Passat / Passat Variant

Original Volkswagen repair manual


19,87 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

5.727 KB

245 Sites

Detailed technical data

Immediately readable

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 control unit J623 and Parts of the exhaust system. Show more
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Repair manual Passat / Passat Variant 6-cylinder injection engine Volkswagen R GmbH 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 (engine code BWS)
    20
  • 1.4 Removing and installing bracket for ancillaries
    21
  • 1.5 Removing and installing poly-V belt
    22
  • 2 Sealing flange and flywheel or drive plate
    24
  • 2.1 Assembly overview - sealing flanges and flywheel
    24
  • 2.2 Assembly overview - sealing flanges and drive plate
    25
  • 2.3 Assembly overview - timing chain covers
    26
  • 2.4 Removing and installing crankshaft seal on gearbox side
    27
  • 2.5 Removing and installing sealing flange on gearbox side
    28
  • 2.6 Removing and installing flywheel
    31
  • 2.7 Removing and installing drive plate
    32
  • 2.8 Renewing crankshaft sealing flange, vibration damper side
    33
  • 3 Assembly overview - crankshaft
    36
  • 3.1 Fitting sender wheel to crankshaft
    37
  • 3.2 Pulling needle bearing out of and driving into crankshaft
    38
  • 3.3 Allocation of crankshaft bearing shells (classification)
    40
  • 4 Pistons and conrods
    42
  • 4.1 Checking piston and cylinder
    43
  • 4.2 Piston and cylinder dimensions
    47
  • Cylinder head, valve gear
    48
  • 1 Cylinder head
    48
  • 1.1 Assembly overview - cylinder head
    48
  • 1.2 Removing and installing cylinder head
    51
  • 1.3 Checking valve timing
    58
  • 1.4 Installing camshaft adjuster with timing chain for camshaft drive
    64
  • 1.5 Installing timing chain for oil pump drive and camshaft drive
    71
  • 1.6 Removing and installing cylinder head cover
    76
  • 1.7 Assembly overview - mechanical vacuum pump
    79
  • 1.8 Removing and installing mechanical vacuum pump
    79
  • 1.9 Installing cover oil seals
    81
  • 1.10 Checking compression
    82
  • 2 Valve gear
    86
  • 2.1 Assembly overview - valve gear
    86
  • 2.2 Camshafts, checking axial clearance
    88
  • 2.3 Assembly overview - timing housing
    89
  • 2.4 Removing and installing camshaft control valves
    90
  • 2.5 Removing and installing camshafts
    94
  • 2.6 Camshaft identification
    101
  • 2.7 Renewing valve stem seals
    101
  • 2.8 Valve dimensions
    104
  • 2.9 Checking valve guides
    104
  • 2.10 Reworking valve seats
    105
  • Lubrication
    107
  • 1 Parts of lubrication system
    107
  • 1.1 Engine oil:
    107
  • 1.2 Assembly overview - sump, oil pump and oil filter bracket
    108
  • 1.3 Removing and installing sump
    110
  • 1.4 Removing and installing oil pump
    113
  • 1.5 Assembly overview – oil filter housing
    117
  • 1.6 Checking oil pressure and oil pressure switch
    118
  • Cooling
    121
  • 1 Parts of cooling system
    121
  • 1.1 Assembly overview - parts of cooling system, body side
    122
  • 1.2 Assembly overview - additional cooler
    123
  • 1.3 Assembly overview - cooling system, engine side
    124
  • 1.4 Coolant hose connection diagram
    126
  • 1.5 Draining and adding coolant
    127
  • 1.6 Removing and installing fan mounting with fans
    130
  • 1.7 Removing and installing radiator
    132
  • 1.8 Removing and installing coolant pump
    134
  • 1.9 Removing and installing thermostat
    136
  • 1.10 Checking cooling system for leaks
    138
  • Fuel supply system
    141
  • 1 Safety precautions and rules for cleanliness
    141
  • 1.1 Safety measures when working on fuel supply
    141
  • 1.2 Releasing pressure in high-pressure area
    142
  • 1.3 Rules for cleanliness
    143
  • 2 Fuel tank, vehicles with four-wheel drive
    144
  • 2.1 Rules for cleanliness
    144
  • 2.2 Assembly overview - fuel tank
    144
  • 2.3 Emptying fuel tank
    146
  • 2.4 Removing and installing fuel tank
    152
  • 2.5 Removing and installing fuel gauge sender 2 G169
    156
  • 2.6 Removing and installing suction-jet pump
    159
  • 3 Repairing fuel supply
    161
  • 3.1 Rules for cleanliness
    161
  • 3.2 Removing and installing fuel delivery unit
    161
  • 3.3 Removing and installing fuel gauge sender G
    165
  • 3.4 Checking fuel pump
    166
  • 4 Electronic power control (EPC)
    176
  • 4.1 Assembly overview - accelerator module
    176
  • 4.2 Removing and installing accelerator pedal module
    176
  • 5 Activated charcoal filter system
    179
  • 5.1 Function
    179
  • 5.2 Assembly overview - activated charcoal filter system
    179
  • 5.3 Checking fuel system for leaks
    180
  • Mixture preparation - injection
    188
  • 1 Injection system
    188
  • 1.1 General notes on the injection system
    189
  • 1.2 Rules for cleanliness
    189
  • 1.3 Technical data
    190
  • 1.4 Assembly overview - intake manifold
    190
  • 1.5 Assembly overview - fuel rail with high-pressure pump and injectors
    191
  • 1.6 Assembly overview - air filter
    194
  • 1.7 Assembly overview - sound generator with resonance air pipe
    195
  • 1.8 Checking intake air preheating
    195
  • 1.9 Removing and installing intake manifold upper part
    196
  • 1.10 Removing and installing lower part of intake manifold with fuel rail
    199
  • 1.11 Removing and installing high-pressure pump
    202
  • 1.12 Checking fuel pressure sender G247
    204
  • 1.13 Removing and installing injectors
    206
  • 1.14 Renewing Teflon seal and support washer on injector
    209
  • 2 Engine control unit J623
    214
  • 2.1 Removing and installing engine (motor) control unit J623
    214
  • 2.3 Removing and installing anti-theft engine control unit J623 (with locking clip)
    219
  • Exhaust system
    222
  • 1 Parts of the exhaust system
    222
  • 1.2 Removing and installing exhaust manifold
    226
  • 1.3 Removing and installing Lambda probe G39 and Lambda probe 2 G108
    227
  • 1.4 Removing and installing front exhaust pipes with catalytic converters and front silencers
    228
  • 1.5 Assembly overview - silencers with mountings
    231
  • Ignition system
    235
  • 1 Ignition system
    235
  • 1.1 General notes on ignition system
    235
  • 1.2 Assembly overview - ignition system
    235
  • 1.3 Test data, spark plugs
    237
  • 1.4 Removing and installing ignition coils with output stage
    237
Manufacturer's designation 6-cylinder injection engine Volkswagen R GmbH
Manufacturer Volkswagen
Suitable for Passat / Passat Variant (2005 - 2008)
Suitable car types 3C
Engine code BWS
Category Reparaturanleitung

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