Repair of 8-valve car engines Volkswagen Passat B4 1988-1996

Removal and installation of the power unit
Remove the battery. Open the cap of the expansion tank. Disconnect hoses from radiator and drain coolant. Drain the oil from the engine oil sump. Remove the air filter assembly...

Engine disassembly
Note. When disassembling, put marks on the removed parts suitable for further use in order to install them in their original places and in their original position during assembly....

Engine Assembly
To assemble the engine, taking into account the instructions of subsection « General requirements for car repair » in the following order. Install a clean cylinder block on the...

Cylinder block. Device Features
Sleeveless cylinder block, cast iron (pic. 2-6). In the lower part of the cylinder block there are five supports for the crankshaft main bearing shells. The main bearing caps are...

Check of a technical condition and repair of the block of cylinders
Thoroughly clean the cylinder block and check its technical condition. To check the cylinder diameters accurately measure the cylinder diameters. Measurements to be made with a...

Crank mechanism device
The crank mechanism consists of a crankshaft, connecting rods with pistons, piston pins and rings and a flywheel, (pic. 2-8). Pic. 2-8. Details of the crank mechanism: 1 -...

Connecting rod and piston group
Device Features The pistons are made of aluminum alloy and have a cylindrical recess in the bottom. Piston pins steel, polished, floating. From axial displacement, they are held...

Crankshaft and flywheel
Device Features Crankshaft steel, forged, five-bearing. with eight counterweights. Main journals diameter, mm: nominal: 54.00 -0,022 -0,042 1st repair size: 53.75 -0,022 -0,042...

Gas distribution mechanism
To the gas distribution mechanism (pic. 2-11) include: cylinder head, camshaft, exhaust and intake valves, valve guides. valve springs with fastening parts, hydraulic pushers, a...

Cylinder head
Device Features Cylinder head cast aluminum alloy (pic. 2-14). The valve seats and valve guides are pressed into the cylinder head. The camshaft bearings are made directly in the...

Removal and installation of a head of cylinders
To remove, disconnect the negative cable from the battery. Place a container under the engine to collect the coolant and drain the coolant from the cooling system by disconnecting...

Features of car engine repair «Passat GT 1.8 G60 Syncro»
«Passat GT 1.8 G60 Syncro» - this is an all-wheel drive version of cars «Passat» Below are the features of the design, verification and repair of this model in comparison with the...

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8-valve car engine Volkswagen Passat B4