Repair of gasoline engine 1.6 l car Volkswagen Passat B6

General recommendations for the maintenance and repair of engines
Passat cars are equipped with four-, five- and six-cylinder engines. On four-cylinder engines, the cylinders are located in one plane, and on six-cylinder engines, the cylinders...

Removal and installation of the top casing of the engine
Attention: When installing the engine cover, namely when fixing it at the attachment points, do not use brute force and do not use a tool. Otherwise, the engine cover may be...

Checking the camshaft timing belt
Remove the toothed belt cover. Pic. 2.3. Toothed belt check Check the toothed belt for tears, transverse fractures, cracks (from the side of the lid), B signs of sidewall wear, C...

Removing the engine
Note: During further operations, the ground wire must be disconnected from the battery. Therefore, you must first check whether a radio with coding is installed in the car. If...

Engine installation
Installation is carried out in the reverse order. Attention: When carrying out all assembly work, in particular in the engine compartment, due to the tight layout, pay attention...

Engine disassembly and assembly
Pic. 2.12. Cylinder Block Components: 1 - cylinder head with camshaft housing; 2 - block of cylinders; 3 - holder; 4 - asterisk; 5 - drive chain; 6 – damper bar; 7 - bolt 25 Nm; 8...

Removal and installation of poly V-belt
Removing Remove the crankcase protection. Mark the running direction of the V-ribbed belt. Pic. 2.13. Turning the tensioner To loosen the V-ribbed belt, turn the tensioner with...

Removal and installation of a cover of the distributive mechanism
Removing Remove the air filter. Remove the crankcase protection. Remove the front right fender liner. Mark the running direction of the V-ribbed belt and remove it. Rotate the...

Replacing the crankshaft oil seal on the side of the belt pulley
Attention: The crankshaft must not be removed. Even unscrewing the bolts of the main bearing caps leads to deformation of the bearing racks of the cylinder block. Due to such...

Tightening method of the belt drive sprocket fixing bolt
Note: A repair kit is gradually introduced to fasten the poly-V-belt drive gear. Note: The repair kit will include one support sleeve and two washers of various inner diameters...

Disassembly and assembly of pistons and connecting rod
Pic. 2.27. Connecting rod and piston group: 1 - piston; 2 - piston pin; 3 - retaining ring; 4 - connecting rod; 5 - bearing shell; 6 – block of cylinders; 7 - connecting rod...

Cylinder head
Pic. 2.31. Cylinder head components: 1 - a box for high-voltage wires; 2 - bolt 10 Nm; 3 - bolt 10 Nm + tighten 1/4 turn. (90°); 4 - bolt 10 Nm; 5 - to the air filter; 6 - Hall...

Checking the valve timing
Checking procedure Remove the air filter. Remove the EGR valve and unscrew the camshaft caps. Remove the spark plug of the first cylinder. To do this, use a puller and a candle...

Valve timing adjustment
Remove the timing cover. Remove the EGR valve. Pic. 2.36. Installing the bolt in the crankshaft pulley To rotate the crankshaft, insert the support sleeve, the crankshaft pulley 2...

Removal and installation of a case of camshafts
Note: In this engine, the camshafts are located in the camshaft housing. Before removing the camshaft housing, the timing cover must be removed. Note: The seating surface of the...

Removal and installation of a head of the block of cylinders
Removing Separate the gearbox and engine. Secure the engine to the engine and transmission bracket. Remove the following parts: intake manifold; the lower part of the intake...

Compression test
Check condition The engine oil temperature must be at least 30°C. Work order Remove the air filter. Remove ignition coils. To do this, use a puller. Unscrew the spark plugs with a...

Valve mechanism repair
Pic. 2.45. Valve mechanism: 1 - bolt 40 Nm + tighten 1/4 turn. (90°); 2 - bolt 50 Nm + tighten 1/4 turn. (90°); 3 - phase shifter; 4 - camshaft drive sprocket; 5 - valve 1 of the...

Checking the valve guides
Checking procedure Insert the new valve into the guide sleeve. The end of the valve stem must be covered by the guide bushing. Due to the different stem diameter, use the inlet...

Replacement of valve stem seals
Withdrawal (with cylinder head installed) Remove the EGR valve. Remove the camshaft housing. Remove the roller arms and place them on a clean surface. Roller levers do not change...

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