Repair of the fuel and exhaust system of diesel vehicles Volkswagen Passat B6 2005-2010

Fuel pressure test
Verification conditions The coolant temperature must be at least 85°C. The injector must be in good working order. The fuel filter and fuel lines must not be clogged. Work order...

Removal and installation of the tandem pump
Attention: The tandem type pump must never be dismantled, otherwise it will cause the vacuum part to malfunction. The consequence may be the failure of the brake booster. Removing...

Fuel pump check
Check condition The fuses must be good. The battery voltage must be at least 11.5 V. All electrical consumers, such as headlights and heated rear window, must be switched off....

Removal and installation of the fuel supply module
Pic. 2.340. Fuel supply module Removing First you need to check if the radio with encoding is installed in the car. If yes, then you should find out the security code. With the...

Removal and installation of the fuel level sensor
Removing Remove the fuel delivery module. Unlock the tabs on the cable plugs and disconnect them. Pic. 2.343. Fuel Level Sensor Clips Pry out the clips 1 with a screwdriver and...

Removing the fuel tank
Note: The rear axle must be lowered to remove the fuel tank. If necessary, pump out the fuel from the tank using a fuel pump. Remove the rear seats. Remove the fuel delivery...

Installation of hose connections with nipple connectors of the pressurization system
Attention: The o-ring of the nipple connector can be damaged if the retaining clip is in the locked position during installation. As a result, leakage occurs. Follow the...

Safety measures when repairing a direct fuel injection system
Attention: When carrying out all assembly work, in particular in the engine compartment, due to the tight layout, pay attention to the following. Highways of all types (e.g. fuel,...

Removal and installation of cable connection pump-injectors and glow plugs
Pic. 2.356. Cable duct for pump injectors and glow plugs: 1 - glow plug plug; 2 - brackets made of stainless steel; 3 - fixing bolt; 4 – adapter ring; 5 – central plug; 6 - plug...

Removal and installation of the pump nozzle
Pic. 2.363. Injector unit components: 1 - bolt 3 Nm + 90° (1/4rev.) + 180° (1/2 vol.); 2 – axis of roller levers; 3 - bolt 20 Nm + tighten by 1/4 rev. (90°); 4 - adjusting screw;...

Replacing the O-rings of the unit injector
Removing Remove the injector. Carefully remove the O-rings from the unit injector using "flexible «tool. Make sure that there are no burrs at the seat of the O-rings. Installation...

Free exhaust system installation
Check condition Work is carried out on a cold engine. Work order Unscrew the clamp connection between the exhaust pipe and the intermediate muffler. Pic. 2.372. Installation...

Exhaust gas recirculation system
Note: The EGR system is controlled by the diesel direct injection system control unit via the EGR valve (electropneumatic) to the EGR valve (mechanical). Note: The mechanical EGR...

Checking glow plugs
Signs of ceramic glow plugs Pic. 2.376. External signs of ceramic glow plugs Caution: Ceramic glow plugs are very susceptible to bending and impact. For this reason, candles that...

Removing, installing, checking ceramic glow plugs
Work order Note: Remove and install ceramic glow plugs without twisting. Remove components damaged during assembly. Remove the engine cover. Remove the cylinder head cover. Remove...

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Fuel and exhaust system of diesel car Volkswagen Passat B6