VW Passat repair


+ 1. Ekspluatatsiiya of the car
+ 2. Maintenance
- 3. Engines
   + 3.1. Petrol engines of configuration of R4
   + 3.2. Petrol engine of configuration of VR6
   - 3.3. Diesel engines
      3.3.1. Technical characteristics
      3.3.2. General information
      3.3.3. Installation of the piston of the cylinder No. 1 in VMT
      3.3.4. Compression check in cylinders
      3.3.5. Gear belt of a drive of GRM
      3.3.6. Mechanism of a tension of a gear belt
      3.3.7. Gear pulley of a camshaft
      3.3.8. Gear pulley of a cranked shaft
      3.3.9. Pulley of an intermediate shaft
      3.3.10. Belts of a drive of auxiliary units
      3.3.11. Cover of a head of the block of cylinders
      3.3.12. Replacement of an epiploon of a camshaft
      3.3.13. Replacement of an epiploon of an intermediate shaft
      3.3.14. Replacement of epiploons of a cranked shaft
      3.3.15. Replacement of an epiploon of a forward cover of a cranked shaft
      3.3.16. Head of the block of cylinders
      3.3.17. Check of work of hydraulic pushers
      3.3.18. Flywheel
      3.3.19. Replacement of support of the power unit
      3.3.20. Oil case
      3.3.21. Oil pump
      3.3.22. Top casing of the AFN engine
      3.3.23. System of prestarting heating of diesel engines
      3.3.24. Glow plugs
+ 4. Cooling system
+ 5. Power supply system
+ 6. Ignition system
+ 7. Coupling
+ 8. Transmission
+ 9. Drive of forward wheels
+ 10. Suspension brackets
+ 11. Steering
+ 12. Brake system
+ 13. Wheels and tires
+ 14. Systems of heating, ventilation and conditioning
+ 15. Electric equipment
+ 16. Body
+ 17. Electric circuits


Repair B3-B4/Passat B3-B4 Volkswagen Passat>> Engines>> Diesel engines>> Head of the block of cylinders
Removal of a head of the block
Removal of a head of the block of cylinders carry out in the following order:
– establish the car on a horizontal surface and fix it;
– remove a cowl from the car;
– disconnect a wire from the negative plug of the storage battery;
– merge engine oil from the engine;
– merge cooling liquid from cooling system;
– remove auxiliary driving belts;
– establish the piston of the first cylinder in situation VMT;

Fig. 3.68. Head of the block of cylinders: 1–a head of the block of cylinders, 2 – laying of a head of the block of cylinders, 3 – the directing plug of the valve, 4 – a forward cover of the bearing of a camshaft, 5 – a bolt of fastening of a head of the block of cylinders, 6 – a maslootrazhatelny plate, 7 – laying of a cover of a head of the block of cylinders, 8 – a cover of a head of the block of cylinders, 9 – a plate, 10 – a stopper of a maslonalivny mouth, 11 – the union of the valve of a regulator of ventilation of a case


– weaken collars and disconnect radiator hoses from unions on a head 1 (see fig. 3.68 .) block of cylinders;
– weaken collars and remove hoses of a broad tank and a heater from unions of a head of the block of cylinders;
– for convenience of access to the engine remove the top forward cross-section slip, headlights, a front grille and the cowl lock;
– disconnect from tube nozzles submitting fuel;
– disconnect the returnable fuel tubes connecting nozzles to the fuel pump;
– mark (not to mix at assembly) and disconnect electric tips;
– uncover heads of the block of cylinders (see section 3.3.10);
– remove a forward casing of a GRM belt and remove a GRM belt from a camshaft pulley;
– remove the mechanism of a tension of a GRM belt, a pulley of a camshaft and a pulley of the fuel pump of a high pressure.
– unscrew screws and remove a back casing of a GRM belt;
– disconnect the tip from the sensor of temperature of cooling liquid;
– unscrew bolts and disconnect a reception exhaust pipe from a final collector.
For the cars equipped with a turbonagnetatel:
– remove a turbonagnetatel from a final collector;
– where it is established, remove the EGR valve and a pipe connecting inlet and final collectors;
– unscrew a nut of fastening of the feeding tire of contact of a glow plug of the 4th cylinder;
– cнимите a spring ring also unscrew the tip of a plait of wires from a head of the block of cylinders;
– check, that all hoses, pipes and wires were disconnected from a head of the block of cylinders;
– consistently, as it should be, the return to a tightening, turn on bolts 5 (see fig. 3.68 ) fastenings of a head of the block of cylinders at first on 0,5–1 turn, and then turn out them completely;
– remove a head of the block of cylinders 1 from the engine;
– remove laying of 2 heads of the block of cylinders from the top part of the block of cylinders. Do not throw out old laying — it is required for identification new;
– take from the block of cylinders directing pins if they are an easy fit and can fall out, and store them together with a head of the block of cylinders;
– unscrew bolts and remove from a head of the block of cylinders an inlet collector and laying;
– unscrew bolts and remove the heat resisting screen from a final collector;
– unscrew nuts and remove a final collector from a head of the block of cylinders;
– clear interfaced surfaces of an inlet and final collector and a head of the block of cylinders. Establish a final collector with new laying on a head of the block of cylinders and fix it nuts the established moment;
– establish the heat resisting screen on racks of a final collector and fix it nuts the established moment;
– establish an inlet collector with new laying on a head of the block of cylinders and fix it bolts the established moment.

Installation of a head of the block of cylinders
Before installation of a head of the block of cylinders it is necessary to carry out the following preparatory work:
– clear interfaced surfaces of a head and the block of cylinders. For their cleaning use a firm plastic or wooden scraper;
– check interfaced surfaces of a head and the block of cylinders on existence of notches, deep scratches and other damages. If defects small, they can be removed with grinding. But at major defects of a detail are subject to replacement;

       PREVENTION
When cleaning be careful, as the aluminum alloy is very easy for damaging. Watch, that the deposit did not get to oil canals and channels of cooling liquid. If necessary clear channels.

– not planeness of interfaced surfaces check by means of a metal ruler;
– clear openings under bolts in the block. Bolt screwing up in the opening filled with oil can break off the block because of hydraulic pressure.
– irrespective of their condition bolts of fastening of a head of the block of cylinders are subject to replacement.
Installation of a head of the block of cylinders carry out in the following order:
– check marking (number on the brink of laying or an opening) old laying of a head of the block of cylinders;
– if at repair pistons did not change, new laying of a head of the block of cylinders should have the same marking, as old;
– if on the engine new pistons are established, it is necessary to measure a vystupaniye of pistons from the block of cylinders and according to this size it is necessary to choose thickness of new laying of a head of the block of cylinders (see tab. 3.5 )
– establish new laying of a head of the block of cylinders on directing pins so that marking of "TORAHS" was directed up;

       GOOD ADVICE
Take two used bolts of fastening of a head of the block of cylinders, cut off heads and in a bolt end face, saw through a groove under a screw-driver. Screw bolts in the block of cylinders of the engine, and they will serve directing at installation of a head of the block of cylinders. After installation of a head of the block of cylinders they are necessary for turning out.

– establish a head of the block of cylinders.
– grease a carving and a reverse side of heads of new bolts of fastening of a head of the block of cylinders with engine oil;
– accurately, without throwing, вствьте bolts of fastening of a head of the block of cylinders in openings also tighten them by hand;

Fig. 3.70. Order of an inhaling of bolts of fastening of a head of the block of cylinders


– in stages (see section 3.1.1) tighten bolts of fastening of a head of the block of cylinders in the sequence shown on fig. 3.70 ;
– establish a back casing of a GRM belt;
– establish the mechanism of a tension of a GRM belt and pulleys;
– be convinced that the piston of the first cylinder is in situation VMT and establish a GRM belt and an external casing of a GRM belt;
– installation of the removed elements make in sequence, return to removal;
– fill in in the engine engine oil;
– fill cooling system.