VW Passat repair


+ 1. Ekspluatatsiiya of the car
+ 2. Maintenance
+ 3. Engines
+ 4. Cooling system
- 5. Power supply system
   - 5.1. Power supply systems of petrol engines
      5.1.2. General information
      5.1.3. PIERBURG 2EZ carburetor
      5.1.4. Air filter
      5.1.5. Fuel pump
      5.1.6. Fuel filter
      5.1.7. Fuel accumulator
      5.1.8. Fuel tank
      5.1.9. Fuel level sensor
      5.1.10. Accelerator cable
      5.1.11. Systems of injection of fuel
      5.1.12. Inlet collector
      5.1.13. System of self-diagnostics and codes of malfunctions
      5.1.14. Check of a control system by the Digifant engine
      5.1.15. Check of a control system by the CIS-E-Motronic engine
      5.1.16. System of production of the fulfilled gases
   + 5.2. Power supply system of the diesel engine
+ 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>> Power supply system>> Power supply systems of petrol engines>> System of production of the fulfilled gases

Fig. 5.75. System of production of the fulfilled gases on cars with PF and RV engines: 1–thermofilter; 2–nut; 3–reception exhaust pipe; 4–sealing ring; 5–final collector; 6–nut; 7–connecting coupling; 8–a pipe of measurement of the contents WITH; 9–cap; 10-reception exhaust pipe (RV); 11-nut; 12-lambda sensor; 13-sealing ring; 14-catalytic converter (RF); 15-forward exhaust silencer; 16-blooming plug; 17-suspension bracket; 18-bolt; 19-b distance = 9–11 mm; 20-back exhaust silencer; 21-a place of drawing of marking (S — a mechanical transmission,
And — an automatic transmission); 22-distance and = 5 mm; 23-average exhaust silencer


Fig. 5.77. System of production of the fulfilled gases on cars with KR engines and 9А: 1–laying; 2, 4, 14 – nuts; 3–final collector; 5–reception exhaust pipe and exhaust silencer; 6–blooming plug; 7–forward exhaust silencer; 8–a place of drawing of marking (S – a mechanical transmission,
And – an automatic transmission); 9–and = 5мм; 10-suspension bracket; 11-back exhaust silencer; 12-average exhaust silencer; 13-thermofilter


Fig. 5.78. System of production of the fulfilled gases on cars with engines 9А with the catalyst: 1–consolidation; 2–nut; 3–final collector; 4–connecting plug; 5–a tube of measurement of the contents WITH; 6–cap; 7, 20 – nuts; 8–reception exhaust pipe; 9–lambda sensor; 10-sealing ring; 11-catalytic converter; 12-blooming plug; 13-forward exhaust silencer; 14-a place of drawing of marking (S – a mechanical transmission, And – an automatic box before); 15-and = 5 mm; 16-suspension bracket; 17-back exhaust silencer; 18-average exhaust silencer; 19-thermofilter



The system of production of the fulfilled gases is necessary for checking (fig. 5.75, 5.76, 5.77, 5.78) regularly on damage existence, прогаров, leaks, integrity and reliability of fixing elements, etc.
Before removal or dismantling of system of release it is necessary to moisten all all places of connections of pipes and fixing elements with the liquid dissolving products of a karrooziya, for example WD-40.
Before any work with system of release wait while its elements will cool down.
To check system on leaks it is possible as follows:
– start the engine;
– after the assistant for short time will close a rag an exhaust pipe, examine attentively from all directions system;
– if from connections, welded seams or elements of system there are fulfilled gases — neokhody repair of the damaged site.
On cars with the RP engine to disconnect an exhaust system it is necessary on connection of a collector with a reception exhaust pipe. Except for cars with the RP engine, it is simpler to remove an exhaust system from the car entirely and then to divide into parts or to cut off a defective part a hacksaw. On cars with the Lambda sensor, at removal of an exhaust system, disconnect the electric socket from the sensor.
Installation of an exhaust system begin with a forward part.
Removal and installation of a final collector carry out in the following order:
– remove an inlet collector;
– unscrew fastening and disconnect a zabornik of warmed-up air from a final collector;
– remove thermofilters;
– lift a forward part of the car and reliably fix it on supports;
– under the bottom of the car disconnect a reception exhaust pipe from a collector flange;
– on all cars except for cars with the RP engine: the flange is attached by nuts 11 (see fig. 5.75 ) and hairpins;
– unscrew nuts and disconnect a reception exhaust pipe 3 from a final collector 3;
– remove laying 2;

Fig. 5.76. System of production of the fulfilled gases on cars with RP engines: 1–laying; 2–final collector; 3–nuts; 4–connecting plug; 5–a tube of measurement of the contents WITH; 6–cap; 7–lambda sensor; 8–fastening bracket; 9–blooming plug; 10-a place of drawing of marking (S – a mechanical transmission, And – an automatic transmission); 11-bolt; 12-distance and = 5 mm; 13-reception exhaust pipe; 14-sealing ring; 15-catalytic converter; 16-nut; 17-intermediate pipe; 18-suspension bracket; 19-average exhaust silencer; 20-back exhaust silencer; 21-suspension bracket arm; 22-b= 9–11 mm; 23-place of drawing of marking; 24-thermofilter; 25-sealing ring


– on cars with the RP engine: connection of a final collector 2 (see fig. 5.76 ) with a reception exhaust pipe 13 is carried out by two rigid brackets 8;
– for a release of each bracket it is necessary to use the special VW 4140A/2 tool which represents a wedge-shaped plate (it it is possible to make easily independently). After installation of a wedge-shaped plate to a bracket move an exhaust pipe to the jammed bracket to reduce a gap in connection and take a bracket. Keep in mind that brackets fasten in a certain situation by basic surfaces on flanges;
– lower a reception exhaust pipe 13 and remove a sealing ring 25;
– unscrew nuts and bolts of fastening of a final collector 2;
– disconnect a collector and laying 1 from a head of the block of cylinders.
Installation carry out to sequences of return to removal. Use new laying and new самоконтрящиеся nuts. If necessary replace a sealing ring 14 on the RP engine.