VW Passat repair


+ 1. Ekspluatatsiiya of the car
+ 2. Maintenance
- 3. Engines
   - 3.1. Petrol engines of configuration of R4
      3.1.1. Technical characteristics
      3.1.2. General information
      3.1.3. Compression definition in cylinders
      3.1.4. Gear belt of a drive of the gas-distributing mechanism
      3.1.5. Camshaft and pushers
      3.1.6. Removal and installation of a head of the block of cylinders
      3.1.7. Repair of a head of the block of cylinders
      3.1.8. Flywheel
      3.1.9. Intermediate shaft
      3.1.10. Oil pallet
      3.1.11. Replacement of epiploons of a cranked shaft
      3.1.12. Oil pump
      3.1.13. Pistons and rods
      3.1.14. Removal and engine installation
      3.1.15. Engine dismantling
      3.1.16. Fault detection of the block of cylinders and cranked shaft
      3.1.17. Engine assembly
      3.1.18. Engine start-up after major maintenance
   + 3.2. Petrol engine of configuration of VR6
   + 3.3. Diesel engines
+ 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>> Petrol engines of configuration of R4>> Engine assembly
Assembly of the engine is carried out in the following sequence:

Fig. 3.27. Block of cylinders, cranked and intermediate shaft: 1–bolts of fastening of a cover of the radical bearing of a cranked shaft; 2–cover of the radical bearing of a cranked shaft; 3–loose leaf of the radical bearing of a cranked shaft; 4, 6 – persistent half rings; 5–loose leaf of the central (persistent) radical bearing of a cranked shaft; 7–cranked shaft; 8–bolt of fastening of a cover of an intermediate shaft; 9–epiploon of an intermediate shaft; 10-cover of an intermediate shaft; 11-sealing ring of a cover of an intermediate shaft; 12-intermediate shaft; 13-forward epiploon of a cranked shaft; 14-bolts of fastening of a forward cover of a cranked shaft; 15-forward cover of a cranked shaft; 16-laying of a forward cover of a cranked shaft; 17-block of cylinders


– establish the block of 17 cylinders (see fig. 3.27 ) a case up;
– clear beds of radical bearings and loose leaves of radical bearings;
– establish loose leaves 3, 5 in a bed of radical bearings. Each loose leaf should be established in that bearing from which it was removed;
– establish persistent half rings 6 central radical bearings;
– grease the established loose leaves with engine oil;
– grease with engine oil all necks of a cranked shaft, including working in contact to epiploons;
– establish a cranked shaft 7 in a bed of the block of cylinders;
– establish loose leaves 3, 5 in covers of 2 radical bearings of a cranked shaft. Each loose leaf should be established in that bearing from which it was removed. On covers of bearings No. 1, 2 and 5 establish loose leaves with a smooth internal surface, on a bearing No. 4 cover – with a flute for greasing. The loose leaf of a cover of the central radical bearing too smooth, on its cover is established by persistent half rings 4;
– establish persistent half rings from two parties of a cover of the radical bearing No. 3. The surface of a persistent half ring with lubricant flutes should be directed outside;
– grease the loose leaf of a cover of the central radical bearing, establish a cover, insert bolts of 1 fastening of a cover and tighten them the demanded moment (see подразд. 3.1.1);
– define axial люфт a cranked shaft (see подразд. 3.1.15);
– grease loose leaves of other radical bearings, establish covers 2, insert bolts of 1 fastening of covers and tighten them the demanded moment;
– turn a cranked shaft manually — it should rotate easily and without breakthroughs;
– establish pistons with rods in collecting (see подразд. 3.1.13);
– turn a cranked shaft manually — it should rotate easily and without breakthroughs;
– establish the oil pump (see подразд. 3.1.12);
– establish a forward cover 15 cranked shaft with new laying 16, tighten bolts 14;

Fig. 3.41. Installation of a forward epiploon of a cranked shaft


– grease working edges of a forward epiploon 13 cranked shaft and establish an epiploon by means of an opravka (fig. 3.41) ;
– establish a back cover of a cranked shaft together with new laying of a cover, tighten bolts of fastening of a back cover;
– grease working edges of a back epiploon of a cranked shaft and establish an epiploon by means of an opravka;
– establish the oil pallet (see подразд. 3.1.10);
– overturn the engine and establish it in normal situation;
– put hermetic for the external bottom end of a tube щупа level of oil and establish a tube in the block of cylinders by means of a kiyanka;

Fig. 3.3. Provision of an adjusting label of a pulley of the cranked shaft, corresponding VMT of the piston of the first cylinder


– establish a gear pulley 11 (see fig. 3.3 ) on a sock of a cranked shaft;
– block a cranked shaft from a provorachivaniye the long core established between two bolts in a back part of a cranked shaft, and tighten a bolt of the 12th fastening of a gear pulley of a cranked shaft;
– establish an intermediate shaft (see подразд. 3.1.9);
– establish an arm of fastening of the generator and tighten bolts of its fastening;
– turn a cranked shaft of the engine clockwise so that all pistons were established in the middle of the course, thus the piston of the cylinder No. 1 should make a compression step;
– establish laying of GBTs and a head of the block of cylinders (see подразд. 3.1.6);
– establish a forward eye and tighten a bolt of its fastening;
– establish a protective plate 7 (see fig. 3.3 ) and tighten bolts of its 2 fastenings;
– establish hydraulic pushers and a camshaft (see подразд. 3.1.5);
– turn an intermediate shaft so that the groove of a segment shponka was directed up, and establish a segment shponka in a groove;
– establish a gear pulley of an intermediate shaft, tighten a bolt of fastening of a pulley of an intermediate shaft, having blocked it from a provorachivaniye;
– establish a tension roller of a gear belt of a drive of GRM, tighten a nut of fastening of a tension roller so that the axis of a roller turned with effort;
– establish a pulley 9 (see fig. 3.3 ) a cranked shaft, fix it on a diagonal two bolts;

Fig. 3.5. Provision of adjusting labels of a gear pulley of a camshaft of the SOHC engines, corresponding VMT of the piston of the first cylinder: 1–head of the block of cylinders; 2–gear pulley; 3–cover of a head of the block; And – an adjusting label


– turn a camshaft in the situation corresponding to position of the piston of the cylinder No. 1 in VMT, i.e. before label combination on a pulley with the plane of a head of the block of cylinders (see fig. 3.5 );
– establish the cylinder No. 1 piston in VMT turn of a cranked shaft clockwise;

Fig. 3.4. Provision of adjusting labels of a pulley of a cranked shaft and gear pulley of the intermediate shaft, corresponding VMT of the piston of the first cylinder


– combine labels on pulleys of intermediate and cranked shaft turn of an intermediate shaft (see fig. 3.4 );
– establish a gear belt of a drive of GRM and check its tension (see подразд. 3.1.4);
– unscrew bolts of fastening and remove a pulley 9 (see fig. 3.3 ), previously having noted its situation;
– check laying existence in the bottom cover of the 10th belt of a drive of GRM, establish a cover 10 and tighten bolts of fastening of a cover;
– establish a pulley 9 cranked shaft on the put labels and tighten bolts of fastening of a pulley;

Fig. 3.8. Head of the block of cylinders of SOHC engines:
1–head of the block of cylinders; 2–laying of a head of the block of cylinders; 3–the directing plug of the valve; 4–maslootrazhatel; 5–laying of a cover of a head of the block of cylinders; 6–cover of a head of the block of cylinders; 7–power strip; 8–stopper of a maslonalivny mouth; 9–bolt of fastening of a head of the block of cylinders; 10-hairpin of fastening of a cover of a head of the block of cylinders; 11-nut of fastening of a cover of a head of the block of cylinders; 12-forward laying of a cover of a head of the block of cylinders; 13-cap


– establish laying 12 (see fig. 3.8 ) and a cap 13 on a head of the block of cylinders;
– establish new laying of the 5th cover of a head of the block of cylinders;
– establish a maslootrazhatel 4;
– establish a cover of the 6th head of the block of cylinders and power strips 7;

Fig. 3.2. Drive of the gas-distributing mechanism (GRM): 1–top cover of GRM; 2–bolts; 3–top protective plate; 4–belt of a drive of a camshaft; 5–tension roller; 6–nut of fastening of a tension roller; 7–protective plate; 8–belt of a drive of the generator and water pump; 9–pulley of a cranked shaft; 10-bottom cover of a belt of a drive of a camshaft; 11-gear pulley of a cranked shaft; 12-bolt of fastening of a gear pulley of a cranked shaft; 13-gear pulley of an intermediate shaft


– establish the top protective plate 3 (see fig. 3.2 );
– establish the top cover of 1 belt of a drive of GRM;
– establish an intermediate plate on adjusting pins of a back part of the block of cylinders;
– establish a flywheel or a leading disk (see подразд. 3.1.8);
– establish auxiliary units on the engine.
If hydraulic pushers were replaced, do not start up the engine within 30 minutes. This time is necessary for an exit from a pusher of superfluous oil, valve and piston impact otherwise is possible.