Repair of gasoline engine 1.6 l car Volkswagen Passat B6

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

Removal and installation the upper engine casing
Caution: When installing the engine cover, namely when fixing it at the mounting points, do not use brute force or tools. Otherwise, the engine cover may be damaged. Removal Fig....

Checking the camshaft drive toothed belt
Remove the timing belt cover. Fig. 2.3. Checking the toothed belt Check the timing belt for tears, transverse fractures, cracks (from the lid side), B traces of sidewall wear, C...

Removal the engine
Note: For further operations, the ground wire must be disconnected from the battery. Therefore, first check whether the car radio is equipped with coding. If necessary, find out...

Engine installation
Installation is carried out in reverse order. Caution: When performing all installation work, particularly in the engine compartment, due to the tight layout, please pay attention...

Disassembly and assembly of the engine
Fig. 2.12. Cylinder block components: 1 – Cylinder head with camshaft housing; 2 – cylinder block; 3 – holder; 4 - star; 5 – drive chain; 6 – damper bar; 7 – bolt 25 Nm; 8 – chain...

Removal and installation a poly V-belt
Removal Remove the crankcase guard. Mark the direction of rotation of the poly V-belt. Fig. 2.13. Turning the tensioner To loosen the poly V-belt, turn the tensioner using a 16 mm...

Removal and installation the timing cover
Removal Remove the air filter. Remove the crankcase guard. Remove the front right fender liner. Mark the direction of the poly V-belt and remove it. Turn the crankshaft in the...

Replacing the crankshaft oil seal on the belt pulley side
Caution: Do not remove the crankshaft. Even unscrewing the main bearing cap bolts will deform the bearing struts of the cylinder block. Such deformations will reduce the clearance...

Method of tightening the belt drive sprocket mounting bolt
Note: A repair kit is gradually being introduced to secure the poly V-belt drive gear. Note: The repair kit includes one support bushing and two washers of different internal...

Disassembly and assembly of pistons and connecting rods
Fig. 2.27. Connecting rod and piston group: 1 – piston; 2 – piston pin; 3 – retaining ring; 4 – connecting rod; 5 – bearing shell; 6 – cylinder block; 7 – connecting rod cover; 8...

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

Checking the valve timing
Verification procedure Remove the air filter. Remove the EGR valve and unscrew the camshaft covers. Remove the spark plug from the first cylinder. Use a puller and a spark plug...

Adjusting the valve timing
Remove the timing cover. Remove the EGR valve. Fig. 2.36. Installing the bolt into the crankshaft belt pulley To rotate the crankshaft, insert the support sleeve, crankshaft belt...

Removal and installation the camshaft housing
Note: This engine has camshafts located in the camshaft housing. The timing cover must be removed before removing the camshaft housing. Note: The camshaft housing seating surface...

Removal and installation the cylinder head
Removal Disconnect the gearbox and engine. Secure the engine to the engine and transmission mount. Remove the following parts: intake manifold; lower part of the intake manifold;...

Compression check
Verification condition The engine oil temperature must be at least 30°C. Work execution procedure Remove the air filter. Remove the ignition coils. Use a puller to do this. Remove...

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

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

Replacing valve stem seals
Removal (with the cylinder head installed) Remove the EGR valve. Remove the camshaft housing. Remove the roller arms and place them on a clean surface. Do not swap the roller...

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