Repair of gasoline engine 2.0 l car Volkswagen Passat B6
Compression check
Verification conditions The engine oil temperature must be at least 30°C. The power supply must be in good condition. Verification procedure Remove the ignition coils with output...
Verification conditions The engine oil temperature must be at least 30°C. The power supply must be in good condition. Verification procedure Remove the ignition coils with output...
Removal and installation the engine
Removal Note: For further operations, the ground wire must be disconnected from the battery. Therefore, it is necessary to first check whether the car radio with coding is...
Removal Note: For further operations, the ground wire must be disconnected from the battery. Therefore, it is necessary to first check whether the car radio with coding is...
Installing a timing belt
Note: When rotating the camshaft, the crankshaft must not be in the TDC position. There is a risk of damage to the valves and the piston crown. Note: The engine should be warm to...
Note: When rotating the camshaft, the crankshaft must not be in the TDC position. There is a risk of damage to the valves and the piston crown. Note: The engine should be warm to...
Valve drive
Note: Cylinder heads with cracks between the valve seats or between the valve seat ring and the spark plug seat thread can be used without reducing service life if the cracks are...
Note: Cylinder heads with cracks between the valve seats or between the valve seat ring and the spark plug seat thread can be used without reducing service life if the cracks are...
Removal and installation camshafts
Removal camshafts Remove the phase shifter. Note: It is prohibited to process the lower seating surface of the camshaft frame and the upper cylinder head. Note: The camshaft...
Removal camshafts Remove the phase shifter. Note: It is prohibited to process the lower seating surface of the camshaft frame and the upper cylinder head. Note: The camshaft...
Replacing the valve stem seals (with the cylinder head installed)
Removal the valve stem seals Remove the camshafts. Vehicles with BLR, BLX, BVX and BVY engines Note: To replace the valve stem seals for the exhaust valves of cylinders 3 and 4,...
Removal the valve stem seals Remove the camshafts. Vehicles with BLR, BLX, BVX and BVY engines Note: To replace the valve stem seals for the exhaust valves of cylinders 3 and 4,...
Replacing the exhaust camshaft seal
Removal the oil seal Remove the timing belt. Fig. 2.112. Unscrewing the camshaft gear Unscrew the camshaft gear (use a counter support to secure it) (fig. 2.112). Fig. 2.113....
Removal the oil seal Remove the timing belt. Fig. 2.112. Unscrewing the camshaft gear Unscrew the camshaft gear (use a counter support to secure it) (fig. 2.112). Fig. 2.113....
Removal and installation the phase shifter
Removal the phase shifter Remove the suction pipe. Remove the high pressure pump. Remove the cylinder head cover. Fig. 2.128. Fastening the housing with the valve timing change...
Removal the phase shifter Remove the suction pipe. Remove the high pressure pump. Remove the cylinder head cover. Fig. 2.128. Fastening the housing with the valve timing change...
Removal and installation valve 1 of the valve timing regulator
Dismantling Fig. 2.134. Valve connector Disconnect connector 1 (fig. 2.134). Unscrew the screws and remove the valve 1 of the variable valve timing system from the housing. Note:...
Dismantling Fig. 2.134. Valve connector Disconnect connector 1 (fig. 2.134). Unscrew the screws and remove the valve 1 of the variable valve timing system from the housing. Note:...
Removal and installation a poly V-belt
Removal the poly V-belt Remove the noise insulation screen. Mark the direction of rotation of the poly V-belt. Fig. 2.135. Loosening the tension of the poly V-belt To loosen the...
Removal the poly V-belt Remove the noise insulation screen. Mark the direction of rotation of the poly V-belt. Fig. 2.135. Loosening the tension of the poly V-belt To loosen the...
Replacing the crankshaft oil seal on the belt pulley side
Fig. 2.137. Sealing flanges and flywheel: 1 – bolt 90 Nm + tighten by 1/4 turn (90°); 2 – crankshaft sprocket; 3 – bolt 15 Nm; 4 – oil seal; 5 – sealing flange; 6 – cylinder...
Fig. 2.137. Sealing flanges and flywheel: 1 – bolt 90 Nm + tighten by 1/4 turn (90°); 2 – crankshaft sprocket; 3 – bolt 15 Nm; 4 – oil seal; 5 – sealing flange; 6 – cylinder...
Removal and installation the sealing flange on the belt pulley side
Removal the flange Remove the poly V-belt. Remove the timing belt Then turn the crankshaft back slightly. Fig. 2.138. Fixing the crankshaft sprocket Remove the crankshaft...
Removal the flange Remove the poly V-belt. Remove the timing belt Then turn the crankshaft back slightly. Fig. 2.138. Fixing the crankshaft sprocket Remove the crankshaft...
Removal and installation the crankshaft flange on the flywheel side
Note: The pressing tool is only required for the sealing flange without a support sleeve. Removal the flange Remove the gearbox. Remove the flywheel and/or driven disk. Remove the...
Note: The pressing tool is only required for the sealing flange without a support sleeve. Removal the flange Remove the gearbox. Remove the flywheel and/or driven disk. Remove the...
Removal and installation the flywheel
Removal Fig. 2.147. Installation position of flywheel bolts Turn flywheel A so that bolts B are centered relative to the holes (fig. 2.147). Note: To avoid damaging the dual mass...
Removal Fig. 2.147. Installation position of flywheel bolts Turn flywheel A so that bolts B are centered relative to the holes (fig. 2.147). Note: To avoid damaging the dual mass...
Removal and installation the slave disk
Unscrewing and screwing the driven disk Fig. 2.149. Counter support fixing diagram Secure the counter support to the driven disk using an M8x45 hex bolt. Install two M10 hex nuts...
Unscrewing and screwing the driven disk Fig. 2.149. Counter support fixing diagram Secure the counter support to the driven disk using an M8x45 hex bolt. Install two M10 hex nuts...
Crankshaft
Note: Before removing the crankshaft, ensure proper storage place to avoid damaging the sensor gear. Note: To perform installation work, the engine must be secured to the engine...
Note: Before removing the crankshaft, ensure proper storage place to avoid damaging the sensor gear. Note: To perform installation work, the engine must be secured to the engine...
Pistons and connecting rods
Fig. 2.154. Piston and connecting rod: 1 – connecting rod cap mounting bolt, 30 Nm + further tighten by 1/4 turn (90°); 2 – pressure reducing valve, 27 Nm; 3 – oil injection...
Fig. 2.154. Piston and connecting rod: 1 – connecting rod cap mounting bolt, 30 Nm + further tighten by 1/4 turn (90°); 2 – pressure reducing valve, 27 Nm; 3 – oil injection...
Checking pistons, piston rings and cylinder diameter
Checking the thermal clearance of piston rings Drive the ring from above at a right angle to the bottom hole of the cylinder, at a distance of about 15 mm from its edge. Checking...
Checking the thermal clearance of piston rings Drive the ring from above at a right angle to the bottom hole of the cylinder, at a distance of about 15 mm from its edge. Checking...
Removal and installation the cylinder head cover
Note: When installing an exchange cylinder head, before installing the cylinder head cover, it is necessary to lubricate all contact surfaces between the support elements, roller...
Note: When installing an exchange cylinder head, before installing the cylinder head cover, it is necessary to lubricate all contact surfaces between the support elements, roller...
Removal the cylinder head
Note: The engine should be warm to the touch. Work execution procedure For further operations, the ground wire must be disconnected from the battery. Therefore, it is necessary to...
Note: The engine should be warm to the touch. Work execution procedure For further operations, the ground wire must be disconnected from the battery. Therefore, it is necessary to...
Installing the cylinder head
Note: There should be no oil or coolant in the blind holes of the cylinder head bolts. The new cylinder head gasket should only be removed from its packaging immediately prior to...
Note: There should be no oil or coolant in the blind holes of the cylinder head bolts. The new cylinder head gasket should only be removed from its packaging immediately prior to...
Characteristics of 2.0 liter petrol engines
Engine letter designation BLR BIX BLY Date of manufacture Passat 12.04 06.05 12.04 Eos - - - Complies with toxicity standards EU 4 Norm EU 4 Norm EU 2 Nomi Working volume, cm³...
Engine letter designation BLR BIX BLY Date of manufacture Passat 12.04 06.05 12.04 Eos - - - Complies with toxicity standards EU 4 Norm EU 4 Norm EU 2 Nomi Working volume, cm³...
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Passat B6
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