VW Passat B5

since 1996 release

Repair and operation of the car



Foltsvagen Passat B5
+ Maintenance instruction
+ 1. Maintenance
- 2. Engines
   2.2. General information
   2.3. Lower mudguard of a motor compartment
   - 2.4. Four-cylinder petrol engine
      2.4.2. Head of the block of cylinders
      2.4.3. Check of hydraulic pushers of valves
      2.4.4. Repair of a head of the block of cylinders
   + 2.5. Diesel engine 1,9-I-TDI
   + 2.6. Drive of the gas-distributing mechanism
   + 2.7. Engine 2,8-I-V6
+ 3. Cooling system
+ 4. Fuel system
+ 5. Engine management
+ 6. Exhaust system
+ 7. Transmission
+ 8. Running gear
+ 9. Steering
+ 10. Brake system
+ 11. Body
+ 12. Heating, ventilation
+ 13. Electric equipment






2.4. Four-cylinder petrol engine

2.4.1. Gear belt

GENERAL INFORMATION

The tension of a gear belt in four-cylinder petrol engines is carried out by a roller of the automatic mechanism of a tension which supports an optimum tension of a belt therefore service life and smoothness of the course of a gear belt increases.
Prevention

On engines with various codes various rollers of the automatic mechanism of a tension of a gear belt are established.


Removal

Combination of adjusting tags


Removal of a gear belt is made on the engine which temperature has to be more than 30 °C. If necessary warm up the engine.

PERFORMANCE ORDER
1. Take off auxiliary maple a belt.
2. Unscrew the mechanism of a tension of a poliklinovy auxiliary driving belt.
3. Remove the top casing of a gear belt.
4. If the gear belt is repeatedly established, using a marker or paint, note the direction of rotation of a gear belt. If to look from a forward part of the engine, pulleys of the engine rotate clockwise.
5. Turn the engine so that the piston of the first cylinder was installed in the top dead point.
It is possible to turn a bent shaft of the engine the next ways:
  – lift a forward part of the car and fix on supports. Include the fifth transfer and tighten the emergency brake. Holding one forward wheel from a provorachivaniye, manually turn the second forward wheel. At the same time the bent shaft of the engine will be turned;
  – install the car on the flat horizontal platform, then include the fifth transfer and manually move the car forward or back;
  – install the transmission in neutral situation and tighten the emergency brake. Using a wrench, for a bolt of fastening of a pulley of a bent shaft turn a bent shaft of the engine.
Prevention

Do not turn a bent shaft of the engine for a bolt of fastening of a pulley of the camshaft as in this case load of a gear belt maximum.


6. Turn a bent shaft of the engine until the tag on a pulley of the camshaft is not combined with the index of VMT on a cover of a head of the block of cylinders (see rice. Combination of adjusting tags. Check that the tag on a pulley of a bent shaft was combined with the index on the lower casing of a gear belt. At combination of tags with indexes the piston of the first cylinder is in VMT in a compression step.

ADP engine

Combination of an adjusting tag of a pulley of the camshaft with the index and tags on pulleys of cranked and intermediate shaft on the ADP engine at installation of the piston of the first cylinder in VMT


On the ADP engine the ignition distributor with the drive from an intermediate shaft is installed. If the tag on a pulley of the camshaft is combined with the index, then tags on pulleys of cranked and intermediate shaft have to be combined.

PERFORMANCE ORDER
1. Holding a pulley of a bent shaft from a provorachivaniye, unscrew four bolts fixing a pulley to a bent shaft. Remove a pulley of a bent shaft.
2. Unscrew screws and remove the lower casing of a gear belt.

AEB, ADP engines

PERFORMANCE ORDER
Weaken a bolt of fastening of a tension rlik of a gear belt.

AHL engine

PERFORMANCE ORDER
Weaken a nut of fastening of a tension roller of a gear belt.

ADR engine

Tension roller of a gear belt on the ADR engine

1 – tension roller,

2 – an opening in the piston case,

3 – bolt


PERFORMANCE ORDER
1. Using a 8-millimeter hexagon, slowly turn counterclockwise a tension roller of a gear belt before combination of openings (2) in the piston and the case (see rice. A tension roller of a gear belt on the ADR engine). Insert a steel core or a shaft of a drill of the corresponding diameter into the combined opening.
Prevention

In work of an element of a tension of a gear belt the principle of a hydraulic uspokoitel is used and it can be squeezed only at a temperature exceeding 30 °C. Do not unscrew a bolt (3), see rice. A tension roller of a gear belt on the ADR engine.


2. Take off a gear belt from engine pulleys.
Prevention

Do not bend sharply gear belt as in use the gear belt in the place of a sharp excess can become torn that will lead to damage of the engine.

After removal of a gear belt do not change the provision of pulleys of a gear belt.

If after removal of a gear belt to turn a bent shaft of the engine, there will be an impact of pistons to valves therefore they will be damaged and serious repair of the engine will be required. Note the provision of a pulley of a bent shaft for what put with paint tags on a pulley and the block of cylinders of the engine. If necessary it is possible to turn a bent shaft of the engine on 90 ° clockwise or counterclockwise.

Check a gear belt for wear, stratification or oiling. If on a gear belt there are oil traces, before installation of a new belt find a source of leak of oil and eliminate it.



Survey
Prevention

Do not overwind and do not bend a gear belt.

Exclude hit on a gear belt of oil, cooling liquid or fuel.


If there was a vykrashivaniye of teeths of a gear belt, perhaps, the ignition distributor, the water pump, the oil pump or the camshaft are jammed.

Prevention

If there was a rupture of a gear belt on the working engine, it is possible that there was an impact of pistons about the valve therefore the valve can be bent. Check gaps of valves. On the bent valves valvate gaps will be much more demanded.


If there is a considerable wear, cracks or stratification on an external surface of a gear belt, check a condition of racetracks of single pulleys.

Wear of one party of a belt indicates not coaxiality of pulleys of a gear belt. Check a guide of a gear belt and alignment of pulleys of a gear belt.

With any defects on a gear belt it needs to be replaced. Periodic replacement of a gear belt has to be made through 100 000 km of a run of the car.

Installation
Prevention

You make installation and a tension of a gear belt on the cold engine.


PERFORMANCE ORDER
1. Establish a gear belt on pulleys of cranked and intermediate shaft.
Prevention

At repeated installation of a gear belt establish it so that the arrow on a belt put before removal of a belt coincided with the direction of rotation of pulleys of the engine. If after installation the gear belt rotates to the opposite side, perhaps, emergence of cracks on a belt and breakage of the engine.


2. Establish into place and fix by bolts the lower casing of a gear belt.
3. Establish a belt pulley of a bent shaft and fix it by bolts, having tightened their moment 25 Nanometers. Keep in mind that the pulley is established only in one situation.
4. Check that tags of pulleys of distributive and cranked shaft are combined with indexes.
5. Put on a gear belt a camshaft pulley.

AEB, ADP engines

Elements of a tension of a gear belt on AEB, ADP engines

And – the holder,
In – a wrench

1 – holder's shoulder,
2 – piston,
3 – the wrench installed on the screw


The control sizes for check of correctness of a tension of a gear belt on AEB, ADP, ADR engines


PERFORMANCE ORDER
1. Using a wrench (V) or a special key of HAZET 2587 turn clockwise the holder (A) of a tension roller of a gear belt so that the piston (1) left against the stop, and the piston (2) rose by 1 mm over the case. Holding a tension roller of a gear belt in this situation, tighten the screw (3) the moment of 25 Nanometers, see rice. Elements of a tension of a gear belt on AEB, ADP engines.
2. Turn a bent shaft of the engine on 2 whole revolutions clockwise and check that tags on pulleys of cranked and distributive shaft were combined with indexes.
3. Check an arrangement of elements of the mechanism of a tension of a gear belt. The size A has to be combined with the top edge of the piston. The size D has to be in limits of 25-29 mm (see rice. The control sizes for check of correctness of a tension of a gear belt on AEB, ADP, ADR engines). In this case the tension of a gear belt is correctly adjusted.
If the top edge of the piston is in limits of the B or S size, it is necessary to make repeated adjustment of a tension of a gear belt, and also to check a condition of a gear belt and a tension roller.
If the top end face of the piston settles down to areas B or the size D more than 29 mm, it is necessary to adjust the provision of a tension roller of a gear belt. If the top end face of the piston settles down in the area C, it is necessary to adjust repeatedly the provision of a tension roller of a gear belt, and also to check a condition of a gear belt together with a tension roller. If necessary establish a new gear belt and a tension roller.

ADR engine

PERFORMANCE ORDER
1. Using a 8-millimeter six-sided key, turn a tension roller of a gear belt counterclockwise and take a steel core or a drill from a piston opening. Release a tension roller and remove a six-sided key. Do not rotate a bolt (3), see rice. A tension roller of a gear belt on the ADR engine.
2. Turn a bent shaft of the engine on 2 whole revolutions clockwise and check that tags on pulleys of cranked and distributive shaft were combined with indexes.
3. Check an arrangement of elements of the mechanism of a tension of a gear belt. The size A has to be combined with the top edge of the piston. The size D has to be in limits of 25-29 mm (see rice. The control sizes for check of correctness of a tension of a gear belt on AEB, ADP, ADR engines). In this case the tension of a gear belt is correctly adjusted.
If the top edge of the piston is in limits of the B or S size, it is necessary to make repeated adjustment of a tension of a gear belt, and also to check a condition of a gear belt and a tension roller.
If the top end face of the piston settles down to areas B or the size D more than 29 mm, it is necessary to adjust the provision of a tension roller of a gear belt. If the top end face of the piston settles down in the area C, it is necessary to adjust repeatedly the provision of a tension roller of a gear belt, and also to check a condition of a gear belt together with a tension roller. If necessary establish a new gear belt and a tension roller.

AHL engine

Use of a wrench for rotation of a tension roller of a gear belt on the clown on the AHL engine

1 – adjusting tag,

2 – index

PERFORMANCE ORDER
1. AHL engine. Using a wrench or a special key, HAZET five times turn in both parties from an emphasis against the stop a tension roller of a gear belt on the clown, see rice. Use of a wrench for rotation of a tension roller of a gear belt on the clown on the AHL engine.
2. A wrench turn a tension roller counterclockwise against the stop, at the same time the tension of a gear belt will be maximum.
3. Having released a wrench, weaken a tension of a gear belt and check that the index was combined with an adjusting tag (see rice. Use of a wrench for rotation of a tension roller of a gear belt on the clown on the AHL engine). In this situation tighten a nut of fastening of a tension roller the moment of 20 Nanometers.
4. For a bolt of fastening of a pulley of a bent shaft turn a bent shaft of the engine clockwise on two whole revolutions and check that all adjusting tags were combined with indexes. Check that the adjusting tag of the mechanism of a tension of a gear belt was combined with the index.

All engines


PERFORMANCE ORDER
1. Turn a bent shaft of the engine on two whole revolutions clockwise and check that all adjusting tags were combined with indexes. Otherwise take off a gear belt and make its repeated installation.
2. Establish the top casing of a gear belt.
3. Tighten an element of a tension of a poliklinovy belt the moment of 25 Nanometers.
4. Establish poliklinovy a belt.

ADP engine

PERFORMANCE ORDER
1. Using the special equipment Volkswagen, define the malfunctions which are written down in memory and erase memory contents.
2. Check installation of a corner of an advancing of ignition.

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