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






2.4.2. Head of the block of cylinders

GENERAL INFORMATION

Head of the block of cylinders of the engine 1,8-I

1 – cover of a maslozalivny mouth,
2 – nut of fastening of a cover of a head of the block of cylinders, 10 Nanometers,
3 – cover of a head of the block of cylinders,
4 – laying. At installation of laying apply a thin film of D2 sealant on its surface.
5 – oil deflector,
6 – head of the block of cylinders,
7 – laying of an inlet collector. At installation it is necessary to use only new laying.
8 – laying of a head of the block of cylinders. At installation it is necessary to use only new laying. After installation of a head of the block of cylinders it is necessary to fill in fresh cooling liquid.
9 – a bolt for fastening of a tension roller, 25 Nanometers,
10 – laying of a final collector. At installation it is necessary to use new laying.
11 – bolts of fastening of a head of the block of cylinders. At installation it is necessary to use only new bolts.
12 – thermofilter,
13 – screw, 25 Nanometers,
14 – screw, 10 Nanometers.

In this subsection operations on removal of a head of the block of cylinders on the four-cylinder petrol engine 1,6-I and 1,8-I are stated.
Prevention

Before removal of a head of the block of cylinders check that all hoses, pipelines and electric sockets are disconnected from a head of the block of cylinders.


You make removal of a head of the block of cylinders on the cold engine. Removal of a head of the block of cylinders is made together with a final collector. At the same time the inlet collector needs to be removed from a head of the block of cylinders previously.

The burned-through or defective laying of a head of the block of cylinders is determined by the following signs:

 – reduction of engine capacity;
 – reduction of level of cooling liquid. At the same time the exhaust pipe comes out white steam;
 – reduction of level of engine oil;
 – existence in engine oil of cooling liquid. At the same time the level of oil increases. In the presence in engine oil of cooling liquid engine oil gains gray color and has vials of foam;
 – availability of engine oil in cooling liquid;
 – intensive allocation of bubbles from cooling liquid;
 – reduction of a compression in two next cylinders of the engine.

Removal

Arrangement of bolts of fastening of an inlet collector on the engine of 125 hp.


Sequence of unscrewing of bolts of fastening of a head of the block of cylinders


PERFORMANCE ORDER
1. Check that the engine cold. Otherwise give time for cooling of the engine.
2. Switch off ignition and remove a weight wire from the accumulator.
3. Merge cooling liquid from the engine cooling system.
4. Mark high-voltage wires in figures and remove high-voltage wires from spark plugs.
5. Clear candles, using a brush, the vacuum cleaner or a stream of compressed air that will exclude hit of dirt in engine cylinders after a vyvinchivaniye of spark plugs. Unscrew spark plugs, using a candle key.
6. Take off pressure in fuel system. For removal of pressure in fuel system wrap up a junction of fuel hoses and, being careful, slowly weaken connection, at the same time gradually pressure in fuel system will decrease.
7. Mark and disconnect the giving and returnable fuel hoses from the fuel distributor. Before disconnect niy hoses weaken a collar and move it on a hose.
8. After a detachment close the ends of pipelines suitable traffic jams.
9. Disconnect electric sockets from fuel nozzles and move the fuel highway down. Mark and disconnect all electric sockets from a head of the block of cylinders.
10. Unscrew the arm supporting an inlet collector about the fuel pressure regulator from a head of the block of cylinders.
11. Unscrew an inlet collector from a head of the block of cylinders, see rice. An arrangement of bolts of fastening of an inlet collector on the engine of 125 hp).
12. Unscrew an inlet collector from two rubber-metal support and move from a head of the block of cylinders aside.
13. Mark and disconnect cooling system hoses from a head of the block of cylinders.
14. Unscrew a reception exhaust pipe with the catalyst from a final collector.
15. Remove the top casing of a gear belt. For a bolt of fastening of a pulley of a bent shaft turn a bent shaft of the engine clockwise before combination of adjusting tags on pulleys from the index ми. At the same time the piston of the first cylinder will be in VMT in a compression step.
16. Using paint or a marker, note the provision of a pulley of a bent shaft in relation to the block of cylinders and turn a bent shaft of the engine on 90 ° clockwise in order that any piston was not in the top dead point.
Before installation of a gear belt establish a bent shaft in situation in which the piston of the first cylinder is in VMT in a compression step.
17. In the sequence shown on rice. The sequence of unscrewing of bolts of fastening of a head of the block of cylinders, gradually and evenly unscrew bolts of fastening of a head of the block of cylinders.
18. Check that all pipelines, hoses and electric sockets are disconnected from a head of the block of cylinders.
19. Remove a head of the block of cylinders from the engine and establish it on two wooden whetstones.
20. Remove laying of a head of the block of cylinders.

Preparation of a head for installation

Place of measurement of height of a head of the block of cylinders

And = 139,2 mm for engines of 1,8 l

And = 132,6 mm for engines of 1,6 l


PERFORMANCE ORDER
1. Remove the plastic caps intended for protection of open valves of a head of the block of cylinders.
2. The interfaced surfaces of a head and the block of cylinders have to be absolutely pure. For their cleaning use a firm plastic or wooden scraper.
Prevention

When cleaning be careful as it is very easy to damage aluminum alloy.


3. Check that the deposit did not get to oil and water canals. It is especially important for the lubrication system as the deposit can block supply of oil to engine components. If necessary clear channels.
4. Check the interfaced surfaces of a head and the block of cylinders for existence of notches, deep scratches and other damages. If defects small, they can be removed with machining.
Prevention

Height of a head of the block of cylinders after machining has to make for the engine 1,8 l = 139,2 mm, and for the engine of 1,6 l = 132,6 mm.


5. Using a metal ruler and the probe, check planeness of the interfaced surfaces.
The deviation from planeness has to be no more than 0,1 mm.
6. Clear openings under bolts in the block of cylinders. Screwing up of a bolt in the opening filled with oil can break off the block because of hydraulic pressure.
Prevention

At installation of a head of the block of cylinders it is necessary to use new bolts of fastening of a head of the block of cylinders and new laying of a head of the block of cylinders.



Installation

Places of a vvinchivaniye of the directing pins of VW-3070 or VW-3450 in the block of cylinders of the engine



The sequence of tightening of bolts of fastening of a head of the block of cylinders on four-cylinder engines


Places of putting D2 sealant before installation of laying of a cover of a head of the block of cylinders

PERFORMANCE ORDER
1. For the correct installation of a head of the block of cylinders and laying of a head of the block of cylinders screw in in an extreme opening of the block of cylinders, the fastenings of a head of the block of cylinders intended for bolts directing VW-3070 pins (for the AHL VW-3450 engine). In the absence of the directing pins they can be made independently for what it is necessary to use two old bolts of fastening of a head of the block of cylinders. Cut off from bolts of a head and instead of them cut through a groove for the screw-driver. After installation of a head of the block of cylinders, using the screw-driver, unscrew the directing pins, see rice. Places of a vvinchivaniye of the directing pins of VW-3070 or VW-3450 in the block of cylinders of the engine.
Prevention

At installation of a head of the block of cylinders it is necessary to use new laying. Take laying from tight packing just before installation on the block of cylinders.


2. Check that new laying of a head of the block of cylinders has the same type, as the original and that marking of TORAHS or OBEN is directed up. Arrange new laying of a head of the block of cylinders on the surface of the block of cylinders on the directing pins. Check that openings were correctly combined with channels of the cooling system and lubricant.
3. Being careful, install a head on the block of cylinders.
4. Insert and tighten manually 8 bolts with washers of fastening of a head of the block of cylinders.
5. The screw-driver unscrew two directing pins and on their place screw in two bolts of fastening of a head of the block of cylinders.
6. Gradually in the sequence shown on rice. The sequence of tightening of bolts of fastening of a head of the block of cylinders on four-cylinder engines, tighten bolts of fastening of a head of the block of cylinders in several stages.
Prevention

Do not tighten bolts of fastening of a head of the block of cylinders on the heated-up engine. At installation of a new head of the block of cylinders with the camshaft after installation of a head of the block of cylinders grease with a thin layer of lubricant the interfaced surfaces of hydraulic pushers and cams of the camshaft.


7. Turn cranked and distribute telny shaft in such situation that they corresponded to installation of the piston of the first cylinder in VMT in a compression step.
8. Before installation of internal laying of a cover of a head of the block of cylinders grease the surfaces interfaced to laying, a thin layer of D2 sealant (see rice. Places of putting D2 sealant before installation of laying of a cover of a head of the block of cylinders). Establish laying of a cover of a head of the block of cylinders.
9. Establish a cover of a head of the block of cylinders and gradually and consistently crosswise tighten nuts of fastening of a cover.
10. Establish a gear belt on a pulley of the camshaft and adjust its tension.
11. Screw a reception exhaust pipe.
12. Establish an inlet collector with new laying on a head of the block of cylinders and fix it by bolts, having tightened them the required moment.
13. Screw the lower part of an inlet collector on rubber-metal support.
14. Establish an arm between a head of the block of cylinders and an inlet collector.
15. Connect the giving and returnable fuel-supply lines to the fuel highway.
16. According to earlier made marking connect all electric sockets to a head of the block of cylinders.
17. Establish casings of a gear belt.
18. Check that all hoses, pipelines and electric sockets are connected according to earlier made marking.
19. Check the level of engine oil and, if necessary, bring it to norm. If in old laying of a head of the block of cylinders there were defects, replace engine oil.
20. Fill in cooling liquid in the cooling system.
21. Fill in cooling liquid in the cooling system.
22. Connect a weight wire to the accumulator.
23. Start the engine and warm up it up to the working temperature. Switch off the engine and check the level of engine oil and cooling liquid, and also tightness of all connections.