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






2.4.4. Repair of a head of the block of cylinders

Dismantling

PERFORMANCE ORDER
1. Remove a head of the block of cylinders.
2. Unscrew and remove inlet and final collectors.
3. Remove camshafts and hydraulic pushers.

4. Squeeze in the order of a spring of valves special adaptation and take crackers of fastening of a persistent top plate of a spring.
5. Remove the top plate.
6. Remove the top and lower springs of the valve, paying attention not to damage a valve core
7. Take the valve from a head of the block of cylinders from the combustion chamber.
8. Remove maslootrazhatelny caps.
9. Remove the lower plate of a valvate spring.
10. Place sets of details of valves in plastic bags and mark them for installation on the places.

Cleaning and check

PERFORMANCE ORDER
1. Clear traces of old laying and sealant from a head of the block of cylinders.
2. Clear a deposit from the combustion chamber and cylinders, then wash up a head of the block of cylinders the corresponding solvent.
3. Clear channels in a head of the block of cylinders with use of a wire brush.
4. Carefully check a head for existence of cracks and other damages. In the presence of cracks on a head, the head is subject to replacement.
5. Using a metal ruler and the probe, check planeness of the interfaced head surface.
6. Saddles of valves with wear tracks or a podgoraniye need to be processed with obligatory preservation of corners and sizes of a facet. If the saddle of the valve needs to be processed, determine the maximum quantity of metal which can be removed. If the excessive amount of metal is removed, hydraulic pushers will not be able correctly to work.
7. Insert the valve into a guide and press it to a valve saddle.
8. Measure distance from the end of a rod of the valve to the top surface of a head of the block of cylinders. The minimum admissible distance of 33,8 mm for inlet valves and 34,1 mm for final valves. At excessive wear of a saddle of the valve processing is inadmissible and the head of the block of cylinders needs to be replaced.
9. After any processing of saddles of valves it is necessary to make their grinding in.
10. Check internal diameters of the directing valves. If values exceed the most admissible size, then it is necessary to replace guides of valves in special repair shop.
Prevention

Replacement of a guide demands also regrinding of a nest of the corresponding valve.


11. Check a plate of each valve for pointed corrosion, burned, cracks and the general wear.
12. If the condition of the valve is satisfactory, then measure diameter of a core of the valve, in several points using a micrometer. Any essential distinction in the obtained data of measurement of a core of the valve indicates wear of a core. In that case the valve is subject to replacement.
13. If valve are in satisfy a telny state, then it is necessary to make their grinding in. Grinding in of valves needs to be made only with use of fine-grained polishing paste. Grease a surface of a saddle of the valve with a small amount of paste and install the valve in the corresponding saddle. Densely press to a plate of the valve a rubber sucker and rotate the valve in one or other party.
14. After the end of process of grinding in carefully clear all details of dirt and paste. Check a saddle and a plate of the valve. The continuous opaque ring on both details which specifies valve facet width has to be visible.
15. Check valve springs for wear and stratification, and also measure their length in a free state. If there is an opportunity, compare each of the existing springs to a new spring.
16. Establish springs on a flat horizontal surface and check their deviations from horizontal position. If at least one of springs is damaged, then replace completely all springs in a set.
17. Check a condition of crackers of the valve, and also an installation site of crackers on the valve. With any defects the damaged details have to be replaced. Maslootrazhatelny caps are subject to replacement every time after their removal.
18. Check details of the valvate mechanism and hydraulic pushers.

Assembly

PERFORMANCE ORDER
1. Before assembly of a head of the block of cylinders carefully clear it.
2. Grease cores of valves and their guides with pure engine oil and insert valves into a head.
3. Install the lower plate of a valvate spring.
4. Wipe the top part of a core of the valve from engine oil.
5. Install the plastic plug or wrap up flutes for crackers in the top part of the valve a piece of an adhesive tape for protection from damage of working edges of maslootrazhatelny caps at their installation.
6. Oil fresh engine a maslootrazhatelny cap and, using a tubular mandrel, establish on a valve guide.
7. Remove an adhesive tape from a valve core.
8. Press into place a maslootrazhatelny cap.
9. Establish springs and the top plate of springs.
10. Supporting the valve in a closed position, special I eat the devices squeeze a valve spring, and establish crackers. Slowly remove the device for compression of a spring of the valve.
Repeat operation on the remained valves.
11. In conclusion strike the end of each core of the valve with the plastic or copper hammer that the valve a neznachitel but was slightly opened, and all elements of the valve fell into place.