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
   - 2.5. Diesel engine 1,9-I-TDI
      2.5.2. Removal and installation of a head of the block of cylinders (diesel engine of 1,9 l)
   + 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






2.5. Diesel engine 1,9-I-TDI

2.5.1. Removal and installation of a gear belt

GENERAL INFORMATION

Drive of the mechanism of gas distribution of the diesel engine

1 – fixing clip;
2 – top casing of a gear belt;
3 – gear belt. Before removal of a gear belt it is necessary to apply on it to the shooter, specifying the direction of a gear belt;
4 – nut, 20 Nanometers;
5 – clown;
6 – tension roller of a gear belt;
7 – bolt, 45 Nanometers;
8 – camshaft pulley;
9 – bolt, 25 Nanometers;
10 – the directing roller;
11 – bolt, 10 Nanometers;
12 – back casing of a gear belt;
13 – fuel Nassau;
14 – arm;
15 – console;
16 – pulley of the fuel pump;
17 – nut, 55 Nanometers;
18 – a pulley of the fuel pump from two sections;
19 – pulley of an intermediate shaft;
20 – pulley of a gear belt of a bent shaft;
21 – a bolt of fastening of a pulley of a bent shaft, 90 Nanometers + to tighten on a corner 90 °;
22 – bolts for fastening of a compound pulley of the fuel pump of high pressure, + to tighten 20 Nanometers on a corner 90 °. At installation it is necessary to use new bolts;
23 – lower casing of a gear belt;
24 – quencher fluctuations/pulley of an auxiliary driving belt. Installation of a pulley is possible only in one situation after combination of openings.

All operations on removal and installation of a gear belt on the diesel engine are similar to operations on removal and installation of a gear belt on four-cylinder petrol engines. Further in this subsection operations which are characteristic only of engines 1,9-I-TDI are stated.

Adaptation necessary for fixing of the camshaft of diesel engines


PERFORMANCE ORDER
1. Using a wrench, turn a tension roller of a poliklinovy belt against the stop counterclockwise and in this provision of a roller remove the top casing of a gear belt.
2. Turn a bent shaft of the engine in the provision of installation of the piston of the first cylinder in the top dead point.
3. For blocking of the camshaft and a pulley of the fuel pump of high pressure in the provision of VMT of the piston of the first cylinder in a step of compression it is necessary to use the special blocking tools, see rice. Adaptation necessary for fixing of the camshaft of diesel engines.

4. Install the tool for blocking in a groove in a camshaft end face.
5. With the instrument of blocking installed in the camshaft turn the camshaft (turning a bent shaft clockwise) so that the instrument of blocking by one party nestled on a surface of a head of the block of cylinders. Using a probe edge, measure a gap between the second end of the instrument of blocking and a head of the block of cylinders. Turn the camshaft slightly back and from two parties between the instrument of blocking and a head of the block of cylinders establish two by probe thickness, an equal half of earlier measured gap.
6. Through an opening in a case of coupling check that VMT tag on a flywheel is combined with the index.

Engines with a monoblock pulley of the fuel pump

PERFORMANCE ORDER
1. Insert a blocking pin through an adjusting opening of a pulley of the fuel pump of high pressure into an opening in an arm behind a pulley of the fuel pump.
2. The pin of blocking can be made independently according to the sizes on rice. Adaptation necessary for fixing of the camshaft of diesel engines.

Engines with a two-section pulley of the fuel pump

PERFORMANCE ORDER
1. Block a pulley of the fuel pump the fixing pin.
2. From a pulley of the fuel pump unscrew bolts (1) and on their place screw in new bolts, having tightened their moment 20 Nanometers. Do not unscrew those the central nut of fastening of a pulley of the fuel pump as at the same time the pulley can be displaced.
3. Weaken a tension of a gear belt, having unscrewed a nut of fastening of a pulley of the mechanism of a tension.
4. Unscrew a bolt and shoot the directing video of a gear belt.
For repeated installation of a gear belt note the direction of its rotation.
5. Weaken a bolt of fastening of a pulley of the camshaft on a half of a turn. Remove a pulley of a gear belt of the camshaft from an adjusting cone of the camshaft, using the drift passed through an opening in a back casing of a gear belt.
6. Establish the directing roller of a gear belt and fix it by a bolt, having tightened its moment 25 Nanometers.
7. Establish a gear belt on a pulley of a bent shaft, a pulley of the fuel pump and a pulley of the camshaft.
8. Establish a gear belt by the flat party on a pulley of an intermediate shaft and a roller of the mechanism of a tension.
9. Remove a pin of blocking of the fuel pump of high pressure.
10. Check that a forward part of a gear belt is hardly tense, and sagging of a belt has to be from a tension mechanism roller.
11. Using a wrench, turn the mechanism of a tension of a gear belt clockwise before combination of tags on a pulley and a nave of the mechanism of a tension.
12. Check a tension of a gear belt, turning it in the center between intermediate and the camshaft. At the same time the belt has to turn only on 90 °.
13. After carrying out adjustment of a tension of a gear belt tighten a tension mechanism lock-nut the moment of 45 Nanometers.
14. Tighten a bolt of fastening of a pulley of the camshaft the required moment.
15. Remove the instrument of blocking of the camshaft.
16. Turn a bent shaft of the engine on two whole revolutions in the normal direction of rotation and repeatedly install the piston of the first cylinder in VMT in a compression step. Check that a pin of a blokirov the niya can be established in установоч Nov an opening of a pulley of the fuel pump of high pressure. Check and, if necessary, repeatedly adjust a tension of a gear belt.
17. Establish casings of a gear belt, a quencher fluctuations/pulley vspomogatelno го a driving belt and a cover of a head of the block of cylinders.
18. Establish poliklinovy an auxiliary belt.
19. Check installation of the moment of injection of the fuel pump of high pressure.
Prevention

On the gear wheel of the fuel pump consisting of two sections after installation of the moment of injection of the fuel pump tighten three bolts of fastening of a gear wheel the moment of 20 Nanometers, and then tighten them on a corner 90 °.