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
   + 2.6. Drive of the gas-distributing mechanism
   - 2.7. Engine 2,8-I-V6
      2.7.2. Removal and installation of a head of the block of cylinders
      2.7.3. Check of a compression in engine cylinders
      2.7.4. Check of the engine by means of the vacuum gage
      2.7.5. Removal and installation of a poliklinovy belt
      2.7.6. General recommendations about engine oils
      2.7.7. Circulation of engine oil
      2.7.8. Check of pressure of oil and sensor of pressure of oil
      2.7.9. Removal and installation of the oil pallet
      2.7.10. Start of the engine after capital repairs
      2.7.11. The main malfunctions at start of the engine
      2.7.12. Main malfunctions of the lubrication system
+ 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






2.7.9. Removal and installation of the oil pallet

GENERAL INFORMATION

Elements of the lubrication system of four - and five-cylinder engines, except the engine 1,6-I with the AHL index

1 – sealing ring. In case of damage use a new sealing ring;
2 – cover;
3 – the probe for measurement of level of engine oil;
4 – probe clamp. At pumping out of oil from the oil pallet it is necessary to remove;
5 – sealing ring. At installation it is necessary to use a new sealing ring;
6 – pipeline of supply of oil, 20 Nanometers. Supply of oil to a turbocharger only on AEB engines;
7 – adapter. In the presence of damages it is necessary  to use a new adapter;
8 – sealing ring.  In the presence of damages it is necessary to use a new sealing ring;
9 – bolt, 25 Nanometers;
10 – holder of an oil filter;
11 – sensor of pressure of oil, 25 Nanometers.  At violation of tightness of installation of the sensor of pressure of oil it is necessary to use a new sealing ring;
12 – sealing ring. In the presence of damages it is necessary to use a new sealing ring;
13 – oil heat exchanger. At installation of the heat exchanger of oil the surface interfaced to a flange needs to be greased with a thin layer of sealant, AMV-18810002;
14 – nut, 25 Nanometers;
15 – oil filter;
16 – cover;
17 – gear wheel of the drive of the oil pump;
18 – rotors of the oil pump;
19 – a cover of the oil pump with the safety valve of pressure of oil. The safety valve of pressure of oil opens with a pressure of 5,7-6,7 bars;
20 – bolt, 10 Nanometers;
21 – bolt, 25 Nanometers;
22 – oil deflector;
23 – bolt. For unscrewing of bolts of fastening of the oil pallet it is necessary to use a hinged key;
24 – masloslivny stopper;
25 – sealing ring;
26 – oil pallet. At installation of the oil pallet it is necessary to clear the interfaced surface of the oil pallet of laying traces;
27 – laying of the oil pallet. At installation it is necessary to use new laying of the oil pallet. Before installation of laying apply a D2 sealant layer on junctions of a sealing flange and the block of cylinders.
On engines 1,6-I with the AHL code and on five-cylinder engines laying of the oil pallet is absent, and instead of it the liquid VW-D176404A2 silicone sealant is used;
28 – laying. In the presence of damages it is necessary to use new laying.
29 – oil return pipeline,
Return of oil from a turbocharger only on AEB engines;
30 – bolt, 10 Nanometers;
31 – tube of a maslozabornik. Before installation by a tube of a maslozabornik it is necessary to clear the mesh filter;
32 – bolt, 10 Nanometers;
33 – sealing ring;
34 – perepuskny valve, 27 Nanometers. Pressure of opening of the valve of 2,5-3,2 bars;
35 – nozzles for dispersion of oil on the lower part of the engine;
36 – locking valve of the pipeline of return of oil, 50 Nanometers.

FOUR - AND FIVE-CYLINDER ENGINES

For removal of the oil pallet it is necessary to weaken fastening of the power unit and, using the load-lifting mechanism, to raise the power unit.

Removal

PERFORMANCE ORDER
1. Remove the lower mudguard of the engine.
2. Merge engine oil for what weaken a masloslivny stopper approximately on a half of a turn. Place a container for discharge of oil under a drain stopper and unscrew a stopper completely. If it is necessary, press a stopper when you unscrew that oil did not proceed prematurely. When oil completely flows down, screw in into place a masloslivny stopper (see the table "Moments of Tightening of a Masloslivny Stopper").
3. Take off poliklinovy a belt.
4. On cars with the air conditioning system, unscrew a roller of the mechanism of a tension and take off a conditioner compressor drive belt.
5. To merge cooling liquid (to remove the lower hose of a radiator).
6. Using a steel core (2) with a diameter of 5 mm, record from a provorachiv a niya a pulley of the fan of a radiator and from a reverse side unscrew a bolt of fastening of the fan of a radiator. Remove the radiator fan.
7. Unscrew an engine arm. The arm on the removed engine is shown.
8. Disunite connection of wires, release clamps and remove a starter wire.
9. In the presence unscrew bolts (2 and 5) and remove the arm located between the oil pallet and an inlet collector. Do not unscrew the bolts 1, 3 and 4 fixing the second arm.
10. Unscrew the top part of the left support of the power unit.
11. Using a marker, note an arrangement of threaded connections 1, the fixing plugs 2 on support of the power unit.
12. Unscrew the lower fastening of both support of the power unit.
13. Hook slings of the load-lifting mechanism on the power unit and raise so that the lower part it only concerned a forward wall of a body.
14. Remove the left support of the power unit.
15. Support by a jack through wooden whetstone an arm of a support of the power unit in order that it remained on the place after unscrewing of bolts.
16. Unscrew nuts of 1 fastening of support of the power unit in the lower left and right parts. First of all unscrew from an arm bolts 2 and 3 from the left and right side, then bolts 4 from the left and right side.
17. Unscrew the lower bolt of fastening of the right support of the transmission 2 on several turns, then unscrew a forward bolt 1.
18. Unscrew a nut as far as that it was at the level of a bolt end face.
19. Being careful, a jack lower an arm of the power unit. At the same time not to displace an axis, lower and release an arm from the forward party.
20. Take a jack and turn the stabilizer down.
21. Unscrew bolts and remove the oil pallet from the block of cylinders.

Installation

ENGINES 1,6-I WITH THE AHL CODE AND FIVE-CYLINDER ENGINES

PERFORMANCE ORDER
1. Using a plastic or wooden scraper, clear the surface of the block of cylinders interfaced to the oil pallet of old laying.
2. Using the rotating metal brush got on an electric sverlilka, purify sealant.
3. Apply a layer of VW-D176404A2 sealant with a diameter of 3 mm on the interfaced surface of the oil pallet.

Prevention

After drawing a layer of sealant on the oil pallet installation of the oil pallet needs to be made within 5 minutes. Time of drying of sealant makes 30 minutes and only after that it is possible to fill in engine oil in the engine.

The layer of sealant has to be only with a diameter of 3 mm as in case of a thick layer of sealant surplus of sealant will get to oil and can block the mesh filter.



FOUR-CYLINDER ENGINES, EXCEPT THE ENGINE 1,6-I WITH THE AHL CODE

PERFORMANCE ORDER
1. Using a wooden or plastic scraper, clear the interfaced surfaces of the oil pallet and the block of cylinders of sealant.
2. Before installation of laying apply a thin film of D2 sealant in a junction of a sealing cover and the block of cylinders of the engine.
3. Establish new laying without sealant use.

ALL ENGINES

Arrangement of bolts of fastening of a support of the power unit

PERFORMANCE ORDER
1. Evenly and gradually tighten bolts of fastening of the oil pallet. Do not draw bolts, otherwise laying of the oil pallet will be deformed.
2. Lower the engine and remove slings of the load-lifting mechanism.
3. A jack through wooden whetstone lift an arm of the engine and from the left and right side screw in bolts and tighten them the required moment.
Prevention

For fastening of an arm of the engine it is necessary to use new bolts.


4. Screw fastening of the support compensating torque of the engine. Tighten all bolts the moment of 25 Nanometers.
5. Tighten M10 bolts fixing a transmission support the moment of 40 Nanometers and a transmission support arm (M8 bolts) the moment of 25 Nanometers.
6. Tighten bolts of fastening of the arm located between the oil pallet and an inlet collector the moment of 25 Nanometers.
7. Arrange a starter wire through an arm on the oil pallet, close the holder of a wire and fix it by new collars.
8. Establish a driving belt and the fan of a radiator.

CARS WITH THE AIR CONDITIONING SYSTEM

PERFORMANCE ORDER
1. Fix a tension roller of a belt of the drive of the compressor of the conditioner.
2. Establish a conditioner compressor drive belt.
3. Establish a lock arm.
4. Lower the car.
5. Fill in engine oil in the engine. Make a control trip and check tightness of installation of the oil pallet. If necessary tighten slightly bolts of fastening of the oil pallet.