DIY Volkswagen Passat B3 engine repair

The RP engine was installed on cars:

Volkswagen Passat B3 / Volkswagen Passat B3 (312) 1988 - 1994
Volkswagen Passat Variant B3 / Volkswagen Passat Variant B3 (315) 1988 - 1994

Volkswagen Golf 2 (191, 193) 1984 - 1988
Volkswagen Jetta 2 / Volkswagen Jetta 2 (165, 167) 1984 - 1988
Volkswagen Golf 2 / Volkswagen Golf 2 (1G1) 1989 - 1992
Volkswagen Jetta 2 / Volkswagen Jetta 2 (1G2) 1989 - 1992

SEAT Toledo (1L)

Good day to everyone, I’ve actually matured a little to somehow describe the whole procedure that I carried out in September.
symptoms: compression disappeared, well, if not completely, then it dropped a lot after the engine had to drive almost 300 km without oil, and then it also boiled without a water pump in addition. I felt very sorry for him, and it was decided to open it and see what was inside him.
some spare parts were bought in advance.
vulture rings
connecting rod / main bearings
oil seals (all 4 pieces)
cylinder head gasket, valve cover, oil seal covers, collectors, pallet
clutch assembly
starter bendix, bendix fitulka (for gearbox)
gearbox oil seals
gearbox oil
engine oil
filter
Coolant
The timing belt and roller, it was decided to leave those that were.

I made a small bar on the ceiling from 16 rebar and bought 2 1-ton winches.

so, away we go.
we drive the car into the garage and forget that we have it.

I went to the second, since I had it.

disconnect the battery and remove it further away. we remove the wires to the generator, high-voltage, disconnect all the chips, unscrew the clutch cylinder, vacuum tubes, air ducts and all the waste.

... small things are done, now about the capital.
... the first thing we need is the bumper. we tear off the fenders from it, remove the grill, unscrew the 4 bolts securing the stiffener and pull it forward.

after that we need to remove the headlights and all the entrails. since I do not have any air ducts there, then in order not to bother, I just took off my whole face all over with the ski. 4 bolts under the hood and 4 somewhere under the headlights, you will find.
there she is.

now. it is now that I propose to drain the liquids, you see, it's much more convenient this way

we substitute a bucket or a basin, remove the hoses and drain everything to the last drop so as not to stain the already dirty floor. the thermostat will have to be removed in order to drain everything from the unit. remove all pipes. then it is good to drain the oil.

so that I could get closer, I picked up the eye with a winch and removed the front beam (I don't know how exactly).

we lower the engine a little, take 2 crowbars and remove the brackets of the intake pipe. careful, they can sometimes fly.

it remains to unscrew 2 pillows and the engine from the gearbox on the floor.

we are sorting everything out on the sly. before. about this state.

block. the distributor of course turned sour.

and the piston state. although there was a breakthrough of gases, the oil rings did not lie down, but the compression rings probably lost their elasticity. set to turn off in kerosene.

to my great regret, the report came out only on removal and a little on disassembly. this is all due to the fact that I was only doing the repairs alone, no one helped, and there was practically no time to take pictures, and when I began to collect, it was not at all up to that.

measurements: the gap in the locks of the rings is 0.2-0.4 according to the book - it fully fits into the standard. The output in the cylinders for the gap in the lock is maximum 0.05, the new rings practically do not change the situation, at least you will not feel with a probe.
axial backlash to / in is not observed. There was no fascist wire for measuring the clearance in the bearings, so I hammered it. like everything is ok.
the condition of the liners can be seen in the photo - a slight starvation without oil is observed.
the condition of the rings is not very good. new more elastic.
In principle, I’m happy that I climbed there, but I’m not happy that everything was so good there that I’m climbing in vain.
in general, that is all for now, I can add.
if you have any questions - ask, I will be happy to answer.

If you didn’t find information on your car, look at the cars built on the platform of your car.
With a high degree of probability, the information on repair and maintenance will be suitable for your car as well.

All documentation in English is marked (eng.), In German - (ger.)
For everyone who has a Volkswagen, hands and the desire to do something with them.
For all who has Volkswagen, hands and desire to do something by them.

Here are photo reports on repair and detailed documentation on cars:

Volkswagen Passat B3 / Volkswagen Passat B3 (model code: 312) 1988 - 1994
Volkswagen Passat Variant B3 1988 - 1994

Overhaul of the 2E engine on the Volkswagen Passat B3 (rus.) Photo report
The 2E engine was installed on cars: VW Passat B3 (31), VW Passat B4 (3A), VW Golf 3 / Vento (1H), VW Corrado (509), SEAT Ibiza / Cordoba (6K), SEAT Toledo (1L).

Repair of the cylinder head of the engine 2E (rus.) Photo report.
The original reasons for cylinder head repair were:
· The sound "chirping" when you press the gas pedal
· Lagging reactions of the lambda probe.
High fuel consumption
Unstable operation of a cold engine
· Poor dynamics.

Engine crankcase ventilation valve 2E, inspection, opening, repair (rus.) Photo report.
Replacing a torn diaphragm, original and non-original crankcase ventilation valves.

Replacing the intermediate shaft liners on the RP engine, without removing the engine (rus.) Photo report
Much has been written about the flashing light and oil pressure buzzer already, I also had this problem. The oil receiver mesh was clean, the pump was working. Replacing the main and connecting rod bearings practically did not help. Reading the forum my.housecope.com/wp-content/uploads/ext/3141 prompted the idea of ​​the need to check the intermediate shaft liners - the check showed play of the intermediate shaft in the rear liner

Replacement of cylinder head gaskets, RP engine for VW Passat B3 (rus.) Photo report
All procedures are described in detail in books, and on the website my.housecope.com/wp-content/uploads/ext/3141, I will note only a few points that seem important to me.

Overhaul of the RP engine on Volkswagen Passat B3 (rus.) Photo report
Symptoms: compression has disappeared, well, if not completely, then it has greatly decreased after the engine had to drive about 300 km almost without oil, and then also boil without a water pump in addition. I felt very sorry for him, and it was decided to open it and see what was inside him.

Bulkhead RP engine for Volkswagen Passat B3 mileage 350,000 km (rus.) Photo report
The bulkhead of the engine, we are at least the third owners, before us the engine was killed, we understood by the state of the drained oil resembling fuel oil. The engine worked with vibration at idle, the oil pressure warning was triggered in the summer, increased oil burn, reduced power.

The flange on the engine burst. Cylinder head repair on VW Passat B3 with RP engine (rus.) Photo report.
The culprit for removing the cylinder head is the flange that stands on the bottom of the cylinder head. I was driving to work at night and suddenly the buzzer sounded and the oil pressure light came on, immediately to the side of the road and turned off the engine, I raise the hood, there is a bathhouse, I looked at the temperature indicator - 80 degrees, I realized that the antifreeze flew out so quickly that the tidy did not have time to react, in general the flange has burst.

Overhaul of the KR engine on VW Passat B3 GT (rus.) Photo report.
Well, finally, he waited in the wings, because it was no longer possible to go on like this. Oil consumption over the last 10 thousand km increased to 1l / 200 km. (which is comparable to the price of gasoline). A thick smoke screen comes out of the muffler during active driving.

Replacing the drive belt on the AAA VR6 2.8 engine (rus.) Photo report
It's time for a little service. It is recommended to change the drive belt every 120 thousand, plus the fact that it is one for everything on this engine. Recently, the belt began to whistle, and why squeeze the maximum, in general, the replacement procedure is described in this report.

Repair of diesel engines VW Passat B3 / B4 (1Y, 1Z, RA, SB, AAZ) (rus.) The manual covers diesel engines: RA 1.6l. 59 kW (80 HP) Turbo SB 1.6L 59 kW (80 HP) Turbo 1Y 1.9L 47 kW (64 HP) 1Z 1.9L 66kW (90 HP) Turbo AAZ 1.9L 55 kW (75 hp)

Technical characteristics and data for adjustments of vehicle systems:
engine and cooling system, ignition, fuel system, suspension, liquid volumes, etc.

Information on the repair of engines VAG / Engines repair
This engine repair information applies to all VAG vehicles. In order to quickly find the documentation for your engine, simply press Ctrl-F on the keyboard and type the letters of your engine. For example: 2E or BSE (English only!)

Cooling, heating, ventilation and air conditioning system
(Cooling, Heating, Air Conditioning and Climate Control Systems)

Automotive climate control systems (rus.)Device and principle of operation. Self-study program. Climate control on a car, The principle of operation of the air conditioner, Refrigerant, Air conditioning device, System regulation, Turning on the cooling fan, Temperature regulation, Service.

Climatronic - Construction and Function (eng.) Design and principle of operation. Self-study program.

Proximity Throttle Position Sensor Installation, Digifant, Engine 2E (rus.) Photo report
It's time to change the throttle position sensor (TPS). Symptoms: instability of idling and dips until the engine stops. In the vastness of the network there is a lot of information about contactless sensors, there was a desire to introduce a modern component into the body of an adult car.

Modernization of the DMRV on the 2E engine for the contactless DPDZ 3102.3855 (rus.) Photo report
All 2E engine owners are aware of this problem. When the car gasses itself, then immediately the revolutions fail, sometimes they return to their place, and sometimes the car stalls, and sometimes even stalls on the move. It was decided to start reanimating the injection.

Replacing a seven-contact TPS with a four-contact one, experience in replacing TPS (rus.) Photo report
Faced the problem of the throttle position sensor (TPS). I had a seven-pin one, tk. there used to be an automatic transmission. I went to the market to look - there were no such ones, there were only four-pin ones. Then I walked through the Internet and found out that these are not for sale at all. How to be? I began to study this critical part of the mono injection.

Injection and ignition systems
This information on injection systems applies to all VW, Skoda, SEAT, Audi vehicles.
General information on ignition systems
Suitable for many cars VW, Skoda, SEAT, Audi

Repair of a fuel pump for the AAM engine (rus.) Photo report.
It all started with the fact that the fuel pump jammed. I went through and started assembling, the photos of the removal turned out to be not very successful, therefore I describe only the assembly process, the disassembly is not very different.

General information on fuel systems
Suitable for many cars VW, Skoda, SEAT, Audi

Replacement of protective covers (anthers) CV joints for VW Passat 1994, engine 2E (rus.) Photo report.
Inspection of the car's running gear revealed wear of protective covers (anthers) of the inner and outer hinges, the left drive shaft. The covers are covered with small cracks, and several tears have formed, grease is released. Replacement of anthers is required.

Removal and disassembly of the right drive shaft on the Volkswagen Passat B3-B4 (rus.) Photo report
When completely disassembling and flushing the hinges, certain wear and tear of the constituent parts may be revealed and their complete replacement may be required. In this case, it is more expedient to purchase a new hinge, complete with a new protective cover, clamps and grease.

Disassembly of the inner and outer CV joints (rus.) Photo report.
When replacing the boot, if dirt has got into the grease, the CV joint must be disassembled, rinsed from the old grease, then assembled and filled with new grease. This work is not at all difficult, but it requires accuracy and attention.

Replacing the boots and rear shock absorbers Volkswagen Passat B3 Variant (rus.) Photo report.
I decided to write a report on replacing the anthers of the rear shock absorbers, in general, that can be said for replacing the ammo with a bulkhead.At first I only wanted to change the anthers, but then the rear springs were confused (they were painfully sagging).

General Suspension Information
Suitable for many cars VW, Skoda, SEAT, Audi

Repair of the ABS pump Teves Mark 2 (ABS Teves 02, Teves Mk II, ATE Mk2) (rus.) Photo report.
Anti-lock braking system ABS Teves 02 / ABS ATE 02 was installed on cars:
Volkswagen Passat B3 / Volkswagen Passat B3 (model code: 312)
Volkswagen Passat Variant B3 / Volkswagen Passat Variant B3 (model code: 315)

Anti-lock braking device "Teves" with electronic differential lock (EDS) (rus.) Design and principle of operation. Self Study Program 117 VW / Audi. This system was installed on VW Golf II / Jetta II, VW Passat B3 / B4, VW Corrado, etc.
Contents: Differential, Mechanical differential lock, Electronic differential lock (EDS), Traction force diagram, General structure of the EDS system, Hydraulic unit with EDS valve block, ABS work with EDS, Control unit with self-diagnosis function, Circuit diagram.
Description of the whole brake system, brake pad replacement, ABS, etc. 5 Mb

Removing and replacing the power steering pump on VW Passat B3-B4 (rus.) Photo report
The power steering pump “snotty” very much, and therefore, it was decided to change it to a new one. A ZF pump and 1 liter of power steering fluid were purchased.

Power steering pump bulkhead for Volkswagen Passat B3, 1.8 RP engine, 1990 (rus.) Photo report
If the power steering pump is noisy, but works, it is possible to restore it by replacing the bearing. It is also best to replace the oil seal and all O-rings immediately. My lateral play in the bearing was somewhere around 1-1.5 mm. The pump was noisy, but it didn't flow. The result after the bulkhead is silence in the cabin and saved 4-5 thousand rubles.

Power steering pump repair, pump knocking, steering rack TWR (rus.) Photo report
The car is equipped with a TRW steering rack with a 1H0 422 155C pump made in the USA. There was not a strong, but audible, knock in the power steering pump. At the same time, this did not affect the operation of the steering in any way. I came to the conclusion that most likely died, the pump bearing. Since the pumps are somewhat different from each other in design, in particular with oil seals, I decided to first disassemble the pump and see what was in it, and then purchase spare parts for repair.

Dismantling the power steering (GUR) for the Volkswagen Passat B3 engine JR 1.6 (rus.) Photo report
It all started with a somewhat strange sound coming from the power steering under load, when turning the steering wheel. There was a suspicion of a belt, but the tension seemed to be normal. Then I found out that everything around the power steering tank is covered in oil - I open the lid - and there is solid foam. This is due to air leaks either directly in the pump (bearing is broken, oil seal is torn or worn out), or air leaks in the supply line. It was decided to sort out the power steering pump. After reading the forum my.housecope.com/wp-content/uploads/ext/3141 and having gathered a lot of useful information, I decided to share my experience as well.

Power steering bulkhead for Volkswagen Passat B3 (rus.) Photo report
So my time has come to sort out the power steering on my Passat, the reasons for the bulkhead: the oil seal dripped, the bearing noise, the fluid in the tank began to foam, the steering wheel became tight. I offer a small photo report.

Complete analysis of the power steering pump for the Volkswagen Passat B3-B4 (rus.) Photo report
It is not so difficult to sort out the power steering pump, disassembled it in half an hour, drove it for a new bearing and assembled it in an hour. Well, plus the time for removal - installation and fluid change. Analysis showed that the valve piston was jammed in a slightly open state (see photo), but it was jammed because a step appeared on the valve wall with a protruding edge on which the piston clung. Details in the report.

Removing the steering shaft on the Volkswagen Passat B3 (rus.) Photo report and horror story at night
I changed the contact group of the ignition lock here, I wanted to do without removing the shaft, from above, but it did not work, I had to remove the shaft. Well, at the same time I took a picture, albeit on the phone, the result is this photo report.

Replacing the steering rack with a Volkswagen Passat B3 without power steering (rus.) Photo report
For work, you will need keys for 13,17,19,22 and a gas wrench or its equivalent, a pair of plastic ties for securing the covers.

Replacing the steering gimbal boot for VW Passat B3-B4 (rus.) Photo report
Changing the steering rod, I noticed the torn boot of the steering cardan and decided to replace it. If this boot is full of holes, then dirt and water will begin to kill the steering rack, and, in addition, water gets into the cabin.

Replacing the steering rod for VW Passat B3-B4 (rus.) Photo report
I decided to share my experience of replacing the tie rod, tk. a backlash was found in the tip and the ball mechanism of the thrust near the rail. At the end of the report, samples of homemade special keys are provided to make the job easier.

The first Volkswagen Passat B3 came off the assembly line in the spring of 1988 and almost immediately became a hit of sales - customers liked the spacious interior with excellent finishing materials, a huge trunk and a simple, but at the same time very attractive design. In addition to decorative changes, the Volkswagen Passat B3 has also undergone technical changes: the wheelbase has become longer, the rear suspension design has changed, and new electrical appliances have appeared. The power unit has also undergone changes: if in previous versions of the trade wind the engine was located longitudinally, then in the top three it (by the way, the power of the most voluminous of them - V6 was 174 hp) received a transverse arrangement. In addition, variants with mono injection appeared in the engine lineup: such cars were somewhat less dynamic, but this was fully compensated for by the low fuel consumption and the absence of problems with the carburetor setting.

In general, the car turned out to be as hardy and reliable as its predecessors: only the steering frame failed, which failed after about 50: 100 thousand kilometers, and the suspension, which did not cope very well with a bad road. However, for the inhabitants of Western Europe, the latter problem was irrelevant.

In 1993, the production of the Volkswagen Passat B3 was discontinued. This undoubtedly magnificent car was replaced by the Volkswagen Passat B4: however, today on European, and even more so on Russian streets, you can find these cars, some of which have traveled more than a million kilometers.

The production of fourth-generation trade winds began in 1994. Outwardly, the car was not very different from the Volkswagen Passat B3: the headlights became a little narrower, and instead of a closed "front end" there was a radiator grill - that's all. The biggest changes took place in the control and safety systems: Volkswagen Passat B4 was equipped with disc brakes, protective beams in the doors, front and side airbags, as well as an ABS system and a safety steering column.

How to return life to a far from new car? How to improve its characteristics with your own hands? Finally, how to restore your dream car - Volkswagen Passat B3?
You will find answers to these and other questions in this video.
Happy viewing,
Best regards, Aleksandr Ignatovich.

oh how many jambs can be seen in the photo, but it saves that with your own hands. If interested, I can explain. I myself am 92 years old. 2E motor. Imported in 95, and we still ride))))) Grodno, my homeland)))

Yes, I did everything perfectly, but the cladding here constantly needs to be removed from the handles, the external handles quickly break down

Respect, golden hands. like

What kind of music is this? What is the Middle Ages in modern processing? Great! Tell me what it's called. Thank you.

No need to know the handle of the lining of the lock

auto class. tell me how to make electric lifts from which car will fit!

Instead of that shiny crap, foam rubber fits well and costs less, and it's not even that it is suitable and cheaper, but that the foam rubber better insulates squeaks and everything like that than this bitoplast or whatever it is.

Nice car, and how much would you need to invest to make it look good?

Volkswagen Passat B3 / B4 with petrol engines: RF / 1F / EZ / ABN / AEK / AFT 1.6 l (1595 cm³) 72-75-100 hp / 53-55-74 kW, AAM / ABS / ADZ / RP / PF / PB / PG / KR 1.8 l (1781 cm³) 75-90-107-112-136-160 HP / 55-66-79-82-100-118 kW, 2E / ADY / AGG / 9A / ABF 2.0 l (1984 cc) 115-136-150 hp / 85-100-110 kW, AAA 2.8 l (2792 cc) 174 hp / 128 kW and ABV 2.9 l (2861 cc) 184 l .s. / 135 kW; Instructions for use, maintenance and repair.Advice on the choice of spare parts, full technical specifications, features of operation and repair, troubleshooting on the way, more than 600 original photographs, wiring diagrams, control dimensions of the body. Volkswagen Passat station wagon (variant), sedan (limousine) model B3 and B4 from 1988 to 1996

Video VW Passat B3 / B4 mono injection tuning and replacement of the front wheel hub and bearing (Volkswagen Passat 88-96)