DIY Volkswagen Passat V3 engine repair

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.

Video (click to play).

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 the place, and sometimes the car stalls, and sometimes even stalls on the move. It was decided to start reanimating the injection.

Replacing a seven-pin TPS with a four-pin 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 about 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 jammed because a step appeared on the valve wall with a protruding edge on which the piston was clinging. 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 steering 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 - buyers 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 - the V6 was 174 hp) received a transverse arrangement. In addition, variants with mono injection appeared in the engine line: such cars were somewhat less dynamic, but this was fully compensated for by the low fuel consumption and the absence of problems with setting the carburetor.

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.

Volkswagen Passat B3 is a popular car that has earned the best reviews from many experienced drivers for its reliability, ease of maintenance, long service life and spaciousness. Bribing with its durable, corrosion-resistant body and reliable engine, despite its age, it remains a frequent visitor on the roads. Naturally, even such a high-quality car is not complete without various breakdowns.

Engine problems can be very diverse, depending on various reasons. So, floating values ​​of engine speed, when the speed starts to decrease while driving, may be associated with malfunctions in the multi-injection. It also happens that, due to malfunctions of the single injection, the Passat b3 does not start at all. A further article will describe how to set up the Passat v3 mono injection.

The computer diagnostics that everyone is used to now is completely useless when it comes to older cars. Fortunately, the diagnostics of the VW Passat B3 mono injection does not apply to tasks that require special education. Troubleshooting a single injection Volkswagen Passat b3 is within the power of any competent owner.

One of the common malfunctions of a single injection Volkswagen Passat b3 is a leakage of the gasket, in which the distribution of fuel becomes uneven. Such a breakdown can be cured quite simply - by replacing the gasket. Another common malfunction is a violation of the connection of the wires located under the yellow sensor on mono injection.The sensor can be easily removed for diagnostics. Do not forget about the rest of the wires - checking their integrity can solve the problem.

Cleaning the single injection Passat b3 will help to cope if carbon deposits have formed on the throttle valve or it is clogged. The question: "how to clean the Passat B3 mono injection?", Has a very simple answer - to disassemble and clean. Fortunately, this unit has a fairly simple design and is easy to maintain.

The distributor cover can cause inconvenience even if penetration is indiscernible to the eye. In this case, only replacement will help. Replacement will also help with clogging of the fuel filter - a common cause of malfunctions. The fuel cell may also need to be replaced, as failure can lead to improper compression.

Of course, this is not a complete list of possible malfunctions, but it is better to entrust the solution of other reasons to the specialists of the car service. If the above tips helped, then the second stage of work is ahead - setting.

The first step is to use a multimeter to measure the resistance value of the temperature sensor of the air supply to the single injection. The resistance value should be approximately 1800-1900 ohms at an air temperature of 20 degrees Celsius. For a working sensor, heating will lead to a decrease in resistance, and cooling will lead to an increase. The injector resistance must correspond to the 1200-1600 ohm range.

Next, you need to adjust the clearance for idle. Throwing 12 V on the contacts of the regulator, we put the accelerator in the extreme position. Using a multimeter, we check for a short circuit by inserting a probe into the gap between the end switch of the aforementioned accelerator and the stem. With an excessive distance between the limit switch and the stem, the multimeter will not show a short circuit. The gap can be adjusted by changing the position of the limit switch with the screw located at the bottom of the mono injection.

The next step is to set the throttle. This action is performed after installing the single injection on the engine with the connection of the injector and sensor connectors. It is also necessary to connect the fuel supply. After completing all the above steps, you must disconnect the battery and turn on the ignition. This action will reset the mono injection settings.

Having connected the battery back, we check the voltage between 1 and 5 pins on the connector that controls the throttle. The result should be 5-6 volts. A measurement between the first and second pins should give a reading of 0.186 volts. For other values, adjustments must be made. When a multimeter is connected to the first and second contacts, it is necessary to turn the damper cover to the side, having previously loosened the screws, fixing the voltage value and bringing it to the required one.

Actually, in such a simple way, the Volkswagen Passat b3 mono-injection is being repaired. For him, the most basic knowledge in car repair and tools available in the garage of any car enthusiast, not to mention professionals, is enough. Following these tips will save you a lot of money in the future due to less frequent visits to the service station.

It's no secret that the Passat B3 is considered the most common car in the entire Volkswagen range. This machine is reliable, roomy, easy to maintain, and durable. It starts up perfectly even in severe frost and has many other advantages. But it also has disadvantages, which include a not very successful single injection system. How to repair and configure the system on a Volkswagen Passat with your own hands, we will tell you in this article.

Monoinjection is a type of fuel supply system to the engine combustion chambers. It differs from all the others in that there is only one injector in it and only through it all the cylinders receive the fuel mixture... Mono injection has both pros and cons.On the one hand, the engine with mono injection is easier to start, since the system is monitored by a special valve, and the mono injection is designed more simply than the classic injector. On the other hand, repairing a single injection is more expensive and depends heavily on the quality of the power supply.

The symptom of an uneven mono injection is most often one: the engine speed suddenly begins to "float", and it does not react well to pressing the gas pedal... This can happen both immediately after starting the engine, and during the trip. The repair of the mono injection system itself does not take much time. Much more time is spent on identifying the cause of the breakdown. This task in the Volkswagen Passat B3 is seriously complicated by the fact that this car does not have a computer connection module, and therefore, it is impossible to quickly carry out a full-fledged diagnosis.

Let's list the most common causes of uneven injection:

• The gasket installed directly under the mono injection has lost its tightness.
• The contacts of the wires under the mono-injection sensor have come off.
• The problem arose after the spark plugs were replaced with new ones.
• The tightness of the distributor cover is broken (moreover, the crack may not be visible to the naked eye, but it will be enough for the appearance of failures in the distribution of fuel).
• The compression generated by the fuel pump is too high (or vice versa - too low).
• The throttle valve is clogged or covered with thick carbon deposits.
• The integrity of the wires going to the sensor that monitors the position of the throttle valve is broken.

1. Flat blade screwdriver (medium).
2. Open-end wrench set.
3. A set of new spark plugs.
4. A set of socket heads with a knob.
5. Multimeter.
6. Sandpaper.
7. Insulating tape.
8. A set of flat probes.
9. New gasket for mono injection.
10. New distributor cover.

1. The hood opens, with the help of the socket head, the single injection is unscrewed by 10, the gasket under it is replaced with a new one. Mono injection is removed with a socket head
2. The contacts of the single injection sensor are carefully checked. If they are oxidized, they are cleaned with sandpaper.
3. If problems persist after replacing the spark plugs, the old plugs are returned to the engine and checked again for stability. If it turns out that the problem is precisely in the spark plugs, another set of new spark plugs is installed in the engine (it is better if they are from another manufacturer) and the check is carried out again.
4. The distributor cover is replaced with a new one.
5. The fuel pump is unscrewed, the throttle valve is cleared of soot. The fuel pump is removed, you can inspect the wires and sensor
6. A visual analysis of the wires on the damper sensor is carried out and the integrity of their insulation and the density of contacts are assessed. In damaged places, the sensor wires are wrapped with electrical tape.
7. As a rule, after one of the above actions, the problem of uneven injection is solved. But before installation on the car, the mono injection must be adjusted. A multimeter is used to measure the resistance at the outputs of the intake air temperature sensor. The measurement result is compared with the value specified in the vehicle operating instructions (roughly: if the air temperature at the time of measurement is room temperature and is 25 ° C, then the resistance should be 1.8 kOhm). Resistance at the sensor outputs is measured with a multimeter
8. Next, the incoming air sensor is slightly heated using a conventional lighter, while the change in its resistance is monitored. If it decreases when the sensor heats up, and increases when it cools, then the sensor is working properly and there will be no problems with it after installation.
9. The injector resistance is measured with the same multimeter (on this Volkswagen model it varies from 1.3 to 1.6 ohms).
10. Mono injection now sets the exact idle clearance. A voltage of 12 V is supplied from the car battery to the contacts of the injection regulator. In this case, the accelerator is set to the extreme position.The multimeter switches to the "short circuit" mode and its contacts are connected to the regulator on the accelerator. It is necessary to ensure that a small gap appears between the end of the accelerator and the rod, the width of which should not exceed 0.5 mm (this distance is checked with a flat probe, which is inserted into the gap formed). At the same time, a short circuit should be displayed on the multimeter. If it is not there, then the gap is too large and it is reduced with the help of the adjusting bolt (it is under mono injection).
11. The throttle valve is now adjusted. The mono injection unit is installed on the engine, the connector is connected to the injector. The sensors for the position of the damper and the incoming air are also connected. Fuel pipes are connected. After that, the negative terminal is removed from the battery, and the key in the ignition switch turns. In this case, all settings in the on-board unit are reset, including the settings for the damper position. They are automatically set to the factory default values. After reset, the negative terminal is reconnected. Mono injection is installed, the damper contacts are checked
12. A multimeter measures the voltage at the fifth and first contacts in the damper connector (while the ignition is on). It should not exceed 6 V. Then the multimeter switches to the first and second contacts of the damper connector. The voltage there should be 0.184 V. So the contacts are located in the throttle valve connector Volkswagen Passat B3
13. If these voltage values ​​are not observed, then the adjustment is made: 4 screws on the damper cover are loosened, the multimeter is connected to the first and second contacts of the connector, the cover turns either in one direction or the other. The voltage recorded by the multimeter changes. Once the position of the cover with the optimum tension is found, the bolts are tightened. This completes the adjustment.