DIY repair Volkswagen Passat B5

In detail: DIY repair Volkswagen Passat B5 from a real master for the site my.housecope.com.

Repair and maintenance of Volkswagen Passat B5. Volkswagen Passat B5 (from 1996 to 2004 of release)

The new fifth generation Volkswagen Passat B5 is one of the largest mid-range cars. It is a spacious, comfortable and reliable car with sedan and station wagon body versions. It is equipped with a choice of five petrol (4-, 5- and 6-cylinder) and three diesel engines. Gasoline engines from 102 to 193 hp. meet the strict requirements of the environmental European standard EU 4. Diesel engines with power from 101 to 150 hp. are certified according to the EU 3 standard. Any of the offered engines can be installed on both the sedan and the station wagon.

The maximum speed, depending on the equipment, ranges from 184 to 238 km / h. Standard features include ABS, front airbags, tinted windows, electric front windows, bottom lifting eyes and radio-controlled central locking. The Passat 2000 quickly took the lead among mid-range executive cars.

The automatic transmission has gained significant popularity over the past 20 years - after all, this method is much more convenient when driving a vehicle. But also the automatic transmission has its own characteristics in terms of the device, so its repair is a separate topic. The Volkswagen Passat B5 car model sometimes causes difficulties for users in terms of gearbox repair, as it has many features. We will find out further how you can fix the device at home, and in order to dive into the topic in more detail, we look at the do-it-yourself video repair of the Volkswagen Passat B5 automatic transmission.

Video (click to play).

The first step in general home car diagnostics should be to identify the cause of the breakdown. The most common ones here are:

Leakage of working fluid. If leaks are visible on the unit, in particular in the area of the sealing gum, then the breakdown happened precisely because of this reason. It is almost impossible to avoid this problem, so it is imperative to visually analyze the state of the box at least once a month.
If this problem occurs, the solution may be to replace the gasket and transmission fluid.
Damage to the torque converter. If you have exactly this problem, then it will be possible to repair the automatic transmission Volkswagen Passat B5 with your own hands only with a complete repair of this unit.
Dysfunction can be identified by the following signs: uncomfortable driving, knocking or crackling in the gearbox, loss of dynamics while driving, strong vibrations in motion.
Valve body malfunctions. This problem is very common among those drivers who, before driving in the winter season, do not warm up the car properly and start driving. On new car models, the on-board computer will inform you about this problem. You will also notice it yourself: the car drives with constant shaking, vibration, or refuses to move at all.
Control unit malfunctions. Most often, this problem occurs with relatively old models. The problem manifests itself in the fact that the unit begins to select inappropriate rpm for gear shifting, and it may even block the automatic transmission, which is generally dangerous during the driving period.
In solving such a problem, a complete replacement of some parts of the control unit and its preliminary professional diagnostics can help.

After accurately identifying the problem, you can proceed directly to the repair. If you failed to diagnose and the cause of the breakdown is unclear, it is better to take the car to a professional service center.

Home repair of the Volkswagen Passat B5 automatic transmission begins with the removal of the unit. This is not so easy to do, so the topic needs to be given considerable attention. The unit can be removed on ramps, lifts or in special pits. The procedure itself will require wrenches. We remove the gearbox in several stages:

We drain the working fluid, after which we dismantle the pallet.
Disconnect hoses, connectors, pipes, rods.
Remove all screws that support the torque converter.
After that, you need to make sure that nothing is holding the gearbox. Then you can carefully remove it while holding the torque converter.

An important feature of this process is that the box cannot be removed without prior preparation. Otherwise, you can complicate the removal procedure and even damage the vehicle.

Self-repair of an automatic transmission for a Volkswagen Passat B5 consists in a complete disassembly of the box and work with its parts. The parsing is carried out as accurately as possible, according to the following algorithm:

The first detail that appears is the gasket. If it is worn out, then a mandatory replacement is required.
Then we study the couplings. Particular attention must be paid here to the friction discs: they must be replaced if they are worn out or malfunctioning.
Valve body processing. We thoroughly rinse this part. To perform this procedure most effectively, use special brushes and liquid.
We check the pistons for suitability: at this stage, the hydrodynamic transformer oil seal and metal seal rings can also be replaced.
Then you can start assembling the unit: we assemble the brake package using recently replaced parts. We install the valve body, rinse the pallet.
We put the gearbox in place and pour in new gear oil.

This is where the whole repair process ends. For more information, see the video repair automatic transmission Passat B5.

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

Volkswagen Passat B5 / Volkswagen Passat B5 (model code: 3B2) 1997 - 2001
Volkswagen Passat Variant B5 / Volkswagen Passat Variant B5 (model code: 3B5) 1997 - 2001

Power loss during acceleration, turbine underflow, description of problems, removal of logs and diagnostics (rus.)
In case of problems associated with the loss of power during acceleration, both constant and variable loss of traction when driving. Loss of traction in "full throttle" mode or the transition of the engine to emergency mode (driving, but not pulling or pulling weakly) read this entire text carefully, and 9 out of 10 that this will help you establish the exact cause of the problem.

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.

Dynamic injection angle adjustment on V6 2.5 TDI engines - AKN, AKE, AFB, etc. (rus.) Detailed Photo Report! The basic work sequence is suitable for engines AFB, AKN, AKE, AYM, BAU, BCZ, BDG, BDH, BFC. These engines were installed on cars: VW Passat B5 (3B2, 3B5), VW Passat B5.5 (3B3, 3B6), Audi A6 C5 (4B), Audi A4 B5 (8D), Audi A8 D2 (4D2), Audi A4 B6 (8E), Skoda Superb (3U4).

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 the high pressure fuel pump (TNVD) Bosch VP44 - 059 130 106D (rus.) Photo report
This pump has not been installed anywhere: on VW Passat B5, Audi A4, A6, BMW, Opel, on trucks, etc. It often breaks down - so I think the information will not hurt.
So, if after pumping with a pear or something from the nozzle pipes when scrolling with a starter, nothing presses, then you have problems with mechanics: the most likely option is damage to the membrane (or cutting rings), the second option is a defect of the pumping pump. You will see all this in the photo, who has everything in good order - here you can see the injection pump from all angles.

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

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

ESP repair - soldering the lateral acceleration sensor G200 (rus.) Photo report
ESP unit number 1J0 907 657 A / acceleration sensor 1J0 907 651A was installed on cars: VW Golf 4 / Bora (1J), VW New Beetle (1C, 9C), VW Lupo (6X, 6E), VW Polo 3 (6N), VW Sharan (7M), VW Transporter T5 (7H), Skoda Octavia (1U), Audi A2 (8Z), Audi A3 (8L), Audi TT (8N), SEAT Alhambra (7V), SEAT Ibiza / Cordoba (6K) , SEAT Leon / Toledo (1M). This information is likely to apply to other vehicles as well.

Removing the steering rack for VW Passat B5 (rus.) Photo report
Oil flowed sharply from the rail on the right side from under the boot. Exist does not provide a repair kit for the steering rack, and the price of a new one bites. It was decided to take off and see how there and what.

Airbag "spiral" repair, airbag slip ring restoration (rus.) Photo report
Let me disagree with the statements about the unrepairability of the “Airbag spiral”. As they say, “the collective farm was a success for me. "So we need: a soldering iron, a tester, a cross screwdriver, a thin slotted screwdriver, flux, tin, a skin or mini drill, accuracy, patience.

Removing manual transmission 01W and replacing the clutch for VW Passat B5 GP 1.6 AHL (rus.) Photo report
The reason for replacing the clutch is unpleasant vibration when starting off, especially when the car is loaded.

Read also: Pneumatic ratchet DIY repair

Replacing the right manual transmission support bracket for VW Passat B5 + (rus.) Photo report
Gearbox type 01W, gearbox code letter GFY. I flew into the hole with my right wheels, everything seems to be fine. Then I noticed some kind of ringing when I slowly get under way. Verdict - the eyelet has broken off from the right bracket of the gearbox support.

Automatic gearbox 01V (rus.) Factory repair manual for gearbox 01V.
Automatic gearbox 01V, with gear letters and gearboxes: EZY, FNL, FAD, EYF, FEV installed on cars:
Volkswagen Passat B5 / Volkswagen Passat B5 (model code: 3B2),
Volkswagen Passat Variant B5 / Volkswagen Passat Variant B5 (model code: 3B5),
Contents (repair groups): 00 - Technical data, 32 - Torque converter, 37 - Control, gearbox housing, 38 - Gears, regulation, 39 - Main gear, differential. 142 pages. 21 Mb.

Information on the repair of gearboxes VAG / Transmission repair
This gearbox repair information applies to all VAG vehicles.

Repair of the central door lock and installation of a window regulator repair kit VW Golf 4 / Bora, VW Passat B5, etc. (rus.) Photo report
Frequent occurrence of all VW Golf 4, VW Passat B5, Skoda Octavia A4, etc.- these are the problems of the central lock - we press close, the lock closes and opens immediately. Sometimes you have to suffer for a long time to close the car. The culprit is a cracked PCB inside the lock. I hope this article will help many to save some money on their own on their own.

Window regulator repair on VW Passat B5 + (rus.) Photo report
This is not the first time I encountered the problem of a window regulator breakdown on the Passat. I decided to post a photo report on how it can be repaired. The power window cable breaks in approximately the same place. It seems to me that this is due to its design, it uses 3 rollers and one slider, apparently it is the cause of the breaks.

How to properly assemble a glove box (glove compartment) cover Golf 4, Bora, Passat B5, etc. (rus.) Photo report
When disassembling the passenger compartment or replacing a light bulb, the glove compartment illumination lamp often fell apart when pulled out. Collecting it is a non-trivial task, not everyone can do it. I had to take my flashlight out of the glove compartment in order to disassemble it and show how it is then going. Here's what we have: 8 structural elements.

Withdrawal
1. Remove the front engine compartment beam assembly.
2. Drain the coolant.
Cars with automatic transmission
3. Disconnect the ATF lines (arrows) from the transmission fluid radiator (Fig. 2.2).

For all cars
4. Remove the connecting air line between the charge air cooler and the throttle body assembly.
5. Remove the ribbed accessory drive belt.
6. Remove the power steering pump from the bracket and set it aside without disconnecting the tubes.
7. Remove the air filter.
8. Remove the catalytic converter.
9. Disconnect the connecting pipes, coolant hoses, vacuum pipes and air intake ducts from the engine.
10. Disconnect and place aside all electrical wiring connectors from the transmission, alternator and starter.
11. Remove the starter.
12. Disconnect the fuel supply line and the return line from the fuel rail.
13. Disconnect the secondary air discharge from the connecting tube.
14. Remove the tube (1) crankcase ventilation (Fig. 2.3).
15. Disconnect the discharge port (2) from the combination valve (arrow) and head cover.
16. Remove the combination valve together with the holder (3) and set aside. Do not disconnect the vacuum tube.
17. Remove the crankcase ventilation T-piece (5).

18. Disconnect the coolant hoses to the heat exchanger and expansion tank from the engine.
19. Disconnect the appropriate connecting and vacuum hoses from the engine.
20. Disconnect the ECU connector block.
21. Disconnect and set aside all other electrical wiring connectors. Leave the engine cable harness on the engine.
22. Remove the upper bolts securing the transmission to the engine.
Attention! One bolt should only be loosened, not loosened.
23. Remove the nuts from the left and right engine mounts from below.

Cars with automatic transmission
24. Unscrew the three nuts securing the torque converter to the drive disc (Fig. 2.4). Crank the crankshaft 120 '(1/3 turn) each time.
Note. Hold the crankshaft from turning by the pulley / damper bolt. After removing the engine, secure the torque converter to prevent it from falling out.

For all cars
25. Unscrew the bolts (arrows) and remove the engine stop (1) (Fig. 2.5). Tightening torque: 30 Nm.
26. Fix the T10062 bracket in the central hole of the oil pan with a bolt (arrow) with three washers (each 4 mm thick) (Fig. 2.6). Tightening torque: 30 Nm.
27. Lift the engine and gearbox using the V.A.G 1383 A lifter so that the lower gearbox mounting bolts can be removed.
Note. When lifting the engine, make sure that hoses and pipes are not pinched.

28.Remove the lower bolts securing the transmission to the engine.
29. Install the stand for lifting the MP 9-200 engine (fig. 2.7). Attach bracket T30062 to the bolt hole on the transmission case (engine not shown).

30. Suspend the MP 9-201 traverse in the indicated way and lift the engine with the V.A.G 1202 A crane (fig. 2.8):
• pulley side: 2nd hole of the vertical bar in position 1;
• flywheel side: 1st hole of the vertical bar in position 8.
31. Raise the engine so that the studs on the engine support brackets protrude from the holes in the supports. At the same time, raise the gearbox using the MP 9-200 stand.
32. Remove the remaining upper transmission-to-engine bolt.
33. Raise the engine and remove it from the engine compartment forward.
34. To work on the removed engine, fix it on the MP 9-101 stand using the MP 1-202 brackets (Fig. 2.9).

Installation
35. Installation is carried out in the reverse order of removal. When installing, follow the recommendations below.
36. Cars with manual transmission: Check for wear and apply a light coat of grease G 000 100 to the bearing and splines on the input / output shaft of the gearbox.
37. Cars with automatic transmission: Check that the distance from the edge of the crankcase flange to the torque converter bearing surface is 23 mm (Fig. 2.10). Adjust it if necessary. Before installing the engine, adjust the position of the torque converter and drive disc so that one of the connecting holes is level with the drain hole.
38. Check that the distance from the edge of the crankcase flange to the torque converter bearing surface is 23 mm. Check the position of the dowel sleeves in the cylinder block; install them if necessary.
39. Replace self-locking nuts.
40. Tighten only certified bolts / nuts to the specified torque. Unless otherwise specified, the nominal tightening torques of the screwed connections apply.
41. Carry out the necessary checking and adjustment work.

Passat. For the first time this name in the history of Volkswagen AG appeared in 1973, when the novelty of the same name replaced the rear-wheel drive models of the 1600 series. As time went on, four generations of Passat were replaced in 23 years. Therefore, there was an incentive to wait for the next, new. The VW Passat B5 was presented at the Paris Auto Show last year.
Seeing pleasing shapes delights
The fifth generation of this car is perhaps the most successful and unique. Especially you start to think so after a close acquaintance with the car, which took place on one of the spring and, unfortunately, snowy days.

At first glance at the new dark green acquaintance, “set” on cool five-spoke alloy wheels, it seemed that there is something sporty in it (later this assumption was confirmed). And the more you look at the car, the more you find and notice new things in it.

In our opinion, the body styling is based on the arc, which manifests itself in all its parts. And this is the guarantee of an attractive and, in its own way, original appearance of the car. The forms of the B5 claim to be one of the most perfect and have obvious family traits, since once the idea of an arched shape was already embodied in the people's car Volkswagen Beetle and, as we can see, is still not outdated.

The body of the Passat is not only beautiful, but also strong enough, as evidenced by the very small and, which testifies to the good build quality, absolutely the same clearances. Hefty and powerful bumpers - downright homogeneous body with a metal part. By the way, the drag coefficient of the Passat B5 is the best in its class - 0.27. Both the headlights and the car's lanterns are organically integrated into the overall style. Moreover, the first ones can be cleaned without leaving the car. Washers slide out of the bumper, and the water coming from them under significant pressure performs its function.

Device, maintenance, repair and operation of Volkswagen Passat B5 cars with gasoline engines: ADP / AHL 1.6 l 1595 cm³) 100 hp / 74 kW, ADR / AEB / APT / ARG / ANB / APU 1.8 l FSI / TFSI (1781 cm³) 125-150 HP / 92-110 kW, AGZ 2.3 l (2327 cm³) 150 HP / 110 kW, ACK / ALG / APR / AQD 2.8 l (2771 cm³) 193 HP / 142 kW and diesel AHU / AHH / AFN / AJM 1.9 l (1896 cc) 90-110-115 hp / 66-81-85 kW, AFB 2.5 l (2496 cc) 150 hp / 110 kW. Study guide, wiring diagrams, control dimensions of the body Volkswagen Passat station wagon (variant), sedan (limousine) model B5 front-wheel drive and all-wheel drive (syncro) since 1996

Video Volkswagen Passat B5 "how to replace the front wheel bearing and timing belt" (Volkswagen Passat B5)

Self-replacement of the steering rack on a Volkswagen Passat b 5 (Volkswagen Passat B5).

The Volkswagen Passat b 5 has a hydraulic steering rack, it is the main part of the steering, and therefore it must be treated with great attention. Timely replacement of the hydraulic fluid will significantly increase the resource of the steering rack.
In this article I will tell you how you can change the hydraulic steering rack yourself, and what tool you need for this.
On this car, the steering rack had a snack when the steering wheel was turned, and it was decided to replace it with a similar used steering rack, in good condition.