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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Volkswagen Passat B5 (from 1996 to 2004, the year of issue)

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Volkswagen Passat B5
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The bottom mudguard of a motor compartment
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Checking the hydraulic valve lifters
Repair of the cylinder head
Diesel engine 1,9-TDI-I
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Repair of the cylinder head



Dismantling

PERFORMANCE ORDER
1. Remove the cylinder head.
2. Unscrew and remove the inlet and exhaust manifolds.
3. Remove the camshafts and hydraulic tappets.

4. Squeeze the order of the valve springs and remove the special tool crackers fixing stubborn upper spring seat.
5. Remove the top plate.
6. Remove the upper and lower valve spring, taking care not to damage the valve stem
7. Remove the valve from the cylinder head from the side of the combustion chamber.
8. Remove the valve stem seals.
9. Remove the bottom plate of the valve spring.
10. Place the valve kits in plastic bags and label them for installation in its place.

Cleaning and checking

PERFORMANCE ORDER
1. Clean traces of the old gasket and sealing with the cylinder head.
2. Clean the carbon deposits from the combustion chamber and the cylinder, then wash the cylinder head with a suitable solvent.
3. Clean channels in the cylinder head by using a wire brush.
4. Carefully check the head for cracks and other damage. In the presence of cracks on the head, the head must be replaced.
5. Using a metal ruler and a feeler gauge, check the flatness of the mating surface of the head.
6. Saddles of valves with wear tracks or overcooking must be treated with obligatory preservation of corners and facet sizes. If the valve seat must be processed, determine the maximum amount of metal that can be removed. If you remove an excessive amount of metal hydraulic tappets will not function correctly.
7. Insert the valve into the guide and press it against the valve seat.
8. Measure the distance from the end of the valve stem to the upper surface of the cylinder head. The minimum allowable distance of 33.8 mm for intake valves and 34.1 mm for the exhaust valves. In case of excessive wear of the valve seat and unacceptable treatment of the cylinder head must be replaced.
9. After any processing of saddles of valves necessary to make their grinding.
10. Check the internal diameter of the valve guide. If the values exceed the maximum permissible value, replace the valve guides in a special garage.
A warning

Replacing the guide also requires rounding slot corresponding valve.


11. Check each valve plate to pitting, burn-through, cracks and general wear and tear.
12. If the valve condition satisfactory, measure the diameter of the valve stem at several points using a micrometer. Any significant difference in the obtained measurement data indicate the valve stem rod wear. In this case, the valve must be replaced.
13. If the valve are in satisfactory state of enforcement, it is necessary to make their grinding. Grinding the valves must be carried out only with the use of fine-grained polishing paste. The surface of the valve seat Apply a small amount of paste and install valves in the saddle. Press firmly to the valve plate a rubber sucker and rotate the valve in one direction or another.
14. After the process of grinding in all details carefully clear of a dirt and paste. Check saddle and a valve plate. It must be seen continuous matte ring on both details which specifies width of a facet of the valve.
15. Check the valve springs for wear and delamination as well as measure their length in a free state. If possible, compare each of the existing springs with new springs.
16. Install the spring on a flat surface and check the deviation from the horizontal position. If at least one of the springs is damaged, replace completely all the springs in the kit.
17. Check the condition of the valve biscuits and crackers on the location of the valve. If there are any defects in damaged parts must be replaced. Valve stem seals must be replaced each time after their withdrawal.
18. Check the details of the valve mechanism and hydraulic tappets.

Assembly

PERFORMANCE ORDER
1. Before assembling the cylinder head, clean it thoroughly.
2. Grease cores of valves and directing clean engine oil and insert the valve into the head.
3. Install the bottom plate of the valve spring.
4. Clean the top of the valve stem from engine oil.
5. Replace the plastic sleeve or wrap grooves for crumbs at the top of the valve segment of tape to protect from damage working edges of stem seals when they are installed.
6. Apply fresh engine oil cap and valve stem, using a tube, so replace the valve guide.
7. Remove the tape from the valve stem.
8. Press in the place of valve stem seal.
9. Install the spring and the upper spring seat.
10. Supporting the valve in the closed position, squeeze it specially adapted valve spring and establish crackers. Slowly remove the adaptation for compression of the valve spring.
Repeat the operation on the remaining valves.
11. Finally, hit the end of each valve stem plastic or copper hammer to insignificant but the valve opened and all the elements of the valve began to fall into place.




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Diesel engine 1,9-TDI-I

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