4-cylinder injection engine (2.0 l engine, turbocharger)

Kapitelübersicht

• Technical data
  1
• 1 Engine number
  1
• 2 Engine data
  2
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Removing engine
  4
• 1.2 Securing engine to assembly stand
  9
• 1.3 Installing engine
  11
• 1.4 Assembly mountings
  13
• Crankshaft group
  15
• 1 Dismantling and assembling engine
  15
• 1.1 Assembly overview
  15
• 1.2 Removing and installing poly-V belt
  22
• 2 Sealing flange and flywheel or drive plate
  25
• 2.1 Assembly overview - sealing flange
  25
• 2.2 Renewing crankshaft oil seal (belt pulley end)
  26
• 2.3 Removing and installing sealing flange (belt pulley end)
  28
• 2.4 Removing and installing crankshaft sealing flange (flywheel end)
  31
• 2.5 Removing and installing flywheel
  32
• 2.6 Removing and installing drive plate
  33
• 3 Crankshaft
  35
• 3.1 Assembly overview - crankshaft
  35
• 3.2 Pulling needle bearing out of and driving into crankshaft
  37
• 3.3 Crankshaft dimensions
  39
• 3.4 Identification of crankshaft upper bearing
  39
• 4 Pistons and conrods
  40
• 4.1 Assembly overview - pistons and conrods
  40
• 4.2 Separating new conrod
  41
• 4.3 Removing and installing pistons
  42
• 4.4 Checking pistons and cylinder bores
  43
• Cylinder head, valve gear
  46
• 1 Cylinder head
  46
• 1.1 Assembly overview - cylinder head
  46
• 1.2 Removing and installing cylinder head cover
  48
• 1.3 Removing and installing cylinder head
  50
• 1.4 Removing and installing toothed belt, vehicles without split toothed belt guard
  55
• 1.5 Removing and installing toothed belt, vehicles with split toothed belt guard
  66
• 1.6 Checking compression
  76
• 2 Valve gear
  79
• 2.1 Assembly overview - valve gear
  79
• 2.2 Valve dimensions
  81
• 2.3 Checking valve guides
  81
• 2.4 Renewing valve stem seals
  82
• 2.5 Renewing exhaust camshaft seal
  86
• 2.6 Removing and installing camshaft adjuster
  89
• 2.7 Removing and installing camshaft control valve 1 N205
  92
• 2.8 Removing and installing camshafts
  94
• Lubrication
  98
• 1 Parts of lubrication system
  98
• 1.1 Engine oil:
  98
• 1.2 Assembly overview - parts of lubrication system
  98
• 1.3 Drain oiling filter housing
  103
• 1.4 Removing and installing sump
  104
• 1.5 Removing and installing oil pump with balance shaft gear assembly
  107
• 1.6 Removing and installing oil filter bracket
  111
• 1.7 Removing and installing oil pressure switch F1
  112
• 1.8 Checking oil pressure and oil pressure switch (single pin oil pressure switch)
  113
• 1.9 Checking oil pressure and oil pressure switch (2-pin oil pressure switch)
  115
• Cooling
  118
• 1 Parts of cooling system
  118
• 1.1 Assembly overview - parts of cooling system, engine side
  118
• 1.3 Assembly overview - coolant circulation pump V50 (vehicles with no bypass thermostat)
  121
• 1.4 Assembly overview - parts of cooling system, body side
  122
• 1.5 Coolant hose schematic diagram (vehicles to 06.2005)
  123
• 1.6 Coolant hose schematic diagram (vehicles from 06.2005)
  124
• 1.7 Bypass thermostat
  125
• 1.8 Draining and adding coolant
  126
• 1.9 Removing and installing coolant pump
  129
• 1.10 Removing and installing coolant pipes
  131
• 1.11 Removing and installing coolant thermostat housing with thermostat
  133
• 1.12 Removing and installing radiator fan V7 and radiator fan 2 V177
  134
• 1.13 Removing and installing radiator, Golf and Eos
  134
• 1.14 Removing and installing radiator, Passat
  136
• 1.15 Checking cooling system for leaks
  137
• Fuel supply system
  140
• 1 Safety precautions
  140
• 1.1 Safety regulations for working on fuel supply
  140
• 1.2 Releasing fuel pressure in high-pressure section
  141
• 2 Rules for cleanliness
  143
• 3 Fuel tank, Golf
  144
• 3.1 Assembly overview - fuel tank (engine code BPY)
  144
• 3.2 Assembly overview - fuel tank (engine codes AXX, BWA)
  146
• 3.3 Emptying fuel tank
  147
• 3.4 Removing and installing fuel tank
  152
• 4 Fuel tank, Eos
  155
• 4.1 Assembly overview - fuel tank (engine code BWA)
  155
• 4.2 Assembly overview - fuel tank (engine code BPY)
  157
• 4.3 Emptying fuel tank
  159
• 4.4 Removing and installing fuel tank
  163
• 5 Fuel tank, Passat
  167
• 5.1 Assembly overview - fuel tank (engine code BPY)
  167
• 5.2 Assembly overview - fuel tank (engine codes AXX, BWA)
  169
• 5.3 Emptying fuel tank
  170
• 5.4 Removing and installing fuel tank
  174
• 6 Repairing fuel supply system, Golf, Eos
  179
• 6.1 Removing and installing fuel delivery unit
  179
• 6.2 Removing and installing fuel gauge sender G
  182
• 6.3 Checking fuel pump G6
  183
• 7 Repairing fuel supply system, Passat
  196
• 7.1 Removing and installing fuel delivery unit
  196
• 7.2 Removing and installing fuel gauge sender G
  199
• 7.3 Checking fuel pump
  200
• 8 Electronic power control (EPC)
  210
• 8.1 Function of EPC system
  210
• 8.2 Assembly overview - accelerator module
  210
• 8.3 Removing and installing accelerator pedal module
  211
• 9 Activated charcoal filter system (Golf, Eos)
  214
• 9.1 Assembly overview - activated charcoal filter system (engine codes AXX, BWA)
  214
• 9.2 Checking fuel tank breather (engine codes AXX, BWA)
  215
• 9.3 Schematic diagram of activated charcoal filter system (engine code BPY)
  217
• 9.4 Assembly overview - activated charcoal filter system (Golf with engine code BPY)
  219
• 9.5 Assembly overview - activated charcoal filter system (Eos with engine code BPY)
  220
• 9.6 Removing and installing activated charcoal filter (engine code BPY)
  221
• 9.7 Removing and installing fuel system diagnostic pump V144 (Golf with engine code BPY)
  222
• 9.8 Removing and installing fuel system diagnostic pump V144 (Eos with engine code BPY)
  223
• 9.9 Checking fuel system for leaks
  223
• 10 Activated charcoal filter system (Passat)
  231
• 10.1 Assembly overview - activated charcoal filter system (engine codes AXX, BWA)
  231
• 10.2 Checking fuel tank breather (engine codes AXX, BWA)
  232
• 10.3 Schematic diagram of activated charcoal filter system (engine code BPY)
  233
• 10.4 Assembly overview - activated charcoal filter system (engine code BPY)
  235
• 10.5 Checking fuel system for leaks
  235
• Turbocharging/supercharging
  243
• 1 Exhaust turbocharger
  243
• 1.1 Fitting hose connections with plug-in connectors
  243
• 1.2 Rules for cleanliness
  244
• 1.3 Assembly overview - turbocharger
  244
• 1.4 Removing and installing turbocharger
  248
• 1.5 Checking vacuum unit for turbocharger
  256
• 1.6 Removing and installing vacuum unit for turbocharger
  257
• 1.7 Adjusting vacuum unit for turbocharger
  257
• 2 Charge air system
  262
• 2.1 Assembly overview - charge air cooling, Golf
  262
• 2.2 Assembly overview - sound amplifier, Golf
  263
• 2.3 Assembly overview - charge air cooling, Eos, Passat
  264
• 2.4 Removing and installing charge air cooler (Golf, Eos)
  264
• 2.5 Removing and installing charge air cooler, Passat
  266
• 2.6 Schematic diagram of turbocharging system
  267
• 2.7 Checking charge air system for leaks
  268
• Mixture preparation - injection
  271
• 1 Injection system
  271
• 1.1 General notes on injection
  271
• 1.2 Technical data
  272
• 1.3 Assembly overview - engine cover panel/air filter
  272
• 1.4 Removing and installing engine cover panel/air filter
  273
• 1.5 Removing and installing air filter element
  274
• 1.6 Assembly overview - intake manifold
  275
• 1.7 Removing and installing intake manifold
  277
• 1.9 Assembly overview - fuel rail (vehicles up to 05.2006)
  282
• 1.10 Assembly overview - fuel rail (vehicles from 05.2006)
  283
• 1.11 Removing and installing fuel rail
  285
• 1.12 Removing and installing throttle valve module J338
  286
• 1.13 Cleaning throttle valve module J338
  286
• 1.14 Assembly overview - high-pressure pump
  287
• 1.15 Removing and installing high-pressure pump
  289
• 1.16 Removing and installing fuel pressure sender G247
  290
• 1.17 Checking fuel pressure sender G247
  292
• 1.18 Removing and installing injectors
  295
• 1.19 Renewing Teflon seal on injector
  296
• 2 Checking components
  299
• 3 Engine control unit J623 , Golf, Eos
  300
• 3.1 Removing and installing engine (motor) control unit J623
  300
• 3.2 Removing and installing anti-theft engine control unit J623
  300
• 4 Engine control unit J623 (Passat)
  304
• 4.1 Removing and installing engine (motor) control unit J623
  304
• 4.3 Removing and installing anti-theft engine control unit J623 (with locking clip)
  309
• Exhaust system
  312
• 1 Removing and installing parts of exhaust system
  312
• 1.1 Assembly overview - exhaust system; Golf, Eos
  312
• 1.2 Assembly overview - exhaust system, Passat
  314
• 1.3 Clamps
  315
• 1.4 Separating centre and rear silencers, Golf, Eos
  316
• 1.5 Separating centre and rear silencers, Passat
  317
• 1.6 Removing and installing front exhaust pipe with catalytic converter
  318
• 1.7 Aligning exhaust system free of stress
  320
• Ignition system
  322
• 1 Repairing ignition system
  322
• 1.1 General notes on ignition system
  322
• 1.2 Safety precautions
  322
• 1.3 Assembly overview - ignition system
  322
• 1.4 Removing and installing ignition coils with output stage
  323
• 1.5 Test data, spark plugs
  324