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  • Examplepage for repair manual 4-cylinder common rail engine (2.0 l, 4V, turbocharger)
  • Examplepage for repair manual 2 4-cylinder common rail engine (2.0 l, 4V, turbocharger)
  • Examplepage for repair manual 3 4-cylinder common rail engine (2.0 l, 4V, turbocharger)

4-cylinder common rail engine (2.0 l, 4V, turbocharger)

For Jetta 4-türig Ll

Original Volkswagen repair manual


31,38 €7% VAT incl.

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Language: English

Digital PDF file

44.347 KB

421 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Assembly mountings, Engine cover panel, Cylinder block (pulley end), Crankshaft, Pistons and conrods, Toothed belt drive, Valve gear, Sump, oil pump, Oil filter, oil pressure switch, Cooling system/coolant, Radiator, radiator fan, Exhaust turbocharger, Injectors/high-pressure accumulator (rail), Intake manifold, Lambda probe and SCR system (selective catalytic reduction). Show more
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Repair manual Jetta 4-türig Ll 4-cylinder common rail engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Safety information
    1
  • 1.1 Safety regulations for working on fuel supply
    1
  • 1.2 Safety measures when working on vehicles with a start/stop system
    2
  • 1.4 Safety precautions when working on the cooling system
    2
  • 1.5 Safety precautions when working on SCR system
    3
  • 2 Identification
    4
  • 2.1 Engine number/engine data
    4
  • 3 Repair instructions
    6
  • 3.1 Rules for cleanliness
    6
  • 3.2 Adapting learnt value for SCR system
    6
  • 3.3 Foreign objects in engine
    6
  • 3.4 Contact corrosion
    7
  • 3.5 Routing and attachment of lines
    7
  • 3.6 Fitting radiator and condensers
    7
  • 4 Technical data
    8
  • 4.1 Coolant
    8
  • Removing and installing engine
    9
  • 1 Removing and installing engine
    9
  • 1.1 Removing engine
    9
  • 1.2 Separating engine and gearbox
    19
  • 1.3 Securing engine on engine and gearbox support
    20
  • 1.4 Installing engine
    22
  • 2 Assembly mountings
    26
  • 2.1 Assembly overview - assembly mountings
    26
  • 2.2 Removing and installing engine mounting
    28
  • 2.3 Removing and installing gearbox mounting
    29
  • 2.4 Removing and installing pendulum support
    30
  • 2.5 Supporting engine in installation position
    31
  • 2.6 Adjusting assembly mountings
    35
  • 2.7 Checking adjustment of assembly mountings (engine and gearbox mountings)
    36
  • 3 Engine cover panel
    37
  • 3.1 Removing and installing engine cover
    37
  • Crankshaft group
    38
  • 1 Cylinder block (pulley end)
    38
  • 1.1 Assembly overview - cylinder block (pulley end)
    38
  • 1.2 Assembly overview - sealing flange, belt pulley end
    40
  • 1.3 Removing and installing poly-V belt
    40
  • 1.4 Removing and installing tensioner for poly V-belt
    42
  • 1.5 Removing and installing vibration damper
    42
  • 1.6 Removing and installing bracket for ancillaries
    43
  • 1.7 Removing and installing engine support
    44
  • 1.8 Removing and installing sealing flange on pulley end
    45
  • 2 Cylinder block, gearbox end
    48
  • 2.1 Assembly overview - cylinder block, gearbox end
    48
  • 2.2 Removing and installing flywheel
    49
  • 2.3 Removing and installing sealing flange on gearbox side
    50
  • 3 Crankshaft
    59
  • 3.1 Assembly overview - crankshaft
    59
  • 3.2 Crankshaft dimensions
    60
  • 3.3 Renewing needle bearing in crankshaft
    60
  • 3.4 Measuring axial clearance of crankshaft
    62
  • 4 Pistons and conrods
    64
  • 4.1 Assembly overview - pistons and conrods
    64
  • 4.2 Removing and installing pistons
    66
  • 4.3 Measuring piston projection at TDC
    67
  • 4.4 Checking pistons and cylinder bores
    69
  • 4.5 Separating new conrod
    71
  • 4.6 Checking radial clearance of conrods
    71
  • 4.7 Removing and installing oil spray jets
    71
  • Cylinder head, valve gear
    73
  • 1 Cylinder head
    73
  • 1.1 Assembly overview - cylinder head
    73
  • 1.2 Assembly overview - cylinder head cover
    75
  • 1.3 Removing and installing cylinder head
    77
  • 1.4 Removing and installing cylinder head cover
    86
  • 1.5 Removing and installing injector seals
    88
  • 1.6 Removing and installing camshaft housing
    89
  • 1.7 Checking compression
    94
  • 2 Toothed belt drive
    96
  • 2.1 Assembly overview - toothed belt cover
    96
  • 2.2 Assembly overview - toothed belt
    97
  • 2.3 Removing and installing toothed belt guard
    98
  • 2.4 Removing and installing toothed belt
    101
  • 2.5 Removing toothed belt from camshaft
    112
  • 3 Valve gear
    117
  • 3.1 Assembly overview - valve gear
    117
  • 3.2 Measuring axial play of camshaft
    120
  • 3.3 Removing and installing camshaft oil seal
    121
  • 3.4 Removing and installing camshaft adjuster
    122
  • 3.5 Removing and installing camshaft control valve 1 N205
    125
  • 3.6 Removing control valve from and installing on inlet camshaft control valve 1 N205
    126
  • 3.7 Checking hydraulic compensation elements
    128
  • 3.8 Removing and installing valve stem seals
    129
  • 4 Inlet and exhaust valves
    136
  • 4.1 Checking valve guides
    136
  • 4.2 Checking valves
    137
  • 4.3 Valve dimensions
    137
  • Lubrication
    138
  • 1 Sump, oil pump
    138
  • 1.1 Assembly overview - sump/oil pump
    138
  • 1.2 Engine oil:
    143
  • 1.3 Removing and installing sump
    143
  • 1.4 Removing and installing lower part of sump
    146
  • 1.5 Removing and installing upper part of sump
    150
  • 1.6 Removing and installing oil pump
    154
  • 1.7 Removing and installing oil level and oil temperature sender G266
    155
  • 2 Engine oil cooler
    157
  • 2.1 Removing and installing engine oil cooler
    157
  • 3 Oil filter, oil pressure switch
    158
  • 3.1 Assembly overview - oil filter housing, oil pressure switch
    158
  • 3.2 Removing and installing oil pressure switch F1
    159
  • 3.3 Removing and installing oil pressure switch for reduced oil pressure F378
    160
  • 3.4 Checking oil pressure
    161
  • 3.5 Removing and installing oil filter housing
    161
  • 3.6 Removing and installing oil pressure regulating valve N428
    163
  • Cooling
    165
  • 1 Cooling system/coolant
    165
  • 1.1 Connection diagram - coolant hoses
    165
  • 1.2 Assembly overview - engine preheater
    171
  • 1.3 Checking cooling system for leaks
    171
  • 1.4 Draining coolant
    173
  • 1.5 Filling with coolant
    175
  • 1.6 Checking electric vacuum pump VAS 6096/2
    184
  • 1.7 Flushing cooling system
    184
  • 1.8 Flushing cooling system, quick reference guide
    205
  • 2 Coolant pump, regulation of cooling system
    207
  • 2.1 Assembly overview - coolant pump, thermostat
    207
  • 2.2 Assembly overview - electric coolant pump
    209
  • 2.3 Assembly overview - coolant temperature sender
    214
  • 2.4 Removing and installing electric coolant pump
    215
  • 2.5 Removing and installing coolant pump
    226
  • 2.6 Removing and installing thermostat
    227
  • 2.7 Checking thermostat
    227
  • 2.8 Removing and installing coolant valve for cylinder head N489
    228
  • 2.9 Removing and installing coolant temperature sender G62
    228
  • 2.10 Removing and installing radiator outlet coolant temperature sender G83
    229
  • 3 Coolant pipes
    231
  • 3.1 Assembly overview - coolant pipes
    231
  • 3.2 Removing and installing coolant pipes
    232
  • 4 Radiator, radiator fan
    242
  • 4.1 Assembly overview - radiator/radiator fan
    242
  • 4.2 Removing and installing radiator
    244
  • 4.3 Removing and installing water radiator for charge air cooling circuit
    245
  • 4.4 Removing and installing radiator cowl with radiator fan
    248
  • 4.5 Removing and installing radiator fan
    249
  • Turbocharging/supercharging
    250
  • 1 Exhaust turbocharger
    250
  • 1.1 Assembly overview - turbocharger
    250
  • 1.2 Removing and installing turbocharger
    252
  • 1.3 Renewing vacuum unit for turbocharger
    255
  • 1.4 Removing and installing connection for turbocharger
    260
  • 2 Charge air system
    262
  • 2.1 Assembly overview - charge air system
    262
  • 2.2 Removing and installing charge pressure sender G31
    264
  • 2.3 Checking charge air system for leaks
    264
  • Mixture preparation - injection
    267
  • 1 Injection system
    267
  • 1.1 Schematic overview - fuel system
    267
  • 1.2 Overview of fitting locations - injection system
    268
  • 1.3 Filling/bleeding fuel system
    274
  • 1.4 Checking fuel system for leaks
    274
  • 2 Vacuum system
    275
  • 2.1 Connection diagram - vacuum system
    275
  • 2.2 Checking vacuum system
    276
  • 3 Injectors/high-pressure accumulator (rail)
    277
  • 3.1 Assembly overview - injectors
    277
  • 3.2 Assembly overview - fuel rail
    279
  • 3.3 Adapting correction values for injectors
    280
  • 3.4 Testing injectors
    280
  • 3.5 Checking return flow rate of injectors with engine running
    280
  • 3.6 Checking return flow rate of injectors at starter speed
    283
  • 3.7 Testing jammed-open injectors
    284
  • 3.8 Removing and installing injectors
    285
  • 3.9 Removing and installing high-pressure lines
    288
  • 3.10 Removing and installing fuel rail
    290
  • 4 Air filter
    292
  • 4.1 Assembly overview - air filter housing
    292
  • 4.2 Removing and installing air filter housing
    293
  • 5 Intake manifold
    296
  • 5.1 Assembly overview - intake manifold
    296
  • 5.2 Removing and installing intake manifold
    298
  • 5.3 Removing and installing throttle valve module J338
    301
  • 6 Senders and sensors
    304
  • 6.1 Removing and installing fuel pressure regulating valve N276
    304
  • 6.2 Checking fuel pressure regulating valve N276
    310
  • 6.3 Removing and installing fuel pressure sender G247
    311
  • 6.4 Removing and installing air mass meter G70
    312
  • 6.5 Removing and installing pressure differential sender G505
    314
  • 6.6 Removing and installing exhaust gas pressure sensor 1 G450
    315
  • 6.7 Removing and installing NOx sender 2 G687
    316
  • 6.8 Removing and installing control unit for NOx sender GX30
    318
  • 6.10 Removing and installing fuel temperature sender G81
    324
  • 7 Engine control unit
    327
  • 7.1 Removing and installing engine (motor) control unit J623
    327
  • 8 High-pressure pump
    331
  • 8.1 Assembly overview - high-pressure pump
    331
  • 8.2 Removing and installing high-pressure pump
    331
  • 9 Lambda probe
    335
  • 9.1 Assembly overview - Lambda probe
    335
  • 9.2 Removing and installing Lambda probe
    337
  • Exhaust system
    341
  • 1 Exhaust pipes and silencers
    341
  • 1.1 Assembly overview - silencers
    341
  • 1.2 Assembly overview - front exhaust pipe
    343
  • 1.3 Removing and installing front exhaust pipe
    344
  • 1.4 Separating exhaust pipes from silencers
    345
  • 1.5 Removing and installing rear silencer
    346
  • 1.6 Aligning exhaust system free of stress
    347
  • 1.7 Checking exhaust system for leaks
    347
  • 1.8 Installation position of clamp
    348
  • 1.9 Align end exhaust pipes
    348
  • 2 Exhaust gas cleaning
    350
  • 2.1 Assembly overview - emission control
    350
  • 2.2 Removing and installing emission control module
    352
  • 2.3 Removing and installing exhaust flap control unit J883
    358
  • 3 SCR system (selective catalytic reduction)
    360
  • 3.1 Assembly overview - tank for reducing agent
    360
  • 3.2 Assembly overview - reducing agent delivery line
    362
  • 3.3 Assembly overview - delivery module for reducing agent
    363
  • 3.4 Assembly overview - injector for reducing agent
    364
  • 3.5 Removing and installing reducing agent tank
    365
  • 3.6 Removing and installing reducing agent supply line
    367
  • 3.7 Disconnecting reducing agent supply line
    370
  • 3.8 Removing and installing delivery module for reducing agent
    374
  • 3.9 Removing and installing injector for reduction agent N474
    376
  • 3.10 Removing and installing control unit for reducing-agent heater J891
    377
  • 3.11 Draining reducing agent tank
    378
  • 4 Exhaust gas temperature regulation
    381
  • 4.1 Assembly overview - exhaust gas temperature regulation
    381
  • 4.2 Removing and installing exhaust gas temperature sender 1 G235
    384
  • 4.3 Removing and installing exhaust gas temperature sender 2 G448
    385
  • 4.4 Removing and installing exhaust gas temperature sender 3 G495
    388
  • 4.5 Removing and installing exhaust gas temperature sender 4 G648
    389
  • 5 Exhaust gas recirculation
    392
  • 5.1 Assembly overview - exhaust gas recirculation
    392
  • 5.2 Assembly overview - exhaust gas recirculation valve 1 GX5
    396
  • 5.3 Removing and installing exhaust gas recirculation cooler
    396
  • 5.4 Checking exhaust gas recirculation cooler for leaks
    399
  • 5.5 Removing and installing exhaust gas recirculation valve 1 GX5
    401
  • 5.6 Removing and installing exhaust gas recirculation valve 2 GX6
    402
  • 5.7 Removing and installing exhaust gas recirculation temperature sensor G98
    405
  • Glow plug system
    407
  • 1 Glow plug system
    407
  • 1.1 Assembly overview - glow plug system
    407
  • 1.2 Removing and installing glow plug
    409
  • 1.3 Removing and installing automatic glow period control unit J179
    411
  • 1.4 Removing and installing Hall sender G40
    412
  • 1.5 Removing and installing engine speed sender G28
    412
Manufacturer's designation 4-cylinder common rail engine (2.0 l, 4V, turbocharger)
Manufacturer Volkswagen
Suitable for Jetta 4-türig Ll (1980 - 1984)
Suitable car types 163
Engine code CUUB, CVCA, DEJA, DELA, DEBA, DGMA
Category Reparaturanleitung

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