4-cylinder diesel engine (1.6 l engine, common rail)

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• Removing and installing engine
  2
• 1 Removing and installing engine
  2
• 1.1 Removing and installing engine cover
  2
• 1.2 Removing engine
  3
• 1.3 Separating gearbox from engine and assembling
  11
• 1.4 Securing engine on engine and gearbox support VAS 6095
  12
• 1.5 Notes on installing
  14
• 2 Assembly mounting, except Jetta 2011 ▶
  17
• 2.1 Assembly mountings
  17
• 2.2 Checking adjustment of engine assembly mountings
  19
• 2.3 Adjusting assembly mountings
  19
• 3 Assembly mounting, Jetta 2011 ▶
  23
• 3.1 Assembly overview - assembly mountings
  23
• 3.2 Removing and installing engine mounting
  24
• 3.3 Removing and installing gearbox mounting
  27
• 3.4 Removing and installing pendulum support
  29
• 3.5 Supporting engine in installation position
  30
• 3.6 Adjusting assembly mountings
  34
• 3.7 Checking adjustment of assembly mountings (engine and gearbox mountings)
  35
• Crankshaft group
  36
• 1 Dismantling and assembling engine
  36
• 1.1 Assembly overview - poly V-belt drive
  36
• 1.2 Removing and installing poly V-belt without air conditioner compressor
  39
• 1.3 Removing and installing poly V-belt with idler roller and air conditioner compressor
  40
• 1.4 Removing and installing poly V-belt with tensioning element
  41
• 1.5 Removing and installing tensioning element for poly V-belt
  42
• 1.6 Removing and installing vibration damper
  44
• 1.7 Removing and installing bracket for ancillaries
  44
• 1.8 Assembly overview - toothed belt drive
  46
• 1.9 Removing and installing engine bracket
  48
• 1.10 Assembly overview - crankcase
  51
• 2 Removing and installing sealing flange and flywheel
  53
• 2.1 Assembly overview - cylinder block, gearbox end
  53
• 2.2 Removing and installing dual-mass flywheel
  55
• 2.3 Renewing crankshaft sealing flange, flywheel end
  56
• 2.4 Renewing crankshaft oil seal, pulley end
  64
• 2.5 Removing and installing sealing flange - pulley end
  66
• 2.6 Removing and installing engine speed sender G28
  69
• 3 Pistons and conrods
  71
• 3.1 Assembly overview - pistons and conrods
  71
• 3.2 Separating new conrod
  74
• 3.3 Piston and cylinder dimensions
  74
• 3.4 Checking piston projection at TDC
  74
• 4 Crankshaft
  77
• 4.1 Assembly overview - crankshaft
  77
• 4.2 Renewing needle bearing in crankshaft, vehicles with dual clutch gearbox only
  78
• 4.3 Crankshaft dimensions
  79
• Cylinder head, valve gear
  80
• 1 Cylinder head
  80
• 1.1 Assembly overview - cylinder head cover
  80
• 1.2 Removing and installing Hall sender G40
  81
• 1.3 Removing and installing cylinder head cover
  83
• 1.4 Removing and installing injector seals
  89
• 1.5 Assembly overview - cylinder head
  89
• 1.6 Removing, installing and tensioning toothed belt
  92
• 1.7 Removing and installing cylinder head
  106
• 1.8 Removing and installing vacuum pump
  118
• 1.9 Checking compression
  118
• 2 Valve gear
  120
• 2.1 Assembly overview - valve gear
  120
• 2.2 Checking valve guides
  121
• 2.3 Renewing valve stem seals
  122
• 2.4 Removing and installing camshafts
  126
• 2.5 Checking hydraulic compensation elements
  133
• 2.6 Removing and installing camshaft oil seal
  133
• Lubrication
  136
• 1 Engine oil:
  136
• 1.1 Oil capacities
  136
• 1.2 Checking engine oil level
  136
• 2 Parts of lubrication system
  137
• 2.1 Assembly overview - oil pump, sump
  137
• 2.2 Removing and installing sump
  139
• 3 Oil filter bracket, oil pressure, engine oil cooler and oil supply line
  143
• 3.1 Assembly overview - oil filter bracket and engine oil cooler
  143
• 3.2 Checking oil pressure and oil pressure switch
  144
• 4 Oil supply line and turbocharger support
  147
• 4.1 Assembly overview - oil supply line and turbocharger support
  147
• 4.2 Removing and installing oil supply line and turbocharger support
  147
• Cooling
  153
• 1 Parts of cooling system
  153
• 1.1 Assembly overview - parts of cooling system, body side
  154
• 1.2 Assembly overview - parts of cooling system, engine side
  156
• 1.3 Connection diagram for coolant hoses - not for Jetta from MY 2011
  158
• 1.6 Assembly overview - coolant pump and thermostat
  161
• 1.7 Assembly overview - coolant pump and 4/2-way valve with thermostat
  162
• 2 Repairing cooling system
  163
• 2.1 Removing and installing cowling with radiator fan V7 and radiator fan 2 V177
  163
• 2.2 Draining and adding coolant
  164
• 2.3 Removing and installing radiator
  169
• 2.4 Removing and installing coolant pump
  171
• 2.5 Removing and installing thermostat
  172
• 2.6 Checking thermostat
  174
• 2.7 Removing and installing 4/2-way valve with thermostat
  174
• 2.8 Checking cooling system for leaks
  180
• 2.9 Checking engine oil cooler for leaks
  182
• Fuel supply system
  184
• 1 Safety measures when working on fuel supply
  184
• 2 Rules for cleanliness
  185
• 3 Procedure should vehicle be misfueled
  186
• 3.1 Step 1 (Engine was started with incorrect fuel)
  186
• 3.2 Step 2 (Engine was not started with incorrect fuel)
  187
• 3.3 Step 3 (There are filings in fuel delivery unit and fuel tank)
  188
• 3.4 Step 4 (There are no filings in fuel delivery unit and fuel tank)
  189
• 3.5 Step 5 (There are filings in high-pressure pump)
  189
• 3.6 Step 6 (There are no filings in high-pressure pump)
  189
• 4 Parts of fuel supply system
  190
• 4.1 Assembly overview - fuel tank, all vehicles apart from Jetta from MY 2011
  190
• 4.2 Assembly overview - fuel tank, only Jetta from MY 2011
  192
• 4.3 Emptying fuel tank
  194
• 4.4 Removing and installing fuel tank
  197
• 4.5 Removing and installing fuel delivery unit
  200
• 4.6 Removing and installing fuel gauge sender
  204
• 5 Repairing fuel supply
  206
• 5.1 Assembly overview - fuel filter, all vehicles but Jetta from MY 2011
  206
• 5.2 Assembly overview - fuel filter, only Jetta from MY 2011
  208
• 5.3 Removing and installing fuel filter
  208
• 5.5 Assembly overview - fuel filter, 6.0 bar low pressure fuel system
  212
• 5.6 Removing and installing fuel filter, 6.0 bar low pressure fuel system
  213
• 5.7 Checking fuel pump (pressurisation pump) G6 / fuel pump 2 V277
  214
• 5.8 Checking fuel pump - vehicles with 6.0 bar low pressure fuel system
  220
• 6 Electronic power control (EPC)
  232
• 6.1 Function of EPC system
  232
• 6.2 Assembly overview - accelerator module
  232
• 6.3 Removing and installing accelerator pedal module
  233
• Turbocharging/supercharging
  236
• 1 Safety precautions when working on charge air system and turbocharger
  236
• 2 Rules for cleanliness
  237
• 3 Turbocharger
  238
• 3.1 Assembly overview - turbocharger
  238
• 3.2 Tightening exhaust gas temperature sender 1 G235
  241
• 3.3 Removing and installing turbocharger
  242
• 4 Charge air system
  250
• 4.1 Assembly overview - charge air system
  250
• 4.2 Removing and installing charge air cooler
  251
• 4.3 Assembly overview - charge-air hose connections
  253
• 4.4 Vacuum hose connection diagram
  256
• 4.5 Checking charge air system for leaks
  257
• 4.6 Checking vacuum system
  260
• Mixture preparation - injection
  263
• 1 Observe safety precautions when working on diesel direct injection fuel system
  263
• 2 Rules for cleanliness
  264
• 3 Instructions for working on fuel system
  265
• 4 Diesel direct injection system
  267
• 4.1 System layout
  268
• 4.2 Assembly overview - fuel system
  270
• 4.3 Assembly overview - installation position of clamp
  275
• 4.4 Removing and installing injectors (piezo injectors)
  276
• 4.5 Removing and installing fuel rail
  280
• 4.6 Removing and installing high-pressure lines
  284
• 4.7 Checking fuel pressure regulating valve N276
  289
• 4.8 Removing and installing fuel pressure regulating valve N 276
  290
• 4.9 Removing and installing fuel pressure sender G247
  292
• 4.10 Removing and installing high-pressure pump
  294
• 4.11 Filling/bleeding high-pressure pump/fuel system
  300
• 4.12 Checking for leaks in the fuel system
  301
• 4.13 Check pressure retention valve in fuel return line
  302
• 4.14 Checking injectors (piezo injectors) with vacuum
  303
• 4.16 Assembly overview \- intake manifold with attachments, vehicles without intake manifold flap
  307
• 4.18 Removing and installing throttle valve module J338
  311
• 4.19 Assembly overview - air filter
  312
• 4.20 Removing and installing air filter housing
  314
• 4.21 Removing and installing air filter element
  315
• 4.22 Removing and installing air mass meter G70
  317
• 5 Engine control unit
  319
• 5.3 Removing and installing engine control unit J623 , only Jetta from MY 2011
  324
• Exhaust system
  327
• 1 Exhaust system
  327
• 1.2 Assembly overview - particulate filter, only Jetta from MY 2011
  330
• 1.3 Tightening exhaust gas temperature sender 3 G495
  331
• 1.4 Removing and installing pressure differential sender G 505
  332
• 1.5 Assembly overview - front exhaust pipe with catalytic converter
  335
• 1.6 Removing and installing particulate filter
  337
• 1.7 Assembly overview - silencers
  345
• 1.8 Separating exhaust system
  345
• 1.9 Aligning exhaust system free of stress
  347
• 1.10 Installation position of clamp
  348
• 2 Exhaust gas recirculation
  349
• 2.1 Assembly overview - exhaust gas recirculation
  349
• 2.2 Checking changeover for exhaust gas recirculation cooler
  350
• 2.3 Removing and installing exhaust gas recirculation cooler
  351
• 2.4 Checking exhaust gas recirculation cooler for leaks
  354
• 2.5 Cleaning exhaust gas recirculation system
  357
• Glow plug system
  364
• 1 Glow plug system
  364
• 1.1 Removing and installing glow plug
  364
• 1.2 Checking glow plugs
  366