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  • Examplepage for repair manual 4-cylinder diesel engine (1.6 l engine, common rail)
  • Examplepage for repair manual 2 4-cylinder diesel engine (1.6 l engine, common rail)
  • Examplepage for repair manual 3 4-cylinder diesel engine (1.6 l engine, common rail)
  • Examplepage for repair manual 4-cylinder diesel engine (1.6 l engine, common rail)
  • Examplepage for repair manual 2 4-cylinder diesel engine (1.6 l engine, common rail)
  • Examplepage for repair manual 3 4-cylinder diesel engine (1.6 l engine, common rail)

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

For Jetta / Jetta 2-türig Rl / Jetta 4-türig Ll / Golf VI Variant

Original Volkswagen repair manual


28,41 €7% VAT incl.

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Language: English

Digital PDF file

16.367 KB

372 Sites

Detailed technical data

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This repair manual contains: Removing and installing engine, Assembly mounting, except Jetta 2011 ▶, Pistons and conrods, Crankshaft, Cylinder head, Engine oil:, Oil filter bracket, oil pressure, engine oil cooler and oil supply line, Oil supply line and turbocharger support, Rules for cleanliness, Procedure should vehicle be misfueled, Parts of fuel supply system, Observe safety precautions when working on diesel direct injection fuel system and Exhaust gas recirculation. Show more
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Repair manual 4-cylinder diesel engine PDF download has the following content:

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
Manufacturer's designation 4-cylinder diesel engine (1.6 l engine, common rail)
Manufacturer Volkswagen
Suitable for Jetta (2005 - 2007) / Jetta 2-türig Rl (1980 - 1984) / Jetta 4-türig Ll (1980 - 1984) / Golf VI Variant (2010)
Suitable car types 1K2, 163, AJ5
Engine code CAYB
Category Reparaturanleitung

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