4-cylinder diesel engine (1.9 l engine)

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• 2 Safety instructions
  3
• 2.1 Safety precautions when working on fuel supply system
  3
• 2.3 Safety precautions when working on cooling system
  4
• 3 General repair notes
  5
• 3.1 Rules for cleanliness
  5
• 3.2 Foreign objects in engine
  5
• Removing and installing engine
  6
• 1 Removing and installing engine
  6
• 1.1 Removing engine (Golf, Golf Plus)
  6
• 1.2 Removing engine (Touran)
  11
• 1.3 Removing engine (Passat)
  17
• 1.4 Securing engine to assembly stand
  24
• 1.5 Notes on installing
  25
• 1.6 Assembly mountings
  27
• Crankshaft group
  29
• 1 Dismantling and assembling engine
  29
• 1.1 Assembly overview - poly V-belt drive
  29
• 1.2 Assembly overview - toothed belt drive
  32
• 1.3 Removing and installing engine support
  34
• 1.4 Assembly overview - crankcase
  36
• 2 Removing and installing sealing flange and flywheel
  38
• 2.1 Assembly overview - sealing flanges and flywheel
  38
• 2.2 Removing and installing dual-mass flywheel
  39
• 2.3 Renewing crankshaft oil seal - pulley end
  40
• 2.4 Removing and installing sealing flange - pulley end
  42
• 2.5 Renewing crankshaft sealing flange - flywheel end
  45
• 3 Crankshaft
  52
• 3.1 Assembly overview - crankshaft
  52
• 4 Pistons and conrods
  58
• 4.1 Assembly overview - pistons and conrods
  58
• 4.2 Separating new conrod
  59
• 4.3 Checking piston projection at TDC
  60
• 4.4 Piston and cylinder dimensions
  61
• 4.5 Piston rings, cylinder bore and piston installation position
  61
• Cylinder head, valve gear
  64
• 1 Cylinder head
  64
• 1.1 Assembly overview - cylinder head
  64
• 1.2 Removing and installing cylinder head cover
  67
• 1.3 Removing, installing and tensioning toothed belt
  70
• 1.4 Removing and installing cylinder head
  88
• 1.5 Checking compression
  93
• 2 Valve gear
  96
• 2.1 Assembly overview - valve gear
  96
• 2.2 Checking valve guides
  98
• 2.3 Renewing valve stem seals
  99
• 2.4 Removing and installing camshaft
  101
• 2.5 Removing and installing camshaft oil seal
  105
• Lubrication
  108
• 1 Engine oil
  108
• 1.1 Oil capacities
  108
• 1.2 Checking engine oil level, observing differences in dip sticks
  108
• 2 Parts of lubrication system
  110
• 2.1 Assembly overview - oil pump, sump
  110
• 2.2 Removing and installing oil sump
  111
• 3 Oil filter bracket, oil pressure, engine oil cooler and oil supply line
  115
• 3.1 Assembly overview - oil filter bracket and engine oil cooler
  115
• 3.2 Checking oil pressure and oil pressure switch
  116
• 3.3 Assembly overview - oil supply line to turbocharger
  117
• 3.4 Removing and installing oil supply line to turbocharger
  118
• Cooling
  121
• 1 Parts of cooling system
  121
• 1.1 Coolant hoses
  122
• 1.2 Draining and filling coolant
  125
• 1.3 Coolant pump, regulation of cooling system
  129
• 1.4 Parts of cooling system, body side (radiator with two fans)
  133
• 1.5 Assembly overview - parts of cooling system, body side (radiator with one fan)
  135
• 1.6 Removing and installing fan support with fans (Golf, Golf Plus, Touran)
  135
• 1.7 Removing and installing fan support with fans (Passat)
  137
• 1.8 Parts of cooling system - engine side
  137
• 1.9 Removing and installing radiator (Golf, Golf Plus, Touran)
  140
• 1.10 Removing and installing radiator (Passat)
  141
• 1.11 Checking engine oil cooler for leaks
  142
• Fuel supply system
  144
• 1 Safety precautions
  144
• 1.1 Safety precautions when working on fuel supply system
  144
• 2 Rules for cleanliness
  145
• 2.1 Rules for cleanliness when working on fuel supply system
  145
• 3 Parts of fuel supply system (Golf, Golf Plus)
  146
• 3.1 Fuel tank, vehicles with front-wheel drive
  146
• 3.2 Fuel tank, vehicles with four-wheel drive
  149
• 3.3 Emptying fuel tank
  156
• 3.4 Removing and installing fuel delivery unit
  158
• 3.5 Removing and installing fuel gauge sender
  159
• 3.6 Checking fuel pump
  160
• 3.7 Assembly overview - fuel filter
  164
• 3.8 Removing and installing fuel cooler
  166
• 4 Parts of fuel supply system (Touran)
  168
• 4.1 Assembly overview - fuel tank with attachments
  168
• 4.2 Emptying fuel tank
  170
• 4.3 Removing and installing fuel tank
  173
• 4.4 Assembly overview - fuel filter
  174
• 4.5 Removing and installing fuel cooler
  176
• 4.6 Removing and installing fuel delivery unit
  176
• 4.7 Removing and installing fuel gauge sender
  178
• 4.8 Checking fuel pump
  179
• 5 Parts of fuel supply system (Passat)
  184
• 5.1 Fuel tank, vehicles with front-wheel drive
  184
• 5.2 Emptying fuel tank, vehicles with front-wheel drive
  191
• 5.3 Checking fuel pump
  193
• 5.4 Assembly overview - fuel filter
  198
• 5.5 Removing and installing fuel cooler
  200
• 6 Accelerator mechanism
  202
• 6.1 Assembly overview - accelerator mechanism
  202
• 7 Tandem pump
  204
• 7.1 Checking tandem pump
  204
• 7.2 Removing and installing tandem pump
  207
• Turbocharging/supercharging
  210
• 1 Turbocharger
  210
• 1.1 Safety precautions
  210
• 1.2 Rules for cleanliness
  210
• 1.3 Assembly overview - turbocharger
  211
• 1.4 Removing and installing turbocharger
  224
• 1.5 Vacuum hose schematic diagram
  226
• 2 Charge air system
  229
• 2.1 Assembly overview - parts of charge air cooling
  229
• 2.2 Hose connections
  232
• 2.3 Checking charge air system for leaks
  233
• Mixture preparation - injection
  236
• 1 Injection system
  236
• 1.1 Safety precautions
  236
• 1.2 Rules for cleanliness
  237
• 1.3 Removing and installing pre-wired wiring harness for unit injectors and glow plugs
  237
• 1.4 Assembly overview - unit injector
  240
• 1.5 Removing and installing unit injector
  241
• 1.6 Adjusting non-contact gap of unit injectors
  243
• 1.7 Removing and installing O-rings for unit injector
  244
• 2 Air filter
  246
• 2.1 Assembly overview - air filter
  246
• 3 Intake manifold
  247
• 3.1 Assembly overview - intake manifold
  247
• 4 Engine control unit
  251
• 4.1 Reading and deleting engine control unit event memory
  251
• 4.2 Adapting functions and components
  252
• 4.3 Removing and installing engine control unit (Golf)
  253
• 4.4 Removing and installing anti-theft engine control unit (Golf)
  253
• 4.5 Removing and installing engine control unit (Golf Plus)
  256
• 4.6 Removing and installing anti-theft engine control unit (Golf Plus)
  256
• 4.7 Removing and installing engine control unit (Touran)
  258
• 4.8 Removing and installing anti-theft engine control unit (Touran)
  259
• 4.9 Engine control unit (Passat)
  261
• Exhaust system
  267
• 1 Exhaust system
  267
• 1.1 Assembly overview - front exhaust pipe with catalytic converter
  267
• 1.2 Assembly overview - silencer with mountings (vehicles with front wheel drive)
  268
• 1.3 Assembly overview - silencers (Passat)
  270
• 1.4 Assembly overview - silencer with mountings (vehicles with four-wheel drive)
  271
• 1.5 Aligning exhaust system free of stress
  272
• 2 Emission control
  273
• 2.1 Assembly overview - front exhaust pipe with particulate filter
  273
• 3 Exhaust gas recirculation
  276
• 3.1 Assembly overview - parts of exhaust gas recirculation
  276
• 3.2 Checking mechanical exhaust gas recirculation valve
  280
• Glow plug system
  281
• 1 Glow plug system
  281
• 1.1 Removing, installing and checking glow plugs
  281
• 1.2 Characteristics of ceramic glow plugs
  282
• 1.3 Removing, installing and checking ceramic glow plugs
  282
• 1.4 Removing and installing engine speed sender G28
  284