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  • Examplepage for repair manual 4-cylinder diesel engine (1.9 l engine)
  • Examplepage for repair manual 2 4-cylinder diesel engine (1.9 l engine)
  • Examplepage for repair manual 3 4-cylinder diesel engine (1.9 l engine)

4-cylinder diesel engine (1.9 l engine)

For Golf / Touran / Passat / Passat Variant / Golf Plus

Original Volkswagen repair manual


23,09 €7% VAT incl.

Immediately available for download

Language: English

Digital PDF file

9.034 KB

291 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Crankshaft, Pistons and conrods, Cylinder head, Engine oil, Oil filter bracket, oil pressure, engine oil cooler and oil supply line, Safety precautions, Rules for cleanliness, Parts of fuel supply system (Golf, Golf Plus), Tandem pump, Turbocharger and Exhaust system. 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
  • 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
Manufacturer's designation 4-cylinder diesel engine (1.9 l engine)
Manufacturer Volkswagen
Suitable for Golf (2004 - 2007) / Touran (2003 - 2011) / Passat / Passat Variant (2005 - 2008) / Golf Plus (2005 - 2007)
Suitable car types 1K1, 3C, 5M
Engine code BXE, BXF, AVQ, BJB, BKC, BRU, BLS
Category Reparaturanleitung

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