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
• Removing and installing engine
  2
• 1 Removing and installing engine
  2
• 1.1 Removing engine
  2
• 1.2 Securing engine to assembly stand
  7
• 1.3 Notes on installing
  7
• 1.4 Assembly mountings
  10
• Crankshaft group
  12
• 1 Dismantling and assembling engine
  12
• 1.1 Assembly overview - poly V-belt drive
  12
• 1.2 Removing and installing poly V-belt
  13
• 1.3 Assembly overview - toothed belt drive
  15
• 1.4 Assembly overview - crankcase
  19
• 2 Removing and installing sealing flange and flywheel
  20
• 2.1 Assembly overview - sealing flanges and flywheel
  20
• 2.2 Renewing crankshaft oil seal - pulley end
  21
• 2.3 Removing and installing sealing flange - pulley end
  23
• 2.4 Renewing crankshaft sealing flange - flywheel end
  25
• 2.5 Removing and installing engine speed sender G28
  31
• 3 Crankshaft
  33
• 3.1 Assembly overview - crankshaft
  33
• 3.2 Crankshaft dimensions
  38
• 4 Pistons and conrods
  39
• 4.1 Assembly overview - pistons and conrods
  39
• 4.2 Separating new conrod
  40
• 4.3 Checking piston projection at TDC
  41
• 4.4 Piston and cylinder dimensions
  42
• 4.5 Piston rings, cylinder bore and piston installation position
  42
• Cylinder head, valve gear
  44
• 1 Cylinder head
  44
• 1.1 Assembly overview - cylinder head
  45
• 1.2 Removing and installing cylinder head cover
  48
• 1.3 Removing, installing and tensioning toothed belts
  50
• 1.4 Removing and installing cylinder head
  67
• 1.5 Checking compression
  71
• 2 Valve gear
  74
• 2.1 Assembly overview - valve gear
  74
• 2.2 Checking valve guides
  76
• 2.3 Renewing valve stem seals
  78
• 2.4 Removing and installing camshaft
  80
• 2.5 Removing and installing camshaft oil seal
  84
• Lubrication
  86
• 1 Engine oil
  86
• 1.1 Oil capacities
  86
• 1.2 Checking engine oil level
  86
• 2 Parts of lubrication system
  87
• 2.1 Assembly overview - oil pump, sump
  87
• 2.2 Removing and installing sump
  88
• 3 Oil filter bracket, oil pressure, engine oil cooler and oil supply line
  92
• 3.1 Assembly overview - oil filter bracket and engine oil cooler
  92
• 3.2 Checking oil pressure and oil pressure switch
  93
• 3.3 Assembly overview - oil supply line to turbocharger
  94
• 3.4 Removing and installing oil supply line to turbocharger
  95
• Cooling
  97
• 1 Parts of cooling system
  97
• 1.1 Parts of cooling system, body side
  98
• 1.2 Parts of cooling system, engine side
  99
• 1.3 Coolant hose schematic diagram
  101
• 1.4 Draining and filling with coolant
  102
• 1.5 Removing and installing radiator
  105
• 1.6 Removing and installing coolant pump
  106
• 1.7 Removing and installing thermostat
  108
• 1.8 Checking cooling system for leaks
  110
• 1.9 Checking engine oil cooler for leaks
  112
• Fuel supply system
  114
• 1 Safety precautions when working on fuel supply system
  114
• 2 Rules for cleanliness
  115
• 3 Fuel tank, vehicles with front-wheel drive
  116
• 3.1 Assembly overview - fuel tank
  116
• 3.2 Emptying fuel tank
  117
• 3.3 Removing and installing fuel tank
  121
• 3.4 Removing and installing fuel delivery unit
  123
• 3.5 Removing and installing fuel gauge sender
  124
• 3.6 Checking fuel pump
  125
• 4 Fuel tank, vehicles with four-wheel drive
  127
• 4.1 Assembly overview - fuel tank
  127
• 4.2 Emptying fuel tank
  128
• 4.3 Removing and installing fuel tank
  132
• 4.4 Removing and installing fuel gauge sender 2 G169
  135
• 4.5 Removing and installing suction-jet pump
  137
• 4.6 Checking fuel pump
  138
• 5 Repairing fuel supply system
  140
• 5.1 Assembly overview - fuel filter
  140
• 5.2 Removing and installing fuel cooler
  141
• 5.3 Assembly overview - accelerator mechanism
  142
• 5.4 Checking tandem pump
  143
• 5.5 Removing and installing tandem pump
  147
• Turbocharging/supercharging
  151
• 1 Charge air system with turbocharger
  151
• 1.1 Safety precautions
  151
• 1.2 Rules for cleanliness
  151
• 1.3 Assembly overview - turbocharger
  152
• 1.4 Removing and installing turbocharger
  156
• 1.5 Assembly overview - parts of charge air cooling
  158
• 1.6 Hose connections
  161
• 1.7 Checking charge air system for leaks
  162
• 1.8 Vacuum hose schematic diagram
  164
• Mixture preparation - injection
  166
• 1 Diesel direct injection system
  166
• 1.1 Safety precautions
  166
• 1.2 Rules for cleanliness
  167
• 1.3 Assembly overview - unit injector
  167
• 1.4 Removing and installing unit injector
  169
• 1.5 Adjusting non-contact gap of unit injectors
  171
• 1.6 Removing and installing O-rings for unit injector
  172
• 1.7 Assembly overview - intake manifold
  174
• 1.8 Cleaning the intake manifold flap support, Engine code BLS and BXJ
  176
• 1.9 Assembly overview - air filter
  177
• 2 Engine control unit
  178
• 2.1 Reading and erasing engine control unit fault memory
  178
• 2.2 Adapting functions and components
  179
• 2.3 Removing and installing engine control unit, Golf
  180
• 2.4 Removing and installing anti-theft engine control unit, Golf
  180
• 2.5 Removing and installing engine control unit, Golf Plus
  183
• 2.6 Removing and installing anti-theft engine control unit, Golf Plus
  183
• Exhaust system
  186
• 1 Exhaust system
  186
• 1.1 Assembly overview - front exhaust pipe with catalytic converter
  186
• 1.2 Assembly overview - front exhaust pipe with particulate filter
  187
• 1.3 Assembly overview - silencer with mountings (vehicles with front wheel drive)
  189
• 1.4 Assembly overview - silencer with mountings (vehicles with four-wheel drive)
  191
• 1.5 Aligning exhaust system free of stress
  192
• 2 Exhaust gas recirculation system
  193
• 2.1 Assembly overview - parts of exhaust gas recirculation
  193
• Glow plug system
  198
• 1 Checking glow plug system
  198
• 1.1 Removing, installing and checking glow plugs
  198
• 1.2 Characteristics of ceramic glow plugs
  199
• 1.3 Removing, installing and checking ceramic glow plugs
  200