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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 Touran

Original Volkswagen repair manual


16,19 €7% VAT incl.

Immediately available for download

Language: English

Digital PDF file

7.641 KB

194 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Sealing flange, seals and flywheel, Crankshaft, Cylinder head, Engine oil, Parts of lubrication system and Oil filter bracket, oil pressure, engine oil cooler and oil supply line. Show more
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Repair manual Touran 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 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 Sealing flange, seals 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
  • 3 Crankshaft
    33
  • 3.1 Assembly overview - crankshaft
    33
  • 3.2 Crankshaft dimensions
    38
  • 4 Dismantling and assembling 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
    45
  • 1 Cylinder head
    45
  • 1.1 Assembly overview - cylinder head
    46
  • 1.2 Removing and installing cylinder head cover
    49
  • 1.3 Removing, installing and tensioning toothed belts
    51
  • 1.4 Removing and installing cylinder head
    66
  • 1.5 Checking compression
    71
  • 2 Valve gear
    73
  • 2.1 Assembly overview - valve gear
    73
  • 2.2 Checking valve guides
    75
  • 2.3 Renewing valve stem seals
    77
  • 2.4 Removing and installing camshaft
    79
  • 2.5 Removing and installing camshaft oil seal
    83
  • Lubrication
    85
  • 1 Engine oil
    85
  • 1.1 Oil capacities
    85
  • 1.2 Checking engine oil level
    85
  • 2 Parts of lubrication system
    86
  • 2.1 Assembly overview - oil pump, sump
    86
  • 2.2 Removing and installing sump
    87
  • 3 Oil filter bracket, oil pressure, engine oil cooler and oil supply line
    91
  • 3.1 Assembly overview - oil filter bracket and engine oil cooler
    91
  • 3.2 Checking oil pressure and oil pressure switch
    92
  • 3.3 Assembly overview - oil supply line to turbocharger
    93
  • 3.4 Removing and installing oil supply line to turbocharger
    94
  • Cooling
    97
  • 1 Removing and installing parts of cooling system
    97
  • 1.1 Assembly overview - parts of cooling system, body side (radiator with two radiator fans)
    98
  • 1.3 Parts of cooling system, engine side
    100
  • 1.4 Coolant hose schematic diagram
    102
  • 1.5 Draining and filling with coolant
    103
  • 1.6 Removing and installing radiator
    106
  • 1.7 Removing and installing coolant pump
    107
  • 1.8 Removing and installing thermostat
    109
  • 1.9 Checking cooling system for leaks
    111
  • 1.10 Checking oil cooler for leaks
    113
  • Fuel supply system
    115
  • 1 Parts of fuel supply system
    115
  • 1.1 Safety precautions when working on fuel supply system
    115
  • 1.2 Rules for cleanliness
    116
  • 1.3 Fuel tank with attachments
    117
  • 1.4 Assembly overview - fuel filter (AVQ, BKC, BRU)
    119
  • 1.5 Assembly overview - fuel filter (BLS, BXE, BXF, BXJ)
    120
  • 1.6 Removing and installing fuel cooler
    121
  • 1.7 Emptying fuel tank
    122
  • 1.8 Removing and installing fuel tank
    126
  • 1.9 Removing and installing fuel delivery unit
    127
  • 1.10 Removing and installing fuel gauge sender
    129
  • 1.11 Checking fuel pump
    130
  • 1.12 Checking voltage supply and current draw of fuel pump
    132
  • 1.13 Assembly overview - accelerator mechanism
    134
  • 1.14 Checking tandem pump
    136
  • 1.15 Removing and installing tandem pump
    140
  • Turbocharging/supercharging
    144
  • 1 Charge air system with turbocharger
    144
  • 1.1 Safety precautions
    144
  • 1.2 Rules for cleanliness
    144
  • 1.3 Hose connections
    145
  • 1.4 Assembly overview - turbocharger
    146
  • 1.5 Removing and installing turbocharger
    150
  • 1.6 Assembly overview - parts of charge air cooling
    152
  • 1.7 Vacuum hose schematic diagram
    155
  • 1.8 Checking charge air system for leaks
    156
  • Mixture preparation - injection
    159
  • 1 Diesel direct injection system
    159
  • 1.1 Safety precautions
    159
  • 1.2 Rules for cleanliness
    160
  • 1.3 Assembly overview - unit injector
    160
  • 1.4 Removing and installing unit injector
    162
  • 1.5 Adjusting non-contact gap of unit injectors
    164
  • 1.6 Removing and installing O-rings for unit injector
    165
  • 1.7 Assembly overview - intake manifold
    167
  • 1.8 Assembly overview - air filter
    169
  • 2 Engine control unit
    170
  • 2.1 Reading and erasing engine control unit fault memory
    170
  • 2.2 Adapting functions and components
    171
  • 2.3 Removing and installing engine control unit
    171
  • 2.4 Removing and installing anti-theft engine control unit
    172
  • Exhaust system
    176
  • 1 Exhaust system
    176
  • 1.1 Assembly overview - front exhaust pipe with catalytic converter
    176
  • 1.2 Assembly overview - front exhaust pipe with particulate filter
    177
  • 1.3 Assembly overview - silencers with mountings
    179
  • 1.4 Aligning exhaust system free of stress
    181
  • 2 Exhaust gas recirculation system
    182
  • 2.1 Assembly overview - parts of exhaust gas recirculation
    182
  • Glow plug system
    185
  • 1 Checking glow plug system
    185
  • 1.1 Checking glow plug system
    185
Manufacturer's designation 4-cylinder diesel engine (1.9 l engine)
Manufacturer Volkswagen
Suitable for Touran (2003 - 2011)
Suitable car types 1T
Engine code BXE, BXF, AVQ, BKC, BRU, BLS
Category Reparaturanleitung

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