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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 Passat / Passat Variant

Original Volkswagen repair manual


16,70 €7% VAT incl.

Immediately available for download

Language: English

Digital PDF file

6.822 KB

201 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, Rules for cleanliness, Parts of fuel supply system and Charge air system with turbocharger. Show more
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Repair manual Passat / Passat Variant 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
    8
  • 1.3 Notes on installing
    9
  • 1.4 Assembly mountings
    10
  • Crankshaft group
    12
  • 1 Dismantling and assembling engine
    12
  • 1.1 Assembly overview - poly V-belt drive
    13
  • 1.2 Removing and installing poly V-belt
    13
  • 1.3 Assembly overview - toothed belt drive
    16
  • 1.4 Assembly overview - crankcase
    20
  • 2 Removing and installing sealing flange and flywheel
    21
  • 2.1 Assembly overview - sealing flanges and flywheel
    21
  • 2.2 Renewing crankshaft oil seal - pulley end
    22
  • 2.3 Removing and installing sealing flange - pulley end
    25
  • 2.4 Renewing crankshaft sealing flange - flywheel end
    27
  • 2.5 Removing and installing engine speed sender G28
    34
  • 3 Crankshaft
    36
  • 3.1 Assembly overview - crankshaft
    36
  • 3.2 Crankshaft dimensions
    41
  • 4 Pistons and conrods
    42
  • 4.1 Assembly overview - pistons and conrods
    42
  • 4.2 Separating new conrods
    45
  • 4.3 Checking piston projection at TDC
    45
  • 4.4 Piston and cylinder dimensions
    47
  • Cylinder head, valve gear
    48
  • 1 Cylinder head
    48
  • 1.1 Assembly overview - cylinder head
    49
  • 1.2 Removing and installing cylinder head cover
    52
  • 1.3 Removing, installing and tensioning toothed belts
    54
  • 1.4 Removing and installing cylinder head
    70
  • 1.5 Checking compression
    75
  • 2 Valve gear
    77
  • 2.1 Assembly overview - valve gear
    77
  • 2.2 Checking valve guides
    79
  • 2.3 Renewing valve stem seals
    81
  • 2.4 Removing and installing camshaft
    83
  • 2.5 Removing and installing camshaft oil seal
    87
  • Lubrication
    89
  • 1 Engine oil
    89
  • 1.1 Oil capacities
    89
  • 1.2 Checking engine oil level
    89
  • 1.3 Checking engine oil level
    89
  • 2 Parts of lubrication system
    90
  • 2.1 Assembly overview - oil pump, sump
    90
  • 2.2 Removing and installing sump
    91
  • 3 Oil filter bracket, oil pressure, engine oil cooler and oil supply line
    95
  • 3.1 Assembly overview - oil filter bracket and engine oil cooler
    95
  • 3.2 Checking oil pressure and oil pressure switch
    96
  • 3.3 Assembly overview - oil supply line to turbocharger
    97
  • 3.4 Removing and installing oil supply line to turbocharger
    98
  • Cooling
    100
  • 1 Parts of cooling system
    100
  • 1.1 Assembly overview - parts of cooling system, body side
    101
  • 1.3 Assembly overview - cooling system, engine side
    103
  • 1.4 Coolant hose schematic diagram
    105
  • 1.5 Draining and filling with coolant
    106
  • 1.6 Removing and installing fan support with fans
    108
  • 1.7 Removing and installing radiator
    110
  • 1.8 Removing and installing coolant pump
    112
  • 1.9 Removing and installing thermostat
    114
  • 1.10 Checking cooling system for leaks
    116
  • 1.11 Checking engine oil cooler for leaks
    118
  • Fuel supply system
    120
  • 1 Safety precautions when working on fuel supply system
    120
  • 2 Rules for cleanliness
    121
  • 3 Parts of fuel supply system
    122
  • 3.1 Assembly overview - fuel tank
    123
  • 3.2 Assembly overview - fuel filter
    125
  • 3.3 Removing and installing fuel cooler
    126
  • 3.4 Emptying fuel tank
    126
  • 3.5 Removing and installing fuel tank
    130
  • 3.6 Removing and installing fuel delivery unit
    132
  • 3.7 Removing and installing fuel gauge sender
    135
  • 3.8 Checking fuel pump
    135
  • 3.9 Assembly overview - accelerator mechanism
    141
  • 3.10 Checking tandem pump
    142
  • 3.11 Removing and installing tandem pump
    146
  • Turbocharging/supercharging
    150
  • 1 Charge air system with turbocharger
    150
  • 1.1 Safety precautions
    150
  • 1.2 Rules for cleanliness
    150
  • 1.3 Hose connections
    151
  • 1.4 Assembly overview - turbocharger
    152
  • 1.5 Removing and installing turbocharger
    156
  • 1.6 Assembly overview - charge air cooling
    158
  • 1.7 Vacuum hose schematic diagram
    161
  • 1.8 Checking charge air system for leaks
    162
  • Mixture preparation - injection
    165
  • 1 Diesel direct injection system
    165
  • 1.1 Safety precautions
    165
  • 1.2 Rules for cleanliness
    166
  • 1.3 Assembly overview - unit injector
    166
  • 1.4 Removing and installing unit injector
    168
  • 1.5 Adjusting non-contact gap of unit injectors
    170
  • 1.6 Removing and installing O-rings for unit injector
    171
  • 1.7 Assembly overview - intake manifold
    172
  • 1.8 Assembly overview - air filter
    175
  • 2 Engine control unit
    176
  • 2.1 Reading and erasing engine control unit fault memory
    176
  • 2.2 Removing and installing engine control unit
    177
  • 2.3 Removing and installing anti-theft engine control unit
    178
  • Exhaust system
    182
  • 1 Exhaust system
    182
  • 1.1 Assembly overview - front exhaust pipe with catalytic converter
    183
  • 1.2 Assembly overview - front exhaust pipe with particulate filter
    184
  • 1.3 Assembly overview - silencers
    186
  • 1.4 Aligning exhaust system free of stress
    187
  • 2 Exhaust gas recirculation system
    188
  • 2.1 Assembly overview - exhaust gas recirculation
    188
  • 2.2 Checking mechanical exhaust gas recirculation valve
    190
  • 2.3 Vacuum hose schematic diagram on solenoid valve block
    191
  • Glow plug system
    192
  • 1 Checking glow plug system
    192
  • 1.1 Checking glow plugs
    192
  • 1.2 Characteristics of ceramic glow plugs
    193
Manufacturer's designation 4-cylinder diesel engine (1.9 l engine)
Manufacturer Volkswagen
Suitable for Passat / Passat Variant (2005 - 2008)
Suitable car types 3C
Engine code BKC, BLS
Category Reparaturanleitung

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