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  • Examplepage for repair manual 4-cylinder diesel engine (2.0 l engine)
  • Examplepage for repair manual 2 4-cylinder diesel engine (2.0 l engine)
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4-cylinder diesel engine (2.0 l engine)

For Passat / Passat Variant

Original Volkswagen repair manual


13,78 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

6.128 KB

161 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Cylinder head, Parts of lubrication system and Additive container. 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 Notes on removing
    4
  • 1.2 Notes on installing
    7
  • 1.3 Torque settings
    8
  • 1.4 Front engine mounting
    8
  • 1.5 Additional information and removal instructions for vehicles with air conditioner
    9
  • Crankshaft group
    11
  • 1 Dismantling and assembling engine
    11
  • 1.1 Overview
    11
  • 1.2 Removing and installing air conditioner compressor poly V-belt
    17
  • 1.3 Removing and installing poly V-belt
    18
  • 2 Removing and installing sealing flanges and flywheel or drive plate
    19
  • 2.1 Assembly overview - sealing flange and flywheel/drive plate
    19
  • 2.2 Renewing crankshaft oil seal - pulley end
    20
  • 2.3 Removing and installing drive plate
    22
  • 2.4 Removing and installing sealing flange - pulley end
    23
  • 3 Removing and installing crankshaft
    27
  • 3.1 Assembly overview - crankshaft
    27
  • 3.2 Pulling needle roller bearing out of and driving into crankshaft
    29
  • 3.3 Crankshaft dimensions
    30
  • 4 Dismantling and assembling pistons and conrods
    31
  • 4.1 Assembly overview - pistons and conrods
    31
  • 4.2 Piston and cylinder
    32
  • 4.3 Checking piston projection at TDC
    34
  • 4.4 Piston and cylinder dimensions
    35
  • Cylinder head, valve gear
    36
  • 1 Cylinder head
    36
  • 1.1 Assembly overview - cylinder head
    36
  • 1.2 Removing, installing and tensioning toothed belts
    39
  • 1.3 Removing and installing cylinder head
    43
  • 1.4 Checking compression
    47
  • 2 Repairing valve gear
    50
  • 2.1 Assembly overview - valve gear
    50
  • 2.2 Checking valve guides
    52
  • 2.3 Renewing valve stem seals
    53
  • 2.4 Removing and installing camshaft
    54
  • 2.5 Removing and installing camshaft oil seal
    58
  • Lubrication
    60
  • 1 Parts of lubrication system
    60
  • 1.1 Engine oil
    60
  • 1.2 Part I
    60
  • 1.3 Part II
    62
  • 1.4 Part III
    65
  • 1.5 Removing and installing oil pump
    66
  • 1.6 Removing and installing balancer shaft module
    68
  • 1.7 Converting balancer shaft module to spur gear drive
    70
  • 1.8 Assembly overview - oil supply line
    76
  • 1.9 Removing and installing sump
    77
  • 1.10 Checking oil pressure and oil pressure switch
    82
  • Cooling
    85
  • 1 Removing and installing parts of cooling system
    85
  • 1.1 Parts of cooling system - body side
    85
  • 1.2 Parts of cooling system - engine side
    87
  • 1.3 Draining and filling coolant
    89
  • 1.4 Removing and installing radiator
    92
  • 1.5 Removing and installing coolant pump
    94
  • 1.6 Removing and installing thermostat
    96
  • 1.7 Removing and installing viscous fan coupling
    98
  • Fuel supply system
    100
  • 1 Parts of fuel system
    100
  • 1.1 Safety precautions when working on fuel supply system
    100
  • 1.2 Rules for cleanliness
    101
  • 1.3 Assembly overview - fuel tank
    101
  • 1.4 Assembly overview - fuel filter
    104
  • 1.5 Removing and installing fuel cooler
    105
  • 1.6 Emptying fuel tank
    106
  • 1.7 Removing and installing fuel tank
    106
  • 1.8 Checking fuel pump
    109
  • 1.9 Removing and installing fuel delivery unit
    113
  • 1.10 Removing and installing fuel gauge sender
    118
  • 1.11 Assembly overview - accelerator mechanism
    118
  • 1.12 Checking tandem pump
    119
  • 1.13 Removing and installing tandem pump
    121
  • 2 Additive container
    124
  • 2.1 Safety precautions when working on additive container
    124
  • 2.2 Removing and installing additive container
    124
  • 2.3 Assembly overview - additive container
    125
  • Turbocharging/supercharging
    128
  • 1 Charge air system with turbocharger
    128
  • 1.1 Safety precautions
    128
  • 1.2 Rules for cleanliness
    128
  • 1.3 Hose connections with push-on connectors
    129
  • 1.4 Assembly overview - turbocharger
    129
  • 1.5 Assembly overview - charge air cooling
    131
  • Mixture preparation - injection
    133
  • 1 Repairing diesel direct injection system
    133
  • 1.1 Safety precautions
    133
  • 1.2 Rules for cleanliness
    134
  • 1.3 Assembly overview - intake manifold with intake manifold flap motor
    134
  • 1.4 Assembly overview - air filter
    136
  • 1.5 Assembly overview - unit injector
    136
  • 1.6 Removing and installing unit injector O-rings
    137
  • 1.7 Removing and installing unit injector
    139
  • 2 Engine control unit
    143
  • 2.1 Reading and erasing engine control unit fault memory
    143
  • 2.2 Adapting functions and components
    144
  • 2.3 Removing and installing engine control unit
    145
  • Exhaust system
    146
  • 1 Removing and installing parts of exhaust system
    146
  • 1.3 Assembly overview - silencer with mountings
    149
  • 2 Exhaust gas recirculation system
    151
  • 2.1 Assembly overview - exhaust gas recirculation
    151
  • Glow plug system
    153
  • 1 Checking glow plug system
    153
  • 1.1 Removing, installing and checking ceramic glow plugs
    153
Manufacturer's designation 4-cylinder diesel engine (2.0 l engine)
Manufacturer Volkswagen
Suitable for Passat / Passat Variant (1997 - 2005)
Suitable car types 3B
Engine code BHW
Category Reparaturanleitung

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