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  • Examplepage for repair manual 4-cylinder diesel engine (2.0 l engine, 2-valve, TDI)
  • Examplepage for repair manual 2 4-cylinder diesel engine (2.0 l engine, 2-valve, TDI)
  • Examplepage for repair manual 3 4-cylinder diesel engine (2.0 l engine, 2-valve, TDI)
  • Examplepage for repair manual 4-cylinder diesel engine (2.0 l engine, 2-valve, TDI)
  • Examplepage for repair manual 2 4-cylinder diesel engine (2.0 l engine, 2-valve, TDI)
  • Examplepage for repair manual 3 4-cylinder diesel engine (2.0 l engine, 2-valve, TDI)

4-cylinder diesel engine (2.0 l engine, 2-valve, TDI)

For Golf / Golf Plus

Original Volkswagen repair manual


15,16 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

6.098 KB

180 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 and oil cooler, Safety precautions when working on fuel supply system, Rules for cleanliness, Fuel tank, vehicles with front-wheel drive and Charge air system with turbocharger. Show more
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Repair manual Golf / Golf Plus 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
    8
  • 1.4 Assembly mountings
    11
  • Crankshaft group
    12
  • 1 Dismantling and assembling engine
    12
  • 1.1 Assembly overview - toothed belt drive
    12
  • 1.2 Assembly overview - poly V-belt drive
    14
  • 1.3 Removing and installing poly V-belt
    14
  • 1.4 Assembly overview - crankcase
    16
  • 2 Removing and installing sealing flange and flywheel
    19
  • 2.1 Assembly overview - sealing flange and flywheel
    19
  • 2.2 Renewing crankshaft oil seal - pulley end
    20
  • 2.3 Removing and installing sealing flange - pulley end
    22
  • 2.4 Renewing crankshaft sealing flange - flywheel end
    24
  • 3 Crankshaft
    33
  • 3.1 Assembly overview - crankshaft
    33
  • 3.2 Crankshaft dimensions
    34
  • 3.3 Pulling needle bearing out of and driving into crankshaft
    34
  • 4 Pistons and conrods
    36
  • 4.1 Assembly overview - pistons and conrods
    36
  • 4.2 Separating new conrods
    37
  • 4.3 Checking piston projection at TDC
    38
  • 4.4 Piston and cylinder dimensions
    39
  • 4.5 Piston rings, cylinder bore and piston installation position
    39
  • Cylinder head, valve gear
    42
  • 1 Cylinder head
    42
  • 1.1 Assembly overview - cylinder head
    42
  • 1.2 Removing and installing cylinder head cover
    45
  • 1.3 Removing, installing and tensioning toothed belt
    47
  • 1.4 Removing and installing cylinder head
    61
  • 1.5 Checking compression
    65
  • 2 Repairing valve gear
    68
  • 2.1 Assembly overview - valve gear
    68
  • 2.2 Checking valve guides
    70
  • 2.3 Renewing valve stem seals
    71
  • 2.4 Removing and installing camshaft
    73
  • 2.5 Removing and installing camshaft oil seal
    77
  • Lubrication
    80
  • 1 Engine oil
    80
  • 1.1 Oil capacities
    80
  • 1.2 Checking engine oil level
    80
  • 2 Parts of lubrication system
    81
  • 2.1 Assembly overview - oil pump, sump
    81
  • 2.2 Removing and installing oil sump
    82
  • 3 Oil filter bracket, oil pressure and oil cooler
    85
  • 3.1 Assembly overview - oil filter bracket and oil cooler
    85
  • 3.2 Checking oil pressure and oil pressure switch
    86
  • Cooling
    88
  • 1 Parts of cooling system
    88
  • 1.1 Parts of cooling system, body side
    88
  • 1.2 Parts of cooling system - engine side
    90
  • 1.3 Coolant hose schematic diagram
    92
  • 1.4 Draining and filling coolant
    93
  • 1.5 Removing and installing fan mounting with fans
    95
  • 1.6 Removing and installing radiator
    96
  • 1.7 Removing and installing coolant pump
    98
  • 1.8 Removing and installing thermostat
    100
  • 1.9 Checking cooling system for leaks
    101
  • 1.10 Checking oil cooler for leaks
    103
  • Fuel supply system
    106
  • 1 Safety precautions when working on fuel supply system
    106
  • 2 Rules for cleanliness
    107
  • 3 Fuel tank, vehicles with front-wheel drive
    108
  • 3.1 Assembly overview - fuel tank
    108
  • 3.2 Emptying fuel tank
    110
  • 3.3 Removing and installing fuel tank
    112
  • 3.4 Removing and installing fuel delivery unit
    114
  • 3.5 Removing and installing fuel gauge sender
    116
  • 4 Fuel tank, vehicles with four-wheel drive
    117
  • 4.1 Assembly overview - fuel tank
    117
  • 4.2 Emptying fuel tank
    118
  • 4.3 Removing and installing fuel tank
    120
  • 4.4 Removing and installing fuel gauge sender 2 G169
    123
  • 4.5 Removing and installing suction-jet pump
    125
  • 5 Repairing fuel supply system
    126
  • 5.1 Assembly overview - fuel filter
    126
  • 5.2 Checking fuel pump
    128
  • 5.3 Removing and installing fuel cooler
    132
  • 5.4 Checking tandem pump
    133
  • 5.5 Removing and installing tandem pump
    137
  • 5.6 Assembly overview - accelerator mechanism
    140
  • Turbocharging/supercharging
    142
  • 1 Charge air system with turbocharger
    142
  • 1.1 Safety precautions
    142
  • 1.2 Rules for cleanliness
    142
  • 1.3 Installing hose connections with plug-in connectors
    143
  • 1.4 Assembly overview - turbocharger
    144
  • 1.5 Removing and installing exhaust gas temperature sender 1 G235
    145
  • 1.6 Removing and installing turbocharger
    146
  • 1.7 Assembly overview - charge air cooling
    147
  • 1.8 Checking charge air system for leaks
    148
  • Mixture preparation - injection
    151
  • 1 Repairing diesel direct injection system
    151
  • 1.1 Safety precautions
    151
  • 1.2 Rules for cleanliness
    152
  • 1.3 Assembly overview - unit injector
    152
  • 1.4 Removing and installing O-rings for unit injector
    153
  • 1.5 Removing and installing unit injector
    154
  • 1.6 Assembly overview - intake manifold with intake manifold flap
    157
  • 1.7 Assembly overview - air filter
    159
  • 2 Engine control unit
    160
  • 2.1 Reading and erasing engine control unit fault memory
    160
  • 2.2 Adapting functions and components
    161
  • 2.3 Removing and installing anti-theft engine control unit
    162
  • Exhaust system
    164
  • 1 Parts of the exhaust system
    164
  • 1.1 Assembly overview - front exhaust pipe with particulate filter
    164
  • 1.2 Assembly overview - silencer with mountings (vehicles with front wheel drive)
    166
  • 1.3 Assembly overview - silencer with mountings (vehicles with four-wheel drive)
    168
  • 1.4 Aligning exhaust system free of stress
    169
  • 2 Exhaust gas recirculation system
    170
  • 2.1 Assembly overview - exhaust gas recirculation
    170
  • 2.2 Assembly overview - exhaust gas recirculation cooler
    171
  • Glow plug system
    172
  • 1 Checking glow plug system
    172
  • 1.1 Characteristics of ceramic glow plugs
    172
  • 1.2 Removing, installing and checking ceramic glow pin plugs
    172
Manufacturer's designation 4-cylinder diesel engine (2.0 l engine, 2-valve, TDI)
Manufacturer Volkswagen
Suitable for Golf (2004 - 2007) / Golf Plus (2005 - 2007)
Suitable car types 1K1, 5M
Engine code BMM
Category Reparaturanleitung

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