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

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

For Passat / Passat Variant

Original Volkswagen repair manual


17,64 €7% VAT incl.

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  • English

Immediately available for download

Language: English

Digital PDF file

6.282 KB

214 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, Fuel tank, vehicles with all-wheel drive, 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
    9
  • 1.3 Notes on installing
    10
  • 1.4 Assembly mountings
    11
  • 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
    16
  • 2 Removing and installing sealing flange and flywheel
    19
  • 2.1 Assembly overview - sealing flanges 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
    25
  • 2.5 Removing and installing engine speed sender G28
    32
  • 3 Crankshaft
    34
  • 3.1 Assembly overview - crankshaft
    34
  • 3.2 Crankshaft dimensions
    35
  • 3.3 Pulling needle bearing out of and driving into crankshaft
    35
  • 4 Pistons and conrods
    37
  • 4.1 Assembly overview - pistons and conrods
    37
  • 4.2 Separating new conrods
    39
  • 4.3 Checking piston projection at TDC
    40
  • 4.4 Piston and cylinder dimensions
    41
  • 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
    60
  • 1.5 Checking compression
    64
  • 2 Valve gear
    67
  • 2.1 Assembly overview - valve gear
    67
  • 2.2 Checking valve guides
    69
  • 2.3 Renewing valve stem seals
    70
  • 2.4 Removing and installing camshaft
    72
  • 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, balancer shaft module with chain drive
    81
  • 2.2 Removing and installing oil pump (for balancer shaft module with chain drive)
    83
  • 2.3 Removing and installing balancer shaft module with chain drive
    86
  • 2.4 Retrofitting spur gear drive for balancer shaft module
    90
  • 2.6 Removing and installing oil pump (for balancer shaft module with spur gear drive)
    96
  • 2.7 Removing balancer shaft module with spur gear drive
    96
  • 2.8 Renewing spur gear for crankshaft
    97
  • 2.9 Installing balancer shaft module with spur gear drive
    100
  • 2.10 Removing and installing oil sump
    106
  • 3 Oil filter bracket, oil pressure and oil cooler
    109
  • 3.1 Assembly overview - oil filter bracket and oil cooler
    109
  • 3.2 Checking oil pressure and oil pressure switch
    110
  • Cooling
    112
  • 1 Parts of cooling system
    112
  • 1.1 Assembly overview - parts of cooling system, body side
    112
  • 1.2 Assembly overview - cooling system, engine side
    114
  • 1.3 Coolant hose schematic diagram
    116
  • 1.4 Draining and filling coolant
    117
  • 1.5 Removing and installing fan mounting with fans
    120
  • 1.6 Removing and installing radiator
    121
  • 1.7 Removing and installing coolant pump
    122
  • 1.8 Removing and installing thermostat
    123
  • 1.9 Checking cooling system for leaks
    125
  • 1.10 Checking oil cooler for leaks
    127
  • Fuel supply system
    130
  • 1 Fuel tank, vehicles with all-wheel drive
    130
  • 1.1 Assembly overview - fuel tank
    130
  • 1.2 Emptying fuel tank
    132
  • 1.3 Removing and installing fuel tank
    135
  • 1.4 Removing and installing fuel gauge sender 2 G169
    140
  • 1.5 Removing and installing suction-jet pump
    143
  • 2 Fuel tank, vehicles with front-wheel drive
    145
  • 2.1 Assembly overview - fuel tank
    145
  • 2.2 Emptying fuel tank
    147
  • 2.3 Removing and installing fuel tank
    149
  • 2.4 Removing and installing fuel delivery unit
    152
  • 2.5 Removing and installing fuel gauge sender
    154
  • 2.6 Checking fuel pump
    154
  • 3 Parts of fuel supply system
    160
  • 3.1 Safety precautions when working on fuel supply system
    160
  • 3.2 Rules for cleanliness
    160
  • 3.3 Assembly overview - fuel filter
    161
  • 3.4 Removing and installing fuel cooler
    163
  • 3.5 Assembly overview - accelerator mechanism
    164
  • 3.6 Checking tandem pump
    166
  • 3.7 Removing and installing tandem pump
    170
  • Turbocharging/supercharging
    174
  • 1 Charge air system with turbocharger
    174
  • 1.1 Safety precautions
    174
  • 1.2 Rules for cleanliness
    174
  • 1.3 Hose connections
    175
  • 1.4 Assembly overview - turbocharger
    176
  • 1.5 Removing and installing turbocharger
    178
  • 1.6 Assembly overview - charge air cooling
    179
  • 1.7 Vacuum hose schematic diagram
    181
  • 1.8 Checking charge air system for leaks
    181
  • Mixture preparation - injection
    184
  • 1 Diesel direct injection system
    184
  • 1.1 Safety precautions
    184
  • 1.2 Rules for cleanliness
    185
  • 1.3 Assembly overview - unit injector
    185
  • 1.4 Removing and installing O-rings for unit injector
    186
  • 1.5 Removing and installing unit injector
    188
  • 1.6 Assembly overview - intake manifold with intake manifold flap motor
    190
  • 1.7 Assembly overview - air filter
    192
  • 2 Engine control unit
    193
  • 2.1 Reading and erasing engine control unit fault memory
    193
  • 2.2 Removing and installing engine control unit
    194
  • 2.3 Removing and installing anti-theft engine control unit
    195
  • Exhaust system
    199
  • 1 Parts of exhaust system
    199
  • 1.1 Assembly overview - front exhaust pipe with particulate filter
    199
  • 1.2 Assembly overview - silencer, vehicles with front-wheel drive
    201
  • 1.3 Assembly overview - silencer, vehicles with all-wheel drive
    202
  • 1.4 Aligning exhaust system free of stress
    202
  • 2 Exhaust gas recirculation system
    204
  • 2.1 Assembly overview - exhaust gas recirculation
    204
  • 2.2 Assembly overview - exhaust gas recirculation cooler
    205
  • Glow plug system
    206
  • 1 Checking glow plug system
    206
  • 1.1 Characteristics of ceramic glow plugs
    206
  • 1.2 Removing, installing and checking ceramic glow pin plugs
    206
Manufacturer's designation 4-cylinder diesel engine (2.0 l engine, 2 valve)
Manufacturer Volkswagen
Suitable for Passat / Passat Variant (2005 - 2008)
Suitable car types 3C
Engine code BMP
Category Reparaturanleitung

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