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

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

For Golf / Touran / Passat / Passat Variant / Golf Plus

Original Volkswagen repair manual


23,43 €7% VAT incl.

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Immediately available for download

Language: English

Digital PDF file

7.597 KB

296 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Pistons and conrods, Crankshaft, Cylinder head, Engine oil, Parts of lubrication system (Golf, Golf Plus, Touran), Oil filter bracket, oil cooler, oil pressure and oil supply line, Safety precautions, Rules for cleanliness, Tandem pump, Charge air system with turbocharger, Front exhaust pipe and Optical characteristics of metal or ceramic glow plugs. Show more
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Repair manual 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
    3
  • 1 Removing and installing engine
    3
  • 1.1 Removing engine
    4
  • 1.2 Securing engine to assembly stand
    11
  • 1.3 Notes on installing
    13
  • 1.4 Assembly mountings
    14
  • Crankshaft group
    15
  • 1 Dismantling and assembling engine
    15
  • 1.1 Assembly overview - poly V-belt drive
    15
  • 1.2 Removing and installing poly V-belt
    16
  • 1.3 Assembly overview - toothed belt drive
    17
  • 1.4 Assembly overview - crankcase
    21
  • 2 Removing and installing sealing flange and flywheel
    23
  • 2.1 Renewing crankshaft sealing flange - flywheel end
    24
  • 2.2 Renewing crankshaft oil seal - pulley end
    31
  • 2.3 Removing and installing sealing flange - pulley end
    33
  • 2.4 Removing and installing engine speed sender G28
    36
  • 3 Pistons and conrods
    38
  • 3.1 Assembly overview - pistons and conrods
    38
  • 3.2 Piston and cylinder dimensions
    39
  • 3.3 Checking piston projection at TDC
    39
  • 3.4 Piston rings, cylinder bore and piston installation position
    41
  • 4 Crankshaft
    43
  • 4.1 Assembly overview - crankshaft
    43
  • 4.2 Crankshaft dimensions
    43
  • 4.3 Pulling needle bearing out of and driving into crankshaft
    44
  • Cylinder head, valve gear
    46
  • 1 Cylinder head
    46
  • 1.1 Assembly overview - cylinder head
    46
  • 1.2 Removing and installing cylinder head cover
    48
  • 1.3 Removing, installing and tensioning toothed belt
    50
  • 1.4 Removing and installing cylinder head
    64
  • 1.5 Checking compression
    70
  • 2 Valve gear
    71
  • 2.1 Assembly overview - valve gear
    71
  • 2.2 Removing and installing roller rocker finger
    73
  • 2.3 Valves
    75
  • 2.4 Removing and installing camshafts
    77
  • 2.5 Removing and installing camshaft oil seal
    82
  • Lubrication
    85
  • 1 Engine oil
    85
  • 1.1 Oil capacities - Golf, Golf Plus, Touran
    85
  • 1.2 Oil capacities - Passat
    85
  • 1.3 Checking engine oil level
    85
  • 2 Parts of lubrication system (Golf, Golf Plus, Touran)
    86
  • 2.1 Assembly overview - oil pump, sump
    86
  • 2.2 Removing and installing oil sump
    88
  • 3 Parts of lubrication system (Passat)
    91
  • 3.1 Assembly overview - oil pump, sump, balancer shaft module with chain drive
    91
  • 3.2 Removing and installing oil pump (for balancer shaft module with chain drive)
    93
  • 3.3 Removing and installing balancer shaft module with chain drive
    96
  • 3.4 Retrofitting spur gear drive for balancer shaft module
    100
  • 3.6 Removing and installing oil pump (for balancer shaft module with spur gear drive)
    106
  • 3.7 Removing balancer shaft module with spur gear drive
    106
  • 3.8 Renewing spur gear for crankshaft
    107
  • 3.9 Installing balancer shaft module
    110
  • 3.10 Removing and installing oil sump
    116
  • 4 Oil filter bracket, oil cooler, oil pressure and oil supply line
    119
  • 4.1 Assembly overview - oil filter bracket and oil cooler
    119
  • 4.2 Checking oil pressure and oil pressure switch
    121
  • 4.3 Assembly overview - oil supply line to turbocharger
    122
  • 4.4 Removing and installing oil supply line to turbocharger
    123
  • Cooling
    124
  • 1 Parts of cooling system
    124
  • 1.1 Parts of cooling system, body side
    124
  • 1.3 Assembly overview - parts of cooling system, engine side (Passat)
    128
  • 1.4 Coolant hose schematic diagram
    130
  • 1.5 Draining and filling coolant
    133
  • 1.6 Removing and installing fan support with fans
    138
  • 1.7 Removing and installing radiator
    139
  • 1.8 Removing and installing coolant pump
    140
  • 1.9 Removing and installing thermostat
    142
  • 1.10 Checking cooling system for leaks
    143
  • 1.11 Checking oil cooler for leaks
    145
  • Fuel supply system
    148
  • 1 Safety precautions
    148
  • 1.1 Safety precautions when working on fuel supply system
    148
  • 2 Rules for cleanliness
    149
  • 2.1 Rules for cleanliness when working on fuel supply system
    149
  • 3 Parts of fuel supply system (Golf, Golf Plus)
    150
  • 3.1 Fuel tank, vehicles with front-wheel drive
    150
  • 3.2 Fuel tank, vehicles with four-wheel drive
    153
  • 3.3 Emptying fuel tank
    160
  • 3.4 Removing and installing fuel delivery unit
    162
  • 3.5 Removing and installing fuel gauge sender
    164
  • 3.6 Checking fuel pump
    164
  • 3.7 Assembly overview - fuel filter
    169
  • 3.8 Removing and installing fuel cooler
    171
  • 4 Parts of fuel supply system (Touran)
    173
  • 4.1 Assembly overview - fuel tank with attachments
    173
  • 4.2 Emptying fuel tank
    175
  • 4.3 Removing and installing fuel tank
    178
  • 4.4 Assembly overview - fuel filter
    179
  • 4.5 Removing and installing fuel cooler
    181
  • 4.6 Removing and installing fuel delivery unit
    181
  • 4.7 Removing and installing fuel gauge sender
    183
  • 4.8 Checking fuel pump
    184
  • 5 Parts of fuel supply system (Passat)
    189
  • 5.1 Fuel tank, vehicles with four-wheel drive
    189
  • 5.2 Emptying fuel tank, vehicles with four-wheel drive
    199
  • 5.3 Fuel tank, vehicles with front-wheel drive
    202
  • 5.4 Emptying fuel tank, vehicles with front-wheel drive
    210
  • 5.5 Checking fuel pump
    212
  • 5.6 Assembly overview - fuel filter
    216
  • 5.7 Removing and installing fuel cooler
    218
  • 6 Accelerator mechanism
    220
  • 6.1 Assembly overview - accelerator mechanism
    220
  • 7 Tandem pump
    222
  • 7.1 Checking tandem pump
    222
  • 7.2 Removing and installing tandem pump
    224
  • Turbocharging/supercharging
    227
  • 1 Charge air system with turbocharger
    227
  • 1.1 Safety precautions
    227
  • 1.2 Rules for cleanliness
    227
  • 1.3 Hose connections
    228
  • 1.4 Assembly overview - turbocharger with attachments
    229
  • 1.5 Removing and installing turbocharger
    232
  • 1.6 Assembly overview - charge air cooling
    234
  • 1.7 Checking charge air system for leaks
    235
  • 1.8 Vacuum hose schematic diagram
    237
  • Mixture preparation - injection
    239
  • 1 Diesel direct injection system
    239
  • 1.1 Safety precautions
    239
  • 1.2 Rules for cleanliness
    240
  • 1.3 Assembly overview - intake manifold with attachments
    240
  • 1.4 Assembly overview - pre-wired wiring harness for unit injectors and glow plugs
    243
  • 1.5 Removing and installing pre-wired wiring harness for unit injectors and glow plugs
    243
  • 1.6 Assembly overview - unit injector
    246
  • 1.7 Removing and installing unit injector
    248
  • 1.8 Cleaning unit injectors (engine codes BMN, BKP, BMA, BUZ and BMR)
    252
  • 1.9 Removing and installing O-rings for unit injector
    254
  • 1.10 Assembly overview - air filter
    255
  • 2 Engine control unit (Golf)
    257
  • 2.1 Removing and installing engine control unit
    257
  • 2.2 Removing and installing anti-theft engine control unit
    257
  • 3 Engine control unit (Golf Plus, Touran)
    261
  • 3.1 Removing and installing engine control unit
    261
  • 3.2 Removing and installing anti-theft engine control unit
    262
  • 4 Engine control unit (Passat)
    265
  • 4.1 Removing and installing engine control unit
    265
  • 4.2 Removing and installing anti-theft engine control unit
    266
  • Exhaust system
    270
  • 1 Front exhaust pipe
    270
  • 1.1 Assembly overview - front exhaust pipe with catalytic converter
    270
  • 1.2 Assembly overview - front exhaust pipe with particulate filter
    271
  • 2 Silencer (Golf, Golf Plus)
    274
  • 2.1 Assembly overview - silencer, vehicles with front-wheel drive
    274
  • 2.2 Assembly overview - silencer, vehicles with four-wheel drive
    275
  • 2.3 Cutting exhaust pipe
    275
  • 2.4 Installation position and specified torque of the clamp
    276
  • 2.5 Aligning exhaust system free of stress
    277
  • 3 Silencer (Touran)
    279
  • 3.1 Assembly overview - silencers
    279
  • 3.2 Cutting exhaust pipe
    280
  • 3.3 Aligning exhaust system free of stress
    280
  • 4 Silencer (Passat)
    281
  • 4.1 Assembly overview - silencer, vehicles with front-wheel drive
    281
  • 4.2 Assembly overview - silencer, vehicles with four-wheel drive
    282
  • 4.3 Aligning exhaust system free of stress
    282
  • 5 Exhaust gas recirculation system
    284
  • 5.1 Assembly overview - exhaust gas recirculation
    284
  • Glow plug system
    287
  • 1 Optical characteristics of metal or ceramic glow plugs
    287
  • 1.1 Removing and installing metal glow plug
    287
  • 1.2 Removing and installing ceramic glow plugs
    288
Manufacturer's designation 4-cylinder diesel engine (2.0 l engine, 4 valve)
Manufacturer Volkswagen
Suitable for Golf (2004 - 2007) / Touran (2003 - 2011) / Passat / Passat Variant (2005 - 2008) / Golf Plus (2005 - 2007)
Suitable car types 1K1, 3C, 5M
Engine code BMR, BUZ, BWV, AZV, BKD, BKP, BMA, BVE
Category Reparaturanleitung

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