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

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