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

Original Volkswagen repair manual


14,80 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

6.084 KB

175 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Pistons and conrods, Crankshaft, Cylinder head, Engine oil, Oil filter holder, oil pressure, oil cooler and oil supply line, Safety precautions when working on fuel supply system, Rules for cleanliness, Fuel tank, vehicles with front-wheel drive, Charge air system with turbocharger and Diesel direct injection system. 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
    8
  • 1.3 Notes on installing
    8
  • 1.4 Assembly mountings
    9
  • Crankshaft group
    11
  • 1 Dismantling and assembling engine
    11
  • 1.1 Assembly overview - poly-V-belt drive
    11
  • 1.2 Removing and installing poly-V-belt
    12
  • 1.3 Assembly overview - poly-V-belt drive
    14
  • 1.4 Assembly overview - crankcase
    15
  • 2 Removing and installing sealing flange and flywheel
    17
  • 2.1 Renewing crankshaft sealing flange - flywheel end
    18
  • 2.2 Renewing crankshaft oil seal - pulley end
    25
  • 2.3 Removing and installing sealing flange - pulley end
    27
  • 2.4 Removing and installing engine speed sender G28
    29
  • 3 Pistons and conrods
    30
  • 3.1 Assembly overview - pistons and conrods
    30
  • 3.2 Piston and cylinder dimensions
    32
  • 3.3 Checking piston projection at TDC
    32
  • 4 Crankshaft
    35
  • 4.1 Assembly overview - crankshaft
    35
  • 4.2 Crankshaft dimensions
    35
  • 4.3 Pulling needle bearing out of and driving into crankshaft
    36
  • Cylinder head, valve gear
    38
  • 1 Cylinder head
    38
  • 1.1 Assembly overview - cylinder head
    38
  • 1.2 Removing and installing cylinder head cover
    40
  • 1.3 Removing, installing and tensioning toothed belts
    41
  • 1.4 Removing and installing cylinder head
    50
  • 1.5 Checking compression
    55
  • 2 Valve gear
    56
  • 2.1 Assembly overview - valve gear
    56
  • 2.2 Removing and installing roller rocker fingers
    58
  • 2.3 Valves
    60
  • 2.4 Removing and installing camshafts
    63
  • 2.5 Removing and installing camshaft oil seal
    67
  • Lubrication
    69
  • 1 Engine oil
    69
  • 1.1 Oil capacities
    69
  • 1.2 Checking engine oil level
    69
  • 2 Parts of lubrication system
    70
  • 2.1 Assembly overview - oil pump, sump
    70
  • 2.2 Removing and installing oil sump
    71
  • 3 Oil filter holder, oil pressure, oil cooler and oil supply line
    74
  • 3.1 Assembly overview - oil filter holder and oil cooler
    74
  • 3.2 Checking oil pressure and oil pressure switch
    75
  • 3.3 Assembly overview - oil supply line to turbocharger
    77
  • 3.4 Removing and installing oil supply line to turbocharger
    77
  • Cooling
    79
  • 1 Parts of cooling system
    79
  • 1.1 Assembly overview - parts of cooling system, body side
    80
  • 1.2 Assembly overview - parts of cooling system, engine side
    81
  • 1.3 Coolant hose schematic diagram
    83
  • 1.4 Removing and installing radiator
    85
  • 1.5 Removing and installing coolant pump
    86
  • 1.6 Removing and installing thermostat
    88
  • 1.7 Draining and filling coolant
    90
  • 1.8 Checking cooling system for leaks
    93
  • 1.9 Checking oil cooler for leaks
    95
  • Fuel supply system
    97
  • 1 Safety precautions when working on fuel supply system
    97
  • 2 Rules for cleanliness
    98
  • 3 Fuel tank, vehicles with front-wheel drive
    99
  • 3.1 Assembly overview - fuel tank
    99
  • 3.2 Emptying fuel tank
    100
  • 3.3 Removing and installing fuel tank
    102
  • 4 Fuel tank, vehicles with four-wheel drive
    105
  • 4.1 Assembly overview - fuel tank
    106
  • 4.2 Emptying fuel tank
    107
  • 4.3 Removing and installing fuel tank
    109
  • 4.4 Removing and installing fuel gauge sender 2 G169
    112
  • 4.5 Removing and installing suction jet pump
    114
  • 5 Repairing fuel supply system
    115
  • 5.1 Checking tandem pump
    115
  • 5.2 Removing and installing tandem pump
    117
  • 5.3 Assembly overview - fuel filter
    120
  • 5.4 Removing and installing fuel cooler
    121
  • 5.5 Assembly overview - accelerator mechanism
    122
  • 5.6 Removing and installing fuel sender
    122
  • 5.7 Checking fuel pump
    123
  • 5.8 Removing and installing fuel cooler
    124
  • 5.9 Removing and installing fuel delivery unit
    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
    129
  • 1.4 Assembly overview - turbocharger with attachments
    130
  • 1.5 Removing and installing turbocharger
    133
  • 1.6 Assembly overview - parts of charge air cooling
    134
  • 1.7 Checking charge air system for leaks
    136
  • Mixture preparation - injection
    139
  • 1 Diesel direct injection system
    139
  • 1.1 Safety precautions
    139
  • 1.2 Rules for cleanliness
    139
  • 1.3 Assembly overview - intake manifold with attachments
    141
  • 1.4 Assembly overview - pre-wired wiring harness for unit injectors and glow plugs
    143
  • 1.5 Removing and installing prewiring for unit injectors and glow plugs
    143
  • 1.6 Assembly overview - unit injector
    146
  • 1.7 Removing and installing unit injector
    147
  • 1.8 Removing and installing O-rings for unit injector
    150
  • 1.9 Assembly overview - air filter
    152
  • 2 Engine control unit
    153
  • 2.1 Reading and erasing engine control unit fault memory
    153
  • 2.2 Adapting functions and components
    154
  • 2.3 Removing and installing engine control unit
    154
  • Exhaust system
    156
  • 1 Exhaust system, vehicles with front-wheel drive
    156
  • 1.1 Assembly overview - front exhaust pipe with catalytic converter
    156
  • 1.2 Assembly overview - front exhaust pipe with particulate filter
    158
  • 1.3 Assembly overview - silencers
    160
  • 1.4 Cutting exhaust pipe
    161
  • 1.5 Aligning exhaust system stress free
    162
  • 2 Exhaust system, vehicles with four-wheel drive
    163
  • 2.1 Assembly overview - exhaust system
    163
  • 2.2 Aligning exhaust system stress free
    163
  • 3 Exhaust gas recirculation system
    165
  • 3.1 Assembly overview - parts of exhaust gas recirculation
    165
  • 3.2 Vacuum hose schematic diagram
    167
  • Glow plug system
    169
  • 1 Removing and installing glow plugs
    169
Manufacturer's designation 4-cylinder diesel engine (2.0 l engine, 4 valve)
Manufacturer Volkswagen
Suitable for Golf (2004 - 2007) / Golf Plus (2005 - 2007)
Suitable car types 1K1, 5M
Engine code AZV, BKD
Category Reparaturanleitung

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