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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 Passat / Passat Variant

Original Volkswagen repair manual


16,99 €7% VAT incl.

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  • English

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Language: English

Digital PDF file

5.712 KB

205 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Sealing flange and flywheel, Crankshaft, Pistons and conrods, Cylinder head, Engine oil, Oil filter bracket, oil pressure, oil cooler and oil supply line, Fuel tank, vehicles with four-wheel drive, Parts of fuel 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
    4
  • 1.2 Securing engine to assembly stand
    8
  • 1.3 Notes on installing
    9
  • 1.4 Assembly mountings
    10
  • Crankshaft group
    11
  • 1 Dismantling and assembling engine
    11
  • 1.1 Assembly overview - poly-V-belt drive
    12
  • 1.2 Removing and installing poly-V-belt
    12
  • 1.3 Assembly overview - toothed belt drive
    15
  • 1.4 Assembly overview - cylinder block
    16
  • 2 Sealing flange and flywheel
    18
  • 2.1 Assembly overview - sealing flange and flywheel
    18
  • 2.2 Renewing crankshaft oil seal - belt pulley end
    19
  • 2.3 Removing and installing sealing flange - pulley end
    22
  • 2.4 Renewing crankshaft sealing flange - flywheel end
    24
  • 2.5 Removing and installing engine speed sender G28
    31
  • 3 Crankshaft
    32
  • 3.1 Assembly overview - crankshaft
    32
  • 3.2 Crankshaft dimensions
    33
  • 3.3 Pulling needle bearing out of and driving into crankshaft
    33
  • 4 Pistons and conrods
    35
  • 4.1 Assembly overview - pistons and conrods
    35
  • 4.2 Piston and cylinder dimensions
    37
  • 4.3 Checking piston projection at TDC
    38
  • Cylinder head, valve gear
    40
  • 1 Cylinder head
    40
  • 1.1 Assembly overview - cylinder head
    40
  • 1.2 Removing and installing cylinder head cover
    42
  • 1.3 Removing, installing and tensioning toothed belt
    43
  • 1.4 Removing and installing cylinder head
    51
  • 1.5 Checking compression
    56
  • 2 Valve gear
    57
  • 2.1 Assembly overview - valve gear
    57
  • 2.2 Removing and installing roller rocker fingers
    59
  • 2.3 Valve dimensions
    61
  • 2.4 Checking valve guides
    61
  • 2.5 Renewing valve stem oil seals
    62
  • 2.6 Removing and installing camshafts
    64
  • 2.7 Removing and installing camshaft oil seal
    68
  • Lubrication
    70
  • 1 Engine oil
    70
  • 1.1 Oil capacities
    70
  • 1.2 Checking engine oil level
    70
  • 2 Parts of lubrication system
    71
  • 2.1 Assembly overview - oil pump, sump, balancer shaft module with chain drive
    72
  • 2.2 Removing and installing oil pump (for balancer shaft module with chain drive)
    74
  • 2.3 Removing and installing balancer shaft module with chain drive
    77
  • 2.5 Removing and installing oil pump (for balancer shaft module with spur gear drive)
    83
  • 2.6 Removing balancer shaft module with spur gear drive
    83
  • 2.7 Installing balancer shaft module
    85
  • 2.8 Removing and installing sump
    89
  • 3 Oil filter bracket, oil pressure, oil cooler and oil supply line
    92
  • 3.1 Assembly overview - oil filter bracket and oil cooler
    92
  • 3.2 Assembly overview - oil supply line to turbocharger
    93
  • 3.3 Removing and installing oil supply line to turbocharger
    93
  • 3.4 Checking oil pressure and oil pressure switch
    96
  • Cooling
    98
  • 1 Removing and installing parts of cooling system
    98
  • 1.1 Assembly overview - parts of cooling system, body side
    99
  • 1.2 Assembly overview - parts of cooling system, engine side
    100
  • 1.3 Coolant hose schematic diagram
    101
  • 1.4 Draining and filling coolant
    104
  • 1.5 Removing and installing fan support with fans
    106
  • 1.6 Removing and installing radiator
    107
  • 1.7 Removing and installing coolant pump
    108
  • 1.8 Removing and installing thermostat
    110
  • 1.9 Checking cooling system for leaks
    112
  • 1.10 Checking oil cooler for leaks
    114
  • Fuel supply system
    116
  • 1 Fuel tank, vehicles with four-wheel drive
    116
  • 1.1 Assembly overview - fuel tank
    116
  • 1.2 Emptying fuel tank
    118
  • 1.3 Removing and installing fuel tank
    121
  • 1.4 Removing and installing fuel gauge sender 2 G169
    126
  • 1.5 Removing and installing suction-jet pump
    129
  • 2 Fuel tank, vehicles with front-wheel drive
    131
  • 2.1 Assembly overview - fuel tank
    131
  • 2.2 Emptying fuel tank
    133
  • 2.3 Removing and installing fuel tank
    135
  • 2.4 Removing and installing fuel delivery unit
    138
  • 2.5 Removing and installing fuel gauge sender
    140
  • 2.6 Checking fuel pump
    140
  • 3 Parts of fuel system
    143
  • 3.1 Safety precautions when working on fuel supply system
    143
  • 3.2 Rules for cleanliness
    144
  • 3.3 Assembly overview - fuel filter
    144
  • 3.4 Removing and installing fuel cooler
    145
  • 3.5 Assembly overview - accelerator module
    146
  • 3.6 Checking tandem pump
    147
  • 3.7 Removing and installing tandem pump
    151
  • Turbocharging/supercharging
    154
  • 1 Charge air system with turbocharger
    154
  • 1.1 Safety precautions
    154
  • 1.2 Rules for cleanliness
    154
  • 1.3 Hose connections
    155
  • 1.4 Assembly overview - turbocharger
    156
  • 1.5 Removing and installing turbocharger
    159
  • 1.6 Assembly overview - charge air cooling
    160
  • 1.7 Checking charge air system for leaks
    162
  • Mixture preparation - injection
    165
  • 1 Diesel direct injection system
    165
  • 1.1 Safety precautions
    165
  • 1.2 Rules for cleanliness
    166
  • 1.3 Assembly overview - pre-wired wiring harness for unit injectors and glow plugs
    167
  • 1.4 Removing and installing pre-wired wiring harness for unit injectors and glow plugs
    167
  • 1.5 Assembly overview - unit injector
    170
  • 1.6 Removing and installing unit injector
    172
  • 1.7 Removing and installing O-rings for unit injector
    175
  • 1.8 Assembly overview - intake manifold with intake manifold flap motor
    177
  • 1.9 Assembly overview - air filter
    179
  • 2 Engine control unit
    180
  • 2.1 Reading and erasing engine control unit fault memory
    180
  • 2.2 Removing and installing engine control unit
    181
  • 2.3 Removing and installing anti-theft engine control unit
    182
  • Exhaust system
    186
  • 1 Exhaust system
    186
  • 1.1 Assembly overview - front exhaust pipe with catalytic converter
    187
  • 1.2 Assembly overview - front exhaust pipe with particulate filter
    188
  • 1.3 Assembly overview - silencer, vehicle with front-wheel drive
    190
  • 1.4 Assembly overview - silencer, vehicle with four-wheel drive
    191
  • 1.5 Aligning exhaust system stress free
    191
  • 2 Exhaust gas recirculation system
    193
  • 2.1 Assembly overview - exhaust gas recirculation
    194
  • 2.2 Schematic diagram for vacuum hoses
    195
  • Glow plug system
    197
  • 1 Checking glow plug system
    197
  • 1.1 Characteristics of ceramic glow plugs
    197
  • 1.2 Removing, installing and checking ceramic glow plugs
    198
Manufacturer's designation 4-cylinder diesel engine (2.0 l engine, 4 valve)
Manufacturer Volkswagen
Suitable for Passat / Passat Variant (2005 - 2008)
Suitable car types 3C
Engine code BUZ, BWV, BKP, BMA, BVE
Category Reparaturanleitung

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