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

4-cylinder diesel engine (2.0 l engine, common rail)

For Golf Variant / Jetta / Jetta 2-türig Rl / Golf VI Variant

Original Volkswagen repair manual


35,51 €7% VAT incl.

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Language: English

Digital PDF file

17.521 KB

495 Sites

Detailed technical data

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This repair manual contains: Removing and installing engine, Assembly mounting, except Jetta 2011 ▶, Pistons and conrods, Crankshaft, Cylinder head, Engine oil:, Parts of lubrication system (engine codes CBEA), Oil filter bracket, oil cooler, oil pressure and oil supply line, Safety regulations for working on fuel supply, Rules for cleanliness, Procedure in event of misfuelling, Separating plug-in connectors, Turbocharger, Diesel direct injection system and 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
    3
  • 1.2 Separating gearbox from engine and assembling
    16
  • 1.3 Securing engine on engine and gearbox support VAS 6095
    19
  • 1.4 Notes on installing
    20
  • 2 Assembly mounting, except Jetta 2011 ▶
    24
  • 2.1 Assembly overview - assembly mountings
    24
  • 2.2 Checking adjustment of engine assembly mountings
    27
  • 2.3 Adjusting assembly mountings
    27
  • 3 Assembly mounting, Jetta 2011 ▶
    33
  • 3.1 Assembly overview - assembly mountings
    33
  • 3.2 Removing and installing engine mounting
    35
  • 3.3 Removing and installing gearbox mounting
    40
  • 3.4 Removing and installing pendulum support
    42
  • 3.5 Supporting engine in installation position
    43
  • 3.6 Adjusting assembly mountings
    48
  • 3.7 Checking adjustment of assembly mountings
    49
  • Crankshaft group
    51
  • 1 Dismantling and assembling engine
    51
  • 1.1 Assembly overview - poly V-belt drive
    51
  • 1.2 Removing and installing poly-V belt
    52
  • 1.3 Removing and installing poly V-belt tensioner
    54
  • 1.4 Removing and installing bracket for ancillaries
    56
  • 1.5 Assembly overview - toothed belt drive
    57
  • 1.6 Removing and installing engine bracket
    60
  • 1.7 Assembly overview - cylinder block
    63
  • 2 Removing and installing sealing flange and flywheel
    66
  • 2.1 Renewing crankshaft sealing flange - flywheel end
    67
  • 2.2 Renewing crankshaft oil seal - pulley end
    78
  • 2.3 Removing and installing sealing flange - pulley end
    81
  • 2.4 Removing and installing engine speed sender G28
    85
  • 3 Pistons and conrods
    88
  • 3.1 Assembly overview - pistons and conrods
    88
  • 3.2 Separating new conrods
    92
  • 3.3 Bearing shells - installation position
    93
  • 3.4 Piston and cylinder dimensions
    93
  • 3.5 Checking piston projection at TDC
    93
  • 4 Crankshaft
    96
  • 4.1 Assembly overview - crankshaft
    96
  • 4.2 Crankshaft dimensions
    97
  • 4.3 Pulling needle bearing out of and driving into crankshaft
    98
  • Cylinder head, valve gear
    101
  • 1 Cylinder head
    101
  • 1.1 Assembly overview - cylinder head cover
    101
  • 1.2 Removing and installing Hall sender G40
    103
  • 1.3 Removing and installing engine cover
    106
  • 1.4 Removing and installing cylinder head cover
    107
  • 1.5 Assembly overview - cylinder head
    113
  • 1.6 Removing, installing and tensioning toothed belt
    116
  • 1.7 Removing and installing cylinder head
    125
  • 1.8 Removing and installing vacuum pump
    150
  • 1.9 Checking compression
    152
  • 2 Valve gear
    154
  • 2.1 Assembly overview - valve gear
    154
  • 2.2 Removing and installing camshafts
    156
  • 2.3 Removing and installing camshaft oil seal
    165
  • 2.4 Renewing valve stem seals (with cylinder head installed)
    167
  • 2.5 Checking valve guides
    171
  • Lubrication
    173
  • 1 Engine oil:
    173
  • 1.1 Oil capacities
    173
  • 1.2 Checking engine oil level
    173
  • 2 Parts of lubrication system (engine codes CBEA)
    175
  • 2.1 Assembly overview - oil pump, sump, balance shaft module
    175
  • 2.2 Removing and installing oil sump
    178
  • 2.3 Removing and installing oil pump
    182
  • 2.4 Removing and installing balance shaft module
    183
  • 2.5 Pulling spur gear off crankshaft and shrink-fitting new spur gear
    191
  • 3 Parts of lubrication system (engine codes CBDA, CBDB, CEGA, CJAA)
    195
  • 3.1 Assembly overview - oil pump, sump
    195
  • 3.2 Removing and installing oil sump
    197
  • 3.3 Removing and installing oil pump
    202
  • 4 Oil filter bracket, oil cooler, oil pressure and oil supply line
    203
  • 4.1 Assembly overview - oil filter bracket and oil cooler
    203
  • 4.2 Removing and installing oil filter bracket together with oil cooler
    205
  • 4.3 Removing and installing oil supply line to turbocharger
    208
  • 4.4 Checking oil pressure and oil pressure switch F1
    211
  • Cooling
    215
  • 1 Parts of cooling system
    215
  • 1.1 Assembly overview - parts of cooling system, body side
    216
  • 1.2 Parts of cooling system - engine side
    218
  • 1.3 Coolant hose connection diagram
    224
  • 1.5 Removing and installing radiator
    230
  • 1.6 Removing and installing coolant pump
    231
  • 1.7 Removing and installing thermostat
    233
  • 1.8 Removing and installing 4/2-way valve with thermostat
    234
  • 1.9 Draining and adding coolant
    237
  • 1.10 Checking cooling system for leaks
    242
  • 1.11 Checking oil cooler for leaks
    244
  • 1.12 Engine preheater (engine codes CBEA, CJAA)
    247
  • Fuel supply system
    250
  • 1 Safety regulations for working on fuel supply
    250
  • 2 Rules for cleanliness
    251
  • 3 Procedure in event of misfuelling
    252
  • 3.1 Step 1 (Engine was started with incorrect fuel)
    252
  • 3.2 Step 2 (Engine was not started with incorrect fuel)
    253
  • 3.3 Step 3 (There are filings in fuel delivery unit and fuel tank)
    255
  • 3.4 Step 4 (There are no filings in fuel delivery unit and fuel tank)
    255
  • 3.5 Step 5 (There are filings in high-pressure pump)
    256
  • 3.6 Step 6 (There are no filings in high-pressure pump)
    256
  • 4 Parts of fuel supply system
    258
  • 4.1 Assembly overview - fuel tank, all vehicles apart from Jetta from MY 2011
    259
  • 4.2 Assembly overview - fuel tank, only Jetta from MY 2011
    261
  • 4.3 Emptying fuel tank
    263
  • 4.4 Removing and installing fuel tank
    267
  • 4.5 Removing and installing fuel delivery unit
    272
  • 4.6 Removing and installing fuel gauge sender G
    276
  • 5 Separating plug-in connectors
    278
  • 6 Repairing fuel supply
    284
  • 6.1 Assembly overview - fuel filter
    284
  • 6.2 Removing and installing fuel filter
    285
  • 6.3 Checking fuel system pressurisation pump G6
    287
  • 6.4 Checking supplementary fuel pump V393 (inline electronic fuel pump)
    293
  • 7 Electronic power control (EPC)
    299
  • 7.1 Function of EPC system
    299
  • 7.2 Assembly overview - accelerator module
    299
  • 7.3 Removing and installing accelerator pedal module
    300
  • Turbocharging/supercharging
    303
  • 1 Safety precautions when working on charge air system and turbocharger
    303
  • 2 Rules for cleanliness
    304
  • 3 Turbocharger
    305
  • 3.1 Assembly overview - turbocharger with exhaust manifold and attachments
    305
  • 3.4 Changing vacuum unit with position sender for charge pressure positioner G581
    317
  • 3.5 Removing and installing exhaust gas temperature sender G235
    325
  • 4 Charge air system
    329
  • 4.1 Assembly overview - parts of charge air cooling
    330
  • 4.3 Checking charge air system for leaks
    334
  • 4.4 Vacuum hose schematic diagram (engine codes CBEA, CJAA)
    337
  • 4.5 Vacuum hose schematic diagram, (engine codes CBDA, CBDB, CEGA)
    338
  • 4.6 Checking vacuum system
    339
  • Mixture preparation - injection
    344
  • 1 Observe safety precautions when working on diesel direct injection fuel system
    344
  • 2 Rules for cleanliness
    346
  • 3 Diesel direct injection system
    347
  • 3.1 System layout
    348
  • 3.2 Assembly overview - fuel system
    351
  • 3.3 Removing and installing injector (piezo injector)
    354
  • 3.4 Checking fuel pressure regulating valve N276
    361
  • 3.5 Removing and installing fuel pressure regulating valve N276
    362
  • 3.6 Removing and installing fuel pressure sender G247
    364
  • 3.7 Removing and installing fuel system high-pressure pump
    366
  • 3.8 Filling/bleeding fuel system
    371
  • 3.9 Checking for leaks in the fuel system
    372
  • 3.10 Checking pressure retention valve in fuel return line
    372
  • 3.11 Assembly overview - intake manifold with attachments
    374
  • 3.12 Removing and installing intake manifold
    375
  • 3.13 Assembly overview - air filter
    379
  • 3.14 Removing and installing air filter housing
    382
  • 3.15 Removing and installing air filter element
    383
  • 3.16 Checking changeover flap for intake air preheating
    385
  • 3.17 Removing and installing changeover flap for intake air preheating
    387
  • 3.18 Removing and installing air mass meter G70
    389
  • 4 Engine control unit (engine codes CBEA, CJAA)
    391
  • 4.3 Removing and installing engine control unit J623, only Jetta from MY 2011
    397
  • 5 Engine control unit (engine codes CBDA, CBDB, CEGA)
    400
  • 5.1 Removing and installing engine control unit J623 with no theft protection
    400
  • 5.2 Removing and installing engine control unit J623 with theft protection
    402
  • Exhaust system
    406
  • 1 Exhaust system (engine codes CBEA, CJAA)
    406
  • 1.1 Assembly overview - particulate filter with NOx storage catalytic converter
    406
  • 1.2 Note installation position of securing clamps and exhaust gas temperature sender
    413
  • 1.3 Removing and installing particulate filter with NOx storage catalytic converter
    415
  • 1.4 Assembly overview - exhaust flap control unit J883 with SCR catalytic converter
    426
  • 1.5 Routing cables/lines of components for exhaust system
    428
  • 1.6 Assembly overview - silencers
    429
  • 1.7 Separating and joining exhaust system
    433
  • 1.8 Aligning exhaust system free of stress
    435
  • 1.9 Checking exhaust system for leaks
    437
  • 1.10 Installation position of clamp
    437
  • 2 Exhaust system (engine codes CBDA, CBDB, CEGA)
    440
  • 2.1 Assembly overview - front exhaust pipe with particulate filter
    440
  • 2.2 Removing and installing particulate filter
    443
  • 2.3 Assembly overview - silencers
    449
  • 2.4 Cutting exhaust pipe
    449
  • 2.5 Aligning exhaust system free of stress
    450
  • 3 Exhaust gas recirculation
    452
  • 3.1 Assembly overview – exhaust gas recirculation
    452
  • 3.2 Removing and installing exhaust gas recirculation filter
    456
  • 3.4 Removing and installing exhaust gas recirculation cooler, engine code CJAA
    463
  • 3.5 Checking exhaust gas recirculation cooler for leaks
    465
  • 3.6 Removing and installing temperature sensor for exhaust gas recirculation
    470
  • 3.7 Cleaning exhaust gas recirculation system
    475
  • Glow plug system
    483
  • 1 Glow plugs
    483
  • 1.1 Removing and installing glow plug
    483
  • 1.2 Removing and installing connectors for glow pin plugs
    487
Manufacturer's designation 4-cylinder diesel engine (2.0 l engine, common rail)
Manufacturer Volkswagen
Suitable for Golf Variant (2007) / Jetta (2005 - 2007) / Jetta 2-türig Rl (1980 - 1984) / Golf VI Variant (2010)
Suitable car types 1K5, 162, AJ5
Engine code CBEA, CBDB, CBDA, CJAA
Category Reparaturanleitung

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