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

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