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

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 and installing engine cover
  3
• 1.2 Removing engine
  4
• 1.3 Separating engine from gearbox
  13
• 1.4 Separating engine from dual clutch gearbox
  15
• 1.5 Securing engine to assembly stand
  18
• 1.6 Installing engine
  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
  39
• 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 Poly V-belt drive with tensioning element and air conditioner compressor
  51
• 1.2 Poly V-belt drive with tensioning roller and air conditioner compressor
  55
• 1.3 Poly V-belt drive without air conditioning compressor
  59
• 1.4 Removing and installing bracket for ancillaries
  61
• 1.5 Assembly overview - toothed belt drive
  63
• 1.6 Removing and installing engine bracket
  65
• 1.7 Assembly overview - crankcase
  69
• 2 Removing and installing sealing flange and flywheel
  71
• 2.1 Assembly overview - Sealing flange, belt pulley end
  71
• 2.2 Renewing crankshaft oil seal, pulley end
  73
• 2.3 Removing and installing sealing flange - pulley end
  75
• 2.4 Assembly overview - Dual-mass flywheel and sealing flange
  79
• 2.5 Removing and installing dual-mass flywheel
  80
• 2.6 Renewing crankshaft sealing flange, flywheel end
  81
• 2.7 Removing and installing engine speed sender G28
  92
• 3 Pistons and conrods
  94
• 3.1 Assembly overview - pistons and conrods
  94
• 3.2 Piston and cylinder dimensions
  98
• 3.3 Separating new conrods
  98
• 3.4 Bearing shells - installation position
  99
• 3.5 Piston and cylinder dimensions
  100
• 3.6 Checking piston projection at TDC
  100
• 3.7 Measuring radial clearance of conrods
  102
• 4 Crankshaft
  103
• 4.1 Assembly overview - crankshaft
  103
• 4.2 Crankshaft dimensions
  103
• 4.3 Pulling needle bearing out of and driving into crankshaft
  104
• Cylinder head, valve gear
  107
• 1 Cylinder head
  107
• 1.1 Assembly overview - cylinder head
  107
• 1.2 Assembly overview - cylinder head cover
  111
• 1.3 Assembly overview - toothed belt
  113
• 1.4 Removing and installing cylinder head cover
  116
• 1.5 Removing, installing and tensioning toothed belt
  119
• 1.6 Removing and installing cylinder head
  128
• 1.7 Removing and installing vacuum pump
  140
• 1.8 Compression test
  141
• 2 Valve gear
  143
• 2.1 Assembly overview - valve gear
  143
• 2.2 Removing and installing camshafts
  145
• 2.3 Measuring axial clearance of camshaft
  154
• 2.4 Measuring radial clearance of camshafts
  155
• 2.5 Removing and installing camshaft oil seal
  156
• 2.6 Checking hydraulic compensation elements
  161
• 2.7 Renewing valve stem seals with cylinder head installed
  162
• 2.8 Renewing valve stem seals with cylinder head removed
  166
• 2.9 Valves
  171
• Lubrication
  174
• 1 Engine oil:
  174
• 1.1 Oil capacities
  174
• 1.2 Checking engine oil level
  174
• 2 Parts of lubrication system
  175
• 2.1 Assembly overview - oil pump, sump
  175
• 2.2 Removing and installing oil level and oil temperature sender G266
  178
• 2.3 Removing and installing oil sump
  178
• 2.4 Removing and installing oil pump
  184
• 3 Oil filter bracket and engine oil cooler
  186
• 3.1 Assembly overview - oil filter bracket and engine oil cooler
  186
• 3.2 Removing and installing oil filter bracket with engine oil cooler
  188
• 3.3 Removing and installing oil pressure switch F1
  191
• 3.4 Checking oil pressure switch F1
  192
• 3.5 Checking oil pressure
  194
• Cooling
  196
• 1 Parts of cooling system
  196
• 1.1 Assembly overview - parts of cooling system, body side
  196
• 1.2 Assembly overview - parts of cooling system, engine side
  197
• 1.3 Assembly overview - coolant pump and thermostat
  199
• 1.4 Coolant hose connection diagram
  199
• 2 Repairing cooling system
  202
• 2.2 Removing and installing radiator
  203
• 2.3 Removing and installing coolant pump
  204
• 2.4 Removing and installing 4/2-way valve with thermostat
  206
• 2.5 Draining and adding coolant
  216
• 2.6 Coolant pipes, coolant temperature sender
  222
• 2.7 Checking cooling system for leaks
  236
• Fuel supply system
  239
• 1 Safety regulations for working on fuel supply
  239
• 2 Rules for cleanliness
  240
• 3 Procedure in event of misfuelling
  241
• 3.1 Procedure for 1st scenario
  241
• 3.2 Procedure for 2nd scenario
  242
• 4 Parts of fuel supply system
  245
• 4.1 Fuel tank, vehicles with front-wheel drive
  245
• 4.2 Fuel tank, vehicles with four-wheel drive
  254
• 4.3 Emptying fuel tank
  263
• 4.4 Removing and installing fuel delivery unit
  267
• 4.5 Removing and installing fuel gauge sender
  269
• 5 Repairing fuel supply
  270
• 5.1 Assembly overview - fuel filter
  270
• 5.2 Removing and installing upper part of fuel filter
  273
• 5.3 Removing and installing fuel filter
  276
• 5.4 Checking fuel system pressurisation pump G6
  277
• 5.7 Assembly overview - accelerator mechanism
  288
• Turbocharging/supercharging
  292
• 1 Turbocharger
  292
• 1.1 Safety precautions
  292
• 1.2 Rules for cleanliness
  292
• 1.3 Assembly overview - turbocharger
  293
• 1.4 Removing and installing turbocharger
  295
• 1.5 Changing vacuum unit with position sender for charge pressure positioner G581
  299
• 2 Charge air system
  307
• 2.1 Installing hose connections with corrugated pipe and hose clips
  307
• 2.2 Assembly overview - parts of charge air cooling
  308
• 2.4 Removing and installing charge air cooler
  310
• 2.5 Checking charge air system for leaks
  312
• 2.6 Vacuum hose connection diagram
  316
• 2.7 Checking vacuum system
  316
• Mixture preparation - injection
  321
• 1 Diesel direct injection system
  321
• 1.1 Safety precautions
  321
• 1.2 Rules for cleanliness
  321
• 1.3 System layout
  322
• 2 High-pressure pump
  324
• 2.1 Assembly overview – high-pressure pump
  324
• 2.2 Removing and installing high-pressure pump
  326
• 2.3 Filling/bleeding fuel system
  330
• 2.4 Checking for leaks in the fuel system
  331
• 3 Injectors
  332
• 3.1 Assembly overview - injectors
  332
• 3.2 Carrying out adaptation for injector delivery calibration
  335
• 3.3 Checking for injectors sticking open
  336
• 3.4 Checking return flow rate of injectors with engine running
  337
• 3.5 Checking return flow rate of injectors at starter speed
  340
• 3.6 Removing and installing injectors
  342
• 3.7 Installing high-pressure lines
  346
• 3.8 Checking fuel pressure regulating valve N276
  348
• 3.9 Checking low pressure fuel system
  349
• 3.10 Removing and installing fuel pressure regulating valve N276
  352
• 3.11 Removing and installing fuel pressure sender G247
  354
• 3.12 Removing and installing fuel rail
  356
• 4 Intake manifold
  360
• 4.1 Assembly overview - intake manifold with attachments
  360
• 4.2 Removing and installing throttle valve module J338
  362
• 4.3 Removing and installing intake manifold
  363
• 5 Air filter
  368
• 5.1 Assembly overview - air filter
  368
• 5.2 Removing and installing air filter housing
  370
• 5.3 Removing and installing air mass meter G70
  372
• 5.4 Checking changeover flap for intake air preheater
  373
• 5.5 Removing and installing changeover flap for intake air preheater
  374
• 6 Lambda probe and pressure differential sender
  377
• 6.1 Removing and installing Lambda probe G391 with Lambda probe heater Z191
  377
• 6.2 Removing and installing pressure difference sender G5051
  378
• 7 Engine control unit J623
  380
• 7.1 Reading and clearing engine control unit fault memory
  380
• 7.2 Adapting functions and components
  380
• 7.5 Removing and installing engine control unit J623, only Jetta from MY 2011
  387
• Exhaust system
  390
• 1 Front exhaust pipe with particulate filter
  390
• 1.1 Assembly overview - front exhaust pipe with particulate filter
  390
• 1.2 Removing and installing particulate filter
  393
• 2 Silencer
  400
• 2.1 Silencer, Jetta, Golf Variant
  400
• 2.2 Aligning exhaust system free of stress
  401
• 2.3 Installation position and specified torque of clamp
  402
• 3 Exhaust gas temperature regulation
  405
• 3.1 Assembly overview - exhaust gas temperature regulation
  405
• 3.2 Removing and installing exhaust gas temperature sender 1 G235
  406
• 3.3 Removing and installing exhaust gas temperature sender 3 G495
  408
• 3.4 Removing and installing exhaust gas temperature sender 4 G648
  410
• 4 Exhaust gas recirculation
  413
• 4.1 Assembly overview – exhaust gas recirculation
  413
• 4.2 Removing and installing exhaust gas recirculation cooler
  415
• 4.3 Checking changeover for exhaust gas recirculation cooler
  418
• 4.4 Checking exhaust gas recirculation cooler for leaks
  419
• 4.5 Cleaning exhaust gas recirculation system
  424
• Glow plug system
  432
• 1 Checking glow plug system
  432
• 1.1 Automatic glow period control unit J179
  432
• 1.2 Removing and installing glow plugs
  432
• 1.3 Removing and installing automatic glow period control unit J179
  435