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

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

For Jetta / Jetta 2-türig Rl / Jetta 4-türig Ll / Golf VI Variant

Original Volkswagen repair manual


32,65 €7% VAT incl.

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Language: English

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14.690 KB

443 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:, Oil filter bracket and engine oil cooler, Safety regulations for working on fuel supply, Procedure in event of misfuelling, Turbocharger, High-pressure pump, Injectors, Front exhaust pipe with particulate filter and Checking glow plug system. 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 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
Manufacturer's designation 4-cylinder diesel engine (2.0 l engine, common rail, generation II)
Manufacturer Volkswagen
Suitable for Jetta (2005 - 2007) / Jetta 2-türig Rl (1980 - 1984) / Jetta 4-türig Ll (1980 - 1984) / Golf VI Variant (2010)
Suitable car types 1K2, 163, AJ5
Engine code CFHB, CFHC, CLCA, CLCB
Category Reparaturanleitung

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