4-cylinder injection engine (2.0 l direct injection)

Chapter overview

• Technical data
  1
• 1 Engine number
  1
• 2 Engine data
  2
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Removing engine
  3
• 1.2 Installing engine
  11
• Crankshaft group
  15
• 1 Cylinder block attachments, engine code AXW
  15
• 1.1 Assembly overview - cylinder block attachments
  15
• 1.2 Removing and installing poly V-belt
  21
• 2 Cylinder block attachments, engine codes BLX, BLY, BLR, BVX, BVY, BVZ
  23
• 2.1 Assembly overview - cylinder block attachments
  23
• 2.2 Removing and installing poly V-belt
  30
• 3 Sealing flange and flywheel or drive plate
  31
• 3.1 Assembly overview - sealing flange
  31
• 3.2 Renewing crankshaft oil seal - pulley end
  32
• 3.3 Removing and installing sealing flange - pulley end
  34
• 3.4 Removing and installing crankshaft sealing flange - flywheel end
  37
• 3.5 Removing and installing flywheel
  41
• 3.6 Removing and installing drive plate
  42
• 4 Crankshaft
  44
• 4.1 Assembly overview - crankshaft
  44
• 4.2 Removing and installing sender wheel
  45
• 4.3 Crankshaft dimensions
  45
• 5 Pistons and conrods
  47
• 5.1 Assembly overview - pistons and conrods
  47
• 5.2 Separating new conrod
  48
• 5.3 Bearing shells - installation position
  49
• 5.4 Checking pistons, piston rings and cylinder bores
  49
• 5.5 Piston and cylinder dimensions
  51
• Cylinder head, valve gear
  52
• 1 Cylinder head
  52
• 1.1 Assembly overview - cylinder head
  52
• 1.2 Removing and installing cylinder head cover
  54
• 1.3 Removing and installing cylinder head
  55
• 1.4 Removing and installing toothed belt, engine code AXW
  64
• 1.7 Removing and installing toothed belt, Golf with split toothed belt guard (BVX, BVY, BVZ)
  90
• 1.8 Removing and installing toothed belt, Touran with split toothed belt guard (BVX, BVY, BVZ)
  100
• 1.9 Checking compression
  108
• 2 Valve gear
  111
• 2.1 Assembly overview - valve gear
  111
• 2.2 Valve dimensions
  113
• 2.3 Checking valve guides
  113
• 2.4 Renewing valve stem seals
  114
• 2.5 Renewing exhaust camshaft seal
  118
• 2.6 Removing and installing camshaft adjuster
  121
• 2.7 Removing and installing inlet camshaft control valve 1 N205
  125
• 2.8 Removing and installing camshafts
  127
• Lubrication
  132
• 1 Parts of lubrication system
  132
• 1.1 Engine oil
  132
• 1.2 Assembly overview - parts of lubrication system
  133
• 1.3 Draining oil filter housing
  139
• 1.4 Removing and installing sump, engine codes AXW, BLX, BLY, BLR
  140
• 1.5 Removing and installing sump, engine codes BVX, BVY, BVZ
  142
• 1.6 Removing and installing oil pump with balancer shaft gear assembly
  145
• 1.7 Removing and installing oil filter bracket
  149
• 1.8 Checking oil pressure and oil pressure switch
  150
• Cooling
  153
• 1 Parts of cooling system
  153
• 1.1 Assembly overview \- cooling system parts, engine side \- engine codes AXW, BLX, BLY, BLR
  153
• 1.2 Assembly overview - cooling system parts, engine side - engine codes BVX, BVY, BVZ
  155
• 1.3 Assembly overview - parts of cooling system, body side
  156
• 1.4 Coolant hose schematic diagram, engine codes AXW, BLX, BLY, BLR
  157
• 1.5 Coolant hose schematic diagram, engine codes BVX, BVY, BVZ
  158
• 1.6 Draining and filling coolant
  159
• 1.7 Removing and installing coolant pump
  163
• 1.8 Removing and installing coolant pipe
  165
• 1.9 Map-controlled cooling system, engine codes AXW, BLX, BLY, BLR
  166
• 1.11 Removing and installing radiator fan V7 and radiator fan 2 V177
  171
• 1.12 Removing and installing radiator
  172
• 1.13 Checking cooling system for leaks
  174
• Fuel supply system
  176
• 1 Safety precautions
  176
• 1.1 Safety precautions when working on fuel supply system
  176
• 1.2 Releasing pressure in high-pressure area
  177
• 2 Fuel tank (Golf with front-wheel drive)
  179
• 2.1 Rules for cleanliness
  179
• 2.2 Assembly overview - fuel tank
  179
• 2.3 Emptying fuel tank
  181
• 2.4 Removing and installing fuel tank
  185
• 3 Fuel tank (Golf with all-wheel drive)
  189
• 3.1 Rules for cleanliness
  189
• 3.2 Assembly overview - fuel tank
  189
• 3.3 Emptying fuel tank
  191
• 3.4 Removing and installing fuel tank
  196
• 3.5 Removing and installing fuel gauge sender 2 G169
  199
• 3.6 Removing and installing suction-jet pump
  201
• 4 Fuel tank (Touran)
  202
• 4.1 Rules for cleanliness
  202
• 4.2 Assembly overview - fuel tank
  202
• 4.3 Emptying fuel tank
  204
• 4.4 Removing and installing fuel tank
  209
• 5 Repairing fuel supply system (Golf)
  212
• 5.1 Rules for cleanliness
  212
• 5.2 Removing and installing fuel delivery unit
  212
• 5.3 Removing and installing fuel gauge sender G
  214
• 5.4 Checking fuel pump G6
  216
• 6 Repairing fuel supply system (Touran)
  229
• 6.1 Rules for cleanliness
  229
• 6.2 Removing and installing fuel delivery unit
  229
• 6.3 Removing and installing fuel gauge sender G
  231
• 6.4 Checking fuel pump
  232
• 7 Electronic power control (EPC)
  244
• 7.1 Function of EPC system
  244
• 7.2 Assembly overview - accelerator module
  244
• 7.3 Removing and installing accelerator module
  245
• 7.4 Removing and installing accelerator module (Touran)
  247
• 8 Activated charcoal filter system (Golf)
  250
• 8.1 Function
  250
• 8.2 Assembly overview - activated charcoal filter system
  250
• 8.3 Checking fuel tank breather
  251
• 9 Activated charcoal filter system (Touran)
  254
• 9.1 Function
  254
• 9.2 Assembly overview - activated charcoal filter system
  254
• 9.3 Checking fuel tank breather
  255
• Mixture preparation - injection
  257
• 1 Injection system
  257
• 1.1 General notes on injection
  257
• 1.2 Rules for cleanliness
  258
• 1.3 Technical data
  258
• 1.4 Assembly overview - intake manifold
  258
• 1.8 Assembly overview - air filter
  266
• 1.9 Removing and installing intake manifold
  267
• 1.10 Removing and installing fuel rail with intake manifold flaps
  268
• 1.11 Assembly overview - high-pressure pump, engine code AXW
  271
• 1.12 Assembly overview - high-pressure pump, engine codes BLR, BLX, BLY, BVX, BVY, BVZ
  272
• 1.13 Removing and installing high-pressure pump
  273
• 1.14 Removing and installing fuel pressure sender G247
  276
• 1.15 Checking fuel pressure sender G247
  277
• 1.16 Removing and installing injectors
  281
• 1.17 Renewing Teflon seal on injector
  283
• 1.18 Cleaning throttle valve module J338
  285
• 2 Checking components
  287
• 3 Engine control unit J623 (Golf)
  289
• 3.1 Removing and installing engine control unit J623
  289
• 3.2 Removing and installing anti-theft engine control unit J623
  289
• 4 Engine control unit J623 (Golf Plus, Touran)
  293
• 4.1 Removing and installing engine control unit J623
  293
• 4.2 Removing and installing anti-theft engine control unit J623
  294
• Exhaust system
  297
• 1 Parts of exhaust system
  297
• 1.3 Assembly overview - exhaust manifold, engine codes BLY, BVZ
  300
• 1.4 Removing and installing exhaust manifold
  300
• 1.5 Assembly overview - exhaust system, engine codes BLR, BVY
  304
• 1.6 Assembly overview - exhaust system, engine codes AXW, BLX
  307
• 1.7 Assembly overview - exhaust system, engine codes BLY, BVZ
  309
• 1.8 Assembly overview - exhaust system, Golf with all-wheel drive
  311
• 1.9 Removing and installing front exhaust pipe with catalytic converter
  312
• 1.10 Separating centre and rear silencers
  314
• 1.11 Aligning exhaust system free of stress
  315
• 1.12 Installation position and specified torque of clamp
  317
• 2 Exhaust gas recirculation system, engine codes AXW, BLX, BLR, BVX, BVY
  319
• 2.1 Assembly overview - exhaust gas recirculation system
  319
• Ignition system
  321
• 1 Repairing ignition system
  321
• 1.1 General notes on ignition system
  321
• 1.2 Safety precautions
  321
• 1.3 Assembly overview - ignition system
  321
• 1.4 Removing and installing ignition coils with output stage
  322
• 1.5 Test data, spark plugs
  323