Name: 4-cylinder injection engine (2.0 l direct injection)
Brand: Volkswagen
SKU: CDG4e9bca3829ff
Price: 25.18 EUR
Availability: InStock

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Repair manual Passat / Passat Variant / EOS 4-cylinder injection engine PDF download has the following content:

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
4
1.2 Installing engine
11
Crankshaft group
16
1 Cylinder block attachments
16
1.1 Assembly overview - cylinder block attachments
16
1.2 Removing and installing poly-V belt
23
2 Sealing flange and flywheel or drive plate
24
2.1 Assembly overview - sealing flange
24
2.2 Renewing crankshaft oil seal - pulley end
25
2.3 Removing and installing sealing flange - pulley end
27
2.4 Removing and installing crankshaft sealing flange - flywheel end
30
2.5 Removing and installing flywheel
34
2.6 Removing and installing drive plate
35
3 Crankshaft
37
3.1 Assembly overview - crankshaft
37
3.2 Removing and installing sender wheel
38
3.3 Crankshaft dimensions
38
3.4 Identification of crankshaft upper bearing
38
4 Pistons and conrods
40
4.1 Assembly overview - pistons and conrods
40
4.2 Separating new conrod
41
4.3 Bearing shells - installation position
42
4.4 Checking pistons, piston rings and cylinder bores
42
4.5 Piston and cylinder dimensions
44
Cylinder head, valve gear
45
1 Cylinder head
45
1.1 Assembly overview - cylinder head
45
1.2 Removing and installing cylinder head cover
47
1.3 Removing and installing cylinder head
48
1.8 Checking compression
89
2 Valve gear
92
2.1 Assembly overview - valve gear
92
2.2 Valve dimensions
94
2.3 Checking valve guides
94
2.4 Renewing valve stem seals
95
2.5 Renewing exhaust camshaft seal
99
2.6 Removing and installing camshaft adjuster
102
2.7 Removing and installing inlet camshaft control valve 1 N205
106
2.8 Removing and installing camshafts
107
Lubrication
111
1 Parts of lubrication system
111
1.1 Engine oil:
111
1.2 Assembly overview - parts of lubrication system
112
1.3 Drain oiling filter housing
117
1.4 Removing and installing sump, engine codes BLX, BLY, BLR
118
1.5 Removing and installing sump, engine codes BVX, BVY, BVZ
120
1.6 Removing and installing oil pump with balance shaft gear assembly
123
1.7 Removing and installing oil filter bracket
128
1.8 Checking oil pressure and oil pressure switch
129
Cooling
132
1 Parts of cooling system
132
1.1 Assembly overview - parts of cooling system, engine side, (engine codes BLX, BLY, BLR)
132
1.2 Assembly overview - parts of cooling system, engine side, (engine codes BVX, BVY, BVZ)
134
1.3 Assembly overview - parts of cooling system, body side
135
1.4 Coolant hose schematic diagram, (engine codes BLX, BLY, BLR)
136
1.5 Coolant hose schematic diagram, (engine codes BVX, BVY, BVZ)
137
1.6 Draining and adding coolant
138
1.7 Removing and installing coolant pump
142
1.8 Removing and installing coolant pipe
143
1.9 Mapped cooling, (engine codes BLX, BLY, BLR)
144
1.10 Removing and installing coolant distributor housing with thermostat
149
1.11 Removing and installing radiator fan V7 and radiator fan 2 V177
149
1.12 Removing and installing radiator
151
1.13 Checking cooling system for leaks
152
Fuel supply system
155
1 Safety precautions
155
1.1 Safety regulations for working on fuel supply
155
1.2 Releasing pressure in high-pressure area
156
2 Fuel tank, vehicles with four-wheel drive (Passat)
158
2.1 Rules for cleanliness
158
2.2 Assembly overview - fuel tank
158
2.3 Emptying fuel tank
160
2.4 Removing and installing fuel tank (vehicles to 06/2007)
166
2.5 Removing and installing fuel tank (vehicles from 06/2007)
171
2.6 Removing and installing fuel gauge sender 2 G169
176
2.7 Removing and installing suction-jet pump
179
3 Fuel tank, vehicles with front-wheel drive (Passat)
181
3.1 Rules for cleanliness
181
3.2 Assembly overview - fuel tank
181
3.3 Emptying fuel tank
183
3.4 Removing and installing fuel tank
187
4 Fuel tank (Eos)
191
4.1 Rules for cleanliness
191
4.2 Assembly overview - fuel tank
191
4.3 Emptying fuel tank
193
4.4 Removing and installing fuel tank
197
5 Repairing fuel supply system (Passat)
201
5.1 Rules for cleanliness
201
5.2 Removing and installing fuel delivery unit
201
5.3 Removing and installing fuel gauge sender G
206
5.4 Checking fuel pump G6
207
6 Repairing fuel supply system (Eos)
217
6.1 Safety regulations for working on fuel supply
217
6.2 Rules for cleanliness
217
6.3 Removing and installing fuel delivery unit
218
6.4 Removing and installing fuel gauge sender G
221
6.5 Checking fuel pump G6
222
7 Electronic power control (EPC)
235
7.1 Function of EPC system
235
7.2 Assembly overview - accelerator module
235
7.3 Removing and installing accelerator pedal module
236
8 Activated charcoal filter system (Passat)
239
8.1 Function
239
8.2 Assembly overview - activated charcoal filter system
239
8.3 Checking fuel tank breather
240
9 Activated charcoal filter system (Eos)
242
9.1 Function
242
9.2 Assembly overview - activated charcoal filter system
242
9.3 Checking fuel tank breather
243
Mixture preparation - injection
246
1 Injection system
246
1.1 General notes on injection
246
1.2 Rules for cleanliness
247
1.3 Technical data
247
1.4 Assembly overview - intake manifold
247
1.7 Assembly overview - air filter
254
1.8 Removing and installing intake manifold
255
1.9 Removing and installing fuel rail with intake manifold flaps
256
1.10 Assembly overview - high-pressure pump
258
1.11 Removing and installing high-pressure pump
259
1.12 Removing and installing fuel pressure sender G247
261
1.13 Checking fuel pressure sender G247
262
1.14 Removing and installing injectors
266
1.15 Renewing Teflon seal on injector
268
1.16 Cleaning throttle valve module J338
270
2 Checking components
272
3 Engine control unit J623 (Passat)
274
3.1 Removing and installing engine (motor) control unit J623
274
3.3 Removing and installing anti-theft engine control unit J623 (with locking clip)
278
4 Engine control unit J623 (Eos)
281
4.1 Removing and installing engine (motor) control unit J623
281
4.2 Removing and installing anti-theft engine control unit J623
281
Exhaust system
284
1 Parts of exhaust system
284
1.2 Assembly overview - exhaust manifold with catalytic converter, (engine code BVY)
286
1.3 Assembly overview - exhaust manifold, (engine codes BLY, BVZ)
287
1.4 Removing and installing exhaust manifold
288
1.5 Assembly overview - exhaust system, engine codes BLR, BVY (Passat)
292
1.6 Assembly overview - exhaust system, engine codes BLX, BVX (Passat)
294
1.7 Assembly overview - exhaust system, engine codes BLY, BVZ (Passat)
296
1.8 Assembly overview - exhaust system, engine code BVY (Eos)
298
1.9 Assembly overview - exhaust system, engine code BVZ (Eos)
300
1.10 Removing and installing front exhaust pipe with catalytic converter
301
1.11 Separating centre and rear silencers
304
1.12 Aligning exhaust system free of stress
308
1.13 Installation position and specified torque of clamp
309
2 Exhaust gas recirculation system, (engine codes BLR, BLX, BVX and BVY)
311
2.1 Assembly overview - exhaust gas recirculation system
311
Ignition system
313
1 Repairing ignition system
313
1.1 General notes on ignition system
313
1.2 Safety precautions
313
1.3 Assembly overview - ignition system
313
1.4 Removing and installing ignition coils with output stage
314
1.5 Test data, spark plugs
315

Manufacturer's designation	4-cylinder injection engine (2.0 l direct injection)
Manufacturer	Volkswagen
Suitable for	Passat / Passat Variant (2005 - 2008) / EOS (2006)
Suitable car types	3C, 1F
Engine code	BVX, BLX, BLY, BLR, BVY
Category	Reparaturanleitung

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