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  • Examplepage for repair manual 4-cylinder injection engine (2.0 l direct injection)
  • Examplepage for repair manual 2 4-cylinder injection engine (2.0 l direct injection)
  • Examplepage for repair manual 3 4-cylinder injection engine (2.0 l direct injection)

4-cylinder injection engine (2.0 l direct injection)

For Passat / Passat Variant / EOS

Original Volkswagen repair manual


25,18 €7% VAT incl.

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Language: English

Digital PDF file

6.454 KB

322 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Cylinder block attachments, Sealing flange and flywheel or drive plate, Crankshaft, Pistons and conrods, Valve gear, Safety precautions, Fuel tank (Eos), Repairing fuel supply system (Passat), Parts of exhaust system and Exhaust gas recirculation system, (engine codes BLR, BLX, BVX and BVY). Show more
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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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