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
  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