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

4-cylinder injection engine (2.0 l engine, turbocharger)

For Golf / Passat / Passat Variant / EOS

Original Volkswagen repair manual


25,77 €7% VAT incl.

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Language: English

Digital PDF file

7.690 KB

331 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Sealing flange and flywheel or drive plate, Crankshaft, Pistons and conrods, Cylinder head, Safety precautions, Rules for cleanliness, Fuel tank, Golf, Repairing fuel supply system, Passat, Activated charcoal filter system (Golf, Eos), Exhaust turbocharger and Checking components. Show more
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Repair manual Golf / 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 Securing engine to assembly stand
    9
  • 1.3 Installing engine
    11
  • 1.4 Assembly mountings
    13
  • Crankshaft group
    15
  • 1 Dismantling and assembling engine
    15
  • 1.1 Assembly overview
    15
  • 1.2 Removing and installing poly-V belt
    22
  • 2 Sealing flange and flywheel or drive plate
    25
  • 2.1 Assembly overview - sealing flange
    25
  • 2.2 Renewing crankshaft oil seal (belt pulley end)
    26
  • 2.3 Removing and installing sealing flange (belt pulley end)
    28
  • 2.4 Removing and installing crankshaft sealing flange (flywheel end)
    31
  • 2.5 Removing and installing flywheel
    32
  • 2.6 Removing and installing drive plate
    33
  • 3 Crankshaft
    35
  • 3.1 Assembly overview - crankshaft
    35
  • 3.2 Pulling needle bearing out of and driving into crankshaft
    37
  • 3.3 Crankshaft dimensions
    39
  • 3.4 Identification of crankshaft upper bearing
    39
  • 4 Pistons and conrods
    40
  • 4.1 Assembly overview - pistons and conrods
    40
  • 4.2 Separating new conrod
    41
  • 4.3 Removing and installing pistons
    42
  • 4.4 Checking pistons and cylinder bores
    43
  • Cylinder head, valve gear
    46
  • 1 Cylinder head
    46
  • 1.1 Assembly overview - cylinder head
    46
  • 1.2 Removing and installing cylinder head cover
    48
  • 1.3 Removing and installing cylinder head
    50
  • 1.4 Removing and installing toothed belt, vehicles without split toothed belt guard
    55
  • 1.5 Removing and installing toothed belt, vehicles with split toothed belt guard
    66
  • 1.6 Checking compression
    76
  • 2 Valve gear
    79
  • 2.1 Assembly overview - valve gear
    79
  • 2.2 Valve dimensions
    81
  • 2.3 Checking valve guides
    81
  • 2.4 Renewing valve stem seals
    82
  • 2.5 Renewing exhaust camshaft seal
    86
  • 2.6 Removing and installing camshaft adjuster
    89
  • 2.7 Removing and installing camshaft control valve 1 N205
    92
  • 2.8 Removing and installing camshafts
    94
  • Lubrication
    98
  • 1 Parts of lubrication system
    98
  • 1.1 Engine oil:
    98
  • 1.2 Assembly overview - parts of lubrication system
    98
  • 1.3 Drain oiling filter housing
    103
  • 1.4 Removing and installing sump
    104
  • 1.5 Removing and installing oil pump with balance shaft gear assembly
    107
  • 1.6 Removing and installing oil filter bracket
    111
  • 1.7 Removing and installing oil pressure switch F1
    112
  • 1.8 Checking oil pressure and oil pressure switch (single pin oil pressure switch)
    113
  • 1.9 Checking oil pressure and oil pressure switch (2-pin oil pressure switch)
    115
  • Cooling
    118
  • 1 Parts of cooling system
    118
  • 1.1 Assembly overview - parts of cooling system, engine side
    118
  • 1.3 Assembly overview - coolant circulation pump V50 (vehicles with no bypass thermostat)
    121
  • 1.4 Assembly overview - parts of cooling system, body side
    122
  • 1.5 Coolant hose schematic diagram (vehicles to 06.2005)
    123
  • 1.6 Coolant hose schematic diagram (vehicles from 06.2005)
    124
  • 1.7 Bypass thermostat
    125
  • 1.8 Draining and adding coolant
    126
  • 1.9 Removing and installing coolant pump
    129
  • 1.10 Removing and installing coolant pipes
    131
  • 1.11 Removing and installing coolant thermostat housing with thermostat
    133
  • 1.12 Removing and installing radiator fan V7 and radiator fan 2 V177
    134
  • 1.13 Removing and installing radiator, Golf and Eos
    134
  • 1.14 Removing and installing radiator, Passat
    136
  • 1.15 Checking cooling system for leaks
    137
  • Fuel supply system
    140
  • 1 Safety precautions
    140
  • 1.1 Safety regulations for working on fuel supply
    140
  • 1.2 Releasing fuel pressure in high-pressure section
    141
  • 2 Rules for cleanliness
    143
  • 3 Fuel tank, Golf
    144
  • 3.1 Assembly overview - fuel tank (engine code BPY)
    144
  • 3.2 Assembly overview - fuel tank (engine codes AXX, BWA)
    146
  • 3.3 Emptying fuel tank
    147
  • 3.4 Removing and installing fuel tank
    152
  • 4 Fuel tank, Eos
    155
  • 4.1 Assembly overview - fuel tank (engine code BWA)
    155
  • 4.2 Assembly overview - fuel tank (engine code BPY)
    157
  • 4.3 Emptying fuel tank
    159
  • 4.4 Removing and installing fuel tank
    163
  • 5 Fuel tank, Passat
    167
  • 5.1 Assembly overview - fuel tank (engine code BPY)
    167
  • 5.2 Assembly overview - fuel tank (engine codes AXX, BWA)
    169
  • 5.3 Emptying fuel tank
    170
  • 5.4 Removing and installing fuel tank
    174
  • 6 Repairing fuel supply system, Golf, Eos
    179
  • 6.1 Removing and installing fuel delivery unit
    179
  • 6.2 Removing and installing fuel gauge sender G
    182
  • 6.3 Checking fuel pump G6
    183
  • 7 Repairing fuel supply system, Passat
    196
  • 7.1 Removing and installing fuel delivery unit
    196
  • 7.2 Removing and installing fuel gauge sender G
    199
  • 7.3 Checking fuel pump
    200
  • 8 Electronic power control (EPC)
    210
  • 8.1 Function of EPC system
    210
  • 8.2 Assembly overview - accelerator module
    210
  • 8.3 Removing and installing accelerator pedal module
    211
  • 9 Activated charcoal filter system (Golf, Eos)
    214
  • 9.1 Assembly overview - activated charcoal filter system (engine codes AXX, BWA)
    214
  • 9.2 Checking fuel tank breather (engine codes AXX, BWA)
    215
  • 9.3 Schematic diagram of activated charcoal filter system (engine code BPY)
    217
  • 9.4 Assembly overview - activated charcoal filter system (Golf with engine code BPY)
    219
  • 9.5 Assembly overview - activated charcoal filter system (Eos with engine code BPY)
    220
  • 9.6 Removing and installing activated charcoal filter (engine code BPY)
    221
  • 9.7 Removing and installing fuel system diagnostic pump V144 (Golf with engine code BPY)
    222
  • 9.8 Removing and installing fuel system diagnostic pump V144 (Eos with engine code BPY)
    223
  • 9.9 Checking fuel system for leaks
    223
  • 10 Activated charcoal filter system (Passat)
    231
  • 10.1 Assembly overview - activated charcoal filter system (engine codes AXX, BWA)
    231
  • 10.2 Checking fuel tank breather (engine codes AXX, BWA)
    232
  • 10.3 Schematic diagram of activated charcoal filter system (engine code BPY)
    233
  • 10.4 Assembly overview - activated charcoal filter system (engine code BPY)
    235
  • 10.5 Checking fuel system for leaks
    235
  • Turbocharging/supercharging
    243
  • 1 Exhaust turbocharger
    243
  • 1.1 Fitting hose connections with plug-in connectors
    243
  • 1.2 Rules for cleanliness
    244
  • 1.3 Assembly overview - turbocharger
    244
  • 1.4 Removing and installing turbocharger
    248
  • 1.5 Checking vacuum unit for turbocharger
    256
  • 1.6 Removing and installing vacuum unit for turbocharger
    257
  • 1.7 Adjusting vacuum unit for turbocharger
    257
  • 2 Charge air system
    262
  • 2.1 Assembly overview - charge air cooling, Golf
    262
  • 2.2 Assembly overview - sound amplifier, Golf
    263
  • 2.3 Assembly overview - charge air cooling, Eos, Passat
    264
  • 2.4 Removing and installing charge air cooler (Golf, Eos)
    264
  • 2.5 Removing and installing charge air cooler, Passat
    266
  • 2.6 Schematic diagram of turbocharging system
    267
  • 2.7 Checking charge air system for leaks
    268
  • Mixture preparation - injection
    271
  • 1 Injection system
    271
  • 1.1 General notes on injection
    271
  • 1.2 Technical data
    272
  • 1.3 Assembly overview - engine cover panel/air filter
    272
  • 1.4 Removing and installing engine cover panel/air filter
    273
  • 1.5 Removing and installing air filter element
    274
  • 1.6 Assembly overview - intake manifold
    275
  • 1.7 Removing and installing intake manifold
    277
  • 1.9 Assembly overview - fuel rail (vehicles up to 05.2006)
    282
  • 1.10 Assembly overview - fuel rail (vehicles from 05.2006)
    283
  • 1.11 Removing and installing fuel rail
    285
  • 1.12 Removing and installing throttle valve module J338
    286
  • 1.13 Cleaning throttle valve module J338
    286
  • 1.14 Assembly overview - high-pressure pump
    287
  • 1.15 Removing and installing high-pressure pump
    289
  • 1.16 Removing and installing fuel pressure sender G247
    290
  • 1.17 Checking fuel pressure sender G247
    292
  • 1.18 Removing and installing injectors
    295
  • 1.19 Renewing Teflon seal on injector
    296
  • 2 Checking components
    299
  • 3 Engine control unit J623 , Golf, Eos
    300
  • 3.1 Removing and installing engine (motor) control unit J623
    300
  • 3.2 Removing and installing anti-theft engine control unit J623
    300
  • 4 Engine control unit J623 (Passat)
    304
  • 4.1 Removing and installing engine (motor) control unit J623
    304
  • 4.3 Removing and installing anti-theft engine control unit J623 (with locking clip)
    309
  • Exhaust system
    312
  • 1 Removing and installing parts of exhaust system
    312
  • 1.1 Assembly overview - exhaust system; Golf, Eos
    312
  • 1.2 Assembly overview - exhaust system, Passat
    314
  • 1.3 Clamps
    315
  • 1.4 Separating centre and rear silencers, Golf, Eos
    316
  • 1.5 Separating centre and rear silencers, Passat
    317
  • 1.6 Removing and installing front exhaust pipe with catalytic converter
    318
  • 1.7 Aligning exhaust system free of stress
    320
  • Ignition system
    322
  • 1 Repairing ignition system
    322
  • 1.1 General notes on ignition system
    322
  • 1.2 Safety precautions
    322
  • 1.3 Assembly overview - ignition system
    322
  • 1.4 Removing and installing ignition coils with output stage
    323
  • 1.5 Test data, spark plugs
    324
Manufacturer's designation 4-cylinder injection engine (2.0 l engine, turbocharger)
Manufacturer Volkswagen
Suitable for Golf (2004 - 2007) / Passat / Passat Variant (2005 - 2008) / EOS (2006)
Suitable car types 1K1, 1F
Engine code BPY, BWA
Category Reparaturanleitung

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