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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 Passat / Passat Variant

Original Volkswagen repair manual


17,13 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

5.624 KB

207 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, Fuel tank, Activated charcoal filter system, engine code BPY, Turbocharger and Checking components. Show more
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Repair manual Passat / Passat Variant 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
    3
  • 1.2 Securing engine to assembly stand
    9
  • 1.3 Installing engine
    10
  • 1.4 Assembly mountings
    12
  • Crankshaft group
    13
  • 1 Dismantling and assembling engine
    13
  • 1.1 Assembly overview
    14
  • 1.2 Removing and installing poly-V-belt
    18
  • 2 Sealing flange and flywheel or drive plate
    20
  • 2.1 Assembly overview - sealing flange
    20
  • 2.2 Renewing crankshaft oil seal - pulley end
    21
  • 2.3 Removing and installing sealing flange - pulley end
    24
  • 2.4 Removing and installing crankshaft sealing flange - flywheel end
    26
  • 2.5 Removing and installing flywheel
    27
  • 2.6 Removing and installing drive plate
    28
  • 3 Crankshaft
    30
  • 3.1 Assembly overview - crankshaft
    31
  • 3.2 Pulling needle bearing out of and driving into crankshaft
    32
  • 3.3 Crankshaft dimensions
    33
  • 4 Pistons and conrods
    35
  • 4.1 Assembly overview - pistons and conrods
    35
  • 4.2 Checking pistons, piston rings and cylinder bores
    36
  • 4.3 Piston and cylinder dimensions
    38
  • Cylinder head, valve gear
    39
  • 1 Cylinder head
    39
  • 1.1 Assembly overview - cylinder head
    40
  • 1.2 Removing and installing cylinder head cover
    41
  • 1.3 Removing and installing cylinder head
    43
  • 1.4 Removing and installing toothed belt
    49
  • 1.5 Checking compression
    58
  • 2 Valve gear
    60
  • 2.1 Assembly overview - valve gear
    61
  • 2.2 Valve dimensions
    62
  • 2.3 Checking valve guides
    62
  • 2.4 Renewing valve stem oil seals
    63
  • 2.5 Renewing exhaust camshaft oil seal
    67
  • 2.6 Removing and installing camshaft adjuster
    69
  • 2.7 Removing and installing inlet camshaft control valve 1 N205
    73
  • 2.8 Removing and installing camshafts
    74
  • Lubrication
    78
  • 1 Parts of lubrication system
    78
  • 1.1 Engine oil
    78
  • 1.2 Assembly overview - parts of lubrication system
    79
  • 1.3 Draining oil filter housing
    83
  • 1.4 Removing and installing sump
    84
  • 1.5 Removing and installing oil pump with balancer shaft gear assembly
    86
  • 1.6 Removing and installing oil filter bracket
    90
  • 1.7 Checking oil pressure and oil pressure switch
    91
  • Cooling
    93
  • 1 Parts of cooling system
    93
  • 1.1 Assembly overview - parts of cooling system - engine side
    94
  • 1.2 Assembly overview - recirculating pump V55 , engine codes AXX, BWA
    95
  • 1.3 Assembly overview - recirculating pump V55 , engine code BPY
    96
  • 1.4 Assembly overview - parts of cooling system - body side
    97
  • 1.5 Coolant hose schematic diagram, engine codes AXX, BWA
    98
  • 1.6 Coolant hose schematic diagram, engine code BPY
    99
  • 1.7 Bypass thermostat
    100
  • 1.8 Draining and filling coolant
    101
  • 1.9 Removing and installing coolant pump
    104
  • 1.10 Removing and installing coolant pipes
    105
  • 1.11 Removing and installing thermostat housing with thermostat
    107
  • 1.12 Removing and installing radiator fan V7 and radiator fan 2 V177
    107
  • 1.13 Removing and installing radiator
    109
  • 1.14 Checking cooling system for leaks
    110
  • Fuel supply system
    112
  • 1 Safety precautions
    112
  • 1.1 Safety precautions when working on fuel supply system
    112
  • 1.2 Releasing fuel pressure in high-pressure section
    113
  • 2 Fuel tank
    115
  • 2.1 Rules for cleanliness
    115
  • 2.2 Assembly overview - fuel tank, engine code BPY
    116
  • 2.3 Assembly overview - fuel tank, engine codes AXX, BWA
    117
  • 2.4 Emptying fuel tank
    118
  • 2.5 Removing and installing fuel tank
    120
  • 3 Repairing fuel supply system
    124
  • 3.1 Removing and installing fuel delivery unit
    124
  • 3.2 Removing and installing fuel gauge sender G
    127
  • 3.3 Checking fuel pump
    128
  • 3.4 Assembly overview - high-pressure pump
    136
  • 3.5 Removing and installing high-pressure pump
    136
  • 4 Electronic power control (EPC)
    138
  • 4.1 Function of EPC system
    138
  • 4.2 Assembly overview - accelerator pedal module
    139
  • 4.3 Removing and installing accelerator module
    139
  • 5 Activated charcoal filter system, engine code BPY
    141
  • 5.1 Function
    141
  • 5.2 Schematic diagram of activated charcoal filter system
    142
  • 5.3 Assembly overview - activated charcoal filter system
    143
  • 5.4 Checking fuel system for leaks
    143
  • 6 Activated charcoal filter system, engine codes AXX, BWA
    147
  • 6.1 Function
    147
  • 6.2 Assembly overview - activated charcoal filter system
    148
  • 6.3 Checking fuel tank breather
    148
  • Turbocharging/supercharging
    150
  • 1 Turbocharger
    150
  • 1.1 Installing hose connections with connector couplings
    150
  • 1.2 Rules for cleanliness
    151
  • 1.3 Assembly overview - turbocharger
    151
  • 1.4 Removing and installing turbocharger
    155
  • 1.5 Checking turbocharger vacuum unit
    161
  • 1.6 Removing and installing turbocharger vacuum unit
    163
  • 1.7 Adjusting turbocharger vacuum unit
    164
  • 2 Charge air system
    167
  • 2.1 Assembly overview - charge air cooling
    167
  • 2.2 Schematic diagram of turbocharging system
    168
  • 2.3 Checking charge air system for leaks
    168
  • Mixture preparation - injection
    171
  • 1 Injection system
    171
  • 1.1 General notes on injection
    171
  • 1.2 Rules for cleanliness
    172
  • 1.3 Technical data
    172
  • 1.4 Assembly overview - intake manifold
    173
  • 1.5 Assembly overview - fuel rail
    174
  • 1.6 Assembly overview - engine cover/air filter
    175
  • 1.7 Removing and installing engine cover/air filter
    175
  • 1.8 Removing and installing air filter element
    176
  • 1.9 Removing and installing throttle valve module J338
    177
  • 1.10 Removing and installing intake manifold
    177
  • 1.11 Removing and installing fuel rail
    180
  • 1.12 Removing and installing fuel pressure sender G247
    180
  • 1.13 Removing and installing injectors
    182
  • 1.14 Renewing Teflon seal on injector
    183
  • 2 Checking components
    186
  • 3 Engine control unit
    187
  • 3.1 Removing and installing engine control unit
    187
  • 3.2 Removing and installing anti-theft engine control unit
    188
  • Exhaust system
    192
  • 1 Removing and installing parts of exhaust system
    192
  • 1.1 Assembly overview - exhaust system
    192
  • 1.2 Separating centre and rear silencers
    194
  • 1.3 Removing and installing front exhaust pipe with catalytic converter
    195
  • Ignition system
    198
  • 1 Repairing ignition system
    198
  • 1.1 General notes on ignition system
    198
  • 1.2 Safety precautions
    198
  • 1.3 Assembly overview - ignition system
    199
  • 1.4 Removing and installing ignition coils with output stages
    199
  • 1.5 Test data, spark plugs
    200
Manufacturer's designation 4-cylinder injection engine (2.0 l engine, turbocharger)
Manufacturer Volkswagen
Suitable for Passat / Passat Variant (2005 - 2008)
Suitable car types 3C
Engine code BPY, BWA
Category Reparaturanleitung

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