4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH

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
  20
• 1.3 Removing and installing tensioner for poly V-belt
  22
• 2 Sealing flange and flywheel or drive plate
  23
• 2.1 Assembly overview - sealing flange
  23
• 2.2 Renewing crankshaft oil seal (belt pulley end)
  24
• 2.3 Removing and installing sealing flange (belt pulley end)
  26
• 2.4 Removing and installing crankshaft sealing flange (flywheel end)
  29
• 2.5 Removing and installing flywheel
  30
• 2.6 Removing and installing drive plate
  31
• 3 Crankshaft
  33
• 3.1 Assembly overview - crankshaft
  33
• 3.2 Pulling needle bearing out of and driving into crankshaft
  35
• 3.3 Crankshaft dimensions
  36
• 3.4 Identification of crankshaft upper bearing
  37
• 4 Pistons and conrods
  38
• 4.1 Assembly overview - pistons and conrods
  38
• 4.2 Checking pistons, piston rings and cylinder bores
  40
• 4.3 Piston and cylinder dimensions
  42
• Cylinder head, valve gear
  43
• 1 Cylinder head
  43
• 1.1 Assembly overview - cylinder head
  43
• 1.2 Removing and installing cylinder head cover
  45
• 1.3 Removing and installing cylinder head
  47
• 1.4 Removing and installing toothed belt
  52
• 1.5 Checking compression
  70
• 2 Valve gear
  72
• 2.1 Assembly overview - valve gear
  72
• 2.2 Valve dimensions
  74
• 2.3 Checking valve guides
  74
• 2.4 Renewing valve stem seals
  75
• 2.5 Renewing exhaust camshaft seal
  80
• 2.6 Removing and installing camshaft adjuster
  82
• 2.7 Removing and installing camshaft control valve 1 N205
  86
• 2.8 Removing and installing camshafts
  88
• Lubrication
  91
• 1 Parts of lubrication system
  91
• 1.1 Engine oil:
  91
• 1.2 Assembly overview - parts of lubrication system
  91
• 1.3 Drain oiling filter housing
  96
• 1.4 Removing and installing sump
  97
• 1.5 Removing and installing oil pump with balance shaft gear assembly
  100
• 1.6 Removing and installing oil filter bracket
  105
• 1.7 Removing and installing oil pressure switch F1
  106
• 1.8 Checking oil pressure and oil pressure switch (single pin oil pressure switch)
  107
• 1.9 Checking oil pressure and oil pressure switch (2-pin oil pressure switch)
  109
• Cooling
  112
• 1 Parts of cooling system
  112
• 1.1 Assembly overview - parts of cooling system, engine side
  112
• 1.4 Assembly overview - parts of cooling system, body side
  115
• 1.5 Coolant hose connection diagram
  117
• 1.6 Bypass thermostat (engine code BYD)
  118
• 1.7 Draining and adding coolant
  119
• 1.8 Assembly overview - coolant pump, thermostat
  123
• 1.9 Removing and installing coolant pump
  124
• 1.10 Removing and installing coolant temperature sender
  126
• 1.11 Removing and installing coolant pipes
  128
• 1.12 Removing and installing coolant thermostat housing with thermostat
  130
• 1.13 Removing and installing fan support with radiator fan V7 and radiator fan 2 V177
  131
• 1.14 Removing and installing radiator (Golf 2004 ►)
  133
• 1.15 Removing and installing radiator (Golf 2009 ►, Golf Cabriolet 2012 ►, Scirocco)
  134
• 1.16 Removing and installing auxiliary radiator (Golf 2009 ►, Golf Cabriolet 2012 ►, Scirocco)
  135
• 1.17 Checking cooling system for leaks
  136
• Fuel supply system
  138
• 1 Safety precautions
  138
• 1.1 Safety regulations for working on fuel supply
  138
• 1.2 Releasing fuel pressure in high-pressure section
  139
• 2 Rules for cleanliness
  141
• 3 Fuel tank (front-wheel drive)
  142
• 3.1 Assembly overview - fuel tank
  142
• 3.2 Emptying fuel tank
  144
• 3.3 Removing and installing fuel tank
  148
• 4 Fuel tank (four-wheel drive)
  151
• 4.1 Assembly overview - fuel tank
  151
• 4.2 Emptying fuel tank
  153
• 4.3 Removing and installing fuel tank
  158
• 4.4 Removing and installing fuel gauge sender 2 G169
  162
• 4.5 Removing and installing suction-jet pump
  164
• 5 Repairing fuel supply
  166
• 5.1 Removing and installing fuel delivery unit
  166
• 5.2 Removing and installing fuel gauge sender G
  170
• 5.3 Checking fuel pump G6
  171
• 6 Electronic power control (EPC)
  183
• 6.1 Assembly overview - accelerator module
  183
• 6.2 Removing and installing accelerator pedal module
  183
• 7 Activated charcoal filter system
  186
• 7.1 Assembly overview - activated charcoal filter system
  186
• 7.2 Checking fuel tank breather
  186
• 7.3 Checking fuel system for leaks
  188
• 8 Activated charcoal filter system
  196
• 8.1 Overview of activated charcoal filter system
  196
• 8.2 Assembly overview - activated charcoal filter system
  198
• 8.3 Removing and installing activated charcoal filter
  199
• 8.4 Removing and installing fuel system diagnostic pump V144
  200
• 8.5 Checking fuel system for leaks
  200
• Turbocharging/supercharging
  209
• 1 Exhaust turbocharger
  209
• 1.1 Fitting hose connections with plug-in connectors
  209
• 1.2 Rules for cleanliness
  210
• 1.3 Assembly overview - turbocharger
  210
• 1.4 Removing and installing turbocharger
  215
• 1.5 Checking vacuum unit for turbocharger
  223
• 1.6 Removing and installing turbocharger vacuum unit (engine code BYD)
  224
• 1.7 Adjusting turbocharger vacuum unit (engine code BYD)
  224
• 2 Charge air system
  229
• 2.1 Assembly overview - charge air cooling (engine code BYD)
  229
• 2.3 Assembly overview - noise booster (engine code BYD)
  233
• 2.5 Schematic diagram of turbocharging system
  236
• 2.6 Removing and installing charge air cooler (Golf and Golf Cabriolet)
  237
• 2.7 Removing and installing charge air cooler (Scirocco)
  238
• 2.8 Checking charge air system for leaks
  239
• Mixture preparation - injection
  242
• 1 Safety precautions and rules for cleanliness
  242
• 1.1 General information on self-diagnosis
  242
• 2 Injection system
  243
• 2.1 Technical data
  243
• 2.2 Assembly overview - engine cover panel/air filter
  243
• 2.3 Removing and installing engine cover panel/air filter
  245
• 2.4 Removing and installing air filter element
  247
• 2.5 Removing and installing air mass meter G70
  248
• 2.6 Assembly overview - intake manifold
  249
• 2.7 Removing and installing intake manifold
  251
• 2.9 Assembly overview - fuel rail (vehicles up to 05.2007)
  256
• 2.10 Assembly overview - fuel rail (vehicles from 05.2007)
  257
• 2.11 Removing and installing fuel rail
  259
• 2.12 Removing and installing throttle valve module J338
  260
• 2.13 Cleaning throttle valve module J338
  260
• 2.14 Assembly overview - high-pressure pump
  261
• 2.15 Removing and installing high-pressure pump
  263
• 2.16 Removing and installing fuel pressure sender G247
  265
• 2.17 Checking fuel pressure sender G247
  266
• 2.18 Removing and installing injectors
  268
• 2.19 Renewing Teflon seal on injector
  271
• 3 Checking components
  274
• 3.1 Checking double non-return valve
  274
• 4 Engine control unit J623 (Golf 2004 ►)
  275
• 4.1 Removing and installing engine (motor) control unit J623
  275
• 4.2 Removing and installing anti-theft engine control unit J623
  275
• 5 Engine control unit J623 (Golf 2009 ► and Golf Cabriolet)
  279
• 5.1 Removing and installing engine control unit
  279
• 5.2 Removing and installing anti-theft engine control unit
  280
• 6 Engine control unit J623 (Scirocco)
  284
• 6.1 Removing and installing engine (motor) control unit J623
  284
• 6.2 Removing and installing anti-theft engine control unit J623
  285
• Exhaust system
  287
• 1 Exhaust system
  287
• 1.1 Assembly overview - exhaust system (Golf 2004 ►)
  287
• 1.2 Assembly overview - exhaust system (Golf 2009 ►)
  290
• 1.3 Assembly overview - exhaust system (Golf Cabriolet 2012 ►)
  292
• 1.4 Assembly overview - exhaust system (Scirocco)
  294
• 1.5 Separating centre and rear silencers (front-wheel drive)
  296
• 1.6 Removing and installing front exhaust pipe with catalytic converters
  297
• 1.7 Aligning exhaust system free of stress
  298
• 1.8 Checking exhaust gas flap (Golf 2009 ►,Golf Cabriolet 2012►, Scirocco)
  299
• Ignition system
  302
• 1 Repairing ignition system
  302
• 1.1 General notes on ignition system
  302
• 1.2 Safety precautions
  302
• 1.3 Assembly overview - ignition system
  302
• 1.4 Removing and installing ignition coils with output stage
  303
• 1.5 Test data, spark plugs
  305