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

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

For Golf / Scirocco / Golf Cabriolet

Original Volkswagen repair manual


24,44 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

7.792 KB

311 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, Repairing fuel supply, Activated charcoal filter system, Exhaust turbocharger, Checking components and Engine control unit J623 (Golf 2004 ►). Show more
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Repair manual Golf / Scirocco / Golf Cabriolet 4-cylinder injection engine Volkswagen R GmbH 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
    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
Manufacturer's designation 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH
Manufacturer Volkswagen
Suitable for Golf (2004 - 2007) / Scirocco (2008) / Golf (2009) / Golf Cabriolet (2012)
Suitable car types 1K1, 5K1, 517
Engine code BYD, CDLC, CDLF, CRZA
Category Reparaturanleitung

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