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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


24,65 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

8.190 KB

314 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 sealing flange on gearbox side
    29
  • 2.5 Removing and installing flywheel
    32
  • 2.6 Removing and installing drive plate
    33
  • 3 Crankshaft
    36
  • 3.1 Assembly overview - crankshaft
    36
  • 3.2 Pulling needle bearing out of and driving into crankshaft
    38
  • 3.3 Crankshaft dimensions
    39
  • 3.4 Identification of crankshaft upper bearing
    40
  • 4 Pistons and conrods
    41
  • 4.1 Assembly overview - pistons and conrods
    41
  • 4.2 Checking pistons, piston rings and cylinder bores
    43
  • 4.3 Piston and cylinder dimensions
    45
  • 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
    55
  • 1.5 Checking compression
    73
  • 2 Valve gear
    75
  • 2.1 Assembly overview - valve gear
    75
  • 2.2 Valve dimensions
    77
  • 2.3 Checking valve guides
    77
  • 2.4 Renewing valve stem seals
    78
  • 2.5 Renewing exhaust camshaft seal
    83
  • 2.6 Removing and installing camshaft adjuster
    85
  • 2.7 Removing and installing camshaft control valve 1 N205
    89
  • 2.8 Removing and installing camshafts
    91
  • Lubrication
    94
  • 1 Parts of lubrication system
    94
  • 1.1 Engine oil:
    94
  • 1.2 Assembly overview - parts of lubrication system
    94
  • 1.3 Drain oiling filter housing
    99
  • 1.4 Removing and installing sump
    100
  • 1.5 Removing and installing oil pump with balance shaft gear assembly
    103
  • 1.6 Removing and installing oil filter bracket
    108
  • 1.7 Removing and installing oil pressure switch F1
    109
  • 1.8 Checking oil pressure and oil pressure switch (single pin oil pressure switch)
    110
  • 1.9 Checking oil pressure and oil pressure switch (2-pin oil pressure switch)
    112
  • Cooling
    115
  • 1 Parts of cooling system
    115
  • 1.1 Assembly overview - parts of cooling system, engine side
    115
  • 1.4 Assembly overview - parts of cooling system, body side
    118
  • 1.5 Coolant hose connection diagram
    120
  • 1.6 Bypass thermostat (engine code BYD)
    121
  • 1.7 Draining and adding coolant
    122
  • 1.8 Assembly overview - coolant pump, thermostat
    126
  • 1.9 Removing and installing coolant pump
    127
  • 1.10 Removing and installing coolant temperature sender
    129
  • 1.11 Removing and installing coolant pipes
    131
  • 1.12 Removing and installing coolant thermostat housing with thermostat
    133
  • 1.13 Removing and installing fan support with radiator fan V7 and radiator fan 2 V177
    134
  • 1.14 Removing and installing radiator (Golf 2004 ►)
    136
  • 1.15 Removing and installing radiator (Golf 2009 ►, Golf Cabriolet 2012 ►, Scirocco)
    137
  • 1.16 Removing and installing auxiliary radiator (Golf 2009 ►, Golf Cabriolet 2012 ►, Scirocco)
    138
  • 1.17 Checking cooling system for leaks
    139
  • Fuel supply system
    141
  • 1 Safety precautions
    141
  • 1.1 Safety regulations for working on fuel supply
    141
  • 1.2 Releasing fuel pressure in high-pressure section
    142
  • 2 Rules for cleanliness
    144
  • 3 Fuel tank (front-wheel drive)
    145
  • 3.1 Assembly overview - fuel tank
    145
  • 3.2 Emptying fuel tank
    147
  • 3.3 Removing and installing fuel tank
    151
  • 4 Fuel tank (four-wheel drive)
    154
  • 4.1 Assembly overview - fuel tank
    154
  • 4.2 Emptying fuel tank
    156
  • 4.3 Removing and installing fuel tank
    161
  • 4.4 Removing and installing fuel gauge sender 2 G169
    165
  • 4.5 Removing and installing suction-jet pump
    167
  • 5 Repairing fuel supply
    169
  • 5.1 Removing and installing fuel delivery unit
    169
  • 5.2 Removing and installing fuel gauge sender G
    173
  • 5.3 Checking fuel pump G6
    174
  • 6 Electronic power control (EPC)
    186
  • 6.1 Assembly overview - accelerator module
    186
  • 6.2 Removing and installing accelerator pedal module
    186
  • 7 Activated charcoal filter system
    189
  • 7.1 Assembly overview - activated charcoal filter system
    189
  • 7.2 Checking fuel tank breather
    189
  • 7.3 Checking fuel system for leaks
    191
  • 8 Activated charcoal filter system
    199
  • 8.1 Overview of activated charcoal filter system
    199
  • 8.2 Assembly overview - activated charcoal filter system
    201
  • 8.3 Removing and installing activated charcoal filter
    202
  • 8.4 Removing and installing fuel system diagnostic pump V144
    203
  • 8.5 Checking fuel system for leaks
    203
  • Turbocharging/supercharging
    212
  • 1 Exhaust turbocharger
    212
  • 1.1 Fitting hose connections with plug-in connectors
    212
  • 1.2 Rules for cleanliness
    213
  • 1.3 Assembly overview - turbocharger
    213
  • 1.4 Removing and installing turbocharger
    218
  • 1.5 Checking vacuum unit for turbocharger
    226
  • 1.6 Removing and installing turbocharger vacuum unit (engine code BYD)
    227
  • 1.7 Adjusting turbocharger vacuum unit (engine code BYD)
    227
  • 2 Charge air system
    232
  • 2.1 Assembly overview - charge air cooling (engine code BYD)
    232
  • 2.3 Assembly overview - noise booster (engine code BYD)
    236
  • 2.5 Schematic diagram of turbocharging system
    239
  • 2.6 Removing and installing charge air cooler (Golf and Golf Cabriolet)
    240
  • 2.7 Removing and installing charge air cooler (Scirocco)
    241
  • 2.8 Checking charge air system for leaks
    242
  • Mixture preparation - injection
    245
  • 1 Safety precautions and rules for cleanliness
    245
  • 1.1 General information on self-diagnosis
    245
  • 2 Injection system
    246
  • 2.1 Technical data
    246
  • 2.2 Assembly overview - engine cover panel/air filter
    246
  • 2.3 Removing and installing engine cover panel/air filter
    248
  • 2.4 Removing and installing air filter element
    250
  • 2.5 Removing and installing air mass meter G70
    251
  • 2.6 Assembly overview - intake manifold
    252
  • 2.7 Removing and installing intake manifold
    254
  • 2.9 Assembly overview - fuel rail (vehicles up to 05.2007)
    259
  • 2.10 Assembly overview - fuel rail (vehicles from 05.2007)
    260
  • 2.11 Removing and installing fuel rail
    262
  • 2.12 Removing and installing throttle valve module J338
    263
  • 2.13 Cleaning throttle valve module J338
    263
  • 2.14 Assembly overview - high-pressure pump
    264
  • 2.15 Removing and installing high-pressure pump
    266
  • 2.16 Removing and installing fuel pressure sender G247
    268
  • 2.17 Checking fuel pressure sender G247
    269
  • 2.18 Removing and installing injectors
    271
  • 2.19 Renewing Teflon seal on injector
    274
  • 3 Checking components
    277
  • 3.1 Checking double non-return valve
    277
  • 4 Engine control unit J623 (Golf 2004 ►)
    278
  • 4.1 Removing and installing engine (motor) control unit J623
    278
  • 4.2 Removing and installing anti-theft engine control unit J623
    278
  • 5 Engine control unit J623 (Golf 2009 ► and Golf Cabriolet)
    282
  • 5.1 Removing and installing engine control unit
    282
  • 5.2 Removing and installing anti-theft engine control unit
    283
  • 6 Engine control unit J623 (Scirocco)
    287
  • 6.1 Removing and installing engine (motor) control unit J623
    287
  • 6.2 Removing and installing anti-theft engine control unit J623
    288
  • Exhaust system
    290
  • 1 Exhaust system
    290
  • 1.1 Assembly overview - exhaust system (Golf 2004 ►)
    290
  • 1.2 Assembly overview - exhaust system (Golf 2009 ►)
    293
  • 1.3 Assembly overview - exhaust system (Golf Cabriolet 2012 ►)
    295
  • 1.4 Assembly overview - exhaust system (Scirocco)
    297
  • 1.5 Separating centre and rear silencers (front-wheel drive)
    299
  • 1.6 Removing and installing front exhaust pipe with catalytic converters
    300
  • 1.7 Aligning exhaust system free of stress
    301
  • 1.8 Checking exhaust gas flap (Golf 2009 ►,Golf Cabriolet 2012►, Scirocco)
    302
  • Ignition system
    305
  • 1 Repairing ignition system
    305
  • 1.1 General notes on ignition system
    305
  • 1.2 Safety precautions
    305
  • 1.3 Assembly overview - ignition system
    305
  • 1.4 Removing and installing ignition coils with output stage
    306
  • 1.5 Test data, spark plugs
    308
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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