Name: 4-cylinder injection engine (2.0 l engine, turbocharger) Volkswagen R GmbH
Brand: Volkswagen
SKU: CDGe6a1806e60a5
Price: 24.65 EUR
Availability: InStock

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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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