5-cylinder injection engine (2.5 l engine, 4-valve)

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• Removing and installing engine
  3
• 1 Removing and installing engine
  3
• 1.1 Removing engine - Jetta up to MY 2010 and Golf Variant
  3
• 1.2 Removing engine - Jetta from MY 2011
  8
• 1.3 Securing engine to assembly stand
  15
• 1.4 Installing engine - Jetta up to MY 2010 and Golf Variant
  18
• 1.5 Installing engine - Jetta from MY 2011
  19
• 1.6 Assembly mountings- specified torques
  21
• Crankshaft group
  22
• 1 Dismantling and assembling engine
  22
• 1.1 Assembly overview - add-on parts
  22
• 1.2 Assembly overview - chain drive
  36
• 1.3 Removing and installing poly V-belt
  40
• 1.4 Removing and installing exhauster pump for brake servo
  43
• 2 Sealing flange and flywheel or drive plate
  46
• 2.1 Assembly overview
  46
• 2.2 Renewing crankshaft sealing flange - belt pulley end
  47
• 2.3 Removing and installing valve timing housing
  50
• 2.4 Removing and installing seal on gearbox side
  53
• 2.5 Removing and installing drive plate
  54
• 3 Crankshaft
  56
• 3.1 Assembly overview - crankshaft
  56
• 3.2 Crankshaft dimensions
  57
• 3.3 Locking crankshaft
  58
• 4 Pistons and conrods
  62
• 4.1 Assembly overview - pistons and conrods
  62
• 4.2 Separating new conrod
  63
• 4.3 Checking pistons, piston rings and cylinder bores
  64
• 4.4 Piston and cylinder dimensions
  66
• Cylinder head, valve gear
  67
• 1 Cylinder head
  67
• 1.1 Assembly overview
  67
• 1.2 Removing and installing cylinder head cover
  69
• 1.3 Removing and installing chain guard cover
  70
• 1.4 Renewing chain guard cover seal
  74
• 1.5 Checking valve timing
  76
• 1.6 Adjusting valve timing
  77
• 1.7 Removing and installing cylinder head
  81
• 1.8 Checking compression
  86
• 2 Valve gear
  88
• 2.1 Assembly overview - valve gear
  88
• 2.2 Valve dimensions
  90
• 2.3 Checking valve guides
  90
• 2.4 Renewing valve stem seals
  91
• 2.5 Removing and installing camshafts
  94
• Lubrication
  99
• 1 Parts of lubrication system
  99
• 1.1 Engine oil
  99
• 1.3 Assembly overview - parts of lubrication system - Jetta from MY 2011
  102
• 1.4 Oil filter bracket with attachments \- Assembly overview \- Jetta up to MY 2010 and Golf Variant
  104
• 1.5 Oil filter bracket with attachments - Assembly overview - Jetta from MY 2011
  105
• 1.6 Draining oil filter housing
  107
• 1.7 Removing and installing lower part of sump
  107
• 1.8 Removing and installing upper part of sump
  109
• 1.9 Removing and installing oil pump, engine codes BGP, BGQ and BTK
  112
• 1.10 Removing and installing oil pump, engine codes CBTA, CBUA and CCCA
  115
• Cooling
  122
• 1 Cooling system components - Jetta up to MY 2010 and Golf Variant
  122
• 1.1 Assembly overview - parts of cooling system, engine side
  123
• 1.2 Assembly overview - parts of cooling system, body side
  126
• 1.3 Coolant hose schematic diagram
  127
• 1.4 Draining and filling coolant
  129
• 1.5 Removing and installing coolant pump
  132
• 1.6 Removing and installing thermostat
  136
• 1.7 Removing and installing radiator fan V7 and radiator fan 2 V177
  138
• 1.8 Removing and installing radiator
  139
• 1.9 Checking cooling system for leaks
  141
• 2 Cooling system components - Jetta from MY 2011
  144
• 2.1 Assembly overview - parts of cooling system, engine side
  145
• 2.2 Assembly overview - parts of cooling system, body side
  148
• 2.3 Coolant hose schematic diagram
  149
• 2.4 Assembly overview - engine preheater
  150
• 2.5 Draining and filling coolant
  151
• 2.6 Removing and installing coolant pump
  154
• 2.7 Removing and installing thermostat
  158
• 2.8 Removing and installing radiator fan V7 and radiator fan 2 V177
  160
• 2.9 Removing and installing radiator
  161
• 2.10 Checking cooling system for leaks
  162
• Fuel supply system
  165
• 1 Parts of fuel supply system
  165
• 1.1 Safety precautions when working on fuel supply system
  165
• 1.2 Rules for cleanliness
  166
• 1.3 Assembly overview - fuel tank, engine codes BGP, BGQ, CBTA, CBUA
  166
• 1.4 Assembly overview - fuel tank, engine codes BTK, CCCA
  169
• 1.5 Emptying fuel tank
  171
• 1.6 Removing and installing fuel delivery unit
  176
• 1.7 Removing and installing fuel gauge sender G
  178
• 1.8 Removing and installing fuel tank - Jetta up to MY 2010 and Golf Variant
  180
• 1.9 Removing and installing fuel tank - Jetta from MY 2011
  183
• 1.10 Assembly overview - fuel filter with attachments
  187
• 1.11 Removing and installing fuel filter
  188
• 1.12 Checking fuel pump
  189
• 1.13 Bleeding fuel system
  197
• 2 Electronic power control (EPC)
  200
• 2.1 Function of EPC system
  200
• 2.2 Assembly overview - accelerator module
  200
• 2.3 Removing and installing accelerator module
  201
• 3.1 Function
  205
• 3.2 Overview of activated charcoal filter system - vehicles to MY 2009
  205
• 3.3 Overview of activated charcoal filter system - vehicles from MY 2010
  207
• 3.4 Assembly overview: activated charcoal filter system
  208
• 3.5 Removing and installing activated charcoal filter
  209
• 3.6 Removing and installing fuel system diagnostic pump V144
  210
• 3.7 Checking fuel system for leaks
  210
• 4.1 Function
  219
• 4.2 Overview of activated charcoal filter system
  219
• 4.3 Assembly overview: activated charcoal filter system
  221
• 4.4 Removing and installing activated charcoal filter
  222
• 4.5 Removing and installing fuel system diagnostic pump V144
  222
• 4.6 Checking fuel system for leaks
  223
• 5 Activated charcoal filter system, engine codes BTK, CCCA
  230
• 5.1 Function
  230
• 5.2 Assembly overview - activated charcoal filter system
  230
• 5.3 Checking fuel tank breather
  231
• Mixture preparation - injection
  234
• 1 Injection system
  234
• 1.1 General notes on injection
  234
• 1.2 Safety precautions
  235
• 1.3 Rules for cleanliness
  236
• 1.4 Technical data
  236
• 1.5 Overview of fitting locations
  237
• 1.9 Assembly overview - intake manifold with attachments, Jetta from MY 2011
  243
• 1.10 Assembly overview - fuel rail with injectors
  244
• 1.11 Assembly overview - air filter
  244
• 1.12 Removing and installing engine cover with air filter
  246
• 1.13 Removing and installing throttle valve module J338
  246
• 1.14 Removing and installing intake manifold
  248
• 1.15 Removing and installing injectors
  252
• 2 Checking components
  254
• 2.1 Checking injectors for leaks and quantity injected
  254
• 2.2 Checking fuel pressure regulator and holding pressure
  257
• 3 Engine control unit
  260
• 3.1 Reading and erasing engine control unit fault memory
  260
• 3.2 Removing and installing engine control unit - up to 10.2008
  261
• 3.4 Removing and installing engine control unit - Jetta from MY 2011
  268
• Exhaust system
  271
• 1 Parts of the exhaust system
  271
• 1.5 Assembly overview - silencers with mountings
  279
• 1.6 Removing and installing front exhaust pipe with catalytic converter
  279
• 1.7 Separating and joining centre and rear silencers
  281
• 1.8 Aligning exhaust system free of stress
  282
• 2 Secondary air system
  284
• 2.1 Function
  284
• 2.2 Assembly overview - secondary air system
  284
• 2.3 Removing and installing secondary air pump motor V101
  286
• 2.4 Checking secondary air inlet valve N112
  286
• Ignition system
  288
• 1 Ignition system
  288
• 1.1 General notes on ignition system
  288
• 1.2 Safety precautions
  288
• 1.3 Assembly overview - ignition system
  288
• 1.4 Removing and installing ignition coils with output stage
  290
• 1.5 Test data, spark plugs
  291