4-Cylinder Diesel Engine (2.0L Engine, Common Rail) Repair Manual (Edition 04.2015)



4-Cylinder Diesel Engine (2.0L Engine, Common Rail) Repair Manual PDF

Volkswagen Golf  Variant 2007 , Golf Variant 2010, Jetta 2005, Jetta 2011 4-Cylinder Diesel Engine (2.0L Engine, Common Rail) Repair Manual Edition 04.2015 (D3E80109914) PDF Free Download. 

Engine ID: CBEA, CJAA

CONTENTS:

General, Technical Data

  • Technical Data
  • Engine Number
  • Engine Specifications

Engine Assembly

  • Engine, Removing and Installing
  • Engine, Removing
  • Transmission and Engine, Disconnecting and Assembling
  • Engine, Securing to Engine and Gearbox Bracket VAS6095A
  • General Installation Information
  • Subframe Mount, except Jetta from MY 2011
  • Overview – Subframe Mount
  • Engine-Subframe Mount Adjustment, Checking
  • Subframe Mount, Adjusting
  • Assembly Mounts, Jetta from 2011
  • Overview – Subframe Mount
  • Engine Mount, Removing and Installing
  • Transmission Mount, Removing and Installing
  • Pendulum Support, Removing and Installing
  • Engine, Supporting in Installation Position
  • Subframe Mount, Adjusting
  • Subframe Mount, Checking Adjustment
  • Special Tools

Crankshaft, Cylinder Block

  • Engine, Disassembling and Assembling
  • Overview – Ribbed Belt Drive
  • Overview – Toothed Belt Drive
  • Overview – Cylinder Block
  • Ribbed Belt, Removing and Installing
  • Ribbed Belt Tensioner, Removing and Installing
  • Sub-Assembly Bracket, Removing and Installing
  • Engine Bracket, Removing and Installing
  • Sealing Flange and Flywheel
  • Overview – Sealing Flange and Flywheel
  • Crankshaft Sealing Flange, Removing and Installing
  • Crankshaft Seal, Replacing, Belt Pulley Side
  • Sealing Flange, Removing and Installing, Belt Pulley Side
  • Engine Speed Sensor G28 , Removing and Installing
  • Pistons and Connecting Rod
  • Overview – Piston and Connecting Rod
  • New Connecting Rod, Separating
  • Bearing Shells – Installation Position
  • Piston and Cylinder Dimensions
  • Piston Projection in Top Dead Center (TDC), Checking
  • Crankshaft
  • Overview – Crankshaft
  • Crankshaft Dimensions
  • Needle Bearings, Removing and Installing from Crankshaft
  • Special Tools

Cylinder Head, Valvetrain

  • Cylinder Head
  • Overview – Cylinder Head Cover
  • Overview – Cylinder Head
  • Camshaft Position Sensor G40 , Removing and Installing
  • Engine Cover, Removing and Installing
  • Cylinder Head Cover, Removing and Installing
  • Toothed Belt, Removing, Installing and Tensioning
  • Cylinder Head, Removing and Installing
  • Vacuum Pump, Removing and Installing
  • Compression, Checking
  • Valvetrain
  • Overview – Valvetrain
  • Camshafts, Removing and Installing
  • Camshaft Seal, Removing and Installing
  • Valve Stem Seals with Cylinder Head Installed, Replacing
  • Valve Guides, Checking
  • Special Tools

Lubrication

  • Engine Oil
  • Oil Capacities
  • Engine Oil, Checking Level
  • Lubrication System Components, Engine Code CBEA
  • Overview – Oil Pump, Oil Pan and Balance Shaft Assembly
  • Oil Pan, Removing and Installing
  • Oil Pump, Removing and Installing
  • Balance Shaft Assembly, Removing and Installing
  • Spur Gear, Removing from Crankshaft and Shrink-Fitting New Spur Gear
  • Lubrication System Components, Engine Code CJAA
  • Overview – Oil Pump and Oil Pan
  • Oil Pan, Removing and Installing
  • Oil Pump, Removing and Installing
  • Oil Filter Bracket, Oil Cooler, Oil Pressure and Oil Supply Line
  • Overview – Oil Filter Bracket and Oil Cooler
  • Oil Filter Bracket with Oil Cooler, Removing and Installing
  • Oil Supply Line to Turbocharger, Removing and Installing
  • Oil Pressure and Oil Pressure Switch F1 , Checking
  • Special Tools

Cooling System

  • Cooling System Components
  • Overview – Cooling System Components, Body Side
  • Cooling System Components, Engine-Side
  • Coolant Hose Connection Diagram
  • Air Shroud with Radiator Fan V7 and Radiator Fan 2 V177 , Removing and Installing
  • Radiator, Removing and Installing
  • Coolant Pump, Removing and Installing
  • Coolant Thermostat, Removing and Installing
  • 4/2-Way Valve with Coolant Thermostat, Removing and Installing
  • Coolant, Draining and Filling
  • Cooling System, Checking for Leaks
  • Oil Cooler, Checking for Leaks
  • Engine Preheater
  • Special Tools

Fuel Supply

  • Safety Precautions when Working on Fuel Supply System
  • Guidelines for Clean Working Conditions
  • Misfueling
  • Step 1 (Engine Was Started with Incorrect Fuel)
  • Step 2 (Engine Was Not Started with Incorrect Fuel)
  • Step 3 (Shavings in the Fuel Delivery Unit and Reservoir)
  • Step 4 (No Shavings in the Fuel Delivery Unit and Reservoir)
  • Step 5 (Shavings in the High Pressure Pump)
  • Step 6 (No Shavings in the High Pressure Pump)
  • Fuel Supply System Components
  • General Information
  • Overview – Fuel Tank, All Vehicles Except Jetta from MY 2011
  • Overview – Fuel Tank, Jetta from MY 2011 Only
  • Fuel Tank, Draining
  • Fuel Tank, Removing and Installing
  • Fuel Delivery Unit, Removing and Installing
  • Fuel Level Sensor G , Removing and Installing
  • Connector Couplings, Disconnecting
  • Fuel Supply System, Servicing
  • General Information
  • Overview – Fuel Filter
  • Fuel Filter, Removing and Installing
  • Transfer Fuel Pump G6 , Checking
  • Auxiliary Fuel Pump V393 (Inline Fuel Pump), Checking
  • Auxiliary Fuel Pump V393 (Inline Fuel Pump), Removing and Installing
  • Electronic Engine Output Control (EPC)
  • EPC System Function
  • Overview – Accelerator Pedal Module
  • Accelerator Pedal Module, Removing and Installing
  • Special Tools

Turbocharger, Supercharger

  • Safety Precautions when Working on Charge Air System And Turbocharger
  • Guidelines for Clean Working Conditions
  • Turbocharger
  • Overview – Turbocharger with Exhaust Manifold and Attachments
  • Turbocharger with Exhaust Manifold, Removing and Installing, Engine Codes CBEA, CJAA
  • Turbocharger with Exhaust Manifold, Removing and Installing, Engine Codes CBDA, CBDB, CEGA
  • Vacuum Diaphragm with Charge Air Pressure Actuator Position Sensor G581 , Replacing
  • Charge Air System
  • General Information
  • Overview – Charge Air Cooler Components
  • Connector Coupling Between Charge Air Cooler and Connecting Hose, Disassembling and Assembling
  • Charge Air System, Checking for Leaks
  • Vacuum Hose Connection Diagram
  • Vacuum Hose Connection Diagram, Engine Codes CBDA, CBDB, CEGA
  • Vacuum System, Checking
  • Special Tools

Diesel Fuel Injection

  • Safety Precautions when Working on Diesel Direct Fuel Injection System
  • Guidelines for Clean Working Conditions
  • Diesel Direct Injection System
  • General Information
  • System Overview
  • Overview – Fuel System
  • Fuel Injector (Piezo Injector), Removing and Installing
  • Fuel Pressure Regulator Valve N276 , Checking
  • Fuel Pressure Regulator Valve N276 , Removing and Installing
  • Fuel Pressure Sensor G247 , Removing and Installing
  • High Pressure Fuel Pump, Removing and Installing
  • Fuel System, Filling/Bleeding
  • Fuel System, Performing Leak Test
  • Pressure Retaining Valve in Fuel Return, Checking
  • Overview – Intake Manifold with Attachments
  • Intake Manifold, Removing and Installing
  • Overview – Air Filter
  • Air Filter Housing, Removing and Installing
  • Air Filter Element, Removing and Installing
  • Mass Airflow Sensor G70 , Removing and Installing
  • Engine Control Module
  • Engine Control Module J623 without Anti-Theft Protection, Removing and Installing, All Vehicles Except Jetta from MY 2011
  • Engine Control Module J623 with Anti-Theft Protection, Removing and Installing, All Vehicles Except Jetta from MY 2011
  • Engine Control Module J623 , Removing and Installing, Jetta from MY 2011 Only
  • Engine Control Module, Engine Codes CBDA, CBDB, CEGA
  • Engine Control Module J623 without Anti-Theft Protection, Removing and Installing
  • Engine Control Module J623 with Anti-Theft Protection, Removing and Installing
  • Special Tools

Exhaust System, Emission Controls

  • General Information
  • Overview – Particulate Filter with NOx Reduction Catalytic Converter
  • Clamps and Exhaust Gas Temperature Sensor Installed Position
  • Particulate Filter with NOx Absorption Catalytic Converter, Removing and Installing
  • Overview – Exhaust Flap Control Module J883 with Slip Catalyst
  • Exhaust System Component Line Routing
  • Overview – Muffler
  • Exhaust System, Disconnecting and Connecting
  • Exhaust System, Installing without Tension
  • Exhaust System, Checking for Leaks
  • Exhaust System, Engine Codes CBDA, CBDB and CEGA
  • Overview – Front Exhaust Pipe with Particulate Filter
  • Particulate Filter, Removing and Installing
  • Overview – Muffler
  • Exhaust Pipe, Disconnecting
  • Exhaust System, Installing without Tension
  • EGR System
  • Overview – Exhaust Gas Recirculation System Components
  • EGR Temperature Sensor G98 , Removing and Installing
  • EGR System, Engine Codes CBDA, CBDB and CEGA
  • Overview – Exhaust Gas Recirculation System Components
  • Special Tools

Ignition/Glow Plug System

  • Glow Plugs
  • General Information
  • Glow Plug, Removing and Installing
  • Glow Plug Connectors, Removing and Installing
  • Special Tools
  • Revision History

Language: English
Format: PDF
Pages: 427
Size: 11.4 Mb
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