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

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Our repair manual covers all aspects of engine repair, including specifications, components, and troubleshooting procedures. With our comprehensive manual, you can easily locate the information you need and perform any necessary repairs on your engine.

4-Cylinder Diesel Engine (2.0L Engine, Common Rail) Repair Manual (Edition 04.2015) PDF. Engine ID: CBEA, CJAA/ Repair Manual for: Golf Variant 2007 -, Golf Variant 2010 -, Jetta 2005 -, Jetta 2011 -.

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

Edition: 04.2015 D3E80109914
Language: English
Format: PDF
Pages: 424

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