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 (Edition 04.2015) PDF free online

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

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