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

ENGINE

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 ➤

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

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

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