VW 4-cylinder Diesel Engine (1.9L engine) Workshop Manual

The 4-Cyl. Diesel Engine (1.9L engine) is installed in the Volkswagen Golf 2004 ➤, Golf Plus 2005 ➤, Passat 2006 ➤, Touran 2003 ➤ 4-cylinder diesel engine.

  • Engine ID: AVQ, BJB, BKC, BLS, BRU, BXE, BXF, BXJ

List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups

Repair Group
00 – Technical data
10 – Removing and installing engine
13 – Crankshaft group
15 – Cylinder head, valve gear
17 – Lubrication
19 – Cooling
20 – Fuel supply system
21 – Turbocharging/supercharging
23 – Mixture preparation – injection
26 – Exhaust system
28 – Glow plug system

CONTENTS

  • 00 – Technical data
    • Technical data
    • Engine number
    • Engine data
  • 10 – Removing and installing engine
    • Removing and installing engine
    • Removing engine (Golf, Golf Plus)
    • Removing engine (Touran)
    • Removing engine (Passat)
    • Securing engine to assembly stand
    • Notes on installing
    • Assembly mountings
  • 13 – Crankshaft group
    • Dismantling and assembling engine
    • Assembly overview – poly V-belt drive
    • Assembly overview – toothed belt drive
    • Removing and installing engine support
    • Assembly overview – crankcase
    • Removing and installing sealing flange and flywheel
    • Assembly overview – sealing flanges and flywheel
    • Removing and installing dual-mass flywheel
    • Renewing crankshaft oil seal – belt pulley end
    • Removing and installing sealing flange – pulley end
    • Renewing crankshaft sealing flange – flywheel end
    • Removing and installing engine speed sender G28
    • Crankshaft
    • Assembly overview – crankshaft
    • Pistons and conrods
    • Assembly overview – pistons and conrods
    • Separating new conrod
    • Checking piston projection at TDC
    • Piston and cylinder dimensions
    • Piston rings, cylinder bore and piston installation position
  • 15 – Cylinder head, valve gear
    • Cylinder head
    • Assembly overview – cylinder head
    • Removing and installing cylinder head cover
    • Removing, installing and tensioning toothed belts
    • Removing and installing cylinder head
    • Checking compression
    • Valve gear
    • Assembly overview – valve gear
    • Checking valve guides
    • Renewing valve stem seals
    • Removing and installing camshaft
    • Removing and installing camshaft oil seal
  • 17 – Lubrication
    • Engine oil
    • Oil capacities
    • Checking engine oil level
    • Checking engine oil level
    • Parts of lubrication system
    • Assembly overview – oil pump, sump
    • Removing and installing oil sump
    • Oil filter bracket, oil pressure, engine oil cooler and oil supply line
    • Assembly overview – oil filter bracket and engine oil cooler
    • Checking oil pressure and oil pressure switch
    • Assembly overview – oil supply line to turbocharger
    • Removing and installing oil supply line
  • 19 – Cooling
    • Parts of cooling system
    • Parts of cooling system, body side (radiator with two radiator fans)
    • Assembly overview – parts of cooling system, body side (radiator with one radiator fan)
    • Removing and installing fan support with fans (Golf, Golf Plus, Touran)
    • Removing and installing fan support with fans (Passat)
    • Parts of cooling system, engine side
    • Coolant hose schematic diagram
    • Draining and filling coolant
    • Removing and installing radiator (Golf, Golf Plus, Touran)
    • Removing and installing radiator (Passat)
    • Removing and installing coolant pump
    • Removing and installing thermostat
    • Checking cooling system for leaks
    • Checking engine oil cooler for leaks
  • 20 – Fuel supply system
    • Safety precautions
    • Safety precautions when working on fuel supply system
    • Rules for cleanliness
    • Rules for cleanliness when working on fuel supply system
    • Parts of fuel supply system (Golf, Golf Plus)
    • Fuel tank, vehicles with front-wheel drive
    • Fuel tank, vehicles with four-wheel drive
    • Emptying fuel tank
    • Removing and installing fuel delivery unit
    • Removing and installing fuel gauge sender
    • Checking fuel pump
    • Assembly overview – fuel filter
    • Removing and installing fuel cooler
    • Parts of fuel supply system (Touran)
    • Assembly overview – fuel tank with attachments
    • Emptying fuel tank
    • Removing and installing fuel tank
    • Assembly overview – fuel filter
    • Removing and installing fuel cooler
    • Removing and installing fuel delivery unit
    • Removing and installing fuel gauge sender
    • Checking fuel pump
    • Parts of fuel supply system (Passat)
    • Fuel tank, vehicles with front-wheel drive
    • Emptying fuel tank, vehicles with front-wheel drive
    • Checking fuel pump
    • Assembly overview – fuel filter
    • Removing and installing fuel cooler
    • Accelerator mechanism
    • Assembly overview – accelerator mechanism
    • Tandem pump
    • Checking tandem pump
    • Removing and installing tandem pump
  • 21 – Turbocharging/supercharging
    • Charge air system with turbocharger
    • Safety precautions
    • Rules for cleanliness
    • Hose connections
    • Assembly overview – turbocharger
    • Removing and installing turbocharger
    • Assembly overview – parts of charge air cooling
    • Checking charge air system for leaks
    • Vacuum hose schematic diagram
  • 23 – Mixture preparation – injection
    • Diesel direct injection system
    • Safety precautions
    • Rules for cleanliness
    • Removing and installing pre-wired wiring harness for unit injectors and glow plugs
    • Assembly overview – unit injector
    • Removing and installing unit injector
    • Adjusting non-contact gap of unit injectors
    • Removing and installing O-rings for unit injector
    • Assembly overview – intake manifold
    • Cleaning the intake manifold flap support, Engine code BLS and BXJ
    • Assembly overview – air filter
    • Engine control unit
    • Reading and clearing engine control unit fault memory
    • Adapting functions and components
    • Removing and installing engine control unit (Golf)
    • Removing and installing anti-theft engine control unit (Golf)
    • Removing and installing engine control unit (Golf Plus)
    • Removing and installing anti-theft engine control unit (Golf Plus)
    • Removing and installing engine control unit (Touran)
    • Removing and installing anti-theft engine control unit (Touran)
    • Engine control unit (Passat)
    • Removing and installing engine control unit
    • Removing and installing anti-theft engine control unit
  • 26 – Exhaust system
    • Exhaust system
    • Assembly overview – front exhaust pipe with catalytic converter
    • Assembly overview – front exhaust pipe with particulate filter
    • Assembly overview – silencer with mountings (vehicles with front wheel drive)
    • Assembly overview – silencers (Passat)
    • Assembly overview – silencer with mountings (vehicles with four-wheel drive)
    • Aligning exhaust system free of stress
    • Exhaust gas recirculation system
    • Assembly overview – parts of exhaust gas recirculation
    • Checking mechanical exhaust gas recirculation valve
  • 28 – Glow plug system
    • Checking glow plug system
    • Removing, installing and checking glow plugs
    • Characteristics of ceramic glow plugs
    • Removing, installing and checking ceramic glow plugs

Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.

Edition: 08.2010 (D3E801CBF41)
Language: English
Format: PDF
Pages: 278

VW 4-cylinder Diesel Engine (1.9L engine) Workshop Manual PDF free online

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