4-cyl. direct injection engine (1.8 l and 2.0 l, 4 V, EA 888 gen III, turbocharger, chain drive)

Kapitelübersicht

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety regulations for working on fuel supply
  1
• 1.2 Safety measures when working on vehicles with a start/stop system
  1
• 1.4 Safety precautions when working on ignition system
  2
• 1.5 Safety precautions when working on the cooling system
  2
• 1.6 Safety precautions when working on exhaust system
  3
• 2 Identification
  4
• 2.1 Engine number/engine data
  4
• 3 Repair instructions
  7
• 3.1 Rules for cleanliness
  7
• 3.2 Foreign objects in engine
  7
• 3.3 Contact corrosion
  7
• 3.4 Routing and attachment of lines
  7
• 3.5 Fitting radiator and condensers
  8
• 3.6 Checking vacuum system
  8
• Removing and installing engine
  9
• 1 Removing and installing engine
  9
• 1.1 Removing engine
  9
• 1.2 Separating engine and gearbox
  30
• 1.3 Securing engine on engine and gearbox support
  40
• 1.4 Installing engine
  43
• 2 Assembly mountings
  47
• 2.1 Assembly overview - assembly mountings
  47
• 2.2 Supporting engine in installation position
  51
• 2.3 Removing and installing engine mounting
  72
• 2.4 Removing and installing gearbox mounting
  74
• 2.5 Removing and installing pendulum support
  76
• 2.6 Checking adjustment of assembly mountings
  77
• 2.7 Adjusting assembly mountings
  78
• 3 Engine cover panel
  81
• 3.1 Removing and installing engine cover
  81
• Crankshaft group
  82
• 1 Cylinder block (pulley end)
  82
• 1.1 Assembly overview - cylinder block (pulley end)
  82
• 1.2 Removing and installing poly-V belt
  85
• 1.3 Removing and installing tensioner for poly V-belt
  87
• 1.4 Removing and installing vibration damper
  88
• 1.5 Removing and installing bracket for ancillaries
  95
• 1.6 Removing and installing engine support
  98
• 1.7 Renewing seal for vibration damper
  100
• 2 Cylinder block, gearbox end
  103
• 2.1 Assembly overview - cylinder block, gearbox end
  103
• 2.2 Removing and installing flywheel
  104
• 2.3 Removing and installing sealing flange on gearbox side
  106
• 3 Crankshaft
  111
• 3.1 Assembly overview - crankshaft
  111
• 3.2 Crankshaft dimensions
  113
• 3.3 Allocation of main bearing shells
  113
• 3.4 Renewing needle bearing in crankshaft
  115
• 3.5 Measuring axial clearance of crankshaft
  117
• 3.6 Measuring radial clearance of crankshaft
  118
• 3.7 Removing and installing sender wheel
  119
• 4 Balancer shaft
  121
• 4.1 Assembly overview - balance shaft
  121
• 4.2 Removing and installing balance shaft
  123
• 5 Pistons and conrods
  130
• 5.1 Assembly overview - pistons and conrods
  130
• 5.2 Removing and installing pistons
  134
• 5.3 Checking pistons and cylinder bores
  136
• 5.4 Separating new conrod
  139
• 5.5 Checking radial clearance of conrods
  139
• 5.6 Removing and installing oil spray jets
  140
• Cylinder head, valve gear
  142
• 1 Cylinder head
  142
• 1.1 Assembly overview - cylinder head
  142
• 1.2 Removing and installing cylinder head
  145
• 1.3 Removing and installing vacuum pump
  152
• 1.4 Checking compression
  154
• 2 Cover for timing chain
  157
• 2.1 Assembly overview - cover for timing chain
  157
• 2.2 Removing and installing timing chain cover
  159
• 3 Chain drive
  168
• 3.1 Assembly overview - camshaft timing chains
  168
• 3.2 Removing and installing camshaft timing chain
  171
• 3.3 Assembly overview - drive chain for balance shaft
  187
• 3.4 Removing and installing drive chain for balance shaft
  190
• 3.5 Checking timing chain
  190
• 3.6 Checking valve timing
  191
• 4 Valve gear
  194
• 4.1 Assembly overview - valve gear
  194
• 4.2 Removing and installing camshaft
  199
• 4.3 Removing and installing camshaft control valve 1 N205
  218
• 4.4 Removing and installing exhaust camshaft control valve 1 N318
  218
• 4.5 Removing and installing valve stem seals
  218
• 5 Inlet and exhaust valves
  230
• 5.1 Checking valve guides
  230
• 5.2 Checking valves
  231
• 5.3 Valve dimensions
  231
• Lubrication
  232
• 1 Sump, oil pump
  232
• 1.1 Assembly overview - sump/oil pump
  232
• 1.2 Removing and installing oil level and oil temperature sender G266
  235
• 1.3 Removing and installing lower part of sump
  236
• 1.4 Removing and installing oil pump
  242
• 1.5 Removing and installing upper part of sump
  245
• 1.6 Engine oil:
  250
• 2 Engine oil cooler
  251
• 2.1 Assembly overview - engine oil cooler
  251
• 2.2 Removing and installing engine oil cooler
  251
• 3 Crankcase ventilation
  254
• 3.1 Assembly overview - crankcase breather system
  254
• 3.2 Removing and installing oil separator
  255
• 4 Oil filter, oil pressure switch
  256
• 4.1 Assembly overview - oil filter
  256
• 4.2 Assembly overview - oil pressure switches/oil pressure control
  256
• 4.3 Removing and installing piston cooling jet control valve N522
  258
• 4.4 Removing and installing oil pressure regulating valve N428
  259
• 4.5 Removing and installing oil pressure switch
  260
• 4.6 Checking oil pressure
  264
• Cooling
  268
• 1 Cooling system/coolant
  268
• 1.1 Connection diagram - coolant hoses
  268
• 1.2 Draining and adding coolant
  278
• 1.3 Checking cooling system for leaks
  287
• 1.4 Flushing cooling system
  291
• 2 Coolant pump, regulation of cooling system
  315
• 2.1 Assembly overview - coolant pump, thermostat
  315
• 2.2 Assembly overview - electric coolant pump
  317
• 2.3 Assembly overview - coolant temperature sender
  321
• 2.4 Removing and installing toothed belt for coolant pump
  322
• 2.5 Removing and installing coolant pump
  324
• 2.6 Removing and installing electric coolant pump
  327
• 2.7 Removing and installing coolant valves
  330
• 2.8 Removing and installing actuator for engine temperature regulation N493
  337
• 2.9 Removing and installing coolant temperature sender G62
  340
• 2.10 Removing and installing radiator outlet coolant temperature sender G83
  341
• 3 Coolant pipes
  343
• 3.1 Assembly overview - coolant pipes
  343
• 3.2 Removing and installing coolant pipes
  343
• 3.3 Removing and installing upper coolant pipes
  345
• 4 Radiator, radiator fan
  348
• 4.1 Assembly overview – radiator
  348
• 4.2 Assembly overview - auxiliary radiator
  352
• 4.3 Assembly overview – radiator cowl and radiator fan
  353
• 4.4 Removing and installing radiator
  356
• 4.5 Removing and installing radiator cowl
  364
• 4.6 Removing and installing radiator fan
  367
• 4.7 Removing and installing auxiliary radiator
  369
• Turbocharging/supercharging
  374
• 1 Turbocharger
  374
• 1.1 Assembly overview - turbocharger
  374
• 1.2 Removing and installing turbocharger
  380
• 1.3 Removing and installing charge pressure positioner V465
  392
• 1.4 Adjusting charge pressure positioner V465
  393
• 2 Charge air system
  397
• 2.1 Assembly overview - charge air system
  397
• 2.2 Assembly overview - charge-air hose connections
  401
• 2.3 Removing and installing charge air cooler
  401
• 2.4 Removing and installing charge pressure sender G31
  407
• 2.5 Checking charge air system for leaks
  407
• Mixture preparation - injection
  412
• 1 Injection system
  412
• 1.1 Overview of fitting locations - injection system
  412
• 2 Injectors
  424
• 2.1 Assembly overview - fuel rail with injectors
  424
• 2.2 Removing and installing fuel rail
  426
• 2.3 Removing and installing injectors
  427
• 2.4 Renewing seals on injectors
  435
• 2.5 Cleaning injectors
  438
• 3 Air filter
  441
• 3.1 Assembly overview - air filter housing
  441
• 3.2 Removing and installing air filter housing
  443
• 4 Intake manifold
  445
• 4.1 Assembly overview – intake manifold
  445
• 4.2 Removing and installing intake manifold
  447
• 4.3 Removing and installing throttle valve module GX3
  453
• 4.4 Cleaning throttle valve module GX3
  456
• 5 Senders and sensors
  458
• 5.3 Removing and installing fuel pressure sender G247
  460
• 5.4 Checking fuel pressure sender G247
  464
• 5.5 Removing and installing fuel pressure sender for low-pressure G410
  469
• 5.6 Removing and installing intake manifold sender GX9
  470
• 5.7 Removing and installing pressure differential sender for particulate filter G1037
  471
• 6 Engine control unit
  473
• 6.1 Removing and installing engine control unit J623
  473
• 6.2 Removing and installing engine (motor) control unit J623 with protective housing
  477
• 7 High-pressure pump
  486
• 7.1 Assembly overview - high-pressure pump
  486
• 7.2 Removing and installing high-pressure pump
  488
• 7.3 Removing and installing high-pressure pipe
  492
• 8 Lambda probe
  496
• 8.1 Assembly overview - Lambda probe
  496
• 8.2 Removing and installing Lambda probe
  497
• Exhaust system
  501
• 1 Exhaust pipes and silencers
  501
• 1.1 Assembly overview – silencers
  501
• 1.2 Removing and installing silencer
  514
• 1.3 Separating exhaust pipes from silencers
  525
• 1.4 Aligning exhaust system free of stress
  532
• 1.5 Checking exhaust system for leaks
  533
• 2 Emission control
  534
• 2.1 Assembly overview – emission control
  534
• 2.3 Removing and installing catalytic converter
  550
• 2.5 Removing and installing exhaust flap control unit J883/J945, Passat CJXA, Arteon
  568
• 3 Exhaust gas temperature regulation
  569
• 3.1 Assembly overview – exhaust gas temperature regulation
  569
• 3.2 Removing and installing parts of exhaust gas temperature regulation
  570
• 4 Secondary air system
  575
• 4.1 Assembly overview - secondary air system
  575
• 4.2 Removing and installing secondary air pump motor V101
  576
• 4.3 Renewing stop buffer for secondary air pump
  576
• 4.4 Removing and installing secondary air inlet valve N112
  577
• Ignition system
  579
• 1 Ignition system
  579
• 1.1 Assembly overview - ignition system
  579
• 1.2 Removing and installing ignition coils with output stage
  581
• 1.3 Removing and installing knock sensor 1 G61
  583
• 1.4 Removing and installing Hall sender
  585
• 1.5 Removing and installing engine speed sender G28
  586