4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger)

Kapitelübersicht

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• Removing and installing engine
  3
• 1 Removing and installing engine (Golf, Golf Plus, Touran)
  3
• 1.1 Removing engine
  3
• 1.2 Securing engine to assembly stand
  13
• 1.3 Installing engine
  13
• 1.4 Specified torques
  15
• 1.5 Assembly mountings
  16
• 1.6 Additional information and assembly work for vehicles with air conditioner
  16
• 2 Removing and installing engine (Tiguan)
  18
• 2.1 Removing engine
  18
• 2.2 Securing engine to assembly stand
  25
• 2.3 Installing engine
  25
• 2.4 Specified torques
  27
• 2.5 Assembly mountings
  27
• 2.6 Additional information and assembly work for vehicles with air conditioner
  28
• Crankshaft group
  30
• 1 Dismantling and assembling engine
  30
• 1.1 Assembly overview - parts l and ll
  30
• 1.2 Assembly overview - part I, belt drive
  31
• 1.3 Assembly overview - part II, cylinder block
  33
• 1.4 Removing and installing poly V-belt (engine codes BLG, BMY)
  36
• 1.5 Removing and installing poly V-belt (engine code BWK)
  38
• 1.6 Removing and installing control housing (Golf, Golf Plus)
  40
• 1.7 Removing and installing valve timing housing (Tiguan, Touran)
  44
• 1.8 Removing and installing bracket for ancillaries
  48
• 2 Removing and installing sealing flanges and flywheel or drive plate
  50
• 2.1 Assembly overview
  50
• 2.2 Removing and installing engine speed sender G28
  51
• 2.3 Removing and installing crankshaft seal on belt pulley end
  53
• 2.4 Removing and installing crankshaft pulley
  55
• 2.5 Removing and installing crankshaft sealing flange on flywheel end
  58
• 3 Crankshaft
  67
• 3.1 Assembly overview
  67
• 3.2 Pulling needle bearing out of and driving into crankshaft
  68
• 3.3 Crankshaft dimensions
  70
• 4 Dismantling and assembling pistons and conrods
  71
• 4.1 Assembly overview
  71
• 4.2 Checking piston
  72
• 4.3 Separating new conrod
  73
• 4.4 Removing and installing pistons
  74
• 4.5 Removing and installing oil spray jets
  75
• Cylinder head, valve gear
  77
• 1 Cylinder head
  77
• 1.1 Assembly overview
  77
• 1.2 Checking valve timing
  79
• 1.3 Adjusting valve timing
  82
• 1.4 Checking timing chain
  88
• 1.5 Removing and installing timing chain and chain drive for oil pump
  94
• 1.6 Removing and installing camshaft housing
  103
• 1.7 Removing and installing cylinder head
  108
• 1.8 Checking compression
  111
• 2 Repairing valve gear
  114
• 2.1 Assembly overview
  114
• 2.2 Checking camshaft axial clearance
  115
• 2.3 Reworking valve seats
  116
• 2.4 Checking valve guides
  117
• 2.5 Renewing valve stem seals
  118
• Lubrication
  121
• 1 Removing and installing parts of lubrication system
  121
• 1.1 Engine oil, oil capacities, engine oil specification (engine codes BLG, BMY)
  121
• 1.2 Engine oil, oil capacities, engine oil specification (engine code BWK)
  121
• 1.3 Assembly overview
  121
• 1.4 Removing and installing sump
  124
• 1.5 Removing and installing oil pump
  126
• 1.6 Checking oil pressure and oil pressure switch
  128
• Cooling
  130
• 1 Removing and installing parts of cooling system
  130
• 1.2 Assembly overview - parts of cooling system, body side (engine code BWK)
  132
• 1.3 Assembly overview - parts of cooling system, engine side
  133
• 1.4 Coolant hose schematic diagram (engine codes BLG, BMY)
  135
• 1.5 Coolant hose schematic diagram (engine code BWK)
  135
• 1.6 Draining and adding coolant
  136
• 1.7 Checking cooling system for leaks
  140
• 1.9 Removing and installing radiator (engine codes BLG, BMY)
  142
• 1.10 Removing and installing radiator and radiator fan V7 (engine code BWK)
  144
• 1.11 Removing and installing coolant pump
  146
• 1.12 Removing and installing coolant pump pulley
  151
• 1.13 Removing and installing coolant circulation pump V50
  155
• Fuel supply system
  158
• 1 Safety precautions
  158
• 1.1 Safety regulations for working on fuel supply
  158
• 1.2 Releasing pressure in high-pressure area
  158
• 2 Fuel tank
  160
• 2.1 Fuel tank - assembly overview (Golf, Golf Plus)
  160
• 2.2 Draining fuel tank (Golf, Golf Plus)
  161
• 2.3 Removing and installing fuel tank (Golf, Golf Plus)
  164
• 2.4 Assembly overview - fuel tank (Touran)
  165
• 2.5 Draining fuel tank (Touran)
  167
• 2.6 Removing and installing fuel tank (Touran)
  170
• 2.7 Assembly overview - fuel tank (Tiguan)
  171
• 2.8 Draining fuel tank (Tiguan)
  173
• 2.9 Removing and installing fuel tank (Tiguan)
  176
• 3 Removing and installing parts of fuel supply system
  180
• 3.1 Rules for cleanliness
  180
• 3.2 Crash fuel shut-off
  181
• 3.3 Removing and installing fuel delivery unit (Golf, Golf Plus)
  181
• 3.4 Removing and installing fuel gauge sender G (Golf, Golf Plus)
  183
• 3.5 Checking fuel pumps (Golf, Golf Plus)
  184
• 3.6 Removing and installing fuel delivery unit (Touran)
  195
• 3.7 Removing and installing fuel gauge sender G (Touran)
  197
• 3.8 Checking fuel pump (Touran)
  198
• 3.9 Removing and installing fuel delivery unit (Tiguan)
  209
• 3.10 Removing and installing fuel gauge sender G (Tiguan)
  212
• 3.11 Removing and installing suction-jet pump (Tiguan)
  212
• 3.12 Removing and installing fuel gauge sender 2 G169 (Tiguan)
  215
• 3.13 Checking fuel pump (Tiguan)
  215
• 3.14 Removing and installing fuel pump control unit J538 (Tiguan)
  223
• 4 Repairing electronic power control (EPC)
  225
• 4.1 Assembly overview
  225
• 4.2 Removing and installing accelerator module (Golf, Golf Plus, Tiguan)
  225
• 4.3 Removing and installing accelerator module (Touran)
  226
• 5 Activated charcoal filter system
  229
• 5.1 Assembly overview (Golf, Golf Plus)
  229
• 5.2 Checking fuel tank breather (Golf, Golf Plus)
  230
• 5.3 Checking fuel tank breather (Touran)
  231
• 5.4 Assembly overview (Tiguan)
  232
• 5.5 Checking fuel tank breather (Tiguan)
  233
• Turbocharging/supercharging
  235
• 1 Exhaust turbocharger
  235
• 1.1 Assembly overview - turbocharger
  235
• 1.2 Part I
  236
• 1.3 Part II
  237
• 1.4 Removing and installing turbocharger
  238
• 1.5 Checking vacuum unit for turbocharger
  244
• 1.6 Removing and installing vacuum unit for turbocharger
  246
• 1.7 Adjusting vacuum unit for turbocharger
  247
• 2 Compressor
  254
• 2.1 Assembly overview - supercharger
  254
• 2.2 Removing and installing compressor (engine codes BLG, BMY)
  255
• 2.3 Removing and installing compressor (engine code BWK)
  263
• 2.4 Removing and installing drive unit seal for supercharger
  271
• 3 Charge air system
  275
• 3.1 Assembly overview - charge air system
  275
• 3.2 Fitting hose connections with plug-in connectors
  276
• 3.3 Checking charge air system for leaks
  277
• 3.4 Removing and installing charge air cooler (Golf, Golf Plus, Touran)
  281
• 3.5 Removing and installing charge air cooler, Tiguan
  283
• Mixture preparation - injection
  287
• 1 Injection system
  287
• 1.1 Assembly overview - parts l and II, intake manifold
  287
• 1.2 Assembly overview - part I, intake manifold
  288
• 1.3 Assembly overview - part II, intake manifold
  290
• 1.4 Assembly overview - fuel rail with injectors
  292
• 1.5 Checking vacuum reservoir for leaks
  294
• 1.6 Assembly overview - air filter
  296
• 1.7 Removing and installing air filter
  297
• 1.8 Removing and installing regulating flap control unit J808 and throttle valve module J338
  298
• 1.9 Cleaning throttle valve module J338
  302
• 1.10 Assembly overview - high-pressure pump
  302
• 1.11 Checking fuel pressure in high-pressure section
  303
• 1.12 Removing and installing high-pressure pump
  307
• 1.13 Removing and installing injectors
  311
• 1.14 Renewing Teflon seal and support washer on injector
  314
• 1.15 Safety precautions
  317
• 1.16 Rules for cleanliness
  319
• 1.17 Technical data
  319
• 2 Engine control unit J623
  320
• 2.1 Removing and installing engine control unit J623 (Golf)
  320
• 2.2 Removing and installing anti-theft engine control unit J623 (Golf)
  321
• 2.3 Removing and installing engine control unit J623 (Golf Plus, Touran)
  323
• 2.4 Removing and installing anti-theft engine control unit J623 (Golf Plus, Touran)
  324
• 2.5 Removing and installing engine control unit J623 (Tiguan)
  326
• 2.6 Removing and installing anti-theft engine control unit J623 (Tiguan)
  328
• Exhaust system
  330
• 1 Removing and installing parts of exhaust system
  330
• 1.2 Assembly overview - catalytic converter and attachments (engine code BWK)
  332
• 1.3 Assembly overview - silencer with mountings (engine codes BLG, BMY)
  333
• 1.4 Assembly overview - silencer with mountings (engine code BWK)
  334
• 1.5 Removing and installing front exhaust pipe (engine code BWK)
  334
• 1.6 Separating centre and rear silencers (engine codes BLG, BMY)
  335
• 1.7 Separating centre and rear silencers (engine codes BWK)
  337
• Ignition system
  339
• 1 Repairing ignition system
  339
• 1.1 Assembly overview - ignition system
  339
• 1.2 Problem solution for Hall sender G40
  340
• 1.3 Removing and installing ignition coils with output stage
  341
• 1.4 Safety precautions
  343
• 1.5 Test data, spark plugs
  343