1.4L 4-cylinder 4-valve TSI turbocharged engine CST/CSS

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• 2 Safety caution
  3
• 2.1 Precautions for fuel supply system working
  3
• 2.2 Safety measures when using testing and measuring devices in trail running
  4
• 2.3 Safety measure when the ignition system is in working
  4
• 2.4 Safety measure when the cooling system is in working
  5
• 2.5 Reduce fuel pressure in high pressure area
  5
• 3 Maintenance instruction
  7
• 3.1 Clean requirements
  7
• 3.2 Foreign objects in engine
  7
• 3.3 Rusting due to contact
  7
• 3.4 Pipe arrangement and fixing
  7
• 3.5 Installation of radiator and condenser
  8
• Removal and installation of engine
  9
• 1.1 Engine removal
  10
• 1.2 Disengage the engine and 5-speed manual gearbox PCM
  20
• 1.3 Disengage engine and 7-gear dual-clutch gearbox PGR/QPH
  20
• 1.4 Fix the engine on assembly bracket
  23
• 1.5 Install the engine
  24
• 2.1 Engine removal
  31
• 2.2 Disengage engine and 7-gear dual-clutch gearbox QFP/QJM
  41
• 2.3 Fix the engine on assembly bracket
  44
• 2.4 Engine removal
  45
• 3 Removal and installation of engine (Lamando)
  50
• 3.1 Engine removal
  51
• 3.2 Disengage the engine and 5-speed manual gearbox 0A4
  63
• 3.3 Disengage engine and 7-gear dual-clutch gearbox 0CW
  63
• 3.4 Fix the engine on assembly bracket
  65
• 3.5 Engine removal
  66
• 4 Removal and installation of engine (Passat 2016)
  71
• 4.1 Engine removal
  72
• 4.2 Disengage the engine and 5-speed manual gearbox 0A4
  83
• 4.3 Disengage engine and 7-gear dual-clutch gearbox 0AM
  84
• 4.4 Fix the engine on assembly bracket
  86
• 4.5 Engine removal
  87
• 5 Removal and installation of the engine (All New Touran L 2016)
  92
• 5.1 Engine removal
  93
• 5.2 Disengage the engine and 5-speed manual gearbox 0A4
  105
• 5.3 Disengage engine and 7-gear dual-clutch gearbox 0CW
  105
• 5.4 Fix the engine on assembly bracket
  107
• 5.5 Engine removal
  108
• 6 Removal and installation of the engine (New Tiguan 2013)
  113
• 6.1 Engine removal
  115
• 6.2 Disengage engine and 6-gear dual-clutch gearbox 02E
  125
• 6.3 Fix the engine on assembly bracket
  127
• 6.4 Engine removal
  129
• 7.1 Unit support-assembly overview (models equipped with 5-speed automatic gearbox PCM)
  134
• 7.3 Remove and install engine mounting
  138
• 7.4 Remove and install engine mounting
  139
• 7.5 Removal and installation of gearbox base
  142
• 7.6 Adjust unit support
  144
• 8 Unit support (applicable for New Santana, New Polo GTI and Gran Santana)
  147
• 8.1 Unit support - assembly overview
  147
• 8.2 Removal and installation of engine mounting
  149
• 8.3 Removal and installation of engine supporting device
  151
• 8.4 Remove and install gearbox mounting
  155
• 8.5 Adjust unit support
  159
• 9 Unit support (Lamando, All New Touran L 2016)
  161
• 9.1 Unit support-assembly overview (models equipped with 5-speed automatic gearbox 0A4)
  161
• 9.3 Removal and installation of engine mounting (Lamando)
  164
• 9.4 Remove and install engine mounting (All New Touran L 2016)
  168
• 9.5 Remove and install engine mounting (Lamando)
  172
• 9.6 Remove and install engine mounting (All New Touran L 2016)
  178
• 9.7 Remove and install gearbox mounting
  184
• 9.8 Remove and install gearbox bracket (All New Touran L 2016)
  188
• 9.9 Adjust unit support (Lamando)
  192
• 9.10 Adjust unit support (All New Touran L 2016)
  198
• 10 Unit support (Passat 2016)
  203
• 10.1 Unit support-assembly overview (models equipped with 5-speed automatic gearbox 0A4)
  203
• 10.3 Removal and installation of engine mounting
  206
• 10.4 Remove and install engine mounting
  210
• 10.5 Remove and install gearbox mounting
  216
• 10.6 Adjust unit support
  220
• 11 Unit support (New Tiguan 2013)
  226
• 11.1 Unit support - assembly overview
  226
• 11.2 Removal and installation of engine mounting
  228
• 11.3 Remove and install engine mounting
  231
• 11.4 Remove and install gearbox mounting
  236
• 11.5 Adjust unit support
  240
• Crank connecting rod mechanism
  245
• 1 Disassembly and assembly of engine
  245
• 1.1 Belt driven - assembly overview
  245
• 1.2 Sealing flange at pulley side- assembly overview
  247
• 1.3 Removal and installation of V-ribbed belt
  248
• 1.6 Remove and install crankshaft pulley
  254
• 1.7 Replace the sealing ring of crankshaft at the pulley belt’s side
  258
• 2 Cylinder block on gearbox side
  269
• 2.3 Removal and installation
  272
• 2.4 Remove and install sealing flange on gearbox side
  273
• 3 Crankshaft
  281
• 3.2 Crankshaft size
  282
• 3.3 Measure the crankshaft axial clearance
  282
• 4 Piston and connecting rod
  284
• 4.1 Piston and connecting rod - assembly overview
  284
• 4.2 Remove and install piston
  286
• 4.3 Check the piston
  288
• 4.4 Check the cylinder inner bore
  288
• Valve mechanism
  290
• 1 Belt driven
  290
• 1.1 Belt protective cover - assembly overview
  290
• 1.2 Toothed belt - assembly overview
  291
• 1.3 Inspect timing
  292
• 1.4 Disengage timing toothed belt from the camshaft
  298
• 1.5 Removal and installation of timing toothed belt
  311
• 2 Cylinder head
  325
• 2.1 Cylinder head - Assembly Overview
  325
• 2.2 Removal and installation of cylinder head
  326
• 2.3 Check cylinder pressure
  331
• 3 Valve mechanism
  335
• 3.1 Camshaft housing - assembly overview
  335
• 3.2 Valve - Assembly Overview
  337
• 1 N318
  338
• 3.4 Check the axial clearance of the camshaft
  338
• 3.5 Removal and installation of camshaft seal ring
  339
• 3.6 Removal and installation of camshaft housing
  344
• 3.7 Remove and install sealing element of valve stem
  348
• 4 Intake valve and exhaust valve
  353
• 4.1 Valve guide pipe
  353
• 4.2 Check the valve
  353
• 4.3 Valve size
  354
• Lubrication system
  355
• 1 Components of lubrication system
  355
• 1.1 Engine oil
  355
• 1.2 Oil pan and oil pump - assembly Overview
  355
• 1.3 Removal and installation of oil pan lower parts
  358
• 1.4 Removal and installation oil pump
  360
• 1.5 Remove and install oil pump drive sprocket
  362
• 1.6 Removal and installation of the upper parts of oil pan
  363
• 2 Engine oil cooler
  366
• 2.1 Engine oil cooler - assembly overview
  366
• 2.2 Removal and installation of engine oil cooler
  366
• 3 Crankcase exhaust system
  368
• 3.1 Crankcase exhaust system - assembly overview
  368
• 3.2 Removal and installation of oil/air separator
  369
• 4 Oil filter / oil pressure switch
  371
• 4.1 Oil filter / oil pressure switch - assembly overview
  371
• 4.2 Removal and installation of the oil pressure switch F1
  371
• 4.3 Remove and install oil pressure switch for reduced oil pressure F378
  373
• 4.4 Remove and install engine oil pressure control valve N428
  375
• 4.5 Test engine oil pressure and engine oil pressure switch
  377
• Cooling System
  380
• 1 Components of cooling System
  380
• 1.1 Coolant hose connection diagram
  380
• 1.2 Discharge and add coolant
  382
• 1.3 Check the tightness of cooling system
  387
• 2 Coolant pump / coolant adjusting unit
  390
• 2.1 Coolant pump / coolant adjusting unit - assembly overview
  390
• 2.2 Coolant circulating pump - assembly overview
  392
• 2.6 Coolant temperature sensor - assembly overview (Passat 2016)
  396
• 2.7 Coolant temperature sensor - assembly overview (New Tiguan 2013)
  397
• 2.8 Removal and installation of coolant pump
  398
• 2.9 Remove and install coolant pump toothed belt pulley
  402
• 2.10 Remove and install thermostat for large coolant circulation
  404
• 2.11 Remove and install thermostat for small coolant circulation
  406
• 2.12 Remove and install coolant circulating pump V51
  407
• 2.13 Remove and install coolant temperature sensor G62
  408
• 3 Coolant pipe
  417
• 3.1 Coolant pipe - assembly overview
  417
• 3.2 Removal and installation of coolant pipe
  417
• 4.1 Radiator - Assembly Overview
  419
• 4.2 Radiator fan - Assembly Overview
  420
• 4.3 Remove and install fan shield
  421
• 4.4 Removal and installation of radiator
  421
• 4.5 Remove and install radiator fan V7 and radiator fan control unit J293
  423
• 4.6 Removal and installation of the radiator of turbocharger system
  424
• 5 Radiator and radiator fan (Applicable for New Santana, New Polo GTI and Gran Santana)
  426
• 5.1 Radiator and radiator fan - Assembly Overview
  426
• 5.2 Remove and install fan shield
  427
• 5.3 Remove and install radiator fan V7
  428
• 5.4 Removal and installation of radiator
  429
• 5.5 Removal and installation of the radiator of turbocharger system
  432
• 6 Radiator and radiator fan (Lamando, All New Touran L 2016)
  434
• 6.1 Radiator - Assembly Overview
  434
• 6.2 Radiator fan - Assembly Overview
  436
• 6.3 Remove and install fan shield
  436
• 6.4 Remove and install radiator fan VX57
  437
• 6.5 Removal and installation of radiator (Lamando)
  438
• 6.6 Removal and installation of radiator (All New Touran L 2016)
  440
• 6.7 Removal and installation of the turbocharged radiator
  442
• 7 Radiator and radiator fan (Passat 2016, New Tiguan 2013)
  445
• 7.1 Radiator - Assembly Overview
  445
• 7.2 Radiator fan - Assembly Overview
  446
• 7.3 Remove and install fan shield
  447
• 7.4 Remove and install radiator fan V7 and radiator fan 2 V177
  448
• 7.5 Removal and installation of radiator
  448
• 7.6 Removal and installation of the radiator of turbocharger system
  450
• Fuel supply system
  452
• 1 Safety measures
  452
• 1.1 Safety measures when operating fuel supply system
  452
• 1.2 Clean requirements
  453
• 1.3 Release the pressure of high pressure area
  453
• 2.1 Fuel tank and installation part - assembly overview
  455
• 2.3 Drain the fuel tank
  460
• 2.5 Removal and installation of secondary beam (Applicable for New Polo GTI)
  465
• 2.6 Fuel pump and fuel quantity transducer - assembly overview
  468
• 2.7 Removal and installation of the fuel pump
  470
• 2.8 Remove and install fuel quantity transducer G
  472
• 2.9 Check fuel pump
  474
• 2.10 Fuel filter and installation part - assembly overview
  486
• 2.11 Remove and install fuel filter
  487
• 3 Fuel tank (Lamando, All New Touran L 2016)
  488
• 3.1 Fuel tank and installation part - assembly overview (Lamando)
  488
• 3.2 Fuel tank and installation part - assembly overview (All New Touran L 2016)
  490
• 3.3 Drain the fuel tank
  492
• 3.4 Removal and installation of the fuel tank (Lamando)
  497
• 3.5 Removal and installation of fuel tank (All New Touran L 2016)
  503
• 3.6 Fuel pump and fuel quantity transducer - assembly overview (Lamando)
  508
• 3.8 Removal and installation of the fuel pump (Lamando)
  511
• 3.9 Remove and install fuel pump (All New Touran L 2016)
  513
• 3.10 Remove and install fuel quantity transducer G
  516
• 3.11 Check fuel pump
  516
• 4 Fuel tank (Passat 2016)
  530
• 4.1 Fuel tank and installation part - assembly overview
  530
• 4.2 Drain the fuel tank
  531
• 4.3 Removal and installation of the fuel tank
  537
• 4.4 Fuel pump and fuel quantity transducer - assembly overview
  541
• 4.5 Removal and installation of the fuel pump
  543
• 4.6 Remove and install the flange with fuel filter
  546
• 4.7 Remove and install fuel quantity transducer G
  547
• 4.8 Check fuel pump
  548
• 5 Fuel tank (New Tiguan 2013)
  561
• 5.1 Fuel tank and installation part - assembly overview
  561
• 5.2 Drain the fuel tank
  563
• 5.3 Removal and installation of the fuel tank
  565
• 5.4 Removal and installation of the fuel pump
  569
• 5.5 Remove and install the flange with fuel filter
  572
• 5.6 Remove and install fuel quantity transducer G
  573
• 5.7 Remove and install fuel quantity transducer G169
  573
• 5.8 Check fuel quantity transducer G
  575
• 5.9 Check fuel quantity transducer 2 G169
  577
• 5.10 Check fuel pump
  579
• 5.11 Check fuel suction jet pump
  590
• 5.12 Fuel filter and installation part - assembly overview
  590
• 5.13 Remove and install fuel filter
  591
• 6 Electronic accelerator (EPC)
  593
• 6.1 Electronic accelerator
  593
• 6.4 Accelerator pedal - assembly overview (Lamando、All New Touran L 2016)
  596
• 6.5 Accelerator pedal - assembly overview (Passat 2016, New Tiguan 2013)
  598
• 7 Activated carbon canister
  603
• 7.1 Functions
  603
• 7.5 Activated carbon canister - assembly overview (applicable to New Polo GTI)
  607
• 7.9 Remove and install activated carbon canister (Lamando, All New Touran L 2016)
  610
• 7.13 Check exhaust of fuel tank (Applicable for New Santana and Gran Santana)
  615
• 7.14 Check fuel tank exhaust (Lamando, All New Touran L 2016)
  618
• 7.15 Check fuel tank exhaust (applicable to New Polo GTI)
  622
• 7.16 Check the exhaust of fuel tank (Passat 2016, New Tiguan 2013)
  625
• Turbocharger System
  630
• 1 Turbocharger
  630
• 1.3 Removal and installation of the turbocharger
  634
• 1.7 Adjust the boost pressure regulator of exhaust gas turbocharger
  644
• 2 Turbocharged air intake system
  649
• 2.1 Turbocharged air intake system – assembly overview
  649
• 2.2 Remove and install boost pressure sensor G31 / air intake temperature sensor 2 G299
  650
• 2.3 Removal and installation of the inter-cooler
  650
• Mixed gas preparation and injection system
  653
• 1 Injection system
  653
• 1.1 Installation position overview:
  653
• 2 Air filter
  660
• 2.3 Air filter - Assembly Overview (Passat 2016)
  662
• 2.4 Remove and install the air filter housing
  663
• 3 Intake manifold assembly
  664
• 3.1 Intake manifold assembly - assembly overview
  664
• 3.2 Remove and install intake manifold assembly
  666
• 3.3 Remove and install the throttle valve module J338
  670
• 3.4 Clean throttle control unit J338
  672
• 3.5 Technical data
  673
• 4 Fuel nozzle
  674
• 4.1 Fuel distributor with fuel nozzle - assembly overview
  674
• 4.2 Remove and install fuel distributor with fuel nozzle
  675
• 4.3 Removal and installation of the fuel nozzle
  676
• 4.4 Clean fuel nozzle
  681
• 5 Sensor
  684
• 5.1 Remove and install intake temperature sensor G42 / intake manifold pressure sensor G71
  684
• 5.2 Remove and install fuel pressure sensor G247
  684
• 5.3 Check fuel pressure sensor signal G247
  686
• 6 High pressure pump
  691
• 6.1 High pressure pump - assembly overview
  691
• 6.2 Removal and installation of HP pump
  692
• 6.3 Removal and installation of high-pressure pipe
  694
• 7 Oxygen sensor
  697
• 8 Engine control unit
  703
• 8.1 Use test box V.A.G 1598/42 to inspect conducting wires and parts
  703
• 8.4 Removal and installation of engine control unit J623 (Lamando, All New Touran L 2016)
  706
• 8.5 Remove and install engine control unit J623 (Passat 2016)
  707
• 8.6 Remove and install engine control unit J623 (New Tiguan 2013)
  708
• 8.7 Matching function and components
  709
• 8.8 Inquire and clear the fault memory of engine control unit
  710
• Exhaust system
  711
• 1.1 Emission-catalytic purifier and installation part - assembly overview
  712
• 1.2 Install the front exhaust pipe with exhaust catalytic converter
  714
• 1.3 Silencer and suspension system - assembly overview
  717
• 1.4 Remove and install silencer
  719
• 1.5 Separate the silencer
  720
• 1.6 Install the exhaust system in non-stress state
  721
• 2 Components of exhaust system (Applicable for New Santana and Gran Santana)
  723
• 2.1 Emission-catalytic purifier and installation part - assembly overview
  723
• 2.2 Install the front exhaust pipe with exhaust catalytic converter
  724
• 2.3 Silencer and suspension system - assembly overview
  728
• 2.4 Remove and install silencer
  730
• 2.5 Separate the silencer
  731
• 2.6 Install the exhaust system in non-stress state
  733
• 3.1 Emission-catalytic purifier and installation part - assembly overview
  734
• 3.2 Remove and install front exhaust pipe with emission-catalytic purifier
  736
• 3.3 Silencer and suspension system - assembly overview (Lamando)
  740
• 3.4 Silencer and suspension system - assembly overview (Passat 2016)
  741
• 3.5 Silencer and suspension system - assembly overview (All New Touran L 2016)
  742
• 3.6 Silencer and suspension system - assembly overview (New Tiguan 2013)
  744
• 3.7 Remove and install silencer (Lamando)
  744
• 3.8 Remove and install silencer (Passat 2016)
  746
• 3.9 Remove and install silencer (All New Touran L 2016)
  748
• 3.10 Remove and install silencer (New Tiguan 2013)
  750
• 3.11 Separate the silencer (Lamando, Passat 2016)
  752
• 3.12 Separate the silencer (All New Touran L 2016)
  753
• 3.13 Separate the silencer (New Tiguan 2013)
  755
• 3.14 Install the exhaust system in non-stress state (Lamando and Passat 2016)
  757
• 3.15 Install the exhaust system in non-stress state (All New Touran L 2016)
  758
• 3.16 Check the tightness of exhaust system (New Tiguan 2013)
  759
• 4 Components of exhaust system (Applicable for New Polo GTI)
  761
• 4.1 Emission-catalytic purifier and installation part - assembly overview
  761
• 4.2 Remove and install front exhaust pipe with emission-catalytic purifier
  763
• 4.3 Silencer and suspension system - assembly overview
  767
• 4.4 Remove and install silencer
  768
• 4.5 Separate the silencer
  769
• 4.6 Install the exhaust system in non-stress state
  771
• Ignition system
  772
• 1 Ignition equipment
  772
• 1.1 Ignition device - assembly overview
  772
• 1.2 Test data, spark plugs
  773
• 1.3 Remove and install ignition coil with power output stage
  774
• 1.4 Remove and install knock sensor 1 G61
  776
• 1.5 Remove and install the light sensor G40
  777
• 1.6 Remove and install Hall sensor 2 G163
  779
• 1.7 Remove and install engine speed sensor G28
  781