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  • Examplepage for repair manual 4-Cyl. injection engine (1.6 l) EA211
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  • Examplepage for repair manual 3 4-Cyl. injection engine (1.6 l) EA211

4-Cyl. injection engine (1.6 l) EA211

For Gol / Saveiro / Saveiro Cab. Dupla

Original Volkswagen repair manual


26,04 €7% VAT incl.

Immediately available for download

Language: English

Digital PDF file

28.933 KB

335 Sites

Detailed technical data

Immediately readable

This repair manual contains: Engine - remove and install, Power-drive unit supports, Cylinder block (pulley side), Crankshaft, Toothed belt drive, Oil filter/Oil pressure switch F1, Cooling system components, Radiator, Engine power electronic adjustment (electronic accelerator), Activated charcoal filter system, Injection valves, Air cleaner, Intake manifold, READINESS code and Exhaust pipes/silencers. Show more
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Repair manual Gol / Saveiro / Saveiro Cab. Dupla 4-Cyl. injection engine EA211 PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 \--- Change history ---
    1
  • 2 Safety instructions
    2
  • 2.1 Safety measures regarding work on the fuel supply
    2
  • 2.2 Safety measures in test drives using testing and measurement devices
    3
  • 2.3 Safety measures when working on the cooling system
    4
  • 2.4 Safety measures when working on the ignition system
    4
  • 3 Identification
    6
  • 3.1 Engine number/engine characteristics
    6
  • 4 Repair instructions
    8
  • 4.1 Cleaning rules
    8
  • 4.2 Foreign bodies on the engine
    8
  • 4.3 Contact corrosion
    8
  • 4.4 Connection installation and fastening
    8
  • 4.5 Radiator and capacitor installation
    9
  • Removing and installing engine
    10
  • 1 Engine - remove and install
    10
  • 1.1 Engine - removal
    10
  • 1.2 Engine - separate gearbox
    19
  • 1.3 Secure the engine to the engine and gearbox swivelling stand
    21
  • 1.4 Engine - installation
    22
  • 2 Power-drive unit supports
    25
  • 2.1 Power unit brackets - assembly overview
    25
  • 2.2 Power-drive unit supports (engine side) - remove and install
    27
  • 2.3 Power-drive unit supports (gearbox side) - remove and install
    29
  • 2.4 Pendulum support (torque limiter) - remove and install
    32
  • 2.5 Additional notes and installation works in vehicles with air conditioning
    33
  • Crankshaft group
    34
  • 1 Cylinder block (pulley side)
    34
  • 1.1 Poly-V belt - assembly overview
    34
  • 1.2 Poly-V belt - remove and install
    36
  • 1.3 Poly-V belt tensioner - remove and install
    39
  • 1.4 Crankshaft pulley (vibration damper) - remove and install
    40
  • 1.5 Engine console - remove and install
    41
  • 1.6 Crankshaft seal (pulley side) - replace
    43
  • 2 Cylinder block (gearbox side)
    47
  • 2.1 Cylinder block (gearbox side) - assembly overview
    47
  • 2.2 Flywheel - remove and install
    48
  • 2.3 Crankshaft flange (flywheel side) - replace
    49
  • 3 Crankshaft
    62
  • 3.1 Crankshaft dimensions
    62
  • 3.2 Crankshaft - check axial clearance
    62
  • 4 Pistons and conrods
    64
  • 4.1 Pistons and conrods - assembly overview
    64
  • 4.2 Pistons - remove and install
    68
  • 4.3 Pistons, rings, and cylinders - check (conrod with bushing)
    69
  • 4.4 Pistons, rings, and cylinders - check (conrod without bushing)
    71
  • 4.5 Connecting rod (radial clearance) - check
    74
  • 4.6 Oil injectors - remove and install
    74
  • Cylinder head, valve gear
    76
  • 1 Engine cylinder head
    76
  • 1.1 Engine cylinder head - assembly overview
    76
  • 1.2 Cylinder head cover with camshafts - assembly overview
    78
  • 1.3 Engine cylinder head - remove and install
    81
  • 1.4 Cylinder head cover with camshafts - remove and install
    88
  • 1.5 Compression - check
    91
  • 2 Toothed belt drive
    95
  • 2.2 Toothed belt - assembly overview
    96
  • 2.3 Mechanical distribution cover - removal and installation
    98
  • 2.4 Valve timing - check
    99
  • 2.5 Remove the toothed belt from the camshafts
    106
  • 2.6 Toothed belt - remove and install
    116
  • 3 Camshaft mechanism - repair
    124
  • 3.1 Camshaft mechanism - assembly overview
    124
  • 3.2 Crankshaft - check axial clearance
    126
  • 3.3 Inlet camshaft regulator - remove and install
    127
  • 3.4 Exhaust camshaft sprocket - remove and install
    133
  • 3.5 Camshaft seal - replace
    138
  • 3.6 Camshaft adjustment valve 1 N205 - remove and install
    145
  • 3.7 Valve stem sealant - replace
    145
  • 4 Inlet and exhaust valves
    156
  • 4.1 Valve guides - check
    156
  • 4.2 Valves - check
    157
  • 4.3 Valves - dimensions
    157
  • Lubrication
    158
  • 1 Crankcase/oil pump
    158
  • 1.1 Crankcase/oil pump - assembly overview
    158
  • 1.2 Lower sump - remove and install
    161
  • 1.3 Upper crankcase - remove and install
    164
  • 1.4 Oil pump - remove and install
    168
  • 1.5 Engine oil
    171
  • 2 Engine oil cooler
    172
  • 2.1 Engine oil cooler - assembly overview
    172
  • 2.2 Engine oil cooler - remove and install
    172
  • 3 Engine crankcase ventilation
    174
  • 3.1 Engine crankcase ventilation - assembly overview
    174
  • 3.2 Crankcase ventilation device - remove and install
    175
  • 4 Oil filter/Oil pressure switch F1
    178
  • 4.1 Oil filter/Oil pressure switch F1 - assembly overview
    178
  • 4.2 Oil pressure switch 0.3...0.6 bar F1 - remove and install
    178
  • 4.3 Oil filter - remove and install
    180
  • 4.4 Oil pressure and Oil pressure switch F1 - check
    181
  • Cooling
    184
  • 1 Cooling system components
    184
  • 1.1 Cooling system - assembly overview
    184
  • 1.2 Hose connection diagram for cooling system
    186
  • 1.3 Cooling system - drainage and replenishment
    187
  • 1.4 Cooling system - check air-tightness
    196
  • 1.5 Coolant tank flap - check safety valve
    198
  • 2 Coolant/cooling system water pump
    200
  • 2.1 Water pump - assembly overview
    200
  • 2.2 Water pump - remove and install
    203
  • 2.3 Water pump sprocket - remove and install
    209
  • 2.4 Thermostat valve - remove and install
    210
  • 2.5 Water pump toothed belt - remove and install
    218
  • 2.6 Coolant temperature sensor G62 - remove and install
    221
  • 3 Radiator
    224
  • 3.1 Radiator - remove and install
    224
  • 3.2 Cowling with Radiator fan V7 - remove and install
    227
  • 3.3 Radiator fan V7 - remove and install
    227
  • Fuel supply system
    228
  • 1 Fuel supply system components
    228
  • 1.1 Fuel tank - assembly overview
    228
  • 1.2 Safety measures regarding work on the fuel supply
    232
  • 1.3 Cleaning rules
    232
  • 1.4 Cold start system components - remove and install
    233
  • 1.5 Fuel pump (pre-supply pump) G6 - remove and install
    234
  • 1.6 Fuel gauge sensor G - remove and install
    238
  • 1.7 Fuel tank - remove and install
    238
  • 1.8 Fuel shutoff in case of crash
    240
  • 1.9 Fuel pump (pre-supply pump) G6 - check
    241
  • 2 Engine power electronic adjustment (electronic accelerator)
    254
  • 2.1 Engine power electronic adjustment (electronic accelerator) - assembly overview
    254
  • 2.2 Electronic accelerator system operation
    254
  • 3 Activated charcoal filter system
    256
  • 3.1 Operation
    256
  • 3.2 Activated charcoal filter system components - repair
    256
  • 3.3 Fuel tank ventilation - check
    258
  • Mixture preparation - injection
    260
  • 1 Injection system
    260
  • 1.1 Sensors, switches (intake side) - assembly overview
    260
  • 1.2 Sensor, ignition coils and lambda probe (exhaust side) - assembly overview
    261
  • 1.3 Injection system - assembly overview
    262
  • 2 Injection valves
    267
  • 2.1 Fuel rail with injection valves - assembly overview
    267
  • 2.2 Injection valves - remove and install
    270
  • 2.3 Injection valves - check
    274
  • 3 Air cleaner
    279
  • 3.1 Air filter - assembly overview
    279
  • 3.2 Air filter - remove and install
    280
  • 4 Intake manifold
    281
  • 4.1 Intake manifold - assembly overview
    281
  • 4.2 Intake manifold - remove and install
    282
  • 4.3 Throttle butterfly valve control unit J338 - remove and install
    286
  • 4.4 Throttle valve control unit J338 - clean
    287
  • 4.5 Supply system pressure, fuel pressure gauge and residual pressure - check
    288
  • 5 READINESS code
    296
  • 5.1 Function
    296
  • 5.2 Creating and Interpreting the READINESS code
    296
  • 6 Transmitters and sensors
    297
  • 7 Engine control unit J623
    299
  • 7.1 Engine control unit J623 - remove and install
    299
  • 8 Lambda probe
    303
  • 8.1 Lambda probe - assembly overview
    303
  • 8.2 Lambda probe - remove and install
    304
  • Exhaust system
    308
  • 1 Exhaust pipes/silencers
    308
  • 1.1 Exhaust pipes/silencers - exploded view
    308
  • 1.2 Separate exhaust pipes/silencers
    309
  • 1.3 Silencers - remove and install
    310
  • 1.4 Exhaust system - free of stress alignment
    311
  • 1.5 Exhaust system - check air-tightness
    311
  • 1.6 Pipe clamp installation position
    312
  • 2 Exhaust gas purging
    313
  • 2.1 Front exhaust pipe with catalytic converters - assembly overview
    313
  • 2.2 Front exhaust pipe with catalytic converters - remove and install
    315
  • Ignition system
    318
  • 1 Ignition system
    318
  • 1.1 Ignition system - assembly overview
    318
  • 1.2 Ignition coils with final power stage - assembly overview
    320
  • 1.3 Test data, spark plugs
    321
  • 1.4 Ignition coil with final power stage - remove and install
    321
  • 1.5 Knock sensor 1 G61 - remove and install
    324
  • 1.6 Hall Sensor G40 - remove and install
    326
  • 1.7 Engine speed sensor G28 - remove and install
    327
Manufacturer's designation 4-Cyl. injection engine (1.6 l) EA211
Manufacturer Volkswagen
Suitable for Gol (2013) / Saveiro (2014) / Saveiro Cab. Dupla (2015 >)
Suitable car types 5U3, 5UB
Engine code CWSA
Category Reparaturanleitung

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