Name: 4-cyl. common rail (2.0 l, 4V, turbocharger, EA 288 EVO)
Brand: Volkswagen
SKU: CDGed1f26160d52
Price: 43.45 EUR
Availability: InStock

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Repair manual Touran / T-Roc / Golf / Tiguan / Golf Variant 4-cyl. common rail PDF download has the following content:

Chapter overview

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 start/stop system
2
1.4 Safety precautions when working on the cooling system
2
1.5 Safety precautions when working on SCR system
2
1.6 Safety precautions when working on exhaust system
3
2 Identification
5
2.1 Engine number/engine data
5
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
8
3.5 Fitting radiator and condensers
8
Removing and installing engine
9
1 Removing and installing engine
9
1.1 Removing engine
9
1.2 Separating engine and gearbox
22
1.3 Securing engine on engine and gearbox support
27
1.4 Installing engine
29
2 Assembly mountings
34
2.1 Assembly overview – assembly mountings
34
2.2 Removing and installing engine mounting
36
2.3 Removing and installing gearbox mounting
37
2.4 Removing and installing pendulum support
39
2.5 Supporting engine in installation position
41
2.6 Adjusting assembly mountings
60
2.7 Checking adjustment of assembly mountings
62
3 Engine cover panel
63
3.1 Removing and installing engine cover
63
Crankshaft group
64
1 Cylinder block (pulley end)
64
1.1 Assembly overview - cylinder block (pulley end)
64
1.2 Assembly overview - sealing flange, belt pulley end
67
1.3 Removing and installing poly-V belt
68
1.4 Removing and installing tensioner for poly V-belt
69
1.5 Removing and installing vibration damper
70
1.6 Removing and installing bracket for ancillaries
71
1.7 Removing and installing engine support
73
1.8 Removing and installing sealing flange on pulley end
74
1.9 Renewing caps in cylinder block (pulley end)
77
2 Cylinder block, gearbox end
79
2.1 Assembly overview - cylinder block, gearbox end
79
2.2 Removing and installing flywheel
82
2.3 Removing and installing sealing flange on gearbox side
84
2.4 Renewing caps in cylinder block (gearbox end)
108
3 Crankshaft
110
3.1 Measuring axial clearance of crankshaft
110
3.2 Renewing needle bearing in crankshaft
111
4 Pistons and conrods
114
4.1 Assembly overview - pistons and conrods
114
4.2 Removing and installing pistons
119
4.3 Measuring piston projection at TDC
121
4.4 Checking pistons and cylinder bores
123
4.5 Checking radial clearance of conrods
126
Cylinder head, valve gear
127
1 Cylinder head
127
1.1 Assembly overview - cylinder head
127
1.2 Assembly overview - cylinder head cover
131
1.3 Removing and installing cylinder head
133
1.4 Removing and installing cylinder head cover
145
1.5 Removing and installing injector seals
146
1.6 Removing and installing camshaft housing
147
1.7 Checking compression
154
2 Toothed belt drive
158
2.1 Assembly overview - toothed belt cover
158
2.2 Assembly overview - toothed belt
159
2.3 Removing and installing toothed belt guard
161
2.4 Removing and installing toothed belt
165
2.5 Removing toothed belt from camshaft
178
3 Valve gear
188
3.1 Assembly overview - valve gear
188
3.2 Measuring axial play of camshaft
190
3.3 Removing and installing camshaft oil seal
191
3.4 Checking hydraulic compensation elements
193
3.5 Removing and installing valve stem oil seals
194
4 Inlet and exhaust valves
211
4.1 Checking valve guides
211
4.2 Checking valves
212
4.3 Valve dimensions
212
Lubrication
214
1 Sump, oil pump
214
1.1 Assembly overview - sump/oil pump
214
1.2 Engine oil:
218
1.3 Removing and installing lower part of sump
218
1.4 Removing and installing upper part of sump
222
1.5 Removing and installing oil pump
226
1.6 Removing and installing oil level and oil temperature sender G266
227
2 Engine oil cooler
228
3 Oil filter, oil pressure switch
229
3.1 Assembly overview - oil filter housing, oil pressure switch
229
3.2 Assembly overview - oil pressure switches/oil pressure control
231
3.3 Removing and installing oil pressure sender G10
232
3.4 Checking oil pressure
233
3.5 Removing and installing oil filter housing
234
3.6 Removing and installing oil pressure regulating valve N428
236
3.7 Removing and installing piston cooling jet control valve N522
237
4 Oil circuit
238
4.1 Removing and installing oil supply line
238
4.2 Removing and installing oil return line for turbocharger
239
Cooling
241
1 Cooling system/coolant
241
1.1 Connection diagram - coolant hoses
241
1.2 Checking cooling system for leaks
243
1.3 Draining coolant
246
1.4 Filling with coolant
248
1.5 Checking filling quality of cooling system
268
1.6 Flushing cooling system
270
2 Coolant pump, regulation of cooling system
292
2.1 Assembly overview - coolant pump, thermostat
292
2.2 Assembly overview - electric coolant pump
295
2.3 Assembly overview - coolant temperature sender
297
2.4 Removing and installing electric coolant pump
299
2.5 Removing and installing coolant pump
307
2.6 Removing and installing coolant distribution module
309
2.7 Removing and installing coolant regulating valve N515
312
2.8 Removing and installing coolant temperature sender G62
313
2.9 Removing and installing engine outlet coolant temperature sender G82
315
2.10 Removing and installing coolant temperature sender for charge air cooler G1130
317
3 Coolant pipes
320
3.1 Assembly overview - coolant pipes
320
3.2 Removing and installing coolant pipes
321
4 Radiator, radiator fan
329
4.1 Assembly overview - radiator/radiator fan
329
4.2 Assembly overview – radiator cowl and radiator fan
332
4.3 Removing and installing radiator
333
4.4 Removing and installing water radiator for charge air cooling circuit
336
4.5 Removing and installing radiator cowl
341
4.6 Removing and installing radiator fan
343
Turbocharging/supercharging
344
1 Turbocharger
344
1.1 Assembly overview - turbocharger
344
1.2 Removing and installing turbocharger
347
1.3 Removing and installing connection for turbocharger
352
2 Charge air system
354
2.1 Assembly overview - charge air system
354
2.2 Removing and installing charge pressure sender GX26
354
2.3 Checking charge air system for leaks
354
2.4 Removing and installing air intake pipe
357
2.5 Checking charge air cooler for leaks
359
2.6 Assembly overview - charge-air hose connections
363
Mixture preparation - injection
365
1 Injection system
365
1.1 Schematic overview - fuel system
365
1.2 Overview of fitting locations - injection system
367
1.3 Filling/bleeding fuel system
379
1.4 Checking fuel system for leaks
379
2 Injectors/high-pressure accumulator (rail)
381
2.1 Assembly overview - injectors
381
2.2 Assembly overview - fuel rail
383
2.3 Adapting correction values for injectors
384
2.4 Testing injectors
385
2.5 Checking return flow rate of injectors with engine running
386
2.6 Checking return flow rate of injectors at starter speed
389
2.7 Checking open injectors
391
2.8 Removing and installing injectors
392
2.9 Removing and installing high-pressure lines
396
2.10 Removing and installing fuel rail
402
3 Air filter
407
3.1 Assembly overview - air filter housing
407
3.2 Removing and installing air filter housing
409
3.3 Removing and installing air guide on lock carrier
411
4 Intake manifold
413
4.1 Assembly overview – intake manifold
413
4.2 Removing and installing intake manifold
418
4.3 Removing and installing throttle valve module GX3
425
5 Senders and sensors
428
5.1 Removing and installing fuel pressure regulating valve N276
428
5.2 Checking fuel pressure regulating valve N276
430
5.3 Removing and installing fuel pressure sender G247
431
5.4 Removing and installing air mass measurement module GX35
433
5.5 Removing and installing pressure differential sender G505
435
5.6 Removing and installing NOx sender 2 G687
437
5.7 Removing and installing NOx sender 3 G932
438
5.10 Removing and installing NOx sender G295
441
5.11 Removing and installing particle sensor G784
443
6 Engine control unit
447
6.1 Removing and installing engine control unit J623
447
6.2 Removing and installing engine control unit J623 (with protective housing)
448
7 High-pressure pump
455
7.1 Assembly overview - high-pressure pump
455
7.2 Removing and installing high-pressure pump
455
8 Lambda probe
460
8.1 Assembly overview - Lambda probe
460
8.2 Removing and installing Lambda probe
461
Exhaust system
463
1 Exhaust pipes and silencers
463
1.1 Assembly overview – silencers
463
1.2 Assembly overview - front exhaust pipe
468
1.3 Separating exhaust pipes from silencers
472
1.4 Removing and installing silencer
473
1.5 Aligning exhaust system free of stress
480
1.6 Checking exhaust system for leaks
481
1.7 Installation position of clamp
481
1.8 Align end exhaust pipes
483
2 Emission control
484
2.1 Assembly overview – emission control
484
2.2 Removing and installing emission control module
486
2.3 Removing and installing exhaust flap control unit J883
494
2.4 Removing and installing ammonia traps
496
3 SCR system (selective catalytic reduction)
499
3.1 Overview of fitting locations – SCR system (selective catalytic reduction)
499
3.2 Assembly overview – reducing agent tank
505
3.3 Assembly overview – filler tube for reducing agent tank
517
3.4 Assembly overview - reducing agent supply line
522
3.5 Assembly overview - delivery unit for reducing agent metering system GX19
532
3.6 Removing and installing reducing agent tank
533
3.7 Removing and installing front section of reducing agent supply line
552
3.9 Removing and installing injector for reduction agent N474
558
3.10 Removing and installing injector 2 for reducing agent N758
560
3.11 Removing and installing control unit for reducing-agent heater J891
562
3.12 Assembly overview - injector for reducing agent N474
579
3.13 Assembly overview – injector 2 for reducing agent N758
580
3.14 Draining reducing agent tank
581
3.15 Removing and installing middle section of reducing agent supply line
585
3.16 Removing and installing rear section of reducing agent supply line
587
3.17 Removing and installing filler pipe for reducing agent tank
599
3.18 Disconnecting reducing agent supply line
615
3.19 SCR - resetting learnt values
620
4 Exhaust gas temperature regulation
621
4.1 Assembly overview – exhaust gas temperature regulation
621
4.2 Removing and installing exhaust gas temperature sender 1 G235
622
4.3 Removing and installing exhaust gas temperature sender 2 G448
624
4.4 Removing and installing exhaust gas temperature sender 3 G495
626
4.5 Removing and installing exhaust gas temperature sender 4 G648
628
5 Exhaust gas recirculation
632
5.1 Assembly overview – exhaust gas recirculation
632
5.2 Removing and installing exhaust gas recirculation cooler
635
5.3 Removing and installing exhaust gas recirculation valve 1 GX5
638
5.4 Removing and installing exhaust gas recirculation valve 2 GX6
639
5.5 Removing and installing exhaust gas recirculation temperature sensor G98
640
5.6 Checking exhaust gas recirculation cooler for leaks
641
Glow plug system
647
1 Glow plug system
647
1.1 Assembly overview – glow plug system
647
1.2 Removing and installing glow plug
649
1.3 Removing and installing automatic glow period control unit J179
653
1.4 Removing and installing Hall sender G40
654
1.5 Removing and installing engine speed sender G28
654

Manufacturer's designation	4-cyl. common rail (2.0 l, 4V, turbocharger, EA 288 EVO)
Manufacturer	Volkswagen
Suitable for	Touran (2016 > ) / T-Roc (2018 >) / Golf (2020 >) / Tiguan (2021 >) / Golf Variant (2021 >)
Suitable car types	5T1, CD1, AX1, CG5
Engine code	DSRB, DSUD, DTRB, DTRD, DTSB, DTSA, DTUA, DTRC, DTTA, DTTC
Category	Reparaturanleitung

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