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  • Examplepage for repair manual 4-cyl. common rail (2.0 l, 4V, turbocharger, EA 288 EVO)
  • Examplepage for repair manual 2 4-cyl. common rail (2.0 l, 4V, turbocharger, EA 288 EVO)
  • Examplepage for repair manual 3 4-cyl. common rail (2.0 l, 4V, turbocharger, EA 288 EVO)
  • Examplepage for repair manual 4-cyl. common rail (2.0 l, 4V, turbocharger, EA 288 EVO)
  • Examplepage for repair manual 2 4-cyl. common rail (2.0 l, 4V, turbocharger, EA 288 EVO)
  • Examplepage for repair manual 3 4-cyl. common rail (2.0 l, 4V, turbocharger, EA 288 EVO)

4-cyl. common rail (2.0 l, 4V, turbocharger, EA 288 EVO)

For Touran / T-Roc / Golf / Tiguan / Golf Variant

Original Volkswagen repair manual


43,45 €7% VAT incl.

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  • English

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Language: English

Digital PDF file

64.842 KB

664 Sites

Detailed technical data

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This repair manual contains: Removing and installing engine, Assembly mountings, Engine cover panel, Cylinder block (pulley end), Crankshaft, Pistons and conrods, Toothed belt drive, Valve gear, Sump, oil pump, Oil filter, oil pressure switch, Cooling system/coolant, Radiator, radiator fan, Turbocharger, Injectors/high-pressure accumulator (rail), Intake manifold, Lambda probe and SCR system (selective catalytic reduction). Show more
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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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Details
car part 1K0122101CK Schlauch

1K0122101CK

Schlauch

59,19 €

Details
car part 4KE998465C Rep.Satz

4KE998465C

Rep.Satz

28,94 €

Details
car part N90435801 Uscheibe

N90435801

Uscheibe

1,03 €

Details
car part 0B5321391A Leitg.Satz

0B5321391A

Leitg.Satz

61,51 €

Details

4-Zyl. Einspritzmotor

Examplepage for repair manual 4-Zyl. Einspritzmotor

For New Beetle Cabrio (2003 - 2010) / New Beetle / New Beetle (USA) (1998 - 2007) / New Beetle (Europe) (1999 - 2002)

21,00 € Details

Fahrwerk, Achsen, Lenkung

Examplepage for repair manual Fahrwerk, Achsen, Lenkung

For Amarok (2011) / Amarok (2013) / Amarok (2017 >) / Amarok (2017)

15,68 € Details

Nr. 233: 2,0 l-Motor

Examplepage for repair manual Nr. 233: 2,0 l-Motor

5,73 € Details

image/svg+xml About Clonck

Original repair manuals und spare parts

Our repair manuals are original, come directly from Volkswagen and meet the highest quality standards.

In our original parts shop we sell high-quality original spare parts from car manufacturers. Use the search function to enter the desired part number (OE number) and order the required spare part quickly and easily.

Highest quality standards

At Clonck, we want to make car mechanics and car professionals happy. That's why you will only find professional and high-quality repair manuals at Clonck that will help you to repair your vehicle professionally.

Our partners

Autohaus Schmidt GmbH
Automag GmbH Filiale Laim
KFZ-VERLAG GmbH
Zimpel und Franke GmbH

Clonck: The car repair shop - also as app!

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Clonck: Fitting car parts for your car repair

4,5 90

With Clonck you can order the right original spare parts in no time.

  • Add your car model
  • Select assembly group
  • Enter vehicle identification number (VIN)
  • Access to over 5,000 original repair manuals
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