Name: 4-cyl. direct injection engine (1.8 l and 2.0 l, 4 V, EA 888 gen III, turbocharger, chain drive)
Brand: Volkswagen
SKU: CDGd1cf9837af08
Price: 40.45 EUR
Availability: InStock

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Repair manual 4-cyl. direct injection engine 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 a start/stop system
1
1.4 Safety precautions when working on ignition system
2
1.5 Safety precautions when working on the cooling system
2
1.6 Safety precautions when working on exhaust system
3
2 Identification
4
2.1 Engine number/engine data
4
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
7
3.5 Fitting radiator and condensers
8
3.6 Checking vacuum system
8
Removing and installing engine
9
1 Removing and installing engine
9
1.1 Removing engine
9
1.2 Separating engine and gearbox
30
1.3 Securing engine on engine and gearbox support
40
1.4 Installing engine
43
2 Assembly mountings
47
2.1 Assembly overview - assembly mountings
47
2.2 Supporting engine in installation position
51
2.3 Removing and installing engine mounting
72
2.4 Removing and installing gearbox mounting
74
2.5 Removing and installing pendulum support
76
2.6 Checking adjustment of assembly mountings
77
2.7 Adjusting assembly mountings
78
3 Engine cover panel
81
3.1 Removing and installing engine cover
81
Crankshaft group
82
1 Cylinder block (pulley end)
82
1.1 Assembly overview - cylinder block (pulley end)
82
1.2 Removing and installing poly-V belt
85
1.3 Removing and installing tensioner for poly V-belt
87
1.4 Removing and installing vibration damper
88
1.5 Removing and installing bracket for ancillaries
95
1.6 Removing and installing engine support
98
1.7 Renewing seal for vibration damper
100
2 Cylinder block, gearbox end
103
2.1 Assembly overview - cylinder block, gearbox end
103
2.2 Removing and installing flywheel
104
2.3 Removing and installing sealing flange on gearbox side
106
3 Crankshaft
111
3.1 Assembly overview - crankshaft
111
3.2 Crankshaft dimensions
113
3.3 Allocation of main bearing shells
113
3.4 Renewing needle bearing in crankshaft
115
3.5 Measuring axial clearance of crankshaft
117
3.6 Measuring radial clearance of crankshaft
118
3.7 Removing and installing sender wheel
119
4 Balancer shaft
121
4.1 Assembly overview - balance shaft
121
4.2 Removing and installing balance shaft
123
5 Pistons and conrods
130
5.1 Assembly overview - pistons and conrods
130
5.2 Removing and installing pistons
134
5.3 Checking pistons and cylinder bores
136
5.4 Separating new conrod
139
5.5 Checking radial clearance of conrods
139
5.6 Removing and installing oil spray jets
140
Cylinder head, valve gear
142
1 Cylinder head
142
1.1 Assembly overview - cylinder head
142
1.2 Removing and installing cylinder head
145
1.3 Removing and installing vacuum pump
152
1.4 Checking compression
154
2 Cover for timing chain
157
2.1 Assembly overview - cover for timing chain
157
2.2 Removing and installing timing chain cover
159
3 Chain drive
168
3.1 Assembly overview - camshaft timing chains
168
3.2 Removing and installing camshaft timing chain
171
3.3 Assembly overview - drive chain for balance shaft
187
3.4 Removing and installing drive chain for balance shaft
190
3.5 Checking timing chain
190
3.6 Checking valve timing
191
4 Valve gear
194
4.1 Assembly overview - valve gear
194
4.2 Removing and installing camshaft
199
4.3 Removing and installing camshaft control valve 1 N205
218
4.4 Removing and installing exhaust camshaft control valve 1 N318
218
4.5 Removing and installing valve stem seals
218
5 Inlet and exhaust valves
230
5.1 Checking valve guides
230
5.2 Checking valves
231
5.3 Valve dimensions
231
Lubrication
232
1 Sump, oil pump
232
1.1 Assembly overview - sump/oil pump
232
1.2 Removing and installing oil level and oil temperature sender G266
235
1.3 Removing and installing lower part of sump
236
1.4 Removing and installing oil pump
242
1.5 Removing and installing upper part of sump
245
1.6 Engine oil:
250
2 Engine oil cooler
251
2.1 Assembly overview - engine oil cooler
251
2.2 Removing and installing engine oil cooler
251
3 Crankcase ventilation
254
3.1 Assembly overview - crankcase breather system
254
3.2 Removing and installing oil separator
255
4 Oil filter, oil pressure switch
256
4.1 Assembly overview - oil filter
256
4.2 Assembly overview - oil pressure switches/oil pressure control
256
4.3 Removing and installing piston cooling jet control valve N522
258
4.4 Removing and installing oil pressure regulating valve N428
259
4.5 Removing and installing oil pressure switch
260
4.6 Checking oil pressure
264
Cooling
268
1 Cooling system/coolant
268
1.1 Connection diagram - coolant hoses
268
1.2 Draining and adding coolant
278
1.3 Checking cooling system for leaks
287
1.4 Flushing cooling system
291
2 Coolant pump, regulation of cooling system
315
2.1 Assembly overview - coolant pump, thermostat
315
2.2 Assembly overview - electric coolant pump
317
2.3 Assembly overview - coolant temperature sender
321
2.4 Removing and installing toothed belt for coolant pump
322
2.5 Removing and installing coolant pump
324
2.6 Removing and installing electric coolant pump
327
2.7 Removing and installing coolant valves
330
2.8 Removing and installing actuator for engine temperature regulation N493
337
2.9 Removing and installing coolant temperature sender G62
340
2.10 Removing and installing radiator outlet coolant temperature sender G83
341
3 Coolant pipes
343
3.1 Assembly overview - coolant pipes
343
3.2 Removing and installing coolant pipes
343
3.3 Removing and installing upper coolant pipes
345
4 Radiator, radiator fan
348
4.1 Assembly overview – radiator
348
4.2 Assembly overview - auxiliary radiator
352
4.3 Assembly overview – radiator cowl and radiator fan
353
4.4 Removing and installing radiator
356
4.5 Removing and installing radiator cowl
364
4.6 Removing and installing radiator fan
367
4.7 Removing and installing auxiliary radiator
369
Turbocharging/supercharging
374
1 Turbocharger
374
1.1 Assembly overview - turbocharger
374
1.2 Removing and installing turbocharger
380
1.3 Removing and installing charge pressure positioner V465
392
1.4 Adjusting charge pressure positioner V465
393
2 Charge air system
397
2.1 Assembly overview - charge air system
397
2.2 Assembly overview - charge-air hose connections
401
2.3 Removing and installing charge air cooler
401
2.4 Removing and installing charge pressure sender G31
407
2.5 Checking charge air system for leaks
407
Mixture preparation - injection
412
1 Injection system
412
1.1 Overview of fitting locations - injection system
412
2 Injectors
424
2.1 Assembly overview - fuel rail with injectors
424
2.2 Removing and installing fuel rail
426
2.3 Removing and installing injectors
427
2.4 Renewing seals on injectors
435
2.5 Cleaning injectors
438
3 Air filter
441
3.1 Assembly overview - air filter housing
441
3.2 Removing and installing air filter housing
443
4 Intake manifold
445
4.1 Assembly overview – intake manifold
445
4.2 Removing and installing intake manifold
447
4.3 Removing and installing throttle valve module GX3
453
4.4 Cleaning throttle valve module GX3
456
5 Senders and sensors
458
5.3 Removing and installing fuel pressure sender G247
460
5.4 Checking fuel pressure sender G247
464
5.5 Removing and installing fuel pressure sender for low-pressure G410
469
5.6 Removing and installing intake manifold sender GX9
470
5.7 Removing and installing pressure differential sender for particulate filter G1037
471
6 Engine control unit
473
6.1 Removing and installing engine control unit J623
473
6.2 Removing and installing engine (motor) control unit J623 with protective housing
477
7 High-pressure pump
486
7.1 Assembly overview - high-pressure pump
486
7.2 Removing and installing high-pressure pump
488
7.3 Removing and installing high-pressure pipe
492
8 Lambda probe
496
8.1 Assembly overview - Lambda probe
496
8.2 Removing and installing Lambda probe
497
Exhaust system
501
1 Exhaust pipes and silencers
501
1.1 Assembly overview – silencers
501
1.2 Removing and installing silencer
514
1.3 Separating exhaust pipes from silencers
525
1.4 Aligning exhaust system free of stress
532
1.5 Checking exhaust system for leaks
533
2 Emission control
534
2.1 Assembly overview – emission control
534
2.3 Removing and installing catalytic converter
550
2.5 Removing and installing exhaust flap control unit J883/J945, Passat CJXA, Arteon
568
3 Exhaust gas temperature regulation
569
3.1 Assembly overview – exhaust gas temperature regulation
569
3.2 Removing and installing parts of exhaust gas temperature regulation
570
4 Secondary air system
575
4.1 Assembly overview - secondary air system
575
4.2 Removing and installing secondary air pump motor V101
576
4.3 Renewing stop buffer for secondary air pump
576
4.4 Removing and installing secondary air inlet valve N112
577
Ignition system
579
1 Ignition system
579
1.1 Assembly overview - ignition system
579
1.2 Removing and installing ignition coils with output stage
581
1.3 Removing and installing knock sensor 1 G61
583
1.4 Removing and installing Hall sender
585
1.5 Removing and installing engine speed sender G28
586

Manufacturer's designation	4-cyl. direct injection engine (1.8 l and 2.0 l, 4 V, EA 888 gen III, turbocharger, chain drive)
Manufacturer	Volkswagen
Suitable for	Golf VII (2013) / Golf Variant (2014) / Passat Lim (2015 >) / Passat Var. (2015 >) / Sharan (2016 > ) / Touran (2016 > ) / Tiguan (2016) / Golf VII (2017) / Arteon () / Tiguan RUS (2017) / Golf (2017) / Passat Variant (2019 >) / Passat Limousine (2019 >) / Golf (2020 >) / Tiguan [RU] (2021 >) / Tiguan (2021 >) / Arteon (2021 >) / Arteon Shooting Brake (2021 >)
Suitable car types	5G1, 3G2, 3G5, 7N2, 5T1, AD1, BQ1, 3H7, BT1, BV5, CB5, CB2, CD1, BT2, AX1, 3H8, 3H9
Engine code	CJSB, CHHA, CHHB, CNTA, CNTC, CJXA, CJXE, CJSC, CJXH, CXDB, DHGA, DLBA, DLRB, DNUA, DKTA, DNUC, CXDA, DEDA, DJHC, DKTB
Category	Reparaturanleitung

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