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Home » Manuals » 4-cyl. direct injection engine (2.0 l, 4V, EA 888 gen III BZ, turbocharger, chain drive) Volkswagen R GmbH
  • Examplepage for repair manual 4-cyl. direct injection engine (2.0 l, 4V, EA 888 gen III BZ, turbocharger, chain drive) Volkswagen R GmbH
  • Examplepage for repair manual 2 4-cyl. direct injection engine (2.0 l, 4V, EA 888 gen III BZ, turbocharger, chain drive) Volkswagen R GmbH
  • Examplepage for repair manual 3 4-cyl. direct injection engine (2.0 l, 4V, EA 888 gen III BZ, turbocharger, chain drive) Volkswagen R GmbH
  • Examplepage for repair manual 4-cyl. direct injection engine (2.0 l, 4V, EA 888 gen III BZ, turbocharger, chain drive) Volkswagen R GmbH
  • Examplepage for repair manual 2 4-cyl. direct injection engine (2.0 l, 4V, EA 888 gen III BZ, turbocharger, chain drive) Volkswagen R GmbH
  • Examplepage for repair manual 3 4-cyl. direct injection engine (2.0 l, 4V, EA 888 gen III BZ, turbocharger, chain drive) Volkswagen R GmbH

4-cyl. direct injection engine (2.0 l, 4V, EA 888 gen III BZ, turbocharger, chain drive) Volkswagen R GmbH

For T-Roc

Original Volkswagen repair manual


31,03 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

50.115 KB

415 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Assembly mountings, Engine cover panel, Cylinder block (pulley end), Crankshaft, Pistons and conrods, Cover for timing chain, Chain drive, Valve gear, Sump, oil pump, Oil filter, oil pressure switch, Coolant pump, regulation of cooling system, Radiator, radiator fan, Turbocharger, Intake manifold and Lambda probe. Show more
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Repair manual T-Roc 4-cyl. direct injection engine Volkswagen R GmbH 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
    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 notes
    5
  • 3.1 Rules for cleanliness
    5
  • 3.2 Foreign objects in engine
    5
  • 3.3 Contact corrosion
    5
  • 3.4 Routing and attachment of lines
    5
  • 3.5 Fitting radiator and condensers
    6
  • 3.6 Checking vacuum system
    6
  • Removing and installing engine
    7
  • 1 Removing and installing engine
    7
  • 1.1 Removing engine
    7
  • 1.2 Separating engine and gearbox
    16
  • 1.3 Securing engine on engine and gearbox support
    20
  • 1.4 Installing engine
    22
  • 2 Assembly mountings
    25
  • 2.1 Assembly overview - assembly mountings
    25
  • 2.2 Removing and installing engine mounting
    27
  • 2.3 Removing and installing gearbox mounting
    28
  • 2.4 Removing and installing pendulum support
    30
  • 2.5 Supporting engine in installation position
    31
  • 2.6 Adjusting assembly mountings
    35
  • 2.7 Checking adjustment of assembly mountings
    37
  • 3 Engine cover panel
    38
  • 3.1 Removing and installing engine cover
    38
  • Crankshaft group
    39
  • 1 Cylinder block (pulley end)
    39
  • 1.1 Assembly overview - cylinder block (pulley end)
    39
  • 1.2 Removing and installing poly-V belt
    42
  • 1.3 Removing and installing tensioner for poly V-belt
    42
  • 1.4 Removing and installing vibration damper
    43
  • 1.5 Removing and installing bracket for ancillaries
    50
  • 1.6 Removing and installing engine support
    53
  • 1.7 Renewing crankshaft oil seal - belt pulley end
    54
  • 2 Cylinder block, gearbox end
    57
  • 2.1 Assembly overview - cylinder block, gearbox end
    57
  • 2.2 Removing and installing flywheel
    58
  • 2.3 Removing and installing sealing flange on gearbox side
    60
  • 3 Crankshaft
    65
  • 3.1 Assembly overview - crankshaft
    65
  • 3.2 Crankshaft dimensions
    68
  • 3.3 Allocation of main bearing shells
    68
  • 3.4 Renewing needle bearing in crankshaft
    70
  • 3.5 Measuring axial clearance of crankshaft
    72
  • 3.6 Measuring radial clearance of crankshaft
    73
  • 3.7 Removing and installing sender wheel
    74
  • 4 Balancer shaft
    76
  • 4.1 Assembly overview - balance shaft
    76
  • 4.2 Removing and installing balance shaft
    78
  • 4.3 Renewing oil seal for balance shaft (inlet side)
    83
  • 5 Pistons and conrods
    86
  • 5.1 Assembly overview - pistons and conrods
    86
  • 5.2 Removing and installing pistons
    90
  • 5.3 Checking pistons and cylinder bores
    92
  • 5.4 Separating new conrod
    94
  • 5.5 Checking radial clearance of conrods
    95
  • 5.6 Removing and installing oil spray jets
    95
  • Cylinder head, valve gear
    97
  • 1 Cylinder head
    97
  • 1.1 Assembly overview - cylinder head
    97
  • 1.2 Assembly overview - vacuum pump
    100
  • 1.3 Removing and installing cylinder head
    101
  • 1.4 Removing and installing vacuum pump
    107
  • 1.5 Checking compression
    110
  • 2 Cover for timing chain
    112
  • 2.1 Assembly overview - cover for timing chain
    112
  • 2.2 Removing and installing timing chain cover
    115
  • 3 Chain drive
    124
  • 3.1 Assembly overview - camshaft timing chains
    124
  • 3.2 Assembly overview - drive chain for balance shaft
    125
  • 3.3 Removing and installing camshaft timing chain
    127
  • 3.4 Removing and installing drive chain for balance shaft
    145
  • 3.5 Checking valve timing
    145
  • 3.6 Checking timing chain
    148
  • 4 Valve gear
    150
  • 4.1 Assembly overview - valve gear
    150
  • 4.2 Removing and installing camshaft
    155
  • 4.3 Removing and installing camshaft control valve 1 N205
    173
  • 4.4 Removing and installing exhaust camshaft control valve 1 N318
    173
  • 4.5 Removing and installing valve stem seals
    174
  • 4.6 Installing ball for sliding piece
    184
  • 4.7 Removing and installing actuators for camshaft adjustment
    186
  • 5 Inlet and exhaust valves
    187
  • 5.1 Checking valve guides
    187
  • 5.2 Checking valves
    188
  • 5.3 Valve dimensions
    188
  • Lubrication
    189
  • 1 Sump, oil pump
    189
  • 1.1 Assembly overview - sump/oil pump
    189
  • 1.2 Engine oil:
    192
  • 1.3 Removing and installing lower part of sump
    192
  • 1.4 Removing and installing upper part of sump
    193
  • 1.5 Removing and installing oil pump
    197
  • 1.6 Removing and installing oil level and oil temperature sender G266
    200
  • 2 Engine oil cooler
    201
  • 2.1 Assembly overview - engine oil cooler
    201
  • 2.2 Removing and installing engine oil cooler
    201
  • 2.3 Removing and installing mechanical switching valve
    203
  • 3 Crankcase ventilation
    204
  • 3.1 Assembly overview - crankcase breather system
    204
  • 3.2 Removing and installing oil separator
    205
  • 4 Oil filter, oil pressure switch
    206
  • 4.1 Assembly overview - oil filter
    206
  • 4.2 Assembly overview - oil pressure switches/oil pressure control
    206
  • 4.3 Removing and installing oil pressure switch
    208
  • 4.4 Checking oil pressure
    211
  • 4.5 Removing and installing oil pressure regulating valve N428
    213
  • 4.6 Removing and installing piston cooling jet control valve N522
    214
  • Cooling
    216
  • 1 Cooling system/coolant
    216
  • 1.1 Connection diagram - coolant hoses
    216
  • 1.2 Checking cooling system for leaks
    220
  • 1.3 Draining and adding coolant
    223
  • 1.4 Flushing cooling system
    230
  • 2 Coolant pump, regulation of cooling system
    254
  • 2.1 Assembly overview - coolant pump, thermostat
    254
  • 2.2 Assembly overview - electric coolant pump
    256
  • 2.3 Assembly overview - coolant temperature sender
    258
  • 2.4 Removing and installing coolant pump
    259
  • 2.5 Removing and installing toothed belt for coolant pump
    261
  • 2.6 Removing and installing coolant temperature sender G62
    263
  • 2.7 Removing and installing radiator outlet coolant temperature sender G83
    265
  • 2.8 Removing and installing coolant valves
    266
  • 2.9 Removing and installing actuator for engine temperature regulation N493
    269
  • 2.10 Removing and installing auxiliary pump for heating V488
    271
  • 3 Coolant pipes
    273
  • 3.1 Assembly overview - coolant pipes
    273
  • 3.2 Removing and installing upper coolant pipes
    273
  • 3.3 Removing and installing front coolant pipe
    275
  • 4 Radiator, radiator fan
    277
  • 4.1 Assembly overview – radiator
    277
  • 4.2 Assembly overview - auxiliary radiator
    278
  • 4.3 Assembly overview – radiator cowl and radiator fan
    280
  • 4.4 Removing and installing radiator
    281
  • 4.5 Removing and installing radiator cowl
    283
  • 4.6 Removing and installing radiator fan
    284
  • 4.7 Removing and installing auxiliary radiator
    285
  • Turbocharging/supercharging
    291
  • 1 Turbocharger
    291
  • 1.1 Assembly overview - turbocharger
    291
  • 1.2 Removing and installing turbocharger
    296
  • 1.3 Removing and installing charge pressure positioner V465
    303
  • 1.4 Adjusting charge pressure positioner V465
    304
  • 2 Charge air system
    308
  • 2.1 Assembly overview - charge air system
    308
  • 2.2 Removing and installing charge air cooler
    309
  • 2.3 Removing and installing charge pressure sender G31
    312
  • 2.4 Checking charge air system for leaks
    312
  • 2.5 Removing and installing air pipe
    315
  • Mixture preparation - injection
    319
  • 1 Injection system
    319
  • 1.1 Overview of fitting locations - injection system
    319
  • 2 Injectors
    328
  • 2.1 Assembly overview - fuel rail
    328
  • 2.2 Removing and installing fuel rail
    329
  • 2.3 Removing and installing injectors
    329
  • 2.4 Renewing seals on injectors
    332
  • 2.5 Cleaning injectors
    336
  • 3 Air filter
    339
  • 3.1 Assembly overview - air filter housing
    339
  • 3.2 Removing and installing air filter housing
    340
  • 3.3 Removing and installing air guide on lock carrier
    341
  • 4 Intake manifold
    343
  • 4.1 Assembly overview – intake manifold
    343
  • 4.2 Removing and installing intake manifold
    345
  • 4.3 Removing and installing throttle valve module GX3
    351
  • 4.4 Cleaning throttle valve module GX3
    352
  • 5 Senders and sensors
    354
  • 5.2 Removing and installing fuel pressure sender G247
    355
  • 5.3 Checking fuel pressure sender G247
    357
  • 5.4 Removing and installing air mass meter G70
    359
  • 5.5 Removing and installing intake manifold sender GX9
    361
  • 5.6 Removing and installing pressure differential sender for particulate filter G1037
    361
  • 5.7 Removing and installing actuator for structure-borne sound R214
    362
  • 6 Engine control unit
    364
  • 6.1 Removing and installing engine control unit J623
    364
  • 6.2 Removing and installing engine (motor) control unit J623 with protective housing
    364
  • 7 High-pressure pump
    368
  • 7.1 Assembly overview - high-pressure pump
    368
  • 7.2 Removing and installing high-pressure pump
    368
  • 7.3 Removing and installing high-pressure pipe
    371
  • 8 Lambda probe
    374
  • 8.1 Assembly overview - Lambda probe
    374
  • 8.2 Removing and installing Lambda probe
    374
  • Exhaust system
    378
  • 1 Exhaust pipes and silencers
    378
  • 1.1 Assembly overview – silencers
    378
  • 1.2 Separating exhaust pipes from silencers
    379
  • 1.3 Removing and installing silencer
    381
  • 1.4 Aligning exhaust system free of stress
    382
  • 1.5 Checking exhaust system for leaks
    383
  • 1.6 Installation position of clamp
    383
  • 2 Emission control
    385
  • 2.1 Assembly overview – emission control
    385
  • 2.2 Assembly overview - pressure differential sender
    388
  • 2.3 Removing and installing exhaust pipe with catalytic converter and particulate filter
    388
  • 2.5 Removing and installing exhaust flap control unit J883/J945
    394
  • 3 Exhaust gas temperature regulation
    395
  • 3.1 Assembly overview – exhaust gas temperature regulation
    395
  • 3.2 Removing and installing parts of exhaust gas temperature regulation
    395
  • Ignition system
    399
  • 1 Ignition system
    399
  • 1.1 Assembly overview - ignition system
    399
  • 1.2 Removing and installing ignition coils with output stage
    401
  • 1.3 Removing and installing knock sensor 1 G61
    403
  • 1.4 Removing and installing Hall sender
    404
  • 1.5 Removing and installing engine speed sender G28
    406
Manufacturer's designation 4-cyl. direct injection engine (2.0 l, 4V, EA 888 gen III BZ, turbocharger, chain drive) Volkswagen R GmbH
Manufacturer Volkswagen
Suitable for T-Roc (2018 >)
Suitable car types A11
Engine code DNUE
Category Reparaturanleitung

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