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  • Examplepage for repair manual 4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive)
  • Examplepage for repair manual 2 4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive)
  • Examplepage for repair manual 3 4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive)
  • Examplepage for repair manual 4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive)
  • Examplepage for repair manual 2 4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive)
  • Examplepage for repair manual 3 4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive)

4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive)

For Golf Cabriolet / Scirocco GP

Original Volkswagen repair manual


31,26 €7% VAT incl.

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Language: English

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46.947 KB

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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, 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 Golf Cabriolet / Scirocco GP 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 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
    6
  • 3.1 Rules for cleanliness
    6
  • 3.2 Foreign objects in engine
    6
  • 3.3 Contact corrosion
    6
  • 3.4 Routing and attachment of lines
    6
  • 3.5 Fitting radiator and condensers
    7
  • 3.6 Checking vacuum system
    7
  • Removing and installing engine
    8
  • 1 Removing and installing engine
    8
  • 1.1 Removing engine
    8
  • 1.2 Separating engine and gearbox
    23
  • 1.3 Securing engine on engine and gearbox support
    29
  • 1.4 Installing engine
    31
  • 2 Assembly mountings
    35
  • 2.1 Assembly overview - assembly mountings
    35
  • 2.2 Supporting engine in installation position
    37
  • 2.3 Removing and installing engine mounting
    44
  • 2.4 Removing and installing gearbox mounting
    45
  • 2.5 Removing and installing pendulum support
    47
  • 2.6 Checking adjustment of assembly mountings
    48
  • 2.7 Adjusting assembly mountings
    48
  • 3 Engine cover panel
    51
  • 3.1 Removing and installing engine cover
    51
  • Crankshaft group
    52
  • 1 Cylinder block (pulley end)
    52
  • 1.1 Assembly overview - cylinder block (pulley end)
    52
  • 1.2 Removing and installing poly-V belt
    55
  • 1.3 Removing and installing tensioner for poly V-belt
    57
  • 1.4 Removing and installing vibration damper
    57
  • 1.5 Removing and installing bracket for ancillaries
    65
  • 1.6 Removing and installing engine support
    68
  • 1.7 Renewing seal for vibration damper
    70
  • 2 Cylinder block, gearbox end
    73
  • 2.1 Assembly overview - cylinder block, gearbox end
    73
  • 2.2 Removing and installing flywheel
    74
  • 2.3 Removing and installing sealing flange on gearbox side
    76
  • 3 Crankshaft
    81
  • 3.1 Assembly overview - crankshaft
    81
  • 3.2 Crankshaft dimensions
    83
  • 3.3 Allocation of main bearing shells
    83
  • 3.4 Renewing needle bearing in crankshaft
    85
  • 3.5 Measuring axial clearance of crankshaft
    87
  • 3.6 Measuring radial clearance of crankshaft
    88
  • 3.7 Removing and installing sender wheel
    89
  • 4 Balancer shaft
    91
  • 4.1 Assembly overview - balance shaft
    91
  • 4.2 Removing and installing balance shaft
    92
  • 4.3 Renewing oil seal for balance shaft (inlet side)
    97
  • 5 Pistons and conrods
    99
  • 5.1 Assembly overview - pistons and conrods
    99
  • 5.2 Removing and installing pistons
    103
  • 5.3 Removing and installing oil spray jets
    105
  • 5.4 Checking pistons and cylinder bores
    106
  • 5.5 Separating new conrod
    109
  • 5.6 Checking radial clearance of conrods
    109
  • Cylinder head, valve gear
    111
  • 1 Cylinder head
    111
  • 1.1 Assembly overview - cylinder head
    111
  • 1.2 Removing and installing cylinder head
    114
  • 1.3 Removing and installing vacuum pump
    121
  • 1.4 Checking compression
    122
  • 2 Cover for timing chain
    125
  • 2.1 Assembly overview - cover for timing chain
    125
  • 2.2 Removing and installing timing chain cover
    127
  • 3 Chain drive
    134
  • 3.1 Assembly overview - camshaft timing chains
    134
  • 3.2 Removing and installing camshaft timing chain
    136
  • 3.3 Assembly overview - drive chain for balance shaft
    153
  • 3.4 Removing and installing drive chain for balance shaft
    156
  • 3.5 Checking timing chain
    156
  • 3.6 Checking valve timing
    157
  • 4 Valve gear
    160
  • 4.1 Assembly overview - valve gear
    160
  • 4.2 Removing and installing camshaft
    165
  • 4.3 Installing ball for sliding piece
    183
  • 4.5 Removing and installing valve stem seals
    185
  • 5 Inlet and exhaust valves
    196
  • 5.1 Checking valve guides
    196
  • 5.2 Checking valves
    197
  • 5.3 Valve dimensions
    197
  • Lubrication
    198
  • 1 Sump, oil pump
    198
  • 1.1 Assembly overview - sump/oil pump
    198
  • 1.2 Removing and installing oil level and oil temperature sender G266
    201
  • 1.3 Removing and installing lower part of sump
    202
  • 1.4 Removing and installing oil pump
    206
  • 1.5 Removing and installing upper part of sump
    209
  • 1.6 Engine oil:
    215
  • 2 Engine oil cooler
    216
  • 2.1 Assembly overview - engine oil cooler
    216
  • 2.2 Removing and installing engine oil cooler
    216
  • 2.3 Removing and installing mechanical switching valve
    218
  • 3 Crankcase ventilation
    219
  • 3.1 Assembly overview - crankcase breather system
    219
  • 3.2 Removing and installing oil separator
    220
  • 4 Oil filter, oil pressure switch
    221
  • 4.1 Assembly overview - oil filter
    221
  • 4.2 Assembly overview - oil pressure switches/oil pressure control
    221
  • 4.3 Removing and installing piston cooling jet control valve N522
    223
  • 4.4 Removing and installing oil pressure regulating valve N428
    224
  • 4.5 Removing and installing oil pressure switch
    226
  • 4.6 Checking oil pressure
    230
  • Cooling
    235
  • 1 Cooling system/coolant
    235
  • 1.1 Connection diagram - coolant hoses
    235
  • 1.2 Draining and adding coolant
    237
  • 1.3 Checking cooling system for leaks
    244
  • 1.4 Flushing cooling system
    248
  • 2 Coolant pump, regulation of cooling system
    272
  • 2.1 Assembly overview - coolant pump, thermostat
    272
  • 2.2 Assembly overview - electric coolant pump
    274
  • 2.3 Assembly overview - coolant temperature sender
    276
  • 2.4 Removing and installing toothed belt for coolant pump
    277
  • 2.5 Removing and installing coolant pump
    280
  • 2.6 Removing and installing auxiliary pump for heating V488
    282
  • 2.7 Removing and installing coolant shut-off valve N82
    285
  • 2.8 Removing and installing coolant valve for gearbox N488, vehicles with dual clutch gearbox
    286
  • 2.9 Removing and installing actuator for engine temperature regulation N493
    288
  • 2.10 Removing and installing coolant temperature sender G62
    291
  • 2.11 Removing and installing radiator outlet coolant temperature sender G83
    292
  • 3 Coolant pipes
    294
  • 3.1 Assembly overview - coolant pipes
    294
  • 3.2 Removing and installing front coolant pipe
    294
  • 3.3 Removing and installing upper coolant pipes
    296
  • 4 Radiator, radiator fan
    299
  • 4.1 Assembly overview – radiator
    299
  • 4.2 Assembly overview – radiator cowl and radiator fan
    301
  • 4.3 Removing and installing radiator
    302
  • 4.4 Removing and installing radiator cowl
    303
  • 4.5 Removing and installing radiator fan V7 and radiator fan 2 V177
    304
  • Turbocharging/supercharging
    305
  • 1 Turbocharger
    305
  • 1.1 Assembly overview - turbocharger
    305
  • 1.2 Removing and installing turbocharger
    309
  • 1.3 Removing and installing charge pressure positioner V465
    315
  • 1.4 Adjusting charge pressure positioner V465
    317
  • 2 Charge air system
    319
  • 2.1 Assembly overview - charge air system
    319
  • 2.2 Assembly overview - charge-air hose connections
    321
  • 2.3 Removing and installing charge air cooler
    321
  • 2.4 Removing and installing charge pressure sender G31
    324
  • 2.5 Checking charge air system for leaks
    324
  • Mixture preparation - injection
    328
  • 1 Injection system
    328
  • 1.1 Overview of fitting locations - injection system
    328
  • 2 Injectors
    337
  • 2.1 Assembly overview - fuel rail with injectors
    337
  • 2.2 Removing and installing fuel rail
    339
  • 2.3 Removing and installing injectors
    340
  • 2.4 Renewing seals on injectors
    346
  • 2.5 Cleaning injectors
    349
  • 3 Air filter
    351
  • 3.1 Assembly overview - air filter housing
    351
  • 3.2 Removing and installing air filter housing
    353
  • 4 Intake manifold
    354
  • 4.1 Assembly overview – intake manifold
    354
  • 4.2 Removing and installing intake manifold
    356
  • 4.3 Removing and installing throttle valve module GX3
    362
  • 4.4 Cleaning throttle valve module
    363
  • 5 Senders and sensors
    365
  • 5.1 Removing and installing fuel pressure sender G247
    365
  • 5.2 Checking fuel pressure sender G247
    367
  • 5.3 Removing and installing fuel pressure sender for low-pressure G410
    370
  • 5.4 Removing and installing intake manifold sender GX9
    371
  • 6 Engine control unit
    373
  • 6.1 Removing and installing engine control unit J623
    373
  • 7 High-pressure pump
    379
  • 7.1 Assembly overview - high-pressure pump
    379
  • 7.2 Removing and installing high-pressure pump
    381
  • 7.3 Removing and installing high-pressure pipe
    385
  • 8 Lambda probe
    388
  • 8.1 Assembly overview - Lambda probe
    388
  • 8.2 Removing and installing Lambda probe
    389
  • Exhaust system
    393
  • 1 Exhaust pipes and silencers
    393
  • 1.1 Assembly overview – silencers
    393
  • 1.2 Removing and installing silencer
    394
  • 1.3 Separating exhaust pipes from silencers
    395
  • 1.4 Aligning exhaust system free of stress
    397
  • 1.5 Checking exhaust system for leaks
    399
  • 2 Emission control
    400
  • 2.1 Assembly overview – emission control
    400
  • 2.2 Removing and installing catalytic converter
    400
  • Ignition system
    405
  • 1 Ignition system
    405
  • 1.1 Assembly overview - ignition system
    405
  • 1.2 Test data, spark plugs
    407
  • 1.3 Removing and installing ignition coils with output stage
    407
  • 1.4 Removing and installing knock sensor I G61
    410
  • 1.5 Removing and installing Hall sender
    411
  • 1.6 Removing and installing engine speed sender G28
    412
Manufacturer's designation 4-cyl. direct injection engine (2.0 l, 4 V, EA 888 Gen III, turbocharger, chain drive)
Manufacturer Volkswagen
Suitable for Golf Cabriolet (2012) / Scirocco GP (2015)
Suitable car types 517, 138
Engine code CULA
Category Reparaturanleitung

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