Name: 4-cyl. direct injection engine (2.0 l, 4 V, EA 888 gen III BZ, turbocharger, chain drive)
Brand: Volkswagen
SKU: CDGc987f1e29faf
Price: 36.51 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 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
24
1.3 Securing engine on engine and gearbox support
34
1.4 Installing engine
37
2 Assembly mountings
41
2.1 Assembly overview - assembly mountings
41
2.2 Removing and installing engine mounting
43
2.3 Removing and installing gearbox mounting
44
2.4 Removing and installing pendulum support
46
2.5 Supporting engine in installation position
48
2.6 Checking adjustment of assembly mountings
69
2.7 Adjusting assembly mountings
69
3 Engine cover panel
72
3.1 Removing and installing engine cover
72
Crankshaft group
73
1 Cylinder block (pulley end)
73
1.1 Assembly overview - cylinder block (pulley end)
73
1.2 Removing and installing poly-V belt
76
1.3 Removing and installing tensioner for poly V-belt
77
1.4 Removing and installing vibration damper
78
1.5 Renewing seal for vibration damper
85
1.6 Removing and installing bracket for ancillaries
88
1.7 Removing and installing engine support
90
2 Cylinder block, gearbox end
93
2.1 Assembly overview - cylinder block, gearbox end
93
2.2 Removing and installing flywheel
94
2.3 Removing and installing sealing flange on gearbox side
96
3 Crankshaft
101
3.1 Assembly overview - crankshaft
101
3.2 Crankshaft dimensions
104
3.3 Allocation of main bearing shells
104
3.4 Renewing needle bearing in crankshaft
106
3.5 Measuring axial clearance of crankshaft
108
3.6 Measuring radial clearance of crankshaft
109
3.7 Removing and installing sender wheel
110
4 Balancer shaft
112
4.1 Assembly overview - balance shaft
112
4.2 Removing and installing balance shaft
114
5 Pistons and conrods
121
5.1 Assembly overview - pistons and conrods
121
5.2 Removing and installing pistons
125
5.3 Checking pistons and cylinder bores
127
5.4 Separating new conrod
129
5.5 Checking radial clearance of conrods
129
5.6 Removing and installing oil spray jets
130
Cylinder head, valve gear
132
1 Cylinder head
132
1.1 Assembly overview - cylinder head
132
1.2 Removing and installing cylinder head
135
1.3 Assembly overview - vacuum pump
141
1.4 Removing and installing vacuum pump
142
1.5 Checking compression
144
2 Cover for timing chain
147
2.1 Assembly overview - cover for timing chain
147
2.2 Removing and installing timing chain cover
150
3 Chain drive
157
3.1 Assembly overview - camshaft timing chains
157
3.2 Assembly overview - drive chain for balance shaft
160
3.3 Removing and installing camshaft timing chain
162
3.4 Removing and installing drive chain for balance shaft
175
3.5 Checking timing chain
178
4 Valve gear
180
4.1 Assembly overview - valve gear
180
4.2 Removing and installing camshaft
184
4.3 Removing and installing actuators for camshaft adjustment
195
4.4 Removing and installing camshaft control valve 1 N205
197
4.5 Removing and installing exhaust camshaft control valve 1 N318
197
4.6 Removing and installing valve stem seals
198
5 Inlet and exhaust valves
209
5.1 Checking valve guides
209
5.2 Checking valves
210
5.3 Valve dimensions
210
Lubrication
211
1 Sump, oil pump
211
1.1 Assembly overview - sump/oil pump
211
1.2 Engine oil:
214
1.3 Removing and installing lower part of sump
214
1.4 Removing and installing upper part of sump
220
1.5 Removing and installing oil pump
226
1.6 Removing and installing oil level and oil temperature sender G266
229
2 Engine oil cooler
231
2.1 Assembly overview - engine oil cooler
231
2.2 Removing and installing engine oil cooler
231
3 Crankcase ventilation
234
3.1 Assembly overview - crankcase breather system
234
3.2 Removing and installing oil separator
235
4 Oil filter, oil pressure switch
237
4.1 Assembly overview - oil filter
237
4.2 Assembly overview - oil pressure switches/oil pressure control
237
4.3 Removing and installing piston cooling jet control valve N522
239
4.4 Removing and installing oil pressure switch
240
4.5 Checking oil pressure
244
4.6 Removing and installing oil pressure regulating valve N428
248
Cooling
250
1 Cooling system/coolant
250
1.1 Connection diagram - coolant hoses
250
1.2 Checking cooling system for leaks
252
1.3 Draining and adding coolant
256
1.4 Flushing cooling system
264
2 Coolant pump, regulation of cooling system
288
2.1 Assembly overview - coolant pump, thermostat
288
2.2 Assembly overview - electric coolant pump
290
2.3 Assembly overview - coolant temperature sender
293
2.4 Removing and installing electric coolant pump
294
2.5 Removing and installing coolant pump
297
2.6 Removing and installing toothed belt for coolant pump
300
2.7 Removing and installing coolant valves
301
2.8 Removing and installing actuator for engine temperature regulation N493
306
2.9 Removing and installing coolant temperature sender G62
309
2.10 Removing and installing radiator outlet coolant temperature sender G83
310
3 Coolant pipes
312
3.1 Assembly overview - coolant pipes
312
3.2 Removing and installing coolant pipes
312
3.3 Removing and installing upper coolant pipes
314
4 Radiator, radiator fan
316
4.1 Assembly overview – radiator
316
4.2 Assembly overview – radiator cowl and radiator fan
320
4.3 Removing and installing radiator
322
4.4 Removing and installing radiator cowl
329
4.5 Removing and installing radiator fan
335
Turbocharging/supercharging
338
1 Turbocharger
338
1.1 Assembly overview - turbocharger
338
1.2 Removing and installing turbocharger
342
2 Charge air system
348
2.1 Assembly overview - charge air system
348
2.2 Assembly overview - charge-air hose connections
351
2.3 Removing and installing charge air cooler
351
2.4 Removing and installing charge pressure sender G31
356
2.5 Checking charge air system for leaks
357
Mixture preparation - injection
361
1 Injection system
361
1.1 Overview of fitting locations - injection system
361
2 Injectors
373
2.1 Assembly overview - fuel rail with injectors
373
2.2 Removing and installing fuel rail
375
2.3 Removing and installing injectors
376
2.4 Renewing seals on injectors
383
2.5 Cleaning injectors
386
3 Air filter
388
3.1 Assembly overview - air filter housing
388
3.2 Removing and installing air filter housing
391
3.3 Removing and installing air guide on lock carrier
393
4 Intake manifold
396
4.1 Assembly overview – intake manifold
396
4.2 Removing and installing intake manifold
398
4.3 Removing and installing throttle valve module GX3
403
4.4 Cleaning throttle valve module GX3
406
4.5 Checking intake manifold change-over
407
5 Senders and sensors
409
5.1 Removing and installing fuel pressure sender G247
409
5.2 Checking fuel pressure sender G247
412
5.3 Removing and installing fuel pressure sender for low-pressure G410
414
5.4 Removing and installing intake manifold sender GX9
415
5.5 Removing and installing air mass meter G70
416
5.7 Removing and installing pressure differential sender for particulate filter G1037
420
6 Engine control unit
422
6.1 Removing and installing engine control unit J623
422
6.2 Removing and installing engine (motor) control unit J623 with protective housing
423
7 High-pressure pump
427
7.1 Assembly overview - high-pressure pump
427
7.2 Removing and installing high-pressure pump
429
7.3 Removing and installing high-pressure pipe
432
8 Lambda probe
436
8.1 Assembly overview - Lambda probe
436
8.2 Removing and installing Lambda probe
437
Exhaust system
441
1 Exhaust pipes and silencers
441
1.1 Assembly overview – silencers
441
1.2 Removing and installing silencer
446
1.3 Separating exhaust pipes from silencers
453
1.4 Aligning exhaust system free of stress
459
1.5 Checking exhaust system for leaks
459
2 Emission control
460
2.1 Assembly overview – emission control
460
2.3 Removing and installing catalytic converter
471
3 Exhaust gas temperature regulation
492
3.1 Assembly overview – exhaust gas temperature regulation
492
3.2 Removing and installing parts of exhaust gas temperature regulation
493
Ignition system
498
1 Ignition system
498
1.1 Assembly overview - ignition system
498
1.2 Removing and installing ignition coils with output stage
500
1.3 Removing and installing knock sensor 1 G61
502
1.4 Removing and installing Hall sender
503
1.5 Removing and installing engine speed sender G28
504

Manufacturer's designation	4-cyl. direct injection engine (2.0 l, 4 V, EA 888 gen III BZ, turbocharger, chain drive)
Manufacturer	Volkswagen
Suitable for	Tiguan (2016) / Arteon () / Tiguan RUS (2017) / Polo (2018) / T-Roc (2018 >) / Passat Variant (2019 >) / Passat Limousine (2019 >) / Tiguan [RU] (2021 >) / Tiguan (2021 >) / Arteon (2021 >) / Arteon Shooting Brake (2021 >)
Suitable car types	AD1, BT1, AW1, A11, CB5, CB2, BT2, AX1, 3H8, 3H9
Engine code	CZPA, DKZA, DKZC, CZPC, DUNA, DRFA
Category	Reparaturanleitung

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