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

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Engine number/engine data
  1
• 2 Safety information
  4
• 2.1 Safety regulations for working on fuel supply
  4
• 2.2 Safety measures when working on vehicles with start/stop system
  4
• 2.4 Safety precautions when working on ignition system
  5
• 2.5 Safety precautions when working on the cooling system
  6
• 2.6 Safety precautions when working on exhaust system
  6
• 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
• 3.6 Checking vacuum system
  8
• Removing and installing engine
  10
• 1 Removing and installing engine
  10
• 1.1 Removing engine
  10
• 1.2 Separating engine and gearbox
  22
• 1.3 Securing engine on engine and gearbox support
  28
• 1.4 Installing engine
  31
• 2 Assembly mountings
  34
• 2.1 Assembly overview - assembly mountings
  34
• 2.2 Supporting engine in installation position
  36
• 2.3 Removing and installing engine mounting
  42
• 2.4 Removing and installing gearbox mounting
  43
• 2.5 Removing and installing pendulum support
  45
• 2.6 Checking adjustment of assembly mountings
  45
• 2.7 Adjusting assembly mountings
  46
• 3 Engine cover panel
  49
• 3.1 Removing and installing engine cover
  49
• Crankshaft group
  50
• 1 Cylinder block (pulley end)
  50
• 1.1 Assembly overview - cylinder block (pulley end)
  50
• 1.2 Removing and installing poly-V belt
  53
• 1.3 Removing and installing tensioner for poly V-belt
  55
• 1.4 Removing and installing bracket for ancillaries
  55
• 1.5 Removing and installing vibration damper
  58
• 1.6 Removing and installing engine support
  65
• 1.7 Renewing crankshaft oil seal - belt pulley end
  66
• 2 Cylinder block, gearbox end
  69
• 2.1 Assembly overview - cylinder block, gearbox end
  69
• 2.2 Removing and installing flywheel
  70
• 2.3 Removing and installing sealing flange on gearbox side
  73
• 3 Crankshaft
  77
• 3.1 Assembly overview - crankshaft
  77
• 3.2 Removing and installing sender wheel
  79
• 3.3 Renewing needle bearing in crankshaft
  80
• 3.4 Allocation of main bearing shells
  83
• 3.5 Crankshaft dimensions
  85
• 3.6 Measuring axial clearance of crankshaft
  85
• 3.7 Measuring radial clearance of crankshaft
  86
• 4 Balancer shaft
  88
• 4.1 Assembly overview - balance shaft
  88
• 4.2 Removing and installing balance shaft
  89
• 4.3 Renewing oil seal for balance shaft (inlet side)
  94
• 5 Pistons and conrods
  97
• 5.1 Assembly overview - pistons and conrods
  97
• 5.2 Removing and installing pistons
  100
• 5.3 Separating new conrod
  101
• 5.4 Checking pistons and cylinder bores
  102
• 5.5 Checking radial clearance of conrods
  104
• Cylinder head, valve gear
  106
• 1 Cover for timing chain
  106
• 1.1 Assembly overview - cover for timing chain
  106
• 1.2 Removing and installing timing chain cover
  109
• 2 Chain drive
  118
• 2.1 Assembly overview - camshaft timing chains
  118
• 2.2 Assembly overview - drive chain for balance shaft
  120
• 2.3 Removing and installing camshaft timing chain
  123
• 2.4 Removing and installing drive chain for balance shaft
  140
• 2.5 Checking timing chain
  140
• 2.6 Checking valve timing
  141
• 3 Cylinder head
  145
• 3.1 Assembly overview - cylinder head
  145
• 3.2 Removing and installing cylinder head
  148
• 3.3 Removing and installing vacuum pump
  157
• 3.4 Checking compression
  158
• 4 Valve gear
  161
• 4.1 Assembly overview - valve gear
  161
• 4.2 Removing and installing camshaft
  166
• 4.3 Removing and installing valve stem seals
  199
• 4.4 Removing and installing camshaft control valve 1 N205
  210
• 4.5 Removing and installing exhaust camshaft control valve 1 N318
  210
• 4.6 Installing ball for sliding piece
  210
• 4.7 Removing and installing actuator for camshaft adjustment N580/N605
  211
• 5 Inlet and exhaust valves
  213
• 5.1 Checking valve guides
  213
• 5.2 Checking valves
  214
• 5.3 Valve dimensions
  214
• Lubrication
  215
• 1 Sump, oil pump
  215
• 1.1 Assembly overview - sump/oil pump
  215
• 1.2 Removing and installing oil level and oil temperature sender G266
  218
• 1.3 Removing and installing lower part of sump
  219
• 1.4 Removing and installing oil pump
  220
• 1.5 Removing and installing upper part of sump
  222
• 1.6 Engine oil:
  226
• 2 Engine oil cooler
  228
• 2.1 Assembly overview - engine oil cooler
  228
• 2.2 Removing and installing engine oil cooler
  228
• 2.3 Removing and installing mechanical switching valve
  230
• 3 Crankcase ventilation
  231
• 3.1 Assembly overview - crankcase breather system
  231
• 3.2 Removing and installing oil separator
  232
• 4 Oil filter, oil pressure switch
  233
• 4.1 Assembly overview - oil filter
  233
• 4.2 Assembly overview - oil pressure switches/oil pressure control
  233
• 4.3 Removing and installing piston cooling jet control valve N522
  235
• 4.4 Removing and installing oil pressure regulating valve N428
  236
• 4.5 Removing and installing oil pressure switch
  237
• 4.6 Checking oil pressure
  241
• Cooling
  244
• 1 Cooling system/coolant
  244
• 1.1 Connection diagram - coolant hoses
  244
• 1.2 Draining and adding coolant
  248
• 1.3 Checking cooling system for leaks
  254
• 1.4 Flushing cooling system
  257
• 2 Coolant pump, regulation of cooling system
  280
• 2.1 Assembly overview - coolant pump, thermostat
  280
• 2.2 Assembly overview - electric coolant pump
  282
• 2.3 Assembly overview - coolant temperature sender
  284
• 2.4 Removing and installing toothed belt for coolant pump
  285
• 2.5 Removing and installing coolant pump
  288
• 2.6 Removing and installing auxiliary pump for heating V488
  290
• 2.7 Removing and installing coolant shut-off valve N82
  292
• 2.8 Removing and installing coolant valve for gearbox N488
  294
• 2.9 Removing and installing actuator for engine temperature regulation N493
  296
• 2.10 Removing and installing coolant temperature sender G62
  298
• 2.11 Removing and installing radiator outlet coolant temperature sender G83
  299
• 3 Coolant pipes
  301
• 3.1 Assembly overview - coolant pipes
  301
• 3.2 Removing and installing coolant pipe at front of engine
  301
• 3.3 Removing and installing coolant pipe on top of engine
  303
• 3.4 Removing and installing coolant pipe on radiator cowl
  305
• 4 Radiator, radiator fan
  308
• 4.1 Assembly overview - radiator/radiator fan
  308
• 4.2 Assembly overview – radiator cowl and radiator fan
  310
• 4.3 Assembly overview - auxiliary radiator
  311
• 4.4 Removing and installing radiator
  311
• 4.5 Removing and installing auxiliary radiator
  314
• 4.6 Removing and installing radiator cowl
  317
• 4.7 Removing and installing radiator fan
  318
• Turbocharging/supercharging
  320
• 1 Turbocharger
  320
• 1.1 Assembly overview - turbocharger
  320
• 1.2 Removing and installing turbocharger
  325
• 1.3 Removing and installing charge pressure positioner V465
  333
• 1.4 Adjusting charge pressure positioner V465
  334
• 2 Charge air system
  337
• 2.1 Assembly overview - charge air system
  337
• 2.2 Assembly overview - charge-air hose connections
  339
• 2.3 Removing and installing charge air cooler
  339
• 2.4 Removing and installing charge pressure sender G31
  341
• 2.5 Checking charge air system for leaks
  341
• Mixture preparation - injection
  346
• 1 Injection system
  346
• 1.1 Overview of fitting locations - injection system
  346
• 2 Air filter
  357
• 2.1 Assembly overview - air filter housing
  357
• 2.2 Removing and installing air filter housing
  359
• 3 Intake manifold
  361
• 3.1 Assembly overview – intake manifold
  361
• 3.2 Removing and installing intake manifold
  363
• 3.3 Removing and installing throttle valve module GX3
  369
• 3.4 Cleaning throttle valve module GX3
  371
• 4 Injectors
  373
• 4.1 Assembly overview - fuel rail with injectors
  373
• 4.2 Removing and installing fuel rail
  376
• 4.3 Removing and installing injectors
  376
• 4.4 Renewing seals on injectors
  384
• 4.5 Cleaning injectors
  387
• 5 Senders and sensors
  390
• 5.2 Removing and installing fuel pressure sender G247
  391
• 5.3 Checking fuel pressure sender G247
  395
• 5.4 Removing and installing intake manifold sender GX9
  400
• 5.5 Removing and installing actuator for structure-borne sound R214
  401
• 5.6 Removing and installing fuel pressure sender for low-pressure G410
  401
• 5.7 Removing and installing pressure differential sender for particulate filter G1037
  403
• 6 High-pressure pump
  405
• 6.1 Assembly overview - high-pressure pump
  405
• 6.2 Removing and installing high-pressure pump
  407
• 6.3 Removing and installing high-pressure pipe
  411
• 7 Lambda probe
  415
• 7.1 Assembly overview - Lambda probe
  415
• 7.2 Removing and installing Lambda probe
  416
• 8 Engine control unit
  419
• 8.1 Removing and installing engine control unit J623
  419
• Exhaust system
  424
• 1 Exhaust pipes and silencers
  424
• 1.1 Assembly overview – silencers
  424
• 1.2 Removing and installing silencer
  428
• 1.3 Separating exhaust pipes from silencers
  429
• 1.4 Aligning exhaust system free of stress
  431
• 1.5 Align end exhaust pipes
  432
• 1.6 Checking exhaust system for leaks
  432
• 1.7 Installation position of clamp
  432
• 2 Emission control
  434
• 2.1 Assembly overview – emission control
  434
• 2.2 Assembly overview - pressure differential sender for particulate filter
  440
• 2.3 Removing and installing catalytic converter
  441
• 2.4 Removing and installing particulate filter
  444
• 2.5 Removing and installing exhaust flap control unit J883/J945
  448
• 3 Exhaust gas temperature regulation
  450
• 3.1 Assembly overview – exhaust gas temperature regulation
  450
• 4 Secondary air system
  451
• 4.1 Assembly overview - secondary air system
  451
• 4.2 Removing and installing secondary air pump motor V101
  452
• 4.3 Renewing stop buffer for secondary air pump
  452
• 4.4 Removing and installing sender 1 for secondary air pressure G609
  453
• 4.5 Removing and installing secondary air inlet valve N112
  454
• Ignition system
  456
• 1 Ignition system
  456
• 1.1 Assembly overview - ignition system
  456
• 1.2 Removing and installing ignition coils with output stage
  458
• 1.3 Removing and installing knock sensor 1 G61
  460
• 1.4 Removing and installing Hall sender
  461
• 1.5 Removing and installing engine speed sender G28
  462