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  • Examplepage for repair manual 4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
  • Examplepage for repair manual 2 4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
  • Examplepage for repair manual 3 4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
  • Examplepage for repair manual 4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
  • Examplepage for repair manual 2 4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
  • Examplepage for repair manual 3 4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH

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

For Golf VII / Golf Variant / Golf

Original Volkswagen repair manual


34,22 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

50.851 KB

471 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, Lambda probe and Secondary air system. Show more
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Repair manual Golf VII / Golf Variant / Golf 4-cyl. direct injection engine Volkswagen R GmbH PDF download has the following content:

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
Manufacturer's designation 4-cyl. direct injection engine (2.0 l, 4 V, turbocharger, chain drive, generation III) Volkswagen R GmbH
Manufacturer Volkswagen
Suitable for Golf VII (2013) / Golf Variant (2014) / Golf (Mexiko) (2014 >) / Golf Variant (Mexiko) (2015 >) / Golf VII (2017) / Golf (2017)
Suitable car types 5G1, AU1, BX5, BQ1, BV5
Engine code CJXC, CYFB, CJXG, CJXD, DJHA, DJHB, DJJA, DNUE, DNUC, DLRA
Category Reparaturanleitung

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