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  • Examplepage for repair manual 4-cyl. injection engine (1.4 l engine, 4V, EA 111, turbocharger)
  • Examplepage for repair manual 2 4-cyl. injection engine (1.4 l engine, 4V, EA 111, turbocharger)
  • Examplepage for repair manual 3 4-cyl. injection engine (1.4 l engine, 4V, EA 111, turbocharger)
  • Examplepage for repair manual 4-cyl. injection engine (1.4 l engine, 4V, EA 111, turbocharger)
  • Examplepage for repair manual 2 4-cyl. injection engine (1.4 l engine, 4V, EA 111, turbocharger)
  • Examplepage for repair manual 3 4-cyl. injection engine (1.4 l engine, 4V, EA 111, turbocharger)

4-cyl. injection engine (1.4 l engine, 4V, EA 111, turbocharger)

For Golf / Passat / Passat Variant / Golf Plus / EOS / Tiguan / Scirocco / Passat/Passat Variant

Original Volkswagen repair manual


28,47 €7% VAT incl.

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Language: English

Digital PDF file

11.797 KB

373 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine (Golf, Golf Plus, Eos, Scirocco), Crankshaft, Cylinder head, Repairing valve gear, Safety precautions, Fuel tank (Passat), Activated charcoal filter system (Tiguan), Exhaust turbocharger and Engine control unit J623. Show more
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Repair manual 4-cyl. injection engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Technical data
    1
  • 1.1 Engine number
    1
  • 1.2 Engine data
    1
  • Removing and installing engine
    3
  • 1 Removing and installing engine (Golf, Golf Plus, Eos, Scirocco)
    3
  • 1.1 Removing engine
    3
  • 1.2 Securing engine to assembly stand
    11
  • 1.3 Installing engine
    11
  • 1.4 Torque settings
    14
  • 1.5 Assembly mountings
    14
  • 1.6 Additional information and assembly work for vehicles with air conditioner
    15
  • 2 Removing and installing engine (Tiguan)
    16
  • 2.1 Removing engine
    16
  • 2.2 Securing engine to assembly stand
    25
  • 2.3 Installing engine
    25
  • 2.4 Torque settings
    27
  • 2.5 Assembly mountings
    28
  • 2.6 Additional information and assembly work for vehicles with air conditioner
    29
  • 3 Removing and installing engine (Passat)
    30
  • 3.1 Removing engine
    30
  • 3.2 Securing engine to assembly stand
    41
  • 3.3 Installing engine
    41
  • 3.4 Torque settings
    44
  • 3.5 Assembly mountings
    44
  • 3.6 Additional information and assembly work for vehicles with air conditioner
    45
  • Crankshaft group
    46
  • 1 Dismantling and assembling engine
    46
  • 1.1 Assembly overview - parts l and ll
    46
  • 1.2 Assembly overview - part I, belt drive
    48
  • 1.3 Assembly overview - part II, cylinder block
    49
  • 1.4 Removing and installing poly-V belt
    51
  • 1.5 Removing and installing valve timing housing (Golf, Golf Plus, Eos, Scirocco)
    52
  • 1.6 Removing and installing valve timing housing (Tiguan)
    57
  • 1.7 Removing and installing valve timing housing (Passat)
    61
  • 1.8 Removing and installing bracket for ancillaries
    66
  • 2 Removing and installing sealing flanges and flywheel or drive plate
    68
  • 2.1 Assembly overview
    68
  • 2.2 Removing and installing engine speed sender G28
    69
  • 2.3 Renewing crankshaft oil seal - belt pulley end
    70
  • 2.4 Removing and installing crankshaft pulley
    72
  • 2.5 Renewing crankshaft sealing flange - flywheel end
    75
  • 3 Crankshaft
    84
  • 3.1 Assembly overview
    84
  • 3.2 Pulling needle bearing out of and driving into crankshaft
    85
  • 3.3 Crankshaft dimensions
    87
  • 4 Dismantling and assembling pistons and conrods
    88
  • 4.1 Assembly overview
    88
  • 4.2 Checking piston
    90
  • 4.3 Separating new conrod
    91
  • 4.4 Piston and cylinder dimensions
    91
  • 4.5 Removing and installing pistons
    92
  • 4.6 Removing and installing oil spray jets
    93
  • Cylinder head, valve gear
    94
  • 1 Cylinder head
    94
  • 1.1 Assembly overview
    94
  • 1.2 Checking valve timing
    97
  • 1.3 Adjusting valve timing
    99
  • 1.4 Checking timing chain
    108
  • 1.5 Removing and installing timing chain and chain drive for oil pump
    114
  • 1.6 Removing and installing camshaft housing
    122
  • 1.7 Removing and installing cylinder head
    128
  • 1.8 Checking compression
    131
  • 2 Repairing valve gear
    134
  • 2.1 Assembly overview
    134
  • 2.2 Checking camshaft axial clearance
    136
  • 2.3 Removing and installing camshaft
    136
  • 2.4 Reworking valve seats
    137
  • 2.5 Checking valve guides
    138
  • 2.6 Renewing valve stem seals
    139
  • Lubrication
    141
  • 1 Removing and installing parts of lubrication system
    141
  • 1.1 Engine oil, oil capacities, engine oil specification
    141
  • 1.2 Assembly overview (► model year 2008)
    141
  • 1.3 Assembly overview (model year 2009 ►)
    144
  • 1.4 Removing and installing oil sump
    146
  • 1.5 Removing and installing oil pump
    149
  • 1.6 Checking oil pressure and oil pressure switch
    151
  • Cooling
    154
  • 1 Removing and installing parts of cooling system
    154
  • 1.1 Assembly overview - parts of cooling system, body side
    155
  • 1.2 Assembly overview - parts of cooling system, engine side
    157
  • 1.3 Coolant hose connection diagram
    158
  • 1.4 Draining and adding coolant
    159
  • 1.6 Removing and installing radiator fan V7 and radiator fan 2 V177 (Tiguan, Passat)
    163
  • 1.7 Checking cooling system for leaks
    164
  • 1.8 Removing and installing radiator (Golf, Golf Plus, Scirocco, Eos)
    165
  • 1.9 Removing and installing radiator (Tiguan, Passat)
    167
  • 1.11 Removing and installing coolant pump
    173
  • 1.12 Removing and installing coolant circulation pump V50
    175
  • Fuel supply system
    178
  • 1 Safety precautions
    178
  • 1.1 Safety regulations for working on fuel supply
    178
  • 1.2 Releasing pressure in high-pressure area
    179
  • 2 Separating plug-in connectors
    180
  • 3 Fuel tank (Golf, Golf Plus, Scirocco)
    183
  • 3.1 Assembly overview - fuel tank
    183
  • 3.2 Emptying fuel tank
    184
  • 3.3 Removing and installing fuel tank
    187
  • 4 Fuel tank (Passat)
    189
  • 4.1 Assembly overview - fuel tank
    189
  • 4.2 Emptying fuel tank
    190
  • 4.3 Removing and installing fuel tank
    193
  • 5 Fuel tank (Eos)
    197
  • 5.1 Assembly overview - fuel tank
    197
  • 5.2 Emptying fuel tank
    199
  • 5.3 Removing and installing fuel tank
    201
  • 6 Fuel tank (Tiguan)
    204
  • 6.1 Assembly overview - fuel tank (Tiguan)
    204
  • 6.2 Draining fuel tank (Tiguan)
    206
  • 6.3 Removing and installing fuel tank (Tiguan)
    208
  • 7 Repairing fuel supply system (Golf, Golf Plus, Scirocco, Eos)
    213
  • 7.1 Rules for cleanliness
    213
  • 7.2 Crash fuel shut-off
    213
  • 7.3 Removing and installing fuel delivery unit (Golf Plus, Golf, Scirocco, Eos)
    214
  • 7.4 Removing and installing fuel gauge sender G
    216
  • 7.5 Checking fuel pump
    217
  • 8 Repairing fuel supply (Passat)
    229
  • 8.1 Rules for cleanliness
    229
  • 8.2 Crash fuel shut-off
    229
  • 8.3 Removing and installing fuel delivery unit
    230
  • 8.4 Removing and installing fuel gauge sender G
    233
  • 8.5 Checking fuel pump
    235
  • 9 Repairing fuel supply (Tiguan)
    244
  • 9.1 Rules for cleanliness
    244
  • 9.2 Crash fuel shut-off
    244
  • 9.3 Removing and installing fuel delivery unit (Tiguan)
    245
  • 9.4 Removing and installing fuel gauge sender G (Tiguan)
    247
  • 9.5 Removing and installing suction-jet pump (Tiguan)
    248
  • 9.6 Removing and installing fuel gauge sender 2 G169 (Tiguan)
    251
  • 9.7 Removing and installing fuel pump control unit J538 (Tiguan)
    251
  • 9.8 Checking fuel pump (Tiguan)
    253
  • 10 Repairing electronic power control (EPC)
    262
  • 10.1 Assembly overview
    262
  • 10.2 Removing and installing accelerator pedal module
    262
  • 11 Activated charcoal filter system (Golf, Golf Plus, Eos, Scirocco)
    264
  • 11.1 Assembly overview (Golf, Golf Plus, Eos, Scirocco)
    264
  • 11.2 Checking fuel tank breather (Golf, Golf Plus, Eos, Scirocco)
    265
  • 11.3 Rules for cleanliness
    265
  • 12 Activated charcoal filter system (Passat)
    267
  • 12.1 Assembly overview
    267
  • 12.2 Checking fuel tank breather
    268
  • 12.3 Rules for cleanliness
    269
  • 13 Activated charcoal filter system (Tiguan)
    270
  • 13.1 Assembly overview (Tiguan)
    270
  • 13.2 Checking fuel tank breather (Tiguan)
    271
  • 13.3 Rules for cleanliness
    272
  • Turbocharging/supercharging
    273
  • 1 Exhaust turbocharger
    273
  • 1.1 Assembly overview - turbocharger
    273
  • 1.2 Part I
    275
  • 1.3 Part II
    276
  • 1.4 Removing and installing turbocharger
    277
  • 1.5 Removing and installing compressor housing and turbine housing
    282
  • 1.6 Checking vacuum unit for turbocharger
    286
  • 1.7 Removing and installing vacuum unit for turbocharger
    288
  • 1.8 Adjusting vacuum unit for turbocharger
    290
  • 2 Charge air system
    297
  • 2.1 Assembly overview - charge air system
    297
  • 2.2 Removing and installing intake manifold charge air cooler
    298
  • Mixture preparation - injection
    300
  • 1 Injection system
    300
  • 1.1 Assembly overview - parts l and II, intake manifold
    300
  • 1.2 Assembly overview - part I, intake manifold
    302
  • 1.3 Assembly overview - part II, intake manifold
    303
  • 1.4 Assembly overview - fuel rail with injectors
    304
  • 1.5 Assembly overview - air filter
    304
  • 1.6 Removing and installing air filter
    305
  • 1.7 Removing and installing throttle valve module J338
    306
  • 1.8 Cleaning throttle valve module J338
    309
  • 1.9 Removing and installing intake manifold
    310
  • 1.10 Assembly overview - high-pressure pump
    311
  • 1.11 Checking fuel pressure sender G247
    312
  • 1.12 Removing and installing high-pressure pump
    315
  • 1.13 Removing and installing injectors
    319
  • 1.14 Renewing Teflon seal and support washer on injector
    322
  • 1.15 Safety precautions
    325
  • 1.16 Rules for cleanliness
    327
  • 1.17 Technical data
    327
  • 2 Engine control unit J623
    328
  • 2.1 Removing and installing engine control unit J623 (Golf ► 2008, Eos)
    328
  • 2.2 Removing and installing anti-theft engine control unit J623 (Golf ► 2008, Eos ► 10.2008)
    329
  • 2.3 Removing and installing engine control unit J623 (Golf 2009 ►)
    331
  • 2.5 Removing and installing engine control unit J623 (Golf Plus)
    335
  • 2.6 Removing and installing anti-theft engine control unit J623 (Golf Plus)
    336
  • 2.7 Removing and installing engine control unit J623 (Passat 2006 ►)
    339
  • 2.8 Removing and installing anti-theft engine control unit J623 (Passat 2006 ►) . . . . .
    340
  • 2.9 Removing and installing engine control unit J623 (Scirocco)
    341
  • 2.10 Removing and installing anti-theft engine control unit J623 (Scirocco ► 09.2008)
    342
  • 2.11 Removing and installing engine control unit J623 (Tiguan)
    344
  • 2.12 Removing and installing anti-theft engine control unit J623 (Tiguan)
    345
  • Exhaust system
    348
  • 1 Removing and installing parts of exhaust system
    348
  • 1.1 Assembly overview - catalytic converter and attachments
    348
  • 1.2 Assembly overview - silencer with mountings (Golf, Golf Plus, Scirocco)
    351
  • 1.3 Assembly overview - silencer with mountings (Passat 2006 ►)
    352
  • 1.4 Assembly overview - silencer with mountings (Passat 2011 ►)
    353
  • 1.5 Assembly overview - silencer with mountings (Eos)
    354
  • 1.6 Assembly overview - silencer with mountings (Tiguan)
    355
  • 1.7 Removing and installing centre and rear silencers (Golf, Golf Plus, Scirocco, Eos)
    355
  • 1.8 Detaching centre and rear silencers (Passat)
    357
  • 1.9 Detaching centre and rear silencers (Tiguan)
    359
  • 1.10 Installation position and specified torque of clamp
    360
  • Ignition system
    362
  • 1 Repairing ignition system
    362
  • 1.1 Assembly overview - ignition system
    362
  • 1.2 Removing and installing ignition coils with output stage
    363
  • 1.3 Safety precautions
    364
  • 1.4 Test data, spark plugs
    365
Manufacturer's designation 4-cyl. injection engine (1.4 l engine, 4V, EA 111, turbocharger)
Manufacturer Volkswagen
Suitable for Golf (2004 - 2007) / Passat / Passat Variant (2005 - 2008) / Golf Plus (2005 - 2007) / EOS (2006) / Tiguan (2008) / Scirocco (2008) / Golf (2009) / Golf Plus (2009) / Passat/Passat Variant (2011 >)
Suitable car types 1K1, 5M, 1F, 5N, 137, 5K1, 521, 362, 365
Engine code CMSB
Category Reparaturanleitung

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