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

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