4-cyl. injection engine (1.8 and 2.0 l engine, chain drive)

Chapter overview

• Technical data
  1
• 1 Engine number
  1
• 2 Engine data
  2
• Removing and installing engine
  4
• 1 Removing and installing engine
  4
• 1.1 Removing engine
  5
• 1.2 Separating gearbox from engine and assembling
  19
• 1.3 Securing engine to assembly stand
  22
• 1.4 Installing engine
  23
• 2 Assembly mountings
  26
• 2.1 Assembly overview - assembly mountings (Golf, Eos, Passat, CC, Scirocco)
  26
• 2.2 Assembly overview - assembly mountings (Tiguan)
  28
• 2.3 Checking adjustment of assembly mountings
  30
• 2.4 Adjusting assembly mountings (Passat 2006 ▶, CC)
  30
• 2.5 Adjusting assembly mountings (Golf, Eos, Scirocco)
  35
• 2.6 Adjusting assembly mounting (Tiguan)
  40
• Crankshaft group
  45
• 1 Cylinder block (pulley end)
  45
• 1.1 Assembly overview - poly V-belt drive
  45
• 1.2 Removing and installing poly-V belt
  48
• 1.3 Removing and installing tensioner for poly V-belt (Passat 2006 ▶, CC)
  49
• 1.4 Removing and installing tensioner for poly V-belt (Golf, Eos, Scirocco)
  54
• 1.5 Removing and installing tensioner for poly V-belt (Tiguan)
  59
• 1.6 Removing and installing bracket for ancillaries
  63
• 1.7 Removing and installing vibration damper
  65
• 1.8 Renewing oil seal for vibration damper
  73
• 2 Cylinder block, gearbox end
  76
• 2.2 Removing and installing dual-mass flywheel
  77
• 2.3 Removing and installing drive plate
  79
• 2.4 Removing and installing sealing flange on gearbox side
  81
• 3 Crankshaft
  90
• 3.1 Assembly overview - crankshaft
  90
• 3.2 Pulling needle bearing out of and driving into crankshaft
  95
• 3.3 Crankshaft dimensions
  97
• 3.4 Measuring axial clearance of crankshaft
  97
• 3.5 Measuring radial clearance of crankshaft
  98
• 4 Pistons and conrods
  100
• 4.1 Assembly overview - pistons and conrods
  100
• 4.2 Removing and installing pistons
  104
• 4.3 Checking pistons and cylinder bores
  106
• 4.4 Separating new conrod
  108
• 4.5 Checking radial clearance of conrods
  109
• Cylinder head, valve gear
  110
• 1 Chain drive
  110
• 1.1 Assembly overview - timing chain covers
  110
• 1.2 Removing and installing camshaft control valve 1 N205
  113
• 1.3 Removing and installing upper timing chain cover
  113
• 1.4 Removing and installing lower timing chain cover (Passat, CC)
  116
• 1.5 Removing and installing lower timing chain cover (Golf, Eos, Scirocco)
  124
• 1.6 Removing and installing bottom timing chain cover (Tiguan)
  133
• 1.7 Camshaft timing chain - exploded view
  141
• 1.8 Removing and installing camshaft timing chain
  143
• 1.9 Assembly overview - drive chain for balance shaft
  160
• 1.10 Removing and installing drive chain for balance shaft
  163
• 1.11 Removing and installing inlet side balance shaft
  163
• 1.12 Removing and installing exhaust side balance shaft
  168
• 1.13 Checking valve timing
  171
• 2 Cylinder head
  174
• 2.1 Assembly overview - cylinder head
  174
• 2.2 Renewing oil non-return valve in cylinder head
  178
• 2.3 Removing and installing engine cover
  179
• 2.4 Removing and installing cylinder head
  180
• 2.5 Checking compression
  227
• 2.6 Removing and installing vacuum pump
  229
• 3 Valve gear
  231
• 3.1 Assembly overview - valve gear
  231
• 3.2 Removing and installing camshaft
  234
• 3.3 Checking axial clearance of camshafts
  255
• 3.4 Renewing valve stem seals
  256
• 3.5 Checking valve guides
  267
• Lubrication
  269
• 1 Sump and oil pump
  269
• 1.1 Assembly overview - sump, oil pump
  269
• 1.2 Removing and installing coarse oil separator
  272
• 1.3 Removing and installing lower part of sump
  273
• 1.4 Removing and installing oil pump
  276
• 1.5 Removing and installing upper part of sump
  279
• 2 Engine oil:
  286
• 3.1 Assembly overview - oil filter, engine oil cooler and oil pressure switch F1
  288
• 3.2 Removing and installing engine oil cooler
  289
• 3.3 Checking oil pressure and oil pressure switch
  291
• 4.1 Assembly overview - oil filter, engine oil cooler
  294
• 4.2 Removing and installing engine oil cooler
  296
• 4.3 Removing and installing oil pressure switch F1
  297
• 4.4 Removing and installing oil pressure switch for reduced oil pressure F378
  299
• 4.5 Checking oil pressure and oil pressure switch
  300
• Cooling
  305
• 1 Cooling system
  305
• 1.1 Coolant hose connection diagram
  305
• 1.2 Draining and adding coolant
  307
• 1.3 Checking cooling system for leaks
  315
• 2 Coolant pump, thermostat, coolant pipes
  319
• 2.1 Assembly overview - coolant pump, thermostat
  319
• 2.2 Removing and installing coolant pump with thermostat housing
  322
• 2.4 Removing and installing toothed belt for coolant pump
  328
• 2.5 Renewing oil seal for coolant pump drive
  331
• 2.6 Removing and installing thermostat
  333
• 2.7 Removing and installing coolant temperature sender G62
  336
• 2.8 Assembly overview - coolant pipes
  339
• 2.9 Removing and installing front coolant pipes
  340
• 2.10 Removing and installing small coolant pipe
  344
• 2.11 Continued coolant circulation pump V51 - exploded view
  345
• 2.12 Removing and installing continued coolant circulation pump V51
  346
• 3 Radiator and radiator fans
  348
• 3.2 Installing radiator identification sensor G611, engine code CBFA
  349
• 3.3 Assembly overview - radiator, radiator cowl and radiator fan (Tiguan)
  350
• 3.4 Removing and installing radiator cowl
  352
• 3.5 Removing and installing radiator fan V7 and radiator fan 2 V177
  354
• 3.6 Removing and installing radiator (Passat, CC, Golf, Eos, Scirocco)
  354
• 3.7 Removing and installing radiator (Tiguan)
  355
• Fuel supply system
  358
• 1 Safety precautions
  358
• 1.1 Safety regulations for working on fuel supply
  358
• 2 Rules for cleanliness
  360
• 3 Fuel tank (Passat, CC)
  361
• 3.2 Assembly overview - fuel tank (engine codes CBFA, CCTA, CCTB)
  363
• 3.3 Emptying fuel tank
  365
• 3.4 Removing and installing fuel tank
  370
• 4 Fuel tank (Golf, Scirocco)
  376
• 4.2 Assembly overview - fuel tank (engine codes CBFA, CCTA, CCTB)
  378
• 4.4 Emptying fuel tank (engine codes CBFA, CCTA, CCTB)
  388
• 4.5 Removing and installing fuel tank
  390
• 5 Fuel tank (Tiguan)
  394
• 5.1 Assembly overview - fuel tank
  394
• 5.2 Emptying fuel tank
  397
• 5.3 Removing and installing fuel tank
  401
• 6 Fuel tank (Eos)
  407
• 6.1 Assembly overview - fuel tank (engine codes CAWA, CAWB, CCZA, CCZB)
  407
• 6.2 Assembly overview - fuel tank (engine codes CBFA, CCTA, CCTB)
  410
• 6.3 Emptying fuel tank
  413
• 6.4 Removing and installing fuel tank
  419
• 7 Repairing fuel supply (Passat, CC)
  423
• 7.1 Removing and installing fuel delivery unit
  423
• 7.2 Removing and installing fuel gauge sender G
  428
• 7.3 Checking fuel pump
  429
• 8 Repairing fuel supply system (Golf, Eos, Scirocco)
  451
• 8.1 Removing and installing fuel delivery unit
  451
• 8.2 Removing and installing fuel gauge sender G
  455
• 8.3 Checking fuel pump G6
  456
• 9 Repairing fuel supply (Tiguan)
  482
• 9.1 Removing and installing fuel delivery unit
  482
• 9.2 Removing and installing fuel gauge sender G
  487
• 9.3 Removing and installing suction-jet pump, fuel filter and pressure limitation valve
  488
• 9.4 Removing and installing fuel gauge sender 2 G169
  491
• 9.5 Removing and installing fuel pump control unit J538
  492
• 9.6 Checking fuel pump
  495
• 10 Electronic power control (EPC)
  514
• 10.1 Assembly overview - accelerator module
  514
• 10.2 Removing and installing accelerator pedal module
  514
• 11 Activated charcoal filter system (Passat, CC, Tiguan)
  518
• 11.4 Check fuel system for leaks (engine codes CBFA, CCTA, CCTB)
  523
• 12.1 Assembly overview - activated charcoal filter system
  533
• 12.2 Checking fuel tank breather
  534
• 13 Activated charcoal filter system (Golf, Eos with engine code CBFA, CCTA, CCTB)
  537
• 13.1 Overview of activated charcoal filter system
  537
• 13.2 Assembly overview - activated charcoal filter system (Golf)
  539
• 13.3 Assembly overview - activated charcoal filter system (Eos)
  540
• 13.4 Removing and installing activated charcoal filter
  541
• 13.5 Removing and installing fuel system diagnostic pump V144 (Golf)
  543
• 13.6 Removing and installing fuel system diagnostic pump V144 (Eos)
  544
• 13.7 Checking fuel system for leaks
  545
• Turbocharging/supercharging
  556
• 1 Turbocharger
  556
• 1.1 Assembly overview - turbocharger
  556
• 1.2 Fitting hose connections with plug-in connectors
  564
• 1.3 Removing and installing turbocharger
  565
• 1.4 Checking vacuum unit for turbocharger
  572
• 1.5 Adjusting turbocharger vacuum unit (engine codes BZB, CGYA, CDAA, CDAB)
  574
• 1.6 Removing and installing vacuum unit for turbocharger
  578
• 2 Charge air system
  580
• 2.1 Assembly overview - charge air cooling (Passat, CC, Tiguan, Eos)
  580
• 2.2 Assembly overview - charge air cooler (Golf, Scirocco)
  581
• 2.3 Assembly overview - sound generator (Golf, Scirocco)
  583
• 2.5 Turbocharging - overview
  585
• 2.6 Removing and installing charge air cooler (Golf, Eos)
  586
• 2.7 Removing and installing charge air cooler (Passat, CC, Scirocco)
  589
• 2.8 Removing and installing charge air cooler, Tiguan
  590
• 2.9 Removing and installing charge air duct to sound generator (Golf, Scirocco)
  591
• 2.10 Checking charge air system for leaks
  593
• Mixture preparation - injection
  596
• 1 Safety precautions and rules for cleanliness
  596
• 1.1 General information on self-diagnosis
  596
• 2 Injection system
  597
• 2.1 Technical data
  597
• 2.2 Overview of fitting locations
  597
• 2.3 Assembly overview - air filter
  603
• 2.4 Removing and installing air filter housing
  605
• 2.5 Removing and installing air filter element
  606
• 2.6 Removing and installing air mass meter G70
  607
• 2.7 Assembly overview - intake manifold
  608
• 2.8 Assembly overview - fuel rail
  610
• 2.9 Removing and installing intake manifold with fuel rail
  612
• 2.10 Removing and installing injectors
  621
• 2.11 Renewing Teflon seal on injector
  625
• 2.12 Cleaning injectors
  628
• 2.13 Removing and installing fuel pressure sender G247
  629
• 2.14 Removing and installing throttle valve module J338
  631
• 2.15 Cleaning throttle valve module J338
  632
• 2.17 Removing and installing high-pressure pump
  636
• 3 Checking components
  639
• 3.1 Checking fuel pressure sender G247
  639
• 3.2 Checking intake manifold change-over
  642
• 4 Engine control unit J623 (Passat, CC up to 11/10)
  645
• 4.1 Removing and installing engine control unit
  645
• 4.2 Removing and installing engine control unit with protective housing
  646
• 5 Engine control unit J623 (Golf, Eos to 11/08)
  649
• 5.1 Removing and installing engine control unit
  649
• 5.2 Removing and installing engine control unit with protective housing
  649
• 6 Engine control unit J623 (Golf, Eos, Scirocco from 11/08; CC from 11/10)
  654
• 6.1 Removing and installing engine control unit
  654
• 6.2 Removing and installing engine control unit with protective housing
  656
• 7 Engine control unit J623 (Tiguan)
  660
• 7.1 Removing and installing engine control unit
  660
• 7.2 Removing and installing engine control unit with protective housing
  661
• 8 Engine control unit J623 (Scirocco to 11/08)
  664
• 8.1 Removing and installing engine control unit
  664
• 8.2 Removing and installing engine control unit with protective housing
  665
• Exhaust system
  668
• 1 Exhaust system (Passat, CC)
  668
• 1.1 Assembly overview - exhaust system (engine codes BZB, CAWA, CAWB, CGYA)
  668
• 1.3 Assembly overview - exhaust system (engine code CBFA)
  672
• 1.4 Separating centre and rear silencers
  674
• 1.5 Aligning exhaust system free of stress
  676
• 1.6 Installation position and specified torque of clamp
  677
• 1.7 Removing and installing catalytic converters with front exhaust pipe
  679
• 1.8 Checking exhaust system for leaks
  682
• 2 Exhaust system (Golf, Eos, Scirocco)
  683
• 2.1 Assembly overview - exhaust system (engine code CAWB)
  683
• 2.3 Assembly overview - exhaust system (engine code CBFA)
  687
• 2.4 Assembly overview - exhaust system (Golf 2009►, engine codes CCZA, CCZB)
  689
• 2.5 Assembly overview - exhaust system (Golf 2009 ►, engine codes CCTA, CDAA)
  691
• 2.6 Separating centre and rear silencers
  693
• 2.7 Aligning exhaust system free of stress
  695
• 2.8 Installation position and specified torque of clamp
  696
• 2.9 Removing and installing catalytic converters with front exhaust pipe
  697
• 2.10 Checking exhaust system for leaks
  700
• 3 Exhaust system (Tiguan)
  701
• 3.2 Assembly overview - exhaust system (engine codes CAWB, CCZA)
  703
• 3.3 Separating centre and rear silencers
  705
• 3.4 Aligning exhaust system free of stress
  706
• 3.5 Removing and installing catalytic converters with front exhaust pipe
  708
• 3.6 Installation position and specified torque of clamp
  713
• 3.7 Checking exhaust system for leaks
  714
• 4 Secondary air system - engine code CBFA
  715
• 4.1 Assembly overview - secondary air system
  715
• 4.2 Removing and installing secondary air pump motor V101
  715
• 4.3 Removing and installing secondary air inlet valve N112
  716
• Ignition system
  718
• 1 Repairing ignition system
  718
• 1.1 General notes on ignition system
  718
• 1.2 Safety precautions
  718
• 1.3 Assembly overview - ignition system
  719
• 1.4 Removing and installing ignition coils with output stage
  719
• 1.5 Removing and installing knock sensor 1 G61
  721
• 1.6 Removing and installing engine speed sender G28
  722
• 1.7 Test data, spark plugs
  723