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  • Examplepage for repair manual 4-cyl. injection engine (1.8 and 2.0 l engine, chain drive)
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  • Examplepage for repair manual 3 4-cyl. injection engine (1.8 and 2.0 l engine, chain drive)
  • Examplepage for repair manual 4-cyl. injection engine (1.8 and 2.0 l engine, chain drive)
  • Examplepage for repair manual 2 4-cyl. injection engine (1.8 and 2.0 l engine, chain drive)
  • Examplepage for repair manual 3 4-cyl. injection engine (1.8 and 2.0 l engine, chain drive)

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

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

Original Volkswagen repair manual


46,09 €7% VAT incl.

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Language: English

Digital PDF file

30.479 KB

731 Sites

Detailed technical data

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This repair manual contains: Removing and installing engine, Assembly mountings, Cylinder block (pulley end), Crankshaft, Pistons and conrods, Chain drive, Valve gear, Engine oil:, Coolant pump, thermostat, coolant pipes, Rules for cleanliness, Fuel tank (Passat, CC), Repairing fuel supply system (Golf, Eos, Scirocco), Turbocharger, Injection system and Engine control unit J623 (Scirocco to 11/08). Show more
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Repair manual 4-cyl. injection engine PDF download has the following content:

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
Manufacturer's designation 4-cyl. injection engine (1.8 and 2.0 l engine, chain drive)
Manufacturer Volkswagen
Suitable for Golf (2004 - 2007) / Passat / Passat Variant (2005 - 2008) / EOS (2006) / Tiguan (2008) / Passat CC (2009) / Scirocco (2008) / Golf (2009)
Suitable car types 1K1, 1F, 5N, 357, 137, 5K1
Engine code CCTB, BZB, CBFA, CCTA, CAWB, CDAA, CCZA, CGYA, CCZB, CCZC, CDAB, CCZD
Category Reparaturanleitung

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