Name: 4-cyl. injection engine (2.0 l engine, EA 888, chain drive)
Brand: Volkswagen
SKU: CDG98ef3ae792db
Price: 24.44 EUR
Availability: InStock

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Repair manual Jetta 2-türig Rl 4-cyl. injection engine PDF download has the following content:

Chapter overview

Technical data
1
1 Safety information
1
1.1 Safety regulations for working on fuel supply
1
1.3 Safety precautions when working on the cooling system
2
1.4 Safety precautions when working on ignition system
2
2 Identification
3
2.1 Engine number/engine data
3
3 Repair notes
5
3.1 Rules for cleanliness
5
3.2 Foreign objects in engine
5
3.3 Contact corrosion
5
3.4 Routing and attachment of lines
5
3.5 Fitting radiator and condensers
6
Removing and installing engine
7
1 Removing and installing engine
7
1.1 Removing engine
7
1.2 Separating engine and gearbox
16
1.3 Securing engine on engine and gearbox support
18
1.4 Installing engine
19
2 Assembly mountings
22
2.1 Assembly overview - assembly mountings
22
2.2 Removing and installing engine mounting
24
2.3 Supporting engine in installation position
28
2.4 Adjusting assembly mountings
32
2.5 Checking adjustment of assembly mountings (engine and gearbox mountings)
34
3 Engine cover panel
35
3.1 Removing and installing engine cover
35
Crankshaft group
36
1 Cylinder block (pulley end)
36
1.1 Assembly overview - poly V-belt drive
36
1.2 Removing and installing poly-V belt
38
1.3 Removing and installing tensioner for poly V-belt
39
1.4 Removing and installing vibration damper
43
1.5 Renewing seal for vibration damper
44
1.6 Removing and installing bracket for ancillaries
46
2 Cylinder block, gearbox end
49
2.1 Assembly overview - cylinder block, gearbox end
49
2.2 Removing and installing flywheel
50
2.3 Removing and installing sealing flange on gearbox side
52
3 Crankshaft
58
3.1 Assembly overview - crankshaft
58
3.2 Crankshaft dimensions
59
3.3 Allocation of main bearing shells
60
3.4 Renewing needle bearing in crankshaft
61
3.5 Measuring axial clearance of crankshaft
63
3.6 Measuring radial clearance of crankshaft
64
3.7 Removing and installing sender wheel
65
4 Pistons and conrods
66
4.1 Assembly overview - pistons and conrods
66
4.2 Checking pistons and cylinder bores
67
4.3 Separating new conrod
70
Cylinder head, valve gear
71
1 Cylinder head
71
1.1 Assembly overview - cylinder head
71
1.2 Removing and installing cylinder head
75
1.3 Removing and installing vacuum pump
91
1.4 Checking compression
92
2 Cover for timing chain
95
2.1 Assembly overview - cover for timing chain
95
2.2 Removing and installing upper timing chain cover
96
2.3 Removing and installing timing chain cover (bottom)
98
3 Chain drive
106
3.1 Assembly overview - camshaft timing chains
106
3.2 Assembly overview - drive chain for balance shaft
107
3.3 Removing and installing camshaft timing chain
109
3.4 Removing and installing drive chain for balance shaft
121
3.5 Removing and installing balance shaft for inlet camshaft
124
3.6 Removing and installing balance shaft for exhaust camshaft
127
3.7 Checking valve timing
130
4 Valve gear
132
4.1 Assembly overview - valve gear
132
4.2 Measuring axial play of camshaft
133
4.3 Removing and installing camshaft
134
4.4 Removing and installing camshaft control valve 1 N205
142
4.5 Removing and installing valve stem seals
143
5 Inlet and exhaust valves
148
5.1 Checking valve guides
148
5.2 Valve dimensions
149
Lubrication
150
1 Sump, oil pump
150
1.1 Assembly overview - sump/oil pump
150
1.2 Engine oil:
153
1.3 Removing and installing lower part of sump
154
1.4 Removing and installing upper part of sump
156
1.5 Removing and installing oil pump
161
2 Crankcase ventilation
164
2.1 Removing and installing oil separator
164
3 Oil filter, oil pressure switch
165
3.1 Assembly overview - oil filter housing, oil pressure switch F1
165
3.3 Removing and installing engine oil cooler
167
3.4 Checking oil pressure and oil pressure switch F1
168
3.5 Checking oil pressure and oil pressure switch for reduced oil pressure F378
171
3.6 Removing and installing oil pressure switch F22
175
3.7 Removing and installing oil pressure switch for reduced oil pressure F378
176
3.8 Removing and installing oil pressure regulating valve N428
177
Cooling
179
1 Cooling system/coolant
179
1.1 Connection diagram - coolant hoses
179
1.2 Checking cooling system for leaks
181
1.3 Draining and adding coolant
183
2 Coolant pump, regulation of cooling system
189
2.1 Assembly overview - coolant pump, thermostat
189
2.2 Assembly overview - electric coolant pump
191
2.3 Removing and installing electric coolant pump
191
2.4 Removing and installing coolant pump
192
2.5 Removing and installing thermostat
193
2.6 Removing and installing toothed belt for coolant pump
196
2.7 Renewing seal for coolant pump drive
199
2.8 Removing and installing coolant temperature sender G62
200
3 Coolant pipes
204
3.1 Assembly overview - coolant pipes
204
3.2 Removing and installing front coolant pipes
205
3.3 Removing and installing small coolant pipe
208
4 Radiator, radiator fan
210
4.1 Assembly overview - radiator/radiator fan
210
4.2 Removing and installing radiator
211
4.3 Removing and installing radiator cowl with radiator fan
212
4.4 Removing and installing radiator fan V7 and radiator fan 2 V177
214
Turbocharging/supercharging
215
1 Exhaust turbocharger
215
1.1 Assembly overview - turbocharger
215
1.2 Removing and installing turbocharger
221
1.3 Checking vacuum unit for turbocharger
227
1.4 Renewing vacuum unit for turbocharger
229
2 Charge air system
231
2.1 Schematic overview - charge air system
231
2.2 Assembly overview - charge air system
232
2.3 Removing and installing charge air cooler
233
2.4 Checking charge air system for leaks
235
Mixture preparation - injection
239
1 Injection system
239
1.1 Overview of fitting locations - injection system
239
1.2 Releasing high pressure in fuel system
245
2 Injectors
246
2.1 Removing and installing injectors
246
2.2 Renewing seals on injectors
249
2.3 Cleaning injectors
251
3 Air filter
253
3.1 Assembly overview - air filter housing
253
3.2 Removing and installing air filter housing
254
3.3 Removing and installing air filter element
256
4 Intake manifold
259
4.1 Assembly overview - intake manifold
259
4.2 Removing and installing intake manifold with fuel rail
261
4.3 Removing and installing throttle valve module J338
268
4.4 Cleaning throttle valve module J338
270
4.5 Checking intake manifold change-over
270
5 Senders and sensors
273
5.1 Removing and installing fuel pressure sender G247
273
5.2 Checking fuel pressure sender G247
275
5.3 Removing and installing air mass meter
277
6 Engine (motor) control unit
279
6.1 Removing and installing engine (motor) control unit J623
279
7 High-pressure pump
281
7.1 Assembly overview - high-pressure pump
281
7.2 Assembly overview - fuel rail with injectors
282
7.3 Removing and installing high-pressure pump
284
Exhaust system
288
1 Exhaust pipes and silencers
288
1.1 Assembly overview - silencers
288
1.2 Removing and installing front exhaust pipe
290
1.3 Separating exhaust pipes from silencers
292
1.4 Aligning exhaust system free of stress
294
1.5 Check exhaust system for leaks
296
2 Secondary air system
297
2.1 Assembly overview - secondary air system
297
2.2 Removing and installing secondary air pump motor V101
297
2.3 Removing and installing secondary air inlet valve N112
298
Ignition system
300
1 Ignition system
300
1.1 Assembly overview - ignition system
300
1.2 Test data, spark plugs
301
1.3 Removing and installing ignition coils with output stage
302
1.4 Removing and installing knock sensor 1 G61
303
1.5 Removing and installing engine speed sender G28
304

Manufacturer's designation	4-cyl. injection engine (2.0 l engine, EA 888, chain drive)
Manufacturer	Volkswagen
Suitable for	Jetta 2-türig Rl (1980 - 1984)
Suitable car types	162
Engine code	CCTA, CAWB, CCZA
Category	Reparaturanleitung

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