Name: 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288)
Brand: Volkswagen
SKU: CDGcd7a6acde458
Price: 43.7 EUR
Availability: InStock

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Repair manual 4-cylinder common rail 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
1.2 Safety measures when working on vehicles with start/stop system
2
1.4 Safety precautions when working on the cooling system
2
1.5 Safety precautions when working on SCR system
2
1.6 Safety precautions when working on exhaust system
3
2 Identification
5
2.1 Engine number/engine data
5
3 Repair instructions
8
3.1 Rules for cleanliness
8
3.2 Foreign objects in engine
8
3.3 Contact corrosion
8
3.4 Routing and attachment of lines
9
3.5 Fitting radiator and condensers
9
4 Technical data
11
4.1 Coolant
12
Removing and installing engine
14
1 Removing and installing engine
14
1.1 Removing engine
14
1.2 Separating engine and gearbox
27
1.3 Securing engine on engine and gearbox support
31
1.4 Installing engine
33
2 Assembly mountings
38
2.1 Assembly overview – assembly mountings
38
2.2 Removing and installing engine mounting
40
2.3 Removing and installing gearbox mounting
41
2.4 Removing and installing pendulum support
43
2.5 Supporting engine in installation position
45
2.6 Adjusting assembly mountings
55
2.7 Checking adjustment of assembly mountings
57
3 Engine cover panel
58
3.1 Removing and installing engine cover
58
Crankshaft group
59
1 Cylinder block (pulley end)
59
1.1 Assembly overview - cylinder block (pulley end)
59
1.2 Assembly overview - sealing flange, belt pulley end
61
1.3 Removing and installing poly-V belt
63
1.4 Removing and installing tensioner for poly V-belt
64
1.5 Removing and installing vibration damper
65
1.6 Removing and installing bracket for ancillaries
66
1.7 Removing and installing engine support
68
1.8 Removing and installing sealing flange on pulley end
69
1.9 Renewing caps in cylinder block (pulley end)
72
2 Cylinder block, gearbox end
74
2.1 Assembly overview - cylinder block, gearbox end
74
2.2 Removing and installing flywheel
75
2.3 Removing and installing sealing flange on gearbox side
78
2.4 Renewing caps in cylinder block (gearbox end)
98
3 Crankshaft
100
3.1 Assembly overview - crankshaft
100
3.2 Crankshaft dimensions
102
3.3 Renewing needle bearing in crankshaft
102
3.4 Measuring axial clearance of crankshaft
105
4 Pistons and conrods
107
4.1 Assembly overview - pistons and conrods
107
4.2 Removing and installing pistons
110
4.3 Measuring piston projection at TDC
112
4.4 Checking pistons and cylinder bores
114
4.5 Separating new conrod
116
4.6 Checking radial clearance of conrods
117
Cylinder head, valve gear
118
1 Cylinder head
118
1.1 Assembly overview - cylinder head
118
1.2 Assembly overview - cylinder head cover
122
1.3 Removing and installing cylinder head
124
1.4 Removing and installing cylinder head cover
135
1.5 Removing and installing injector seals
138
1.6 Removing and installing camshaft housing
139
1.7 Checking compression
145
2 Toothed belt drive
148
2.1 Assembly overview - toothed belt cover
148
2.2 Assembly overview - toothed belt
148
2.3 Removing and installing toothed belt guard
150
2.4 Removing and installing toothed belt
157
2.5 Removing toothed belt from camshaft
171
3 Valve gear
176
3.1 Assembly overview - valve gear
176
3.2 Measuring axial play of camshaft
180
3.3 Removing and installing camshaft oil seal
181
3.4 Removing and installing camshaft adjuster
183
3.5 Removing and installing camshaft control valve 1 N205
190
3.6 Checking hydraulic compensation elements
190
3.7 Removing and installing valve stem seals
191
4 Inlet and exhaust valves
202
4.1 Checking valve guides
202
4.2 Checking valves
203
4.3 Valve dimensions
203
Lubrication
204
1 Sump, oil pump
204
1.1 Assembly overview - sump/oil pump
204
1.2 Engine oil:
211
1.3 Removing and installing oil sump
212
1.4 Removing and installing lower part of sump
216
1.5 Removing and installing upper part of sump
220
1.6 Removing and installing oil pump
224
1.7 Removing and installing oil level and oil temperature sender G266
225
2 Engine oil cooler
228
3 Oil filter, oil pressure switch
229
3.1 Assembly overview - oil filter housing, oil pressure switch
229
3.2 Removing and installing oil pressure switch F1
231
3.3 Removing and installing oil pressure switch for reduced oil pressure F378
233
3.4 Checking oil pressure
234
3.5 Removing and installing oil filter housing
235
3.6 Removing and installing oil pressure regulating valve N428
238
4 Oil circuit
240
4.1 Removing and installing oil supply line
240
4.2 Removing and installing oil return line for turbocharger
241
Cooling
243
1 Cooling system/coolant
243
1.1 Connection diagram - coolant hoses
243
1.2 Checking cooling system for leaks
250
1.3 Draining coolant
253
1.4 Filling with coolant
256
1.5 Checking filling quality of cooling system
269
1.6 Checking electric vacuum pump VAS 6096/2
271
1.7 Flushing cooling system
272
2 Coolant pump, regulation of cooling system
296
2.1 Assembly overview - coolant pump, thermostat
296
2.2 Assembly overview - electric coolant pump
300
2.3 Assembly overview - coolant temperature sender
306
2.4 Removing and installing electric coolant pump
308
2.5 Removing and installing coolant pump
326
2.6 Removing and installing thermostat
327
2.7 Checking thermostat
330
2.8 Removing and installing coolant valve for cylinder head N489
331
2.9 Removing and installing coolant temperature sender G62
331
3 Coolant pipes
333
3.1 Assembly overview - coolant pipes
333
3.2 Removing and installing coolant pipes
335
4 Radiator, radiator fan
351
4.1 Assembly overview - radiator/radiator fan
351
4.2 Assembly overview – radiator cowl and radiator fan
355
4.3 Assembly overview - radiator blind
357
4.4 Removing and installing radiator
360
4.5 Removing and installing water radiator for charge air cooling circuit
363
4.6 Removing and installing radiator cowl
367
4.7 Removing and installing radiator fan
370
4.8 Removing and installing radiator blind
371
4.9 Removing and installing radiator blind control motor V544
373
Turbocharging/supercharging
379
1 Turbocharger
379
1.1 Assembly overview - turbocharger
379
1.2 Removing and installing turbocharger
387
1.3 Renewing vacuum unit for turbocharger
404
1.4 Removing and installing connection for turbocharger
413
2 Charge air system
415
2.1 Assembly overview - charge air system
415
2.2 Removing and installing charge pressure sender G31
418
2.3 Checking charge air system for leaks
418
2.4 Checking charge air cooler for leaks
421
2.5 Removing and installing air pipe
426
Mixture preparation - injection
429
1 Injection system
429
1.1 Schematic overview - fuel system
429
1.2 Overview of fitting locations - injection system
431
1.3 Filling/bleeding fuel system
443
1.4 Checking fuel system for leaks
444
2 Vacuum system
445
2.1 Connection diagram – vacuum system
445
2.2 Checking vacuum system
446
3 Injectors/high-pressure accumulator (rail)
447
3.1 Assembly overview - injectors
447
3.2 Assembly overview - fuel rail
449
3.3 Adapting correction values for injectors
450
3.4 Testing injectors
451
3.5 Checking return flow rate of injectors with engine running
452
3.6 Checking return flow rate of injectors at starter speed
454
3.7 Testing jammed-open injectors
456
3.8 Removing and installing injectors
457
3.9 Removing and installing high-pressure lines
461
3.10 Removing and installing fuel rail
464
4 Air filter
466
4.1 Assembly overview - air filter housing
466
4.2 Removing and installing air filter housing
469
5 Intake manifold
471
5.1 Assembly overview – intake manifold
471
5.2 Removing and installing intake manifold
475
5.3 Removing and installing throttle valve module J338
480
6 Senders and sensors
483
6.1 Removing and installing fuel pressure regulating valve N276
483
6.2 Checking fuel pressure regulating valve N276
488
6.3 Removing and installing fuel pressure sender G247
489
6.4 Removing and installing air mass meter G70
491
6.5 Removing and installing pressure differential sender G505
493
6.6 Removing and installing exhaust gas pressure sensor 1 G450
496
6.7 Removing and installing NOx sender 2 G687
497
6.10 Removing and installing fuel temperature sender G81
500
6.11 Removing and installing control unit for NOx sender GX30
502
7 Engine/motor control unit
512
7.1 Removing and installing engine control unit J623
512
8 High-pressure pump
519
8.1 Assembly overview - high-pressure pump
519
8.2 Removing and installing high-pressure pump
520
9 Lambda probe
524
9.1 Assembly overview - Lambda probe
524
9.2 Removing and installing Lambda probe
527
Exhaust system
531
1 Exhaust pipes and silencers
531
1.1 Assembly overview – silencers
531
1.2 Assembly overview - front exhaust pipe
537
1.3 Removing and installing front exhaust pipe
539
1.4 Separating exhaust pipes from silencers
540
1.5 Removing and installing rear silencer
542
1.6 Aligning exhaust system free of stress
544
1.7 Checking exhaust system for leaks
545
1.8 Installation position of clamp
545
2 Emission control
548
2.1 Assembly overview – emission control
548
2.2 Removing and installing catalytic converter
553
2.3 Removing and installing particulate filter
555
2.4 Removing and installing emission control module
555
2.5 Removing and installing exhaust flap control unit J883
567
3 SCR system (selective catalytic reduction)
569
3.1 Assembly overview – reducing agent tank
569
3.2 Assembly overview - reducing agent supply line
571
3.3 Assembly overview - delivery module for reducing agent
572
3.4 Removing and installing reducing agent tank
572
3.5 Removing and installing front section of reducing agent supply line
575
3.6 Removing and installing delivery module for reducing agent
584
3.7 Removing and installing injector for reduction agent N474
587
3.8 Removing and installing control unit for reducing-agent heater J891
590
3.9 Assembly overview - injector for reducing agent
593
3.10 Draining reducing agent tank
595
3.11 Removing and installing rear section of reducing agent supply line
598
3.12 Removing and installing filler pipe for reducing agent tank
599
3.13 Disconnecting reducing agent supply line
601
3.14 SCR - resetting learnt values
604
4 Exhaust gas temperature regulation
606
4.1 Assembly overview – exhaust gas temperature regulation
606
4.2 Removing and installing exhaust gas temperature sender 1 G235
610
4.3 Removing and installing exhaust gas temperature sender 2 G448
617
4.4 Removing and installing exhaust gas temperature sender 3 G495
627
4.5 Removing and installing exhaust gas temperature sender 4 G648
632
5 Exhaust gas recirculation
635
5.1 Assembly overview – exhaust gas recirculation
635
5.2 Assembly overview - exhaust gas recirculation valve 1 GX5
639
5.3 Removing and installing exhaust gas recirculation cooler
640
5.4 Removing and installing exhaust gas recirculation valve 1 GX5
648
5.5 Removing and installing exhaust gas recirculation valve 2 GX6
649
5.6 Removing and installing exhaust gas recirculation temperature sensor G98
651
5.7 Checking exhaust gas recirculation cooler for leaks
654
Glow plug system
655
1 Glow plug system
655
1.1 Assembly overview – glow plug system
655
1.2 Removing and installing glow plug
657
1.3 Removing and installing automatic glow period control unit J179
660
1.4 Removing and installing Hall sender G40
660
1.5 Removing and installing engine speed sender G28
661

Manufacturer's designation	4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288)
Manufacturer	Volkswagen
Suitable for	Passat Lim (2015 >) / Passat Var. (2015 >) / Arteon () / Passat Variant (2019 >) / Passat Limousine (2019 >)
Suitable car types	3G2, 3H7, CB5, CB2
Engine code	CUPA, DBKA, DBGA, DFCA, DFEA, CLHC, DCZA, DFGA, DFHA, CRLD, DFEB, DBGB, CRGA, DDAA, DCXA
Category	Reparaturanleitung

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