Name: 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288)
Brand: Volkswagen
SKU: CDG635ee82f31d0
Price: 47.05 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 a start/stop system
2
1.4 Safety precautions when working on the cooling system
2
1.5 Safety precautions when working on the 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 notes
10
3.1 Rules for cleanliness
10
3.2 Foreign objects in engine
10
3.3 Contact corrosion
10
3.4 Routing and attachment of lines
11
3.5 Fitting radiator and condensers
11
4 Technical data
13
4.1 Coolant
14
Removing and installing engine
16
1 Removing and installing motor
16
1.1 Removing motor
16
1.2 Separating engine and gearbox
28
1.3 Securing engine on engine and gearbox support
32
1.4 Installing engine
34
2 Assembly mountings
39
2.1 Assembly overview – assembly mountings
39
2.2 Removing and installing engine mounting
41
2.3 Removing and installing gearbox mountings
42
2.4 Removing and installing pendulum support
44
2.5 Supporting engine in installation position
46
2.6 Checking adjustment of assembly mountings (engine and gearbox mountings)
57
2.7 Adjusting assembly mountings
58
3 Engine cover panel
61
3.1 Removing and installing engine cover
61
Crankshaft group
62
1 Cylinder block (pulley end)
62
1.1 Assembly overview - cylinder block (pulley end)
62
1.2 Removing and installing poly-V belt
64
1.3 Removing and installing tensioner for poly V-belt
66
1.4 Removing and installing vibration damper
67
1.5 Removing and installing engine support
67
1.6 Removing and installing bracket for ancillaries
69
1.7 Assembly overview - sealing flange, belt pulley end
71
1.8 Removing and installing sealing flange on pulley end
72
2 Cylinder block, gearbox end
75
2.1 Assembly overview - cylinder block, gearbox end
75
2.2 Removing and installing flywheel
76
2.3 Removing and installing sealing flange on gearbox side
78
3 Crankshaft
99
3.1 Assembly overview - crankshaft
99
3.2 Crankshaft dimensions
101
3.3 Renewing needle bearing in crankshaft
101
3.4 Measuring axial clearance of crankshaft
104
4 Pistons and conrods
106
4.1 Assembly overview - pistons and conrods
106
4.2 Removing and installing pistons
110
4.3 Measuring piston projection at TDC
111
4.4 Checking pistons and cylinder bores
114
4.5 Checking radial clearance of conrods
116
Cylinder head, valve gear
117
1 Cylinder head
117
1.1 Assembly overview - cylinder head
117
1.2 Assembly overview - cylinder head cover
121
1.3 Removing and installing cylinder head
123
1.4 Removing and installing cylinder head cover
134
1.5 Removing and installing injector seals
135
1.6 Removing and installing camshaft housing
136
1.7 Checking compression
142
2 Toothed belt drive
145
2.1 Assembly overview - toothed belt cover
145
2.2 Assembly overview - toothed belt
145
2.3 Removing and installing toothed belt guard
147
2.4 Removing and installing toothed belt
155
2.5 Removing toothed belt from camshaft
168
3 Valve gear
174
3.1 Assembly overview - valve gear
174
3.2 Measuring axial play of camshaft
177
3.3 Removing and installing camshaft oil seal
178
3.4 Removing and installing camshaft adjuster
180
3.5 Removing and installing camshaft control valve 1 N205
184
3.6 Checking hydraulic compensation elements
185
3.7 Removing and installing valve stem seals
186
3.8 Removing and installing control valve for the camshaft adjuster
195
4 Inlet and exhaust valves
199
4.1 Checking valve guides
199
4.2 Checking valves
200
4.3 Valve dimensions
200
Lubrication
201
1 Sump, oil pump
201
1.1 Assembly overview - sump/oil pump
201
1.2 Engine oil:
207
1.3 Removing and installing sump
207
1.4 Removing and installing lower part of sump
211
1.5 Removing and installing upper part of sump
216
1.6 Removing and installing oil pump
219
1.7 Removing and installing oil level and oil temperature sender G266
220
2 Engine oil cooler
223
3 Oil filter, oil pressure switch
224
3.1 Assembly overview - oil filter housing, oil pressure switch
224
3.2 Removing and installing oil pressure switch F1
226
3.3 Removing and installing oil pressure switch for reduced oil pressure F378
228
3.4 Checking oil pressure
230
3.5 Removing and installing oil filter housing
230
3.6 Removing and installing oil pressure regulating valve N428
233
4 Oil circuit
235
4.1 Removing and installing oil supply line
235
4.2 Removing and installing oil return line for turbocharger
236
Cooling
238
1 Cooling system/coolant
238
1.1 Connection diagram - coolant hoses
238
1.2 Checking cooling system for leaks
249
1.3 Draining coolant
253
1.4 Filling with coolant
256
1.5 Checking filling quality of cooling system
268
1.6 Checking electric vacuum pump VAS 6096/2
271
1.7 Flushing cooling system
272
1.8 Flushing cooling system, quick reference guide
294
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
307
2.5 Removing and installing coolant pump
325
2.6 Removing and installing thermostat
326
2.7 Checking thermostat
330
2.8 Removing and installing coolant valve for cylinder head N489
330
2.9 Removing and installing coolant temperature sender G62
331
2.10 Removing and installing radiator outlet coolant temperature sender G83
332
3 Coolant pipes
334
3.1 Assembly overview - coolant pipes
334
3.2 Removing and installing coolant pipes
336
4 Radiator, radiator fan
354
4.1 Assembly overview - radiator/radiator fan
354
4.2 Assembly overview - radiator cowl and radiator fan
360
4.3 Assembly overview - radiator blind
362
4.4 Removing and installing radiator
365
4.5 Removing and installing water radiator for charge air cooling circuit
372
4.6 Removing and installing radiator cowl
376
4.7 Removing and installing radiator fan
379
4.8 Removing and installing radiator blind
380
4.9 Removing and installing radiator blind control motor V544
383
Turbocharging/supercharging
389
1 Turbocharger
389
1.1 Assembly overview - turbocharger
389
1.2 Removing and installing turbocharger
397
1.3 Renewing vacuum unit for turbocharger
416
1.4 Removing and installing connection for turbocharger
425
2 Charge air system
427
2.1 Assembly overview - charge air system
427
2.2 Removing and installing charge pressure sender G31
430
2.3 Checking charge air system for leaks
430
2.4 Removing and installing air pipe
433
2.5 Checking charge air cooler for leaks
435
Mixture preparation - injection
441
1 Injection system
441
1.1 Schematic overview - fuel system
441
1.2 Overview of fitting locations - injection system
444
1.3 Filling/bleeding fuel system
458
1.4 Checking fuel system for leaks
459
2 Vacuum system
460
2.1 Connection diagram - vacuum system
460
2.2 Checking vacuum system
461
3 Injectors/high-pressure accumulator (rail)
462
3.1 Assembly overview - injectors
462
3.2 Assembly overview - fuel rail
464
3.3 Adapting correction values for injectors
465
3.4 Testing injectors
466
3.5 Checking return flow rate of injectors with engine running
467
3.6 Checking return flow rate of injectors at starter speed
473
3.7 Testing jammed-open injectors
478
3.8 Removing and installing injectors
480
3.9 Removing and installing high-pressure lines
486
3.10 Removing and installing fuel rail
489
4 Air filter
494
4.1 Assembly overview - air filter housing
494
4.2 Removing and installing air filter housing
496
5 Intake manifold
499
5.1 Assembly overview - intake manifold
499
5.2 Removing and installing intake manifold
503
5.3 Removing and installing throttle valve module J338
507
6 Senders and sensors
511
6.2 Removing and installing fuel pressure regulating valve N276
513
6.3 Checking fuel pressure regulating valve N276
520
6.4 Removing and installing fuel pressure sender G247
522
6.5 Removing and installing air mass meter G70
523
6.6 Removing and installing pressure differential sender G505
525
6.7 Removing and installing exhaust gas pressure sensor 1 G450
530
6.8 Removing and installing NOx sender 2 G687
531
6.11 Removing and installing fuel temperature sender G81
534
6.12 Removing and installing control unit for NOx sender GX30
535
7 Engine control unit
546
7.1 Removing and installing engine control unit J623
546
7.2 Removing and installing engine control unit J623 (with protective housing)
547
8 High-pressure pump
554
8.1 Assembly overview - high-pressure pump
554
8.2 Removing and installing high-pressure pump
555
9 Lambda probe
559
9.1 Assembly overview - Lambda probe
559
9.2 Removing and installing Lambda probe
562
Exhaust system
566
1 Exhaust pipes and silencers
566
1.1 Assembly overview - silencers
566
1.2 Aligning exhaust system free of stress
575
1.3 Removing and installing front exhaust pipe
576
1.4 Separating exhaust pipes from silencers
577
1.5 Removing and installing rear silencer
581
1.6 Removing and installing silencer
582
1.7 Checking exhaust system for leaks
586
1.8 Assembly overview - front exhaust pipe
586
1.9 Installation position of clamp
590
1.10 Align end exhaust pipes
591
2 Emission control
592
2.1 Assembly overview - emission control
592
2.2 Removing and installing catalytic converter
597
2.3 Removing and installing particulate filter
600
2.4 Removing and installing emission control module
600
2.5 Removing and installing exhaust flap control unit J883
610
3 SCR system (selective catalytic reduction)
613
3.1 Assembly overview - tank for reducing agent
613
3.2 Assembly overview - reducing agent supply line
623
3.3 Assembly overview – filler tube for reducing agent tank
625
3.4 Assembly overview - delivery module for reducing agent
628
3.5 Removing and installing reducing agent tank
629
3.6 Removing and installing front section of reducing agent supply line
646
3.7 Removing and installing delivery module for reducing agent
653
3.8 Removing and installing injector for reduction agent N474
655
3.9 Removing and installing control unit for reducing-agent heater J891
658
3.10 Assembly overview – injector for reducing agent N474
668
3.11 Draining reducing agent tank
670
3.12 Removing and installing rear section of reducing agent supply line
673
3.13 Removing and installing filler pipe for reducing agent tank
683
3.14 Disconnecting reducing agent supply line
694
3.15 SCR - resetting learnt values
699
4 Exhaust gas temperature regulation
700
4.1 Assembly overview - exhaust gas temperature regulation
700
4.2 Removing and installing exhaust gas temperature sender 1 G235
704
4.3 Removing and installing exhaust gas temperature sender 2 G448
707
4.4 Removing and installing exhaust gas temperature sender 3 G495
713
4.5 Removing and installing exhaust gas temperature sender 4 G648
717
5 Exhaust gas recirculation
722
5.1 Assembly overview - exhaust gas recirculation
722
5.2 Assembly overview - exhaust gas recirculation valve 1 GX5
726
5.3 Removing and installing exhaust gas recirculation cooler
727
5.4 Removing and installing exhaust gas recirculation valve 1 GX5
734
5.5 Removing and installing exhaust gas recirculation valve 2 GX6
736
5.6 Removing and installing exhaust gas recirculation temperature sensor G98
737
5.7 Checking exhaust gas recirculation cooler for leaks
740
Glow plug system
742
1 Glow plug system
742
1.1 Assembly overview - glow plug system
742
1.2 Removing and installing glow plug
744
1.3 Removing and installing automatic glow period control unit J179
747
1.4 Removing and installing Hall sender G40
747
1.5 Removing and installing engine speed sender G28
748

Manufacturer's designation	4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288)
Manufacturer	Volkswagen
Suitable for	Golf VII (2013) / Golf Variant (2014) / Golf Sportsvan (2014 >) / Touran (2016 > ) / Golf VII (2017) / Golf (2017) / Golf Sportsvan (2018 >)
Suitable car types	5G1, AM1, 5T1, BQ1, BV5, AN1
Engine code	CRLB, CLHA, CUNA, CLHB, CKFC, CRVA, CRKB, CRVC, CRMB, CXXB, DBKA, DEJA, DEJB, DFEA, DFGA, DFHA, CRLD, DGCA, DDYA, DDYB, DFEB, DCYB, DFGC, DGDA, DFZA, CRKA, CRGA, DCYA, CYKB, CXXA, DFGB, DJGA, DGTE
Category	Reparaturanleitung

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