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  • Examplepage for repair manual 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288)
  • Examplepage for repair manual 2 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288)
  • Examplepage for repair manual 3 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288)
  • Examplepage for repair manual 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288)
  • Examplepage for repair manual 2 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288)
  • Examplepage for repair manual 3 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288)

4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288)

For Tiguan / Tiguan RUS / Polo / T-Roc / T-Cross

Original Volkswagen repair manual


46,61 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

71.282 KB

745 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Assembly mountings, Engine cover panel, Cylinder block (pulley end), Crankshaft, Pistons and conrods, Toothed belt drive, Valve gear, Sump, oil pump, Oil filter, oil pressure switch, Cooling system/coolant, Radiator, radiator fan, Turbocharger, Injectors/high-pressure accumulator (rail), Intake manifold, Lambda probe and SCR system (selective catalytic reduction). Show more
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Repair manual Tiguan / Tiguan RUS / Polo / T-Roc / T-Cross 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
    4
  • 2 Identification
    5
  • 2.1 Motor number/motor data
    5
  • 3 Repair instructions
    9
  • 3.1 Rules for cleanliness
    9
  • 3.2 Foreign objects in engine
    9
  • 3.3 Contact corrosion
    9
  • 3.4 Routing and attachment of lines
    10
  • 3.5 Fitting radiator and condensers
    10
  • 4 Technical data
    12
  • 4.1 Coolant
    13
  • Removing and installing engine
    15
  • 1 Removing and installing engine
    15
  • 1.1 Removing engine
    15
  • 1.2 Separating engine and gearbox
    28
  • 1.3 Securing engine on engine and gearbox support
    34
  • 1.4 Installing engine
    36
  • 2 Assembly mountings
    41
  • 2.1 Assembly overview – assembly mountings
    41
  • 2.2 Removing and installing engine mounting
    45
  • 2.3 Removing and installing gearbox mounting
    46
  • 2.4 Removing and installing pendulum support
    49
  • 2.5 Supporting engine in installation position
    51
  • 2.6 Adjusting assembly mountings
    63
  • 2.7 Checking adjustment of assembly mountings
    67
  • 3 Engine cover panel
    68
  • 3.1 Removing and installing engine cover
    68
  • Crankshaft group
    69
  • 1 Cylinder block (pulley end)
    69
  • 1.1 Assembly overview - cylinder block (pulley end)
    69
  • 1.2 Assembly overview - sealing flange, belt pulley end
    71
  • 1.3 Removing and installing poly-V belt
    73
  • 1.4 Removing and installing tensioner for poly V-belt
    74
  • 1.5 Removing and installing vibration damper
    75
  • 1.6 Removing and installing bracket for ancillaries
    76
  • 1.7 Removing and installing engine support
    78
  • 1.8 Removing and installing sealing flange on pulley end
    79
  • 1.9 Renewing caps in cylinder block (pulley end)
    82
  • 2 Cylinder block, gearbox end
    84
  • 2.1 Assembly overview - cylinder block, gearbox end
    84
  • 2.2 Removing and installing flywheel
    85
  • 2.3 Removing and installing sealing flange on gearbox side
    88
  • 2.4 Renewing caps in cylinder block (gearbox end)
    108
  • 3 Crankshaft
    110
  • 3.1 Assembly overview - crankshaft
    110
  • 3.2 Crankshaft dimensions
    111
  • 3.3 Measuring axial clearance of crankshaft
    112
  • 3.4 Renewing needle bearing in crankshaft
    113
  • 4 Pistons and conrods
    116
  • 4.1 Assembly overview - pistons and conrods
    116
  • 4.2 Removing and installing pistons
    120
  • 4.3 Measuring piston projection at TDC
    121
  • 4.4 Checking pistons and cylinder bores
    124
  • 4.5 Checking radial clearance of conrods
    126
  • Cylinder head, valve gear
    127
  • 1 Cylinder head
    127
  • 1.1 Assembly overview - cylinder head
    127
  • 1.2 Assembly overview - cylinder head cover
    131
  • 1.3 Removing and installing cylinder head
    133
  • 1.4 Removing and installing cylinder head cover
    143
  • 1.5 Removing and installing injector seals
    144
  • 1.6 Removing and installing camshaft housing
    146
  • 1.7 Checking compression
    152
  • 2 Toothed belt drive
    155
  • 2.1 Assembly overview - toothed belt cover
    155
  • 2.2 Assembly overview - toothed belt
    155
  • 2.3 Removing and installing toothed belt guard
    157
  • 2.4 Removing and installing toothed belt
    162
  • 2.5 Removing toothed belt from camshaft
    176
  • 3 Valve gear
    182
  • 3.1 Assembly overview - valve gear
    182
  • 3.2 Measuring axial play of camshaft
    186
  • 3.3 Removing and installing camshaft oil seal
    186
  • 3.4 Removing and installing camshaft adjuster
    189
  • 3.5 Removing and installing camshaft control valve 1 N205
    192
  • 3.6 Checking hydraulic compensation elements
    193
  • 3.7 Removing and installing valve stem seals
    194
  • 3.8 Removing and installing control valve for the camshaft adjuster
    203
  • 4 Inlet and exhaust valves
    207
  • 4.1 Checking valve guides
    207
  • 4.2 Checking valves
    208
  • 4.3 Valve dimensions
    208
  • Lubrication
    209
  • 1 Sump, oil pump
    209
  • 1.1 Assembly overview - sump/oil pump
    209
  • 1.2 Engine oil:
    215
  • 1.3 Removing and installing oil sump
    216
  • 1.4 Removing and installing lower part of sump
    220
  • 1.5 Removing and installing upper part of sump
    224
  • 1.6 Removing and installing oil pump
    228
  • 1.7 Removing and installing oil level and oil temperature sender G266
    229
  • 2 Engine oil cooler
    232
  • 3 Oil filter, oil pressure switch
    233
  • 3.1 Assembly overview - oil filter housing, oil pressure switch
    233
  • 3.2 Removing and installing oil pressure switch F1
    235
  • 3.3 Removing and installing oil pressure switch for reduced oil pressure F378
    237
  • 3.4 Checking oil pressure
    239
  • 3.5 Removing and installing oil filter housing
    239
  • 3.6 Removing and installing oil pressure regulating valve N428
    242
  • 4 Oil circuit
    243
  • 4.1 Removing and installing oil supply line
    243
  • 4.2 Removing and installing oil return line for turbocharger
    244
  • Cooling
    246
  • 1 Cooling system/coolant
    246
  • 1.1 Connection diagram - coolant hoses
    246
  • 1.2 Checking cooling system for leaks
    250
  • 1.3 Draining coolant
    254
  • 1.4 Filling with coolant
    257
  • 1.5 Checking filling quality of cooling system
    270
  • 1.6 Checking electric vacuum pump VAS 6096/2
    272
  • 1.7 Flushing cooling system
    273
  • 2 Coolant pump, regulation of cooling system
    297
  • 2.1 Assembly overview - coolant pump, thermostat
    297
  • 2.2 Assembly overview - electric coolant pump
    301
  • 2.3 Assembly overview - coolant temperature sender
    307
  • 2.4 Removing and installing electric coolant pump
    310
  • 2.5 Removing and installing coolant pump
    328
  • 2.6 Removing and installing thermostat
    328
  • 2.7 Checking thermostat
    332
  • 2.8 Removing and installing coolant valve for cylinder head N489
    333
  • 2.9 Removing and installing coolant temperature sender G62
    333
  • 2.10 Removing and installing radiator outlet coolant temperature sender G83
    335
  • 3 Coolant pipes
    337
  • 3.1 Assembly overview - coolant pipes
    337
  • 3.2 Removing and installing coolant pipes
    339
  • 4 Radiator, radiator fan
    357
  • 4.1 Assembly overview - radiator/radiator fan
    357
  • 4.2 Assembly overview – radiator cowl and radiator fan
    363
  • 4.3 Removing and installing radiator
    364
  • 4.4 Removing and installing water radiator for charge air cooling circuit
    376
  • 4.5 Removing and installing radiator cowl
    382
  • 4.6 Removing and installing radiator fan
    388
  • Turbocharging/supercharging
    391
  • 1 Turbocharger
    391
  • 1.1 Assembly overview - turbocharger
    391
  • 1.2 Removing and installing turbocharger
    399
  • 1.3 Renewing vacuum unit for turbocharger
    415
  • 1.4 Removing and installing connection for turbocharger
    424
  • 2 Charge air system
    426
  • 2.1 Assembly overview - charge air system
    426
  • 2.2 Removing and installing charge pressure sender G31
    429
  • 2.3 Checking charge air system for leaks
    429
  • 2.4 Removing and installing air pipe
    432
  • 2.5 Checking charge air cooler for leaks
    434
  • Mixture preparation - injection
    441
  • 1 Injection system
    441
  • 1.1 Schematic overview - fuel system
    441
  • 1.2 Overview of fitting locations - injection system
    442
  • 1.3 Filling/bleeding fuel system
    452
  • 1.4 Checking fuel system for leaks
    453
  • 2 Vacuum system
    454
  • 2.1 Connection diagram – vacuum system
    454
  • 2.2 Checking vacuum system
    455
  • 3 Injectors/high-pressure accumulator (rail)
    456
  • 3.1 Assembly overview - injectors
    456
  • 3.2 Assembly overview - fuel rail
    458
  • 3.3 Adapting correction values for injectors
    459
  • 3.4 Testing injectors
    460
  • 3.5 Checking return flow rate of injectors with engine running
    461
  • 3.6 Checking return flow rate of injectors at starter speed
    467
  • 3.7 Testing jammed-open injectors
    471
  • 3.8 Removing and installing injectors
    473
  • 3.9 Removing and installing high-pressure lines
    478
  • 3.10 Removing and installing fuel rail
    481
  • 4 Air filter
    486
  • 4.1 Assembly overview - air filter housing
    486
  • 4.2 Removing and installing air filter housing
    488
  • 4.3 Removing and installing air guide on lock carrier
    491
  • 5 Intake manifold
    495
  • 5.1 Assembly overview – intake manifold
    495
  • 5.2 Removing and installing intake manifold
    499
  • 5.3 Removing and installing throttle valve module J338
    503
  • 6 Senders and sensors
    506
  • 6.1 Removing and installing fuel pressure regulating valve N276
    506
  • 6.2 Checking fuel pressure regulating valve N276
    513
  • 6.3 Removing and installing fuel pressure sender G247
    515
  • 6.4 Removing and installing air mass meter G70/intake air temperature sender G42
    516
  • 6.5 Removing and installing pressure differential sender G505
    518
  • 6.6 Removing and installing exhaust gas pressure sensor 1 G450
    522
  • 6.7 Removing and installing NOx sender 2 G687
    523
  • 6.10 Removing and installing fuel temperature sender G81
    526
  • 6.11 Removing and installing control unit for NOx sender GX30
    527
  • 7 Engine/motor control unit
    538
  • 7.1 Removing and installing engine control unit J623
    538
  • 7.2 Removing and installing engine control unit J623 (with protective housing)
    539
  • 8 High-pressure pump
    546
  • 8.1 Assembly overview - high-pressure pump
    546
  • 8.2 Removing and installing high-pressure pump
    546
  • 9 Lambda probe
    551
  • 9.1 Assembly overview - Lambda probe
    551
  • 9.2 Removing and installing Lambda probe
    553
  • Exhaust system
    557
  • 1 Exhaust pipes and silencers
    557
  • 1.1 Assembly overview – silencers
    557
  • 1.2 Assembly overview - front exhaust pipe
    561
  • 1.3 Removing and installing front exhaust pipe
    565
  • 1.4 Separating exhaust pipes from silencers
    567
  • 1.5 Removing and installing silencer
    568
  • 1.6 Aligning exhaust system free of stress
    574
  • 1.7 Checking exhaust system for leaks
    575
  • 1.8 Installation position of clamp
    575
  • 1.9 Align end exhaust pipes
    577
  • 1.10 Removing and installing bracket for front exhaust pipe
    577
  • 2 Emission control
    579
  • 2.1 Assembly overview – emission control
    579
  • 2.2 Removing and installing catalytic converter
    585
  • 2.3 Removing and installing particulate filter
    587
  • 2.4 Removing and installing emission control module
    587
  • 2.5 Removing and installing exhaust flap control unit J883
    599
  • 3 SCR system (selective catalytic reduction)
    601
  • 3.1 Assembly overview – reducing agent tank
    601
  • 3.2 Assembly overview - reducing agent supply line
    609
  • 3.3 Assembly overview - delivery module for reducing agent
    613
  • 3.4 Assembly overview – filler tube for reducing agent tank
    613
  • 3.5 Removing and installing reducing agent tank
    615
  • 3.6 Removing and installing front section of reducing agent supply line
    628
  • 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
    659
  • 3.10 Assembly overview - injector for reducing agent
    666
  • 3.11 Draining reducing agent tank
    668
  • 3.12 Removing and installing rear section of reducing agent supply line
    671
  • 3.13 Removing and installing filler pipe for reducing agent tank
    678
  • 3.14 Disconnecting reducing agent supply line
    688
  • 3.15 SCR - resetting learnt values
    693
  • 4 Exhaust gas temperature regulation
    695
  • 4.1 Assembly overview – exhaust gas temperature regulation
    695
  • 4.2 Removing and installing exhaust gas temperature sender 1 G235
    697
  • 4.3 Removing and installing exhaust gas temperature sender 2 G448
    702
  • 4.4 Removing and installing exhaust gas temperature sender 3 G495
    705
  • 4.5 Removing and installing exhaust gas temperature sender 4 G648
    707
  • 5 Exhaust gas recirculation
    710
  • 5.1 Assembly overview – exhaust gas recirculation
    710
  • 5.2 Assembly overview - exhaust gas recirculation valve 1 GX5
    714
  • 5.3 Removing and installing exhaust gas recirculation cooler
    715
  • 5.4 Removing and installing exhaust gas recirculation valve 1 GX5
    723
  • 5.5 Removing and installing exhaust gas recirculation valve 2 GX6
    724
  • 5.6 Removing and installing exhaust gas recirculation temperature sensor G98
    725
  • 5.7 Checking exhaust gas recirculation cooler for leaks
    728
  • Glow plug system
    730
  • 1 Glow plug system
    730
  • 1.1 Assembly overview – glow plug system
    730
  • 1.2 Removing and installing glow plug
    732
  • 1.3 Removing and installing automatic glow period control unit J179
    735
  • 1.4 Removing and installing Hall sender G40
    735
  • 1.5 Removing and installing engine speed sender G28
    736
Manufacturer's designation 4-cylinder common rail (1.6 l and 2.0 l, 4 V, turbocharger, EA 288)
Manufacturer Volkswagen
Suitable for Tiguan (2016) / Tiguan RUS (2017) / Polo (2018) / T-Roc (2018 >) / T-Cross (2019 >)
Suitable car types AD1, AW1, A11, C11
Engine code DBGA, DFGA, DFHA, DDMA, DCYB, DGDB, DFGC, CRFD, CRGB, CYKC, DBGC, CRFZ, DGTC, DGTD, CRGA, DCYA, CYKB, DFGB, DFFA, DGTE
Category Reparaturanleitung

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