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  • Examplepage for repair manual 4-cylinder common rail engine (1.6 l, EA189)
  • Examplepage for repair manual 2 4-cylinder common rail engine (1.6 l, EA189)
  • Examplepage for repair manual 3 4-cylinder common rail engine (1.6 l, EA189)

4-cylinder common rail engine (1.6 l, EA189)

For Touran / Passat / Passat Variant / Golf / Golf Plus / Polo A05 / Passat/Passat Variant / Golf Cabriolet

Original Volkswagen repair manual


38,41 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

25.542 KB

552 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), Lambda probe, Intake manifold and Exhaust gas temperature regulation. Show more
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Repair manual 4-cylinder common rail engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Identification
    1
  • 1.1 Engine number/engine data
    1
  • 2 Safety information
    3
  • 2.1 Safety measures when working on fuel supply
    3
  • 2.3 Safety measures when working on vehicles with a start/stop system
    4
  • 2.4 Safety precautions when working on the cooling system
    4
  • 2.5 Safety precautions when working on exhaust system
    5
  • 3 Repair notes
    6
  • 3.1 Rules for cleanliness
    6
  • 3.2 Checking vacuum system
    7
  • Removing and installing engine
    8
  • 1 Removing and installing engine
    8
  • 1.1 Removing engine
    8
  • 1.2 Separating engine and gearbox
    48
  • 1.3 Securing engine on engine and gearbox support
    50
  • 1.4 Installing engine
    51
  • 2 Assembly mountings
    60
  • 2.1 Assembly overview - assembly mountings
    60
  • 2.2 Supporting engine in installation position
    66
  • 2.3 Adjusting assembly mountings
    72
  • 3 Engine cover panel
    76
  • 3.1 Removing and installing engine cover
    76
  • Crankshaft group
    77
  • 1 Cylinder block (pulley end)
    77
  • 1.1 Assembly overview - poly V-belt drive
    77
  • 1.2 Removing and installing poly-V belt
    80
  • 1.3 Removing and installing tensioner for poly V-belt
    84
  • 1.4 Removing and installing vibration damper
    88
  • 1.5 Removing and installing bracket for ancillaries
    89
  • 1.6 Renewing crankshaft oil seal - belt pulley end
    91
  • 1.7 Removing and installing sealing flange on pulley end
    92
  • 1.8 Removing and installing engine bracket
    95
  • 2 Cylinder block, gearbox end
    110
  • 2.1 Assembly overview - cylinder block, gearbox end
    110
  • 2.2 Removing and installing flywheel
    111
  • 2.3 Removing and installing sealing flange on gearbox side
    112
  • 3 Crankshaft
    122
  • 3.1 Assembly overview - crankshaft
    122
  • 3.2 Renewing needle bearing in crankshaft
    123
  • 3.3 Crankshaft dimensions
    125
  • 3.4 Measuring axial clearance of crankshaft
    125
  • 3.5 Measuring radial clearance of crankshaft
    125
  • 4 Pistons and conrods
    127
  • 4.1 Assembly overview - pistons and conrods
    127
  • 4.2 Removing and installing pistons
    130
  • 4.3 Measuring piston projection at “TDC”
    131
  • 4.4 Separating new conrod
    133
  • 4.5 Checking radial clearance of conrods
    134
  • Cylinder head, valve gear
    135
  • 1 Cylinder head
    135
  • 1.1 Assembly overview - cylinder head
    135
  • 1.2 Removing and installing cylinder head
    138
  • 1.3 Assembly overview - cylinder head cover
    167
  • 1.4 Removing and installing cylinder head cover
    168
  • 1.5 Removing and installing vacuum pump
    176
  • 1.6 Checking compression
    177
  • 2 Toothed belt drive
    179
  • 2.1 Assembly overview - toothed belt
    179
  • 2.2 Removing and installing toothed belt
    184
  • 3 Valve gear
    199
  • 3.1 Assembly overview - valve gear
    199
  • 3.2 Measuring axial play of camshaft
    200
  • 3.3 Measuring radial play of camshaft
    201
  • 3.4 Removing and installing camshaft oil seal
    202
  • 3.5 Removing and installing camshaft
    204
  • 3.6 Checking hydraulic compensation elements
    211
  • 3.7 Removing and installing valve stem seal
    212
  • 4 Inlet and exhaust valves
    219
  • 4.1 Valve dimensions
    219
  • 4.2 Reworking valve seats
    219
  • 4.3 Checking valve guides
    219
  • 4.4 Checking valves
    219
  • Lubrication
    220
  • 1 Sump, oil pump
    220
  • 1.1 Assembly overview - sump/oil pump
    220
  • 1.2 Removing and installing sump
    222
  • 1.3 Removing and installing oil level and oil temperature sender G 266
    227
  • 1.4 Removing and installing oil pump
    228
  • 1.5 Engine oil:
    229
  • 2 Engine oil cooler
    231
  • 2.1 Assembly overview - engine oil cooler
    231
  • 2.2 Removing and installing engine oil cooler
    232
  • 2.3 Checking engine oil cooler for leaks
    234
  • 3 Oil filter, oil pressure switch
    237
  • 3.1 Assembly overview - oil filter housing
    237
  • 3.2 Removing and installing oil filter housing
    238
  • 3.3 Checking oil pressure and oil pressure switch
    241
  • 3.4 Removing and installing oil pressure switch F1
    244
  • 4 Oil circuit
    246
  • 4.1 Assembly overview - oil circuit
    246
  • 4.2 Removing and installing oil supply line
    248
  • 4.3 Oil spray jets/nozzles
    254
  • Cooling
    255
  • 1 Cooling system/coolant
    255
  • 1.1 Coolant hose connection diagram
    255
  • 1.2 Checking cooling system for leaks
    259
  • 1.3 Draining and adding coolant
    261
  • 2 Coolant pump, regulation of cooling system
    266
  • 2.1 Assembly overview - coolant pump, thermostat
    266
  • 2.2 Removing and installing coolant pump
    269
  • 2.3 Removing and installing thermostat
    270
  • 2.4 Checking thermostat
    273
  • 2.5 Removing and installing 4/2-way valve with thermostat
    273
  • 2.6 Electric coolant pump
    279
  • 2.7 Removing and installing coolant temperature sender
    283
  • 3 Coolant pipes
    288
  • 3.1 Assembly overview - coolant pipes
    288
  • 3.2 Removing and installing coolant pipes
    290
  • 4 Radiator, radiator fan
    306
  • 4.1 Assembly overview - radiator/radiator fan
    306
  • 4.2 Removing and installing radiator
    309
  • 4.3 Removing and installing radiator cowl with radiator fan
    314
  • Turbocharging/supercharging
    318
  • 1 Turbocharger
    318
  • 1.1 Assembly overview - turbocharger
    318
  • 1.2 Removing and installing turbocharger
    324
  • 1.3 Renewing vacuum unit for turbocharger
    347
  • 2 Charge air system
    355
  • 2.1 Assembly overview - charge air system
    355
  • 2.2 Removing and installing charge air cooler
    359
  • 2.3 Assembly overview - charge-air hose connections
    363
  • 2.4 Checking charge air system for leaks
    366
  • Mixture preparation - injection
    369
  • 1 Injection system
    369
  • 1.1 Schematic overview - fuel system
    369
  • 1.2 Assembly overview - fuel system
    374
  • 1.3 Filling/bleeding fuel system
    386
  • 1.4 Checking fuel system for leaks
    386
  • 2 Vacuum system
    388
  • 2.1 Connection diagram - vacuum system
    388
  • 3 Injectors/high-pressure accumulator (rail)
    392
  • 3.1 Assembly overview - injectors
    392
  • 3.2 Adapting correction values for injectors
    393
  • 3.3 Testing jammed-open injectors
    393
  • 3.4 Check pressure retention valve in fuel return line
    395
  • 3.5 Removing and installing injectors
    397
  • 3.6 Removing and installing fuel rail
    402
  • 3.7 Removing and installing high-pressure lines
    406
  • 4 High-pressure pump
    413
  • 4.1 Assembly overview - high-pressure pump
    413
  • 4.2 Removing and installing high-pressure pump
    414
  • 5 Senders and sensors
    420
  • 5.1 Removing and installing fuel pressure regulating valve N 276
    420
  • 5.2 Checking fuel pressure regulating valve N276
    422
  • 5.3 Removing and installing fuel pressure sender G 247
    423
  • 5.4 Checking fuel pressure sender G 247
    425
  • 5.5 Checking fuel metering valve N 290
    425
  • 5.6 Removing and installing pressure differential sender G505
    426
  • 6 Lambda probe
    432
  • 6.1 Assembly overview - Lambda probe
    432
  • 6.2 Removing and installing Lambda probe
    436
  • 7 Air filter
    439
  • 7.1 Assembly overview - air filter housing
    439
  • 7.2 Removing and installing air filter housing
    441
  • 8 Intake manifold
    445
  • 8.1 Assembly overview - intake manifold
    445
  • 8.2 Removing and installing intake manifold
    447
  • 8.3 Removing and installing throttle valve module J338
    451
  • 9 Engine control unit
    453
  • 9.1 Removing and installing engine control unit
    453
  • Exhaust system
    468
  • 1 Exhaust pipes and silencers
    468
  • 1.1 Assembly overview - silencers
    468
  • 1.2 Aligning exhaust system free of stress
    473
  • 1.3 Installation position of clamp
    475
  • 2 Emission control
    476
  • 2.1 Assembly overview - emission control
    476
  • 2.2 Removing and installing particulate filter
    484
  • 2.3 Removing and installing catalytic converter
    505
  • 3 Exhaust gas temperature regulation
    510
  • 3.1 Assembly overview - exhaust gas temperature regulation
    510
  • 3.2 Removing and installing parts of exhaust gas temperature regulation
    513
  • 4 Exhaust gas recirculation
    524
  • 4.1 Assembly overview - exhaust gas recirculation
    524
  • 4.2 Checking changeover for exhaust gas recirculation cooler
    525
  • 4.3 Removing and installing exhaust gas recirculation cooler
    526
  • 4.4 Checking exhaust gas recirculation cooler for leaks
    531
  • 4.5 Cleaning exhaust gas recirculation system
    534
  • Glow plug system
    541
  • 1 Glow plug system
    541
  • 1.1 Removing and installing glow plug
    541
  • 1.2 Checking glow plugs
    543
  • 1.3 Removing and installing Hall sender G40
    543
  • 1.4 Removing and installing engine speed sender G 28
    545
Manufacturer's designation 4-cylinder common rail engine (1.6 l, EA189)
Manufacturer Volkswagen
Suitable for Touran (2003 - 2011) / Passat / Passat Variant (2005 - 2008) / Golf (2009) / Golf Plus (2009) / Polo A05 (2010) / Passat/Passat Variant (2011 >) / Golf Cabriolet (2012)
Suitable car types 1T, 5K1, 521, 6R1, 362, 365, 517
Engine code CAYB, CAYA
Category Reparaturanleitung

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