Name: 4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288)
Brand: Volkswagen
SKU: CDG55a1404660f1
Price: 42.14 EUR
Availability: InStock

Content
Details
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Repair manual 4-cylinder common rail 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
1.2 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
7
3.1 Rules for cleanliness
7
3.2 Foreign objects in engine
7
3.3 Contact corrosion
7
3.4 Routing and attachment of lines
8
3.5 Fitting radiator and condensers
8
Removing and installing engine
9
1 Removing and installing engine
9
1.1 Removing engine
9
1.2 Separating engine and gearbox
21
1.3 Securing engine on engine and gearbox support
24
1.4 Installing engine
25
2 Assembly mountings
30
2.1 Assembly overview - assembly mountings
30
2.2 Removing and installing engine mounting
34
2.3 Removing and installing gearbox mounting
36
2.4 Removing and installing pendulum support
40
2.5 Supporting engine in installation position
41
2.6 Adjusting assembly mountings
58
2.7 Checking adjustment of assembly mountings
61
3 Engine cover panel
62
3.1 Removing and installing engine cover
62
Crankshaft group
63
1 Cylinder block (pulley end)
63
1.1 Assembly overview - cylinder block (pulley end)
63
1.2 Assembly overview - sealing flange, belt pulley end
66
1.3 Removing and installing poly-V belt
68
1.4 Removing and installing tensioner for poly V-belt
69
1.5 Removing and installing vibration damper
70
1.6 Removing and installing bracket for ancillaries
71
1.7 Removing and installing engine support
73
1.8 Removing and installing sealing flange on pulley end
75
1.9 Renewing caps in cylinder block (pulley end)
78
2 Cylinder block, gearbox end
81
2.1 Assembly overview - cylinder block, gearbox end
81
2.2 Removing and installing flywheel
84
2.3 Removing and installing sealing flange on gearbox side
86
2.4 Renewing caps in cylinder block (gearbox end)
96
3 Crankshaft
98
3.1 Assembly overview - crankshaft
98
3.2 Crankshaft dimensions
98
3.3 Renewing needle bearing in crankshaft
98
3.4 Measuring axial clearance of crankshaft
101
4 Pistons and conrods
103
4.1 Assembly overview - pistons and conrods
103
4.2 Removing and installing pistons
106
4.3 Measuring piston projection at TDC
108
4.4 Checking pistons and cylinder bores
110
4.5 Separating new conrod
112
4.6 Checking radial clearance of conrods
113
Cylinder head, valve gear
114
1 Cylinder head
114
1.1 Assembly overview - cylinder head
114
1.2 Assembly overview - cylinder head cover
118
1.3 Removing and installing cylinder head
121
1.4 Removing and installing cylinder head cover
128
1.5 Removing and installing injector seals
131
1.6 Removing and installing camshaft housing
133
1.7 Checking compression
137
2 Toothed belt drive
140
2.1 Assembly overview - toothed belt cover
140
2.2 Assembly overview - toothed belt
140
2.3 Removing and installing toothed belt guard
142
2.4 Removing and installing toothed belt
148
2.5 Removing toothed belt from camshaft
163
3 Valve gear
169
3.1 Assembly overview - valve gear
169
3.2 Measuring axial play of camshaft
172
3.3 Removing and installing camshaft oil seal
172
3.4 Checking hydraulic compensation elements
175
3.5 Removing and installing valve stem seals
176
4 Inlet and exhaust valves
184
4.1 Checking valve guides
184
4.2 Checking valves
185
4.3 Valve dimensions
185
Lubrication
186
1 Sump, oil pump
186
1.1 Assembly overview - sump/oil pump
186
1.2 Engine oil:
188
1.3 Removing and installing oil sump
188
1.4 Removing and installing oil pump
193
1.5 Removing and installing oil level and oil temperature sender G266
194
2 Engine oil cooler
196
3 Oil filter, oil pressure switch
197
3.1 Assembly overview - oil filter housing, oil pressure switch
197
3.2 Removing and installing oil pressure switch F1
199
3.3 Removing and installing oil pressure switch for reduced oil pressure F378
201
3.4 Checking oil pressure
203
3.5 Removing and installing oil filter housing
203
3.6 Removing and installing oil pressure regulating valve N428
206
Cooling
209
1 Cooling system/coolant
209
1.1 Connection diagram - coolant hoses
209
1.2 Checking cooling system for leaks
211
1.3 Draining coolant
215
1.4 Filling with coolant
217
1.5 Checking filling quality of cooling system
237
1.6 Flushing cooling system
239
2 Coolant pump, regulation of cooling system
264
2.1 Assembly overview - coolant pump, thermostat
264
2.2 Assembly overview - electric coolant pump
268
2.3 Assembly overview - coolant temperature sender
270
2.4 Assembly overview - actuator for engine temperature regulation N493
271
2.5 Removing and installing electric coolant pump
273
2.6 Removing and installing coolant pump
279
2.7 Removing and installing thermostat
280
2.8 Checking thermostat
284
2.9 Removing and installing coolant valve for cylinder head N489
285
2.10 Removing and installing coolant temperature sender G62
285
2.11 Removing and installing coolant temperature sender 2 G802
287
2.12 Removing and installing actuator for engine temperature regulation N493
289
3 Coolant pipes
296
3.1 Assembly overview - coolant pipes
296
3.2 Removing and installing coolant pipes
300
4 Radiator, radiator fan
325
4.1 Assembly overview - radiator/radiator fan
325
4.2 Assembly overview - auxiliary radiator
327
4.3 Assembly overview – radiator cowl and radiator fan
328
4.4 Removing and installing radiator
329
4.5 Removing and installing water radiator for charge air cooling circuit
332
4.6 Removing and installing radiator cowl
335
4.7 Removing and installing radiator fan
338
4.8 Removing and installing auxiliary radiator
339
Turbocharging/supercharging
343
1 Turbocharger
343
1.1 Assembly overview - turbocharger
343
1.2 Removing and installing turbocharger
356
1.3 Removing and installing vacuum unit for turbocharger
368
1.4 Removing and installing turbocharger 1 control unit J724
374
2 Charge air system
379
2.1 Assembly overview - charge air system
379
2.2 Removing and installing charge pressure sender G31
381
2.3 Removing and installing charge pressure sender 2 G447
381
2.4 Checking charge air system for leaks
382
2.5 Removing and installing air pipe
384
2.6 Checking charge air cooler for leaks
391
Mixture preparation - injection
397
1 Injection system
397
1.1 Schematic overview - fuel system
397
1.2 Overview of fitting locations - injection system
398
1.3 Filling/bleeding fuel system
412
1.4 Checking fuel system for leaks
412
2 Vacuum system
414
2.1 Connection diagram – vacuum system
414
2.2 Checking vacuum system
417
3 Injectors/high-pressure accumulator (rail)
419
3.1 Assembly overview - injectors
419
3.2 Assembly overview - fuel rail
421
3.3 Adapting correction values for injectors
423
3.4 Testing injectors
424
3.5 Checking return flow rate of injectors with engine running
424
3.6 Checking return flow rate of injectors at starter speed
427
3.7 Removing and installing injectors
429
3.8 Removing and installing high-pressure lines
433
3.9 Removing and installing fuel rail
439
4 Air filter
443
4.1 Assembly overview - air filter housing
443
4.2 Removing and installing air filter housing
445
5 Intake manifold
449
5.1 Assembly overview – intake manifold
449
5.2 Removing and installing intake manifold
452
5.3 Removing and installing throttle valve module J338
458
6 Senders and sensors
461
6.1 Removing and installing fuel pressure regulating valve N276
461
6.2 Checking fuel pressure regulating valve N276
463
6.3 Removing and installing fuel pressure sender G247
465
6.4 Removing and installing air mass meter G70
466
6.5 Removing and installing pressure differential sender G505
468
6.6 Removing and installing exhaust gas pressure sensor 1 G450
469
6.9 Removing and installing fuel temperature sender G81
472
6.10 Removing and installing control unit for NOx sender GX30
473
6.11 Assembly overview - NOx sender control unit GX30
477
6.12 Removing and installing control unit 2 for NOx sender GX46
478
6.13 Removing and installing particle sensor G784
480
7 Engine control unit
482
7.1 Removing and installing engine control unit J623
482
8 High-pressure pump
490
8.1 Assembly overview - high-pressure pump
490
8.2 Removing and installing high-pressure pump
492
9 Lambda probe
496
9.1 Assembly overview - Lambda probe
496
9.2 Removing and installing Lambda probe
496
Exhaust system
499
1 Exhaust pipes and silencers
499
1.1 Assembly overview – silencers
499
1.2 Removing and installing front exhaust pipe
503
1.3 Removing and installing rear silencer
506
1.4 Aligning exhaust system free of stress
510
1.5 Checking exhaust system for leaks
510
1.6 Installation position of clamp
511
1.7 Assembly overview - front exhaust pipe
511
2 Emission control
518
2.1 Assembly overview – emission control
518
2.2 Removing and installing emission control module
525
2.3 Removing and installing exhaust flap control unit J883
529
3 SCR system (selective catalytic reduction)
532
3.1 Assembly overview – reducing agent tank
532
3.2 Assembly overview - reducing agent supply line
536
3.3 Assembly overview - delivery module for reducing agent
537
3.4 Removing and installing reducing agent tank
538
3.5 Removing and installing front section of reducing agent supply line
544
3.6 Removing and installing delivery module for reducing agent
559
3.7 Removing and installing injector for reduction agent N474
561
3.8 Removing and installing control unit for reducing-agent heater J891
564
3.9 Assembly overview - injector for reducing agent
568
3.10 Draining reducing agent tank
569
3.11 Removing and installing rear section of reducing agent supply line
576
3.12 Removing and installing filler pipe for reducing agent tank
578
3.13 Disconnecting reducing agent supply line
582
3.14 SCR - resetting learnt values
585
4 Exhaust gas temperature regulation
586
4.1 Assembly overview – exhaust gas temperature regulation
586
4.2 Removing and installing exhaust gas temperature sender 1 G235
588
4.3 Removing and installing exhaust gas temperature sender 2 G448
594
4.4 Removing and installing exhaust gas temperature sender 3 G495
596
4.5 Removing and installing exhaust gas temperature sender 4 G648
597
5 Exhaust gas recirculation
600
5.1 Assembly overview – exhaust gas recirculation
600
5.2 Removing and installing exhaust gas recirculation cooler
603
5.3 Removing and installing exhaust gas recirculation valve 1 GX5
609
5.4 Removing and installing exhaust gas recirculation valve 2 GX6
611
5.5 Checking exhaust gas recirculation cooler for leaks
614
6 Exhaust manifold
615
6.1 Assembly overview - exhaust manifold
615
6.2 Removing and installing exhaust manifold
616
Glow plug system
618
1 Glow plug system
618
1.1 Assembly overview – glow plug system
618
1.2 Removing and installing glow plug
619
1.3 Removing and installing automatic glow period control unit J179
623
1.4 Removing and installing Hall sender G40
623
1.5 Removing and installing engine speed sender G28
624

Manufacturer's designation	4-cylinder common rail engine (2.0 l, 4V, bi-turbo, EA 288)
Manufacturer	Volkswagen
Suitable for	Passat Lim (2015 >) / Passat Var. (2015 >) / Tiguan (2016) / Arteon () / Passat Variant (2019 >) / Passat Limousine (2019 >) / Arteon (2021 >) / Arteon Shooting Brake (2021 >)
Suitable car types	3G2, AD1, 3H7, CB5, CB2, 3H8, 3H9
Engine code	CUAA
Category	Reparaturanleitung

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