Name: 4-cylinder common rail engine (2.0 l, 4V, turbocharger, EA 288)
Brand: Volkswagen
SKU: CDG76b1b81ce37c
Price: 37.82 EUR
Availability: InStock

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Repair manual Golf Cabriolet / Scirocco GP 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
1
1.4 Safety precautions when working on the cooling system
2
1.5 Safety precautions when working on exhaust system
2
2 Identification
4
2.1 Motor number/motor data
4
3 Repair instructions
6
3.1 Rules for cleanliness
6
3.2 Foreign objects in engine
6
3.3 Contact corrosion
6
3.4 Routing and attachment of lines
7
3.5 Fitting radiator and condensers
7
4 Technical data
9
4.1 Coolant
10
Removing and installing engine
12
1 Removing and installing engine
12
1.1 Removing engine
12
1.2 Separating engine and gearbox
23
1.3 Securing engine on engine and gearbox support
28
1.4 Installing engine
30
2 Assembly mountings
35
2.1 Assembly overview - assembly mountings
35
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
44
2.6 Adjusting assembly mountings
49
2.7 Checking adjustment of assembly mountings
52
3 Engine cover panel
53
3.1 Removing and installing engine cover
53
Crankshaft group
54
1 Cylinder block (pulley end)
54
1.1 Assembly overview - cylinder block (pulley end)
54
1.2 Removing and installing poly-V belt
56
1.3 Removing and installing tensioner for poly V-belt
58
1.4 Removing and installing vibration damper
59
1.5 Removing and installing engine support
59
1.6 Removing and installing bracket for ancillaries
61
1.7 Assembly overview - sealing flange, belt pulley end
63
1.8 Removing and installing sealing flange on pulley end
64
1.9 Renewing caps in cylinder block (pulley end)
67
2 Cylinder block, gearbox end
69
2.1 Assembly overview - cylinder block, gearbox end
69
2.2 Removing and installing flywheel
70
2.3 Removing and installing sealing flange on gearbox side
73
2.4 Renewing caps in cylinder block (gearbox end)
84
3 Crankshaft
86
3.1 Assembly overview - crankshaft
86
3.2 Crankshaft dimensions
87
3.3 Measuring axial clearance of crankshaft
88
3.4 Renewing needle bearing in crankshaft
89
4 Pistons and conrods
92
4.1 Assembly overview - pistons and conrods
92
4.2 Removing and installing pistons
96
4.3 Measuring piston projection at TDC
97
4.4 Checking pistons and cylinder bores
100
4.5 Checking radial clearance of conrods
102
Cylinder head, valve gear
103
1 Toothed belt drive
103
1.1 Assembly overview - toothed belt cover
103
1.2 Assembly overview - toothed belt
104
1.3 Removing and installing toothed belt guard
106
1.4 Removing toothed belt from camshaft
112
1.5 Removing and installing toothed belt
116
2 Cylinder head
131
2.1 Assembly overview - cylinder head cover
131
2.2 Assembly overview - cylinder head
133
2.3 Removing and installing cylinder head cover
137
2.4 Removing and installing cylinder head
140
2.5 Removing and installing injector seals
152
2.6 Checking compression
153
2.7 Removing and installing camshaft housing
155
3 Valve gear
163
3.1 Assembly overview - valve gear
163
3.2 Measuring axial play of camshaft
167
3.3 Removing and installing camshaft oil seal
168
3.4 Removing and installing camshaft adjuster
170
3.5 Removing and installing camshaft control valve 1 N205
177
3.6 Checking hydraulic compensation elements
177
3.7 Removing and installing valve stem seals
178
4 Inlet and exhaust valves
189
4.1 Checking valve guides
189
4.2 Checking valves
190
4.3 Valve dimensions
190
Lubrication
191
1 Sump, oil pump
191
1.1 Assembly overview - sump/oil pump
191
1.2 Removing and installing oil level and oil temperature sender G266
194
1.3 Removing and installing oil sump
195
1.4 Removing and installing oil pump
199
1.5 Engine oil:
200
2 Engine oil cooler
201
3 Oil filter, oil pressure switch
202
3.1 Assembly overview - oil filter housing, oil pressure switch
202
3.2 Removing and installing oil filter housing
204
3.3 Removing and installing oil pressure switch F1
207
3.4 Removing and installing oil pressure switch for reduced oil pressure F378
209
3.5 Removing and installing oil pressure regulating valve N428
211
3.6 Checking oil pressure
212
Cooling
213
1 Cooling system/coolant
213
1.1 Connection diagram - coolant hoses
213
1.2 Checking cooling system for leaks
219
1.3 Draining coolant
222
1.4 Filling with coolant
224
1.5 Checking filling quality of cooling system
236
1.6 Checking electric vacuum pump VAS 6096/2
238
1.7 Flushing cooling system
239
2 Coolant pump, regulation of cooling system
263
2.1 Assembly overview - coolant pump, thermostat
263
2.2 Assembly overview - electric coolant pump
267
2.3 Assembly overview - coolant temperature sender
272
2.4 Removing and installing electric coolant pump
273
2.5 Removing and installing coolant pump
288
2.6 Removing and installing thermostat
289
2.7 Checking thermostat
293
2.8 Removing and installing coolant valve for cylinder head N489
293
2.9 Removing and installing coolant temperature sender G62
294
3 Coolant pipes
296
3.1 Assembly overview - coolant pipes
296
3.2 Removing and installing coolant pipes
298
4 Radiator, radiator fan
314
4.1 Assembly overview - radiator/radiator fan
314
4.2 Assembly overview – radiator cowl and radiator fan
318
4.3 Removing and installing radiator
320
4.4 Removing and installing water radiator for charge air cooling circuit
321
4.5 Removing and installing radiator cowl
324
4.6 Removing and installing radiator fan
325
Turbocharging/supercharging
327
1 Turbocharger
327
1.1 Assembly overview - turbocharger
327
1.2 Removing and installing turbocharger
330
1.3 Renewing vacuum unit for turbocharger
336
1.4 Removing and installing connecting piece
344
2 Charge air system
346
2.1 Assembly overview - charge air system
346
2.2 Removing and installing charge pressure sender G31
349
2.3 Checking charge air system for leaks
349
2.4 Removing and installing air pipe
352
2.5 Checking charge air cooler for leaks
353
Mixture preparation - injection
358
1 Injection system
358
1.1 Overview of fitting locations - injection system
358
1.2 Schematic overview - fuel system
364
1.3 Filling/bleeding fuel system
366
1.4 Checking fuel system for leaks
366
2 Vacuum system
368
2.1 Connection diagram – vacuum system
368
2.2 Checking vacuum system
369
3 Injectors/high-pressure accumulator (rail)
370
3.1 Assembly overview - injectors
370
3.2 Assembly overview - fuel rail
372
3.3 Adapting correction values for injectors
373
3.4 Testing injectors
374
3.5 Checking return flow rate of injectors with engine running
375
3.6 Checking return flow rate of injectors at starter speed
378
3.7 Testing jammed-open injectors
379
3.8 Removing and installing injectors
381
3.9 Removing and installing high-pressure lines
385
3.10 Removing and installing fuel rail
388
4 Air filter
390
4.1 Assembly overview - air filter housing
390
4.2 Removing and installing air filter housing
392
5 Intake manifold
396
5.1 Assembly overview – intake manifold
396
5.2 Removing and installing intake manifold
400
5.3 Removing and installing throttle valve module J338
404
6 Senders and sensors
408
6.1 Removing and installing fuel pressure regulating valve N276
408
6.2 Checking fuel pressure regulating valve N276
412
6.3 Removing and installing fuel pressure sender G247
414
6.4 Removing and installing air mass meter G70
415
6.5 Removing and installing pressure differential sender G505
417
6.6 Removing and installing exhaust gas pressure sensor 1 G450
418
6.9 Removing and installing fuel temperature sender G81
420
7 Engine control unit
423
7.1 Removing and installing engine control unit J623
423
7.2 Removing and installing engine (motor) control unit J623 with protective housing
427
8 High-pressure pump
436
8.1 Assembly overview - high-pressure pump
436
8.2 Removing and installing high-pressure pump
437
9 Lambda probe
442
9.1 Assembly overview - Lambda probe
442
9.2 Removing and installing Lambda probe
445
Exhaust system
450
1 Exhaust pipes and silencers
450
1.1 Assembly overview – silencers
450
1.2 Removing and installing front exhaust pipe
456
1.3 Separating exhaust pipes from silencers
457
1.4 Removing and installing rear silencer
459
1.5 Aligning exhaust system free of stress
460
1.6 Checking exhaust system for leaks
462
1.7 Installation position of clamp
462
1.8 Align end exhaust pipes
466
2 Emission control
467
2.1 Assembly overview – emission control
467
2.2 Removing and installing emission control module
472
2.3 Removing and installing catalytic converter
490
2.4 Removing and installing exhaust flap control unit J883
490
3 Exhaust gas temperature regulation
492
3.1 Assembly overview – exhaust gas temperature regulation
492
3.2 Removing and installing exhaust gas temperature sender 1 G235
496
3.3 Removing and installing exhaust gas temperature sender 2 G448
498
3.4 Removing and installing exhaust gas temperature sender 3 G495
503
3.5 Removing and installing exhaust gas temperature sender 4 G648
509
4 Exhaust gas recirculation
515
4.1 Assembly overview – exhaust gas recirculation
515
4.2 Assembly overview - exhaust gas recirculation valve 1 GX5
517
4.3 Removing and installing exhaust gas recirculation cooler
518
4.4 Removing and installing exhaust gas recirculation valve 1 GX5
521
4.5 Removing and installing exhaust gas recirculation valve 2 GX6
523
4.6 Checking exhaust gas recirculation cooler for leaks
524
Glow plug system
525
1 Glow plug system
525
1.1 Assembly overview – glow plug system
525
1.2 Removing and installing glow plug
526
1.3 Removing and installing automatic glow period control unit J179
530
1.4 Removing and installing Hall sender G40
530
1.5 Removing and installing engine speed sender G28
531

Manufacturer's designation	4-cylinder common rail engine (2.0 l, 4V, turbocharger, EA 288)
Manufacturer	Volkswagen
Suitable for	Golf Cabriolet (2012) / Scirocco GP (2015)
Suitable car types	517, 138
Engine code	CUUB, CUWA, CUXA
Category	Reparaturanleitung

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