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

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

For Tiguan / Passat CC / Sharan

Original Volkswagen repair manual


41,31 €7% VAT incl.

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  • English

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Language: English

Digital PDF file

55.795 KB

614 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 / Passat CC / Sharan 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 a start/stop system
    1
  • 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
    8
  • 3.1 Rules for cleanliness
    8
  • 3.2 Foreign objects in engine
    8
  • 3.3 Contact corrosion
    8
  • 3.4 Routing and attachment of lines
    9
  • 3.5 Fitting radiator and condensers
    9
  • 4 Technical data
    11
  • 4.1 Coolant
    12
  • Removing and installing engine
    14
  • 1 Removing and installing engine
    14
  • 1.1 Removing engine
    14
  • 1.2 Separating engine and gearbox
    26
  • 1.3 Securing engine on engine and gearbox support
    31
  • 1.4 Installing engine
    33
  • 2 Assembly mountings
    38
  • 2.1 Assembly overview - assembly mountings
    38
  • 2.2 Removing and installing engine mounting
    44
  • 2.3 Removing and installing gearbox mounting
    46
  • 2.4 Removing and installing pendulum support
    48
  • 2.5 Supporting engine in installation position
    49
  • 2.6 Adjusting assembly mountings
    59
  • 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
    65
  • 1.3 Removing and installing poly-V belt
    67
  • 1.4 Removing and installing tensioner for poly V-belt
    68
  • 1.5 Removing and installing vibration damper
    69
  • 1.6 Removing and installing bracket for ancillaries
    70
  • 1.7 Removing and installing engine support
    72
  • 1.8 Removing and installing sealing flange on pulley end
    73
  • 1.9 Renewing caps in cylinder block (pulley end)
    76
  • 2 Cylinder block, gearbox end
    78
  • 2.1 Assembly overview - cylinder block, gearbox end
    78
  • 2.2 Removing and installing flywheel
    79
  • 2.3 Removing and installing sealing flange on gearbox side
    82
  • 2.4 Renewing caps in cylinder block (gearbox end)
    92
  • 3 Crankshaft
    94
  • 3.1 Assembly overview - crankshaft
    94
  • 3.2 Crankshaft dimensions
    95
  • 3.3 Renewing needle bearing in crankshaft
    96
  • 3.4 Measuring axial clearance of crankshaft
    99
  • 4 Pistons and conrods
    100
  • 4.1 Assembly overview - pistons and conrods
    100
  • 4.2 Removing and installing pistons
    104
  • 4.3 Measuring piston projection at TDC
    105
  • 4.4 Checking pistons and cylinder bores
    108
  • 4.5 Checking radial clearance of conrods
    110
  • Cylinder head, valve gear
    111
  • 1 Cylinder head
    111
  • 1.1 Assembly overview - cylinder head
    111
  • 1.2 Assembly overview - cylinder head cover
    115
  • 1.3 Removing and installing cylinder head
    117
  • 1.4 Removing and installing cylinder head cover
    128
  • 1.5 Removing and installing injector seals
    130
  • 1.6 Removing and installing camshaft housing
    131
  • 1.7 Checking compression
    138
  • 2 Toothed belt drive
    141
  • 2.1 Assembly overview - toothed belt cover
    141
  • 2.2 Assembly overview - toothed belt
    141
  • 2.3 Removing and installing toothed belt guard
    143
  • 2.4 Removing and installing toothed belt
    150
  • 2.5 Removing toothed belt from camshaft
    164
  • 3 Valve gear
    170
  • 3.1 Assembly overview - valve gear
    170
  • 3.2 Measuring axial play of camshaft
    174
  • 3.3 Removing and installing camshaft oil seal
    175
  • 3.4 Removing and installing camshaft control valve 1 N205
    177
  • 3.5 Removing and installing camshaft adjuster
    177
  • 3.6 Checking hydraulic compensation elements
    184
  • 3.7 Removing and installing valve stem seals
    185
  • 4 Inlet and exhaust valves
    196
  • 4.1 Checking valve guides
    196
  • 4.2 Checking valves
    197
  • 4.3 Valve dimensions
    197
  • Lubrication
    198
  • 1 Sump, oil pump
    198
  • 1.1 Assembly overview - sump/oil pump
    198
  • 1.2 Removing and installing sump
    200
  • 1.3 Engine oil:
    205
  • 1.4 Removing and installing oil pump
    205
  • 1.5 Removing and installing oil level and oil temperature sender G266
    206
  • 2 Engine oil cooler
    208
  • 3 Oil filter, oil pressure switch
    209
  • 3.1 Assembly overview - oil filter housing, oil pressure switch
    209
  • 3.2 Removing and installing oil pressure switch F1
    211
  • 3.3 Removing and installing oil pressure switch for reduced oil pressure F378
    213
  • 3.4 Checking oil pressure
    215
  • 3.5 Removing and installing oil filter housing
    215
  • 3.6 Removing and installing oil pressure regulating valve N428
    218
  • Cooling
    220
  • 1 Cooling system/coolant
    220
  • 1.1 Connection diagram - coolant hoses
    220
  • 1.2 Checking cooling system for leaks
    225
  • 1.3 Draining coolant
    228
  • 1.4 Filling with coolant
    232
  • 1.5 Checking filling quality of cooling system
    245
  • 1.6 Checking electric vacuum pump VAS 6096/2
    247
  • 1.7 Flushing cooling system
    248
  • 2 Coolant pump, regulation of cooling system
    272
  • 2.1 Assembly overview - coolant pump, thermostat
    272
  • 2.2 Assembly overview - electric coolant pump
    276
  • 2.3 Assembly overview - coolant temperature sender
    281
  • 2.4 Removing and installing electric coolant pump
    282
  • 2.5 Removing and installing coolant pump
    296
  • 2.6 Removing and installing thermostat
    296
  • 2.7 Checking thermostat
    300
  • 2.8 Removing and installing coolant valve for cylinder head N489
    301
  • 2.9 Removing and installing coolant temperature sender G62
    301
  • 3 Coolant pipes
    304
  • 3.1 Assembly overview - coolant pipes
    304
  • 3.2 Removing and installing coolant pipes
    306
  • 4 Radiator, radiator fan
    320
  • 4.1 Assembly overview - radiator/radiator fan
    320
  • 4.2 Assembly overview – radiator cowl and radiator fan
    325
  • 4.3 Removing and installing radiator
    326
  • 4.4 Removing and installing water radiator for charge air cooling circuit
    332
  • 4.5 Removing and installing radiator cowl
    337
  • 4.6 Removing and installing radiator fan
    341
  • Turbocharging/supercharging
    343
  • 1 Turbocharger
    343
  • 1.1 Assembly overview - turbocharger
    343
  • 1.2 Removing and installing turbocharger
    346
  • 1.3 Renewing vacuum unit for turbocharger
    352
  • 1.4 Removing and installing connection for turbocharger
    358
  • 2 Charge air system
    361
  • 2.1 Assembly overview - charge air system
    361
  • 2.2 Removing and installing charge pressure sender G31
    364
  • 2.3 Checking charge air system for leaks
    364
  • 2.4 Removing and installing air pipe
    367
  • 2.5 Checking charge air cooler for leaks
    368
  • Mixture preparation - injection
    374
  • 1 Injection system
    374
  • 1.1 Schematic overview - fuel system
    374
  • 1.2 Overview of fitting locations - injection system
    376
  • 1.3 Filling/bleeding fuel system
    382
  • 1.4 Checking fuel system for leaks
    383
  • 2 Vacuum system
    384
  • 2.1 Connection diagram – vacuum system
    384
  • 2.2 Checking vacuum system
    385
  • 3 Injectors/high-pressure accumulator (rail)
    386
  • 3.1 Assembly overview - injectors
    386
  • 3.2 Assembly overview - fuel rail
    388
  • 3.3 Adapting correction values for injectors
    389
  • 3.4 Testing injectors
    390
  • 3.5 Checking return flow rate of injectors with engine running
    391
  • 3.6 Checking return flow rate of injectors at starter speed
    394
  • 3.7 Testing jammed-open injectors
    396
  • 3.8 Removing and installing injectors
    397
  • 3.9 Removing and installing high-pressure lines
    401
  • 3.10 Removing and installing fuel rail
    404
  • 4 Air filter
    406
  • 4.1 Assembly overview - air filter housing
    406
  • 4.2 Removing and installing air filter housing
    410
  • 5 Intake manifold
    417
  • 5.1 Assembly overview – intake manifold
    417
  • 5.2 Removing and installing intake manifold
    421
  • 5.3 Removing and installing throttle valve module J338
    426
  • 6 Senders and sensors
    429
  • 6.1 Removing and installing fuel pressure regulating valve N276
    429
  • 6.2 Checking fuel pressure regulating valve N276
    433
  • 6.3 Removing and installing fuel pressure sender G247
    435
  • 6.4 Removing and installing air mass meter G70
    436
  • 6.5 Removing and installing pressure differential sender G505
    438
  • 6.6 Removing and installing exhaust gas pressure sensor 1 G450
    439
  • 6.9 Removing and installing fuel temperature sender G81
    441
  • 6.10 Removing and installing control unit for NOx sender GX30
    443
  • 6.11 Assembly overview - NOx sender control unit GX30
    446
  • 7 Engine control unit
    448
  • 7.1 Removing and installing engine control unit J623
    448
  • 7.2 Removing and installing engine (motor) control unit J623 with protective housing
    452
  • 8 High-pressure pump
    464
  • 8.1 Assembly overview - high-pressure pump
    464
  • 8.2 Removing and installing high-pressure pump
    465
  • 9 Lambda probe
    470
  • 9.1 Assembly overview - Lambda probe
    470
  • 9.2 Removing and installing Lambda probe
    473
  • Exhaust system
    479
  • 1 Exhaust pipes and silencers
    479
  • 1.1 Assembly overview – silencers
    479
  • 1.2 Removing and installing front exhaust pipe
    484
  • 1.3 Separating exhaust pipes from silencers
    485
  • 1.4 Removing and installing silencer
    488
  • 1.5 Aligning exhaust system free of stress
    492
  • 1.6 Checking exhaust system for leaks
    493
  • 1.7 Installation position of clamp
    494
  • 1.8 Assembly overview - front exhaust pipe
    498
  • 1.9 Align end exhaust pipes
    501
  • 2 Emission control
    502
  • 2.1 Assembly overview – emission control
    502
  • 2.2 Removing and installing emission control module
    508
  • 2.3 Removing and installing catalytic converter
    526
  • 2.4 Removing and installing exhaust flap control unit J883
    526
  • 3 SCR system (selective catalytic reduction)
    528
  • 3.1 Assembly overview – reducing agent tank
    528
  • 3.2 Assembly overview - reducing agent supply line
    531
  • 3.3 Assembly overview - delivery module for reducing agent
    532
  • 3.4 Removing and installing reducing agent tank
    533
  • 3.5 Removing and installing front section of reducing agent supply line
    540
  • 3.6 Removing and installing delivery module for reducing agent
    542
  • 3.7 Removing and installing injector for reduction agent N474
    545
  • 3.8 Removing and installing control unit for reducing-agent heater J891
    547
  • 3.9 Assembly overview - injector for reducing agent N474
    550
  • 3.10 Draining reducing agent tank
    551
  • 3.11 Removing and installing rear section of reducing agent supply line
    559
  • 3.12 Disconnecting reducing agent supply line
    561
  • 3.13 SCR - resetting learnt values
    564
  • 4 Exhaust gas temperature regulation
    565
  • 4.1 Assembly overview – exhaust gas temperature regulation
    565
  • 4.2 Removing and installing exhaust gas temperature sender 1 G235
    569
  • 4.3 Removing and installing exhaust gas temperature sender 2 G448
    571
  • 4.4 Removing and installing exhaust gas temperature sender 3 G495
    578
  • 4.5 Removing and installing exhaust gas temperature sender 4 G648
    583
  • 5 Exhaust gas recirculation
    589
  • 5.1 Assembly overview – exhaust gas recirculation
    589
  • 5.2 Assembly overview - exhaust gas recirculation valve 1 GX5
    591
  • 5.3 Removing and installing exhaust gas recirculation cooler
    592
  • 5.4 Removing and installing exhaust gas recirculation valve 1 GX5
    595
  • 5.5 Removing and installing exhaust gas recirculation valve 2 GX6
    597
  • 5.6 Checking exhaust gas recirculation cooler for leaks
    598
  • Glow plug system
    599
  • 1 Glow plug system
    599
  • 1.1 Assembly overview - glow plug system
    599
  • 1.2 Removing and installing glow plug
    600
  • 1.3 Removing and installing automatic glow period control unit J179
    604
  • 1.4 Removing and installing Hall sender G40
    604
  • 1.5 Removing and installing engine speed sender G28
    605
Manufacturer's designation 4-cylinder common rail engine (2.0 l, 4V, turbocharger, EA 288)
Manufacturer Volkswagen
Suitable for Tiguan (2008) / Passat CC (2009) / Sharan (2016 > )
Suitable car types 5N, 7N2
Engine code DLTA, DLTC, DLUB, CUWA, CUVE, CUVA, DFMA, DFLA, DFLD, DLUA
Category Reparaturanleitung

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