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  • Examplepage for repair manual 4-cylinder common rail engine (2.0 l, EA189)
  • Examplepage for repair manual 2 4-cylinder common rail engine (2.0 l, EA189)
  • Examplepage for repair manual 3 4-cylinder common rail engine (2.0 l, EA189)

4-cylinder common rail engine (2.0 l, EA189)

For Passat / Passat Variant / EOS / Tiguan / Passat CC / Scirocco / Golf / Golf Plus

Original Volkswagen repair manual


29,70 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

16.043 KB

393 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, Exhaust turbocharger, Injectors/high-pressure accumulator (rail), Intake manifold, Lambda probe and SCR system (selective catalytic reduction). 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 precautions when working on fuel system
    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 the SCR system
    5
  • 2.6 Safety precautions when working on exhaust system
    5
  • 3 Repair notes
    7
  • 3.1 Rules for cleanliness
    7
  • 3.2 Foreign objects in engine
    7
  • 3.3 Checking vacuum system
    8
  • Removing and installing engine
    9
  • 1 Removing and installing engine
    9
  • 1.1 Removing and installing engine
    9
  • 1.2 Securing engine on engine and gearbox support
    22
  • 1.3 Installing engine
    23
  • 2 Assembly mountings
    27
  • 2.1 Assembly overview - assembly mountings
    27
  • 2.2 Supporting engine in installation position
    28
  • 2.3 Adjusting assembly mountings
    36
  • 3 Engine cover panel
    41
  • 3.1 Removing and installing engine cover
    41
  • Crankshaft group
    42
  • 1 Cylinder block (pulley end)
    42
  • 1.1 Assembly overview - poly V-belt drive
    42
  • 1.2 Removing and installing poly-V belt
    46
  • 1.3 Removing and installing tensioner for poly V-belt
    50
  • 1.4 Removing and installing bracket for ancillaries
    51
  • 1.5 Removing and installing engine bracket
    53
  • 1.6 Assembly overview - cylinder block (pulley end)
    63
  • 1.7 Removing and installing sealing flange on pulley end
    64
  • 1.8 Renewing crankshaft oil seal - belt pulley end
    66
  • 2 Cylinder block, gearbox end
    69
  • 2.1 Assembly overview - cylinder block, gearbox end
    69
  • 2.2 Removing and installing sealing flange on gearbox side
    70
  • 3 Crankshaft
    79
  • 3.1 Assembly overview - crankshaft
    79
  • 3.2 Renewing needle bearing in crankshaft
    79
  • 3.3 Crankshaft dimensions
    82
  • 4 Pistons and conrods
    83
  • 4.1 Assembly overview - pistons and conrods
    83
  • 4.2 Measuring piston projection at TDC
    86
  • 4.3 Separating new conrod
    87
  • Cylinder head, valve gear
    89
  • 1 Cylinder head
    89
  • 1.1 Assembly overview - cylinder head
    89
  • 1.2 Removing and installing cylinder head
    91
  • 1.3 Assembly overview - cylinder head cover
    100
  • 1.4 Removing and installing cylinder head cover
    101
  • 1.5 Removing and installing vacuum pump
    104
  • 1.6 Checking compression
    105
  • 2 Toothed belt drive
    107
  • 2.1 Assembly overview - toothed belt
    107
  • 2.2 Removing and installing toothed belt
    109
  • 3 Valve gear
    116
  • 3.1 Assembly overview - valve gear
    116
  • 3.2 Removing and installing camshaft oil seal
    117
  • 3.3 Removing and installing camshaft
    121
  • 3.4 Removing and installing valve stem seals
    128
  • 4 Inlet and exhaust valves
    133
  • 4.1 Valve dimensions
    133
  • 4.2 Reworking valve seats
    133
  • 4.3 Checking valve guides
    133
  • Lubrication
    134
  • 1 Sump, oil pump
    134
  • 1.1 Assembly overview - sump/oil pump
    134
  • 1.2 Removing and installing oil sump
    140
  • 1.3 Removing and installing oil pump
    143
  • 1.4 Engine oil:
    144
  • 2 Engine oil cooler
    146
  • 2.1 Assembly overview - engine oil cooler
    146
  • 3 Oil filter, oil pressure switch
    148
  • 3.1 Assembly overview - oil filter/oil pressure switch
    148
  • 3.2 Removing and installing oil filter housing
    149
  • 3.3 Checking oil pressure and oil pressure switch
    152
  • 4 Oil circuit
    154
  • 4.1 Removing and installing oil supply line for turbocharger
    154
  • 5 Balancer shaft module
    156
  • 5.1 Assembly overview - balancer shaft module
    156
  • 5.2 Removing and installing balance shaft module
    159
  • Cooling
    170
  • 1 Cooling system/coolant
    170
  • 1.1 Coolant hose connection diagram
    170
  • 1.2 Checking cooling system for leaks
    174
  • 1.3 Draining and adding coolant
    178
  • 1.4 Assembly overview - engine preheater
    182
  • 2 Coolant pump, regulation of cooling system
    186
  • 2.1 Removing and installing coolant pump
    186
  • 2.2 Removing and installing thermostat
    187
  • 2.3 Removing and installing 4/2-way valve with thermostat
    189
  • 3 Coolant pipes
    191
  • 3.1 Assembly overview - coolant pipes
    191
  • 4 Radiator, radiator fan
    195
  • 4.1 Assembly overview - radiator/radiator fan
    195
  • 4.2 Removing and installing radiator
    198
  • 4.3 Removing and installing radiator cowl with radiator fan
    199
  • Turbocharging/supercharging
    200
  • 1 Exhaust turbocharger
    200
  • 1.1 Assembly overview - turbocharger
    200
  • 1.2 Removing and installing turbocharger
    206
  • 1.3 Renewing vacuum unit for turbocharger
    210
  • 2 Charge air system
    218
  • 2.1 Assembly overview - charge air system
    218
  • 2.2 Assembly overview - charge-air hose connections
    220
  • 2.3 Checking charge air system for leaks
    221
  • Mixture preparation - injection
    224
  • 1 Injection system
    224
  • 1.1 Schematic overview - fuel system
    224
  • 1.2 Assembly overview - fuel system
    226
  • 1.3 Filling/bleeding fuel system
    229
  • 1.4 Checking fuel system for leaks
    230
  • 2 Injectors/high-pressure accumulator (rail)
    231
  • 2.1 Check pressure retention valve in fuel return line
    231
  • 2.2 Removing and installing injectors
    232
  • 2.3 Removing and installing high-pressure lines
    236
  • 2.4 Removing and installing fuel rail
    238
  • 3 Vacuum system
    242
  • 3.1 Assembly overview - vacuum system
    242
  • 3.2 Checking vacuum system
    243
  • 4 Air filter
    247
  • 4.1 Assembly overview - air filter housing
    247
  • 4.2 Removing and installing air filter housing
    249
  • 4.3 Checking changeover flap for intake air preheating
    250
  • 4.4 Removing and installing changeover flap for intake air preheating
    251
  • 5 Intake manifold
    254
  • 5.1 Assembly overview - intake manifold
    254
  • 5.2 Removing and installing intake manifold
    254
  • 6 Senders and sensors
    258
  • 6.1 Checking fuel pressure regulating valve
    258
  • 6.2 Removing and installing fuel pressure regulating valve N276
    259
  • 6.3 Removing and installing fuel pressure sender
    261
  • 7 High-pressure pump
    265
  • 7.1 Removing and installing high-pressure pump
    265
  • 8 Engine (motor) control unit
    269
  • 8.1 Removing and installing engine control unit
    269
  • 9 Lambda probe
    287
  • 9.1 Removing and installing lambda probe
    287
  • Exhaust system
    291
  • 1 Exhaust pipes and silencers
    291
  • 1.1 Assembly overview - silencers
    291
  • 1.2 Separating exhaust pipes from silencers
    299
  • 1.3 Aligning exhaust system free of stress
    301
  • 1.4 Check exhaust system for leaks
    303
  • 1.5 Installation position of clamp
    304
  • 2 Exhaust gas cleaning
    306
  • 2.1 Assembly overview - emission control
    306
  • 2.2 Removing and installing particulate filter
    316
  • 2.3 Removing and installing particulate filter with NOx storage catalytic converter
    324
  • 2.4 Removing and installing NOx storage catalytic converter
    332
  • 3 SCR system (selective catalytic reduction)
    334
  • 3.1 Assembly overview - tank for reducing agent
    334
  • 3.2 Draining reducing agent tank
    335
  • 3.3 Removing and installing reducing agent tank
    338
  • 3.4 Assembly overview - delivery module for reducing agent
    340
  • 3.5 Assembly overview - reducing agent delivery line
    342
  • 3.6 Removing and installing reducing agent supply line
    343
  • 3.7 Removing and installing injector for reducing agent
    345
  • 3.8 Removing and installing heater element (heater cup)
    346
  • 4 Exhaust gas recirculation
    351
  • 4.1 Assembly overview - exhaust gas recirculation
    351
  • 4.2 Removing and installing exhaust gas recirculation filter
    354
  • 4.3 Removing and installing exhaust gas recirculation cooler
    356
  • 4.4 Checking exhaust gas recirculation cooler for leaks
    360
  • 4.5 Removing and installing temperature sensor for exhaust gas recirculation
    363
  • 4.6 Cleaning exhaust gas recirculation system
    367
  • Glow plug system
    374
  • 1 Glow plug system
    374
  • 1.1 Removing and installing automatic glow period control unit J179
    374
  • 1.2 Removing and installing glow plug
    375
  • 1.3 Removing and installing Hall sender
    382
  • 1.4 Removing and installing engine speed sender
    386
Manufacturer's designation 4-cylinder common rail engine (2.0 l, EA189)
Manufacturer Volkswagen
Suitable for Passat / Passat Variant (2005 - 2008) / EOS (2006) / Tiguan (2008) / Passat CC (2009) / Scirocco (2008) / Golf (2009) / Golf Plus (2009)
Suitable car types 3C, 5N, 357, 137, 5K1, 521
Engine code CBBB, CBBA, CBAB, CBDB, CBDC, CBDA, CBAC, CJAA
Category Reparaturanleitung

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