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

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

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

Original Volkswagen repair manual


36,04 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

18.143 KB

505 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing motor, Assembly mountings, Engine cover panel, Cylinder block (pulley end), Crankshaft, Pistons and conrods, Toothed belt drive, Valve gear, Inlet and exhaust valves, 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 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 regulations for 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 the SCR system
    4
  • 2.6 Safety precautions when working on exhaust system
    5
  • 3 Repair instructions
    7
  • 3.1 Rules for cleanliness
    7
  • 3.2 Foreign objects in engine
    8
  • 3.3 Checking vacuum system
    8
  • Removing and installing engine
    9
  • 1 Removing and installing motor
    9
  • 1.1 Removing motor
    9
  • 1.2 Separating engine and gearbox
    33
  • 1.3 Securing engine on engine and gearbox support
    38
  • 1.4 Installing engine
    40
  • 2 Assembly mountings
    44
  • 2.1 Assembly overview - assembly mountings
    44
  • 2.2 Supporting engine in installation position
    46
  • 2.3 Adjusting assembly mountings
    62
  • 3 Engine cover panel
    72
  • 3.1 Removing and installing engine cover
    72
  • Crankshaft group
    74
  • 1 Cylinder block (pulley end)
    74
  • 1.1 Assembly overview - poly V-belt drive
    74
  • 1.2 Removing and installing poly-V belt
    78
  • 1.3 Removing and installing tensioner for poly V-belt
    83
  • 1.4 Removing and installing bracket for ancillaries
    84
  • 1.5 Removing and installing engine bracket
    86
  • 1.6 Assembly overview - cylinder block (pulley end)
    102
  • 1.7 Renewing crankshaft oil seal - belt pulley end
    105
  • 1.8 Removing and installing sealing flange on pulley end
    108
  • 2 Cylinder block, gearbox end
    113
  • 2.1 Assembly overview - cylinder block, gearbox end
    113
  • 2.2 Removing and installing flywheel
    114
  • 2.3 Removing and installing sealing flange on gearbox side
    116
  • 3 Crankshaft
    127
  • 3.1 Assembly overview - crankshaft
    127
  • 3.2 Renewing needle bearing in crankshaft
    128
  • 3.3 Crankshaft dimensions
    130
  • 4 Pistons and conrods
    131
  • 4.1 Assembly overview - pistons and conrods
    131
  • 4.2 Separating new conrod
    136
  • 4.3 Measuring piston projection at TDC
    137
  • 4.4 Checking radial clearance of conrods
    139
  • Cylinder head, valve gear
    140
  • 1 Cylinder head
    140
  • 1.1 Assembly overview - cylinder head
    140
  • 1.2 Removing and installing cylinder head
    144
  • 1.3 Removing and installing cylinder head cover
    155
  • 1.4 Assembly overview - cylinder head cover
    159
  • 1.5 Removing and installing vacuum pump
    161
  • 1.6 Checking compression
    162
  • 2 Toothed belt drive
    164
  • 2.1 Assembly overview - toothed belt
    164
  • 2.2 Removing and installing toothed belt
    166
  • 3 Valve gear
    188
  • 3.1 Assembly overview - valve gear
    188
  • 3.2 Measuring axial play of camshaft
    190
  • 3.3 Measuring radial play of camshaft
    191
  • 3.4 Removing and installing camshaft
    192
  • 3.5 Removing and installing camshaft oil seal
    201
  • 3.6 Checking hydraulic compensation elements
    206
  • 3.7 Removing and installing valve stem seals
    207
  • 4 Inlet and exhaust valves
    216
  • 4.1 Valve dimensions
    216
  • 4.2 Reworking valve seats
    216
  • 4.3 Checking valve guides
    216
  • 4.4 Checking valves
    218
  • Lubrication
    219
  • 1 Sump, oil pump
    219
  • 1.1 Assembly overview - sump/oil pump
    219
  • 1.2 Removing and installing sump
    225
  • 1.3 Removing and installing oil pump
    230
  • 1.4 Removing and installing oil level and oil temperature sender
    233
  • 1.5 Engine oil:
    234
  • 2 Engine oil cooler
    235
  • 2.1 Assembly overview - engine oil cooler
    235
  • 2.2 Removing and installing engine oil cooler
    236
  • 3 Oil filter, oil pressure switch
    240
  • 3.1 Assembly overview - oil filter housing, oil pressure switch
    240
  • 3.2 Removing and installing oil pressure switch
    241
  • 3.3 Checking oil pressure
    242
  • 3.4 Checking oil pressure and oil pressure switch
    243
  • 3.5 Removing and installing oil filter housing
    244
  • 4 Balancer shaft module
    249
  • 4.1 Assembly overview - balancer shaft module
    249
  • 4.2 Removing and installing balance shaft module
    252
  • Cooling
    262
  • 1 Cooling system/coolant
    262
  • 1.1 Coolant hose connection diagram
    262
  • 1.2 Draining and adding coolant
    263
  • 1.3 Checking cooling system for leaks
    269
  • 2 Coolant pump, regulation of cooling system
    274
  • 2.1 Assembly overview - coolant pump, thermostat
    274
  • 2.2 Removing and installing coolant pump
    274
  • 2.3 Removing and installing 4/2-way valve with thermostat
    276
  • 2.4 Removing and installing coolant temperature sender
    282
  • 3 Coolant pipes
    286
  • 3.1 Assembly overview - coolant pipes
    286
  • 3.2 Removing and installing coolant pipes
    288
  • 4 Radiator, radiator fan
    300
  • 4.1 Assembly overview - radiator/radiator fan
    300
  • 4.2 Removing and installing radiator
    300
  • 4.3 Removing and installing radiator cowl with radiator fan
    302
  • Turbocharging/supercharging
    304
  • 1 Turbocharger
    304
  • 1.1 Assembly overview - turbocharger
    304
  • 1.2 Removing and installing turbocharger
    306
  • 1.3 Renewing vacuum unit for turbocharger
    311
  • 2 Charge air system
    318
  • 2.1 Assembly overview - charge air system
    318
  • 2.2 Assembly overview - charge-air hose connections
    319
  • 2.3 Removing and installing charge air cooler
    320
  • 2.4 Removing and installing charge pressure sender
    322
  • 2.5 Checking charge air system for leaks
    322
  • Mixture preparation - injection
    326
  • 1 Injection system
    326
  • 1.1 Schematic overview - fuel system
    326
  • 1.2 Filling/bleeding fuel system
    328
  • 1.3 Checking fuel system for leaks
    329
  • 2 Vacuum system
    330
  • 2.1 Assembly overview - vacuum system
    330
  • 2.2 Checking vacuum system
    330
  • 3 Injectors/high-pressure accumulator (rail)
    335
  • 3.1 Assembly overview - injectors
    335
  • 3.2 Adapting correction values for injectors
    338
  • 3.3 Testing jammed-open injectors
    339
  • 3.4 Checking return flow rate of injectors with engine running
    341
  • 3.5 Checking return flow rate of injectors at starter speed
    344
  • 3.6 Removing and installing injectors
    346
  • 3.7 Removing and installing high-pressure lines
    350
  • 3.8 Removing and installing fuel rail
    352
  • 4 Intake manifold
    356
  • 4.1 Assembly overview - intake manifold
    356
  • 4.2 Removing and installing intake manifold
    357
  • 4.3 Removing and installing throttle valve module
    361
  • 5 Air filter
    364
  • 5.1 Assembly overview - air filter housing
    364
  • 5.2 Removing and installing air filter housing
    366
  • 6 Senders and sensors
    368
  • 6.1 Checking fuel pressure regulating valve
    368
  • 6.2 Removing and installing fuel pressure regulating valve
    369
  • 6.3 Removing and installing fuel pressure sender
    371
  • 6.4 Removing and installing fuel temperature sender G81
    374
  • 6.5 Removing and installing differential pressure sensor
    375
  • 6.6 Removing and installing air mass meter
    377
  • 7 High-pressure pump
    378
  • 7.1 Assembly overview - high-pressure pump
    378
  • 7.2 Removing and installing high-pressure pump
    380
  • 8 Lambda probe
    385
  • 8.1 Removing and installing Lambda probe
    385
  • 9 Engine control unit
    387
  • 9.1 Removing and installing engine control unit
    387
  • 9.2 Removing and installing engine control unit with protective housing
    397
  • Exhaust system
    414
  • 1 Exhaust pipes and silencers
    414
  • 1.1 Assembly overview - silencers
    414
  • 1.2 Aligning exhaust system free of stress
    423
  • 1.3 Installation position of clamp
    424
  • 2 Emission control
    426
  • 2.1 Assembly overview - emission control
    426
  • 2.2 Removing and installing particulate filter
    430
  • 2.3 Removing and installing catalytic converter
    439
  • 3 SCR system (selective catalytic reduction)
    445
  • 3.1 Assembly overview - tank for reducing agent
    445
  • 3.2 Draining reducing agent tank
    446
  • 3.3 Removing and installing reducing agent tank
    450
  • 3.4 Assembly overview - reducing agent supply line
    453
  • 3.5 Removing and installing reducing agent supply line
    454
  • 3.6 Removing and installing injector for reducing agent
    457
  • 3.7 Assembly overview - delivery module for reducing agent
    458
  • 3.8 Removing and installing heater element (heater cup)
    460
  • 4 Exhaust gas temperature regulation
    465
  • 4.1 Assembly overview - exhaust gas temperature regulation
    465
  • 4.2 Removing and installing exhaust gas temperature sender
    467
  • 5 Exhaust gas recirculation
    473
  • 5.1 Assembly overview - exhaust gas recirculation
    473
  • 5.2 Removing and installing exhaust gas recirculation cooler
    475
  • 5.3 Checking changeover for exhaust gas recirculation cooler
    478
  • 5.4 Checking exhaust gas recirculation cooler for leaks
    479
  • 5.5 Cleaning exhaust gas recirculation system
    484
  • Glow plug system
    492
  • 1 Glow plug system
    492
  • 1.1 Removing and installing glow plug
    492
  • 1.2 Removing and installing automatic glow period control unit
    494
  • 1.3 Removing and installing Hall sender
    495
  • 1.4 Removing and installing engine speed sender
    497
Manufacturer's designation 4-cylinder common rail engine (2.0 l, EA189 Gen II)
Manufacturer Volkswagen
Suitable for Touran (2003 - 2011) / Tiguan (2008) / Passat CC (2009) / Scirocco (2008) / Golf (2009) / Golf Plus (2009) / Passat/Passat Variant (2011 >) / EOS (2011)
Suitable car types 1T, 357, 137, 5K1, 521, 362, 365, 1F8
Engine code CFFA, CFFB, CLJA, CFHB, CFHC, CFJA, CLCA, CFHF, CFFD, CLLA, CFGC, CFJB
Category Reparaturanleitung

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