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  • 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 Golf Cabriolet / Passat CC

Original Volkswagen repair manual


33,61 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

19.022 KB

460 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), Lambda probe, Intake manifold and SCR system (selective catalytic reduction). Show more
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Repair manual Golf Cabriolet / Passat CC 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
    7
  • 3.3 Checking vacuum system
    7
  • Removing and installing engine
    8
  • 1 Removing and installing motor
    8
  • 1.1 Removing motor
    8
  • 1.2 Separating engine and gearbox
    31
  • 1.3 Securing engine on engine and gearbox support
    36
  • 1.4 Installing engine
    38
  • 2 Assembly mountings
    42
  • 2.1 Assembly overview - assembly mountings
    42
  • 2.2 Supporting engine in installation position
    43
  • 2.3 Adjusting assembly mountings
    48
  • 3 Engine cover panel
    50
  • 3.1 Removing and installing engine cover
    50
  • Crankshaft group
    52
  • 1 Cylinder block (pulley end)
    52
  • 1.1 Assembly overview - poly V-belt drive
    52
  • 1.2 Removing and installing poly-V belt
    56
  • 1.3 Removing and installing tensioner for poly V-belt
    61
  • 1.4 Removing and installing bracket for ancillaries
    61
  • 1.5 Removing and installing engine bracket
    64
  • 1.6 Assembly overview - cylinder block (pulley end)
    72
  • 1.7 Removing and installing sealing flange on pulley end
    74
  • 1.8 Renewing crankshaft oil seal - belt pulley end
    77
  • 2 Cylinder block, gearbox end
    81
  • 2.1 Assembly overview - cylinder block, gearbox end
    81
  • 2.2 Removing and installing flywheel
    82
  • 2.3 Removing and installing sealing flange on gearbox side
    84
  • 3 Crankshaft
    97
  • 3.1 Assembly overview - crankshaft
    97
  • 3.2 Renewing needle bearing in crankshaft
    98
  • 3.3 Crankshaft dimensions
    101
  • 4 Pistons and conrods
    102
  • 4.1 Assembly overview - pistons and conrods
    102
  • 4.2 Measuring piston projection at TDC
    107
  • 4.3 Separating new conrod
    109
  • 4.4 Checking radial clearance of conrods
    110
  • Cylinder head, valve gear
    111
  • 1 Cylinder head
    111
  • 1.1 Assembly overview - cylinder head
    111
  • 1.2 Removing and installing cylinder head
    115
  • 1.3 Assembly overview - cylinder head cover
    125
  • 1.4 Removing and installing cylinder head cover
    127
  • 1.5 Removing and installing vacuum pump
    131
  • 1.6 Checking compression
    133
  • 2 Toothed belt drive
    136
  • 2.1 Assembly overview - toothed belt
    136
  • 2.2 Removing and installing toothed belt
    138
  • 3 Valve gear
    161
  • 3.1 Assembly overview - valve gear
    161
  • 3.2 Measuring axial play of camshaft
    163
  • 3.3 Measuring radial play of camshaft
    164
  • 3.4 Removing and installing camshaft oil seal
    165
  • 3.5 Removing and installing camshaft
    172
  • 3.6 Checking hydraulic compensation elements
    181
  • 3.7 Removing and installing valve stem seals
    182
  • 4 Inlet and exhaust valves
    191
  • 4.1 Valve dimensions
    191
  • 4.2 Reworking valve seats
    191
  • 4.3 Checking valve guides
    191
  • 4.4 Checking valves
    193
  • Lubrication
    194
  • 1 Sump, oil pump
    194
  • 1.1 Assembly overview - sump/oil pump
    194
  • 1.2 Removing and installing sump
    200
  • 1.3 Removing and installing oil level and oil temperature sender
    204
  • 1.4 Removing and installing oil pump
    206
  • 1.5 Engine oil:
    207
  • 2 Engine oil cooler
    209
  • 2.1 Assembly overview - engine oil cooler
    209
  • 2.2 Removing and installing engine oil cooler
    210
  • 3 Oil filter, oil pressure switch
    213
  • 3.1 Assembly overview - oil filter
    213
  • 3.2 Removing and installing oil filter housing
    214
  • 3.3 Removing and installing oil pressure switch
    218
  • 3.4 Checking oil pressure and oil pressure switch
    219
  • 4 Balancer shaft module
    222
  • 4.1 Assembly overview - balancer shaft module
    222
  • 4.2 Removing and installing balance shaft module
    225
  • Cooling
    235
  • 1 Cooling system/coolant
    235
  • 1.1 Coolant hose connection diagram
    235
  • 1.2 Checking cooling system for leaks
    236
  • 1.3 Draining and adding coolant
    240
  • 2 Coolant pump, regulation of cooling system
    247
  • 2.1 Assembly overview - coolant pump, thermostat
    247
  • 2.2 Removing and installing coolant pump
    247
  • 2.3 Removing and installing 4/2-way valve with thermostat
    249
  • 2.4 Electric coolant pump
    255
  • 2.5 Removing and installing coolant temperature sender
    260
  • 3 Coolant pipes
    265
  • 3.1 Assembly overview - coolant pipes
    265
  • 3.2 Removing and installing coolant pipes
    267
  • 4 Radiator, radiator fan
    279
  • 4.1 Assembly overview - radiator/radiator fan
    279
  • 4.2 Removing and installing radiator
    279
  • 4.3 Removing and installing radiator cowl with radiator fan
    282
  • 4.4 Removing and installing radiator fan
    283
  • Turbocharging/supercharging
    285
  • 1 Turbocharger
    285
  • 1.1 Assembly overview - turbocharger
    285
  • 1.2 Removing and installing turbocharger
    287
  • 1.3 Renewing vacuum unit for turbocharger
    295
  • 2 Charge air system
    302
  • 2.1 Assembly overview - charge air system
    302
  • 2.2 Removing and installing charge air cooler
    303
  • 2.3 Assembly overview - charge-air hose connections
    305
  • 2.4 Removing and installing charge pressure sender
    306
  • 2.5 Checking charge air system for leaks
    307
  • Mixture preparation - injection
    311
  • 1 Injection system
    311
  • 1.1 Schematic overview - fuel system
    311
  • 1.2 Filling/bleeding fuel system
    313
  • 1.3 Checking fuel system for leaks
    314
  • 2 Injectors/high-pressure accumulator (rail)
    315
  • 2.1 Assembly overview - injectors
    315
  • 2.2 Adapting correction values for injectors
    318
  • 2.3 Testing jammed-open injectors
    319
  • 2.4 Removing and installing injectors
    321
  • 2.5 Removing and installing fuel rail
    325
  • 2.6 Removing and installing high-pressure lines
    329
  • 3 High-pressure pump
    334
  • 3.1 Assembly overview - high-pressure pump
    334
  • 3.2 Removing and installing high-pressure pump
    336
  • 4 Senders and sensors
    342
  • 4.1 Checking fuel pressure regulating valve
    342
  • 4.2 Removing and installing fuel pressure regulating valve
    343
  • 4.3 Removing and installing fuel pressure sender
    345
  • 4.4 Removing and installing air mass meter
    348
  • 4.5 Removing and installing NOx sender 2 G687
    349
  • 4.6 Removing and installing differential pressure sensor
    349
  • 5 Lambda probe
    351
  • 5.1 Removing and installing Lambda probe
    351
  • 6 Vacuum system
    353
  • 6.1 Vacuum hose connection diagram
    353
  • 6.2 Checking vacuum system
    354
  • 7 Air filter
    357
  • 7.1 Assembly overview - air filter housing
    357
  • 7.2 Removing and installing air filter housing
    359
  • 8 Intake manifold
    362
  • 8.1 Assembly overview - intake manifold
    362
  • 8.2 Removing and installing intake manifold
    363
  • 8.3 Removing and installing throttle valve module
    368
  • 9 Engine control unit
    370
  • 9.1 Removing and installing engine control unit
    370
  • Exhaust system
    375
  • 1 Exhaust pipes and silencers
    375
  • 1.1 Assembly overview - silencers
    375
  • 1.2 Aligning exhaust system free of stress
    378
  • 1.3 Installation position of clamp
    379
  • 2 Emission control
    381
  • 2.1 Assembly overview - emission control
    381
  • 2.2 Removing and installing particulate filter
    384
  • 2.3 Removing and installing catalytic converter
    393
  • 3 SCR system (selective catalytic reduction)
    399
  • 3.1 Assembly overview - tank for reducing agent
    399
  • 3.2 Draining reducing agent tank
    400
  • 3.3 Removing and installing reducing agent tank
    404
  • 3.4 Assembly overview - delivery module for reducing agent
    407
  • 3.5 Removing and installing heater element (heater cup)
    409
  • 3.6 Assembly overview - reducing agent supply line
    414
  • 3.7 Removing and installing reducing agent supply line
    415
  • 3.8 Removing and installing injector for reducing agent
    418
  • 4 Exhaust gas temperature regulation
    420
  • 4.1 Assembly overview - exhaust gas temperature regulation
    420
  • 4.2 Removing and installing parts of exhaust gas temperature regulation
    422
  • 5 Exhaust gas recirculation
    429
  • 5.1 Assembly overview - exhaust gas recirculation
    429
  • 5.2 Checking changeover for exhaust gas recirculation cooler
    431
  • 5.3 Removing and installing exhaust gas recirculation cooler
    431
  • 5.4 Checking exhaust gas recirculation cooler for leaks
    434
  • 5.5 Cleaning exhaust gas recirculation system
    440
  • Glow plug system
    448
  • 1 Glow plug system
    448
  • 1.1 Removing and installing glow plug
    448
  • 1.2 Removing and installing automatic glow period control unit
    450
  • 1.3 Removing and installing Hall sender
    451
  • 1.4 Removing and installing engine speed sender
    452
Manufacturer's designation 4-cylinder common rail engine (2.0 l, EA189 Gen II)
Manufacturer Volkswagen
Suitable for Golf Cabriolet (2012) / Passat CC (2009)
Suitable car types 517, 358
Engine code CFFA, CFFB, CFHC, CLLA, CFGC
Category Reparaturanleitung

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