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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)

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

For Sharan

Original Volkswagen repair manual


25,44 €7% VAT incl.

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Language: English

Digital PDF file

16.313 KB

326 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Pistons and conrods, Crankshaft, Cylinder head, Engine oil:, Oil filter bracket and engine oil cooler, Safety regulations for working on fuel supply, Repair instructions if tank has been filled with incorrect fuel, Exhaust turbocharger, Charge air system, High-pressure pump, Injectors, Lambda probe and pressure differential sender and SCR system (selective catalytic reduction). Show more
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Repair manual Sharan 4-cylinder common rail engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Technical data
    1
  • 1.1 Engine number
    1
  • 1.2 Engine data
    1
  • 2 Safety information
    3
  • 2.1 Safety regulations for working on fuel supply
    3
  • 2.2 Safety measures when working on vehicles with a start/stop system
    3
  • 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
  • Removing and installing engine
    7
  • 1 Removing and installing engine
    7
  • 1.1 Removing and installing engine cover
    7
  • 1.2 Removing engine
    7
  • 1.3 Separating engine from gearbox
    14
  • 1.4 Separating engine from dual clutch gearbox
    16
  • 1.5 Securing engine to assembly stand
    18
  • 1.6 Installing engine
    20
  • 1.7 Assembly mountings
    22
  • 1.8 Adjusting assembly mountings
    23
  • Crankshaft group
    27
  • 1 Dismantling and assembling engine
    27
  • 1.1 Poly V-belt drive with tensioning element and air conditioner compressor
    27
  • 1.2 Poly V-belt drive with tensioning roller and air conditioner compressor
    30
  • 1.3 Poly V-belt drive without air conditioning compressor
    34
  • 1.4 Removing and installing bracket for ancillaries
    35
  • 1.5 Assembly overview - toothed belt drive
    36
  • 1.6 Removing and installing engine bracket
    38
  • 1.7 Assembly overview - crankcase
    42
  • 2 Removing and installing sealing flange and flywheel
    44
  • 2.1 Assembly overview - Sealing flange, belt pulley end
    44
  • 2.2 Renewing crankshaft oil seal - pulley end
    45
  • 2.3 Removing and installing sealing flange - pulley end
    47
  • 2.4 Assembly overview - Dual-mass flywheel and sealing flange
    49
  • 2.5 Removing and installing dual-mass flywheel
    51
  • 2.6 Renewing crankshaft sealing flange - flywheel end
    52
  • 2.7 Removing and installing engine speed sender G28
    59
  • 3 Pistons and conrods
    61
  • 3.1 Assembly overview - pistons and conrods
    61
  • 3.2 Piston and cylinder dimensions
    64
  • 3.3 Separating new conrods
    64
  • 3.4 Bearing shells - installation position
    65
  • 3.5 Piston and cylinder dimensions
    65
  • 3.6 Checking piston projection at TDC
    65
  • 3.7 Measuring radial clearance of conrods
    67
  • 4 Crankshaft
    69
  • 4.1 Assembly overview - crankshaft
    69
  • 4.2 Crankshaft dimensions
    69
  • 4.3 Renewing needle bearing in crankshaft
    70
  • Cylinder head, valve gear
    72
  • 1 Cylinder head
    72
  • 1.1 Assembly overview - cylinder head cover
    72
  • 1.2 Removing and installing cylinder head cover
    74
  • 1.3 Removing, installing and tensioning toothed belt
    77
  • 1.4 Assembly overview - cylinder head
    84
  • 1.5 Removing and installing cylinder head
    86
  • 1.6 Removing and installing vacuum pump
    95
  • 1.7 Compression test
    96
  • 2 Valve gear
    98
  • 2.1 Assembly overview - valve gear
    98
  • 2.2 Removing and installing camshafts
    101
  • 2.3 Measuring axial clearance of camshaft
    108
  • 2.4 Measuring radial clearance of camshafts
    109
  • 2.5 Removing and installing camshaft oil seal
    109
  • 2.6 Checking hydraulic compensation elements
    112
  • 2.7 Renewing valve stem seals with cylinder head installed
    112
  • 2.8 Renewing valve stem seals with cylinder head removed
    116
  • 2.9 Valves
    119
  • Lubrication
    121
  • 1 Engine oil:
    121
  • 1.1 Oil capacities
    121
  • 1.2 Checking engine oil level
    121
  • 2 Parts of lubrication system
    122
  • 2.1 Assembly overview - oil pump, sump, balance shaft module
    122
  • 2.2 Removing and installing oil level and oil temperature sender G266
    126
  • 2.3 Removing and installing oil sump
    126
  • 2.4 Removing and installing oil pump
    130
  • 2.5 Removing balancer shaft module
    131
  • 2.6 Installing a new balancer shaft module
    133
  • 2.7 Installing a previously used balancer shaft module again
    135
  • 3 Oil filter bracket and engine oil cooler
    137
  • 3.1 Assembly overview - oil filter bracket and engine oil cooler
    137
  • 3.2 Removing and installing oil filter bracket with engine oil cooler
    138
  • 3.3 Removing and installing oil pressure switch F1
    141
  • 3.4 Checking oil pressure switch F1
    142
  • 3.5 Checking oil pressure
    143
  • Cooling
    145
  • 1 Parts of cooling system
    145
  • 1.1 Assembly overview - parts of cooling system, body side
    145
  • 1.2 Assembly overview - parts of cooling system, engine side
    147
  • 1.3 Assembly overview - coolant pump and thermostat
    148
  • 1.4 Coolant hose connection diagram
    149
  • 2 Repairing cooling system
    150
  • 2.2 Removing and installing radiator
    151
  • 2.3 Removing and installing coolant pump
    152
  • 2.4 Removing and installing 4/2-way valve with thermostat
    154
  • 2.5 Draining and adding coolant
    159
  • 2.6 Coolant pipes, coolant temperature sender
    163
  • 2.7 Checking cooling system for leaks
    174
  • Fuel supply system
    178
  • 1 Safety regulations for working on fuel supply
    178
  • 2 Rules for cleanliness
    179
  • 3 Repair instructions if tank has been filled with incorrect fuel
    180
  • 3.1 Step 1 (Engine was started with incorrect fuel)
    180
  • 3.2 Step 2 (Engine was not started with incorrect fuel)
    181
  • 3.3 Step 3 (There are filings in fuel delivery unit and fuel tank)
    182
  • 3.4 Step 4 (There are no filings in fuel delivery unit and fuel tank)
    182
  • 3.5 Step 5 (There are filings in high-pressure pump)
    183
  • 3.6 Step 6 (There are no filings in high-pressure pump)
    183
  • 4 Parts of fuel supply system
    184
  • 4.1 Assembly overview - fuel tank
    184
  • 4.2 Assembly overview - fuel delivery unit, fuel gauge sender and suction jet pump
    185
  • 4.3 Removing and installing fuel delivery unit
    186
  • 4.4 Removing and installing fuel gauge sender G
    188
  • 4.5 Emptying fuel tank
    189
  • 4.6 Removing and installing fuel tank
    192
  • 5 Repairing fuel supply
    194
  • 5.1 Assembly overview - fuel filter
    194
  • 5.2 Removing and installing fuel filter
    195
  • 5.3 Checking fuel system pressurisation pump G6
    196
  • 5.4 Assembly overview - accelerator mechanism
    200
  • 5.5 Removing and installing accelerator pedal module
    201
  • Turbocharging/supercharging
    204
  • 1 Exhaust turbocharger
    204
  • 1.1 Safety precautions
    204
  • 1.2 Rules for cleanliness
    204
  • 1.3 Assembly overview - turbocharger
    205
  • 1.4 Removing and installing turbocharger
    207
  • 1.5 Replacing vacuum unit with position sender for charge pressure positioner G581
    211
  • 2 Charge air system
    217
  • 2.1 Installing hose connections with plug-in connectors
    217
  • 2.2 Installing hose connections with corrugated pipe connection
    218
  • 2.3 Assembly overview - parts of charge air cooling
    218
  • 2.4 Removing and installing charge air cooler
    219
  • 2.5 Checking charge air system for leaks
    220
  • 2.6 Vacuum hose connection diagram
    224
  • 2.7 Checking vacuum system
    224
  • Mixture preparation - injection
    228
  • 1 Diesel direct injection system
    228
  • 1.1 Safety precautions
    228
  • 1.2 Rules for cleanliness
    228
  • 1.3 System layout
    229
  • 2 High-pressure pump
    231
  • 2.1 Assembly overview - high-pressure pump
    231
  • 2.2 Removing and installing high-pressure pump
    232
  • 2.3 Filling/bleeding fuel system
    235
  • 2.4 Checking for leaks in the fuel system
    236
  • 3 Injectors
    237
  • 3.1 Assembly overview - injectors
    237
  • 3.2 Carrying out adaptation for injector delivery calibration
    240
  • 3.3 Checking for injectors sticking open
    241
  • 3.4 Removing and installing injectors
    242
  • 3.5 Installing high-pressure lines
    246
  • 3.6 Checking fuel pressure regulating valve N276
    247
  • 3.7 Removing and installing fuel pressure regulating valve N276
    249
  • 3.8 Removing and installing fuel pressure sender G247
    250
  • 3.9 Removing and installing fuel rail
    252
  • 4 Intake manifold
    256
  • 4.1 Assembly overview - intake manifold with attachments
    256
  • 4.2 Removing and installing throttle valve module J338
    257
  • 4.3 Removing and installing intake manifold
    258
  • 5 Air filter
    262
  • 5.1 Assembly overview - air filter
    262
  • 5.2 Removing and installing air filter housing
    263
  • 5.3 Removing and installing air mass meter G70
    265
  • 6 Lambda probe and pressure differential sender
    266
  • 6.1 Removing and installing Lambda probe G39 with Lambda probe heater Z19
    266
  • 6.2 Removing and installing pressure differential sender G505
    267
  • 7 Engine (motor) control unit
    269
  • 7.1 Removing and installing engine (motor) control unit J623
    269
  • 7.2 Removing and installing anti-theft engine control unit J623
    270
  • Exhaust system
    272
  • 1 Front exhaust pipe with particulate filter
    272
  • 1.1 Assembly overview - front exhaust pipe with particulate filter
    272
  • 1.2 Removing and installing particulate filter
    274
  • 2 Silencer
    282
  • 2.1 Assembly overview - silencers
    282
  • 2.2 Aligning exhaust system free of stress
    283
  • 2.3 Installation position and specified torque of clamp
    283
  • 3 Exhaust gas temperature regulation
    285
  • 3.1 Assembly overview - exhaust gas temperature regulation
    285
  • 3.2 Removing and installing exhaust gas temperature sender 1 G235
    286
  • 3.3 Removing and installing exhaust gas temperature sender 3 G495
    287
  • 3.4 Removing and installing exhaust gas temperature sender 4 G648
    289
  • 4 SCR system (selective catalytic reduction)
    290
  • 4.1 Assembly overview - reduction catalytic converter
    290
  • 4.2 Assembly overview - tank for reducing agent
    292
  • 4.3 Removing and installing heater element (heater cup)
    293
  • 4.4 Removing and installing injector for reduction agent N474
    297
  • 4.5 Draining reducing agent tank
    298
  • 4.6 Removing and installing reducing agent tank
    300
  • 5 Exhaust gas recirculation system
    304
  • 5.1 Assembly overview - exhaust gas recirculation
    304
  • 5.2 Checking changeover for exhaust gas recirculation cooler
    305
  • 5.3 Removing and installing exhaust gas recirculation cooler
    305
  • 5.4 Checking exhaust gas recirculation cooler for leaks
    308
  • 5.5 Cleaning exhaust gas recirculation system
    312
  • Glow plug system
    318
  • 1 Checking glow plug system
    318
  • 1.1 Removing and installing glow plugs
    318
  • 1.2 Removing and installing automatic glow period control unit J179
    320
Manufacturer's designation 4-cylinder common rail engine (2.0 l, EA189 Gen II)
Manufacturer Volkswagen
Suitable for Sharan (2011)
Suitable car types 7N1
Engine code CFFA, CFFB, CFFE, CFGC
Category Reparaturanleitung

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