Name: 4-cylinder common rail engine (2.0 l, EA189 Gen II)
Brand: Volkswagen
SKU: CDG64f13408d18d
Price: 25.44 EUR
Availability: InStock

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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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