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  • Examplepage for repair manual 4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger)
  • Examplepage for repair manual 2 4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger)
  • Examplepage for repair manual 3 4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger)
  • Examplepage for repair manual 4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger)
  • Examplepage for repair manual 2 4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger)
  • Examplepage for repair manual 3 4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger)

4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger)

For Golf / Touran / Golf Plus / Tiguan

Original Volkswagen repair manual


27,01 €7% VAT incl.

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Language: English

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10.961 KB

350 Sites

Detailed technical data

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This repair manual contains: Removing and installing engine (Golf, Golf Plus, Touran), Crankshaft, Cylinder head, Repairing valve gear, Safety precautions, Fuel tank, Activated charcoal filter system, Exhaust turbocharger, Compressor and Engine control unit J623. Show more
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Repair manual Golf / Touran / Golf Plus / Tiguan 4-cylinder direct-injection 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
  • Removing and installing engine
    3
  • 1 Removing and installing engine (Golf, Golf Plus, Touran)
    3
  • 1.1 Removing engine
    3
  • 1.2 Securing engine to assembly stand
    13
  • 1.3 Installing engine
    13
  • 1.4 Specified torques
    15
  • 1.5 Assembly mountings
    16
  • 1.6 Additional information and assembly work for vehicles with air conditioner
    16
  • 2 Removing and installing engine (Tiguan)
    18
  • 2.1 Removing engine
    18
  • 2.2 Securing engine to assembly stand
    25
  • 2.3 Installing engine
    25
  • 2.4 Specified torques
    27
  • 2.5 Assembly mountings
    27
  • 2.6 Additional information and assembly work for vehicles with air conditioner
    28
  • Crankshaft group
    30
  • 1 Dismantling and assembling engine
    30
  • 1.1 Assembly overview - parts l and ll
    30
  • 1.2 Assembly overview - part I, belt drive
    31
  • 1.3 Assembly overview - part II, cylinder block
    33
  • 1.4 Removing and installing poly V-belt (engine codes BLG, BMY)
    36
  • 1.5 Removing and installing poly V-belt (engine code BWK)
    38
  • 1.6 Removing and installing control housing (Golf, Golf Plus)
    40
  • 1.7 Removing and installing valve timing housing (Tiguan, Touran)
    44
  • 1.8 Removing and installing bracket for ancillaries
    48
  • 2 Removing and installing sealing flanges and flywheel or drive plate
    50
  • 2.1 Assembly overview
    50
  • 2.2 Removing and installing engine speed sender G28
    51
  • 2.3 Removing and installing crankshaft seal on belt pulley end
    53
  • 2.4 Removing and installing crankshaft pulley
    55
  • 2.5 Removing and installing crankshaft sealing flange on flywheel end
    58
  • 3 Crankshaft
    67
  • 3.1 Assembly overview
    67
  • 3.2 Pulling needle bearing out of and driving into crankshaft
    68
  • 3.3 Crankshaft dimensions
    70
  • 4 Dismantling and assembling pistons and conrods
    71
  • 4.1 Assembly overview
    71
  • 4.2 Checking piston
    72
  • 4.3 Separating new conrod
    73
  • 4.4 Removing and installing pistons
    74
  • 4.5 Removing and installing oil spray jets
    75
  • Cylinder head, valve gear
    77
  • 1 Cylinder head
    77
  • 1.1 Assembly overview
    77
  • 1.2 Checking valve timing
    79
  • 1.3 Adjusting valve timing
    82
  • 1.4 Checking timing chain
    88
  • 1.5 Removing and installing timing chain and chain drive for oil pump
    94
  • 1.6 Removing and installing camshaft housing
    103
  • 1.7 Removing and installing cylinder head
    108
  • 1.8 Checking compression
    111
  • 2 Repairing valve gear
    114
  • 2.1 Assembly overview
    114
  • 2.2 Checking camshaft axial clearance
    115
  • 2.3 Reworking valve seats
    116
  • 2.4 Checking valve guides
    117
  • 2.5 Renewing valve stem seals
    118
  • Lubrication
    121
  • 1 Removing and installing parts of lubrication system
    121
  • 1.1 Engine oil, oil capacities, engine oil specification (engine codes BLG, BMY)
    121
  • 1.2 Engine oil, oil capacities, engine oil specification (engine code BWK)
    121
  • 1.3 Assembly overview
    121
  • 1.4 Removing and installing sump
    124
  • 1.5 Removing and installing oil pump
    126
  • 1.6 Checking oil pressure and oil pressure switch
    128
  • Cooling
    130
  • 1 Removing and installing parts of cooling system
    130
  • 1.2 Assembly overview - parts of cooling system, body side (engine code BWK)
    132
  • 1.3 Assembly overview - parts of cooling system, engine side
    133
  • 1.4 Coolant hose schematic diagram (engine codes BLG, BMY)
    135
  • 1.5 Coolant hose schematic diagram (engine code BWK)
    135
  • 1.6 Draining and adding coolant
    136
  • 1.7 Checking cooling system for leaks
    140
  • 1.9 Removing and installing radiator (engine codes BLG, BMY)
    142
  • 1.10 Removing and installing radiator and radiator fan V7 (engine code BWK)
    144
  • 1.11 Removing and installing coolant pump
    146
  • 1.12 Removing and installing coolant pump pulley
    151
  • 1.13 Removing and installing coolant circulation pump V50
    155
  • Fuel supply system
    158
  • 1 Safety precautions
    158
  • 1.1 Safety regulations for working on fuel supply
    158
  • 1.2 Releasing pressure in high-pressure area
    158
  • 2 Fuel tank
    160
  • 2.1 Fuel tank - assembly overview (Golf, Golf Plus)
    160
  • 2.2 Draining fuel tank (Golf, Golf Plus)
    161
  • 2.3 Removing and installing fuel tank (Golf, Golf Plus)
    164
  • 2.4 Assembly overview - fuel tank (Touran)
    165
  • 2.5 Draining fuel tank (Touran)
    167
  • 2.6 Removing and installing fuel tank (Touran)
    170
  • 2.7 Assembly overview - fuel tank (Tiguan)
    171
  • 2.8 Draining fuel tank (Tiguan)
    173
  • 2.9 Removing and installing fuel tank (Tiguan)
    176
  • 3 Removing and installing parts of fuel supply system
    180
  • 3.1 Rules for cleanliness
    180
  • 3.2 Crash fuel shut-off
    181
  • 3.3 Removing and installing fuel delivery unit (Golf, Golf Plus)
    181
  • 3.4 Removing and installing fuel gauge sender G (Golf, Golf Plus)
    183
  • 3.5 Checking fuel pumps (Golf, Golf Plus)
    184
  • 3.6 Removing and installing fuel delivery unit (Touran)
    195
  • 3.7 Removing and installing fuel gauge sender G (Touran)
    197
  • 3.8 Checking fuel pump (Touran)
    198
  • 3.9 Removing and installing fuel delivery unit (Tiguan)
    209
  • 3.10 Removing and installing fuel gauge sender G (Tiguan)
    212
  • 3.11 Removing and installing suction-jet pump (Tiguan)
    212
  • 3.12 Removing and installing fuel gauge sender 2 G169 (Tiguan)
    215
  • 3.13 Checking fuel pump (Tiguan)
    215
  • 3.14 Removing and installing fuel pump control unit J538 (Tiguan)
    223
  • 4 Repairing electronic power control (EPC)
    225
  • 4.1 Assembly overview
    225
  • 4.2 Removing and installing accelerator module (Golf, Golf Plus, Tiguan)
    225
  • 4.3 Removing and installing accelerator module (Touran)
    226
  • 5 Activated charcoal filter system
    229
  • 5.1 Assembly overview (Golf, Golf Plus)
    229
  • 5.2 Checking fuel tank breather (Golf, Golf Plus)
    230
  • 5.3 Checking fuel tank breather (Touran)
    231
  • 5.4 Assembly overview (Tiguan)
    232
  • 5.5 Checking fuel tank breather (Tiguan)
    233
  • Turbocharging/supercharging
    235
  • 1 Exhaust turbocharger
    235
  • 1.1 Assembly overview - turbocharger
    235
  • 1.2 Part I
    236
  • 1.3 Part II
    237
  • 1.4 Removing and installing turbocharger
    238
  • 1.5 Checking vacuum unit for turbocharger
    244
  • 1.6 Removing and installing vacuum unit for turbocharger
    246
  • 1.7 Adjusting vacuum unit for turbocharger
    247
  • 2 Compressor
    254
  • 2.1 Assembly overview - supercharger
    254
  • 2.2 Removing and installing compressor (engine codes BLG, BMY)
    255
  • 2.3 Removing and installing compressor (engine code BWK)
    263
  • 2.4 Removing and installing drive unit seal for supercharger
    271
  • 3 Charge air system
    275
  • 3.1 Assembly overview - charge air system
    275
  • 3.2 Fitting hose connections with plug-in connectors
    276
  • 3.3 Checking charge air system for leaks
    277
  • 3.4 Removing and installing charge air cooler (Golf, Golf Plus, Touran)
    281
  • 3.5 Removing and installing charge air cooler, Tiguan
    283
  • Mixture preparation - injection
    287
  • 1 Injection system
    287
  • 1.1 Assembly overview - parts l and II, intake manifold
    287
  • 1.2 Assembly overview - part I, intake manifold
    288
  • 1.3 Assembly overview - part II, intake manifold
    290
  • 1.4 Assembly overview - fuel rail with injectors
    292
  • 1.5 Checking vacuum reservoir for leaks
    294
  • 1.6 Assembly overview - air filter
    296
  • 1.7 Removing and installing air filter
    297
  • 1.8 Removing and installing regulating flap control unit J808 and throttle valve module J338
    298
  • 1.9 Cleaning throttle valve module J338
    302
  • 1.10 Assembly overview - high-pressure pump
    302
  • 1.11 Checking fuel pressure in high-pressure section
    303
  • 1.12 Removing and installing high-pressure pump
    307
  • 1.13 Removing and installing injectors
    311
  • 1.14 Renewing Teflon seal and support washer on injector
    314
  • 1.15 Safety precautions
    317
  • 1.16 Rules for cleanliness
    319
  • 1.17 Technical data
    319
  • 2 Engine control unit J623
    320
  • 2.1 Removing and installing engine control unit J623 (Golf)
    320
  • 2.2 Removing and installing anti-theft engine control unit J623 (Golf)
    321
  • 2.3 Removing and installing engine control unit J623 (Golf Plus, Touran)
    323
  • 2.4 Removing and installing anti-theft engine control unit J623 (Golf Plus, Touran)
    324
  • 2.5 Removing and installing engine control unit J623 (Tiguan)
    326
  • 2.6 Removing and installing anti-theft engine control unit J623 (Tiguan)
    328
  • Exhaust system
    330
  • 1 Removing and installing parts of exhaust system
    330
  • 1.2 Assembly overview - catalytic converter and attachments (engine code BWK)
    332
  • 1.3 Assembly overview - silencer with mountings (engine codes BLG, BMY)
    333
  • 1.4 Assembly overview - silencer with mountings (engine code BWK)
    334
  • 1.5 Removing and installing front exhaust pipe (engine code BWK)
    334
  • 1.6 Separating centre and rear silencers (engine codes BLG, BMY)
    335
  • 1.7 Separating centre and rear silencers (engine codes BWK)
    337
  • Ignition system
    339
  • 1 Repairing ignition system
    339
  • 1.1 Assembly overview - ignition system
    339
  • 1.2 Problem solution for Hall sender G40
    340
  • 1.3 Removing and installing ignition coils with output stage
    341
  • 1.4 Safety precautions
    343
  • 1.5 Test data, spark plugs
    343
Manufacturer's designation 4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger)
Manufacturer Volkswagen
Suitable for Golf (2004 - 2007) / Touran (2003 - 2011) / Golf Plus (2005 - 2007) / Tiguan (2008)
Suitable car types 1K1, 5M, 5N
Engine code BLG, BWK
Category Reparaturanleitung

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