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

Chapter overview

• Technical data
  1
• 1 Engine number/engine data
  1
• 2 Safety precautions
  5
• 2.1 Safety regulations for working on fuel supply
  5
• 2.2 Safety precautions when working on ignition system
  5
• 2.3 Releasing pressure in high-pressure area
  6
• 3 General repair instructions
  7
• 3.1 Rules for cleanliness
  7
• Removing and installing engine
  8
• 1 Removing and installing motor
  8
• 1.1 Removing engine (Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet)
  8
• 1.2 Installing engine (Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet)
  18
• 1.3 Removing engine (Tiguan)
  20
• 1.4 Installing engine (Tiguan)
  28
• 1.5 Removing engine (Polo)
  31
• 1.6 Installing engine (Polo)
  39
• 1.7 Removing engine (Sharan)
  40
• 1.8 Installing engine (Sharan)
  48
• 1.9 Removing engine (Passat, Passat CC)
  50
• 1.10 Installing engine (Passat, Passat CC)
  60
• 2 Assembly mountings
  64
• 2.2 Assembly overview - assembly mountings (Tiguan)
  65
• 2.3 Assembly overview - assembly mountings (Polo)
  66
• 2.4 Assembly overview - assembly mountings (Sharan)
  67
• 2.5 Assembly overview - assembly mountings (Passat, Passat CC)
  67
• Crankshaft group
  69
• 1 Cylinder block (pulley end)
  69
• 1.1 Assembly overview - poly V-belt drive
  71
• 1.2 Assembly overview - cylinder block, belt pulley end
  73
• 1.4 Removing and installing poly V-belt (Tiguan)
  78
• 1.5 Removing and installing bracket for ancillaries
  80
• 1.6 Renewing crankshaft oil seal - pulley end
  81
• 1.7 Removing and installing crankshaft pulley
  83
• 2 Cylinder block, gearbox end
  87
• 2.1 Assembly overview - cylinder block, gearbox end
  87
• 2.2 Removing and installing sealing flange on gearbox side
  89
• 3 Crankshaft
  97
• 3.1 Assembly overview - crankshaft
  97
• 3.2 Pulling needle bearing out of and driving into crankshaft
  98
• 3.3 Crankshaft dimensions
  100
• 4 Pistons and conrods
  101
• 4.1 Assembly overview - pistons and conrods
  101
• 4.2 Checking piston
  103
• 4.3 Checking cylinder bores
  104
• 4.4 Separating new conrod
  104
• 4.5 Removing and installing pistons
  104
• 4.6 Removing and installing oil spray jets
  105
• Cylinder head, valve gear
  107
• 1 Cylinder head
  107
• 1.1 Assembly overview - cylinder head
  107
• 1.2 Removing and installing camshaft housing
  110
• 1.3 Removing and installing cylinder head
  116
• 1.4 Checking compression
  118
• 2 Valve gear
  121
• 2.1 Assembly overview - valve gear
  121
• 2.2 Measuring axial clearance of camshaft
  123
• 2.3 Reworking valve seats
  123
• 2.4 Checking valve guides
  125
• 2.5 Removing and installing valve stem seals
  125
• 3 Cover for timing chain
  128
• 3.2 Removing and installing valve timing housing (Touran, Tiguan)
  132
• 3.3 Removing and installing valve timing housing (Passat CC, Passat)
  138
• 4 Chain drive
  143
• 4.1 Checking valve timing
  143
• 4.2 Adjusting valve timing
  145
• 4.3 Checking timing chain
  152
• 4.4 Removing and installing timing chain and chain drive for oil pump
  159
• Lubrication
  168
• 1 Sump, oil pump
  168
• 1.1 Engine oil:
  168
• 1.2 Assembly overview - sump, oil pump
  168
• 1.3 Removing and installing sump
  171
• 1.4 Removing and installing oil pump
  175
• 2 Oil filter, oil pressure switch
  178
• 2.1 Checking oil pressure and oil pressure switch
  178
• Cooling
  180
• 1 Cooling system/coolant
  180
• 1.2 Schematic diagram for coolant hoses (Tiguan)
  182
• 1.3 Schematic diagram for coolant hoses (Sharan)
  183
• 1.4 Coolant hose schematic diagram (Passat, Passat CC)
  184
• 1.6 Draining and filling coolant (Polo)
  189
• 1.7 Draining and filling coolant (Sharan)
  193
• 1.8 Draining and filling coolant (Passat, Passat CC)
  198
• 1.10 Checking cooling system for leaks (Sharan, Tiguan)
  206
• 1.11 Checking cooling system for leaks (Passat, Passat CC)
  208
• 2 Coolant pump, regulation of cooling system
  211
• 2.1 Assembly overview - thermostat
  211
• 2.2 Assembly overview - thermostat (Passat, Passat CC)
  213
• 2.6 Removing and installing coolant pump (Sharan)
  225
• 2.7 Removing and installing coolant pump belt pulley (Sharan)
  230
• 2.8 Removing and installing coolant circulation pump V50 (Sharan)
  234
• 2.9 Removing and installing coolant pump belt pulley (Passat, Passat CC)
  236
• 2.10 Removing and installing coolant pump (Passat, Passat CC)
  242
• 3 Radiator, radiator fan
  256
• 3.2 Assembly overview - parts of cooling system, body side (Tiguan)
  258
• 3.3 Assembly overview - radiator/radiator fan (Polo)
  260
• 3.4 Assembly overview - radiator/radiator fan (Sharan)
  261
• 3.5 Assembly overview - radiator/radiator fan (Passat, Passat CC)
  262
• 3.7 Removing and installing radiator fan V7 and radiator fan 2 V177 (Polo)
  264
• 3.8 Removing and installing radiator, radiator fan V7 and radiator fan 2 V177 (Sharan)
  265
• 3.9 Removing and installing radiator (Passat, Passat CC)
  267
• 3.10 Removing and installing fan cowling (Passat, Passat CC)
  270
• 3.12 Removing and installing radiator (Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet)
  272
• 3.13 Removing and installing radiator and radiator fan V7 (Tiguan)
  273
• 3.14 Removing and installing radiator with charge air cooler (Polo)
  275
• Turbocharging/supercharging
  278
• 1 Turbocharger
  278
• 1.1 Assembly overview - turbocharger
  278
• 1.2 Removing and installing turbocharger
  282
• 1.3 Checking vacuum unit for turbocharger
  287
• 1.4 Removing and installing vacuum unit for turbocharger
  289
• 1.5 Adjusting vacuum unit for turbocharger
  291
• 2 Compressor
  297
• 2.1 Assembly overview - supercharger
  297
• 2.2 Removing and installing supercharger
  299
• 2.3 Removing and installing supercharger (Tiguan with four-wheel drive)
  307
• 2.4 Removing and installing drive unit seal for supercharger
  315
• 3 Charge air system
  319
• 3.2 Assembly overview - charge air system (Polo)
  321
• 3.3 Assembly overview - charge air system (Passat, Passat CC)
  322
• 3.4 Fitting hose connections with plug-in connectors
  323
• 3.5 Checking charge air system for leaks
  324
• 3.7 Removing and installing charge air cooler, Sharan
  329
• 3.8 Removing and installing charge air cooler (Scirocco)
  331
• 3.9 Removing and installing charge air cooler, Tiguan
  333
• 3.10 Removing and installing charge air cooler (Passat, Passat CC)
  335
• Mixture preparation - injection
  340
• 1 Air filter
  340
• 1.1 Assembly overview - air filter
  340
• 1.2 Assembly overview - air filter (Polo)
  341
• 1.3 Removing and installing air filter housing
  342
• 1.4 Removing and installing air filter housing (Polo)
  343
• 2 Intake manifold
  344
• 2.1 Assembly overview - intake manifold
  344
• 2.2 Removing and installing regulating flap control unit J808 and throttle valve module J338
  349
• 2.3 Cleaning throttle valve module J338
  351
• 3 Injectors
  353
• 3.1 Assembly overview - fuel rail with injectors
  353
• 3.2 Removing and installing injectors
  355
• 3.3 Renewing seals on injectors
  358
• 4 Senders and sensors
  362
• 4.1 Checking fuel pressure sender
  362
• 5 High-pressure pump
  368
• 5.1 Assembly overview - high-pressure pump
  368
• 5.2 Removing and installing high-pressure pump
  369
• 6 Engine control unit J623
  373
• 6.1 Removing and installing engine control unit J623 (Golf Plus, Touran)
  373
• 6.3 Removing and installing engine control unit J623 (Eos)
  377
• 6.4 Removing and installing engine control unit J623 with protective housing (Eos► 10.2008)
  378
• 6.5 Removing and installing engine control unit J623 (Tiguan)
  380
• 6.6 Removing and installing engine control unit J623 with protective housing (Tiguan)
  381
• 6.7 Removing and installing engine control unit J623 (Scirocco)
  383
• 6.9 Removing and installing engine control unit J623 (Golf, Golf Cabriolet)
  386
• 6.10 Removing and installing engine control unit J623 (Passat, Passat CC)
  387
• 6.12 Removing and installing engine control unit J623 (Polo)
  391
• 6.13 Removing and installing engine control unit J623 with protective housing (Polo)
  392
• 6.14 Removing and installing engine control unit J623 (Sharan)
  393
• 6.15 Removing and installing engine control unit J623 with protective housing (Sharan)
  394
• Exhaust system
  396
• 1 Exhaust pipes and silencers
  396
• 1.2 Assembly overview - silencers (Tiguan)
  398
• 1.3 Assembly overview - silencers (Polo)
  399
• 1.4 Assembly overview - silencers (Sharan)
  400
• 1.5 Assembly overview - silencer (Passat, Passat CC)
  401
• 1.6 Removing and installing front exhaust pipe (Tiguan with four-wheel drive)
  402
• 1.8 Removing and installing front exhaust pipe (Sharan)
  404
• 1.9 Removing and installing (Passat, Passat CC)
  405
• 1.10 Separating exhaust pipes, silencers (Tiguan)
  407
• 1.11 Separating exhaust pipes/silencers (Golf Plus, Eos, Scirocco, Golf, Touran, Golf Cabriolet)
  408
• 1.12 Separating exhaust pipes, silencers (Polo)
  410
• 1.13 Separating exhaust pipes, silencers (Sharan)
  411
• 1.14 Separating exhaust pipes/silencers (Passat, Passat CC)
  412
• 1.15 Aligning exhaust system free of stress (Passat, Passat CC)
  414
• 1.16 Installation position of clamp
  415
• 2 Emission control
  416
• 2.2 Assembly overview - exhaust gas treatment (Tiguan with four-wheel drive)
  418
• 2.3 Assembly overview - exhaust gas treatment (Polo)
  420
• 2.4 Assembly overview - exhaust gas treatment (Sharan)
  421
• 2.5 Assembly overview - exhaust gas treatment (Passat, Passat CC)
  422
• 2.6 Removing and installing catalytic converter (Polo)
  424
• 2.7 Removing and installing (Passat, Passat CC)
  425
• Ignition system
  428
• 1 Ignition system
  428
• 1.1 Assembly overview - ignition system
  428
• 1.2 Removing and installing ignition coils with output stage
  429
• 1.3 Removing and installing engine speed sender G28
  431
• 1.4 Test data, spark plugs
  433