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  • 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 Touran / Golf Plus / EOS / Tiguan / Passat CC / Scirocco / Golf / Sharan / Polo A05 / Passat/Passat Variant / Golf Cabriolet

Original Volkswagen repair manual


32,54 €7% VAT incl.

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  • English

Immediately available for download

Language: English

Digital PDF file

17.430 KB

441 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing motor, Assembly mountings, Cylinder block (pulley end), Crankshaft, Pistons and conrods, Valve gear, Cover for timing chain, Chain drive, Sump, oil pump, Oil filter, oil pressure switch, Coolant pump, regulation of cooling system, Radiator, radiator fan, Turbocharger, Intake manifold, Injectors and Engine control unit J623. Show more
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Repair manual 4-cylinder direct-injection engine PDF download has the following content:

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
Manufacturer's designation 4-cylinder direct-injection engine (1.4 l, EA 111, turbocharger, supercharger)
Manufacturer Volkswagen
Suitable for Touran (2003 - 2011) / Golf Plus (2005 - 2007) / EOS (2006) / Tiguan (2008) / Passat CC (2009) / Scirocco (2008) / Golf (2009) / Golf Plus (2009) / Sharan (2011) / Polo A05 (2010) / Passat/Passat Variant (2011 >) / Golf Cabriolet (2012)
Suitable car types 1T, 1F, 5N, 357, 137, 5K1, 521, 7N, 6R1, 362, 365, 517
Engine code CAVD, CAVB, CAVC, CAVE, CKMA, CNWA, CTKA, CTHA, CTHD, CTHB, CTHC, CTHE
Category Reparaturanleitung

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