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

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Engine number, engine data
  1
• 2 Safety instructions
  3
• 2.1 Safety precautions when working on fuel supply system
  3
• 2.2 Safety precautions when working on natural gas system
  4
• 2.4 Safety precautions when working on cooling system
  7
• 2.5 Safety precautions when working on ignition system
  8
• 3 Repair instructions
  9
• 3.1 Rules for cleanliness
  9
• 3.2 Foreign objects in engine
  9
• 3.3 Contact corrosion
  9
• 3.4 Routing and securing lines
  9
• 3.5 Installing coolers, condensers and radiators
  10
• Removing and installing engine
  11
• 1 Removing and installing engine
  11
• 1.1 Removing engine
  11
• 1.2 Installing engine
  20
• 2 Assembly mountings
  25
• 2.1 Assembly overview - assembly mountings
  25
• Crankshaft group
  26
• 1 Cylinder block (pulley end)
  26
• 1.1 Assembly overview - poly V-belt drive
  26
• 1.2 Assembly overview - cylinder block (pulley end)
  28
• 1.3 Removing and installing poly V-belt
  30
• 1.4 Removing and installing ancillary bracket
  33
• 1.5 Removing and installing pulley
  34
• 1.6 Renewing crankshaft oil seal - belt pulley end
  36
• 2 Cylinder block, gearbox end
  40
• 2.1 Assembly overview - cylinder block, gearbox end
  40
• 2.2 Renewing crankshaft sealing flange - flywheel end
  41
• 3 Crankshaft
  49
• 3.1 Assembly overview - crankshaft
  49
• 3.2 Crankshaft dimensions
  50
• 3.3 Renewing needle bearing in crankshaft
  50
• 4 Pistons and conrods
  52
• 4.1 Assembly overview - pistons and conrods
  52
• 4.2 Checking piston and cylinder bore
  53
• 4.3 Removing and installing oil spray jets
  55
• 4.4 Separating new conrod
  56
• Cylinder head, valve gear
  57
• 1 Cylinder head
  57
• 1.1 Assembly overview - cylinder head
  57
• 1.2 Removing and installing cylinder head
  59
• 1.3 Removing and installing camshaft housing
  64
• 1.4 Checking compression
  72
• 2 Cover for timing chain
  74
• 2.1 Removing and installing valve timing housing (timing case)
  74
• 3 Chain drive
  88
• 3.1 Checking valve timing
  88
• 3.2 Adjusting valve timing
  90
• 3.3 Checking timing chain
  99
• 3.4 Removing and installing timing chain and chain drive for oil pump
  106
• 4 Valve gear
  117
• 4.1 Assembly overview - valve gear
  117
• 4.2 Measuring axial play of camshaft
  119
• 4.3 Removing and installing valve stem seals
  119
• 5 Inlet and exhaust valves
  122
• 5.1 Checking valve guides
  122
• 5.2 Reworking valve seats
  122
• Lubrication
  124
• 1 Sump, oil pump
  124
• 1.1 Assembly overview – sump/oil pump
  124
• 1.2 Engine oil
  126
• 1.3 Removing and installing sump
  127
• 1.4 Removing and installing oil pump
  130
• 2 Oil filter, oil pressure switch
  133
• 2.1 Checking oil pressure and oil pressure switch
  133
• Cooling
  135
• 1 Cooling system, coolant
  135
• 1.1 Coolant hose schematic diagram
  135
• 1.2 Draining and filling coolant
  137
• 1.3 Checking cooling system for leaks
  141
• 2 Coolant pump, regulation of cooling system
  144
• 2.1 Assembly overview - thermostat
  144
• 2.2 Removing and installing coolant pump
  145
• 2.3 Removing and installing coolant pump pulley
  151
• 2.4 Removing and installing coolant circulation pump V50
  155
• 3 Radiator/radiator fan
  158
• 3.1 Assembly overview – radiator/radiator fan
  158
• 3.3 Removing and installing radiator
  160
• Turbocharging/supercharging
  162
• 1 Turbocharger
  162
• 1.1 Assembly overview - turbocharger
  162
• 1.2 Removing and installing turbocharger
  166
• 1.3 Checking vacuum unit for turbocharger
  170
• 1.4 Adjusting vacuum unit for turbocharger
  172
• 1.5 Renewing vacuum unit for turbocharger
  177
• 2 Charge air system
  180
• 2.1 Assembly overview - charge air system
  180
• 2.2 Assembly overview - charge-air hose connections
  181
• 2.3 Checking charge air system for leaks
  182
• 2.4 Removing and installing charge air cooler
  186
• 3 Supercharger
  192
• 3.1 Assembly overview - supercharger
  192
• 3.2 Removing and installing supercharger
  194
• 3.3 Removing and installing drive unit seal for supercharger
  201
• Mixture preparation - injection
  205
• 1 Injection system
  205
• 1.1 General notes on injection
  205
• 2 Injectors
  206
• 2.1 Assembly overview - fuel rail with injectors
  206
• 2.2 Releasing high pressure in fuel system
  207
• 2.3 Removing and installing injectors
  208
• 2.4 Renewing seal on injector
  211
• 3 Checking natural gas supply system for leaks
  214
• 3.1 Different pressure sections of natural gas supply system
  214
• 3.2 Determining pressure in gas system
  217
• 3.3 Determining operating mode of natural gas vehicles
  217
• 3.4 Activating/deactivating natural gas mode
  218
• 3.5 Checking gas system for leaks
  219
• 4 Gas injectors
  225
• 4.1 Removing and installing gas rail with gas injectors N366 , N367 , N368 , N369
  225
• 5 Gas pressure regulator
  228
• 5.1 Assembly overview - gas pressure regulator
  228
• 5.2 Removing and installing gas pressure regulator
  233
• 5.3 Removing and installing tank pressure sensor G400
  238
• 6 Air filter
  242
• 6.1 Assembly overview - air filter housing
  242
• 6.2 Removing and installing air filter housing
  243
• 7 Intake manifold
  244
• 7.1 Assembly overview - intake manifold
  244
• 7.2 Removing and installing upper part of intake manifold
  251
• 7.3 Removing and installing lower part of intake manifold
  256
• 7.4 Removing and installing regulating flap control unit J808 and throttle valve module J338
  258
• 7.5 Cleaning throttle valve module J338
  260
• 8 High-pressure pump
  262
• 8.1 Assembly overview - high-pressure pump
  262
• 8.2 Removing and installing high-pressure pump
  263
• 9 Senders and sensors
  268
• 9.1 Checking fuel pressure sender G247
  268
• 10 Engine control unit
  272
• 10.1 Removing and installing engine control unit J623 (Passat ▶10.2010)
  272
• 10.3 Removing and installing engine control unit J623 (Passat 11.2010▶)
  274
• 10.5 Removing and installing engine control unit J623 (Touran)
  278
• 10.6 Removing and installing engine control unit J623 with protective housing (Touran)
  279
• Exhaust system
  283
• 1 Emission control
  283
• 1.1 Assembly overview – emission control
  283
• 2 Exhaust pipes, silencers
  285
• 2.1 Assembly overview - silencers
  285
• 2.2 Removing and installing front exhaust pipe
  286
• Ignition system
  287
• 1 Ignition system
  287
• 1.1 General notes
  287
• 1.2 Assembly overview - ignition system
  287
• 1.3 Test data, spark plugs
  289
• 1.4 Removing and installing ignition coils with output stage
  289
• 1.5 Removing and installing engine speed sender G28
  291