Name: 4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger)
Brand: Volkswagen
SKU: CDG67d6565ea9fc
Price: 31.26 EUR
Availability: InStock

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Repair manual 4-cylinder direct injection engine PDF download has the following content:

Chapter overview

Technical data
1
1 Safety information
1
1.1 Safety regulations for working on fuel supply
1
1.2 Safety measures when working on vehicles with start/stop system
1
1.4 Safety precautions when working on the cooling system
2
1.5 Safety precautions when working on ignition system
2
2 Identification
3
2.1 Engine number/engine data
3
3 Repair notes
5
3.1 Rules for cleanliness
5
3.2 General information
5
3.3 General repair instructions
6
3.4 Foreign objects in engine
6
3.5 Contact corrosion
6
3.6 Routing and attachment of lines
6
3.7 Fitting radiator and condensers
6
3.8 Checking vacuum system
6
Removing and installing engine
8
1 Removing and installing engine
8
1.1 Removing engine
8
1.2 Separating engine and gearbox
37
1.3 Securing engine on engine and gearbox support
39
1.4 Installing engine
40
2 Assembly mountings
44
2.1 Assembly overview - assembly mountings
44
2.2 Removing and installing engine mounting
52
2.3 Removing and installing gearbox mountings
56
2.4 Removing and installing pendulum support
60
2.5 Supporting engine in installation position
63
2.6 Adjusting assembly mountings
80
2.7 Checking adjustment of assembly mountings (engine and gearbox mountings)
82
Crankshaft group
84
1 Cylinder block (pulley end)
84
1.1 Assembly overview - poly V-belt drive
84
1.2 Removing and installing poly-V belt
88
1.3 Removing and installing tensioner for poly V-belt
90
1.4 Removing and installing vibration damper
91
1.5 Removing and installing engine support
92
1.6 Renewing crankshaft oil seal - belt pulley end
95
2 Cylinder block, gearbox end
98
2.1 Assembly overview - cylinder block, gearbox end
98
2.2 Removing and installing flywheel
99
2.3 Removing and installing sealing flange on gearbox side
100
3 Crankshaft
109
3.1 Crankshaft dimensions
109
3.2 Measuring axial clearance of crankshaft
109
3.3 Renewing needle bearing in crankshaft
110
4 Pistons and conrods
113
4.1 Assembly overview - pistons and conrods
113
4.2 Removing and installing pistons
115
4.3 Checking pistons and cylinder bores
116
4.4 Separating new conrod
117
4.5 Checking radial clearance of conrods
118
4.6 Removing and installing oil spray jets
118
4.7 Setting piston to TDC position
119
Cylinder head, valve gear
123
1 Cylinder head
123
1.1 Assembly overview - cylinder head
123
1.2 Assembly overview - camshaft housing
125
1.3 Removing and installing cylinder head
126
1.4 Removing and installing camshaft housing
131
1.5 Checking compression
133
2 Toothed belt drive
136
2.1 Assembly overview - toothed belt cover
136
2.2 Assembly overview - toothed belt
137
2.3 Removing and installing toothed belt guard
139
2.4 Preassembling and installing valve timing tool
139
2.5 Removing and installing toothed belt
148
2.6 Checking valve timing
154
2.7 Adjusting valve timing
156
2.8 Removing toothed belt from camshaft
165
3 Valve gear
169
3.1 Assembly overview - valve gear
169
3.2 Measuring axial play of camshaft
171
3.3 Removing and installing camshaft adjuster
172
3.4 Removing and installing toothed belt pulley
176
3.5 Removing and installing camshaft oil seal
178
3.6 Removing and installing camshaft control valve 1 N205
185
3.7 Removing and installing valve stem seals
185
4 Inlet and exhaust valves
194
4.1 Checking valve guides
194
4.2 Checking valves
194
4.3 Valve dimensions
195
Lubrication
196
1 Sump, oil pump
196
1.1 Assembly overview - sump/oil pump
196
1.2 Engine oil:
200
1.3 Removing and installing sump
201
1.4 Removing and installing oil pump
206
1.5 Removing and installing oil level and oil temperature sender G266
209
2 Engine oil cooler
210
2.1 Assembly overview - engine oil cooler
210
2.2 Removing and installing engine oil cooler
210
3 Crankcase ventilation
212
3.1 Assembly overview - crankcase breather system
212
3.2 Removing and installing oil separator
213
4 Oil filter, oil pressure switch
216
4.1 Assembly overview - oil filter/oil pressure switch
216
4.2 Removing and installing oil pressure switch for reduced oil pressure F378
217
4.3 Checking oil pressure and oil pressure switch
218
4.4 Removing and installing oil filter housing
219
Cooling
221
1 Cooling system/coolant
221
1.1 Connection diagram - coolant hoses
221
1.2 Checking cooling system for leaks
225
1.3 Draining and adding coolant
227
2 Coolant pump, regulation of cooling system
235
2.1 Assembly overview - coolant pump, thermostat
235
2.2 Assembly overview - electric coolant pump
238
2.3 Assembly overview - coolant temperature sender
240
2.4 Removing and installing electric coolant pump
241
2.5 Removing and installing coolant pump
243
2.6 Removing and installing thermostat
248
2.7 Removing and installing toothed belt pulley for coolant pump
250
2.8 Removing and installing coolant temperature sender G62
251
2.9 Removing and installing radiator outlet coolant temperature sender G83
252
2.10 Removing and installing radiator fan thermal switch F18
252
3 Coolant pipes
254
3.1 Assembly overview - coolant pipes
254
3.2 Removing and installing coolant pipes
254
4 Radiator, radiator fan
258
4.1 Assembly overview - radiator/radiator fan
258
4.2 Assembly overview - radiator cowl and radiator fan
265
4.3 Removing and installing radiator
268
4.4 Removing and installing water radiator for charge air cooling circuit
276
4.5 Removing and installing radiator cowl
285
4.6 Removing and installing radiator fan V7
290
Turbocharging/supercharging
293
1 Turbocharger
293
1.1 Assembly overview - turbocharger
293
1.2 Removing and installing turbocharger
295
1.3 Removing and installing charge pressure positioner V465
298
1.4 Removing and installing connection for turbocharger
299
2 Charge air system
302
2.1 Assembly overview - charge air system
302
2.2 Removing and installing charge air cooler
304
2.3 Removing and installing charge pressure sender GX26
306
2.4 Checking charge air system for leaks
306
2.5 Removing and installing air pipe
308
Mixture preparation - injection
311
1 Injection system
311
1.1 Overview of fitting locations - injection system
311
2 Air filter
320
2.1 Assembly overview - air filter housing
320
2.2 Removing and installing air filter housing
323
2.3 Removing and installing resonator for intake air
324
3 Intake manifold
325
3.1 Assembly overview - intake manifold
325
3.2 Removing and installing intake manifold
327
3.3 Removing and installing throttle valve module GX3
329
3.4 Cleaning throttle valve module GX3
330
4 Injectors
331
4.1 Assembly overview - fuel rail with injectors
331
4.2 Removing and installing fuel rail
332
4.3 Removing and installing injectors
333
4.4 Cleaning injectors
343
5 Senders and sensors
346
5.1 Removing and installing intake manifold sender GX9
346
5.2 Removing and installing fuel pressure sender G247
346
5.3 Checking fuel pressure sender G247
347
6 High-pressure pump
350
6.1 Assembly overview - high-pressure pump
350
6.2 Removing and installing high-pressure pump
352
6.3 Removing and installing high-pressure pipe
353
7 Lambda probe
356
7.1 Assembly overview - Lambda probe
356
7.2 Removing and installing Lambda probe
357
8 Engine control unit
360
8.1 Removing and installing engine control unit J623
360
8.2 Assembly overview - engine control unit
371
Exhaust system
373
1 Exhaust pipes and silencers
373
1.1 Assembly overview - silencers
373
1.2 Separating exhaust pipes from silencers
383
1.3 Removing and installing silencer
389
1.4 Aligning exhaust system free of stress
395
1.5 Checking exhaust system for leaks
395
1.6 Installation position of clamp
396
2 Emission control
397
2.1 Assembly overview - emission control
397
2.2 Removing and installing catalytic converter
400
Ignition system
408
1 Ignition system
408
1.1 Assembly overview - ignition system
408
1.2 Removing and installing ignition coils with output stage
409
1.3 Removing and installing knock sensor 1 G61
411
1.4 Removing and installing Hall sender
411
1.5 Removing and installing engine speed sender G28
412

Manufacturer's designation	4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger)
Manufacturer	Volkswagen
Suitable for	Golf Cabriolet (2012) / Golf VII (2013) / Golf Variant (2014) / Polo (2014) / Golf Sportsvan (2014 >) / Touran (2016 > ) / Golf VII (2017) / Golf (2017)
Suitable car types	517, BA5, 6C1, AM1, 5T1, BQ1, BV5
Engine code	CJZB, CYVA, CYVB, CYVD, CJZC, CJZD
Category	Reparaturanleitung

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