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  • Examplepage for repair manual 4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger)
  • Examplepage for repair manual 2 4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger)
  • Examplepage for repair manual 3 4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger)
  • Examplepage for repair manual 4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger)
  • Examplepage for repair manual 2 4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger)
  • Examplepage for repair manual 3 4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger)

4-cylinder direct injection engine (1.2 l engine, 4V, EA 211, turbocharger)

For Golf Cabriolet / Golf VII / Golf Variant / Polo / Golf Sportsvan / Touran / Golf

Original Volkswagen repair manual


31,26 €7% VAT incl.

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Language: English

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47.940 KB

419 Sites

Detailed technical data

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This repair manual contains: Removing and installing engine, Assembly mountings, Cylinder block (pulley end), Crankshaft, Pistons and conrods, Toothed belt drive, Valve gear, Sump, oil pump, Engine oil cooler, Oil filter, oil pressure switch, Cooling system/coolant, Radiator, radiator fan, Turbocharger and Lambda probe. 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 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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