4-cylinder direct injection engine (1.4 l and 1.6 l engines, 4 V, EA 111, FSI)

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• Removing and installing engine
  2
• 1 Removing and installing engine (Golf, Golf Plus)
  2
• 1.1 Removing engine
  3
• 1.2 Securing engine to assembly stand
  8
• 1.3 Installing engine
  8
• 1.4 Specified torques
  9
• 1.5 Assembly mountings
  10
• 1.6 Additional information and assembly work for vehicles with air conditioner
  11
• 2 Removing and installing engine (Touran)
  12
• 2.1 Removing engine
  13
• 2.2 Securing engine to assembly stand
  16
• 2.3 Installing engine
  16
• 2.4 Specified torques
  18
• 2.5 Assembly mountings
  19
• 2.6 Additional information and assembly work for vehicles with air conditioner
  20
• 3 Removing and installing engine (Passat)
  21
• 3.1 Removing engine
  22
• 3.2 Securing engine to assembly stand
  26
• 3.3 Installing engine
  26
• 3.4 Specified torques
  27
• 3.5 Assembly mountings
  28
• 3.6 Notes on repairs to air conditioning system
  28
• 4 Removing and installing engine (Eos)
  30
• 4.1 Removing engine
  31
• 4.2 Securing engine to assembly stand
  35
• 4.3 Installing engine
  35
• 4.4 Assembly mountings
  38
• Crankshaft group
  40
• 1 Dismantling and assembling engine
  40
• 1.1 Assembly overview - parts l and ll
  40
• 1.2 Assembly overview - part I, belt drive
  42
• 1.3 Assembly overview - part II, cylinder block
  43
• 1.4 Removing and installing poly-V belt
  45
• 1.5 Removing and installing valve timing housing (timing case)
  46
• 1.6 Removing and installing valve timing housing (Touran)
  50
• 2 Sealing flange and flywheel or drive plate
  55
• 2.1 Assembly overview
  56
• 2.2 Removing and installing engine speed sender G28
  57
• 2.3 Renewing crankshaft oil seal - belt pulley end
  58
• 2.4 Poly V-belt pulley securing bolt tightening procedure
  61
• 2.6 Renewing crankshaft sealing flange - flywheel end ( assembly tool T10134 )
  64
• 2.7 Renewing crankshaft sealing flange - flywheel end ( assembly tool T10017 )
  72
• 2.8 Renewing crankshaft sealing flange at flywheel end (Eos)
  80
• 2.9 Crankshaft dimensions
  88
• 3 Dismantling and assembling pistons and conrods
  89
• 3.1 Assembly overview
  89
• 3.2 Checking piston
  91
• 3.3 Piston and cylinder dimensions
  92
• Cylinder head, valve gear
  93
• 1 Cylinder head
  93
• 1.1 Assembly overview
  93
• 1.2 Checking valve timing
  96
• 1.3 Adjusting valve timing
  97
• 1.6 Removing and installing camshaft housing
  116
• 1.7 Removing and installing cylinder head
  121
• 1.8 Checking compression
  124
• 2 Repairing valve gear
  127
• 2.1 Assembly overview
  127
• 2.2 Checking camshaft axial clearance
  129
• 2.3 Reworking valve seats
  129
• 2.4 Checking valve guides
  131
• 2.5 Renewing valve stem seals
  131
• Lubrication
  134
• 1 Removing and installing parts of lubrication system
  134
• 1.1 Engine oil:
  134
• 1.2 Assembly overview
  134
• 1.3 Removing and installing sump
  137
• 1.4 Removing and installing oil pump
  138
• 1.5 Checking oil pressure and oil pressure switch
  140
• Cooling
  143
• 1 Removing and installing parts of cooling system
  143
• 1.4 Assembly overview - parts of cooling system, body side, radiator with two fans (Touran)
  148
• 1.7 Assembly overview - parts of cooling system, engine side
  152
• 1.8 Coolant hose connection diagram
  155
• 1.9 Draining and adding coolant
  155
• 1.10 Removing and installing radiator fan V7 and radiator fan 2 V177
  159
• 1.11 Removing and installing radiator
  160
• 1.12 Removing and installing coolant pump
  162
• 1.13 Checking cooling system for leaks
  163
• Fuel supply system
  166
• 1 Safety precautions
  166
• 1.1 Safety regulations for working on fuel supply
  166
• 1.2 Releasing pressure in high-pressure area
  166
• 2 Rules for cleanliness
  168
• 3 Fuel tank (Golf, Golf Plus)
  169
• 3.1 Fuel tank - assembly overview (Golf, Golf Plus)
  169
• 3.2 Emptying fuel tank
  170
• 3.3 Removing and installing fuel tank
  173
• 4 Fuel tank (Touran)
  176
• 4.1 Assembly overview - fuel tank
  176
• 4.2 Emptying fuel tank
  178
• 4.3 Removing and installing fuel tank
  180
• 5 Fuel tank (Passat)
  183
• 5.1 Assembly overview - fuel tank
  183
• 5.2 Emptying fuel tank
  184
• 5.3 Removing and installing fuel tank
  186
• 6 Fuel tank (Eos)
  190
• 6.1 Assembly overview - fuel tank
  190
• 6.2 Emptying fuel tank
  192
• 6.3 Removing and installing fuel tank
  194
• 7 Repairing fuel supply system (Golf, Golf Plus, Eos)
  197
• 7.1 Removing and installing fuel delivery unit
  197
• 7.2 Removing and installing fuel gauge sender G
  200
• 7.3 Crash fuel shut-off
  202
• 7.4 Checking fuel pump
  202
• 8 Repairing fuel supply (Touran)
  214
• 8.1 Removing and installing fuel delivery unit
  214
• 8.2 Removing and installing fuel gauge sender G
  216
• 8.3 Crash fuel shut-off
  218
• 8.4 Checking fuel pump
  218
• 9 Repairing fuel supply (Passat)
  230
• 9.1 Removing and installing fuel delivery unit
  230
• 9.2 Removing and installing fuel gauge sender G
  233
• 9.3 Checking fuel pump
  234
• 10 Electronic power control; EPC (Golf, Golf Plus, Passat, Eos)
  244
• 10.1 Assembly overview - accelerator module
  244
• 10.2 Removing and installing accelerator pedal module
  244
• 11 Electronic power control; EPC (Touran)
  247
• 11.1 Assembly overview - accelerator module
  247
• 11.2 Removing and installing accelerator pedal module
  247
• 12 Activated charcoal filter system (Golf, Golf Plus, Eos)
  249
• 12.1 Assembly overview - activated charcoal filter system
  249
• 12.2 Checking fuel tank breather
  249
• 13 Activated charcoal filter system (Touran)
  252
• 13.1 Checking fuel tank breather
  252
• 14 Activated charcoal filter system (Passat)
  254
• 14.1 Assembly overview - activated charcoal filter system
  254
• 14.2 Checking fuel tank breather
  254
• Mixture preparation - injection
  256
• 1 Injection system
  256
• 1.1 General notes on injection
  256
• 1.2 Technical data
  257
• 1.3 Assembly overview - air filter
  257
• 1.4 Removing and installing air filter
  258
• 1.5 Assembly overview - intake manifold (engine codes BAG, BKG)
  259
• 1.6 Assembly overview - intake manifold (engine codes BLF, BLN, BLP)
  262
• 1.7 Assembly overview - fuel rail with injectors
  264
• 1.8 Cleaning throttle valve module J338
  265
• 1.9 Removing and installing high-pressure pump (engine codes BAG, BKG)
  265
• 1.10 Removing and installing high-pressure pump (engine codes BLF, BLN, BLP)
  267
• 1.11 Removing and installing injectors
  271
• 2 Checking components
  276
• 2.1 Checking function of intake manifold flap
  276
• 2.2 Checking vacuum reservoir in intake manifold for leaks
  276
• 2.3 Checking intake air preheating
  277
• 3 Engine control unit J623 (Golf, Eos)
  278
• 3.1 Removing and installing engine (motor) control unit J623
  278
• 4 Engine control unit J623 (Golf Plus, Touran)
  282
• 4.1 Removing and installing engine (motor) control unit J623
  282
• 5 Engine control unit J623 (Passat)
  286
• 5.1 Removing and installing engine (motor) control unit J623
  286
• 5.2 Removing and installing engine control unit J623 with locking plate
  287
• 5.3 Removing and installing engine control unit J623 with locking clip
  290
• Exhaust system
  292
• 1 Parts of exhaust system (Golf, Golf Plus, Touran)
  292
• 1.2 Assembly overview - catalytic converters and attachments, engine codes BLN, BLP, BLF
  294
• 1.3 Assembly overview - silencers with mountings
  296
• 2 Parts of exhaust system (Passat)
  297
• 2.1 Assembly overview - catalytic converters and attachments
  297
• 2.2 Assembly overview - silencers with mountings
  298
• 3 Parts of exhaust system (Eos)
  300
• 3.1 Assembly overview - catalytic converters and attachments
  300
• 3.2 Assembly overview - silencers with mountings
  302
• 3.3 Separating centre and rear silencers
  302
• 4 Exhaust gas recirculation system
  304
• 4.1 Assembly overview - exhaust gas recirculation system
  304
• 4.2 Removing and installing exhaust gas recirculation valve N18
  305
• Ignition system
  307
• 1 Repairing ignition system
  307
• 1.1 General notes on ignition system
  307
• 1.2 Safety precautions
  307
• 1.3 Assembly overview - ignition system
  307
• 1.4 Removing and installing ignition coils with output stage
  308
• 1.5 Test data, spark plugs
  310