Name: 4-cylinder direct injection engine (1.4 l engine, 4V, EA 211, turbocharger)
Brand: Volkswagen
SKU: CDG39a9b2ca9df8
Price: 40.31 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
5
3.4 Foreign objects in engine
7
3.5 Contact corrosion
7
3.6 Routing and attachment of lines
7
3.7 Fitting radiator and condensers
7
3.8 Checking vacuum system
7
Removing and installing engine
9
1 Removing and installing motor
9
1.1 Removing motor
9
1.2 Separating engine and gearbox
60
1.3 Securing engine on engine and gearbox support
61
1.4 Installing engine
63
2 Assembly mountings
68
2.1 Assembly overview - assembly mountings
68
2.2 Removing and installing engine mounting
80
2.3 Removing and installing gearbox mountings
85
2.4 Removing and installing pendulum support
87
2.5 Supporting engine in installation position
89
2.6 Checking adjustment of assembly mountings (engine and gearbox mountings)
117
2.7 Adjusting assembly mountings
118
Crankshaft group
122
1 Cylinder block (pulley end)
122
1.1 Assembly overview - poly V-belt drive
122
1.2 Assembly overview - sealing flange, belt pulley end
126
1.3 Removing and installing poly-V belt
129
1.4 Removing and installing tensioner for poly V-belt
133
1.5 Removing and installing vibration damper
134
1.6 Removing and installing engine support
136
1.7 Renewing crankshaft oil seal - belt pulley end
139
1.8 Removing and installing sealing flange on pulley end
142
2 Cylinder block, gearbox end
146
2.1 Assembly overview - cylinder block, gearbox end
146
2.2 Removing and installing flywheel
147
2.3 Removing and installing sealing flange on gearbox side
148
3 Crankshaft
160
3.1 Renewing needle bearing in crankshaft
160
3.2 Crankshaft dimensions
163
3.3 Measuring axial clearance of crankshaft
163
4 Pistons and conrods
165
4.1 Assembly overview - pistons and conrods
165
4.2 Removing and installing pistons
168
4.3 Removing and installing oil spray jets
169
4.4 Checking pistons and cylinder bores
170
4.5 Checking radial clearance of conrods
173
4.6 Separating new conrod
173
4.7 Setting piston to TDC position
174
Cylinder head, valve gear
179
1 Cylinder head
179
1.1 Assembly overview - cylinder head
179
1.2 Assembly overview - camshaft housing
181
1.3 Removing and installing cylinder head
185
1.4 Removing and installing camshaft housing
190
1.5 Checking compression
196
2 Toothed belt drive
198
2.1 Assembly overview - toothed belt cover
198
2.2 Assembly overview - toothed belt
199
2.3 Removing and installing toothed belt guard
203
2.4 Preassembling and installing valve timing tool
205
2.5 Checking valve timing
213
2.6 Adjusting valve timing
216
2.7 Removing and installing toothed belt
227
2.8 Removing toothed belt from camshaft
234
3 Valve gear
242
3.1 Assembly overview - valve gear
242
3.2 Removing and installing camshaft oil seal
244
3.3 Removing and installing camshaft adjuster
256
3.4 Removing and installing toothed belt pulley
277
3.5 Removing and installing camshaft control valve 1 N205
282
3.6 Removing and installing exhaust camshaft control valve 1 N318
283
3.7 Removing and installing valve stem seals
284
4 Inlet and exhaust valves
296
4.1 Checking valve guides
296
4.2 Checking valves
297
4.3 Valve dimensions
297
Lubrication
298
1 Sump, oil pump
298
1.1 Assembly overview - sump/oil pump
298
1.2 Engine oil:
302
1.3 Removing and installing lower part of sump
302
1.4 Removing and installing upper part of sump
308
1.5 Removing and installing oil pump
312
1.6 Removing and installing oil level and oil temperature sender G266
314
2 Engine oil cooler
315
2.1 Assembly overview - engine oil cooler
315
2.2 Removing and installing engine oil cooler
315
3 Crankcase ventilation
317
3.1 Assembly overview - crankcase breather system
317
3.2 Removing and installing oil separator
318
4 Oil filter, oil pressure switch
322
4.1 Assembly overview - oil filter/oil pressure switch
322
4.2 Removing and installing oil pressure switch F1
324
4.3 Removing and installing oil pressure switch for reduced oil pressure F378
325
4.4 Checking oil pressure
326
4.5 Removing and installing oil pressure regulating valve N428
328
Cooling
330
1 Cooling system/coolant
330
1.1 Connection diagram - coolant hoses
330
1.2 Checking cooling system for leaks
332
1.3 Draining and adding coolant
340
2 Coolant pump, regulation of cooling system
348
2.1 Assembly overview - coolant pump, thermostat
348
2.2 Assembly overview - electric coolant pump
351
2.3 Assembly overview - coolant temperature sender
352
2.4 Removing and installing electric coolant pump
354
2.5 Removing and installing coolant pump
356
2.6 Removing and installing thermostat
362
2.7 Removing and installing toothed belt pulley for coolant pump
366
2.8 Removing and installing coolant temperature sender G62
367
2.9 Removing and installing radiator outlet coolant temperature sender G83
370
3 Coolant pipes
374
3.1 Assembly overview - coolant pipes
374
3.2 Removing and installing coolant pipes
374
4 Radiator, radiator fan
379
4.1 Assembly overview - radiator/radiator fan
379
4.2 Assembly overview - radiator cowl and radiator fan
388
4.3 Removing and installing radiator
392
4.4 Removing and installing water radiator for charge air cooling circuit
399
4.5 Removing and installing radiator cowl
407
4.6 Removing and installing radiator fan V7
413
Turbocharging/supercharging
416
1 Turbocharger
416
1.1 Assembly overview - turbocharger
416
1.2 Removing and installing turbocharger
420
1.3 Removing and installing charge pressure positioner V465
426
1.4 Removing and installing connection for turbocharger
429
2 Charge air system
433
2.1 Assembly overview - charge air system
433
2.2 Removing and installing charge air cooler
435
2.3 Removing and installing charge pressure sender GX26
438
2.4 Checking charge air system for leaks
439
2.5 Removing and installing air pipe
441
Mixture preparation - injection
444
1 Injection system
444
1.1 Overview of fitting locations - injection system
444
2 Injectors
449
2.1 Assembly overview - fuel rail with injectors
449
2.2 Removing and installing fuel rail
453
2.3 Removing and installing injectors
454
2.4 Cleaning injectors
468
3 Air filter
470
3.1 Assembly overview - air filter housing
470
3.2 Removing and installing air filter housing
472
3.3 Removing and installing air guide on lock carrier
474
3.4 Removing and installing resonator for intake air
476
4 Intake manifold
478
4.1 Assembly overview - intake manifold
478
4.2 Removing and installing intake manifold
481
4.3 Removing and installing throttle valve module GX3
484
4.4 Cleaning throttle valve module GX3
485
5 Senders and sensors
487
5.1 Removing and installing intake manifold sender GX9
487
5.2 Removing and installing fuel pressure sender G247
487
5.3 Checking fuel pressure sender G247
489
5.4 Removing and installing exhaust gas pressure sensor 1 G450
493
6 Engine control unit
495
6.1 Assembly overview - engine control unit J623
495
6.2 Removing and installing engine control unit J623
496
6.3 Removing and installing engine (motor) control unit J623 with protective housing
502
7 High-pressure pump
519
7.1 Assembly overview - high-pressure pump
519
7.2 Removing and installing high-pressure pump
525
7.3 Removing and installing high-pressure pipe
527
8 Lambda probe
530
8.1 Assembly overview - Lambda probe
530
8.2 Removing and installing Lambda probe
531
Exhaust system
536
1 Exhaust pipes and silencers
536
1.1 Assembly overview - silencers
536
1.2 Separating exhaust pipes from silencers
546
1.3 Removing and installing silencer
550
1.4 Installation position of clamp
559
1.5 Aligning exhaust system free of stress
560
1.6 Checking exhaust system for leaks
567
2 Emission control
568
2.1 Assembly overview - emission control
568
2.2 Removing and installing catalytic converter
570
2.3 Removing and installing particulate filter
577
Ignition system
578
1 Ignition system
578
1.1 Assembly overview - ignition system
578
1.2 Removing and installing ignition coils with output stage
580
1.3 Removing and installing knock sensor 1 G61
583
1.4 Removing and installing Hall sender
584
1.5 Removing and installing engine speed sender G28
585

Manufacturer's designation	4-cylinder direct injection engine (1.4 l engine, 4V, EA 211, turbocharger)
Manufacturer	Volkswagen
Suitable for	Tiguan (2008) / Golf Cabriolet (2012) / Passat CC (2009) / Scirocco GP (2015) / Sharan (2016 > ) / T-Roc (2018 >) / Golf (2020 >) / Golf Variant (2021 >)
Suitable car types	5N, 358, 138, 7N2, A11, CD1, CG5
Engine code	CZDB, CZDC, DJKA, CZDA
Category	Reparaturanleitung

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