4-cylinder direct injection engine (1.4 l engine, 4 V, EA 211, turbocharger, hybrid)

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety precautions when working on a high-voltage system
  1
• 1.2 Safety precautions when working in the vicinity of high-voltage components
  2
• 1.3 Safety regulations for working on fuel supply
  2
• 1.5 Safety precautions when working on ignition system
  3
• 1.6 Safety precautions when working on the cooling system
  3
• 2 Identification
  4
• 2.1 Engine number/engine data
  4
• 3 Repair instructions
  6
• 3.1 Rules for cleanliness
  6
• 3.2 Foreign objects in engine
  6
• 3.3 Contact corrosion
  6
• 3.4 Routing and attachment of lines
  7
• 3.5 Fitting radiator and condensers
  7
• 3.6 Checking vacuum system
  7
• 4 Hazard classification of high-voltage system
  8
• Removing and installing engine
  16
• 1 Removing and installing engine
  16
• 1.1 Removing engine
  16
• 1.2 Supporting engine and gearbox using scissor-type assembly platform VAS 6131 B
  25
• 1.3 Separating engine and gearbox
  31
• 1.4 Securing engine on engine and gearbox support
  35
• 1.5 Installing engine
  37
• 2 Assembly mountings
  42
• 2.1 Assembly overview – assembly mountings
  42
• 2.2 Removing and installing engine mounting
  45
• 2.3 Removing and installing gearbox mounting
  46
• 2.4 Removing and installing pendulum support
  47
• 2.5 Supporting engine in installation position
  48
• 2.6 Checking adjustment of assembly mountings
  68
• 2.7 Adjusting assembly mountings
  69
• 3 Engine cover panel
  72
• 3.1 Removing and installing engine cover
  72
• Crankshaft group
  73
• 1 Cylinder block (pulley end)
  73
• 1.1 Assembly overview - sealing flange, vibration-damper end
  73
• 1.2 Removing and installing engine support
  75
• 1.3 Removing and installing vibration damper
  76
• 1.4 Renewing crankshaft oil seal - belt pulley end
  78
• 1.5 Removing and installing sealing flange on pulley end
  81
• 2 Cylinder block, gearbox end
  85
• 2.1 Assembly overview - cylinder block, gearbox end
  85
• 2.2 Removing and installing flywheel
  87
• 2.3 Removing and installing sealing flange on gearbox side
  88
• 3 Crankshaft
  101
• 3.1 Crankshaft dimensions
  101
• 3.2 Measuring axial clearance of crankshaft
  101
• 4 Pistons and conrods
  103
• 4.1 Assembly overview - pistons and conrods
  103
• 4.2 Removing and installing pistons
  107
• 4.3 Checking pistons and cylinder bores
  108
• 4.4 Checking radial clearance of conrods
  110
• 4.5 Removing and installing oil spray jets
  111
• 4.6 Setting piston to TDC position
  112
• Cylinder head, valve gear
  118
• 1 Cylinder head
  118
• 1.1 Assembly overview - cylinder head
  118
• 1.2 Assembly overview - camshaft housing
  120
• 1.3 Removing and installing cylinder head
  123
• 1.4 Removing and installing camshaft housing
  129
• 1.5 Checking compression
  141
• 2 Toothed belt drive
  144
• 2.1 Assembly overview - toothed belt cover
  144
• 2.2 Assembly overview - toothed belt
  144
• 2.3 Removing and installing toothed belt guard
  146
• 2.4 Preassembling and installing valve timing tool
  147
• 2.5 Removing and installing toothed belt
  156
• 2.6 Checking valve timing
  162
• 2.7 Adjusting valve timing
  164
• 2.8 Removing toothed belt from camshaft
  175
• 3 Valve gear
  181
• 3.1 Assembly overview - valve gear
  181
• 3.2 Measuring axial play of camshaft
  183
• 3.3 Removing and installing camshaft oil seal
  184
• 3.4 Removing and installing camshaft adjuster
  191
• 3.5 Removing and installing camshaft control valve 1 N205
  201
• 3.6 Removing and installing exhaust camshaft control valve 1 N318
  202
• 3.7 Removing and installing valve stem seals
  203
• 4 Inlet and exhaust valves
  213
• 4.1 Checking valve guides
  213
• 4.2 Checking valves
  214
• 4.3 Valve dimensions
  214
• Lubrication
  215
• 1 Sump, oil pump
  215
• 1.1 Assembly overview - sump/oil pump
  215
• 1.2 Engine oil:
  219
• 1.3 Removing and installing lower part of sump
  219
• 1.4 Removing and installing upper part of sump
  225
• 1.5 Removing and installing oil pump
  230
• 1.6 Removing and installing oil level and oil temperature sender G266
  232
• 2 Engine oil cooler
  233
• 2.1 Assembly overview - engine oil cooler
  233
• 2.2 Removing and installing engine oil cooler
  233
• 3 Crankcase ventilation
  235
• 3.1 Assembly overview - crankcase breather system
  235
• 3.2 Removing and installing oil separator
  236
• 4 Oil filter, oil pressure switch
  240
• 4.1 Assembly overview - oil filter/oil pressure switch
  240
• 4.2 Removing and installing oil pressure switch F22
  242
• 4.3 Removing and installing oil pressure switch for reduced oil pressure F378
  244
• 4.4 Removing and installing oil pressure regulating valve N428
  246
• 4.5 Checking oil pressure
  246
• Cooling
  248
• 1 Cooling system/coolant
  248
• 1.1 Connection diagram - coolant hoses
  248
• 1.2 Coolant hose schematic diagram, high-voltage system
  252
• 1.3 Checking cooling system for leaks
  255
• 1.4 Checking cooling system of high-voltage system for leaks
  259
• 1.5 Draining and adding coolant
  270
• 1.6 Draining and adding coolant, high-voltage system
  277
• 1.7 Checking filling quality, high-voltage system
  286
• 2 Coolant pump, regulation of cooling system
  290
• 2.1 Assembly overview - coolant pump, thermostat
  290
• 2.2 Overview of fitting locations - electric coolant pumps
  293
• 2.3 Assembly overview - electric coolant pump
  294
• 2.4 Assembly overview - coolant temperature sender
  296
• 2.5 Assembly overview – coolant valves
  296
• 2.6 Removing and installing electric coolant pump
  298
• 2.7 Removing and installing coolant pump
  312
• 2.8 Removing and installing thermostat
  315
• 2.9 Removing and installing toothed belt pulley for coolant pump
  319
• 2.10 Removing and installing coolant temperature sender G62
  321
• 2.11 Removing and installing radiator outlet coolant temperature sender G83
  322
• 2.12 Removing and installing coolant valves
  324
• 2.13 Removing and installing coolant temperature sender for heater G241
  331
• 2.14 Removing and installing engine temperature sender 2 G788
  332
• 3 Coolant pipes
  334
• 3.1 Assembly overview - coolant pipes
  334
• 3.2 Removing and installing coolant pipes
  335
• 4 Radiator, radiator fan
  344
• 4.1 Assembly overview - radiator/radiator fan
  344
• 4.2 Assembly overview – radiator cowl and radiator fan
  347
• 4.3 Removing and installing radiator
  348
• 4.4 Removing and installing radiator cowl
  363
• 4.5 Removing and installing radiator fan V7
  370
• Turbocharging/supercharging
  371
• 1 Turbocharger
  371
• 1.1 Assembly overview - turbocharger
  371
• 1.2 Removing and installing turbocharger
  376
• 1.3 Removing and installing charge pressure positioner V465
  382
• 1.4 Removing and installing connection for turbocharger
  385
• 2 Charge air system
  389
• 2.1 Assembly overview - charge air system
  389
• 2.2 Removing and installing charge pressure sender GX26
  391
• 2.3 Removing and installing charge air cooler
  392
• 2.4 Checking charge air system for leaks
  393
• 2.5 Removing and installing air pipe
  395
• Mixture preparation - injection
  398
• 1 Injection system
  398
• 1.1 Overview of fitting locations - injection system
  398
• 2 Injectors
  406
• 2.1 Assembly overview - fuel rail with injectors
  406
• 2.2 Removing and installing fuel rail
  410
• 2.3 Removing and installing injectors
  411
• 2.4 Cleaning injectors
  426
• 3 Air filter
  428
• 3.1 Assembly overview - air filter housing
  428
• 3.2 Removing and installing air filter housing
  430
• 3.3 Removing and installing resonator for intake air
  431
• 4 Intake manifold
  433
• 4.1 Assembly overview – intake manifold
  433
• 4.2 Removing and installing intake manifold
  435
• 4.3 Removing and installing throttle valve module GX3
  438
• 4.4 Cleaning throttle valve module GX3
  439
• 5 Senders and sensors
  441
• 5.1 Removing and installing fuel pressure sender G247
  441
• 5.2 Checking fuel pressure sender G247
  442
• 5.3 Removing and installing intake manifold sender GX9
  446
• 5.4 Removing and installing pressure differential sender for particulate filter G1037
  447
• 6 Engine control unit
  449
• 6.1 Removing and installing engine control unit J623
  449
• 7 High-pressure pump
  454
• 7.1 Assembly overview - high-pressure pump
  454
• 7.2 Removing and installing high-pressure pump
  460
• 7.3 Removing and installing high-pressure pipe
  463
• 8 Lambda probe
  465
• 8.1 Assembly overview - Lambda probe
  465
• 8.2 Removing and installing Lambda probe 1 before catalytic converter GX10
  468
• 8.3 Removing and installing Lambda probe 1 after catalytic converter GX7
  469
• Exhaust system
  473
• 1 Exhaust pipes and silencers
  473
• 1.1 Assembly overview - silencers
  473
• 1.2 Separating exhaust pipes from silencers
  478
• 1.3 Removing and installing silencer
  479
• 1.4 Installation position of clamp
  482
• 1.5 Aligning exhaust system free of stress
  482
• 1.6 Checking exhaust system for leaks
  483
• 2 Emission control
  484
• 2.1 Assembly overview – emission control
  484
• 2.3 Removing and installing catalytic converter
  492
• 2.4 Removing and installing particulate filter
  501
• 3 Exhaust gas temperature regulation
  502
• 3.1 Assembly overview – exhaust gas temperature regulation
  502
• 3.2 Removing and installing parts of exhaust gas temperature regulation
  504
• Ignition system
  507
• 1 Ignition system
  507
• 1.1 Assembly overview - ignition system
  507
• 1.2 Removing and installing ignition coils with output stage
  509
• 1.3 Removing and installing knock sensor 1 G61
  512
• 1.4 Removing and installing Hall sender
  513
• 1.5 Removing and installing engine speed sender G28
  515
• Electric drive systems
  517
• 1 Warning stickers
  517
• 1.1 Checking warning stickers
  517
• 2 High-voltage components
  524
• 2.1 Overview of fitting locations - high-voltage components
  524
• 3 High-voltage battery unit
  527
• 3.1 Assembly overview - high-voltage battery, Golf ►08.2020, Passat ►09.2019
  527
• 3.3 Visual inspection of high-voltage battery 1 AX2
  529
• 3.4 Removing and installing high-voltage battery 1 AX2
  530
• 3.5 Leakage test of high-voltage battery 1 AX2
  537
• 3.6 Searching for leaks from high-voltage battery
  538
• 3.7 Raising high-voltage battery 1 AX2
  538
• 3.8 Removing and installing battery regulation control unit J840
  540
• 4 Repairing high-voltage battery unit
  550
• 4.1 Overview of fitting locations - high-voltage battery 1 AX2
  550
• 4.2 Overview of fitting locations - battery modules
  553
• 4.3 Overview of fitting locations - high-voltage connector
  556
• 4.4 Assembly overview - battery housing
  561
• 4.5 Assembly overview - switching unit for high-voltage battery SX6
  564
• 4.6 Assembly overview - battery module assembly
  567
• 4.7 Assembly overview - battery modules
  570
• 4.8 Assembly overview - high voltage system connection
  571
• 4.9 Assembly overview - cooling system high-voltage battery 1 AX2
  573
• 4.10 Assembly overview - wiring harnesses
  574
• 4.11 Diagnosis of high-voltage battery 1 AX2
  576
• 4.12 Leakage test in cooling system of high-voltage battery 1 AX2
  576
• 4.13 Charging and discharging battery modules
  578
• 4.14 Opening high-voltage battery 1 AX2
  580
• 4.15 Voltage and insulation measurement
  585
• 4.16 Removing and installing switching unit for high-voltage battery SX6
  587
• 4.17 Removing and installing wiring harness for high-voltage battery 1 AX2
  597
• 4.18 Removing and installing coolant pipe
  602
• 4.19 Removing and installing battery module assembly
  605
• 4.20 Removing and installing battery module assembly wiring harness
  625
• 4.21 Removing and installing high voltage system connection
  626
• 4.23 Closing high-voltage battery 1 AX2
  630
• 4.24 Removing and installing battery modules J1068/J991
  638
• 4.25 Removing and installing battery modules J992/J993
  647
• 4.26 Removing and installing battery modules J994/J995
  655
• 4.27 Removing and installing battery modules J996/J997
  664
• 5 Power and control electronics for electric drive
  672
• 5.1 Assembly overview - power and control electronics for electric drive
  672
• 5.2 Assembly overview - mounting for power and control electronics for electric drive
  676
• 5.3 Removing and installing power and control electronics for electric drive
  679
• 5.5 Removing and installing high-voltage system fuse 3 S353
  694
• 6 Charging unit for high-voltage battery
  700
• 6.1 Assembly overview – charging unit for high-voltage battery
  700
• 6.2 Removing and installing charging unit 1 for high-voltage battery AX4
  702
• 6.3 Removing and installing bracket for charging unit 1 for high-voltage battery AX4
  708
• 7 Electric drive motor
  711
• 7.1 Removing and installing three-phase current drive VX54
  711
• 7.2 Removing and installing drive motor temperature sender G712
  711
• 7.3 Removing and installing drive motor rotor position sender 1 G713
  711
• 8 High-voltage cables
  712
• 8.1 Overview of fitting locations - high-voltage cables
  712
• 8.2 Removing and installing high-voltage wiring harness for high-voltage battery
  716
• 8.3 Removing and installing high-voltage wiring harness for drive motor
  727
• 8.5 Removing and installing high-voltage cable for high-voltage heater (PTC)
  736
• 9 Charging socket
  741
• 9.1 Assembly overview – charging socket
  741
• 9.2 Removing and installing high-voltage battery charging socket 1 UX4
  746
• 9.3 Manual release mechanism for charging socket
  756
• 9.4 Removing and installing module for battery charge selector buttons EX32
  762
• 10 De-energising high-voltage system
  765
• 11 Re-energising high-voltage system
  767
• 12 Potential equalisation lines
  768
• 12.1 General notes - potential equalisation lines
  768
• 12.2 Overview of fitting locations - potential equalisation lines
  768
• 12.3 Removing and installing potential equalisation line for high-voltage battery 1 AX2
  773