Name: 4-cylinder direct injection engine (1.5 l engine, 4V, EA 211, turbocharger)
Brand: Volkswagen
SKU: CDG5651fa33f74f
Price: 38.32 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 a 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 instructions
7
3.1 Rules for cleanliness
7
3.2 General information
7
3.3 General repair instructions
8
3.4 Foreign objects in engine
8
3.5 Contact corrosion
8
3.6 Routing and attachment of lines
8
3.7 Fitting radiator and condensers
8
3.8 Checking vacuum system
8
Removing and installing engine
10
1 Removing and installing engine
10
1.1 Removing engine
10
1.2 Separating engine and gearbox
20
1.3 Securing engine on engine and gearbox support
23
1.4 Installing engine
24
2 Assembly mountings
29
2.1 Assembly overview – assembly mountings
29
2.2 Removing and installing engine mounting
41
2.3 Removing and installing gearbox mounting
42
2.4 Removing and installing pendulum support
44
2.5 Supporting engine in installation position
45
2.6 Adjusting assembly mountings
78
2.7 Checking adjustment of assembly mountings
80
3 Engine cover panel
82
3.1 Removing and installing engine cover
82
Crankshaft group
83
1 Cylinder block (pulley end)
83
1.1 Assembly overview - poly V-belt drive
83
1.2 Removing and installing poly-V belt
89
1.3 Removing and installing tensioner for poly V-belt
94
1.4 Removing and installing vibration damper
96
1.5 Removing and installing engine support
99
1.6 Renewing crankshaft oil seal - belt pulley end
101
2 Cylinder block, gearbox end
105
2.1 Assembly overview - cylinder block, gearbox end
105
2.2 Removing and installing flywheel
108
2.3 Removing and installing sealing flange on gearbox side
110
3 Crankshaft
123
3.1 Renewing needle bearing in crankshaft
123
3.2 Crankshaft dimensions
125
3.3 Measuring axial clearance of crankshaft
125
4 Pistons and conrods
127
4.1 Assembly overview - pistons and conrods
127
4.2 Removing and installing pistons
129
4.3 Checking pistons and cylinder bores
131
4.4 Separating new conrod
133
4.5 Checking radial clearance of conrods
133
4.6 Removing and installing oil spray jets
134
4.7 Setting piston to TDC position
135
Cylinder head, valve gear
138
1 Cylinder head
138
1.1 Assembly overview - cylinder head
138
1.2 Assembly overview - camshaft housing
140
1.3 Removing and installing cylinder head
143
1.4 Removing and installing camshaft housing
147
1.5 Checking compression
153
2 Toothed belt drive
156
2.1 Assembly overview - toothed belt cover
156
2.2 Assembly overview - toothed belt
157
2.3 Assembly overview - valve timing tool
160
2.4 Removing and installing toothed belt guard
160
2.5 Removing and installing toothed belt
161
2.6 Preassembling and installing valve timing tool
168
2.7 Checking valve timing
178
2.8 Adjusting valve timing
181
2.9 Removing toothed belt from camshaft
192
3 Valve gear
197
3.1 Assembly overview - valve gear
197
3.2 Removing and installing camshaft oil seal
200
3.3 Removing and installing camshaft adjuster
212
3.4 Removing and installing cam actuators
224
3.5 Removing and installing inlet camshaft control valve 1 N727
226
3.6 Removing and installing exhaust camshaft control valve 1 N318
227
3.7 Removing and installing valve stem seals
228
3.8 Removing and installing holder for oil seal
243
4 Inlet and exhaust valves
247
4.1 Checking valve guides
247
4.2 Checking valves
248
4.3 Valve dimensions
248
Lubrication
249
1 Sump, oil pump
249
1.1 Assembly overview - sump/oil pump
249
1.2 Engine oil:
254
1.3 Removing and installing sump
254
1.4 Removing and installing oil pump
259
1.5 Removing and installing oil level and oil temperature sender G266
262
2 Engine oil cooler
263
2.1 Assembly overview - engine oil cooler
263
2.2 Removing and installing engine oil cooler
263
3 Crankcase ventilation
265
3.1 Assembly overview - crankcase breather system
265
3.2 Removing and installing oil separator
267
4 Oil filter, oil pressure switch
271
4.1 Assembly overview - oil pressure switches/oil pressure control
271
4.2 Removing and installing oil pressure sender G10
271
4.3 Checking oil pressure and oil pressure switch
273
4.4 Removing and installing oil filter housing
273
4.5 Removing and installing oil pressure regulating valve N428
274
Cooling
276
1 Cooling system/coolant
276
1.1 Connection diagram - coolant hoses
276
1.2 Checking cooling system for leaks
278
1.3 Draining and adding coolant
282
1.4 Flushing cooling system
290
2 Coolant pump, regulation of cooling system
305
2.1 Assembly overview - coolant pump, thermostat
305
2.2 Assembly overview - electric coolant pump
307
2.3 Assembly overview - coolant temperature sender
307
2.4 Removing and installing electric coolant pump
308
2.5 Removing and installing coolant pump
311
2.6 Removing and installing toothed belt pulley for coolant pump
316
2.7 Removing and installing coolant temperature sender G62
320
2.8 Removing and installing radiator outlet coolant temperature sender G83
322
2.9 Removing and installing engine outlet coolant temperature sender G82
324
2.10 Removing and installing engine temperature regulation module GX33
326
2.11 Checking coolant pump
330
3 Coolant pipes
336
3.1 Assembly overview - coolant pipes
336
3.2 Removing and installing coolant pipes
338
4 Radiator, radiator fan
347
4.1 Assembly overview - radiator/radiator fan
347
4.2 Assembly overview – radiator cowl and radiator fan
349
4.3 Assembly overview - radiator blind
351
4.4 Removing and installing radiator
354
4.5 Removing and installing water radiator for charge air cooling circuit
357
4.6 Removing and installing radiator cowl
362
4.7 Removing and installing radiator fan
363
4.8 Removing and installing radiator blind
365
4.9 Removing and installing radiator blind control motor V544
367
Turbocharging/supercharging
373
1 Turbocharger
373
1.1 Assembly overview - turbocharger
373
1.2 Removing and installing turbocharger
379
1.3 Removing and installing connection for turbocharger
384
1.4 Removing and installing charge pressure control module GX34
386
2 Charge air system
391
2.1 Assembly overview - charge air system
391
2.2 Removing and installing charge air cooler
394
2.3 Removing and installing charge pressure sender GX26
397
2.4 Checking charge air system for leaks
398
2.5 Removing and installing air pipe
402
2.6 Checking charge air cooler for leaks
409
Mixture preparation - injection
415
1 Injection system
415
1.1 Overview of fitting locations - injection system
415
2 Air filter
425
2.1 Assembly overview - air filter housing
425
2.2 Removing and installing air filter housing
427
2.3 Removing and installing air guide on lock carrier
429
3 Intake manifold
433
3.1 Assembly overview – intake manifold
433
3.2 Removing and installing intake manifold
436
3.3 Removing and installing throttle valve module GX3
442
3.4 Cleaning throttle valve module GX3
444
4 Injectors
446
4.1 Assembly overview - fuel rail with injectors
446
4.2 Removing and installing fuel rail
448
4.3 Removing and installing injectors
449
4.4 Cleaning injectors
457
5 Senders and sensors
459
5.1 Removing and installing intake manifold sender GX9
459
5.2 Removing and installing fuel pressure sender G247
460
5.3 Checking fuel pressure sender G247
462
5.4 Removing and installing exhaust gas pressure sensor 1 G450
466
5.5 Removing and installing air mass measurement module GX35
467
6 High-pressure pump
469
6.1 Assembly overview - high-pressure pump
469
6.2 Removing and installing high-pressure pump
470
6.3 Removing and installing high-pressure pipe
472
7 Lambda probe
474
7.1 Assembly overview - Lambda probe
474
7.2 Removing and installing Lambda probe
475
8 Engine control unit
477
8.1 Removing and installing engine control unit J623
477
Exhaust system
485
1 Exhaust pipes and silencers
485
1.1 Assembly overview – silencers
485
1.2 Removing and installing silencer
501
1.3 Separating exhaust pipes from silencers
516
1.4 Aligning exhaust system free of stress
518
1.5 Checking exhaust system for leaks
518
1.6 Installation position of clamp
519
1.7 Assembly overview - front exhaust pipe
520
1.8 Removing and installing bracket for front exhaust pipe
521
2 Emission control
523
2.1 Assembly overview – emission control
523
2.2 Removing and installing catalytic converter
526
2.3 Removing and installing particulate filter
531
2.4 Removing and installing exhaust flap control unit J883
532
Ignition system
533
1 Ignition system
533
1.1 Assembly overview - ignition system
533
1.2 Removing and installing ignition coils with output stage
535
1.3 Removing and installing knock sensor 1 G61
539
1.4 Removing and installing engine speed sender G28
540
1.5 Removing and installing inlet camshaft position sender G1002
542
1.6 Removing and installing exhaust camshaft position sender G1003
543

Manufacturer's designation	4-cylinder direct injection engine (1.5 l engine, 4V, EA 211, turbocharger)
Manufacturer	Volkswagen
Suitable for	Passat Lim (2015 >) / Passat Var. (2015 >) / Touran (2016 > ) / Tiguan (2016) / Golf VII (2017) / Arteon () / Golf (2017) / Polo (2018) / T-Roc (2018 >) / Golf Sportsvan (2018 >) / Passat Variant (2019 >) / Passat Limousine (2019 >) / T-Cross (2019 >) / Golf (2020 >) / T-Roc Cabriolet (2020 >) / Tiguan (2021 >) / Arteon (2021 >) / Arteon Shooting Brake (2021 >) / Golf Variant (2021 >)
Suitable car types	3G2, 5T1, AD1, BQ1, 3H7, BV5, AW1, A11, AN1, CB5, CB2, C11, CD1, AC7, AX1, 3H8, 3H9, CG5
Engine code	DADA, DACB, DFYA, DPCA, DPBE, DPBA
Category	Reparaturanleitung

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