4-cylinder injection engine (1.4 l direct injection EA 111 engine, turbocharger and supercharger)

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  2
• 2 Safety precautions
  3
• 2.1 Safety regulations for working on fuel supply
  3
• 2.2 Safety precautions when working on ignition system
  3
• 2.3 Releasing pressure in high-pressure area
  4
• 3 General repair instructions
  6
• 3.1 Rules for cleanliness
  6
• Removing and installing engine
  7
• 1 Removing and installing motor
  7
• 1.1 Removing motor
  7
• 1.2 Separating gearbox from engine and assembling
  23
• 1.3 Securing engine to assembly stand
  24
• 1.4 Installing engine
  26
• 1.5 Torque settings
  29
• 2 Assembly mountings
  30
• 2.1 Assembly mountings- specified torques
  30
• 2.2 Checking adjustment of engine assembly mountings
  31
• 2.3 Adjusting assembly mountings
  32
• Crankshaft group
  36
• 1 Dismantling and assembling engine
  36
• 1.1 Overview
  36
• 1.2 Assembly overview - belt drive
  37
• 1.3 Assembly overview - cylinder block
  39
• 1.4 Removing and installing poly-V belt
  42
• 1.5 Removing and installing valve timing housing (timing case)
  45
• 1.6 Removing and installing bracket for ancillaries
  52
• 2 Sealing flanges and flywheel
  54
• 2.1 Assembly overview
  54
• 2.2 Removing and installing engine speed sender G28
  56
• 2.3 Removing and installing crankshaft pulley
  57
• 2.4 Renewing crankshaft oil seal - pulley end
  61
• 2.5 Renewing crankshaft sealing flange - flywheel end
  64
• 3 Crankshaft
  75
• 3.1 Assembly overview - crankshaft
  75
• 3.2 Crankshaft dimensions
  77
• 4 Pistons and conrods
  79
• 4.1 Assembly overview
  79
• 4.2 Separating new conrod
  81
• 4.3 Checking pistons and cylinder bores
  82
• 4.4 Piston and cylinder dimensions
  84
• Cylinder head, valve gear
  85
• 1 Cylinder head
  85
• 1.1 Assembly overview
  85
• 1.2 Checking valve timing
  88
• 1.3 Adjusting valve timing
  91
• 1.4 Checking timing chain
  100
• 1.5 Removing and installing timing chain and drive chain for oil pump
  109
• 1.6 Removing and installing camshaft housing
  120
• 1.7 Removing and installing cylinder head
  128
• 1.8 Checking compression
  132
• 2 Valve gear
  135
• 2.1 Assembly overview
  135
• 2.2 Checking camshaft axial clearance
  138
• 2.3 Checking valve guides
  139
• 2.4 Reworking valve seats
  139
• 2.5 Renewing valve stem seals
  141
• Lubrication
  144
• 1 Parts of lubrication system
  144
• 1.1 Engine oil:
  144
• 1.2 Assembly overview - engine codes BLG and BMY
  145
• 1.3 Assembly overview - engine code CAVD
  147
• 1.4 Removing and installing sump
  149
• 1.5 Removing and installing oil pump
  152
• 1.6 Checking oil pressure and oil pressure switch
  155
• Cooling
  158
• 1 Parts of cooling system
  158
• 1.1 Assembly overview - parts of cooling system, body side
  159
• 1.2 Assembly overview - parts of cooling system, engine side
  161
• 1.3 Coolant hose connection diagram - engine codes BLG and BMY
  163
• 1.4 Coolant hose connection diagram - engine code CAVD
  163
• 1.5 Draining and adding coolant
  164
• 1.6 Removing and installing radiator fan V7 and radiator fan 2 V177
  170
• 1.7 Removing and installing radiator
  171
• 1.8 Removing and installing coolant pump
  173
• 1.9 Removing and installing coolant pump pulley
  179
• 1.10 Removing and installing coolant circulation pump V50
  184
• 1.11 Checking cooling system for leaks
  186
• Fuel supply system
  190
• 1 Safety precautions
  190
• 1.1 Safety regulations for working on fuel supply
  190
• 1.2 Reducing pressure in high-pressure section of fuel system
  191
• 2 Fuel
  193
• 2.1 Assembly overview - fuel tank
  193
• 2.2 Emptying fuel tank
  196
• 2.3 Removing and installing fuel tank
  203
• 3 Repairing fuel supply system
  207
• 3.1 Rules for cleanliness
  207
• 3.2 Removing and installing fuel delivery unit
  207
• 3.3 Removing and installing fuel gauge sender G
  210
• 3.4 Crash fuel shut-off
  212
• 3.5 Checking fuel pump G6
  213
• 4 Electronic power control (EPC)
  229
• 4.1 Function of EPC system
  229
• 4.2 Assembly overview - accelerator module
  229
• 4.3 Removing and installing accelerator pedal module
  230
• 5 Activated charcoal filter system
  233
• 5.1 Function
  233
• 5.2 Assembly overview - activated charcoal filter system
  233
• 5.3 Checking fuel tank breather
  234
• Turbocharging/supercharging
  238
• 1 Turbocharger
  238
• 1.1 General repair instructions
  238
• 1.2 Safety precautions
  240
• 1.3 Rules for cleanliness
  240
• 1.4 Assembly overview - turbocharger, engine codes BLG and BMY
  240
• 1.5 Assembly overview part I - turbocharger, engine codes BLG and BMY
  241
• 1.6 Assembly overview part II - turbocharger, engine codes BLG and BMY
  242
• 1.7 Assembly overview - turbocharger, engine code CAVD
  244
• 1.8 Assembly overview part I - turbocharger, engine code CAVD
  245
• 1.9 Assembly overview part II - turbocharger, engine code CAVD
  246
• 1.10 Removing and installing turbocharger
  248
• 1.11 Checking vacuum unit for turbocharger
  255
• 1.12 Removing and installing vacuum unit for turbocharger
  257
• 1.13 Adjusting vacuum unit for turbocharger
  259
• 2 Compressor
  266
• 2.1 Assembly overview - supercharger
  266
• 2.2 Removing and installing supercharger
  268
• 2.3 Removing and installing drive unit seal for supercharger
  278
• 3 Charge air system
  283
• 3.1 Assembly overview - charge air system
  283
• 3.2 Hose connections with plug-in connectors
  284
• 3.3 Removing and installing charge air cooler
  285
• 3.4 Checking charge air system for leaks
  288
• Mixture preparation - injection
  293
• 1 Injection system
  293
• 1.1 General notes on injection
  293
• 1.2 Safety precautions
  294
• 1.3 Rules for cleanliness
  295
• 1.4 Technical data
  295
• 1.5 Overview - intake manifold, engine codes BLG and BMY
  296
• 1.6 Assembly overview part I - intake manifold, engine codes BLG and BMY
  296
• 1.7 Assembly overview part II - intake manifold, engine codes BLG and BMY
  299
• 1.8 Overview - intake manifold, engine code CAVD
  301
• 1.9 Assembly overview part I - intake manifold, engine code CAVD
  302
• 1.10 Assembly overview part II - intake manifold, engine code CAVD
  306
• 1.13 Checking vacuum reservoir for leaks - engine codes BLG and BMY only
  313
• 1.14 Assembly overview - air filter
  314
• 1.15 Removing and installing air filter
  315
• 1.17 Cleaning throttle valve module J338
  320
• 1.18 Assembly overview - high-pressure pump, engine codes BLG and BMY
  321
• 1.19 Assembly overview - high-pressure pump, engine code CAVD
  322
• 1.20 Checking fuel pressure in high-pressure section
  323
• 1.21 Removing and installing high-pressure pump, engine codes BLG and BMY
  327
• 1.22 Removing and installing high-pressure pump - engine code CAVD
  332
• 1.23 Removing and installing injectors
  337
• 1.24 Renewing Teflon seal and support washer on injector
  340
• 2 Engine control unit
  345
• 2.1 Reading and erasing engine control unit fault memory
  345
• 2.2 Removing and installing engine control unit, Jetta 2006 >, Golf Estate 2007 >
  346
• 2.3 Removing and installing engine control unit - Golf Estate 2010 >
  351
• Exhaust system
  357
• 1 Parts of the exhaust system
  357
• 1.1 Assembly overview - catalytic converter and attachments
  358
• 1.2 Assembly overview - silencers with mountings
  360
• 1.3 Removing and installing exhaust pipe
  362
• 1.4 Separating and joining front and rear silencers
  364
• 1.5 Aligning exhaust system free of stress
  366
• Ignition system
  368
• 1 Repairing ignition system
  368
• 1.1 General notes on ignition system
  368
• 1.2 Safety precautions
  368
• 1.3 Assembly overview - ignition system
  369
• 1.4 Problem solution for Hall sender G40
  371
• 1.5 Removing and installing ignition coils with output stage
  371
• 1.6 Test data, spark plugs
  374